RollSeal PolarCool 36" VS User manual

Manual No. 4801-6404 Rev08-12-2013
PORTABLE EVAPORATIVE
COOLING SYSTEM
USER’S MANUAL
Manufactured
by
PO Box 140
Bremen, Alabama 35033
Phone [phone]
Fax [phone]

Manual No. 4801-6404 Rev08-12-2013
Table of Contents
Section Description Page
1. WARNINGS ..........................................................................................................................................................3
2. LIMITED WARRANTY........................................................................................................................................4
3. POLARCOOL PERFORMANCE..........................................................................................................................5
3.1 TEMPERATURE DIFFERENTIAL READINGS ......................................................................................................5
4. CONTROLS...........................................................................................................................................................5
4.1 CONTROL PANEL ............................................................................................................................................6
5. INSTALLATION AND PREPARATION.............................................................................................................7
5.1 UNPACKING POLARCOOL...............................................................................................................................7
5.2 START-UP.......................................................................................................................................................7
5.3 SHUT DOWN ...................................................................................................................................................8
6. OPERATION .........................................................................................................................................................8
6.1 VENTILATION IS VERY IMPORTANT ................................................................................................................8
6.2 NORMAL OPERATION .....................................................................................................................................8
7. MAINTENANCE...................................................................................................................................................8
7.1 MAINTENANCE ACCESSIBILITY ......................................................................................................................8
7.2 FREQUENCY OF PAD REPLACEMENT..............................................................................................................9
7.3 EXTENDING PAD LIFE.....................................................................................................................................9
7.3.1 Algae......................................................................................................................................................9
7.3.2 Scale.......................................................................................................................................................9
7.3.3 Dirt and Dust.........................................................................................................................................9
7.3.4 Why Drain Water From The System?....................................................................................................9
7.3.5 Water Distribution...............................................................................................................................10
7.4 FLUSHING THE RESERVOIR ...........................................................................................................................10
7.5 CLEANING THE PUMP FILTER........................................................................................................................11
7.6 CLEANING THE PADS ....................................................................................................................................11
7.7 REPLACING PADS .........................................................................................................................................11
7.8 WINTERIZATION ...........................................................................................................................................11
7.9 FLOW CONTROL ADJUSTMENT .....................................................................................................................12
8. FLOAT ADJUSTMENT 13
9. POLARCOOL PREVENTIVE MAINTENANCE REQUIREMENTS...............................................................14
10.TROUBLESHOOTING GUIDE..........................................................................................................................14
11.WIRING DIAGRAM...........................................................................................................................................15
12.REPLACEMENT PARTS FOR POLARCOOL ZONE ......................................................................................16

Manual No. 4801-6404 Rev 08-12-2013 PolarCool Page 3 of 17
1. Warnings
WARNING
•Whenever water and electricity are combined in the same enclosed environment the
possibility of electric shock exists. This unit must only be plugged into a three conductor,
grounded GFI (Ground Fault Interrupt), power source. Do not open the unit with power
applied to the unit. Do not place the unit on a slope or where it can accidentally fall or
roll into water.
•Wiring And Connections Must Comply With All National And Local Electrical Codes.
•Installation By Qualified Electrician Required!
WARNING
•Hazardous rotating fan blade. Do not place fingers, arms, or other appendages into the
path of the blade, or operate the machine without the guards in place.
•Use Caution When Handling Sharp Metal.
WARNING
Once per month, inspect the internals of the PolarCool for signs of electrical insulation
breakdown. Check the seal at the motor, as any holes may allow water to come in contact with
open electrical circuits.
WARNING
Do not operate any fan with a damaged cord or plug. Discard fan or return to an authorized
service facility for examination and/or repair.
WARNING
Do not run cord under carpeting. Do not cover cord with throw rugs, runners, or similar coverings.
Do not route cord under furniture or appliances. Arrange cord away from traffic area and where it
will not be tripped over
!
!
!
!
!

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 4 of 17
2. Limited Warranty
All products are warranted to be free from defects in material and workmanship for a period of one year
from the date of purchase if installed and used in strict accordance with the installation instructions.
Liability is limited to the sale price of any products proved to be defective or, at manufacturer’s option, to
the replacement of such products upon their return. No products are to be returned to the manufacturer,
until there is an inspection and/or a return-goods authorization (RGA) number is issued.
All complaints should be directed first to the authorized distributor who sold the product. If satisfaction is
not obtained or the name of the distributor is not known, write the manufacturer that appears below,
directed to the attention of Customer Service Manager.
This limited warranty is expressly in lieu of any and all representations and warranties expressed or
implied, including any implied warranty of merchantability or fitness for a particular purpose. The remedy
set forth in this limited warranty shall be the exclusive remedy available to any person. No person has
authority to bind the manufacturer to any representation or warranty other than this limited warranty. The
manufacturer shall not be liable for any consequential damages resulting from the use of our products or
caused by any defect, failure or malfunction of our products (Some areas do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to
you.)
This warranty gives you specific legal rights and you may also have other rights that vary from area to area.
Warrantor: RollSeal, Inc.
PO Box 140
Bremen, Alabama 35033
Phone [phone]
Fax: [phone]

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 5 of 17
3. PolarCool Performance
The following table shows estimates of the performance of the PolarCool Zone Evaporative Cooling System. These
values will vary depending on the particular installation and operating conditions.
PolarCool
Model Drive Water Consumption
Rates
(See Note 1)
Power Consumption
(Voltage)
Typical Air
Movement Rates
(cubic feet per
minute - See Note
2)
Cooling
Area
Reservoir
(in
Gallons)
36” VS Direct 12 gallons per hr. 8 amps @ 115v /60hz 11,000 3000 ft² 38
Note 1: This estimate is under 90+ degree conditions; cooler temperatures will result in less
water usage.
Note 2: The cooling area is very dependent on the relative humidity, temperature, and the space
being cooled.
3.1Temperature Differential Readings
The temperature drop from inlet to exit is very dependent on relative humidity and temperature. The higher the
ambient temperature and the drier the air, the greater the drop. A temperature drop of 10 to 20 degrees is common.
4. Controls
The PolarCool Zone features a user friendly control panel interface with status indicator lights.

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 6 of 17
4.1Control Panel
•Power Indicator Light – The red Power Indicator Light is located at the bottom-center of the control panel label
and illuminates the Danger High Voltage Triangle. The Power Indicator Light remains ON constantly while
power is applied to the PolarCool unit.
•Fan Control ON/OFF Button – This button is used to start and stop the fan.
•+ and – Speed Control Buttons – Used to select the fan speed to any position between LO and HI. These
buttons control the fan speed only and do not turn the fan on or off.
•Water Pump Control ON/OFF Button – This button is used to start and stop the water pump.
•Pump ON – The green indicator PUMP ON light is ON solid when the water pump is running.
•Low Water – The red indicator LOW WATER light is ON blinking when the water level is low for less than 1
minute. After the first minute, the red indicator light is ON solid.
•Fill – The green indicator FILL light turns ON blinking when the water level has remained low for a constant
time of more than 1 minute. Also after the first minute of constant low water level, the water pump will
automatically turn off, the Pump ON and Fill green indicator lights will be blinking, and the Low Water red
indicator light will be ON solid.
NOTE: The water must be filled above the low level switch and remain above the switch for a minimum of 1
minute solid before the water pump will turn back On.

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 7 of 17
5. Installation and Preparation
5.1 Unpacking PolarCool
1. Carefully unpack PolarCool Zone from shipping carton. The unit
comes completely assembled and ready to use.
5.2 Start-Up
The PolarCool Zone is easy to prepare for operation. There are five easy steps.
1. Hook-up water hose to inlet tap.
2. Check safety of electrical cords, and plug in unit. Caution: The system must always be plugged into a three
conductor, grounded GFI (Ground Fault Interrupt), power source.
WARNING: Do not place the unit on a slope or where the unit can accidentally fall or roll into water. The
lockable wheels provide resistance to movement although do not prevent movement or turn-
over.
Note: Float may be locked in the off position.
3. Turn on water supply.
4. On the PolarCool Zone control panel, turn on the pump. The pump itself will not activate until the low water
level switch is tripped. (See Figure A, page 8)
IF PADS ARE NEW:
When pads are new, their slick surface will prevent the fast water absorption that will happen with older pads.
For this reason, it is important to allow the pump to run for two or three hours with the fan set to low speed the
first time new pads are used. This will "soak-in" the pads, and allow faster start-up later.
After soaking new pads, turn off the pump, fan, and water supply, unplug the unit, and drain the reservoir. The
reservoir can be drained using the Drain Outlet. This eliminates chemical residues that have washed out of the
new pads.
NOTE: Do not allow the pump to run without water in the reservoir. Without water, the pump may be
damaged.
Foaming can occur with new pads. If excessive foaming takes place, repeat the procedure described above two
or three times to flush chemical residues from the pads. Reducing the water flow to the pads may also be
helpful to reduce foaming.
NORMAL OPERATION :
Let the water run for twenty to thirty minutes before turning on fan. This will allow time for the reservoir to
fill.
5. Turn on fan and enjoy the cool air output.

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 8 of 17
FIGURE A
5.3 Shut Down
When you are finished with the PolarCool Zone, follow these steps for shutting down the unit.
1. Turn off pump.
2. Wait ten to fifteen minutes (This will dry the pad and minimize algae growth).
3. Turn off fan.
4. Disconnect water and power to the unit.
5. If water is not disconnected, turn off water supply to PolarCool whenever PolarCool is not in use.
6. Operation
6.1 Ventilation is Very Important
Fresh air is very important for proper operation of evaporative cooling. Ventilation can be provided by air flow
from open windows and doors, or exhaust fans. Positioning the PolarCool intake close to an open door is a common
way to assure fresh air. Evaporative cooling will not function properly in a closed environment.
6.2 Normal Operation
Under normal conditions, the pump should run constantly when air is being drawn through the pads. If outside
conditions are not warm enough to run evaporative cooled air, an alternative is to run the fan
with the pump off.
Dry the pads completely each night by turning off the pump and drawing air through the pads with the fan.
7. Maintenance
7.1 Maintenance Accessibility
Since evaporative coolers require maintenance, the PolarCool Zone has been designed to make maintenance as easy
as possible. By simply removing the pad cover plates and the pads, basically all critical parts are within easy reach
for inspection, including the pads, spray bar, pump, strainer, and water reservoir. To open, see figure on the next
page.
Low Water Level Swithch
Float Valve

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 9 of 17
Pad Removal
7.2 Frequency Of Pad Replacement
PolarCool pads, produced from a cellulose base and impregnated with a plastic resin anti-rot agent, can give years of
trouble free operation with proper maintenance (3 to 5 years is typical).
7.3 Extending Pad Life
As you use the PolarCool system, you will notice the need for good preventive maintenance. Algae growth, scale
(hard crusty deposits), and dirt accumulation are typical problems associated with poor maintenance.
Maintaining the PolarCool is very simple. It only takes a small amount of time and effort. If you follow the
guidelines below, your pads will last much longer, and be much more efficient.
7.3.1 Algae
To prevent algae, allow the pads to dry out each day, by running the fan without the pump running until the pads are
completely dry (about 15 minutes).
7.3.2 Scale
Scale is a concentration of solids that “plate” the surface of the pads if the water contains too many impurities.
Scale formation can be prevented by using water with a pH between 6 and 9 and silica levels below 150 ppm. If this
is impractical, scale can be minimized by increasing the drain-off rate. To clean pads, spray pads frequently with
water hose.
7.3.3 Dirt and Dust
If the pads are allowed to get excessively dirty, they should be removed from the system and washed down with a
water hose.
7.3.4 Why Drain Water From The System?
If you have ever left a pot of coffee warming on the coffee maker you know the two principles at work in
evaporative cooling systems. First, as the coffee sits on the warming plate, the level of water in the pot goes down.
Second, the remaining coffee gets stronger as the water evaporates.
In your cooling system, these effects still apply. As water evaporates, no impurities are carried along. This leaves
all sorts of minerals, chemicals, and other impurities behind. The concentration of impurities in the reservoir and
system will quickly rise.
Drain the reservoir daily in dusty conditions, and twice a week in clean air.
Thumb screws
Pad
Pad Cover Plate
Instructions:
1. Unscrew thumb screws and remove
pad cover plate.
2. Remove Pads.

Manual No. 4801-6404 Rev08-12-2013 PolarCool Page 10 of 17
7.3.5 Water Distribution
Maintaining even water distribution to the pads is the most important way of extending pad life. If an area of pad
does not receive enough water, cooling efficiency will be degraded. The Spray Bar Adjustment Valve should be
increased until the pads are fully wet, but not to the extent that a mist is blown out of the fan.
Dry spots or streaks can also be caused by clogged holes in the spray bar. Investigate by removing the pad cover
plates and running a pipe cleaner, or small dowel into the holes in the spray bar to clear any clogged holes. The
spray bar end caps may be removed for easier cleaning. Ensure the holes in the spray bar point upward during
operation.
7.4 Flushing the Reservoir
The pads and the complete water system should be flushed out at least once a week and the reservoir wiped clean.
1. Turn off the pump, fan, and water source, unplug the unit and drain the reservoir. The reservoir can be drained
using the Drain Outlet.
2. Wipe out the reservoir.
NOTE:Do not allow the pump to run without water in the reservoir. Without water, the pump may be damaged.
3. Restore the water source and fill the reservoir.
4. Run the pump for at least 15 minutes.
5. Pump the reservoir out again and refill with fresh water.
6. Start the pump and fan.
Drain Outlet W/Cap

Manual No. 4801-6404 Rev 08-12-2013 PolarCool Page 11 of 17
7.5 Cleaning the Pump Filter
The water pump includes a removable plastic filter on the bottom of the pump which should be cleaned weekly
when the reservoir is flushed.
1. Turn off the pump, fan, and water source, and
unplug the unit.
2. Remove the pump from the reservoir, remove
and clean the screen on the bottom of the motor,
and reinstall the pump in the same location and
method as removed.
NOTE: Do not allow the pump to run without water
in the reservoir. Without water, the pump may be
damaged.
3. Restore the water source and fill the reservoir.
4. Reconnect power and run the pump for at least
15 minutes.
5. Turn the fan ON.
7.6 Cleaning the Pads
1. Turn off fans.
2. Remove thumb screws on each side of pad cover
plates.
3. Remove pad cover plates and remove pads.
4. Hose down each side of pads.
CAUTION: Do Not Use High Pressure Washer To
Hose Down Pads!
5. Drain the reservoir.
6. Shut off pump and clean out strainer.
7. Refill reservoir with clean water.
8. Replace pads.
9. Turn on the pump to run fresh water over the
pads for about 20 minutes. Use as much water as
possible.
10. Gently hose stubborn deposits from the face of
the pads.
11. Completely empty the reservoir to remove all the
old algae and dirt that will rinse off the pads.
12. Refill with clean water.
7.7 Replacing Pads
1. Remove old pads from PolarCool.
2. Look for Air Flow Diagram on side of new pad.
Refer to diagram at right.
3. IMPORTANT! Install new pad into PolarCool
with Air Flow in direction of arrow and with up
arrow pointing UP.
4. Replace all pads as described in step 3.
7.8 Winterization
When storing for extended periods:
1. Flush and clean reservoir. Never leave water in reservoir for extended periods.
2. Remove and backwash pads. Remove any debris or deposits from pad.
3. Remove the drain outlet cap to prevent water accumulation inside the reservoir.
Pad Orientation
Pump
Pump
Pump Location (Pads not shown)

Manual No. 4801-6404 Rev 08-12-2013 PolarCool Page 12 of 17
7.9 Flow Control Adjustment
The Flow Control Valve for the PolarCool Zone is shown to the
right. Flow adjustments are factory preset, however can be
adjusted by the user based upon local water pressure and
evaporative conditions at the site. The amount of water flow
affects the efficiency and operation of the PolarCool Zone.
During operation the flow should be adjusted so that sufficient
water soaks the pads, but only enough to completely soak the
pads.
If there is too much water flow, the pads become over-soaked -
that is, there is more water flow than required for proper
evaporation. Surplus water may be sucked into the fan producing
a water droplet spray directly in front of the PolarCool. In some
cases, if you stand in front of the PolarCool you may feel the
water spray! The efficiency of the Polar cool is reduced in this
case. If this happens, reduce the water flow.
If there is too little flow, there will not be enough water to fully soak the pads. Dry spots in the pads will be
visible. Again, this reduces the efficiency of the PolarCool. If this is the case, increase the flow until the pads
become fully soaked.
Adjust the Water Flow
as described above. The
FULL
OPEN and CLOSED
positions of the Valve are
shown in figures at the right.
Valve
Closed
Valve
Full Open
Increase
Pressure
Adjust Water Flow
Flow Control Adjustment
(Pads not shown)
Flow
Control
Valve
Pump
Flow
Control
Valve
Pump
Decrease
Pressure

Manual No. 4801-6404 Rev 08-12-2013 PolarCool Page 13 of 17
8. Float Adjustment
If adjustment is required, perform the
following steps:
1. Disconnect all electrical power to
PolarCool appliance!
2. Carefully remove pads.
3. Locate float valve inside PolarCool.
4. Use a screwdriver and loosen arm
adjustment screw
5. To decrease water level in reservoir,
move float arm downward
Retighten arm adjustment screw.
6. To increase water level in reservoir,
move float arm upward Retighten
arm adjustment screw.
7. Replace pads. Return PolarCool to
operation.
8. Repeat steps 1 thru 7 above as
required for proper adjustment of
water level. Do not allow the
reservoir water to contact the pads
when the reservoir water level is at
the highest point.
9. After adjusting water level, return
PolarCool to service.
Note: This float has a locking device.
•To lock the float in the off position raise arm and slide lock in.
•To unlock lift arm and slide arm out.
Float Adjustment
Locking Device
Spout
Arm Adjustment

Manual No. 4801-5035 Rev 08-12-2013 PolarCool Page 14 of 17
9. PolarCool Preventive Maintenance Requirements
•Flush the system at least once per week and wipe
the reservoir clean to prevent damage to the unit.
Refer to Section 7.4.
•Allow the pads to dry out each day, by running
the fan without the pump running until the pads
are completely dry (about 15 minutes).
•Drain the system during extended shutdowns.
•Disinfect the whole system once per quarter.
•Inspect spray bar for debris in holes.
•Turn off water hose to PolarCool whenever
PolarCool is not in use.
•Have the right amount of water running over the
pad.
•If power cord extension is necessary, ensure that
you use 12 AWG or larger wire.
•Ensure that air is not limited or restricted from
entering or exiting the unit.
•Identify and correct leaks in the system.
•Excessive dust, fumes, and harsh cleaners should
be avoided.
•Do not use in closed environment. Fresh air is a
necessity.
•Do not add chlorine or bleach to water.
•Never use phosphate based water treatment
chemicals.
10. Troubleshooting Guide
Problem Check/Action Reference
Section
Swivel casters will not turn. Check installation of caster hardware.
Hardware must be in the proper order and
location.
Water is splashing off of pads Pads may be in backwards; Check Flow chart
on side of pad.
6.8
Water spraying out from cover. Ensure the holes in the spray bar point
upward into the spray deflector. (Vertical
Spray).
7.3.5
Water is not spraying out of ANY
spray bar holes. Ensure pump switch is ON; Check for sufficient water in reservoir; Check the Flow
Control Valve; Check screen on bottom of
pump for obstructions.
6.5 and 6.9
Water is not spraying out of SOME
spray bar holes.
Excessive dry streaks in the pads.
Adjust spray using the Spray Bar Adjustment
Valve, the spray bar should be cleaned, OR
the pump screen should be cleaned.
Remove spray bar and clean the bar and all
holes.
Error!
Reference
source not
found., 6.5
and 6.9
Fan motor doesn’t turn ON and no
sound from the motor.
Check PolarCool Switches, power cord, GFCI
outlet, and circuit breaker.
Motor overheats and shuts off then
restarts minutes later.
Extension cord gauge is too small or the air
passage is blocked or partially obstructed.
Pump does not work.
Check for low water-level and low-level switch.
0 and 4.2

Manual No. 4801-5035 Rev 08-12-2013 PolarCool Page 15 of 17
11. Wiring Diagram

Manual No. 4801-6404 Rev 08-12-2013 PolarCool Page 16 of 17
12. Replacement Parts List
Part Description Part No.
Cooling Pads 0050-9601
Complete Pad Set 6450-6014 (4)
Water Pump 6422-0615
Fan Motor 3017-5600
Fan Prop 6403-5600
Fan Guard (PVC
Coated)
6403-0000
Solenoid Valve 1009-0000
Control Board 6407-1624
Drain Cap 0006-0001
Liquid Level
Switch
3001-0050
3 Position
Connector
3006-5082
(2008 and
newer models)
Low-Level
Switch/Harness
3001-0050
(2008 and later
models)
Swiveling Caster
Tire
1065-0100
Rigid Caster Tire 1065-0101
Cord Set 1902-4700
Large Front Label 4501-6310
Small Side Label 4501-6308
Control Panel
Label
4501-6306
Operation and
Maintenance
Label
4501-6307
Rubber Seal -
Control Box
1028-6013
Inlet Label 4501-0212
Jobe Float 1009-0108
Motor
Pads
Pump
Fan Guard
Prop
Allen Wrench
Circuit Board
Spray Bar

Manual No. 4801-6404 Rev 08-12-2013