ESSICKAIR SI-500S Evaporative Air Cooler Owner’s Manual

ESSICKAIR SI-500S Evaporative Air Cooler

Product Information

Specifications

• Model: ESSICK SI-500S
• Type: Evaporative Air Cooler
• Inlet: Single
• Discharge: Horizontal and Downward
• Part Number: 70093 REV 4/02

Product Usage Instructions

Installation

1. Ensure the unit is installed on a sturdy structure capable of supporting its weight.
2. Verify the cooler circuit has a slow-blow breaker of sufficient capacity.
3. Separate the fan section from the wet section before transporting the cooler to reduce weight.
4. Plan a safe method for transporting the cooler to the installation site without causing damage or injury.
5. Do not connect power to the cooler until the installation is complete.
6. Wear gloves and protective eyewear during installation or servicing.

Servicing

1. Disconnect the unit from the power source before servicing.
2. Avoid draining water onto the roof to prevent slipping or staining.
3. If the motor shuts off due to thermal overload, investigate and address the issue promptly.

Tools and Supplies Needed for Installation

• Pliers
• Drill bits
• Screwdrivers
• Hammer
• Adjustable wrenches
• Duct tape
• Tubing cutter
• Caulk
• 5/32 hex key wrench
• Sheet metal screws
• Level
• ECR-6 wall switch
• Electric drill
• Safety glasses

Motor Mounting

1. Place the motor into the cradles ensuring they fit into the groove in the motor grommets.
2. Secure with the saddle clamps provided, avoiding over-tightening.

Frequently Asked Questions

Q: Can I use a solid-state speed control device with this cooler?

A: To reduce the risk of fire or electrical shock, DO NOT use any solid- state speed control device with this fan.

Q: What should I do if the motor shuts off due to thermal overload?

A: Check into the problem immediately to prevent permanent damage. If the motor shuts off, investigate and address the issue promptly.

Q: What precautions should I take during installation?

A: Ensure the unit is installed on a sturdy structure, wear protective gear, and do not connect power until installation is complete.

Our Mission: We Will Respond to Our Customers With High-Quality Products and Service While Eliminating Waste From Our Processes.

Evaporative Cooling

• Evaporative cooling uses the principle of evaporation to lower the air temperature. Hot, dry air is passed through wetted filters and is converted to refreshingly cooled air.
• Essick Coolers make the best use of the evaporative process by controlling the flow of water, spreading the water evenly over the filters, and keeping a steady stream of cooled air entering your home.
• It is exhausted out of open windows or doors, carrying heat, smoke, and odors along with it. Essick evaporative coolers are 80% less costly to operate than refrigerated air conditioners.
• Cautions: To prevent harm to yourself and others, and to avoid damage to your cooler, PLEASE follow these guidelines.

SAFETY GUIDE LINES & CAUTIONS

When Installing| When Operating| When Servicing
Make sure that the unit is installed on a sound structure that will support the full operating weight of the cooler.| Make sure that the cooler circuit is equipped with a (slow blow) breaker large enough to support the full amperage of the cooler.| Be sure to disconnect the unit from the power source before servicing. If not, it can be turned on from inside the house and start unexpectedly.
Before attempting to transport the cooler to the roof. Separate the fan section from the wet section to reduce weight. Always plan a safe method of transporting the cooler to the installation site without damage to the cooler or injury to yourself.| To reduce the risk of fire or electrical shock, DO NOT use this fan with any Solid-state speed control device.| Never drain water onto your roof. Water residue could cause you to slip or may stain your roof.
Do Not connect power to the cooler before installation is complete.| This cooler is equipped with an automatic thermally protected motor. If it shuts off on its own for any reason, it can restart without warning.| If the motor shuts off because of thermal overload,       check into the problem immediately. If allowed to continue, permanent damage will occur.
Wear gloves and protective eyewear when installing or servicing.

Tools and supplies needed for installation

• Pliers
• Screwdrivers
• Adjustable wrenches
• Tubing cutter
• 5/32 hex key wrench
• Level
• Electric drill
• Drill bits
• Hammer
• Duct tape
• Caulk
• Sheet metal screws
• ECR-6 wall switch
• Safety glasses
• Wiring supplies – It is recommended that a licensed electrician do all electrical work.
• Ductwork – A local sheet metal shop can supply ductwork.
• ¼” water line
• Saddle valve or faucet adapter
• Roof stand (if the cooler is roof-mounted)
• Roof flashing and pitch

Mounting

1. Prepare duct to fit the model used (500 series coolers 17 ¾” square; 700 series 19 ¾” square).
2. Cut an opening in the wall or roof to fit the duct. If wall studs or roof joists are cut, reinforce them.
3. Mount the duct in the opening. The duct will fit inside the cooler opening. The duct length from the roof to the bottom of the cooler should be a minimum of 4” at the closest point, so there is access to the water drain.
4. Install flashing around the roof opening to prevent water entry. Use pitch to seal the seams.
5. Measure cooler and layout mounting location.
6. Mount cooler to stand or pad. Cooler must be level front to back and left to right. Note: It is best that the fan section end of the cooler face up the roof to achieve a lower profile and allow better access to the drain.
7. Be sure to securely fasten all four corners of cooler to the stand or pad.
8. Caulk duct to the cooler to prevent air leakage.

Motor mounting

Warning: Do Not energize the cooler until the installation is complete.

1. Place the motor into the cradles. Be sure that the cradles fit into the groove in the motor grommets.
2. Secure with the saddle clamps provided in the installation package. DO NOT OVERTIGHTEN.

Electrical connections

CAUTION: Disconnect all electrical power at the breaker or fuse box before you begin to install or service any cooler.

• The wiring for this cooler must comply with all applicable codes. It is recommended that a licensed electrician install any required wiring.
• To remotely operate this unit, use an ECR-6 switch. It is equipped with 2 cooling positions, 2 vent positions, and a pump-only position to wash or pre-wet the pads.
• The junction box mounts in the corner post of the fan section. Receptacles are provided for the motor and pump.
• All wiring connections must be made inside the junction box. See the wiring diagram below.

Motor pulley installation

1. Loosen both set screws on the pulley. Use a 5/32” hex key Allen wrench.
2. Slide the pulley onto the motor shaft with the threaded side out.
3. Install the belt and align the motor pulley and blower pulley.
4. Align the set screw on the motor side of the pulley with the flat portion of the motor shaft and tighten.

Motor pulley adjustment

1. Turn the outside jaw of the motor pulley clockwise until the pulley is fully closed.
2. Align the outside set screw with the nearest flat spot on the threaded portion of the pulley. This is the zero position.
3. Turn the outside jaw of the pulley counterclockwise for 3 full turns. Align the set screw with a flat on the threaded portion of the pulley and tighten.
   • This step will ensure that your cooler will run without overloading the motor. Further adjustment may be required.
   • Warning: if the set screw is tightened onto threads, damage will occur and the pulley will no longer be able to be adjusted.
   • When the installation is complete and all panels are in place, check the motor amperage using a clamp-on type ammeter.
   • Since all the cooler access panels must be in place to get a true reading, check amperage at a disconnect box, breaker, or fuse box.
4. Find out the amperage from the motor nameplate.
5. Clamp the ammeter around the incoming white lead.
6. Start the cooler on HI VENT.
7. If the amperage is less than the motor nameplate rating, loosen the outer set screw of the motor pulley, then turn the outer jaw of the pulley clockwise ½ turn and tighten the outer set screw. Recheck the amperage and repeat the step if necessary.
8. If the amperage is more than the motor nameplate rating, loosen the outer set screw of the motor pulley, then turn the outer jaw of the pulley counterclockwise ½ turn and tighten the outer set screw. Recheck the amperage and repeat the step if necessary.
9. Proper belt tension is crucial to efficient operation and motor and belt life. See the maintenance section for instructions on achieving proper belt tension.

Install overflow and drain

1. Slide the rubber washer onto the drain bushing and place it through a hole in the reservoir from the top side.
2. Secure it from below with the lock nut. Make sure the rubber washer does not twist while tightening, which could cause it to leak. Hand tighten first and then tighten ¾ turn further with a proper tool. Do not over-tighten.
3. Thread the plastic overflow tube into the drain bushing and hand tighten until snug.
   • Note: If leakage occurs after the reservoir is filled, further snug the fitting until leakage stops. Plumber’s tape or thread putty may be used if necessary.

Float valve installation

1. Place the threaded portion of the Float Valve through the hole provided in the Corner Post from the inside.
2. Slip the Fiber Washer over the threaded portion outside the corner post and secure it with the Nut. Be sure the Float does not turn while you are tightening the Nut.
3. Slip the Float Tube onto the float so that the keyhole is just behind the water inlet and the float rod can move up and down freely. The object is to contain any spray.

Water line connection

1. Find the closest outside water faucet, and install a Water Connection Kit (not included with cooler) as shown. If an exterior faucet is unavailable, locate the closest cold water pipe and install a saddle valve assembly.
2. Route tubing to a cooler. Place the Compression Nut and Ferrule over the end of the tubing. Insert the tubing into the float valve and tighten the Compression Nut to secure it.

• Note: Tightening a compression fitting will cause that fitting to leak. It is best to secure the connections, turn on the water, and snug the fitting until the leaking stops.

Adjusting water level and float

• In order for the float to shut off the flow of water at the desired level, you must adjust the float.

1. Fill the reservoir to ½” below the top of the overflow tube.
2. Bend the float rod slightly until adequate pressure is achieved and the float shuts off completely.

• Note: Never use “soft water” from water-softening equipment. This water is very corrosive and will cause damage to your cooler.
• Using a water softener in conjunction with this cooler will void the warranty.
• Use of caustic cleaners or other harsh chemicals will also void the warranty.

Start-up inspection

Before starting the cooler, make sure all installations are correct.

Be sure that:

1. A cooler is grounded and electrical connections are safe and secure.
2. A cooler is level and the duct is sealed
3. The blower wheel does not rub the housing.
4. The water supply is turned on.
5. Drain fitting and water connections are secure and do not leak.
6. The float is adjusted to the proper level.
7. Important: The motor pulley is set at the correct diameter. If not, the motor can overheat and fail.
8. Belt tension is OK.
9. Pulley alignment is OK.
10. Check the switch for proper operation.

ECR-6 switch operation

Switch setting| Blower motor| Pump
Off| Off| Off
Pump Only| Off| On
Low Vent| Low| Off
High Vent| High| Off
Low Cool| Low| On
High Cool| high| On

Troubleshooting

replace bearings
Water draining from overflow| Float improperly adjusted Lime build up in float valve| Adjust float Clean or replace the float
Blower shakes| Belt or pulley lose| Adjust or tighten
Fails to start| No electrical power Blown fuse or popped circuit breaker| Check power Replace or reset
Not cooling| The water supply was turned off Blocked the water distributor| Check the water supply Clean the distributor

Maintenance

• Caution: turn off all electrical power to the cooler before opening or attempting service of any kind.
• The motor is equipped with automatic thermal protection. If it shuts off for any reason, it can start back up without warning!
• Occasionally inspect your cooler for leaks, loose belts, blocked water lines, correct belt alignment, or excessive residue build up on the pads.

Belt tension

• At the proper tension, the belt will deflect ½” to ¾” when 3 to 5 pounds of pressure is applied to the belt approximately halfway between the blower and motor pulleys.
• Adjust the belt tension using the motor bracket do not change the diameter of the pulley to adjust the belt tension.

Lubrication

• Lube the oil cups on the blower bearing. Use SAE20 or SAE30 Non-Detergent oil. Oil the blower motor only if oil holes exist.

End of season

1. Drain and clean the reservoir. Do not get water on the blower motor or pump motor.
2. Remove the belt and hang it from the motor pulley.
3. Remove the pads and clean them carefully.
4. Remove the water distributor and hose out with the garden hose. Use a small nail to clean any deposits from the water holes.

Pad Replacement

Lime build-up can occur in the water reservoir and on the pads. Clean this off at least once per season. If any rust or bare metal spots occur on the cabinet, the metal should be sanded, primed and painted with good-quality paint.

1. Remove the wet section top.
2. Remove the water distributor assembly.
3. Remove and discard old pads.
4. Install new pad set. Refer to the diagram below or pad installation instructions for the correct orientation.
5. Ensure that the water distributor pad is centered over cooler pads.
6. Carefully replace the water distributor; ensure pads are not damaged while replacing the assembly.
7. Replace the wet section top.

Replacement Parts

No.| Description| Qty| SI500S| SI500D| SI700S| SI700D
---|---|---|---|---|---|---
1| Fan section| 1| 70018| 70001| 70023| 70038
2| Access Panel| 2| 70005| 70005| 70027| 70027
3| Blower Housing| 1| 70021| 70014| 70034| 70040
4| Blower Brace| 2| 70151| 70045| 70151| 70045
5| Blower bearing| 2| 30289| 30289| 30288| 30288
6| Motor| 1| | | |
7| Motor pulley| 1| 70170| 70170| 583041| 583041
8| Motor mount| 1| 70154| 70154| 70125| 70125
9| Blower Pulley| 1| 583013| 583013| 30314| 30314
10| Blower wheel| 1| 30322| 30322| 70120| 70120
11| Blower belt| 1| 582090| 582009| 4L690| 582001
12| Set collar| 1| 524331| 524331| 524331| 524331
13| Blower shaft| 1| 30238-02| 30238-02| 30238-01| 30238-01
14| Float valve| 1| 524198| 524198| 524198| 524198
15| Float tube| 1| 70132| 70132| 70132| 70132
16 | Wet section top| 1| 70009| 70009| 70009| 70009
17 | Wet section housing| 1| 70006| 70006| 70028| 70028
18| Water hose| 1| 70196| 70196| 70197| 70197
19| Pump bracket| 1| 70067| 70067| 70067| 70067
20| Pump| 1| 506674| 506674| 506674| 506674
21| Water distributor tube| 1| 70116| 70116| 70116| 70116
22 | Water distributor| 1| 70043| 70043| 70043| 70043
23 | Pad media set| 1| 70054| 70054| 70055| 70055
24 | Water shield set| 1| 70095| 70095| 70098| 70098
25 | Pad support tray| 1| 70010| 70010| 70010| 70010
26| Overflow kit| 1| 70613| 70613| 70613| 70613
27 *****| Reservoir| 1| 70053| 70053| 70053| 70053
28| Inlet Screen| 1| 70012| 70012| 70031| 70031
29| Electrical junction box| 1| 70130| 70130| 70130| 70130
30| Motor plug| 1| 595098| 595098| 595098| 595098
31| Pump plug| 1| 595121| 595121| 595121| 595121
32| Blower cutoff| 1| 504280| 504280| 70124| 70124
33| Water distributor pad| 1| 70155| 70155| 70155| 70155

• Speak with Essick Air Products representative for specific motor requirements.
• For units with 12” media, refer to the table below for Wet Section parts.

No.| Description| Qty| SI500S- 12| SI500D- 12| SI700S- 12| SI700D- 12
---|---|---|---|---|---|---
16| Wet section top| 1| 70877| 70877| 70877| 70877
17| Wet section housing| 1| 70907| 70907| 70879| 70879
22| Water distributor| 1| 70872| 70872| 70872| 70872
23| Pad media set| 1| 70912| 70912| 70875| 70875
24| Water shield| 2| 70909| 70909| 70874| 70874
25| Pad support tray| 1| 70887| 70887| 70887| 70887
27*| Reservoir| 1| 70871| 70871| 70871| 70871

Limited Warranty

• This warranty is extended to the original purchaser only of an evaporative cooler installed and used under normal conditions.
• It does not cover damages incurred during shipping or through accident, neglect, or abuse by the owner.
• Essick Air Products does not authorize any person or representative to assume any other or different liability in connection with this product.

Terms and conditions of warranty

• This warranty includes lifetime limited coverage on the water reservoir against any leakage due to defects in material.
• From the date of installation, if any original part provided by Essick Air Products fails due to a defect in material or factory workmanship only, Essick Air Products will provide the replacement parts as follows.
• Cabinet components for one year from the date of installation
• Evaporative media for five years from the date of installation

Exclusions from this warranty

• Essick Air Products is not responsible for incidental or consequential damage resulting from any malfunction.
• Essick Air Products is not responsible for any damage occurring from the use of water softeners, chemicals, descale material, or if a higher horsepower motor than what Essick Air Products recommends is used in the unit.
• Essick Air Products is not responsible for the cost of service calls to diagnose the cause of trouble, or labor charges to repair and/or replace parts.

How to obtain service under this warranty

• Contact the Dealer where you purchased the evaporative cooler. If for any reason you are not satisfied with the response for the Dealer, contact.
• Customer Service Department: Essick Air Products Inc. 5800 Murray Street, Little Rock, Arkansas 72209. 1-800-643-8341.

References

• Repair Your Grill: Shop Replacement Parts for 24,880 Models
• Essick Evaporative Cooler Parts - Select From 70 Models

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