WayCool 1HP - Series User manual

Portable Evaporative Cooler

WayCool®1HP - Series

USER'S MANUAL

INTRODUCTION ..................................................................................................................................................................1

Why use evaporative coolers in your work place?................................................................................................................1

How evaporative cooling works? ..........................................................................................................................................1

ABOUT THIS MANUAL........................................................................................................................................................2

SAFETY INFORMATION ..................................................................................................................................................2-3

SAFETY RECOMMENDATIONS ..........................................................................................................................................3

WC-1HP SPECIFICATIONS ................................................................................................................................................4

WC-1HP UNIT DESCRIPTION ............................................................................................................................................5

WATER SUPPLY SYSTEM................................................................................................................................................6-7

COOLING PAD ASSEMBLY ................................................................................................................................................8

BLOWER AND DUCTWORK ..............................................................................................................................................9

CONTROL ..........................................................................................................................................................................10

OPERATION AND MAINTENANCE ..................................................................................................................................11

Unit Placement and Other Considerations ..........................................................................................................................11

Unpacking and Initial Setup ................................................................................................................................................12

Regular Cleaning ................................................................................................................................................................13

Normal Startup ....................................................................................................................................................................13

Normal Shutdown................................................................................................................................................................13

TROUBLESHOOTING ........................................................................................................................................................14

Cooling Pads not Wetting....................................................................................................................................................14

Foaming ..............................................................................................................................................................................14

Line Clogs or Obstructions..................................................................................................................................................14

Odor Control........................................................................................................................................................................14

Scale Buildup ......................................................................................................................................................................14

Splattering out Front............................................................................................................................................................14

Leaking out Bottom ............................................................................................................................................................14

OPTIONAL ACCESSORIES ..............................................................................................................................................15

Manual Fill and Water Gauge ............................................................................................................................................15

Pneumatic Wheel Option ....................................................................................................................................................15

Water Conditioner & Cleaner ..............................................................................................................................................15

Oscillating WayCool ............................................................................................................................................................16

Automatic Shutoff Option ....................................................................................................................................................17

General................................................................................................................................................................................18

Warranty ..............................................................................................................................................................................19

Table of Contents

Introduction

WHY USE EVAPORATIVE COOLERS INYOUR WORKPLACE?

• The WayCool®evaporative cooler requires little space, has a low initial cost, is inexpensive and simple to operate and requires

minimal scheduled maintenance.

• Due to the design and construction of the cooling pads, cooling efficiency is normally maintained near optimum throughout the life

of the pads. (Approximately two seasons)

• In many cases, evaporative coolers are a better solution than mechanical refrigeration systems because they are more economical

to operate and maintain and do not use environmentally sensitive and costly refrigerants.

HOW EVAPORATIVE COOLING WORKS

Figure WC-1HP.02 - Evaporative Cooling Principle

Evaporative cooling is the same process your body uses to cool itself.When you perspire, and air moves across your skin, a portion of the

perspiration (water) evaporates. Evaporation requires heat to change liquid water-to-water vapor and this heat is taken from your skin,

producing the cooling effect.

In an evaporative cooler, the cellulose cooling pads take the place of your skin, water instead of perspiration wets them and a fan moves the

air.The air blows across the cooling pads and evaporates moisture. Heat is drawn from the pads and the air, dropping the air temperature

and producing the cooling effect.The cooled air is then forced through a building or space and displaces the warm air out building openings,

cooling the surroundings. In addition, air velocity increases the cooling effect as it moves over the skin of people in the airflow path.

WayCool®evaporative coolers are portable and use the latest technology to provide large volumes of cool air, efficiently and inexpensively

for cooling small to medium size areas. Simply adding more units can accommodate larger areas. With proper sizing and application, a

WayCool®portable evaporative cooler can lower the effective air temperature by up to 20°. Even in high humidity, the efficiency of the

WayCool®evaporative cooler provides effective cooling.

Cool moist air

less than 80

degrees F.

Warm dry air

greater than 90

degrees F.

Pipe dripping

water onto

pads.

Wetted cellulose

pads

Fan

About this Manual

The intent of this manual is to help you in two ways: to provide you with step-by-step instructions for quick and easy assembly of your

product and to serve as a reference for simple maintenance and questions regarding your product.

Important! Read ALL instructions carefully before starting your WayCool®.

• Optional equipment contains necessary instructions for assembly or operation.

Important! Pay particular attention to all SAFETY information.

Important! The WayCool

Evaporative Cooler is labeled with a serial number. The serial number is located inside the unit on the

aluminum frame, behind the switch. Note: Removal of the serial number label will void all warranties.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of printing.

We reserve the right to make changes at any time without notice.

Warning and Danger Decals have been placed on the equipment to warn of potentially dangerous situations. Care should be taken to

keep this information intact and easy to read at all times. Replace missing or damaged safety decals immediately.

Using the equipment for purposes other than specified in this manual may cause personal injury and/or damage to the equipment.

Safety-Alert Symbol

This is a safety-alert symbol. When you see this symbol on your equipment, be alert to the potential for personal injury.This

equipment is designed to be installed and operated as safely as possible… however, hazards do exist.

Signal words are used in conjunction with the safety-alert symbol to identify the severity of the warning.

CAUTION indicates an imminently hazardous situation, which, if not avoided, COULD cause damage to your equipment or equipment

failure.

WARNING indicates a potentially hazardous situation, which, if not avoided, COULD result in death or serious injury.

Safety Information

Safety Recommendations

Follow Safety Instructions

Carefully read all safety messages in this manual and on your equipment safety decals. Follow recommended precautions and safe

operating practices.

Keep safety decals in good condition. Replace missing or damaged safety decals.

Decal Descriptions

This diagram shows the proper location of the safety decals as shipped from the factory. Replace damaged or missing decals. Make sure

the decals are easy to see at all times.

WARNING!

Interference with the oscillating spout while the

unit is operating, or manually directing the

oscillating spout, will cause damage to the gear

motor. Keep oscillating path clear of obstructions.

This warning decal is found on the top of

oscillating units only.

READ AND SAVE THESE INSTRUCTIONS!

• This is an electric device with moving components.There is the possibility of fire, electric shock, or injury to persons. Ensure all the

safety recommendations are adhered to in order to minimize this risk.

• Disconnect all power and unplug the unit before you inspect, clean or perform maintenance on the components of the unit.

• Never reach into the unit when it is running; you could become entrapped by the v-belt or injured by the rotating fan blades.

• The metal frame edges are sharp; don't run your hand along them. Be careful and wear gloves when you reach under the frame to

inspect the PVC pipes and mesh socks.

• A GFCI (Ground Fault Circuit Interrupter) is recommended for use with this product.

• If pads and grates are removed for servicing, they must be replaced prior to operating unit.

Start Unit -Turn Water pump on 5-10 minutes

before running blower. To wet evaporative cooling

pads.

Shut Down -Turn Pump off and run only blower until

evaporative cooling pads are dry. This prolongs the

life of the pads.

WARRANTY- VOID IF YOU RUN THE PUMP

WITHOUT WATER.

CAUTION - ALWAYS TURN OFF AT SWITCH AND

DISCONNECT POWER BEFORE REMOVING

EVAPORATIVE COOLING PADS FOR CLEANING

OR INTERNAL MAINTENANCE.

CLEANING- Clean pads a minimum of once every

two weeks. Remove pads from unit and clean with

garden hose only - DO NOT use chemicals or high

pressure hose.

WC-1HP Specifications

•Height and Width - 33" X 33" wide X 54" high (with casters and directional blower duct)

•Shipping Weight - 225 pounds

•Blower - Double-Inlet Centrifugal

•Motor - 1 HP, 115V 2 speed, 60 HZ (also available in 230V and 50 HZ)

•Pump - Submersible pump, Vane Type, 280 GPH (Gallons Per Hour)

•Pump Filter - Washable Polyethylene Filter

•Pump Discharge Filter - 480 Micron Stainless Steel

•Reservoir Capacity - 24 Gallons

•Optional Water Supply - Standard 3/4" hose connection (garden hose size)

•Housing - High impact ABS plastic w/UV protection

•Evaporation Media - Chemically treated cellulose paper

Figure WC-1HP-04.WayCool®Evaporative Cooler Overview

Actual WC-1HP WayCool®varies

slightly from unit shown here.

WC-1HP Unit Description

The WayCool®evaporative cooler is a completely self-contained, portable unit capable of delivering 40 MPH velocity of air with a temperature

drop of up to 20°.The unit is composed of:

• Level-controlled water supply system

• Cooling pad assembly

• Motor-driven blower and ductwork

• Controls

• Frame and housing

The bottom is made of high impact ABS plastic and holds approximately 24 gallons at normal operating level (about 5" deep).

A float-operated valve automatically maintains proper water level when the unit is connected to a water supply.

The bottom rests on, and is fixed to, an aluminum cradle.The bottom, in turn, is secured to the aluminum frame. Four casters (2 locking, 2

regular) are attached to the underside of the aluminum cradle.

A pump draws water from the bottom and discharges it through the vinyl hose to the PVC pipes located above the cooling pads. The PVC

pipes distribute water onto the top of the cooling pads; saturating them. Excess water drips back into the bottom through the holes in the

cooling pad support channels.

The cellulose cooling pads sit in support channels and are held in place by plastic retaining grates.The grates also help prevent damage to

the cooling pads.Two pad sections fit in each side of the unit (total eight sections) to totally enclose the unit.

The blower is hung from the top of the frame and powered by a belt driven 1HP electric motor.The blower draws room air through the cooling

pads where it picks up moisture and cools by evaporation.The blower then discharges the cooled air.

Note: It is important the cooled space has sufficient air openings so the warmer air can flow out and be replaced by the cooled air.

A closed-in space or high humidity will reduce the cooling effect.See Unit Placement and Other Considerations in the "Operations

and Maintenance" section of this manual.

A screen covers the discharge duct to prevent foreign objects from entering the blower. A threaded rod screws through a threaded brace

above the screen to hold the blower duct in position. A plastic knob secures the blower duct to the rod.The blower duct is made of a tough,

durable plastic and can be manually rotated 360 degrees to provide cool air in any direction without moving the unit.

Note: Water weighs about eight pounds per gallon, so when the unit is full, it weighs over 375 pounds. During setup and before

startup, place the unit in the desired location and then fill the bottom. Do not attempt to lift the unit once it is filled and be careful

to avoid spills when moving it; even over smooth ground. Do not try to push it over rough or soft ground as you can overstress

the wheels and frame and cause structural and component damage, which is not covered by warranty.

Water Supply System

Actual WC-1HP

WayCool® varies slightly

from unit shown here.

The bottom can be supplied continuously with an ordinary garden hose by attaching the supplied hose adapter (see Figure WC-1HP.07)

to the fill connection, or it can be filled manually.

With a continuous water supply connected, the float valve in the bottom (like the one in your toilet tank) rises and falls with the water level.

A linkage attaches the float to the shutoff valve in the fill connection. As the water level rises to normal operating level (about 5" deep), the

float valve shuts off the water supply. When the water level drops, the float valve reopens to maintain a normal operating level.

After unplugging the unit, the bottom can also be manually filled with a hose or bucket; if a hose connection is impractical. Simply remove

any of the plastic retaining grates and one of the cooling pad sections and place the hose, or pour the water, directly into the bottom.

When you fill the bottom manually it can be filled to a higher level, but make sure someone monitors the filling operation to avoid

overfilling and flooding.

Note:Water damage due to overfilling is not covered by the warranty.

Note:When you run the unit and manually fill it, check the water level frequently so it does not run dry. Operating the pump

without water will damage it or reduce its service life.This is not covered by the warranty.The cooling effect also stops if the

pads dry.

Note: Pads and grates must be replaced before operating unit.

Figure WC-1HP.05 - Water Supply System

Water Supply System

A drain in the bottom allows you to drain the unit for cleaning and maintenance. A drain cap on the underside of the aluminum tray covers

the drain during operation. Make sure the cap is in place before you fill the bottom.The drain cap should be finger-tightened only.

The pump is attached to a bracket, which in turn is fixed to the blower housing.The bracket holds the pump in its proper position on top of

the foam filter and slightly above the bottom; allowing sufficient space for water to enter the pump suction.

The pump can be easily removed and replaced with the services of a qualified electrician.

A small plastic screen covers the pump inlet to prevent foreign matter from entering and damaging the pump impeller.The screen snaps in

place and can be easily removed for inspection or cleaning.

The pump sits on a foam filter; somewhat like a sponge.The filter traps dirt that could enter the water distribution system and build up on

the cooling pads; reducing their effectiveness. Dirt could also accumulate in the PVC pipes and plug up the spray holes.

The pump discharges through a fine, washable screen filter which decreases the contamination of the cooling pads and water system.The

discharge filter casing is a clear plastic so dirt buildup on the internal screen is easily visible. As dirt builds up, water flow to the cooling

pads is reduced and performance decreases.The clear filter housing is threaded and screws into the filter body for easy removal to

access the screen.

Note: A dirty water supply will quickly reduce the unit's performance and the unit will require more frequent cleaning to maintain

cooling effectiveness. Always try to use a filtered, treated water supply.

A clear vinyl hose connects the pump to the filter. From the filter, a "T" connector supplies two lines that run along the bottom and up

opposite frame corners to supply the PVC pipe with water. Each vinyl hose connects to two PVC pipes, which run horizontally along the

top of the frame above the cooling pads.

The PVC pipes have a series of holes that run the full length of the pipe. Each PVC pipe is covered with a plastic mesh sock which helps

break up the water as it leaves the spray holes.This gives a more even water distribution across the cooling pad and reduces splashing.

The holes direct the water inward at a 90° angle to continuously saturate the cooling pads from the top down. Excess water drains back to

the bottom through drainage holes in the bottom support channels which support the cooling pads.

Note:Water cleanliness has a major effect on the cooler's performance. Use a clean water supply and consider a water softener

if your water is hard. Dissolved solids in hard water deposit on the cooling pad surfaces and reduce the airflow through the unit

and therefore the amount of evaporation.

Figure WC-1HP.06 - Pump

Pump Impeller Plasitc Screen

Cooling Pad Assembly

The cooling pads are critical for proper, efficient cooler operation.They are made of laminated cellulose (paper) fibers and arranged to

give a large surface area for evaporation and to provide a rigid structure.The shape of the cells allows high velocity airflow through the

pad at a minimum pressure drop. At the same time, the air passages between the cells force the incoming air to impinge on the wet cell

surfaces and maximize evaporation.

Note:The WayCool® evaporative cooler also acts as an air filter and removes dust and other particles from the air.This dirt

collects on the cooling pads and lowers cooler efficiency.The pads should be cleaned at least weekly and more frequently in

dusty conditions. See Regular Cleaning under "Operation & Maintenance".

The pump supplies a continuous flow of water over the pads causing a "sheet flow" which constantly replaces the water lost to evaporation

and keeps the pads saturated.

One cubic foot of the cooling pad material holds about a gallon of water during operation. One cubic meter holds about 100 liters of water.

Note:The cooling pads are relatively strong but are subject to crushing, especially when wet. Always run the unit with the plastic

retaining grates in place and handle them carefully when you clean them. Crushed cells reduce the total airflow through the unit

and therefore lowers it's cooling capacity.

The cooling pad sections, two sections for each side (eight sections total), sit in metal channels at the top and bottom of the unit.The

channels hold the cooling pads in position and form four sidewalls to completely enclose the unit.

The top channels house the PVC pipe, which run horizontally along the channel directly above the cooling pads.The bottom channels

have a series of holes drilled through them to allow excess water flowing down the cooling pads to return to the bottom.

The plastic retaining grates fit in front of the cooling pads and sit in the same channels as the pads; holding them in place and protecting

them from accidental damage.The plastic grates and cooling pads are easily

removed by placing a flat blade under the bottom and lifting upwards, then outwards. Once one pad is removed, the others can be lifted up

and out by hand without using a blade.

Note: Do not remove or handle the cooling pads when they are wet, as they damage easily. Run the blower without the pump

until pads are dry. With normal care, the pads should last at least two seasons. Abuse or mishandling will reduce their

effectiveness and shorten their life.

Table of contents

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