owner`s guide - Phoenix Manufacturing Inc.

owner`s guide - Phoenix Manufacturing Inc.
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Congratulations: You have purchased a product of superior
performance and design, which will give the best service when
properly operated and maintained. These coolers can be used as
convenient, roll-around spot coolers.
This guide was designed to provide you with the information
needed to assemble the unit for roll-around spot-cooling. It also
contains information on how to safely operate, inspect, maintain
and troubleshoot your evaporative air cooler.
The first section, Assembly, contains instructions to prepare your
cooler for roll-around portable service. The second section,
Maintenance, contains operational and maintenance instructions
to aid in keeping your unit in good working order, while
Troubleshooting includes information to help diagnose and repair
commonly encountered problems.
02-999-1773 – (Rev - )
Install drain bushing and standpipe
Install overflow drain bushing in bottom
of cooler. Slide rubber washer over drain
bushing, push drain bushing through
bottom of cooler, and tighten nut. Screw
plastic overflow standpipe into the drain
bushing and tighten snugly (hand-tight)
to prevent leakage. Where conditions
allow for drainage, connect a drain line
(garden hose) to drain bushing and drain
Your evaporative air cooler was thoroughly tested and inspected
before leaving the factory. This is your guide to economical, trouble
free comfort cooling over the years with reasonable care and regular
maintenance. Failure to follow these instructions may damage your
cooler, impair its operation and/or void the warranty.
Read it carefully.
Unpacking the unit
Figure 2
Remove the pad frames by slightly lifting the pad frame from the
bottom, pull outwards until clear of cabinet bottom pan, then
downwards until frame clears cabinet top. Remove the following
items from the cooler:
1. Box containing swivel casters and attachment hardware.
2. Plastic bag containing small parts, float valve, garden hose
adapter, hose nut, hose washer, o-ring.
3. Bag with hose adapter for float valve (roll-around use)
Install float valve and hose adapter
Attach the float valve to the cabinet as shown in The garden
hose adapter attaches to the brass inlet fitting on the float valve
(see). NOTE: verify that the hose washers are correctly in place.
Water connection and float adjustment
Move cooler to desired location (this should be a level area for
proper operation of the cooler).
1. Locate a knock-out in the bottom of any of the four corner posts.
2. Connect to water supply using a commercial grade of water
hose(not supplied with cooler, obtained separately) to the adapter on
the float valve and turn water on. CAUTION: water inlet pressure
should be limited to a maximum of 65 PSI to avoid rupturing the
water hose. If pressure exceeds this value, an inline pressure
regulator should be installed (obtainable from a local plumbing or
hardware store).
3. Check that all connections are tight by visually inspecting hose,
float valve, etc. for leakage.
4. Set float valve for a water depth of 2.5”. The float is adjusted by
lightly bending the float rod.
Gather tools required to assemble & install unit
The following tools are required to assemble the unit:
7/16” box or open end wrench
6” crescent wrench
3/8” box or open end wrench
1/4” nut driver
1. Open parts box & remove casters from parts bag. Assemble
each caster (Fig.1) per caster plate using supplied 1/4-20 nuts &
carriage bolts.
2. Place casters w/ brakes on the front of the unit, and the casters
without the brakes should be mounted on the back of the cooler. Use
4 of the 1/4-20 bolts from the parts bag to secure all 4 of the casters
to their respective caster plates. Apply brakes before lifting cooler
upright to complete
Figure 3
Cooler checkout and first time start-up
Congratulations, once you re-install the pad frames, your roll-around
Master Blaster cooler will be complete and ready for use. Please
proceed to the Pre-startup inspection checklist on page 3 before
starting unit for the first time.
Motor and blower wheel check
Check motor mounting to be sure all screws and nuts are tightened
down properly. Rotate blower wheel by hand to see that it moves
freely without rubbing against housing.
Figure 1
Figure 4
02-999-1773 – (Rev - )
In case of trouble in any of these stages, refer to the Troubleshooting
Chart on page 6.
Electric Power
Cabinet Inspection Checklist
After initial start-up and during periodic inspections, check for and/or
observe the following: Refer to the Troubleshooting Chart on page 6
if necessary.
This cooler is designed for connection to 120 volt AC, 60
Hz (cycle) power only. NOTE: Improper voltage will void
the pump and/or motor warranties and may cause
serious personal injury or property damage.
This cooler must be plugged into a GFCI protected
receptacle, which has been properly installed in
accordance with all local and national codes. If you are
not sure that the receptacle is GFCI protected, consult
with a qualified electrician.
This cooler is equipped with a power cord having
equipment grounding conductor and grounding plug. Do
not attempt to defeat this safety device by removing the
grounding pin.
Guidelines and location
Always make sure that the roll-around unit is operated on a solid,
level surface strong enough to hold its weight (unit can weigh 270 lbs
when full). Make sure the two locking casters have been locked to
prevent the cooler from accidentally moving while in use. Use
caution when rolling the unit to avoid splashing or spilling of water.
Unless the move is for a short distance, it is best to drain the unit,
move it and then refill it in its new location.
Pre-Start-up Inspection Checklist
Before start-up of the cooler motor and pump for the first time, or at
the beginning of each cooling season, make sure all connections
and adjustments have been made.
Cooler is on a level surface, casters locked to prevent
unnecessary movement (prevent spillage).
 Power supply cord is plugged into a GFCI protected
receptacle; cord is secure from accidental damage.
 Drain and float valve installed.
 Water hose connected securely without leaks.
 Water faucet or supply is turned on.
 Float adjusted for proper water level.
 Pad frames and air outlet grille correctly installed.
 Pump impeller turns freely. Remove impeller cover
(see“Cleaning Pump”), and check rotation.
 Blower wheel, shaft, pulley and motor sheave set
bolts/screws are snug. (see figure 4 )
 Motor sheave / Blower pulley alignment is okay; belt tension
is okay (see for instructions).
Rocker-type control switches are used
to select the operating mode of the
cooler. These switches control fan
speed (FAN-HIGH/OFF/LOW) and the
pump operation (COOL-ON/OFF).
To eliminate a rush of warm air when
starting the cooler, be sure to turn the
pump (COOL) on for a few minutes
before turning on the blower motor
(FAN) in low or high speed.
Regular maintenance and periodic inspection is a key to long and
successful service of your Master Blaster Cooler. The cooler should
be serviced at least once a year or more often if required. For
maximum efficiency, longer life and appearance, every two months
during operation, the cooler should be inspected and cleaned.
Note: Do Not Undercoat the Water Reservoir
Your cooler's water reservoir is finished with our Peblar XT®
appliance-type finish. Asphalt-type cooler undercoating will not stick
to it. Undercoating will break free, clogging the pump and water
To verify and check out the cooler installation on initial start-up, the
following procedure should be followed.
Figure 5
Maintenance Schedule
Start-up Checklist
CAUTION: Never operate unit with pad frame(s) and/or
air outlet grille removed. This will result in an overloaded
condition and may damage the fan motor. The motor and
pump have an internal automatic thermal overload switch
that will shut the motor and/or the pump off if it
overheats! The motor and/or pump can restart
automatically when they cool down.
Leaks from water lines, pad frames, cabinet, etc.
Observe cooler pads for uneven wetting
Confirm water level setting is correct.
Verify full, even flow in water distribution system.
Blower wheel / motor rotates freely.
Belt condition / tension / alignment.
Check that set screws on pulleys, blower wheel are tight.
Check motor mounting and cabinet hardware.
NOTE: Do not use cooler cleaners, cooler treatments or other
chemical additives in this evaporative cooler. Use of any additives or
water treatment other than bleed-off will void your warranty and
impair the life of the cooler.
Before starting any maintenance operation, read all operating and
maintenance instructions and observe all cautions and warnings
Push “COOL” switch to ON position (pump on).
Verify that pump starts and pads are evenly wet.
Open windows, doors or vents in building.
Push “FAN” switch to LOW position (low speed on).
Observe that motor starts and runs. Check high-speed
function by turning “FAN” switch to HIGH (high speed on).
When switching from Low to Hi speed you should pause in
center position (OFF) for 2 seconds to extend motor life.
02-999-1773 – (Rev - )
CAUTION: Disconnect all electrical power to the
Cleaning Water Pump & Hose
cooler by removing plug from receptacle before
attempting to install, open, or service your cooler.
CAUTION: Do not allow pump to fall over and become
Even while routinely inspecting or servicing the inside, the cooler can
be accidentally started. Keep all personnel away from the cooler and
electrical supply when you are working on it. Before servicing or
cleaning unit, switch “COOL” and “FAN” to the OFF position and
remove power cord from receptacle.
Clean water pump and hose assembly as follows:
1. Unplug pump cord, remove mounting bracket screw and
remove pump from cooler. Shake gently to remove water.
2. To prevent breakage, carefully release and remove impeller base
plate from the pump body. (see figure 9)
3. Using a mild detergent solution and clean cloth, clean deposits
from pump screen, around impeller and base plate.
4. Spin impeller to dislodge any foreign material.
5. Remove any foreign material in the adapter between the pump
and hose, or between the hose and the water
distributor assembly.
6. Rinse and reinstall impeller base plate.
7. Reinstall pump and reconnect pump cord.
submerged; water will damage pump motor.
All foreign materials, scale, salt deposits, lime, etc. can and should
be removed from louvers, bottom pan, and other components. Your
cooler's long lasting finish can be brought to like-new condition by
using warm water and a soft cloth.
NOTE: Avoid using scouring pads, steel wool or wire brushes, as
these will damage the finish and encourage corrosion.
Maintenance & Inspection
CAUTION: Disconnect all electrical power to the
cooler by removing the plug from the receptacle before
attempting to install, open, or service your cooler.
IMPORTANT: Before operating cooler at beginning of
each cooling season, turn blower wheel, cooler motor
and pump motor shafts by hand to make sure they turn
freely. Failure to do so may result in burning out the
Periodic inspection of your cooler will enhance long, trouble-free
service life. For maximum efficiency, every two months during
operation, or any time the cooler is opened, the cooler should be
inspected. Some suggested items:
Check for leaks from pad frames, cabinet, etc.
Are there any dry spots on the media when cooler is in
Are bolts, nuts and set screws snug?
Are the bearings making unusual noises?
Does the blower wheel turn freely?
Is float level set correctly?
Is water in the bottom pan clean?
Belt condition / tension / alignment?
Figure 6
Drain the cooler cabinet (with power off and
panels removed) as follows:
1. Connect a drain hose to the drain fitting on the bottom of
the reservoir, if not already connected to drain line.
2. Remove overflow standpipe from the drain fitting.
3. Drain, clean and dry reservoir.
Set Screws, Bolts and Nuts
The hardness, adhesion and smoothness of the internal and external
finish on your cooler makes it extremely unlikely that scratches or
chipping will occur. In the event that finish damage does occur, it
should be promptly repaired by the following procedures:
Check torque on set screws and cabinet hardware:
 Motor and Blower Pulley set screws (95 in-lbs.)
 Blower Wheel set screws (1 per side, 150 in-lbs)
 Cabinet hardware (25 in-lbs)
1. Sand the area around bare metal spots.
2. Prime and paint with a quality paint.
CAUTION: Disconnect all electrical power to the
cooler and insure that belt is not rotating before adjusting
belt tension.
Do not use asphalt type cooler undercoat material in water
reservoir. Undercoat will break free, clogging the pump and
water distributor.
Motor Bearings
Some motors used in Master Blaster coolers have ports for
lubricating the motor and are oiled at the factory. They should be
checked after 20-30 days of operation. If the need for oiling is
indicated, see the motor nameplate for specific instructions on re-
Adjust Belt Tension
Each time you inspect your cooler, be sure to check belt tension on
motor/blower assembly. Check belt condition and replace it if trays or
cracks appear. Check alignment of blower pulley with motor pulley.
02-999-1773 – (Rev - )
lubricating the motor. Under normal use, these motors require oiling
about every 12 months of operation.
Do Not Over-Oil.
Blower Shaft Bearings
Blower shaft bearings need periodic lubrication. The oil cups on the
bearings should be filled with SAE 30W non-detergent oil when
necessary. Under normal use, oiling is required every three months
of operation.
Do Not Over-Oil.
Pump Bearings
The pump motor bearings are permanently lubricated
Changing Cooler Pads
Scale may build up on outside of the Rigid Pad, which will restrict the
airflow. The Rigid Pad should be removed and replaced if scale
cannot be removed using the methods described below. Failure to
do so may result in premature failure of components.
Replace pads as follows:
1. Remove pad assembly from cabinet.
2. Remove pad retainers from frame. Carefully remove all rigid
media from the louver panel, paying attention to the bottom of the
medial as there is a cut made at the bottom. Remove and discard old
3. If passages are clogged or pad is dirty, hose off the inlet face of
the pad. Light, gentle brushing of the inlet edges of the pad with a
stiff bristle brush (don’t use a wire brush) will not harm the pad and
will remove stubborn scaling.
4. If necessary, replace with new rigid media pads. Aspen,
expanded paper or other types of evap cooling pads will not work
and will void your warranty.
5. Lay new rigid media pads into the louver panel assy., paying
attention to how the slit at the bottom of the pad is oriented.
6. Return the rigid media retainer so that it fits on top of the rigid
media pads and holds them securely against the louver panel.
7. Pre-soak pads and check for air gaps along edges, reinstall pad
frames into unit.
8. Start pump and allow troughs to fill… check water level in troughs
by slightly tilting each pad frame out.
Figure 7
When ordering replacement parts, always refer to the serial and
model number of your cooler. Use the part numbers listed in the
accompanying parts list, as illustrated in the diagrams for your
02-999-1773 – (Rev - )
TROUBLESHOOTING GUIDE: Should an obvious problem occur with your cooler consult the following table. If you
cannot correct the problem, or if it persists, contact qualified service personnel.
02-999-1773 – (Rev - )
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