Document

CO60PM Evaporative Air Cooler

EVAPORATIVE AIR COOLER SERVICE MANUAL
CAUTION: Before servicing the unit, read the “Safety Precautions” in this manual. Only for authorized service.
MODEL NO.: CO60PM (FOR INDOOR & OUTDOOR USE)
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CONTENT

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1. Preface 1.1. Safety Precautions 1.2. Insulation Resistance Test 1.3. Specifications 1.4. Features 1.5. Warning & Safety Rules 1.6. Parts Description 1.7. Operations 1.8. Cleaning & Maintenance
2. Disassembly Instructions 2.1. How To Change Honeycomb Cooling Media 2.1.1. Back Panel 2.1.2. Back Honeycomb Cooling Media 2.1.3. Right Side Panel 2.1.4. Right Side Honeycomb Cooling Media 2.1.5. Left Side Panel 2.1.6. Left Side Honeycomb Cooling Media 2.2. How To Change Switch 2.2.1. Switch Box 2.2.2. Switch(cool/speed/swing) 2.2.3. Wiring Color Connection 2.3. How To Change Water Pump 2.3.1. Water pump pipe and water pump clip 2.3.2. Cool Switch And Wiring Connector 2.3.3. Water Pump Wiring Connection 2.4. How To Change Main Motor 2.4.1. Speed Switch And Wiring Connector 2.4.2. Fan Blade And Fan Motor 2.4.3. Main Motor Wiring Connection 2.5. How To Change Swing Motor 2.5.1. Swing Switch And Wiring Connector 2.5.2. Swing Motor And Swing Motor Wheel 2.5.3. Swing Motor Wiring Connection
3. Troubleshooting Guide 3.1. Outside Dimensions 3.2. Cooling System 3.3. Troubleshooting Guide
4. Schematic Diagram 4.1. Wiring Diagram 4.2. Wiring Color Description
5. Exploded View
6. Replacement Parts List

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1. PREFACE

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This manual is designed to provide you with important service information. Be sure to read the safety precautions prior to servicing the unit.

1.1 Safety Precautions
1 When servicing, set the POWER of the CONTROL PANEL to OFF and unplug the power cord.
2 Observe the original lead dress. If a short circuit is found, replace all parts which have been overheated or damaged by the short circuit.
3 After servicing, make an insulation resistance test to prevent the customer’s exposure to shock hazards.

1.2 Insulation Resistance Test
1 Unplug the power cord and connect a jumper between 2 pins. 2 The grounding conductor (green or green & yellow) is to be open. 3 Measure the resistance value with an ohm meter between the jumper lead and each exposed
metallic part on the equipment at all MODES (except POWER OFF). 4 The value should be over 1 M.

1.3 Specifications

MODELS
ITEMS Power Supply Input (W) Running Current (A) Fan Type Fan Speeds Operation Control
Air Direction Control
Protector
Filter
Power Cord Water Fill System
Drain System Water Tank Capacity Net Weight Outer Dimension (W x D x H)

CO60PM
120V, 50Hz 220W 1.83A
16” metal fan blade 3
Control Panel Vertical Louver (Right & Left) – Auto Horizontal Louver (Up & Down) – Manual Fan Motor Internal Thermal Protector Water Pump Internal Thermal Protector
3 Sides Honeycomb media (Back 591.5 x 538 x 40mm 2 Sides 591.5 x 270 x 40mm) 2.5 m (3 wire with grounding)
Manual (from top cover) Auto (from continuous water supply connection)
Manual drain plug 15.8 US Gallon / 60 L*
39.2 lbs / 17.8 kg 27.56” x 18.35″ x 40.0″ 700 x 466 x 1017 mm

*Due to continuous updates to product on account of compliance requirements, tank capacity may be changed by manufacturer over a period of time

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CONFIDENTIAL
Website: http://www.honeywellaircoolers.com
Features
Three functions in one: air cooler, humidifier & fan. Very powerful airflow: up to 2610 m3/hr or 1540 CFM Cooling area: up to 80 m2 or 850 ft2 Air throw distance: 11 m or 36 ft. 3 sides honeycomb cooling media for optimum performance. Oscillating louvers. Mounted with castors for easy mobility. 3 speeds: high, medium and low. 60 liter water tank capacity.
1.4 Warning & Safety Rules
WARNING – This appliance is intended for use in outdoors, home or office environment. Any other use is not recommended by the manufacturer and may cause fire, electrical shocks or other injury to person or property.
When using electrical appliances, basic safety precautions should always be followed: Your cooler should run on 120V Volt AC, 50 Hz current only. Check the household voltage to ensure it matches the appliance’s rate specification. Before operating the product remove it from its packaging and check it is in good condition. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or
similarly qualified persons in order to avoid a hazard. DO NOT operate any product with a damaged cord or plug. DO NOT use an extension cord with this appliance. DO NOT run power cord under carpeting, or cover with rugs or runners. Arrange the cord
away from areas where it may be tripped over. Unplug the appliance during filling and cleaning. Always unplug the appliance from the power source before servicing or removing the unit. Disconnect the power supply before servicing or cleaning operation. Remove the power cord from the electrical receptacle by grasping and pulling on the power
cord plug-end only, never from the cord. DO NOT use the product in areas where gasoline, paint or other flammable goods and
objects are stored. When using the `’COOL” setting, please check the water indicator level to ensure it is above
minimum water level. Operation of this unit on the `’COOL” setting on or below minimum water level could result in damage to the water pump. DO NOT attempt repair or adjustment to any electrical or mechanical functions of the cooler. Verify that the voltage power source matches the appliance electrical specifications. Improper voltage will burn out the blower/fan, oscillating and/or pump motor windings and will void the warranty. DO NOT cover the air inlet or outlet on the appliance as this may cause motor damage. DO NOT insert or allow objects to enter any ventilation, exhaust opening or water tank as this may damage the product and could cause an electrical shock or fire. DO NOT operate with media removed as this will overload and damage the motor. To reduce the risk of fire or electric shock, do not use this fan with any solid state speed control device. DO NOT leave the appliance operating unattended for any extended period of time. This appliance is not intended for use by persons (including children or elderly) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
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DO NOT let children play with any appliance packaging or plastic bags. Injury may result from such practice.
Children should be supervised to ensure that they do not play with the appliance. If the unit is damaged or it malfunctions, do not continue to operate it. Place the unit on the floor only. This product is not intended for use in wet or damp locations. Never locate the product
where it may fall into a bathtub or other water container. DO NOT use in bathrooms. When it is not in use always store in a dry area. Don’t use indoor extension cords outside. Look for extension cords specifically marked for outdoor use. Look for extension cords that have a GFCI (Ground Fault Circuit Interrupter) built in. Make sure the amperage rating for the extension cord is higher than the amperage rating for the appliance. Check labels and owner’s manuals on the appliance and the extension cord for amperage ratings. Power cords have to be contained. If they must run along the ground, make sure every inch of them is secured so they will not be tripped over. The wiring and connections must be waterproof. Be sure the connections (to the air cooler) never get wet. Your unit is waterproof, but everything attached to it must be waterproof, too. Set up your unit so it cannot be tripped over or wobble loose. It must rest on a solid support. NOTE: OPERATE THE UNIT WHEN THE WATER TANK IS FILLED WITH CLEAN WATER 1.5 Parts Description
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1.6 Operations Control Panel:

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NOTE: Speed control may be marked as High/Med/Low in certain units.
Operation Instructions:
Cooler Location: Place the cooler in front of an open door or window. Ensure that there is adequate cross ­ ventilation in the room by leaving a door or window open opposite the cooler. Following these guidelines will ensure your cooler will work as effectively as possible.
Not an Air Conditioner: The evaporative air cooler is not an air conditioner as it does not use a compressor or refrigerant gas. It should not be expected to cool as efficiently as a refrigerated air conditioner. The recommended maximum relative humidity level is 60% or less, which allows a noticeable temperature decrease. The temperature decrease will be greater in drier climates because higher evaporation occurs when the humidity is low.
The evaporative air cooler should not be used in enclosed spaces. It must be kept level and there must be water in the water tank. The room should have doors and windows opened to allow free air flow. The evaporative air cooler works best when placed near an open window, so that outside air is drawn into the evaporative air cooler, the air circulates in the room, and then exits via the door. The maximum cooling effect is felt when a person is in the flow of air coming out of the evaporative air cooler.
The evaporative air cooler can also be used to humidify dry air during cool weather. To be used for humidification the windows and doors should be closed to allow the humidified air to accumulate. The evaporative air cooler is not an air conditioner as it does not use a compressor or refrigerant gas. It should not be expected to cool as efficiently as a refrigerated air conditioner.
NOTE: When the product is used for the first time the Honeycomb Cooling Media will have an odor which will dissipate in a week or so of initial use.
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FILL WATER: Water can be filled into the air cooler by: Water Inlet (Manually) Water / Ice can be put into the tank through the top opening. There is a hole for water to flow into the tank. Continuous water supply (Auto Refill) Connect a garden hose to the continuous water supply inlet.
Control Knobs Speed / On – Off Connect to the power supply and turn the Speed knob. The fan will start. Change the speed from 1 for Low to 2 for Medium to 3 High. To switch OFF the unit turn the Speed knob to “0”.
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Cool To begin cooling the desired area turn the “COOL” switch ON. The water pump will operate. You can feel the cooler air after the Honeycomb media is completely wet. Swing Vertical Louvers Turn the “SWING” switch ON. The louvers will begin to move from right to left automatically. Manually adjust the horizontal louvers to change vertical airflow. Horizontal Louvers Manually adjust the horizontal louvers to change vertical airflow. CLEANING & MAINTENANCE
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2. DISASSEMBLY INSTRUCTIONS

WARNING ­ Before the following disassembly, POWER is set to OFF and disconnected the power cord.

2.1 How To Change Honeycomb Cooling Media(3 sides)

2.1.1 Back Panel. Use screw driver to remove 5 galvanized screw with plate head (ST4*12) on the back panel.

Remove the back panel.

2.1.2 Back Honeycomb Cooling Media. Use screw driver to remove 4 Remove the honeycomb galvanized screw with plate holder. head(ST4*12) on the honeycomb holder.

Remove the honeycomb cooling media from the back panel.

2.1.3 Right Side Panel. Use screw driver to remove 4 galvanized screw with plate head (ST4*12) on the right side panel.

Remove the right side panel.

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2.1.4 Right Side Honeycomb Cooling Media. Use screw driver to remove 4 Remove the honeycomb galvanized screw with plate holder. head(ST4*12) on the honeycomb holder.

Remove the honeycomb cooling media from the right side panel.

2.1.5 Left Side Panel. Use screw driver to remove 4 galvanized screw with plate head (ST4*12) on the left side panel.

Remove the left side panel.

2.1.6 Left Side Honeycomb Cooling Media. Use screw driver to remove 4 Remove the honeycomb galvanized screw with plate holder. head(ST4*12) on the honeycomb holder.

Remove the honeycomb cooling media from the left side panel.

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2.2 How To Change Switch

Remove the back panel follow the procedure 2.1.1 Remove the right side panel follow the procedure 2.1.3

2.2.1. Switch Box Use screw driver to remove 4 galvanized screws with plate head(ST3*12) on the switch box.

Remove switch box.

2.2.2. Switch(cool/speed/swing) Use screw driver to remove 2 Cool switch galvanized screws (ST3X10) on each switch of the control panel(cool/speed/swing).

Speed switch

Swing switch

2.2.3. Wiring Color Connection Wiring color connection refers to part 4.2 Wiring Color Description.
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CONFIDENTIAL
Website: http://www.honeywellaircoolers.com
2.3 How To Change Water Pump
Remove the back panel follow the procedure 2.1.1 Remove the right side panel follow the procedure 2.1.3 Remove the switch box follow the procedure 2.2.1
2.3.1 Water pump pipe and water pump clip. Remove the water pump pipe. Use screw driver to remove 2 SS screws(ST4*12) on the water pump clip.

2.3.2 Cool Switch And Wiring Connector Use screw driver to remove 2 Remove the brown wire on the galvanized screws (ST3X10) on cool switch. cool switch of the control panel.

Remove the wiring cap (below picture shown) to get the water pump. Note: connection is between water pump and N wire of power cord.

2.3.3 Water Pump Wiring Connection Water pump wiring connection refers to part 4.2 Wiring Color Description.

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2.4 How To Change Fan Motor

Remove the back panel follow the procedure 2.1.1 Remove the right side panel follow the procedure 2.1.3 Remove the switch box follow the procedure 2.2.1

2.4.1 Speed Switch And Wiring Connector. Use screw driver to remove 2 Remove the white/yellow/ galvanized screws (ST3X10) blue wire on the speed on speed switch of the control switch. panel.

Remove the wiring cap (below picture shown). Note: connection is between fan motor COM wire(black) and N wire of power cord.

Remove the wiring cap (below picture shown). Note: connection is between motor and power cord earth wire.

Remove the wiring cap (below picture shown). Note: connection is between capacitor and the motor.

Remove the wiring cap (below picture shown). Note: connection is between capacitor and the motor.

2.4.2 Fan Blade And Fan Motor Use screw driver to remove 1 Remove the fan blade. galvanized screws (M6X14) on fan blade.

Use screw driver to remove 8 galvanized screws (M5X12) on fan motor to get the fan motor.

2.4.3 Main Motor Wiring Connection Main motor wiring connection refers to part 4.2 Wiring Color Description.
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2.5 How To Change Swing Motor

Remove the back panel follow the procedure 2.1.1 Remove the right side panel follow the procedure 2.1.3 Remove the switch box follow the procedure 2.2.1

2.5.1 Swing Switch And Wiring Connector. Use screw driver to remove 2 Remove the pink wire on the galvanized screws (ST3X10) on swing switch. swing switch of the control panel.

Remove the wiring cap (below picture shown). Note: connection is between swing motor and N wire of power cord.

2.5.2 Swing Motor And Swing Motor Wheel. Use screw driver to remove 2 Remove the swing motor. galvanized screws(ST4X12) on swing motor.

Use screw driver to remove 1 galvanized screw(ST3*8) on the swing motor wheel.

Remove the swing motor wheel.

Get the swing motor.

2.5.3 Swing Motor Wiring Connection Swing motor wiring connection refers to part 4.2 Wiring Color Description.
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3. TROUBLESHOOTING GUIDE

CONFIDENTIAL Website: http://www.honeywellaircoolers.com

3.1 Outside Dimensions

Width: 700 mm (27.56”) Depth: 466 mm (18.35”) Height: 1017 mm (40.0”)
3.2 Cooling System Honeywell Evaporative Air Coolers are built to maximize energy efficiency and keep costs low. Warm air is drawn into the cooler through a dust and odor-reducing carbon filter and enters the Honeycomb Cooling Media. Water pumped from the tank pours over the honeycomb media. As the warm air passes through the media, the water absorbs the heat, naturally cooling and humidifying the air. A fan propels the cooled air out into the room. This no-compressor system cools naturally, efficiently and inexpensively.
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3.3 Troubleshooting Guide

The following troubleshooting guide is intended to address the most common symptoms and is by no means exhaustive. If symptoms persist, call a qualified service provider. Only a certified electrician should complete any electrical work. Unplug and disconnect the appliance from the power source before attempting to troubleshoot any of the following symptoms.

Problem No discharge of air

Possible Cause Cord is not plugged in.
Power is not on.

Solution Make sure power cord is plugged in and the supply switch is on.
Turn the unit ON.

Humidity output minimal to none
Water color yellowish at initial use
Abnormal noise inside the product
Musty or unpleasant odor

Water is below minimum water level in tank.
Water pump is damaged. Color fasts from honeycomb filter. Noise of water pump when water not up-to min water level.
Motor or blade problem.
When the Cooler is new.
Stale or stagnant water in water tank. Media mildewed or clogged.

Turn off the unit. Follow instruction to fill the water tank with clean water.
Replace the water pump according to the procedure 2.3. This is natural. After several use, the water color will be clean. Turn off the product. Add water, and then turn on the product again. Turn off and unplug the product or change the main motor according to the procedure 2.4. When the unit is used for the first time, the Honeycomb Cooling Media will have an odor, which will dissipate within a few hours of initial use. Drain, flush and clean water tank Replace media according to the procedure 2.1.

Not cooling

Pump is not turned on. Low or no water. Damaged water pump.

Check the water level and turn on the pump.
Replace the water pump according to the procedure 2.3.

NOTE: The form is only for reference. If any help, please call customer service.

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4. SCHEMATIC DIAGRAM
4.1 Wiring Diagram

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4.2 Wiring Color Description

Power Cord: (1) Brown (2) Blue (3) Green + Yellow

Live Neutral Earth (Ground)

Main Motor: (1) White (2) Yellow (3) Blue (4) Black (5) Red (6) Brown (7) Green + Yellow

High speed Medium speed Low speed Neutral
Earth (Ground)

Water Pump: (1) Brown (2) Blue

Swing Motor: (1) Pink (2) Pink

to speed switch(4) motor COM(black) to motor earth
to speed switch(1) to speed switch(2) to speed switch(3) to N wire of power cord to capacitor by end-closed connector to capacitor by end-closed connector to power cord earth
to pump control switch(1) to N wire of power cord
to swing control switch(1) to N wire of power cord

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5. EXPLODED VIEW

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6. REPLACEMENT PARTS LIST

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Sr.

PART NAME

1

Up/Down swing knob

2

Swing knob press board

3

Horizontal louver 1

4

Horizontal louver 2

5

Horizontal louver 3

6

Horizontal louver 4

7

Horizontal louver 5

8

Horizontal louver middle link

9

Horizontal louver press board A

10

Horizontal louver link A

11

Horizontal louver press board B

12

Horizontal louver link B

13

Swing/Cool knob

14

Speed knob

15

Control plane

16

Swing/Cool switch

17

Speed switch

18

Air outlet panel

19

Front panel

20

Rubber washer

21

Vertical louver base

22

Short vertical louver

23

Long vertical louver

24

Switch box

25

Side panel

26

Side honeycomb pad

QUANTITY 2 1 2 2 2 2 2 1 2 2 2 2 2 1 1 2 1 1 1 20 4 2 2 1 2 2

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27

Side water distributor cover

28

Side water distributor

29

Side honeycomb pad holder

30

Swing motor

31

Swing motor wheel

32

Vertical louver drive

33

Base of fan motor frame

34

Fan motor frame

35

Fan blade assembly

36

Fan motor

37

Top cover

38

Water fill door

39

Four directions pipe

40

Back water distributor tube

41

Left/Right water distributor tube

42

Water fill door link

43

Back water distributor

44

Back water distributor cover

45

Left stand pillar

46

Back honeycomb pad holder

47

Back honeycomb pad

48

Back panel

49

Right stand pillar

50

Motor capacitor

51

Suction pipe

52

Water fill pipe

53

Float cap

54

Float holder

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2 2 4 1 1 1 2 4 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 1 1

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55

Float tube

1

56

Water level board

1

57

Vertical louver link

1

58

Water tank

1

59

Water pump

1

60

Water pump clip

1

61

Continuous water supply connection

1

62

Castor

2

63

Castor with brake

2

64

Water drainage plug

1

65

Silica gel ring

1

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