Cumberland Stacked Evaporative Cooling System Owner's manual

Brand: Cumberland

Model: Stacked Evaporative Cooling System

Type: Owner's manual

PNEG-2161

Stacked Evaporative Cooling

System

Installation Manual

PNEG-2161

Version: 3.0

Date: 02-07-20

2 PNEG-2161 Stacked Evaporative Cooling System

NOTE: To achieve maximum efficiency and performance while ensuring long life from your

Recirculating Cooling System, it is imperative that it be installed and maintained correctly.

Please read all instructions carefully before beginning installation.

Table of Contents

PNEG-2161 Stacked Evaporative Cooling System 3

Contents

Chapter 1 Safety .....................................................................................................................................................4

Safety Guidelines ...................................................................................................................................4

Cautionary Symbols Definitions .............................................................................................................5

Safety Cautions ......................................................................................................................................6

Safety Sign-Off Sheet ............................................................................................................................8

Chapter 2 Introduction to Evaporative Cooling ..................................................................................................9

Dry Bulb Temperature ............................................................................................................................9

Wet Bulb Temperature ...........................................................................................................................9

Wet Bulb Depression .............................................................................................................................9

Evaporative Pad Cooling Efficiency .......................................................................................................9

Enthalpy .................................................................................................................................................9

Specific Volume .....................................................................................................................................9

Dew Point Temperature .........................................................................................................................9

Relative Humidity ...................................................................................................................................9

Chapter 3 Evaporative Cooling Theory and Benefits .......................................................................................10

Evaporative Cooling Theory .................................................................................................................10

Benefits ................................................................................................................................................10

Placing the Evaporative Cooling System .............................................................................................10

Chapter 4 Evaporative System Installation .......................................................................................................11

Framing Rough Opening ......................................................................................................................11

Open Top Cover Installation ................................................................................................................12

Installing the Middle Section ................................................................................................................15

Installing the Bottom Trough Section ...................................................................................................21

Jet Pump System .................................................................................................................................24

Installing the End Panels ......................................................................................................................27

Open Top System ................................................................................................................................29

Jet Pump System Parts ........................................................................................................................32

Installing the Float Valve Assembly .....................................................................................................35

Wiring the Re-Circulating Cooling System ...........................................................................................35

Chapter 5 Operation and Maintenance of the Re-Circulating Cooling System ..............................................36

Initial Start-Up New Media ...................................................................................................................36

Normal Operation .................................................................................................................................36

Annual Shut Down and Start-Up Process ............................................................................................37

Annual Start-Up ....................................................................................................................................37

Algae/Bacteria Control .........................................................................................................................38

Maintenance/Water Chemistry .............................................................................................................39

Re-Circulating Open Top Cooling System Parts ..................................................................................40

Chapter 6 Warranty ..............................................................................................................................................43

4 PNEG-2161 Stacked Evaporative Cooling System

1. Safety

Safety Guidelines

Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is

written to help you understand safe operating procedures and problems that can be encountered by the

operator and other personnel when using this equipment. Read and save these instructions.

As owner or operator, you are responsible for understanding the requirements, hazards, and precautions

that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.

Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in

SERIOUS INJURY or DEATH.

This equipment must be installed in accordance with the current installation codes and applicable

regulations, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted

before installations are made.

When necessary, you must consider the installation location relative to electrical, fuel and water utilities.

Personnel operating or working around equipment must read this manual. This manual must be delivered

with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the

equipment. ST-0001-4

1. Safety

PNEG-2161 Stacked Evaporative Cooling System 5

Cautionary Symbols Definitions

Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential

safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we

use the symbols that are defined below.

DANGER

WARNING

CAUTION

NOTICE

This symbol indicates an imminently hazardous situation

which, if not avoided, will result in serious injury or death.

This symbol indicates a potentially hazardous situation

which, if not avoided, can result in serious injury or death.

This symbol indicates a potentially hazardous situation which,

if not avoided, can result in minor or moderate injury.

This symbol is used to address practices not related to

personal injury.

This symbol indicates a general hazard.

This symbol indicates a prohibited activity.

This symbol indicates a mandatory action.

ST-0005-2

1. Safety

6 PNEG-2161 Stacked Evaporative Cooling System

Safety Cautions

Use Personal Protective Equipment

Eye

Protection

Hearing

Protection

Hand

Protection

Head

Protection

Respiratory

Protection Foot

Protection

Fall

Protection

• Use appropriate personal protective equipment:

• Wear clothing appropriate to the job.

• Remove all jewelry.

• Tie long hair up and back.

ST-0004-1

Follow Safety Instructions

• Carefully read all safety messages in this manual and

safety signs on your machine. Keep signs in good

condition. Replace missing or damaged safety signs.

Be sure new equipment components and repair parts

include the current safety signs. Replacement safety

signs are available from the manufacturer.

• Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without

instruction.

• If you do not understand any part of this manual or

need assistance, contact your dealer.

ST-0002-1

1. Safety

PNEG-2161 Stacked Evaporative Cooling System 7

Maintain Equipment and Work Area

• Understand service procedures before doing work. Keep area

clean and dry.

• Never service equipment while it is operating. Keep hands, feet,

and clothing away from moving parts.

• Keep your equipment in proper working condition. Replace worn

or broken parts immediately.

ST-0003-1

Sharp Edge Hazard

• This product has sharp edges, which can cause serious injury.

• To avoid injury, handle sharp edges with caution and always use

proper protective clothing and equipment

ST-0036-2

Install and Operate Electrical Equipment Properly

• Electrical controls must be installed by a qualified electrician

and must meet the standards set by applicable local codes

(National Electrical Code for the US, Canadian Electric Code,

or EN60204 along with applicable European Directives

for Europe).

• Lock-out power source before making adjustments, cleaning,

or maintaining equipment.

• Make sure all equipment is properly grounded.

ST-0027-4

1. Safety

8 PNEG-2161 Stacked Evaporative Cooling System

Safety Sign-Off Sheet

Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety

instructions. This sign-off sheet is provided for your convenience and personal record keeping.

Date Employee Name Supervisor Name

ST-0007

PNEG-2161 Stacked Evaporative Cooling System 9

2. Introduction to Evaporative Cooling

When non-saturated air comes in contact with free moisture and the two are thermally isolated from an

outside heat source, there is a transfer of mass and heat. Because the vapor pressure of the free water

surface is higher than that of the unsaturated air, water transfers in response to the differential. The

transfer involves a change of state from liquid to vapor, requiring heat of vaporization. The heat recovery

for this change of state comes from the sensible heat content of both the air and water, resulting in a drop

of temperature of both. As the temperature in the immediate vicinity of the interface drops and creates a

temperature differential within the air vapor mixture, a transfer of heat occurs as the whole system

changes to a thermodynamic balance. Since no outside heat is added during the process, total heat

content does not change. There is simply an adiabatic exchange of latent heat for sensible heat.

A change in environment results, however, from the change of the state of water and change in

temperature of the air vapor mixture.

Dry Bulb Temperature

Dry bulb temperature is measured by a mercury in glass thermometer properly shielded from radiation,

wiped dry and given sufficient time to reach a steady state reading.

Wet Bulb Temperature

Wet bulb temperature is a value indicated on an ordinary mercury glass thermometer, whose bulb is

covered by a wet wick and placed in a 1000 FPM moving stream of air.

Wet Bulb Depression

Wet bulb depression is the difference in degrees between dry bulb and wet bulb temperature.

Evaporative Pad Cooling Efficiency

Evaporative pad cooling efficiency is the percentage of wet bulb depression that the air is cooled as it

passes through the pad.

Enthalpy

Enthalpy is the internal energy content of an air-water-vapor mixture. The energy contained in the mixture

can be present both as sensible heat (indicated by dry bulb temperature) and latent heat of vaporization

(energy content of the water vapor).

Specific Volume

Specific volume is the cubic feet of the mixture per pound of dry air.

Dew Point Temperature

Dew point temperature is the temperature at which moisture will start to condense from the air.

Relative Humidity

Relative humidity is the ratio of the partial pressure of the water vapor in moist air to the vapor pressure.

The relationship for the relative humidity is expressed as a percent.

10 PNEG-2161 Stacked Evaporative Cooling System

3. Evaporative Cooling Theory and Benefits

Evaporative Cooling Theory

Evaporative cooling works by evaporating water into the air. In order for water to evaporate, it must absorb

heat, which is supplied by the outside air brought into the house for ventilation. As hot outside air comes

in contact with the wet evaporative cooling pad, some of the heat is absorbed by water and the air

becomes cooler. The water does not increase in temperature during this process, but only changes in

state from a liquid to a vapor.

How well evaporative cooling works depends partly on the weather. The air temperature in the building

can only be theoretically lowered to the dew point temperature. The dew point temperature can be

measured when the air is completely saturated with water (when the relative humidity is 100 percent).

Generally, the difference between the air temperature and the dew point temperature is greatest during

the warmest hours of the day. Therefore, an evaporative cooling system is most effective during the

hottest hours of the day.

The theoretical efficiency of the system is limited by the dew point temperature. The actual air temperature

in the building cannot be cooled to dew point temperature. Using a properly maintained system, however,

the air temperature in the building can be reduced to within 3°F - 5°F of the dew point temperature.

Benefits

Livestock and poultry cannot adequately remove excess body heat through sweating. The main way

animals lose heat is by the atmosphere. However, when the air temperature approaches the body

temperature of the animal, it becomes difficult to reduce body temperature through heat loss to the

atmosphere. Therefore, external cooling must be provided.

Evaporative cooling is a very cost effective way of reducing heat stress incurred by warm summer

temperatures. By providing a comfortably cooled environment, animals and poultry can experience better

weight gain, better production and improved reproductive characteristics.

Placing the Evaporative Cooling System

Each building and system is a little different just as management styles differ. The system can be located

such that it will be more of an outside attachment to the building or may be incorporated into the building

structure so that it is considered inside. Some of this depends on whether it is preferred to service from

inside or outside. It may depend on environmental conditions, especially in the winter where the system

is subject to less harsh conditions if located between a curtain and the animals. A closed curtain will serve

to prevent blowing dust, debris, rain and ice from entering the system.

PNEG-2161 Stacked Evaporative Cooling System 11

4. Evaporative System Installation

Framing Rough Opening

Before you can begin installation, you must frame in a rough opening for the evaporative system using

treated lumber (not supplied).

IMPORTANT: The frame bottom, middle and top header must be level.

1. Install the frame bottom to the wall, making sure it has a height of 13'' when mounting the trough on

brackets and a height of 7'' when mounting the trough on concrete.

2. The length of the frame should equal the length of the pad.

3. Install studs at 4' intervals the length of the system.

4. Install a double 2'' x 6'' for the middle frame using 4-1/2'' screws or longer.

NOTE: The middle frame should be located at the height of the pad minus 1/2'', measuring from the

top of the bottom frame.

5. Install a double 2'' x 4'' for the top frame.

NOTE: The top frame should be located at the height of the pad plus 2-1/2'', measuring from the top

of the middle frame.

6. Make sure there is a clearance of 6'' above the top frame, measuring from the bottom of the

top header.

Figure 4A Frame Opening Figure 4B Pad Installation

4. Evaporative System Installation

12 PNEG-2161 Stacked Evaporative Cooling System

Open Top Cover Installation

1. Measure 2-1/4'' up from the bottom of the 2'' x 4'' top header (2) and mark along the length of

the header.

2. Align the top back cover (1) with the mark on the header and install using a #10 x 1-1/4'' screw (3) at

each end. (See Figure 4C.)

Figure 4C

3. Align the spray bar supports (5) with the sets of two holes in the top back cover (1). (See Figure 4D.)

NOTE: Two supports per 10' section.

4. Install the spray bar supports (5) using two washers (4) and #10 x 1-1/4'' screws (3) per bracket.

Figure 4D

Ref # Description

1Top Back Cover

2 2'' x 4'' Top Header

3#10 x 1-1/4'' Screw

Ref # Description Ref # Description

1Top Back Cover 4Washers

3 #10 x 1-1/4'' Screw 5 Spray Bar Supports

4. Evaporative System Installation

PNEG-2161 Stacked Evaporative Cooling System 13

5. Align the middle two holes in the spray bar deflector (6) with the two middle holes in the top back

cover (1) and install the spray bar deflector (6) using two #10 x 1/2'' stainless steel screws (8).

6. Join the spray bar deflectors using the splice plate (7) using two #10 x 1/2'' stainless steel

screws (8) at each splice.

7. Continue installing the deflectors (6) and the splices (7) for the length of the systems, but do not

install splices at the ends of the spray bar deflectors. (See Figure 4E.)

Figure 4E

Ref # Description

1Top Back Cover

6 Deflector

7Splices

8 #10 x 1/2'' Stainless Steel Screws

4. Evaporative System Installation

14 PNEG-2161 Stacked Evaporative Cooling System

8. Install the PVC spray bar (9) onto the wire support brackets (5) and connect them together with the

1-1/2'' PVC couplers (10). (See Figure 4F.)

IMPORTANT: Make sure the holes are on the top and directed at the deflector lip towards the side

of the incoming air.

IMPORTANT: Do not Glue the spray bars to the couplers.

Figure 4F

9. Later, after the pad and pad retainer have been installed, insert the spray bar retainer (11) through

pipe support bracket (5) as shown. (See Figure 4G.)

10. Flip the spray bar retainer (11) up so the ends rest on the top of the pad retainer.

Figure 4G

Ref # Description Ref # Description

1Top Back Cover 9Spray Bar

6 Deflector 10 1-1/2'' PVC Couplers

Ref # Description

5Spray Bar Support

11 Spray Bar Retainer

4. Evaporative System Installation

PNEG-2161 Stacked Evaporative Cooling System 15

Installing the Middle Section

The middle section is same for open top system.

1. Align the back rail (1) with the top edge of the 2'' x 6'' header (2) and install using a #10 x 1-1/4'' screw

(3) in the hole locations as shown in Figure 4H.

2. Mount the next back rail (1) flush with the previous one and continue installing the back rails the full

length of the system.

NOTE: Cut the last piece of back rail to fit as needed.

Figure 4H

Ref # Description

1Back Rail

2 2'' x 6'' Header

3#10 x 1-1/4'' Screw

4. Evaporative System Installation

16 PNEG-2161 Stacked Evaporative Cooling System

3. Install the angle brackets (5) to the upper mount (4) using two #10 x 3/4'' self-drilling screws (6).

(See Figure 4I.)

Figure 4I

4. Align the pipe support brackets (9) with each set of two holes in the back rail (1) and install using two

washers (10) and screws (11). (See Figure 4J.)

Figure 4J

Ref # Description

4Upper Mount

5 Angle Brackets

6#10 x 3/4'' Self-Drilling Screws

Ref # Description Ref # Description

1Back Rail 10 Washers

9 Pipe Support Brackets 11 Screws

4. Evaporative System Installation

PNEG-2161 Stacked Evaporative Cooling System 17

5. Align the upper mount brackets (4) with one of the sets of three holes in the back rail (1) and install

using three 3/8'' lag screws (8). (Not provided.)

IMPORTANT: Only install five brackets (4) at a time to allow room to install the water deflector (7).

6. Slide the water deflectors (7) into the slot in the upper mount brackets (4).

NOTE: Make sure each deflector (7) is inserted the same direction each time so the tab end overlaps

the straight end of the next deflector (7).

7. Repeat Steps 5 and 6 to install the next five upper mount brackets (4) and water deflector (7).

8. Overlap the tab end of the water deflector (7) with the straight end of the next deflector (7) and fasten

together using a self-drilling screw (6) through the pre-drilled hole. (See Figure 4K.)

9. Continue installing the upper mount brackets (4) and the water deflectors (7) the full length of

the system.

Figure 4K

Ref # Description

4Upper Mount Bracket

6 #10 x 3/4'' Self-Drilling Screws

7Water Deflector

8 3/8'' Lag Screws

4. Evaporative System Installation

18 PNEG-2161 Stacked Evaporative Cooling System

10. Install the front rail (12) to the angle brackets (5) using #10 x 3/4'' self-drilling screws (6).

(See Figure 4L.)

NOTE: Only fasten to the five middle brackets, leaving the ends open to be installed with a

splice plate.

Figure 4L

11. Use the front rail splice (13) to connect the front rails (12) together using #10 x 3/4'' self-drilling

screws (6). (See Figure 4M.)

NOTE: The splice should be installed on the bottom side of the front rails (12) and the middle set of

screws must be installed into the angle bracket (5).

Figure 4M

Ref # Description

5Angle Brackets

6 #10 x 3/4'' Self-Drilling Screws

12 Front Rail

Ref # Description

6#10 x 3/4'' Self-Drilling Screws

12 Front Rails

13 Rail Splice

4. Evaporative System Installation

PNEG-2161 Stacked Evaporative Cooling System 19

12. Install one self-drilling screw (3) through either hole on the top of the upper mount bracket (4).

(See Figure 4N.)

Figure 4N

13. Slide the trough cover (14) over the back rail (1) then over the front rail (12). Butt the next

trough cover (14) up to the previous. (See Figure 4O.)

Figure 4O

Ref # Description

3#10 x 3/4'' Self-Drilling Screw

4 Upper Mount Bracket

Ref # Description

1Back rail

12 Front Rail

14 Trough Cover

4. Evaporative System Installation

20 PNEG-2161 Stacked Evaporative Cooling System

14. Install the PVC spray bar (15) onto the wire support brackets (9) and connect them together with the

1-1/2'' PVC couplers (16). (See Figure 4P.)

IMPORTANT: DO NOT GLUE THE SPRAY BAR and make sure all the holes in the spray bar are

facing up.

Figure 4P

15. Later, after the pad and pad retainer have been installed, insert the spray bar retainer (18) through

pipe support bracket (17) as shown. (See Figure 4Q.)

16. Flip the spray bar retainer (18) up so the ends rest on the top of the pad retainer.

Figure 4Q

Ref # Description Ref # Description

9Support Bracket 16 1-1/2'' PVC Couplers

15 PVC Spray Bar

Ref # Description Ref # Description

17 Spray Bar Support 18 Spray Bar Retainer

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Cumberland Stacked Evaporative Cooling System Owner's manual

Cumberland Stacked Evaporative Cooling System Owner's manual

Cumberland Stacked Evaporative Cooling System Owner's manual

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