Cumberland Stacked Evaporative Cooling System Owner's manual

Type
Owner's manual
PNEG-2161
Stacked Evaporative Cooling
System
Installation Manual
PNEG-2161
Version: 1.0
Date: 03-14-18
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
Chapter 2 Introduction to Evaporative Cooling ..................................................................................................8
Dry Bulb Temperature ............................................................................................................................8
Wet Bulb Temperature ...........................................................................................................................8
Wet Bulb Depression .............................................................................................................................8
Evaporative Pad Cooling Efficiency .......................................................................................................8
Enthalpy .................................................................................................................................................8
Specific Volume .....................................................................................................................................8
Dew Point Temperature .........................................................................................................................8
Relative Humidity ...................................................................................................................................8
Chapter 3 Evaporative Cooling Theory and Benefits .........................................................................................9
Evaporative Cooling Theory ...................................................................................................................9
Benefits ..................................................................................................................................................9
Placing the Evaporative Cooling System ...............................................................................................9
Chapter 4 Evaporative System Installation .......................................................................................................10
Framing Rough Opening ......................................................................................................................10
Open Top Cover Installation ................................................................................................................11
Installing the Middle Section ................................................................................................................14
Installing the Bottom Trough Section ...................................................................................................20
Jet Pump System .................................................................................................................................23
Installing the End Panels ......................................................................................................................26
Open Top System ................................................................................................................................28
Jet Pump System Parts ........................................................................................................................31
Installing the Float Valve Assembly .....................................................................................................34
Wiring the Re-Circulating Cooling System ...........................................................................................34
Chapter 5 Operation and Maintenance of the Re-Circulating Cooling System ..............................................35
Initial Start-Up New Media ...................................................................................................................35
Normal Operation .................................................................................................................................35
Annual Shut Down and Start-Up Process ............................................................................................36
Annual Start-Up ....................................................................................................................................36
Algae/Bacteria Control .........................................................................................................................36
Maintenance/Water Chemistry .............................................................................................................37
Re-Circulating Open Top Cooling System Parts ..................................................................................38
Chapter 6 Warranty ..............................................................................................................................................41
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. Save these safety guidelines for future
reference.
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-0001-3
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
8 PNEG-2161 Stacked Evaporative Cooling System
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.
PNEG-2161 Stacked Evaporative Cooling System 9
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.
10 PNEG-2161 Stacked Evaporative Cooling System
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 4'' 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
PNEG-2161 Stacked Evaporative Cooling System 11
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
12 PNEG-2161 Stacked Evaporative Cooling System
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
PNEG-2161 Stacked Evaporative Cooling System 13
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
14 PNEG-2161 Stacked Evaporative Cooling System
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 4'' 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 4'' Header
3#10 x 1-1/4'' Screw
4. Evaporative System Installation
PNEG-2161 Stacked Evaporative Cooling System 15
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
16 PNEG-2161 Stacked Evaporative Cooling System
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
PNEG-2161 Stacked Evaporative Cooling System 17
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
18 PNEG-2161 Stacked Evaporative Cooling System
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
PNEG-2161 Stacked Evaporative Cooling System 19
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
4. Evaporative System Installation
20 PNEG-2161 Stacked Evaporative Cooling System
Installing the Bottom Trough Section
1. Install the trough support bracket (1) 7'' down from the top of the bottom frame (2) and spaced 42''
apart the full length of the system using 3/8'' lag screws (3) (not provided). (See Figure 4R.)
Figure 4R
Ref # Description
1Support Bracket
2 Bottom Frame
33/8'' Lag Screws
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Cumberland Stacked Evaporative Cooling System Owner's manual

Type
Owner's manual

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