(The Converta-Pak is a registered tradename in Arizona)
The Super Conversion/Upgrade Unit
The "Swamp Cooler" is probably the oldest form of the evaporative cooler technology still around. This type unit is used extensively throughout the Southwest as well as many hot dry climates around the world. The major problem with it is the low cooling efficiency it delivers. The name "Swamp" cooler is descriptive of the type of cooling it provides except during very hot, dry conditions. Maintenance of this type cooler is also a nightmare due to the need to replace the cooling pad often (sometimes as often as every 2 or 3 months during the cooling season), the annual clean up, pump replacement and float adjustment and general deterioration of the housing due to the presence of water directly under the blower in the so called "dry section" of the cooler.
The Premier Converta-Pak consists of 1 or 2 stainless steel, self contained media sections, complete with high efficiency Rigid Cooling Media, made to replace the existing "straw pad" panels used in older coolers. These sections have their own sumps so there is no longer water contained in the housing of the cooler, thus extending the life of the blower and the housing. The remaining openings where the original pad panels fit are then covered with aluminum or stainless "blank off" panels. As the pad panels are often the first part of an older cooler to rust out, while the blower, housing and motor are still serviceable, the Converta-Pak can extend the useful life of your existing swamp cooler. Better yet, the increased efficiency of the rigid media used in the Converta-Pak will provide discharge air 10 to 15 degrees cooler than the original straw pads did even when they were new (based on 100º ambient air temperature and 12" rigid media - see comparison below).
On this installation in Phoenix Arizona, 2 Converta-Pak units were used on each end of an existing downdraft cooler. Unlike the original galvenized media panels, the stainless steel Converta-Pak won't rust away in a few years.
This unit is installed on a warehouse roof where the building owner has retrofitted all the existing coolers with Converta-Pak units. In addition to the new media sections, the blank off panels can be seen clearly in these pictures. The benefits include longer cooler life, increased cooling and less maintenance - all for a fraction of the cost of a new evaporative cooler!
SWAMP COOLER BEFORE AND AFTER CONVERSION WITH A CONVERTA-PAK(tm-az)
The Converta-Pak is a self-contained "wet section" with Rigid Media, water distribution pump and float system if preferred. The water in the existing cooler is contained completely in the stainless steel sump of the Converta-Pak. The existing housing, blower and motor are all retained and used which cuts the cost considerably as compared to replacing the entire cooler.
The following table compares the performance of the old technology (Swamp Cooler) using 1" to 2" thick media and the new technology (Converta-Pak) with Rigid Media either 8" or 12" thick. Also compared is the "Rotary Wheel" type cooler.
|
Intake |
Intake |
Discharge Temperatures (Degrees f) |
|||||
|---|---|---|---|---|---|---|---|
|
Dry Bulb |
Relative |
Swamp Cooler |
After Conversion with Converta-Pak (tm-AZ) |
||||
|
Temp (f) |
Humidity (%) |
Before Conversion |
6" Media |
8" Media |
12" Media |
16" Media |
18" Media |
100 |
10% |
83 (f) |
75 (f) |
71 (f) |
67 (f) |
65 (f) |
64 (f) |
100 |
20% |
86 (f) |
79 (f) |
76 (f) |
72 (f) |
70 (f) |
69 (f) |
100 |
30% |
88 (f) |
82 (f) |
80 (f) |
77 (f) |
75 (f) |
74 (f) |
100 |
40% |
90 (f) |
84 (f) |
82 (f) |
80 (f) |
79 (f) |
78 (f) |
Step 1. The down discharge swamp cooler has 4 louver panels over open air intake openings. The side discharge unit has 3 louver panels over open air intake openings. One of these panels are removed to accommodate the installation of the Converta-Pak. This panel should be located immediately adjacent to the rounded side of the blower housing.
Step 2. The Converta-Pak unit is mounted over this open area. Attachment to the existing housing is accomplished by bolting through flanges on each side and top of the back side of the Converta-Pak. Self drilling screws (stainless steel) are used for this purpose. The joint is then caulked with silicone or similar sealer to block off any air flow around the cooling media.
Step 3. The remaining louver panels are to be covered with solid blank panels to close off any air flow around the cooling media. All air entering the cooler must be through the cooling media in the Converta-Pak only!
Step 4. Change the existing plumbing water supply and drain to the Converta-Pak unit. Seal off the openings in the existing cabinet to preclude air flow.
Click here for illustration of upgrade installation!
| Unit | CFM | Intake | Intake | Discharge | Discharge Temperatures by Media Thickness | ||||
|---|---|---|---|---|---|---|---|---|---|
- |
- |
Temp (f) | Rel. Hum. | Rotary Unit | 6" | 8" | 12" | 16" | 18" |
| Rotary | 10000 | 100 (f) |
20% |
81 (f) |
--- |
--- |
--- |
--- |
--- |
| W/Converta-Pak | 16000 | 100 (f) |
20% |
----- |
78(f) |
75(f) |
72(f) |
69(f) |
68(f) |
| Improvement | +6000 | ----- |
---- |
----- |
3(f) |
6(f) |
9(f) |
12(f) |
13(f) |
Note: The reason for greater air volume is due to the design of the Rotary Wheel Unit. Approximately half the face area of the unit is closed to air flow due to the high sump through which the rotary wheel turns to be wetted.
Table 3: Standard Converta-Pak(c) sizes for most relative "Swamp Coolers"!
| Swamp | Premier | Cabinet | Cabinet | Sump | Pump* | Cabinet Depth for Media Thickness of: | |||
|---|---|---|---|---|---|---|---|---|---|
| Cooler | Model | Width | Height | Depth | HP | 6" Media | 8" Media | 12" Media | 16" Media |
| 3300 CFM | CP3300 | 32" |
34" |
4" |
1/60 |
13" |
16" |
19" |
23" |
| 4500 CFM | CP4500 | 34" |
36" |
4" |
1/60 |
13" |
16" |
19" |
23" |
| 6500 CFM | CP6500 | 36" |
44" |
4" |
1/60 |
13" |
16" |
19" |
23" |
| 8500 CFM | CP8500 | 42" |
44" |
4" |
1/60 |
13" |
16" |
19" |
23" |
| 12500CFM | CP12500 | 52" |
52" |
4" |
1/60 |
13" |
16" |
19" |
23" |
| 14500CFM | CP14500 | 54" |
58" |
4" |
1/40 |
13" |
16" |
19" |
23" |
| 21000CFM | CP21000 | 60" |
62" |
4" |
1/40 |
13" |
16" |
19" |
23" |
Note: CFM levels shown are nominal and will vary due to the motor HP and static pressure of the air delivery system. Sizes of Converta-Pak is for the most common swamp coolers. Swamp cooler manufacturers sizing may vary slightly.
Installation procedure for Converta-Pak to Rotary Wheel units.
Step 1. Remove the entire wet section, including the rotary wheel. Disconnect plumbing water supply and drain line. Set the wheel and sump aside or discard.
Step 2. Attach the Converta-Pak to the opening caused by the removal of the wheel assembly. Attach through the side and top flanges with self drilling screws (stainless steel).
Step 3. Replace the plumbing water supply line and drain line to the Converta-Pak unit.
The replacement of the wheel assembly will allow for up to 60% more air volume to be processed through the new, higher efficient cooling media. A double bonus. More air at a colder temperature!
Written Specifications for Converta-Pak!
Installation Instructions for Converta-Pak!
