General: The Converta-Pak is a self contained
Stainless Steel, grade 304 evaporative cooling module with Rigid Media designed to
convert and upgrade existing Swamp Coolers and Rotary Wheel units. General: The Converta-Pak is a self contained
Stainless Steel, grade 304 evaporative cooling module with Rigid Media designed to
convert and upgrade existing Swamp Coolers and Rotary Wheel units.
Disconnect all electrical power and water to the Swamp Cooler to be converted before beginning the conversion!
Preparation for Installation: The Swamp Cooler to be converted is either a down discharge type with 4 louver panels through which air flows or a side discharge type with 3 louver panels. All these panels should be removed and the cooling pad removed and discarded. One of these panels will be discarded (replaced by the Converta-Pak unit), the others will be covered by a blank-off panel (usually galvanized steel, painted to match the cooler housing).
The blower, motor and drives (including belts) should be serviced and adjusted accordingly and the fan housing cleaned and repaired if necessary to prevent air leakage. The Converta-Pak will be mounted over the opening immediately adjacent to the rounded part of the blower. (The openings of the blower will be at 90 degree angles to the opening of the Converta-Pak)
Blank-off Panels: Each of the louver panels to be replaced on the unit will become access panels to the interior of the fan section. These panels must be covered by a blank metal panel over the outside. This blank-off panel can be galvanized steel painted to match the cooler or left unfinished. It should be cut large enough to cover the louvers and leave a space to use for attachment using self drilling screws. It is important that these panels be removeable from the fan housing as access openings, so some space must be allowed around the outside edge to fit in the allowable slots in the housing. After afixing the blank-off panels to the louvered panel, set them aside until the Converta-Pak is attached.
Attaching the Converta-Pak: The Converta-Pak should be attached to the existing swamp cooler housing over the opening provided (closest to the rounded edge of the blower). Allow all the open face area possible in alignment with the opening provided. If possible, align the top of the sump with the bottom of the opening. Attach the Converta-Pak through the side and top flanges only. Do not drill holes in the sump of the Converta-Pak. After attachment to the existing housing, seal the joint with silicone to prevent air leakage around the cooling media. It is imperative that all air entering the cooler flows through the cooling media only!
Replace covered louver panels: After
the Converta-Pak is attached, replace the covered louver panels in the appropriate slots
in the existing housing. The end result should be that the entire housing will now
have all openings covered except the Converta-Pak unit. The louvered panels must be
removeable to provide
necessary access.
Plumbing/Electrical connections: The existing make-up water, drain and overflow plumbing fittings are to be disconnected to the original housing and transferred to the Converta-Pak fittings. Electrical supply to the original pump should also be transferred to the Cycle-Flow(r) control panel (or to the new pump in the Converta-Pak unit)
Start-up with Cycle-Flow(r) system: After checking out the unit to confirm everything is attached and/or installed correctly, turn on the electrical power and water supply to the unit. If the cooler is controlled by a thermostat, turn the thermostat to a point to cause the cooler to run. The Cycle-Flow(r) controls will initially delay the water flow for the period of time pre-set on the time delay relay (usually about 3 minutes). After this period, the Cycle-Flow(r) controls will automatically control water flow over the media. Refer to seperate operation instructions on the Cycle-Flow(r) system provided with the Converta-Pak for further information about the Cycle-Flow(r) system.
Start-up with pump recirculating system: If a pump recirculating system is being used, the sump must be filled with water to a level about 1/2" below the bottom of the cooling media before starting up the pump. It is essential that the media not be allowed to stand in water. The pump cannot be operated if the water level is too low. The float must be adjusted to maintain a water level to no lower than 1" below the cooling media. Run the pump for several minutes to fully wet the media before starting the fan if possible using the controls available.
Check-out the normal operation of the unit: After all the above steps are completed and the unit is sucessfully running, turn off the unit and check the start up and operation to assure it is performing properly. After the cooling media is fully wetted, you can measure the discharge temperature for efficiency by comparison between actual and predicted temperature. Refer to "Formulas and Tables" for the method to accomplish this.
Measure the motor amperage draw which will indicate how the motor is performing. Amperage cannot be allowed to exceed the nameplate rating because of the possiblity of motor burn-out. Too low amperage (below 60% of nameplate rating) may indicate too little load (too little air flow through the blower). Check the belt tension from motor to the blower. If it is too tight, it can wear out bearings early. If it is too loose it can allow slippage and move too little air.
