ACME KOOL-CEL PDR 4 Manual
ACME ENGINEERING & MANUFACTURING CORP.
P.O. Box 978
Muskogee, Oklahoma 74402
918/682-7791 FAX: 918/682-0134
www.acmeag.com • www.acmehort.com
Form 610260
Model PDR 4” and 6”
Cooling Systems
Owners Manual &
Instructions for
Acme PDR 4” and 6”
Kool-Cel
Evaporative Cooling
System
Page 2
PDR 4” and 6” Evaporative Cooling
System
Table of Contents
Components ...........................................2
Building Preparation .......................................3
System Installation.......................................4-8
Exploded Drawing of System ..................................9
Plumbing Installation ....................................10-11
8” PVC Transition Pump Tank (optional) ...........................12
Start Up and Testing ......................................13
Maintenance .........................................13-14
Pad Care .............................................14
Warranty .............................................16
Components
Packaging
Your Kool-Cel system consists of five major components:
1. Kool-Cel pads 4” or 6” x 12” x 24”, 36”, 48”, 60” and 72” (Two pads are used for 84” and 96” high
pads.) Note: 4” pads over 48” high require tall pad supports installed between every other pad.
2. Water Pump
3. Distribution and return system - a combination of the following packages for the length of the system.
See exploded view and parts list on page 9 for parts identification.
a. 5’ Basic Package e. 10’ Regular Package
b. 7’ Basic Package f. 10’ Basic w/o Outlet Package
c. 10’ Basic Package g. 10’ Regular with Outlet Package
d. 5’ Regular Package
Note: A maximum system length of 50’ is recommended. Longer system applications can be
installed as shown on page 11, figures 24 and 25.
4. Plumbing Kit
5. End Closure Package
* Optional Pump Reservoir for use with 8” PVC Pipe
* Optional Extension Kit
By Owner
Framing material
Sump tank, drain and cover or optional 8” PVC Transition Pump Tank
Water supply to float valve
Return pipe from down spout to sump and filter
Page 3
Building Preparation
Location of Pad System: Typical Pad/Fan Relative
Locations
The Kool-Cel pad should be placed away from the fans
(opposite) so that cooled air can flow through the
building without turbulence. Pads should be no more
than 250’ from the fans in greenhouse buildings to
avoid excessive temperature rise and velocities. In a
greenhouse, the top of the pad should be near the top
of the crop or have its midpoint centered on the
midpoint of the crop.
In poultry and livestock installations the pad is
generally placed on the outside of the building so that
the top of the pad is not below the highest desired
cooling level. An eave extending beyond the PDR
system is recommended.
Framed Opening and Sizes
Note: If the 12” Extension Kit is to be used, refer to the
Extension Kit instructions for proper framing
dimensions.
Note: The side wall structural members should be left
intact as shown in figure 1.
Stringers
The framing and support stringers could be any type of material (metal channels, rectangular or square tubes,
treated wood, etc.). The design should provide a flat surface for mounting support brackets and the lower stringer
should be capable of carrying a load of 2.74 lbs. per sq. ft. of pad for the 4” system or 4.11 lbs. per sq. ft. for the
6” system. All framing in this manual refers to 2” x 6” treated wood. The framed opening must be vertical and
square for proper installation of the system. The use of a chalk line during stringer installation will aid in keeping
the system square.
Clear Opening For The Pad System
A (Vertical) Ordered pad height less ½”
B (Horizontal) Ordered pad length
Overall Height Of The System
C Ordered pad height plus 10 ½”
DStandard: 8” minimum for return piping
Optional: 12 1/4” minimum for 8” PVC Transition Pump Tank.
E 7 1/4” Typical
Figure 1
Page 4
PDR 4" and 6” Evaporative Cooling
System
Sump Tank and Cover
Provide a tank with a capacity of 3/4 gallon per square foot of pad area for 4” pads and 1 gallon per square foot of
pad area for 6” pads. A tank cover should be provided capable of supporting the pump (#30-35 lbs., #60-50 lbs.).
The sump should be set in place prior to start of the installation of the distribution and return system.
Optional Transition Pump Tank
See page 12.
System Installation
After installing all framing materials, the Kool-Cel distribution and return system will go together simply and quickly
following the instructions step by step.
Gutter Installation
Gutter Support Brackets
1. To locate the gutter support bracket position on the bottom stringer, refer to chalk line shown in
figure 2. The chalk line should be 1” down from the top of the stringer and run its full length. The
chalk line will be used to locate the top hole position of the brackets. Hole spacing is shown in
figure 2 and figure 3.
Hints:
Framing - Verify framing installation using instructions in framed opening B and in figure 1 on page 3. If
framing is not properly installed as shown the system will not operate properly.
Caulking - Where the following instructions refer to caulking, use the ½” caulking tape provided with the
system unless otherwise specified.
Packages - Place all cartons in the areas of installation and open the top of the carton. Do not remove the
material until needed. The "basic" package contains all parts for each end of the system, end
sections, elbows, plugs, etc. A packing slip describes all parts and is included in every box.
The "regular" packages (5’ and 10’) contain all the parts between each end to make your system
the desired length. All regular packages contain a packing slip listing all materials contained in
the packages. Note: All packing slips and maintenance instructions should be retained for future
reference.
Figure 2
A = Ordered Pad Height
B = Ordered Pad Length
C = Ordered Pad Height plus
3”
D = Minimum dimension for 8”
pipe system is 17 3/4”
(Ground level to top of
lower stringer.)
Page 5
2. Install all gutter support brackets (1) as shown in figure 3, making sure brackets are vertical.
Gutter
Once assembled, the entire gutter simply sits in the gutter support brackets, therefore it may be easier to
assemble the entire gutter on level ground then set it into the brackets in one piece. Ground must be level
or gutter will be warped when assembled.
1. Locate the gutter end section (1) that includes an end cap and pre-drilled drain hole. Install the 4”
threaded tank fitting into the pre-drilled drain hole.
2. At the open end of the gutter end section, place caulking tape on each side of the bolt holes as in
figure 4. Place the next gutter section inside the gutter end section, overlapping the first section with
the notched end (located under flange) toward the drain end. Line up the bolt holes and secure with
#10 - 24 x ½” hex head screws and #10 - 24 whiz lock nuts. Continue assembling gutter sections
until complete, always overlapping with the notched end toward the drain end.
3. Attach the pad support sections to the gutter sections by lining up the holes and securing with #10 -
24 x ½” hex head screws and #10 - 24 whiz lock nuts.
Figure 3
Figure 5
Figure 4
Assembled View
1 Gutter Support Bracket
2 2" x 6" Bottom Stringer
3 1/4"x1½"HexHead Screw
1 Gutter End Section Assembly
2 Gutter Section Sub-Assembly
Note: For system installations with
center drain, refer to Form 610421.
Page 6
PDR 4" and 6” Evaporative Cooling
System
System Top Installation
1. Beginning at the drain end, install the top
cover support sections and the pipe
hangers to the top stringer by lining up the
top holes of the top cover support sections
with the chalkline on the top stringer.
Attach the hangers and the top cover
support sections to the stringers with 1/4” x
1 ½” hex head screws as shown in figure 6,
and figure 7 (4” systems) or figure 8
(6” systems).
2. Caulk the top cover support sections at the seams then center the top cover connectors over each
seam and attach with #10 24 x ½” screws as shown in figure 9.
3. Place a 10’ section of 1 ½” pipe with the metered holes up into the pipe hangers at the drain end of
the system. Enough pipe should extend beyond the end of the top cover support to later attach a
90° elbow for plumbing installation as in figure 10.
Figure 6
Figure 7 Figure 8
Figure 10
Figure 9
2” 2”
Page 7
4. Installa1½”slip joint coupling on the pipe end away from the drain and assemble another 10’
section of pipe. Do not use PVC cement on these joints. The coupling and pipe should be
pushed tightly together but not cemented. Make sure the metered holes are at the top so the
water will spray directly upward for proper water distribution.
5. Install the remaining pipe using the 1 ½” couplings (no cement), always making certain that the
metered holes point directly upward. Again, enough pipe should extend beyond the opposite end to
later attacha1½”teeforinstallation of the bleed-off clean-out assembly.
End Panel Installation
1. Locate the two end closure panels. Select the panel that will have the channel legs toward the pads
on the drain end. Set the bottom of the end closure panel inside the gutter (see figure 11) and attach
with #10 - 24 hex head screws and whiz lock nuts. Locate the proper top cover end cap and slip it
over the pipe. Attach it to the top stringer with two 1/4” x 1 1/4” screws.
2. Next, attach the end closure panel to the top cover end cap with #10 - 24 hex head screws and whiz
lock nuts (see figure 12). Install the end closure panel and top cover end cap on the opposite end in
the same manner.
Note: If the chalklines on the top and bottom stringer were marked correctly and all sections
installed on the chalklines, the end closure panels will match the pre-drilled holes in the gutter end
cap and the top cover end cap.
Top/Pipe Cover Installation
Beginning at the drain end, install the end section of the top cover assembly with #10 ½” hex head screws. The
pipe cover should be assembled to the top cover as shown in figure 13 for 4” systems and figure 14 for 6”
systems. Continue installing top/pipe cover sections until complete. Top cover connectors should match the
joints of the top/pipe cover sections to prohibit leaks between the joints.
Figure 11 Figure 12
Figure 13 Figure 14
Page 8
PDR 4" and 6” Evaporative Cooling
System
Pad Installation
1. Install the pads before installing the top cover. (Installing pads with top cover in place could
result in pad damage and the “springing” of the top cover which could result in improper channeling
of the water.) Place the bottom of the pad firmly on the pad support and under the pipe as shown in
figure 15 for 4” systems and figure 16 for 6” systems. 4” Pads install in any direction. 6” pads must
be installed as shown below with the higher angle of the flutes pointing upward and toward
the building. (If you can see through the flutes you should be looking at the ceiling of the building).
2. 4” pads over 48” tall require tall pad supports.
Install between every other pad, centered
between the top and bottom and the front and
back of the pads. Holding the tall pad support
in position, press the pads together until the
support sticks into both pads.
Note: The last pad installed should not be at
either end since it may need to be trimmed to
fit remaining space easily. Do not force the
last pad into a space that is smaller than the
pad. Pad retainers cannot be used on either
side of the last pad installed.
3. To seal the ends of the system apply caulking
tape to the pipe extending outside the end cap
as shown in figure 18. Cut the tape to fit
around the pipe. Press the end plate firm
against the top cover and wrap the tape
around the pipe, snug against the end plate.
Trim away excess tape.
Figure 17
Figure 18
6” Pad Installation
4” Pad Support Assembly
Figure 15
6” Pad Support Assembly
Figure 16
Kool-Cel Top End Section
Typical Both Ends
Page 9
Bill of Material
1 Top stringer (by others)
2 Bottom Stringer (by others)
3 Gutter support bracket
4 Gutter end section w/drain hole
5 Gutter section
6 Pad support end section
7 Pad support section
8 End closure panel
9 Top cover end cap
10 Pipe hanger
11 Distribution pipe
12 Slip coupling
13 Pipe cover end section (4”)
14 Pipe cover section (4”)
15 Pipe cover end section (6”)
16 Pipe cover section (6”)
17 End cover connector
18 Top cover section
19 Top cover connector
20 Top cover support section (4”)
21 Top cover support section (6”)
22 Pad (4”)
23 Pad retainer
Top Cover Assembly - 6” System
Figure 19
Exploded View - 4” System
Page 10
PDR 4" and 6” Evaporative Cooling
System
Plumbing Installation
A complete plumbing kit is available through your distributor. Extra items are included in this kit so that one kit
may fit all installations. If you have not purchased this kit, refer to figures 20 & 21 for items required. Assemble
the plumbing as shown in figures 20 & 21 after the system has been installed.
Notes
A. 2” PVC leader pipe (by others)
B. Screen over leader pipe (by others)
C. Sump tank and cover (by others)
Figure 21
Figure 20
Centrifugal Pumps
Pump
Model
Distance From Pump
Mounting Holes To
Centerline of Sump Tank
Mounting Hole Spacing
AB
#30 21 ½” 5 5/8”
#60 20 ½” 5”
Drain End
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