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Cumberland 4801-5405 Installation Manual

Unitized system komfort kool
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Unitized System Komfort Kool
Installation Manual
4801-5405
Version 4.0
Date: 07-15-22
4801-5405

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Summary of Contents for Cumberland 4801-5405

  • Page 1 Unitized System Komfort Kool Installation Manual 4801-5405 Version 4.0 Date: 07-15-22 4801-5405...
  • Page 2 Sidewall System for Komfort Kool Evaporative Cooling with Agriculture and Horticulture Structures All information, illustrations, photos, and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. 4801-5405 Unitized System Komfort Kool...

  • Page 3: Table Of Contents

    Setting the Limit Switches of Tubular Motor .................53 Chapter 4 Parts List ..........................55 Sidewall Left End Track (6421-0307) ..................56 Sidewall Right End Track (6421-0308) ..................58 Center Track Assembly (6421-0300)...................60 Limited Warranty - Protein Products ..................63 4801-5405 Unitized System Komfort Kool...
  • Page 4 NOTES 4801-5405 Unitized System Komfort Kool...

  • Page 5: Chapter 1 Safety Precautions

    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 4801-5405 Unitized System Komfort Kool...

  • Page 6: Cautionary Symbol Definitions

    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 4801-5405 Unitized System Komfort Kool...

  • Page 7: Safety Cautions

    • 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 4801-5405 Unitized System Komfort Kool...
  • Page 8 • Make sure all equipment is properly grounded. ST-0027–4 Lifting Hazard • Single person lift can cause injury. • Use a mechanical lifting device to lift or move the equipment during installation. ST-0021–2 4801-5405 Unitized System Komfort Kool...
  • Page 9 • Entanglement in rotating shafts will cause serious injury or death. • Keep all guards and covers in place at all times. • Lock-out power source before making adjustments, cleaning, or maintaining equipment. ST-0096–1 4801-5405 Unitized System Komfort Kool...

  • Page 10: 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 4801-5405 Unitized System Komfort Kool...

  • Page 11: Chapter 2 Overview

    When the limit switch adjustment buttons are pushed in, the motor has no stop shut off points. The number of revolutions is unlimited. WARNING The assembled drive pipe is heavy. Do not attempt to lift the drive pipe without a sufficient number of workers. WARNING 4801-5405 Unitized System Komfort Kool...

  • Page 12: Description Of Unitized System

    NOTE: Unitized Right End Cap, Unitized Left End Cap, Unitized Back Flashing, and Komfort Kool Pump Assembly are NOT SHOWN in this figure. These parts must be ordered separately. Figure 2-1 Unitized System 4801-5405 Unitized System Komfort Kool...

  • Page 13: Chapter 3 Installation

    ▪ Installing the Tubular Motor to Motor Mount ▪ Tubular Motor Electrical Wiring Diagram ▪ Tubular Motor Tester Wiring Diagram ▪ Connecting the Power and Testing the Motor ▪ Setting the Limit Switches of Tubular Motor 4801-5405 Unitized System Komfort Kool...

  • Page 14: Framing Diagram For System On Brackets

    5' Pad 87-3/4" 222.89 cm 6' Pad 71-1/2" 181.61 cm 6' Pad 99-3/4" 253.37 cm • End mounted drive system from 10' to 120' maximum. • Center mounted drive system from 10' to 200' maximum. 4801-5405 Unitized System Komfort Kool...

  • Page 15: Framing Diagram For System On Concrete

    5' Pad 81-7/8" 207.96 cm 6' Pad 71-1/2" 181.61 cm 6' Pad 93-7/8" 238.44 cm • End mounted drive system from 10' to 120' maximum. • Center mounted drive system from 10' to 200' maximum. 4801-5405 Unitized System Komfort Kool...

  • Page 16: Framings For System On Brackets And System On Concrete

    Center the end of the first 2" x 4" and the last 2" x 4" filler board (or steel equivalent) 2" x 4" on the 4" x 4" post 4" x 4" post (or steel equivalent) 2" x 4" header board 4801-5405 Unitized System Komfort Kool...

  • Page 17: Flat Bottom Reservoir Support Brackets For End Pump Only

    Figure 3-4, page 17. The spacing for the system on concrete is the same. Figure 3-4 Support bracket locations Splice #14 x 1" hex head TEK screw 1/4" x 1-1/2" lag screw Metal support brackets 4801-5405 Unitized System Komfort Kool...
  • Page 18 4. Assemble the L-brackets (30) to the support brackets (31) as shown below with 1/4"-20 hex bolts (1) and 1/4" nuts (12). Figure 3-5 Assembling the L-brackets 1/4"-20 hex bolts L-bracket Metal support bracket 1/4" nuts 4801-5405 Unitized System Komfort Kool...

  • Page 19: Installing The Bottom Support Brackets

    Figure 3-6 Installing the bottom support brackets Trough bracket for wall mount 1/4"-20 x 1/2" hex bolts Concrete tapcon screws Trough bracket for concrete mount 1/4" lock nuts Drill 3/16" hole in concrete Bottom support bracket 4801-5405 Unitized System Komfort Kool...

  • Page 20: Installing The Top Mounting Brackets

    Figure 3-7 Installing the top mounting brackets 1/4" x 1-1/2" lag screw 2" x 4" board (or steel equivalent) Top mounting bracket 2" x 6" filler boards Horizontal Spacing for Top Mounting Brackets Back plate Spacing 4801-5405 Unitized System Komfort Kool...

  • Page 21: Installing The Back Plates

    (38) as the vertical members will be installed later. Figure 3-8 Installing the back plates #14 x 1" hex TEK screws Wall boards Top mounting bracket Back plate 4801-5405 Unitized System Komfort Kool...

  • Page 22: Installing The Left Track

    1/4" hex nut (14). Figure 3-9 Installing the left track Top mounting bracket 1/4"-20 x 1/2" hex bolt #14 x 1" hex TEK screws Wall boards Back plate 1/4" hex nut Bottom support bracket Left track 4801-5405 Unitized System Komfort Kool...

  • Page 23: Installing The Center Tracks

    5. Repeat steps 1-4 to install the center track (40) at locations where two back plates (38) butt together. Figure 3-10 Installing the center tracks Top mounting bracket 1/4"-20 x 1/2" hex bolt Back plate #14 x 1" hex TEK screws 1/4" hex nut Center track Bottom support bracket 4801-5405 Unitized System Komfort Kool...

  • Page 24: Installing The Right Track

    (2) and 1/4" hex nut (14). Figure 3-11 Installing the right track Back plate 1/4"-20 x 1/2" hex bolt #14 x 1" hex TEK screws Center track Right track 1/4" hex nut Bottom support bracket 4801-5405 Unitized System Komfort Kool...

  • Page 25: Installing The Top Bar

    NOTE: Install bolts (2) and nuts (14) to the four holes as indicated in the guide bracket. Figure 3-13 Installing the bearing mount Bearing mount 1/4"-20 x 1/2" hex bolt 1/4" hex nut Track Back plate 4801-5405 Unitized System Komfort Kool...

  • Page 26: Installing The Lock Motor Mount

    #14 x 1" hex TEK screws Motor Lock motor assembly 3/8"-16 x 1" screw 3/8" x 2" lag screw Mounting bracket brace 3/8" lock nut Motor mount bracket Mounting bracket Drive pipe Back plates Sprocket of motor Drive shaft assembly 4801-5405 Unitized System Komfort Kool...
  • Page 27 (38) to install the cover splice at the end of the system. Figure 3-15 Mounting the lock motor at the end of the system Drive shaft assembly Sprocket of motor Motor Lock motor limit switch Motor mount bracket 4801-5405 Unitized System Komfort Kool...

  • Page 28: Connecting The Drive Shafts For Lock Motor

    Slide the drive insert (55) into the end of drive pipe (50) and align the holes. NOTE: Make sure that end of drive insert (55) is flush with the end of drive pipe (50). Figure 3-17 Assembling the lock drive insert Drive pipe Drive insert 4801-5405 Unitized System Komfort Kool...

  • Page 29: Installing The Lock Motor

    Figure 3-18 Installing the lock motor 3/8" x 2" lag screws Pinion sleeve 3/8"-16 x 1" hex bolts Drive shaft 3/8" nuts Drive insert Mounting bracket Lock screws Motor mount bracket Lock motor Drive pipe 4801-5405 Unitized System Komfort Kool...
  • Page 30 Figure 3-19 Removing the limit switch cover Drive unit Motor shaft Output shaft Adaptor Copper sealing ring Electric drill Double chain Hand Crank Limit switch cover Chain Connector Direction arrow Terminal box cover Worm wheel Electric motor Bracket Warning label Seal 4801-5405 Unitized System Komfort Kool...
  • Page 31 HI setting ring screw Switch HI Setting ring Terminal rail SI Setting ring HII setting ring screw SII setting ring HII setting ring SII setting ring screw Limit switch roller SI setting ring screw Switch groove 4801-5405 Unitized System Komfort Kool...
  • Page 32 1. Remove the limit switch cover (91) and locate the allen wrench (94) and the hex shaft (93) packaged with the vinyl storage seal (92). Figure 3-22 Removing the limit switch cover Hex shaft (for manually rotating motor) Limit switch cover removed Vinyl storage seal Allen wrench (for adjusting limit switches) 4801-5405 Unitized System Komfort Kool...
  • Page 33 4. With the curtain at the bottom limit, turn the three setting rings (97) of the left limit switch until the limit switch roller (95) snaps into place in the switch groove (105). Figure 3-24 Left limit switch roller (curtain opens) Limit switch roller 4801-5405 Unitized System Komfort Kool...
  • Page 34 9. Verify the operation of the limit switch settings by operating the curtain from the controller. 10.Re-install the tools in the vinyl seal (92) and re-install the vinyl seal (92) followed by the limit switch cover (61). 4801-5405 Unitized System Komfort Kool...

  • Page 35: Installing The Manual Drive (Chain Hoist)

    6. Align the gearbox (98) and tighten the lock screws (56) that are installed in step 3. Figure 3-27 Attaching the drive pipes to gearbox 3/8"-16 x 1" hex bolts Drive shaft 3/8" nuts Drive insert Mounting bracket Lock screws Drive pipe Gearbox Pinion sleeve 4801-5405 Unitized System Komfort Kool...

  • Page 36: Assembling The Drive Pipes

    NOTE: Keep hook and loop strips (99) aligned when assembling the drive pipe (50). NOTE: To install the lock motor (90), refer to Installing the Lock Motor, page Figure 3-28 Assembling the drive pipes Hook and loop strip Swaged end Stainless steel pop rivets 4801-5405 Unitized System Komfort Kool...

  • Page 37: Placement Of The Drive Pipe Into The Guide Brackets If Assembled On The Ground

    NOTE: Lift the drive pipe assembly and place it on the guide brackets (119) at the top of the track units (120). Figure 3-29 Installing the drive pipe into guide brackets Drive pipe Track units Guide brackets 4801-5405 Unitized System Komfort Kool...

  • Page 38: Installing The Curtain

    Front panel (102): This panel has 1" wide strips (99) on the top and 2" wide strips (99) running down on each side. This panel attaches to the top bar plate. Figure 3-30 Identifying the panels Back plate Front panel Drive pipe Back panel Hook and loop strip Center panel 4801-5405 Unitized System Komfort Kool...
  • Page 39 Figure 3-31 Attaching the back panel to back plate Back plate Front panel (hook and loop strip is located at the end of curtain roll) Drive pipe Back panel Hook and loop strip Center panel 4801-5405 Unitized System Komfort Kool...
  • Page 40 Press these hook and loop strips (99) firmly to secure the panels. Make sure the panels are installed straight along the complete length of the track units. 4801-5405 Unitized System Komfort Kool...
  • Page 41 Chapter 3: Installation Figure 3-32 Attaching the center panel and top panel Center panel TEK screw Back plate Outside track Top bar Inside track Drive pipe Hook and loop seal Front panel Tension pipes Back panel 4801-5405 Unitized System Komfort Kool...

  • Page 42: Installing The Tension Pipes

    3. After required adjustments, reset limits if necessary. 4. Make sure that all of the required TEK screws (9) are installed through the panels at the back plate (38), drive pipe (50) and top bar (41). 4801-5405 Unitized System Komfort Kool...

  • Page 43: Installing The Top Covers And Top Flashing

    4. Also, attach the top flashing (111) to the top of the support bracket (31) with #14 x 1" TEK screws (3) at 1/2" from the bottom edge of support bracket (31). Figure 3-34 Installing the top covers and top flashing 1/4" x 1-1/2" lag screw Flashing Splice Top cover Support bracket End cap 4801-5405 Unitized System Komfort Kool...

  • Page 44: Installing The System End Covers

    2. Also, attach the top flashing (116) to the top of the support bracket (31) with #14 x 1" TEK screw (3) at 1/2" from the bottom edge of the support brackets (31). Figure 3-36 Installing the top flashing Support bracket #14 x 1" hex TEK screws 1/4" x 1-1/2" lag screws Top flashing 4801-5405 Unitized System Komfort Kool...

  • Page 45: Installing The Bearing Mount (Tubular (Somfy) Motor)

    NOTE: Install bolts (2) and nuts (14) to the four holes as indicated in the guide bracket. Figure 3-37 Installing the bearing mount for tubular motor Back plate 1/4"-20 x 1/2" hex bolt Bearing mount 1/4" hex nut 4801-5405 Unitized System Komfort Kool...

  • Page 46: Assembling The Drive Pipes (For Tubular Motor)

    NOTE: Keep hook and loop strips (99) aligned when assembling the drive pipes (50). Figure 3-38 Assembling the drive pipes for tubular motor 7.5 mm (0.295") x 35 mm (1.38") tubular motor only Stainless steel pop rivets Hook and loop strip Swaged end 4801-5405 Unitized System Komfort Kool...

  • Page 47: Installing The Tubular Motor

    NOTE: Dimensions of slot is in millimeters. To convert to inches, multiply mm by 0.0394. Do not drill into motor when installing the pop rivets. CAUTION Figure 3-39 Installing the tubular motor Drive pipe Tube notch Raised key Tubular motor 4801-5405 Unitized System Komfort Kool...

  • Page 48: Installing The Tubular Motor Mount

    2. Follow the above procedure to install the bearing mount (43) to the opposite end of the system. Figure 3-40 Installing the tubular motor mount Back plate 1/4"-20 x 1/2" hex bolt 1/4" hex nut Motor mount Top mounting bracket 4801-5405 Unitized System Komfort Kool...

  • Page 49: Installing The Tubular Motor To Motor Mount

    Press the tubular motor (89) axially into the motor bracket (96) in any of six positions, so that the limit switch adjustment buttons are always easily accessible. Figure 3-42 Mounting the motorized tube Tubular motor Tubular motor bracket 4801-5405 Unitized System Komfort Kool...

  • Page 50: Tubular Motor Electrical Wiring Diagram

    Use personal protection equipment specific to your installation and follow all local CAUTION and national regulatory codes. 1. Disconnect all the electrical power sources. 2. Connect wiring to motor as shown in Figure 3-43, page Figure 3-43 Tubular motor wiring diagram 4801-5405 Unitized System Komfort Kool...

  • Page 51: Tubular Motor Tester Wiring Diagram

    (89) as viewed from connection end of the motor.) 3. Connect the electrical power. 4. Test the motor. 5. Disconnect the electrical power. 6. Remove the test wires. Figure 3-44 Tubular motor test wiring diagram 4801-5405 Unitized System Komfort Kool...

  • Page 52: Connecting The Power And Testing The Motor

    NOTE: Somfy recommends using a test cable to set the motor limits, and to make sure the system is operating properly before the final electrical connection is made. NOTE: Refer to Tubular Motor Tester Wiring Diagram, page 51 for test cable. Figure 3-45 Connecting the power and testing the motor 4801-5405 Unitized System Komfort Kool...

  • Page 53: Setting The Limit Switches Of Tubular Motor

    Changing the Set STOP Position • Press the limit switch adjustment button that lies in the direction of rotation. Bring the curtain into the desired STOP position. Release the limit switch adjustment button by pressing it down again. 4801-5405 Unitized System Komfort Kool...
  • Page 54 Chapter 3: Installation Figure 3-46 Setting the limit switches of tubular motor 4801-5405 Unitized System Komfort Kool...

  • Page 55: Chapter 4 Parts List

    Parts List Topics Covered in this Chapter ▪ Sidewall Left End Track (6421-0307) ▪ Sidewall Right End Track (6421-0308) ▪ Center Track Assembly (6421-0300) 4801-5405 Unitized System Komfort Kool...

  • Page 56: Sidewall Left End Track (6421-0307)

    Chapter 4: Parts List Sidewall Left End Track (6421-0307) Figure 4-1 Sidewall left end track (6421-0307) 4801-5405 Unitized System Komfort Kool...
  • Page 57 N/S 1001-1445 Nut Fin 1/4"-20 HX Z N/S 6421-7410 RS SW F-Vel PLT/PIM 10' N/S 6421-7406 RS SW F-Vel PLT/PIM 6' RS Floating Velcro Assembly N/S 6421-8276 RS Floating Velcro Assembly 10' RT N/S 6421-8264 6' RT 4801-5405 Unitized System Komfort Kool...

  • Page 58: Sidewall Right End Track (6421-0308)

    Chapter 4: Parts List Sidewall Right End Track (6421-0308) Figure 4-2 Sidewall right end track (6421-0308) 4801-5405 Unitized System Komfort Kool...
  • Page 59 N/S 1001-1445 Nut Fin 1/4"-20 HX Z N/S 6421-7410 RS SW F-Vel PLT/PIM 10' N/S 6421-7406 RS SW F-Vel PLT/PIM 6' RS Floating Velcro Assembly N/S 6421-8276 RS Floating Velcro Assembly 10' RT N/S 6421-8264 6' RT 4801-5405 Unitized System Komfort Kool...

  • Page 60: Center Track Assembly (6421-0300)

    Chapter 4: Parts List Center Track Assembly (6421-0300) Figure 4-3 Center track assembly (6421-0300) 4801-5405 Unitized System Komfort Kool...
  • Page 61 0404-8867 FAB GS RS Back Track 7' 6421-0358 RS Guide Bracket Assembly 0404-8863 FAB GS RS Right Track 7' 0404-8864 FAB GS RS Left Track 7' 6421-7407 RS SW F-Vel PLT/PIM 7' 1001-1445 Nut Fin 1/4"-20 HX Z 4801-5405 Unitized System Komfort Kool...
  • Page 62 NOTES 4801-5405 Unitized System Komfort Kool...

  • Page 63: Limited Warranty - Protein Products

    GSI warrants, subject to all other conditions described in this Warranty, Service Parts which it manufactures for a period of 12 months from the date of purchase, unless specified in Enhancements above. Parts not manufactured by GSI will carry the Manufacturer’s Warranty. (Protein Limited Warranty_REV01_ 06 November 2018) 4801-5405 Unitized System Komfort Kool...
  • Page 64 This equipment shall be installed in accordance with the current installation codes and applicable regulations which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made. 1004 E. Illinois St. Assumption, IL 62510-0020 Phone: 1-217-226-4421 Fax: 1-217-226-4420 www.cumberlandpoultry.com...

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