Transcription
Glycol SystemsEngineering ManualPump Packages and Remote Outdoor Drycoolers1/2 - 10 HP Pumps and 10.5 - 667 kW / 60 Hz Drycoolers
0Glycol Systems Engineering ManualNoticeThis document contains information protected by copyright. All rights are reserved. The owner ofthe equipment for which this manual is written may photocopy the contents of this manual forinternal purposes only. No part of this document may be photocopied, reproduced, or translatedinto another language for use by anyone other than the owner of the equipment for which thismanual is written without the prior written consent of STULZ Air Technology Systems, Inc.(STULZ).This document contains confidential and proprietary information of STULZ Air TechnologySystems, Inc. Distributing or photocopying this document for external distribution is in directviolation of United States copyright laws and is strictly prohibited without the express writtenconsent of STULZ.Unpublished rights reserved under the copyright laws of the United States and of other countries.Other brands and trade names are trademarks of their respective owners. 2018 STULZ Air Technology Systems, Inc.Printed in the United States of America.All rights reserved.STULZ Air Technology Systems, Inc.1572 Tilco DriveFrederick, MD 21704 USAhttps://www.stulz-usa.com
Glycol Systems Engineering Manual1Table of ContentsPressure Drop/Flow Rate Curves . 3Recommended Piping Schematic — Single Pump . 11Single Pump Systems . 11Recommended Piping Schematic — Dual Pump. 12Dual Pump Systems . 12Dual Row Drycooler Capacities. 16Altitude Correction Table . 16Single Row Drycooler Technical Data . 17Dual Row Drycooler Technical Data . 18Single Point Power Calculations . 19Glycol Pump Package Electrical Data . 19Single Row Drycooler Electrical Data . 20Dual Row Drycooler Electrical Data . 21Product Guide Specifications . 22Glycol Pump Packages . 22Single Pump Packages . 22Quality Assurance . 22Cabinet Construction . 22Component Access . 22Electrical System . 22Standard Fan Cycling Controls . 23Free-Cooling Fan Cycling Controls . 23Coils . 23Fan Motors . 23Fan Blades . 23Dimensional Data — Remote Outdoor Drycooler Configuration . 24Single Row Fan Configurations . 24FSS-103A & FSS 104A. 24FSS-201A thru FSS-203A . 24FSS-204A thru FSS-211A . 24NOTE: Mounting legs are retracted for shipping. . 24Single Row Fan Configurations . 25FSS-601A thru FSS-603A . 25FSS-701A thru FSS-703A . 25Dimensional Data — Remote Outdoor Drycooler Configuration . 26Remote Dual Row Fan Configurations . 26FDS-401B thru FDS-404B . 26FDS-602B & FDS-603B . 26FDS-801B thru FDS-804B . 26FDS-1001B thru FDS-1003B . 26Dimensional Data — Remote Outdoor Drycooler Configurations . 27Dual Row Fan Configurations . 27
Glycol Systems Engineering Manual2Pump Package Model NomenclaturePump Package Technical SpecificationsHPTypeCabinet 41.442.1387Pump PackageModelApprox.Weight (lb)200
Glycol Systems Engineering Manual3Pressure Drop/Flow Rate CurvesThis section provides pressure drop/flow rate curves for the different GPS pump models. The GPS series providesone to three models per HP rating, specified as A, B, or C in the model number. The A models are ideal forapplications with high head pressures with low flow rate. The B models are best for average head pressure andflow rate to achieve higher efficiencies. The C models are designed for situations of low head pressures and highflow rates.A graph containing a pressure drop curve is provided for each model. Note that curves reflect 40% Ethylene Glycol at 45 .
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11Recommended Piping Schematic — Single PumpSingle Pump SystemsGlycol Systems Engineering Manual
12Recommended Piping Schematic — Dual PumpDual Pump SystemsGlycol Systems Engineering Manual
Glycol Systems Engineering Manual15Drycooler Model NomenclatureSingle Row Drycooler CapacitiesSINGLE ROW FAN CONFIGURATIONS (95 oF Ambient)SINGLE ROW FAN CONFIGURATIONS (105 oF Ambient)95 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT) 105 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT)Models FSS()Maximum FlowRateTotal HeatofRejection(BTU/H)Numberof FeedsCon Size(Qty)*ModelsFSS-( )Maximum FlowRateTotal HeatofRejection(BTU/H)Numberof FeedsConn. Size(Qty)*n/a103A7PD(ftH2O)233,20061 ¼” An/an/an/an/an/a201A166.576,80081 ¼” (1)201A62.428,40061 ¼” (1)n/agpmgpm202A225.6102,500121 ½” (1)202An/an/an/an/a203A243.9112,300161 ½” ,80018181 ½” (1)1 ½” (1)204A205A12135.73.157,00060,5009121 ¼” (1)1 ¼” (1)206A4212.2196,900182” (1)206A162.175,000181 ¼” (1)207A4714.9221,500182” (1)207A192.988,400181 ¼” (1)208A567.1263,800272” (1)208A244.5111,800181 ½” (1)209A618.2285,400272” (1)209A275.5125,500181 ½” (1)210A211A64725.44.4301,500337,20036452” (1)2” (1)210A211A28303.53130,100149,70024301 ½” (1)1 ½” (1)301A843.3393,700542 ½” (1)301A395183,400271 ½” (1)302A872.1406,300722 ½” (1)302A363.2192,000361 ½” (1)303A1003.2470,200722 ½” (1)303A442.5207,100452” (1)401A1217.7567,500543” (1)401A5812.7271,800272” (1)402A403A1261354.93.7593,700635,70072903” (1)3” (1)402A403A61668.36.4286,400310,80036452” (1)2” (1)404A1424.1666,900903” (1)404A717.3332,900452” (1)501A1669.6777,500722 ½” (2)501A8016.3376,400362 ½” (1)502A1787.3838,300902 ½” (2)502A8813414,400452 ½” (1)503A1867.9876,400902 ½” (2)503A9414.6441,700452 ½” (1)601A602A20522016.212.3959,7001,030,70072902 ½” (2)3" (2)601A602A808532.2375,500400,40072902 ½” (1)2 ½” (1)603A23013.41,075,400903" (2)603A952.7441,900902 ½” (1)701A215201,017,200723" (2)701A773.2366,000722 ½” (1)702A23515.71,091,100903" (2)702A902.8420,700902 ½” (1)703A24016.31,127,800903" (2)703A953.1442,100902 ½” (1)
Glycol Systems Engineering Manual16Dual Row Drycooler CapacitiesDual Row Fan Configurations (95 oF Ambient)Dual Row Fan Configurations (105 oF Ambient)95 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT)105 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT)ModelsFDS-( )Maximum FlowRategpmPD(ftH2O)Total HeatofRejection(BTU/H)Numberof FeedsConn. Size(Qty)*ModelsFDS-( )Maximum FlowRategpmPD(ftH2O)Total HeatofRejection(BTU/H)Numberof FeedsConn. Size(Qty)*401B1208567,400542" (2)401B504.8238,700361 ½” (2)402B1305.5606,600722" (2)402B553.4257,400481 ½” (2)403B1404.2647,800902 ½” (2)403B602.7280,600601 ½” (2)404B601B15516514.63.2720,800780,700601082 ½” (2)2 ½” (2)404B601B65763.14.7302,200360,60060541 ½” (2)1 ½” (2)602B1742.1812,7001442 ½” (2)602B823.2384,000722" (2)603B22012.81,032,100903” (2)603B10510492,200602" (2)801B2407.61,131,7001083” (2)801B11512.6541,000542" (2)802B2555.11,192,8001443” (2)802B1208.1567,400722" � (2)3” (2)803B804B1301406.27.1616,300660,60090902" (2)2 ½” (2)1001B3309.51,552,1001443” (3)1001B16016.3752,900722 ½” (2)1002B3607.41,682,6001803” (3)1002B17512.8826,300902 ½” (2)1003B37581,757,1001803” (3)1003B18514.2876,200902 ½” (2)1201B41016.21,919,4001443” (3)1201B16037509001442 ½” 03” (3)3” (3)1202B1203B1701852.22.6800,800868,5001801802 ½” (2)2 ½” (2)1401B48524.92,281,2001443" (4)1401B1703.8799,7001442 ½” (2)1402B52018.92,447,0001803" (4)1402B1953.2913,2001802 ½” (2)1403B54520.52,553,7001803" (4)1403B2053.5958,2001802 ½” (2)* All connections are MPTDrycooler selection: Select drycooler based on your required Maximum Glycol System Flow Rate (GPM)@ design summerambient air temperature (95 F or 105 F).Note: Control panel is located on header connection side (opposite the return bend end).Altitude Correction TableAltitude CorrectionAltitude (ft)0100020003000400050006000Correction Factor10.9710.9580.9450.9320.9190.905
Glycol Systems Engineering Manual17Single Row Drycooler Technical DataFluid DataDrycoolerModelUnit WeightDry (lb)FluidWeightFan DataOperatingCharge(gallons)Quantity ofFansFanDiameterNominal HPFanConfigurationTotal ft3/min1140 RPMSINGLE ROW FAN .901FSS-201A25822.32.68222"22"1/31/31 14,5001 14,0501 29,200FSS-202A28533.64.0321 28,300FSS-203A31244.75.3621 27,600FSS-204A45144.85.3821 216,000FSS-205A46044.85.3821 215,900FSS-206A48067.18.0521 215,600FSS-207A50167.18.0521 215,400FSS-208A54567.18.0521 221,300FSS-209A57267.18.0521 220,700FSS-210A60589.510.7421 219,700FSS-211A660111.913.4321 219,000FSS-301A88099.411.9331 331,90030" - 3P30" - 4P30" - 4P1-1/21-1/21-1/2FSS-302A990132.715.9231 331,000FSS-303A1100165.819.9031 329,500FSS-401A1160131.815.8241 442,500FSS-402A1210175.721.0841 SS-503A1640273.532.82FSS-601A1860261.931.4330" - 4P1-1/21 439,2501 437,7501 551,6501 549,00051 547,15061 662,00030" - 4P30" - 4P1-1/21-1/2FSS-602A1930327.439.2961 658,800FSS-603A2020327.439.2961 656,550FSS-701A2170305.636.6771 772,300FSS-702A2250381.945.8371 768,600FSS-703A2350381.945.8371 765,97030" - 4P1-1/2
Glycol Systems Engineering Manual18Dual Row Drycooler Technical DataFluid DataDrycoolerModelUnit WeightDry (lb)FluidWeightOperatingCharge(gallons)Fan DataQuantity ofFansFanDiameterNominal HPFanConfigurationTotal ft3/min1140 RPMDUAL ROW FAN CONFIGURATIONSFDS-401B1188134.316.1242 243,000FDS-402B1254179.121.5042 241,400FDS-403B1310223.926.8842 239,400FDS-404B1365223.926.8842 3250547.065.6710FDS-1003B3390547.065.67102 B3990654.678.58122 6117,600FDS-1203B4130654.678.58122 6113,100FDS-1401B4360611.073.35142 7144,600FDS-1402B4650763.791.68142 7137,200FDS-1403B4820763.791.68142 7131,95030" - 4P1-1/22 363,8002 362,00062 359,00082X485,0002 482,7002 478,5002 475,5002 5103,3002 598,00030" - 4P30" - 4P30" - 4P30" - 4P30" - 4P1-1/21-1/21-1/21-1/21-1/2
Glycol Systems Engineering Manual19Electrical DataSingle Point Power CalculationsTermCalculationDescriptionFLAFull Load AmpsAdd up the FLA’s of the dry cooler fan motors, add 0.5 amps for the controltransformer, and add the FLA of one of the pump motors. This total is the FLA.See the example below.Pump motor: 8.2 ampsDry cooler: 8.0 ampsControl transformer: 0.5 amps8.28.0 0.516.7 FLAMCAMinimum CircuitAmps/Wire SizeTake the FLA of the highest load (typically the pump motor) and multiply it by 1.25and add all the remaining FLA’s without the multiplier. This number is the MCA.MFSMaximum FuseSizeTake the FLA of the highest load and multiply it by 2.25, then add all the remainingFLA’s without the multiplier. Take this number and round down to the next loweststandard fuse size.Pump NEC standard fuse sizes: 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 100, 125, 150, 175 so the final MFS wouldbe 35 amps.Glycol Pump Package Electrical DataPumpPackage 0151.92.4151.51.915GPS-020-S-A/B/C2.012.1 /an/an/a12.0 8.5 a24.9 31.15011.6 51.51.915GPS-020-D-A/B/C2.012.1 /an/an/a12.0 8.5 a24.9 31.15011.6 14.5259.311.620
Glycol Systems Engineering Manual20Single Row Drycooler Electrical DataMODELFSS-( )Fan HPFan HP @@ CA MFS460-1460-3FLAMCAFLA460MCA MFS575-1575-3575FLAMCAFLAMCA 0n/an/a23.12425n/an/a15.115.620* - 1/2 HP Motors
Glycol Systems Engineering Manual21Dual Row Drycooler Electrical Data208-230/3460/3575/3MODEL FDS-( )Fan HP .710046.247.15030.130.635
Glycol Systems Engineering ManualProduct Guide Specifications½ to 10 HP Pumps10.5 to 667 kW Drycoolers 60 Hz DataGlycol Pump Packages22Quality AssuranceThe manufacturer shall maintain a set of internationalstandards of quality management to ensure product quality.Each system shall be subjected to a complete operationaland functional test procedure at the factory prior to shipment.Cabinet ConstructionThe pumps and main electrical enclosure shall be mounted on awelded aluminum frame and protected by a removable galvanizedsteel weather cover. The pump controls shall be mounted in aNEMA-3R enclosure at the end of the pump package.Component AccessPumps shall be easily accessible via a removable galvanized steelweather cover. Electrical components shall be accessible via aNEMA-3R electrical enclosure with hinged front door.Electrical SystemSingle Pump Packages(Models GPS-( )-S-( ) )The system shall be a single pump package designed toprovide the total required glycol condenser coolant flow rateat the total rated system pressure drop.Dual Pump Packages(Models GPS-( )-D-( ) )The system shall be a dual (two), redundant, pump packagedesigned to provide the total required glycol condenser coolantflow rate at the total rated system pressure drop.The pump shall be sized to provide:The system shall incorporate overcurrent and overloadprotection in accordance with UL 1995 requirements. Thecontrol circuit shall be a 24 Vac Class 2 low voltage circuit.The system shall be complete with: 24-Volt Control TransformerGPM (total system flow rate) Main Power Non-Fused Disconnectft. w.g. (total system press drop) Switch with Lockable Handle% Ethylene Glycol Solution, or Main Power Distribution Block and% Propylene Glycol Solution Grounding Lug Individual Pump Motor ContactorsThe drycooler shall be electrically interfaced with the pumppackage via 24 VAC signal connection.
Glycol Systems Engineering ManualStandard Fan Cycling Controls(Models F()S-( ))23Fan MotorsDrycooler fans shall automatically cycle ON/OFF basedon the leaving glycol temperature as sensed by factoryprovided Aquastat(s) to maintain proper glycol solutiontemperature.Fan motors shall be energy efficient direct driven at 1140 RPM(see note) and designed for outdoor drycooler applications. Fanmotors shall have thermal overload protection and permanentlylubricated ball bearings.Fan Cycling ArrangementNOTE Lower RPM, low sound power drycoolers areoptionally available. Consult your local STULZ SalesRepresentative for more details.FanConfigurationTotal # ofStages1 21 31 41 51 61 72 22 32 42 52 62 7234567234567# FansCycled perStage12Free-Cooling Fan Cycling Controls(Models F( )S-( )-FC)Drycoolers for use with the Free-Cooling economizer coolingmode shall be provided with fan cycling controls. Thedrycooler capacity shall be increased by reversing the typicaldrycooler fan(s) cycling sequence of operation during lowambient conditions to provide the maximum cooling effectfor the free-cooling glycol coolant solution.In addition to the above standard drycooler fan cycling controlsFree-Cooling Fan Cycling Controls shall include the following: Ambient Free-Cooling Mode Enabling Thermostat Free-Cooling Mode Aquastat(s) to Sense and maintain proper coolant Temperature during Free Cooling modeNote: Consult your STULZ Sales Representative whenmixing FC and Non-FC A/C units on the same glycolcondenser source loop.CoilsDrycooler coils shall be high efficiency with corrugatedaluminum fins bonded to staggered copper tubes. Coil endplates shall be hot dipped galvanized. Coils shall be pressuretested and pressurized for shipment.Fan BladesThe drycooler shall incorporate direct-driven propeller fan(s). Thefan blades shall be made from aluminum and have zinc plated hubsfor strength and corrosion protection. Multiple fan drycoolers shallhave internal air baffles to prevent air bypass from one fan sectionto another and to maximize air through each coil section.
Glycol Systems Engineering Manual24Dimensional Data — Remote Outdoor Drycooler ConfigurationSingle Row Fan ConfigurationsFSS-103A & FSS 104A1 Row x Quantity 1 FanFSS-204A thru FSS-211A1 Row x Quantity 2 FansNOTE: Mounting legs are retracted for shipping.FSS-201A thru FSS-203A1 Row x Quantity 2 FansFSS-301A thru FSS-303A1 Row x Qty. 3 Fans
Glycol Systems Engineering Manual25Single Row Fan ConfigurationsFSS-501A thru FSS-503A1 Row x Quantity 5 FansFSS-601A thru FSS-603A1 Row x Quantity 6 FansFSS-701A thru FSS-703A1 Row x Quantity 7 Fans
Glycol Systems Engineering Manual26Dimensional Data — Remote Outdoor Drycooler ConfigurationRemote Dual Row Fan ConfigurationsFDS-401B thru FDS-404B2 Rows x 2 FansFDS-602B & FDS-603B2 Rows x 3 FansFDS-801B thru FDS-804B2 Rows x 4 FansFDS-1001B thru FDS-1003B2 Rows x 5 Fans
Glycol Systems Engineering ManualDimensional Data — Remote Outdoor Drycooler ConfigurationsDual Row Fan Configurations27
North American HeadquartersSTULZ Air Technology Systems, Inc.1572 Tilco Drive Frederick, MD 21704301.620.2033 Fax: 301.662.5487 info@stulz-ats.comTechnical Support: 888.529.1266www.stulz-usa.comQERU020A March 2019 STULZ Air Technology Systems, Inc. - Specifications subject to change without notice.
95 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT) 105 F Ambient Selection (40% ethylene glycol, 120 F EGT / 110 F LGT) Models FDS-( ) Maximum Flow Rate of Total Heat Rejection (BTU/H) Number of Feeds Conn. Size (Qty)* Models FDS-( ) Maximum Flow Rate Total Heat of Rejection (BTU/H) Number of Feeds Conn. Size
