Glycol Systems. Engineering Manual. 1/2 to 10 Hp Pumps 3 to 190 Tons Drycoolers (60 Hz Data) Pump Packages & Remote Outdoor Drycoolers

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1 Glycol Systems Engineering Manual 1/2 to 10 Hp Pumps 3 to 190 Tons Drycoolers (60 Hz Data) Pump Packages & Remote Outdoor Drycoolers

2 Stulz Table of Contents Section - 1 Table of Contents Glycol Pump Packages & Drycooler Product Overview STULZ-ATS is dedicated to providing innovative solutions for critical temperature and humidity control needs. STULZ- ATS designs and manufactures specialized environmental control equipment for commercial, industrial and custom military applications. SATS serves a diverse marketplace - including telecommunications, information technology, medical, financial, educational, industrial process and government contracts - utilizing world-class island manufacturing processes in a modern, 150,000 ft 2 facility. STULZ-ATS combines a global network of sales and service companies with an extensive factory engineering staff and highly flexible manufacturing resources dedicated to providing world-class quality, innovation and customer service. ISO-9001:2001Quality Registered Stulz-ATS is committed to satisfying customer expectations by meeting and exceeding requirements. Our Quality Policy ensures that every Employee is committed to Customer Satisfaction, Teamwork and utilizing Continuous Process Improvement methods in order to deliver an exceptional product. We will continually measure our performance to improve the effectiveness of our quality management system. Glycol Pump Packages (Single & Dual Pump Systems) Section - 2 Guide Specifications Pump Packages Drycoolers Section - 3 Technical Data Glycol Pump Packages Technical Data Dimensional Data Performance Selection Curves Recommended Field Glycol Loop Piping Schematic /3 Electrical Data Glycol Drycoolers Drycooler Performance/Selection Table /5 Drycooler Dimensional Data /10 Electrical Data Glycol Drycoolers (Outdoor Propeller Fan) Standard Features: From 1/2 to 10 Hp in 9 Increments Welded Aluminum Pump Package Frame with Galvanized Steel Weather Cover Heavy Duty Cast Iron, Single Stage End-Suction Centrifugal Pumps Close Coupled to NEMA Standard Motors Precision Machined and Balanced Bronze Impellers High Effiency 3500 RPM TEFC Pump Motors Pump Motor Contactors with Overload Protection 24 VAC Control Transformer Manual Lead-Lag Switch - Dual Pump Packages Main Power Non-Fused Disconnect Single Point and Separate Pump / Drycooler Main Power Connection Options UL 1995 & NYC MEA Approved and Listed Field Installed Features: Flow Switch - Dual Pump Packages Standard Features: From 3 Tons to 190 Tons THR in 40 Increments Single Row & Dual Row Fan Systems Heavy Duty Galvanized Cabinets Vertical or Horizontal Airflow Aluminum Fan Blades Al 2 Fin/Cu Tube Multi-Row Coils Low RPM Direct Driven Propeller Fans Energy Efficient Fan Motors Fan Motor Contactors with Overload Protection 24 VAC Control Transformer Fan Cycling Aquastat Sensors Main Power Non-Fused Disconnect UL/CSA & NYC MEA Approved and Listed 1-1

3 Guide Specifications - Glycol Pump Packages GENERAL GUIDE SPECIFICATIONS Glycol Pump Packages General Description Single Pump Packages (Models GPS-( )-S) The system shall be a single pump package designed to provide the total required glycol condenser coolant flow rate at the total rated system pressure drop. Dual Pump Packages (Models GPS-( )-D) The system shall be a dual (two), redundant, pump package designed to provide the total required glycol condenser coolant flow rate at the total rated system pressure drop. The pump shall be sized to provide: GPM (total system flow rate) ft. w.g. (total system press drop) % Ethylene Glycol Solution or % Propylene Glycol Solution Quality Assurance / UL 1995 The system shall be factory assembled, tested and shipped complete. The system shall be designed for outdoor installation and year round service. The glycol pump package manufacturer shall be an ISO-9001 registered and approved company. The pump package shall be MET Laboratory (an NRTL) listed and labeled in compliance with UL The system shall be a model GPS- - ( HP) Glycol Pump Package as manufactured by Stulz Air Technology Systems, Inc. (SATS) in Frederick, Maryland, USA. Cabinet Construction The pumps and main electrical enclosure shall be mounted on a welded aluminum frame and protected by a removable galvanized steel weather cover. The pump controls shall be mounted in a NEMA-3R enclosure at the end of the pump package. Component Access Pumps shall be easily accessible via a removable galvanized steel weather cover. Electrical components shall be accessible via a NEMA-3R electrical enclosure with hinged front door. Electrical System The system shall incoporate overcurrent and overload protection in accordance with UL 1995 requirements. The control circuit shall be a 24 Vac Class 2 low voltage circuit. The system shall be complete with: 24 Volt Control Transformer Main Power Non-Fused Disconnect Switch with Lockable Handle Main Power Distribution Block and Grounding Lug Individual Pump Motor Contactors with Branch Circuit Protection via Fuses and Overload Protection Dual Pump Status (ON/OFF) Dry- Contact Closure Connection As a safety, each indoor air conditioner s and drycooler s control circuit shall require a pump package power intialization signal via field connection to the pump package s 24 VAC interface connections. Single Point - Pump/Drycooler Main Power Supply: The pump package electric circuit shall be designed for single point main power supply to the pump package for both the pump package and associated drycooler. Drycooler main power connection with fuse protection shall be factory prewired in the pump package main electric box for field connection. Separate - Pump/Drycooler Main Power Supply: (All GPS Pumps & Multi-Drycooler Loops) The pump package electric circuit shall be designed for single point main power supply for pump package operation only. Drycooler main power supply shall require a separate main power supply source. Dual Pump Packages: Flow Switch - field installed: A factory provided, field installed coolant sensing flow switch shall be provided for automatic switchover from primary to backup pump operation in the event of a loss of coolant flow. Manual Lead-Lag Switch: To allow for equal pump run-time and/or to ensure pump operation, a manual lead-lag toggle switch shall be factory included with the Dual Pump Package controls. Pumps - Motors / Impellers Pumps shall be a single stage end suction centrifugal type close coupled to a NEMA standard motor. Pumps shall be constructed of heavy duty cast iron with precision machined and balanced bronze, non-overloading impellers secured to the motor shaft with a stainless steel locknut. Pump motors shall be weather resistant high efficiency TEFC type rated for outdoor installation. Each pump motor shall be Hp at 3500 RPM. Motors shall have overload protection and a minimum NEMA service factor of time rotation control (Optional)A programmable, 7-day electronic timer is available for automatic pump sequencing to even the pump operating hours. The timer shall have a 7-day battery backup with LCD display for ease of programming. The timer shall be factory wired and surface mounted for operation. Guide Specifications - Glycol Pump Packages 2-1

4 Guide Specifications - Remote Glycol Drycoolers Guide Specifications - Remote Glycol Drycoolers GENERAL GUIDE SPECIFICATIONS Remote Outdoor Propeller Fan Glycol Drycoolers (Models F()S-( ) General Description The system shall be a remote outdoor propeller fan, air cooled glycol drycooler (fluid cooler). The drycooler shall provide the condenser heat rejection source for the specified glycol cooled air conditioners. The drycooler shall be sized to provide the following performance: Total Heat of Rejection: BTUH Ambient Air Rating: 95 F DB Glycol Flow Rate: GPM Entering Glycol Temp: 120 F Leaving Glycol Temp: 110 F Percent Glycol: % Type Glycol: (ethylene or propylene) Quality Assurance / UL 1995 The system shall be factory assembled, tested and shipped complete. The system shall be designed for outdoor installation and year round service. The drycooler shall be NRTL listed and labeled in compliance with UL The system shall be a model F()S-. Glycol Drycooler supplied by Stulz Air Technology Systems, Inc. (SATS) in Frederick, Maryland, USA. Cabinet Construction Drycooler casings shall be fabricated from heavy gauge galvanized steel for corrosion protection and appearance. Structural components shall be fabricated from galvanized steel for support. Component Access Fans and Fan Motors shall be accessible by removing fan guards. Electrical components shall be accessible via a removable electrical enclosure panel. Electrical System The electrical components shall be located in a weatherproof enclosure mounted on the end of the drycooler. The system shall incorporate overcurrent and overload protection in accordance with UL 1995 requirements. The control circuit shall be a 24 Vac Class 2 low voltage circuit. The system shall be complete with: 24 Volt Control Transformer Main Power Non-Fused Disconnect Switch Main Power Distribution Block and Grounding Lug Individual Fan Motor(s) Contactors The drycooler shall be electrically interfaced with the pump package via 24 VAC signal connection. Standard Fan Cycling Controls: (Models F()S-( )) Drycooler fans shall automatically cycle ON/OFF based on the leaving glycol temperature as sensed by factory provided Aquastat(s) to maintain proper glycol solution temperature. Fan Cycling Arrangement Fan Config Total # of Stages # Fans Cycled per Stage 1 x x x x x x x x x x Free-Cooling Fan Cycling Controls: (Models F()S-( )-FC) Drycoolers for use with the Free-Cooling economizer cooling mode shall be provided with fan cycling controls. The drycooler capacity shall be increased by reversing the typical drycooler fan(s) cycling sequence of operation during low ambient conditions to provide the maximum cooling effect for the free-cooling glycol coolant solution. In addition to the above standard drycooler fan cycling controls Free-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 mode. (Note: Please consult your local SATS Sales Representative when mixing FC and Non- FC A/C units on the same Glycol Condenser Source Loop.) Coils Drycooler coils shall be high efficiency with corrugated aluminum fins bonded to staggered copper tubes. Coil end plates shall be hot dipped galvanized. Coils shall be pressure tested and pressurized for shipment. Fan Motors Fan motors shall be energy efficient direct driven at 1140 RPM (see note) and designed for outdoor drycooler applications. Fan motors shall have thermal overload protection and permanently lubricated ball bearings. (Note: Lower RPM, low sound power drycoolers are optionally available. Please consult your local SATS Sales Representative for more details.) Fan Blades The drycooler shall incorporate direct-driven propeller fan(s). The fan blades shall be made from aluminum and have zinc plated hubs for strength and corrosion protection. Multiple fan drycoolers shall have internal air baffles to prevent air bypass from one fan section to another and to maximize air through each coil section. 2-2

5 Technical Data - Glycol Pump Packages (1/2-10 Hp) Pump Package Model Size Type Cabinet Dimensions (inches) H W D GPS-005-S-A 1/2 Hp Single GPS-007-S-A 3/4 Hp Single GPS-010-S-A 1 Hp Single GPS-015-S-A 1-1/2 Hp Single GPS-020-S-A 2 Hp Single GPS-030-S-A 3 Hp Single GPS-050-S-A/B 5 Hp Single GPS-075-S-A/B 7-1/2 Hp Single GPS-100-S-A 10 Hp Single GPS-005-D-A 1/2 Hp Dual GPS-007-D-A 3/4 Hp Dual GPS-010-D-A 1 Hp Dual GPS-015-D-A 1-1/2 Hp Dual GPS-020-D-A 2 Hp Dual GPS-030-D-A 3 Hp Dual GPS-050-D-A/B 5 hp Dual GPS-075-D-A/B 7-1/2 Hp Dual GPS-100-D-A 10 Hp Dual Pump Package Model Nomeclature GPS-050-D-A A B S D = A Pump Curve = B Pump Curve = Single Pump Package = Dual Pump Package 005 = 1/2 Hp 007 = 3/4 Hp 010 = 1 Hp 015 = 1-1/2 Hp 020 = 2 Hp 030 = 3 Hp 050 = 5 Hp 075 = 7-1/2 Hp 100 = 10 Hp GPS = Glycol Pump System Technical Data - Glycol Pump Packages (1/2-10 Hp) 3-1

6 Recommeded Piping Schematic Recommended Piping Schematic - Single Pump Package Systems Single Pump Package Systems 3-2

7 Recommeded Piping Schematic Dual Pump Package Systems Recommended Piping Schematic - Dual Pump Package Systems 3-3

8 Performance Data - Glycol Drycoolers Performance Data - Glycol Drycoolers SINGLE ROW FAN CONFIGURATIONS DRYCOOLER SELECTION TABLE SINGLE ROW FAN CONFIGURATIONS 95 F Ambient Selection (40% ethylene glycol, 120F EGT / 110F LGT) 105 F Ambient Selection (40% ethylene glycol, 120F EGT / 110F LGT) Models FSS-( ) Maximum Flow Rate GPM PD (Ft. w.g.) Total Heat of Rejection (BTUH) No. of Feeds Conn. Size (Qty)* 103A , /4 (1) Models FSS-( ) Maximum Flow Rate GPM PD (Ft. w.g.) Total Heat of Rejection (BTUH) No. of Feeds Conn. Size (Qty)* 104A , /4 (1) 104A , /4 (1) 201A , /4 (1) 201A , /4 (1) 202A , /4 (1) 202A , /4 (1) 203A , /4 (1) 203A , /4 (1) 204A , /2 (1) 204A , /4 (1) 205A , /2 (1) 205A , /4 (1) 206A , /2 (1) 206A , /4 (1) 207A , /2 (1) 207A , /4 (1) 208A , (1) 208A , /2 (1) 209A , (1) 209A , /2 (1) 210A , (1) 210A , /2 (1) 211A , (1) 211A , /2 (1) 301A , /2 (1) 301A , /2 (1) 302A , /2 (1) 302A , /2 (1) 303A , /2 (1) 303A , (1) 401A , (1) 401A , (1) 402A , (1) 402A , (1) 403A , (1) 403A , (1) 404A , (1) 404A , (1) 501A , (1) 501A , /2 (1) 502A , /2 (2) 502A , /2 (1) 503A , /2 (2) 503A , /2 (1) 601A , /2 (2) 601A , /2 (1) 602A , /2 (2) 602A , /2 (1) 603A , /2 (2) 603A , /2 (1) Dual Row Fan Configurations 95F Ambient Selection (40% ethylene glycol, 120F EGT / 110F LGT) Models FDS-( ) Maximum Flow Rate GPM PD (Ft. w.g.) Total Heat of Rejection (BTUH) No. of Feeds Conn. Size (Qty)* Dual Row Fan Configurations 105F Ambient Selection (40% ethylene glycol, 120F EGT / 110F LGT) Models FDS-( ) Maximum Flow Rate GPM PD (Ft. w.g.) Total Heat of Rejection (BTUH) No. of Feeds 401B , (1) 401B , (1) 402B , (1) 402B , (1) 403B , (1) 403B , (1) 404B , (1) 404B , (1) 601B , (1) 601B , (1) Conn. Size (Qty)* 602B , /2 (2) 602B , /2 (1) 603B , /2 (2) 603B , /2 (1) 801B , /2 (2) 801B , /2 (1) 802B ,021, (2) 802B , /2 (2) 803B ,131, (2) 803B , /2 (2) 804B ,206, (2) 804B , /2 (2) 1001B ,328, (2) 1001B , /2 (2) 1002B ,484, (3) 1002B , /2 (2) 1003B ,572, (3) 1003B , /2 (2) 1201B ,638, (3) 1201B n/a n/a n/a n/a n/a 1202B ,816, (3) 1202B , /2 (2) 1203B ,919, (3) 1203B , /2 (2) Drycooler Selection: Select drycooler based on your required Maximum Glycol System Flow Rate (GPM)@ design summer ambient air temperature (95 F or 105 F). NOTE: 1. Control panel is located on header connection side (opposite the return bend end) *All Connections are MPT Altitude Correction Altitude 0 ft 1000 ft 2000 ft 3000 ft 4000 ft 5000 ft 6000 ft Correction Factor

9 Technical Data - Glycol Drycoolers Drycooler Model Unit Weight Dry (lbs) DRYCOOLER TECHNICAL DATA Fluid Weight (lbs) Fluid Data Operating Charge (gallons) Fan Data HES-( )-CAA - Remote Centrifugal Blower, Indoor Air Cooled Condenser Quantity of Fans Fan /3/60 Fan Configuration Total CFM 1140 RPM SINGLE ROW FAN CONFIGURATIONS FSS-103A , x 1 FSS-104A ,900 FSS-201A /3 8,550 FSS-202A ,700 FSS-203A ,000 FSS-204A ,400 FSS-205A ,250 FSS-206A x 2 15,000 FSS-207A ,850 FSS-208A ,500 FSS-209A ,000 FSS-210A ,500 FSS-211A ,000 FSS-301A ,000 FSS-302A x 3 31,500 FSS-303A /2 31,000 FSS-401A ,000 FSS-402A , x 4 FSS-403A ,500 FSS-404A ,000 FSS-501A ,250 FSS-502A x 5 50,625 FSS-503A ,000 FSS-601A ,500 FSS-602A x 6 61,750 FSS-603A ,000 DUAL ROW FAN CONFIGURATIONS FDS-401B ,000 FDS-402B , X 2 FDS-403B ,500 FDS-404B ,000 FDS-601B ,000 FDS-602B X 3 63,000 FDS-603B ,000 FDS-801B ,000 FDS-802B /2 82, X 4 FDS-803B ,000 FDS-804B ,000 FDS-1001B ,500 FDS-1002B x 5 101,250 FDS-1003B ,000 FDS ,000 FDS-1202B X 6 121,500 FDS-12035B ,000 Technical Data - Glycol Drycoolers Drycooler Model Nomenclature: FSS-5 03 A Number of Header Sets A = (1) Intlet (1) Outlet Model Size Number of Fans FSS - Single Row, FDS - Dual Row Drycooler Configurations: Please see pages 3-4 & 3-5 for isometric drawings of drycooler configurations. 3-5

10 Electrical Data - Glycol Drycoolers Electrical Data - Glycol Drycoolers model FSS-( ) Single Row Remote Outdoor, Glycol Drycooler - Electrical Data Fan 1-phase Fan 3-phase fla mca fla mca MFS fla mca fla mca MFS fla mca fla mca MFS 103A 1/3 1/ N/A N/A N/A 104A 1/3 1/ N/A N/A N/A 201A 1/3 1/ N/A N/A N/A 202A 1/3 1/ N/A N/A N/A 203A 1/3 1/ N/A N/A N/A 204A N/A N/A N/A N/A A N/A N/A N/A N/A A N/A N/A N/A N/A A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A A N/A N/A N/A N/A N/A N/A Dual Row Remote Outdoor, Glycol Drycooler - Electrical Data model FDS-( ) fla mca MFS fla mca MFS fla mca MFS 401B B B B B B B B B B B B B B B B B

11 Electrical Data - Glycol Pump Packages Pump Package Model Glycol Pump Packages - Electrical Data Size FLA MCA MFS 208/1/60 208/3/60 460/3/60 575/3/60 208/1/60 208/3/60 460/3/60 575/3/60 208/1/60 208/3/60 460/3/60 575/3/60 GPS-005-S-A 1/2 Hp GPS-007-S-A 3/4 Hp GPS-010-S-A 1 Hp GPS-015-S-A 1-1/2 Hp GPS-020-S-A 2 Hp GPS-030-S-A 3 Hp N/A N/A N/A GPS-050-S-A/B 5 Hp N/A N/A N/A GPS-075-S-A/B 1-1/2 Hp N/A N/A N/A GPS-100-S-A 10 Hp N/A N/A N/A GPS-005-D-A 1/2 Hp GPS-007-D-A 3/4 Hp GPS-010-D-A 1 Hp GPS-015-D-A 1-1/2 Hp GPS-020-D-A 2 Hp GPS-030-D-A 3 Hp N/A N/A N/A GPS-050-D-A/B 5 Hp N/A N/A N/A GPS-075-D-A/B 7-1/2 Hp N/A N/A N/A GPS-100-D-A 10 Hp N/A N/A N/A Single point power calculation FLA (full load amps) Calculation: Add up the FLA s of the dry cooler fan motors, add 0.5 amps for the control transformer, and then add the FLA of one of the pump motors. This total is the FLA. MCA (minimum circuit amps/wire size) Calculation: Take the FLA of the highest load (typically the pump motor) and multiply it by 1.25, then add all the remaining FLA s without the multiplier. This number is your MCA. MFS (maximum fuse size) Calculation: Take your FLA of the highest load and multiply it by 2.25, then add all the remaining FLA s without the multiplier. Take this number and round down to the next lowest standard fuse size. Electrical Data - Glycol Pump Packages Example: Pump motor 8.2 amps per motor Dry cooler Fans X 4 amps per fan Control transformer 0.5 amps FLA (8.2) X 1.25 = MCA (8.2) X 2.25 = MFS NEC standard fuse sizes: 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 100, 125, 150, 175 so the final MFS in this case would be 25 amps. 3-7

12 Dimensional Data - Glycool Drycoolers (SINGLE ROW) Dimensional Data - Glycol Drycoolers (SINGLE ROW) FSS-201A thru FSS-202A 1 Row x Qty. 2 Fans Remote Outdoor Drycooler (SINGLE Row Fan Configurations) FSS-103A & FSS 104A 1 Row x Qty. 1 Fan FSS-204A thru FSS-211A 1 Row x Qty. 2 Fans FSS-301A & FSS-302A 1 Row x Qty. 3 Fans NOTES: Mounting legs are retracted for shipping purposes and must be lowered into position for unit installation. Control panel mounted at return end. 3-8

13 Dimensional Data - Glycol Drycoolers (DUAL ROW) FSS-402A, FSS-403A, & FSS-404A 1 Row x Qty. 4 Fans FSS-502A & FSS-503A 1 Row x Qty. 5 Fans Dimensional Data - Glycool Drycoolers (DUAL ROW) FSS-602A & FSS-603A 1 Row x Qty. 6 Fans NOTES: Mounting legs are retracted for shipping purposes and must be lowered into position for unit installation. Control panel mounted at return end. 3-9

14 Dimensional Data - Glycol Drycoolers (DUAL ROW) Dimensional Data - Glycool Drycoolers (DUAL ROW) FDS-401B thru FDS-404B 2 Rows x 2 Fans FDS-602B & FDS-603B 2 Rows x 3 Fans Remote Outdoor Drycooler (DUAL Row Fan Configurations) FDS-1001B thru FDS-1003B 2 Rows x 5 Fans FDS-1202B thru 12035B 2 Rows x 6 Fans FDS-801B thru FDS-804B 2 Rows x 4 Fans 3-10

15

16 the greener way of cooling your data center Tilco Drive, Frederick, Maryland Phone: , Fax: This document was printed on recycled paper, with ecosmart tm environmentally responsible ink products. Registered ISO9001 Quality System ISO-9001:2001 Quality Registered Copyright, September 2008 QE-GLY0032 Rev - Specifications subject to change without notice.

Glycol Systems. Engineering Manual. 1/2 to 10 Hp Pumps 3 to 190 Tons Drycoolers (60 Hz Data) Pump Packages & Remote Outdoor Drycoolers

Glycol Systems. Engineering Manual. 1/2 to 10 Hp Pumps 3 to 190 Tons Drycoolers (60 Hz Data) Pump Packages & Remote Outdoor Drycoolers Glycol Systems Engineering Manual 1/2 to 10 Hp Pumps 3 to 190 Tons Drycoolers (60 Hz Data) Pump Packages & Remote Outdoor Drycoolers Stulz Air Technology Systems, Inc. Table of Contents Section - 1 Table

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