GPS Series Pump Package Installation, Operation ...ats.stulz.com/.../documents/PDF/Precision_AC/glycolpumpsystems.pdf · (©March, 2007) GPS Series Pump Package Installation, Operation

(©March, 2007)

GPS Series Pump Package Installation, Operation & Maintenance Manual

Air Technology Systems, Inc.

(©March, 2007)



MODEL NOMENCLATURE

GPS-020-S-A

S = Single Pump Package

D = Dual Pump Package

A = “A” Pump CurveB = “B” Pump CurveGlycol Pump System

005 = 1/2 Hp

007 = 3/4 Hp

010 = 1 Hp

015 = 1 1/2 Hp

020 = 2 Hp030 = 3 Hp

050 = 5 Hp

075 = 7 1/2 Hp

100 = 10 HpNotice

This document contains information protected by copyright. All rights are reserved. The owner of the equipment forwhich this manual is written may photocopy the contents of this manual for internal use only. No part of this docu-ment may be photocopied, reproduced, or translated into another language for use by anyone other than the ownerof the equipment for which this manual is written without the prior written consent of Stulz Air Technology Systems,Inc. (SATS).

This document contains confidential and proprietary information of Stulz Air Technology Systems, Inc. Distributing orphotocopying this document for external distribution is in direct violation of U.S. copyright laws and is strictlyprohibited without the express written consent of SATS.

Unpublished — rights reserved under the copyright laws of the United States and of other countries.Other brands and tradenames are trademarks of their respective owners.

Copyright 2007 by Stulz Air Technology Systems, Inc.Printed in the United States of America.All rights reserved.

Stulz Air Technology Systems, Inc.1572 Tilco DriveFrederick, MD 21704USA

03/07

(©March, 2007)



1.0 Introduction ....................................... 1-11.1 General ...................................................... 1-1

1.2 Product Description ................................... 1-1

1.2.1 Capabilities and Features .......................... 1-1

1.3 Safety ........................................................ 1-2

1.3.1 General ...................................................... 1-2

1.3.2 Safety Summary ........................................ 1-2

1.4 Product Warranty ...................................... 1-3

1.5 General Design .......................................... 1-4

2.0 Installation ......................................... 2-12.1 Receiving the Equipment. .......................... 2-1

2.2 Site Preparation ......................................... 2-1

2.3 Rigging ...................................................... 2-1

2.4 Mounting/Placement .................................. 2-1

2.4.1 Pump Package .......................................... 2-1

2.4.2 Expansion Tank ......................................... 2-2

2.4.3 Flow Switch (Dual Pump Systems) ............ 2-2

2.5 Piping Connections .................................... 2-2

2.6 Utility Connections .................................... 2-4

2.6.1 Main Power/Control Wiring ........................ 2-4

3.0 Start-Up/Commissioning .................. 3-13.1 Procedure .................................................. 3-1

3.2 Operational Description.............................. 3-2

3.2.1 Dual Pump Systems.................................. 3-2

3.2.2 Automatic Pump Sequencing (Optional) .... 3-2

4.0 Maintenance/Repairs ....................... 4-14.1 Periodic General Maintenance ................... 4-1

4.1.1 General ...................................................... 4-1

4.1.2 Lubrication ................................................. 4-1

4.2 Troubleshooting ......................................... 4-3

4.3 Field Service .............................................. 4-4

4.3.1 Leak Detection and Repair ......................... 4-4

4.3.2 General Common Repairs/Component Replacement ........................... 4-4

TABLE OF CONTENTS5.0 Product Support Group ................... 5-15.1 Technical Support ...................................... 5-1

5.2 Obtaining Warranty Parts .......................... 5-1

5.3 Obtaining Spare/Replacement Parts .......... 5-1

List of Figures

Figure 1- Typical Layout- GPS with Single Pump .. 1-5

Figure 2- Typical Layout- GPS with Dual Pumps ... 1-5

Figure 3- Recommended Mounting ........................ 2-2

Figure 4- Single Pump Piping Installation .............. 2-3

Figure 5- Dual Pump Piping Installation ................. 2-3

Figure 6- Field Wiring ............................................ 2-4

Figure 7- Sample Nameplate ................................. 2-5

Figure 8- Electric Box ........................................... 2-6

Appendix A - Forms

Checklist for Completed Installation .........................A-1

Periodic General MaintenanceChecks and Service Checklist ..................................A-2

Appendix B - Glossary

Definition of Terms and Acronyms ............................B-1

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1.0 INTRODUCTION

1.1 General

The GPS Glycol Pump Package System (GPS)covered by this manual is designed and manufacturedby Stulz Air Technology Systems, Inc. (SATS). Recog-nized as a world leader, SATS provides precisioncooling systems with the highest quality craftsmanshipusing the finest materials available in the industry. Theunit will provide years of trouble free service if installedand maintained in accordance with this manual.Damage to the unit from improper installation, opera-tion or maintenance is not covered by the warranty.

This manual contains information for installation,operation, maintenance, troubleshooting and repair.STUDY the instructions contained in this manual.They must be followed to avoid difficulties. Spare partsare available from Stulz Air Technology Systems toinsure continuous operation. Using substitute parts orbypassing electrical components in order to continueoperation is not recommended and will VOID THEWARRANTY. Due to technological advancements,components are subject to change without notice.

SATS GPS systems are designed to deliver the flowof coolant for water/glycol based A/C condensingsystems. Any use beyond this is deemed to be notintended. SATS is not liable for any damage resultingfrom improper use. The system is designed to beinstalled outdoors unless otherwise noted on theequipment nameplate.

1.2 Product Description

SATS GPS Pump Package Systems are designed tobe the most compact and dependable packaged pumpsystems in the industry. The unit utilizes highly reliablesingle stage, end-suction type centrifugal pump(s)constructed in a heavy duty cast iron housing.Pump(s) are close coupled to weather resistant, 3500RPM TEFC motor(s) rated for outdoor use.

GPS systems are self contained on a light weight,corrosion resistant, welded aluminum frame designedfor mounting to a horizontal surface. The systemincludes the pump(s), drive motor(s), electricalcontrols and aluminum frame with removable weathercover. The electrical controls are in a NEMA 3Routdoor rated enclosure which is installed on the frontof the frame. The mounting frame comes in varioussizes depending on the number and size of pumps

used with the system. Refer to the installationdrawing supplied with your unit for the layout anddimensions of the system.

The flow capacity in GPM will depend on the systemsize which can range from 1/2 to 10 horsepower. SeeSection 1.5 of this manual for the pump capacitycurves. The pump system is designed for use in aclosed-loop circuit in which coolant is continuouslycirculated by the suction pressure created by thepump. The pump is designed to provide the totalrequired coolant flow at the rated system pressuredrop.

SATS GPS systems are designed to operate witheither single or dual (back-up) pumps. Refer to theunit nameplate to identify the model number andcapacity rating of your unit.

NOTE

SATS GPS systems are strictly for non-resi-dential applications.

1.2.1 Capabilities and FeaturesAll Aluminum Welded Frame Construction.Available in sizes ranging from 1/2 to10 Horsepower.Centrifugal Pump with Precision Machined andBalanced, Bronze Pump Impellers.High Efficiency Direct Drive TEFC Motors.Removable Cover For Easy Access To AllComponents.Unit Mounted Control Enclosure with LockableDisconnect Switch.15 Gallon Expansion Tank with Airtrol Fitting.Automatic Pump Switchover, (Dual PumpSystems).Field Installed Flow Switch, (Dual PumpSystems).

1-1

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1-2

1.3 Safety

1.3.1 General

Stulz Air Technology Systems, Inc. uses NOTESalong with CAUTION and WARNING symbols through-out this manual to draw your attention to importantoperational and safety information.

A bold text NOTE marks a short message in theinformation to alert you to an important detail.

A bold text CAUTION safety alert appears withinformation that is important for protecting yourequipment and performance. Be especially careful toread and follow all cautions that apply to your applica-tion.

A bold text WARNING safety alert appears withinformation that is important for protecting you fromharm and the equipment from damage. Pay veryclose attention to all warnings that apply to yourapplication.

A safety alert symbol accompanies a generalWARNING or CAUTION safety statement.

A safety alert symbol accompanies an electricalshock hazard WARNING or CAUTION safety state-ment.

1.3.2 Safety Summary

The following statements are general guidelinesfollowed by warnings and cautions applicablethroughout the manual.

Prior to performing any installation, operation, mainte-nance or troubleshooting procedure read and under-stand all instructions, recommendations and guide-lines contained within this manual.

CAUTION

Never lift any component in excess of 35 poundswithout help. If a lifting device is used to move aunit ensure it is capable of supporting the unit.

CAUTION

All maintenance and/or repairs must be per-formed by a qualified technician.

WARNING

High voltage is used in the operation of thisequipment. Death on contact may result ifpersonnel fail to observe safety precautions.

CAUTION

All personnel working on or near equipmentshould be familiar with hazards associated withelectrical maintenance.

CAUTION

When working on electrical equipment, removeall jewelry, watches, rings, etc. Keep one handaway from the equipment to reduce the hazardof current flowing through vital organs of the body.

CAUTION

Always disconnect the main power supply tothe equipment at the main power disconnectswitch before beginning work on the equipment.A lock-out tag-out procedure should be followedto ensure that power is not inadvertently recon-nected.

CAUTION Never work on electrical equipment unless an-other person who is familiar with the operationand hazards of the equipment and competent inadministering first aid is nearby.

CAUTION Ensure the unit is properly phased. Improperphasing can cause severe damage.

WARNING

Always refer to the manufacturer's MSDS whenhandling glycol coolant.

WARNING

Avoid skin contact with the coolant and wearprotective goggles or glasses to protect eyes.Wear rubber gloves to protect hands.

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1-3

2-Year Standard Limited Warranty:

Stulz Air Technology Systems, Inc., warrants to the original buyer of itsproducts that the goods are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s obligation under this warranty is torepair or replace, at its option, free of charge to the customer, any part orparts which are determined by Stulz Air Technology Systems Inc. to bedefective. The warranty is in effect for 24 months from date of shipment if acompleted Warranty Registration and Start Up Form is submitted to Stulz AirTechnology Systems, Inc. within 90 days from shipment. In the event that acompleted start-up form is not received by Stulz Air Technology Systems, Inc.within 90 days from shipment, the company’s obligation will be for a period of12 months from date of shipment. Parts replaced under warranty are war-ranted for a period of 90 days from shipment or for the remainder of the unitwarranty period, whichever is greater.

Stulz Air Technology Systems, Inc.’s warranty does not cover failures causedby improper installation, abuse, misuse, misapplication, improper or lack ofmaintenance, negligence, accident, normal deterioration including wear and tear,or the use of improper parts or improper repair as determined by SATS. Thiswarranty does not include costs for transportation, costs for removal or reinstal-lation of equipment or labor for repairs or replacement made in the field.

THIS OBLIGATION AND LIABILITY OF STULZ AIR TECHNOLOGY SYS-TEMS, INC. UNDER THIS WARRANTY DOES NOT INCLUDE LOSSES,DIRECT OR INDIRECT, FOR INCIDENTAL OR CONSEQUENTIAL DAM-AGES. THIS WARRANY IS IN LIEU OF ALL OTHER WARRANTIES,EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR MERCHANTABIL-ITY AND FITNESS FOR A PARTICULAR PURPOSE, AND THERE ARE NOWARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACEHEREOF.

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1.4 Product Warranty

SATS offers a two year standard limited warranty as stated below.

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1-4

1.5 General Design

GPS units are selected by total pressure drop (ft.w.g.) and flow rate (GPM) as indicated by the performance curvesshown below. The pump curves designate 2 variations for units with 5 Hp and higher motors. The variations, “A” or“B”, are designated by the suffix incorporated in the unit model number, (see inside cover). For a typical layoutidentifying the major components, see Figure 1 for single pump GPS systems and Figure 2 for dual pump GPSsystems.

1.5.1 Pump

The pump(s) are mounted on an aluminum frame withvibration isolators to eliminate noise and vibrationduring operation. The pump(s) are driven by directdrive motor(s) rated for continuous operation.

1.5.2 Pump Motor

The pump motor(s) are rated at the Hp indicated bythe unit model number. The pump motor(s) haveindividual motor contactors. Each pump motor isprotected from over-current by fuses located in theelectric box.

1.5.3 Electric Box

The electrical components are protected in a NEMA 3Renclosure located on the front of the unit. The electricbox has a lockable front access door which is safetyinterlocked with the service disconnect switch prevent-ing the door from being opened when the switch is inthe “On” position. The switch must be turned “Off” togain access to the electrical components.

The service disconnect switch may be used to turn theunit off for emergency shutdown or during routinemaintenance. The handle of the switch may be lockedin the “Off” position to prevent unintended operation.

Tota

l Sys

tem

Pres

sure

Dro

p (ft

. w.g

.)

Flow Rate - GPM

0 10 20 30 40 50 60 70 80 120 160 200 250 300

0 10 20 30 40 50 60 70 80 120 160 200 250 300

160

140

120

100

80

60

40

20

160

140

120

100

80

60

40

20

1/2 HP - A

3/4 HP - A

1 HP - A

1-1/2 HP - A

2 HP - A

3 HP - A

5 HP - B

7-1/2 HP - B 10 HP - A

5 HP - A7-1/2 HP - A

1.5.4 Expansion Tank

A 15 gallon expansion tank allows for storage ofexcess coolant as it changes in volume due to thermalexpansion. The expansion tank is rated at 75 psiand the inlet/outletholes are 3/4”NPT. The tankis providedwith anautomatic airvent, (fieldinstalled).

The automatic air vent includes an air separating trapand liquid control baffle to assure unrestricted air flowto the tank and air-free liquid flow from the tank. Italso includes a manual vent for adjusting the airvolume in the tank. The expansion tank is to beinstalled at the highest point of the glycol system.

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1-5

1.5.6 Pump Selector Switch (Dual PumpSystems)

The Pump selector switch is mounted on the front of thepump package electric box. It’s used to select whichpump; A or B, is to operate as the primary pump.

1.5.7 Optional Automatic Pump Sequenc-ing Timer (Dual Pump Systems)

Also called “Lead/Lag Switch”, allows for equal pumprun time by automatically cycling operation betweenthe two pumps. The adjustable timer is typically set torotate pump duty after every 7 days of operation. Aselector switch labeled “Manual/ Auto” is provided withthe automatic pump sequencing option. The switchmust be set in the “Auto” position to enable automaticsequencing.

Figure 2- Typical Layout- GPS with Dual Pumps

PUMP SELECTOR SWITCH

RECOMMENDED ENTRY LOCATION FOR FIELD WIRING

SERVICE DISCONNECT SWITCH

ELECTRIC BOX

WEATHER COVER

AUTO SEQUENCING SELECTOR SWITCH (OPTIONAL)

Top View- Weather Cover Removed Front View

MOUNTING HOLES (4)

ELECTRIC BOXPUMP A

PUMP B

INLET

OULET

Top View- Weather Cover Removed Front View

Figure 1- Typical Layout- GPS with Single Pump

SERVICE DISCONNECT SWITCH

ELECTRIC BOX

RECOMMENDED ENTRY LOCATION FOR FIELD WIRING

WEATHER COVER

PUMP

MOUNTING HOLES (4)

ELECTRIC BOXINLET

OULET

1.5.5 Flow Switch (Dual Pump Systems)

A field-installed flow switch verifies fluid flow while theunit is operating. If flow is lost for at least 10 seconds,(adjustable time delay), the unit automatically changesoperation from the primary pump to the back-up pump.

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2-1

2.0 INSTALLATION

2.1 Receiving the Equipment

Your GPS Pump Package System has been testedand inspected prior to shipment. To ensure that yourequipment has been received in excellent condition,make a visual inspection of the equipment immediatelyupon delivery. Carefully remove the shipping containerand all protective packaging. Open the electric boxdoor and thoroughly inspect the unit for any signs oftransit-incurred damage. If there is shipping damage, itmust be noted on the freight carrier's delivery formsBEFORE signing for the equipment. Any freight claimsMUST be done through the freight carrier. SATS shipsall equipment FOB factory. SATS is not liable for anyequipment damage while in transit. SATS can assist inthe claim filing process with the freight carrier. Shouldany such damage be present, notify the SATS ProductSupport Group prior to attempting any repairs. Refer tosection five of this manual for instructions.

Check the equipment against the packing slip to see ifthe shipment is complete. Report all discrepancies tothe appropriate authority.

A Data Package has been sent with your unit. Itcontains this manual, system drawings, applicableMSDS’s and other applicable instructions based onthe configuration and options of your unit. The datapackage has been placed in your unit in a clear plasticenvelope. These documents need to be kept with theunit for future reference.

2.2 Site Preparation

SATS GPS systems are designed with easy serviceaccess in mind. Install the GPS system in a securelocation where the unit cannot be tampered with andthe main power disconnect switch cannot be inadvert-ently turned off. Allow access to the unit for routineoperation, servicing and for necessary maintenance.Refer to the installation drawing provided with your unitfor the dimensions of the GPS system.

NOTE

Working clearance requirements need to be es-tablished prior to mounting the unit. Refer to lo-cal and national electrical codes.

2.3 Rigging

The GPS system is designed to be kept level in avertical position. Move the unit with a suitable device,such as a forklift, or attach an overhead lifting sling,supporting the unit from the mounting base. Avoiddropping or jarring the unit to prevent damage to themotor bearings or pump parts. Use an appropriatecapacity lifting device that can safely handle theweight of the equipment. Weight estimates can befound on the installation drawing provided with yourunit. If using an overhead lifting device, utilize liftingbars that exceed the cabinet width so as to avoidcrushing the sides of the unit. GPS systems areshipped on a skid to facilitate moving prior to installa-tion. Units should always be stored in a dry locationprior to installation.

2.4 Mounting/Placement

2.4.1 Pump Package

GPS systems are designed for mounting to a flatsurface. Locate the unit with the suction side as closeto the suction supply as possible. Install the GPSsystem in a secure location with adequate space foraccessing components for installation, maintenanceand repair procedures. In order to have full serviceaccess, the unit must be placed so that there are noobstructions in front or overhead. The components maybe accessed from all four sides of the unit and from thetop by removing the cover. The electric box is accessedfrom the front of the unit.

GPS systems must not be located in the vicinity ofsteam, hot air or fume exhausts. Avoid areas that areprone to flooding. Avoid ground level sites that areaccessible to the public.

Install a solid base, capable of supporting the weight ofthe equipment. Refer to the installation drawing for thenon-charged system weight. The base should be atleast 2 inches higher than the surrounding grade and 2inches larger then the dimensions of the GPS unitbase. (See Figure 3.)

In order to reduce the amount of vibration transmitted tothe mounting surface, insert the factory provided vibrationisolators between the GPS system and the base, asshown in Figure 3. Secure the unit with fasteners (fieldsupplied by others) so that the system will not moveduring operation.

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2-2

outlet use (NPT) fittings. Pipe size may not necessar-ily be the same size as the unit connection.

Piping should be sized to match the total systempressure drop and pump capacity. Piping must besized according to the piping distance from the pumpto the rest of the equipment. Each valve, fitting andbend in the line must be considered in the calculation.

The piping should be isolated from the building by theuse of vibration isolating supports. To prevent damageand to reduce vibration transmission, use a softflexible material to pack around the pipes when sealingopenings in walls.

NOTE

When making the connections to the pump(s),a teflon tape thread sealant is recommended tominimize internal fouling of the piping.

2.5.1 Minimum Recommended SuctionSide Piping

Install a concentric reducer at the pump suctionopening and make all suction piping at least one-(1)size larger than the diameter of the suction inlet.Install a suction strainer with a net area 2-3 timeslarger than the suction piping. The piping leaving theheat exchanger should enter the pump suction port.Install an isolation valve in the suction line for mainte-nance purposes.

2.5.2 Minimum Recommended DischargeSide Piping

Install a concentric reducer at the pump dischargeopening and make all discharge piping at least one-(1)size larger than the diameter of the discharge outlet.Install a check valve in the discharge line to preventback flow that may damage the pump on shut down.Install an isolation valve in the discharge line formaintenance purposes.

CAUTION

A by-pass flow valve must be provided aroundthe pump suction and discharge connections.This provides a path for the coolant to return tothe suction side of the pump, allowing the pumpto continuously operate at full speed. This willprevent damage to the pump seals which wouldresult from an insufficient load on the pump,causing the motor to over-heat.

BUSHING

FRAME

FLAT WASHER

LOCK WASHER

FLAT WASHER

HEX NUT

HEX NUT

MOUNTING STUD

VIBRATIONPAD

Figure 3- Recommended Mounting

2.4.2 Expansion Tank

The expansion tank must be installed at the highestpoint of the glycol system. The pump should be at least3 feet below the height of the expansion tank. Install theautomatic air vent in the top of the expansion tank.

2.4.3 Flow Switch (Dual Pump Systems)

The flow switch (shipped loose) is to be installeddirectly in the suction pipeline to detect the totalamount of coolant flow. When installing the flowswitch refer to the piping diagram provided with yourunit and follow the the manufacturers installationinstructions provided in the box with the switch.

When installed, the paddle of the flow switch must beallowed to fully travel (swing), to the point where themechanism of the switch actuates. If the switch is toohigh above the body of the “Tee” fitting, the paddlecould then be obstructed by the inside of the fitting.

2.5 Piping

The pump system will require a field installed suctionline and discharge line. Refer to the piping diagramprovided with your unit for details. The pump inlet and

GOOD

DO NOT ALLOW PADDLE TOSTRIKE PIPE FITTING

FLOW SWITCH

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2-3

Figure 4- Single Pump Piping

Figure 5- Dual Pump Piping

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2.6 Utility Connections

2.6.1 Main Power And Control Wiring

The pump package requires field power and controlwiring (see Figure 6). The unit electric box is providedwith main power and control terminal positions forconnection of field-wiring (supplied by others). It isimportant to identify the options that were purchasedwith the unit in order to confirm which field connectionsare required. The number of control conductors neededwill vary depending on the type of control being usedwith your equipment. Refer to the electrical drawingsupplied with your unit to determine the total numberof interconnecting conductors required for your systemand for the proper wire terminations.

The GPS system is available in the following voltages:

208-230 VAC 1-phase

208-230 VAC 3-phase

277 VAC 1-phase

460 VAC 3-phase

575 VAC 3-phase

Verify that the main power supply coincides with thevoltage, phase and frequency information specified onthe system nameplate. The supply voltage measured

2-4

at the unit must be within ±10% of the voltage speci-fied on the nameplate (see Figure 7). The nameplatealso provides the full load amps (FLA), the current thatthe unit will draw under full design load, the minimumcircuit ampacity (MCA) for wire sizing, and the maxi-mum fuse size (MFS) for circuit protection. The unit'snameplate is located inside the electric box.

Entrance holes for the conduit may be made in theside of the electric box. The main power wires areterminated at the line side of the service disconnectswitch, located within the electric box. A separateequipment ground lug is provided within the electricbox for termination of the earth ground wire (see Figure8).

WARNINGHigh voltage is used in the operation of thisequipment. Death on contact may result ifpersonnel fail to observe safety precautions.

WARNINGVerify power is turned off before making connec-tions to the equipment.

Figure 6- GPS Field Wiring

GLYCOL PUMP SYSTEM

WITH NFPA 70, N.E.C.)

INTERCONNECTING FIELD WIRING(TO BE INSTALLED IN ACCORDANCE

MAIN POWER SUPPLY

L2

L3

L1

CONTROL WIRES(QUANTITY VARIES)

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2-5

NOTE

All wiring must conform to local and national elec-trical code requirements. Use copper conduc-tors only. Wiring terminations may become looseduring transit of the equipment therefore; verifyall wiring terminations are secure prior to opera-tion.

It is important to note that the control transformersupplied with the equipment is sized and selectedbased upon the expected load for the system.

CAUTION

Do not connect any additional loads to the sys-tem control transformer. Connecting additionalloads to the factory supplied control transformermay result in overloading of the transformer, whichwill cause the transformer circuit breaker to trip.

Figure 7- Sample Nameplate

Model Number:Item Number:

Serial Number:

Electrical Data:Phase: Hz:

No. Wires: (Including Ground) 0.5FLA: MCA: MFS: A

FLA:FLA:FLA:FLA:FLA:FLA:FLA:FLA:FLA:FLA:

SATS1

Q.A. Acceptance:

Fax: (301) 620-1396

www.stulz-ats.com

GPS-XXX-X

Voltage:

Job Number:

Manufactured By

Frederick, Maryland, USA

Cage Code OB716Tel: (301) 620-2033

Drycooler Fan (3) HP:Drycooler Fan (4) HP:Drycooler Fan (5) HP:Drycooler Fan (6) HP:

Pump Motor (1) HP:Pump Motor (2) HP:Drycooler Fan (1) HP:Drycooler Fan (2) HP:

Drycooler Fan (7) HP:Drycooler Fan (8) HP:

Date of Manufacture:

Suitable for Outdoor Use

Minumum Installation Clearance: 0.0 in.

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2-6

The number call outs in Figure 8 coincide with thenumbered items listed below:

1. Fuses2. Ground Lug3. Motor Contactors4. Service Disconnect Switch5. Timer For Pump Failure Switchover (For Dual

Pump Systems)6. Control Transformer7. Control Wiring Terminals8. Lockable Access Door9. Disconnect Switch Handle Interface

Figure 8- Electric Box(Shown with access door opened)

2

1

3

4

8

6

7

9

5

NOTE

The electric box shown in Figure 8 is for referenceonly. The electric box furnished with your system maylook different depending upon the unit model numberand the options selected.

NOTE

Disconnect switch handle must be in the “Off”position to open the electric box.

CAUTION

Improper wire connections will result in reverserotation of the pump. To correct this problem,exchange any two of the incoming main powerwires at the service disconnect switch. DoNOT rewire the unit's individual components.

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3-1

3.0 START-UP/COMMISIONING

3.1 Procedure

For new installations, ensure the unit is ready tooperate by going through the Checklist for CompletedInstallation, located in Appendix A, prior to start-up.

NOTE

A Warranty Registration and Start-Up Checklistis provided with the unit data package. It shouldbe completed during start-up and sent to SATS.This checklist should be used as a guideline foritems that need to be confirmed during start-up.

CAUTION

It is recommended that start-up be performedby qualified technician.

The following precautions must be observed whenfilling the glycol loop:

All air must be bled from the piping system.

The piping system must be cleaned prior toadding the glycol solution to the system.

Use only water glycol solution with inhibitorsfor corrosion protection.

1. Once all piping connections have been made andtested for leaks, the system is ready to be filledwith water/glycol coolant. Fill the system with pre-mixed glycol solution before turning the pump on.The pump is not self priming so it’s important thatthere is a pressure on the suction inlet. This iswhy the expansion tank must be located abovethe pump.

CAUTION

Do not fill the system with water and then addthe glycol. They will not mix in the piping sys-tem. Pump failure may occur as the glycol “slug”passes through the pump.

2. Turn the pump package on using the servicedisconnect switch on the door of the electric box.

3. Apply power to the A/C system controller. Refer tothe separate controller operation instructions sentwith your A/C unit in the data package. Testcooling operation by adjusting the temperaturesetpoint at the system controller. The pump willstart running, providing coolant flow through thepiping system, when there is a call for cooling.

NOTE

The the system controllewr may have a timedelay for pumping system to start-up.

4. If the pump has no discharge pressure, partiallyclose the discharge valve to back up liquid in thepump and to keep the impeller from getting toohot. Make sure there is always liquid flowingthrough the pump. If there is no flow, shut off thepump immediately to prevent damage to thepump.

CAUTION

Do not allow the pump to run dry.

5. The A/C system controller may be bypassed totest pump operation. With the service disconnectswitch in the “Off” position, install a jumperbetween the terminals labeled “24 volt Interface ToThe System Controller”, terminals 1 and 2 (Seethe electrical drawing supplied with your unit).When the service disconnect switch is turned tothe “On” position, the pump will operate.

NOTE

Ensure the jumper is removed prior tocommisioning the pump package for use.

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3-2

3.2 Operational Description

When the service disconnect switch is in the “On”position, 24 volts is supplied from the pump packageto the A/C system controller’s “Pump Enable” drycontact. When the air conditioner has a call (demand)for cooling, the controller “Pump Enable” dry contactsclose, completing the circuit to the GPS unit. Power isapplied to the interface terminals labeled ”RemoteDrycooler” inside the electric box. The pump turns onand coolant flows from the pump. The “RemoteDrycooler” interface terminals may be used to cycleDrycooler fans on.

3.2.1 Dual Pump Systems

A Pump Selector Switch is provided for dual pumpsystems to allow the operator to manually switchoperation from the primary pump to the back-up pump.The normal position for the selector switch is in the“Pump A” position. Switching to Pump B manuallyoverrides the primary pump control and only thesecondary pump will operate.

A flow switch senses if there is a loss of fluid flowwhen the unit is operating. When the unit is first turnedon, a time delay overrides the flow switch long enoughto allow the pump to begin circulating the coolant. Thistime delay is factory set for 10 seconds (adjustable). Ifflow is lost and not re-established after the time delay,the flow switch closes a 24 VAC control circuit to alatching switchover relay which turns off the primarypump contactor and turns on the secondary pump.The latching relay prevents the pumps from switchingback and forth from primary to secondary until manu-ally reset by toggling the Pump Selector Switch orcycling power off and on with the Service DisconnectSwitch. Whatever position the Pump Selector Switchis in, the GPS will automatically switch pumps shouldthe flow switch detect a loss of coolant flow.

3.2.2 Automatic Pump Sequencing(Optional)

A Manual/Auto selector switch is mounted on the frontof the pump package electric box if the optionalautomatic pump sequencing feature is provided.Normally the switch is kept in the “Auto” position,which allows the controller to rotate the pumps (autosequence), every 7 days. When the Manual/Autoselector switch set to the “Auto” position, the PumpSelector Switch is disabled. When switched to the

“Manual” position, automatic pump sequencing isdisabled and the Pump Selector Switch is enabled forthe operator to manually switch the pumps.

Switching to the “Manual” position manually overridesthe automatic pump control and only the selectedpump will operate. With the Manual/Auto SelectorSwitch in the “Manual” position, the pump package willstill automatically switch the pumps in the event of aloss of coolant flow.

1. When the service disconnect switch is in the “On”position and the A/C unit is calling for cooling (orpins 1 and 2 are jumped on the terminal block),power is applied to the Time Delay Relay, theRemote Drycooler interface terminals and the PumpSequencing Timer.

2. If the flow switch does not detect fluid flowingthrough the piping after the time delay has expired,the Lockout relay coil is energized (24 volts). Thisautomatically switches over to the secondary pump.This is a one-time event, unless power is cycled onand off.

3. When the flow switch proves flow, the normally opencontacts of the flow switch close, sending 24 voltsthrough the contacts of the Lockout Relay to thepump’s Manual/Auto mode selector switch.

Manual Mode: Power is supplied to either the primaryor standby pump; (Pump A or Pump B), as indicatedon the Pump Selector Switch.

Auto Mode: Power is supplied to the Pump Sequenc-ing Timer and Pump Selection Latching Relay coil.This allows the timer to switch pumps after a period oftime to give equal run times. The factory setting is 7days (field adjustable). When the selector switch is inthe Auto mode, the pump selector switch is bypassed.

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4-1

Use a vacuum cleaner with a soft bristle brush to cleandirt from components. The following lists preventivemaintenance checks and services that should beperformed at recommended intervals:

• Examine all wiring for signs of chafing, looseconnections or other obvious damage. (Semi-annually)

• Examine brackets, motor mounts and hardware forloose or missing parts or other damage. (Semi-annually)

• Clean accumulations of dust and dirt from exteriorsurfaces. (Semi-annually)

• Lubricate motor bearings if applicable. (See below.)

4.1.2 Lubrication

For motors that require periodic lubrication, a greasefitting is provided. Generally a grease fitting is found onlarger pump motors (>7 1/2 Hp).

NOTE

Some motors are provided with permanently lu-bricated bearings and will not require service forthe lifetime of the equipment.

The lubricating ability of bearing grease dependsprimarily on the type of grease, the size of the bearing,the speed at which the bearing operates and theseverity of the operating conditions. This lubricatingability can be lost over time. The following recom-mended lubrication interval and procedure should befollowed:

1. A high grade ball or roller bearing grease shouldbe used. Several recommended greases forstandard service conditions are Shell Dolium R(factory installed), Texaco Polystar, Amoco RykonPremium #2 or Chevron SRI#2.

2. Lubrication should be performed at the recom-mended intervals shown in the table below. Theserecommended intervals are based on average use.See the name plate on the motor for frame sizeand rated speed.

Table 1 - Lubrication Intervals

Rated Speed - RPM

NEMA/(IEC) Frame Size 3600 1800

Up to 210 incl. (132) 5500 Hrs. 12000 Hrs

Over 210 to 280 incl. (180) 3600 Hrs. 9500 Hrs.

Over 280 2200 Hrs 7400 Hrs.

4.0 MAINTENANCE/REPAIRS

4.1 Periodic General Maintenance

Systematic, preventive maintenance of the GPSsystem is recommended for optimum system perfor-mance. Routine periodic maintenance should include,but is not limited to the following: tightening electricalconnections, cleaning, inspecting the unit’s compo-nents visually. Checking level of coolant and ensuringno leaks are present.

A system should be established to record any prob-lems, defects and deficiencies noted by operators anddiscovered during mauntenance inspections, togetherwith the actions taken. Use copies of the PeriodicGeneral Maintenance Checklist in this manual, (seeAppendix A), to record periodic general maintenanceinspections. For assistance, contact the SATSProduct Support Group. Ensure adherence to allsafety statements while performing any type ofmaintenance.

This unit employs high voltage equipment with rotatingcomponents. To prevent personal injury, stay clear ofrotating components because automatic controls maystart them unexpectedly. Exercise extreme care toavoid accidents and ensure proper operation.

WARNING

Turn off power to the unit at the service discon-nect switch unless you are performing tests thatrequire power. With power and controls ener-gized, the unit could begin operating automati-cally at any time.

Always disconnect power prior to performing anyservice or repairs. Hazardous voltage will still bepresent even with the unit turned off at the servicedisconnect switch. To totally isolate the unit formaintenance, ensure power is turned off at the mainsource of power.

4.1.1 General

Maintenance access to the pump package is throughthe front and rear of the unit when the optional weathercover is in place. The pump should require no mainte-nance other than the motor bearings, if applicable (seesection 4.1.2). Routinely examine the areas aroundthe pump motor(s) and inlets and outlets. Checkcoolant and piping for signs of leaks. Check all coolantlines for vibration isolation and support as necessary.

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4-2

Sample Lubrication DeterminationAssume NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient temperature of 43°C and an atmosphere that ismoderately corrosive.

1. Table 1 lists 9500 hrs for standard conditions.2. Table 2 classifies severity of service as “Severe”.3. Table 3 lists a multiplier of 0.5 for severe conditions.4. Table 4 shows 1.2 in³ or 3.9 teaspoons of grease to be added.

4.1.2.1 Lubrication Procedure

Be sure that the grease you are adding is compatiblewith the grease already in the motor. Consult thefactory or the motor manufacturer if you are using agrease other than the recommended type.

CAUTION

To avoid damage to motor bearings, keep greasefree of dirt. If you have an extremely dirty envi-ronment, contact the factory or the motor manu-facturer for additional information.

1. Clean the grease fitting.

2. If the motor has a grease outlet plug remove it.

3. If the motor is stopped, slowly add the recom-mended amount of grease. If the motor is to begreased while running, add a slightly greaterquantity of grease.

4. Add grease slowly until new grease appears atshaft hole in the endplate or purge outlet plug.

5. Re-install grease outlet plug if removed.

Table 2 - Service Conditions

Severity Ambient Temperature Atmospheric Type of Service Maximum Contamination of Bearing

Standard 40°C Clean, Little Corrosion Deep Groove Ball Bearing

Severe 50°C

Moderate dirt, Ball Thrust, Roller Corrosion

Extreme>50°C* or Class H Severe dirt, All Bearings Insulation Abrasive dust, Corrosion

Low Temperature <-30°C**

*Special high temperature grease is recommended (Darmex 707).**Special low temperature grease is recommended (Arrowshell 7).

Table 4 - Bearing Sizes and Types

Bearing Description (These are the “Large” bearings (shaft end) in each frame size)

Frame Size Weight of Grease Volume of grease NEMA (IEC) Bearing OD mm Width mm to add oz to be added

(grams) in3 teaspoon

Up to 210 incl. (132) 630 8 21 0.30 (8.4) 0.6 2.0

Over 210 to 280 incl. (180) 6311 120 29 0.61 (17.4) 1.2 3.9

Over 280 6313 140 33 0.81 (23.1) 1.5 5.2

Table 3 - Lubrication Interval Multiplier

Severity of Service Multiplier

Standard 1.0

Severe 0.5

Extreme 0.1

(©March, 2007)



4-3

SYMPTOM PROBABLE CAUSE RECOMMENDATION

Unit Fails to Start a. Incorrect phasing or voltage. Correct phase or voltage input.

b. Low line voltage. Check power source for cause of lowline voltage.

c. Power failure. Check power source, power inlet andfuses. Check power cables andconnections.

d. Overload protection tripped. Check for cause of overload and replacefuse(s) or reset motor contactor(s).

Control is Erratic Wiring improperly connected or 1. Check wires for continuity.broken.

2. Check wiring against schematicdiagram.

Low Flow a. Valve stuck or obstructed. Repair or replace valve.

b. Loss of fluid. Locate leak and repair. Replace lostfluid in system.

c. Clogged strainer. Replace with new strainer.

A/C and/or Drycooler a. Temperature setpoint too high. Adjust to desired temperature.Fails to Start

b. Control wiring is open. Ensure that wiring is not broken andconnections are not loose.

c. Time delay has not expired. Wait for time to expire.

4.2 Troubleshooting

WARNING Turn off all power to the unit before conducting any troubleshooting procedures, unless the procedure specifi-cally requires the system to operate. Keep hands, clothing and tools clear of the electrical terminals androtating components. Ensure that your footing is stable at all times.

(©March, 2007)



4-3

4.3 Field Service

It may be necessary to perform repairs on the GPSsystem. If field repairs are necessary, the followingprocedures apply:

NOTE

Do not attempt to make repairs without theproper tools.

4.3.1 Leak Detection and Repair

Visually inspect the pipe inlet/outlet fittings andobserve the area around the pump and the base forsigns of leaking coolant.

NOTE

Repairs must be performed by a qualified tech-nician.

If a leak is located in the piping, isolate that section ofpiping using appropriate shut-off valves. It may benecessary to drain some of the coolant. When repairsare complete, pressure check the system, checkingfor leaks prior to refilling the system with water/glycol.In 24 hours, observe the piping system for leaks.

4.3.2 General Common Repairs/Component Replacement

If a failure has occurred, determine whether it is anelectrical or a mechanical failure. An electrical failuremay be indicated by the distinct pungent odor oncethe electric box has been opened. A mechanical failuremay be indicated by an abnormal or excessive noisefrom the pump or motor.

All electrical connections should be checked to besure that they are tight and properly made. Check allfuses, contactors and wiring. The contactor should beexamined and replaced if contacts are worn or pitted.

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5-1

5.0 PRODUCT SUPPORT GROUP

SATS provides to its customers a Product SupportGroup (PSG) which not only provides technical supportand parts but the following additional services, asrequested: performance evaluations, start-up assis-tance and training.

5.1 Technical Support

The SATS Product Support Group (PSG) is dedicatedto the prompt reply and solution to any problemencountered with a unit. Should a problem develop thatcannot be resolved using this manual, you maycontact PSG at (240) 529-1399 Monday throughFriday from 8:00 a.m. to 5:00 p.m. EST. If a problemoccurs after business hours, dial the page number(301) 414-4514 and follow the steps below:

1. Wait for the dial tone.

2. Dial your telephone number (including area code).

3. Press the pound (#) key.

4. Wait for a busy signal.

5. Hang up the telephone.

One of our service technicians will return your call.When calling to obtain support, it is vital to have thefollowing information readily available, (information isfound on unit's nameplate):

• Unit Model Number (GPS-XXX-X-X)

• SATS Item Number (123456)

• Unit Serial Number (1234567)

• Description of Problem

5.2 Obtaining Warranty Parts

Warranty inquires are to be made through the ProductSupport Group (PSG) at (240) 529-1399 Mondaythrough Friday from 8:00 a.m. to 5:00 p.m. EST. Aservice technician at SATS will troubleshoot thesystem over the telephone with a field service techni-cian to determine the defect of the part. If it is deter-mined that the part may be defective a replacementpart will be sent UPS ground. If the customer requeststhat warranty part(s) be sent by any other method thanUPS ground the customer is responsible for theshipping charges. If you do not have established creditwith SATS you must provide a freight carrier accountnumber.

A written (or faxed) purchase order is required onwarranty parts and must be received prior to 12:00p.m. for same day shipment. The purchase order mustcontain the following items:

• Purchase Order Number

• Date of Order

• SATS Stated Part Price (obtained from PSG)

• Customer Billing Address

• Shipping Address

• Customer's Telephone and Fax Numbers

• Contact Name

• Unit Model No., Serial No. & SATS Item No.

The customer is responsible for the shipping costincurred for shipping the defective part(s) back toSATS. Return of defective part(s) must be within 30days at which time an evaluation of the part(s) isconducted and if the part is found to have a manufac-turing defect a credit will be issued.

When returning defective part(s) complete the ReturnMaterial Authorization Tag and the address labelreceived with the replacement part.

See SATS Standard Warranty located in section oneof this manual.

5.3 Obtaining Spare/Replacement Parts

Spare and replacement parts requests are to be madethrough the Product Support Group (PSG) by fax (301)620-1396, telephone (240) 529-1399 or E-mail([email protected]). Quotes are given for specifiedlisted parts for a specific unit.

SATS accepts Visa and MasterCard. SATS mayextend credit to its customers; a credit applicationmust be prepared and approved (this process couldtake one week).

A 25% minimum restocking charge will be applied onreturned stocked parts that were sold as spare/replacement parts. If the returned part is not a stockeditem, a 50% restocking charge may be applied.Additionally a Return Material Authorization Number isrequired when returning parts. To receive credit forreturned repair/replacement parts, the parts must bereturned to SATS within 30 days of the purchase date.Spare part sales over 30 days old will be consideredfinal and the parts will remain the sole property of theordering party.

(©March, 2007)




APPENDIX A - FORMSStulz Air Technology Systems Inc.Frederick, Maryland USA 21704

Telephone: (301) 620-2033 Facsimile: (301) 620-1396

Checklist for Completed Installation

Frederick, Maryland USA 21704

GPS Series Pump Package Telephone: (301) 620-2033Facsimile: (301) 620-1396

❏ 1 Proper clearances for service access havebeen maintained around equipment.

❏ 2 Equipment is level and mounting fasteners aretight.

❏ 3 Piping completed to equipment.

❏ 4 All field installed piping leak tested.

❏ 5 Water/glycol added.

❏ 6 Incoming line voltage matches the equipmentnominal nameplated rating ± tolerances.

❏ 7 Main power wiring connections to the

equipment, including earth ground, have beenproperly installed. Ensure correct phasing perthe wiring diagram supplied with your unit.

❏ 8 Customer supplied main power circuit breaker

(HACR type) or fuses have proper ratings forequipment installed.

❏ 9 Control wiring connections completed to A/C

unit and drycooler.

❏ 10 All wiring connections are tight.

❏ 11 Foreign materials have been removed from

inside and around all equipment installed(shipping materials, construction materials,tools, etc.).

❏ 12 Pump motor rotates freely, in the proper

direction and without unusual noise.

❏ 13 Inspect all piping connections for leaks during

initial operation.

A-1

(©March, 2007)



NOTES

(©March, 2007)



Frederick, Maryland USA 21704

GPS Series Pump Package Telephone: (301) 620-2033Facsimile: (301) 620-1396

Periodic General Maintenance Checks and Services Checklist

Date: ____________________________ Prepared By: ___________________________

Model Number: ____________________________ Serial Number: __________________________

Item Number: ____________________________

Monthly

❏ Remove oil, dust, dirt, water, chemicals from extreior of motor and pump.

Semi-Annually

❏ Check water/glycol solution level ❏ Tighten Electrical Connections

❏ Clean out open motors with low pressure ❏ Ensure Motor Mount is Secured

compressed air. ❏ Clean Unit as Necessary

❏ Ensure Piping is Secured

Annually

❏ Inspect System for Leaks and Corrosion

❏ Check motor bearings and replace if necessary

❏ Conduct a Complete Check of All Services ListedAbove

Notes:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Signature:________________________________

*** If factory assistance is required for any reason, provide the model number, serial number, and SATS item numberfound on the unit nameplate. This will speed the process and ensure accuracy of information. ***

A-2


(©March, 2007)



NOTES

(©March, 2007)



Appendix B- Glossary

Definition of Terms and Acronyms

SATS - Stulz Air Technology Systems, Inc.

BMS - Building Management System

BTU/Hr - British Thermal Units Per Hour

ESD - Electrostatic Discharge

º F - Degrees Fahrenheit

FLA - Full Load Amps

FOB - Freight on Board

GPM - Gallons per Minute

HACR - Heating, Air Conditioning, Refrigeration

Hp - Horse Power

Hz - Hertz

KVA - Kilo Volt Amps

kW - Kilowatt

MAX CKTBKR - Maximum Circuit Breaker

B-1

MAX FUSE - Maximum Fuse

MCA - Minimum Circuit Ampacity

MSDS - Material Safety Data Sheet

NEC - National Electric Code

NFPA - National Fire Protection Agency

NPT - National Pipe Thread

PSG - Product Support Group

PSI - Pounds Per Square Inch

PSIG - Pounds Per Square Inch Gauge

RLA - Run Load Amps

SPDT - Single Pole, Double Throw

V - Volt

VAC - Volt, Alternating Current

(©March, 2007)



Documents

GPS Series Pump Package Installation, Operation ...ats.stulz.com/.../documents/PDF/Precision_AC/glycolpumpsystems.pdf · (©March, 2007) GPS Series Pump Package Installation, Operation