Sterling Fan 25001301 User Manual

SC3-600  
March 2000  
Part No. 25001301  
Direct Drive  
Fluid Coolers  
Installation and  
Maintenance Data  
Table of Contents  
Inspection  
System Warranty  
Installation ........................................2  
Mixing Glycol and Water  
Glycol Sludge Prevention  
Fluid Circulating Pump....................................8  
Rigging Instructions...........................3  
Internal Volume and Weight ..............4  
Start-up  
Space and Location Requirements ............9-10  
Typical Piping  
In-Warranty Return Material Procedure..........11  
Electrical Wiring ............................ 4-6  
System Installation  
Piping Installation  
Replacement Parts ....................................... 12  
Glycol Charge ...................................7  
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Figure 1. Rigging Instructions.  
similar distance should be maintained between adjacent units.  
Sufficient free area should be left around and below unit to  
avoid air restriction to coil.  
Vertical airflow type units should be located no closer  
than the width of the unit from a wall or other obstruction. It  
two or more units are to be positioned in the same area, a  
3
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Table 1. Fluid Cooler Internal Volume and Weight  
Fluid  
Cooler  
Fan Configuration  
Number  
of  
Fans  
Number  
of  
Rows  
Internal  
Volume  
Gallons  
Approximate  
Net Weight  
(Lbs.)  
1 x 2  
1 x 2  
1 x 2  
1 x 3  
1 x 3  
1 x 4  
1 x 4  
1 x 5  
1 x 5  
2
2
2
3
3
4
4
5
5
2
3
4
3
4
3
4
3
4
6.7  
9.2  
1540  
1590  
1600  
2360  
2420  
3150  
2190  
3510  
3990  
11.8  
13.0  
16.7  
16.7  
21.7  
20.4  
26.6  
1 x 6  
6
4
31.6  
4790  
2 x 2  
2 x 2  
2 x 2  
2
2
2
2
3
4
13.5  
18.5  
23.5  
1540  
1620  
1760  
2 x 3  
2 x 3  
2 x 4  
2 x 4  
2 x 5  
2 x 5  
3
3
4
4
5
5
3
4
3
4
3
4
25.9  
33.4  
33.3  
43.3  
40.7  
53.1  
2420  
2480  
3230  
3510  
4040  
4390  
2 x 6  
6
4
63.1  
5270  
Electrical Wiring  
Electrical leads from each motor terminate at the unit  
junction box. Field connections must be made from these leads  
through a contactor, fuse and disconnect in accordance with  
local, state and national codes.  
The electrical installation should be in accordance with  
National Electrical Code, local codes and regulations. Proper  
overcurrent protection should be provided for the fan motors.  
Wiring diagrams shown are only basic and do not show fuses,  
disconnect switches, etc., which must be provided in the field.  
Three-phase motors must be connected to three-phase  
power of voltage to agree with motor and unit dataplate.  
All standard motors have internal inherent overload  
protectors. Therefore, contactors can be used instead of  
starters requiring thermal protectors, eliminating the problem  
of furnishing the proper heating elements.  
The motors are wired into a common junction box. The  
motors must be checked for proper rotation. Be sure to check  
that motor voltage and control connection agree with electric  
services furnished.  
All dry coolers or units are furnished with either single-  
phase or three-phase fan motors which are identified by the  
unit dataplate.  
4
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Diagram 1. Typical Fluid Cooler Wiring Diagram Without Fan Cycle Controls.  
Single Row of Fans  
Double Row of Fans  
5
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Diagram 2. Typical Fluid Cooler Wiring Diagram With Standard Fan Cycle Controls.  
Single Row of Fans  
Double Row of Fans  
6
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System Installation  
tain the proper glycol-to-water ratio.  
NOTE: All installation and maintenance are to be performed  
only by qualified personnel who are familiar with local codes  
and regulations, and experienced with this type of  
equipment. CAUTION: Sharp edges and coil surfaces are  
a potential injury hazard. Avoid contact with them.  
Table 3 shows pressure drops for various pipe sizes at  
flow rates commonly used with a typical dry cooler. These  
pipe sizes are not necessarily always correct for the run from  
the condenser to the dry cooler. Proper pipe size will depend  
on available pump head. This can be determined by subtract-  
ing from the total available pump head at design flow, the con-  
denser pressure drop and the dry cooler pressure drop. Allow  
some safety factor for last minute pipe fittings added to the  
system and for eventual fouling of the system.  
General  
1. Structure supporting unit must be designed to support both  
the unit and the fluid. Table 2 provides weight of fluid per  
gallon. Tables 3 and 4 provide unit weight and volume  
data. Provide suitable flashing of the roof, if this is a roof  
installation. For ground level mounting, a concrete pad is  
a. Glycol piping requires no insulation except when fluid tem-  
perature will be below ambient dewpoint temperatures.  
Dry coolers normally produce about 70° or higher fluid  
temperatures.  
recommended. Mounting holes permit the unit to be bolted b. Vents are required at all high points in the piping to bleed  
down to withstand wind pressures. Provide adequate clear-  
ance for unobstructed air flow to coils. See page 2 for  
Space and Location requirements.  
air when filling the system. If fluid coolers are at high  
points, vent valves should be installed at each fluid cooler.  
c. It is recommended that gate valves be installed on  
both sides of the pump to prevent loss of fluid in the event  
the pump should require repair or replacement. Shut-off  
valves are also recommended at water cooled condensers  
in case the condensing unit is to be moved or requires  
maintenance involving the coolant system.  
2. Level mounting is necessary to assure proper fluid distr-  
Table 2. Fluid Weight Per Gallon  
Percent Glycol  
Pounds Per Gallon  
0 (Water)  
8.345  
8.395  
8.495  
8.604  
8.712  
8.804  
10  
20  
30  
40  
50  
Table 3. Pressure Loss in Feet of Water  
Pipe Type "L" Schedule 40 Steel Copper Tube Head  
Size  
Steel  
O.D.  
Head Ft./100 Ft. Head Ft./100 Ft.  
Flow  
GPM  
15  
20  
25  
25  
30  
35  
40  
40  
45  
60  
60  
Copper Equiv. Length  
Equiv. Length  
1
1
1
1
1
1
1
/
8
17.6  
30.2  
15.0  
23.1  
1
/
8
1
/
8
34.6  
12.6  
17.4  
23.0  
26.3  
12.9  
15.7  
26.3  
7.0  
1 1/4  
1 1/4  
1 1/4  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 5/8  
1 5/8  
1 5/8  
2 1/8  
2 1/8  
2 5/8  
2 5/8  
3 1/8  
3 1/8  
3 5/8  
4 1/8  
4 1/8  
4 1/8  
11.5  
16.3  
21.8  
13.0  
16.5  
bution through the coil as well as flooded suction for the  
pump.  
3. Water piping must comply with local codes. Correct pipe  
sizing will help reduce pumping power and operating costs.  
1
1
1
/
/2  
2
1
4.  
In case of doubt, consult the manufacturer for the dry  
cooler fluid pressure drop at the specific conditions on  
your job.  
2
7.9  
80  
2
13.7  
12.0  
100  
150  
200  
250  
300  
300  
350  
400  
2 1/2  
2 1/2  
3
8.5  
6.1  
12.9  
9.1  
13.7  
9.2  
5.  
Provide sufficient valves and unions to permit easy ac-  
cess to parts subject to wear and possible repair or re-  
placement.  
18.6  
10.7  
16.5  
11.1  
5.9  
3
3 1/2  
4
6. After fluid piping is completed, all joints should be leak  
tested.  
4.9  
4
4
7.9  
6.5  
10.2  
8.2  
7. Where city water makeup is required, follow local codes,  
making certain that disconnecting provisions are provided.  
8. Select wire in accordance with nameplate data and local  
codes.  
Glycol Charge  
The amount of ethylene glycol required depends upon  
the following:  
Piping Installation  
a. The holding volume of the system which includes the hold-  
ing capacity of the condenser, the holding capacity of the  
interconnecting piping (Table 3) and the holding capacity  
of the dry cooler (see Table 3).  
The piping system should provide maximum leak pre-  
vention. Weld or sweat joints should be used where possible  
or tightly drawn Teflon tape threaded pipe joints should be made  
if needed. The fact that glycol solutions or other heat transfer  
fluids will leak where water will not, must be taken into ac-  
count.  
b. Percentage of glycol required by volume to provide pro-  
tection at the design minimum outside temperature (see  
Table 2).  
The glycol system should not employ a pressure reduc-  
ing valve. This is because a slight leak would lead to dilution  
of the mixture. Any refill should be controlled so as to main-  
7
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Table 4. Percentage of Ethylene Glycol to be Added by  
Volume.  
Fluid Circulating Pump  
Mechanical seal type pumps must be used for glycol  
systems. Gland type pumps would cause glycol waste and, if  
used with a pressure reducing valve, will lead to dilution of the  
glycol mixture and eventual freeze-up.  
Percent %  
20% 30% 40% 45% 50%  
Minimum Outside Design  
Temperature °F  
+15 -3 -14 -23 -38  
Table 4 is intended to be used as a guide only. Proper precautions need to  
be taken to prevent freeze damage during low ambients. Consult glycol ven-  
dor recommendations for specific freeze protection for your location.  
Pump is selected for piping friction loss plus fluid pres-  
sure drop through the dry cooler coil, plus pressure drop  
through the heat source. No allowance for vertical lift is made  
since in a closed system a counterhead acts on the pump suc-  
tion.  
Mixing Glycol and Water  
With glycol solution the pump performance curve will  
drift to the right from its design point, due to differences in  
circuit design, control valve application, pressure drop calcu-  
lations, etc. The pump should be selected high on the curve  
so as to provide for the "drift". The pump curve should be  
"flat" so that the pump will compensate for our inability to ex-  
actly predict the final operating system flow condition and to  
provide sufficient flow for satisfactory heat transfer and maxi-  
mum protection against freezing at the far end of the circuit.  
The pump motor should have sufficient power for operating  
over the entire pump curve to prevent motor overload at re-  
duced voltages. Paralleled pumps can also be used for good  
power economy and continuous and automatic standby op-  
eration. Properly applied parallel pumps will guard against  
system breakdown caused by a simple pump failure. Certain  
older systems have nonoperating standby pumps of equal  
capacity to the operating unit. We recommend parallel pumps  
in continuous operation because they provide practically the  
same type of standby, in addition to being completely auto-  
matic, at lower initial and operating cost.  
Regardless of the strength of the mixture, you MUST  
pre-mix the glycol and water prior to adding it to the system.  
The chemical reaction between the two will release oxygen,  
which is extremely undesirable in a close-loop system.  
WARNING: For dry coolers operating without glycol  
mixture, adequate freeze protection is  
necessary during ambients below 32° F.  
Glycol Sludge Prevention  
Glycol systems may be subject to sludge formation in  
coils, due to one or more of the following causes:  
1. Reaction of the corrosion inhibitor with galvanized piping  
(zinc).  
2. Reaction of the glycol with chromate type water additives.  
3. Reaction of the glycol with pipe dope, cutting oils, solder  
flux, and other system dirt.  
Glycol manufacturers offer a specially inhibited glycol  
(formulated for snow melting systems) which does not react  
with zinc. This glycol is also suitable for heat transfer sys-  
tems. Glycol manufacturers also provide inhibitor check ser-  
vices on a regular basis.  
Consequently, good glycol system design requires the  
following precautions:  
1. No galvanized piping is to be used.  
2. System piping must be thoroughly cleaned and flushed  
with a heated trisodium phosphate solution before filling  
wit the water/glycol mixture.  
3. No chromate inhibitor treatment must be used.  
4. The glycol manufacturer should provide inhibitor check  
service and supply additional inhibitor as required.  
8
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Start-up  
1. Prestart:  
Connect a pump and hose to the hose bibb away  
from the pump and a hose to the hose bibb closest  
to the pump. Begin pumping the glycol mixture into  
the system at FULL PRESSURE. For the return  
hose you should close the hose bibb so that you  
get only a small flow of fluid or air. This is  
necessary so you will build a head of fluid which will  
force the air from the system. Once all the air is out  
you will have a steady flow of only fluid. At this joint  
you should close off the two hose bibbs and open  
the shut off valve. See Diagram 3.  
Check for correct dry cooler fan rotation. This can be done  
by quickly jogging the fan contactor. Be sure that the fans  
run freely. The same check is recommended for pumps.  
2. Filling and Purging the System  
The system should be pressure tested before adding glycol.  
The system can be tested with air or water, however if the  
ambient temperature is at or below freezing the use of air  
is recommended. Test pressure should not exceed 60  
PSIG.  
a.  
Roof Mounted Fluid Cooler  
3.  
4.  
Flow Adjustment Procedure:  
To fill the system, pour the premixed water and glycol  
into the expansion tank. Fill the system until the  
expansion tank is half full, then purge the air from  
ALL vents. Operate the system for a minute, then  
purge ALL vents again, and add glycol as required.  
Repeat the purging of all vents after the first hour of  
operation and again after several hours of operation.  
Once the system is completely full of fluid, start the fluid  
circulating pump. To assure proper fluid flow, adjust the  
shut-off valve for required GPM by checking pump curve  
and observing gauge pressure, or by using an in-line flow  
meter.  
Instruction Envelope:  
b.  
Ground Mounted Fluid Cooler  
Keep wiring diagrams, instructions, list of spare parts, in  
an envelope within easy reach of the installed dry cooler.  
The fluid cooler may be lowest point in the system,  
consequently the premixed water and glycol will have  
to be pumped into the system. Close the shut off valve  
and open the two hose bibbs installed in the piping  
run on the leaving side of the pump, see piping  
diagram.  
Diagram 3.  
Space and Location Requirements  
Another consideration which must be taken is that the  
The most important consideration which must be taken  
into account when deciding upon the location of air-cooled  
equipment is the provision for a supply of ambient air to the  
condenser, and removal of heated air from the fluid cooler  
area. Where this essential requirement is not adhered to, it  
will result in higher head pressures, which cause poor operation  
and possible eventual failure of equipment. Units must not be  
located in the vicinity of steam, hot air or fume exhausts.  
unit should be mounted away from noise sensitive spaces  
and must have adequate support to avoid vibration and noise  
transmission into the building. Units should be mounted over  
corridors, utility areas, rest rooms and other auxiliary areas  
where high levels of sound are not an important factor. Sound  
and structural consultants should be retained for  
recommendations.  
9
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Walls or Obstructions  
The unit should be located so that air may circulate freely room is left for maintenance work through access doors and  
and not be recirculated. For proper air flow and access all panels. Overhead obstructions are not permitted. When the  
unit is in an area where it is enclosed by three walls the unit  
must be installed as indicated for units in a pit.  
sides of the unit should be a minimum of “W” away from any  
wall or obstruction. It is preferred that this distance be increased  
whenever possible. Care should be taken to see that ample  
Multiple Units  
For units placed side by side, the minimum distance  
between units is the width of the largest unit. If units are placed  
end to end, the minimum distance between units is 4 feet.  
Units in Pits  
The top of the unit should be level with the top of the pit,  
and side distance increased to “2W”.  
If the top of the unit is not level with the top of pit, dis-  
charge cones or stacks must be used to raise discharge air to  
the top of the pit. This is a minimum requirement.  
Decorative Fences  
unit. If these requirements are not met, unit must be installed  
as indicated for “Units in pits”.  
Fences must have 50% free area, with 1 foot undercut,  
a “W” minimum clearance, and must not exceed the top of  
* “W” = Total width of the fluid cooler.  
10  
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Diagram 4. Typical Piping  
In-Warranty Return Material Procedure  
Material may not be returned except by permission of  
authorized factory service personnel of Sterling, Inc. in  
The return of a part does not constitute an order for  
replacement. Therefore, a purchase order must be entered  
New Berlin, Wisconsin. A “Return Goods” tag will be sent through your nearest Sterling, Inc. representative. The  
to be included with the returned material. Enter the required  
information on the tag in order to expedite handling at our  
factories and prompt issuance of credits. All parts shall be  
returned to the factory designated on the “Return Goods” tag,  
transportation charges prepaid.  
order should include part number, model number and serial  
number of the unit involved.  
Following our careful inspection of the returned part and if  
it is determined that the failure is due to faulty material or  
workmanship, credit will be issued on customer's purchase order.  
11  
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Sterling, Inc.  
2900 S. 160th Street  
New Berlin, WI 53151  
262-641-8610 y Fax: 262-641-8653  
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