Stulz Split-Air CST 40 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Stulz Manuals
  4. Air Conditioner
  5. Split-Air CST 40
  6. Operating instructions manual
Stulz Split-Air CST 40 Operating Instructions Manual

Stulz Split-Air CST 40 Operating Instructions Manual

A/c units split-air
Hide thumbs
Table of Contents

Advertisement

Quick Links

A/C UNITS
SPLIT-AIR
230/1/50 400/3/50
Index 39
Edition 2.04

AIR CONDITIONING

PRECISION A/C UNITS
OPERATING INSTRUCTIONS

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Split-Air CST 40 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Stulz Split-Air CST 40

Summary of Contents for Stulz Split-Air CST 40

  • Page 1: Air Conditioning

    A/C UNITS SPLIT-AIR 230/1/50 400/3/50 Index 39 Edition 2.04 AIR CONDITIONING PRECISION A/C UNITS OPERATING INSTRUCTIONS...
  • Page 2 E/0204/39/2...

  • Page 3: Table Of Contents

    Contents Page Introduction Technical Data Electrical Data Dimensions 1. Unpacking and Inspection 2. Unit Identificaton 3. Operating Principle 4. Precautions 5. Safety Considerations 6. Precautions when handling the Unit 7. Vibrations 8. Mechanical Parts 9. Cooling Components 10. Motors 11. Control, Monitoring and Safety Components 12.

  • Page 4: Introduction

    - KPDC1010 - Keypad, SERC1010 - serial adapter RS485 for gateway connection, SPLIT- TER - LAN-Y-plug for sequencing. The following information is supplied in accordance with Standards:CE73/23,CE93/68,CE89/392: MANUFACTURER'S NAME AND ADDRESS STULZ GmbH Holsteiner Chaussee 283 22480 Hamburg DATA REGARDING THIS MODEL...
  • Page 5 IN THE EVENT OF SALE OF THE PRODUCT Please advise STULZ GmbH of the address of the new owner so as to enable the dispatch of any updates to the manual, otherwise STULZ GmbH shall be relieved of any subsequent...

  • Page 6: Technical Data

    Technical Data Split-Air CST 40 / 50 CST 40 CST 50 Cooling capacity * Sensible cooling capacity* R407c Refrigerant R407c Refrigerant charge 1.95 Condenser fan 1 / 315 axial Number / Type 1 / 315 axial 2000 Air flow m³/h...
  • Page 7 Technical Data Split-Air CST 60 / 80 CST 60 CST 80 Cooling capacity * Sensible cooling capacity* Refrigerant R407c R407c Refrigerant charge Condenser fan Number / Type 1 / 420 axial 1 / 450 axial Air flow m³/h 2800 3400 External static pressure Evaporator fan (Type 1)*** Voltage...

  • Page 8: Electrical Data

    Electrical Data Split-Air CST 40 / 50 CST 40 CST 50 Outdoor Unit Power Supply Code Nominal voltage 220-240±10% 380-420±10% 220-240±10% 380-420±10% Tolerance on voltage Phase Frequency ±2% ±2% ±2% ±2% Tolerance on frequency Power consumption* Operating current (OA)* 43.6 22.6...
  • Page 9 Electrical Data Split-Air CST 60 / 80 CST 60 CST 80 Outdoor Unit Power Supply Code Nominal voltage 220-240±10% 380-420±10% 220-240±10% 380-420±10% Tolerance on voltage Phase Frequency ±2% ±2% ±2% ±2% Tolerance on frequency Power consumption* 11.3 13.0 Operating current (OA)* 61.7 32.7 76.9...

  • Page 10: Dimensions

    Dimensions - Inside Unit CST 40/50 without free cooling E/0204/39/10...
  • Page 11 Dimensions - Inside Unit CST 40/50 with free cooling center point E/0204/39/11...
  • Page 12 Dimensions - Inside Unit CST 60/80 without free cooling E/0204/39/12...
  • Page 13 Dimensions - Inside Unit CST 60/80 with free cooling 424.5 center point E/0204/39/13...
  • Page 14 Dimensions - Outside Unit CST 40/50 E/0204/39/14...
  • Page 15 Dimensions - Outside Unit CST 60/80 E/0204/39/15...

  • Page 16: Unpacking And Inspection

    Any damage that is encountered must be notified to the carrier by registered letter within 8 days of receipt. The carrier is responsible for any damage caused during shipment. STULZ is not responsible for damage caused to the merchandise by the shipper but will do all in its power to assist customers in these situations.

  • Page 17: Unit Identification

    2. Unit Identification This unit can be correctly identified by the Constructor Trademark technical name-plate containing all the Model This identifies the product family. information for its correct use. Series Product identification number. In addition to the manufacturer's identification Date Date on which the product is placed data and the product trade-marks, the name- on the market and date of...

  • Page 18: Operating Principle

    3. Operating Principle Split-Air STULZ conditioners are designed to cool rooms containing technological systems. They are designed for internal installation. Their use allows to eliminate problems caused by high temperatures, dirt and humidity which are present in the environment. The unit, which is basically made up of a sealed cooling circuit where the refrigerant circulates, is divided into two sections, where the air in the environment and the air in the cabinet are treated without coming into contact with each other during cooling mode.
  • Page 19 ADDITIONAL OPERATING MODES Standard versions type 1 (with C1010 controller) Free-cooling mode. On units type 1, there is a damper equipped with servomotor which directs internal and external air flows. This damper is proportionally controlled by a modulating signal coming from C1010 controller (for free-cooling logic see Chapter 11: Control, Monitoring and Safety Components).
  • Page 20 Airflow - Inside Unit CST - without Free Cooling Horizontal Installation Refrigerant connections Evaporator fan E-box Evaporator Filter Vertical Installation E/0204/39/20...
  • Page 21 Airflow - Inside Unit CST - with Free Cooling Compressor Operation Horizontal Installation Evaporator fan Refrigerant connections E-box Damper Filter Evaporator Outside Vertical Installation Outside Outside E/0204/39/21...
  • Page 22 Airflow - Inside Unit CST - with Free Cooling Free Cooling Operation Horizontal Installation Evaporator fan Refrigerant connections E-box Filter Evaporator Damper Outside Vertical Installation Outside Outside E/0204/39/22...
  • Page 23 Airflow - Outside Unit CST Refrigerant connections Condenser fan Condenser Compressor E/0204/39/23...

  • Page 24: Precautions

    If traces of oil are present on the unit, which point to a loss of coolant, on the inside or the outside, then the equipment must be thoroughly checked before starting the unit and, if necessary, STULZ's technical department should be contacted.

  • Page 25: Precautions When Handling The Unit

    6. Precautions when handling the Unit Handle these units, when they are packaged, using a fork lift. When they are not packaged use a hoisting machine equipped with cables or chains suited for supporting their weight. 7. Vibrations The cooling unit does not produce any significant vibrations as the parts which generate them are installed on anti-vibration devices.

  • Page 26: Cooling Components

    9. Cooling Components The components inside each unit (outdoor and indoor) are connected by copper piping, appropriately welded to ensure a greater seal. The two units must be connected to each other, as described in chapter 12. 9.1 REFRIGERANT The refrigerant that is used can be: R407c (HFC). OPTIONAL: R134a, R22.

  • Page 27: Motors

    STULZ engineering service, by specialized product expert. STULZ air conditioner are equipped with a set of devices designed to ensure proper operation. Intervention by any one of these automatic safety device is a sign of a malfunction and it is absolutely necessary to eliminate the cause of the malfunction.
  • Page 28 11.3 CONTACTORS control the motors by operating with auxiliary voltage. They refer to IEC947-4-1 standards. 11.4 AUTOMATIC CIRCUIT BREAKERS protect against short circuits and excessive motor current. They have adjustable thermal and magnetic triggering devices. 11.5 AUTOTRANSFORMER This device is necessary, when the power supply voltage differs from the standard voltage. The autotransformer adapts the supplied voltage to the standard voltage.
  • Page 29 STANDARD COMPONENTS with ELECTRONIC CONTROL 11.10 Electronic control C1010 This microprocessor-based electronic board is equipped with a set of terminals which are necessary to connect the board to the controlled devices (e.g. valves, compressors, fans). The program has been written in the eprom whilst the set parameters are permanently stored (even in case of power failure).
  • Page 30 c) Configuration • Use the keypad installed on unit 1. • On the main page of the C1010 press „SET“ to choose unit 1 using arrow up/down keys, press „SET“ again. • Press „Menu“ to choose the menue. • Press 1x Arrow-Up key to go to „Manufacturer Menue“, press „SET“ •...
  • Page 31 b) Jumper setting The jumpers TU2 and TD2 of the first and the last units C1010-boards have to be closed. The jumpers TU2 and TD2 of the unit between first and last units C1010-boards have to be OPEN. Jumper TL2 of all C1010-boards must be open. First and last unit: Units between first and last: c) Configuration...
  • Page 32 Input Assignment Digital Inputs (supplied by the board, therefore all inputs should be connected to potential free contacts) Silk Terminals logic ID logic ID Description Terminal screen minifit DI 1 X12 pin 1,2 Fire-smoke presence /* 2 of 4x2 X12 pin 3,4 Humidity switch /* 2 of 4x2 X12 pin 5,6...

  • Page 33: Digital Outputs

    Output Assignment Digital Outputs Silk Terminals Logic Description Rate Terminal Terminal screen number minifit COMP X9 pin 1 Compressor contactor 3A / 48Vdc 1 of 2x2 (to contactor coil A1) Compressor contactor 3A / 48Vdc 1 of 2x2 X9 pin 2 (to auxiliary line) X9 pin 3 Compressor...
  • Page 34 Fan Management (Input / Output) Condenser Fan Speed Control - Internal Phase Cut Terminal number Silk screen Terminals Description Rate 1 of 2x2 AC FAN X8 pin 1 1 of 2x2 X8 pin 2 Fan L 1 of 2x2 X8 pin 3 1 of 2x2 X8 pin 4 Fan N...
  • Page 35 Operating Diagrams - C1010 no free cooling conditions Unit 1 heating element compressor 12,5°C 15°C 27,5°C 25°C 2,5°C 2,5°C SET2 SET1 Conditioner 1 operates with setting at 25°C, between 27.5°C and 25°C. Heating elements operate with setting at 15°C, between 12.5°C and 15°C. Unit 2* heating element compressor...
  • Page 36 Operating Diagrams - C1010 Free Cooling Conditions Unit 1 heating element compressor 29,5°C 12,5°C 15°C 32°C 25°C 2,5°C 2,5°C 7°C SET2 SET1 Conditioner 1 operates with setting at 25°C, between 32°C and 29.5°C. Heating elements operate with setting at 15°C, between 12.5°C and 15°C. Unit 2* heating element compressor...
  • Page 37 Operating Diagrams - C1010 Unit 1 free cooling 100% 25°C 28,75°C 3,75°C With setting at 25°C, free cooling of unit 1 operates in the proportional range between 25°C and 28.75°C. Unit 2* free cooling 100% 25°C 27°C 30,75°C 2°C 5,75°C Free cooling unit 2 operates with setting at 25°C, between 27°C and 30.75°C.
  • Page 38 Dehumidification control The dehumidification control is differently carried out corresponding to the unit equipment (with/ without el. reheat). The following diagrams are valid only with the optional humidity sensor. The dehumidification is controlled via the room humidity and the room temperature. Dehumidification Dehum.
  • Page 39 Dehumidification with el. reheat As above described, the dehumidification is obtained by reducing the fan speed and simultaneous compressor operation. An electric reheat is additionally operated, if the temperature difference to the cooling set point exceeds a certain value below the set point. Dehumidification Start value Dehumidification...
  • Page 40 ADJUSTING SET-POINT/ALARM SET POINT PROCEDURE Proceed as follows: Before entering menus the display appears as shown on the left. Press “MENU” key to enter the menus. The display appears as shown on the left. Using (UP) and (DOWN) keys you can move through the various menus of C1010.
  • Page 41 IdCode Mask Description Range PresSet Unit S01. Set point for the temperature variable 25°C °C/F control managed by the Cooling setpoint compressor S02. Set point for the temperature variable 15°C °C/F control managed by the heating Heating setpoint resistor 15°C °C S03.
  • Page 42 IdCode Mask Description Range PresSet Unit Set point for the low humidity S14. 0/100% alarm Alarm limit Low humidity Set point for the high humidity S15. 0/100% alarm Alarm limit High humidity Alarm delay time (temperature, 0/9999 20 sec. Sec. S16.
  • Page 43 SENSOR ADJUSTMENT - How to configure To adjust the sensors for temperature and humidity (if installed) sensors proceed as follows: • Start the unit evaporator fans only (when more units are present in the same location on a sequencing LAN, is better to start with the master unit). •...
  • Page 44 11.11 MECHANICAL HYGROSTAT ( only in units controlled by C1010) It is included in the standard configuration of units controlled by the C1010 microprocessor and measures the air humidity at the internal intake. If the humidity exceeds an adjustable limit value, the hygrostat sends a signal to the C1010 controller for high humidity alarm and enabling dehumidification.

  • Page 45: Installation

    12. Installation Unpack the unit taking care not to damage its exposed parts. Before discarding it, check the packaging for any parts or documents, check the packaging for any parts or documents. Check that the supply voltage is as designated. POSITIONING OF INDOOR UNIT 1.

  • Page 46: Water Connections

    POSITIONING OF OUTDOOR (MOTOR-CONDENSING) UNIT 1. The condensing unit must be positioned outside the shelter. 2. The condensing unit must be connected to the indoor unit by two refrigerant pipes. These pipes should be as short as possible, and in any case their length must not be more than 30m for R407c.
  • Page 47 CONNECTION OF REFRIGERANT CIRCUIT NOTE: in this paragraph with distance* is meant the length of the liquid line, including the bends, between the internal and the external units. TABLE 1: Standard diameters of R407c pipes Gas pipe Liquid pipe Model Piping distance* Problems diameter [mm]...
  • Page 48 The Split-Air unit is supplied pre-charged with the right quantity of refrigerant for 5 m distance* between the evaporating and motor-condensing unit. 80% of the pre-filled refrigerant is in the motor- condensing unit, the remaining 20% is in the evaporating unit. After having connected the refrigerant circuit, an additional quantity of the same refrigerant must be added according to table 2 below, if the distance is more than 5 m.
  • Page 49 1. Refrigerant lines must be made of hard or soft copper. In case of R407c, diameter of pipes must be those indicated in Table 1. 2. Routing must be over the shortest routes. 3. Limit the number of pre-shaped bends; if this is not possible every bend must have a radius of at least 100 mm.
  • Page 50 8. Pipe mountings have to be provided at least every 2 m. The pipe mountings are to be insulated against vibrations. The first pipe mountings behind the indoor unit as well as upstream of the outdoor unit should be flexible. So that the pressure lines can expand, the pipe mountings are to be attached at least 1m from the bend.

  • Page 51: Oil Charge

    12. After having connected the refrigerant lines, connect a suitable vacuum pump (complete with vacuum meter) to both the refrigerant taps of the motor-condensing unit. Evacuate the air inside the lines. 13. Then, open the refrigerant taps of both units following this order: •...

  • Page 52: Electrical Connections

    13. Electrical Connections WARNING! It is absolutely necessary, before making any connections, to use a suitable tester to check the supply voltage. This must be the same as the voltage indicated on the technical data plate. The user must furnish and install, upstream from the unit, an isolating switch with pre- fuse and capacity as specified on the technical plate in order to be able to perform maintenance on the unit in the absence of electricity.
  • Page 53 INSTRUCTIONS FOR ELECTRICAL CONNECTIONS: 1. The electrical panel of the evaporating unit can be accessed removing its bottom panel. Its position is in the middle of the unit. The electrical panel of the condensing unit can be accessed removing its front panel. 2.
  • Page 54 Configuration for cable connections On electrical panel in the unit, the following socket configurations can be found: E/0204/39/54...

  • Page 55: Start-Up

    • After having completed the start-up, please fill up the Start-up form supplied with each unit and send a copy of it to the address, which is specified on the form. NOTE: the start-up can only be made by personnel trained by Stulz. 15. First Checks after Starting the Unit Check that no alarms have occurred.
  • Page 56 Space required for maintenance Indoor unit: vertical application without free-cooling A = min 200mm C = min 1000mm vertical application with free-cooling B = min 500mm C = min 1000mm 1: option (DVIN) for vertical application E/0204/39/56...
  • Page 57 horizontal application with and without free-cooling A = min 200 mm B = 200 mm C = 300 mm D = 300 mm Outdoor unit: A = 200 mm B = 500 mm C = 250 mm D = 1000 mm A free space of >...
  • Page 58 17.2 EXTRAORDINARY MAINTENANCE INTERVALS Every 3 years or every 10,000 operating hours the unit must undergo a general overhaul either at the manufacturer's factory or at companies authorized by STULZ or by qualified agencies at the customer's own expense. 17.3 REPLACEMENT OF PARTS To guarantee continuity of service to the units, it is recommended to replace some components according to their MTBF (medium time before failure).

  • Page 59: Inactivity

    A set of spare filters may be requested from STULZ's service department. To change the air filter, remove the bottom panel of the evaporating unit and draw the air filter out.

  • Page 60: Options

    IMPORTANT NOTE IN CASE THE SHELVES ARE NOT PROVIDED AS OPTION BY STULZ: In any case, the support of the outdoor unit must not obstruct, even partially, the air flow through the condenser coil, and reduce the condenser coil efficiency this way.
  • Page 61 19.3 PROTECTIVE TREATMENT ON COILS - TREAT Epoxy treatment on condenser and evaporator coil surfaces to protect them against corrosion. This treatment reduces condenser coil efficiency. Not suitable to very corrosive ambients (salt deposits, etc.). 19.4 R134a REFRIGERANT With standard R407c the upper limit of external temperature is +45°C. With R134a, units can work up at higher external temperatures (60-65°C), although also the operating temperature limit of the condenser fans has to be verified.
  • Page 62 1: Option (DVIN) for vertical application IMPORTANT NOTE IN CASE DUCTS ARE NOT PROVIDED AS OPTION BY STULZ: condenser air, passing through connection ducts (not supplied by STULZ) has pressure losses, depending on the dimensioning of these ducts. Pressure losses through these ducts may not exceed the available static pressure specified in the technical data sheets of this manual (see first pages of this manual).
  • Page 63 19.8 EXTENSIBLE RECTANGULAR SECTION DUCT KIT FOR HORIZONTAL INDOOR UNIT – DHINRECxx This option is the connecting duct between the opening on the cabinet wall and the opening on the evaporating unit for fresh air intake during free-cooling. The rear side of internal unit must be installed with a minimum distance of 200 mm from cabinet wall, due to the position of the refrigerant connections.
  • Page 64 8: Indoor unit with Free Cooling option (and optional rectangular intake: DHINREC) 9: wall plate for Free Cooling rectangular duct IMPORTANT NOTE IN CASE DUCTS ARE NOT PROVIDED AS OPTION BY STULZ: condenser air, passing through connection ducts (not supplied by STULZ) has pressure losses, depending on the dimensioning of these ducts.
  • Page 65 19.9 FLEXIBLE ROUND SECTION DOUBLE DUCT KIT FOR HORIZONTAL INDOOR UNIT – DHINROxx This option is the connecting duct between the opening on the cabinet wall and the opening on the evaporating unit for fresh air intake during free-cooling. The rear side of internal unit must be installed with a minimum distance of 200 mm from cabinet wall, due to the position of the refrigerant connections.
  • Page 66 6: flexible ducts for Free Cooling with fixing clamps (max length 2 m - min length 0.2 m) 7: Indoor unit with Free Cooling option (and optional circular intake: DHINRO) MPORTANT NOTE IN CASE DUCTS ARE NOT PROVIDED AS OPTION BY STULZ: condenser air, passing through connection ducts (not supplied by STULZ) has pressure losses, depending on the dimensioning of these ducts.
  • Page 67 The unit whose data you would like to be displayed can be selected via the key-pad itself. 19.14 STULZ TELECOMPTROL MONITORING SOFTWARE - TCO Monitoring software to supervise the main unit functions, remote on-off, setting parameters, and alarm management by modem (requires GAT on unit side).
  • Page 68 -display on the key-pad of internal humidity value; -control of dehumidification function; -control of humidification function. Outside the shelter, humidity probe measures external humidity in order to enable free-cooling function according also to the value of this parameter. Range of measurement is RH between 15% and 90%. The probe is supplied loose, to be mounted on site.
  • Page 69 SIGNAL CABLE 3m - SIGC3 SEQUENCING CABLE 2m - SEQC2 RJ11 connector 4 conductors E/0204/39/69...
  • Page 70 19.23 SIGNAL CABLE 3m - SIGC3 This cable is provided with 3 minifit connectors to match the corresponding C1, C2 and C3 sockets on the back plate of the unit. It is used to bring alarm signal out from the unit to an external user and to give some input signals to C1010 (door open, fire/smoke alarm) from external devices provided by the installer.

  • Page 71: Residual Hazards And Emergency Information

    20. Residual Hazards and Emergency Information This unit was designed to reduce danger sources or situations to a minimum. These dangers arise from improper use of the product or from failure to comply with installation and operating instructions. All personnel who work on or near the unit must be familiar with these instructions. 20.1 GENERAL SAFETY PROVISIONS All personnel charged with testing and maintaining the unit must be familiar with the following safety regulations:...
  • Page 72 20.3 HAZARDS ARISING FROM ELECTRICAL FAULTS 20.3.1 SAFETY STANDARDS FOR ELECTRICAL EQUIPMENT Introduction The causes of electrical risks are well known and it is not difficult to prevent these risks by applying constant care and attention. Assigned personnel must be informed regarding potential dangers and trained regarding safety procedures in order to reduce the number of potential electrical accidents.
  • Page 73 maintenance procedures before starting to work; · use protective gloves; · open all contacts that bring power to the equipment before measuring resistance values; · check that there is no high voltage in the low voltage circuits; · do not use magnetic tools near strong magnetic fields. 20.3.6 SAFETY STANDARDS TO COMPLY WITH DURING MAINTENANCE If continuous operation is not required, the system must be turned off.
  • Page 74 20.4 SAFETY STANDARDS TO COMPLY WITH WHEN WORKING ON REFRIGERATION CIRCUITS The refrigerant used for this machine can be dangerous if it is not properly used. Several precautions must be taken when handling this substance: · never release, store or use the refrigerant near open flames. The refrigerant is non-toxic. Contact with flames causes combustion which generates toxic gases that can corrode metal surfaces;...

  • Page 75: Disassembling The Unit

    This unit must be disassembled by authorised organisations. STULZ is able and has equipment for disposing of these units and performing almost total recuperation of components without harm to the environment. While awaiting disposal the unit must be kept stored protected from weather.

  • Page 76: Faults, Probable Causes, Possible Remedies

    .3 Where present, start-up condenser defective; .1 Replace start-up condenser; .4 Compressor motor defective; .1 Contact STULZ refrigerant system technician or service department. .5 High pressure switch defective; .1 Contact STULZ refrigerant system technician or service department; .6 Where present, compressor remote control switch defective .1 Replace remote control switch.
  • Page 77 Contact STULZ refrigerant system technician or service department; .3 Where present, solenoid valve defective; .1 Replace solenoid valve coil; .2 Contact STULZ refrigerant system technician or service department; .2 Condenser fan, evaporator fan working, compressor working intermittently; .1 Where present, service high pressure switch;...

This manual is also suitable for:

Split-air cst 60Split-air cst 50Split-air cst 80

Table of Contents