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Summary of Contents for Stulz CeilAiR Series
- Page 1 CeilAiR Series Supplemental Air Conditioners 3.5 – 35 kW Systems Ceiling Mounted, 60 Hz Data Installation, Operation and Maintenance Manual...
- Page 2 STULZ Air Technology Systems, Inc. (STULZ). This document contains confi dential and proprietary information of STULZ Air Technology Systems, Inc. Distributing or photocopying this document for external distribution is in direct violation of U.S. copyright laws and is strictly prohibited without the express written consent of STULZ.
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Page 3: Table Of Contents
2.4.3 Controls ................10 2.7.5 Remote Shut Down ............24 2.4.3.1 A-Tech Programmable Thermostats .....10 2.7.6 Optional Equipment ............24 2.4.3.2 Advanced STULZ E² Controller ......12 2.7.6.1 Condensate Pump ............24 2.4.4 Optional Equipment ............12 2.7.6.2 Humidistat/Dehumidistat .........24 2.4.4.1 Condensate Pump (Field Installed) .......12 2.7.6.3... - Page 4 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 2.8.1 Water/Glycol Systems ..........25 Commissioning, Operation And Decommis- sioning ............35 2.8.1.1 Pump ................25 Commissioning the Unit ..........35 2.8.2 DX Unit Charging Requirements ......25 3.1.1 Commissioning Steps ..........35 2.8.3 Remote Air-Cooled Systems (AR/AHU) ....26 Operating the Unit ............36 2.8.4 R407C/R410A Refrigerant ........26...
- Page 5 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Obtaining Warranty Parts .........46 Tables Obtaining Spare/Replacement Parts ....46 Table 1. Pipe Equivalent Lengths........15 Appendix A - OHS Preventive Maintenance Table 2. Recommended Discharge Line Sizes For Inspection Checklist ........47 R407C Refrigerant ..........15 Table 3.
- Page 6 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL...
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Page 7: Introduction
An STULZ CeilAiR OHS systems are designed to be the most operating manual for the controller is provided with the unit versatile and fl exible ceiling-mounted air conditioning under separate cover. -
Page 8: Safety Summary
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL A bold text WARNING provides information important for WARNING protecting you from harm. Pay very close attention to all warnings that apply to your application. To prevent personal injury, stay clear of rotating components, as automatic controls may start them unexpectedly. -
Page 9: General Design
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL istics. It is heavier than air and will disperse rapidly CAUTION in a well-ventilated area. In an unventilated area it presents a danger as a suffocant. After interconnecting piping is installed, the piping system must be cleaned. -
Page 10: Coil(S)
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Figure 3. CeilAiR OHS-032-AR (Access Panels Removed) conditions and provides input signal(s) to the thermostat. 1.5.2 Coil(s) The thermostat manages the operation of the A/C unit The cooling and optional hot water reheating coils are alu- consistent with the setpoints entered. -
Page 11: Temperature/Humidity Sensor
1.6.8 Water Detector matic sensible reheating during the dehumidifi cation cycle. As an option, STULZ offers spot type or strip/cable type A hot water heating coil is factory installed in the supply air- water detectors. In units equipped with an E² controller, stream. -
Page 12: Figure 4. Free Cooling Diagram
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL plus dead band. The drycooler pump activates and the 3-way control valve directs chilled water/glycol coolant to the FC coil. The outdoor fl uid cooler is controlled by fi rst switching the leaving fl uid control setpoint from typical DX heat rejection to free-cooling control (adjustable setpoint, ambient air) and by controlling the leaving fl... -
Page 13: Aws Operation
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL As the outside air temperature increases above the ambient air switch-over setting, the fl uid cooler controls cycle back to typical DX heat rejection allowing the leaving fl uid control setpoint to increase above the prevailing ambient conditions. The indoor unit’s inlet fl... -
Page 14: Installation
STULZ ships all equipment In the event of loss of water fl ow during AWS operation, the Factory FOB. STULZ can assist in the claim fi ling process AWS control valve is closed and the compressor system with the freight carrier. -
Page 15: Rigging
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL To minimize the effects of the environment surrounding a minimum (as it adds to the cooling, heating, dehumidifi ca- the conditioned space, certain steps must be taken. This tion and humidifying loads), while maintaining the require- is especially true for critical/precision room preparation ment of the Indoor Air Quality (IAQ) standard. -
Page 16: Indoor Equipment
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL NOTES 2.4.3.1 A-Tech Programmable Thermostats • Do not install the A/C system directly above Mount the thermostat upright on an inside wall within the electronic equipment that may hinder service- conditioned room at a location that best represents the ability. -
Page 17: Figure 8. Spot Cooler Grille
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL .75 in/19 mm THICK GASKET Figure 8. Spot Cooler Grille SUPPLY AIR OUTLET IN/OUT 90° / RIGHT ANGLE STRAIGHT-THRU SAME FACE Figure 9. Ducted System Typical Air Patterns... -
Page 18: Advanced Stulz E² Controller
The switch is typically mount- ed to the A/C cabinet; however, it may be shipped loose If the optional STULZ E² controller is furnished, a separate for fi eld installation. The case has a top keyhole mounting manual is included in the unit data package provided with slot and two holes in each bottom corner for mounting. -
Page 19: Remote Temperature/Humidity Sensor (E²)
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 3. Use the sub-base as a template to mark the mounting ensuring the word TOP on the PC board is oriented hole locations on the mounting surface. Drill size for upward. the wall anchors is 1/4 in. -
Page 20: Spot Water Detector
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 2.4.7 Spot Water Detector NOTE Placement of the grilles is important. The hinged The spot water detector is normally placed on the fl oor or in fi lter grille goes on the return air side of the unit. The a fi... -
Page 21: Pipe Equivalent Lengths
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL of the refrigeration circuits. The refrigerant piping should NOTE be isolated by the use of vibration isolating supports. In the following tables: Provide supports (clamps or hangers) as necessary every 5 to 10 ft along piping runs to minimize vibration and noise •... -
Page 22: Recommended Suction Line Sizes For R407C Refrigerant
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Compressor to Condensor O.D. (inches) Receiver to Evaporator O.D. (inches) Model No./Total Model No./Total BTU/H Capacity BTU/H Capacity or less or less or less or less or less or less 50 ft 100 ft 150 ft 50 ft... -
Page 23: Remote Air Cooled Condensers (Ar Models)
The recommended ethylene glycol solution ratio is 40% charge Line Sizes table (Table 2 or Table 3), Recommended glycol to 60% water. (STULZ recommends Dowtherm Liquid Line Sizes table (Table 4 or Table 5) and Recom- SR1 manufactured by Dow Chemical Co.) Glycol-cooled mended Suction Line Sizes table (Table 6 and Table 7). -
Page 24: Condensate Drain Line
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL removes any foreign objects. The strainer screen should be cleaned periodically. 2.6.3 Condensate Drain Line 2.6.3.1 Gravity Drain A 7/8 in. O.D. copper (sweat type) line is provided to drain the condensate drain pan. This line also drains the hu- midifi... -
Page 25: Single-Phase Units 208/230V
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL The nameplate also provides the full load amps (FLA) the NOTE unit will draw under full design load, the minimum circuit All wiring must be provided in accordance with Na- ampacity (MCA) for wire sizing, and the maximum fuse size tional Electrical Code and local code requirements. -
Page 26: Controls
2.7.2 Controls See OHS Electrical Drawing for Equivalent Terminal Points STULZ offers a wide range of control systems to meet air conditioning control/alarm requirements. If the unit is equipped with an A-Tech controller, see the Robertshaw 9701i/9725i2 User’s Manual shipped with the unit for programming instructions. -
Page 27: Figure 15. A-Tech 1.1 Control Wiring
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Figure 15. A-Tech 1.1 Control Wiring Figure 16. A-Tech 1.2 Control Wiring... -
Page 28: Figure 17. Interconnection Field Wiring Remote Condenser
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL CONTROL CONFIGURATION (OPTIONAL) E² 6 CNDCT. PHONE TYPE 3 CONDUCTOR NON-SHIELDED CABLE SHIELDED CABLE SEE NOTE 3 REMOTE TEMPERATURE/ E² CONTROLLER DISPLAY HUMIDITY SENSOR E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL) CONTROLLER INSIDE THE ELECTRIC BOX CONTROL THERMOSTAT... -
Page 29: Figure 19. Interconnection Field Wiring Remote Condensing Unit With Dual Compressors
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL E² CONTROL CONFIGURATION (OPTIONAL) 6 CNDCT. PHONE TYPE 3 CONDUCTOR NON-SHIELDED CABLE SHIELDED CABLE SEE NOTE 3 REMOTE TEMPERATURE/ E² CONTROLLER DISPLAY HUMIDITY SENSOR E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL) CONTROLLER INSIDE THE ELECTRIC BOX THERMOSTAT CONTROL... -
Page 30: Remote Condenser
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL the terminal board within the A/C unit to the pump pack- CAUTION age electric box. Refer to the electrical drawing(s) supplied with your unit to determine the exact number of fi eld wires Do not connect any additional loads to the system and proper wire terminations required specifi... -
Page 31: Remote Water Detector
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 2.7.6.3 Remote Water Detector 2.8 System Charging Procedures There are two types of water detector available with OHS 2.8.1 Water/Glycol Systems units: Spot type and strip/cable type. All self-contained water/glycol cooled units (units that Spot Type: require no refrigerant fi... -
Page 32: Remote Air-Cooled Systems (Ar/Ahu)
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL • Label the system when charging is complete a change in composition and saturation temperature as (if it is not labeled already). evaporation and condensation occur. Typically, the com- position of R407C vapor is different than that of R407C •... -
Page 33: Preparing System For Charging
(OHS-060-AR) A/C unit with Flooded Head Pressure Control connected with a 1/2 in. x 30 ft liquid line and 7/8” NOTE x 30 ft discharge line to a STULZ Model SCS-096-SAA Use high quality hoses, ensuring they are free of condenser: defects and don’t leak. -
Page 34: Refrigerant Charging Procedures
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL and discharge service ports and the service port of the 26, calculate the minimum amount of refrigerant needed receiver (if applicable). for your system. NOTE When charging a system with a blended refrigerant, maintaining the composition of the refrigerant is essential. -
Page 35: ºf Fan Cycling And -20 ºf Variable Speed Control
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL tual room temperature, thus ensuring cooling remains valve must be open to allow refrigerant to fl ow into the on as the unit is charged. reheat coil to obtain the proper amount of refrigerant charge. -
Page 36: Refrigerant Characteristics
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 2.9.2 Saturated Refrigerant Pressure Tables CAUTION The Table 11 refrigerant pressures are provided for refer- Remove the blockage to the air intake of the con- ence for R407C and R410A refrigerant. denser. -
Page 37: System Settings And Adjustments
The fan speed controller will automatically control the head pressure at a level to maintain design refrigerant discharge See the Head Pressure Controls section of the STULZ SCS pressures. On systems with more than one fan on the Series Remote Air Cooled Condensers IOM for informa-... -
Page 38: Flooded Head Pressure Control (Condenser Model Scs-Aa With Fan Cycling, -30 °F)
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 2.10.2.5 Flooded Head Pressure Control (Condenser in Section 2.10.2.5. Instead of cycling the fan on and off, Model SCS-AA With Fan Cycling, -30 °F ) the condenser fan speed is continuous. The head pressure control valve diverts discharge gas to the receiver causing Used for outdoor installations where ambient condenser air liquid to back up in the condenser, as described in Section... -
Page 39: Blower Adjustment
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL and motor pulleys when a fi rm pressure is placed on CAUTION the side of the blower belt. Adjust the blower belt ten- sion by raising (to tighten) or lowering (to loosen) the Adjusting the capacity potentiometer too high may nuts on the adjustment rods of the motor base. -
Page 40: Hot Gas Reheat (Optional)
2.10.8 Hot Gas Bypass (Optional) (discharge) regulating valve has a normal suction pressure The two most common systems provided by STULZ for control setting at 75 psig (R407C) and 121 psig (R410A) hot gas bypass are snap acting and full fl oating, described read from the suction (low) side of the compressor as it op- below. -
Page 41: Commissioning, Operation And Decommissioning
It should be humidifi cation. Use an amp meter to determine the completed during start-up and sent to STULZ. This current draw of the humidifi er. Visually check for vapor checklist should be used as a guideline for items that leaving the steam head or feel if the cylinder is warm need to be confi... -
Page 42: Operating The Unit
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 3.2 Operating the Unit 3.4 Decommissioning the Unit This section provides simple instructions for powering an Personnel performing the decommissioning must be com- OHS unit on and off. The procedures differ depending on pletely familiar with the unit before starting. -
Page 43: Recovering Refrigerant
Checklist" in Appendix A to record periodic general mainte- Empty recovery cylinders must be evacuated and, if nance inspections. For assistance, contact STULZ Product possible, cooled before recovery occurs. Support. Follow all safety instructions while performing any type of maintenance. -
Page 44: A/C Unit
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL controller. To isolate the unit for maintenance, turn off • if unit has an oil-level sight glass, verify com- power at a non-fused service switch. pressor oil level during operation (all compres- sors) Always disconnect main power prior to performing any 4.1.1.2 Heater... -
Page 45: Condensate Pump
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 4.1.1.7 Condensate Pump Also, perform the maintenance operations described in the humidifi er manual. The optional condensate pump should be inspected semi- annually and cleaned. Ensure that the fl oat works freely. 4.1.2 Condenser/Condensing Unit Wipe the fl... -
Page 46: Troubleshooting
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 4.2 Troubleshooting Troubleshooting steps are listed in Table 12. Turn off all power to the unit before conducting any troubleshooting pro- cedures unless the procedure specifi cally requires the system to operate. Keep hands, clothing and tools clear of the electrical terminals and rotating components. - Page 47 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Symptom Probable Cause Recommendation Condenser Pressure Too High a. Non-condensable gas or air in system. Recover system and recharge. Replace drier/strainer. Evacuate to 50 microns and recharge. b. Condenser air intake is blocked. Remove debris and clean condenser.
- Page 48 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Symptom Probable Cause Recommendation System Short of Capacity a. Low refrigerant (indicated by bubbles in Check for leaks. Repair and recharge sight glass). system. b. Expansion valve stuck or obstructed Remove valve and clear obstruction or (short cycling or continuous running).
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Page 49: Field Service
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 4.3.4 General Common Repairs/ Component 4.3 Field Service Replacement NOTE 4.3.4.1 Compressor Failure Do not attempt to make repairs without the proper The compressor is the most important component of the tools. -
Page 50: Standard Cleanout Procedure
R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL 4.3.4.2 Standard Cleanout Procedure 5. Install a suction line fi lter-drier designed for acid removal. WARNING 6. Remove the liquid line drier and install the appropriate Avoid touching or contacting refrigerant gas and oil liquid line fi... -
Page 51: Air Filter Replacement
Failure to perform the recommended Extended The STULZ Product Support coordinates all Factory Au- Shutdown procedure before a prolonged shut-down thorized Services and ensures only STULZ certifi ed techni- cians are dispatched to perform your Factory Authorized period will drastically shorten the cylinder life. -
Page 52: Obtaining Warranty Parts
To receive credit for returned repair/replacement Technical Support. The replacement part will then be parts, the parts must be returned to STULZ within 30 days shipped via UPS ground. If the customer requests that war- of the purchase date. Spare part sales over 30 days old ranty part(s) be sent by any other method than UPS ground, will be considered fi... - Page 53 Room Temperature: Room Humidity: Unit Setpoints Return Temperature: Return Humidity: Remote/Supply Temperature: Remote/Supply Humidity: Electrical Panel (Safety Note: The following should be performed by Stulz Trained Service Personnel only) Pass Fail N/A Inspect unit disconnect for proper operation: Pass Fail N/A...
- Page 54 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Blower Section Pass Fail N/A Inspect motor pulleys and sheaves for excessive grooves: Pass Fail N/A Inspect bearings for excessive wear: Pass Fail N/A Inspect Blower Section for any loose parts or debris: Replace Good N/A...
- Page 55 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL Check Humidifi er Operation N/A Yes No N/A Check electrical connections: Yes No N/A Canister arching replace: Yes No N/A Test humidifi er drain cycle: Yes No N/A Inspect humidifi er section for water leaks: Good Replace Canister capacity:...
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Page 56: Appendix B - Acronyms And Abbreviations
Safety Data Sheet IAQ - Indoor Air Quality SPDT - Single Pole, Double Throw in - Inches STULZ - STULZ Air Technology Systems, Inc. in. w.g. - Inches of Water Gauge TEV - Thermal Expansion Valve kVA - Kilo Volt Amp Volt... - Page 57 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL NOTES...
- Page 58 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL NOTES...
- Page 59 R OHS S ERIES NSTALLATION PERATION AND AINTENANCE ANUAL NOTES...
- Page 60 STULZ North American Headquarters STULZ AIR TECHNOLOGY SYSTEMS (STULZ USA) , INC. 1572 Tilco Drive | Frederick, MD 21704 Tel: 301.620.2033 | Fax: 301.662.5487 | info@stulz-ats.com STULZ Company Headquarters STULZ GmbH Holsteiner Chaussee 283 22457 Hamburg products@stulz.de STULZ Subsidiaries STULZ Australia Pty. Ltd.
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