Stulz SplitAir3 SAL40 Operating Instructions Manual

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SplitAir3

Operating instructions

Air Conditioners

230/1/50 - 400/3+N/50

Index 39B

Issue 06.2018

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Page 1 SplitAir3 Operating instructions Air Conditioners Index 39B Issue 06.2018 230/1/50 - 400/3+N/50...
Page 2 SA L A B O U T S T U L Z Since it was founded in 1947, the STULZ company has evolved into one of the world’s leading system suppliers of air-conditioning technology. Since 1974 the group has seen continual international expansion of its air condition- ing technology business, specialising in A/C for data cen- tres and telecommunications installations.
Page 3 It's the result of decades of research and design studies, with a fine search of materials and technologies to obtain an high quality unit. The CE mark guarantees that the STULZ products satisfy the requirements of the European Machinery Directive for safety.
Page 5: Table Of Contents
11.4. Main switches - SWTS/SWMS......................64 11.5. Crankcase heater for compressor – CRA ..................65 11.6. Refrigerant R134a ..........................65 11.7. Soft start for three-phase compressor – SOFTT ................68 11.8. Soft start for single-phase compressor – SOFTM ..............70 © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 6 11.12.Stainless steel casing - PAKIN ......................72 11.13.Seaworthy case packaging - SEAPACK ..................72 STULZ reserves the right to update the product and the relevant manual without having to update products and manuals sold previously except under exceptional circumstances. Contact your local STULZ partner when requesting or receiving any updates of instruction manuals or corrections when which are considered to be integral parts of the manual.
Page 7: Introduction
The following documents are attached to this manual, as its integral part: • Use and maintenance manual part 2, which contains the electrical drawing and the conformity declaration CE of the unit. • User manual of the electronic controller. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 8: Safety Directions
(i.e. gloves, glasses, helmet, shoes), according to the indications of safety manager and applicable regulations. • The unit may only be used to cool according to the STULZ specification. • Before any maintenance operation, read and follow instructions in the corresponding chapter.
Page 9: Residual Hazard
Be sure to remove power during maintenance bruises maintenance and wait the stop of the moving parts. Wear PPE. Internal hot components Contact with hot surfaces. Burns Wear PPE (compressor, condenser, refrigerant lines) © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 10: Safety Data
Keep in a cool, well-ventilated place. Protect full conditions containers from sources of heat to avoid over pressurization. Packaging materials Recommended Ordinary steel To be avoided Alloys containing more that 2% of magnesium. Plastic materials. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 11: Labels
D. 1999/45/EC amended by D.2001/60/CE Further information The product does not need to be labelled in accordance with EC directives or respective national laws. 2.5. Labels DANGER: MOVING COMPONENTS DANGER: HOT COMPONENTS DANGER: HIGH VOLTAGE © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 12 Dispositif contenant fluides HFC à effet de serre disciplinés par le protocole de Kyoto Ermeticamente sigillato - hermetically sealed Ermeticamente sigillato - hermetically sealed Hermetische Verschluss - Scellè Hermetiquement MADE IN ITALY Hermetische Verschluss - Scellè Hermetiquement MADE IN ITALY EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 13 • IPX4 of the whole combination of: internal unit, freecooling module and rainproof grille. This system is protected from harmful effects of splashing of water against the enclosure from any direction (see picture below). © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 14 Shelter wall Labels on the packaging of external and internal unit, on both sides CE marked Fragile Keep dry Position Do not step Lift cart here Maximum 2 units one above the other EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 15: Intended And Non-Intended Use
The internal side of the room/ shelter must not be accessible to the general public (see EN 60335- 2-40, paragraph 3.119). The SplitAir3 conditioners cannot be used outside safety limits specified on the name-plate. STULZ is not responsible for an malfunctions caused by failure to comply with these instructions. The operator bears the entire risk. DANGER The conditioners may not be used or transported in a position other than that for which they have been designed.
Page 16 With ex-works delivery conditions, carrier is the sole responsible for any damage caused during transport. STULZ is not responsible for damages to the goods caused by the carrier, but it will do everything in its power to assist clients on those situations.
Page 17: Precautions When Handling The Unit
3.1.1. 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. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 18: Storage
Use original packing to ship the air conditioner to any other destination If packing disposal is necessary, we remind to dispose different materials suitably (see chapter "10. Uninstalling and disposal of the unit") EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 19: Description
W = C2020 + WIB1485 0 = Cooling F = Cooling + Freecooling H = Cooling + Freecooling + Emergency ventilation 48 Vdc direct connected According to the technical data sheet SAL = SplitAir3 © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 20 According to the technical data sheet SAO = External split ON-OFF Type code - Free cooling module Free cooling module Size SFC 80 80 = 4 - 8 kW A5 = 10 - 14,6 kW EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 21 Z lose their original meaning and act as the progressive number for special versions. Every SAL unit is composed by the external unit SAO and the internal unit SSI; if free cooling mode in enabled, the free cooling module SFC is also included. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 22: Component Lay-Out And Operating Methods
Cable entry holes are located on the right side of the unit on the top of the right panel near the electrical box, and the refrigerant connectors to the internal unit are on the lower part of the right panel. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 23 Internal Unit Differential pressure switch Refrigerant connectors Filter Internal Unit + Free Cooling Module in cooling Main switch (optional) Free cooling module Damper Internal Unit + Free Cooling Module in free cooling © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 24 SA L Layout external unit Electrical box Microchannel Condenser Thermostatic Fans Compressor Connectors valve External unit size 1 External unit size 2 EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 25 According to the signal of humidity inside the room, supplied by the optional humidity probe ACTRHC1, air conditioner C2020 controller reduces evaporator fan speed. Consequent air flow reduction causes a higher temperature difference between inlet and outlet air, helping condensation of humidity in it. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 26: Refrigerant Circuit
The system works as follows: the compressor compresses the refrigerant gas bringing it to a high pressure and temperature. The hot gas, by going through the condenser, is cooled and liquefied thus EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 27: Safety Components Of Refrigerant Circuit
Filter dryer This is a mixed mechanical/chemical filter and it serves the purpose of filtering the impurities of the coolant which goes through it and, at the same time, eliminating humidity particles. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 28: Mechanical Components
SAL40-60-80 SALA0-A2-A5 Nominal voltage Weight Height x Width x Depth 350 x 682 x 310 410 x 892 x 370 Inside operating limit temperatures min/max °C -20 / +60 -20 / +60 EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 29: Motors
• Surface temperature of the evaporator for antifreeze purpose, the probe is located inside the evaporator fins. External unit: • External air temperature, the probe is under the base of the external unit. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 30 When shielded cables are used for that link, exploit the screw near the slave port to perform grounding (see picture) and put a washer between the eyelet and the plate. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 31 For controller input / output assignation, please refer to the electrical diagram on manual part 2, specific for each unit. C2020 Internal Unit SLAVE USER WIB1000 / WIB1485 or Communication with (optional) accessory ACTHKEY the external unit Sequencing Keypad (optional) © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 32: Technical Data
** Sound pressure level at 2 m obtained from the measured sound power according to the EN ISO 9614-2 on normal condition of use and nominal operating condition. This information must be made known to all personnel operating this unit and in the proximity thereof. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 33 400/3 230/1 400/3 230/1 400/3 230/1 400/3 230/1 Power consumption* Operating current 12,3 13,2 17,0 20,7 (OA)* Maximum operating 11,9 11,4 17,3 23,1 23,5 current (FLA) Locked rotor current 65,5 (LRA) © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 34 0,25 0,32 0,46 Operating current (OA)* Maximum operating current (FLA) Air flow in free cooling mode 1200 2300 2350 3300 Air flow in free cooling mode with ACTODALFCLxx 1000 1900 1950 2850 EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 38 Indoor unit - horizontal installation Minimum distances: Minimum distances: A = 500 mm A = 200 mm B = 1000 mm B = 300 mm (without free cooling) C = 1000 mm D = 500 mm EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 40: Installation
The rear side of the indoor unit must be installed with a minimum distance from the wall, please refer to the measures indicated in the drawings in paragraph "Drawings". EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 42 • ACTDVINSAL: rectangular section duct for vertical indoor unit; • ACTSHDROSALxx: flexible round section double duct kit for horizontal indoor unit. If no-one of these accessories is ordered, suitable ducts must be provided. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 43 Improper operation of this type can also cause irreparable harm to the compressor. Do not obstruct circulation of air being sucked into or expelled from the air conditioner. Positioning of the free cooling module © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 44: Refrigerant Connections
In this paragraph with distance is meant the length of the liquid line, including the bends, between the internal and the external units. DANGER Work on refrigerant circuits must be carried out only by qualified personnel or by the STULZ Service personnel. Making the refrigeration connection includes the following phases (described below): 1.
Page 45 6. Maximum distance allowed between evaporating unit and motor-condensing unit is 30 m. 7. Maximum height difference covered by connecting pipes must not exceed 10 m (please refer to the drawings of the refrigerant connections in the following pages). © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 47 SA L Refrigerant connections Liquid/gas pipeline 30 m max horizontal equivalent length Gas pipeline (Sloping 1%) Siphons (mandatory) Liquid/gas pipeline A + B < 30 m © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 48 Value to be reached is 0.3 mbar absolute. Check after 3 hours if pressure within the pipes has risen over 1.3 mbar absolute. If so, this means that there is a leakage on connection pipes, which have to be repaired before proceeding with the next phase. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 49 ICI Emkarate RL 32 F or Mobil EAL Arctic 22 CC, if 3MA is not available. Rotary compressor with R407C is supplied with ester oil VG74. Reciprocating compressor with R407C is supplied with polyester lubricant. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 50: Hydraulic Connections
Maintenance must be done after disconnecting the power supply of the unit (see note above). Electrical connections may only be performed by authorised technicians. The system must be connected to an efficient earth circuit. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 51 For kind and section of this cable, please refer to the interconnection diagram in manual part 2. ATTENTION Provide proper sealing to the hole in cabinet wall for this cable, to prevent any water (rain) infiltration. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 52 The connecting cable is a pin-to-pin cable with RJ11 plug and it's not supplied with the unit, but available as STULZ accessory ACTSEQCxx. To ground shielded cables, if any, use the insert near the connector of the outdoor unit (see image below).
Page 53 For connections between internal and external unit, please see C2020 I/O Controller, paragraph "Electrical components of protection and control". Electrical connections size 1 Internal unit with AC fans Main power supply Communication cable Power supply to the internal unit © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 54 Electrical connections size 2 Internal unit with AC fans Communication cable Main power supply Power supply to the internal unit Internal unit with DC fans Main power supply Communication cable Emergency 48 VDC power supply EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 55: Start-Up
4. Check, while the unit is running, that the supply voltage remains within the values indicated on the technical name-plate; 5. Check that the unit works according to the set logic. 7.3. Switching off To switch off the unit, turn off all the power supplies. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 56: Maintenance
Failure to perform maintenance, in addition to affecting the unit durability and operation, invalidates the warranty. If air conditioner works in particularly dirty environment or if experience shows that a more frequent maintenance is needed, this must be made as necessary. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 57: Air Circuit
• On the bottom side of the evaporating unit, open the panel nearest to the rear side. To remove the filter, rotate the proper locking device. • Extract the air filter and replace it. Replacing air filter © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 58: Refrigerant Circuit
Spare filters must have filtering medium with the same thickness and density as the original one. A set of spare filters can be ordered to your local STULZ service partner. Replacing free cooling damper motor (if free cooling module is present) To replace the motor of the free cooling damper, unscrew the 2 fixing screws of the damper motor box on the right side of the free cooling module.
Page 59: General Cleaning
• Repair the leak; • The circuit has to be run dry by several (at least 3x) fillings and extractions of nitrogen. When necessary change the filter dryer; • Fill with R407C. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 60: Troubleshooting
Defective protection Contact STULZ service 5. Evaporator fan x Evaporator fan broken Contact STULZ service blocked Fan cables disconnected Contact STULZ service Wrong configuration of number of fans on C2020 Contact STULZ service EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 61 Replace it with a pin-to-pin cable Wrong setting of sequencing jumpers Contact STULZ service Wrong setting of sequencing parameters Contact STULZ service Sequencing part of C2020 controller is damaged Contact STULZ service © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 62: Uninstalling And Disposal Of The Unit
The following are the instructions for proper disposal of the unit during the various phases of its life. For further clarification or additional information, please contact info@stulz.it. INFORMATION To ensure proper and safe disposal activities, operator must equip themselves with the necessary PPE including: anti-cut gloves, oil resistant gloves, heat resistant gloves, safety footwear, safety eye-wear against liquid and gas splashes.
Page 63: Options
When minimum outdoor temperature is below -25°C and cooling function is still required,units must be provided with this option. With this kit, minimum outdoor working temperature is -40°C. The kit is installed in factory and it's composed of: © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 64: Main Switches - Swts/Swms
SWTS is the version for 3-phase main power supply, SWMS is the version for single-phase main power supply. Main switches don't disconnect DC voltage, if present. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 65: Crankcase Heater For Compressor - Cra
30°C / Internal relative humidity 30% ** Sound pressure level at 2 m obtained from the measured sound power according to the EN ISO 9614-2 on normal condition of use and nominal operating condition. © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 66 (FLA) Compressor Nominal voltage V/ph 400/3 230/1 400/3 230/1 400/3 230/1 400/3 400/3 400/3 Power consumption* Operating current (OA)* 14,4 Maximum operating 14,8 17,3 23,5 current (FLA) Locked rotor current 65,5 (LRA) EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 68: Soft Start For Three-Phase Compressor - Softt
The overload reset option can be operated either manually or automatically. • Fault indication: this device monitors both the pre-start and running modes. A single LED is used EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 69 Soft stop Not used Kick start Kick start Overload class selection Overload class selection Overload reset Auxiliary relay #1 (normal or up-to-speed) Optional auxiliary relay #2 (normal or up-to-speed) Phase rotation check © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 70: Soft Start For Single-Phase Compressor - Softm
Hazardous voltage: will cause death or serious injury. Disconnect power before working on equipment. ATTENTION Setting of this component is made in factory and shown in the wiring diagram. Before altering it, contact STULZ service. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 71 Technical data Power supply 230 V AC +10% / -15% / 50/60Hz Nominal operating current 25A / 32A max. / AC-53a; AC-58a Protection class according to IEC 529 IP 20 © STULZ SpA . – all rights reserved EN/39B/06.2018...
Page 72 As standard, with stainless steel casing,units are painted like the units with zinc plated sheet casing. 11.13. Seaworthy case packaging - SEAPACK Wooden packaging with special treatment suitable for sea freight. Option available for internal and external unit. EN/39B/06.2018 © STULZ SpA – all rights reserved...
Page 73 Fax +43 (1) 616 02 30 SPAIN ventas@stulz.com.mx info@stulz.at FRANCE STULZ España S. A. STULZ France S. A. R. L. NETHERLANDS Tel. +34 (91) 517 83 20 Tel. +33 (1) 34 80 47 70 STULZ GROEP B. V. Fax +34 (91) 517 83 21...

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Stulz SplitAir3 SAL40 Operating Instructions Manual

1 Introduction

2 Safety Directions

3 Handling and Storage

4 Description

5 Technical Data

6 Installation

7 Start-Up

8 Maintenance

9 Troubleshooting

10 Uninstalling and Disposal of the Unit

11 Options

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