Stulz Tel-Air-2 Series Operating Instructions Manual
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Stulz Tel-Air-2 Series Operating Instructions Manual

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EN
English
STULZ the natural choice
Index 35A
Operating instructions
Edition 06.18
Tel-Air-2
Air conditioner
230/1/50 - 400/3+N/50

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  • Page 1 English STULZ the natural choice Index 35A Operating instructions Edition 06.18 Tel-Air-2 Air conditioner 230/1/50 - 400/3+N/50...

  • Page 3: Table Of Contents

    Table of Contents Safety directions ......................... 6 Attachments ......................6 General information ....................7 Handling refrigerants ....................8 Safety and environmental requirements ..............8 Unit identification ......................10 Intended and non-intended use ................13 Components and operating principle ................14 Layout of components .....................
  • Page 4 10. Residual Hazards and Emergency Information .............. 55 10.1 General safety provisions ..................55 10.2 Hazards arising from the product coming into contact with things or persons ..55 10.3 Hazards arising from electrical faults ............... 55 10.4 Safety standards to comply with when working on refrigeration circuits ....57 10.5 Hazards arising in case of fire .................
  • Page 5 STULZ reserves the right to update the product and relevant manual without being required to update previous products and manuals other than in exceptional circumstances.

  • Page 6: Safety Directions

    Safety directions This manual contains the basic instructions which must be respected during installation, use and maintenance of the unit. Therefore, installer and specialized personnel / user must read and respect these indications before mounting and commissioning the unit. Read carefully the whole information on this manual, with particular attention to the norms marked with the symbol on the left.

  • Page 7: General Information

    (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 8: Handling Refrigerants

    Handling refrigerants According to EN 378, refrigerants are divided in groups, concerning health and safety. Refrigerants used in Telecom Line units belongs to group L1 (non-flammable, non-toxic).  Adherence to the regulations by law and guide-lines.  Execution only by competent staff. ...
  • Page 9  Independent conversion and manufacture of replacement parts.  The system may only be converted or modified after consultation with STULZ. Original replacement parts and replacement parts/accessories authorized by STULZ are an aid to safety. Independent conversion and manufacture of replacement parts The system may only be converted or modified after consultation with STULZ.

  • Page 10: Unit Identification

    Unit identification Technical name-plate This unit can be correctly identified by the technical name-plate containing all the information for its correct use. The name-plate is attached both to the external casing of the unit (generally on one of the sides) and to the door of the electrical panel.
  • Page 11 IP protection degree is the protection, from the outdoor environment, of the unit when installed in its normal use. The IP protection degree of STULZ Tel-Air-2 unit, installed combined with a suitable external rainproof grille (available as Stulz accessory ACTGRxxTL), is IPX4, therefore the unit is protected from harmful effects of splashing of water against the enclosure from any direction (according to EN 60529, considering the prescriptions of EN 60335).
  • Page 12 Code The table summarises the available options for the Tel-Air-2 family. Some of the options or combinations are not available on all the products in the family. Product family Nominal cooling capacity Operating method Type of control system Application and fans Main power supply Compressor - refrigerant Heating...

  • Page 13: Intended And Non-Intended Use

    Their use eliminates the problems caused by high temperatures, dirt and humidity present in the area where they are installed. STULZ Tel-Air-2 units are designed to be installed inside a shelter / room whose internal side is not accessible to the general public (see EN 60335-2-40, paragraph 3.119).

  • Page 14: Components And Operating Principle

    3. Components and operating principle Layout of components TLF – DISPLACEMENT SUPPLY The internal air return is located in the roof of the unit. Taken in by the radial fan located at the bottom of the unit behind the supply opening, the air crosses the treatment filter in the centre of the unit, is blown onto the evaporator coil and leaves from the opening in the lower front panel.
  • Page 15 TLF/TLD 40-60 TLF/TLD 80-A4 Condenser fan Display Condenser Damper block Air filter Electrical panel Evaporator Compressor Evaporator fan Water discharge Layout of the internal TLF/TLD components E/0618/35A/15...
  • Page 16 Evaporator fan Electrical panel Display Evaporator Compressor Air filter Damper block Condenser Condenser fan Water discharge Layout of the internal TLU components E/0618/35A/16...
  • Page 17 COOLING FREE-COOLING Air flow diagram TLF/TLD units (a unit size 2 is shown in these drawings) E/0618/35A/17...
  • Page 18 COOLING FREE-COOLING Air flow diagram TLU units (a unit size 2 is shown in these drawings) E/0618/35A/18...

  • Page 19: Operating Method

    Operating method Cooling The shelter air is taken in by the radial fan, filtered and then cooled as it crosses the evaporator coil. The treated air is then returned to the shelter through the supply air opening. The compressor operates in order to cool the air. Free-cooling There is a damper equipped with servomotor which directs internal and external air flows.

  • Page 20: Mechanical Parts

    Mechanical parts Structure These machines are built using self-supporting panels made of painted galvanised sheet metal to guarantee good corrosion resistance (not suitable for corrosive and saline environments). They make the machine easy to inspect and, at the same time, offer adequate protection to its internal components.
  • Page 21 Compressor A reciprocating compressor is used for the TLx40 model with 400V/3Ph+N/50Hz power supply. TLx40 with 230V/1Ph/50Hz power supply is provided with a rotary compressor. Scroll compressors are used for all the other models. Compressors are basically composed of an electric motor and a mechanical section which is powered by this motor for pumping the refrigerant gas.

  • Page 22: Motors

    Thermostatic expansion valve Condenser fan Filter dryer pressure switch Evaporator fan Evaporator Condenser fan Condenser HP switch LP switch Compressor Antifreeze thermostat / probe Regulating thermostat / internal temperature probe Motors Compressor Electric motor positioned inside the compressor. It is mounted on vibration dampers to reduce vibrations.

  • Page 23: Control, Monitoring And Safety Components

    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 24 STANDARD COMPONENTS with ELECTRONIC CONTROL C2020 I/O CONTROLLER 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). Software with working logic and parameter settings are written in the EEPROM so that they remain permanently stored even in case of power failure.
  • Page 25 Dirty filter alarm device RFS – air flow alarm FL It provides a signal, via the display; which indicates the need to service the air filter Range : 0.4 - 2.0 mbar Differential press. : 0.2 mbar + 15% P1 : Connection of the high pressure P2 : Connection of the low pressure Adjustment: Using a screwdriver, you can adjust the desired differential...

  • Page 26: Technical Data And Drawings

    4. Technical data and drawings Application limits Operation limits Outside operating limit temperature -20° (with R407C) +50° +20° Inside operating limit temperature +40° 5,5 °C dew point Return air humidity 60% r.h. and 15 °C dew point Nominal power supply 400 V / 3 ph +N / 50 Hz Voltage tolerance ±...
  • Page 27 TLD/F 40-TLD/F 80 TLD/F 40 TLD/F 60 TLD/F 80 E/0618/35A/27...
  • Page 28 TLD/F 90-TLD/F A4 TLD/F A2 TLD/F A4 TLD/F 90 E/0618/35A/28...
  • Page 29 E/0618/35A/29...
  • Page 30 E/0618/35A/30...
  • Page 31 E/0618/35A/31...
  • Page 32 HP fans TLx90-TLxA4 MODEL TLx90 TLF/DA2 TLUA2 TLF/DA4 TLUA4 Condenser fan - HPFAN option Q.ty / Type 1 / radial 1 / radial 1 / radial 3200 3500 3500 Air flow Available static pressure External sound pressure level** dB(A) Nominal voltage V AC Phases Power consumption*...
  • Page 33 Overall dimensions and air flows TLF / TLD 40 - 60 FRONT VIEW SIDE VIEW REAR VIEW INTERNAL AIR (CONDENSER AIR INTAKE RETURN DISCHARGE APERTURES) CONDENSER AIR INTAKE - DISCHARGE INTERNAL AIR SUPPLY - TLF INTERNAL AIR WATER DISCHARGE SUPPLY - TLD TOP VIEW (INTERNAL AIR RETURN APERTURE)
  • Page 34 Overall dimensions and air flows TLU 40 - 60 FRONT VIEW SIDE VIEW REAR VIEW (CONDENSER AIR INTAKE DISCHARGE APERTURES) INTERNAL AIR SUPPLY INTERNAL AIR RETURN CONDENSER AIR INTAKE - DISCHARGE WATER DISCHARGE TOP VIEW E/0618/35A/34...
  • Page 35 Overall dimensions and air flows TLF / TLD 80 – A4 FRONT VIEW SIDE VIEW REAR VIEW INTERNAL AIR (CONDENSER AIR INTAKE RETURN DISCHARGE APERTURES) CONDENSER AIR INTAKE - DISCHARGE INTERNAL AIR SUPPLY - TLF INTERNAL AIR WATER DISCHARGE SUPPLY - TLD TOP VIEW (INTERNAL AIR RETURN APERTURE)
  • Page 36 Overall dimensions and air flows TLU 80 – A4 FRONT VIEW SIDE VIEW REAR VIEW (CONDENSER AIR INTAKE DISCHARGE APERTURES) INTERNAL AIR SUPPLY INTERNAL AIR RETURN CONDENSER AIR INTAKE - DISCHARGE WATER DISCHARGE TOP VIEW E/0618/35A/36...
  • Page 37 Cut-out TLF / TLD 40 - 60 (EXTERNAL OUTSIDE) E/0618/35A/37...
  • Page 38 Cut-out FLOOR TLD 40 - 60 FRONT SIDE REAR SIDE E/0618/35A/38...
  • Page 39 Cut-out TLU 40 - 60 (EXTERNAL OUTSIDE) E/0618/35A/39...
  • Page 40 Cut-out TLF/TLD 80 - A4 (EXTERNAL OUTSIDE) E/0618/35A/40...
  • Page 41 Cut-out FLOOR TLD 80 - A4 FRONT SIDE REAR SIDE E/0618/35A/41...
  • Page 42 Cut-out TLU 80 – A4 (EXTERNAL OUTSIDE) E/0618/35A/42...
  • Page 43 Space for installation and maintenance The unit in the drawing, shown purely for the sake of example, indicates the air apertures of a size 2 TLF unit TLF / TLD TLF / TLD MODEL 40 – 60 80 – A4 40 –...

  • Page 44: Unpacking And Inspection

    5. Unpacking and Inspection STULZ products are shipped ex-works. All units have been individually inspected in all their parts and carefully packaged. Immediately inspect the unit upon receipt, making sure it has been shipped in its proper position. Note improper shipment on the shipping document.

  • Page 45: Precautions When Handling The Unit

    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 technical department should be contacted. Precautions when handling the unit Handle these units, when they are packaged, using a fork lift.

  • Page 46: Positioning The Unit

    Positioning the unit 1. Tel-Air-2 conditioners must be installed inside the shelter. 2. Check that:  there is enough room for easy application, installation and servicing, both inside and outside the shelter. Always observe the minimum spaces indicated in the drawing at the end of this manual;...

  • Page 47: Hydraulic Connections

    Hydraulic connections Make sure the condensate drain pipes do not interfere with the air flow. Connections are carried out by the installer. h > 0 mm  Use PVC pipes with an internal diameter of 14 mm  Connect the pipes to the plastic union at the rear of the conditioner ...
  • Page 48  Section of power supply cables must be selected in accordance to their length, kind of power supply and the current absorbed by the unit, as prescribed by current regulations. These cables must comply with currently applicable standards. In any case we recommend using shielded cables unless the installer carries out, at his expense, tests that demonstrate that shielding is not necessary.
  • Page 49 TLF / TLD 40-60 TLF / TLD 80-A4 Plate with power supply cable access and signal connectors Route of cables inside TLF / TLD unit E/0618/35A/49...
  • Page 50 TLU 40-60 TLU 80-A4 Plate with power supply cable access and signal connectors Route of cables inside TLU unit E/0618/35A/50...
  • Page 51 SUB-D CONNECTOR C1 SUB-D CONNECTOR C2 1/14 Common warning Internal relative humidity probe 2/15 Low pressure 2/10 External relative humidity probe (3) 3/16 High pressure 3/11 Smoke / fire sensor 4/17 Air flow 4/12 Door open / intrusion (3) 5/18 Dirty filter 5/13 External on-off...

  • Page 52: Start-Up

    8. Start-up Before performing initial start-up, install and connect the system as described in the “Installation” chapter.  Make sure the general switch is turned off and that the system is not live.  Check that all the power switches and control fuses in the electrical system are off. ...

  • Page 53: Maintenance

    AIR FILTERS: check the air filter, clean it or replace if necessary (dirty filter alarm). If you decide to change the filter, the medium and thickness of the spare must be the same as the original. A set of spare filters can be ordered to the STULZ service dept. Once quarterly ...
  • Page 54  Loosen the screws securing the filter holder.  Pull the filter holder towards you.  Rotate free-cooling damper in cooling position (complete recirculation), pushing the unblocking button on free-cooling damper motor.  Remove the filter. Unblocking button of free cooling damper motor Cleaning the exchangers Proceed as follows:...

  • Page 55: Residual Hazards And Emergency Information

    10. 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. 10.1 General safety provisions All personnel charged with testing and maintaining the unit must be familiar with the following...
  • Page 56 TASKS ASSIGNED TO PLANT MANAGERS Plant managers must be informed regarding potential risks in the system and must superintend personnel that works with electrical equipment. Superintending tasks consist of localizing possible risk situations and investigating problems encountered by personnel when performing maintenance. Each defective component must be immediately repaired or replaced.

  • Page 57: Safety Standards To Comply With When Working On Refrigeration Circuits

     measuring instruments must be periodically calibrated;  check work procedures before starting the job. Check the wiring diagram and get an overall picture of how the system is structured. It is necessary, while maintenance is being done:  for the maintenance person to be aware of which circuits are under high voltage; ...

  • Page 58: Hazards Arising In Case Of Fire

    This unit must be disassembled by authorised organisations. 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. 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 59 1. Disposal of packaging The packaging of the unit must be disposed of ensuring separation of the following materials:  Paper and Cardboard  Wood Packing–Packing materials are not chemically treated unless they are declared to be “fumigate”  Plastic pallets- high- density polyethylene HDPE ...

  • Page 60: Options

    12. Options On TLx40 – 60 options VCC, PSCR, SWT, SWM in combination with options SOFTM or SOFTT, CRA, RSC do not fit all together. Please contact technical support for further information. Protective treatment on coils – TREATT 12.1 It’s a protective treatment on condenser and evaporator surface in order to protect them against corrosion by salt spray.
  • Page 61 E/0618/35A/61...
  • Page 62 E/0618/35A/62...
  • Page 63 E/0618/35A/63...
  • Page 64 E/0618/35A/64...

  • Page 65: Kit For Low External Temperatures - Winter Kit

    Kit for low external temperatures – WINTER KIT 12.5 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 is composed of: ...

  • Page 66: Soft Start For Three-Phase Compressor - Softt

    Soft start for three-phase compressor – SOFTT 12.9 Hazardous voltage: will cause death or serious injury. Disconnect power before working on equipment. Setting of this component is made in factory and must not be altered. The soft start is installed inside the e-box on the supply line to the compressor. Its purpose is the reduction of compressor starting current.
  • Page 67 Terminal Terminal Description Description number number Control power input N.O. relay - aux. contact for fault indication Control power common N.O. relay - aux. contact for fault indication Start input N.O. auxiliary relay #1 (normal/up-to-speed) Stop input N.O. auxiliary relay #1 (normal/up-to-speed) Auxiliary contacts Two hard contacts are provided as standard.
  • Page 68 Start time Current limit start setting ( when selected) DIP switch number DIP switch number Time [S] 4 Current limit % FLA 150 % 250 % 350 % 450 % Start time (current limit or soft start) Soft start initial torque setting (when selected) DIP switch number DIP switch number Initial torque % LRT...

  • Page 69: Soft Start For Single-Phase Compressor - Softm

    R134a is not possible to add other options with Soft Start. To verify the availability of SOFTM option with 230V/1ph/60Hz power supply, please contact your local partner STULZ. Setting of this component is made in factory and must not be altered.

  • Page 70: Voltage Control Device - Vcc

    12.11 Voltage control device – VCC The voltage control relay, is an additional device which stops the power supply to prevent faults if the voltage not in rated tolerance. The relays monitors according to the respective setting an voltage whether it exceeds or falls below a specified value or is within a certain range (window monitoring).

  • Page 71: Wib1000 / Wib1485

    12.12 WIB1000 / WIB1485 The WIB1000 / WIB1485 is a single-point Ethernet interface and it’s used for the SNMP supervision, web monitoring and OnBoard communication. It’s also possible to update the firmware and the parameters list through an USB key, formatted as FAT32. When present, WIB1000 / WIB1485 is soldered directly on the SPI connector of the mother board.

This manual is also suitable for:

Tl 40 seriesTl 60 seriesTl 80 seriesTl 90 seriesTel-air-2 tld40Tel-air-2 tld60 ... Show all

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