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Summary of Contents for Stulz CeilAir CW
- Page 1 CeilAir CW & DX ® Installation, Operation, and Maintenance Manual 3.5–35 kW / 60 Hzw...
- Page 2 C W & DX I O M 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 computer room air conditioners and air handlers.
- Page 3 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. Unpublished rights reserved under the copyright laws of the United States and of other countries.
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Page 4: Table Of Contents
2.4.3 Controls ........... 24 2.7.3.2 Remote Condensing Unit ...... 45 2.4.3.1 A-Tech Programmable Thermostats 24 2.7.4 Water/Glycol Systems ....... 45 2.4.3.2 Advanced STULZ E² Controller ..26 2.7.5 Remote Shut Down ......45 2.4.4 Optional Equipment ......26 2.7.6 Optional Equipment ......46 2.4.4.1 Condensate Pump (Field Installed) . - Page 5 C O N T E N T S C E I L A I R ® C W & DX I O M 2.7.6.4 Remote Temperature Sensor (A-Tech) 2.10.3.1 Pressure Valves Rated 150 psig (1.03 ................46 MPa) ............... 59 2.7.6.5 Remote Temperature/Humidity Sensor 2.10.3.2 Pressure Valves Rated 350 psig and ) ................47 450 psig (2.41 and 3.10 MPa) ......
- Page 6 C E I L A I R ® C W & DX I O M C O N T E N T S 4.3 Field Service ........ 75 Figures Figure 1. A-Tech Digital Thermostats ..11 4.3.1 Leak Detection ........75 Figure 2.
- Page 7 C O N T E N T S C E I L A I R ® C W & DX I O M Tables Table 1. Nomenclature ........9 Table 2. Recommended Minimum Thermal Resistance ............ 22 Table 3. Pipe Equivalent Lengths ....31 Table 4.
- Page 8 C E I L A I R ® C W & DX I O M C O N T E N T S This page intentionally left blank OCH0006F 08/13/2024...
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Page 9: Table 1. Nomenclature
Cooling fluid. CeilAir units utilize refrigerant (AHU, AR, or AS), chilled water (C), water (W), or glycol (G). Refrigerant type. CeilAir units using refrigerant may be charged with R407C or R410A. Condensers and condensing units. STULZ condensers and condensing units are documented in our Heat Rejection Engineering Manual. -
Page 10: Introduction And Safety
1.3 Control Devices STULZ offers a variety of control devices for CeilAir units. Control interfaces are typically remotely mounted to a wall or control panel. The default control device for CeilAir units is the A-Tech digital thermostat, which provides basic control of the system. -
Page 11: Safety
Microprocessor Controller and Display 1.4 Safety 1.4.1 General STULZ uses notes, cautions, and warnings in its manuals to draw attention to important operating and safety information. A bold text NOTE alerts you to an important detail. A bold text CAUTION provides information that is important for protecting your equipment and performance. - Page 12 C E I L A I R ® C W & DX I O M 1. 4.1 G E N E R A L precedes a general WARNING or CAUTION safety statement. precedes an electrical shock hazard WARNING or CAUTION safety statement. 1.4.2 Safety Summary The following warnings and cautions appear in this manual.
- Page 13 1 . 4 . 1 G E N E R A L C E I L A I R ® C W & DX I O M WARNING Never operate the unit with any cover, guard, or screen panel, removed unless the instructions specifically state otherwise, then do so with extreme caution to avoid personal injury.
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Page 14: General Design
C E I L A I R ® C W & DX I O M 1.5 G E N E R A L D ES I G N CAUTION When the air conditioner operates in cooling mode the return air intake and discharge (supply) must be free of obstructions. -
Page 15: Coil(S)
1 . 5 . 4 T E M P E R AT U R E S E N S O R C E I L A I R ® C W & DX I O M Figure 3. CeilAir OHS-032-AR (Access Panels Removed) 1.5.2 Coil(s) The cooling coils and optional hot water reheating coils have aluminum finned and copper tube construction. -
Page 16: Optional Equipment
C E I L A I R ® C W & DX I O M 1 .6 O P T I O N A L Eq U I P M E N T 1.6 Optional Equipment 1.6.1 Humidistat/Dehumidistat As an option for systems employing an A-Tech 1.1 or A-Tech 1.2 thermostat, a room mounted humidistat and/or dehumidistat may be shipped loose for field installation. -
Page 17: Condensate Pump
1.6.8 Water Detector As an option, STULZ offers spot type or strip/cable type water detectors. In units equipped with an E² controller, when water is detected the controller turns off cooling and humidification, while the blower(s) continue to operate. -
Page 18: Figure 4. Free Cooling Diagram
C E I L A I R ® C W & DX I O M 1.6.5 C O N D E N SAT E P U M P Figure 4. Free Cooling Diagram OCH0006F 08/13/2024... -
Page 19: Aws Operation
1 . 8 AW S O P E R AT I O N C E I L A I R ® C W & DX I O M The compressor activates if the DX cooling stage enable-temperature setpoint has been reached or if the control valve position reaches 100% open for 240 seconds (default compressor-on time delay). -
Page 20: Figure 5. Alternate Water Source Diagram
C E I L A I R ® C W & DX I O M 1.8 AW S O P E R AT I O N Figure 5. Alternate Water Source Diagram If the return air temperature rises to the compressor cut-in setpoint or if the AWS control valve reaches 100% open for 240 seconds (default compressor-on time delay), the compressor turns on and operates in parallel with AWS cooling. -
Page 21: Installation
Freight claims must be submitted to the freight carrier. STULZ ships all equipment factory free on board (FOB). STULZ Product Support can assist in the claim filing process with the freight carrier. Should any damage be present, notify STULZ Product Support prior to attempting any repairs (see section 5.0). -
Page 22: Rigging
C E I L A I R ® C W & DX I O M 2.3 R I G G I N G Table 2. Recommended Minimum Thermal Resistance STRUCTURE R-VALUE Ceiling R-38 Wall R-21 Floor R-19 Door The vapor barrier is the single most important requirement for maintaining environmental control in the conditioned space. -
Page 23: Indoor Equipment
2 . 4 . 2 O U T D O O R Eq U I P M E N T C E I L A I R ® C W & DX I O M (BY OTHERS) Figure 6. Typical Installation 2.4.1 Indoor Equipment CeilAir systems have a frame and panel construction for unit rigidity and full service accessibility while the unit is mounted in place. -
Page 24: Controls
C E I L A I R ® C W & DX I O M 2.4. 3 C O N T R O L S There should be at least one equipment-width of clearance around the condenser to ensure adequate airflow to the coil. -
Page 25: Figure 8. Spot Cooler Grille
2 . 4 . 3 . 1 A-T EC H P R O G R A M M A B L E T H E R M O S TAT S C E I L A I R ® C W & DX I O M 4. -
Page 26: Advanced Stulz E² Controller
2.4.3.2 Advanced STULZ E² Controller If the optional STULZ E² controller is furnished, a separate manual is included in the unit data package provided with the unit. The controller user interface display may be field mounted to a wall within the conditioned space, or it may be located outside the conditioned space if desired. -
Page 27: Non-Fused Service Switch
When locating the sensor, consider the length of wire to be used. As an option, a 75 ft or 150 ft cable may be provided by STULZ. Refer to the applicable section that follows to mount the sensor. For wiring details, refer to section 2.7.2 and to the electrical drawing provided with the unit. -
Page 28: Remote Temperature/Humidity Sensor (E²)
C E I L A I R ® C W & DX I O M 2 .4 .5.2 R E M OT E T E M P E R AT U R E / H U M I D I T Y S E N S O R ( E ² ) 3. -
Page 29: Humidistat/Dehumidistat (Used With A-Tech1.1/1.2 Thermostat)
2 . 4 . 7 S P OT WAT E R D E T EC TO R C E I L A I R ® C W & DX I O M 5. Route the sensor control cable up to the control terminal block in the electric box and terminate the control wire. -
Page 30: Cable Type Water Detector
C E I L A I R ® C W & DX I O M 2.4.8 C A B L E T Y P E WAT E R D E T EC TO R For wiring details, refer to section 2.7.6.3 and to the electrical drawing provided with the unit. 2.4.8 Cable Type Water Detector CAUTION Do not allow the cable water detector to contact metal (frame or condensate pan). -
Page 31: Piping Connections
2 . 6 . 1 . 2 S P L I T SYS T E M S C E I L A I R ® C W & DX I O M 2.6 Piping Connections 2.6.1 Refrigerant 2.6.1.1 Self-Contained Systems No refrigeration connections are required for self-contained air, water, or glycol-cooled systems, like models OHS-012/040-AS, OHS-012/120-C, OHS-012/120-W, and OHS-012/120-G. -
Page 32: Table 4. Recommended Discharge Line Sizes For R407C Refrigerant
C E I L A I R ® C W & DX I O M 2.6.1 .2 S P L I T SYS T E M S Oil traps must be included every 20 ft inside the vertical risers and the refrigerant lines must be sloped at 1/4 in for every 10 ft on the horizontal lines to ensure proper oil return to the compressor. -
Page 33: Table 6. Recommended Liquid Line Sizes For R407C Refrigerant (Condenser To Receiver )
2 . 6 . 1 . 2 S P L I T SYS T E M S C E I L A I R ® C W & DX I O M Table 5. Recommended Discharge Line Sizes For R410A Refrigerant, Continued Model Total Btu/h Total kW... -
Page 34: Table 8. Recommended Suction Line Sizes For R407C Refrigerant
C E I L A I R ® C W & DX I O M 2.6.1 .2 S P L I T SYS T E M S Table 8. Recommended Suction Line Sizes For R407C Refrigerant Line O.D. (inches) Model Total Btu/h Total kW 50 ft or less... -
Page 35: Remote Air Cooled Condensers (Ar Models)
2 . 6 . 1 . 4 R E M OT E A I R C O O L E D CO N D E N S I N G U N I T S ( A H U M O D E L S ) C E I L A I R ®... -
Page 36: Piping For Chilled Water, Water/Glycol, And Hot Water Reheat
The piping system must be flushed prior to operating the system. Failure to do so will result in equipment problems. The recommended ethylene glycol solution ratio is 40% glycol to 60% water. STULZ recommends Dowtherm SR1 manufactured by Dow Chemical Co. Piping should be insulated on glycol-cooled systems with a low entering fluid temperature and all chilled water systems. -
Page 37: Condensate Pump
2 . 6 . 4 H U M I D I F I E R (O P T I O N A L ) C E I L A I R ® C W & DX I O M NOTE Optional Humidifier Drain Line During normal operation, the humidifier drains hot water into the condensate drain line. -
Page 38: Utility Connections
C E I L A I R ® C W & DX I O M 2.7 U T I L I T Y C O N N EC T I O N S 2.7 Utility Connections 2.7.1 Main Power CeilAir units are available in single- or three-phase variations and in a wide range of voltages. Examine the unit nameplate, located on the outside of the cabinet close to the electric box, to determine the operating voltage, frequency, and phase of the system (see Figure 15). -
Page 39: Single-Phase Units 208/230 V
2 . 7 . 1 . 3 T H R E E- P H AS E U N I T S C E I L A I R ® C W & DX I O M WARNING Verify power is turned off before making electrical connections to the equipment. NOTE National Electric Code Wiring All wiring must be provided in accordance with the National Electrical Code and local code requirements. -
Page 40: Controls
Wiring contacts on the single- and dual-stage versions of the A-Tech controller are shown in Figure 16. If the unit is equipped with an E² controller, see the STULZ E² Series Microprocessor Controller IOM manual shipped with your unit. For utility connections refer to the appropriate manual above and the wiring diagram(s) provided with the unit. -
Page 41: Figure 16. A-Tech 1.1 (Top) And 1.2 (Bottom)
2 . 7 . 2 . 2 A-T EC H 1 . 2 P R O G R A M M A B L E T H E R M O S TAT C E I L A I R ®... -
Page 42: Figure 17. A-Tech 1.1 Control Wiring
C E I L A I R ® C W & DX I O M 2.7. 2 C O N T R O L S Figure 17. A-Tech 1.1 Control Wiring Figure 18. A-Tech 1.2 Control Wiring OCH0006F 08/13/2024... -
Page 43: Figure 19. Interconnection Field Wiring Remote Condenser
2 . 7 . 2 . 2 A-T EC H 1 . 2 P R O G R A M M A B L E T H E R M O S TAT C E I L A I R ®... -
Page 44: Figure 21. Interconnection Field Wiring Remote Condensing Unit With Dual Compressors
C E I L A I R ® C W & DX I O M 2.7. 2 C O N T R O L S E² CONTROL CONFIGURATION (OPTIONAL) 6 CNDCT. PHONE TYPE 3 CONDUCTOR NON-SHIELDED CABLE SHIELDED CABLE SEE NOTE 3 REMOTE TEMPERATURE/ E²... -
Page 45: Remote Condenser
2 . 7 . 5 R E M OT E S H U T D O W N C E I L A I R ® C W & DX I O M CAUTION Do not connect any additional loads to the system control transformers. Connecting additional load to a factory supplied control transformer may result in overloading the transformer. -
Page 46: Optional Equipment
C E I L A I R ® C W & DX I O M 2.7.6 O P T I O N A L Eq U I P M E N T NOTE National Electric Code Wiring All wiring must be provided in accordance with the National Electrical Code and local code requirements for Class 2 circuits. -
Page 47: Remote Temperature/Humidity Sensor
2 . 7 . 2 . 2 A-T EC H 1 . 2 P R O G R A M M A B L E T H E R M O S TAT C E I L A I R ®... -
Page 48: Dx Unit Charging Requirements
C E I L A I R ® C W & DX I O M 2.8.2 DX U N I T C H A R G I N G R Eq U I R E M E N T S 2.8.2 DX Unit Charging Requirements When performing the specific DX charging procedures in this section, follow these best practices: •... -
Page 49: Estimating Refrigerant Charge
2 . 8 . 5 ES T I M AT I N G R E F R I G E R A N T C H A R G E C E I L A I R ® C W & DX I O M Refrigerant R410A is similar to R407C in that it is a blended refrigerant that consists of component parts, however, the component parts of R410A refrigerant have the same composition at various operating temperature/pressures in the liquid phase and gas phase, reducing the temperature glide effect experienced... -
Page 50: Preparing System For Charging
5 ton (OHS-060-AR) A/C unit with flooded head pressure control connected with a 1/2 in x 30 ft liquid line and a 7/8 in x 30 ft discharge line to a STULZ model SCS-096-SAA condenser: Condenser = 3.6 lb Condenser = 1.64 kg... -
Page 51: Evacuate The System
2. 8 . 6 .1 EVAC UAT E T H E SYS T E M C E I L A I R ® C W & DX I O M 2.8.6.1 Evacuate the System CAUTION A proper vacuum must be drawn on the refrigerant system to remove moisture prior to charging. If this is not done, the refrigerant charge will combine with moisture in the pipes to form an acid that will eventually lead to compressor failure. -
Page 52: Refrigerant Charging Procedures
C E I L A I R ® C W & DX I O M 2.8.7 R E F R I G E R A N T C H A R G I N G P R O C E D U R ES 7. -
Page 53: ºf Fan Cycling And -20 ºf Variable Speed Control
2 . 8 . 7 . 3 0 º F FA N CYC L I N G A N D - 20 º F VA R I A B L E S P E E D CO N T R O L C E I L A I R ®... -
Page 54: Refrigerant Characteristics
C E I L A I R ® C W & DX I O M 2.9 R E F R I G E R A N T C H A R AC T E R I S T I C S -30 °F Flooded Head Pressure Control For units using flooded head pressure control, a receiver is used to store the refrigerant during the time the condenser is not utilizing the extra refrigerant charge. -
Page 55: Table 12. Refrigerant Pressure/Temperature Settings
C E I L A I R ® C W & DX I O M Table 12. Refrigerant Pressure/Temperature Settings Refrigerant Pressure/Temperature Settings Setting Type Normal Min. Max. Refrigerant Sub-cooling (°F) Superheat (°F) Design Condensing Temp. (°F) @ 95 °F Ambient Suction Pressure, psig (MPa) R407C 70 (0.48) -
Page 56: Saturated Refrigerant Pressure Tables
C E I L A I R ® C W & DX I O M 2.9.2 SAT U R AT E D R E F R I G E R A N T P R ES S U R E TA B L ES 2.9.2 Saturated Refrigerant Pressure Tables The Table 13 refrigerant pressures are provided for reference for R407C and R410A refrigerant. -
Page 57: System Settings And Adjustments
See Table 1 and Table 2 of the STULZ SCS Series Remote Air Cooled Condensers IOM for information about the fan cycling pressure control settings (cut-in and cut-out pressures) for the supported refrigerants. Note that the pressure values vary according to both the refrigerant type and the number of fans in the SCS unit. -
Page 58: Variable Condenser Fan Speed (Condenser Model Scs-Sa, -20 °F)
C E I L A I R ® C W & DX I O M 2.10. 2.3 VA R I A B L E CO N D E N S E R FA N S P E E D (CO N D E N S E R M O D E L S C S - SA , - 20 ° F ) 2.10.2.3 Variable Condenser Fan Speed (Condenser Model SCS-SA, -20 °F) Used for outdoor installations where ambient temperatures may fall to -20 °F, a variable speed condenser fan motor control is used to maintain head pressure. -
Page 59: Flooded Head Pressure Control (Condenser Model Hes-Caa, -30 °F)
2 . 1 0. 4 H U M I D I F I E R A Dj U S T M E N T C E I L A I R ® C W & DX I O M When using this method of head pressure regulation there must be enough refrigerant in the system to ensure adequate charge at the lowest expected ambient temperature in which the system will be operating. -
Page 60: Blower Adjustment
C E I L A I R ® C W & DX I O M 2.10.5 B LO W E R A Dj U S T M E N T If the capacity potentiometer requires adjustment, verify it in small increments. Refer to the humidifier manual sent with your unit for the location of the capacity potentiometer. -
Page 61: Ec Fan (Optional)
2 . 1 0. 7 H OT G AS R E H E AT (O P T I O N A L ) C E I L A I R ® C W & DX I O M 6. Adjust the blower speed by closing the sheave one half turn to increase speed or opening the sheave one half turn to decrease speed. -
Page 62: Hot Gas Bypass (Optional)
No adjustment to the valve is necessary. 2.10.8 Hot Gas Bypass (Optional) The two most common systems provided by STULZ for hot gas bypass are snap acting and full floating, described below. 2.10.8.1 Snap Acting Hot Gas Bypass The snap acting hot gas bypass system provides for some modulated capacity control and freeze protection. - Page 63 2 . 1 0. 8 . 2 F U L L F LOAT I N G H OT G AS BY PAS S C E I L A I R ® C W & DX I O M compressor as it operates in full hot gas bypass mode. The valve is factory set and no adjustment should be necessary.
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Page 64: Commissioning, Operation, And Decommissioning
NOTE Warranty Registration and Start-Up Checklist A Warranty Registration and Start-Up Checklist is provided in the unit data package. These should be completed during start-up and sent to STULZ. The checklist should be used as a guideline for crucial tasks during start-up. -
Page 65: Operating The Unit
3 . 2 . 2 S TA R T- U P P R O C E D U R E C E I L A I R ® C W & DX I O M 5. Test heating operation by setting the temperature set-point above the actual room temperature. The heater will energize to increase the discharge air temperature. -
Page 66: Programming The Thermostat
C E I L A I R ® C W & DX I O M 3.3 P R O G R A M M I N G T H E T H E R M O S TAT 3.3 Programming the Thermostat 3.3.1 A-Tech Controller The A-Tech controller is a programmable thermostat that provides: •... -
Page 67: Recovering Refrigerant
3 . 4 . 2 L A B E L I N G D EC O M M I S S I O N E D Eq U I P M E N T C E I L A I R ®... -
Page 68: Maintenance
For assistance, contact STULZ Product Support. Follow all safety instructions while performing any type of maintenance. STULZ recommends a general schedule of quarterly preventive maintenance inspections. Some items, such as filters or coil fins, may need more frequent inspection and maintenance, depending on environmental conditions. -
Page 69: A/C Unit
4. 1 . 1 .4 B LO W E R C E I L A I R ® C W & DX I O M 4.1.1 A/C Unit • Check the refrigerant sight glass monthly while the unit is running. Excessive bubbles in the sight glass indicate a low refrigerant charge or a clogged filter-drier. -
Page 70: Coils
C E I L A I R ® C W & DX I O M 4. 1.1 .5 CO I L S mounts, housing bolts, and blower wheel set screw. Ensure all electrical connections are tight. Check that all mounts are secure, and that the blower wheel is tightly mounted on the shaft without rubbing against the fan housing. -
Page 71: Troubleshooting
4 . 2 T R O U B L E S H O OT I N G C E I L A I R ® C W & DX I O M units in winter, do not permit snow to accumulate on or around the condensing unit. Check all refrigerant lines and capillaries for vibration isolation and support as necessary. - Page 72 C E I L A I R ® C W & DX I O M 4 .2 T R O U B L ES H O OT I N G Table 14. Troubleshooting Table, Continued Symptom Probable Cause Recommendation Blower Fails to Start a.
- Page 73 4 . 2 T R O U B L E S H O OT I N G C E I L A I R ® C W & DX I O M Table 14. Troubleshooting Table, Continued Symptom Probable Cause Recommendation Condenser Pressure a.
- Page 74 C E I L A I R ® C W & DX I O M 4 .2 T R O U B L ES H O OT I N G Table 14. Troubleshooting Table, Continued Symptom Probable Cause Recommendation Compressor Short a.
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Page 75: Field Service
4 . 3 . 4 . 1 CO M P R ES S O R FA I L U R E C E I L A I R ® C W & DX I O M 4.3 Field Service It may be necessary to perform repairs on the refrigeration system. If field repairs are necessary, the following procedures apply: NOTE Use Proper Tools Do not attempt to make repairs without the proper tools. -
Page 76: Standard Cleanout Procedure
C E I L A I R ® C W & DX I O M 4.3.4.2 S TA N DA R D C L E A N O U T P R O C E D U R E If a compressor failure has occurred, determine whether it is an electrical or a mechanical failure. An electrical failure is indicated by a distinct pungent odor when the system is opened. -
Page 77: Burn-Out/Acidic Cleanup Procedure
4 . 3 . 4 . 3 B U R N - O U T/AC I D I C C L E A N U P P R O C E D U R E C E I L A I R ®... -
Page 78: Humidifier Cylinder Replacement
C E I L A I R ® C W & DX I O M 4.3.4.4 H U M I D I F I E R CY L I N D E R R E P L AC E M E N T 13. -
Page 79: Product Support
C E I L A I R ® C W & DX I O M 5.0 PRODUCT SUPPORT STULZ provides its customers with Product Support which not only provides technical support and parts but the following additional services, as requested: • Performance Evaluations • Start-up Assistance •... -
Page 80: Obtaining Warranty Parts
If the customer requests that warranty part(s) be sent by any other method than UPS ground, the customer is responsible for the shipping charges. If you do not have established credit with STULZ you must provide a freight carrier account number. -
Page 81: Appendix A. Ohs Preventive
Return Temperature: Return Humidity: Remote/Supply Remote/Supply Temperature: Humidity: Electrical Panel (Safety Note: The following should be performed by STULZ Trained Service Personnel only) Inspect unit disconnect for proper operation: … Pass … Fail … N/A Inspect internal wire for discoloration: …... - Page 82 C E I L A I R ® C W & DX I O M A P P E N D I X A . O H S P R EV E N T I V E M A I N T E N A N C E I N S P EC T I O N C H EC K L I S T Unit Operation Verify Control Device Operation: …...
- Page 83 A P P E N D I X A . O H S P R EV E N T I V E M A I N T E N A N C E I N S P EC T I O N C H EC K L I S T C E I L A I R ®...
- Page 84 UL standard 60335-1 and UL standard 60335-2-40 • Certified to CSA standard C22.2 # 60335-1 and CSA standard C22.2 # 60335-2-40 • Intertek control number 55789 www.stulz-usa.com OCH0006F 08/13/2024 © STULZ USA – Specifications subject to change without notice. OCH0006F 08/13/2024...
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