Related Manuals for Stulz FLAIR series
Summary of Contents for Stulz FLAIR series
- Page 1 FLAiR Series Installation, Operation & Maintenance Manual (©Aug, 2007) Air Technology Systems, Inc.
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Page 2: Model Nomenclature
No part of this docu- ment may be photocopied, reproduced, or translated into another language for use by anyone other than the owner of the equipment for which this manual is written without the prior written consent of Stulz Air Technology Systems, Inc. (SATS). -
Page 3: Table Of Contents
FLAiR Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS Introduction ........1-1 2.7.1 Main Power ..........2-7 2.7.2 Controls ............2-8 General ............1-1 2.7.3 Optional Equipment ........2-8 Product Description ........1-1 2.7.3.1 Condensate Pump ........2-8 Product Warranty ........1-2 2.7.3.2 Remote Temperature/Humidity Sensor .. - Page 4 FLAiR Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS (Continued) List of Figures 4.3.4.2 Burn-Out/Acidic Clean-out Procedure ..4-8 Figure 1 Typical Layout with C6000 Controller ..1-6 4.3.4.4 Humidifier Cylinder Replacement ....4-9 Figure 2 Typical Layout with A-Tech 20 4.3.4.5 Filter Replacement ........
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Page 5: Introduction
FLAiR Series Installation, Operation & Maintenance Manual INTRODUCTION The functional modes of operation, in addition to cooling, are heating, humidification and dehumidifica- tion, which provide complete environmental control of a General conditioned space. The FLAiR unit is housed in a steel... -
Page 6: Product Warranty
2-Year Standard Limited Warranty: Stulz Air Technology Systems, Inc., warrants to the original buyer of its products that the goods are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s obligation under this warranty is to repair or replace, at its option, free of charge to the customer, any part or parts which are determined by Stulz Air Technology Systems Inc. - Page 7 FLAiR Series Installation, Operation & Maintenance Manual Optional Limited Extended Warranty (5 Years Total) Stulz Air Technology Systems, Inc., warrants to the original buyer of its product that the compressor(s) listed below are warranted for parts replacement (not including labor) for extended period of 4 years from the date of expiration of the standard equipment warranty.
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Page 8: Safety
FLAiR Series Installation, Operation & Maintenance Manual Safety When working on electrical equipment, remove all jewelry, watches, rings, etc. 1.4.1 General Always disconnect the main power supply to the equipment at the main power disconnect switch before Stulz Air Technology Systems, Inc. uses NOTES beginning work on the equipment. - Page 9 FLAiR Series Installation, Operation & Maintenance Manual excessive heat to any component will cause CAUTION extreme pressure and may result in a rupture. When the air conditioner is in the cooling mode, Exposure of refrigerant to an open flame or a...
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Page 10: General Design
FLAiR Series Installation, Operation & Maintenance Manual 1.5 General Design turned “Off” to gain access to the electrical compart- ment. The service disconnect switch may be used to The FLAiR precision A/C unit is housed in a steel turn the unit off for emergency shutdown or when frame type cabinet and is rated for indoor use. -
Page 11: Blowers
FLAiR Series Installation, Operation & Maintenance Manual 1.5.3 Blower(s) 1.5.5 Coil(s) FLAiR A/C units furnished with A-Tech 20 controllers The cooling and optional hot water re-heating coils are are equipped with direct drive centrifugal blower(s) with aluminum finned/copper tube construction and are forward curved blades. -
Page 12: Installation
FLAiR Series Installation, Operation & Maintenance Manual INSTALLATION NOTE Working clearance requirements need to be es- 2.1 Receiving the Equipment tablished prior to the mounting of the unit. Refer to local and national electrical codes. Your FLAiR system has been tested and inspected prior to shipment. -
Page 13: Mounting/Placement
FLAiR Series Installation, Operation & Maintenance Manual NOTE CAUTION Equipment must be level to operate properly. When moving the unit, it must be kept level and in the vertical position to prevent damage to the 2.4.2 Outdoor Equipment unit. Install the remote condenser/condensing unit in a 2.4 Mounting/Placement... -
Page 14: Optional Equipment (Field Installed)
FLAiR Series Installation, Operation & Maintenance Manual 2.4.3 Optional Equipment (Field Installed) 5. Make the wiring connections. See Section 2.7, Utility Connections. NOTE 6. Replace the cover plate on the base. Do not mount any optional equipment on the unit access doors. -
Page 15: Air Distribution
FLAiR Series Installation, Operation & Maintenance Manual Clear all pipe connections of debris and prepare 2.5 Air Distribution connections for soldering. Use only "L" or "K" grade 2.5.1 Upflow Configuration Air Pattern refrigerant copper tubing. Be careful not to allow solder/piping debris to get inside refrigerant lines. -
Page 16: Water/Glycol
FLAiR Series Installation, Operation & Maintenance Manual 2.6.2.1 Remote Air Cooled Condensers (AR) Recommended Discharge Line Sizes If the condenser is installed above the evaporator, the (For R22 or R407C Refrigerant) discharge line should include a P-trap at the evapora- Equivalent Length Ft* Model No./... -
Page 17: Condensate Drain Line
FLAiR Series Installation, Operation & Maintenance Manual CAUTION If an optional field installed pump is selected, a p-trap must be installed for proper condensate drainage, (see The piping system must be flushed prior to op- Figure 5). The height of the trap must be a minimum of erating the system. -
Page 18: Utility Connections
FLAiR Series Installation, Operation & Maintenance Manual 2.7 Utility Connections 2.7.1 Main Power The FLAiR product offering is available in single or three phase variations and a wide range of voltages. It is imperative that the unit nameplate be examined to verify operating voltage, frequency and phase of the system, (see Figure 6). -
Page 19: Controls
FLAiR Series Installation, Operation & Maintenance Manual NOTE 2.7.3 Optional Equipment The installer must ensure the power and control NOTE conduits allow for full accessibility to compo- All wiring must be provided in accordance with nents that require service. local and national electrical code requirements. -
Page 20: Air-Cooled Split Systems
FLAiR Series Installation, Operation & Maintenance Manual 2.7.4 Air-Cooled Split Systems 2.7.4.1 Remote Condenser (AR Models) Systems equipped with a remote condenser will The following system interconnecting field wiring require field wiring between the A/C system and the sections detail the number of conductors required for a remote condenser, see, (Figure 7). -
Page 21: Remote Condensing Unit
FLAiR Series Installation, Operation & Maintenance Manual 2.7.4.2 Remote Condensing Unit (AHU Models) based upon the control options provided. Refer to the supplied electrical schematic to determine the exact Systems equipped with a remote condensing unit number of field wires needed and appropriate wire require field control wiring between the A/C system terminations required for your specific system. -
Page 22: Glycol Cooled Systems
FLAiR Series Installation, Operation & Maintenance Manual 2.7.5 Glycol Cooled Systems (G Models) Systems equipped with a glycol-cooled system/pump within the glycol unit, to the pump package electrical package require field wiring between the glycol unit box. Refer to the electrical schematic supplied with and pump package, (see Figure 9). -
Page 23: System Settings And Adjustments
FLAiR Series Installation, Operation & Maintenance Manual 2.8 System Settings and Adjustments FINE TUNING THE SYSTEM CHARGE Refrigerant charging procedures vary depending on the 2.8.1.2.1 0ºF Fan Cycling and -20ºF Variable type of refrigerant used in the unit. Before charging,... -
Page 24: R407C Refrigerant Charging Procedures
FLAiR Series Installation, Operation & Maintenance Manual NOTE CAUTION Under cold climate conditions it is recommended An adequate heat load must be supplied to the to do the following: unit to ensure a proper charge. 6. Block off the intake air to the condenser with 3. -
Page 25: Preparing System For Charging
FLAiR Series Installation, Operation & Maintenance Manual constant, however, the refrigerant vapor tends to FINE TUNING THE SYSTEM CHARGE separate into its component parts even when circulat- ing. When charging a system using a blended 4. Disconnect the refrigerant cylinder from the... -
Page 26: Low/High Limit Switch
FLAiR Series Installation, Operation & Maintenance Manual ball” while the unit is running. If the “float ball” is 255 psig will close the low fan speed contacts and positioned at the bottom of the sight indicator, addi- reduce the fan speed. Setpoint range is 170 to 400 tional refrigerant charge is needed. -
Page 27: Water/Glycol-Cooled Systems
FLAiR Series Installation, Operation & Maintenance Manual refrigeration circuit to back up liquid refrigerant into the closes as the refrigerant pressure falls). The regulating condenser coil. The head pressure control valve is a 3- valve is factory set for the correct condensing tempera-... -
Page 28: Thermal Expansion Valve
FLAiR Series Installation, Operation & Maintenance Manual 2.8.6 Thermal Expansion Valve one half of the coil and remove adjustment cap from the end of the valve. Using a 5/16 inch allen wrench, FLAiR units utilize a thermal expansion valve (TEV) to... -
Page 29: Refrigerant Characteristics
FLAiR Series Installation, Operation & Maintenance Manual Refrigerant Characteristics 2.9.2 Saturated Refrigerant Pressure Tables 2.9.1 Pressure/Temperature Settings The following refrigerant pressure tables are provided for The following chart is provided to assist with the reference: normal settings of the system for R22 and R407C refrigerant. -
Page 30: Start-Up/Commissioning
FLAiR Series Installation, Operation & Maintenance Manual START-UP/COMMISSIONING ture setpoint above the actual room temperature. The source of heat should be energized to in- crease discharge air temperature. 3.1 Operation 6. Test humidification operation by creating a de- For new installations, ensure the unit is ready to mand for humidification. -
Page 31: Maintenance
FLAiR Series Installation, Operation & Maintenance Manual MAINTENANCE CAUTION 4.1 Periodic General Maintenance This equipment should be serviced and repaired by a journeyman or a qualified refrigeration tech- Systematic, periodic general maintenance of the nician only. FLAiR unit is recommended for optimum system performance. -
Page 32: Condenser
FLAiR Series Installation, Operation & Maintenance Manual 4.1.1.6 Humidifier Check that the discharge line is open and water can pass through it freely. The steam cylinder has a limited lifetime and must be replaced periodically. Because water conditions and 4.1.2... - Page 33 FLAiR Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE RECOMMENDATION Water/Glycol Valve fails c. Actuator failed. Replace actuator. to Close (cont.) Evaporator Coil Ices a. Low airflow. 1. Check filters. Replace as needed. 2. Check for and clear any obstructions across or in the (supply) discharge airstream.
- Page 34 FLAiR Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE RECOMMENDATION Condenser Pressure f. Water/glycol temperature too high. Check flow and operation of drycooler. too High (cont.) g. Condenser pressure regulating valve Adjust to obtain correct pressure. setting too high.
- Page 35 FLAiR Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE RECOMMENDATION Compressor Fails to Start e. Minimum off time has not expired Wait for time to expire (cont.) System Short of Capacity a. Low refrigerant (indicated by bubbles Check for leaks Repair and recharge in sight glass).
- Page 36 FLAiR Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE RECOMMENDATION Humidifier Inoperative a. Water supply has been turned off Connect and/or turn on water supply. Note: See Humidifier or not connected. Manual for Additional Help. b. Humidifier Switch is in “Off” position.
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Page 37: Field Service
FLAiR Series Installation, Operation & Maintenance Manual 4.3 Field Service 4.3.4 General Common Repairs/Component Replacement NOTE 4.3.4.1 Compressor Failure Do not attempt to make repairs without the proper tools. The compressor is the most important component of the air conditioner. Numerous safety devices are It may be necessary to perform repairs on the refrig- provided to protect the compressor from failing. -
Page 38: Standard Cleanout Procedure
FLAiR Series Installation, Operation & Maintenance Manual entire refrigeration circuit must be cleaned of the 4.3.4.3 Burn-Out/Acidic Cleanup Procedure harmful contaminants left by the burnout. See section CAUTION 4.3.4.3 (Burn-Out/Acidic Cleanup) for the proper procedure. Avoid touching or contacting the gas and oil with If there is no acid in the oil, there has been a mechani- exposed skin. -
Page 39: Humidifier Cylinder Replacement
FLAiR Series Installation, Operation & Maintenance Manual 11. In 24 hours, take an oil sample. Observe the color 8. Place the new cylinder on the side mounting slots and test for acidity. If the oil is dirty or acidic, within the unit; ensuring the cylinder mounting replace the suction line filter-drier. - Page 40 FLAiR Series Installation, Operation & Maintenance Manual NOTES (©Aug, 2007) Air Technology Systems, Inc.
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Page 41: Product Support Group
FLAiR Series Installation, Operation & Maintenance Manual PRODUCT SUPPORT GROUP A written (or faxed) purchase order is required on warranty parts and must be received prior to 12:00 SATS provides to its customers a Product Support p.m. for same day shipment. The purchase order must... - Page 42 FLAiR Series Installation, Operation & Maintenance Manual (©Aug, 2007) Air Technology Systems, Inc.
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Page 43: Appendix A - Forms
FLAiR Series Installation, Operation & Maintenance Manual Air Technology Systems, Inc. Frederick, Maryland USA 21704 Telephone: (301) 620-2033 Facsimile: (301) 620-1396 CyberAiR Series APPENDIX A - FORMS Stulz Air Technology Systems Inc. Frederick, Maryland USA 21704 Telephone: (301) 620-2033 Facsimile: (301) 620-1396 Checklist for Completed Installation ❏... - Page 44 FLAiR Series Installation, Operation & Maintenance Manual (©Aug, 2007) Air Technology Systems, Inc.
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Page 45: Periodic General Maintenance Checks And Service Checklist
FLAiR Series Installation, Operation & Maintenance Manual Frederick, Maryland USA 21704 Air Technology Systems, Inc. Telephone: (301) 620-2033 Facsimile: (301) 620-1396 CyberAiR Series Periodic General Maintenance Checks and Services Checklist Date: ____________________________ Prepared By: ___________________________ Model Number: ____________________________ Serial Number: __________________________... - Page 46 FLAiR Series Installation, Operation & Maintenance Manual (©Aug, 2007) Air Technology Systems, Inc.
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Page 47: Appendix B - Glossary
FLAiR Series Installation, Operation & Maintenance Manual Appendix B – Glossary Definition of Terms and Acronyms SATS - Stulz Air Technology Systems, Inc. MCA - Minimum Circuit Ampacity BTU/Hr - British Thermal Units Per Hour MSDS - Material Safety Data Sheet... - Page 48 FLAiR Series Installation, Operation & Maintenance Manual (©Aug, 2007) Air Technology Systems, Inc.
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