Stulz CeilAiR Series, Installation, Operation & Maintenance Manual

Page 1: ... Mar 2012 CeilAiR OHS Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 2: ...AWS Alternate Water Source FC Free Cooling LP Low Profile Configuration SF Same Face Air Pattern SP Special Configuration AHU Air Handling Unit AR Air Cooled Remote Split AS Air Cooled Self Contained C Chilled Water System CAA Indoor Centrifugal Condenser D Dual Two Circuit System G Glycol Cooled H Horizontal Discharge H Series RCU I Indoor Centrifugal Remote Condensing Unit W Water Cooled ...

Page 3: ... 2 15 2 7 3 1 Condensate Pump 2 15 2 7 3 2 Remote Temperature Sensor 2 15 TABLE OF CONTENTS 2 7 3 3 Remote Water Detector 2 15 2 7 4 Air Cooled Split Systems 2 16 2 7 4 1 Remote Condenser 2 16 2 7 4 2 Remote Condensing Unit 2 16 2 7 5 Glycol Systems 2 16 2 7 6 Remote Shut Down 2 19 2 8 System Charging Procedures 2 19 2 8 1 R22 Refrigerant Charging Procedures 2 19 2 8 2 R407C Refrigerant Charging P...

Page 4: ...2 17 Figure 10 Interconnecting Field Wiring Remote Condensing Unit A Tech 1 1 1 2 2 17 Figure 11 Interconnecting Field Wiring Remote Condensing Unit A Tech 20 2 17 Figure 12 Interconnecting Field Wiring Notice This document contains information protected by copyright All rights are reserved The owner of the equipment for which this manual is written may photocopy the contents of this manual for in...

Page 5: ...a conditioned space The cabinet configuration is available in a 2 x 4 frame for units ranging from 12 000 to 40 000 BTU Hr spot cooler or ducted or a larger frame for units ranging from 48 000 to 120 000 BTU Hr ducted only For ducted units there are three basic configurations of airflow patterns 90º Right Angle Straight Thru and In Out Same Face reference Figure 3 Refer to the installation drawing pr...

Page 6: ...art up Parts repaired or replaced under this warranty are shipped FOB factory ground and warranted for the balance of the original warranty period or for 90 days from the date of installation whichever is greater If the factory is not allowed to start the equipment within 180 days from the date of shipment the warranty will commence on the 181st day from equipment shipment This limited warranty do...

Page 7: ...l deterioration including wear and tear or the use of improper parts or improper repair Purchaser s remedies are limited to replacement or repair of non conforming materials in accordance with the written warranty This warranty does not include cost for torch charges reclaim charges Freon transportation travel expenses costs for removal or reinstallation of equipment or labor for repairs or replac...

Page 8: ...troller To isolate the unit for maintenance turn off power at the main power disconnect switch Always disconnect main power prior to performing any service or repairs WARNING To prevent personal injury stay clear of rotating components as automatic controls may start them unexpectedly Turn off power to the unit unless you are performing tests that require power With power and controls energized th...

Page 9: ...orming soldering or desoldering op erations make certain the refrigeration system is fully recovered and purged and dry nitrogen is flowing through the system at the rate of not less than 1 2 CFM 0 028 0 57 M minute 1 5 CAUTION Certain maintenance or cleaning procedures may call for the use and handling of chemi cals solvents or cleansers Always refer to the manufacturer s Material Safety Data Shee...

Page 10: ...t housing The blower is dynamically and statically balanced to minimize vi bration The blower motor is ODP industrial duty and utilizes permanently lubricated ball bearings Smaller CeilAiR units models OHS 012 040 use direct drive blowers except H series models config ured for horizontal discharge Larger units models OHS 048 120 and horizontal discharge units models OHS 012 040 H use a belt driven ...

Page 11: ...ed in the supply air stream A valve is provided to control the flow of hot water through the coil to maintain the correct reheat temperature Hot Gas Reheat may be selected for CeilAiR units with DX cooling only for automatic sensible reheat 1 7 ing during the dehumidification cycle Hot compres sor discharge gas is diverted from the condenser to a hot gas heating coil mounted in the supply air stream...

Page 12: ...nts may be obtained through the bottom of the unit on spot cooler configurations These units can be fully serviced in the ceiling plenum In order to have full service access the air conditioner must be located so that adequate space is provided in front of all access panels NOTE Working clearance requirements need to be established prior to the mounting of the unit Refer to local and national elect...

Page 13: ...are for the application An auxiliary drain pan is recommended and can be mounted directly under the cabinet only on ducted models 2 4 2 Outdoor Equipment Install remote condensers condensing units in a se cure location where the unit cannot be tampered with and the power service switch cannot be inadvertently turned off Locate the remote condenser condens ing unit where the fan is not likely to dr...

Page 14: ...ast 18 from an outside wall and approximately 5 ft above the floor Controls may be installed either on a flush switch box or on a surface switch box Follow the steps below to mount Instructions for wiring of unit are provided in Section 2 7 Utility Connections 1 Pull dial knob off loosen screw located at bot tom of unit and remove cover 2 Make wiring connections see Section 2 7 3 Mount with the two ...

Page 15: ...and to the electrical diagrams provided with the unit 2 4 5 1 Remote Temperature Sensor A Tech 1 1 A Tech 1 2 NOTE The remote temperature sensor has a maxi mum range of 300 feet 1 Open the sensor case by depressing the button on the bottom edge of the case until the latch releases 2 Remove the cover by pulling it out and up at the bottom 3 Remove the circuit board from the base by pulling back the...

Page 16: ...n 2 5 1 Spot Cooler See Figure 2 For units that are not ducted the air conditioner should be mounted above the ceiling grid leaving sufficient space for the air grilles to rest on the ceiling T bar NOTE Placement of the grilles is important The hinged filter grille goes on the return air side of the unit The 3 way directional grille goes on the conditioned air discharge side of the air conditioner G...

Page 17: ... of 100 psig 2 6 1 2 1 Remote Air Cooled Condensers AR Models Systems utilizing a remote condenser will require a copper liquid line and discharge line The piping must not have a refrigerant line pressure drop over 14 psig across the condenser and the interconnecting piping to the condenser sections If the condenser is installed above the evaporator the discharge line should include a P trap at th...

Page 18: ... the discharge line of the remote condenser to help prevent oil and liquid from flooding back to the compressor NOTE In the following 3 tables the line sizes represent the correct size for individual refrigeration cir cuits Dual circuit units Models 048D to 120D have two separate pairs of refrigeration lines One per compressor EQUIVALENT LENGTH FT OF STRAIGHT PIPE OD In Globe Angle 90 45 Tee Tee Li...

Page 19: ...ld be trapped with an inverted trap the height of the evaporator coil This prevents migration of liquid refrigerant to the com pressor during off cycles All suction lines must be insulated to prevent conden sation from forming on the pipes Refer to provided pipe size charts for recommended pipe sizing 2 6 2 Chilled Water Water Glycol and Hot Water Reheat Piping The piping connections for water gly...

Page 20: ...e humidifier if applicable A p trap must be installed for proper condensate drainage The height of the trap must be a minimum of 2 inches on most standard systems to ensure proper water drainage of the drain pan The condensate pump discharge line should be 1 2 inch OD maximum copper or vinyl tubing to prevent excessive back flow to unit Figure 4 Condensate Pump NOTE Pour some water into the condensa...

Page 21: ...ng The unit is provided with terminals for all required field wiring It is important to identify the options that were purchased with the unit in order to confirm which field connections are required Refer to the electrical drawing s supplied with the unit for the power and control field wiring WARNING Verify power is turned off before making connections to the equipment NOTE All wiring must conform t...

Page 22: ...erate with a tolerance of 5 if the following change is performed The control transformers within the system must have the primary wire connected to its respective 240V tap instead of the 208V tap 2 7 1 2 Single Phase Units 277V Single phase units require that the hot leg of power be connected to terminal L1 and the neutral wire to terminal L2 of the main power distribution block 2 7 1 3 Single Pha...

Page 23: ...rminating at L2 of the unit main power distribution block 4 wires under this splice cap 3 Splice wires X2 and X3 together 2 wires un der this splice cap 4 Splice H3 H1 X4 and the wire terminating at L1 of the unit main power distribution block 4 wires under this splice cap 5 The transformer chassis should be grounded After all wiring connections are complete check the voltage at the main power dis...

Page 24: ...1 1 Control Wiring A Tech 1 1 Dip Switch Settings OFF ON OFF ON 1 4 min on off 2 min on off Minimum time Y and W terminal will be energized and minimum time must elapse between call Minimum OFF times can be overridden by raising and lowering the setpoint Minimum ON times can only be overridden by changing the mode 2 Keypad unlocked Keypad locked In locked position only the arrow keys and outdoor t...

Page 25: ...a call for heat When on the furnace controls the fan 6 Single Stage Multi Stage In Single Stage position terminals Y2 and W2 are locked out 7 No LCD w LED 1 Filter LCD w LED 1 In Filter position when terminal LED 1 is energized a replace filter picture appears on the LCD in addition to LED 1 illuminating 8 No LCD w LED 2 Wrench LCD w LED 2 In wrench position when terminal LED 2 is energized a pictu...

Page 26: ...in power terminals to the air conditioning unit A ground wire must be connected to the unit ground stud located within the unit electric box Two control conductors must be wired to the control terminal board located within the unit electric box The condensate pump provides pigtail leads for splice type wire connections with twist on connectors wire caps Refer to the supplied electrical diagram for...

Page 27: ... box The installer must provide main power wiring to the main power distribution block located within the remote condenser control box A separate equip ment ground lug is provided within the electrical box for termination of the earth ground wire The installer must also wire two control conductors from the terminal board within the evaporator unit to the control terminal board within the remote co...

Page 28: ...3 CONDUCTOR SHIELDED CABLE E CONTROLLER DISPLAY E DISPLAY PLUGS DIRECTLY INTO THE CONTROLLER INSIDE THE ELECTRIC BOX 6 CNDCT PHONE TYPE NON SHIELDED CABLE Figure 10 Interconnection Field Wiring Remote Condensing Unit SEE NOTE 3 3 OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A C UNIT TERMINAL BLOCK REMOTE CONDENSING UNIT REMOTE TEMPERATURE HUMIDITY SENSOR OPTIONAL SEE NOTE 3 3 CONDUCTOR SHIELDE...

Page 29: ...SOR OPTIONAL SEE NOTE 3 3 CONDUCTOR SHIELDED CABLE E CONTROLLER DISPLAY E DISPLAY PLUGS DIRECTLY INTO THE CONTROLLER INSIDE THE ELECTRIC BOX 6 CNDCT PHONE TYPE NON SHIELDED CABLE Figure 12 Interconnection Field Wiring Glycol Systems 3 OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A C UNIT TERMINAL BLOCK SEE NOTE 3 REMOTE TEMPERATURE HUMIDITY SENSOR OPTIONAL SEE NOTE 3 3 CONDUCTOR SHIELDED CABLE...

Page 30: ...e system Pull a vacuum of 50 microns or less using the suction and discharge service ports and the service port of the receiver if applicable Hold the vacuum for 2 hours Ensure no portion of system has been isolated from the evacuation process liquid suction or discharge lines CAUTION Aproper vacuum must be drawn on the refriger ant system prior to charging If this is not done the refrigerant will...

Page 31: ... ensure cooling remains on during charging procedure CAUTION An adequate heat load must be supplied to the unit to ensure a proper charge 3 After starting the system immediately supply R22 vapor to the suction port until the liquid line sight glass is clear of all bubbles 4 Raise the discharge pressure to 300 325 psig and hold it constant by blocking the air intake of the condenser 5 Once the disc...

Page 32: ...sary to restrict the airflow across the con denser or reduce the water glycol flow to raise the pressure 7 Slowly meter R407C liquid refrigerant through the suction side while watching for the sight glass to clear of bubbles CAUTION Add liquid refrigerant slowly to prevent the refrigerant oil from washing out of the compressor 8 Take a superheat reading near the feeler bulb from the thermal expansio...

Page 33: ... motor s speed The controller is factory installed in the outdoor condenser condensing unit The fan speed controller requires no adjustment The fan speed controller will automatically control the head pressure On systems with more than one fan on the condenser the remaining motors cycle on and off based on pressure 2 9 2 4 Intelligent Control Condenser Model SCS EC only 20 F Used for outdoor insta...

Page 34: ...se the condensing temperature Head pressure regulating valves are available in 2 way or 3 way configurations Refer to the piping diagram to determine which type of valve is provided The location and size of regulating valves varies with the size and model of the A C unit Methods for adjusting the valves for condensing pressure differ with the valve types which can be differentiated by the maximum w...

Page 35: ...ontroller The controller is set by the factory and should not require adjustment If it is determined that the air flow needs adjustment this may be done using the controller s programming menu selections Refer to the operator s manual provided under separate cover for the system controller It is recommended that SATS Product Support be contacted before making adjustments to the controller 2 9 6 The...

Page 36: ...compressor the hot gas and quench solenoid valves are open and the liquid line solenoid valve cycles on the demand of the controller The hot gas bypass valve allows refrigerant to flow from the discharge line directly to the suction line The hot gas bypass entering the suction side of the compressor would raise the operating temperature of the compressor to a point where failure could occur To prev...

Page 37: ...15 130 336 135 358 140 381 Bubble Point Dew Point 2 10 2 Saturated Refrigerant Pressure Tables The following refrigerant pressure tables are provided for reference Pressure Temperature Settings For R22 R407C Normal Min Max Sub Cooling F 10 5 20 Superheat F 15 10 20 Condensing Temperature Air Cooled F 125 105 140 Condensing Temperature Water Cooled F 105 105 140 Condensing Temperature Glycol Cooled...

Page 38: ...ations Manual sent with your unit 4 Test cooling operation by setting the temperature setpoint below the actual room temperature The compressor should come on and the discharge air should feel cooler than the return air 5 Test heating operation by setting the temperature setpoint above the actual room temperature The source of heat should be energized to increase discharge air temperature 6 Test h...

Page 39: ...t provided before beginning program ming NOTE While programming you must press a button at least every 15 seconds or the thermostat will revert to the operational mode If this hap pens simply repeatedly press the PROGRAM button until you get back to where you left off The information you have already entered has been retained If it is desired at any time to change the clock sched uled times and or...

Page 40: ...rease but ton until the display shows the desired start minutes Start minutes are in 10 minute increments STEP 6 Press and release the PROGRAM button The current heating temperature will begin to flash STEP 7 Press the decrease or increase but ton until the desired heating temperature is displayed for the morning event STEP 8 Repeat programming steps 2 through 7 for each desired event NOTE You may ...

Page 41: ...wer part of the display indicating the fan is continuously operating To return the fan to normal operating mode press the FAN button again which will remove the fan symbol from the display 3 3 1 4 Setback Feature Setting the Weekday and Weekend Cooling Temperatures Since the programmed time schedules are the same for both heating and cooling you only need to set the cooling temperatures providing ...

Page 42: ...d it is suggested that your person al schedule be programmed It can be programmed for either a two events per day Day and Night only or four It is factory programmed for four events If a two day event is desired during installation the cor rect No 1 dip switch selection must be made Com plete the program schedule chart provided before beginning programming NOTE While programming you must press a b...

Page 43: ...ng to program same times repeatedly or continue to step 8 to program the next day STEP 8 Press and release the PROGRAM button to continue to the next day to be programmed Repeat steps 2 through 6 for each day 3 3 2 3 Setting Heating Temperatures STEP 1 Press and release the MODE button until the word HEAT and the heating symbol and either morning or the day event symbol ap pears on the display STE...

Page 44: ...bility of displaying either Celsius or Fahrenheit temperatures Simultaneously press the decrease and increase button to switch between Celsius and Fahrenheit 3 3 2 9 Continuous Auto Fan At any time the system fan may be set to run continu ously by pressing the FAN button The fan symbol will appear at the lower part of the display indicating the fan is continuously operating To return the fan to no...

Page 45: ...nt with rotating components Exercise extreme care to avoid accidents and ensure proper operation WARNING Phosgene a deadly poisonous gas is gen erated when refrigerant is exposed to flame Always ensure adequate ventilation during refrigeration repairs Always recover all refrigerant prior to any system repairs failure to do so may result in system over pressurization and rupture 4 1 1 Precision A C ...

Page 46: ...s 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 Check all refrigerant and coolant lines for signs of leaks CAUTION The compressor crank case heater is energized as long as power is applied to the unit If the main switch is disconnected for long periods do not attempt to start ...

Page 47: ...te pan is draining properly Clear obstructions e Thermal overload tripped Reset overload and check amperage of motor Compare to setting on overload and adjust to FLA All direct drive motors are internally protected and do not require overload Control is Erratic Wiring improperly connected or broken Check wiring against schematic diagram Condenser Pressure a Non condensable gas or air in Recover sy...

Page 48: ...compressor compressor knocking suction pressure rises faster than 2lbs min after shutdown c Worn or scarred compressor bearings Replace compressor d Liquid slugging System overcharged Reclaim excess refrigerant e Scroll compressor not properly Phase correctly at main power phased source DO NOT REWIRE COMPRESSOR Compressor Fails to Start a Thermostat set too high Adjust to desired temperature b Com...

Page 49: ...rmostat set too low Increase temperature setpoint c Overheat switch open Insufficient airflow across heater elements Check for dirty filters or obstructions that may reduce air flow Correct or replace as needed d Fuse link blown Replace fuse link See item immediately above e Heater element burned out Check continuity with an ohmmeter Replace heater element Humidifier Inoperative a Water supply has been...

Page 50: ...omponent Replacement 4 3 4 1 Compressor Failure The compressor is the most important component of the air conditioner Numerous safety devices are provided to protect the compressor from failing If a compressor failure has occurred determine whether it is an electrical or a mechanical failure An electrical failure will be indicated by the distinct pungent odor once the system has been opened If a b...

Page 51: ...install the new compressor 4 Install a suction line filter drier designed for acid removal 5 Remove the liquid line drier and install an oversized liquid line filter drier one size larger than the normal selection size 6 Check the expansion valve sight glass and other controls to see if cleaning or replacement is required 7 Evacuate the system according to standard procedures Normally this will incl...

Page 52: ... steam hose clamp s and pull the steam hose off vertically 11 Using a flathead screwdriver press the tab on the cable tie to release it Lift the cylinder straight up to disengage it from the humidifier 12 Place the new cylinder on the side mounting slots within the unit ensuring the cylinder mounting stubs are seated properly 13 Replace the cylinder plugs on the pins ensur ing the white sensor plug ...

Page 53: ... carrier ac count number A written or faxed purchase order is required on warranty parts and must be received prior to 12 00 p m for same day shipment The purchase order must contain the following items Purchase Order Number Date of Order SATS Stated Part Price Customer Billing Address Shipping Address Customer s Telephone and Fax Numbers Contact Name Unit Model No Serial No SATS Item No The custo...

Page 54: ... Mar 2012 CeilAiR OHS Series Installation Operation Maintenance Manual Air Technology Systems Inc NOTES ...

Page 55: ... if required 13 Duct work completed or optional plenum installed if required 14 Incoming line voltage matches equipment nominal nameplated rating tolerances 15 Main power wiring connections to the equip ment including earth ground have been properly installed 16 Customer supplied main power circuit breaker HACR type or fuses have proper ratings for equipment installed 17 All wiring connections are...

Page 56: ... Mar 2012 CeilAiR OHS Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 57: ...ck Glycol Solution Concentration in System Clean Unit as Necessary Clean Coils Test the Glycol Solution Inhibitors flush if necessary Heat Reheat Operational Clean Condensate Pump Annually Refrigerant Systems Chilled Water Systems Inspect Glycol System for Leaks and Corrosion Inspect Chilled Water System for Leaks and Corrosion Conduct a Complete Check of All Services Listed Conduct a Complete Chec...

Page 58: ... Mar 2012 CeilAiR OHS Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 59: ...National Electric Code ESD Electrostatic Discharge NFPA National Fire Protection Agency º F Degrees Fahrenheit PH Phase FLA Full Load Amps PSI Pounds Per Square Inch FOB Freight on Board psig Pounds Per Square Inch Gauge HACR Heating Air Conditioning Refrigeration RLA Rated Load Amps HP Horse Power R Value Thermal Resistance Hz Hertz R410A Blended Refrigerant IAQ Indoor Air Quality SPDT Single Pol...

Page 60: ...CeilAiR OHS Series Installation Operation Maintenance Manual Air Technology Systems Inc OCH0006 B March 2012 OHS Series Installation Operation Maintenance 03 11 Specifications are subject to change without notice ...