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CyberOne EC DX IOM Manual 

 

 

 

CAUTIONS 

 

 

Damage to a replacement compressor caused 
by improper system cleaning constitutes abuse 

under the terms of the warranty. This will void the 
compressor warranty. Always consult the factory 
prior to replacing the compressor.

 

 
POE oil is used in systems with R407C refrigerant. 
If a replacement compressor is provided, ensure that 
it is filled with POE oil before installing.

 

4.3.4.2

 

Standard Cleanout Procedure

 

NOTE

 

Cleaning operations must  be  performed  by  
a  journeyman,  refrigeration  mechanic,  or  air 
conditioning technician.

 

1.

 

Turn off  power to unit at the main power disconnect 
switch.

 

2.

 

Remove the old compressor and install the new com- 
pressor.

 

3.

 

Remove the liquid line drier and  install  an oversized 
liquid line filter-drier (one size larger than the normal 
selection size).

 

4.

 

Evacuate the system according to standard procedures. 
Normally,  this will include the use of a high-vacuum 
pump and a low-vacuum micron gauge for measuring 
the vacuum obtained.

 

5.

 

Recharge the system.

 

6.

 

Turn on the power at the main power disconnect switch 
and start the system.

 

4.3.4.3

 

Burn-Out/Acidic Cleanup Procedure

 

CAUTION 

 

 

Avoid touching or allowing the gas and oil from 
contacting bare skin. Severe burns will result. Use 
long rubber gloves to handle contaminated parts.

 

NOTE

 

Cleaning operations must  be  performed  by  
a  journeyman,  refrigeration  mechanic,  or  air 
conditioning technician.

 

1.

 

These systems should be cleaned using the suction line 
filter-drier method.

 

2.

 

Turn off power to the unit at the main power disconnect 
switch.

 

3.

 

Remove the burned-out compressor and 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 include the use of a high-vacuum 
pump and a low-vacuum micron gauge for measuring 
the vacuum obtained.

 

8.

 

Recharge the system through the access valve on the 
suction line filter-drier.

 

9.

 

Turn on power at the main power disconnect switch and 
start the system.

 

10.

 

The permanently installed suction line filter-drier permits 
small-system cleanup to be completed in one service 
call. The pressure drop across the suction line filter-drier 

should be measured during the first hour of operation. If 
the pressure drop becomes excessive, the suction line 
filter-drier should be replaced (See Sporlan Bulletin 40- 
10, for the maximum recommended pressure drop (PSI) 
for the suction line filter drier).

 

11.

 

In 24 hours, take an oil sample. Observe the color and 
test for acidity. If the oil is dirty or acidic, replace the suc- 

tion line filter-drier.

 

12.

 

In 2 weeks, examine oil to determine if another suction 
line filter-drier change is necessary.

 

4.3.4.4

 

Humidifier     Cylinder      Replacement 

After an extended period of operation, the yellow LED on the 
humidifier cabinet will repeatedly flash four times indicating

 

that the cylinder is completely used and a replacement 
cylinder must be installed. The cylinder is disposable and 

cylinder life is dependent on water supply conditions and 
humidifier usage. Refer to the humidifier operator’s manual 
supplied under separate cover for detailed instructions on 
changing the cylinder. The following procedures are to be 
followed when replacing the cylinder.

 

CAUTION

  

 

Failure to replace the cylinder at the end of cylinder 
life may result in humidifier damage.

 

 

NOTE

 

Decrease the humidity set point below ambient 
humidity to allow the cylinder to cool down before 
removing the cylinder.

 

1.

 

Turn the A/C unit off by pressing and holding the Enter 
key.

 

 

 

39 

Summary of Contents for CyberOne EC DX

Page 1: ...on Operation and Maintenance Manual Chilled Water Systems 12 35 kW Systems Vertical Floor Mounted 60 Hz Data CyberOne EC DX Installation Operation and Maintenance Manual Perimeter Precision Air Condit...

Page 2: ...Systems Inc STULZ This document contains con dential and proprietary information of STULZ Air Technology Systems Inc Distributing or photocopying this document for external distribution is in direct...

Page 3: ...ping 13 2 6 1 1 Self Contained Systems 13 2 6 1 2 Split Systems 13 2 6 1 3 Remote Air CooledCondensers AR 15 2 6 1 4 Remote AirCooled Condensing Units AHU 15 2 6 2 Water Glycol 15 2 6 3 Condensate Dra...

Page 4: ...2 4 1 1 5 Heat Reheat 32 4 1 1 6 Humidi er 32 4 1 1 7 Condensate Pump 33 4 1 2 Condenser 33 4 2 Troubleshooting 33 4 3 Field Service 38 4 3 1 Leak Detection 38 4 3 2 Leak Repair 38 4 3 3 Refrigerant P...

Page 5: ...U Air Handling Unit AR Air Cooled Remote Split G Glycol Cooled RCU O Outdoor Propeller Remote Condensing Unit RCU I Indoor Centrifugal Remote Condensing Unit S Single Pump AWS Alternate Water Source F...

Page 6: ...con gurations The cooling capacity will depend on the unit size which can range from 24 000 to 120 000 BTU H CyberOne EC systems are designed to operate with R407C refrigerant Refer to the unit namep...

Page 7: ...all jewelry watches rings etc Hazardous voltage will still be present inside the electric box at the motor start protectors and circuit breakers even with the unit turned off at the microprocessor co...

Page 8: ...ased water conditioning additives in condensate drain pans Thiswill cause corrosion to occur on the coil ns 1 4 General Design The CyberOne EC DX system is housed in a steel frame type cabinet and is...

Page 9: ...ELECTRIC BOX HEATER EC FAN Figure 1 Typical Internal Layout Down ow Con guration Model COS 024 060 Shown for Reference Figure 2 Typical Internal Layout Up ow Con guration Model COS 096 120 Shown for R...

Page 10: ...icallystops andanalarm is signaled a Locked rotor1 b Loss of a phase1 c Low main supplyvoltage2 d Over heating of electronics2 e Over heating of motor2 1 Upon correction ofthese failure conditions the...

Page 11: ...justable set point Thefree cooling controlvalve opens proportionallyto the demand for cooling basedonthereturnairtemperature sdeviationfromsetpoint Ifthereturnairtemperaturecontinuestorise thefree coo...

Page 12: ...thecompressor turns onandthe AWS control valve closes shuttingoffthe owofchilledwater intothe AWScoolingcoil AWScoolingremains disabled andthe compressor runs until the cut out set point temperature...

Page 13: ...ach side In order to have full service access to internal components no permanent obstructions should be placed in front of the unit See Figure 5 for the minimum recommended front installation clearan...

Page 14: ...usedto minimizeleakage Outsideor freshairshouldbekepttoaminimum asitaddstothecooling heating dehumidification and humidifying loads while maintaining the requirement of the Indoor Air Quality IAQ stan...

Page 15: ...orto match the blower discharge opening s and cut out the holes required for piping and wiring through the raised oor NOTE The equipment must be level to operate properly 2 3 2 Outdoor Equipment Remot...

Page 16: ...unit the conditioned supply air has two methods of discharge Ducted or through a 2 or 3 way grilled plenum box see Figure 8 There are two basic air patterns Frontfreereturnandrearductedreturn If ductw...

Page 17: ...r to the system drawings and supplemental controller manual sent in the data package with your unit 2 5 3 Remote Temperature Humidity Sensor The remote temperature humidity T H sensor must be locateds...

Page 18: ...tach the plates to the A C cabinet Ensure the space between the plates and the pipes are adequately sealed to preventleakage 2 6 1 Refrigerant Piping 2 6 1 1 Self Contained Systems No refrigerant conn...

Page 19: ...2 6 0 1 0 0 5 0 8 2 5 7 8 15 8 0 1 5 0 7 1 0 3 5 1 1 8 22 12 1 8 0 9 1 5 4 5 1 3 8 28 15 2 4 1 2 1 8 6 0 1 5 8 35 17 2 8 1 4 2 0 7 0 2 1 8 45 22 3 9 1 8 3 0 10 2 5 8 51 26 4 6 2 2 3 5 12 3 1 8 65 34 5...

Page 20: ...micalCo Useonlyethyleneglycol with inhibitors for corrosionprotection WARNING Glycol is hazardous Consult the manufacturer s SDS for detailed safetyinformation CAUTIONS After the interconnecting pipin...

Page 21: ...holes for connection of the field wiring conduits These pilot holes are located on the CyberOne EC unit based on the con guration Onan up ow con guration the pilot holes are located inthetop of thecab...

Page 22: ...s within the range of 277V plus 5 the control transformers within the system must have the primary wire connected to its respective 240V tap instead of the 208Vtap Upon examination of the buck boost t...

Page 23: ...th the shield being terminated at the unit electric box The number of conductors needed depends on which system controller is utilized For systems utilizing the model E controller three control conduc...

Page 24: ...control wiring may be installed for the system controller to enable condenser operation only when the compressor is running You must remove the jumper from the remote condenser terminal board see the...

Page 25: ...age electrical box Refer to the electrical drawing supplied with your unit for the number of eldwiresneededandappropriatewireterminationsrequired speci cally for yoursystem Figure 14 Interconnecting F...

Page 26: ...Figure 15 Interconnecting Field Wiring Glycol Systems 21 COS 024 060 G U SHOWN FOR REFERENCE NOTES 1 PHANTOM WIRES NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES 2 NUMBER OF CONDUCTORS VARY DEPENDING...

Page 27: ...ing pressures vary depending on the type of refrigerant used in the unit Before charging check the unit nameplate to con rm the type of refrigerant to use Tables are provided in Section 2 8 8 showing...

Page 28: ...r for HGRHand HGBP 3 2 lb Estimated Refrigerant Charge 22 226 lb 2 8 6 Preparing System for Charging 1 With all the system piping connections made perform a dry nitrogen leak detection test on the sys...

Page 29: ...itial vacuum release the vacuum and pressurize the system with 2 3 lbs of drynitrogen Allowthesystemtostandfortwohourswith the dry nitrogen charge This gives time for the nitrogen moleculestodispersei...

Page 30: ...erature reading near the feeler bulbfromthethermalexpansionvalvewiththetempera ture measuring device being well insulated The ideal superheattemperatureis12 15 F Maximumallowable superheat temperature...

Page 31: ...Design Condensing Temp 95 F Ambient 125 105 140 Suction Pressure psig R407C 70 55 85 Fan Cycling Control Fan On psig R407C 320 240 340 Fan Speed Control psig R407C 320 Flooded HP Control Valve psig R...

Page 32: ...or control is used to maintain head pressure The variable speed motor is located closest to the header end of the condenser The fan speed control is a continual modulation of the motor s speed The con...

Page 33: ...h 10 VDC corresponding to the valve opening 100 Thesystemcontrollerisfactorysetforthecorrectcondensing pressure however it can be adjustedto increase ordecrease thecondensingpressure Adjustmentismadeb...

Page 34: ...llen wrench turn clockwise to increase pressure or counterclockwise to lower pressure 3 2 1 1 Full Floating A full oating hot gas bypass system is provided for split AHU Remote Condensing Units The fu...

Page 35: ...peration and Maintenance manual for the humidi er is provided with your unit under separate cover Refer to that manual for detailed information on the humidi er operation 7 Test dehumidi cation operat...

Page 36: ...eavailableandthat allcylinderstobeusedaredesignatedfortherecovered refrigerant and labelled for that refrigerant i e special cylindersforthe recoveryofrefrigerant Cylinders must be complete with press...

Page 37: ...a lowrefrigerant charge ora clogged lter drier Check for humidity in the refrigerant by viewing the color of the indicator in the center of the sight glass and comparing it to the color scale on the...

Page 38: ...oil cleaner Check for bent or damaged coil ns and repair as necessary On outdoor units in winter do not permit snowto accumulate on or aroundthe condensing unit Check all refrigerant lines and capilla...

Page 39: ...ator blower b Temperature setting too low Increase temperature setpoint 68 Fmin c Discharge air short cycling back to return Check discharge grilleorientation d Low refrigerant charge Find leak repair...

Page 40: ...Condenser air intakeis blocked Remove debris and clean condenser c Overcharge ofrefrigerant Reclaim excess refrigerant fromsystem d Lowwater glycol owto water cooled condenser Reset determine cause an...

Page 41: ...ck condenser for obstructions e Minimum off time hasnot expired Wait for time toexpire System Short of Capacity a Low refrigerant indicated by bubblesin sight glass b Expansion valve stuck or obstruct...

Page 42: ...lement Humidi er Inoperative a Water supplyhas been turned offor not connected Connect and or turn on water supply Note See humidifier manual for additional help b Humidi er switch is in Off position...

Page 43: ...are providedto protect the compressor fromfailing If a compressor failure has occurred determine whether it is an electrical or a mechanical failure An electrical failure will beindicatedbythedistinc...

Page 44: ...one size larger than the normal selection size 6 Checktheexpansionvalve sightglassandothercontrols to see if cleaning or replacement isrequired 7 Evacuatethesystemaccordingtostandardprocedures Normall...

Page 45: ...the A C unit On by pressing the Enterkey 8 Readjust the humidity to the desired setpoint If the humidi er is to be shut down for an extended period follow the steps of the Extended Shutdown procedure...

Page 46: ...UPS groundthecustomerisresponsiblefortheshipping charges If you do not have established credit with STULZ you must give a freight carrier accountnumber A written or faxed purchase order is required o...

Page 47: ...valve 9 Humidifier On Off Drain switch is in the on position 10 Filter s installed 11 Duct plenums sealed 12 Incoming line voltage matches equipment nominal nameplated rating tolerances 13 Main power...

Page 48: ...ndensate pan safety switch operates freely Additional Check chilled water hot water circuits for air bleed as required Coils clean and clear of obstructions Humidifier cylinder and controls operate pr...

Page 49: ...upport call 888 529 1266 or email stulztechnicalsupport stulz ats com Support is available 24 7 365 Provide the model number serial number and STULZ item number from the unit nameplate This will speed...

Page 50: ...DF Downflow NFPA National Fire Protection Agency EC Electronically Commutated PH Phase DP Dewpoint PSI Pounds Per Square Inch DX Direct Expansion PSIG Pounds Per Square Inch Gauge ESD Electrostatic D...

Page 51: ...Air Technology Systems Inc 1572 Tilco Drive Frederick MD 21704 301 620 2033 Fax 301 662 5487 info stulz ats com Technical Support 888 529 1266 www stulz usa com OCC0096A Feb 2020 STULZ Air Technology...

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