Stulz FLAIR series, Installation, Operation And Maintanance Manual

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FLAiR Series Installation, Operation & Maintenance Manual
(©Aug, 2007)
Air Technology Systems, Inc.
1.0 Introduction ........................................ 1-1
1.1 General ....................................................... 1-1
1.2 Product Description ..................................... 1-1
1.3 Product Warranty ........................................ 1-2
1.4 Safety ......................................................... 1-4
1.4.1 General ....................................................... 1-4
1.4.2 Safety Summary ......................................... 1-4
1.5 General Design ........................................... 1-6
1.5.1 Electrical Compartment ............................... 1-6
1.5.2 Impeller Fans .............................................. 1-6
1.5.3 Blowers ....................................................... 1-7
1.5.4 Heaters ....................................................... 1-7
1.5.5 Coils .......................................................... 1-7
1.5.6 Temperature/Humidity Sensor ..................... 1-7
1.5.7 Humidifier .................................................... 1-7
1.6 Optional Features ........................................ 1-7
1.6.1 Condensate Pump ....................................... 1-7
1.6.2 Smoke Detector .......................................... 1-7
1.6.3 Firestat ....................................................... 1-7
2.0 Installation .......................................... 2-1
2.1 Receiving the Equipment. ............................ 2-1
2.2 Site Preparation .......................................... 2-1
2.3 Rigging ........................................................ 2-1
2.4 Mounting/Placement ................................... 2-2
2.4.1 Indoor Equipment ........................................ 2-2
2.4.2 Outdoor Equipment ..................................... 2-2
2.4.3 Optional Equipment (Field Installed) ............ 2-3
2.4.3.1 Remote Display ........................................... 2-3
2.4.3.2 Condensate Pump ....................................... 2-3
2.4.3.3 Remote Temperature/Humidity Sensor ........ 2-3
2.4.3.4 Remote Water Detector ............................... 2-3
2.5 Air Distribution ............................................. 2-4
2.5.1 Upflow Configuration Air Pattern ................... 2-4
2.6 Piping Connections ..................................... 2-4
2.6.1 Refrigerant ................................................... 2-4
2.6.2 Water/Glycol ............................................... 2-5
2.6.3 Condensate Drain Line ................................ 2-6
2.6.3.1 Gravity Drain ............................................... 2-6
2.6.3.2 Condensate Pump ....................................... 2-6
2.6.4 Humidifier .................................................... 2-6
2.7 Utility Connections ...................................... 2-7
TABLE OF CONTENTS
2.7.1 Main Power ................................................. 2-7
2.7.2 Controls ...................................................... 2-8
2.7.3 Optional Equipment ..................................... 2-8
2.7.3.1 Condensate Pump ....................................... 2-8
2.7.3.2 Remote Temperature/Humidity Sensor ........ 2-8
2.7.3.3 Remote Water Detector ............................... 2-9
2.7.4 Air-Cooled Split Systems ............................ 2-9
2.7.4.1 Remote Condenser ...................................... 2-9
2.7.4.2 Remote Condensing Unit ........................... 2-10
2.7.5 Glycol Cooled Systems .............................. 2-11
2.8 System Settings and Adjustments ............ 2-12
2.8.1 R22 Refrigerant Charging Procedures ........ 2-12
2.8.2 R407C Refrigerant Charging Procedures .... 2-13
2.8.3 Low/High Limit Switch ............................... 2-15
2.8.4 Head Pressure Controls ............................ 2-15
2.8.4.1 Air-Cooled Systems .................................. 2-15
2.8.4.2 Water/Glycol-Cooled Systems .................. 2-16
2.8.5 Humidifier Adjustment ................................ 2-16
2.8.6 Thermal Expansion Valve .......................... 2-17
2.8.7 Hot Gas Reheat (Optional) ........................ 2-17
2.8.8 Hot Gas Bypass (Optional) ....................... 2-17
2.9 Refrigerant Characteristics ........................ 2-18
2.9.1 Pressure / Temperature Settings ............... 2-18
2.9.2 Saturated Refrigerant Pressure Settings .... 2-18
3.0 Start-Up/Commissioning ................... 3-1
3.1 Operation .................................................... 3-1
3.2 Step by Step Start-Up Instructions ............... 3-1
3.3 Microprocessor Controller Programming ...... 3-1
4.0 Maintenance ....................................... 4-1
4.1 Periodic General Maintenance ..................... 4-1
4.1.1
FLAiR Precision A/C Unit ............................ 4-1
4.1.2 Condenser ................................................... 4-2
4.2 Troubleshooting ........................................... 4-2
4.3 Field Service ............................................... 4-7
4.3.1 Leak Detection ............................................ 4-7
4.3.2 Leak Repair ................................................. 4-7
4.3.3 Refrigerant Piping ........................................ 4-7
4.3.4 General Common Repairs/
Component Replacement ............................ 4-7
4.3.4.1 Compressor Failure ..................................... 4-7
4.3.4.2 Standard Clean-out Procedure ..................... 4-8
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