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Stulz FLAIR series, Installation, Operation And Maintanance Manual

The Stulz FLAIR series is a technologically advanced and efficient cooling solution for various applications. To ensure a seamless experience, we provide a comprehensive Installation, Operation, and Maintenance Manual. Easily accessible on our website, users can download this manual for free to properly install, operate, and maintain their Stulz FLAIR series product.

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FLAiR Series Installation, Operation & Maintenance Manual

(©Aug, 2007)

Air Technology Systems, Inc.

CyberAiR Series

Periodic General Maintenance Checks and Services Checklist

Date:

____________________________

Prepared By: ___________________________

Model Number: ____________________________

Serial Number: __________________________

Item Number:

____________________________

Monthly

Filters

Blower Section

Condensate Drain

❏

Cleanliness

❏

Blower Turns

❏

Drain is Open

❏

No Obstructions

❏

Belts (if applicable)

❏

Condensate Pan Safety
Switches Operate Freely

Miscellaneous

❏

Check Glycol or Chilled Water for Air (bleed as required)

❏

External Heat Exchanger Clean and Clear of Obstructions

❏

Humidifier Cylinder and Controls Operate Properly

Semi-Annually

❏

Check Refrigerant Charge (bubbles in sight-glass)

❏

Tighten Electrical Connections

❏

Check Suction & Discharge Pressure

❏

Check Contacts on Contactors

for Pitting

❏

Check 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 Check of

Above and Clean Unit's Interior

All Services Listed Above and
Clean Unit's Interior

Notes:

___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Signature:________________________________

*** If factory assistance is required for any reason, provide the model number, serial number, and SATS item

number found on the unit nameplate. This will speed the process and ensure accuracy of information. ***

A-2

Frederick, Maryland USA 21704

Telephone: (301) 620-2033

Facsimile: (301) 620-1396

Air Technology Systems, Inc.

Summary of Contents for FLAIR series

Page 1: ...FLAiR Series Installation Operation Maintenance Manual Aug 2007 Air Technology Systems Inc ...

Page 2: ...anual for internal use only 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 This document contains confidential and proprietary information of Stulz Air Technology Systems Inc Distributing or ...

Page 3: ...F 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 Proced...

Page 4: ...s List of Figures Figure 1 Typical Layout with C6000 Controller 1 6 Figure 2 Typical Layout with A Tech 20 Controller 1 7 Figure 3 Recommended Installation Clearance 1 5 Figure 4 Typical Installation 2 2 Figure 5 Condensate Pump 2 6 Figure 6 Sample Nameplate 2 7 Figure 7 Interconnecting Field Wiring Remote Condenser 2 9 Figure 8 Interconnecting Field Wiring Remote Condensing Unit 2 10 Figure 9 Int...

Page 5: ...e unit size which can range from 18 000 to 60 000 BTU Hr FLAiR systems are designed to operate with either R22 or R407C refriger ant Refer to the unit nameplate to identify which refrigerant is used with your system NOTE The FLAiR systems have been designed to sup ply air to only one room The functional modes of operation in addition to cooling are heating humidification and dehumidifica tion whic...

Page 6: ...ry and warranted for the balance of the original warranty period or for 90 days from the date of installation whicheverisgreater Stulz Air Technology Systems Inc s warranty does not cover failures caused by improper installation abuse misuse misapplication improper or lack of maintenance negligence accident normaldeterioration includingwearandtear ortheuseofimproperpartsorimproper repair Purchaser...

Page 7: ...igence accident normal deterioration including normal wear and tear or the use of improper parts or improper repair as determined by SATS This warranty does not include costs of transportation cost for removal or reinstallation of equipment or labor for repairs or replacement made in the field The obligation and liability of StulzAir Technology Systems under this warranty does not include losses d...

Page 8: ...g on electrical equipment remove all jewelry watches rings etc Always disconnect the main power supply to the equipment at the main power disconnect switch before beginning work on the equipment A lock out tag out procedure should be followed to ensure that power is not inadvertently reconnected Equipment may contain components subject to Electrostatic Discharge ESD Before attempting to mount or s...

Page 9: ...ons 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 03 0 06M minute CAUTION When the air conditioner is in the cooling mode the return air intake and discharge supply must be free of obstructions Ensure panels are secure and latched into position CAUTION Do not use cleaning solvents near open ...

Page 10: ...ff to gain access to the electrical compart ment The service disconnect switch may be used to turn the unit off for emergency shutdown or when routine maintenance is performed The handle of the switch may be locked in the Off position to prevent unintended operation 1 5 1 2 Fuses Circuit Breakers Motor Start Protectors Individual overload protection is provided by fuses or circuit breaker s and mo...

Page 11: ...HOW INTERNAL PARTS FRONT SERVICE DISCONNECT SWITCH NOTES 1 2 FIRESTAT OPTIONAL Figure 3 Typical Layout with A Tech 20 Controller 1 5 5 Coil s The cooling and optional hot water re heating coils are aluminum finned copper tube construction and are sized for the BTU capacity required by the application 1 5 6 Temperature Humidity Sensor As a standard for room air control a temperature humidity T H se...

Page 12: ...cated on the front of the unit In order to have full service access through the front no permanent obstructions can be placed within 30 inches in front of units ranging from 18 000 to 36 000 BTU Hr and 40 inches in front of 60 000 BTU Hr units see Figure 1 NOTE Working clearance requirements need to be es tablished prior to the mounting of the unit Refer to local and national electrical codes To m...

Page 13: ...nsure the mounting surface is able to support the weight of the equipment Before mounting the unit refer to the weight table provided on the installation drawing NOTE Equipment must be level to operate properly 2 4 2 Outdoor Equipment Install the remote condenser condensing unit in a secure location where the unit cannot be tampered with and the service disconnect switch cannot be inadvertently tu...

Page 14: ... a flat head screwdriver remove the cover plate from the base of the sensor 2 Place the base temporarily over the wire hole opening in the wall Level the base and mark the mounting hole locations through the two slots 3 Drill the mounting holes and insert the wall anchors provided 4 Run the wires coming out of the wall through the opening in the base then secure the base with the screws provided 5...

Page 15: ...en sealing openings in walls and to reduce vibration transmission use a soft flexible material to pack around the tubing Oil traps must be included every 20 feet in vertical risers and the refrigerant lines must be sloped inch for every 10 feet in horizontal lines to ensure proper oil return to the compressor Clear all pipe connections of debris and prepare connections for soldering Use only L or ...

Page 16: ...oner Glycol cooled systems with low entering fluid tempera tures should have insulated piping The recommended ethylene glycol solution ratio is 40 glycol to 60 water SATS recommends Dowtherm SR1 manufactured by Dow Chemical Co Use only ethylene glycol with inhibitors for corrosion protection WARNING Glycol is hazardous Consult the manufacturer s MSDS for detailed safety information NOTE When insta...

Page 17: ...t The drain line may be 1 2 ID vinyl tubing or a 1 2 copper to copper sweat connec tion may be used If an optional field installed pump is selected a p trap must be installed for proper condensate drainage see Figure 5 The height of the trap must be a minimum of 2 inches on standard systems to ensure proper water drainage The condensate pump discharge line should be 1 2 inch OD maximum copper pipe...

Page 18: ... options that were purchased with the unit in order to confirm which field connections are required WARNING Verify power is turned off before making connec tions to the equipment NOTE All wiring must conform to local and national elec trical code requirements Use of copper conduc tors only is required Wiring terminations may become loose during transit of the equipment therefore it is required to ...

Page 19: ...lectrical code requirements 2 7 3 1 Condensate Pump If an optional condensate pump is selected it is normally factory installed and wired inside the A C unit Systems supplied with an optional field installed condensate pump will require power and control wiring to be connected to the unit After proper installation of the condensate pump the installer must connect two power conductors from the cond...

Page 20: ... typically located in the condenser electric box The installer must provide main power wiring to the main power distribution block located within the remote condenser control box A separate equipment ground lug is provided within the electrical box for termination of the earth ground wire The installer must also wire control conductors from the terminal board within theA C unit to the control term...

Page 21: ...EE NOTE 1 INTERCONNECTING FIELD WIRING TO BE INSTALLED IN ACCORDANCE MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz FCS 018 060 AHU NOTES 1 PHANTOM WIRES NOT APPLICABLE FOR SINGEL PHASE POWER SUPPLIES 2 NUMBER OF CONDUCTORS VARY DEPENDING ON OPTIONS PROVIDED 3 OPTIONAL REMOTE MOUNTED DEVICES 2 7 4 2 Remote Condensing Unit AHU Models Systems equipped with a remote condensing unit require field control wir...

Page 22: ...Figure 9 Interconnecting Field Wiring Glycol Systems TO BE INSTALLED IN ACCORDANCE GLYCOL UNITS ONLY GPS 005 010 ELECTRIC 24VAC PUMP PACKAGE BOX SEE NOTES 1 2 WITH NFPA 70 N E C INTERCONNECTING FIELD WIRING MAIN POWER SUPPLY 208 460V 1PH 3PH 60Hz DRYCOOLER L3 L1 L2 SEE NOTE 3 4 CONDUCTOR NON SHIELDED CABLE SHIELDED CABLE 2 CONDUCTOR 6 CONDUCTOR PHONE TYPE NON SHIELDED CABLE WITH NFPA 70 N E C SEE ...

Page 23: ... ant system prior to charging If this is not done the refrigerant will combine with moisture in the pipes to form an acid that will eventually lead to compressor failure 2 12 FINE TUNING THE SYSTEM CHARGE 2 8 1 2 1 0ºF Fan Cycling and 20ºF Variable Speed Control The following instructions are for charging systems with condenser fan cycling or variable speed control using R22 refrigerant 1 Bleed ai...

Page 24: ...er the temperature set point 3 5 F below room temperature This will 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 has cleared of all bubbles 4 Raise the discharge pressure to 300 325 psig and hold i...

Page 25: ...g system The proper charge can be determined by viewing the position of the float constant however therefrigerantvaportendsto separate into its component parts even when circulat ing When charging a system using a blended refrigerant it is essential that the composition of the refrigerant is maintained To ensure correct composi tion introduce R407C into the system in liquid form rather than vapor ...

Page 26: ...ay fall to 30 F flooded head pressure control is designed to maintain head pressure during low ambient conditions Ahead pressure control valve and a receiver is used in the ball while the unit is running If the float ball is positioned at the bottom of the sight indicator addi tional refrigerant charge is needed When the float ball reaches the top of the indicator the unit is fully charged 2 8 3 L...

Page 27: ...essure Regulating Valve In a water glycol condenser condensing temperature is maintained by the liquid flowing through a regulating valve and then into a tube in tube or brazed plate liquid cooled condenser The regulating valve opens to increase water flow as the refrigerant pressure rises or closes as the refrigerant pressure falls The regulating valve is factory set for the correct condensing te...

Page 28: ...the suction low side of the compressor as it operates in full hot gas bypass operation The valve is factory set and no adjustment should be necessary If adjustment is required block one half of the coil and remove adjustment cap from the end of the valve Using a 5 16 inch allen wrench turn clockwise to increase pressure or counterclock wise to lower pressure 2 8 8 2 Full Floating A full floating h...

Page 29: ...34 60 4 36 63 1 38 65 9 40 68 7 42 71 7 44 74 7 46 77 8 48 81 0 50 84 2 55 92 7 60 102 65 111 70 122 75 132 80 144 85 156 90 168 95 182 100 196 105 210 110 226 115 242 120 260 125 278 130 296 135 316 140 337 R407C Refrigerant Temp Pressure F psig Superheat 20 37 0 22 39 1 24 41 3 26 43 6 28 46 0 30 48 4 32 50 9 34 53 5 36 56 2 38 58 9 40 61 7 42 64 6 44 67 6 46 70 7 48 73 8 50 77 1 Sub cooling 95 ...

Page 30: ... by creating a de mand for humidification Use an amp meter to determine current draw of humidifier Visually check for humidity leaving the steam head or feel the cylinder to verify if the humidifier is operational In all cases 1 to 6 hours might be required to see the desired level or a rise of humidity in the conditioned space Once room conditions have been programmed or set a repeat visit to the...

Page 31: ...ith rotating components Exercise extreme care to avoid accidents and ensure proper operation WARNING Phosgene a deadly poisonous gas is generated when refrigerant is exposed to flame Always ensure adequate ventilation during refrigeration repairs CAUTION This equipment should be serviced and repaired by a journeyman or a qualified refrigeration tech nician only WARNING Always recover all refrigera...

Page 32: ...k all refrigerant lines and capillaries for vibration isolation and support as necessary Check all refriger ant and coolant lines for signs of leaks CAUTION The compressor crankcase 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 a condensing unit until 8 hours after applying power This allows enough time for a...

Page 33: ...Check for short circuit or ground fault If breaker tripped none reset circuit breaker c Defective contactor Repair or replace d Condensate switch open 1 Ensure unit is level 2 Check that condensate pan is draining properly Clear obstructions e Motor circuit controller tripped Reset motor circuit controller and check amperage of motor Compare to setting on motor circuit controller and adjust to FLA...

Page 34: ...just or repair controls properly c Water regulating valve adjusted Readjust to 240 250 psig too low Noisy Compressor a Expansion valve stuck in open Ensure feeder bulb is tight on suction line position abnormally cold suction line Check operation and superheat b Broken compressor valve Replace compressor compressor knocking suction pressure rises faster than 2lbs min after shutdown c Worn or scarr...

Page 35: ... belt tension when applicable d Lack of refrigerant Check for leak Repair and recharge system e Short cycling of conditioned air 1 Supply and or return grilles are incorrectly oriented Reorient 2 Supply and return grilles are too close together Move further apart 3 Insufficient heat load Add temporary heat load to compensate f Remote temperature sensor is Check for supply registers that may improp...

Page 36: ...nections d Humidifier fuses or circuit breaker Check for over current by the humidifier tripped electrodes Drain water from tank and refill Replace fuses or re set circuit breaker e Relative humidity is above setpoint Adjust humidity setpoint f Electrode canister change cylinder 1 Consult humidifier manual light is on 2 Water conductivity is too low and water is at the top of the cylinder see next...

Page 37: ...ponent 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 bur...

Page 38: ...in power disconnect switch and start the system 4 3 4 3 Burn Out Acidic Cleanup Procedure CAUTION Avoid touching or contacting the gas and oil with exposed skin Severe burns will result Use long rubber gloves in handling contaminated parts NOTE Cleaning operations must be performed by a journeyman refrigeration mechanic or air con ditioning technician 1 These systems should be cleaned using the su...

Page 39: ...of the cylinder Pull these plugs vertically off the pins CAUTION The cylinder and steam hose may be hot and burns may result 6 Loosen the steam hose clamp s and pull the steam hose off vertically 7 Lift the cylinder straight up to disengage it from the humidifier 8 Place the new cylinder on the side mounting slots within the unit ensuring the cylinder mounting stubs are seated properly 9 Replace t...

Page 40: ... Aug 2007 FLAiR Series Installation Operation Maintenance Manual Air Technology Systems Inc NOTES ...

Page 41: ...s If you do not have established credit with SATS you must provide a freight carrier account 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 obtained from PSG Customer BillingAddress ShippingAddress Custo...

Page 42: ... Aug 2007 FLAiR Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 43: ...10 Filter box installed if required 11 Filter s installed if required 12 Ductwork completed or optional plenum installed if required 13 Incoming line voltage matches equipment nominal nameplated rating tolerances 14 Main power wiring connections to the equip ment including earth ground have been properly installed 15 Customer supplied main power circuit breaker HACR type or fuses have proper ratin...

Page 44: ... Aug 2007 FLAiR Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 45: ..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...

Page 46: ... Aug 2007 FLAiR Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

Page 47: ... ESD Electrostatic Discharge OHS Overhead System º F Degrees Fahrenheit PH Phase FLA Full Load Amps PSG Product Support Group FOB Freight on Board PSI Pounds Per Square Inch HACR Heating Air Conditioning Refrigeration PSIG Pounds Per Square Inch Gauge HP Horse Power RLA Rated LoadAmps Hz Hertz R Value Thermal Resistance IAQ Indoor Air Quality R22 Refrigerant HCFC 22 in w g Inches of Water Gauge R4...

Page 48: ... Aug 2007 FLAiR Series Installation Operation Maintenance Manual Air Technology Systems Inc ...

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