stulz minispace

Mini-Space Series Installation, Operation & Maintenance Manual

(©April, 2008)

Air Technology Systems, Inc.

(©April, 2008)



MODEL NOMENCLATURE

Mini-Space - Vertical Floor Systems

4

6

8

12 = Nominal Capacity in kW

17

20

CC = Compact Line System

A = Air Cooled

CW = Chilled Water System

G = Glycol Cooled

W = Water Cooled

CC U-12 1-G

Number of Refrigeration Circuits

U = Upfl ow Air Pattern

D = Downfl ow Air Pattern

CCU= Upfl ow

Air PatternsCCD= Downfl ow

Air Patterns

AIR INLET

AIR OUTLET

AIR INLET

AIR OUTLET


(©April, 2008)


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

1.6 Optional Equipment .....................................1-7

2.0 Installation ...........................................2-1

2.1 Receiving the Equipment. ............................2-1

2.2 Site Preparation ...........................................2-1

2.3 Rigging ........................................................2-2

2.4 Mounting/Placement ....................................2-2

2.4.1 Precision A/C Unit ........................................2-3

2.4.2 Outdoor Equipment .....................................2-3

2.5 Optional Equipment (Field Installed) ...........2-3

2.5.1 Floor Stand ..................................................2-3

2.5.2 Plenum Box Assembly .................................2-4

2.5.3 Remote Display ...........................................2-4

2.5.4 Condensate Pump .......................................2-4

2.5.5 Remote Temperature/Humidity Sensor .......2-4

2.5.6 Remote Water Detector ...............................2-5

2.6 Air Distribution Connection ..........................2-5

2.6.1 Downfl ow Confi guration Air Patterns ...........2-5

2.6.2 Upfl ow Confi guration Air Patterns ................2-6

2.7 Piping Connections ......................................2-7

2.7.1 Refrigerant ...................................................2-7

2.7.2 Water/Glycol, Chilled Water

Air Cooled Systems ...................................2-17

2.7.3 Pump Package ............................................2-9

2.7.4 Condensate Drain Line ................................2-9

2.7.4.1 Gravity Drain................................................2-9

2.7.4.2 Condensate Pump .......................................2-9

2.7.5 Humidifi er ....................................................2-9

2.8 Utility Connections .....................................2-10

2.8.1 Main Power ................................................2-10

2.8.2 Controls ..................................................... 2-11

2.8.3 Optional Equipment ...................................2-12

2.8.3.1 Condensate Pump .....................................2-12

2.8.3.2 Remote Temperature/Humidity Sensor .....2-12

2.8.3.3 Remote Water Detector .............................2-12

TABLE OF CONTENTS

2.8.4 Split Systems .............................................2-12

2.8.4.1 Remote Condenser ...................................2-12

2.8.4.2 Glycol Systems ..........................................2-12

2.9 System Charging Procedures ....................2-14

2.9.1 R22 Refrigerant Charging Procedures ......2-14

2.9.2 R407C Refrigerant Charging Procedures ..2-15

2.9.3 Water/Glycol Systems ..............................2-17

2.10 System Settings and Adjustments ............2-17

2.10.1 Low/High Pressure Limit Switch ...............2-17

2.10.2 Head Pressure Controls-

Air Cooled Systems ...................................2-17


Water/Glycol Cooled Systems ...................2-18

2.10.4 Humidifi er Adjustment ................................2-19

2.10.5 Blower Adjustment .....................................2-19

2.10.6 Thermal Expansion Valve ..........................2-20

2.10.7 Hot Gas Reheat (Optional) ........................2-20

2.10.8 Snap Acting Hot Gas Bypass (Optional) ....2-20

2.11 Refrigerant Characteristics ........................2-21

2.11.1 Pressure / Temperature Settings ...............2-21

2.11.2 Saturated Refrigerant Pressure Tables .....2-21

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 Precision A/C Unit ........................................4-1

4.1.2 Condenser ...................................................4-4

4.1.3 Pump Package ............................................4-4

4.2 Troubleshooting ...........................................4-5

4.3 Field Service ................................................4-9

4.3.1 Leak Detection .............................................4-9

4.3.2 Leak Repair .................................................4-9

4.3.3 Refrigerant Piping ........................................4-9

4.3.4 General Common Repairs/

Component Replacement ............................4-9

4.3.4.1 Compressor Failure .....................................4-9

4.3.4.2 Standard Cleanout Procedure ...................4-10

4.3.4.3 Burn-Out/Acidic Clean Up Procedure ........4-10

4.3.4.4 Humidifi er Cylinder Replacement .............. 4-11

4.3.4.5 Filter Replacement .................................... 4-11

i

(©April, 2008)



TABLE OF CONTENTS (Continued)

ii

5.0 Product Support Group ......................5-1

5.1 Technical Support ........................................5-1

5.2 Obtaining Warranty Parts ............................5-1

5.3 Obtaining Spare/Replacement Parts ...........5-1

List of Figures

Figure 1. Typical Upfl ow Internal Layout .......1-6

Figure 2. Typical Downfl ow Internal Layout ...1-6

Figure 3. Installation Clearance .....................2-1

Figure 4. Typical Installation ..........................2-2

Figure 5. Optional Floor Stand Installation ....2-3

Figure 6. Downfl ow Confi guration

Typical Air Patterns .........................2-5

Figure 7. Upfl ow Confi guration Typical

Air Patterns .....................................2-6

Figure 8. Condensate Pump ..........................2-9

Figure 9. Sample Nameplate .......................2-10

Figure 10. Electric Box ................................... 2-11

Figure 11. Interconnecting Field Wiring

Remote Condenser ......................2-13

Figure 12. Interconnecting Field Wiring

Glycol Systems .............................2-13

Figure 13. Blower Speed Controller ...............2-19

Figure 14. Belt Drive Blower ..........................2-20

Appendix A - Forms

Checklist for Completed Installation ................. A-1

Periodic General Maintenance Checks

and Service Checklist ....................................... A-2

Appendix B - Glossary

Defi nition of Terms and Acronyms .................... B-1

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 internal use only. No part of this document may be photo-

copied, 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 confi dential and proprietary information of Stulz Air Technology Systems, Inc. Distributing or photo-

copying this document for external distribution is in direct violation of U.S. copyright laws and is strictly prohibited without the

express written consent of SATS.

Unpublished — rights reserved under the copyright laws of the United States and of other countries.

Other brands and tradenames are trademarks of their respective owners.

Copyright 2008 by Stulz Air Technology Systems, Inc.

Printed in the United States of America.

All rights reserved.

Stulz Air Technology Systems, Inc.

1572 Tilco Drive

Frederick, MD 21704

USA

List of Figures Cont.)


(©April, 2008)


1-1

1.0 INTRODUCTION

1.1 General

Congratulations, the Mini-Space™ fl oor mounted

precision air conditioning system covered by this

manual is designed and manufactured by Stulz Air

Technology Systems, Inc. (SATS) using the latest

state-of-the-art control technology. Recognized as a

world leader, SATS provides air conditioning systems

with the highest quality craftsmanship using the fi n-

est materials available in the industry. The unit will

provide years of trouble free service if installed and

maintained in accordance with this manual. Damage

to the unit from improper installation, operation or

maintenance is not covered by the warranty.

STUDY the instructions contained in this manual.

They must be followed to avoid diffi culties. Spare

parts are available from SATS to insure continuous

operation. Using substitute parts or bypassing electri-

cal or refrigeration components in order to continue

operation is not recommended and will VOID THE

WARRANTY. Due to technological advancements,

components are subject to change without notice.

Mini-Space systems and centrifugal condensers are

designed to be installed indoors, unless otherwise

noted on the equipment. Propeller-type condensers,

drycoolers and pump packages are designed for

outdoor use.

1.2 Product Description

Mini-Space precision A/C systems are designed to be

the most compact and fl exible, fl oor mounted air con-

ditioning systems in the industry. The unit is available

in air-cooled, water-cooled and glycol-cooled confi gu-

rations. The cooling capacity in BTU/Hr will depend

on the unit size, which can range from 12,000 to

84,000 BTU/Hr. Mini-Space systems are designed to

operate with either R22 or R407C refrigerant. Refer

to the unit nameplate to identify which refrigerant is

used with your system.

NOTE

Mini-Space systems are designed to supply air

to only one room.

Mini-Space precision A/C units are compact and ver-

satile. The functional modes of operation in addition

to cooling are heating, humidifi cation and dehumidifi -

cation, which provide complete environmental control

of a conditioned space. The cabinet is available in

two footprint sizes. A compact 23.6 inches wide by

23.6 inches deep frame for units ranging from 18,000

to 48,000 BTU/Hr and a compact 39.4 inches wide by

31.9 inches deep frame for units ranging from 48,000

to 76,000 BTU/Hr. The cabinet is designed for conve-

nient, 100% front access and may easily be tucked

between cabinetry or placed side-by-side.

There are two airfl ow pattern confi gurations; upfl ow

and downfl ow. The basic cabinet height remains the

same, (72.8”), regardless of the confi guration. An op-

tional plenum box may be selected (for upfl ow units

only), which adds an extra 18.5” to the height. See

the installation drawing provided with your unit for the

layout and dimensions of the cabinet.

The Mini-Space unit is provided with a factory mount-

ed main power disconnect switch with a lockable

handle. The disconnect switch electrically isolates the

unit during routine maintenance. The system incorpo-

rates state-of-the-art component protection with the

use of motor start protectors and circuit breakers.

The standard controller for the Mini-Space unit is

the C1002 microprocessor, which provides the fol-

lowing features: input/output monitoring status, full

integrated control of heating, cooling, humidifi cation

and dehumidifi cation; multi-unit control and remote

communication with building management systems.

The controller is typically factory mounted on the

front hinged access door of the unit. As an option

the controller may be remotely mounted to a wall or

control panel.

SATS offers the C5000 microprocessor controller as

an option if required for selected special applications.

An operating manual for the system controller is pro-

vided under separate cover. Refer to that manual for

detailed instructions on operating the system control-

ler provided with your unit.

C1002 C5000

(©April, 2008)



1-2

1.3 Product Warranty

SATS offers a two year standard limited warranty as stated on the following pages. Additionally an extended

warranty may be purchased on the unit’s compressor. Consult the factory to verify if the extended compressor

warranty was purchased for your system. The extended compressor warranty as stated on the next page will be

sent with your unit and should be retained for future reference.

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. to be

defective for a period of 24 months from date of shipment when a completed start-up form

has been submitted to Stulz Air Technology Systems, Inc. within 90 days from shipment. In

the event that a completed start-up form is not received by Stulz Air Technology Systems, Inc.

within 90 days from shipment, the company’s obligation will be for a period of 12 months from

date of shipment. Parts repaired or replaced under this warranty are shipped FOB Factory,

and warranted for the balance of the original warranty period or for 90 days from the date of

installation, whichever is greater.

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, normal deterioration (including wear and tear), or the use of improper parts or

improper repair.

Purchaser’s remedies are limited to replacement or repair of nonconforming materials in ac-

cordance with the written warranty. This warranty does not include costs for transportation,

costs for removal or reinstallation of equipment or labor for repairs or replacement made in

the fi eld.

If any sample was shown to the buyer, such sample was used merely to illustrate the general

type and quality of the product, and not to represent that the equipment would necessarily

conform to the sample.

This is the only warranty given by the seller, and such warranty is only given to buyers for

commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is

paid in full.

THE FOREGOING SHALL CONSTITUTE SATS’S ENTIRE LIABILITY AND YOUR EXCLU-

SIVE REMEDY. IN NO EVENT SHALL SATS BE LIABLE FOR ANY DIRECT, INDIRECT,

SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING

LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY

WAY OUT OF THE INSTALLATION, USE OR MAINTENANCE OF THE EQUIPMENT. THIS

WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING

WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

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(©April, 2008)


1-3


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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 an extended period of 4 years from the date of expiration of the standard

equipment warranty.

Stulz Air Technology Systems’ warranty does not cover failures caused by improper in-

stallation, abuse, misuse, misapplication, improper or lack of maintenance, negligence,

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 fi eld.

The obligation and liability of Stulz Air Technology Systems under this warranty does

not include losses, direct or indirect, for incidental or consequential damages.

Compressor Serial No.: __________________________________

Unit Model No.: __________________________________

Unit Serial No.: __________________________________

Stulz Air Technology Systems Job No.: __________________________________

End User: __________________________________

Date: __________________________________


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(©April, 2008)



1-4

1.4 Safety

1.4.1 General

Stulz Air Technology Systems, Inc. uses NOTES

along with CAUTION and WARNING symbols

throughout this manual to draw your attention to im-

portant operational and safety information.

A bold text NOTE marks a short message in the infor-

mation to alert you to an important detail.

A bold text CAUTION safety alert appears with infor-

mation that is important for protecting your equipment

and performance. Be especially careful to read and

follow all cautions that apply to your application.

A bold text WARNING safety alert appears with infor-

mation that is important for protecting you from harm

and the equipment from damage. Pay very close at-

tention to all warnings that apply to your application.

A safety alert symbol precedes a general

WARNING or CAUTION safety statement.

A safety alert symbol precedes an electrical

shock hazard WARNING or CAUTION safety state-

ment.

1.4.2 Safety Summary

The following statements are general guidelines fol-

lowed by warnings and cautions applicable through-

out the manual.

Prior to performing any installation, operation,

maintenance or troubleshooting procedure read and

understand all instructions, recommendations and

guidelines contained within this manual.

Never operate the unit with any cover, guard,

screen panel, etc. removed unless the instructions

specifi cally state otherwise, then do so with extreme

caution to avoid personal injury.

Never lift any component in excess of 35 pounds

without help. If a lifting device is used to move a unit,

ensure it is capable of supporting the unit.

When working 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.

Never work on electrical equipment unless another

person, who is familiar with the operation and haz-

ards of the equipment and competent in administer-

ing fi rst aid, is nearby.

All personnel working on or near equipment should

be familiar with hazards associated with electrical

maintenance. Safety placards/stickers have been

placed on the unit to call attention to all personal and

equipment damage hazard areas.

Certain maintenance or cleaning procedures may

call for the use and handling of chemicals, solvents,

or cleansers. Always refer to the manufacturer’s

Material Safety Data Sheet (MSDS) prior to using

these materials. Clean parts in a well-ventilated area.

Avoid inhalation of solvent fumes and prolonged

exposure of skin to cleaning solvents. Wash exposed

skin thoroughly after contact with solvents.

WARNING

This equipment should be serviced and re-

paired by journeyman, refrigeration mechanic

or an air conditioning technician.

WARNING

This unit employs high voltage equipment with

rotating components. Exercise extreme care to

avoid accidents and ensure proper operation.

WARNING

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 controller. To isolate

the unit for maintenance, turn off power at the

main power disconnect switch. Always discon-

nect main power prior to performing any service

or repairs.


(©April, 2008)


1-5

WARNING

Refrigerant (R22 or R407C) is used with this

equipment. Death or serious injury may result if

personnel fail to observe proper safety precau-

tions. Great care must be exercised to prevent

contact of liquid refrigerant or refrigerant gas,

discharged under pressure, with any part of the

body. The extremely low temperature resulting

from the rapid expansion of liquid refrigerant

or pressurized gas can cause sudden and ir-

reversible tissue damage.

As a minimum, all personnel should wear ther-

mal protective gloves and face-shield/goggles

when working with refrigerant. Application of

excessive heat to any component will cause

extreme pressure and may result in a rupture.

Exposure of refrigerant to an open fl ame or a

very hot surface will cause a chemical reaction

that will form carbonyl chloride (hydrochloric/hy-

drofl uoric acid), a highly poisonous and corro-

sive gas commonly referred to as PHOSGENE.

In its natural state, refrigerant is a colorless,

odorless vapor with no toxic characteristics. It

is heavier than air and will disperse rapidly in

a well-ventilated area. In an unventilated area,

it presents a danger as a suffocant.

WARNING

When performing soldering or de-solder-

ing operations, make certain the refrigeration

system is fully recovered and purged and dry

nitrogen is fl owing through the system at the rate

of not less than 1-2 CFM (0.03-0.06M³/minute).

CAUTION

When the air conditioner is in the cooling mode,

the return air-intake and discharge (supply) must

be free of obstructions. Ensure access panels/

doors are secure and latched into position.

CAUTION

Do not use cleaning solvents near open fl ame

or excessive heat. Wear eye protection when

blowing solvent from parts. The pressure-wash

should not exceed 30 psig. Solvent solutions

should be disposed of in accordance with local

and state regulatory statutes.

CAUTION

The unit must be kept in its normal installed

position when moving. If the unit is not kept

level and vertical, damage to the compressor

will result.

(©April, 2008)



1-6

1.5 General Design

The Mini-Space unit is housed in a steel frame type cabinet and is rated for indoor use. The exterior of the cabi-

net is coated with a powder coat fi nish to protect against corrosion. Hinged doors are located in the front of the

cabinet for easy access to components. Operator controls are conveniently located on the front of the cabinet.

Figure 1 depicts a typical internal layout of a CCU-121-A (upfl ow) unit and identifi es the major components.

Location of the major components vary depending on Mini-Space model number and options purchased.

Figure 1- Typical Upfl ow Internal Layout

(Model CCU-041-A shown for reference)

Figure 2 depicts a typical internal layout of a CCD-171-W/G (downfl ow) unit and identifi es the major compo-

nents. Location of the major components vary depending on Mini-Space model number and options purchased.

Figure 2- Typical Downfl ow Internal Layout

(Model CCD-171-W/G shown for reference)

FRONTLEFT SIDE

CONTROLLER

HEATERS (ELECTRIC)

BLOWER

COIL

ELECTRIC BOX

T/H SENSOR

FIRESTAT

SMOKE DETECTOR

COMPRESSOR

RECEIVER

HUMIDIFIER

POP-OFF FILTER/ACCESS PANEL

(CUT-AWAY TO SHOW INTERIOR)

SIDE PANEL (CUT-AWAY

TO SHOW INTERIOR)

SERVICE DISCONNECT SWITCH

CONDENSATE PAN

DOOR LOCK (2 PLACES)

CONTROLLER

HEATER

BLOWER MOTOR

COIL

ELECTRIC BOX

FIRESTAT

SMOKE

DETECTOR

COMPRESSOR

RECEIVER

HUMIDIFIER

FRONT RIGHT SIDE

SIDE PANEL (CUT-AWAY

TO SHOW INTERIOR)

FILTER

(CCD-171-201 UNITS)

BLOWER

T/H SENSOR

SERVICE DISCONNECT

SWITCH

CONDENSATE PAN

DOOR LOCK

(2 PLACES)

FILTER

(CCD-041/121 UNITS)


(©April, 2008)


1-7

1.5.1 Electric Box Access

The electrical components are protected behind the

front, hinged access door located on the right side of

the unit. The electric box door is locked in 2 places.

To open the access door, turn the door locks with the

triangular key wrench provided. The electric box door

is also safety interlocked with the main power service

disconnect switch preventing the door from opening

when the switch is in the “On” position. The switch

must be turned “Off” to gain access to the electrical

compartment.

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 unin-

tended operation.

1.5.2 Circuit Breakers / Motor Start Protectors

Individual overload protection is provided by circuit

breaker(s) and motor start protectors. These switches

must be manually reset once the overload condition

is cleared.

1.5.3 Heaters (Optional)

Heaters may be furnished for reheating the supply

air, as required to offset the sensible cooling of the

system during the dehumidifi cation cycle, and for

the automatic heating mode. As a standard, electric

resistance heating elements are factory installed in

the supply airstream to heat the supply air.

As an option, hot water reheat may be selected. A hot

water heating coil is factory installed in the supply air

stream to heat the supply air. A valve is provided to

control the fl ow of hot water through the coil to main-

tain the correct reheat temperature.

1.5.4 Coil(s)

The cooling and optional hot water reheating coils are

aluminum fi nned/copper tube construction. The coils

are leak tested and cleaned before installation by the

factory.

1.5.5 Blower

The unit is equipped with a centrifugal blower with

forward curved blades. The blower is dynamically and

statically balanced to minimize vibration. The blower

is contained in a double-width, double-inlet housing.

The blower motor is ODP industrial duty. Smaller

units, models CCU/D-41/121, use a direct drive blow-

er which may be adjusted via a fan speed controller

located in the electric box.

Larger units, models CCU/D-171/201 use a belt drive

blower. The motor is mounted on an adjustable base

for belt tensioning and is furnished with an adjustable

pitch sheave to adjust the blower speed.

1.5.6 Temperature/Humidity Sensor

As a standard for room air control, a temperature/hu-

midity (T/H) sensor is factory mounted in the return

air stream. The (T/H) sensor monitors the return air

conditions and provides input signal(s) to the system

controller to manage the operation of the A/C unit

consistent with the setpoints entered in the system

controller. As an option, sensor(s) may be shipped

loose for fi eld installation. Refer to the electrical

drawing supplied with your unit for details specifi c to

your system.

1.6 Optional Equipment

1.6.1 Humidifi er (Optional)

Mini-Space systems may utilize an optional elec-

trode, steam humidifi er. The humidifi er is factory

installed inside the air conditioner and includes fi ll

and drain valves and associated piping. Operation

of the humidifi er’s fi ll and drain cycles is based on

water conductivity and is maintained by the humidifi er

controller. An operating manual for the humidifi er is

provided under separate cover. Refer to that manual

for detailed information on operation of the humidifi er.

1.6.2 Condensate Pump

An optional condensate pump may be used for auto-

matic removal of condensate from the air conditioner

and fl ush water from the humidifi er. An internal over-

fl ow safety switch is wired to the system controller

to automatically shut down the precision A/C system

should an overfl ow occur.

1.6.3 Smoke Detector

Optionally mounted in the return air stream, a photo-

electric smoke detector is used to sense the pres-

ence of smoke and signal the controller when a

smoke alarm condition exists.

1.6.4 Firestat

Optionally mounted in the return air stream, a fi re de-

tector senses high return air temperature and signals

the controller when a fi re alarm condition exists.

(©April, 2008)



STRUCTURE R-VALUE

Ceiling R-38

Wall R-21

Floor R-19

Door R-5

2-1

2.0 INSTALLATION

2.1 Receiving the Equipment

Your Mini-Space precision A/C system has been

tested and inspected prior to shipment. To ensure

that your equipment has been received in excellent

condition, make a visual inspection of the equipment

immediately upon delivery. Carefully remove the ship-

ping container and all protective packaging. Open

the access panels/doors and thoroughly inspect the

unit interior for any signs of transit-incurred damage.

If there is shipping damage, it must be noted on the

freight carrier’s delivery forms BEFORE signing for

the equipment. Any freight claims MUST be done

through the freight carrier. SATS ships all equipment

FOB. SATS can assist in the claim fi ling process

with the freight carrier. Should any damage be pres-

ent, notify the SATS Product Support Group prior to

attempting any repairs. Refer to section fi ve of this

manual for instructions.

A unit Data Package has been sent with your unit. It

contains this manual, a supplemental microproces-

sor controller manual, system drawings, applicable

MSDS’s, other component manuals, warranty regis-

tration and other applicable instructions based on the

confi guration and options of your unit. The data pack-

age has been placed in your unit in a clear plastic

envelope. These documents need to be retained with

the unit for future reference.

NOTE

Items that have been shipped loose, such as

controllers, temperature sensors, water detec-

tors, buck/boost transformers etc., are shipped

inside the air conditioner unless specifi ed oth-

erwise by the customer. The duct connection

plate or plenum box (if applicable) are placed on

top of the air conditioner inside the unit’s carton.

Remove and store these items in a safe place

unless you are using them immediately.

2.2 Site Preparation

Mini-Space systems are designed with easy service

access in mind. Component access panels are lo-

cated on the front of the equipment. In order to have

full service access through the front hinged access

door, no permanent obstructions can be placed within

28 inches in front of the unit. (See Figure 3)

NOTE

Working clearance requirements need to be

established prior to the mounting of the unit.

Refer to local and national electrical codes.

To minimize the effects of the environment surround-

ing the conditioned space, certain steps must be

taken. This is especially true for critical/precision

room preparation (computer rooms/labs) requiring

close tolerance control of temperature and humidity.

The conditioned space should be well insulated and

include a vapor barrier. The installer should ensure

that the proper insulation rating is used based on the

design of the space, which was the basis for the sys-

tem selected. The following chart is a recommended

minimum R-value (thermal resistance) to ensure

optimum equipment operation.

The vapor barrier is the single most important

requirement for maintaining environmental con-

trol in the conditioned space. The vapor barrier in

the ceiling and walls can be a polyethylene fi lm.

Concrete walls and fl oors should be painted with a

Figure 3- Installation Clearance

2.0"

CONTROLLER

HIINGED ELECTRIC BOX

ACCESS DOOR

2.0"

28.0"

POP-OFF

ACCESS PANELS


(©April, 2008)


2-2

rubber or plastic based paint. Doors and windows

should be properly sealed and a door sweep used

to minimize leakage. Outside or fresh air should be

kept to a minimum (as it adds to the cooling, heat-

ing, dehumidifi cation and humidifying loads), while

maintaining the requirement of the Indoor Air Quality

(IAQ) standard. Lack of these steps can cause er-

ratic operation, unstable room control and excessive

maintenance costs.

2.3 Rigging

Mini-Space systems are designed to be kept in a

vertical position. Move the unit with a suitable device

such as a forklift, pallet jack or roller bar and dollies.

A weight table is provided on the installation drawing

provided with your unit for reference. The Mini-Space

unit is shipped on a skid to facilitate moving prior to

installation. The unit should always be stored indoors

in a dry location prior to installation.

CAUTION

When moving the unit, it must be kept level and

in the vertical position to prevent damage.

2.4 Mounting/Placement

Mini-Space systems that are not ducted, are de-

signed to be located in the conditioned space.

Ducted units may be located either inside or outside

the conditioned space but are designed to supply air

to only one room. Mini-Space units have a compact

footprint which allows the units to be placed in a cor-

ner or between cabinetry. It is recommended that the

unit be positioned to obtain optimum air circulation.

NOTE

Placement of the fl oor or ceiling registers is

important. If they are too close to the unit, the

supply air will be recirculated back to the unit

before it has circulated throughout the space.

See Figure 4. The unit is designed to be located on

top of the fl oor (typically upfl ow) or on a raised fl oor

(typically downfl ow).

CAUTION

Ensure the mounting surface is able to support

the weight of the equi[pment. On some raised

floor installations a floor stand is required,

depending on the load capacity of the existing

raised fl oor. Before mounting the unit, refer to

the weight table on the installation drawing.

Figure 4- Typical Installation

OPTIONAL 2 OR 3 WAY PLENUM BOX(FIELD INSTALLED)

OPTIONAL DUCT CONNECTION PLATE (NOT REQUIRED WITH PLENUM BOX)

UPFLOW

OPTIONAL FLOOR STAND

OPTIONAL TURNING VANE

OPTIONAL DUCT CONNECTION PLATE

DOWNFLOW

(©April, 2008)



2-3

2.4.1 Precision A/C Unit

See Figure 6. The Mini-Space precision A/C system

uses a frame and panel construction for unit rigidity

and full service accessibility while the unit is mounted

in place. Ensure the mounting surface is capable

of supporting the weight of the equipment. Before

mounting the unit, refer to the installation drawing for

the weight of your unit.

If a fl oor stand is selected refer to the installation

drawing provided and cut out the raised fl oor to

match the unit’s overall base dimension. If a fl oor

stand is not selected, use the installation drawing and

cut out the raised fl oor to match the blower discharge

opening and cut out the holes required for piping and

wiring through the raised fl oor.

NOTE

Equipment must be level to operate properly.

An optional duct connection plate may be shipped

loose for fi eld installation. To install the duct connec-

tion plate, place it on top of the A/C unit and attach it

with the supplied self-tapping screws. Holes are pre-

drilled in the unit and the connection plate.

2.4.2 Outdoor Equipment

Before installing outdoor equipment, refer to the

installation manual provided with the equipment.

Install the equipment (remote condenser, fl uid cooler,

pump package) in a secure location where it cannot

be tampered with and the service disconnect switch

cannot be inadvertently turned off. Provide a solid

base capable of supporting the weight of the equip-

ment. Mount the equipment to the base to prevent

it from moving during operation. It is recommended

that outdoor equipment be mounted with vibration

isolators to reduce the vibration transmitted to the

mounting surface.

Locate remote condenser/condensing units where

the blower(s) are not likely to draw dirt and debris

into the coil fi ns. There should be at least 24 inches

of clearance around the condenser to ensure ad-

equate airfl ow to the coil.

Install a pump package (if applicable) in accordance

with the installation manual and piping diagram pro-

vided with the unit. The pump should be at least 3 feet

below the height of the expansion tank. Do not form

piping loops adjacent to the pump. Avoid piping very

rigid lines.

2.5 Optional Equipment (Field Installed)

NOTE

Do not mount any optional equipment on unit

access doors.

2.5.1 Floor Stand

Install the optional fl oor stand directly on the sub-fl oor,

ensuring the side with the “FRONT” label is facing the

same direction as the front of the precision A/C unit (see

Figure 5). Refer to the fl oor stand assembly drawing

for the dimensions required to cut the raised fl oor. The

fl oor stand is designed with adjustable feet on all the

legs, allowing for leveling and overall height adjust-

ment. Refer to the fl oor stand assembly drawing for

minimum and maximum height adjustability of your

fl oor stand. To adjust the height, fi rst loosen the middle

nuts on each leg. Next, turn the top hex nuts to raise or

lower the fl oor stand. Once the fl oor stand is level and

even with the raised fl oor, lock all feet in place by tight-

ening the middle hex nuts against the top hex nuts.

2.5.2 Plenum Box Assembly

If an optional 2 or 3-way air distribution plenum box

is selected it is typically shipped loose. To install a

plenum box, fi rst apply a strip of sealing foam around

the top fl ange of the A/C unit or run a bead of silicone

sealant. Place the plenum assembly on top of the unit

(see Figure 4). Attach the plenum with self-tapping

screws (customer supplied). Holes are predrilled in the

unit and the plenum box. Remove the front grille for

access to the mounting holes.

Figure 5- Optional Floor Stand Installation

TURNING VANE

(OPTIONAL)

"FRONT" LABEL

THREADED ROD

MIDDLE HEX NUT

TOP HEX NUT

ISOLATION PAD

FLOOR STAND LEG


(©April, 2008)


2-4

2.5.3 Remote Display

The C1002 or C5000 Microprocessor controller is

supplied with the Mini-Space system. As an option, a

factory supplied control panel may be remote mount-

ed. For mounting and wiring instructions, refer to the

system drawings and supplemental controller manual

sent in the data package with your unit.

2.5.4 Condensate Pump

An optional factory installed condensate pump may

be provided for automatically eliminating condensate

and humidifi er fl ush water from the drain pan. The

condensate pump is typically installed by the fac-

tory inside the A/C unit. If an optional fi eld installed

condensate pump is selected, it should be located

as near as possible to the air conditioning system.

The pump should be positioned so the inlet hole in

the pump is below the drain pan inside the A/C unit.

Secure the pump in place with a mounting clamp or

use an adhesive that’s appropriate for the mounting

surface. Ensure the pump is level for proper opera-

tion.

2.5.5 Remote Temperature/Humidity Sensor

The remote (T/H) sensor must be located so that it

will properly sense the temperature/humidity condi-

tions to be controlled. Depending on the type of

control desired (see Section 2.5.5.1), the sensor(s)

may be factory mounted and/or shipped loose for

fi eld installation.

The T/H sensor should not be mounted near a door-

way, near or above any heat producing equipment

or in an area where it would be exposed to direct

sunlight. Follow the steps below to mount the sensor.

1. Using a fl at 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 mount-

ing slots.

3. Drill the mounting holes and insert the wall an-

chors provided.

4. Run the wires coming out of the wall through the

base, then secure the base with the screws provided.

5. Make the wiring connections. See Section 2.8,

Utility Connections and refer to the wiring diagram

supplied with your unit for details.

6. Replace unit cover plate on the base.

CAUTION

Take care not to damage the exposed tempera-

ture/humidity sensors on the PC board while the

cover is removed. The sensors can be damaged

if handled improperly.

2.5.5.1 Types of control

Room Air Control (standard)- The A/C unit is provided

with a temperature and humidity (T/H) sensor, factory

mounted in the return air stream of the A/C unit. The

return air temperature and humidity are monitored by

the system controller and compared to limit values set

at the factory. Control outputs are based on setpoints

entered into the system controller by the user.

As an alternative to locating the T/H sensor inside the

A/C unit, it may be fi eld installed on a wall in the con-

ditioned space for sensing actual room conditions.

Supply Air Control- (Optional only with C5000 system

controllers.) A fi eld installed T/H sensor may be used

for supply air control. The sensor is fi eld installed in

the supply air stream. The supply air temperature and

humidity are monitored by the system controller and

compared to limit values set at the factory. Control out-

puts are based on setpoints entered into the system

controller by the user.

Room Air Control with Supply Air Limitation- (Optional

only with C5000 system controllers.) The control-

ler monitors the T/H sensor located in the return air

stream and the T/H sensor located in the supply air

stream. Control is similar to “Room Air Control” except,

the temperature setpoint is automatically increased by

the controller when the measured supply air tempera-

ture exceeds the Start Temperature entered by the

user. The extent of the setpoint increase is determined

by a factor which the user enters in the controller as

a gradient. A high gradient signifi cantly corrects the

failure to meet the supply air tempertaure but has the

risk that the control circuit starts to hunt.

With humidity control, the setpoint shift acts in the

opposite direction. If the starting humidity entered by

COVER SCREW

(©April, 2008)



2-5

the user is exceeded by the measured supply air

humidity, the setpoint is autimatically reduced by the

controller. The user may also enter a gradient factor

for humidity control.

Formula:

New setpoint = old setpoint+ [gradient • (start value -ac-

tual value)]

Example (temperature): 70.5 = 70 + [0.5 • (61 - 60)]

Example (humidity): 49 = 50 + [0.5 • (70 - 72)]

Supply Air Control with Room Air Limitation- (Optional

only with C5000 system controllers.) Based on the

same principle as “Room Air Control with Supply Air

Limitation” however, in this case the setpoint shift

works in the opposite direction on the basis that the

supply air is colder than the return air. The tempera-

ture setpoint is automatically reduced by the system

controller when the measured room air temperature

exceeds the Start Temperature entered by the user.

The humidity setpoint is automatically increased

by the system controller when the measured room

humidity drops below the starting humidity entered by

the user.

2.5.6 Remote Water Detector

The remote water detector is normally placed on

the subfl oor or in a fi eld supplied auxiliary drain pan

located beneath the unit. SATS provides 2 types of

water detectors:

Spot type water detector-

Remove the protective cover and connect

two control wires to the terminals on the

base (terminal lugs are provided). Place

the water detector(s) on the fl oor with the

metal electrodes facing down. The base is provided

with a mounting hole in the center which may be

used to secure the water detector in place. Replace

the cover. When water is present, current will fl ow

between the electrodes.

NOTE

Do not place the spot type water detector on

an electrically conductive surface.

Cable type water detector-

Lay the cable water detec-

tor fl at across the subfl oor

where water could collect.

When water is present,

current will fl ow between

the two wires. A two conductor wire harness is provided

with a quick connect fi tting on the end. The harness

mates to the fi tting on the water detector and connects

it to the control board inside the electric box.

2.6 Air Distribution Connection

2.6.1 Downfl ow Confi guration Air Patterns

In a downfl ow confi gured unit the conditioned supply

air discharge is through the bottom of the unit into the

raised fl oor. There are two basic air patterns: top free

return and top ducted return (see Figure 6).

If ductwork is to be installed always consult your local or

state codes. The duct system should be designed to al-

low the air to move with as little resistance as possible.

The connection of ductwork to the unit is typically

accomplished with the addition of a factory installed

duct connection plate (refer to the installation drawing

provided with the unit). The connection of the duct to

the A/C unit may be made with self-tapping screws

(customer supplied).

Figure 6- Downfl ow Confi guration

Typical Air Patterns

RETURN AIR INLET

SUPPLY AIR OUTLET

RETURN AIR INLET

SUPPLY AIR OUTLET

TOP FREE RETURN TOP DUCTED RETURN

DUCT


(©April, 2008)


2.6.2 Upfl ow Confi guration Air Patterns

In an upfl ow confi gured unit the conditioned supply air has two methods of discharge from the top of the unit:

ducted or through a 2 or 3-way grilled plenum box. There are two basic return air patterns: front free return or

rear ducted return (see Figure 7). If ductwork is to be installed always consult your local or state codes. The

duct system should be designed to allow the air to move with as little resistance as possible.

Units with an optional, factory installed rear ducted return are provided with a duct fl ange for connection of the

ducting (refer to the installation drawing provided with the unit). The connection of the duct to the unit may be

made with either pop rivets or self-tapping screws.

Figure 7- Upfl ow Confi guration Typical Air Patterns

FRONT FREE RETURN REAR DUCTED RETURN

DUCT

SUPPLY AIR OUTLET

RETURN AIR INLET

SUPPLY AIR OUTLET

RETURN AIR INLET

TOP DISCHARGE WITH 2 OR 3 WAY PLENUM BOX

REAR DUCTED RETURN

SUPPLY AIR OUTLET

RETURN AIR INLET

SUPPLY AIR OUTLET

RETURN AIR INLET

DUCT

DUCT

FRONT FREE RETURN

DUCT

TOP DUCTED DISCHARGE

2-6

(©April, 2008)



Equivalent Length (ft) of Straight Pipe

OD (In.) Globe Angle 90º 45º Tee Tee

Line Size Valve Valve Elbow Elbow Line Branch

1/2 9.0 5.0 0.9 0.4 0.6 2.0

5/8 12 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 5.5 2.7 4.5 15

3 5/8 80 40 6.5 3.0 5.0 17

2-7

2.7 Piping Connections

2.7.1 Refrigerant

2.7.1.1 Self-Contained Systems

No refrigerant connections are required for self-contained,

water/glycol-cooled systems (models CC( )-041/201-W/G)

and chilled water systems (models CC( )-110/200-CW).

2.7.1.2 Split Systems

Split air-cooled systems with a remote condenser will

require fi eld installed refrigerant piping. All split systems

are shipped with a dry nitrogen charge of 50 psig.

NOTE

Mini-Space precision A/C units are not available

in a remote condensing unit confi guration.

Split systems coupled with a remote condenser will

require a copper discharge line and copper liquid line.

The following instructions should be followed to ensure

proper installation:

1. Loosen the two clamps located on the bracket in

the fl oor of the cabinet. Run the refrigerant lines

through the openings in the cabinet and then se-

cure them with the clamps. The clamps are labeled;

i.e. “Discharge”, “Liquid Line” to indicate which line

it secures.

2. Measure the distance to the refrigerant lines in the

cabinet. Mark each pipe and cut to length.

3. Join the piping together and solder using standard

refrigeration practices. Tighten the clamps.

All refrigeration piping should be installed with high

temperature soldered joints. Use standard refrigeration

practices for piping supports, leak testing, dehydration

and charging of the refrigeration circuits. The refrigera-

tion piping should be isolated from the building by the

use of vibration isolating supports. To prevent tube

damage when sealing openings in walls and to reduce

vibration transmission, use a soft fl exible material to

pack around the tubes.

Clear all pipe connections of debris and prepare the

connections for soldering. Use only “L” or “K” grade

refrigerant copper piping. Be careful not to allow solder/

piping debris to get inside refrigerant lines. Silver solder

containing a minimum of 15% silver is recommended.

Dry nitrogen should be fl owing through the tubing while

soldering at a rate of not less than 1-2 CFM (.03 - .06

M3/minute).

Refrigerant lines for split systems must be sized ac-

cording to the piping distance between the evapora-

tor and the condenser/condensing unit. Each valve,

fi tting and bend in the refrigerant line must be consid-

ered in this calculation. Refer to the following chart

provided for determining the standard equivalent

lengths, in feet, of straight pipe.

When installing remote condenser(s) above the

evaporator, the discharge line should include a shal-

low P-trap at the evaporator. The highest point in the

discharge line should be above the condenser coil.

An inverted trap is required on the discharge line at

the remote condenser to help prevent oil and liquid

refrigerant from fl ooding back to the compressor.

Oil traps must be included every 20 feet in the verti-

cal risers and the refrigerant lines must be sloped ¼

inch for every 10 feet in the horizontal lines to ensure

proper oil return to the compressor.


(©April, 2008)


2-8

Refer to line size charts provided below for recom-

mended line sizing.

*Equivalent Ft. accounts for the linear pipe length as well as

equivalent length of Valves, Elbows & Tee’s as shown in the chart

on the previous page.

NOTE

Vertical runs are based on a total rise of 30

equivalent feet. For longer sizes, individual

calculations must be made. Sizes assume

the use of single risers; double risers may be

necessary.

Consult the Copeland applications data guide for

more detailed information regarding refrigerant line

traps and line sizing.

2.7.2 Water/Glycol, Chilled Water and Hot

Water Reheat Piping

The piping connections for water/glycol, chilled water

systems and systems with optional hot water reheat

are sweat connections. Pipe sizes may not neces-

sarily be the same size as the unit connection. Piping

should be sized to match the required system pres-

sure drop and pump capacity (if applicable) and may

require reducing fi ttings to match the connection size

on the air conditioner.

Water/glycol/chilled water-cooled systems with low

entering fl uid temperatures 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.

CAUTION

When installing and fi lling the water/glycol/

chilled water loop and optional hot water re-

heat loop, all air must be bled from the piping

system.

CAUTION

The piping system must be fl ushed prior to op-

erating the system. Failure to do so will result

in equipment problems.

A strainer should be included in the water/glycol/

chilled water line and optional hot water reheat line.

Once the system is operational, the fl uid runs through

the strainer where any foreign objects are removed.

The strainer screen should be cleaned periodically.

2.7.3 Pump Package

Install a concentric reducer at the pump suction and

discharge openings and make all piping at least one-

(1) size larger than the diameter of the openings. If

a suction strainer necessary, install one with a net

area 2-3 times larger than the suction piping. The

piping leaving the drycooler should enter the pump

suction port. Install a check valve in the discharge

line to prevent back fl ow that may damage the pump

on shut down. Install a ball valve in the suction and

discharge lines for maintenance purposes.

Recommended Discharge Line Sizes

(For R22 or R407C Refrigerant)

Total Unit Equivalent Length Ft*

BTU/Hr 50’ 100’ 150’

Capacity or less or less or less

12,000 1/2 1/2 5/8

18,000 5/8 5/8 5/8

24,000 5/8 7/8 7/8

36,000 7/8 7/8 7/8

42,000 7/8 7/8 7/8

48,000 7/8 7/8 7/8

60,000 7/8 1-1/8 1-1/8

72,000 7/8 1-1/8 1-1/8

96,000 1-1/8 1-1/8 1-3/8

Recommended Liquid Line Sizes

(For R22 or R407C Refrigerant)

Total Unit Receiver to Evaporator (Equivalent Ft.*)

BTU/Hr 50’ 100’ 150’

Capacity or less or less or less

12,000 3/8 3/8 3/8

18,000 3/8 3/8 1/2

24,000 3/8 1/2 1/2

36,000 1/2 1/2 1/2

42,000 1/2 5/8 5/8

48,000 1/2 5/8 5/8

60,000 1/2 5/8 5/8

72,000 1/2 5/8 5/8

96,000 5/8 7/8 7/8

(©April, 2008)



2-9

2.7.4 Condensate Drain Line

2.7.4.1 Gravity Drain

A drain line is installed to drain the condensate pan. If

an optional humidifi er is used, the drain line from the

humidifi er is typically connected to the condensate

drain line. The end of the drain line is clamped inside

the cabinet. The installer must install a customer

supplied drain to the end of the drain line to remove

water from the cabinet. See the installation drawing

provided with your unit for the size and location of the

condensate drain line.

NOTE

During normal operation the humidifi er drains

(hot) water into the condensate drain line dur-

ing normal operation. As an option, a separate

drain line may be provided for the humidifi er.

The drain line must be located so it will not be ex-

posed to freezing temperatures. The diameter of the

drain line should be the full size of the connection.

NOTE

Pour some water into the condensate drain

pan(s) prior to start-up. This fi lls the trap and

prevents air from being drawn up the drain

lines.

2.7.4.2 Condensate Pump

An optional condensate pump is available for auto-

matic removal of condensate from the air conditioner

and fl ush water from the humidifi er. The pump is

typically factory installed inside the cabinet for CCU-

171& 201 systems. Otherwise, the condensate pump

must be fi eld installed.

If a fi eld installed pump is selected, a P-trap must

be installed for proper condensate drainage (see

Figure 8). 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

to prevent excessive back fl ow to the condensate

pump.

2.7.5 Humidifi er

Mini-Space precision A/C systems use an electrode

steam humidifi er. In most cases the humidifi er emp-

ties into the condensate drain line during the fl ush/

drain cycle. As an option, the drain for the humidifi er

may have a separate connection. Refer to the instal-

lation drawing provided with your unit for the size and

location of the connection.

A water supply line for the humidifi er must be con-

nected to the end of the copper tubing provided by

the factory. Refer to the installation drawing provided

with your unit for the size and location of the connec-

tion. The humidifi er requires normal tap water for the

water supply. If the supply water is high in particulate,

an external fi lter may be needed.

CAUTION Do not use demineralized water.

Refer to the humidifi er operator’s manual supplied

with the equipment, for complete manufacturer’s

information on the humidifi er and the supply water

recommendations.

INLET 7/8" OD

OUTLET 1/2" OD

NOTES:1. MIMIMUM HEIGHT IN INCHES.2. P-TRAP MUST BE LOCATED IN THE INLET SIDE OF PUMP WHEN FIELD INSTALLED.

2.00SEE NOTE 1

SEE NOTE 2

Figure 8- Condensate Pump


(©April, 2008)


2-10

2.8 Utility Connections

2.8.1 Main Power

The Mini-Space product offering is available in single

or three phase variations and a wide range of volt-

ages. It is imperative that the unit nameplate be

examined to determine the operating voltage, fre-

quency and phase of the system (see Figure 9). The

nameplate also provides the full load amps (FLA), the

current the unit will draw under full design load, the

minimum circuit ampacity (MCA) for wire sizing, and

the maximum fuse or HACR (Heating, Air Condition-

ing, Refrigeration) breaker size (MAX FUSE/CKT

BKR) for circuit protection. The unit’s nameplate is

located inside the cabinet within the electrical box.

NOTE

If the nameplate states MAX FUSE/CKT BKR, it

is required to use fuses or a HACR type circuit

breaker to protect the system. Other protection

devices are not allowed based upon the product

listing.

The unit is provided with terminals for all required

fi eld-wiring connections. Refer to the electrical drawing

supplied with the unit for all power and control fi eld-

wiring. It is important to identify the options that were

purchased with the unit in order to confi rm which fi eld

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

electrical code requirements. Use of copper con-

ductors only is required. Wiring terminations may

become loose during transit of the equipment

therefore; it is required to verify that all wiring

terminations are secure.

It is important to verify that the main power supply co-

incides with the voltage, phase and frequency informa-

tion specifi ed on the system nameplate. The supply

voltage measured at the unit must be within ±10% of

the voltage specifi ed on the system nameplate except

for 208/230V single-phase units which have a different

tolerance listed in the sections to follow.

A main distribution panel must be provided with a

manual fused disconnect switch or HACR type circuit

breaker per local and national electrical codes for

service to the equipment. Do not mount a customer

supplied manual fused disconnect switch or HACR

type circuit breaker to the surface of the A/C unit.

The unit is provided with a main power pilot hole and

a control wiring pilot hole for connection of the fi eld-

wiring conduits. Typically, these pilot holes are located

on the side of the Mini-Space cabinet. A label stating

“MAIN POWER INPUT” is placed in close proximity.

Terminate the main power wires at the line side of the

main power service disconnect switch located within

the electric box (see Figure 10). A separate equipment

ground lug is provided in the electrical box for termina-

tion of the earth ground wire.

Figure 8- Sample Nameplate

(©April, 2008)



2-11

2.8.1.1 Single-Phase Units 208/230V

The supply voltage for units that are designed for 208V

operation must have a tolerance within -5% and +10%.

If the measured supply voltage is 230V, the unit can

operate with a tolerance of ±5% if the following change

is made. The control transformers within the system

must have the primary wire connected to its respective

240V tap instead of the 208V tap.

2.8.1.2 Three-Phase Units

Three-phase units are designed to have the L1, L2 and

L3 supply wires connected to corresponding L1, L2

and L3 line terminals of the non-fused service switch.

The unit will operate correctly if the supply wires are

connected in this manner. A ground lug is provided in

each unit near the non-fused service switch. Prior to

unit operation, an adequate unit-to-earth ground must

be connected to the unit.

CAUTION

Improper wire connections will result in the

reverse rotation of the fans/blower motors and

compressor (if applicable) and may eventually

result in damage to the compressor. To correct

this problem, exchange any two of the incom-

ing main power wires at the main power service

switch. Do NOT rewire the unit’s individual

components.

2.8.2 Controls

Stulz Air Technology Systems offers a wide range of

control features to solve your air conditioning con-

trol/alarm requirements. The C1002 Microprocessor

is the standard controller for Mini-Space precision A/C

systems. As an option the C5000 controller is available

for certain special applications.

If the controller is mounted on the unit (standard), no

utility connection is required. As an option, the dis-

play may be factory supplied for remote mounting. A

cable harness is typically provided for the interconnect

wiring. Refer to Figures 11 and 12 and the electrical

drawing supplied with your unit for details on intercon-

necting the fi eld wiring.

2.8.3 Optional Equipment

NOTE

All wiring must be provided in accordance with

local and national electrical code requirements.

The size of the electric box and location of components

vary according to the Mini-Space model. Figure 10

shows a sample electric box layout and identifi es the

major components. The numbered callouts in Figure 10

coincide with the numbered items listed below:

1. Control Transformer

2. Power Switches/Motor Starter Protectors

(Quantity varies by size of A/C unit)

3. Fan Speed Controller (only on models with

direct drive blowers.)

4. Air Proving Switches

5. Control Interface Terminals

6. Main Power Disconnect Switch

7. Ground Lug

CAUTION

Prior to unit operation, an adequate unit-to-

earth ground must be connected.

Figure 10- Electric Box

4

6

7

5

2

1

3


(©April, 2008)


2-12


Systems supplied with a fi eld installed condensate

pump require power and control wiring to be con-

nected to the unit. After proper installation of the con-

densate pump, the installer must connect two power

conductors from the condensate pump main 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 A/C unit electric

box. The control wires from the terminal board in

the electric box should be run through the overfl ow

switch in the condensate pump housing. The conden-

sate pump is equipped with pigtail leads for splice-

type wire connections with twist-on connectors (wire

caps). Refer to the electrical schematic supplied with

your unit for proper wire terminations.

2.8.3.2 Remote Temperature/Humidity Sensor

Each remote temperature/humidity sensor requires a

three conductor shielded cable with the shield being

terminated at the unit electric box. Both the electric

box and the sensor include a terminal strip with box

type lugs for wire connections. Refer to the electri-

cal drawing supplied with your unit for proper wire

terminations.

2.8.3.3 Remote Water Detector

Each remote water detector used will require two

conductors to be wired to the control terminal board

within the unit electrical box. The wire insulation must

be rated at 600V. Refer to the electrical drawing sup-

plied with your unit for proper wire terminations.

2.8.4 Split Systems

The following system interconnecting fi eld wiring

sections detail the number of conductors required for

a typical system. Additional control conductors may

be required depending on the options purchased with

the equipment. Refer to the supplied electrical sche-

matic to determine the total number of interconnect-

ing conductors required for your system. It is impor-

tant to note that the control transformer(s) supplied

with the equipment have been sized and selected

based upon the expected loads for each system.

CAUTION

Do not connect any additional loads to the

system control transformers. Connecting ad-

ditional loads to the factory supplied control

transformer(s) may result in overloading of

the transformer(s).

NOTE

All wiring must be provided in accordance with lo-

cal and national electrical code requirements.

2.8.4.1 Remote Condenser

Systems equipped with a remote condenser will

require fi eld wiring between the A/C unit and the

remote condenser (see Figure 11). Refer to the

electrical drawing supplied with your unit and the

wiring diagram supplied with the condenser (typically

located in the condenser electric box). The installer

must provide main power wiring to the main power

distribution block located within the remote con-

denser 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 the A/C unit to the control

terminal board within the remote condenser electric

box. Refer to the electrical drawing for the correct

number of fi eld wires needed and for the appropriate

wire terminations required for your specifi c unit.

2.8.4.2 Glycol Systems

Systems equipped with a glycol-cooled system/pump

package require fi eld wiring between the glycol unit

and pump package (see Figure 12). The installer

must wire two control conductors from the terminal

board within the glycol unit, to the pump package

electrical box. Refer to the electrical drawing supplied

with your unit for the number of fi eld wires needed

and appropriate wire terminations required for your

specifi c system.

(©April, 2008)



2-13

Figure 11- Interconnecting Field Wiring- Remote Condenser

2. NUMBER OF CONDUCTORS VARY DEPENDING ON NUMBER OF FAN MOTORS.

1. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES.IRES ( )

NOTES:

AIR COOLED CONDENSER

WITH NFPA 70, N.E.C.)

INTERCONNECTING FIELD WIRING

(TO BE INSTALLED IN ACCORDANCE

24VAC

208-460V/1PH-3PH/60Hz

MAIN POWER SUPPLY

L2

L3

L1

SEE NOTE 2

MODELS CCU/D-041/201-AR

MAIN POWER SUPPLY

208-460V/1PH-3PH/60Hz

L1




Figure 12- Interconnecting Field Wiring- Glycol Systems


INTERCONNECTING FIELD WIRING(TO BE INSTALLED IN ACCORDANCE

MAIN POWER SUPPLY208-460V/1PH-3PH/60Hz


24VAC

(GLYCOL UNITS ONLY)PUMP PACKAGE

ELECTRICBOX

SEE NOTE 2WITH NFPA 70, N.E.C.)


MAIN POWER SUPPLY208-460V/1PH-3PH/60Hz

DRYCOOLER

L1 L1

2. NUMBER OF CONDUCTORS VARY DEPENDING ON NUMBER OF FAN MOTORS.1. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES.

NOTES:

MODELS CCU/D-041/201-W/G


(©April, 2008)


2-14

2.9 System Charging Procedures

2.9.1 R22 Refrigerant Charging Procedures

Refrigerant charging procedures vary depending on

the type of refrigerant used in the unit. Before charg-

ing, check the unit nameplate to confi rm the refriger-

ant type. If the unit operates with R22 refrigerant see

section 2.9.1. If R407C is used, see section 2.9.2.

NOTE

Refrigerant charging must be performed by a

journeyman, refrigeration mechanic or an air

conditioning technician.

2.9.1.1 Self-Contained Systems

All self-contained water/glycol cooled units (units that

require no refrigerant fi eld piping) are factory charged

with R22. No fi eld charging is required.

2.9.1.2 Remote Air Cooled Split Systems

Remote air cooled units are delivered from the fac-

tory with a dry nitrogen holding charge which must be

removed before piping and charging the unit.

PREPARING SYSTEM FOR CHARGING

1. Once all connections have been made, pres-

surize the system to 150 psig with dry nitrogen.

Leaks may be detected by checking the standing

pressure.

2. After ensuring there are no leaks, relieve pres-

sure and evacuate the 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 minimum. Ensure no portion of system

has been isolated from the evacuation process

(liquid, suction or discharge lines).

CAUTION

A proper vacuum must be drawn on the refrigerant

system prior to charging. If this is not done the refrig-

erant will combine with the moisture in the pipes to

form an acid that will eventually cause compressor

failure.

FINE TUNING THE SYSTEM CHARGE

2.9.1.2.1 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 air from hoses and “break” the system vac-

uum by supplying R22 vapor. Supply R22 vapor

to the suction port until the pressure is raised to

about 50 psig. This small holding charge allows

the low pressure switch to “make” through out

the process of fi ne tuning the system charge.

WARNING

Do not add liquid R22 refrigerant to suction

side of system.

2. Referring to Section 3.0, start the system and

use the system controller to lower the tempera-

ture set-point 3-5°F below room temperature.

This will ensure the cooling mode stays on during

the charging procedure.

CAUTION

An adequate heat load must be supplied to the

unit to ensure a proper charge.

3. Supply R22 vapor to the suction port until the

liquid line sight glass is cleared of all bubbles.

4. After the unit has stabilized, the liquid line sight

glass should be clear and the discharge pressure

should be a minimum of 200 psig. A superheat

reading should be taken on the suction line near

the feeler bulb from the thermal expansion valve,

ensuring the temperature-measuring device is

well insulated. The superheat should be approxi-

mately 12-15ºF. Maximum allowable superheat

temperature is 20°F

5. A subcooling reading should be taken on the

output side of the condenser, with the tempera-

ture measuring device being well insulated. The

sub-cooling temperature should be approximately

10-20ºF.

NOTE

Under cold climate conditions it is recom-

mended to do the following:

(©April, 2008)



6. Block off the intake air to the condenser with

cardboard (or reduce the water glycol fl ow) until

a constant discharge pressure (225-280 psig)

can be obtained. This will lower the possibility of

overcharging and avoid the occasional bubbles

that may appear in the sight glass during fan

cycling (for units with fan cycling only).

7. If the unit has a hot gas reheat option, the previ-

ous steps are still followed except the hot gas

reheat valve must be opened to allow refrigerant

to fl ow into the reheat coil to obtain the proper

amount of unit charge. This process may need to

be repeated several times, which can be done by

enabling a call for dehumidifi cation. After cycling

the system through the hot gas reheat cycle, re-

check the system charge in the COOLING-ONLY

mode.

8. Ensure the crankcase heater is operational by

checking the amperage.

CAUTION

Remove the blockage to the air intake of the con-

denser (or restore the water/glycol fl ow).

9. Fill out applicable blocks of Warranty Registration

and Start-Up Checklist.

2.9.1.2.2 -30ºF Flooded Head Pressure Control

The following instructions are for charging systems with

fl ooded head pressure control using R22 refrigerant.

1. Bleed air from hoses and “break” the system vacu-

um by supplying R22 liquid to the service valve of

the receiver until the receiver is full. Then supply

R22 vapor to the suction port until the pressure

is raised to about 50 psig (low pressure switch

makes).

2. Start the system and use the microprocessor

controller to lower the temperature set point

3-5°F below room temperature. This will ensure

cooling remains on during the charging proce-

dure.

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 it constant by blocking the air intake of

the condenser.

5. Once the discharge pressure has stabilized for 5

to 10 minutes, additional refrigerant R22 vapor

must be added to the suction port until the “fl oat

ball” in the level indicator of the receiver begins to

fl oat.

CAUTION

Remove the blockage to the air intake of the con-

denser.

6. Take a superheat temperature reading on the

suction line near the feeler bulb from the thermal

expansion valve. The ideal superheat tempera-

ture is 12-15°F. The maximum allowable super-

heat temperature is 20°F.

7. Ensure that the crankcase heater is operational

by checking the amperage.

8. Fill out applicable sections of the Warranty Regis-

tration and Start-Up Checklist.

2.9.2 R407C Refrigerant Charging Procedures

R407C is a blended refrigerant recognized for being

safer for the environment. R407C refrigerant contains

no chlorine, the component in HCFC’s that destroy

the earth’s ozone layer. The same care should be

taken to prevent leakage however, because R407C

can contribute to the greenhouse effect if released.

Refrigerants that are multi-component blends have

component parts with different volatilities that result in

a change in composition and saturation temperature

as evaporation and condensation occur. Typically, the

composition of R407C vapor is different than that of

R407C liquid within a contained system. The compo-

sition of liquid R407C refrigerant remains relatively

constant however, the refrigerant vapor tends to

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 composition, intro-

duce R407C into the system in liquid form rather than

2-15


(©April, 2008)


2-16

vapor form. Cylinders which are not provided with dip

tubes should be inverted to allow only liquid refriger-

ant to charge the system. Keeping the temperature of

the cylinder below 85°F will help maintain the correct

refrigerant composition while the cylinder is emptied.

CAUTION

POE oil is used in systems with R407C refrig-

erant. POE oil quickly absorbs moisture when

exposed to air. High POE oil moisture levels

react with refrigerant to form acid, which results

in system contamination. Keep the entire sys-

tem sealed as much as possible and minimize

exposure of POE oil to outside air.

Familiarize yourself with the charging procedures

discussed in Section 2.9.1 of this manual. Instead of

adding R22 vapor to the suction port as described

under “Preparing System for Charging”, the initial

charge will be performed by introducing R407C liq-

uid to the discharge side of the compressor. (See the

following steps.)

PREPARING SYSTEM FOR CHARGING

1. With all the system piping connections made,

perform a dry nitrogen leak detection test on the

system. Using dry nitrogen only, pressurize the

system to 150 psig. Since there is no refrigerant

in the system to detect, leaks may be detected by

observing the standing pressure.

2. After ensuring there are no leaks, evacuate the

system to 50 microns and hold the vacuum for 2

hours minimum.

3. Break the vacuum by supplying R407C liquid to

the discharge port near the compressor until the

pressure is raised to about 50 psig. This small

holding charge allows the low pressure switch

to “make” through the process of fi ne tuning the

system charge.

FINE TUNING THE SYSTEM CHARGE

4. Disconnect the refrigerant cylinder from the dis-

charge side of the compressor and connect it to

the suction side.

5. Referring to Section 3.0, start the system and

use the microprocessor controller to lower the

temperature setpoint 3-5°F below room tempera-

ture, ensuring cooling remains on as the unit is

charged.

6. Allow the discharge pressure to rise to 225-280

psig and hold it constant. On cool days it may be

necessary to restrict the airfl ow across the con-

denser (or reduce the water glycol fl ow), to raise

the pressure.

7. Slowly meter R407C liquid refrigerant through the

suction side while watching the sight glass to clear

of bubbles.

CAUTION

Add liquid refrigerant slowly to prevent the refrig-

erant oil from “washing out” of the compressor.

8. Take a superheat temperature reading on the

suction line near the feeler bulb from the thermal

expansion valve. The ideal superheat tempera-

ture is 12-15°F. The maximum allowable super-

heat temperature is 20°F.

9. While monitoring the sight glass, take a subcool-

ing temperature reading on the output side of the

condenser. The subcooling temperature should

be 10-20°F.

10. If necessary, add liquid refrigerant to maintain

adequate subcooling temperature.

2.9.2.1 Flooded Head Pressure Control Systems

In units with R407C refrigerant using fl ooded head

pressure control, a receiver is provided to store the

refrigerant during the time the condenser is not using

the extra refrigerant charge. Once a clear sight glass

has been achieved, additional refrigerant must be

added to the receiver.

A level indicator is located on the side of the re-

ceiver to assist the service technician in charging

the air conditioning system. The proper charge can

be determined by viewing the position of the “fl oat

ball” while the unit is running. If the “fl oat ball” is

positioned at the bottom of the sight indicator, addi-

tional refrigerant charge is needed. When the “fl oat

ball” reaches the top of the indicator, the unit is fully

charged.

(©April, 2008)



2-17


Air Cooled Systems

2.10.2.1 Condenser Fan Cycling

(Condenser Model SCS-AA, 0°F)

Used for outdoor installations where ambient con-

denser air inlet temperatures are 0°F or higher, this

method utilizes a high-pressure differential control

switch with SPST (Single Pole, Single Throw) con-

tacts and an automatic reset. The switch activates

the condenser blower contactor when the discharge

pressure reaches 275 psig to maintain the condens-

ing temperature.

Factory setting: Switch contacts are set to close on

a pressure rise to 275 psig and open at 205 psig.

Setpoint range is 170 to 375 psig. The differential is

non-adjustable and set at 70 psi.

2.10.2.2 Condenser Multi-Speed Fan Switch

(Model HES-CAA , 0°F)

Used for indoor installations where ambient con-

denser air inlet temperatures are 0°F or higher, the

condenser fan speed switch senses refrigerant dis-

charge pressure and changes the condenser blower

speed to maintain proper condenser pressures. The

condenser fan speed switch changes the fan (blower)

from low to high speed at approximately 325 psig and

returns the fan (blower) from high speed to low speed

at approximately 255 psig.

Factory setting: On pressure rise, the high fan speed

contacts are set to close at 325 psig. This will increase

the condenser fan speed. A pressure drop to 255 psig

will close the low fan speed contacts and reduce the

fan speed. Set point range is 170 to 400 psig. The dif-

ferential is nonadjustable and set at 70 psi.

NOTE

This switch and settings does not apply to units

designed for a power supply greater than 277V.

2.10.2.3 Variable Condenser Fan Speed

(Condenser Model SCS-SA, -20°F)

Used for outdoor installations where ambient tempera-

tures may fall to -20°F, a variable speed condenser

motor 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 con-

tinual modulation of the motor’s speed. The controller is

2.9.3 Water/Glycol Systems

In water/glycol cooled units the refrigerant system is

already charged with R22 or R407C. The following

precautions must be observed when installing and

fi lling the water/glycol loop:

• The piping system must be cleaned prior to

adding wate/glycol to the system.

• Glycol must be mixed with water before it is

added to the system. All air must be bled from the

piping system. Use only water/glycol solution with

inhibitors for corrosion protection.

1. Open the vent valve at highest point of the sys-

tem.

2. Fill the system until the solution is discharging

from the vent with minimal signs of foaming due to

air in the system.

2.9.3.1 Pump

If a pump is to be used, ensure the system is fi lled

before turning the pump on. The pump is not self-

priming so it is important that there is a pressure on

the suction inlet.

CAUTION

Do not run the pump dry.

If the pump has no pressure on the discharge side,

leave the discharge valve partially shut to create a

back pressure in the pump so that liquid can build up

in the impeller housing to keep the impeller housing

from getting too hot. Make sure there is always liquid

fl owing through the pump to cool the impeller and

housing. If there is no liquid leaving the pump, shut

the pump off immediately to prevent damage to the

pump. Check for proper rotation of the motor observ-

ing the arrow on the side of the impeller.

2.10 System Settings and Adjustments

2.10.1 Low/High Pressure Limit Switch

Air conditioning systems utilizing thermal expansion

valves are equipped with hermetically sealed high-

pressure and low-pressure switches. These switches

are preset by the manufacturer and cannot be ad-

justed. The high-pressure switch opens at 410 psig

and has a manual reset. The low-pressure switch

opens at 10 psig (± 4) and closes at 32 psig (± 5) and

has an automatic reset.


(©April, 2008)


2-18

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.

2.10.2.4 Intelligent Control

(Condenser Model SCS-EC only, -20°F)


denser air inlet temperatures may fall to -20°F, intelli-

gent pressure control is designed to maintain dis-

charge pressure by constantly modulating condenser

fan speed. SCS outdoor condensers are equipped

with highly effi cient, electronically commutated (EC),

axial fan(s). The EC fan speed is infi nitely variable

up to full speed. The control system utilizes refriger-

ant pressure transducer(s) to monitor refrigerant

discharge pressure and control the EC fan(s) to the

precise speed needed to maintain design refrigerant

discharge pressures.

2.10.2.5 Flooded Head Pressure Control

(Condenser Model SCS-AA with Fan

Cycling, -30°F)


denser air inlet temperatures may fall to -30°F, fl ood-

ed head pressure control is designed to maintain

head pressure during low ambient conditions. A head

pressure control valve and a receiver are used in the

refrigeration circuit to back up liquid refrigerant into

the condenser coil. The head pressure control valve

is a 3-way modulating valve controlled by discharge

pressure.

When the A/C unit begins to operate, the discharge

pressure rises to 275 psig and the condenser fan is

cycled on, as described in Section 2.10.2.1. When

ambient temperature drops, the discharge pressure

drops also. When the discharge pressure drops to

approximately 180 psig, the head pressure control

valve diverts discharge gas away from the condenser

to the receiver. Liquid fl ow from the condenser is

restricted, causing liquid to back up in the condenser.

Flooding the condenser reduces the area available

for heat transfer. The desired result is to increase the

pressure into the condenser, maintaining a minimum

discharge pressure during low ambient operation

thus ensuring proper condensing temperature. The

head pressure control valve requires no adjustment.

This method of controlling head pressure allows the

condenser fan to run continuously. While the fan is

running, the fl ooded head pressure control valve

modulates the amount of discharge gas entering the

receiver. As the pressure increases, the valve diverts

more discharge gas to the condenser, allowing more

liquid to fl ow from the condenser to the receiver.

When using this method of head pressure regulation

there must be enough refrigerant in the system to en-

sure adequate charge at the lowest expected ambient

temperature in which the system will be operating. A

receiver is used to store the extra refrigerant when the

condenser is not using it.

NOTE

Systems utilizing air cooled condensers must not

have a refrigerant line pressure drop over 14 psig

across the condenser and the interconnecting

piping to the condenser sections.

2.10.2.6 Flooded Head Pressure Control

(Condenser Model HES-CAA , 30°F)

Used for indoor installations where ambient condenser

air inlet temperatures may fall to -30°F. First, familiar-

ize yourself with Flooded Head Pressure Control as

discussed in Section 2.10.2.5. Instead of cycling the

fan on and off, the condenser fan speed is continuous.

The head pressure control valve diverts discharge gas

to the receiver causing liquid to back up in the con-

denser, as described in Section 2.10.2.5, while the fan

continues to run.


Water/Glycol Cooled Systems

In a water/glycol condenser, condensing temperature

is maintained by the liquid fl owing through a regulat-

ing valve and then into a liquid-cooled condenser. The

regulating valve opens to increase the liquid fl ow as

the refrigerant pressure rises (or closes as the refriger-

ant pressure falls). The regulating valve is factory set

for the correct condensing temperature however, it can

be adjusted to increase or decrease the condensing

temperature.

Head pressure regulating valves are available in 2-way

or 3-way confi gurations. Refer to the piping diagram to

(©April, 2008)



2-19

determine which type 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 differs with the valve types

which can be differentiated by the maximum water

pressure rating of the valve, (150, 350, or 450 psig).

2.10.3.1 150 psig Pressure Valves

Adjustment is made by turning the slotted square stem

on top of the valve clockwise to increase the condens-

ing temperature or decrease water/glycol fl ow and

counterclockwise to decrease the condensing tem-

perature or increase the water/glycol fl ow. A directional

arrow is stamped on the metal housing of the valve

stem.

2.10.3.2 350 psig and 450 psig

High Pressure Valves

Adjustment is made by turning the round-holed knob,

located inside the valve’s metal housing counterclock-

wise to increase condensing pressure or decrease

water/glycol fl ow and clockwise to decrease the con-

densing temperature or increase the water/glycol fl ow.

A directional arrow is stamped on the metal housing of

the valve stem.

2.10.4 Humidifi er Adjustment

The humidifi er has an adjustable capacity potentiom-

eter on the humidifi er control circuit board. The poten-

tiometer may need to be fi eld adjusted if the humidifi er

is not supplying enough capacity for the current room

conditions.

It is recommended that if the humidifi er capacity poten-

tiometer requires adjustment, the adjustment is made

in small increments and verifi ed. Refer to the humidi-

fi er manual sent with your unit for the capacity potenti-

ometer location.

CAUTION

Adjusting the capacity potentiometer too high

may result in the formation of condensate in the

system.

2.10.5 Blower Adjustment

The blower speed may be adjusted to the specifi c

static pressure and CFM requirements of the area in

which the A/C unit is installed. There are two methods

of adjusting the blower speed depending on whether

the blower is direct drive (CCU/D-41-121) or belt drive

(CCU/D-171-201).

CAUTION

Adjusting the blower speed too low may cause

ice to form on the evaporator coils or cause the

electric reheating coils to overheat.

2.10.5.1 Direct Drive Blower

Systems with direct drive blowers are furnished with a

speed controller located in the electric box (see Figure

10). Blower motor speed is adjusted via two potentiom-

eters labeled PHI 1 and PHI 2 on the speed controller

PC Board (see Figure 13).

Potentiometer PHI 1 adjusts blower speed for operat-

ing the unit when dehumidifi cation is not required (non-

dehumidifying speed). Potentiometer PHI 2 adjusts

blower speed for operating the unit when dehumidi-

fi cation is called for. Blower speed for dehumidifi ca-

tion should always be slower than non-dehumidifying

blower speed to ensure dehumidifi cation does occur.

The potentiometers have the same control range to

adjust the motor’s speed from a minimum RPM to the

full rated RPM.

Two LED’s on the speed controller PC board indicate

which potentiometer is controlling blower motor speed.

When the system is in a non-dehumidifying mode, LED

I1 illuminates indicating that PHI-1 is controlling the

blower speed. When the system is dehumidifying, LED

I2 illuminates indicating that PHI-2 is controlling the

blower speed.

2.10.5.2 Belt Drive Blower

See Figure 14. Systems with belt drive blowers are

supplied with adjustable sheaves to change the blower

speed and adjustable motor bases for belt tensioning.

Use the following procedure to change the blower speed:

1. Turn system off.

2. Turn off all power to unit at the main power service

disconnect switch; use lock-out tag-out procedure.

Figure 13- Blower Speed Controller


(©April, 2008)


2-20

3. Loosen the locking bolt on the side of the motor

base. Turn the jam nut away from the lockdown

plate. Rotate the tension rod to move the motor

on its’ base to release belt tension.

4. Remove the blower belt(s).

5. Loosen the set screw in the side of the sheave

with an Allen wrench.

6. Remove the sheave key.

7. Adjust the blower speed by closing the sheave

one half turn to increase speed or opening the

sheave one half turn to decrease speed.

8. Replace the sheave key and tighten set screw.

9. Replace the blower belt.

10. Proper belt tension is achieved when the belt

has a defl ection of ¾ inch per foot of span with a

fi rm pressure placed on the blower belt between

the blower and motor pulley. Rotate the tension

rod to move the motor on its’ base to increase or

decrease belt tension. Retighten the jam nut and

tighten the locking bolt on the motor base.

CAUTION

If the belt tension is too tight, it will cause pre-

mature blower and/or motor bearing failure. If

the belt is too loose, the belt will slip and cause

belt squeals and eventual belt failure.

11. Restore power to system.

12. Check the current draw on the blower motor to

ensure it does not exceed the nameplate rating

of the motor.

13. If current draw exceeds the nameplate rating of

the motor repeat steps 1 through 12. If the motor

still draws too much current, slow the blower

down by opening the adjustable sheave one

half turn at a time until the motor current is at or

below the nameplate FLA.

14. Check the motor overload on the blower starter

to confi rm its setting is correct for the FLA of the

motor.

2.10.6 Thermal Expansion Valve

Mini-Space precision A/C units utilize a Thermal

Expansion Valve (TEV). The TEV maintains constant

superheat of the refrigerant vapor at the outlet of the

evaporator by metering the fl ow of refrigerant into the

evaporator. Superheat is the difference between the

refrigerant vapor temperature and its saturation tem-

perature at a given suction pressure. By controlling

superheat, the TEV keeps nearly the entire evapora-

tor surface active while preventing liquid refrigerant

from returning to the compressor. As a standard,

superheat is factory set at 12-15°F and should not

need adjustment.

2.10.7 Hot Gas Reheat (Optional)

The hot gas reheat option incorporates a hot gas

reheat solenoid valve and a hot gas reheat coil.

Under normal operation when no reheat is required,

the hot gas reheat valve is de-energized and hot gas

fl ows directly from the compressor discharge to the

condenser. When there is a call for reheat, the con-

troller energizes the hot gas reheat solenoid valve.

The hot gas reheat solenoid valve diverts hot gas to

the reheat coil, mounted directly downstream of the

evaporator coil, before it travels to the condenser. No

adjustment to the valve is necessary.

2.10.8 Snap Acting Hot Gas Bypass

(Optional)

The snap acting hot gas bypass system provides

some modulated capacity control and freeze protec-

tion. The hot gas bypass system includes a discharge

bypass valve that allows some hot gas from the com-

pressor discharge line to pass into the evaporator coil

in order to maintain a preset suction pressure.

The snap acting hot gas bypass system also pro-

vides freeze protection for the evaporator coil by

limiting the minimum refrigerant pressure, thereby

preventing the surface temperature of the evaporator

coil from dropping below 32°F.

Figure 14- Belt Drive Blower

MOTOR

BASE

MOTOR

TENSION ROD

ADJUSTMENT

BLOWER

LOCK DOWN

PLATE

ADJUSTABLE

PULLEY

JAM NUT

BASE LOCKING

BOLT

(©April, 2008)



2-21

The normal control setting is 50-55 psig (suction

pressure) read from 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.

CAUTION

Do not exceed 20°F superheat. Exceeding this

temperature may cause failure of the compres-

sor.

2.11 Refrigerant Characteristics

2.11.1 Pressure/Temperature Settings

The following charts are provided to assist with the

normal settings of the system for R22 and R407C

refrigerant. Where applicable minimum and maxi-

mum settings are given along with normal operating

pressures.

(Saturated

Vapor)

(Saturated

Liquid)

R22 Refrigerant

Temp. Pressure

(°F) (psig)

20 43.2

22 45.5

24 47.8

26 50.2

28 52.6

30 55.1

32 57.7

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

Subcooling

95 206

100 222

105 239

110 257

115 275

120 294

125 315

130 336

135 358

140 381

Bubble

Point

Dew

Point

Pressure/Temperature Settings for R22 & R407C

Normal Min. Max.

Subcooling °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 (°F) 130 105 140

Suction Pressure (psig) 70 58 84

Condenser Fan Switch ON Air Cooled (psig) 275 265 285

Condenser Fan Speed Air Cooled (psig) 325 - -

Opens Closes

Low Pressure Switch (psig) 10 32

High Pressure Switch (psig) 410 Manual Reset

2.11.2 Saturated Refrigerant Pressure

Tables

The following refrigerant pressure tables are provided

for reference.


(©April, 2008)


3-1

3.0 START-UP/COMMISSIONING

3.1 Operation

For new installations, ensure the unit is ready to

operate by going through the Checklist for Completed

Installation, located in Appendix A, prior to start-up.

NOTE

A Warranty Registration and Start-Up Checklist

is provided in the unit data package. It should

be completed during start-up and sent to SATS.

This checklist should be used as a guideline for

items that need to be confi rmed during start-up.

Start-up must be performed by a journeyman, refrig-

eration mechanic or an air conditioning technician.

3.2 Step-by-Step Start-Up Instructions

CAUTION

For air-cooled outdoor condensers, apply pow-

er to the condenser eight hours before operat-

ing system. This time is required to allow liquid

refrigerant to be driven out of the compressor.

The compressor crankcase heater is ener-

gized as long as power is applied to the unit.

1. Replace all access panels and equipment re-

moved prior to performing the start-up checks.

2. Apply power to the precision A/C system at the

main power disconnect switch. Turn the system

on at the controller.

3. Ensure that all blowers and fans are rotating cor-

rectly and freely without any unusual noise.

NOTE

The compressor may have a time delay on start-

up.

Water/glycol-cooled units have a head pres-

sure regulating valve that has been factory

set. A valve adjustment may be required

based on water temperatures or water/glycol

fl ow conditions at your site. (Refer to Section

2.9.5 for making adjustments.)

4. Test cooling operation by adjusting the tempera-

ture setpoint below the actual room temperature.

The compressor should come on and the dis-

charge air should feel cooler than the return air.

5. Test heating operation by adjusting the tempera-

ture setpoint above the actual room temperature.

The source of heat should be energized to in-

crease discharge air temperature.

6. Test humidifi cation operation by creating a de-

mand for humidifi cation. Use an amp meter to de-

termine current draw of humidifi er. A visual check

of the humidity leaving the steam head or feeling

the cylinder to ensure it’s warming can also indi-

cate if the humidifi er is operational. In all cases, 1

to 6 hours might be required to see a desired level

or rise of humidity in the conditioned space. Once

room conditions have been programmed or set, a

repeat visit to the conditioned site may be required

to ensure the humidifi er is meeting the rooms’

requirements.

7. Test dehumidifi cation operation by creating a de-

mand for dehumidifi cation. Decrease the dehumid-

ifi cation setpoint 10% below the actual room condi-

tions. The compressor circuit will be energized to

begin the dehumidifi cation process. While in this

mode, the room temperature may decrease and

the reheat function may activate. As conditions in

the room change, you may have to

readjust the setpoint as you check the operation.

An adequate heat load within the space is re-

quired.

8. For Electric Reheat, use an amp meter on the

heater circuit to determine if heater is operational.

For Hot Gas Reheat, utilize a voltmeter and a point

to point method, ensure the control signal has

energized the hot gas reheat solenoid coil. For Hot

Water or Steam Reheat ensure that the control

signal has energized the control valve and the

temperature of the steam or water has decreased

as it passes through the unit.

In all cases 1 to 6 hours might be required to see

a desired level or decrease of humidity in the

conditioned space. Once room conditions have

been programmed or set, a repeat visit to the

conditioned site may be required to ensure the de-

humidifi cation mode is meeting the rooms’ require-

ments.

3.3 Microprocessor Controller

Programming

The microprocessor controller is factory programmed

based on the optional features selected. Most applica-

tions require no fi eld start-up or program adjustment

beyond setting the current date and time. Separate op-

erating instructions for the controller have been sent with

your unit, including each feature’s factory “default” setting

and the available adjustment range, if applicable.

(©April, 2008)



4-1

4.0 MAINTENANCE

4.1 Periodic General Maintenance

Systematic, periodic general maintenance of the pre-

cision A/C unit is recommended for optimum system

performance. General maintenance should include,

but is not limited to the following: replacing fi lters and

humidifi er cylinders, tightening electrical connections,

checking the condensate line to ensure it is free of

debris, cleaning the interior of the unit, inspecting the

units’ components visually, checking the blower as-

sembly, checking level of refrigerant and ensuring no

moisture is in the refrigerant.

Use copies of the Periodic General Maintenance

Checklist in this manual (see Appendix A) to record

periodic general maintenance inspections. For as-

sistance, contact the SATS Product Support Group.

Ensure adherence to all safety statements while

performing any type of maintenance.

WARNING

This equipment should be serviced and re-

paired by a journeyman or a qualifi ed refrigera-

tion technician only.

WARNING

This unit employs high voltage equipment with

rotating components. Exercise extreme care to

avoid accidents and ensure proper operation.

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 micro-

processor controller. To isolate the unit for main-

tenance, turn off power at the main power discon-

nect switch. Always disconnect main power prior to

performing any service or repairs.

WARNING

Turn off power to the unit unless you are per-

forming tests that require power. With power

and controls energized, the unit could begin

operating automatically at any time. To prevent

personal injury, stay clear of rotating compo-

nents as automatic controls may start them

unexpectedly.

WARNING

Phosgene, a deadly, poisonous gas, is

generated when refrigerant is exposed to

flame. Always ensure adequate ventilation

during refrigeration repairs.

WARNING

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 Unit

4.1.1.1 Filter

The fi lter is usually the most neglected item in an air

conditioning system. To maintain effi cient operation,

the fi lter should be checked at least monthly and re-

placed as required. Refer to Section 4.3.4.5 for fi lter

replacement instructions.

NOTE

Conditions of spaces vary and fi lters should be

checked based on those conditions.

4.1.1.2 Blower

Periodic checks of the blower system should include

checking the wiring, blower motor mounts, housing,

V-belts (if applicable) and blower wheel. Ensure all

electrical connections are tight. Check that all mounts

are secure and the blower wheel is tightly mounted

on the shaft and does not rub against the fan hous-

ing. Inspect the blower vanes to ensure they are free

of debris.

For belt drive blowers ensure the pulleys are aligned,

the V-belt tension is correct and the belt is not worn

out. To adjust the blower belt tension refer to Figure

14. Loosen the locking bolt on the side of the motor

base. Turn the jam nut away from the lockdown plate.

Rotate the tension rod to move the motor on its’ base

to increase or decrease belt tension. Retighten the

jam nut and tighten the locking bolt on the motor

base.

Blower motors that require periodic lubrication are

equipped with grease fi ttings. Blower motors without

grease fi ttings have permanently lubricated bearings

and should not require maintenance for the normal

lifetime of the equipment.


(©April, 2008)


4-2

4.1.1.2.1 Lubrication and Bearings

(For motors with grease fi ttings only)

The lubricating ability of grease depends primarily on

the type of grease, the size of the bearing, the speed

at which the bearing operates and the severity of the

operating conditions. This ability can be lost over

time. The following steps should be followed for best

results:

1. A high grade ball or roller bearing grease should

be used. Several recommended greases for stan-

dard service conditions are Polyrex EM (pregreased

by factory), Texaco Polystar, Amoco Rykon Premium

#2, Pennzoil Pen 32 Lube or Chevron SRI.

2. Lubrication should be performed at the recom-

mended intervals shown in the table below. These

recommended intervals are based on average use.

See name plate on motor for frame size and rated

speed.

TABLE 1, BLOWER MOTOR LUBRICATION INTERVALS

NEMA/(IEC) Frame Size Rated Speed - RPM

3600 1800 1200 900

Up to 210 incl. (132) 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.

Over 210 to 280 incl. (180) 3600 Hrs. 9500 Hrs. 15000 Hrs. 18000 Hrs.

Over 280 *2200 Hrs 7400 Hrs. 12000 Hrs. 15000 Hrs.

TABLE 2, SERVICE CONDITIONS

Severity of Service Ambient Temperature Atmospheric Hours per Day

Maximum Contamination of Operation

Standard 40°C Clean, Little 8

Corrosion

Severe 50°C Moderate dirt, 16 Plus

Corrosion

Extreme >50°C* or Class H Severe dirt, Abrasive Dust, 16 Plus

Insulation Corrosion, Heavy Vibration

Low Temperature <-30°C**

*Special high temperature grease is recommended (Dow Corning DC44). Note that Dow Corrning DC44

does not mix well with other types of grease. Thoroughly clean bearing and cavity before adding grease.

**Special low temperature grease is recommended (Aeroshell 7).

(©April, 2008)



Sample Lubrication Determination

Assume NEMA 182T, 1725 RPM motor driving a blower in an ambient temperature of 43°C and an atmosphere

that is moderately corrosive.

1. Table 1 lists 12,000 hrs. interval for standard conditions.

2. Table 2 classifi es severity of service as “Severe”.

3. Table 3 lists an interval multiplier of 0.5 for severe conditions. (0.5 x 12,000 hrs= 6,000 hrsinterval.)

4. Table 4 shows 0.3 in³ or 1.0 teaspoons of grease to be added.

4.1.1.2.2 Lubrication Procedure

Be sure that the grease you are adding is compat-

ible with the grease already in the motor. Consult the

factory or the motor manufacturer if you are using a

grease other than the recommended type.

CAUTION

To avoid damage to motor bearings, keep

grease free of dirt. If you have an extremely dirty

environment, contact the factory or the motor

manufacturer for additional information.

1. With the motor stopped, clean the grease fi ttings

with a clean cloth.

2. If the motor has a grease outlet (purge) plug, remove

it.

3. Add the recommended amount of grease.

4. Operate the motor for 15 minutes with the grease

plug removed to allow excess grease to purge.

5. Re-install the grease outlet plug if removed.

CAUTION

Do not over-lubricate the motor as this may

cause premature bearing failure.

4-3

TABLE 3, LUBRICATION INTERVAL MULTIPLIER

Severity of Service Multiplier

Standard 1.0

Severe 0.5

Extreme 0.1

TABLE 4, BEARING SIZES AND TYPES

Bearing Description

(These are the “Large” bearings (Shaft End) in each frame size)

Frame Size Weight of Volume of Grease

NEMA (IEC) Bearing Grease to to be Added

add oz.

(grams) In3 Teaspoon

140 (90) 6205 0.15 (3.9) 0.2 0.8

180 (100-112) 6206 0.19 (5.0) 0.3 1.0

Up to 210 incl. (132) 6307 0.30 (8.4) 0.6 2.0

Over 210 to 280 incl. (180) 6311 0.61 (17.4) 1.2 3.9

Over 280 6313 0.81 (23.1) 1.5 5.2


(©April, 2008)


4.1.1.3 Drain Pan

To ensure proper drainage, inspect the drain pan reg-

ularly. Make sure the drain pan outlet is always free

of debris and ensure the drain pan does not leak.

4.1.1.4 Coils

Coil(s) should be inspected semiannually and

cleaned as required following standard coil cleaning

practices. Using a brush, clean the coil fi ns of all de-

bris that will inhibit airfl ow. This can also be done with

compressed air or with a commercial coil cleaner.

Check for bent or damaged coil fi ns and repair as

necessary. Check all piping for signs of leaks.

4.1.1.5 Heat/Reheat

The heat/reheat equipment should be inspected

semi-annually to ensure it is operational. If you have

electric heat/reheat, inspect the heating elements to

ensure they are free of debris.

4.1.1.6 Humidifi er

The steam cylinder has a limited lifetime and must be

replaced periodically. Because water conditions and

humidifi er usage rates vary greatly, it is diffi cult to

establish intervals for changing the cylinder. Indi-

vidual maintenance schedules must be determined

for each location, based upon periodic examination of

the humidifi er. A change cylinder light on the humidi-

fi er cabinet will illuminate (red) when the cylinder

requires replacement.

NOTE

The red light may illuminate during initial start-

up but it doesn’t necessarily mean the cylinder

needs to be replaced.

Refer to the humidifi er operator’s manual supplied

under separate cover for detailed instructions on

changing the cylinder.


The condensate pump should be inspected semi-an-

nually and cleaned. Ensure that the fl oat works freely.

Wipe the fl oat with a wet cloth and detergent to re-

move dirt. Clean the tank bottom. Check the discharge

line to ensure it is open and water can pass through

it freely.

4.1.2 Condenser

Maintenance access to the condenser is through one

or two removable panels (depending on model). For

air-cooled condensers, clean the condenser coil of all

debris that will inhibit airfl ow. This can be done with

compressed air or with a commercial coil cleaner.

Check for bent or damaged coil fi ns and repair as

necessary. On outdoor units 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 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 all liquid refrigerant to be driven out of

the compressor. This is especially important at

low ambient conditions.

4.1.3 Pump Package

Routinely examine the areas around the pump

motor(s) and inlets and outlets. Check coolant and

piping for signs of leaks. Examine all wiring for signs

of chafi ng, loose connections or other obvious dam-

age. Examine brackets, motor mounts and hardware

for loose or missing parts or other damage. Lubricate

motor bearings if applicable. (See the instruction

manual provided with the pump package.)

4-4

(©April, 2008)



4-5

SYMPTOM PROBABLE CAUSE RECOMMENDATION

Suction Pressure Too Low a. Loss of refrigerant (bubbles in Locate leak and repair. Recharge system.

sight glass).

b. Expansion valve stuck or obstructed Remove and clean or replace valve.

(short cycle or continuous running).

c. Clogged drier/strainer (feels cold). Replace with new drier/strainer.

d. Dirty air fi lters (reduced airfl ow). Clean/replace fi lters.

Water/Glycol Valve Fails a. Temperature setpoint too high. Adjust to correct temperature setting.

to Open or Close

b. No control power to the valve. Valve actuator is wired incorrectly. Check

wiring schematic and rewire if required.

c. Actuator failed. Replace actuator.

Evaporator Coil Ices a. Low airfl ow. 1. Check fi lters. Replace as needed.

2. Check for and clear any obstructions

across or in the (supply) discharge

airstream.

3. Check correct rotation of evaporator

blower.

4. Check evaporator blower speed.

5. Check clearance height of raised fl oor.

b. Temperature setting too low Increase temperature setpoint.

(68°F min.).

c. Discharge air short cycling Check discharge grille orientation.

back to return.

d. Low refrigerant charge. Find leak, repair and recharge system.

Blower Fails to Start a. Power failure. Check main voltage power source input

cable.

b. Control transformer circuit Check for short circuit or ground fault, if

breaker tripped. none reset circuit breaker.

4.2 Troubleshooting

Turn off all power to the unit before conducting any troubleshooting procedures, unless the procedure spe-

cifi cally requires the system to operate. For troubleshooting purposes, the system may be operated with

the doors open by using a pair of channel lock pliers to turn the shaft of the main power disconnect switch

to the “On” position. When the switch is turned on, high voltage will be present inside the cabinet.

WARNING

To prevent injury, keep hands, clothing and tools clear of the electrical terminals and rotating components.

Ensure that your footing is stable at all times.


(©April, 2008)


4-6


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 starter protector tripped. Reset motor starter protector and check

amperage of motor. Compare to setting

on motor starter protector and adjust to

FLA.

Control is Erratic Wiring improperly connected or broken. Check wiring against schematic diagram.

Condenser Pressure a. Noncondensable gas or air in the Recover system, vacuum to 50 microns

too High system. and recharge. Install new drier/strainer.

b. Condenser air intake is blocked. Remove debris and clean condenser.

c. Overcharge of refrigerant. Reclaim excess refrigerant from system.

d. Low water/glycol fl ow to Determine cause and fi x.

condenser.

e. Condenser fan not operating. Check pressure/temperature operating

switches and motor. Replace as needed.

f. Water/glycol temperature too high. Check fl ow and operation of drycooler.

g. Condenser pressure regulating valve Adjust to obtain correct pressure.

setting too high.

h. Flow of water/glycol too low. 1. Check glycol solution level and

concentration.

2. Valves not open or partially open.

Repair/replace as needed.

3. Air in system - bleed system.

4. Check all strainers and clean if needed.

i. Water/glycol solution not mixed prior Remove solution and premix.

to adding to system. Refi ll system.

Condenser Pressure too a. Loss of refrigerant (indicated by Locate and repair leak. Recharge system.

Low bubbles in sight glass).

b. Condenser fan controls not set Adjust or repair controls.

properly.

c. Water regulating valve adjusted Readjust to 240-250 psig.

too low.

Blower Fails to Start

(cont.)

(©April, 2008)



4-7


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 scarred compressor Replace compressor.

bearings.

d. Liquid slugging. System overcharged. Reclaim excess

refrigerant.

e. Scroll compressor not properly Phase correctly at main power source.

phased. DO NOT REWIRE THE COMPRESSOR

Compressor Fails to Start a. Temperature setpoint too high. Adjust to desired temperature.

b. Compressor internal protector Check compressor for short circuit

is open. or ground.

c. Complete loss of refrigerant charge Locate and repair leak. Recharge system.

(low pressure safety switch).

d. Condenser pressure too high Check condenser for obstructions.

(high pressure safety switch).

e. Minimum off time has not expired. Wait for time to expire.

System Short of Capacity a. Low refrigerant (indicated by bubbles Check for leaks. Repair and recharge

in sight glass). system.

b. Expansion valve stuck or obstructed Remove valve and clear obstruction or

(short cycling or continuous running). replace valve.

c. Clogged drier/strainer (feels cold). Replace with new drier/strainer.

d. Reduced airfl ow. Check belt tension, fi lters and

evaporator coil.

Compressor Short Cycles a. Low line voltage causing Check power source for cause of low

compressor to overheat. line voltage.

b. Dirty or iced-over evaporator coil. Defrost and/or clean coil.

c. Reduced airfl ow. Check fi lter and belt tension (when

applicable).

d. Lack of refrigerant. Check for leak. Repair and recharge

system.


(©April, 2008)


4-8

Compressor Short Cycles e. Short cycling of conditioned air. 1. Supply and/or return grilles are

(cont.) incorrectly oriented. Reorient.

2. Supply and return grilles are too close

together. Move further apart.

3. Insuffi cient heat load. Add temporary

heat load to compensate.

f. Remote temperature sensor is Check for supply registers that may

improperly located. be too close to the remote temperature

sensor. Relocate if necessary.

Heater Inoperative a. Fuses blown. Check for short circuit, replace fuse.

b. Temperature setpoint too low. Increase temperature setpoint.

c. Overheat switch open. Insuffi cient air across heater elements.

Check for dirty fi lters or obstructions that

may reduce air fl ow. Correct or replace

as needed.

d. Manual reset overheat safety Reset manual overheat safety switch

switch tripped. (See item immediately above).

e. Heater element burned out. Check continuity with an ohmmeter.

Replace heater element.

Humidifi er Inoperative a. Water supply has been turned off Connect and/or turn on water supply.

Note: See Humidifi er or not connected.

Manual for Additional

Help. b. Humidifi er switch is in “Off” position. Turn switch to “Auto/On” position.

c. Electrical connections are loose. Tighten electrical connections.

d. Humidifi er circuit breaker tripped. Check for over current by the humidifi er

electrodes. Drain water from tank and

refi ll. Reset circuit breaker.

e. Relative humidity is above setpoint. Adjust humidity setpoint.

f. Electrode canister change cylinder 1. Consult humidifi er manual.

light is on.

2. Water conductivity is too low

and water is at the top of the

cylinder (see next item).

g. Water conductivity is too low. Add a teaspoon of table salt to the water

through the top of the cylinder. Typically

only on initial start-up.


(©April, 2008)



4-9

4.3 Field Service

NOTE

Do not attempt to make repairs without the

proper tools.

It may be necessary to perform repairs on the re-

frigeration system. If fi eld repairs are necessary, the

following procedures apply:

4.3.1 Leak Detection

Several methods can be used to detect a leak in the

refrigeration system. The most modern and easiest

method is to use an electronic leak detector. Fol-

low the manufacturer’s directions and any leak can

be quickly located. A second method is to use soap

bubbles. Apply a solution of soapy water with a brush

or sponge to the joints and connections in the refrig-

eration lines. A leak in the lines will cause bubbles to

form.

NOTE

Halogen leak detectors are ineffective with

R407C refrigerant because R407C does not

contain chlorine like R22 refrigerant.

4.3.2 Leak Repair

When a leak is located, properly reclaim the remain-

ing refrigerant charge before beginning repairs.

Adjacent piping must be thoroughly cleaned by

removing all paint, dirt and oily fi lm. Use a wire brush,

sandcloth or sandpaper and wipe the area with clean,

dry cloths. Protect nearby parts from heat damage by

wrapping with water-soaked cloths.

4.3.3 Refrigerant Piping

When replacing components within the cabinet of the

unit, the following consumable materials are recom-

mended: Use Silfos alloy for copper-to-copper (piping

discharge or suction line repairs). Silver solder (Stay-

Silv #45) and fl ux are to be used on copper-to-brass

or copper-to-steel repairs. For liquid line repairs at

the drier, strainer, sight glass, or expansion valve,

use a 95% tin to 5% antimony solder with fl ux.

When component replacement is complete, remove

all traces of fl ux. After any repair, pressure check

the system and ensure there are no leaks prior to

recharging the system.

4.3.4 General Common

Repairs/Component 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

burnout has occurred, the oil will be black and acidic.

A mechanical failure will have no burned odor and

the motor will attempt to run, an abnormal or exces-

sive noise may be present.

An analysis of the oil is the only way to determine the

proper procedure for cleaning the refrigerant system.

Acid test kits are available from several manufactur-

ers for measuring the acid level in the oil. These are

capable of making accurate acid measurements, but

if they are not available, a check of the oil by sight

and smell can give a quick indication if contamination

remains in the system. Since refrigeration oils vary

in color, a sample of the new oil in the replacement

compressor should be removed prior to installation

and sealed in a small glass bottle for comparison

purposes. If the oil has been exposed to refrigerant,

the bottle should not be tightly capped, since the re-

sidual refrigerant may create a high pressure if tightly

sealed and exposed to high temperature.

CAUTION

Avoid touching or contacting the gas and oil with

exposed skin. Severe burns will result. Use long

rubber gloves in handling contaminated parts.

All electrical connections should be checked to

ensure they are tight and properly made. Check all

circuit breakers, contactors and wiring. The contac-

tors should be examined and replaced if contacts are

worn or pitted.

If there is acid in the oil, there has been an electrical

failure which has caused the compressor motor to

burn out. The acid diffuses throughout the refrigera-

tion system and must be removed by using a burnout

fi lter kit before a new compressor is placed in ser-

vice. Not only must the compressor be replaced, but

also the entire refrigeration circuit must be cleaned


(©April, 2008)


4-10

of the harmful contaminants left by the burnout. See

section 4.3.4.3 (Burn-Out/Acidic Cleanup) for the

proper procedure.

If there is no acid in the oil, there has been a me-

chanical failure. See section 4.3.4.2 (Standard Clea-

nout) for the proper cleaning procedure.

CAUTION

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 com-

pressor.

CAUTION

POE oil is used in systems with R407C refriger-

ant. If a replacement compressor is provided,

ensure that it is fi lled with POE oil before install-

ing.

4.3.4.2 Standard Cleanout Procedure

NOTE

Cleaning operations must be performed by

a journeyman, refrigeration mechanic, or air


1. Turn off power to unit at the main power discon-

nect switch.

2. Remove the old compressor and install the new

compressor.

3. Remove the liquid line drier and install an over-

sized liquid line fi lter-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 at the controller.

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


1. These systems should be cleaned using the suc-

tion line fi lter-drier method.

2. Turn off power to the unit at the main power dis-

connect switch.

3. Remove the burned out compressor and install

the new compressor.

4. Install a suction line fi lter-drier designed for acid

removal.

5. Remove the liquid line drier and install an over-

sized liquid line fi lter-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 fi lter-drier.

9. Turn on power at the main power disconnect

switch and start the system at the controller.

10. The permanently installed suction line fi lter-drier

permits small-system cleanup to be completed

in one service call. The pressure drop across the

suction line fi lter-drier should be measured during

the fi rst hour of operation. If the pressure drop

becomes excessive, the suction line fi lter-drier

should be replaced (See Sporlan Bulletin 40-10,

for the maximum recommended pressure drop

(PSI) for the suction line fi lter drier).

(©April, 2008)



11. In 24 hours, take an oil sample. Observe the

color and test for acidity. If the oil is dirty or

acidic, replace the suction line fi lter-drier.

12. In 2 weeks, examine oil to determine if another

suction line fi lter-drier change is necessary.

4.3.4.4 Humidifi er Cylinder Replacement

After an extended period of operation a red light will

illuminate on the humidifi er cabinet indicating that the

cylinder is completely used and a replacement cylin-

der must be installed. The cylinder is disposable and

cylinder life is dependent on water supply conditions

and humidifi er usage. The following procedures are

to be followed when replacing the cylinder.

CAUTION

Failure to replace cylinder at the end of cylinder

life may result in humidifi er damage.

NOTE

Decrease the low humidity setpoint below ambi-

ent humidity to allow the cylinder to cool down

before removing the cylinder.

1. Turn off water supply to the humidifi er.

2. Drain the cylinder by pushing the “Auto/On-Off-

Drain” switch to the “Drain” position.

3. When drained, push the “Auto/On-Off-Drain”

switch to the “Off” position.

4. Disconnect power to the humidifi er at the main

power disconnect switch.

5. The power wires to the cylinder are attached by

cylinder plugs to the electrode pins on top of the

cylinder. Pull these plugs vertically off the pins.

6. Loosen the steam hose clamp(s) and pull the

steam hose off vertically.

CAUTION

The cylinder and steam hose may be hot and

burns may result.

7. Lift the cylinder straight up to disengage it from

the humidifi er.

8. Place the new cylinder on the side mounting slots

within the unit ensuring the cylinder mounting

stubs are seated properly.

9. Replace the cylinder plugs on the pins, ensur-

ing the white sensor plug goes on the single pin

which is offset from the others.

10. Ensure the plugs are secured on the pins. If the

fi tting plugs are loose, they may be temporar-

ily squeezed together however, the plugs must

be replaced since a loose plug could generate

enough heat to melt and destroy the plug.

11. Replace the steam hose and tighten the

clamp(s).

12. Connect main power to the humidifi er at the main

power disconnect switch.

13. Push the “Auto/On-Off-Drain” switch to the “Auto/

On” position.

14. Turn on the water supply to the humidifi er.

15. Readjust the humidity setpoint.

If the humidifi er is to be shut down for an extended

period, always drain the cylinder fi rst. Follow the

above steps 1 through 4 ensuring the “Auto/On-Off-

Drain” switch is in the “Off” position. Failure to do this

will drastically shorten the cylinder life.

4.3.4.5 Filter Replacement

The fi lters are located either internal to the cabinet

or external to the cabinet depending on the con-

fi guration of the unit. On downfl ow units the fi lter is

accessed from the top. On upfl ow units, the fi lter is

accessed by opening the electric compartment door

and pulling off the adjacent front panel. The front

panel is secured with ball pins and can be simply

popped off by hand. Open and/or remove the ac-

cess panel and old fi lter. Ensuring directional airfl ow

arrows on the fi lters are correct, insert the new fi lters

then close and/or replace the access panel.

4-11


(©April, 2008)


5-1

5.0 PRODUCT SUPPORT GROUP

SATS provides to its customers a Product Support

Group (PSG) which not only provides technical sup-

port and parts but the following additional services,

as requested: performance evaluations, start-up as-

sistance and training.

5.1 Technical Support

The SATS Product Support Group (PSG) is dedi-

cated to the prompt reply and solution to any problem

encountered with a unit. Should a problem develop

that cannot be resolved using this manual, you may

contact PSG at (240) 529-1399 Monday through

Friday from 8:00 a.m. to 5:00 p.m. EST. If a problem

occurs after business hours, dial the page number

(301) 414-4514 and follow the steps below:

1. Wait for the dial tone.

2. Dial your telephone number (including area

code).

3. Press the pound (#) key.

4. Wait for a busy signal.

5. Hang up the telephone.

One of our service technicians will return your call.

When calling to obtain support, it is vital to have the

following information readily available, (information is

found on unit’s nameplate):

• Unit Model Number (CCU/D-XXX-XX)

• SATS Item Number (123456)

• Unit Serial Number (1234567)

• Description of Problem

5.2 Obtaining Warranty Parts

Warranty inquires are to be made through the Prod-

uct Support Group (PSG) at (240) 529-1399 Monday

through Friday from 8:00 a.m. to 5:00 p.m. EST. A

service technician at SATS will troubleshoot the sys-

tem over the telephone with a fi eld service technician

to determine the defect of the part. If it is determined

that the part may be defective a replacement part will

be sent UPS ground. If the customer requests that

warranty part(s) be sent by any other method than

UPS ground the customer is responsible for the ship-

ping charges. 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 Billing Address

• Shipping Address

• Customer’s Telephone and Fax Numbers

• Contact Name

• Unit Model No., Serial No. & SATS Item No.

The customer is responsible for the shipping cost

incurred for shipping the defective part(s) back to

SATS. Return of defective part(s) must be within 30

days at which time an evaluation of the part(s) is

conducted and if the part is found to have a manufac-

turing defect a credit will be issued.

When returning defective part(s), complete the Re-

turn Material Authorization Tag and the address label

received with the replacement part.

See SATS Standard Warranty located in section one

of this manual.

5.3 Obtaining Spare/Replacement Parts

Spare and replacement parts requests are to be

made through the Product Support Group (PSG) by

fax (301) 620-1396, telephone (240) 529-1399 or

E-mail ([email protected]). Quotes are given for

specifi ed listed parts for a specifi c unit.

SATS accepts Visa and MasterCard. SATS may ex-

tend credit to its customers; a credit application must

be prepared and approved (this process could take

one week).

A 25% minimum restocking charge will be applied on

returned stocked parts that were sold as spare/re-

placement parts. If the returned part is not a stocked

item, a 50% restocking charge may be applied.

Additionally a Return Material Authorization Number

is required when returning parts. To receive credit

for returned repair/replacement parts, the parts must

be returned to SATS within 30 days of the purchase

date. Spare part sales over 30 days old will be

considered fi nal and the parts will remain the sole

property of the ordering party.


(©April, 2008)


APPENDIX A - FORMS

Stulz Air Technology Systems Inc.

Frederick, Maryland USA 21704

Telephone: (301) 620-2033 Facsimile: (301) 620-1396

Checklist for Completed Installation

o 1 Proper clearances for service access have

been maintained around equipment.

o 2 Equipment is level and mounting fasteners (if

applicable) are tight.

o 3 Piping completed to refrigerant or coolant loop

(if required).

o 4 All fi eld installed piping leak tested.

o 5 Refrigerant charge added (if required).

o 6 Condensate pump installed (if required).

o 7 Drain line connected.

o 8 Water supply line connected to humidifi er

(if required). If manual cut-off valve is in-

stalled, open valve.

o 9 Humidifi er “Auto/On/Off/Drain” switch is in

“Auto” position.

o 10 Safety pan installed under ceiling mounted

equipment (if required).

o 11 Filter box installed (if required).

o 12 Filter (s) installed (if required).

o 13 Ductwork completed or optional plenum in-

stalled (if required).

o 14 Incoming line voltage matches equipment

nominal nameplated rating ± tolerances.

o 15 Main power wiring connections to the equip-

ment, including earth ground, have been

properly installed.

o 16 Customer supplied main power circuit breaker

(HACR type) or fuses have proper ratings for

equipment installed.

o 17 All wiring connections are tight.

o 18 Control wiring connections completed to

evaporator and condenser/condensing unit

(if required), including wiring to wall mounted

control panel and optional controls.

o 19 Foreign materials have been removed from

inside and around all equipment installed

(shipping materials, construction materials,

tools, etc.).

A-1


Telephone: (301) 620-2033

Facsimile: (301) 620-1396


(©April, 2008)




(©April, 2008)


Periodic General Maintenance Checks and Services Checklist

Date: ____________________________ Prepared By: ___________________________

Model Number: ____________________________ __________________________Serial Number:

Item Number: ____________________________

Monthly

Filters Blower Section Condensate Drain

o Cleanliness o Blower Turns o Drain is Open

o No Obstructions o Belts (if applicable) o Condensate Pan Safety

Switches Operate Freely

Miscellaneous

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

o External Heat Exchanger Clean and Clear of Obstructions

o Humidifi er Cylinder and Controls Operate Properly

Semi-Annually

o Check Refrigerant Charge (bubbles in sight-glass) o Tighten Electrical Connections

o Check Suction & Discharge Pressure o Check Contacts on Contactors

for Pitting

o Check Glycol Solution Concentration in System o Clean Unit as Necessary

o Clean Coils o Test the Glycol Solution

Inhibitors (fl ush if necessary)

o Heat/Reheat Operational o Clean Condensate Pump

Annually

Refrigerant Systems Chilled Water Systems

o Inspect Glycol System for Leaks and Corrosion o Inspect Chilled Water System

for Leaks and Corrosion

o Conduct a Complete Check of All Services Listed o 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


Telephone: (301) 620-2033

Facsimile: (301) 620-1396


(©April, 2008)




(©April, 2008)


B-1

Appendix B – Glossary

Defi nition 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

CFM - Cubic Feet Per Minute NEC - National Electric Code

CNDCT - Conductor NFPA - National Fire Protection Agency

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 Load Amps

Hz - Hertz R-Value - Thermal Resistance

IAQ - Indoor Air Quality R22 - Refrigerant (HCFC-22)

in. w.g. - Inches of Water Gauge R407C - Blended Refrigerant

KVA - Kilo Volt Amp SPDT - Single Pole, Double Throw

kW - Kilowatts TEV - Thermal Expansion Valve

LRA - Locked Rotor Amps V - Volt

MAX FUSE - Maximum Fuse VAC - Volt, Alternating Current

(©April, 2008)



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