Stulz Cyberair 3 DX 17 0811 en

STULZ the natural choice
Instructions
CyberAir 3 DX
Index 17 Issue 8.2011
Precision Air Conditioning Units 380-415/3/50
Original instructions
Contents
1. Safety ...........................................................................................................................3
1.1 Marking..............................................................................................................................................3 1.2 Safety instructions .............................................................................................................................3 1.3 Handling refrigerants .........................................................................................................................3 1.4 Safety and environmental requirements ............................................................................................4
2. Residual risks .............................................................................................................5 3. Transport / Storage .....................................................................................................7

3.1 Delivery of units .................................................................................................................................7 3.2 Transport............................................................................................................................................7 3.3 Storage ..............................................................................................................................................7
4. Description ..................................................................................................................8
4.1 Type code ..........................................................................................................................................8 4.2 Intended use ......................................................................................................................................9 4.3 Function of the A/C unit .....................................................................................................................9
5. Technical data ...........................................................................................................10

5.1 Application limits ..............................................................................................................................10 5.2 Technical Data - ASD/U ... A/G/ACW/GCW - 1-circuit .....................................................................11 5.3 Technical Data - ASD/U ... A2/G/ACW2/GCW - 2-circuits .................................................................12 5.4 Technical Data - ASD/U ... GE and ALD/U ... GE - 1-circuit ............................................................13 5.5 Technical Data - ALD/U ... GE - 2-circuits ........................................................................................14 5.6 Dimensional drawings .....................................................................................................................15
6. Installation .................................................................................................................16
6.1 Positioning .......................................................................................................................................16 6.2 Connection of the piping ..................................................................................................................17 6.2.1 Position of the refrigerant connections (A/ACW units) .............................................................17 6.2.2 Filling systems with R407C refrigerants ...................................................................................18 6.2.3 Water piping .............................................................................................................................19 6.2.4 Condensate drain connection...................................................................................................21 6.3 Electrical connection ......................................................................................................................22
7. Commissioning .........................................................................................................23 8. Maintenance ..............................................................................................................25

8.1 Safety instructions ...........................................................................................................................25 8.2 Maintenance intervals .....................................................................................................................25 8.3 Refrigerant circuit ............................................................................................................................26 8.4 Air circuit ..........................................................................................................................................27 8.5 Water circuit .....................................................................................................................................28 8.6 Unit in general .................................................................................................................................28 8.7 Competences ..................................................................................................................................28
9. Malfunction ...............................................................................................................29 10. Dismantling and disposal ......................................................................................30 11. Contents of the CE Declaration of Conformity ....................................................31 12. Options
Subject to technical modications.
EN /08.2011/17/2
1. Safety
1.1 Marking
Danger threatening danger, grievous bodily harm and death
Attention
dangerous situation, light bodily injury and material damage
Information ESD note
important information and application notice risk of damaging electronical components
1.2 Safety instructions

General
These operating instructions contain basic information which is to be complied with for installation, operation and maintenance. They must therefore be read and complied with by the tter and the responsible trained staff/operators before assembly and commissioning. They must be permanently available at the place where the system is used.
This cooling unit contains uorinated greenhouse gas covered by the Kyoto protocol.
R407C refrigerants are used in STULZ units as standard. Refrigerants are volatile, or highly volatile uorinated hydrocarbons which are liqueed under pressure. They are incombustible and not hazardous to health when used as intended. Works have to be carried out by competent staff only Observance of the regulations for accident prevention Stay out of danger when lifting and setting off the unit Secure the unit to avoid the risk of overturning Safety devices may not be bypassed. Respect the corresponding VDE-, EN- and IEC standards for the electrical connection of the unit and observe the conditions of the power supply companies - Switch off the voltage from the unit when working on it. - Observe the national regulations of the country where the unit will be installed - The refrigerant circuit contains refrigerant and refrigerating plant oil, observe professional disposal for maintenance and when setting the unit out of service. - Cooling water additives have an acidic effect on skin and eyes, wear safety glasses and safety gloves - Observe personal protective equipment when working on the refrigerant circuit. - The unit may only be used to cool air according to the Stulz specication. - Respect material compatibility in the whole hydraulic circuit. - The male triangular wrench is to be placed in a visible location in the immediate vicinity of the unit.
1.3 Handling refrigerants

According to EN 378, refrigerants are divided in groups in respect of health and safety: R407C and R134a belong to Group L1. - Adherence to the regulations by law and guide-lines - Execution only by competent staff
EN/04.2011/DX/3
Responsability for correct disposal of refrigerant and system parts is incumbent on the operator. Refrigerants have a narcotic effect when inhaled in high concentrations. The room is to be evacuated immediately if high concentrations of refrigerant suddenly occur. The room may only be entered again after adequate ventilation. If unavoidable work is required in the presence of a high concentration of refrigerant, breathing apparatus must be worn. This does not mean simple lter masks. Comply with breathing protection data sheet. Safety glasses and safety gloves are to be worn. Do not eat, drink or smoke at work. Liquid refrigerant must not get onto the skin (risk of burns). Only use in well ventilated areas. Do not inhale refrigerant vapours. Warn against intentional misuse. It is absolutely essential to comply with the rst aid measures if accidents occur. Refrigerants containing FCs contribute to the global warming and with this to climate changes. The FCs must therefore be disposed of in accordance with the regulations, i.e. only by companies specially qualied and licensed as recognised disposal companies for refrigerants.
1.4 Safety and environmental requirements

The following requirements relate to the operation of refrigerating plants within the European Community. - The used components must correspond to the pressure equipment guide-line EC/97/23 and EN 378 part 1-4. - Independent of the design, the equipment and inspection before the delivery, also the operator of such plants has duties according to EN 378 and national regulations. This concerns the installation, the operation and the repeated inspection: - Installation: according to EN 378 Operation: Determination of emergency measures (accidents, malfunctions) Creation of an abbreviated instruction and notication (template page) a. A unit protocol must be kept. b. To be stored in the proximity of the unit c. Access for competent staff in case of repairs and repeated inspection must be ensured. according to EN 378 The operator is responsible for the execution.
Repeated inspection:
The operator must ensure that all maintenance, inspection and assembly work is carried out by authorised and qualied specialist staff who have made an in-depth study of the operating instructions. It is absolutely essential to comply with the procedure for shutting down the system described in the operating instructions. Before maintenance work, the unit must be switched off at the main switch and a warning sign displayed to prevent unintentional switching-on.
First aid measures

If health problems occur during or after handling uorinated hydrocarbons, a doctor is to be consulted immediately. The doctor is to be informed that the work involved the use of uorinated hydrocarbons. In the case of acute effects, the casualty is to be brought into the fresh air as quickly as possible. Splashes of uorinated hydrocarbons in the eyes can be blown out or fanned out by an assistant. Then rinse with water.
Independent conversion and manufacture of replacement parts

The system may only be converted or modied after consultation with STULZ. Original replacement parts and replacement parts/accessories authorised by STULZ are an aid to safety.
Unacceptable operating methods

The operating safety of the system is only guaranteed when it is used as intended. The limit values stipulated in the technical data must not be exceeded under any circumstances.
EN/04.2011/DX/4
2. Residual risks
Transport, Installation Area Under the unit Beside the unit Cause Defective lifting device Uneven or insufcient foundation or raised oor stand Danger Bruising Bruising by tipping over of the unit Safety note Keep away from under the unit Make sure, the foundation is even and stable and that the raised oor stand is correctly mounted. Wear protective equipment (helmet, gloves, safety shoes). Wear safety glasses and gloves, don't put your head into the unit. Check and make sure the unit is deenergized. Stand on isolated ground. Take care that sharp edges are always protected by rubber grommets
In the lower part of the unit Electrical box
Heat by soldering ame, Burns, cuts, concussharp edges, built-in parts sion damage Electric shock, cable Connection cable under damage at positioning voltage, sharp edges of the openings for the cable introduction
Start-up Area In the lower part of the unit, refrigerant piping Cause Defective lling line for refrigerant, leaks in the refrigerant piping, closed stop valves, defective safety valve Leaks in the water lines, closed stop valves Danger Discharge of refrigerant under high pressure, burns in case of contact to the skin, formation of acid vapours with open ames Discharge of water under high pressure, contact with the skin of ethylen glycol, irritation of eyes and respiratory system by glycol vapours, increased risk of electric shock in combination with electricity, risk of slipping Small parts can be thrown out of the fan when the unit starts. Risk of injury by rotating parts. Hanging parts of the clothing or long hair can be wound around the rotating shaft. Electric arc, acid vapours Safety note Open stop valves. Wear safety glasses and gloves, don't put your head into the unit. Open stop valves. Wear rubber gloves, ethylen glycol is absorbed by the skin. Avoid swallowing water with glycol additives.
In the lower part of the unit, water piping
Fan outlet of upow units Fan, V-belt drive (if existant)
Small parts fallen into the fan Unit operation to check the sightglass
Keep away from above the fan outlet. Keep the distance to fan and V-belt drive. Tie up long hair, wear hair protection. Retighten terminal connections, Wear protective gloves
Electrical box
Short circuit
EN/04.2011/DX/5
Operation Area In the lower part of the unit, refrigerant piping Unit bottom, eventually raised oor Cause Leaks in the refrigerant piping, defective safety valve/high pressure switch, re Accumulation of condensate and water discharge by too small or clogged drain pipe Falsely dimensioned cables or protection devices Danger Discharge of refrigerant under high pressure, explosion of pipe sections, formation of acid vapours with open ames Corrosion and development of mould by moistness. Humidity in combination with electric connections. Short-circuit, re, acid vapours Safety note In case of re wear protective mask.
De-energize water discharge area.
Electrical alimentation
Correctly design alimentation cables and protection elements. Wear protective mask.
Maintenance Area In the lower part of the unit, refrigerant piping Cause Leaks in the refrigerant piping, defective safety valve/high pressure switch. Danger Discharge of refrigerant under high pressure, burns in case of contact to the skin, formation of acid vapours with open ames Burns in case of contact to the skin Safety note Wear safety glasses and gloves, don't put your head into the unit.
Pressure lines, Heat compressor, reheat behind heat exchanger Heat exchanger Steam humidier Electrical box Sharp edges, ns Discharge of steam Live components, supposed to be voltage-free.
Wear safety gloves. Avoid contact to hot unit parts.
Injuries by cutting Burns Electric shock
Wear safety gloves. Avoid area around the steam lance. Secure master switch against being switched on again.
Dismantling Area In the lower part of the unit, refrigerant piping Cause Soldering off or cutting the refrigerant pipes still under pressure. Danger Discharge of refrigerant under high pressure, burns in case of contact to the skin. Safety note Depressurize pipes before disconnecting them. Wear safety glasses and gloves, don't put your head into the unit.
In the lower part of the unit, water piping
Discharge of water under Drain of cooling water by Unscrewing the water drain valve. pipes still under pressure. high pressure, contact with the skin of ethylen glycol, in- Wear rubber gloves. creased risk of electric shock in combination with electricity, risk of slipping Live electrical alimentation cable Electric shock Check de-energized state of the alimentation before dismantling, Wear safety gloves.
Electrical box
EN/04.2011/DX/6
3. Transport / Storage
3.1 Delivery of units
Stulz A/C units are mounted on pallets and packed several times in plastic lm. They must always be transported upright on the pallets. Unit version A: The refrigerant circuit is lled with nitrogene up to atmospheric pressure. Unit version G: The refrigerant circuit is lled with refrigerant ready for use. Construction of protective covering (from inside to outside) 1. Neopolene cushioning 2. Shrink lm 3. Additional board in container shipments The following information can be found on the packing. 1) Stulz logo 2) Stulz order number 3) Type of unit 4) Packing piece - contents 5) Warning symbols also upon request 6) Gross weight 7) Net weight 8) Dimensions 9) Customer order number 10) Additional customer requirements When delivery is accepted, the unit is to be checked against the delivery note for completeness and checked for external damage which is to be recorded on the consignment note in the presence of the freight forwarder. The delivery note can be found on the A/C unit when delivered. The shipment is made ex works, in case of shipment damages, please assert your claim towards the carrier. Hidden damage is to be reported in writing within 6 days of delivery.
3.2 Transport
The Stulz A/C units can be moved by lifting devices with ropes, for this the ropes have to be xed at the pallet, and the upper unit edges have to be protected by wooden laths or metal brackets in such a way that they could not be caved in. You can move the unit still packaged on the pallet with a fork lift, if you take care that the centre of gravity is within the fork surface. Take care that the unit is in an upright position at the transport.
Never move the unit on rollers and never transport it without pallet on a fork lift, for the risk of distorting the frame.
3.3 Storage
If you put the unit into intermediate storage before the installation, the following measures have to be carried out to protect the unit from damage and corrosion: Make sure that the water connections are provided with protective hoods. If the intermediate storage exceeds 2 months, we recommend lling the pipes with nitrogen. the temperature at the storage point should not be higher than 42C, and the site should not be exposed to direct sunlight. the unit should be stored packaged to avoid the risk of corrosion especially of the heat exchanger ns.
EN/04.2011/DX/7
4. Description
4.1 Type code
The type code represents the unit variant of your A/C unit and can be found on the rating plate. The rating plate is located in the door in front of the electrical compartment.
Unit type internal part no. Order number + alternative
ASD 321 A
A99403
--Serial no.
Explanation
A
Unit variants
Product range Energy index Airow direction Output of unit in kW Number of refrigeration circuits Cooling system: A: air-cooled* G: water/glycol-cooled GE: glycol-cooled + free cooling D 32 1 A CW: chilled water cooling (directly) A, G, GE, ACW, GCW 1, 2 19 ... 107 D, U - Downow, Upow S, L - Standard, Low energy A = CyberAir
* one condenser per refrigerant circuit is required.
Page code
Page code: DE - German EN - English FR - French ES - Spanish PL - Polish IT - Italian PT - Portuguese
EN/ 08.2011 / 17 / 7
Page number Date of issue Index month/year number
Manufacturer address:
STULZ GmbH Klimatechnik Holsteiner Chaussee 283 22457 Hamburg Tel: +49 40 55 85-0 Fax: +49 40 55 85-404
EN /08.2011/17/8
4.2 Intended use

This A/C unit is used to control room temperature and air humidity. The A/C unit is designed for indoor installation. Any use beyond this is not deemed to be use as intended. STULZ is not liable for any damage resulting from such misuse. The operator alone bears the risk.
4.3 Function of the A/C unit

The A/C unit is exclusively operated by the controller in the front panel and the main switch in the electric box. In the air inlet a temperature/humidity sensor is located which provides the measured values for the temperature/humidity control. In general the cooling is achieved by compressor operation in the refrigerant circuit. In the unit versions ACW, GCW and GE a direct cooling by a chilled water coil is also possible. The A/C unit control is effected by the on board I/O controller. The operational conception is designed such as to allow to control up to 19 units from one unit. These units can be installed separately with a maximum control line length of 1000 m.
Dehumidication
To achieve a dehumidication, the electronic expansion valve is partially closed in the rst step. The reduction of the refrigerant mass ow makes the evaporation temperature drop, which lets the surface temperature in a part of the evaporator fall below the dew point of the air. This causes dehumidication. For a bigger dehumidication, the fan speed is reduced. With a constant cooling capacity, the temperature of the air which ows through the heat exchanger coil, passes below the dew point. The moisture contained in the air condenses on the heat exchanger gathers in the condensate pan and is carried away by the drain.
Downow unit with 2 refrigerant circuits electrical box
Filter dryer Sightglass Expansion valve
Receiver
Humidier (optional)
EN /08.2011/17/9
5. Technical data
5.1 Application limits
The STULZ CyberAir units are provided for operation within the following ranges: - Admissible return air conditions: Temperature: Lower limit: 18C Upper limit: 35C Humidity: Lower limit: Upper limit: 5,5C dew point 60% r.h. and 15C dew point - Voltage: Standard
380V / 3ph / 60Hz; N; PE 460V / 3ph / 60Hz; PE 380V / 3ph / 50Hz; N; PE 400V / 3ph / 50Hz; N; PE 415V / 3ph / 50Hz; N; PE
- Voltage tolerance: +/- 10% (not for permanent operation) - Frequency: 50 Hz +/- 1% 60 Hz +/- 1% - Max. length of piping between A/C unit and aircooled condenser: 30 m equivalent. - Max. level difference between condenser and A/C unit: 5 m (when condenser is below the A/C unit). The warranty is invalidated for any possible damage or malfunction that may occur during or in consequence of operation outside the application ranges.
- Outdoor ambient conditions: lower limit: -10C, depending on selected option down to 45C upper limit: depending on selected condenser - Chilled water- /cooling water pipes: max. water head pressure: 16 bar - Hot water conditions for optional heating coil: max. inlet water temperature: 110C max. water head pressure: 8.5 bar - Storage conditions: Temperature [C]: -20 - +42 Humidity [% rel. h.]: 5 - 95 Atmosphere pressure [kPa]: 70 - 110
Adjustment of the pressure switches:

LP switch: releases at: automatic reset at: 1,0 (3,0)* bar 3,0 (5,0)* bar
HP switch: releases at: 24,5 (36)* bar manual reset possible at: 18,0 (29)* bar Safety valve: 28 (40)* bar
* The values outside of the brackets are valid for the refrigerants R407C and R134a, the values inside the brackets for R410A.
Design conditions for technical data:

Electrical connection: for Downow units with an external static pressure: for Upow units with an external static pressure: DX Units Return air conditions for evaporator capacity: Cooling uid (G, GCW): Cooling uid (GE): Fluid inlet temperature: Fluid outlet temperature: Condensation temperature: Max. condensation temperature: CW Units Return air conditions for cooling capacity: EWT - Entering water temperature: LWT - Leaving water temperature: Cooling uid: 400V/3ph/50Hz 20 Pa 50 Pa 24C, 50% rel. humidity Water, 0% Glycol Water, 30% Glycol 30C 40C 45C 60C 24C, 50% rel. humidity 7C 12C Water, 0% Glycol
The sound pressure levels are valid at a height of 1m and distance of 2m in front of the unit under free eld conditions and with nominal data. The values take into account the effects of all installation and design parts contained in the standard unit. The values for upow units assume an installed discharge duct.
EN /08.2011/17/10
5.2 Technical Data - ASD/U ... A/G/ACW/GCW - 1-circuit

Type Modell
DX-cooling cap. R407C DX-Klteleistung R407C 24C/50% r.F. r.h. DX-Klteleistung R410A DX-cooling cap. R410A 24C/50% r.F. r.h. DX-Klteleistung R134a DX-cooling cap. R134a 24C/50% r.F. r.h. CW-Klteleistung CW-cooling capacity 24C/50% r.F. r.h. Wasservolumenstrom G Water ow G Druckverlust KondensatorG Pressure loss condenser G Wasservolumenstrom CW Water ow CW Druckverlust wasserseitigCW Pressure loss water side CW CW-Registerinhalt CW coil content CW - Ventilgre (3-Wege) valve size (3-way) Luftvolumenstrom Airow Rckluftlterklasse Return air lter class Downow Sound pressure level Schalldruckpegel - A/GA/G Sound pressure level - ACW/GCW Schalldruckpegel - ACW/GCW Weight - A Gewicht - A Weight - - G Gewicht G Weight - - ACW Gewicht ACW Weight - - GCW Gewicht GCW Upow Sound pressure level - A/G Schalldruckpegel - A/G Sound pressure level - ACW/GCW Schalldruckpegel - ACW/GCW Weight - A Gewicht - A Weight - - G Gewicht G Weight - - ACW Gewicht ACW Weight - - GCW Gewicht GCW Cabinet size Baugre
1
191
total kW sensibel sensible total kW sensibel sensible total kW sensibel sensible total kW sensibel sensible
kg m/h kPa m/h kPa dm inch Zoll m/h
221
20,6 20,6 21,2 21,2 18,4 18,4 21,2 20,1 2,8 2,7 52 3,7 41 9,6 1" 6500 G4 55,6 56,4 330 335 348 351 57,5 58,5 320 327 339 345 1
251
27,3 24,0 26,5 23,7 22,8 22,8 22,5 21,6 3,2 3,3 52 4,0 46 1" 7000 G4 56,8 57,7 348 355 367 372 58,7 59,7 338 347 359 366
281
29,8 25,0 30,0 25,0 27,5 24,1 22,9 21,6 3,4 3,7 65 4,0 46 1" 7000 G4 56,8 57,7 352 360 370 375 58,7 59,7 342 352 359 369
321
31,9 30,3 32,0 30,3 29,2 29,2 33,5 31,3 3,9 3,8 57 5,8 45 1 1/4" 9500 G4 56,0 57,0 463 475 488 501 57,8 58,6 428 442 455 464
371
36,3 33,6 36,8 33,7 31,7 31,7 37,4 34,7 4,1 4,4 75 6,5 55 14,3 1 1/4" G4 57,7 58,6 463 475 489 501 59,1 60,2 428 442 456 464 2
391
40,4 35,6 40,7 35,7 36,8 34,2 38,6 35,6 4,3 4,9 91 6,7 59 1 1/4" G4 58,2 59,1 465 476 490 502 59,8 60,6 430 443 457 465
421
41,7 37,9 41,3 37,8 37,3 37,3 38,8 36,4 4,4 5,0 47 6,7 38 1 1/4" G4 54,4 55,4 548 560 591 606 56,4 57,3 510 522 556 568
461
46,5 43,7 46,6 43,7 48,2 44,4 4,6 5,6 58 8,3 58 18,3 1 1/4" G4 56,9 57,9 550 562 592 607 58,7 59,6 512 524 557 569 3
541
52,1 47,3 53,3 47,8 51,8 47,4 5,1 6,4 71 9,0 75 1 1/4" G4 57,8 58,7 550 563 593 608 59,6 60,5 512 525 558 570
18,1 18,1 18,8 18,8 17,3 17,3 19,3 18,4 2,4 2,2 35 3,3 33 1" 5900 G4
Auslegungsfllmenge fr G,G, GCW 1 Nominal refrigerant charge GCW 1
10500 10800 11500 14000 15000
dBA dBA kg kg kg kg
54,0 54,9 329 334 348 351 56,1 57,0 319 326 339 345
dBA dBA kg kg kg kg
The indicated refrigerant charge is valid for R407C, R410A and R134a. Units of version A/ACW contain a protective gas lling under atmospheric pressure.
For electrical data, (compressor and fan power consumption) see e-data sheet. The electrical power consumption of the fans must be added to the room load.
EN/08.2011/17/11
5.3 Technical Data - ASD/U ... A2/G/ACW2/GCW - 2-circuits

Type Modell
DX-cooling cap. R407C DX-Klteleistung R407C 24C/50% r.F. r.h. DX-Klteleistung R410A DX-cooling cap. R410A r.F. 24C/50% r.h. DX-Klteleistung R134a DX-cooling cap. R134a r.F. 24C/50% r.h. CW-Klteleistung CW-cooling capacity r.F. 24C/50% r.h. Wasservolumenstrom G Water ow G Druckverlust Kondensator G Pressure loss condenser G Wasservolumenstrom CW Water ow CW Druckverlust wasserseitig CW Pressure loss water side CW CW-Registerinhalt CW coil content CW - Ventilgre (3-Wege) valve size (3-way) Luftvolumenstrom Airow Rckluftlterklasse Return air lter class Downow Sound pressure level - A/G Schalldruckpegel - A/G Sound pressure level - ACW/GCW Schalldruckpegel - ACW/GCW Weight - - A Gewicht A Weight - - G Gewicht G Weight - - ACW Gewicht ACW Weight - - GCW Gewicht GCW Upow Sound pressure level - A/G Schalldruckpegel - A/G Sound pressure level - ACW/GCW Schalldruckpegel - ACW/GCW Weight - - A Gewicht A Weight - - G Gewicht G Weight - - ACW Gewicht ACW Weight - - GCW Gewicht GCW Cabinet size Baugre
1
412
kg m/h kPa m/h kPa dm inch Zoll m/h
422
45,9 43,3 48,7 44,4 40,8 40,8 46,3 42,8 2,4 5,8 62 8,0 54 18,3 1 1/4" 13500 G4 56,4 57,4 574 589 617 632 58,3 59,2 540 553 577 598 3
522
53,7 47,8 52,4 47,3 45,5 45,5 50,0 45,9 3,2 6,4 70 8,6 70 1 1/4" 14500 G4 57,3 58,3 608 623 651 666 59,1 60,1 574 587 610 632
562
56,8 53,6 54,0 54,0 48,1 48,1 57,1 52,8 3,5 6,6 49 9,9 44 1 1/2" 16500 G4 56,9 57,5 710 745 776 802 58,7 59,2 661 695 728 757
622
63,3 60,1 63,2 60,0 57,9 57,9 66,7 60,8 3,9 7,5 64 11,5 60 22,9 1 1/2" 19000 G4 58,7 59,3 719 747 784 810 60,4 61,0 669 697 735 764 4
712
71,8 64,8 72,4 65,1 62,4 62,4 70,4 64,0 4,1 8,6 84 12,2 67 1 1/2" 20000 G4 59,3 59,9 721 748 786 813 61,0 61,6 671 698 737 767
812
83,2 75,3 82,7 75,2 74,7 74,7 77,5 70,2 4,3 9,8 68 13,4 42 2" 21500 G4 59,6 61,0 826 853 905 932 62,0 63,3 786 812 866 891
872
91,4 81,1 91,5 81,2 83,1 75,0 4,6 10,9 84 14,4 50 27,5 2" 23000 G4 60,9 62,4 828 855 906 933 63,3 64,6 788 814 867 892 5
1072
102,4 88,0 104,8 89,0 88,6 79,5 5,2 12,5 87 15,3 56 2" 24500 G4 62,2 63,7 829 857 907 938 64,6 65,9 789 816 868 897
40,4 37,9 42,3 38,6 35,6 35,6 38,8 36,4 2,2 5,1 48 6,7 38 1 1/4" 11500 G4
Auslegungsfllmenge fr G/GCW 1 Nominal refrigerant charge G, GCW 1
dBA dBA kg kg kg kg
54,4 55,4 574 588 617 631 56,4 57,3 540 552 577 597
dBA dBA kg kg kg kg
The indicated refrigerant charge is valid per refrigerant circuit for R407C, R410A and R134a. Units of version A/ACW contain a protective gas lling under atmospheric pressure. 2 Two condensers required. For electrical data, (compressor and fan power consumption) see e-data sheet. The electrical power consumption of the fans must be added to the room load.
EN /08.2011/17/12
5.4 Technical Data - ASD/U ... GE and ALD/U ... GE - 1-circuit

Type ASD/U Modell
DX-cooling cap. R407C DX-Klteleistung R407C 24C/50% r.h. r.F. DX-Klteleistung R410A DX-cooling cap. R410A r.F. 24C/50% r.h. DX-Klteleistung R134a DX-cooling cap. R134a r.F. 24C/50% r.h. CW-Klteleistung CW-cooling capacity r.F. 24C/50% r.h. Auslegungsfllmenge 1 Nominal refrigerant charge 1 Wasservolumenstrom Water ow Druckverlust wasserseitig Sommer Pressure loss water side - -summer Druckverlust wasserseitig Winter Pressure loss water side - -winter GE-Registerinhalt GE coil content Ventilgre (2-Wege) Valve size (2-way) Luftvolumenstrom Airow Rckluftlterklasse Return air lter class Sound pressure level - Downow Schalldruckpegel - Downow Gewicht Downow Weight - - Downow Schalldruckpegel - Upow Sound pressure level - Upow Gewicht Upow Weight - - Upow Baugre Cabinet size
dBA kg dBA kg
191
kg m/h kPa kPa dm inch Zoll m/h
221
20,6 20,6 21,2 21,2 18,4 18,4 20,2 20,2 3,3 4,5 77 44 9,6 1 1/4" 6500 G4 56,4 352 58,5 337 1
251
27,3 24,0 26,5 23,7 22,8 22,8 22,6 21,4 3,7 5,6 70 44 1 1/4" 7000 G4 57,7 375 59,7 366
281
29,8 25,0 30,0 25,0 27,5 24,1 24,1 22,3 3,9 6,2 86 54 1 1/4" 7000 G4 57,7 381 59,7 372
18,1 18,1 18,8 18,8 17,3 17,3 18,3 18,3 2,9 4,1 65 38 1 1/4" 5900 G4 54,9 352 57,0 337
Type Modell ALD/U

DX-cooling cap. R407C DX-Klteleistung R407C 24C/50% r.F. r.h. DX-Klteleistung R410A DX-cooling cap. R410A 24C/50% r.F. r.h. DX-Klteleistung R134a DX-cooling cap. R134a 24C/50% r.F. r.h. CW-Klteleistung CW-cooling capacity 24C/50% r.F. r.h. Auslegungsfllmenge 1 Nominal refrigerant charge 1 Wasservolumenstrom Water ow Druckverlust wasserseitig- -summer Pressure loss water side Sommer Druckverlust wasserseitig Winter Pressure loss water side - -winter GE-Registerinhalt GE coil content Ventilgre (2-Wege) Valve size (2-way) Luftvolumenstrom Airow Rckluftlterklasse Return air lter class Downow Schalldruckpegel Sound pressure level Gewicht Weight Upow Sound pressure level Schalldruckpegel Weight Gewicht Cabinet size Baugre
1
191
221
21,4 21,4 24,8 23,1 19,0 19,0 22,3 22,3 3,3 4,9 70 42 9,6 1 1/4" 6800 G4 51,5 479 53,4 448 2
251
27,8 24,9 27,0 24,6 23,5 23,5 25,3 24,0 3,7 6,3 72 33 1 1/4" 7200 G4 52,4 496 54,3 464
281
30,8 26,6 30,6 26,5 28,4 25,7 27,2 25,5 3,9 7,0 88 41 1 1/4" 7500 G4 53,1 497 54,4 465
321
32,0 32,0 31,7 31,7 29,6 29,6 30,4 29,8 4,1 7,5 65 44 1 1/2" 9500 G4 53,0 609 55,1 575
371
37,0 34,6 37,0 34,5 32,3 32,3 33,8 32,6 4,4 8,3 79 53 14,3 1 1/2" G4 54,2 610 56,2 576 3
391
41,5 36,8 41,2 36,7 37,2 35,1 36,8 34,5 4,6 9,3 99 66 1 1/2" G4 54,6 612 56,6 578
421
43,0 39,8 42,3 39,5 38,5 38,5 38,6 37,0 4,7 9,8 69 38 1 1/2" G4 52,9 704 55,0 654
461
48,0 45,2 47,4 45,0 43,6 42,1 5,1 10,8 84 47 18,3 1 1/2" G4 54,9 705 56,8 655 4
541
54,1 50,1 55,0 50,4 50,3 47,3 5,6 12,5 110 62 1 1/2" G4 56,2 706 58,1 656
18,7 18,7 21,7 20,3 17,8 17,8 19,9 19,9 2,9 4,3 54 33 1 1/4" 5900 G4
10500 10800 11500 13500 15000
dBA kg
49,2 479 51,3 448
dBA kg
The indicated refrigerant charge is valid for R407C, R410A and R134a. For electrical data, (compressor and fan power consumption) see e-data sheet. The electrical power consumption of the fans must be added to the room load.
EN/08.2011/17/13
5.5 Technical Data - ALD/U ... GE - 2-circuits

Type Modell ALD/U
DX-cooling cap. R407C DX-Klteleistung R407C 24C/50% r.F. r.h. DX-Klteleistung R410A DX-cooling cap. R410A r.F. 24C/50% r.h. DX-Klteleistung R134a DX-cooling cap. R134a r.F. 24C/50% r.h. CW-Klteleistung CW-cooling capacity r.F. 24C/50% r.h. Auslegungsfllmenge 1 Nominal refrigerant charge 1 Wasservolumenstrom Water ow Druckverlust wasserseitig Sommer Pressure loss water side - -summer Druckverlust wasserseitig Winter Pressure loss water side - -winter GE-Registerinhalt GE coil content Ventilgre (2-Wege) Valve size (2-way) Luftvolumenstrom Airow Rckluftlterklasse Return air lter class Downow Sound pressure level Schalldruckpegel Gewicht Weight Upow Sound pressure level Schalldruckpegel Weight Gewicht Cabinet size Baugre
1
412
462
47,4 45,0 49,5 45,8 41,8 41,8 44,0 42,3 2,9 10,9 98 77 22,9 1 1/2" 13500 G4 54,9 758 56,8 710 4
522
55,5 49,8 53,7 49,1 47,0 47,0 50,1 46,7 3,7 12,7 93 65 1 1/2" 14500 G4 55,8 792 57,7 743
562
58,0 58,0 55,5 55,5 49,8 49,8 54,0 51,5 3,9 13,2 77 65 2" 16500 G4 55,6 923 58,3 889
622
64,8 64,8 64,3 64,3 59,6 59,6 61,2 58,1 4,4 14,6 94 80 27,5 2" 19000 G4 58,5 930 60,9 896 5
712
74,0 69,2 74,1 69,2 64,4 64,4 68,9 63,7 4,6 16,9 119 102 2" 20000 G4 59,5 939 61,9 905
812
83,2 75,3 82,7 75,2 74,7 74,7 76,3 69,5 4,6 18,9 76 77 2" 21500 G4 61,0 952 63,3 918
872
91,4 81,1 91,5 81,2 84,2 75,6 4,6 21,2 97 98 27,5 2" 23000 G4 62,4 954 64,6 920 5
1072
102,4 88,0 104,8 89,0 92,9 82,0 5,2 24,1 124 127 2" 24500 G4 63,7 954 65,5 920
41,7 39,3 42,7 39,7 36,9 36,9 37,9 36,7 2,6 9,6 77 60 1 1/2" 11500 G4
dBA kg
52,9 756 55,0 708
dBA kg
The indicated refrigerant charge is valid per refrigerant circuit for R407C, R410A and R134a.
For electrical data, (compressor and fan power consumption) see e-data sheet. The electrical power consumption of the fans must be added to the room load.
EN /08.2011/17/14
5.6 Dimensional drawings

Cabinet size 1 Cabinet size 2
Cabinet size 3
Cabinet size 4
Cabinet size 5
Side view
(for all sizes)
EN/08.2011/17/15
6. Installation
6.1 Positioning
Check that the installation site is appropriated for the unit weight, which you can read in the technical data. The A/C unit is designed for the inside installation on a level base. The solid base frame contributes signicantly to an even weight distribution. When selecting the installation site take into account the necessary clearances for the maintenance and the air ow. Children, unauthorized persons and animals may not have access to the installation site of the A/C unit. Vibrations emanate from the A/C unit due to compressor operation. To avoid such vibrations, we recommend installing the unit on a vibration absorbing base, as it is realized in case of a positioning on a raised oor socket e.g. by Mafund strips. The A/C unit should not be operated in ofce rooms or other rooms sensitive to noise.
The unit may not be operated in an explosive atmosphere!
1m
Maintenance clearance Air intake area for Downow units and air outlet area for Upow units without duct connection
EN /08.2011/17/16
0,5m
6.2 Connection of the piping

6.2.1 Position of the refrigerant connections (A/ACW units)
Downow unit (A version) Upow unit (ACW version)
Chilled water piping Pipe entrance area for refrigerant lines

144
63
144
43 *(63)
98
454
Pipe entrance area for chilled water piping, see page 20 also.
*distance from the exterior side of the side panel to the zone of introduction. This dimension is decisive if several units are installed tting exactly side by side.
Diameter of refrigerant lines (1 circuit) in mm Gert Unit Pressure line Druckleitung Liquid line Flssigkeitsleitung 191 16 10 221 16 12 251 16 12 281 22 16 321 22 16 371 22 16 391 22 16 421 22 16 461 22 16 541 22 16
Diameter of refrigerant lines (2 circuits) in mm Gert Unit Pressure line Druckleitung Liquid line Flssigkeitsleitung 412 16 12 462 16 12 522 16 12 562 16 12 622 22 16 712 22 16 812 22 16 872 22 16 1072 22 16
The refrigerant connections are located near the compressor and are labelled by the inscriptions "pressure pipe" and "liquid pipe" respectively "pressure pipe 1" and "pressure pipe 2" etc. for 2-circuit units. The lines to be connected have to be soldered. For the connection of the external pipework please note the pipe entrance area shown on top of the page.
EN/08.2011/17/17
128
454
6.2.2 Filling systems with R407C refrigerants

- Connect the unit electrically as described on top of page 22. - Turn the main switch to the ON position (the C7000 controller should now be in the Stop mode). - Switch on the control-circuit fuses. - Do not switch on neither power switches nor the controller. C7000AT: - Select the Cong menu. - Enter the password. - Go to menu "Components/ Manual oper./Cooling/Valves. - Change the parameter in the column "EN" line "EEV 1" from "0" to "1". - Set the parameter in the column "Value" of the same line to 100%. C7000IOC: - Enter the command: "eev 1 hand 1" and "eev 1 handon 100". The expansion valve is now completely open.
Safety valve
Non-return valve (option)
Receiver Open stop valves !
Condenser
TCE
Compressor
external installation
A/C unit Open the stop valves. The refrigerant circuit is lled with a nitrogene lling under atmospheric pressure. Evacuate the refrigerant circuit by the Schrader valves until approximately 0 bar. Fill the refrigerant circuit with refrigerant by the Schrader valves. Systems without refrigerant receiver or sight glass must always be lled according to weight. Systems with refrigerant receiver should be lled according to weight but can also be lled by checking the sight glass. If you use the refrigerant R407C, please note that R407C is a ternary blend. Take care that you add refrigerant in a liquid state, as the ratio of the refrigerant components changes if one of the three compounds passes over into the gaseous phase.
PSL
PZH
Before the system is lled with refrigerant, it must be clean and dry inside. (Refer to evacuation instructions). Then proceed as follows: The standing refrigerant bottle is connected to the suction side via a pressure gauge station. The weight is noted shortly before lling. The specied amount of refrigerant is now added when the system is operating. During lling the pressure in the refrigerant bottle will adjust to that of the system. Filling is then no longer necessary. This can be seen by the icing up of the bottle or by checking the pressure gauge. The bottle valve must then be closed until a pressure increase has taken place which is above the suction pressure of the system. This process can be accelerated if the bottle is wrapped in hot moist towels or it is placed in a water bath at a maximum temperature of 50C. Never heat up the refrigerant bottle with a naked ame as there is a risk of explosion.
For R410A, R134a: Refer to the special requirements of the refrigerant manufacturer.
EN /08.2011/17/18
6.2.3 Water piping

External water circuit
To seal the water circuit you must connect the unit to a chilled water ring mains, which contains for the generation of cold water either a chiller or a dry cooler or cooling tower. If the water quality is insufcient, we recommend the additional installation of a ne mesh strainer. For an efcient protection against corrosion, the anti-freezing agent is mostly sufcient, which should be used if the water temperature passes under 5C or if the outside temperature is less than 0C. We recommend to add the Mont.EPS following quantities of ethylenglycol (indicated as percentage of weight of the water quantity) : water or outside air temperature from +5 to -5C from -5 to -10C from -10 to -15C from -15 to -20C from -20 to -25C correction coefcient for the pressure drop in the water circuit when using ethylenglycol
1.50 1.45 1.40 1.35 1.30 1.25 1.20 1.15 1.10 1.05 -10 -8 -6 -4 -2 0 2 4 6 8 50% 40% 30% 20% 10%
ethylenglycol 10% 20% 28% 35% 40%
average chilled water temperature (C) For connecting the unit to the external system remove the protective caps from the anges of the water pipes. Water remaining from the test run may escape when the protective caps are removed. The water connections are executed in the shape of a screw connection with a soldering connection. Solder the part with the external thread of the connection to the external pipes and screw the lines of the external system to the lines of the unit respecting the designation at the unit. If any seals are missing, these must only be replaced by glycolresistant rubber seals. Insulate the water pipes with the insulating material supplied, to prevent the introduction of ambient air heat as well as possible. Screw the water pipes of the A/C unit together with the local water pipes of the dry-cooler or the chiller. Fill and bleed air from the cooling water circuit by means of the lling connections and the schrader valves for bleeding (see refrigerant diagram, not part of the manual but part of unit documents).
Union screwed connection
Water pipe insulation
EN/08.2011/17/19
Downow unit (GCW version)
Upow unit (GCW version)
144
63
128
43 ) *(63
454
144
98
To connect the piping notice the labels on the pipe ends. Durchmesser Diameter 15 16 22 28 35 42 54 70 S: width across ats Water pipe diameters (1 ref. circuit) in mm Unit Gert G pipes Leitung - G GE pipes Leitung - GE CW pipes* Leitung - CW* 191 28 35 35 221 28 35 35 251 35 35 35 281 35 35 35 321 35 42 42 371 35 42 42 391 35 42 42 421 42 42 42 461 42 42 42 541 42 42 42 S 30 30 37 46 53 65 82 95
Water pipe diameters (2 ref. circuits) in mm Gert Unit Leitung - G G pipes Leitung - GE GE pipes Leitung - CW* CW pipes* 412 35 42 42 462 35 42 42 522 35 42 42 562 35 54 54 622 35 54 54 712 42 54 54 812 42 54 54 872 42 54 54 1072 54 54 54
*CW pipes only exist in units of version ACW and GCW.
EN /08.2011/17/20
454
6.2.4 Condensate drain connection

The condensate drain connection is located in the middle section, right bottom. The syphon is delivered with the unit and has to be mounted in the raised oor on site after the A/C unit has been installed.
332
59
Syphon installation
Ensure that there is a sufcient height difference between the fan pan and the upper bow of the syphon or the highest part of the drain tube, in order to avoid a water column in the drain syphon caused by the pressure in the suction area of the A/C unit, which prevents the draining of the condensate water
Example: Static pressure in the suction area: -300Pa h = p / ( g) h = -300Pa / (1000kg/m 10m/s) h = -3 cm If the height h is smaller than 3 cm with a pressure of 300 Pa in the suction area, a water column rests in the drain, the water is not transported and lls the fan pan. This water can be drawn dropwise in the fan or can drop out of the unit if the pan is full.
>10 cm
unit limit
possible installation at the customer side: funnel
Connect the condensate water drains to the local waste water system. Comply with the regulations of the local water supply authority.
EN/08.2011/17/21
6.3 Electrical connection

Ensure that the electric cables are de-energized. The electric cables are only to be connected by an authorised specialist. The unit must dipose of an effective earthing. Do not touch electronical components, without taking care of protective ESD measures. The power supply system on site and the pre-fuses must be designed for the total current of the unit (see e-data sheet). Route the electric cable into the electrics box from below and connect the hree phases to the main switch, the PE conductor at the PE rail and the neutral conductor at the neutral terminal, in accordance with the wiring diagram (part of the unit documents) and secure these cables by the pull relief screw. Make sure that the phase rotation is correct, the rotating eld must turn right ! The scroll compressor is dependent on correct phase rotation. The sense of rotation will be checked at the factory before dispatch. On site, if the rotating eld of the compressor is incorrect, it must be corrected by changing two phases of the power supply at the isolator. An inverse rotating eld can be detected by a raised compressor noise level and results in overheating and destruction of the compressor after several hours of operation.
61
536
125 235
Insertion for the power supply cable, Downow
Power supply, Upow
For use of leakage-current (FI) circuit breakers, EN 50178 5.2.11.2 must be taken into account. Only type B pulse-current FI circuit breakers are permitted. FI circuit breakers do not provide protection against bodily harm during operation of the unit or frequency converters. Make sure that the power supply corresponds to the indications on the rating plate and that the tolerances according to the "Application limits" are not exceeded. In addition to this, the asymmetry of phase between the conductors may amount to 2% maximally. The asymmetry of phase is determined by measuring the voltage difference between the phase conductors. The average value of the voltage differences may not exceed 8 V.
EN /08.2011/17/22
90
7. Commissioning
The unit must be installed and connected in accordance with the chapter on "installation" before initial commissioning.
Make sure that the master switch is off and the unit is de-energized. Open the electrical compartment door of the unit using the key provided. Check whether all power switches and control-circuit fuses in the electrical section of the unit are switched off. Retighten all screw connections in the electric cabinet. Verify the smooth function of the contactors.
Power switch off
Electrical compartment
Power switches
Control-circuit fuses
IO Controller
Master switch
Do not turn the adjustment screw beyond the end of the calibrated scale range, as it may result in overheating and short-circuit at the consumer or in the destruction of the power switch.
Adjustment of the power switches according to electrical data sheet. Switch on the A/C unit at the master switch. Switch on the control-circuit fuses and the power switches of the fan and the compressor in sequence. Close all doors of the A/C unit.
non-calibrated range
The controller is now supplied with power, so you can use it for adjustments. Make sure that the heat rejecting system is operating. A - air-cooled condenser G, GE - dry cooler ACW - air-cooled condenser + chiller GCW - dry cooler + chiller Switching on power switch
EN/08.2011/17/23
The doors can only be opened with the key provided and represent a protective device. During operation the doors may not be opened and the rear panels may not be removed. Adjust the desired return air temperature at the controller. Start the A/C unit by pressing the Start/Stop-key on the controller. Check after 20 minutes operation, whether bubbles are visible in the sight glass of the liquid line. If this is the case, refrigerant might have escaped by a leak. Check the circuit on leaks, eliminate these and top up the circuit with R407C in regard of the chapter "Maintenance". Check the oil level at the compressor in respect of the right level. The oil level should be between the lower quarter and the middle of the sight glass. Check the current consumption of the compressors and the fans comparing it with the values of the e-data sheet. Instruct the operational staff of the controller manipulation (refer to the controller manual).
Controller C7000, Start/stop-key
Oil level at the compressor
EN /08.2011/17/24
8. Maintenance
8.1 Safety instructions
All maintenance work is to be carried out under strict compliance with the country-specic accident prevention regulations. In particular we refer to the accident prevention regulations for electrical installations, refrigerating machines and equipment. Non-compliance with the safety instructions can endanger people and the environment. Maintenance work is only to be carried out on the units by authorized and qualied specialist staff. Procedure instructions Work on the system must always only be carried out when it is shut down. To do this, the unit must be switched off at the controller and at the master switch. A DO NOT SWITCH ON warning sign must be displayed. Live electrical components are to be switched to de-energized and checked to ensure that they are in the de-energized state. Some verications must be effected with the unit in operation (measuring the current, pressures, temperatures). In such a case the unit must only be switched on at the master switch after all mechanical connections have been carried out. The unit must be switched off immediately after the measuring procedure. Warning notes! When the master switch is switched on and the controller is stopped the power contactors are live, even if the components are not operating. At the fan contactor, dangerous voltages occur. Do not open the unit within the rst 5 minutes after disconnection of all phases. Be sure that the unit is being isolated. In units with 2 or 3 fans dangerous charges of >50C can occur between AC line terminals and PE after disconnection. The electronics housing can get hot. The fans have an operation delay after the unit is stopped ! (Risk of injury)
8.2 Maintenance intervals

Component monthly Refrigerant circ. Refrigerant charge HP/LP switch Sight glass Compressor Expansion valve Air circuit Heat exchanger Fan Air lter Water circuit Tightness Condenser Unit in general Electrics Mechanics x x x x Maintenance interval quarterly half-yearly x x x x x x x x yearly
EN /08.2011/DX/25
8.3 Refrigerant circuit

Refrigerant charge - Quantity and Purity
Quantity - Check the sight glass and the LP switch. An unsufcient charge causes the formation of bubbles in the sight glass or in extreme cases the triggering of the LP-switch. An operation with an unsufcient refrigerant quantity over a longer period leads to a reduction of cooling capacity and to high superheating temperatures, which have a disadvantageous effect on the compressor lifetime. If a leak is detected: let out the refrigerant in a collecting device down to a pressure of 1 barabsolut connect a vacuum pump via a pressure gauge station on the high and low pressure side extract the refrigerant by the vacuum pump (not by the compressor !) to approx. 0 barabsolut. dispose the refrigerant according to the national regulations ll the circuit with nitrogen to 1 barabsolut repair the leak the circuit has to be run dry by several (at least 3x) llings and extractings of nitrogen, eventually change the lter drier. ll with R407C according to weight (see technical data) R407C must be charged in a liquid state, in order that the composition of the refrigerant does not change.
Quantity - Check the HP switch An overlling of the circuit makes the condensation pressure rise and by that the power consumption of the compressor. In the extreme the HP-switch triggers.
Purity - Check the sight glass and the lter drier. Bubbles in the sight glass indicate that the charge is unsufcient or that the lter drier is clogged. A pollution of the lter drier, whose origin task is to clear the refrigerant from impurities and humidity, can be detected by a temperature difference upstream and downstream the lter drier. Compare the colour indicator in the centre of the sight glass with the outer ring scale. purple to blue ---> ok. rose to red ---> humidity critical. With too much humidity in the circuit, the expansion valve can freeze. In addition to this the ester oil in the compressor, which comes in touch with the refrigerant, takes up humidity and loses its ability to lubricate. In this case the refrigerant must be completely evacuated and recharged according to the above described evacuation instruction.
Sight glass
EN /08.2011/DX/26
Compressor
In the compressor there is an ester oil charge, which does not have to be renewed under normal operation conditions and holds out for the unit's lifetime. However, it is possible that the ester oil, as it reacts hygroscopically, has taken up humidity of the air after repeated recharging of the refrigerant circuit due to repair works. The interaction between ester oil and water results in the formation of acid. Owing to a hyperacidity, corrosive processes take place inside the compressor. In this case the ester oil should be exchanged. The oil level can be checked by looking at the sight glass of the compressor.
Expansion valve
The refrigerant circuit is equipped with a electronic expansion valve, which controls the superheating in the evaporator.The superheating is adjusted to 7 K at the factory and may not be modied. The expansion valve can freeze, if the humidity in the system is excessive. Do not thaw by soldering ame, danger of explosion ! Thaw with moist warm cloth. Check the sight glass.
8.4 Air circuit

Heat exchanger (Evaporator / GE/CW-coil)
The heat exchanger consists of copper tubes with aluminium ns. If refrigerant leaks occur, they should be searched for at the heat exchanger. Beyond that, the heat exchanger is exposed to the air pollution, the particles of which settle at the ns and reduce the heat transmission the same as raise the air resistance. The latter shows when the fan current increases. The heat exchanger can be cleaned by pressurized air which has to be blown opposite to the normal air ow direction along the ns.
Do not distort the ns while cleaning, this also increases the air resistance !
Fan
The bearings of the fans are lifetime lubricated and do not need maintenance. Check the operation current. An increased operation current indicates either a higher air resistance by a clogged pre-lter or a winding short circuit in the fan motor. The fans are speed controlled in dependance of the required cooling capacity. You can manually modify the speed at the controller for test purposes, so as to compare the measured current with the values on the pages with the technical data or with those of the planning tool.
Air lter
A lter monitor controls the state of the lter. As soon as the pressure loss exceeds an adjustable value, a lter alarm via the controller is released. The controller can be congured such as to compensate the pressure loss by a higher fan speed, however you should not wait too long for exchanging the lter. The lters can be accessed by the front doors, depending on the cabinet size the number of lter elements varies. The clogged lter elements can not be cleaned with pressurized air, as the lter structure would be destroyed otherwise. When you re-install the lter elements after the exchange, take care that the side with the coloured mark (dirt side) is turned away from the heat exchanger.
EN /08.2011/DX/27
8.5 Water circuit

Tightness
Check the water circuit visually for tightness. Beyond that a level indication at the storage tank, if existant, can give information about changes of the water quantity. A lack of water in the circuit is replaced by air, which reduces the heat capacity of the chilled water circuit and is detrimental to the pump.
Condenser (only at G, GE, GCW)

Check the water side pollution of the plate condenser by comparing the cooling water inlet temperature to the outlet temperature. If the difference is less than 3 K, it indicates a limited heat transmission and thus pollution. Another possibility to verify this consists in the comparison of the outlet temperature with the medium condensation temperature (by measuring the condensation pressure at the high pressure side of the compressor). If this difference exceeds 7 K, the condenser is probably polluted. In this case the condenser has to be cleaned chemically.
8.6 Unit in general

Electrics
Check the connection terminals for tight xation when the unit is installed and once again after an operation time of 30 days.
Mechanics
Clean the unit's inside with a vacuum cleaner. Clean pipes simplify the search for leaks. Check the pipes, the compressor and the condenser for a tight seat. Vibrations of pipes and circuit components can result in leaks. Check also the insulation of the water piping. Condensing air humidity on cold water pipes means a loss of cooling capacity.
8.7 Competences
Repairs on the refrigerant circuit (tightness, lter drier exchange) Repairs on the main components of the refrigerant circuit (compressor, expansion valve, condenser, evaporator) Repairs on the water circuit (tightness) Repairs on the electrics Trained refrigeration technician Stulz service technician Trained service technician Trained electrician
EN /08.2011/DX/28
9. Malfunction
Alarm message Cause for alarm C7000: Compressor # error High pressure switch has triggered or Cause 1. outside temperature too high 2. cooling water temperature too high 3. condenser fan defective. 4. condenser pressure switch adjusted too high. 5. condenser coil soiled. 6. overcharge of refrigerant circuit 7. electric connection of high pressure switch loose. Cable defective. 8. trigger point adjusted too low. Elimination Install bigger condenser. Check drycooler. Check function. Modify setting. Clean condenser. Discharge and dispose refrigerant. Check connection and cable. Check setting of high pressure switch. Press blue release button at HP switch after elimination of error. Check compressor motor on voltage continuity and current consumption. Check alimentation under load. Modify setting. Rell refrigerant. Check connection and cable. Check setting of low pressure switch. Exchange expansion valve. Check electric alimentation with voltage meter. Check fan motor on voltage continuity and current consumption. Fan mechanically blocked? Check air lter. Clean hoses and check whether they are kinked . Check room on Hotspots or chilled air zones, moist zones. Check measured value with an external measuring instrument.
Compressor power interruptor has triggered.
1. compressor motor defective. 2. feeding voltage too low.
C7000: Low pressure # error
Low pressure switch has triggered.
1. condenser pressure switch adjusted too low. 2. Insufcient refrigerant charge 3. electric connection of low pressure switch loose. Cable defective. 4. trigger point adjusted too high. 5. Expansion valve defective. 6. Solenoid valve in liquid line defective.
C7000: Airow failure
Differential pressure for airow switch has triggered.
1. Fan motor defective. Fan speed too low. 2. Air lter extremely clogged. 3. Hoses to the airow monitor dirty or kinked.
C7000: Sensor # error
The tolerance to the average 1. Big difference of measeured value adjustable in the contvalues in selected zone. roller has been exceeded. 2. sensor defective.
C7000: The measured voltage/curSensor # defec- rent is outside the range tive dened in the controller.
1. electrical connection defective. Check connections. Check cable on continuity. 2. sensor cable defective. 3. sensor defective. Check measured value with external thermometer, hygrostat, pressure gauge.
Depending on the option congured in the controller further alarm messages exist. # stands for a number in case of several components of the same kind.
EN /08.2011/DX/29
10. Dismantling and disposal

The A/C unit can only be dismantled by qualied specialists. Switch off the A/C unit at the controller and at the master switch. Switch off power conducting cables to the unit and secure them against being switched on again. Disconnect the A/C unit from the de-energized network. Dispose of the refrigerant in the unit in accordance with the disposal and safety regulations applicable on site
The refrigerant may not be discharged into the atmosphere, but must be returned to the manufacturer, if it is not reused. The ester oil in the compressor must also be disposed. As it contains dissolved refrigerant, it can not be disposed like usual oils, but must be returned to the oil manufacturer.
Disconnect the depressurized refrigerant pipes from the external system (version A/ACW).
If glycol or similar additives had been used, this liquid also has to be collected and disposed in an appropriate manner and may under no circumstances be introduced in the local waste water system. Disconnect the unit from the external water circuit by closing the shut-off valves and drain the water circuit of the unit (version G/GE/GCW). Disconnect the depressurized cooling water pipes of the unit from the external system. Move the unit, as described in the chapter "transport", with a lifting device of sufcient load-carrying capacity. Dispose of the A/C unit in accordance with the disposal and safety regulations applicable on site. We recommend a recycling company for this. The unit basically contains the raw materials aluminium (heat exchanger), copper (pipelines, wiring), and iron (condenser, panelling, mounting panel).
EN /08.2011/DX/30
11. Contents of the CE Declaration of Conformity

The undersigned
STULZ GmbH Klimatechnik Holsteiner Chaussee 283 22457 Hamburg
hereby conrms that the units listed below, in the version marketed by us, full the requirements of the harmonised EC directives and EC safety standards listed below. In the case of a modication of the equipment not co-ordinated with us this declaration loses its validity. Air conditioning unit
Cyber Air 3 ... A / ACW / G / GCW

ASD 191 ... ASD 221 ... ASD 251 ... ASD 281 ... ASD 321 ... ASD 371 ... ASD 391 ... ASD 421 ... ASD 461 ... ASD 541 ... / / / / / / / / / / ASU 191 ... ASU 221 ... ASU 251 ... ASU 281 ... ASU 321 ... ASU 371 ... ASU 391 ... ASU 421 ... ASU 461 ... ASU 541 ... ASD 412 ... ASD 462 ... ASD 522 ... ASD 562 ... ASD 622 ... ASD 712 ... ASD 812 ... ASD 872 ... ASD 1072 ... / / / / / / / / / ASU 412 ... ASU 462 ... ASU 522 ... ASU 562 ... ASU 622 ... ASU 712 ... ASU 812 ... ASU 872 ... ASU 1072 ...
Cyber Air 3 ... GE

ASD 191 ... ASD 221 ... ASD 251 ... ASD 281 ... / / / / ASU 191 ... ASU 221 ... ASU 251 ... ASU 281 ... ALD 191 ... ALD 221 ... ALD 251 ... ALD 281 ... ALD 321 ... ALD 371 ... ALD 391 ... ALD 421 ... ALD 461 ... ALD 541 ... / / / / / / / / / / ALU 191 ... ALU 221 ... ALU 251 ... ALU 281 ... ALU 321 ... ALU 371 ... ALU 391 ... ALU 421 ... ALU 461 ... ALU 541 ... ALD 412 ... ALD 462 ... ALD 522 ... ALD 562 ... ALD 622 ... ALD 712 ... ALD 812 ... ALD 872 ... ALD 1072 ... / / / / / / / / / ALU 412 ... ALU 462 ... ALU 522 ... ALU 562 ... ALU 622 ... ALU 712 ... ALU 812 ... ALU 872 ... ALU 1072 ...
EC-Directives
EC machinery directive 2006/42/EC EC directive for low voltage 2006/95/EC EC EMC directive 2004/108/EC EC pressure equipment directive 97/23/EC
Harmonised EN
EN 378 -1, -2, -3, -4 EN ISO 12100 -1/2 EN ISO 13857 EN 60204 -1 EN 61000-6-2 EN 61000-6-4
National regulation
BGV A3 BGV D4
Hamburg, 01.08.2011
Place, date
ppa.
Works management: Mr. Panknin
EN /08.2011/DX/31
12.1 Steam humidier

The steam humidier is an optional extra for your A/C unit. It is installed complete and integrated within the function and method of operation of the A/C unit. Details concerning the connection assignment for the power supply can be found in the electrical diagrams in the appendix.
12.1.1 Description
The steam humidier OEM2 is a pressureless steam generator that utilizes an electrode heating and is designed for air humidication via a steam distributor (steam distribution pipe, steam nozzle).
Steam generation
Any time steam is requested, the electrodes (2) are supplied with voltage via main contactor (1). Simultaneously, the inlet valve (7) opens and water enters the steam cylinder (3) from the bottom via water cup (4) and supply line (5). As soon as the electrodes come in contact with the water, current begins to ow between the electrodes, eventually heating and evaporating the water. The more the electrode surface is exposed to water, the higher is the current consumption and thus the steam capacity. Upon reaching the requested steam capacity, the inlet valve closes. If the steam generation decreases below a certain percentage of the required capacity, due to lowering of the water level (e.g. because of the evaporation process or drainage), the inlet valve opens until the required capacity is available again. If the required steam capacity is lower than the actual output, the inlet valve is closed until the desired capacity is achieved by lowering of the water level (evaporation process).
Level monitoring
A sensor provided in the steam cylinder cover detects when the water level gets too high. The moment the sensor comes in contact with water, the inlet valve closes.
Drainage
As a result of the evaporation process, the conductivity of the water increases due to an escalating mineral concentration. Eventually, an inadmissibly high current consumption would take place if this concentration process were permitted to continue. To prevent this concentration from reaching a value, unsuitably high for the operation, a certain amount of water is periodically drained from the cylinder and replaced by fresh water. During the drainage process, the drain valve (6) is opened. Following a predetermined time of drainage, the drain valve is closed again.
On/Off control
Proportional control
Control
With the ECCM/S control unit either On/Off control or proportional control can be employed for steam production. Below a minimum controllable steam output, proportional control will work in two-point operation (on/off control).
X = steam capacity in % Y = Output signal controller
EN/04.2011/humidier/1
Danger that may arise from the unit

DANGER! Danger of electric hazard! The steam humidier OEM2 is operated with mains voltage. One may get in touch with live parts when the unit is open. Touching live parts may cause severe injury or danger to life. Prevention: Before carrying out any work set the steam humidier OEM2 out of operation as described in chapter 12.1.3.5 (switch off the unit, disconnect it from the mains and stop the water supply) and secure the unit against inadvertent power-up. WARNING! Danger of burning! The steam humidier OEM2 produces steam. When producing steam, the steam cylinder inside the humidier gets very hot (up to 100 C). If the unit is opened immediately after having produced steam there is danger of burning when touching the steam cylinder. Prevention: Before carrying out any work set the steam humidier OEM2 out of operation as described in chapter 12.1.3.5, then wait until the steam cylinder has cooled down sufciently thus preventing danger of burning.
12.1.1.1 Technical data

Steam capacity [kg/h] Dampeistung [kg/h] 2,0 4,0 4,0 8,0 10,0 4,0 8,0 15,0 Nominal power[kW] Nennleistung [kW] 1,5 3,0 3,0 6,0 7,5 3,0 6,0 11,25 Nominal current [A] Nennstrom [A] 7,5 ... 6,5 15,0 ... 13,0 8,7 ... 7,5 17,3 ... 15,1 21,7 ... 18,8 4,6 ... 3,8 9,1 ... 7,5 17,1 ... 14,1 Maximalstrom[A] Max. current [A] 9,4 ... 8,2 18,8 ... 16,3 10,8 ... 9,4 21,7 ... 18,8 27,1 ... 23,5 5,7 ... 4,7 11,4 ... 9,4 21,4 ... 17,6 200 ... 230V / 1N~ / 50 ... 60Hz
200 ... 230V / 3~ / 50 ... 60Hz
380 ... 460V / 3~ / 50 ... 60Hz
Operating conditions Admissible water pressure Water quality Admissible water temperature Admissible ambient temperature Admissible ambient humidity Adm. back pressure at steam connection Type of protection Conformity 1 ... 10 bar Drinking water with a conductivity of 125 - 1250S/cm 1 ... 40 C 1 ... 50 C (control unit 1 ... 40 C) max. 75% rh, non-condensing - 0,5 kPa ... 1,0 kPa IP00 produced according VDE regulations 0700 and 0700 part 98
EN04.2011/humidier/2
12.1.1.2 Wiring diagram of the control unit ECCM/S
input signal from the C7000 controller
to C7000 alarm input
Danger Mains voltage
B5 F1 F2/Q2 F3/Q3 H1 H2 H3 JP1 JP2
Level sensor steam cylinder Fuse control board (2 A, time-lag) Automatic fuse control voltage MCB humidier Red LED: Error Yellow LED: Service, Warning Green LED: Steam production Jumper block 1 Jumper block 2
S1 S2 Sx% %rH Y1 Y2 Y3 T1
Rotary switch unit type Drain/Info key Potentiometer power limitation Potentiometer humidity value Main contactor heating voltage Inlet valve Drain valve Current sensor
12.1.1.3 Conguration of the control unit ECCM/S

Setting the capacity limitation Sx%
Use the potentiometer Sx% to set the capacity limitation in % of the maximum capacity (setting range: 25...100%, factory setting: 100%).
Setting the control signal

With the jumpers on jumper block JP1 you can set the control signal. The control signal is adjusted on 0-10V, none of the jumpers "mA", "SP", "2P" on jumper block "JP1" may be set for this.
General unit settings

With the jumpers on the jumper blocks JP1 and JP2 you can set different unit parameters. Pos. Fi DRN CDY DSP K with jumper Connection to a mains supply with ground fault circuit interrupter ** Increased drain operation factor Low water conductivity (<125 S/cm) Exchangeable steam cylinder ** Fault No. 4 steam cylinder maintenance due: the unit triggers a warning only (the error switch on the control unit ECCM/S is not activated). without jumper Connection to a mains supply without ground fault circuit interrupter Regular drain operation factor ** Normal water conductivity (125 S/cm) ** Cleanable steam cylinder Fault No. 4 steam cylinder maintenance due: 72 hours after the warning an error is triggered and the unit is switched off (red LED lights). However, the error switch on the control unit ECCM/S is activated already in warning status. ** Fault No. 3 Fill time: the unit directly triggers an error after 20 minutes lling time exceeding (red LED lights and the error switch on the control unit ECCM/S is activated). However, the unit is switched off after 220 minutes lling time exceeding.
Fault No. 3 Fill time: a warning is triggered after 20 minutes lling time exceeding. After 220 minutes lling time exceeding an error is triggered and the unit is switched off (red LED lights and the error switch on the control unit ECCM/S is activated). ** no function (spare)
Z, M, N
** Factory settings
12.1.2 Supply connections

The steam humidier is installed and electrically connected in the A/C unit. The local regulations of the water supply company are to be complied with when making the hydraulic connection. We recommend the installation of an Aqua-stop valve in the water supply of the humidier. In addition to this, the room, in which the A/C unit with the humidier is installed, should be equipped with a water detection system.
Legend: 1 Level sensor 2 Steam outlet connector 22.5 - 30 mm 3 Heating electrodes 4 Inlet valve 5 Outlet valve 6 Drain connector 22.1 mm 7 Water supply connector G 3/4
Water supply
The water connection is made from the cold water mains and is to be equipped with a shut-off valve. It is recommended to install a lter to retain solid particles of pollution. The humidier can be connected directly to the mains by a threaded tenon of 3/4" when the water pressure is between 1 and 10 bar. The pipe should have a diameter of at least 6 mm. In the factory a 680 mm hose with 3/4 inch nut on each side is mounted to simplify the connection to the piping on site. If the line pressure is more than 10 bar, the connection must be made via a pressure reducing valve (set to 4-6 bar). In each case it is to be ensured that the manufactured water pipe upstream of the connection to the humidier is ushed properly. We recommend only using copper pipes. The water supply temperature must not exceed 40C.
Water drain
The drain connection has an outside diameter of 22.1 mm. A plastic hose can be connected to the drain connection which can be routed out of the unit by means of the openings in the unit provided for this purpose. When creating the drain, attention is to be paid to provision for cleaning. the water drain depressurized, we recommend routing the drain hose passing through a syphon, as described in As the water drain isis depressurized, we recommend routing the drain hose rst into an open collector funnel and then passing through a syphon to the drainage system to into an open collector the unit operating instructions under "syphon installation", ensure free discharge. funnel to ensure free discharge. The drainage pipe should be routed to the sewerage system with sufcient gradient (at least 5%) and should be located approx. 30 cm below the humidier. Attention is to be paid to temperature resistance when plastic pipes are used. If copper pipe is used, it must be earthed. For the drainage pipe an inside diameter of at least 22 mm is required.
12.1.3 Operation
12.1.3.1 Function of the display and operating elements on the control unit ECCM/S
1 Drain/Info key press key shortly: opens and closes the drain valve (manual draining). Note: the drain valve is automatically closed after 10 minutes. press key for a extended period of time: activating the info mode 2 Error indication (red LED) in normal operating mode The LED lights in case of a malfunction of the unit. Further operation is no longer possible, the heating voltage is interrupted. An alarm signal is sent to the C7000 controller. At the C7000AT the alarm "HUMIDIFIER 1 FAILURE" is displayed. in info mode LED blinks in intervals if a malfunction is present. The number of blinks per interval indicates the number of the error (see chapter 12.1.4.3). 3 Warning and info indication (yellow LED) in normal operating mode The LED blinks, if manual draining is in progress. The LED lights if the cylinder maintenance is due or the maintenance indication is not reset after the maintenance. in info mode LED blinks in intervals if a malfunction with status warning is present. The number of blinks per interval indicates the number of the error (see chapter 12.1.4.3). 4 Steam production (green LED) in normal operating mode The LED lights if the unit produces steam. in info mode LED blinks in intervals. The number of blinks per interval multiplied by 10 indicates the current steam output in % (see chapter 12.1.3.3).
12.1.3.2 Commissioning
Proceed as follows when putting the unit into operation: 1. 2. 3. 4. Examine the steam humidier and installation for possible damage. Open the shut-off valve (if existant) in the water supply line. Switch on control fuse and humidier power switch in electric box. Switch on main switch. Adjust the humidity set value at the C7000 controller. To force humidifer operation for a functional test you can either increase the set value or start the humidier by the manual operation function of the C7000.
After switching on the control unit ECCM/S carries out a system test, during which all the LEDs on the control unit light up in sequence. If, after the system test (or during operation) the yellow or red LED lights up, an error has occurred (see information in chapter 12.1.4 Fault elimination). After switching on the steam humidier is ready for operation. As soon as the C7000 controller requires humidity, power is switched on and the green LED lights on the control unit ECCM/S. The inlet valve opens after approx. 60 seconds and the steam cylinder lls with water. The submerged electrodes heat the water up and after a few minutes (approx. 510 minutes, depending on the conductivity of the water) steam is produced. Note: If the water has low conductivity, it is possible in the rst few hours of operation that the maximum steam output is not achieved. This is normal. As soon as the water reaches adequate conductivity through the vaporization process, the steam humidier will work at maximum output.
12.1.3.3 Function of the LEDs in info mode

The info mode is activated by pressing the drain/info key for an extended period of time (> 3 seconds). In info mode the LEDs on the control unit indicate the current operating status of the steam humidier. Note: The info mode is automatically reset after 15 minutes, or manually by pressing the drain/info key again. the green LED blinks. The number of blinks indicates the current steam output in % of the maximum steam capacity: green LED blinks... Steam capacity in % 1x 10 2x 20 3x 30 4x 40 5x 50 6x 60 7x 70 8x 80 9x 90 10x 100
12.1.3.4 Manual draining

1. Briey press the drain/info key. The heating voltage is interrupted and the drain valve opens. The yellow LED blinks. Note: the drain valve closes after 10 minutes automatically 2. To stop the drain cycle briey press the drain/info key again.
12.1.3.5 Taking the unit out of operation

1. If the unit has to be switched off because of a malfunction, please activate the info mode (see chapter 4.4.1) and note the number (number of blinks of the red LED) of the actual error. 2. Close the shut-off valve in the water supply line. 3. Start manual draining and wait until the steam cylinder is empty (approx. 5-10 minutes). 4. Disconnect the steam humidier from the mains: Switch off the humidier power switch in the electric box.
12.1.4 Fault elimination

Important! Most operational malfunctions are not caused by faulty equipment but rather by improper installation or disregarding of planning guidelines. Therefore, a complete fault diagnosis always involves a thorough examination of the entire system. Often, the steam hose connection has not been properly executed, or the fault lies with the humidity control system.
12.1.4.1 Fault indication

LED on control unit ECCM/S yellow blinks permanently lights lights red lights lights Drain/info key has been pressed shortly (manual draining in progress) Steam cylinder maintenance due or maintenance indication not reset. Steam cylinder maintenance not executed or maintenance indication not reset. Fatal malfunction. Description
If the yellow or red LED lights, press drain/info key (at least 3 seconds) until yellow (Warning) or red (Error) LED starts blinking intermittently (info mode). The amount of blinks per interval indicates the type of malfunction. Yellow LED Warning blinks intermittently A malfunction is present. The control unit checks whether there is a temporary problem (e.g. water supply interrupted for a short time) or whether it can resolve the problem by taking necessary measures. Red LED Error blinks intermittently The control unit, after several attempts, fails to solve the problem (number of attempts depends on the type of malfunction) or the problem obstructs further operation. In this case the heating voltage is interrupted via the main contactor.
12.1.4.2 Notes on fault elimination

DANGER! Danger of electric hazard! For the elimination of faults set the steam humidier out of operation as described in chapter 12.1.3.5, separate the unit from the mains (test with voltage tester) and secure it against inadvertent power-up.
Do not touch electronical components, without taking care of protective ESD measures.
12.1.4.3 Malfunction lists

Warning yellow LED blinks 1x Control board defective 2x Max. lling level of steam cylinder reached 3x Permissible lling time exceeded for more than 20 minutes (rst automatic cleaning cycle) Error red LED blinks --Water conductivity too low (after initial operation). Water conductivity too low for type of steam cylinder. Phase failure heating voltage. Wait. Select correct steam cylinder type. Check mains fuse(s) and replace if applicable. Check mains fuse(s) and replace if applicable. Open shut-off valve in the water supply pipe, clean water inlet lter, check water pressure, inspect/replace inlet valve. Inspect steam installation. Clean/replace drain valve. Cause Control board defective Remedy Please contact your unit supplier.
---
3x Phase failure heating voltage. Permissible lling time exceeded for Water supply obstructed, water presmore than sure too low, inlet valve defective. 220 minutes. Excessive steam back pressure, causing water loss via lling cup. Drain valve is leaking.
Note: if the Jumper L is removed from the ECCM/S control unit, the unit automatically triggers an error without prior warning if the admissible lling time has been exceeded for more than 20 minutes (red LED lights and the error switch on the control unit ECCM/S is activated). However the unit switches off after 220 minutes of lling time exceeding (see chapter 12.1.1.3). 4x Steam cylinder needs servicing 4x Interval for steam cylinder service exceeded for more than 72 hours Interval for steam cylinder service exceeded. Mineral deposits and/or electrodes spent. Replace steam cylinder type A, clean steam cylinder type D (see chapter 5, original instruction). Important! Refer to chapter 5.6 for resetting the maintenance indicator. (see chapter 5.6, original instr.).
Note: if the Jumper K is installed on the ECCM/S control unit, the unit remains in warning status even if the interval time has been exceeded for more than 72 hours. No error is triggered (red LED does not light) and the error switch on the control unit ECCM/S is not activated (see chapter 12.1.1.3). Steam cylinder (electrodes) defective. 6x Faulty auto-drain function. Electrode current Faulty drain valve/coil. too high Steam cylinder outlet obstructed. Water conductivity too high for type of steam cylinder. 7x Foam control impossible 8x Main contactor jammed Replace steam cylinder or electrodes. Inspect installation/control system. Replace drain valve/coil. Clean/replace steam cylinder. Select correct steam cylinder type.
6x Electrode current too high
7x Foam detection in the steam cylinder ---
Formation of foam in steam cylinder. Empty/ush steam cylinder. Set jumper on DRN (see chapter 12.1.1.3). Main contactor jammed in activated Check/replace main contactor. position. Clean/replace drain valve. Clean steam cylinder outlet.
9x 9x Drain valve blocked or defective. Drain valve blocked Drain valve blocked Steam cylinder outlet blocked. --10x Rotary switch in wrong position
Rotary switch on control unit ECCM/ Set rotary switch on control unit S is set to an invalid position. ECCM/S to the position for the corresponding steam cylinder type (see chapter 3.4.3, original instruction).
12.1.4.4 Replacement of ne-wire fuse on the control unit ECCM/S

If the ne-wire fuse on the control unit ECCM/S blows this is usually due to a faulty coil of the inlet or drain valve or the main contactor. Therefore you should test these components before replacing the fuse. To replace the ne-wire fuse proceed as follows: 1. Set the steam humidier OEM2 out of operation as described in chapter 12.1.3.5, separate the unit from the mains and secure it against unintentional switching on. Take care that the electricity supply to the control unit ECCM/S is disconnected (check with voltage tester). 2. Replace ne-wire fuse (see gure below) with a fuse of the given type with the specied nominal current rating. 2 A, time-lag
CAUTION! It is not permitted to use repaired fuses or to short-circuit the fuse holder.
12.1.4.5 Resetting fault indication (red LED lights in normal operating mode)
To reset the error indication: Disconnect the steam air humidier from the mains. Wait approx. 5 seconds, then reconnect the unit to the mains. Note: If the fault has not been eliminated, the error indication reappears after a short while.
12.1.5 Maintenance
You nd a detailed description of the maintenance procedures in chapter 5 of the original instruction. Here you can only see a diagram, which shows the average life cycle of a steam cylinder in dependance of the runtime and the total hardness. The humidier runtime can be read in the Info menu of the C7000AT or by the command "humi h" in the C7000.
Service intervals for steam cylinder depending on steam production in hours
Life time range GH: Gesamthrte DT: Duret totale TH: Total hardness Time/ hours
12.2 Reheat
The reheat is an optional extra for your A/C unit. It is installed complete and integrated in the function and method of operation of the A/C unit. It is used to heat up the air. The following versions of the heater are available: - Electrical reheat - Hot water reheat (HW) - Hotgas reheat (HG)
Description Electrical reheat

Cabinet size 1
HW reheat
HG reheat
Cabinet size 2 The reheat is connected in accordance with the electric diagram. It is controlled and monitored by the controller. The values for switching on and off are adjusted in the "operate/components/ heating" menu on the controller. Refer to the operating instructions C7000. C1002: menu item 12-14 (E, F, H) C6000: Control/module functions/Heating/E-heating
The HW reheat is to be connected to an external hot water circuit. The water supply is controlled via an electrically actuated HW valve. The HW valve is controlled via the controller. The control parameters are adjusted in the "operate/components/heating/HWR valve" menu on the controller. Refer to the operating instructions C7000. C1002: menu item 12-14 (E, F, H) C6000: Control/module functions/ Heating/HWR-valve
The hotgas reheat is integrated in the refrigerant circuit in accordance with the refrigerant diagram in the appendix. The refrigerant supply is controlled via an electrically-actuated 3-way solenoid valve. The solenoid valve is controlled via the controller. The control parameters are adjusted in the "operate/components/heating" menu on the controller. Refer to the operating instructions C7000. C1002: menu item 12-14 (E, F, H)
Operation
The reheat is controlled and monitored by the controller. No further measures are required for operation.
Maintenance
Clean the reheat annually from contaminations and check it for damage.
EN/01.2010/reheat/1
Installation
The reheats are installed and connected in the A/C unit. The HW reheat is to be connected on site to the external hot water circuit. The pipelines are to be routed out of the A/C unit. The thread sizes for the connection piping of the HW reheat are listed in the following table. Temperatures: Water inlet: 60C Water outlet: 40C Air inlet: 13C Glycol: 0%
Cabinet size Pipe - Thread size mm inch
1 16 1/2
2 22 3/4
3 22 3/4
4 22 3/4
5 22 3/4
Commissioning
The reheats are controlled and monitored by the controller of your A/C unit. No further measures are required for commissioning.
Malfunction causes
Alarm: Reheat defect All reheat alarms are received by the controller and can be requested according to the equipment. C7000-control system: C7000 advanced terminal: C1002: no display (display only externally) indication on the display display: HEA
EN/01.2010/reheat/2
12.3 Air side connection

12.3.1 Unit base
The unit base is available in the versions: open, with damper, with exible connection or with supply grilles. The unit base can be installed in two ways, with the opening to the front or with the opening to the rear.
450
L3
L1 L1 L1 A D C B
865
Cabinet size Baugre A B C D E L1 L2 L3 N mm mm mm mm
1 910 75/67,5*
2 1360 210 68 1015 1000 315 1
3 1710 182 927 68 615 600 315 2
4 2160 69 1276 67,5 815 800 315 2
5 2510 173 993 1738 68 615 600 315 3
mm 130/47,5*
mm 700/815* mm 700/800* mm 300/315* 1
* version with grilles N: Number of openings
Caution! Each of the unit base versions must be screwed to the unit by 4x M10 screws!
EN /08.2011/air/1
Unit base with grilles
The standard grilles are equipped with horizontal ns which can be adjusted to conduct the air which is blown out.
Unit base with exible connection 150 L2
Unit base with damper
120
L2
38
Caution! Each of the unit base versions must be screwed to the unit by 4x M10 screws!
EN/08.2011/air/2
300
300
12.3.2 Filter base

The lter base is designed for the option "suction from bottom". With this option for upow units the front panels are not provided with an air inlet perforation as otherwise usual. The air is drawn in from the bottom, in consequence there is no unit bottom plate, but supporting bars instead, on which compressors and other components are mounted.
Filter base
Unit base or raised oor stand
Construction size Baugre unit width Gertebreite A B N of lters Filteranzahl mm mm mm mm
1 1000 950 910 960 400 270 2 3
2 1400 1360 293 4
3 1750 1710 376
4 2200 2150 2160 2110 376 5
5 2550 2510 456
EN /08.2011/air/3
For the air side connection on top of the unit exist different options, which are delivered in a completely assembled condition. On the installation site these set-ups must be set upon the unit and must be connected to it.
12.3.3 Duct
The duct will be set on top of the unit and be screwed with the unit. The duct is available with two different heights (500 or 800 mm) for all units.
500
B
A
Cabinet size Baugre A B E mm mm mm
1 884 950 -
2 884 1400 -
3 884 1750 -
4 884 2200 1027
5 884 2550 1202
Top view:
panel
frame
E B
EN/08.2011/air/4
A=
12.3.4 Discharge plenum

The discharge plenum is availale in two different versions for all units. The discharge plenum will be set on top of the unit and be screwed with the unit. Discharge plenum with front grilles
500 400
L1 L1 C
884
Discharge plenum with front and side grilles
500 400
L1 L1 C
600 884
Only one front grille for size 1, 2.
Cabinet size Baugre B C D L1 mm mm mm mm
1 950 75 800
2 1400 100 1200
3 1750 45 905 2 x 800
4 2200 112,5 1287,5
5 2550 100 1450
2 x 800 2 x 1000
400 EN /08.2011/air/5
12.3.5 Bag lter top

The bag lter is available for all downow units. The bag lter serves for the pre- ltration of the air which is sucked in and can be obtained in the qualities F6, F7 and F9 (according to EN779). The bag lter top will be set on top of the unit and be screwed with the unit.
500
B
884
12.3.6 Sound insulation plenum

The sound insulation plenum is available for all units. The plenum will be set on top of the unit and be screwed with the unit.
500
B = unit width
B
884
EN/08.2011/air/6
12.3.7 Adapter plate with damper or exible connection

- Connection on the unit
The adapter plate serves to attach a damper or a exible connection on top of the unit or a duct. First install the actuator onto the louver shaft on the right side looking at the unit front. Then x the louver with the actuator on the adapter plate. Now mount the adapter plate with pre-mounted louver on the unit top by means of a screw connection. The damper actuator, which is controlled via a 24 V signal by the controller, has to be electrically connected. For this the cable, which is already connected at the motor, must be routed through an opening in the adapter plate into the unit and then be connected at the controller in the electric box according to the electric diagram. In downow units route the cable through the side panel. Adapter plate with damper Adapter plate with exible connection
150
25 B
5
2550 275 2000 106 675 175
20
25
C A
Cabinet size Baugre
A B C D E H mm mm mm mm mm mm
1
950 190 650 147 650 120
2
1400 187 1100 97 675 120
3
1750 237 1400 107 675 175
4
2200 237 1800 106 675 175
If the air side has to be continued by a duct, the installation of a exible connection is necessary. Take into account the installation of pressure compensations in the exible connection.
890
EN /08.2011/air/7
Adapter plate with damper or exible connection

- Connection under the unit
The adapter plate serves to attach a damper or a exible connection under the unit. First install the actuator onto the louver shaft on the right side looking at the unit front. Then x the louver with the actuator under the adapter plate. Now mount the adapter plate with pre-mounted louver on the oor stand frame by means of bolts. Please take care that the adapter plate does not pass over the frame to avoid canting of the oor stand within the raised oor. The damper actuator, which is controlled via a 24 V signal by the controller, has to be electrically connected. For this the cable, which is already connected at the motor, must be routed through an opening in the adapter plate into the unit and then be connected at the controller in the electric box according to the electric diagram.
Bottom view Knock-out openings for supply connections Unit front
Cabinet size Baugre A B C D E F mm mm mm mm mm mm
1 950 143,5 650 345,75
2 1400 200 1000 345,75
3 1750 148,5 650 951,5 345,75 120 mm 150 mm
4 2200 203,5 800 1196,5 364
5 2550 123 650 950 1755 345,75
Damper height for all units: Flexible connection height for all units:
If the air side has to be continued by a duct, the installation of a exible connection is necessary. Take into account the installation of pressure compensations in the exible connection.
EN/08.2011/air/8
12.3.8 Recessed rear wall

For better ow dynamics Downow units can be equipped with a rear wall which is recessed by 50 mm.
50 940
EN /08.2011/air/9
12.4 Raised oor stand

The oor stand is used to adjust the height of the A/C unit to the existing raised oor and consists of an encircling rectangular prole of galvanized steel with adjustable screw sockets. Anti vibration compound is recommended between concrete oor and base plate.
L2 L1
Locating the supports (correspondingly on the other side)
865
785
B Cabinet size Baugre B L1 L2 Supports Sttzen Rectangular proles 70 40 Rechteckprole 70 x x 40 Mafundstreifen Mafund strips Schrauben M8 30 Screws M8 x x 30 mm mm mm Stk n Stk n Stk n Stk n 1 910 4 4 4 8 2 1360 3 1710 795 6 5 6 14 4 2160 1020 5 2510 784 1607 8 6 8 16
Dimensions from inner side of the lateral prole to the middle of the support L1 - Position of the support without cross beam L2 - Position of the support with cross beam
e.g. for size 5 and 7: Cabinet size: 1 2 3 4 5
EN /08.2011/raisedoor/1
Connecting the bars

Angle Connection
(View from below)

Butt Joint Cross Connection
Minimum distances and mounting instructions

Please observe that the oor stand must be decoupled from the surrounding oor plates by damping insertions and that mafund plates are laid under the oor supports. The raised oor cutting (notch) should at least be 15 and must not have any contact to the raised oor stand, which could result in bone-conduction. If the oor stand is placed near a wall, a minimum distance of 50 mm should be respected. The gap between wall and oor stand should be closed by tin stripes. The dimensions of the openings in the raised oor (X and Y) are 10 mm longer than the raised oor stand. The joint must be closed by customers with a continuous seal. A concrete foundation is recommended in the area of the raised oor supports. Raised oor stand Z (min. 50)
Z (min. 50)
Z (min. 800)
X/Y = Opening in raised oor Z = Limit of distance The raised oor supports have to be installed on vibration dampening material (do not screw down the supports!). Prior to installation of the A/C unit, the raised oor must be installed 7 mm higher than the raised oor plates, as the mafund plates are compressed by the weight of the A/C unit.
General design of the raised foor stand

Unit width
Raised oor connection for details, see next page
Raised oor Continuous seal Raised oor stand Raised oor support Mafund strips Upper edge of rough oor Upper support part
Range of adjustment : 25mm
max 545 min 495
Hammer head screw M8 x 30

Recommended concrete foundations (no (oor) nish)
Supporting pipe
Detail of raised oor connection
1 2 3 4 5 6 7 8 9 10 11 12 13
Raised oor stand Adjustable support plate Adjusting nut Support pipe Support base Mafund strips Raised oor cut out angle Continuous seal prole Before unit installation Raised oor plate Angled bracket Permanently elastic seal Fixing
Sealing detail when distance Z < 100 mm
Sealing detail when distance Z > 100 mm
Other mounting options (e.g. louvers)

If louvers shall be installed beneath the unit, these must be rst mounted onto the adapter plate. If there are two or three louvers, the louver shafts are connected by a coupling piece. The louver actuator, which has to be installed on the shaft, will later be on the right unit side in the proximity of the electric cabinet.
Positioning of the A/C unit on the oor stand

When positioning the A/C unit on the oor stand, it must be brought precisely into the correct position above the oor stand from the front (under no circumstances diagonally). Hereby use mounting aids to bring in the unit and secure these by xing belts. We recommend further to lay in advance at least two securing instruments (e. g. square steel bars) on the stand to avoid a slip-off. When the unit is in the right position the securing aids can be taken away and the unit can be set down. Now the mounting aids can be pulled away under the unit.
Mounting aid
12.5 Electrical Options

12.5.1 Three Phase Control
The phase control module checks the presence of all phases. In case of a phase failure the module switches off the A/C unit and protects it from excessive currents on the existant phases this way. When the defective phase returns the unit is restarted automatically and does not have to be switched on manually. You can adjust a time at the phase control module within which a phase failure shall be detected as an error. This time may be set to 4 seconds maximally. After 5 seconds the safety circuit of the EC fan would otherwise cut off the EC fan, release the airow alarm and set the A/C unit out of operation, without a restart after phase return.
12.5.2 Second Power Supply

This option provides the connection of a second power supply. Both power supplies are switched on to the A/C unit. A contactor circuit ensures that the priority is set on power supply 1. All three phases of both power supplies are checked constantly on overvoltage, undervoltage and phase failure. In case of failure of supply 1 the unit is switched off. After a lapse of time which can be set at the time relay (preadjusted: 10 seconds) power supply 2 is switched onto the unit. The unit starts by the automatic restart which is integrated in the controller. When the voltage of power supply returns, the unit is switched off again. On a second time relay a delay can be set (preadjusted: 10 seconds), after which power supply 1 is switched onto the unit. The unit starts by the automatic restart.
12.5.3 Compressor Softstart

This option consists of a softstart controller which is installed in the electrical cabinet and limits the current when the compressor starts. In units with two compressors each compressor needs a softstart controller. The control characteristic of the softstart controller can be modied by 16 dip switches. Moreover the softstart controller includes an overload protection and devices to monitor the thyristor temperature, the phase rotation, the existence of all phases, the phase balance and to check all thyristors and load connections for shorts. When an alarm is detected according to the above mentioned criteria the alarm is indicated by a LED. The number of ashes indicates the cause of error. Flashes Error 1x 2x 3x 4x 5x 6x Overload Overtemperature Phase reversal Phasen loss/Open load Phase imbalance Shorted thyristor
EN/01.2010/electric/1
Adjusting the softstart controller The softstart controller can be set as a current limitation or as softstart device. The factory setting is current limitation. In this function the softstart controller allows the current to exceed the nominal operating current for an adjustable time after the compressor start. In the softstart function the initial torque (by means of the voltage) at the compressor start is reduced to an adjustable value and will be increased to the nominal voltage within an adjustable time.
L1
L2
L3
I
1 2 3 4 5 6 7 8
Dip Switches 1-16 Reset/Test-Button Adjusting the nominal operating current Run/Alarm LED
9 10 11 12 13 14 15 16
The nominal operating current (FLA) can be adjusted by the potentiometer as shown on the left. The adjusted current is a reference not only for the above mentioned current limitation but also for releasing the overload protection. If the current achieves 120% of the adjusted value the overload protection is activated and the voltage supply will be cut. With selectable overload-trip-curves, which in case of exceeding the nominal operating current also takes into account the time of the exceeding, the trip behaviour can be chosen. The higher the trip class, the slower the tripping takes place. The trip class can be adjusted by the dip switches 11 and 12. Trip class 15 is factory set. With dip switch 13 you can set, whether the alarm shall be reset manually by the reset button or automatically (when motor thermal model drops below 75% of motor thermal capacity). The manual reset is the factory setting. With dip switch 3 you can set the principal function (Current limitation or soft start).
Dip Switch 11, 12:

A1 A2 N1 N2 97 98 13 14 2 T1 4 T2 6 T3
I O 11 12 11 12 11 12 11 12
Off
Class 10
Class 15
Class 20
Dip Switch 13:

I O 13
Reset: manually
13
Reset: automatically
Dip Switch 3:
I O 3 Is Ie Us
Current limitation (Factory setting)

3
Soft start
Ue
t1
t1
Ie: Nom. operating current (Potentiometer) Is: Maximum current (Dip switch 4, 5) t1: Start time (Dip switch 1, 2, 8)
Ue: Nominal voltage Us: Initial voltage (Dip switch 4, 5)
in case of function as current limitation: Dip Switch 4, 5 (Is):

I O 4 5 4 5 4 5 4 5
in case of function as soft start: Dip Switch 4, 5 (Us):

I O 4 5 4 5 4 5 4 5
150% 250%
350% 450%
15%
25%
35%
65%
The maximum current can be set as percentage to the nominal operating current. (Factory setting: 350%)
The initial voltage can be set as percentage to the nominal voltage.
Dip Switch 1, 2, 8 (t1):

I O 1 2 8 1 2 8 1 2 8 1 2 8 1 2 8 1 2 8 1 2 8
2s
5s
10 s
15 s
20 s
25 s
30 s
The start time can be set in seconds. (Factory setting: 2 sec.) For the sake of completeness the possibility to adjust a kickstart and a soft stop must also be mentioned. However these functions are not used. In the factory setting both functions are disabled. Dip Switch 9, 10 (t2 for Kickstart):
I O 9 10 9 10 9 10 9 10 6 7 6 7 6 7 6 7
Dip Switch 6, 7 (t3 Reduction time):

I O
Off
0,5 s
1,0 s
1,5 s
Off
1x t1
2x t1
3x t1
Dip Switch 14:

I O 14
Normal
Error detection during nominal operation only 14 (without exceeding Ie during the start phase).
The soft start controller is checked for overload in position "Normal" (Factory setting) during the start sequence. If an error is detected it is sent to the C7000 controller and indicated there.
Dip Switch 15:

I O 15
Possibilty for a star delta start

15
Direct motor connection
From the factory the dip switch 15 is set for a direct connection of the compressor motor.
Dip Switch 16:

I O 16
Phase rotation control enabled

16
Phase rotation control disabled
With dip switch 16 you can disable the phase rotation control.
12.6 Waterside connection

3-way-cooling water control valve
The 3-way cooling water control valve is controlled by the C7000 relating to the condenser pressure by means of a pressure sensor at the refrigerant side. This valve controls the distribution of the water ow through the condenser and the bypass.
Modell Type 191 221 181 / 211 251/281/321/371/391 261/291/311/361/401 421 461 541 411 / 451 / 531 412 462 522 402 / 452 / 512 562 622 712 552 / 612 / 702 812 872 1072 802 / 862 / 1062
Ventilgre Valve size 3/4" 1" 1 1/4"
f(PC1)
condenser
1 1/2"
PC1
2-way-cooling water control valve

The 2-way cooling water control valve is controlled by the C7000 relating to the condenser pressure by means of a pressure sensor at the refrigerant side. This valve controls the water ow through the condenser.In the table below, the admissible maximum differential pressures are listed per valve size. Up to these pressures the valve is kept close safely. (Closing pressure). The admissible maximum differential pressure, at which the valve can control throughout the whole range, is 2 bar for all valve sizes.
f(PC1)
Modell Type 191 221 181 / 211 251/281/321/371/391 261/291/311/361/401 421 461 541 411 / 451 / 531 412 462 522 402 / 452 / 512 562 622 712 552 / 612 / 702 812 872 1072 802 / 862 / 1062
Ventilgre Valve size 3/4" 1" 1 1/4" 1 1/2"
Closing pressure [bar] Schliedruck [bar] 10 6,5 4 2,5

PC1
condenser
EN /08.2011/water/1

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Index 17 Issue 8.2011

Precision Air Conditioning Units 380-415/3/50

2. Residual risks .............................................................................................................5 3. Transport / Storage .....................................................................................................7

5. Technical data ...........................................................................................................10

7. Commissioning .........................................................................................................23 8. Maintenance ..............................................................................................................25

Subject to technical modications.

dangerous situation, light bodily injury and material damage

Information ESD note

important information and application notice risk of damaging electronical components

1.2 Safety instructions

1.3 Handling refrigerants

1.4 Safety and environmental requirements

First aid measures

Independent conversion and manufacture of replacement parts

Unacceptable operating methods

In the lower part of the unit Electrical box

In the lower part of the unit, water piping

Fan outlet of upow units Fan, V-belt drive (if existant)

De-energize water discharge area.

Wear safety gloves. Avoid contact to hot unit parts.

Injuries by cutting Burns Electric shock

In the lower part of the unit, water piping

Unit type internal part no. Order number + alternative

4.2 Intended use

4.3 Function of the A/C unit

Downow unit with 2 refrigerant circuits electrical box

Filter dryer Sightglass Expansion valve

Adjustment of the pressure switches:

Design conditions for technical data:

5.2 Technical Data - ASD/U ... A/G/ACW/GCW - 1-circuit

Auslegungsfllmenge fr G,G, GCW 1 Nominal refrigerant charge GCW 1

10500 10800 11500 14000 15000

5.3 Technical Data - ASD/U ... A2/G/ACW2/GCW - 2-circuits

Auslegungsfllmenge fr G/GCW 1 Nominal refrigerant charge G, GCW 1

5.4 Technical Data - ASD/U ... GE and ALD/U ... GE - 1-circuit

Type Modell ALD/U

10500 10800 11500 13500 15000

49,2 479 51,3 448

5.5 Technical Data - ALD/U ... GE - 2-circuits

52,9 756 55,0 708

5.6 Dimensional drawings

(for all sizes)

The unit may not be operated in an explosive atmosphere!

6.2 Connection of the piping

Chilled water piping Pipe entrance area for refrigerant lines

6.2.2 Filling systems with R407C refrigerants

Non-return valve (option)

Receiver Open stop valves !

6.2.3 Water piping

ethylenglycol 10% 20% 28% 35% 40%

Union screwed connection

Water pipe insulation

Downow unit (GCW version)

Upow unit (GCW version)

6.2.4 Condensate drain connection

possible installation at the customer side: funnel

6.3 Electrical connection

Insertion for the power supply cable, Downow

Power supply, Upow

Power switch off

Controller C7000, Start/stop-key

Oil level at the compressor