Stulz Compact CW Series Installation, Operation & Maintenance Manual

Compact CW Series Installation, Operation & Maintenance Manual

A

(© Oct, 2007)

ir Technology Systems, Inc.

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Compact CW Series Installation, Operation & Maintenance Manual

Compact CW - Precision Air Conditioners

CC = Compact CW System

Model Nomenclature

CC U-30 0-CW

U = Up-Flow Air Pattern

D = Down-Flow Air Pattern

Nominal Capacity in kW

CW = Chilled Water System

Number of Refrigeration Circuits

Notice

This document contains information protected by copyright. All rights are reserved. The owner of the equipment for
which this manual is written may photocopy the contents of this manual for internal use only. No part of this docu­ment may be photocopied, reproduced, or translated into another language for use by anyone other than the owner
of the equipment for which this manual is written without the prior written consent of Stulz Air Technology Systems,
Inc. (SATS).

This document contains confidential and proprietary information of Stulz Air Technology Systems, Inc. Distributing or
photocopying this document for external distribution is in direct violation of U.S. copyright laws and is strictly
prohibited without the express written consent of SATS.

Unpublished — rights reserved under the copyright laws of the United States and of other countries.
Other brands and tradenames are trademarks of their respective owners.

Copyright 2007 by Stulz Air Technology Systems, Inc.
Printed in the United States of America.
All rights reserved.

Stulz Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704
USA

08/07

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Compact CW Series Installation, Operation & Maintenance Manual

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TABLE OF CONTENTS

1.0 Introduction ....................................... 1-1

1.1 General ...................................................... 1-1

1.2 Product Description ................................... 1-1

1.3 Product Warranty ...................................... 1-2

1.4 Safety ........................................................ 1-3

1.4.1 General ...................................................... 1-3

1.4.2 Safety Summary ........................................ 1-3

1.5 General Design .......................................... 1-4

1.5.1 Electric Box Access .................................. 1-4

1.5.2 Circuit Breakers/ Motor Start Protectors .... 1-4

1.5.3 Heaters...................................................... 1-4

1.5.4 Coils .......................................................... 1-4

1.5.5 Blower(s) ................................................... 1-4

1.5.6 Temperature/ Humidity Sensor ................... 1-5

1.5.7 Humidifier .................................................. 1-5

1.6 Optional Equipment ................................... 1-5

1.6.1 Condensate Pump ..................................... 1-5

1.6.2 Smoke Detector ........................................ 1-5

1.6.3 Firestat ...................................................... 1-5

1.6.4 Auto Transfer Switching ............................. 1-5

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

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

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

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

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

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

2.5 Air Distribution Connection ........................ 2-3

2.5.1 Downflow Configuration Air Patterns ........... 2-3

2.5.2 Upflow Configuration Air Patterns ............... 2-3

2.6 Optional Equipment (Field Installed) .......... 2-5

2.6.1 Floor Stand ................................................ 2-5

2.6.2 Plenum Box Assembly .............................. 2-5

2.6.3 Remote Display ......................................... 2-5

2.6.4 Condensate Pump ..................................... 2-5

2.6.5 Remote Temperature/Humidity Sensor ....... 2-5

2.6.6 Remote Water Detector ............................. 2-6

2.7 Piping Connections .................................... 2-6

2.7.1 Chilled Water/Hot Water ............................ 2-6

2.7.2 Condensate Drain ...................................... 2-7

2.7.2.1 Gravity Drain .............................................. 2-7

2.7.2.2 Condensate Pump ..................................... 2-7

2.7.3 Humidifier .................................................. 2-7

2.8 Utility Connections .................................... 2-8

2.8.1 Main Power ............................................... 2-8

2.8.2 Controls ..................................................... 2-9

2.8.3 Optional Equipment ................................... 2-9

2.8.3.1 Remote Temperature/Humidity Sensor ....... 2-9

2.8.3.2 Remote Water Detector ............................. 2-9

2.9 System Settings and Adjustments ........... 2-10

2.9.1 Chilled Water Circuit ................................ 2-10

2.9.2 Humidifier Adjustment .............................. 2-10

2.8.3 Blower ..................................................... 2-10

3.0 Start-Up/Commissioning .................. 3-1

3.1 Operation ................................................... 3-1

3.2 Step by Step Start-Up Instructions ............. 3-1

3.3 Microprocessor Controller

Programming ............................................ 3-1

4.0 Maintenance/Repairs ....................... 4-1

4.1 Periodic General Maintenance ................... 4-1

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

4.1.1.1 Filter .......................................................... 4-1

4.1.1.2 Blower ....................................................... 4-1

4.1.1.3 Drain Pan .................................................. 4-1

4.1.1.4 Coils .......................................................... 4-1

4.1.1.5 Heat/Reheat .............................................. 4-1

4.1.1.6 Humidifier .................................................. 4-1

4.1.1.7 Condensate Pump ..................................... 4-1

4.2 Troubleshooting ...................................... 4-2/3

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

4.3.1 Piping ........................................................ 4-4

4.3.2 General Common Repairs/

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

4.3.2.1 Humidifier Cylinder Replacement ............... 4-4

4.3.2.2 Filter Replacement .................................... 4-4

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

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

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

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

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Compact CW Series Installation, Operation & Maintenance Manual

TABLE OF CONTENTS

List of Figures

Figure 1 Typical Internal Layout ............................ 1-4

Figure 2 Auto Transfer Disconnect Switches ........ 1-5

Figure 3 Preferred Power Selecton Switch ............ 1-5

Figure 4 Installation Clearance ............................. 2-1

Figure 5 Typical Installation Upflow ....................... 2-2

Figure 6 Typical Installation Downflow ................... 2-2

Figure 7 Downflow Configuration

Typical Air Patterns ................................ 2-3

Figure 8 Upflow Configuration Typical

Air Patterns (Top Discharge) ................... 2-4

Figure 9 Upflow Configuration Typical Air

Patterns (Top Ducted Discharge) ............ 2-4

Figure 10 Optional Floor Stand Installation ............. 2-5

Figure 11 Condensate Pump .................................. 2-7

Figure 12 Sample Nameplate ................................. 2-8

Figure 13 Electric Box ........................................... 2-9

Figure 14 Blower Assembly .................................. 2-10

(Continued)

Appendix A - Forms

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

Periodic General Maintenance

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

Appendix B - Glossary

Definition of Terms and Acronyms ............................B-1

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1.0 INTRODUCTION

1.1 General

Congratulations, the
precision air conditioning system covered by this
manual is designed and manufactured by Stulz Air
Technology Systems, Inc. (SATS) using the latest,
state-of-the-art control technology. Recognized as a
world leader, SATS provides air conditioning systems
with the highest quality craftsmanship using the finest
materials available in the industry. The unit will provide
years of trouble free service if installed and maintained
in accordance with this manual. Damage to the unit
from improper installation, operation or maintenance is
not covered by the warranty.

STUDY the instructions contained in this manual.
They must be followed to avoid difficulties. Spare parts
are available from SATS to insure continuous opera­tion. Using substitute parts or bypassing electrical or
cooling components in order to continue operation is
not recommended and will VOID THE WARRANTY.
Due to technological advancements, components are
subject to change without notice.

All

Compact CW

indoors, unless otherwise noted on the equipment.

Compact CW™

floor mounted

systems are designed to be installed

1.2 Product Description

Compact CW

versatile and flexible floor mounted precision air
conditioning systems in the industry. The unit is
available in up-flow or down-flow configurations. The
cooling capacity, in kW, will depend on the unit size,
which can range from 30 to 180 kW, (1 kW = 3415
BTU/Hr). Refer to the unit nameplate to identify the
model number and cooling capacity of your unit.

Compact CW

source of chilled water. The chilled water system is a
closed loop circuit in which cold water is circulated
through a chilled water coil. On demand for cooling,
the microprocessor controller begins modulating the
chilled water valve open. Chilled water flows to the coil
at a rate that varies proportionally to the amount of
cooling required to meet the user selectable tempera­ture setpoint. Heat from the surrounding air is trans­ferred through the finned tubing of the coil into the cold
water. Water is then re-circulated back to the cold
water source.

Compact CW

air to only one room.

systems are designed to be the most

systems operate with an external

systems have been designed to supply

NOTE

Compact CW

systems are strictly for non-resi-

dential applications.

The functional modes of operation, in addition to
cooling, are heating, humidification and dehumidifica­tion, which provide complete environmental control of a
conditioned space.

There are two air pattern configurations, upflow and
downflow, and several cabinet sizes based on the type
of system and capacity. Regardless of configuration,
the

Compact CW

system is compact and versatile.
See the Installation drawing provided with the unit for
the layout and dimensions of the cabinet.

The

Compact CW

unit is provided with a factory
mounted, main power disconnect switch with a lockable
handle. The disconnect switch electrically isolates the
unit during routine maintenance. The system incorpo­rates state of the art component protection with the use
of motor start protectors and circuit breakers.

An operating manual for the system controller is
provided under separate cover. Refer to that manual for
detailed instructions on operating the system control­ler provided with your unit.

The standard controller for

Compact CW

precision A/C
units sizes CCD/U-300 through CCD/U-900 is SATS
model C1002. For larger units, CCD/U-1500 through
CCD/U-1800, the standard controller is the SATS
model C6000. These microprocessor controllers
provide the following features: input/output monitoring
status, full integrated control of heating, cooling,
humidification and dehumidification; multi-unit control
and remote communication with building management
systems. The controller is typically factory mounted
on the front hinged access door of the unit. As an
option the controller may be remotely mounted to a
wall or control panel.

C1002 C6000

SATS offers the C6000 microprocessor controller as
an option for models CCD/U-300 through CCD/U-900
A/C units.

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Compact CW Series Installation, Operation & Maintenance Manual

1.3 Product Warranty

SATS offers a two year standard limited warranty as stated below:



2-Year Standard Limited Warranty:

Stulz Air Technology Systems, Inc., warrants to the original buyer of its products that the goods
are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s
obligation under this warranty is to repair or replace, at its option, free of charge to the customer,
any part or parts which are determined by Stulz Air Technology Systems Inc. to be defective
for a period of 24 months from date of shipment when a completed start-up form has been
submitted to Stulz Air Technology Systems, Inc. within 90 days from shipment. In the event
that a completed start-up form is not received by Stulz Air Technology Systems, Inc. within 90
days from shipment, the company’s obligation will be for a period of 12 months from date of
shipment. Parts repaired or replaced under this warranty are shipped FOB Factory, and
warranted for the balance of the original warranty period or for 90 days from the date of
installation, whichever is greater.

Stulz Air Technology Systems, Inc.’s warranty does not cover failures caused by improper
installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence,
accident, normal deterioration (including wear and tear), or the use of improper parts or improper
repair.

Purchaser’s remedies are limited to replacement or repair of non-conforming materials in
accordance with the written warranty. This warranty does not include costs for transportation,
costs for removal or reinstallation of equipment or labor for repairs or replacement made in the
field.

If any sample was shown to the buyer, such sample was used merely to illustrate the general
type and quality of the product, and not to represent that the equipment would necessarily
conform to the sample.

This is the only warranty given by the seller, and such warranty is only given to buyers for
commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is paid
in full.

THE FOREGOING SHALL CONSTITUTE SATS’S ENTIRE LIABILITY AND YOUR EXCLUSIVE
REMEDY. IN NO EVENT SHALL SATS BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL,
INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS
(EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE
INSTALLATION, USE OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.





1-2



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1.4 Safety

1.4.1 General

Stulz Air Technology Systems, Inc. uses NOTES
along with CAUTION and WARNING symbols through-
out this manual to draw your attention to important
operational and safety information.

A bold text NOTE marks a short message in the
information to alert you to an important detail.

A bold text CAUTION safety alert appears with
information that is important for protecting your
equipment and performance. Be especially careful to
read and follow all cautions that apply to your applica­tion.

A bold text WARNING safety alert appears with
information that is important for protecting you from
harm and the equipment from damage. Pay very
close attention to all warnings that apply to your
application.

A safety alert symbol
WARNING or CAUTION safety statement.

A safety alert symbol accompanies an electrical
shock hazard WARNING or CAUTION safety state-

ment.

1.4.2 Safety Summary

accompanies a general

Always disconnect the main power supply to the
equipment at the main power disconnect switch before
beginning work on the equipment. A lock-out tag-out
procedure should be followed to ensure that power is
not inadvertently reconnected.

Equipment may contain components subject to
Electrostatic Discharge (ESD). Before attempting to
mount or service these electronic devices, ensure
you have no charge built up by touching a ground
source. When possible, use a wrist-grounding strap
when working on or near electronic devices.

Never work on electrical equipment unless another
person who is familiar with the operation and hazards
of the equipment and competent in administering first
aid is nearby.

All personnel working on or near equipment should be
familiar with hazards associated with electrical
maintenance. Safety placards/stickers have been
placed on the unit to call attention to all personal and
equipment damage hazard areas.

Certain maintenance or cleaning procedures may call
for the use and handling of chemicals, solvents, or
cleansers. Always refer to the manufacturer's Material
Safety Data Sheet (MSDS) prior to using these
materials. Clean parts in a well-ventilated area. Avoid
inhalation of solvent fumes and prolonged exposure
of skin to cleaning solvents. Wash exposed skin
thoroughly after contact with solvents.

The following statements are general guidelines
followed by warnings and cautions applicable
throughout the manual.

Prior to performing any installation, operation, mainte­nance or troubleshooting procedure, read and under­stand all instructions, recommendations and guide­lines contained within this manual.

All maintenance and/or repairs must be performed by
a journeyman, refrigeration mechanic or an air
conditioning technician.

Never operate the unit with any cover, guard, screen,
panel, etc., removed unless the instructions specifi­cally state otherwise, then do so with extreme caution
to avoid personal injury.

Never lift any component in excess of 35 pounds
without help. If a lifting device is used to move a unit,
ensure it is capable of supporting the unit.

When working on electrical equipment, remove all
jewelry, watches, rings, etc.

CAUTION

When the air conditioner is in the cooling mode,
the return air-intake and discharge (supply)
must be free of obstructions. Ensure panels are
secure and latched into position.

CAUTION

Do not use cleaning solvents near open flame or
excessive heat. Wear eye protection when blow­ing solvent from parts. The pressure-wash should
not exceed 30 psig. Solvent solutions should be
disposed of in accordance with local and state
regulatory statutes.

CAUTION

The unit must be kept level and vertical in its
normal installed position.

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Compact CW Series Installation, Operation & Maintenance Manual

1.5 General Design

The Compact CW unit is housed in a steel frame type cabinet and is rated for indoor use. The exterior of the
cabinet is coated with a powder coat finish to protect against corrosion. Hinged doors are located in the front of the
cabinet for easy access to all components. Operator controls are conveniently located on the front of the cabinet.
Figure 1 depicts a typical internal layout of a CCD-1800-CW unit and identifies the major components.

FILTER ACCESS

(DOWNFLOW UNITS)

COILS

ELECTRIC HEATERS

(OPTIONAL)

Figure 1- Typical Internal Layout

(Model CCD-1800-CW shown for reference)

1.5.1 Electric Box Access

The electrical components are protected behind the
hinged access door located on the right side of the
unit. The access door is safety interlocked with the
main power service disconnect switch, (See Figure 4),
preventing the door from opening when the switch in
the “On” position. The switch must be turned “Off” to
gain access to the electrical components.

The service disconnect switch may be used to turn the
unit off for emergency shutdown or during routine

maintenance. The handle of the switch may be locked
in the “Off” position to prevent unintended operation

.

CHILLED WATER VALVE

HUMIDIFIER
(OPTIONAL)

PREFERRED POWER
SELECTOR SWITCH
(OPTIONAL)

AIR PROVING SWITCH & DIRTY
FILTER SWITCH (OPTIONAL)

ELECTRIC BOX

CONDENSATE PUMP
(OPTIONAL)

BLOWER(S)

BLOWER MOTOR

As an option, hot water re-heat may be selected. A hot
water heating coil is factory installed in the supply air
stream after the cooling coil to heat the supply air. A
valve is provided to control the flow of hot water through
the coil to maintain the correct re-heat temperature.

1.5.4 Coil(s)

The cooling and optional hot water re-heating coils are
aluminum finned/copper tube construction. The coils
are leak tested and cleaned before installation by the
factory.

1.5.5 Blower(s)

1.5.2 Circuit Breakers / Motor Start Protectors

Individual overload protection is provided by circuit
breaker(s) and motor start protectors. These switches
must be manually re-set once the overload condition is
cleared.

1.5.3 Heaters (Optional)

The precision A/C unit incorporates heaters for re-heating
the supply air, as required to offset the sensible cooling of
the system during the dehumidification cycle, and for the
automatic heating mode. As a standard, electric resis­tance heating elements are factory installed in the supply
airstream after the cooling coil to heat the supply air.

1-4

The unit is equipped with belt driven centrifugal
blower(s) with forward curved blades. The quantity of
blowers varies depending upon the capacity of the A/C
unit. Each blower is dynamically and statically
balanced to minimize vibration. The blower is con­tained in a double-width, double-inlet housing. The
blower motor uses dual drive belts.

The blower motors are ODP industrial duty and utilize
permanently lubricated ball bearings. The motor is
mounted on an adjustable base for belt tensioning and
is furnished with an adjustable pitch sheave to change
the blower speed.

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1.5.6 Temperature/Humidity Sensor

As a standard for room air control, a temperature/
humidity (T/H) sensor is factory mounted in the return
air stream. The (T/H) sensor monitors the return air
conditions and provides input signal(s) to the system
controller to manage the operation of the A/C unit
consistent with the setpoints entered in the system
controller.

1.5.7 Humidifier (Optional)

Compact CW systems utilize an electrode, steam
humidifier. The humidifier is factory installed inside the
air conditioner and includes fill and drain valves and
associated piping. Operation of the humidifier’s fill and
drain cycles is based on water conductivity and is
maintained by the humidifier controller. An operating
manual for the humidifier is provided under separate
cover. Refer to that manual for detailed information on
operation of the humidifier.

1.6 Optional Equipment

1.6.1 Condensate Pump

source. If power is transferred, the system controller
provides an alarm signal and the alarm display indicates
which power source failed. When the primary power
source is functionally restored, the A/C system load is
automatically transferred back to the primary power
source.

FRONT DOOR OF
A/C SYSTEM

INDICATOR LIGHTS
(OPTIONAL)

OPTIONAL DUAL
DISCONNECT SWITCHES
(LOCATION MAY VARY)

An optional condensate pump may be used for auto­matic removal of condensate from the air conditioner
and flush water from the humidifier. An internal overflow
safety switch is wired to the system controller to
automatically shut down the precision A/C system
should an overflow occur.

1.6.2 Smoke Detector

Optionally mounted in the return air stream, a photo­electric smoke detector is used to sense the presence
of smoke and signal the controller when a smoke
alarm condition exists.

1.6.3 Firestat

Optionally mounted in the return air stream, a fire
detector senses high retun air temperature and signals
the controller when a fire alarm condition exists.

1.6.4 Auto Transfer Switching

An automatic transfer, main power switching system is
optionally available for critical operation. With this
option, two main power service disconnect switches are
provided on the door of the cabinet to connect two
independent power sources, (see Figure 2). If the user
selectable, main power source is interrupted, or if a
phase loss or imbalance occurs, the automatic transfer
switching circuitry immediately transfers operation of
the precision A/C system to the secondary power

Figure 2- Auto Transfer Disconnect Switches

With the auto-transfer switching option, a preferred
power selection switch is mounted inside the cabinet
to the top of the electric box, (see Figures 1 & 3). This
switch may be used to manually transfer the power
source and/or to test the auto transfer switching
function.

Figure 3- Preferred Power Selection Switch

1.6.4.1 Indicator Lights

As an additional option, an indicator light may be
provided above each main power service disconnect
switch for a visual indication that power is available.

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40.0"

(

)

S

E

S

S

E

S

SCO

CH

2.0 INSTALLATION

2.1 Receiving the Equipment

Your

Compact CW

tested and inspected prior to shipment. To ensure that
your equipment has been received in excellent condi­tion, make a visual inspection of the equipment
immediately upon delivery. Carefully remove the
shipping container and all protective packaging. Open
the access doors and thoroughly inspect the unit
interior for any signs of transit-incurred damage. If
there is shipping damage, it must be noted on the
freight carrier's delivery forms BEFORE signing for the
equipment. Any freight claims MUST be done through
the freight carrier. SATS ships all equipment FOB.
SATS can assist in the claim filing process with the
freight carrier. Should any damage be present, notify
the SATS Product Support Group prior to attempting
any repairs. Refer to section five of this manual for
instructions.

precision A/C system has been

EE NOT

MINIMUM FRONT

CLEARANCE

ERVICE

DI

EE NOT

NNECT SWIT

A Data Package has been sent with your unit. It
contains this manual, a supplemental microprocessor
controller manual, system drawings, applicable
MSDS’s, other component manuals, warranty registra­tion and other applicable instructions based on the
configuration and options of your unit. The data
package has been placed in your unit in a clear plastic
bag. These documents need to be retained with the
unit for future reference.

NOTE

Items that have been shipped loose, such as
controllers, temperature/humidity sensors, wa­ter detectors, etc., are shipped inside the air
conditioner, unless specified otherwise by the
customer. The filter box or plenum box assem­bly (if applicable) is shipped separately. Unpack
and store these items in a safe place unless
you are using them immediately.

2.2 Site Preparation

Compact CW

access in mind. Component access panels are
located on the front of the equipment. The number of
panels may vary depending on size and configuration
of the unit. Each unit has one front hinged panel for
accessing the electrical box. In order to have full
service access, no permanent obstructions can be
placed in front of the unit. See Figure 4 for the mini­mum recommended clearance in front of the unit.

systems are designed with easy service

NOTE: FOR UPFLOW UNITS, ALLOW SPACE ON

IDES TO PERMIT ENTRANCE OF PIPING AND WIRING.

Figure 4- Recommended Installation Clearance

NOTE

Working clearance requirements need to be es­tablished prior to mounting the unit. Refer to lo­cal and national electrical codes.

To minimize the effects of the environment surrounding
the conditioned space, certain steps must be taken.
This is especially true for critical/precision room
preparation (computer rooms/labs) requiring close
tolerance control of temperature and humidity. The
conditioned space should be well insulated and
include a vapor barrier. The installer should ensure that
the proper insulation rating is used based on the
design of the space, which was the basis for the
system selected. The following chart is a recom­mended minimum R-value (thermal resistance) to
ensure optimum equipment operation.

STRUCTURE R-VALUE

Ceiling R-38

Wall R-21
Floor R-19
Door R-5

The vapor barrier is the single most important require­ment for maintaining environmental control in the
conditioned space. The vapor barrier in the ceiling and

2-1

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S

H

HINGED

OOR

OPTIONAL
FLOOR STAND

OX

Y

(

)

HINGED

OOR

S

S

CH

walls can be a polyethylene film. Concrete walls and
floors should be painted with a rubber or plastic based
paint. Doors and windows should be properly sealed
and a door sweep used to minimize leakage. Outside
or fresh air should be kept to a minimum (as it adds to
the cooling, heating, dehumidification and humidifying
loads), while still maintaining the requirement of the
Indoor Air Quality (IAQ) standard. Lack of attention to
these factors can cause erratic operation, unstable
room control and excessive maintenance costs.

2.3 Rigging

Compact CW

vertical position. Move the unit with a suitable device
such as a forklift, roller bar, pallet jack or dollies. For
reference, a weight table is provided on the installation
drawing. Units are shipped on a skid to facilitate
moving prior to installation. Units should always be
stored indoors in a dry location prior to installation.

systems are designed to be kept in the

Figure 5- Typical Installation Upflow

PLENUM B
ASSEMBL

OPTIONAL

ERVICE
WIT

D

CAUTION

When moving the unit, it must be kept level and
in the vertical position to prevent damage.

2.4 Mounting/Placement

Compact CW

signed to be located in the conditioned space. Ducted
units may be located inside or outside the conditioned
space, but are designed to supply air to only one
room. The
which allows the units to be placed in a corner or
between cabinetry. It is recommended that the unit is
positioned to obtain optimum air circulation.

Placement of the floor or ceiling registers is im­portant. If they are too close to the unit, the sup­ply air will be re-circulated back to the unit be­fore it has circulated throughout the space.

See Figures 5 and 6. The unit is designed to be
located directly on top of the floor (typically upflow) or
on a raised floor (typically downflow).

systems that are not ducted are de-

Compact CW

systems are front accessible,

NOTE

D

ERVICE

SWITC

Figure 6- Typical Installation Downflow

CAUTION

Ensure the mounting surface is capable of sup­porting the weight of the equipment. Before mount­ing the unit, refer to the weight table provided on
the installation drawing. On some raised floor in­stallations, a floor stand is required, depending
on the load capacity of the existing raised floor.

(© Oct, 2007)

2.4.1 Precision A/C Unit

The
construction for unit rigidity and full service accessibil­ity without moving the unit. If a floor stand is used,
refer to the installation drawing provided and cut out
the raised floor to match the unit’s overall base
dimension. If a floor stand is not used, cut out the

ir Technology Systems, Inc.

Compact CW

system uses a frame and panel

2-2

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Compact CW Series Installation, Operation & Maintenance Manual

N

SU

Y

T

N

SU

Y

T

raised floor to match blower discharge opening(s) and
any required piping and wiring holes. Refer to the
installation drawing supplied with the unit for dimen­sional information.

NOTE

Equipment must be level to operate properly.

2.5 Air Distribution Connection

2.5.1 Downflow Configuration Air Patterns

In a downflow configured unit, the conditioned supply
air discharges through the bottom of the unit into a
raised floor. There are two basic return air patterns: top
free return and top ducted return (see Figure 7).

When determining ducting requirements, always
consult your local or state codes. The duct system
should be designed to allow the air to move with as
little resistance as possible.

The return inlet is provided with a turned-in flange on
top of the unit for connection of the ductwork. Refer to
the installation drawing provided with the unit. The
connection of ductwork to the unit may be made with
either pop rivets or self-tapping screws.

2.5.2 Upflow Configuration Air
Patterns

In an upflow configured unit, the conditioned supply air
has two methods of discharge: ducted or through a 2
or 3-way grilled plenum box. There are two basic return
air patterns: front free return and rear ducted return
(see Figures 8 and 9).

The supply air outlet and the rear ducted return air inlet
are provided with a flange for connection of the
ductwork (refer to the installation drawing provided with
the unit). The connection of ductwork to the unit may
be made with either pop rivets or self-tapping screws.

RETUR

PPL

AIR OUTLE

RETUR

PPL

AIR OUTLE

TOP FREE RETURN

Figure 7- Downflow Configuration Typical Air Patterns

2-3

TOP DUCTED RETURN

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A

A

N

SUPPLY

AIR OUTLE

N

SU

Y

T

TOP DISCHARGE 2 OR 3 WAY PLENUM BOX

SUPPLY

AIR OUTLET

SUPPLY

IR OUTLET

RETURN

AIR INLET

FRONT FREE RETURN

REAR DUCTED RETURN

Figure 8- Upflow Configuration Typical Air Patterns (Top Discharge)

TOP DUCTED DISCHARGE

PPL

AIR OUTLE

RETURN

AIR INLET

FRONT FREE RETURN

Figure 9- Upflow Configuration Typical Air Patterns (Top Ducted Discharge)

(© Oct, 2007)

R

R

REAR DUCTED RETURN

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Compact CW Series Installation, Operation & Maintenance Manual

2.6 Optional Equipment (Field Installed)

NOTE

Do not mount any optional equipment on the
unit access doors.

2.6.1 Floor Stand

Install the floor stand directly on the sub-floor, ensuring
the side with the "FRONT" label is facing the same
direction as the front of the precision A/C unit (see
Figure 10). Refer to the floor stand assembly drawing for
the dimensions required to cut the raised floor. The
optional floor stand is designed with adjustable feet on
all the legs, allowing for leveling and and overall height
adjustment. Refer to the floor stand assembly drawing
for minimum and maximum height adjustability of your
floor stand. To adjust the height, first loosen the middle
nuts on each leg. Next, turn the top hex nuts to raise or
lower the floor stand. Once the floor stand is level and
even with the raised floor, lock all feet in place by
tightening the middle hex nuts against the top hex nuts.

refer to the system drawings and the supplemental
manual sent in the data package with your unit.

2.6.4 Condensate Pump

An optional, factory installed condensate pump may be
provided for automatically eliminating condensate and
humidifier flush water from the drain pan. The conden­sate pump is typically installed by the factory inside
the A/C unit. If an optional, field installed condensate
pump is selected, it should be located as near as
possible to the air conditioning system. The pump
should be positioned so the inlet hole in the pump is
below the drain pan inside the A/C unit. The pump
includes a mounting bracket with two holes to secure
it in place. Ensure that the pump is level for proper
operation.

2.6.5 Remote Temperature/Humidity Sensor

The remote (T/H) sensor must be located so that it will
properly sense the temperature/humidity conditions to
be controlled. Depending on the type of control desired
(see Section 2.6.5.1), the sensor(s) may be factory
mounted and/or shipped loose for field installation.

"FRONT" LABEL

FLOOR STAND LEG

THREADED ROD

TOP HEX NUT

MIDDLE HEX NUT

ISOLATION PAD

Figure 10- Optional Floor Stand Installation

2.6.2 Plenum Box Assembly

The plenum box assembly is shipped loose. To install
the 2 or 3-way optional plenum box, place the assembly
on top of the unit (see Figure 5). Remove the front grille
for access to attach the plenum with the supplied self­tapping screws. Holes are pre-drilled in the unit and the
plenum box assembly.

2.6.3 Remote Display

The T/H sensor should not be mounted near a door­way, near or above any heat producing equipment or in
an area where it would be exposed to direct sunlight.
Follow the steps below to mount the sensor.

COVER
SCREW

Temperature/Humidity Sensor

1. Using a flat head screwdriver, remove the cover

plate from the base.

2. Place the base temporarily over the wire hole

opening in the wall. Level the base and mark the
mounting hole locations through the two slots.

3. Drill the mounting holes and insert the wall

anchors provided.

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

hole in the base, then secure the base with the
screws provided.

5. Make the wiring connections. For wiring details,

see Section 2.8 (Utility Connections) and refer to
the wiring diagram supplied with your unit.

As an option, a factory supplied control panel may be
remote mounted. For mounting and wiring instructions,

2-5

6. Replace the unit cover plate on the base.

(© Oct, 2007)

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CAUTION

Take care not to damage the exposed tempera­ture/humidity sensors on the PC board while screw­ing in the cover fastening screw. The sensors can
be damaged if handled improperly.

2.6.5.1 Types of control

Room Air Control (standard)- The A/C unit is provided
with a temperature and humidity (T/H) sensor, factory
mounted in the return air stream of the A/C unit. The
return air temperature and humidity are monitored by
the system controller and compared to limit values set
at the factory. Control outputs are based on setpoints
entered into the system controller by the user.

As an alternative to locating the T/H sensor inside the
A/C unit, it may be field installed on a wall in the
conditioned space for sensing actual room conditions.

Supply Air Control- As an option, a field installed T/H
sensor may be used for supply air control. The sensor
is field installed in the supply air stream. The supply
air temperature and humidity are monitored by the
system controller and compared to limit values set at
the factory. Control outputs are based on setpoints
entered into the system controller by the user.

Room Air Control with Supply Air Limitation- The
controller monitors the T/H sensor located in the
return air stream and the T/H sensor located in the
supply air stream. Control is similar to “Room Air
Control” except, the temperature setpoint is automati­cally increased by the controller when the measured
supply air temperature exceeds the Start Temperature
entered by the user. The extent of the setpoint
increase is determined by a factor which the user
enters in the controller as a gradient. A high gradient
significantly corrects the failure to meet the supply air
tempertaure but has the risk that the control circuit
starts to hunt.

With humidity control, the setpoint shift acts in the
opposite direction. If the starting humidity entered by
the user is exceeded by the measured supply air
humidity, the setpoint is autimatically reduced by the
controller. The user may also enter a gradient factor
for humidity control.

Supply Air Control with Room Air Limitation- Based
on the same principle as “Room Air Control with
Supply Air Limitation” however, in this case the
setpoint shift works in the opposite direction on the
basis that the supply air is colder than the return air.
The temperature setpoint is automatically reduced by
the system controller when the measured room air
temperature exceeds the Start Temperature entered
by the user. The humidity setpoint is automatically
increased by the system controller when the mea­sured room humidity drops below the starting humidity
entered by the user.

2.6.6 Remote Water Detector

The remote water detector is normally placed on the
sub-floor or in a field supplied auxiliary drain pan located
beneath the unit. SATS provides 2 types of water
detectors:

Spot type water detector

-

Remove the protective cover and connect two control
wires to the terminals on the base
(terminal lugs are provided). Place the
water detector(s) on the floor with the
metal electrodes facing down. The base
is provided with a mounting hole in the
center which may be used to secure the water detec­tor in place. Replace the cover. When water is present,
current will flow between the electrodes.

NOTE

Do not place the spot type water detector on
an electrically conductive surface.

Cable type water detector

-

Lay the cable water detector flat across the sub-floor
where water could collect.
When water is present,
current will flow between the
two wires. A two conductor
wire harness is provided with a
quick connect fitting on the end. The harness mates to
the fitting on the water detector and connects it to the
control board inside the electric box.

2.7 Piping Connections

2.7.1 Chilled Water/Hot Water

Formula:
New setpoint = old setpoint+ [gradient • (start value -actual

value)]

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

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

(© Oct, 2007)

For CCD (downflow) units, the pipe openings for the
chilled water and optional hot water reheat piping are
located in the base of the unit. For CCU (upflow) units,
pilot holes are provided inside the unit in the lower side
panel(s). These pilot holes may be enlarged from
inside the unit. Refer to the installation drawing

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Compact CW Series Installation, Operation & Maintenance Manual

supplied with your unit for the location of the openings.
Generally, all pipe connections (sweat connections)
terminate inside the unit. Upflow (CCU) units may be
provided with (optional) pipe connections protruding
from the top of the unit.

For pipe connection sizes, refer to the following table:

INLET/OUTLET PIPE CONNECTIONS

CW HW

Model # (Inches O.D.) (Inches O.D.)

CCU/D-300 1 1/8” 7/8”

CCU/D-600 1 5/8” 7/8”

CCU/D-900 1 5/8” 7/8”

CCU/D-1500 2 1/8” 7/8”

CCU/D-1800 2 1/8” 7/8”

Field piping is not necessarily the same size as the
unit connections. Piping should be sized to match the
required system pressure drop and flow capacity, and
may require reducing fittings to match the connection
size on the air conditioner. A filling connection and
several shrader valves are installed in the A/C unit.
Refer to the piping diagram supplied with your unit.

The drain line must be located so it will not be ex­posed to freezing temperatures. The diameter of the
drain line should be the full size of the connection.

NOTE

Pour some water into the condensate drain
pan(s) prior to start-up. This fills the trap and
prevents air from being drawn up the drain lines.

2.7.2.2 Condensate Pump

An optional condensate pump is normally factory
installed. The drain connection line may be 1/2” ID
vinyl tubing or a 1/2” O.D. copper (sweat connection)
may be used.

If an optional field installed condensate pump is used,
a p-trap must be installed to allow proper condensate
drainage (see Figure 11). The height of the trap must
be a minimum of 2 inches on standard systems to
ensure proper water drainage. The condensate pump
discharge line should be 1/2 inch O.D. (maximum)
copper pipe to prevent excessive back flow to the
condensate pump.

INLET 7/8" OD

OUTLET 1/2" OD

CAUTION

When installing and filling the chilled water and/
or hot water loops, all air must be bled from the
piping system and the piping system must be
cleaned prior to operating the system. Failure to
do so could result in equipment problems.

NOTE

All chilled water lines must be insulated to
prevent condensation from forming on the pipes.

2.7.2 Condensate Drain

2.7.2.1 Gravity Drain

A 7/8 inch OD copper (sweat type) line is provided to
drain the condensate pan. An “S” trap is installed at
the end of piping for the installer to connect a 7/8 inch
ID drain line to remove water from the cabinet. This line
also drains the optional humidifier.

NOTE

The humidifier drains (hot) water into the
condensate drain during normal operation.

SEE NOTE 2

NOTES:

1. MIMIMUM HEIGHT IN INCHES.

2. P-TRAP MUST BE LOCATED IN THE INLET SIDE OF PUMP WHEN FIELD INSTALLED.

2.00

SEE NOTE 1

Figure 11- Condensate Pump

2.7.3 Humidifier

Compact CW

humidifier. The humidifier empties into the condensate
drain line during the flush/drain cycle. A water supply
line must be connected to the ¼ inch O.D. copper
tubing connection supplied by the factory. The humidi­fier requires normal tap water for the water supply. If
the supply water is high in particulate, an external filter
may be needed. Do not use de-mineralized water.
Refer to the humidifier operator’s manual, supplied with
the equipment, for complete manufacturer’s informa­tion on the humidifier and the supply water recommen­dations.

systems utilize an electrode steam

2-7

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Compact CW Series Installation, Operation & Maintenance Manual

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2.8 Utility Connections

2.8.1 Main Power

The

Compact CW

460 and 575 volt three-phase configurations. It is
imperative that the unit nameplate be examined to
determine the operating voltage, frequency and phase
of the system (see Figure 12). The nameplate also
provides the full load amps (FLA), the current the unit
will draw under full design load, the minimum circuit
ampacity (MCA) for wire sizing, and the maximum
fuse or HACR (Heating, Air Conditioning, Refrigeration)
breaker size (MAX FUSE/CKT BKR) for circuit protec­tion. The unit's nameplate is located inside the
cabinet, within the electrical box.

product offering is available in 208,

NOTE

If the nameplate states MAX FUSE/CKT BKR,
it is required to use fuses or a HACR type cir­cuit breaker to protect the system. Other pro­tection devices are not allowed based upon the
product listing.

The unit is provided with terminals for all required field­wiring connections. Refer to the electrical schematic
supplied with the unit for all power and control field­wiring. It is important to identify the options that were
purchased with the unit in order to confirm which field
connections are required.

WARNING

Verify power is turned off before making connec­tions to the equipment.

NOTE

All wiring must conform to local and national elec­trical code requirements. Use of copper conduc­tors only is required. Wiring terminations may
become loose during transit of the equipment;
therefore, it is required to verify that all wiring
terminations are secure.

It is important to verify that the main power supply
coincides with the voltage, phase and frequency
information specified on the system nameplate. The
supply voltage measured at the unit must be within
±10% of the voltage specified on the system name­plate.

Each unit is provided with pilot holes for connection of
main power and control field-wiring. These pilot holes
are located on the

Compact CW

unit based on
configuration. On a downflow configuration, the pilot
holes are located in the floor of the cabinet. On an
upflow configuration, pilot holes are located inside the
cabinet in the side wall. These pilot holes may be
enlarged from inside the unit. A label stating "MAIN
POWER INPUT" is in close proximity. See the
installation drawing supplied with your unit for pilot
hole locations.

Terminate the main power wires at the line side of the
main power disconnect switch, located within the
electric box (see Figure 13). A separate equipment
ground lug is provided within the electrical box for
termination of the earth ground wire.

Figure 12- Sample Nameplate

(© Oct, 2007)

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Compact CW Series Installation, Operation & Maintenance Manual

2.8.2 Controls

7

6

5

1

SATS offers a wide range of control features to solve
your air conditioning control/alarm requirements. The

Compact CW

system is furnished with a C1002 or
C6000 Microprocessor controller. If it is mounted on
the unit (standard), no utility connection is required. As
an option a factory supplied display may be remote

2

mounted. A six-conductor cable harness is provided for
interconnect wiring. Refer to the electrical drawing
provided with the unit for details on interconnecting
field wiring.

2.8.3 Optional Equipment

Figure 13- Electric Box

The number callouts in Figure 13 coincide with the
numbered items listed below:

1. Control I/O Board

2. Interface Terminals

3. Main Power Disconnect Switch

4. Ground Lug

5. Power Switches/Motor Start Protectors
(Quantity varies by size of A/C unit)

6. Water Detector Circuit Board (Optional)

7. Transformer Circuit Breakers

CAUTION

Improper wire connections may result in the re­verse rotation of the fans/blower motors and may
eventually result in damage to the unit. To cor­rect this problem, exchange any two of the in­coming main power wires at the main power dis­connect switch. Do NOT rewire the unit's indi­vidual components.

CAUTION

3

Additional control conductors may be required depend­ing on the options purchased with the equipment.

4

Refer to the electrical diagram supplied with your unit
to determine the total number of interconnecting
conductors required for your system. It is important to
note that control transformer(s) supplied with the
equipment are sized and selected based upon the
expected loads for each system.

CAUTION

Do not connect any additional loads to the sys­tem control transformers. Connecting additional
loads to the factory supplied control transformer
may result in overloading of the transformer.

NOTE

All wiring must be provided in accordance with
local and national electrical code requirements.

2.7.3.1 Remote Temperature/Humidity Sensor

The remote temperature/humidity sensor requires a
three conductor shielded cable, with the shield
terminated at the unit electric box. Both the electric
box and the sensor are provided with a terminal strip
for the wire connections. Refer to the electrical
schematic supplied with your unit for proper wire
terminations.

Prior to unit operation, an adequate unit-to-earth
ground must be connected to the unit.

2-9

2.7.3.2 Remote Water Detector

Each remote water detector used will require two
conductors to be wired to the control terminal board
within the unit electrical box (see Figure 13). The wire
insulation must be rated at 600V. Refer to the electri­cal schematic supplied with your unit for proper wire
terminations.

(© Oct, 2007)

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Compact CW Series Installation, Operation & Maintenance Manual

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2.9 System Settings and Adjustments

2.9.1 Chilled Water Circuit

In a chilled water A/C unit, cooling is maintained by
flowing chilled water through a cooling coil. A water
valve proportionally opens to increase fluid flow as the
temperature rises (or closes as the temperature falls).
If the unit is turned off, the valve will return to the
closed position, shutting off flow through the coil.
Chilled Water control valves are available in 2-way or 3­way configurations. Refer to the piping drawing
supplied with your unit to determine which type valve is
provided.

Location and size of chilled water valves differs with
the size of the A/C unit. The chilled water valves are
factory set for the correct operation and should not
require field adjustment.

2.9.2 Humidifier Adjustment

The humidifier has a capacity adjustment potentiom­eter on the humidifier control circuit board. The capac­ity potentiometer may need to be field adjusted if the
humidifier is not supplying enough capacity for current
room conditions.

It is recommended that if the humidifier capacity
potentiometer requires adjustment, the adjustment is
made in small increments and verified. Refer to the
humidifier manual sent with your unit for the capacity
potentiometer location.

CAUTION

Adjusting the capacity potentiometer too high may
result in formation of condensation within the system.

2.9.3 Blower

The blower motor (see Figure 14) is supplied with an
adjustable sheave (pulley), to change blower speed, and
an adjustable base for belt tensioning. Use the following
procedure to change the blower speed.

1. Turn the A/C system off.

2. Turn off all power to unit at the main power discon­nect switch; use lock-out tag-out procedure.

3. Remove the blower belt(s).

4. Loosen the set screw in the side of the motor
sheave with an allen wrench.

5. Remove the sheave key.

6. Adjust blower speed by closing the sheave one half

turn to increase speed or opening the sheave one
half turn to decrease speed.

7. Replace the sheave key and tighten set screw.

ADJUSTABLE
SHEAVE

MOTOR

BASE LOCKING
BOLT

JAM NUT

LOCK DOWN
PLATE

MOTOR
BASE

BLOWER

TENSION ROD
ADJUSTMENT

Figure 14- Blower Assembly

8. Proper belt tension is achieved when the belt has a
deflection of ¾ inch per foot of span between the
blower and motor pulleys, with firm pressure
placed mid-span on the blower belt. To adjust
blower belt tension, loosen the locking bolt on the
side of the motor base. Turn the jam nut away from
the lockdown plate. Rotate the tension rod to move
the motor on it’s base to increase or decrease belt
tension. Re-tighten the jam nut and tighten the
locking bolt on the motor base.

CAUTION

If the belt tension is too tight, it will cause premature
blower and/or motor bearing failure. If the belt is too
loose, the belt will slip and cause belt squeals and
eventual belt failure.

9. Restore power to system.

10. Check the current draw on the blower motor to
make sure it does not exceed the nameplate
rating of the motor.

11. If current draw exceeds nameplate rating of motor,
repeat steps 1 through 9 to decrease the blower
speed. If the motor pulls too much current, slow
the blower down by opening the adjustable sheave
one half turn at a time, until the motor current is at
or below the nameplate FLA.

12. Check the motor overload on the blower starter to
confirm its setting is correct for the FLA of the motor.

(© Oct, 2007)

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Compact CW Series Installation, Operation & Maintenance Manual

3.0 START-UP/COMMISSIONING

3.1 Operation

For new installations, ensure the unit is ready to
operate by going through the Checklist for Completed
Installation, located in Appendix A, prior to start-up.

NOTE

A Warranty Registration and Start-Up Checklist
is provided with the unit data package. It should
be completed during start-up and sent to SATS.
This checklist should be used as a guideline for
items that need to be confirmed during start-up.

Start-up must be performed by a journeyman, refrig­eration mechanic or an air conditioning technician.

3.2 Step by Step Start-Up Instructions

1. Replace all equipment removed prior to performing
start-up checks.

2. Ensure that the control circuit breakers, fan motor
starter switch and additional built in optional
equipment power switches are turned on.

3. Apply power to the
main power disconnect switch.

4. Turn on the A/C unit at the system controller and
set the desired values (setpoints) for room
temperature and humidity. (Refer to the separate
controller operation instructions included in the
data package with your unit.)

5. Ensure that all blowers and fans are rotating
correctly and freely without any unusual noise.

Compact CW

system at the

8. Test dehumidification operation by creating a
demand for dehumidification. If necessary, set the
dehumidification setpoint 10% below actual room
conditions (the set point may already be below the
actual room conditions, especially at start-up).
The chilled water valve should open to begin the
dehumidification process. While in this mode, room
temperature may decrease and the reheat function
may activate. As conditions in the room change,
you may have to readjust the setpoint as you
check operation. An adequate heat load within the
space is required.

9. For Electric Reheat, use an amp meter on the
heater circuit to determine if the heater is opera­tional. For Hot Water Reheat ensure that the
control signal has energized the control valve and
the temperature of the water has decreased as it
passes through the unit. In all cases, 1 to 6 hours
might be required to see a desired level or decrease
in humidity in the conditioned space. Once room
conditions have been programmed or set, a repeat
visit to the conditioned space may be required to
ensure the dehumidification mode is meeting the
room’s requirements.

3.3 Microprocessor Controller Programming

The microprocessor controller is factory programmed
based on the optional features selected. Most applica­tions require no field start-up or program adjustment
beyond setting the current date and time. Separate
operating instructions for the controller have been sent
with your unit, including each feature's factory "default"
setting and the available adjustment range, if appli­cable.

6. Test cooling operation by setting the temperature
setpoint below actual room temperature. The
chilled water valve should open and the discharge
air should feel cooler than the return air.

7. Test humidification operation by creating a
demand for humidification. Use an amp meter to
determine current draw of the humidifier. Visually
check for vapor leaving the steam head or feel if
the cylinder is warm to verify if the humidifier is
operational. In all cases, 1 to 6 hours might be
required to see a desired level or rise in humidity
in the conditioned space. Once room conditions
have been programmed or set, a repeat visit to the
conditioned space may be required to ensure the
humidifier is meeting the room's requirements.

3-1

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Compact CW Series Installation, Operation & Maintenance Manual

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4.0 MAINTENANCE

4.1 Periodic General Maintenance

Systematic, periodic general maintenance of the

Compact CW

system performance. General maintenance should
include, but is not limited to the following: replacing
filters and humidifier cylinders, tightening electrical
connections, checking the water lines to ensure they
are free of debris, ensuring no air is in the water
line(s), cleaning the interior of the unit, checking belt
tension and inspecting the unit’s components visually.

Use copies of the Periodic General Maintenance
Checklist in this manual (see Appendix A) to record
periodic general maintenance inspections. For
assistance, contact the SATS Product Support Group.
Ensure adherence to all safety statements while
performing any type of maintenance.

unit is recommended for optimum

WARNING

This equipment should be serviced and repaired
by a journeyman or a qualified refrigeration
technician only.

WARNING

This unit employs high voltage equipment with
rotating components. Exercise extreme care to
avoid accidents and ensure proper operation.

Hazardous voltage will still be present inside the
electric box at the motor start protectors and at the
heater and humidifier circuit breakers, even with the
unit turned off at the microprocessor controller. To
isolate the unit for maintenance, turn off power at the
main power disconnect switch. Always disconnect
main power prior to performing any service or repairs.

4.1.1

4.1.1.1 Filter

The filter is usually the most neglected item in an air
conditioning system. To maintain efficient operation,
the filter should be checked at least monthly and
replaced as required.

4.1.1.2 Blower

The blower motor is provided with permanently lubri­cated bearings and should not require maintenance for
the lifetime of the equipment. Periodic checks of the
blower system should include checking the blower
motor mounts, housing, belts and blower wheel.
Check that all mounts are secure and the blower
wheel is tightly mounted on the shaft and does not rub
against the fan housing. The blower vanes should be
kept free of debris.

4.1.1.3 Drain Pan

To ensure proper drainage, inspect the drain pan
regularly. Make sure the drain pan outlets are always
free of debris and ensure the drain pan does not leak.

4.1.1.4 Coils

The coil(s) should be inspected semi-annually and
cleaned as required, following standard coil cleaning
practices. Using a brush, clean the coil fins of all
debris that will inhibit airflow. This can also be done
with compressed air or with a commercial coil cleaner.
Check for bent or damaged coil fins and repair as
necessary. Check all piping for signs of leaks.

4.1.1.5 Heat/Reheat

Compact CW

Air quality conditions of spaces vary and filters
should be checked based on those conditions.

Precision A/C Unit

NOTE

WARNING

Turn off power to the unit unless you are per­forming tests that require power. With power and
controls energized, the unit could begin operat­ing at any time. To prevent personal injury, stay
clear of rotating components as automatic con­trols may start them unexpectedly.

(© Oct, 2007)

The heat/reheat equipment should be inspected semi­annually to ensure it is operational. If you have electric
heat/reheat, inspect the heating elements to ensure
they are free of debris.

4.1.1.6 Humidifier

The steam cylinder has a limited lifetime and must be
replaced periodically. Because water conditions and
humidifier usage rates vary greatly, it is difficult to
establish intervals for changing the cylinder. Individual
maintenance schedules must be determined for each
location, based upon periodic examination of the

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humidifier. A change cylinder light on the humidifier
cabinet will illuminate (red) when the cylinder requires
replacement.

NOTE

The red light may illuminate during initial start­up but it doesn’t necessarily mean the cylinder

4.1.1.7 Condensate Pump

The condensate pump should be inspected semi­annually and cleaned. Ensure that the float works freely.
Wipe the float with a wet cloth and detergent to remove
dirt. Clean the tank bottom. Check that the discharge
line is open and water can pass through it freely.

needs to be replaced.

Refer to the humidifier operator’s manual supplied
under separate cover for detailed instructions for
changing the cylinder.

4.2 Troubleshooting

Turn off all power to the unit before conducting any troubleshooting procedures, unless the procedure specifi­cally requires the system to operate. For troubleshooting purposes, the system may be operated with the
doors open by using the yellow knob to turn the shaft of the main power disconnect switch to the "On"
position. When the switch is turned on, high voltage will be present inside the cabinet. Exercise caution
to prevent injury. Keep hands, clothing and tools clear of the electrical terminals and rotating components.
Ensure that your footing is stable at all times.

SYMPTOM PROBABLE CAUSE RECOMMENDATION

Chilled Water Valve Fails a. Temperature setpoint too high Adjust to correct temperature setting
to Open or Close

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

Check wiring schematic and rewire if
required.

c. Actuator failed Replace actuator

Blower(s) Fail to Start a. Power failure Check main voltage power source

input cable

b. Control transformer circuit Check for short circuit or ground fault,
breaker tripped if none re-set circuit breaker.

c. Motor starter protector tripped Reset motor starter protector and check

amperage of motor. Compare to setting
on motor starter protector and adjust to
FLA.

d. Condensate overflow switch open. 1. Ensure unit is level

2. Check that condensate pan is draining
properly. Clear obstructions.

e. Defective contactor Repair or replace

Control is Erratic Wiring improperly connected or Check wiring against schematic

broken diagram

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SYMPTOM PROBABLE CAUSE RECOMMENDATION

System Short of Capacity a. Low Chilled Water flow Check for leaks. Repair and recharge

system.

b. Supply water temperature too high Check chilled water supply

c. Reduced airflow Check filters

d. Dirty Coil Clear coil fins of debris

Electric Heater a. Circuit breaker tripped Check for short circuit, reset circuit
Inoperable breaker

b. Temperature setpoint too low Increase temperature setpoint

c. Overheat switch open Insufficient air flow across heater

elements. Check for dirty filters or
obstructions that may reduce air flow.
Correct or replace as needed.

d. Manual reset overheat safety Reset manual overheat safety switch
switch tripped (see item immediately above).

e. Heater element burned out Check continuity with an ohmmeter

Replace heater element

Hot Water Heater a. Low hot water flow Check hot water flow at supply source
Inoperable Inspect piping for leaks or obstructions

b. Low hot water supply temperature Check hot water supply

c. Temperature setpoint too low Increase temperature setpoint

d. Control power interrupted Check for loose or broken wires

Humidifier Inoperable a. Water supply has been turned Connect and/or turn on water supply
Note:

See Humidifier

off or not connected

Manual for Additional Help

b. Humidifier switch is in “Off” position Turn switch to “Auto/On” position

c. Electrical connections are loose Tighten electrical connections

d. Humidifier circuit breaker tripped Check for over current by the humidifier

electrodes. Drain water from tank and
refill. Reset circuit breaker.

e. Relative humidity is above setpoint. Adjust humidity setpoint

f. Electrode canister change cylinder 1. Consult humidifier manual
light is on

2. Water conductivity is too low and
water is at the top of the cylinder,
(see next item).

(© Oct, 2007)

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

through the top of the cylinder. Typically
only required on initial start-up.

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4.3 Field Service

NOTE

Do not attempt to make repairs without the
proper tools.

It may be necessary to perform repairs on the A/C
system. If field repairs are necessary, the following
procedures apply:

1. All electrical connections should be checked to
ensure they are tight and properly made.

2. Check all circuit breakers, contacts and wiring.
The contacter should be examined and replaced if
contacts are worn or pitted.

4.3.1 Piping

When replacing components within the cabinet of the
unit, the following consumable materials are recom­mended: Use Silfos alloy for copper-to-copper (piping
discharge or suction line repairs). Silver solder (Stay­Silv #45) and flux are to be used on copper-to-brass or
copper-to-steel repairs.

When component replacement is complete, remove all
traces of flux. After any repair, pressure check the
system to check for leaks prior to recharging the
system.

4.3.2 General Common Repairs/

Component Replacement

4.3.2.1 Humidifier Cylinder Replacement

After an extended period of operation a red light will
illuminate on the humidifier cabinet indicating that the
cylinder is completely used and a replacement
cylinder must be installed. The cylinder is disposable
and cylinder life is dependent on water supply condi­tions and humidifier usage. The following procedures
are to be followed when replacing the cylinder.

CAUTION

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

3. When drained, push the “Auto On/Off/Drain”
switch to the “Off” position.

4. Turn off power at the main power disconnect
switch.

5. The power wires to the cylinder are attached by
cylinder plugs to the electrode pins on top of the
cylinder. Pull these plugs vertically off the pins.

CAUTION

The cylinder and steam hose may be hot and
burns may result.

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

7. Lift the cylinder straight up to disengage it from
the humidifier.

8. Place the new cylinder on the side mounting slots
within the unit, ensuring the cylinder mounting
stubs are seated properly.

9. Replace the cylinder plugs on the pins, ensuring
the white sensor plug goes on the single pin,
which is offset from the others.

10. Ensure the plugs are secured on the pins. If the
plugs are loose, they may be temporarily
squeezed together, however, the plugs must be
replaced since a loose plug could generate
enough heat to melt and destroy the plug.

11. Replace the steam hose and tighten the clamp(s).

12. Turn on main power at the main power disconnect
switch.

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

14. Turn on the water supply to the humidifier.

15. Re-adjust the humidity setpoint.

If the humidifier is to be shut down for an extended
period, always drain the cylinder first. Follow the above
steps (1 through 4) ensuring the “Auto On/Off/Drain”
switch is in the “Off” position. Failure to do this will
drastically shorten the cylinder life.

4.3.2.2 Filter Replacement

NOTE

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

1. Turn off water supply to the humidifier.

2. Drain the cylinder by pushing the “Auto/On-Off­Drain” switch to the “Drain” position.

4-4

The filters are located either internal to the cabinet or
external to the cabinet, depending on the configuration
of the unit. Regardless of location, all filter access
locations, except for the front hinged access door, are
labeled "FILTER ACCESS". Remove the old filter(s).
Insert the new filter(s), ensuring directional airflow
arrows on the filters are correct, then close the access
panel.

(© Oct, 2007)

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5.0 PRODUCT SUPPORT GROUP

SATS provides to its customers a Product Support
Group (PSG) which not only provides technical
support and parts but the following additional services,
as requested: performance evaluations, start-up
assistance and training.

5.1 Technical Support

The SATS Product Support Group (PSG) is dedicated
to the prompt reply and solution to any problem
encountered with a unit. Should a problem develop
that cannot be resolved using this manual, you may
contact PSG at [phone] Monday through
Friday from 8:00 a.m. to 5:00 p.m. EST. If a problem
occurs after business hours, dial the page number
[phone] and follow the steps below:

1. Wait for the dial tone.

2. Dial your telephone number (including area
code).

3. Press the pound (#) key.

A written (or faxed) purchase order is required on
warranty parts and must be received prior to 12:00
p.m. for same day shipment. The purchase order must
contain the following items:

• Purchase Order Number

• Date of Order

• SATS Stated Part Price (obtained from PSG)

• Customer Billing Address

• Shipping Address

• Customer's Telephone and Fax Numbers

• Contact Name

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

The customer is responsible for the shipping cost
incurred for returning the defective part(s) back to
SATS. Return of defective part(s) must be within 30
days at which time an evaluation of the part(s) is
conducted and if the part is found to have a manufac­turing defect a credit will be issued.

4. Wait for a busy signal.

5. Hang up the telephone.

One of our service technicians will return your call.
When calling to obtain support, it is vital to have the
following information readily available, (information is
found on unit's nameplate):

• Unit Model Number (CCU/D-XXX-XX)

• SATS Item Number (123456)

• Unit Serial Number (1234567)

• Description of Problem

5.2 Obtaining Warranty Parts

Warranty inquires are to be made through the Product
Support Group (PSG) at [phone] Monday
through Friday from 8:00 a.m. to 5:00 p.m. EST. A
service technician at SATS will troubleshoot the
system over the telephone with a field service techni­cian to determine the defect of the part. If it is deter­mined that the part may be defective a replacement
part will be sent UPS ground. If the customer requests
that warranty part(s) be sent by any other method than
UPS ground the customer is responsible for the
shipping charges. If you do not have established credit
with SATS you must provide a freight carrier account
number.

When returning defective part(s), complete the Return
Material Authorization Tag and the address label
received with the replacement part.

See SATS Standard Warranty located in section one
of this manual.

5.3 Obtaining Spare/Replacement Parts

Spare and replacement parts requests are to be made
through the Product Support Group (PSG) by fax (301)
620-1396, telephone [phone] or e-mail
([e-mail]). Quotes are given for specified
listed parts for a specific unit.

SATS accepts Visa and MasterCard. SATS may
extend credit to its customers; a credit application
must be prepared and approved (this process could
take one week).

A 25% minimum restocking charge will be applied on
returned stocked parts that were sold as spare/
replacement parts. If the returned part is not a stocked
item, a 50% restocking charge may be applied.
Additionally a Return Material Authorization Number is
required when returning parts. To receive credit for
returned repair/replacement parts, the parts must be
returned to SATS within 30 days of the purchase date.
Spare part sales over 30 days old will be considered
final and the parts will remain the sole property of the
ordering party.

(© Oct, 2007)

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NOTES

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APPENDIX A - FORMS

Stulz Air Technology Systems Inc.

Frederick, Maryland USA 21704

Telephone: [phone] Facsimile: [phone]

Checklist for Completed Installation

1 Proper clearances for service access have

❏

been maintained around equipment.

2 Equipment is level and mounting fasteners (if

❏

applicable) are tight.

3 Piping completed to refrigerant or coolant loop

❏

(if required).

4 All field installed piping leak tested.

❏

Frederick, Maryland USA 21704

Telephone: [phone]

Facsimile: [phone]

12 Ductwork completed or optional plenum

❏

installed (if required).

13 Incoming line voltage matches equipment

❏

nominal nameplated rating ± tolerances.

❏ 14 Main power wiring connections to the

equipment, including earth ground, have been
properly installed.

5 Refrigerant charge added (if required).

❏

6 Condensate pump installed (if required).

❏

7 Condensate drain line connected and trap is

❏

filled with water.

8 Water supply line connected to humidifier

❏

(if required).

9 Safety pan installed under ceiling mounted

❏

equipment (if required).

10 Filter box installed (if required).

❏

11 Filter (s) installed (if required).

❏

❏ 15 Customer supplied main power circuit breaker

(HACR type) or fuses have proper ratings for
equipment installed.

❏ 16 All wiring connections are tight.

❏ 17 Control wiring connections completed to

optional equipment and devices including wiring
to a wall mounted control panel (if required).

❏ 18 Foreign materials have been removed from

inside and around all equipment installed
(shipping materials, construction materials,
tools, etc.).

❏ 19 Inspect all piping connections for leaks during

initial operation.

(© Oct, 2007)

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Frederick, Maryland USA 21704

Telephone: [phone]

Facsimile: [phone]

Periodic General Maintenance Checks and Services Checklist

Date: ____________________________ Prepared By: ___________________________

Model Number: ____________________________ Serial Number: __________________________

Item Number: ____________________________

Monthly

Filters Blower Section Condensate Drain

❏
❏

Miscellaneous

❏
❏
❏

Cleanliness
No Obstructions

Check Chilled Water/Hot Water circuits for Air (bleed as required)
Coils Clean and Clear of Obstructions
Humidifier Cylinder and Controls Operate Properly

❏
❏

Blower Turns
Belts (if applicable)

❏
❏

Drain is Open
Condensate Pan Safety
Switches Operate Freely

Semi-Annually

❏
❏

❏

Tighten Electrical Connections

Check Contacts on Contactors

for Pitting

Heat/Reheat Operational

❏
❏
❏

Clean Unit as Necessary

Clean Coils

Clean Condensate Pump

Annually

❏

❏

Inspect Chilled Water System
for Leaks and Corrosion
Conduct a Complete Check of All Services Listed
Above and Clean Unit's Interior

Notes:

___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Signature:________________________________

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

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

(© Oct, 2007)

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Appendix B- Glossary

Definition of Terms and Acronyms

SATS - Stulz Air Technology Systems, Inc.

BTU/Hr - British Thermal Units per Hour

CFM - Cubic Feet per Minute

CNDCT - Conductor

CW - Chilled Water

ESD - Electrostatic Discharge

º F - Degrees Fahrenheit

FLA - Full Load Amps

FOB - Freight on Board

HACR - Heating, Air Conditioning, Refrigeration

HP - Horse Power

Hz - Hertz

IAQ - Indoor Air Quality

in. w.g. - Inches of Water Gauge

KVA - Kilo Volt Amps

kW - Kilowatt

MAX CKT
BKR - Maximum Circuit Breaker

MAX FUSE - Maximum Fuse

MCA - Minimum Circuit Ampacity

MSDS - Material Safety Data Sheet

NEC - National Electric Code

NFPA - National Fire Protection Agency

PH - Phase

PSG - Product Support Group

PSI - Pounds per Square Inch

PSIG - Pounds per Square Inch Gauge

RLA - Run Load Amps

R-Value - Thermal Resistance

SPDT - Single Pole, Double Throw

V - Volt

VAC - Volt, Alternating Current

(© Oct, 2007)

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