installation, operation & maintenance cybertwo™...

(Revised 08/05)

CyberTWO Series Installation, Operation & Maintenance Manual

Installation, Operation& Maintenance

Dual Circuit - Vertical Floor MountedPrecision Air Conditioners

SATS

The

Nat

ural

Alte

rnat

ive

CyberTWO™ SERIESCyberTWO™ SERIES

(Revised 08/05)


MODEL NOMENCLATURE

VFS-120-DG-FC-U

OHS = Overhead SystemVFS = Vertical Floor SystemFCS = Floor Console SystemGPS = Glycol Pump SystemCOS = CyberONE SystemMCS = Modular Cyber System

Nominal Capacity in1,000’s of BTU/Hr

D ( )=Dual (Two) Circuit SystemH ( )=Horizontal Discharge (H-Series)

AHU = Air Handling Unit

AR = Air-Cooled Remote (Split)

AS = Air-Cooled Self-Contained

C = Chilled Water System

CAA = Indoor Centrifugal Condenser

G = Glycol-Cooled

GRC = Glycol-Cooled Remote Condensing Unit

RCU-O = Outdoor Propeller Remote Condensing Unit

RCU-I = Indoor Centrifugal RemoteCondensing Unit

S = Single Pump

W = Water Cooled

WRC = Water-Cooled Remote Condensing Unit

D = DownflowU = Upflow

AWS = Alternate Water SourceFC = Free Cooling

(Revised 08/05)


1.0 Introduction ....................................... 1-11.1 General ...................................................... 1-11.2 Product Description ................................... 1-11.3 Product Warranty ...................................... 1-11.4 Safety ........................................................ 1-41.4.1 General ...................................................... 1-41.4.2 Safety Summary ........................................ 1-4

2.0 Installation ......................................... 2-12.1 Receiving the Equipment. .......................... 2-12.2 Site Preparation ......................................... 2-12.3 Rigging ...................................................... 2-12.4 Mounting/Placement .................................. 2-22.4.1 Indoor Equipment ....................................... 2-22.4.2 Outdoor Equipment .................................... 2-22.4.3 Optional Equipment (Field Installed) .......... 2-22.4.3.1 Remote Display ......................................... 2-22.4.3.2 Remote Temperature/Humidity Sensor ....... 2-32.4.3.3 Remote Water Detector ............................. 2-32.4.3.4 Floor Stand ................................................ 2-42.4.3.5 Plenum Box Assembly .............................. 2-42.5 Air Distribution Connection ........................ 2-42.5.1 Downflow Configuration Air Patterns ........... 2-42.5.2 Upflow Configuration Air Patterns ............... 2-52.6 Piping Connections .................................... 2-52.6.1 Refrigerant ................................................. 2-62.6.2 Water/Glycol ............................................. 2-82.6.3 Condensate Drain ...................................... 2-82.6.3.1 Gravity Drain .............................................. 2-82.6.3.2 Condensate Pump ..................................... 2-82.6.4 Humidifier .................................................. 2-92.7 Utility Connections .................................... 2-92.7.1 Main Power ............................................... 2-92.7.2 Controls ................................................... 2-102.7.3 Optional Equipment ..................................2-112.7.3.1 Remote Temperature/Humidity Sensor ......2-112.7.3.2 Remote Water Detector ............................2-112.7.4 Interconnecting Field Wiring ......................2-112.7.4.1 Air-Cooled Split Systems

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

TABLE OF CONTENTS2.7.4.2 Glycol Systems ....................................... 2-122.8 System Settings and Adjustments ........... 2-132.8.1 R-22 Refrigerant Charging Procedures ..... 2-132.8.2 R-407C Refrigerant Charging Procedures . 2-142.8.3 Low/High Pressure Limit Switch .............. 2-152.8.4 Head Pressure Controls ........................... 2-152.8.4.1 Air-Cooled Systems ................................. 2-152.8.4.2 Water/Glycol-Cooled Systems................. 2-162.8.5 Humidifier Adjustment .............................. 2-162.8.6 Blower ..................................................... 2-172.8.7 Thermal Expansion Valve ......................... 2-172.8.8 Snap Acting Hot Gas Bypass (Optional) .. 2-172.8.9 Hot Gas Reheat (Optional) ....................... 2-182.9 Refrigerant Characteristics ....................... 2-182.9.1 Pressure/Temperature Settings ................ 2-182.9.2 Saturated Refrigerant Pressure Tables ..... 2-182.9.3 Estimated Refrigerant for Liquid Line ........ 2-18

3.0 Start-Up/Commissioning .................. 3-13.1 Operation ................................................... 3-13.2 Step by Step Start-Up Instructions ............. 3-13.3 Microprocessor Controller

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

4.0 Maintenance...................................... 4-14.1 Periodic General Maintenance ................... 4-14.1.1 CyberTWO Unit ......................................... 4-14.1.2 Condenser ................................................. 4-24.2 Troubleshooting ......................................... 4-24.3 Field Service .............................................. 4-64.3.1 Refrigerant Piping ...................................... 4-64.3.2 General Common Repairs/

Component Replacement .......................... 4-64.3.2.1 Compressor Failure .................................. 4-64.3.2.2 Humidifier Cylinder Replacement .............. 4-84.3.2.3 Filter Replacement .................................... 4-9

5.0 Product Support Group ........................... 5-15.1 Technical Support ...................................... 5-15.2 Obtaining Warranty Parts .......................... 5-15.3 Obtaining Spare/Replacement Parts .......... 5-1

i

(Revised 08/05)


TABLE OF CONTENTS (Continued)

ii

List of FiguresFigure 1. Installation Clearance ............................. 1-2Figure 2. Typical Installation Downflow................... 2-2Figure 3. Typical Installation Upflow ....................... 2-3Figure 4. Optional Floor Stand Installation ............. 2-4Figure 5. Downflow Configuration

Typical Air Patterns ................................ 2-5Figure 6. Upflow Configuration Typical

Air Patterns (Top Discharge) .................. 2-6Figure 7. Upflow Configuration Typical Air

Patterns (Top Ducted Discharge) ........... 2-7Figure 8. Condensate Pump .................................. 2-9Figure 9. Sample Nameplate ............................... 2-10Figure 10. Interconnecting Field Wiring

Remote Condenser ................................2-11Figure 11. Interconnecting Field Wiring

Glycol Systems.................................... 2-12Figure 12. Blower .................................................. 2-17

Appendix A - FormsChecklist for Completed Installation .........................A-1Periodic General MaintenanceChecks and Service Checklist ..................................A-2

Appendix B - GlossaryDefinition of Terms and Acronyms ............................B-1

(Revised 08/05)


1-1

1.0 INTRODUCTION

1.1 GeneralCongratulations, the CyberTWO™ floor mounted airconditioning system covered by this manual is de-signed and manufactured by Stulz Air TechnologySystems, Inc. (SATS) using the latest, state-of-the-artcontrol technology. Recognized as a world leader,SATS provides air conditioning systems with thehighest quality craftsmanship using the finest materi-als available in the industry. The unit will provide yearsof trouble free service if installed and maintained inaccordance with this manual. Damage to the unit fromimproper installation, operation or maintenance is notcovered by the warranty.

STUDY the instructions contained in this manual.They must be followed to avoid difficulties. Spare partsare available from Stulz Air Technology Systems toinsure continuous operation. Using substitute parts orbypassing electrical or refrigeration components inorder to continue operation is not recommended andwill VOID THE WARRANTY. Due to technologicaladvancements, components are subject to changewithout notice.

All CyberTWO systems and centrifugal condensersare designed to be installed indoors unless otherwisenoted on the equipment. Propeller-type condensers,drycoolers and pump packages are designed foroutdoor use.

1.2 Product DescriptionCyberTWO systems are designed to be the mostversatile and flexible floor mounted air conditioningsystems in the industry. The unit is available in air-cooled, water-cooled and glycol-cooled configurations.The cooling capacity, in BTU/Hr, will depend on theunit size, which can range from 72,000 to 312,000BTU/Hr. CyberTWO systems are designed to operatewith either R22 or R407C refrigerant. Refer to the unitnameplate to identify which refrigerant is used withyour unit.

NOTE

The CyberTWO systems are strictly for non-resi-dential applications.

The CyberTWO systems have been designed tosupply air to only one room.

The functional modes of operation in addition tocooling are heating, humidification and dehumidifica-tion, which provide complete environmental control of aconditioned space.

There are two configurations of air patterns, upflow anddownflow and several cabinet sizes based on the typeof system and capacity. Regardless of configuration,the vertical floor system (VFS) is compact andversatile. The cabinet heights range from 76 inches to94.5 inches. The depth is 33 inches with the exceptionof a rear ducted unit which is 39 inches deep. Thewidth dimensions range from 70 inches to 114 inches.

The CyberTWO unit is provided with a factory mountedmain power disconnect switch with a lockable handle.The disconnect switch isolates the unit during routinemaintenance. The system incorporates state of the artcomponent protection with the use of motor startprotectors and circuit breakers.

An operating manual for the system controller isprovided under separate cover. Refer to that manual fordetailed instructions on operating the system control-ler provided with your unit.

The standard controller for the CyberTWO unit is theC6000 microprocessor, which provides the followingfeatures: input/output monitoring status, full integratedcontrol of heating, cooling, humidification and dehu-midification; multi-unit control and remote communica-tion with building management systems. The controlleris typically factory mounted on the front hinged accessdoor of the unit. As an option the controller may beremotely mounted to a wall or control panel.

SATS offers the A-Tech-20 microprocessor controlleras an option, if required, for selected special applica-tions.

1.3 Product WarrantySATS offers a two year standard limited warranty asstated on the following pages. Additionally an ex-tended warranty may be purchased on the unit'scompressors. Consult the factory to verify if theextended compressor warranty was purchased for yoursystem. The compressor warranty as stated on thenext page will be sent with your unit and should beretained for future reference.

(Revised 08/05)


1-2

2-Year Standard Limited Warranty:Stulz Air Technology Systems, Inc., warrants to the original buyer of itsproducts that the goods are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s obligation under this warranty is torepair or replace, at its option, free of charge to the customer, any part orparts which are determined by Stulz Air Technology Systems Inc. to bedefective. The warranty is in effect for 24 months from date of shipment if acompleted Warranty Registration and Start Up Form is submitted to Stulz AirTechnology Systems, Inc. within 90 days from shipment. In the event that acompleted 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 of12 months from date of shipment. Parts replaced under warranty are war-ranted for a period of 90 days from shipment or for the remainder of the unitwarranty period, whichever is greater.

Stulz Air Technology Systems, Inc.’s warranty does not cover failures causedby improper installation, abuse, misuse, misapplication, improper or lack ofmaintenance, negligence, accident, normal deterioration including wear and tear,or the use of improper parts or improper repair as determined by SATS. Thiswarranty does not include costs for transportation, costs for removal or reinstal-lation of equipment or labor for repairs or replacement made in the field.

THIS OBLIGATION AND LIABILITY OF STULZ AIR TECHNOLOGY SYS-TEMS, INC. UNDER THIS WARRANTY DOES NOT INCLUDE LOSSES,DIRECT OR INDIRECT, FOR INCIDENTAL OR CONSEQUENTIAL DAM-AGES. THIS WARRANY IS IN LIEU OF ALL OTHER WARRANTIES,EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR MERCHANTABIL-ITY AND FITNESS FOR A PARTICULAR PURPOSE, AND THERE ARE NOWARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THE FACEHEREOF.

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

�

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

(Revised 08/05)


1-3

Optional Limited Extended Warranty (5 Years Total)Stulz Air Technology Systems, Inc., warrants to the original buyer of its product thatthe compressor(s) listed below are warranted for parts replacement (not includinglabor) for extended period of 4 years from the date of expiration of the standardequipment warranty.

Stulz Air Technology Systems' warranty does not cover failures caused by improperinstallation, abuse, misuse, misapplication, improper or lack of maintenance, negli-gence, accident, normal deterioration including normal wear and tear, or the use ofimproper parts or improper repair as determined by SATS.

This warranty does not include costs of transportation, cost for removal or reinstallationof equipment or labor for repairs or replacement made in the field.

The obligation and liability of Stulz Air Technology Systems under this warranty doesnot include losses, direct or indirect, for incidental or consequential damages.

Compressor Serial No.: __________________________________

Unit Model No.: __________________________________

Unit Serial No.: __________________________________

Stulz Air Technology Systems Job No.: __________________________________

End User: __________________________________

Date: __________________________________

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

�

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

��

(Revised 08/05)


1-4

1.4 Safety1.4.1 GeneralStulz Air Technology Systems, Inc. uses NOTESalong with CAUTION and WARNING symbols through-out this manual to draw your attention to importantoperational and safety information.

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

A bold text CAUTION safety alert appears withinformation that is important for protecting yourequipment and performance. Be especially careful toread and follow all cautions that apply to your applica-tion.

A bold text WARNING safety alert appears withinformation that is important for protecting you fromharm and the equipment from damage. Pay veryclose attention to all warnings that apply to yourapplication.

A safety alert symbol precedes a general WARN-ING or CAUTION safety statement.

A safety alert symbol precedes an electricalshock hazard WARNING or CAUTION safety state-ment.

1.4.2 Safety SummaryThe following statements are general guidelinesfollowed by warnings and cautions applicablethroughout the manual.

Prior to performing any installation, operation, mainte-nance or troubleshooting procedure read and under-stand all instructions, recommendations and guide-lines contained within this manual.

All maintenance and/or repairs must be performed bya journeyman, refrigeration mechanic or an airconditioning technician.

Never operate the unit with any cover, guard, screenpanel, etc., removed unless the instructions specifi-cally state otherwise, then do so with extreme cautionto avoid personal injury.

Never lift any component in excess of 35 poundswithout help. If a lifting device is used to move a unitensure it is capable of supporting the unit.

When working on electrical equipment, remove alljewelry, watches, rings, etc.

Always disconnect the main power supply to theequipment at the main power disconnect switch beforebeginning work on the equipment. A lock-out tag-outprocedure should be followed to ensure that power isnot inadvertently reconnected.

Equipment may contain components subject toElectrostatic Discharge (ESD). Before attempting tomount or service these electronic devices, ensureyou have no charge built up by touching a groundsource. When possible, use a wrist-grounding strapwhen working on or near electronic devices.

Never work on electrical equipment unless anotherperson who is familiar with the operation and hazardsof the equipment and competent in administering firstaid is nearby.

All personnel working on or near equipment should befamiliar with hazards associated with electricalmaintenance. Safety placards/stickers have beenplaced on the unit to call attention to all personal andequipment damage hazard areas.

Certain maintenance or cleaning procedures may callfor the use and handling of chemicals, solvents, orcleansers. Always refer to the manufacturer's MaterialSafety Data Sheet (MSDS) prior to using thesematerials. Clean parts in a well-ventilated area. Avoidinhalation of solvent fumes and prolonged exposureof skin to cleaning solvents. Wash exposed skinthoroughly after contact with solvents.

WARNING Refrigerant (R-22 or R-407C) is used with thisequipment. Death or serious injury may result ifpersonnel fail to observe proper safety precau-tions. Great care must be exercised to preventcontact of liquid refrigerant or refrigerant gas, dis-charged under pressure, with any part of thebody. The extremely low temperature resultingfrom the rapid expansion of liquid refrigerant orpressurized gas can cause sudden and irrevers-ible tissue damage.

As a minimum, all personnel should wear ther-mal protective gloves and face-shield/goggleswhen working with refrigerant. Application of ex-cessive heat to any component will cause ex-treme pressure and may result in a rupture.

(Revised 08/05)


1-5

Exposure of refrigerant to an open flame or avery hot surface will cause a chemical reactionthat will form carbonyl chloride (hydrochloric/hy-drofluoric acid); a highly poisonous and corro-sive gas commonly referred to as PHOSGENE.In its natural state, refrigerant is a colorless, odor-less vapor with no toxic characteristics. It isheavier than air and will disperse rapidly in awell-ventilated area. In an unventilated area, itpresents a danger as a suffocant.

Always refer to the manufacturer's MSDS pro-vided with the unit.

WARNING When performing soldering or desoldering op-erations, make certain the refrigeration systemis fully recovered and purged and dry nitrogenis flowing through the system at the rate of notless than 1-2 CFM (.03 - .06 M³/minute).

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

CAUTION Do not use cleaning solvents near open flame orexcessive heat. Wear eye protection when blow-ing solvent from parts. The pressure-wash shouldnot exceed 30 psig. Solvent solutions should bedisposed of in accordance with local and stateregulatory statutes.

CAUTION Units must be kept in its normal installed posi-tion. If the unit is not kept level and vertical,damage to the unit's compressors will result.

40.0"

30(MINIMUM SIDECLEARANCE)

(MINIMUM FRONTCLEARANCE)

30.0"(MINIMUM SIDECLEARANCE)

Figure 1- Recommended InstallationClearance

Front and side service access.

(Revised 08/05)


STRUCTURE R-VALUECeiling R-38

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

2-1

2.0 INSTALLATION

2.1 Receiving the EquipmentYour CyberTWO system has been tested and in-spected prior to shipment. To ensure that yourequipment has been received in excellent condition,make a visual inspection of the equipment immedi-ately upon delivery. Carefully remove the shippingcontainer and all protective packaging. Remove theaccess panels and thoroughly inspect the unit interiorfor any signs of transit-incurred damage. If there isshipping damage, it must be noted on the freightcarrier's delivery forms BEFORE signing for theequipment. Any freight claims MUST be done throughthe freight carrier. SATS ships all equipment FOB.SATS can assist in the claim filing process with thefreight carrier. Should any such damage be present,notify the SATS Product Support Group prior toattempting any repairs. Refer to section five of thismanual for instructions.

A Data Package has been sent with your unit. Itcontains this manual, a supplemental microprocessorcontroller manual, system drawings, applicableMSDS’s, other component manuals, warranty registra-tion and other applicable instructions based on theconfiguration and options of your unit. The datapackage has been placed in your unit in a clear plasticenvelope. These documents need to be kept with theunit for future reference.

NOTE

Items that have been shipped loose, such ascontrollers, temperature/humidity sensors, wa-ter detectors, etc., are shipped inside the airconditioner unless specified otherwise by the cus-tomer. The filter box or plenum box assembly (ifapplicable) is shipped separately. Unpack andstore these items in a safe place unless you areusing them immediately.

2.2 Site PreparationThe CyberTWO systems were designed with easyservice access in mind. Component access panelsare located on the front and sides of the equipment.The number of panels may vary depending on sizeand configuration. Each unit has one front hingedaccess panel, housing the electrical box. In order tohave full service access, through the front of unit, nopermanent obstructions can be placed within 40

inches of the front of unit. Side access panels requirea minimum of 30 inches of clearance. See Figure 1.

NOTE

Working clearance requirements need to be es-tablished prior to the mounting of the unit. Referto local and national electrical codes.

To minimize the effects of the conditions surroundingthe conditioned space, certain steps must be taken.This is especially true for critical/precision roompreparation (computer rooms/labs) requiring a closetolerance of temperature and humidity variation. Theconditioned space should be well insulated andinclude a vapor barrier. The installer should ensure thatthe proper insulation rating is used based on thedesign of the space, which was the basis for thesystem selected. The following chart is a recom-mended minimum R-value (thermal resistance) toensure optimum equipment operation.

The vapor barrier is the single most important require-ment for maintaining environmental control in the

conditioned space. The vapor barrier in the ceiling andwalls can be a polyethylene film. Concrete walls andfloors should be painted with a rubber or plastic basedpaint. Doors and windows should be properly sealedand a door sweep used to minimize leakage. Outsideor fresh air should be kept to a minimum because itadds to the cooling, heating, dehumidification andhumidifying loads, while maintaining the requirement ofthe Indoor Air Quality (IAQ) standard. Lack of thesesteps can cause erratic operation, unstable roomcontrol and excessive maintenance costs.

2.3 RiggingThe CyberTWO systems are designed to be kept inthe vertical position. Move the unit with a suitabledevice such as a forklift, pallet jack, roller bar anddollies. Weight tables are provided on the installationdrawings. Units are shipped on a skid to facilitate

(Revised 08/05)


2-2

moving prior to installation. Units should always bestored indoors in a dry location prior to installation.

CAUTION

Units must be kept level and in the vertical posi-tion when lifting to prevent damage to the unit.

2.4 Mounting/PlacementCyberTWO systems that are not ducted, are designedto be located in the conditioned space. Ducted unitsmay be either inside or outside the conditioned space,but are designed to supply air to only one room. TheCyberTWO systems are 100% front accessible, whichallows the units to be placed in a corner or betweencabinetry. It is recommended to position the unit toobtain optimum air circulation.

NOTE

Placement of the floor or ceiling registers isimportant. If they are too close to the unit, thesupply air will be recirculated back to the unitbefore it has circulated throughout the space.

The unit has been designed to be located directly ontop of the floor (typically upflow) or on a raised floor(typically downflow). On some raised floor installa-tions, a floor stand is required, depending on the loadcapacity of the existing raised floor.

2.4.1 Indoor EquipmentSee Figure 2 and 3. The CyberTWO system uses aframe and panel construction for unit rigidity and fullservice accessibility while the unit is mounted inplace. Ensure the mounting surface is able to supportthe equipment. Before mounting the unit, refer to theappropriate weight tables that are provided in theinstallation drawings.

If a floor stand is selected, refer to the installationdrawing provided and cut out the raised floor to matchthe units overall base dimension. If a floor stand is notselected, use the installation drawing and cut out theraised floor to match the blower discharge opening(s)and cut out the holes required for piping and wiringthrough the raised floor.

NOTE

Equipment must be level to operate properly.

2.4.2 Outdoor EquipmentInstall the remote condenser in a secure locationwhere the unit cannot be tampered with and the mainpower circuit breaker cannot be inadvertently turnedoff. Locate the remote condenser where the coil is notlikely to draw dirt and debris into the coil fins. Thereshould be at least 24 inches of clearance around thecondenser to ensure adequate airflow to the coil.Secure the condenser so that the system will notmove during operation. Refer to the installation drawingfor the non-charged system weight. It is recommendedthat the remote condenser be mounted with fieldsupplied vibration mounts to reduce the amount ofvibration transmitted to the mounting surface.

2.4.3 Optional Equipment (Field Installed)NOTE

Do not mount any optional equipment on unitaccess doors.

2.4.3.1 Remote Display

The C6000 Microprocessor is the standard controllersupplied with the CyberTWO systems. As an option

Figure 2- Typical Installation Downflow

TURNINGVANE(OPTIONAL)

FLOORSTAND(OPTIONAL)

C6000 SERIESCONTROLLER

HINGEDDOOR

SERVICESWITCH

(Revised 08/05)


2-3

the control panel may be remote mounted. Formounting and wiring instructions, refer to the systemdrawings and the supplemental manual sent in thedata package with your unit.

2.4.3.2 Remote Temperature/Humidity Sensor

The remote temperature/humidity sensor must belocated so that it will properly sense the temperature/humidity conditions to be controlled. The sensorshould not be mounted near a doorway or an areawhere it would be exposed to direct sunlight. Followthe steps below to mount the sensor. For unit wiringdetails, reference section 2.7, Utility Connections.

1. Using a flat head screwdriver, remove the coverscrew from the top, right corner of the sensor andremove the cover plate from the base.

2. Place the base temporarily over the wire holeopening in the wall. Level the base and mark thelocation through the two provided mounting slots.

3. Drill the holes and insert the provided wall an-chors.

4. Place the base over the wires coming out of thewall and mount with screws provided.

5. Make wiring connections. (See Utility Connection.)

6. Replace unit cover.

CAUTION Do not damage the exposed temperature/humid-ity sensors on the PC board while screwing inthe top, right cover fastening screw. The sen-sors can be damaged if handled improperly.

2.4.3.3 Remote Water Detector

The remote water detector is normally placed on thesub-floor or in a field supplied auxiliary drain panlocated beneath the unit. It may be attached usingdouble sided tape. Prepare surface before installingtape. Apply tape to the water detector and secure inplace.

Figure 3- TypicalInstallation Upflow

C6000 SERIESCONTROLLER

HINGEDDOOR

SERVICESWITCH

PLENUM BOXASSEMBLY(OPTIONAL)

(Revised 08/05)


2-4

2.4.3.4 Floor Stand

See Figure 4. Install the floor stand directly on thesub-floor, ensuring the side with the "FRONT" label isfacing the same direction as the front of the A/C unit.Use the installation drawing to cut out the raised floor.The floor stand is adjustable. Refer to the floor standassembly drawing for minimum and maximum heightof your floor stand. To adjust height, turn the floorstand foot in the desired direction to raise or lower thestand. Install turning vane (if applicable) so that the airis diverted towards the front of the unit. Ensure top offloor stand is even with the raised floor and level. Raisethe hex nuts to meet the floor stand legs to lock thefeet in place.

2.4.3.5 Plenum Box Assembly

The plenum box assembly is shipped loose. To installthe 2 or 3-way optional plenum box assembly, placethe assembly on top of the unit. Remove the front grillefor access and attach with the supplied self-tappingscrews. Holes are pre-drilled in the unit and theplenum box assembly.

2.5 Air Distribution Connection2.5.1 Downflow Configuration Air PatternsIn a downflow configured unit there are two basic airpatterns: top free return and top ducted return. SeeFigure 5. The conditioned supply air discharge isthrough the bottom of the unit into the raised floor.

The only air distribution connection required on adownflow system is on units that require ducting.When determining ducting requirements, alwaysconsult your local or state codes. The duct systemshould be designed to allow the air to move as freelyas possible.

The connection of the ducting to the unit is typicallyaccomplished with a one-inch duct flange. Returninlets are provided with a factory installed duct flangefor connection of the ductwork (refer to the installationdrawing provided with the unit). The connection of theduct to the unit may be made with either pop rivets orself-tapping screws.

FLOOR STAND LEG

TURNING VANE

FLOOR STAND FOOT

HEX NUT

(OPTIONAL)

Figure 4- Optional FloorStand Installation

(Revised 08/05)


2-5

2.5.2 Upflow Configuration AirPatterns

In an upflow configured unit there are two basic airpatterns: front free return and rear ducted return. SeeFigures 6 and 7.The conditioned supply air has twomethods of discharge: ducted or through a 2 or 3-waygrilled plenum box.

The only air distribution connection required on aupflow system is on units that require ducting. Whendetermining ducting requirements, always consult yourlocal or state codes. The duct system should bedesigned to allow the air to move as freely as possible.

The connection of the ducting to the unit is typicallyaccomplished with a one-inch duct flange. Supply air

outlet and the rear ducted return are provided with afactory installed duct flange for connection of theductwork. Refer to the installation drawing providedwith the unit. The connection of the duct to the unitmay be made with either pop rivets or self-tappingscrews.

2.6 Piping Connections2.6.1 Refrigerant

2.6.1.1 Self-Contained Systems

No refrigeration connections are required for self-contained glycol-cooled systems (Models VFS-072/312-DW/DG-( )).

Figure 5- Downflow Configuration Typical Air Patterns

RETURNAIR INLET

SUPPLYAIR OUTLET

RETURNAIR INLET

SUPPLYAIR OUTLET

TOP DUCTED RETURNTOP FREE RETURN

(Revised 08/05)


2-6

2.6.1.2 Split Systems

Split air-cooled systems with a remote condenser willrequire field refrigeration piping. All split systems areshipped with a dry nitrogen charge of 50 psig.

Split systems coupled with a remote condensing unitwill require a copper discharge and a copper liquid line.

All refrigeration piping should be installed with hightemperature soldered joints. Use standard refrigerationpractices for piping supports, leak testing, dehydrationand charging of the refrigeration circuits. The refrigera-tion piping should be isolated from the building by theuse of vibration isolating supports. To prevent tubedamage when sealing openings in walls and to reducevibration transmission, use a soft flexible material topack around the tubes.

Clear all pipe connections of debris and prepare theconnections for soldering. Use only "L" or "K" graderefrigerant copper piping. Be careful not to allowsolder/piping debris to get inside refrigerant lines.

Silver solder containing a minimum of 15% silver isrecommended. Dry nitrogen should be flowing throughthe tubing while soldering at a rate of not less than 1-2CFM (.03 - .06 M3/minute).

Refrigerant lines for split systems must be sizedaccording to the piping distance between the evapo-rator and the condenser. Each valve, fitting and bendin the refrigerant line must be considered in thiscalculation. Refer to the chart provided on the followingpage for standard equivalent lengths, in feet, of straightpipe.

Oil traps must be included every 20 feet in the verticalrisers and the refrigerant lines must be sloped ¼ inchfor every 10 feet in the horizontal lines to ensureproper oil return to the compressor. An inverted trap isrequired on the discharge line of the remote condenserto help prevent oil and liquid from flooding back to thecompressor.

Figure 6- Upflow Configuration Typical Air Patterns (Top Discharge)

RETURN

AIR INLET

FRONT FREE RETURN

SUPPLY

AIR OUTLET

ETURN

R INLET

REAR DUCTED RETURN

SUPPLY

AIR OUTLET

TOP DISCHARGE 2 OR 3-WAY PLENUM BOX

(Revised 08/05)


2-7

Equivalent Length (ft) of Straight PipeOD (In.) Globe Angle 90º 45º Tee Tee

Line Size Valve Valve Elbow Elbow Line Branch

1/2 9.0 5.0 0.9 0.4 0.6 2.0

5/8 12 6.0 1.0 0.5 0.8 2.5

7/8 15 8.0 1.5 0.7 1.0 3.5

1-1/8 22 12 1.8 0.9 1.5 4.5

1-3/8 28 15 2.4 1.2 1.8 6.0

1-5/8 35 17 2.8 1.4 2.0 7.0

2-1/8 45 22 3.9 1.8 3.0 10

2-5/8 51 26 4.6 2.2 3.5 12

3-1/8 65 34 5.5 2.7 4.5 15

3-5/8 80 40 6.5 3.0 5.0 17

All suction lines must be insulated to prevent conden-sation from forming on the pipes. Refer to providedpipe size charts for recommended pipe sizing.

NOTE

In the following (3) charts, the line sizes repre-sent the sizing for individual refrigeration circuits.CyberTWO units have two separate pairs of re-frigeration lines. (One per compressor.)

Figure7- Upflow Configuration Typical Air Patterns (Top Ducted Discharge)

RETURN

AIR INLET

SUPPLY

AIR OUTLET

FRONT FREE RETURN

SUPPLY

AIR OUTLET

RETURN

AIR INLET

REAR DUCTED RETURN

TOP DUCTED DISCHARGE

(Revised 08/05)


2-8

*Equivalent Ft. accounts for the linear pipe length as well asequivalent length of Valves, Elbows & Tee’s as shown in thechart on the previous page.

NOTEVertical runs are based on a total rise of 30 equivalentfeet. For longer sizes, individual calculations must bemade. Sizes assume the use of single risers; doublerisers may be necessary.

Consult the Copeland applications data guide for moredetailed information regarding refrigerant line traps andline sizing.

*Equivalent Ft. accounts for the linear pipe length as well asequivalent length of Valves, Elbows & Tee’s as shown in thechart on the previous page.

2.6.2 Water/GlycolPiping connections for the water/glycol condensersare sweat connections. Pipe sizes may not necessar-ily be the same as the unit connection. Piping shouldbe sized to match the system pressure drop and

pump capacity and may require a reducing fitting tomatch the connection size on the air conditioner.Glycol-cooled systems with low entering fluid tempera-tures should have insulated piping.

The recommended ethylene glycol solution ratio is40% glycol to 60% water. (SATS recommendsDowtherm SR1 manufactured by Dow Chemical Co.)Use only ethylene glycol with inhibitors for corrosionprotection.

WARNING Glycol is hazardous. Consult the manufacturer'sMSDS for detailed safety information.

CAUTION When installing and filling the water/glycol loop allair must be bled from the piping system and thepiping system must be cleaned prior to operatingthe system. Failure to do so will result in equip-ment problems.

2.6.3 Condensate Drain

2.6.3.1 Gravity Drain

A 7/8 inch OD copper (sweat type) line is provided forthe evaporator coil condensate drain. This line alsodrains the (optional) humidifier. The drain line must belocated so it will not be exposed to freezing tempera-tures. The drain line should be the full size of theconnection.

2.6.3.2 Condensate Pump (See Figure 8)

A condensate pump is used for automatic removal ofcondensate from the air conditioner and flush waterfrom the humidifier. If an optional field installed conden-sate pump is selected, a p-trap must be installed forproper condensate drainage. The height of the trapmust be a minimum of 2 inches on most standardsystems to ensure proper water drainage of the drainpan. The condensate pump discharge line should be1/2 inch OD maximum copper or vinyl tubing to preventexcessive back flow to the unit.

NOTEPour some water into the condensate drains priorto start-up. This fills the trap and prevents airfrom being drawn up the drain lines.

Recommended Liquid Line Sizes

(For R-22 or R-407C Refrigerant)Model No./ Receiver to Evaporator (Equivalent Ft.)*Total Unit 50' 100' 150'Capacity or less or less or less

072 / 72,000 1/2 1/2 1/2

096 / 96,000 1/2 5/8 5/8

120 / 120,000 1/2 5/8 5/8

180 / 180,000 5/8 7/8 7/8

240 / 240,000 7/8 7/8 7/8

312 / 312,000 7/8 7/8 7/8

Recommended Discharge Line Sizes

(For R-22 or R-407C Refrigerant)Model No./ Equivalent Length Ft.*Total Unit 50' 100' 150'Capacity or less or less or less

072 / 72,000 7/8 7/8 7/8

096 / 96,000 7/8 7/8 7/8

120 / 120,000 7/8 1-1/8 1-1/8

180 / 180,000 1-1/8 1-1/8 1-3/8

240 / 240,000 1-1/8 1-3/8 1-3/8

312 / 312,000 1-1/8 1-3/8 1-3/8

(Revised 08/05)


2-9

2.6.4 HumidifierCyberTWO systems use an electrode steam cylinderhumidifier requiring normal tap water for operation.One, ¼ inch water supply line to the compressionfitting in the side of the humidifier mounting chassis isrequired for operation. The humidifier drains into thecondensate pan drain line for the flush/drain cycle.

2.7 Utility Connections2.7.1 Main PowerThe CyberTWO product offering is available in 208, 460and 575 volt three-phase configurations. It is imperativethat the unit nameplate be examined to determine theoperating voltage, frequency and phase of the system.See Figure 9. The nameplate also provides the full loadamps (FLA), the current that the unit will draw underfull 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'snameplate is located inside the cabinet within theelectrical box.

NOTE

If the nameplate states MAX FUSE/CKT BKR,it is required to utilize fuses or HACR type cir-cuit breakers to protect the system. Other pro-tection devices are not allowed based upon theproduct listing.

Each unit is provided with terminals for all requiredfield-wiring connections. Refer to the electrical sche-matic supplied with the unit for all power and controlfield-wiring connections. It is important to identify theoptions that were purchased with the unit in order toconfirm which field connections are required.

WARNING Verify power is turned off before making connec-tions to the equipment.

NOTE

All wiring must conform to local and national elec-trical code requirements. Use of copper conduc-tors only is required. Wiring terminations maybecome loose during transit of the equipment;therefore, it is required to verify that all wiringterminations are secure.

Figure 8- Condensate Pump

INLET 7/8" OD

OUTLET 1/2" OD

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

2.00

SEE NOTE 1

SEE NOTE 2

(Revised 08/05)


2-10

It is important to verify that the main power supplycoincides with the voltage, phase and frequencyinformation specified on the system nameplate. Thesupply voltage measured at the unit must be within±10% of the voltage specified on the system name-plate.

A manual fused disconnect switch or HACR typecircuit breaker must be installed per local and nationalelectrical codes for service of equipment. Do notmount a customer supplied manual fused disconnectswitch or HACR type circuit breaker to the surface ofthe unit.

Each unit is provided with a main power and controlpilot hole for connection of the field-wiring conduit.These pilot holes are located on the CyberTWO unitbased on configuration. On an upflow configuration,the pilot holes are located in the top of the cabinetand on a downflow configuration, they are located inthe floor of the cabinet. A label stating "MAIN POWERINPUT" is in close proximity. The main power wiresshall be terminated at the line side of the main powerdisconnect switch located within the electric box. Aseparate equipment ground lug is provided within theelectrical box for termination of the earth ground wire.

CAUTION Improper wire connections will result in the re-verse rotation of the fans/blower motors andcompressor (if applicable) and may eventuallyresult in damage to the scroll compressor. Tocorrect this problem, exchange any two of theincoming main power wires at the main powercircuit breaker. Do NOT rewire the unit's indi-vidual components.

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

2.7.2 ControlsStulz Air Technology Systems offers a wide range ofcontrol features to solve your air conditioning control/alarm requirements. The C6000 Microprocessor is thestandard controller for the CyberTWO system. If it ismounted on the unit (standard), no utility connection isrequired. As an option the display may be remotemounted. A six-conductor cable harness is provided forinterconnect wiring. Refer to the supplied electricalschematic and Figures 10 and 11 for details oninterconnecting field wiring.

Figure 9- Sample Nameplate

(Revised 08/05)


2-11

2.7.3 Optional EquipmentNOTE

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

2.7.3.1 Remote Temperature/Humidity Sensor

The remote temperature/humidity sensor requires athree conductor shielded cable with the shield beingterminated at the unit electric box. Both the electricbox and the sensor provide a terminal strip with boxtype lugs for wire connections. Refer to the suppliedelectrical schematic for proper wire terminations.

2.7.3.2 Remote Water Detector

The optional remote water detector requires twoconductors to be wired to the control terminal boardwithin the unit electrical box. The wire insulation mustbe rated at 600V. The water detector includes screwtype terminals for wire connections. Refer to thesupplied electrical schematic for proper wire termina-tions.

2.7.4 Interconnecting Field WiringThe following system interconnecting field wiringsections detail the number of conductors required fora typical system. Additional control conductors maybe required depending on the options purchased withthe equipment. Refer to the supplied electrical sche-matic to determine the total number of interconnectingconductors required for your system. It is important tonote that the control transformer(s) supplied with theequipment has been sized and selected based uponthe expected loads for each system.

CAUTION

Do not connect any additional loads to the sys-tem control transformers. Connecting additionalloads to the factory supplied control transformermay result in overloading of the transformer, whichwill cause the transformer circuit breaker to trip.

NOTE

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

Figure 10- Interconnecting Field Wiring Remote Condenser

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

REMOTE TEMPERATURE/HUMIDITY SENSOR

NOTES:

4 CONDUCTOR NON-

SHIELDED CABLE3 CONDUCTOR

SHIELDED CABLE

C6000

SEE NOTE 2

2. OPTIONAL REMOTE MOUNTING.

AIR COOLED CONDENSER

WITH NFPA 70, N.E.C.)

INTERCONNECTING FIELD WIRING(TO BE INSTALLED IN ACCORDANCE

24VAC

208-575V/3PH/60HzMAIN POWER SUPPLY

L3

L1

SEE NOTE 1

L3

L1

208-575V/3PH/60HMAIN POWER SUPPLY

IN ACCORDANCE WITH

INTERCONNECTING FIELDWIRING (TO BE INSTALLED

NFPA 70, N.E.C.)

2 CONDUCTORSHIELDED CABLE

(Revised 08/05)


2-12

2.7.4.1 Air-Cooled Split System Remote Condenser

See Figure 10. Systems equipped with a remotecondenser may require field wiring between theevaporator system and the remote condenser. Refer tothe wiring diagram supplied with the condenser(typically located in the condenser electric box).Outdoor rated remote condensers must be inspectedto determine if the remote condenser controls aremounted within the remote condenser electrical box orif a field mounted remote condenser control box isprovided.

The field mounted remote condenser control boxmust be mounted on or near the remote condenser. Asuitable ground must be installed between the remotecondenser control box and remote condenser frame.The installer must provide wiring from the condensermotor contactor(s) to the condenser motor terminalboard located within the remote condenser electricbox or directly to the motor(s). Refer to the nameplatefor proper wire sizing for the remote condenser motorwiring. The installer must also provide main power

wiring to the main power distribution block locatedwithin the remote condenser control box. A separateequipment ground lug is provided within the electricalbox for termination of the earth ground wire.

The installer must wire two control conductors from theterminal board within the evaporator unit to the controlterminal board within the remote condenser controlbox. Refer to the supplied electrical schematic forproper wire terminations.

2.7.4.2 Glycol Systems

See Figure 11. Systems equipped with a glycol-cooledsystem/pump package require field wiring between theglycol unit and pump package. The installer must wiretwo control conductors from the terminal board withinthe glycol unit to the pump package electrical box.Refer to the supplied electrical schematic for properwire terminations.

Figure 11- Interconnecting Field Wiring Glycol Systems

(TO BE INSTALLED IN ACCORDANCE

(GLYCOL UNITS ONLY)GPS-005/100-( )

ELECTRIC24VAC

PUMP PACKAGE

BOX

SEE NOTE 1WITH NFPA 70, N.E.C.)

INTERCONNECTING FIELD WIRING

MAIN POWER SUPPLY208-575V/3PH/60Hz

(GLYCOL UNITS ONLY)DRYCOOLER

WIRING (TO BE INSTALLEDINTERCONNECTING FIELD

IN ACCORDANCE WITHNFPA 70, N.E.C.)

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

VFS-072/312-DW/DG

208-575V/3PH/60HzMAIN POWER SUPPLY

2. OPTIONAL REMOTE MOUNTING.

NOTES:

L3

L1

L2

REMOTE TEMPERATURE/HUMIDITY SENSOR

2 CONDUCTOR

SHIELDED CABLE3 CONDUCTOR

SHIELDED CABLE C6000

SEE NOTE 2

4 CONDUCTOR NON-SHIELDED CABLE

(Revised 08/05)


2-13

2.8 System Settings and Adjustments

2.8.1 R-22 Refrigerant Charging ProceduresNOTE

Refrigerant charging must be performed by a jour-neyman, refrigeration mechanic or an air condi-tioning technician.

2.8.1.1 Self-Contained Systems

All self-contained water/glycol-cooled units (units thatrequire no refrigerant field piping) are factory chargedwith refrigerant. No field charging is required.

2.8.1.2 Remote Air-Cooled Split Systems

Remote air-cooled units come equipped with a factorydry nitrogen holding charge, which must be removedbefore piping and charging the unit.

PREPARING SYSTEM FOR CHARGING

1. Once all connections have been made, pressurizethe system to 150 psig with dry nitrogen. Leaksmay be detected by observing the standingpressure.

2. After ensuring there are no leaks, relieve pressureand evacuate the system. Pull a vacuum of 50microns or less using the suction and dischargeservice ports and the service port of the receiver (ifapplicable). Hold the vacuum for 2 hours. Ensureno portion of system has been isolated from theevacuation process (liquid, suction or dischargelines).

CAUTION A proper vacuum must be drawn on the refrigerantsystem prior to charging. If this is not done therefrigerant will combine with the moisture in the pipesto form an acid that will eventually cause compressorfailure.

FINE TUNING THE SYSTEM CHARGE

2.8.1.2.1 0ºF Fan Cycling and -20 ºF VariableSpeed Control

The following instructions are for charging systemswith condenser fan cycling or variable speed controlusing R-22 refrigerant.

1. Bleed air from hoses and "break" the systemvacuum by supplying R-22 vapor. Supply R-22vapor until the pressure is raised to about 50psig. This small holding charge allows the lowpressure switch to “make” throughout the pro-cess of fine tuning the system charge

WARNING Do not add liquid R-22 refrigerant to suction side ofsystem.

2. Start the system and use the microprocessorcontroller to lower the temperature set-point 3-5°Fbelow room temperature. This will ensure thecooling mode stays on during the chargingprocedure.

CAUTION An adequate heat load must be supplied to the unit toensure a proper charge.

3. Supply R-22 vapor to the suction port until theliquid line sight glass is cleared of all bubbles.

4. After the unit has stabilized, the liquid line sightglass should be clear and the discharge pressureshould be a minimum of 200 psig. A superheatreading should be taken 6 inches from the com-pressor, with the temperature-measuring devicebeing well insulated. The superheat should beapproximately 10-12 ºF.

5. A sub cooling reading should be taken on theoutput side of the condenser, with the tempera-ture-measuring device being well insulated. Thesub-cooling temperature should be approximately10-20 ºF.

NOTE

Under cold climate conditions it is recommended to dothe following:

6. Block off the intake air to the condenser withcardboard (or reduce the water glycol flow) until aconstant discharge pressure (225-280 psig) canbe obtained. This will lower the possibility ofovercharging and avoid the occasional bubblesthat may appear in the sight glass during fancycling. (For units with fan cycling only.)

(Revised 08/05)


2-14

5. Once the discharge pressure has stabilized for 5 to10 minutes, additional refrigerant R-22 vapor mustbe added to the suction port until the "float ball" inthe level indicator of the receiver begins to float.

CAUTION Remove the blockage to the air intake of the con-denser.

6 Take a superheat reading on the suction line 6"from the compressor. The superheat should be 10-20°F.

7. Ensure that the crankcase heater is operational bychecking the amperage.

8. Fill out applicable blocks of Warranty Registrationand Start-Up Checklist.

2.8.2 R407C Refrigerant Charging ProceduresR-407C is a blended refrigerant recognized for beingsafer for the environment. Refrigerants that are multi-component blends have component parts with differentvolatilities that result in a change in composition andsaturation temperature as evaporation and condensa-tion occur. Typically the composition of R-407C vaporis different than that of R407C liquid within a con-tained system. The composition of liquid R-407Crefrigerant remains relatively constant, however, therefrigerant vapor tends to separate into its componentparts even when circulating. When charging a systemusing blended refrigerants, it is essential that thecomposition of the refrigerant is maintained. Toensure correct composition, introduce R-407C into thesystem in liquid form rather than vapor form. Cylinderswhich are not provided with dip tubes should beinverted to allow only liquid refrigerant to charge thesystem. Keeping the temperature of the cylinderbelow 85°F will help to maintain the correct refrigerantcomposition while the cylinder is emptied.

CAUTION POE oil is used in systems with R-407C refrigerant.POE oil quickly absorbs moisture when exposed toair. High POE oil moisture levels react with refrigerantto form acid, which results in system contamination.Keep entire system sealed as much as possible andminimize exposure of POE oil to outside air.

7. If the unit has a hot gas reheat option, the previoussteps are still followed except the hot gas reheatvalve must be opened to allow refrigerant to flowinto the reheat coil to obtain the proper amount ofunit charge. This process may need to be re-peated several times, which can be done byenabling a call for dehumidification. After cyclingthe system through the hot gas reheat cycle,recheck the system charge in the COOLING-ONLY mode.

8. Ensure the crankcase heater is operational bychecking the amperage.

CAUTION Remove the blockage to the air intake of the con-denser (or restore the water/glycol flow).

9. Fill out applicable blocks of Warranty Registrationand Start-Up Checklist.

2.8.1.2.2 -30 ºF Flooded Head Pressure Control

The following instructions are for charging systems withflooded head pressure control using R-22 refrigerant.

1. Bleed air from hoses and "break" the systemvacuum by supplying R-22 liquid to the service valveof the receiver until the receiver is full. Then supplyR-22 vapor to the suction port until the pressure israised to about 50 psig (low pressure switchmakes).

2. Start the system and use the microprocessorcontroller to lower the temperature set-point 3-5°Fbelow room temperature. This will ensure coolingremains on during charging procedure.

CAUTION An adequate heat load must be supplied to the unit toensure a proper charge.

3. After starting the system, immediately supplyR-22 vapor to the suction port until the liquid linesight glass has cleared of all bubbles.

4. Raise the discharge pressure to 300-325 psig andhold it constant by blocking the air intake of thecondenser.

(Revised 08/05)


2-15

8. While monitoring the sight glass, take a sub-cooling temperature reading on the output side ofthe condenser. The sub-cooling temperatureshould be 10-12°F.

9. If necessary, add liquid refrigerant to maintainadequate sub-cooling temperature.

10. Take a superheat reading on the suction line 6"from the compressor. The superheat should be 12-20°F.

2.8.2.1 Flooded Head Pressure Control SystemsIn units with R-407C refrigerant using flooded headpressure control, a receiver is provided to store therefrigerant during the time the condenser is not usingthe extra refrigerant charge. Once a clear sight glasshas been achieved, additional refrigerant must beadded to the receiver.

A level indicator is located on the side of the receiverto assist the service technician in charging the airconditioning system. The proper charge can bedetermined by viewing the position of the “float ball”while the unit is running. If the “float ball” is positionedat the bottom of the sight indicator, additional refriger-ant charge is needed. When the “float ball” reachesthe top of the indicator, the unit is fully charged.

2.8.3 Low/High Pressure Limit SwitchCyberTWO units utilizing thermal expansion valves areequipped with hermetically sealed high-pressure andlow-pressure switches. These switches are preset bythe manufacturer and cannot be adjusted. The high-pressure switch opens at 410 psig and has a manualreset. The low-pressure switch opens at 10 psig (± 4)and closes at 32 psig (± 5) and has an automaticreset.

2.8.4 Head Pressure Controls

2.8.4.1 Air-Cooled Systems

2.8.4.1.1 Condenser Fan Cycling

This is a high-pressure differential control switch withSPDT contacts and an automatic reset. The switchactivates the condenser blower contactor when thedischarge pressure reaches 275 psig, to maintain thecondensing temperature.

Factory setting: Red to yellow contacts will close on apressure rise to 275 psig and open at 205 psig.

Familiarize yourself with the charging proceduresdiscussed in section 2.8.1 of this manual. Instead ofadding R-22 vapor to the suction port as describedunder “Preparing System For Charging”, the initialcharge will be performed by introducing R-407C liquidto the discharge side of the compressor. (See below)

PREPARING SYSTEM FOR CHARGING

1. With all the system piping connections made,perform a dry nitrogen leak detection test on thesystem. Using dry nitrogen only, pressurize thesystem to 150 psig. Since there is no refrigerantin the system to detect, leaks may be detectedby observing the standing pressure.

2. After ensuring there are no leaks, evacuate thesystem to 50 microns and hold the vacuum for 2hours.

3. Break the vacuum by supplying R-407C liquid tothe discharge port near the compressor until thepressure is raised to about 50 psig. This smallholding charge allows the low pressure switch to“make” through the process of fine tuning thesystem charge.

FINE TUNING THE SYSTEM CHARGE

4. Disconnect the refrigerant cylinder from thedischarge side of the compressor and connect itto the suction side.

5. Start the system and use the microprocessorcontroller to lower the temperature setpoint 3-5°Fbelow room temperature, ensuring coolingremains on as the unit is charged.

6. Allow the discharge pressure to rise to 225-280psig and hold it constant. On cool days it may benecessary to restrict the airflow across thecondenser (or reduce the water glycol flow), toraise the pressure.

7. Slowly meter R-407C liquid refrigerant through thesuction side while watching the sight glass to clearof bubbles.

CAUTION Add liquid refrigerant slowly to prevent the refrigerantoil from “washing out” of the compressor.

(Revised 08/05)


2-16

Differential is non-adjustable and set at 70 psig. Setpoint range is 170 to 375 psig.

2.8.4.1.2 Condenser Fan Speed

Remote air-cooled condensers use variable speedcondenser motor control to maintain head pressure.The variable speed motor is located closest to theheader end of the condenser. The fan speed control isa continual modulation of the motor's speed. Thecontroller is mounted in an electrical box for fieldinstallation or could be prepackaged with outdoorcondenser. Mount the condenser control box on theheader end of the condenser. The fan speed controllerrequires no adjustments.

After wiring the condenser in accordance with appropri-ate codes and electrical schematic, attach the fanspeed control pressure sensing capillary to theschraeder valve in the liquid line. In the case of a twocompressor system, there will be two capillaryconnections, one to each liquid line header. The fanspeed controller will then automatically control headpressure. On systems with more than one fan on thecondenser, the remaining motors cycle on and offthrough additional thermostat(s).

2.8.4.1.3 Flooded Head Pressure Control

Flooded head pressure control is designed to maintainhead pressure during low ambient conditions. Whenreceiver pressure drops, a valve diverts discharge gasaway from the condenser. Liquid flow from the con-denser is restricted, causing liquid to back up in thecondenser. Flooding the condenser reduces the areaavailable for condensing thus raising the condensingpressure. As the pressure increases, the valve divertsthe discharge gas to the condenser, allowing liquid toflow from the condenser to the receiver.

These systems must not have a refrigerant linepressure drop over 14 psig across the condenser andthe interconnecting piping to the condenser sections.

When using this method of head pressure regulationthere must be enough refrigerant in the system toensure adequate charge at the lowest expectedambient temperature in which the system will beoperating. A receiver is used to store the extra refriger-ant when the condenser is not using it. The headpressure control valve does not allow refrigerant topass to the receiver until the discharge pressure is atleast 180 psig. This valve requires no adjustment.

2.8.4.2 Water/Glycol-Cooled Systems

2.8.4.2.1 Head Pressure Regulating Valve

In a water/glycol condenser, condensing temperatureis maintained by the liquid flowing through a regulatingvalve and then into a tube-in-tube or brazed plateliquid-cooled condenser. The regulating valve opens toincrease liquid flow as the pressure rises (or closes asthe refrigerant pressure falls). The regulating valve isfactory set for the correct condensing temperaturehowever, it can be adjusted to increase or decreasethe condensing temperature as follows:

Head pressure regulating valves are available withpressure rating of 150, 350, and 450 psig. They arealso available in 2-way or 3-way configurations. Thelocation and method for adjusting the valves forcondensing pressure differs with the valve types.

2.8.4.2.1.1 150 PSIG Pressure Valves

Adjustment is made by turning the slotted squarestem on top of the valve clockwise to increase thecondensing temperature or decrease water/glycol flowand counterclockwise to decrease the condensingtemperature or increase the water/glycol flow. Adirectional arrow is stamped on the metal housing ofthe valve stem.

2.8.4.2.1.2 350 PSIG and 450 PSIG HighPressure Valves

Adjustment is made by turning the round-holed knob,located inside the valve's metal housing, counterclock-wise to increase condensing pressure or decreasewater/glycol flow and clockwise to decrease thecondensing temperature or increase the water/glycolflow. A directional arrow is stamped on the metalhousing of the valve stem.

2.8.5 Humidifier AdjustmentThe humidifier has a capacity adjustment pot on thehumidifier control circuit board. The capacity pot mayneed to be field adjusted if the humidifier is not supply-ing enough capacity for the current room conditions.

(Revised 08/05)


2-17

It is recommended that if the humidifier capacity potrequires adjustment, the adjustment is made in smallincrements and verified. Refer to the humidifier manualsent with your unit for the capacity pot location.

CAUTION Adjusting the capacity pot too high may result in theformation of condensate within the system.

2.8.6 BlowerSee Figure 12. The blowers are supplied with adjustablesheaves to change the blower speed and adjustablemotor bases for belt tensioning. Follow the followingprocedure to change the blower speed.

1. Turn system off.

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

3. Remove the blower belt(s).

4. Loosen the set screw in the side of the sheave withan Allen wrench.

5. Remove the sheave key.

6. Adjust the blower speed by closing the sheave onehalf turn to increase speed or opening the sheaveone half turn to decrease speed.

7. Replace the sheave key and tighten set screw.

8. Proper belt tension is achieved when the belt has adeflection of ¾ inch per foot of span between theblower and motor pulleys, with a firm pressureplaced on the side of the blower belt. Adjust theblower belt tension by raising (to tighten) orlowering (to loosen) the nuts on the adjustmentrods of the motor base.

CAUTION If the belt tension is too tight, it will cause prematureblower and/or motor bearing failure. If the belt is tooloose, the belt will slip and cause belt squeals andeventual belt failure.

9. Restore power to system.

10. Check the current draw on the blower motor tomake sure it does not exceed the nameplaterating of the motor.

11. If current draw exceeds nameplate rating of motorrepeat steps 1 through 9 to decrease the blowerspeed. If the motor pulls too much current, slowthe blower down by opening the adjustable sheaveone half turn at a time until the motor current is ator below the nameplate FLA.

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

2.8.7 Thermal Expansion ValveAll CyberTWO units utilize a thermal expansion valve(TEV) to control the flow of refrigerant entering theevaporator in order to maintain a constant superheat ofthe refrigerant vapor at the outlet of the evaporator.Superheat is the difference between the refrigerantvapor temperature and its saturation temperature atthat pressure. By controlling superheat, the TEVkeeps nearly the entire evaporator surface active whilenot permitting liquid refrigerant to return to the com-pressor. The standard superheat is factory set at 12-20°F and should not need adjustment.

2.8.8 Snap Acting Hot Gas Bypass (Optional)The snap acting hot gas bypass system providessome modulated capacity control and freeze protec-tion. The hot gas bypass system consists of adischarge bypass valve that allows some hot gas fromthe compressor discharge line to flow directly to theevaporator coil, in order to maintain a preset suctionpressure.

Figure 12- Blower

MOTOR

BLOWER

MOTOR BASE

VARIABLE ORADJUSTABLEPULLEY

FIXED PULLEY

TENSION NUT

LOCKNUT

BELT

MOTOR BASE

(Revised 08/05)


2-18

The snap acting hot gas bypass system also providesfreeze protection for the evaporator coil by limiting theminimum refrigerant pressure, thereby preventing thesurface temperature of the evaporator coil from drop-ping below 32°F.

The normal control setting is 50-55 psig (suctionpressure), read from the suction (low) side of thecompressor as it operates in full hot gas bypassoperation. The valve is factory set and no adjustmentshould be necessary. If adjustment is required, blockone half of the coil and remove the adjustment capfrom the end of the valve. Using a 5/16 inch Allenwrench, turn clockwise to increase pressure orcounterclockwise to lower pressure.

2.8.9 Hot Gas Reheat (Optional)The hot gas reheat option incorporates a hot gasreheat solenoid valve and a hot gas reheat coil. Undernormal operation, when no reheat is needed, the hotgas reheat solenoid valve is de-energized and hot gasflows directly from the compressor discharge to thecondenser. When there is a call for reheat, the control-ler energizes the hot gas reheat solenoid valve. Thehot gas reheat solenoid valve diverts hot gas to thereheat coil, mounted directly downstream of theevaporator coil, before it travels to the condenser. Noadjustment to the valve is necessary.

2.9 Refrigerant Characteristics2.9.1 Pressure/Temperature SettingsThe following chart is provided to assist with thenormal settings of the system for R-22 and R407Crefrigerant. Where applicable, minimum and maximumsettings are given along with normal operating pres-sures.

2.9.2 Saturated Refrigerant Pressure TablesThe following refrigerant vapor pressure tables areprovided for reference.

(SaturatedVapor)

(SaturatedLiquid)

R-22 RefrigerantTemp. Pressure (°F) (psig)

20 43.222 45.524 47.826 50.228 52.6

30 55.132 57.734 60.436 63.138 65.9

40 68.742 71.744 74.746 77.848 81.0

50 84.255 92.760 10265 11170 122

75 13280 14485 15690 16895 182

100 196105 210110 226115 242120 260

125 278130 296135 316140 337

R-407C RefrigerantTemp. Pressure (°F) (psig)

Superheat

20 37.022 39.124 41.326 43.628 46.0

30 48.432 50.934 53.536 56.238 58.9

40 61.742 64.644 67.646 70.748 73.8

50 77.1

Sub-cooling

95 206100 222105 239110 257115 275

120 294125 315130 336135 358140 381

BubblePoint

DewPoint

Pressure/Temperature Settings For R-22 & R407CNormal Min. Max.

Sub-cooling°F 10 5 20

Superheat°F 15 10 20

Condensing Temperature Air-Cooled°F 125 105 140

Condensing Temperature Water-Cooled°F 105 105 140

Condensing Temperature Glycol-Cooled°F 130 105 140

Suction Pressure (psig) 70 58 84

Opens Closes

Low Pressure Switch (psig) 10 32

High Pressure Switch (psig) 410 Manual Reset

2.9.3 Estimated Refrigerant Needed for Liquid LineThe following refrigerant charging information is providedfor reference for R-22 and R407C refrigerant.

Estimated CondenserRefrigerant Charge Volumes (lbs)

Model Refrigerant Type Number R22 R407C

WCS008B 2.60 2.24WCS010B 3.80 3.27WCS012B 5.30 4.56WCS016 6.10 5.25WCS022 9.10 7.83WCS025 6.22 5.35WCS028 9.32 8.02WCS036 12.43 10.69WCS041 13.62 11.71

(Revised 08/05)


3-1

3.0 START-UP/COMMISSIONING

3.1 OperationFor new installations, ensure the unit is ready tooperate by going through the Checklist for CompletedInstallation, located in Appendix A, prior to start-up.

NOTE

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

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

3.2 Step by Step Start-Up Instructions1. Replace all equipment removed prior to performing

start-up checks.

2. Apply power to start the CyberTWO system at themain power disconnect switch.

NOTE

The compressor(s) may have a time delay on start-up.

Water/glycol-cooled units have a head pressure water-regulating valve that has been factory set. A valveadjustment may be required based on water tempera-tures or water/glycol flow conditions at your site.(Refer to System Settings and Adjustments.)

Both refrigeration circuits must be tested at start-up.There are several ways to force the second circuitinto operation. Refer to the separate controller opera-tion instructions sent with your unit in the data pack-age.

3. Test cooling operation by adjusting the tempera-ture setpoint below the actual room temperature.The compressor should come on and the dis-charge air should feel cooler than the return air.

4. Test heating operation by adjusting the tempera-ture setpoint above the actual room temperature.The source of heat should be energized toincrease discharge air temperature.

5. Test humidification operation by creating a de-mand for humidification. Use an amp meter todetermine current draw of the humidifier. A visualcheck of humidity leaving the steam head or a hotcannister/cylinder bottle can also indicate if thehumidifier is operational. In all cases, 1 to 6 hoursmight be required to see a desired level or rise ofhumidity in the conditioned space. Once roomconditions have been programmed or set, a repeatvisit to the conditioned site may be required toensure the humidifier is meeting the room'srequirements.

6. Test dehumidification operation by creating ademand for dehumidification. Decrease thedehumidification setpoint 10% below actual roomconditions. The compressor circuit will be energizedto begin the dehumidification process. While in thismode, room temperature may decrease and thereheat function may activate. As conditions in theroom change, you may have to readjust thesetpoint as you check the operation. An adequateheat load within the space is required. For ElectricReheat, use an amp meter on the heater circuit todetermine if heater is operational. For Hot GasReheat, utilizing a voltmeter and a point to pointmethod, ensure the control signal has energizedthe hot gas reheat solenoid coil. For Hot Water orSteam Reheat ensure that the control signal hasenergized the control valve and the temperature ofthe steam or water has decreased as it passesthrough the unit. In all cases, 1 to 6 hours might berequired to see a desired level or decrease ofhumidity in the conditioned space. Once roomconditions have been programmed or set, a repeatvisit to the conditioned site may be required toensure the dehumidification mode is meeting therooms requirements.

7. Ensure that all blowers and fans are rotatingcorrectly and freely without any unusual noise.

3.3 Microprocessor Controller ProgrammingThe microprocessor controller is factory programmedbased on the optional features selected. Most applica-tions require no field start-up or program adjustmentbeyond setting the current date and time. Separateoperating instructions for the controller have been sentwith your unit, including each feature's factory "default"setting and the available adjustment range, if appli-cable.

(Revised 08/05)


4-1

4.0 MAINTENANCE

4.1 Periodic General MaintenanceSystematic, periodic general maintenance of theCyberTWO unit is recommended for optimum systemperformance. General maintenance should include,but is not limited to the following: replacing filters andhumidifier cylinders, tightening electrical connections,checking the condensate line to ensure it is free ofdebris, cleaning the interior of the unit, inspecting theunits' components visually, checking belt tension,checking level of refrigerant and ensuring no moistureis in the refrigerant.

Use copies of the Periodic General MaintenanceChecklist in this manual (see Appendix A) to recordperiodic general maintenance inspections. Forassistance, contact the SATS Product Support Group.Ensure adherence to all safety statements whileperforming any type of maintenance.

WARNING Turn off power to the unit at the main power dis-connect switch unless you are performing teststhat require power. With power and controls en-ergized, the unit could begin operating automati-cally at any time.

Hazardous voltage will still be present at the evapora-tor section heat/reheat, condenser and humidifier evenwith the unit turned off at the control panel. To isolatethe unit for maintenance, turn off power at the mainpower disconnect switch.

Always disconnect main power prior to performing anyservice or repairs. To prevent personal injury, stay clearof rotating components because automatic controlsmay start them unexpectedly.

This unit employs high voltage equipment withrotating components. Exercise extreme care to avoidaccidents and ensure proper operation.

WARNING Phosgene, a deadly, poisonous gas, is gener-ated when refrigerant is exposed to flame. Al-ways ensure adequate ventilation during refrig-eration repairs.

This equipment should be serviced and repaired by a

journeyman or a qualified refrigeration technician only.

Always recover all refrigerant prior to any systemrepairs, failure to do so may result in system overpressurization and rupture.

4.1.1 CyberTWO Unit

4.1.1.1 Filter

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

NOTE

Conditions of spaces vary and filters should bechecked based on those conditions.

4.1.1.2 Blower

Periodic checks of the blower system should includechecking the fan motor mounts, housing and theblower wheel. Check that all mounts are secure andblower wheel is tightly mounted on the fan shaft anddoes not rub against the fan housing. The blowervanes should be free of debris.

4.1.1.3 Drain Pan

To ensure proper drainage, inspect the drain panregularly. Make sure the drain pan outlet is alwaysfree of debris and ensure the drain pan does not leak.

4.1.1.4 Evaporator Coil

The evaporator coil should be inspected semi-annuallyand cleaned as required following standard evapora-tor coil cleaning practices.

4.1.1.5 Heat/Reheat

The heat/reheat equipment should be inspected semi-annually to ensure it is operational. If you have electricheat/reheat, inspect the heating elements to ensurethey are free of debris.

4.1.1.6 Humidifier

Because water conditions vary greatly, it is difficult toestablish intervals for changing the cylinder. A changecylinder light (red) will illuminate on the humidifiercabinet when the cylinder requires replacement.Individual maintenance schedules must be determined

(Revised 08/05)


4-2

SYMPTOM PROBABLE CAUSE RECOMMENDATION

for each location, based upon periodic examination ofthe humidifier.

4.1.1.7 Condensate Pump

The condensate pump should be inspected semi-annually and cleaned. Ensure that the float stemworks freely. Wipe the float with a wet cloth anddetergent to remove dirt. Clean the bottom tank.Check that the discharge line is open and water canpass through it freely.

4.1.2 CondenserMaintenance access to the condenser is through oneor two removable panels (depending on model). For air-cooled condensers, clean the coil of all debris that willinhibit airflow. This can be done with compressed air orwith a commercial coil cleaner. Check for bent or

damaged coil fins and repair as necessary. On outdoorunits in winter, do not permit snow to accumulate on oraround the condenser. Check all refrigerant lines andcapillaries for vibration isolation and support asnecessary. Check all refrigerant and coolant lines forsigns of leaks.

4.2 Troubleshooting

WARNING Turn off all power to the unit before conductingany troubleshooting procedures, unless theprocedure specifically requires the system tooperate. Keep hands, clothing and tools clear ofthe electrical terminals and rotating components.Ensure that your footing is stable at all times.

Suction Pressure Too Low a. Loss of refrigerant (bubbles in Locate leak and repair. Rechargesight-glass). system.

b. Expansion valve stuck or obstructed Remove and clean or replace valve.(short cycle or continuous running).

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

d. Dirty air filters. (reduced airflow) Clean/replace filters.

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

b. No control power to the valve. Valve actuator is wired incorrectly.Check wiring schematic and rewire ifrequired.

c. Actuator failed. Replace actuator.

Evaporator Coil Ices a. Low airflow. 1. Check filters. Replace as needed.

2. Check for and clear any obstructionsacross or in the (supply) dischargeairstream.

3. Check correct rotation of evaporatorblower.

4. Check clearance height of raised floor.

(Revised 08/05)



4-3

Evaporator Coil Ices b. Temperature setting too low Increase temperature setpoint.(Cont.) (68°F min.).

c. Discharge air short cycling back Check discharge grille orientation.to return.

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

Blower Fails to Start a. Power failure. Check main voltage power sourceinput cable.

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

c. Defective contactor. Repair or replace.

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

2. Check that condensate pan isdraining properly. Clear obstructions.

e. Motor circuit controller tripped. Reset motor circuit controller and checkamperage of motor. Compare to settingon motor circuit controller and adjust toFLA.

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

Condenser Pressure a. Non-condensable gas or air in the Recover system and recharge. Installtoo High system. new drier/strainer.

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

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

d. Low water/glycol flow to condenser. Determine cause and fix.

e. Condenser fan not operating. Check pressure/temperature operatingswitches and motor. Replace as needed.

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

g. Condenser pressure regulating Adjust to obtain correct pressure.valve setting too high.

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

2. Valves not open or partially open.Repair or replace as needed.

(Revised 08/05)


4-4


Condenser Pressure 3. Air in system - bleed system. Too High (Cont.)

4. Check all strainers and clean ifneeded.

i. Water/glycol solution not mixed Remove solution and premix.prior to adding to system. Refill system.

Condenser Pressure a. Loss of refrigerant (indicated by Locate and repair leak. Rechargetoo Low bubbles in sight glass). system.

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

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

Noisy Compressor a. Expansion valve stuck in open Ensure feeder bulb is tight on suctionposition (abnormally cold suction line). line. Check operation and superheat.

b. Broken compressor valve Replace compressor.(compressor knocking, suctionpressure rises faster than 2lbs/minafter shutdown).

c. Worn or scarred compressor Replace compressor.bearings.

d. Liquid slugging. System overcharged. Reclaim excessrefrigerant.

e. Scroll compressor not properly Phase correctly at main power source.phased. DO NOT REWIRE COMPRESSOR.

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

b. Compressor internal protector Check compressor for short circuit oris open. ground.

c. Complete loss of refrigerant charge Locate and repair leak. Recharge(low pressure safety switch). system.

d. Condenser pressure too high (high Check condenser for obstructions.pressure safety switch).

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

System Short of Capacity a. Low refrigerant (indicated by Check for leaks Repair and rechargebubbles in sight glass). system.

(Revised 08/05)


4-5


System Short of Capacity b. Expansion valve stuck or Remove valve and clear obstruction or(Cont.) obstructed (short cycling or replace valve.

continuous running).

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

d. Reduced airflow. Check belt tension, filters and evaporator coil.

Compressor Short Cycles a. Low line voltage causing Check power source for cause of lowcompressor to overheat. line voltage.

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

c. Reduced airflow. Check filter and belt tension (whenapplicable).

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

e. Short cycling of conditioned air. 1. Supply and/or return grilles areincorrectly oriented. Reorient.

2. Supply and return grilles are too closetogether. Move further apart.

3. Insufficient heat load. Add temporaryheat load to compensate.

f. Remote temperature sensor is Check for supply registers that may beimproperly located. too close to the remote temperature

sensor. Relocate if necessary.

Heater Inoperative a. Circuit breaker tripped. Check for short circuit, reset circuitbreaker.

b. Temperature setpoint too low. Increase temperature setpoint.

c. Overheat switch open. Insufficient air across heater elements.Check for dirty filters or obstructionsthat may reduce air flow. Correct orreplace as needed.

d. Manual reset overheat safety Reset manual overheat safety switchswitch tripped. (See item immediately above).

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

(Revised 08/05)


4-6


NOTE- R-407C Leak DetectionHalogen leak detectors are ineffective with R-407C refrigerant because unlike R-22 refriger-ant, R-407C does not contain chlorine. Othermethods may be used to detect a leak in thesystem. The most modern and easiestmethod to use is an electronic leak detector.Follow the manufacturers’ instructions andany leak can be quickly located. A secondmethod is to use soap bubbles. Apply asolution of soapy water with a brush orsponge to the joints and connections in therefrigeration lines. A leak in the lines willcause bubbles to form.

4.3 Field ServiceNOTE

Do not attempt to make repairs without theproper tools.

It may be necessary to perform repairs on the refrig-eration system. If field repairs are necessary, thefollowing procedures apply:

4.3.1 Refrigerant PipingWhen replacing components within the cabinet of theunit, the following consumable materials are recom-mended: Use Silfos alloy for copper-to-copper (pipingdischarge or suction line repairs). Silver solder (Stay-Silv #45) and flux are to be used on copper-to-brassor copper-to-steel repairs. For liquid line repairs at thedrier, strainer, sight glass, or expansion valve, use a95 % tin to 5 % antimony solder with flux.

When component replacement is complete, removeall traces of flux. After any repair, pressure check thesystem, checking for leaks prior to recharging thesystem.

4.3.2 General Common Repairs/Component Replacement

4.3.2.1 Compressor Failure

The compressor is the most important component ofthe air conditioner. Numerous safety devices areprovided to protect the compressor from failing.

If a compressor failure has occurred, determinewhether it is an electrical or a mechanical failure. Anelectrical failure will be indicated by the distinctpungent odor once the system has been opened. If a

Humidifier Inoperative 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. Electrical connections are loose. Tighten electrical connections.

c. Humidifier circuit breaker tripped. Check for over current by the humidifierelectrodes. Drain water from tank andrefill. Reset circuit breaker.

d. Relative humidity is above setpoint. Adjust humidity setpoint.

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

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

f. Water conductivity is too low. Add a teaspoon of table salt to the waterthrough the top of the cylinder. Typicallyonly on initial start-up.

(Revised 08/05)


4-7

burnout has occurred, the oil will be black and acidic.A mechanical failure will have no burned odor and themotor will attempt to run, an abnormal or excessivenoise may be present.

An analysis of the oil is the only way to ensure theproper procedure for cleaning the refrigerant system.Acid test kits are available from several manufactur-ers for measuring the acid level in the oil. These arecapable of making accurate acid measurements, butif they are not available, a check of the oil by sightand smell can give a quick indication if contaminationremains in the system. Since refrigeration oils vary incolor, a sample of the new oil in the replacementcompressor should be removed prior to installation andsealed in a small glass bottle for comparison pur-poses. If the oil has been exposed to refrigerant, thebottle should not be tightly capped, since the residualrefrigerant may create a high pressure if tightly sealedand exposed to high temperature.

CAUTION Avoid touching or contacting the gas and oil withexposed skin. Severe burns will result. Use longrubber gloves in handling contaminated parts.

All electrical connections should be checked to besure that they are tight and properly made. Check allcircuit breakers, contactors and wiring. The contactorshould be examined and replaced if contacts are wornor pitted.

If there is acid in the oil, there has been an electricalfailure which has caused the compressor motor toburn out. The acid diffuses throughout the refrigerationsystem and must be removed by using a burnout filterkit before a new compressor is placed in service. Notonly must the compressor be replaced, but also theentire refrigeration circuit must be cleaned of theharmful contaminants left by the burnout. See section4.3.2.1.2 (Burn-Out/Acidic Cleanup) for the propercleaning procedure.

CAUTION Damage to a replacement compressor causedby improper system cleaning constitutes abuseunder the terms of the warranty. This will VOIDTHE COMPRESSOR WARRANTY. Always con-sult the factory prior to replacing the compres-sor.

If there is no acid in the oil, there has been a mechani-cal failure. See section 4.3.2.1.1 (Standard Cleanout)for the proper cleaning procedure.

CAUTION POE oil is used in systems with R-407C refrig-erant. If a replacement compressor is provided,ensure that it is filled with POE oil before install-ing.

4.3.2.1.1 Standard Cleanout Procedure

CAUTION Avoid touching or contacting the gas and oil withexposed skin. Severe burns will result. Use longrubber gloves in handling contaminated parts.

NOTE

Cleaning operations must be performed by a jour-neyman, refrigeration mechanic, or air condition-ing technician.

1. Turn off power to the unit at the main powerdisconnect switch.

2. Remove the burned-out compressor and install thenew compressor.

3. Remove the liquid line drier and install an over-sized liquid line filter-drier (one size larger thanthe normal selection size).

4. Evacuate the system according to standardprocedures. Normally, this will include the use ofa high-vacuum pump and a low-vacuum microngauge for measuring the vacuum obtained.

5. Recharge the system.

6. Turn on the power at the main power disconnectswitch and start the system.

(Revised 08/05)


4-8

4.3.2.1.2 Burn-Out/Acidic Cleanup Procedure

NOTE

Cleaning operations must be performed by a jour-neyman, refrigeration mechanic, or air condition-ing technician.

1. These systems should be cleaned using thesuction line filter-drier method.

2. Turn off power to the unit at the main powerdisconnect switch.

3. Remove the burned-out compressor and install thenew compressor.

4. Install a suction line filter-drier designed for acidremoval.

5. Remove the liquid line drier and install an over-sized liquid line filter-drier (one size larger than thenormal selection size).

6. Check the expansion valve, sight glass and othercontrols to see if cleaning or replacement isrequired.

7. Evacuate the system according to standardprocedures. Normally, this will include the use of ahigh-vacuum pump and a low-vacuum microngauge for measuring the vacuum obtained.

8. Recharge the system through the access valve onthe suction line filter-drier.

9. Turn on power at the main power disconnectswitch and start the system.

10. The permanently installed suction line filter-drierpermits small-system cleanup to be completed inone service call. The pressure drop across thesuction line filter-drier should be measured duringthe first hour of operation. If the pressure dropbecomes excessive, the suction line filter-driershould be replaced (See Sporlan Bulletin 40-10, formaximum recommended pressure drop (PSI) forsuction line filter drier).

11. In 24 hours, take an oil sample. Observe the colorand test for acidity. If the oil is dirty or acidic,replace the suction line filter-drier.

12. In 2 weeks, examine oil to determine if anothersuction line filter-drier change is necessary.

4.3.2.2 Humidifier Cylinder Replacement

After an extended period of operation a red light willilluminate on the humidifier cabinet indicating that thecylinder is completely used and a replacementcylinder must be installed. The cylinder is disposableand cylinder life is dependent on water supply condi-tions and humidifier usage. The following proceduresare to be followed when replacing cylinder.

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

NOTE

Decrease the low humidity setpoint below am-bient humidity to allow the cylinder to cool downbefore removing the cylinder.

1. Turn off water supply to the humidifier.

2. Drain the cylinder by pushing the AUTO/ON-OFF-DRAIN switch to the DRAIN position.

3. When drained, push the AUTO ON/OFF/DRAINswitch to the OFF position.

4. Disconnect power to the humidifier at the mainpower disconnect switch.

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

CAUTION The cylinder and steam hose may be hot andburns may result.

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

7. Lift the cylinder straight up to disengage from thehumidifier.

8. Place the new cylinder on the side mounting slotswithin the unit, ensuring the cylinder mountingstubs are seated properly.

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

(Revised 08/05)


4-9

10. Ensure the plugs are secured on the pins. If thefitting plugs are loose, they may be temporarilysqueezed together, however, the plugs must bereplaced since a loose plug could generateenough heat to melt and destroy the plug.

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

12. Connect main power to the humidifier at the mainpower disconnect switch.

13. Push the AUTO/ON-OFF-DRAIN switch to theAUTO/ON position.

14. Turn on the water supply to the humidifier.

If the humidifier is to be shut down for an extendedperiod, always drain the cylinder first. Follow the abovesteps 1 through 4 ensuring the AUTO/ON-OFF-DRAINswitch is in the OFF position. Failure to do this willdrastically shorten the cylinder life.

4.3.2.3 Filter Replacement

The filters are located either internal to the cabinet orexternal to the cabinet, depending on the configurationof the unit. Regardless of location, the filter is ac-cessed through an access panel; all filter accesspanels, except for the front hinged access door, arelabeled "FILTER ACCESS". Open and/or remove theaccess panel and old filter. Ensuring directional airflowarrows on the filters are correct, insert the new filtersthen close the access panel.

(Revised 08/05)


5-1

5.0 PRODUCT SUPPORT GROUP

SATS provides to its customers a Product SupportGroup (PSG) which not only provides technicalsupport and parts but the following additional services,as requested: performance evaluations, start-upassistance and training.

5.1 Technical SupportThe SATS Product Support Group (PSG) is dedicatedto the prompt reply and solution to any problemencountered with a unit. Should a problem developthat cannot be resolved using this manual, you maycontact PSG at (240) 529-1399 Monday throughFriday from 8:00 a.m. to 5:00 p.m. EST. If a problemoccurs after business hours, dial the page number(301) 414-4514 and follow the steps below:

1. Wait for the dial tone.

2. Dial your telephone number (including areacode).

3. Press the pound (#) key.

4. Wait for a busy signal.

5. Hang up the telephone.

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

• Unit Model Number (VFS-XXX-XX-X)

• SATS Item Number (123456)

• Unit Serial Number (1234567)

• Description of Problem

5.2 Obtaining Warranty PartsWarranty inquires are to be made through the ProductSupport Group (PSG) at (240) 529-1399 Mondaythrough Friday from 8:00 a.m. to 5:00 p.m. EST. Aservice technician at SATS will troubleshoot thesystem over the telephone with a field service techni-cian to determine the defect of the part. If it is deter-mined that the part may be defective a replacementpart will be sent UPS ground. If the customer requeststhat warranty part(s) be sent by any other method thanUPS ground the customer is responsible for theshipping charges. If you do not have established creditwith SATS you must give a freight carrier accountnumber or accept COD (freight only).

A written (or faxed) purchase order is required onwarranty parts and must be received prior to 12:00p.m. for same day shipment. The purchase order mustcontain 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 costincurred for shipping the defective part(s) back toSATS. Return of defective part(s) must be within 30days at which time an evaluation of the part(s) isconducted and if the part is found to have a manufac-turing defect a credit will be issued.

When returning defective part(s) complete the ReturnMaterial Authorization Tag and the address labelreceived with the replacement part.

See SATS Standard Warranty located in section oneof this manual.

5.3 Obtaining Spare/Replacement PartsSpare and replacement parts requests are to be madethrough the Product Support Group (PSG) by fax (301)620-1396, telephone (240) 529-1399 or E-mail([email protected]). A parts inquiry form is provided(see Appendix A) to use as an order form or a quotesheet. Quotes are given for specified listed parts for aspecific unit.

There is a minimum order of $100.00 on spare orreplacement parts. SATS accepts Visa andMasterCard or will ship COD. SATS may extend creditto its customers; a credit application must be preparedand approved (this process could take one week).

A 25% minimum restocking charge will be applied onreturned stocked parts that were sold as spare/replacement parts. If the returned part is not a stockeditem, a greater restocking charge may be applied.Additionally a Return Material Authorization Number isrequired when returning parts.

(Revised 08/05)


APPENDIX A - FORMSStulz Air Technology Systems Inc.Frederick, Maryland USA 21704

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

Checklist for Completed Installation

Frederick, Maryland USA 21704

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

❏ 1 Proper clearances for service access havebeen maintained around equipment.

❏ 2 Equipment is level and mounting fasteners (ifapplicable) are tight.

❏ 3 Piping completed to refrigerant or coolant loop(if required).

❏ 4 All field installed piping leak tested.

❏ 5 Refrigerant charge added (if required).

❏ 6 Condensate pump installed (if required).

❏ 7 Drain line connected.

❏ 8 Water supply line connected to humidifier(if required).

❏ 9 Safety pan installed under ceiling mountedequipment (if required).

❏ 10 Filter box installed (if required).

❏ 11 Filter (s) installed (if required).

❏ 12 Ductwork completed or optional plenuminstalled (if required).

❏ 13 Incoming line voltage matches equipmentnominal nameplated rating ± tolerances.

❏ 14 Main power wiring connections to theequipment, including earth ground, have beenproperly installed.

❏ 15 Customer supplied main power circuit breaker(HACR type) or fuses have proper ratings forequipment installed.

❏ 16 All wiring connections are tight.

❏ 17 Control wiring connections completed toevaporator and condenser/condensing unit(if required), including wiring to wall mountedcontrol panel and optional controls.

❏ 18 Foreign materials have been removed frominside and around all equipment installed(shipping materials, construction materials,tools, etc.).

❏ 19 Fans and blowers rotate freely without unusualnoise.

❏ 20 Inspect all piping connections for leaks duringinitial operation.

A-1

(Revised 08/05)


NOTES

(Revised 08/05)


Frederick, Maryland USA 21704

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

Periodic General Maintenance Checks and Services ChecklistDate: ____________________________ Prepared By: ___________________________

Model Number: ____________________________ Serial Number: __________________________

Item Number: ____________________________

MonthlyFilters Blower Section Condensate Drain❏ Cleanliness ❏ Blower Turns ❏ Drain is Open❏ No Obstructions ❏ Belts (if applicable) ❏ Condensate Pan Safety

Switches Operate Freely

Miscellaneous❏ Check Glycol or Chilled Water for Air (bleed as required)❏ External Heat Exchanger Clean and Clear of Obstructions❏ Humidifier Cylinder and Controls Operate Properly

Semi-Annually

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

❏ Check Suction & Discharge Pressure ❏ Check Contacts on Contactorsfor Pitting

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

❏ Clean Coils ❏ Test the Glycol Solution Inhibitors (flush if necessary)

❏ Heat/Reheat Operational ❏ Clean Condensate Pump

AnnuallyRefrigerant Systems Chilled Water Systems❏ Inspect Glycol System for Leaks and Corrosion ❏ Inspect Chilled Water System

for Leaks and Corrosion❏ Conduct a Complete Check of All Services Listed ❏ Conduct a Complete Check of

Above and Clean Unit's Interior All Services Listed Above andClean Unit's Interior

Notes:____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Signature:________________________________

*** If factory assistance is required for any reason, provide the model number, serial number, and SATS itemnumber found on the unit nameplate. This will speed the process and ensure accuracy of information. ***

A-2

(Revised 08/05)


NOTES

(Revised 08/05)


B-1

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

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

LRA - Locked Rotor Amps

MAX CKTBKR - 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

R-22 - Refrigerant (HCFC-22)

R-407C - Blended Refrigerant

SPDT - Single Pole, Double Throw

TEV - Thermal Expansion Valve

V - Volt

VAC - Volt, Alternating Current

VFS - Vertical Floor System

(Revised 08/05)


Globally close to you.

1572 Tilco Drive, Frederick, Maryland 21704, USA www.stulz-ats.comTel: (301) 620-2033, Fax: (301) 662-5487, Email: [email protected]

Stulz-ATS, located in Frederick, MD USA, is part of The STULZGroup with headquarters in Hamburg, Germany and productionfacilities world wide. Our network of manufacturer’s representa-tives and sales partners span the globe, providing innovativesolutions to your unique environmental control needs.

North American Headquarters:

©08/05 - VFS-IOM-08/05-03Installation, Operation & MaintenanceSpecifications are subjectto change without notice

STULZ GmbHHolsteiner Chaussee 283, D-22457 HamburgTel: +49(40)55 85 269; Fax: +49(40)55 85 308, Email: [email protected]

World Headquarters:

installation, operation & maintenance cybertwo™...

Documents