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CyberAir 3PRO CW2

Original instructions
Precision Air Conditioning Units
ASD/ASU series
Index G18D
400 V / 3 Ph+N+PE / 50 Hz Issue 6.2017
CY B E R A I R 3 P R O C W 2 O R I G I N A L I N S T R U C T I O N S

ABOUT STULZ
Since it was founded in 1947, the STULZ company has
evolved into one of the world’s leading system suppliers of
air-conditioning technology.
Since 1974 the group has seen continual international
expansion of its air conditioning technology business, spe-
cialising in A/C for data centres and telecommunications
installations.
STULZ has seven production plants (Germany, Italy, the
USA, 2 in China, Brazil and Indiaand) and seventeen sub-
sidiaries (in France, Italy, Great Britain, Belgium, Brazil,
the Netherlands, New Zealand, Mexico, Austria, Poland,
Spain, Singapore, China, India, South Africa, Australia and
the USA).
The company also co-operates with sales and service Editor
partners in over 130 other countries, and therefore boasts
an international network of air-conditioning specialists. STULZ GmbH
Holsteiner Chaussee283
22457 Hamburg

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CY B E R A I R 3 P R O C W 2 O R I G I N A L I N S T R U C T I O N S

CyberAir 3PRO CW2 – Progress


for energy efficient closed-circuit
air conditioning

Dear customer,

thank you for having chosen the CyberAir 3PRO CW2 from STULZ.
CyberAir 3PRO CW2 is the result of consistent further development of our thoroughly successful
CyberAir 3 series. With our CyberAir 3PRO CW2 units, STULZ is introducing a new series of units
offering maximum potential savings. The units control the climate in the data center with the utmost
precision, reliability and energy efficiency.

For general inquiries our hotline is available


at +49 40 5585-5000
Our service hours are weekdays from 7am – 4pm.

For further information concerning our


products and services visit our website :
www.stulz.com

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Contents
1. Safety................................................................................................................... 6
1.1 Marking....................................................................................................................................... 6
1.2 Safety instructions.................................................................................................................. 6
1.3 Duties of the operator............................................................................................................ 7
2. Transport / Storage............................................................................................ 8
2.1 Delivery of units....................................................................................................................... 8
2.2 Transport.................................................................................................................................... 8
2.3 Storage....................................................................................................................................... 9
3. Description........................................................................................................ 10
3.1 Type code................................................................................................................................ 10
3.2 Intended use.......................................................................................................................... 11
3.3 Function of the A/C unit..................................................................................................... 11
4. Technical Data................................................................................................... 12
4.1 Application limits.................................................................................................................. 12
4.2 Technical Data - ASD ... CW2........................................................................................... 13
4.3 Technical Data - ASU ... CW2........................................................................................... 13
4.4 Dimensional drawings........................................................................................................ 14
5. Installation........................................................................................................ 16
5.1 Selection of the installation site...................................................................................... 16
5.2 Positioning the unit.............................................................................................................. 17
5.3 Water piping connection.................................................................................................... 19
5.3.1 Pipe entrance area - Downflow version................................................................... 20
5.3.2 Pipe entrance area - Upflow units.............................................................................. 24
5.3.3 Condensate drain connection...................................................................................... 25
5.4 Electrical connection ......................................................................................................... 26
6. Commissioning................................................................................................. 29
6.1 Filling of the water circuit................................................................................................... 29
6.2 Control of the electrical box.............................................................................................. 30
7. Maintenance...................................................................................................... 32
7.1 Safety instructions............................................................................................................... 32
7.2 Maintenance intervals........................................................................................................ 32
7.3 Air circuit.................................................................................................................................. 33
7.4 Water circuit........................................................................................................................... 34
7.5 Unit housing........................................................................................................................... 34
8. Malfunction....................................................................................................... 35
9. Dismantling and disposal................................................................................. 36
10. Contents of the CE Declaration of Conformity............................................. 37
11. Options

Subject to technical modifications.

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1. Safety
1.1 Marking

danger threatening danger, grievous bodily harm and death

warning dangerous situation, grievous bodily injury

caution dangerous situation, light bodily injury

notice material damage, important information and application notice

esd note risk of damaging electronical components

1.2 Safety instructions

These operating instructions contain basic information which is to be complied with for installation, operation
and maintenance. They must therefore be read and complied with by the fitter and the responsible trained
staff/operators before assembly and commissioning. They must be permanently available at the place where
the system is used.

danger
• Works have to be carried out by competent staff only.
• Safety devices may not be bypassed.

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1.3 Duties of the operator

The following requirements relate to the operation of refrigerating plants within the European Community.

• T
 he used components must correspond to the pressure equipment guide-line EC/97/23 and EN 378 part
1-4.
• Independent of the design, the equipment and inspection before the delivery, also the operator of such
plants has duties according to EN 378 and national regulations.
This concerns the installation, the operation and the repeated inspection:
• Installation: according to EN 378
• Operation: Determination of emergency measures (accidents, malfunctions)
Creation of an abbreviated instruction and notification (template page)
a. A unit protocol must be kept.
b. To be stored in the proximity of the unit
c. Access for competent staff in case of repairs and repeated inspection must be ensured.
• Repeated inspection: according to EN 378
The operator is responsible for the execution.

The operator must ensure that all maintenance, inspection and assembly work is carried out by authorised
and qualified specialist staff who have made an in-depth study of the operating instructions.

Independent conversion and manufacture of replacement parts


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

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2. Transport / Storage
2.1 Delivery of units

Stulz A/C units are mounted on pallets and packed several times in plastic film.

Construction of protec- The following information can be found on the packing:


tive covering:
(from inside to outside)
1. Neopolene cushioning 1) Stulz logo also upon request
2. Shrink film 2) Stulz order number 6) Gross weight
3. Additional board in con- 3) Type of unit 7) Net weight
tainer shipments 4) Packing piece - contents 8) Dimensions
5) Warning symbols 9) Customer order number
10) Additional customer
requirements

notice
When delivery is accepted, check the unit against the delivery note for completeness and
for external damage and record it on the consignment note in the presence of the freight
forwarder.
• The delivery note can be found on the A/C unit when delivered.
• The shipment is made ex works, in case of shipment damages, please assert your claim towards the carrier.
• Hidden damage is to be reported in writing within 6 days of delivery.

2.2 Transport

danger
Mortal danger by crushing
A defective lifting device can lead to the uncontrolled fall of the A/C unit.
Do not stay under suspended loads!

The Stulz A/C units can be moved by lifting devices with belts or ropes.
• fix the belts or ropes at the pallet,
• protect the upper unit edges by wooden laths or metal brackets in such a way that they could not be caved
in.

notice

Risk of distorting the frame


Never move the unit on rollers and never transport it on a fork lift without pallet.

You can move the unit still packaged on the pallet with a fork lift.
• take care that the centre of gravity is within the fork surface.
• take care that the unit is in an upright position at the transport.

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2.3 Storage

If you put the unit into intermediate storage before the installation, the following measures have to be carried
out to protect the unit from damage and corrosion:
• the storage point must not be exposed to direct sunlight. Observe the storage conditions in the chapter
“Application limits“.
• store the unit packaged to avoid the risk of corrosion.
• make sure that the water connections are provided with protective hoods.

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3. Description
3.1 Type code

The type code represents the unit variant of your A/C unit and can be found on the rating plate. The
rating plate is located in the door in front of the electrical compartment.

Typenschild/type plate
plaque d’appareil

Lieferant
manufacturer Stulz GmbH Hamburg
vendeur Holsteiner Chaussee 283, D-22457 Hamburg

Unit type Typ Versorgunsspannung


400 V ±10%
type ASD 700 CW2 supply voltage
type tension de service 50 Hz ± 1%

internal part no. Artikel-Nr. Kältemittel


Item-no. B99648 refrigerant WaTer/
numéro d’article refrigerant GlyCol
Order number Kommission/Alt Max. Betriebsdruck
+ alternative commission/alt 0530111234/01 max. operation pressure 16 bar
commission/alt pression de fonction max.

Baujahr Max. Füllgewicht


model 2017 max. filling change ––– kg
modele charge max. de rempliss.

Serial no. S. Nr.


s.-no.
no. serie

Made in Germany

Product range Energy index


Explanation
Airflow direction
Output of unit in kW
Number of refrigeration circuits

A S D 70 0 CW2
Unit variants D = Downflow Cooling system:
U = Upflow CW2 = chilled water cooling with 2 circuits
S = Standard
A = CyberAir

Page code
eN/06.2017/G18D

Date of issue Index number


month/year

Language: Manufacturing base:


EN = English G = Germany
DE = German C = China
FR = french I = Italy
ES = spanish
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3.2 Intended use

This A/C unit serves to control room temperature and air humidity within the application limits stated in
chapter 4.1. The A/C unit is designed for indoor installation. Any use beyond this is not deemed to be
use as intended.

3.3 Function of the A/C unit

The A/C unit is exclusively operated by the controller in the front panel and the main switch in the electric box.
To adapt the airflow to the needs of the system the fan speed can be adjusted gradually at the controller by
means of a 0-10V signal. Minimum speed corresponds to 4V.

At the air inlet a temperature and hunidity sensor is installed. The setpoints can be set at the controller.

To control the supply air temperature the controller adjusts the 3 way valve, which is part of the chilled water
circuit and controls the amount of chilled water which flows through the chilled water coil. For optional heating
two variants are available: electrical heating and hot water reheat

To achieve a dehumidification, the fan speed is reduced.


A humidification can be obtained by using the optional humidifier.

The A/C unit control is effected by the


Electrical box
on board I/O controller. The operational
conception is designed such as to allow
to control up to 19 units from one unit.
These units can be installed separately
with a maximum control line length of
1000 m.

Downflow unit Upflow unit

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4. Technical Data
4.1 Application limits
Admissible return air conditions:
Temperature: Lower limit: 18 °C The cooling capacity, air flow, water flow, pressure loss,
Upper limit: 40 °C sound pressure level and valve sizes change with a voltage
Humidity:  Lower limit: 5 °C dew point different from the standard voltage (400V/3Ph/50 Hz). In
Upper limit: 60 % r. h. and 16 °C dew point this case, see the technical data by the help of the „Stulz
Select“ planning tool.
Storage conditions: The unit design, the external dimensions, the weight, the
Temperature [°C]: -20 - +60 position and size of the supply connections are indepen-
Humidity [% rel. h.]: 5 - 95 dent of the supply voltage and can be found in this manual.
Atmosphere pressure [kPa]: 70 - 110
Requirements for UPS systems:
Chilled water conditions: (in case of permanent operation of the EC fans with a UPS
min. temperature at the unit inlet: 5 °C system)
min. temp. difference with 5 °C EWT: 4K • the output voltage of the UPS system must be groun-
max. head pressure: 16 bar ded neutral (wye).
• the voltage distortions must be within the limits stated
Water conditions for optional hot water reheat: below and no inadmissibly high DC voltage portions
max. water inlet temperature: 110 °C may exist.
max. water head pressure: 16 bar • all-pole sinus filters must be provided at the UPS sys-
tem output.
Voltage:
400 V / 3ph+N+PE / 50 Hz transient peak over-voltage phase to ground:
max. 4 kV (1,2/50µs wave form; Z=12 Ohms in acc. to
Voltage tolerancy: ANSI)
+/- 10 % (not for permanent operation)
transient peak over-voltage phase to phase:
Frequency tolerancy: +/- 1 % max. 2 kV (1,2/50µs wave form; Z=2 Ohms in acc. to
ANSI)
The following voltages are also available for this A/C unit
series: ripple voltage phase to ground:
230V/3Ph/50Hz; PE (not supported by StulzSelect) dV/dt < 1V/µs (≡1000V/ms)
208V/3Ph/60Hz; PE voltage harmonics: THD(V) < 8%
230V/3Ph/60Hz; PE
380V/3Ph/60Hz; N; PE The warranty is invalidated for any possible damage or
460V/3Ph/60Hz; PE malfunction that may occur during or in consequence of
Other voltages on request. operation outside the application limits.
Voltage/frequency tolerances as for 400V/3Ph/50Hz.

Design conditions

Electrical connection: 400 V / 3ph+N+PE / 50 Hz


Downflow units with an external static pressure: 20 Pa
Upflow units with an external static pressure: 50 Pa
Return air conditions for cooling capacity: 26 °C, 40 % rel. h.
Water inlet temperature: 10 °C
Water outlet temperature: 15 °C
Cooling fluid: Water, 0 % glycol

The sound pressure levels are valid at a height of 1m and distance of 2m in front of the unit under free field conditions
and with nominal data. The values take into account the effects of all installation and design parts contained in the stan-
dard unit. The values for upflow units assume an installed discharge duct.

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4.2 Technical Data - ASD ... CW2

Modell
Type 280 480 700 850 1090 1280

CW-Kälteleistungtotal
CW-cooling capacity total 22,7 35,4 51,5 61,0 80,8 103,9
kW
F. 
26 °C/40 % r. h. sensibel
sensible 22,7 35,4 51,5 61,0 80,8 103,9

Luftvolumenstrom
Air flow m³/h 7500 11000 16500 19500 26500 34500

Rückluftfilterklasse
Return air filter class M5 M5 M5 M5 M5 M5

Wasservolumenstrom
Water flow m³/h 3,9 6,1 8,8 10,4 13,8 17,8

Druckverlust,
Pressure loss,wasserseitig
water side kPa 45 59 50 43 51 51

CW-Ventilgröße
CW (2-Wege)
valve size (2 way) Zoll DN25 DN32 DN40 DN40 DN50 DN50

Wasserinhalt
Content of water dm³ 11 17 21 29 33 45

Schalldruckpegel
Sound pressure level dBA 51 54 53 55 57 55

Baugröße
Cabinet size 1 2 3 4 5 7

Gewicht
Weight kg 300 387 467 561 651 855

4.3 Technical Data - ASU ... CW2

Modell
Type 280 480 700 850 1090

CW-Kälteleistungtotal
CW-cooling capacity total 22,7 34,2 50,9 60,1 80,2
kW
26°C/40
26 °C/40%
% r.r.F.
h. sensibel
sensible 22,7 34,2 50,9 60,1 80,2

Luftvolumenstrom
Air flow m³/h 7500 10500 16200 19100 26200

Rückluftfilterklasse
Return air filter class M5 M5 M5 M5 M5

Wasservolumenstrom
Water flow m³/h 3,9 5,9 8,7 10,3 13,7

Druckverlust,
Pressure loss,wasserseitig
water side kPa 43 54 49 44 52

CW-Ventilgröße
CW valve size (2 (2-Wege)
way) Zoll DN25 DN32 DN40 DN40 DN50

Wasserinhalt
Content of water dm³ 11 17 21 29 33

Schalldruckpegel
Sound pressure level dBA 54 55 55 57 59

Baugröße
Cabinet size 1 2 3 4 5

Gewicht
Weight kg 303 392 480 581 725

For electrical data, (fan power consumption) see e-data sheet.


The electrical power consumption of the fans must be added to the room load.

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4.4 Dimensional drawings

Cabinet size 1 Cabinet size 2 Side view


35
(for all sizes)

10
1980

950 1400 890/980*


935/1025*
* for size 7

Cabinet size 3 Cabinet size 4

1750 2200

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Cabinet size 5
Projecting main switch

45

Main switch

2550

Cabinet size 7

3110

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5. Installation
5.1 Selection of the installation site

The A/C unit is designed for the inside installation on a level base. The A/C unit is not appropriate for opera-
tion in office rooms or other rooms sensitive to noise.

danger
Risk of explosion
The unit may not be operated in an explosive atmosphere!

• children, unauthorized persons and animals may not have access to the installation site of the A/C unit.
• check that the installation site is appropriate for the unit weight, which you can read in the technical data.
• take into account the necessary clearances for the maintenance and the air flow.

Downflow unit Air intake area for Downflow units


The A/C unit must be accessible from the front. Air outlet area for Upflow units without duct connection
0,5 m
min
1m

Maintenance clearance

Upflow unit
The A/C unit must be accessible from the front and requires
space on the left and right side for the supply connections.

Electrical connection
Supply connections for:
- humidifier (optional)

Clearance for chilled


water connection
1m

Maintenance clearance
min 0,5 m

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5.2 Positioning the unit

You will need two mounting aids as shown below.


When placing the unit on a raised floor stand, this must be installed first. Refer to the instructions in the chap-
ter „Raised floor stand“.

warning
Risk of crushing limbs
A defective lifting device can lead to the uncontrolled fall of the A/C unit.
Do not stay under suspended loads! Wear safety boots.

Transport with a fork lift


• transport the A/C unit on the pallet as close
as possible to the installation site.
• keep at hand mounting aids at the left and
right unit side.
• lift the units of cabinet size 1-4 with one fork
lift, the units of cabinet size 5-7 with two fork
lifts by 50mm.
• remove the pallet.
• put the mounting aids at the left and right unit
side.
• drop the A/C unit.
• lift the support surface of the mounting aids

165
22
at a sufficient height so that the weight of the
A/C unit lies on the mounting aids. Secure the
mounting aids by belts around the unit.
• take away the fork lift from under the unit. Pallet height

• drive the unit by the mounting aids to the


installation site.
• drop the unit, loosen the belts and pull away
the mounting aids.

A/C unit transport with mounting aids

Mounting aids

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Transport without fork lift


You will need scantlings of at least 1m length and a height of 150-160mm.
Cabinet size N° of scantlings
1-3 2
4-5 3
7 4

warning
Risk of crushing by tipping of the unit
Select starting point for pushing not higher than 1m. Do not stay behind the unit. Wear safety
boots.

• lay the scantlings flush against the pallet and secure them against slipping.
• push the unit on the scantlings by two persons.
• put the mounting aids at the left and right unit side.
• lift the support surface of the mounting aids at a sufficient height so that the weight of the A/C unit lies on
the mounting aids. Secure the mounting aids by belts around the unit.
• take away the scantlings from under the unit.
• drive the unit by the mounting aids to the installation site.
• drop the unit, loosen the belts and pull away the mounting aids.

notice
Place the male triangular wrench in a visible location in the immediate vicinity of the A/C unit.

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5.3 Water piping connection

External water circuit


To seal the water circuit you must connect the unit to a chilled water ring mains, which contains either a chiller
or a dry cooler or cooling tower for the generation of cold water. If the water quality is insufficient, install a fine
mesh strainer at the water inlet of the A/C unit.

notice
Respect material compatibility in the whole hydraulic circuit, when installing additional
components.

Connecting the A/C unit to the external system


The water connections end with an external thread.
• read the thread size and the diameter of the chilled water lines out of the
drawings in chapter 5.3.1 for Downflow units resp. 5.3.2 for Upflow units, to
establish the lines between the external system and the A/C unit.
• take the position of the connections out of these drawings, to conduct the
lines to the unit.
• remove the protective caps or sealing disks of the screwed connections.

Connection with external thread


notice
Water remaining from the test run may escape when the protective caps
are removed.

• screw the lines of the external system to the lines of the unit respecting the designation at the unit (inlet/
outlet).
• insulate the water pipes with the diffusion tight insulating material, to prevent the introduction of ambient air
heat and the formation of condensate at the pipes.

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5.3.1 Pipe entrance area - Downflow version

Bottom view

ASD 280 CW2

3
8 5
7 1

unit rear side

ASD 480 CW2


3

6
5

1 4
2
7
8

unit rear side

Diameter of the chilled water lines Legend:


1 - chilled water inlet 1 6 - humidifier in-/outlet
ASD ... CW2 280 480
2 - chilled water outlet 1 7 - chilled water inlet 2
ø by
bauseits
client mm 28 35 3 - power supply 8 - chilled water outlet 2
4 - condensate drain
Außengewinde
external thread inch
Zoll 1 1 1/4
5 - control lines

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Bottom view

ASD 700 CW2

8 3

7 4

unit rear side

ASD 850 CW2


7 8 3

6 5

2
4

unit rear side

Diameter of the chilled water lines Legend:


1 - chilled water inlet 1 6 - humidifier in-/outlet
ASD ... CW2 700 850 2 - chilled water outlet 1 7 - chilled water inlet 2
3 - power supply 8 - chilled water outlet 2
ø by
bauseits
client mm 42 54
4 - condensate drain
Außengewinde
external thread inch
Zoll 1 1/2 2 5 - control lines

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ASD 1090 CW2 Bottom view

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7 8 3 5

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unit rear side


Diameter of the chilled water lines Legend:
1 - chilled water inlet 1 6 - humidifier in-/outlet
ASD ... CW2 1090
2 - chilled water outlet 1 7 - chilled water inlet 2
ø by
bauseits
client mm 54 3 - power supply 8 - chilled water outlet 2
4 - condensate drain
Außengewinde
external thread inch
Zoll 2
5 - control lines

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ASD 1280 CW2 Bottom view


6 1 2 7 8 3
5
4

EN/06.2017/G18D
© STULZ GmbH – all rights reserved
unit rear side
Diameter of the chilled water lines Legend:
1 - chilled water inlet 1 6 - humidifier in-/outlet
ASD ... CW2 1280 2 - chilled water outlet 1 7 - chilled water inlet 2
3 - power supply 8 - chilled water outlet 2
ø by
bauseits
client mm 64
4 - condensate drain
Außengewinde
external thread inch
Zoll 2 1/2 5 - control lines
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5.3.2 Pipe entrance area - Upflow units


Connection from the left Connection from the right

L1 L2
R4
R1
L4 R5
L5 L3 R8

ASU ... CW2 280 480 700 850 1090

Ø Kaltwasserleitung,
chilled water line, bybauseits
client [mm]
[mm] 28 35 42 54 54 The openings R1
and R4 can not be
external thread [Zoll]
Außengewinde [inch] 1 1 1/4 1 1/2 2 2
used.
water inlet, circuit
Wassereintritt, 1 1
Kreis L1
water outlet, circuit
Wasseraustritt, Kreis11 L2
water inlet, circuit
Wassereintritt, 2 2
Kreis L3
water outlet, circuit
Wasseraustritt, Kreis22 L4
condensate drain
Kondensatablauf L5
power supply
Elektro-Einspeisung R8
humidifier inlet/outlet
Befeuchterzu-/ablauf R5

For the routing of the piping into the unit there are several possibilities. The most favourable openings are
those which are recommended in the tables. The lines for the power supply, the humidifier connections and
the condensate drain can be routed through the remaining openings as desired.

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5.3.3 Condensate drain connection

The position of the condensate drain is marked in the following


schemes for the pipe entrance areas.
The condensate drain is designed in the shape of a loop which
complies with the function of a syphon.
The internal diameter of the condensate drain tube is 25 mm.

View from behind

Syphon installation Example:


Ensure that there is a sufficient height difference Static pressure in the suction area: –300 Pa
between the fan pan and the upper bow of the
syphon or the highest part of the drain tube, in order h = p / (r ∙ g)
to avoid a water column in the drain syphon caused h = –300 Pa / (1000 kg/m³ ∙ 10 m/s²)
by the pressure in the suction area of the A/C unit, h = –3 cm
which prevents the draining of the condensate water.

If the height h is smaller than 3 cm with a pressure of 300 p = -300Pa


Pa in the suction area, a water column remains in the drain,
the water does not drain off and fills the fan pan. This h 3 cm
water can be drawn dropwise in the fan or can drop out of
the unit through the panels if the pan is full.

>10 cm

Connect the condensate water drains to the local waste


water system. unit limit

information
Comply with the regulations of the local water sup-
ply authority. possible installation at the custo-
mer side: funnel

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5.4 Electrical connection

The power supply system on site and the pre-fuse must be designed for the total current of the unit (see e-da-
ta sheet).
Make sure that the power supply corresponds to the indications on the rating plate and that the tolerances
according to the „Application limits“ are not exceeded.
The asymmetry of phase between the conductors may amount to 2% maximally.
The asymmetry of phase is determined by measuring the voltage difference between the phase conductors.
With a supply voltage of 400V, the average value of the voltage differences may not exceed 8 V.

danger
Mortal danger by electric hazard
Ensure that the power supply at the connection cable is de-energized.
The electric cables are only to be connected by an authorized specialist.

notice
Make sure that the phase rotation is correct, the rotating field must turn right! Otherwise a three
phase control device (optional) triggers an alarm.

notice
For use of leakage-current (FI) circuit breakers, take into account the EN 50178 5.2.11.2 .
Only type B pulse-current FI circuit breakers are permitted. FI circuit breakers do not provide
protection against bodily harm during operation of the unit or frequency converters.

• establish an effective earthing to the A/C unit frame.


• open the unit door, on which the main switch is located.
• check that the feedthrough openings in the unit are provided with rubber grommets. If the rubber grommets
are lacking, the cable insulation can be damaged.

esd note

Do not touch electronical components,


without taking care of protective ESD
measures.

Electronical components:
- C7000 IO controller (1) 1
- Humidifier board (option)

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Connection of the power supply cable

• route the power supply cable in the unit as shown in the following illustrations and fix it at the unit frame.
• route the electric cable into the electrical box from below and connect the PE conductor at the PE rail, the
neutral conductor at the neutral terminal and the three phases to the main switch, in accordance with the
wiring diagram (part of the unit documents).
• secure these cables by the pull relief screw.

Downflow units
Cabinet size 1 Cabinet sizes 2 - 7

control line
power supply cable

Connection of control lines (optional)

If the A/C unit shall be connected to other Stulz units by the IO bus, to a BMS or contains opional extensions
as louvers, you must route control lines and connect them in the electric box of the A/C unit.
• route the control lines in the unit as shown in the illustrations and fix them at the unit frame.
• route the control lines into the electrical box from below and connect them in accordance with the wiring dia-
gram (part of the unit documents).

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Upflow units
Cabinet size 1 Cabinet sizes 2 - 7

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6. Commissioning
Notice
The A/C unit must be installed and connected in accordance with the chapter on „installation“
before initial commissioning.

6.1 Filling of the water circuit

• Check whether you need an anti-freezing agent.

If the water temperature passes under 5°C or if the outside temperature is less than 0°C, you must add an
anti-freezing agent. We recommend to add the following quantities of glycol (indicated as percentage of
weight of the water quantity):

Ethylene glycol Water or outside air temperature


20% until -9,0°C
25% until -12,3°C
30% until -16,1°C
35% until -20,4°C
40% until -25,2°C
45% until -30,8°C
50% until -37,6°C

Propylene glycol Water or outside air temperature


25% until -10,7°C
30% until -14,0°C
35% until -17,6°C
40% until -21,5°C
45% until -26,0°C
50% until -32,4°C

It is difficult to produce a homogeneous glycol mixture. You can purchase ready-made glycol mixtures.
• calculate the water content of the water circuit and the required amount of glycol.

warning
Risk of glycol intoxication
Do not swallow ethylene glycol. Ethylene glycol is highly toxic in oral ingestion.
Lethal dose: 0,4 g ethylene glycol/kg body weight, severe intoxication: already at 0,1 ml/kg.
Glycol is absorbed through the skin. Therefore immediately change clothing soaked with glycol.
Wear protective gloves made of rubber.

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• fill the chilled water circuit by means of the filling connections (see refrigerant diagram, part of the unit
documents).
• bleed air from the chilled water circuit by means of the schrader valves for bleeding.

6.2 Control of the electrical box

• make sure that the master switch is off and the unit is de-energized.
• open the electrical box door (most right door) using the key provided.
• check whether all power switches and control-circuit fuses in the electrical section of the unit are switched
off.
• retighten all screw connections in the electric cabinet.
• verify the smooth function of the contactors.

non-calibrated range

Power switch off Power switch on

warning
Fire hazard
Do not turn the adjustment screw beyond the end of the calibrated scale range, as it may result
in overheating and short-circuit at the consumer or in the destruction of the power switch.

• check the settings of the power switches according to electrical data sheet (part of the unit documents).
• switch on the control-circuit fuses and the power switch of the fan.
• close all doors of the A/C unit.
• switch on the power supply for the A/C unit.
• switch on the A/C unit at the master switch.

The controller is now supplied with power, so you can use it for adjustments.

• make sure that the heat rejecting system (chiller) is operating.

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Electrical box

Control fuses

Power Main switch C7000IOC


switches

caution
Risk of bruising limbs
Through air intake limbs can be clamped at the slamming of doors. The doors represent a pro-
tective device. During operation the doors may not be opened and the rear panels may not be
removed.

A/C unit with C7000Advanced Terminal:


• familiarize yourself with the operation of the C7000 con-
troller. To do this, there is a separate manual.
• adjust the desired return air temperature at the controller.

A/C unit without C7000Advanced Terminal:


• open the electrical box door with the main switch
switched on.
• connect a notebook at the service port X15 on the
C7000IOC board, to carry out possible configurations
(setting the setpoint).
• shut the electrical box door.

• start the A/C unit by pressing the Start/Stop-key on the


controller. Controller C7000Advanced
Terminal, Start/stop-key

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7. Maintenance
7.1 Safety instructions

All maintenance work has to be carried out under strict compliance with the country-specific accident pre-
vention regulations. In particular we refer to the accident prevention regulations for electrical installations,
refrigerating machines and equipment. Non-compliance with the safety instructions can endanger people
and the environment.
Maintenance work is only to be carried out on the units by authorized and qualified specialist staff.

Procedure instructions
• carry out work on the system only when it is shut down.
• switch off the A/C unit at the controller and at the master switch.
• display a „DO NOT SWITCH ON“ warning sign.
• switch off power conducting cables to the unit and secure them against being switched on again.
• check to ensure that they are in the de-energized state.

7.2 Maintenance intervals

Maintenance interval
Component
quarterly half-yearly yearly

Air circuit

Heat exchanger x

Fan x

Air filter x

Water circuit

Tightness X

Unit housing

Electrical box x

Unit interior x

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7.3 Air circuit

Heat exchanger
The heat exchanger consists of copper tubes with aluminium fins. If leaks occur, they should be searched for
at the heat exchanger. Beyond that, the heat exchanger is exposed to the air pollution, the particles of which
settle at the fins and reduce the heat transmission the same as raise the air resistance. The latter shows when
the fan current increases.

Notice

Do not distort the fins while cleaning, this also increases the air resistance.

• c lean the heat exchanger by pressurized air by blowing it opposite to the normal air flow direction along the
fins.

warning
Risk of injury by burns and rotation
The electronics housing can get hot.
The fans have an operation delay after the unit is stopped !

Fan
The bearings of the fans are lifetime lubricated and do not need maintenance.

Air filter
A filter monitor controls the state of the filter. As soon as the pressure loss exceeds an adjustable value, a filter
alarm via the controller is released. The controller can be configured such as to compensate the pressure loss
by a higher fan speed, however you should not wait too long for exchanging the filter.
The filters can be accessed by the front doors, depending on the cabinet size the number of filter elements
varies. The clogged filter elements can not be cleaned with pressurized air, as the filter structure would be
destroyed otherwise.
When you re-install the filter elements after the exchange, take care that the side with the coloured mark (dirt
side) is turned away from the heat exchanger.

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7.4 Water circuit

Tightness
A lack of water in the circuit is replaced by air, which reduces the heat capacity of the chilled water circuit and
is detrimental to the pump. A level indication at the storage tank, if existant, can give information about chan-
ges of the water quantity.
• check the water circuit visually for tightness.

7.5 Unit housing

danger
Mortal danger by electric hazard
When the master switch is switched on and the controller is stopped, the power contactors are
live, even if the components are not operating.
At the fan contactor, dangerous voltages occur. Do not open the unit within the first 5 minutes
after disconnection of all phases.
In units with 2 or 3 fans dangerous charges of >50µC can occur between AC line terminals and
PE after disconnection.

Electrical box
• check the connection terminals for tight fixation when the unit is installed and once again after an operation
time of 30 days.

Unit interior
Clean pipes simplify the search for leaks.
• clean the unit‘s inside with a vacuum cleaner.

Vibrations of pipes and circuit components can result in leaks.


• check the pipes for a tight seat.

Condensing air humidity on cold water pipes means a loss of cooling capacity.
• check the insulation of the water piping.

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8. Malfunction
Alarm message Cause for alarm Cause Elimination

Airflow failure Differential pressure for airflow 1. Fan motor defective. Fan speed Check fan motor on voltage continuity and cur-
switch has triggered. too low. rent consumption.
Check if fan is mechanically blocked.

2. Air filter extremely clogged. Check air filter.

3. Hoses to the airflow monitor dirty Clean hoses and check whether they are kinked
or kinked. .

Sensor # error The tolerance to the average 1. Big difference of measeured Check room on Hotspots or chilled air zones,
value adjustable in the control- values in selected zone. moist zones.
ler has been exceeded.

2. sensor defective. Check measured value with an external measu-


ring instrument.

Sensor # defective The measured voltage/current 1. electrical connection defective. Check connections.
is outside the range defined in
the controller. 2. sensor cable defective. Check cable on continuity.

3. sensor defective. Check measured value with external thermo-


meter, hygrostat, pressure gauge.

Depending on the option configured in the controller further alarm messages exist.
# stands for a number in case of several components of the same kind.

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9. Dismantling and disposal


The A/C unit may only be dismantled by qualified specialists.

• switch off the A/C unit at the controller and at the master switch.
• switch off power conducting cables to the unit and secure them against being switched on again.
• disconnect the A/C unit from the de-energized network.

caution
If glycol or similar additives had been used, this liquid has to be collected and disposed in an
appropriate manner and may under no circumstances be introduced in the local waste water
system.

• d
 isconnect the unit from the external water circuit by closing the shut-off valves and drain the water circuit
of the unit.
• disconnect the depressurized chilled water pipes of the unit from the external system.

• m
 ove the unit, as described in the chapter „transport“, with a lifting device of sufficient load-carrying
capacity.

• dispose of the A/C unit in accordance with the disposal and safety regulations applicable on site.

We recommend a recycling company for this. The unit basically contains the raw materials aluminium (heat
exchanger), copper (pipelines, wiring), and iron (panelling).

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10. C
 ontents of the CE Declaration of
Conformity
The undersigned STULZ GmbH
Klimatechnik
Holsteiner Chaussee 283
22457 Hamburg 2017

hereby confirms that the units listed below, in the version marketed by us, fulfil the requirements of
the harmonised EC directives and EC safety standards listed below.

In the case of a modification of the equipment not co-ordinated with us this declaration loses its
validity.

Air conditioning unit


CyberAir 3PRO ... CW2

ASD 280 / ASU 280


ASD 480 / ASU 480
ASD 700 / ASU 700
ASD 850 / ASU 850
ASD 1090 / ASU 1090
ASD 1280

EC-Directives National regulation Harmonised EN


EC machinery directive 2006/42/EC BGR 500 chapter 2.35 EN 378 -1, -2, -3, -4
EC directive for low voltage 2014/35/EU BGV A3 EN ISO 12100
EC EMC directive 2014/30/EU EN ISO 13857
RoHS directive 2011/65/EU EN 60204 -1
EC pressure equipment directive 2014/68/EU EN 61000-6-2
EN 61000-6-4

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s t e a m h u m i d i f i e r I N STRU C TI O N S

11.1 Steam humidifier


The steam humidifier is an optional extra for your A/C unit. It is installed complete and integrated within the
function and method of operation of the A/C unit. Details concerning the connection assignment for the pow-
er supply can be found in the electrical diagrams in the appendix.

11.1.1 Description

The steam humidifier OEM2 is a pressureless steam generator that utilizes an electrode heating and is desi-
gned for air humidification via a steam distributor (steam distribution pipe, steam nozzle).

Steam generation
Any time steam is requested, the electrodes (2) are supplied with voltage via
main contactor (1). Simultaneously, the inlet valve (7) opens and water enters
the steam cylinder (3) from the bottom via water cup (4) and supply line (5). As
soon as the electrodes come in contact with the water, current begins to flow
between the electrodes, eventually heating and evaporating the water. The
more the electrode surface is exposed to water, the higher is the current con-
sumption and thus the steam capacity.
Upon reaching the requested steam capacity, the inlet valve closes. If the
steam generation decreases below a certain percentage of the required
capacity, due to lowering of the water level (e.g. because of the evaporation
process or drainage), the inlet valve opens until the required capacity is availa-
ble again.
If the required steam capacity is lower than the actual output, the inlet valve
is closed until the desired capacity is achieved by lowering of the water level
(evaporation process).

Level monitoring
A sensor provided in the steam cylinder cover detects when the water level
gets too high. The moment the sensor comes in contact with water, the inlet
valve closes.

Drainage
As a result of the evaporation process, the conductivity of the water increases
On/Off control due to an escalating mineral concentration. Eventually, an inadmissibly high
current consumption would take place if this concentration process were per-
mitted to continue. To prevent this concentration from reaching a value, unsuit-
ably high for the operation, a certain amount of water is periodically drained
from the cylinder and replaced by fresh water.
Proportional control During the drainage process, the drain valve (6) is opened. Following a prede-
termined time of drainage, the drain valve is closed again.

Control
With the ECCM/S control unit either On/Off control or proportional control can
be employed for steam production.
Below a minimum controllable steam output, proportional control will work in
two-point operation (on/off control).
X = steam capacity in %
Y = Output signal controller

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11.1.1.1 Technical data

Steam capacity [kg/h] Nominal power [kW] Nominal current [A] Max. current [A]
200 ... 230V / 1N~ / 50 ... 60Hz
2.0 1.5 7.5 ... 6.5 9.4 ... 8.2
4.0 15.0 ... 13.0 18.8 ... 16.3
200 ... 230V / 3~ / 50 ... 60Hz
4.0 3.0 8.7 ... 7.5 10.8 ... 9.4
8.0 6.0 17.3 ... 15.1 21.7 ... 18.8
10.0 7.5 21.7 ... 18.8 27.1 ... 23.5
380 ... 460V / 3~ / 50 ... 60Hz
4.0 3.0 4.6 ... 3.8 5.7 ... 4.7
8.0 6.0 9.1 ... 7.5 11.4 ... 9.4
15.0 11.25 17.1 ... 14.1 21.4 ... 17.6

Operating conditions

Admissible water pressure 1 ... 10 bar


Water quality Drinking water with a conductivity of 125 - 1250μS/cm
Admissible water temperature 1 ... 40 °C
Admissible ambient temperature 1 ... 50 °C (control unit 1 ... 40 °C)
Admissible ambient humidity max. 75% rh, non-condensing
Adm. back pressure at steam connection - 0.5 kPa ... 1.0 kPa
Type of protection IP00
Conformity produced according VDE regulations 0700 and 0700 part 98
Maximum discharge water flow 0.5 l/min (1.2 l/min for the model with 15 kg/h)

notice

Do not treat the water with softeners !


This results in corrosion of the electrodes and in the formation of foam with insufficient filling of
the steam cylinder.

A reverse osmosis plant (ROP) can be used to soften water. The water from the ROP has a low conductivity
and must be mixed with raw water for evaporation.

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11.1.1.2 Wiring diagram of the control unit ECCM/S

input signal from the C7000 controller

to C7000

{ alarm input

Danger
Mains voltage

B5 Level sensor steam cylinder S1 Rotary switch unit type


F1 Fuse control board (2 A, time-lag) S2 Drain/Info key
F2/Q2 Automatic fuse control voltage Sx% Potentiometer power limitation
F3/Q3 MCB humidifier %rH Potentiometer humidity value
H1 Red LED: Error Y1 Main contactor heating voltage
H2 Yellow LED: Service, Warning Y2 Inlet valve
H3 Green LED: Steam production Y3 Drain valve
JP1 Jumper block 1 T1 Current sensor
JP2 Jumper block 2

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11.1.1.3 Configuration of the control unit ECCM/S

danger
Mortal danger by electric hazard
The steam humidifier OEM2 is operated with mains voltage. One may get in touch with live
parts when the unit is open. Touching live parts may cause severe injury or danger to life.
• Before carrying out any work set the steam humidifier OEM2 out of operation as described in
chapter 11.1.3.5 (switch off the unit, disconnect it from the mains and stop the water supply)
and secure the unit against inadvertent power-up.

Setting the capacity limitation “Sx%”


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

Setting the control signal


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

General unit settings


With the jumpers on the jumper blocks “JP1” and “JP2” you can set different unit parameters.

Pos. with jumper without jumper


Connection to a mains supply with ground fault circuit inter- Connection to a mains supply without ground
FI
rupter ** fault circuit interrupter

DRN Increased drain operation factor Regular drain operation factor **

CDY Low water conductivity (<125 μS/cm) Normal water conductivity (≥125 μS/cm) **

DSP Exchangeable steam cylinder ** Cleanable steam cylinder

Fault No. 4 “steam cylinder maintenance due”:


Fault No. 4 “steam cylinder maintenance due”: 72 hours after the warning an error is triggered and the
K the unit triggers a warning only (the error switch unit is switched off (red LED lights). However, the error
on the control unit ECCM/S is not activated). switch on the control unit ECCM/S is activated already
in warning status. **

Fault No. 3 “Fill time”: a warning is triggered after Fault No. 3 “Fill time”: the unit directly triggers an
20 minutes filling time exceeding. After 220 minutes filling error after 20 minutes filling time exceeding (red
L time exceeding an error is triggered and the unit is switched LED lights and the error switch on the control unit
off (red LED lights and the error switch on the control unit ECCM/S is activated). However, the unit is switched off
ECCM/S is activated). ** after 220 minutes filling time exceeding.

Z, M, N no function (spare)

** Factory settings

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Setting the rotary switch S1

Power supply Steam capacity [kg/h]


2 4 8 10 15

200V 1N~ 0 0 - - -
208V 1N~ 1 1 - - -
220V 1N~ 2 2 - - -
230V 1N~ 3 3 - - -

200V 3~ - 4 8 C -
208V 3~ - 5 9 D -
220V 3~ - 6 A E -
230V 3~ - 7 B F -

380V 3~ - 0 4 - 8
400V 3~ - 1 5 - 9
415V 3~ - 2 6 - A
460V 3~ - 3 7 - B

11.1.2 Supply connections


The steam humidifier is installed and electrically connected in the A/C unit. The local regulations of the water
supply company are to be complied with when making the hydraulic connection.

notice

We recommend the installation of an Aqua-stop valve in the water supply of the humidifier. In
addition to this, the room, in which the A/C unit with the humidifier is installed, should be equip-
ped with a water detection system.

Legend:
1 Level sensor
2 Steam outlet connector ø22.5 - 30 mm
3 Heating electrodes
4 Inlet valve
5 Outlet valve
6 Drain connector ø30 mm
7 Water supply connector G 3/4“

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Water supply
The water connection at the cold water mains must be equipped with a shut-off valve and must be carried out
according to the EU directive 98/83/EC and EN1717. It is recommended to install a filter to retain solid par-
ticles of pollution. The humidifier can be connected directly to the mains by a threaded tenon of 3/4“ when the
water pressure is between 1 and 10 bar. The pipe should have a diameter of at least 6 mm.
If the line pressure is more than 10 bar, the connection must be made via a pressure reducing valve (set to
4-6 bar). In each case it is to be ensured that the manufactured water pipe upstream of the connection to the
humidifier is flushed properly. We recommend only using copper pipes. The water supply temperature must
not exceed 40°C.

Water drain
The drain connection has an outside diameter of 30 mm. A plastic hose can be connected to the drain con-
nection which can be routed out of the unit by means of the openings in the unit provided for this purpose.
When creating the drain, attention is to be paid to provision for cleaning.
As the water drain is depressurized, we recommend routing the drain hose first into an open collector funnel
and then passing through a syphon to the drainage system to ensure free discharge.
The drainage pipe should be routed to the sewerage system with sufficient gradient (at least 5%) and should
be located approx. 30 cm below the humidifier. Attention is to be paid to temperature resistance when plastic
pipes are used. If copper pipe is used, it must be earthed. For the drainage pipe an inside diameter of at least
30 mm is required.

11.1.3 Operation

11.1.3.1 Function of the display and operating elements on the control unit ECCM/S

1 Drain/Info key
• press key shortly: opens and closes the drain valve (manual draining).
Note: the drain valve is automatically closed after 10 minutes.
• press key for a extended period of time: activating the info mode

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2 Error indication (red LED)


• in normal operating mode
The LED lights in case of a malfunction of the unit. Further operation is no longer possible, the heating volt-
age is interrupted. An alarm signal is sent to the C7000 controller. At the C7000AT the alarm „HUMIDIFI-
ER 1 FAILURE“ is displayed.
• in info mode
LED blinks in intervals if a malfunction is present. The number of “blinks” per interval indicates the number
of the error (see chapter 11.1.4.4).

3 Warning and info indication (yellow LED)


• in normal operating mode
• The LED blinks, if manual draining is in progress.
• The LED lights if the cylinder maintenance is due or the maintenance indication is not reset after the
maintenance.
• in info mode
LED blinks in intervals if a malfunction with status warning is present. The number of “blinks” per interval
indicates the number of the error (see chapter 11.1.4.4).

4 Steam production (green LED)


• in normal operating mode
The LED lights if the unit produces steam.
• in info mode
LED blinks in intervals. The number of “blinks” per interval multiplied by 10 indicates the current steam
output in % (see chapter 11.1.3.3).

warning

Risk of burns
The steam humidifier OEM2 produces steam. When producing steam, the steam cylinder inside
the humidifier gets very hot (up to 100 °C). If the unit is opened immediately after having pro-
duced steam there is danger of burning when touching the steam cylinder.
• Before carrying out any work set the steam humidifier OEM2 out of operation as described
in chapter 11.1.3.5, then wait until the steam cylinder has cooled down sufficiently thus pre-
venting danger of burning.

11.1.3.2 Commissioning

Proceed as follows when putting the unit into operation:


1. Examine the steam humidifier and installation for possible damage.
2. Open the shut-off valve (if existant) in the water supply line.
3. Switch on control fuse and humidifier power switch in electric box. Switch on main switch.
4. Adjust the humidity set value at the C7000 controller. To force humidifer operation for a functional test you
can either increase the set value or start the humidifier by the manual operation function of the C7000.

After switching on the control unit ECCM/S carries out a system test, during which all the LEDs on the control
unit light up in sequence. If, after the system test (or during operation) the yellow or red LED lights up, an error
has occurred (see information in chapter 11.1.4 “Fault elimination”).

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After switching on the steam humidifier is ready for operation. As soon as the C7000 controller requires
humidity, power is switched on and the green LED lights on the control unit ECCM/S. The inlet valve opens
after approx. 60 seconds and the steam cylinder fills with water. The submerged electrodes heat the water
up and after a few minutes (approx. 5–10 minutes, depending on the conductivity of the water) steam is
produced.

notice
If the water has low conductivity, it is possible in the first few hours of operation that the maxi-
mum steam output is not achieved. This is normal. As soon as the water reaches adequate con-
ductivity through the vaporization process, the steam humidifier will work at maximum output.

11.1.3.3 Function of the LEDs in info mode

The info mode is activated by pressing the drain/info key for an extended period of time (> 3 seconds). In info
mode the LED‘s on the control unit indicate the current operating status of the steam humidifier.

notice

The info mode is automatically reset after 15 minutes, or manually by pressing the drain/info
key again.

• the green LED blinks. The number of blinks indicates the current steam output in % of the maximum steam
capacity:

green LED blinks... 1x 2x 3x 4x 5x 6x 7x 8x 9x 10x


steam capacity in % 10 20 30 40 50 60 70 80 90 100

11.1.3.4 Manual draining

1. Briefly press the drain/info key. The heating voltage is interrupted and the drain valve opens. The yellow
LED blinks. Note: the drain valve closes after 10 minutes automatically
2. To stop the drain cycle briefly press the drain/info key again.

11.1.3.5 Taking the unit out of operation

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

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11.1.4 Fault elimination

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

11.1.4.1 Fault indication

LED on control unit ECCM/S Description


yellow red
blinks permanently ––– Drain/info key has been pressed shortly (manual draining in progress)
lights ––– Steam cylinder maintenance due or maintenance indication not reset.
lights lights Steam cylinder maintenance not executed or maintenance indication not reset.
––– lights Fatal malfunction.

If the yellow or red LED lights, press drain/info key (at least 3 seconds) until yellow (“Warning”) or red (“Error”)
LED starts blinking intermittently (info mode). The amount of “blinks” per interval indicates the type of
malfunction.

– Yellow LED “Warning” blinks intermittently


A malfunction is present. The control unit checks whether there is a temporary problem (e.g. water supply
interrupted for a short time) or whether it can resolve the problem by taking necessary measures.

– Red LED “Error” blinks intermittently


The control unit, after several attempts, fails to solve the problem (number of attempts depends on the type of
malfunction) or the problem obstructs further operation. In this case the heating voltage is interrupted via the
main contactor.

11.1.4.2 Resetting the maintenance indication

After completing maintenance work, the maintenance indication (yellow LED) must be reset as follows:
• De-energize the humidifier board.
• Press drain key and keep pressed.
• Switch on humidifier board.
• Keep drain key pressed until the system test is completed (approx. 10 seconds).

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11.1.4.3 Notes on fault elimination

danger

Danger of electric hazard


The steam humidifier OEM2 is operated with mains voltage. One may get in touch with live
parts when the unit is open. Touching live parts may cause severe injury or danger to life.
• For the elimination of faults set the steam humidifier out of operation as described in chap-
ter 11.1.3.5, separate the unit from the mains (test with voltage tester) and secure it against
inadvertent power-up.

11.1.4.4 Malfunction lists

“Warning” “Error”
Cause Remedy
yellow LED blinks red LED blinks

1x Control board defective Please contact your unit supplier.


Control board defec- ---
tive

Water conductivity too low (after initial Wait.


2x
operation).
Max. filling level
--- Water conductivity too low for type of steam Select correct steam cylinder type.
of steam cylinder
cylinder.
reached
Phase failure heating voltage. Check mains fuse(s) and replace if applicable.

3x 3x Phase failure heating voltage. Check mains fuse(s) and replace if applicable.
Permissible filling Permissible filling Water supply obstructed, water pressure too Open shut-off valve in the water supply pipe, clean
time exceeded for time exceeded for low, inlet valve defective. water inlet filter, check water pressure, inspect/
more than 20 minutes more than replace inlet valve.
(first automatic clea- 220 minutes. Excessive steam back pressure, causing Inspect steam installation.
ning cycle) water loss via filling cup.
Drain valve is leaking. Clean/replace drain valve.

notice
If the Jumper “L” is removed from the ECCM/S control unit, the unit automatically triggers an error without prior
warning if the admissible filling time has been exceeded for more than 20 minutes (red LED lights and the error
switch on the control unit ECCM/S is activated). However the unit switches off after 220 minutes of filling time
exceeding (see chapter 11.1.1.3).

4x 4x Interval for steam cylinder service Replace steam cylinder type A, clean steam
Steam cylinder Interval for steam exceeded. cylinder type D (see chapter 5, humidifier ser-
needs servicing cylinder service Mineral deposits and/or electrodes vice manual).
exceeded for more spent. Important! Refer to chapter 11.1.4.2 for reset-
than 72 hours ting the maintenance indicator.

notice
If the Jumper “K” is installed on the ECCM/S control unit, the unit remains in warning status even if the interval time
has been exceeded for more than 72 hours. No error is triggered (red LED does not light) and the error switch on the
control unit ECCM/S is not activated (see chapter 11.1.1.3).

6x 6x Steam cylinder (electrodes) defective. Replace steam cylinder or electrodes.


Electrode current Electrode current Faulty auto-drain function. Inspect installation/control system.
too high too high Faulty drain valve/coil. Replace drain valve/coil.
Steam cylinder outlet obstructed. Clean/replace steam cylinder.
Water conductivity too high for type of Select correct steam cylinder type.
steam cylinder.

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7x 7x Formation of foam in steam cylinder. Empty/flush steam cylinder.


Foam detection in the Foam control Set jumper on “DRN” (see chapter 11.1.1.3).
steam cylinder impossible

8x Main contactor jammed in activated Check/replace main contactor.


--- Main contactor position.
jammed

9x 9x Drain valve blocked or defective. Clean/replace drain valve.


Drain valve blocked Drain valve blocked Steam cylinder outlet blocked. Clean steam cylinder outlet.

10x Rotary switch on control unit ECCM/S is Set rotary switch on control unit ECCM/S to the
--- Rotary switch in set to an invalid position. position for the corresponding steam cylinder
wrong position type (see chapter 11.1.1.3).

11.1.4.5 Replacement of fine-wire fuse on the control unit ECCM/S

If the fine-wire fuse on the control unit ECCM/S blows this is usually due to a faulty coil of the inlet or drain
valve or the main contactor. Therefore you should test these components before replacing the fuse.
To replace the fine-wire fuse proceed as follows:

2 A, time-lag

1. S et the steam humidifier OEM2 out of opera-


tion as described in chapter 11.1.3.5, separate
the unit from the mains and secure it against
unintentional switching on. Take care that the
electricity supply to the control unit ECCM/S is
disconnected (check with voltage tester).
2. Replace fine-wire fuse (see figure below) with a
fuse of the given type with the specified nominal
current rating.

caution
It is not permitted to use repaired fuses or to short-circuit the fuse holder.

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11.1.4.6 Resetting fault indication (red LED lights in normal operating mode)

To reset the error indication:


Disconnect the steam air humidifier from the mains. Wait approx. 5 seconds, then reconnect the unit to the
mains.
Note: If the fault has not been eliminated, the error indication reappears after a short while.

11.1.5 Maintenance
You find a detailed description of the maintenance procedures in chapter 5 of the humidifier service manual.
This manual is available on the website www.stulz.com in the e-Stulz area under „Downloads/Precision A/C“
as a pdf document.
Here you can only see a diagram, which shows the average life cycle of a steam cylinder in dependance of the
runtime and the total hardness.
The humidifier runtime can be read in the Info menu of the C7000AT or by the command „humi h“ in the
C7000.

Service intervals for steam cylinder


depending on steam production in hours

Life time
range

GH: Gesamthärte
DT: Dureté totale
TH: Total hardness
Time/
hours

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11.2 Reheat
The reheat is an optional extra for your A/C unit. It is installed complete and integrated in the function and
method of operation of the A/C unit. It is used to heat up the air. The following versions of the heater are
available:
• Electrical reheat
• Hot water reheat (HW)
• Hotgas reheat (HG)

Description

Electrical reheat HW reheat HG reheat

The reheat is connected The water supplyof the HW reheat is The hotgas reheat is integrated in the
in accordance with the controlled via an electrically actuated refrigerant circuit in accordance with
electric diagram. It is cont- HW valve. The HW valve is controlled the refrigerant diagram in the appen-
rolled and monitored by the via the C7000 controller. dix. The refrigerant supply is control-
controller. Set the control parameters in the led via an electrically-actuated 3-way
Set the values for switching „operate/components/heating/ solenoid valve. The solenoid valve is
on and off in the „operate/ HWR valve“ menu on the controller. controlled via the C7000 controller.
components/heating“ Refer to the operating instructions Set the control parameters in the
menu on the C7000 cont- C7000. „operate/components/heating“
roller. Refer to the opera- menu on the controller. Refer to the
ting instructions C7000. operating instructions C7000.

Operation
No further measures are required for operation.

Maintenance
Clean the reheat annually from contaminations and check it for damage.

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Installation
The electric reheat and the hotgas reheat are installed and connected in the A/C unit. The HW reheat must be
connected on site to an external hot water circuit.
• route the pipelines out of the A/C unit.
• the thread sizes for the connection piping of the HW reheat are listed in the following table.

Cabinet size 1 2 3 4 5 7
Pipe - ø mm 16 22 22 22 28 28
Thread size inch 1/2 3/4 3/4 3/4 1 1

Temperatures:
Water inlet: 60°C
Water outlet: 40°C
Air inlet: 13°C
Glycol: 0%

Commissioning
No measures are required for commissioning.

Malfunction causes
Alarm: Reheat defect

All reheat alarms are detected and displayed by the C7000 controller.

C7000-control system: no display (display only externally)


C7000 advanced terminal: indication on the display

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11.3 Air side connection


11.3.1 Unit base

The unit base is available in the versions: open, with damper, with flexible connection or with supply grilles.
The unit base can be installed in two ways, with the opening to the front or with the opening to the rear.
450
L2 E

L1
L3

L1
C B
A D

Baugröße
Cabinet size 1 2 3 4 5 7
A mm 910 1360 1710 2160 2510 3070
B mm 130/47,5* 210 182 69 173 42,5/65*
C mm - - - - 993 -/1027,5*
D mm - - 927 1276 1738 1728/2190*
E mm 75/67,5* 68 68 67,5 68 52,5/67,5*
L1 mm 700/815* 1015 615 815 615 1300/815*
L2 mm 300/315* 315 315 315 315 345/315*
L3 mm - - - - 615 1015*
T mm 865 865 865 865 865 955
N° 1/1* 1/1* 2/2* 2/2* 3/3* 2/3*

*version with grilles N°: number of openings

notice
Each of the unit base versions must be screwed to the unit by 4x M10 screws!

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Unit base with grilles

L4/L5

The standard grilles are equipped with horizontal fins which can be adjusted to conduct the air which is blown out.

L5 for middle position at size 5 and 7.

Unit base with flexible connection

150 L4/L5

300
Unit base with damper
120 L4/L5 38

300

L4/L5
175
Cabinet size 7:
345

Cabinet
Baugrößesize 1 2 3 4 5 7
L4 mm 700/800* 1000 600 800 600 1300/800*
L5 mm - - - - 600 1000

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11.3.2 Filter base

The filter base is designed for the option „suction from bottom“. With this option for upflow units the front
panels are not provided with an air inlet perforation as otherwise usual. The air is drawn in from the bottom, in
consequence there is no unit bottom plate.

Filter base

Unit base or raised floor


stand

Baugröße
Cabinet size 1 2 3 4 5
Gerätebreite
unit width mm 950 1400 1750 2200 2550
A mm 910 1360 1710 2160 2510
B mm 400 293 376 376 456
Filteranzahl
N° of filters 2 4 4 5 5

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a i r s i d e co n n ec t i o n

For the air side connection on top of the unit exist different options, which are delivered in a completely
assembled condition. On the installation site these set-ups must be set upon the unit and connected to it.

11.3.3 Duct

• set the duct on top of the unit and screw it with the unit.
500

Cabinet
Baugrößesize 1 2 3 4 5 7
A mm 884 884 884 884 884 974
A1 mm 840 840 840 840 840 930
A2 mm 784 784 784 784 784 874
B mm 950 1400 1750 2200 2550 3110
E mm - - - - - 939

Top view:

Panel

Frame
A2
A1
A

E E E
B B

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11.3.4 Discharge plenum

The discharge plenum is availale in two versions.


• Set the discharge plenum on top of the unit and screw it with the unit.

Discharge plenum with front grilles


500
400

L1

L1
B D C
T

Discharge plenum with front and side grilles


500
400

400

L1

L1 T1
B D C
T
Only one front grille for size 1, 2.

Cabinet
Baugrößesize 1 2 3 4 5 7
B mm 950 1400 1750 2200 2550 3110
C mm 75 100 45 112,5 100 140
D mm - - 905 1287,5 1450 1770
L1 mm 800 1200 2x800 2x800 2x1000 2x1200
T mm 884 884 884 884 884 974
T1 mm 600 600 600 600 600 800

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11.3.5 Bag filter top

The bag filter is available for all downflow units. The bag filter serves for the pre- filtration of the air which is
sucked in and can be obtained in the qualities F7 and F9 (according to EN779).
• Set the bag filter top on top of the unit and screw it with the unit.

500

B
974*
884/

11.3.6 Sound insulation plenum

• Set the plenum on top of the unit and screw it with the unit.
500

B
974*
B = unit width 884/
*for cabinet size 7

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11.3.7 Adapter plate with damper or flexible connection

- Connection on the unit


The adapter plate serves to attach a damper or a flexible connection on top of the unit or a duct. First install
the actuator onto the louver shaft on the right side looking at the unit front. Then fix the louver with the actua-
tor on the adapter plate. Now mount the adapter plate with pre-mounted louver on the unit top by means of a
screw connection.
The damper actuator, which is controlled via a 24 V signal by the controller, has to be electrically connected.
For this the delivered cable must be connected at the motor, be routed through an opening in the adapter
plate into the unit and then be connected at the controller in the electric box according to the electric diagram.
In downflow units route the cable through the side panel.

Adapter plate with damper Adapter plate with flexible connection

If the air side has to be

150
continued by a duct, the
H

installation of a flexible
connection is necessary.
Take into account the
installation of pressure
compensations in the
flexible connection.

20

25

890
T
E
25

C B

C F

Cabinet
Baugrößesize 1 2 3 4 5 7
A mm 950 1400 1750 2200 2550 3110
B mm 190 187 237 237 275 187
C mm 650 1100 1400 1800 2000 1200/1300
D mm 147 97 107 107 107 198
E mm 650 675 675 675 675 675
F mm - - - - - 1797
T mm 890 890 890 890 890 980
H mm 120 175 175 175 175 175

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Adapter plate with damper or flexible connection

- Connection under the unit


The adapter plate serves to attach a damper or a flexible connection under the unit. First install the actuator
onto the louver shaft on the right side (at the front construction size 1 and 2) looking at the unit front. Then fix
the louver with the actuator under the adapter plate. Now mount the adapter plate with pre-mounted louver on
the floor stand frame by means of bolts. Please take care that the adapter plate does not pass over the frame
to avoid canting of the floor stand within the raised floor.
The damper actuator, which is controlled via a 24 V signal by the controller, has to be electrically connected.
For this the delivered cable must be connected at the motor, be routed through an opening in the adapter
plate into the unit and then be connected at the controller in the electric box according to the electric diagram.

Bottom view
Knock-out openings for Unit front
supply connections

25
D
J

890/980*
E
K

20
C B

G F

*for cabinet size 7

H C/G 38
Cabinet size
E/K

Damper height for all units: 120 mm


Flexible connection height for all units: 150 mm

If the air side has to be continued by a duct, the installation of a flexible connection is necessary.
Take into account the installation of pressure compensations in the flexible connection.

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11.3.8 Recessed rear wall


For better flow dynamics Downflow units can be equipped with a rear wall which is recessed by 50 mm.

ASD...CW2
ASD...CW

Baugröße
Cabinet size 1 2 3 4 5 7
A mm 950 1400 1750 2200 2550 3110
B mm 174
92 145
250 247 282
220 257 237
228
C mm 675
600 1005
1000 1400 750 950 1200
D mm 210 260
300 258 210 195 185
E mm 600
550 550
510 550 600 600 675
F mm - - - 1342 1492 1805
G mm - - - 750 950 1200
H mm 175
120 175
120 175
120 120 120 120
J mm - - - 260 245 350
K mm - - - 550 550 510

Flexible connection height for all units: 150 mm

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11.4 Raised floor stand


The floor stand is used to adjust the height of the A/C unit to the existing raised floor and consists of an encir-
cling rectangular profile of galvanized steel with adjustable screw sockets. Anti vibration compound is recom-
mended between concrete floor and base plate.

L2
L1 L1

Locating the supports


(same on the other side)
T1
T

Baugröße
Cabinet size 1 2 3 4 5 7
B mm 910 1360 1710 2160 2510 3070
L1 mm - - 815 - 598 738
L2 mm - - - 1040
1095 1215 1495
T mm 865 865 865 865 865 955
T1 mm 785 785 785 785 785 875
Supports
Stützen Stk
n° 4 4 6 6 10 10
Rectangular profiles
Rechteckprofile 70x40
70x40 n°
Stk 4 4 4 5 5 5
Mafund strips
Mafundstreifen n°
Stk 4 4 6 6 10 10
Screws M8x30
Schrauben M8x30 n°
Stk 8 8 12 14 22 22

Dimensions from inner side of the lateral profile to the middle of the support
L1 - Position of the support without cross beam
L2 - Position of the support with cross beam

Cabinet size: 1

5
e.g. for size 5 and 7:
7
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Mounting

• A concrete foundation is recommended in the Raised floor stand Z (min. 50)


area of the raised floor supports.
• If the floor stand is placed near a wall, a minimum
distance of 50 mm must be respected. The gap Y
between wall and floor stand must be closed by
tin stripes.
• Choose the dimensions of the openings in the Z X Z Z (min. 800)
(min. 50)
raised floor (X and Y) 10 mm longer than the
raised floor stand dimensions.
• Close the joint with a continuous seal. X/Y = Opening in raised floor
Z = Limit of distance
• The raised floor cutting (notch) should at
least be 15° and must not have any contact
to the raised floor stand, which could result in
bone-conduction. • P
 rior to installation of the A/C unit, install the
raised floor 7 mm higher than the raised floor
• Install the raised floor supports on vibration plates, as the mafund plates are compressed by
dampening material (Mafund plate) (do not screw the weight of the A/C unit.
down the supports!).

General design of the raised foor stand


Raised floor connection
for details, see next page
Unit width

Hmin — Hmax
Raised floor Hmin — Hmax [mm]

Continuous seal 995 — 1045


Hammer head screw M8 x 30
Raised floor stand 895 — 945
Raised floor support 795 — 845
Mafund plate Recommended concrete
foundations (no floor finish) 695 — 745
Upper edge of 595 — 645
rough floor
495 — 545
355 — 405
270 — 320

Connecting the bars (View from below)

Angle Connection Butt Joint Cross Connection

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Detail of raised floor connection

1 Raised floor stand


2 Adjustable support plate
3 Adjusting nut
4 Support pipe
5 Support base
6 Mafund plate
7 Raised floor cut out angle
8 Continuous seal profile
(use closed-cell material only)
9 Before unit installation
10 Raised floor plate
11 Angled bracket
12 Permanently elastic seal
13 Fixing

when distance Z < 100 mm when distance Z > 100 mm

Other mounting options (e.g. louvers)

If louvers shall be installed beneath the unit, these must be first mounted onto the adapter plate.
• install the louver actuator on the shaft, so that it will later be on the right unit side in the proximity of the elec-
tric cabinet.

Positioning of the A/C unit on the floor stand

When positioning the A/C unit on the floor stand, it must be brought precisely into the correct position above
the floor stand from the front (under no circumstances diagonally).

• use mounting aids to bring in the unit and


secure these by fixing belts at the A/C unit.
• lay at least two securing instruments (e. g.
square steel bars) on the stand to avoid a
slip-off.
• when the unit is in the right position take away
the securing aids and set down the unit.
• now pull away the mounting aids under the
unit.

Mounting aid

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e l ec t r i c a l o p TIO N S

11.5 Electrical Options


11.5.1 Three Phase Control

The phase monitoring relay monitors a phase failure and a phase reversal. Excess voltage, undervoltage and
the phase imbalance are monitored in relation to the set values.
In case of a phase failure the phase monitoring relay is de-energized without delay and triggers an alarm. If the
monitoring relay detects a wrong phase sequence during the A/C unit start, it is not energized and prevents
the unit start.
You can adjust a triggering delay on the relay for the errors excess voltage, undervoltage and phase imbalance
(excess of the adjusted limit values).

Automatic restart
When the defective phase returns and if the voltage is within the limit values and the phase imbalance within
the adjusted tolerance, the A/C unit is restarted automatically.
For this the parameter „Phase restart“ must be set to „1“, either in the menu „Config/Values/Misc.“ of the
C7000AT or by the command „phase start 1“.

Error Adjustment range Factory setting Relay


Excess voltage
off, 106-173% 108%
(upper limit value)
Excess voltage
off, 103-173% 105%
(restart value) *
Undervoltage
off, 50-94% 92%
(lower limit value)
Undervoltage 1
off, 50-97% 95%
(restart value) *
Phase imbalance off, 4-40% 5%
Phase imbalance
off, 1-40% 3%
(restart value) *
Triggering delay
0,1-20s 3s
Relay 1
Rotating field control 1 5-45° 35°
off, L1-L2-L3,
Rotating field control 2 L1-L2-L3 2
L3-L2-L1, L-L-L
Triggering delay
0,1-20s 0,1s
Relay 2

*The restart value can be set on maximum 3% hysteresis from the triggering value.

When a limit value is exceeded the display lights up in red.


Only when the corresponding restart value is reached
again, the display colour changes to green.
The original display dimensions are 32x16mm.

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e l ec t r i ca l o p t IO N S

Modification of the adjusted values

• touch all four contact fields for 1 second to enter the change mode.
• after having completed the modifications select the „House“ icon on the display using the contact fields (the
symbol flashes) and then touch all four contact fields.

Display colour
On delivery, the display is green when swit-
ched on.
After changing the basic setting, the display
is blue.

Contact field

means: touch all four contact fields means: touch the right contact field (to
select the next menu)

means: touch upper and lower contact field (to select


and adjust a value on the display)

S1: Selecting the mains form


Note: select the setting “3P“ also for mains with neutral conductor.

S2: Selecting the nominal voltage

S3:  Setting the delay times


for relay 1 (releases at S4, S5, S6) and relay 2 (releases at S7).

continued on next page

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S4: Setting the limit values for undervoltage release


S5: Setting the limit values for excess voltage release
S6: Setting the limit values for phase imbalance
Function only for three-phase networks available.

S7: Setting the rotating field control


Function only for three-phase networks available.

11.5.2 Second Power Supply

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

© STULZ GmbH – all rights reserved EN/04.2017 3


e l ec t r i ca l o p t IO N S

11.5.3 Manual override board

The manual override board is located in the E box and is used for the manual control of components in the
event of a controller failure. With the help of this board, 4 digital outputs and 3 analog outputs can be oper-
ated manually. If the A/C unit is equipped with a damper, a timer in the E-box ensures the delayed start of the
fans, after the damper is opened.
The assignment of the outputs can be set customer-specifically and is documented in the E-plan.

notice
The fan must run for 15 seconds, before the compressor may be switched on.

End the manual control, as soon as the controller is ready for use again by setting all toggle switches into the
„off“ position.

Toggle switches for


digital outputs in „off“
Potentiometers for
position
analog outputs

The image shows the


board in the delivery
condition, all toggle
switches for the digital
outputs are switched off.

4 EN/04.2017 © STULZ GmbH – all rights reserved


e l ec t r i c a l o p TIO N S

Wiring diagram of the circuit board

© STULZ GmbH – all rights reserved EN/04.2017 5


cy b e r a i r 3 p r o c w 2 o r i g i n a l i n s t r u c t i o n s

STULZ Top Service – More than


just quick emergency assistance

Technical Manage-
Advice Maintenance Implementation Test Center Climate Customized Service-Portal
ment Facility

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