CWC-S

Custom Air Handling Unit

Installation, Operation and Maintenance Manual
DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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,
specialising in A/C for data centres and telecommunica-
tions installations.
STULZ has ten production plants (2 in Germany, Italy, the
USA, Great Britain, Spain, 2 in China, Brazil and India)
and twenty subsidiaries (in Germany, France, Italy, Great
Britain, Belgium, Brazil, the Netherlands, New Zealand,
Mexico, Austria, Poland, Spain, Singapore, China, India,
Indonesia, South Africa, Sweden, Australia and the USA).
Editor
The company also co-operates with sales and service
partners in over 140 other countries, and therefore boasts
STULZ GmbH
an international network of air-conditioning specialists. Holsteiner Chaussee 283
22457 Hamburg

EN/11.2022 © STULZ GmbH – all rights reserved

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Contents
1. Safety .......................................................................................................................................... 4
1.1 Marking ............................................................................................................................................ 4
1.1.1 Safety signs .............................................................................................................................. 4
1.2 Intended use .................................................................................................................................... 4
1.3 Safety instructions............................................................................................................................ 5
1.4 Duties of the operator ...................................................................................................................... 5
2. Transport / Storage .................................................................................................................... 6
2.1 Delivery of units ............................................................................................................................... 6
2.2 Transport .......................................................................................................................................... 6
2.2.1 Transport with forklift ................................................................................................................ 7
2.2.2 Transport with crane ................................................................................................................. 7
2.3 Storage ............................................................................................................................................. 8
3. Description ................................................................................................................................. 9
3.1 Air Handling Unit Design .................................................................................................................. 9
3.1.1 Dimensional drawings .............................................................................................................. 9
3.1.2 Operation ................................................................................................................................ 10
4. Technical data........................................................................................................................... 11
4.1 Operation and storage limits ...........................................................................................................11
4.2 Other data .......................................................................................................................................11
5. Assembly and installation ....................................................................................................... 12
5.1 Requirement for the installation site .............................................................................................. 12
5.1.1 Structure-borne sound insulation ........................................................................................... 12
5.1.2 Space requirements for installation, maintenance and operation ......................................... 13
5.2 Positionning and assembly of the unit ........................................................................................... 14
5.3 Electrical connection ...................................................................................................................... 19
5.4 Air connections............................................................................................................................... 22
5.5 Cooling coils connection ................................................................................................................ 22
5.6 Condensate drain connection ........................................................................................................ 23
6. Commissioning ........................................................................................................................ 24
6.1 Coil filling ........................................................................................................................................ 24
6.2 Unit powering up ............................................................................................................................ 26
6.3 Unit starting from controller ............................................................................................................ 27
7. Maintenance ............................................................................................................................. 28
7.1 Safety instructions.......................................................................................................................... 28
7.2 Periodic maintenance .................................................................................................................... 28
7.3 Air fillers ......................................................................................................................................... 30
7.4 Water coils...................................................................................................................................... 31
7.5 EC fans .......................................................................................................................................... 31
7.6 Unit housing ................................................................................................................................... 33
8. Dismantling and disposal ........................................................................................................ 34
9. Troubleshooting ....................................................................................................................... 35

EN/06.2023 © STULZ GmbH – all rights reserved 3

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1. Safety
1.1 Marking

1.1.1 Safety signs

threatening danger, grievous bodily harm and death

dangerous situation, grievous bodily injury

dangerous situation, light bodily injury

Materials damage, important information and application notice

risk of damaging electronical components

1.2 Intended use

The DATA HALL unit must only be used for air conditioning of data centers or rooms that are not
intended to receive public.

It includes:
• filtering normally polluted air.
• air cooling.
• air dehumidifying.

Proper use also includes observance of the operation manual and instructions from the
manufacturer of the individual components, as well as the inspection and maintenance intervals
stipulated by STULZ.

Any use other than that described above is considered improper. If necessary, check if your units
are suitable for your intended purpose and application. The manufacturer/supplier is not liable for
any damages arising from improper use. The user alone bears the risk.

Misuse particularly includes:

• Conveying any other gases except air.
• Conveying steam or water.
• Coarse filtering and/or filtering any other media except air.
• Chopping up or reducing size of materials.
• Drying out clothing.
• The unit is not suitable for handling abrasive media.

4 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.3 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.

• Works have to be carried out by competent staff only.

• Safety devices may not be bypassed.

1.4 Duties of the operator

The operator must ensure that all maintenance, inspection and assembly work is carried out by
authorized 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 authorized by STULZ are an aid to safety.

EN/06.2023 © STULZ GmbH – all rights reserved 5

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2. Transport / Storage
2.1 Delivery of units

The CWC unit unit is delivered packed with heat shrinkable plastic film in separated modules as
indicated in the unit drawing. Modules must be assembled together following the instructions of
the part 5. Assembly and installation.

If you use a cutting tool (e.g. cutter) to remove the package, take care not to damage the
unit (scratching).

When delivery is accepted, check the unit against the consignment papers for
completeness and for external damage and record it on the consignment note in the
presence of the freight forwarder.
• You receive the consignment papers with the delivery of the Air Handling unit.
• The shipment is made ex works, in case of shipment damages, please assert your claim
towards the carrier.

2.2 Transport

Mortal danger by crushing

A defective lifting device can lead to the uncontroler fall of the air handling unit.
Do not stay under suspended loads!

Only individual module shall be lifted.

Transporting the unit completely assembled or several modules assembled together can
lead to the uncontrolled fall of the unit and/or serious damages on the unit or objects
around the unit.

Service doors must always be closed during transport.

6 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2.2.1 Transport with forklift

Each module is provided with openings on the baseframe to introduce the forks of forkslift. The
transport procedure is as following:

• transport the unit on the pallet as close as possible to the installation site.
• remove the sheets which cover the cut-outs for the forklift. (2 screws each).
• Introduce the forks in the openings, making sure the forks croos the whole baseframe.
• lift the unit with a forklift.
• remove the pallet.
• put the unit with the forklift in final position and remove the forks from the baseframe.
• fasten the sheets on the cut-outs again.

Introduce the forks carefully to avoid any damage on the unit.

2.2.2 Transport with crane

Modules of the CWC unit units are provided with lifting eyes so that they can be moved using
lifting devices with belts or ropes.
In order to ensure a safe craning of the units, instructions here below must be followed:
• Mount appropriate shackles on the lifting lugs on the base frame.
• Use crossbeams with the appropriate width to prevent the sling to rub against the unit.
• With weatherproof units, make sure the protruding parts of the roof are not damaged by the
lifting gear.
• Do not lift any other loads together with the module which is to be transported.

Crossbeams Detail of the attachment system

Eyebolt dimensions:

W = 40 mm

Ø = 34 mm

Individual module
Lifting gear

For transportation of modules, make sure that lifting gear is attached to all eyebolts of the
baseframe.

EN/06.2023 © STULZ GmbH – all rights reserved 7

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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:
• Make sure that the water connections are provided with protective hoods. If the intermediate
storage exceeds 2 months; we recommend filling the pipes with nitrogen.
• Storage conditions should be in accordance with the table of point 4.1 Operation and storage
limits.
• The unit should be stored packaged to avoid the risk of corrosion especially of the heat
exchanger fins.

8 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

3. Description
3.1 Air Handling Unit Design

3.1.1 Dimensional drawings

CWC unit – dimensional drawing

EN/06.2023 © STULZ GmbH – all rights reserved 9

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

The drawing of your unit is sent with the order and on demand, contacting Stulz sales
department.

3.1.2 Operation

The unit is equipped with a controller that ensures optimum operation.

In particular, from the controller display, following actions can be performed:
• Start/stop the units.
• Change temperature setpoints.
• Adjust PID parameters.
• See status of all the components.

For more information on controller handling, refer to the specific user manual.

10 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

4. Technical data
4.1 Operation and storage limits

• Return air conditions

Lower limit Upper limit
Temperature 20ºC 45ºC

• Storage conditions
Lower limit Upper limit
Temperature -10ºC 50ºC
Humidity Dry, non-condensing atmosphere

• Supply voltage

Voltage See wiring diagram of the unit

Voltage tolerance ± 10%
Frequency tolerance ± 1%

• Chilled water conditions

Lower limit Upper limit
Water pressure 10 bar
Water temperature 5ºC

4.2 Other data

Refer to the order-related documentation for the specific configuration of your CWC unit (unit
drawing, electrical diagram, technical data sheets).

EN/06.2023 © STULZ GmbH – all rights reserved 11

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5. Assembly and installation

5.1 Requirement for the installation site

The CWC unit is designed to be installed on a level foundation (concrete base or steel beam).

Uneven or insufficient foundation or a bad positioning of the unit on the foundation

can lead the unit to overturn.
See foundations requirements for a correct installation.

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

• The base on which the unit is to be installed must be level, flat and of adequate load-bearing
capacity.
• The whole baseframe of the unit must rest on the base and make full surface contact with it.
• The minimum height of the base must correspond to the siphon height (for siphon calculation
see 5.4 Cooling coil connection).
• Children, unauthorized persons and animals may not have access to the installation site of the
A/C.
• Take into account the necessary clearances for the maintenance and the air flow (see 5.1.2
Space requirements for installation, maintenance and operation).

5.1.1 Structure-borne sound insulation

In order to insulate the supporting structure from the vibrations produced by the unit, it is
recommended to use suitable anti-vibration mounts, such as rubber strip.

Unit’s baseframe

Vibration
absorber

Steel beam

Concrete base

Installation on concrete base Installation on steel beam

Vibration absorber must be installed according to the instructions of the manufacturer.

12 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.1.2 Space requirements for installation, maintenance and operation

The unit must be accessible from the front and from the sides for maintenance and installation
purpose.
The recommended minimum clearance is indicated on the drawing below.
1000

Clearance

1000

Clearance Clearance

500 1000
Clearance

Recommended installation and maintenance clearance

EN/06.2023 © STULZ GmbH – all rights reserved 13

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.2 Positionning and assembly of the unit

Modules are delivered as shown on the images below.

Bottom module at delivery Top module at delivery

Before assembled the modules together, check that a rubber strip is installed to ensure a correct
tightness between 2 modules (installed in factory).

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.

14 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

The assembly procedure is as following.

Step 1: opening Victaulic coupling

Piping of bottom module are connected to top module piping through Victaulic coupling system.
Before positioning top module on bottom module, Victaulic coupling must be opened,
untightening the nuts of the flanges mounted on the pipes of top module as indicated on the
image below.

Victaulic coupling flange :

untighten nuts before
positioning top module

Openings for pipes of the

bottom module.

Top module – inlet water circuit

Top module – outlet water circuit

Detail of Victaulic flange

EN/06.2023 © STULZ GmbH – all rights reserved 15

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Step 2: positioning top module on bottom module

• Transport top module with a suitable lifting gear (see chapter 2.2 Transport) and place above
the bottom module.
• Move down carefully the top module until the water pipes of the bottom module pass through
the floor panels.
• Put the blue rubber ring on the joining pipe (attached to the water piping in top module)

Detail A Detail B

Joining pipe
Inlet Outlet

Top module positioning Modules in final position

Top module

Rubber ring

Joining pipe

Bottom module

Detail A – water inlet pipe Detail B – water outlet pipe

• Put the top module in its final position, making sure the pipes of the bottom module enter into
the Victaulic couplings as indicated below.

Align the centerlines of the two grooved mating component

ends and bring them to within the appropriate pipe-end
separation dimension. Slide the gasket into position and center
it between the groove of each mating component
NOTE: Verify that no portion of the gasket extends into the
groove of either mating component.

Position the top module very carefully to avoid damages in panels or piping

16 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Step 3: Securing Upper/lower modules

All the required parts for the on-site assembly are supplied with the unit. In case there is one part
missing, contact Stulz sales department.

Necessary parts
• Hex tapping screw DIN 7976, A2 stainless steel, 8,0 x 25 mm.

Assembly sequence
• Insert a screw in each hole of the profiles of the lower module, passing it first through the
intermediate baseframe.
• Secure the screw with a wrench.

Upper module

Intermediate baseframe

Lower module

Assembly of upper / lower modules

EN/06.2023 © STULZ GmbH – all rights reserved 17

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Step 3: Closing the Victaulic coupling

JOIN MATING COMPONENTS

Align the centerlines of the two grooved mating component
ends and bring them to within the appropriate pipe-end
separation dimension. Slide the gasket into position and
center it between the groove of each mating component
NOTE: Verify that no portion of the gasket extends into the
groove of either mating component.

TIGHTEN NUTS
Using an impact tool or a standard socket wrench with a
deep-well socket, tighten the nuts evenly by alternating
sides, maintaining nearly uniform bolt pad gaps, until metal-
to-metal contact occurs at the bolt pads. Verify that the oval
neck of each bolt seats properly in the bolt holes.
DO NOT continue to tighten the nuts after the visual, metal-
to-metal bolt pad inspection requirement is achieved.
If you suspect that any hardware has been over-tightened
(as indicated by a bend in the bolt, bulging of the nut at the
bolt pad interface, or damage to the bolt pad, etc.),
the entire coupling assembly shall be replaced immediately.

Oval neck of bolt seated properly Oval neck of bolt not seated properly

VISUAL INSPECTION
Visually inspect each bolt pad location at every joint to verify that metal-to-metal contact is
achieved across the entire bolt pad section.

18 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.3 Electrical connection

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.

Power supply connection

The power supply system on site and the pre-fuse must be designed for the total current of the
unit (see data sheet).
Make sure that the power supply corresponds to the indications on the rating plate and that the
tolerances according to the “Operation limits” are not exceeded.
The asymmetry of phase between the conductors may amount to 2% maximally.
To determine the asymmetry of phase measure the voltage difference between the phase
conductors (L1-L2, L2-L3, L1-L3) and calculate the average value of the measured voltages. With
a voltage supply of 400V, the maximum deviation to the average value of the voltages may not
exceed 8 V.

Make sure that the phase rotation is correct, the rotating field must turn right!

Power supply cable connecting

Cable cross section must be chosen according to electrical data of the unit (available in the
technical data sheet on request) and adapted to local requirements, laying and cable length.
The insertion point for supply power and external data cables is on the side of the unit.
Cables must be introduced into the electrical box through the cable glands on the side of the unit.

EN/06.2023 © STULZ GmbH – all rights reserved 19

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Top module

Detail of cable glands

Bottom module

Power and data cables insertion

Cables must be connected to the corresponding terminal of the e-box according to the wiring
diagram of the unit.

Inter-modules connection

Top and bottom modules must be electrically connected (power and signal) using the cable
harnesses in the electrical and control boxes.
Each cable is provided with a connector and duly labelled for an easy and safe connection.
Drive the harnesses from one electric box to the other through the openings in the bottom and top
of the boxes and connect the harnesses to their matching sockets.

The éléments of the inter-modules connection are shown on the pictures below

20 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Connector for power lines

Electrical box – Top module Connector for data lines

Openings for
passage of cables

Sockets for power lines

Electrical box – Bottom module Sockets for data lines

EN/06.2023 © STULZ GmbH – all rights reserved 21

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.4 Air connections

Ductwork must be installed by qualified staff.

Ductwork must have independent supporting devices.

The Data Hall unit cannot be used for supporting the ductwork.

Units are equipped with frame on the air inlet/outlet where the duct must be fixed.
In order to avoid the transmission of noise to the structure, the connection between the unit and
ductwork must be free of tensions, using flexible duct connectors.
The length of the flexible duct connection once mounted must always be smaller than its
maximum length.
Dimensions of the duct connection frames are indicated on the units drawing.

5.5 Cooling coils connection

Coils are to be connected to a chilled water production system through Victaulic flanges installed
on the water inlet and outlet pipes.
Connection points location and details are indicated on the unit drawing (available on demand
contacting your STULZ representative).

Before connecting the unit to the external system,

Pay attention to the following points when connecting the external system:
• Rinse thoroughly water lines of the external system to remove possible particles or dirt.
• It is recommended to install a 20 mesh stainless steel strainer (865 micron opening size) in the
supply line. The strainer screen should be cleaned periodically.
• Chilled water lines should be insulated to prevent condensation from forming on the pipes.

Make sure the external system lines don’t put mechanical stress on the connection.

22 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.6 Condensate drain connection

Each condensate tray drain must be provided with a siphon and connected separately to the local
wastewater system (see siphon calculation here below).
Each tray is provided with a pipe ending with an 1” ½ external thread.
Drain connection points location and details are indicated on the unit drawing (available on
demand contacting your STULZ representative).
Siphon calculation
Siphons installed on the condensate drain must fullfil the requirements indicated on the sketch
below.

The siphon height H (in mm) must be greater than

the max. negative or positive pressure P (in Pa)
inside the unit.
P (Pa)
H ሺmmሻ=
10
The difference in height between the unit outlet
and the siphon overflow should also be equal to H
(in mm).

Siphon characteristics

In order the siphon work properly, do not connect several water outlets to the same
siphon.

EN/06.2023 © STULZ GmbH – all rights reserved 23

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6. Commissioning

The unit must be installed and connected in accordance with the chapter 5. Assembly and
installation before initial commissioning. siphon.

Commissioning have to be carried out by qualified staff, properly trained for this type
of unit.

6.1 Coil filling

• Check whether you need an anti-freezing agent.

If you need to add an anti-freezing agent, performances of your chilled water coil might be
slightly reduced. Consult STULZ for more information.

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

24 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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.

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.

Filling and venting the water coils

The system must be filled with the fluid named in the design data sheet to the correct
concentration.
Fill the chilled water circuit and bleed air from the circuit using the venting valve located on the
highest point of the cooling coil (or open a separate one in another point of the water circuit).

Venting screw

Coil venting and draining Draining valve

It is important to remove all the air inside the water circuit to avoid any reduction of coil
performances.

EN/06.2023 © STULZ GmbH – all rights reserved 25

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6.2 Unit powering up

• Make sure that the master switch is off and the unit is de-energized.
• Open the electrical box door of the unit.
• 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.
• Check the settings of the power switches according to electrical data sheet (part of the unit
documents).

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.

• Switch on the control-circuit fuses and the power switch of the fan
• Close the E-box and all doors of the Air Handling Unit.
• Switch on the power supply for the unit.
• Switch on the A/C unit at the master switch.
• Make sure that the heat rejecting system (chiller) is operating.

26 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6.3 Unit starting from controller

Once the unit is powered up according to 6.1 Unit powering up, the controller is supplied with
power and can be used for adjustments.

• Familiarize yourself with the operation of the unit controller with the separate manual.
• Adjust the desired return/supply air temperature at the controller.
• Start the CWC unit pressing the Start/Stop button.
• When the unit is ready to start, fans start.
• Check the measured values of the temperature/humidity sensors (outdoor, return and supply
air).

EN/06.2023 © STULZ GmbH – all rights reserved 27

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7. Maintenance
7.1 Safety instructions

All maintenance work has to be carried out under strict compliance with the country-specific
accident prevention regulations. In particular we refer to the accident prevention regulations for
electrical installations, refrigerating machines and equipment. Non-compliance with the safety
instructions can endanger people and the environment.

Maintenance work is only to be carried out on the units by authorized and qualified specialist
staff.

Procedure instructions
• Carry out work on the system only when it is shut down.
• Switch off the unit at the controller and 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 Periodic maintenance

Activity Action if required Maintenance interval
DAMPERS
Check for contamination, damage
Clean / repair. 6 months
and corrosion.
Check mechanical function. Repair. 6 months
Check actuators. Repair / replace. 6 months

s
AIR FILTERS
When filter alarm is displayed and at
Replace
least every 6 months.
Check for damage, corrosion and
Replace the filter(s) if needed. 3 months
odors.

COILS
Check for contamination, damage
Clean / repair. 6 months
and corrosion.
Check Drip tray (cooling and
Clean. 6 months
evaporator coils).
Check water inlet/outlet (water
Clean. 6 months
coils).
Check Siphon function and water
level of siphon (Cooling and Clean / top-up. 6 months
evaporator coils).
Check flow control valves (water
Clean / repair / replace. 6 months
coils).

28 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Activity Action if required Maintenance interval

EC FANS
Check Blades and housing for
contamination, damage and Clean / replace. 6 months
corrosion.
Check impeller for
wear/deposits/corrosion and Clean / replace. 6 months
damage.
Check bearings for noise. Replace. 6 months
Recommended every 6 months or in
Vibration test. Clean / rebalance impeller / replace.
case of abnormal noise.
For more information, consult the specific fan manual, available on request.

UNIT HOUSING
Check for contamination,
Clean / repair. 12 months
damage and corrosion.
Check for water formation
Clean / determination of cause. 12 months
(condensation, leaks).
Check function of drains. Clean. 12 months
Check flexible connections for
12 months
leaks.

ELECTRICS
Retighten electrical connection. 12 months

EN/06.2023 © STULZ GmbH – all rights reserved 29

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7.3 Air fillers

Filters are equipped with a pressure switch. When the maximum allowed differential pressure
across the filter is exceeded because of clogging an alarm message is showed on Controller’s
display and filters must be replaced.

Procedure for filters replacement

Filters are accessible from the front side of the unit, behind the fans.
• Open the access door to the filters (Fan doors).
• Open clamping device.
• Remove the filters to be changed pulling them out of the frame individually.
• Clean filter seals, check and replace damaged seals as needed.
• Put new filters.
• Close clamping device.
• Close access door

Coil venting and draining

30 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7.4 Water coils

Plate-fin heat exchangers are static elements inside the unit and there is no special maintenance
required.

It’s necessary keep coils clean in order to ensure its capacity is maximum.

The fins can be cleaned using:

• Compressed air, directing the airstream against airflow direction and perpendicularly to the fins.
• Low pressure Hot water, eventually adding neutral soap, to avoid any damages or corrosion
troubles.
• Vacuum extraction.
Condensate pans (cooling coils only) must be cleaned with a neutral soap.

7.5 EC fans

To make sure all electronics components are de-energized, after disconnecting main
power supply wait 5 minutes before opening the device.
The electronics housing of the fan motor can get hot.

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

Vibration test procedure (recommended every 6 months)

• Place vibration sensors on the motor support plate as indicated on the drawing here below.

1: vibration sensor towards

motor’s axis of rotation.

2: vibration sensor perpendicular

1
2 to motor’s axis of rotation.

Positionning of the accelerometer

• Check vibration severity is lower than 3.5 mm/s.

Cleaning fans
Use a soft cloth and water with a neutral soap to clean the fan (housing, impeller).

Do not use high pressure water to clean the device.

Do not use alkaline or corrosive substance to clean the device.
Do not use any pointed or sharp-edged objects for cleaning.

EN/06.2023 © STULZ GmbH – all rights reserved 31

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Replacing fans

We recommend to perform this operation between two persons.

The fan replacement procedure is as following :

1. Switch unit power OFF at the main electric box and lock the electric box door to prevent
accidental unit activation while servicing the unit.
2. Disconnect power and data cables from the fan.
3. Disconnect the pressure tubes from the fan.
4. Remove the cable ties to free the cables.
5. If the new fan is not provided with a guard grille, disassemble the guard grille from the fan to
be replaced.
6. Remove the eight nuts securing the fan mounting plate to the door and separate the fan +
plate from the door.

Fan + mounting plate are heavy. Use an appropriate lifting device to handle it.

7. Put the new set fan+plate on the door and secure it with the eight nuts.
8. Manually spin the fan blade to verify it spins freely.
9. Connect power and data cable to the fan.
10. Connect the pressure tubes to the fan.
11. Fix the cables to the fan mounting frame with cable ties.
12. Close the fan door and If necessary, install the fan grill of the old fan on the new fan.

Fan door

Guard grille
Nut Nut Nut

Mounting plate

Fan
Nut Nut

Power cable

Pressure tube
Nut Nut Nut

Data cables

Fan door - inside Fan door - outside

32 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7.6 Unit housing

Clean the unit casing with a microfiber cloth with lukewarm water (possibly add a neutral soap
solution). If necessary, panels can be removed for replacement.

EN/06.2023 © STULZ GmbH – all rights reserved 33

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

8. Dismantling and disposal

The air handling unit can only be dismantled by qualified specialists.

• Switch off the unit at the controller and the master switch.
• Switch off power conducting cables to the unit and secure them against being switched on
again.
• Disconnect the unit from the de energized network.
• Disconnect the unit from the external water circuit by closing the shut-off valves and drain the
water circuit of the unit.

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

• Move the unit, as described in the chapter “transport”, with a lifting device of sufficient load-
carrying capacity.
• Dispose of the air handling unit in accordance with the disposal and safety regulations
applicable on site. We recommend a recycling company for this.

The unit basically contains the following raw materials:

• Aluminium (profiles, coils).
• Stainless steel (condensing tray).
• Galvanized steel (frames, panels, roof).
• Zinc aluminium (panels).
• Copper (pipelines, wiring).

34 EN/06.2023 © STULZ GmbH – all rights reserved

 DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

9. Troubleshooting
Symptom Probable cause Recommendation

a. Temperature set point too high/low. Adjust to correct temperature setting.

Chilled water valve b. No control power to the chilled water valve. Check wiring diagram and rewire if
fails to open or close required.

c. Actuator failed. Replace actuator.

EC fan(s) fail to start a. Power failure. 1. Check main power source voltage.
2. Check power Input cable.

b. Motor starter protector (MSP) tripped. Reset motor starter protector and check
amperage of motor. Compare to setting on
the motor starter protector and adjust to the
correct FLA if necessary.

c. Control transformer circuit breaker tripped. Check for short circuit or ground fault.
If none, reset circuit breaker.

d. EC fan’s internal overheat protection Determine the cause of the interruption and
interrupted fan motor operation. correct. Possible causes are :
1. Blocked rotor.
2. Low supply voltage > 5 seconds.
3. Loss of phase > 5 seconds.
After causes 1, 2, and 3 are corrected, the
motor will automatically reset.

4. Over-temperature of electronics.
5. Over-temperature of motor.
After causes 4 and 5 are corrected, the
fan(s) must be manually reset by turning off
power for 20 seconds.

e. Defective fan. Repair or replace.

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

Water in the coil Condensate tray is not correctly drained Check that water draining is not blocked.
section

a. Low chilled water flow. Check coil and water piping for leaks.

b. Supply water temperature too high. Check chilled water supply.

System short of Check fans operation
capacity c. Reduced airflow. Check air filters (change them if necessary)
Check dampers

d. Dirty coil Clear coil fins of debris.

s

Most of the possible troubles (not only those of this list) generate an alarm on the controller
display.
You will find a more detailed list of alarm and causes in the controller manual.
In case the actions described in this list is not effective to fix the problem, contact STULZ.

EN/06.2023 © STULZ GmbH – all rights reserved 35

DATA HALL UNIT INSTALLATION, OPERATION AND MAINTENANCE MANUAL

STULZ Top Service – More than

just quick emergency assistance

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

For general inquiries about our products and services, our hotline is available
at +49 40 5585-5000. Our service hours are weekdays from 7 am – 4 pm.

Or directly contact our representative in your area:

STULZ COMPANY CHINA MEXICO SPAIN

HEADQUARTERS STULZ Air Technology and STULZ México S.A. de C.V. STULZ España S. A.
Services Shangai Co., Ltd. Tel. +52 (55) 52 92 85 96 Tel. +34 (91) 517 83 20
STULZ GmbH Tel. +86 (21) 3360 7133 Fax +52 (55) 52 54 02 57 Fax +34 (91) 517 83 21
Holsteiner Chaussee 283 Fax +86 (21) 3360 7138 ventas@stulz.com.mx info@stulz.es
22457 Hamburg info@stulz.cn
Tel. +49 40 5585-0 NETHERLANDS SOUTH AFRICA
Fax +49 40 5585-352 FRANCE STULZ GROEP B. V. STULZ South Africa Pty. Ltd.
products@stulz.de STULZ France S.A.R.L. Tel. +31 (20) 54 51 111 Tel. +27 (0) 11 397 2363
Tel. +33(1)34 8047 70 Fax +31 (20) 64 58 764 Fax +27 (0) 11 397 3945
Fax +33(1)34 8047 79 stulz@stulz.nl aftersales@stulz.co.za
STULZ SUBSIDIARIES
info@stulz.fr
NEW ZEALAND SWEDEN
AUSTRALIA
ITALY STULZ New Zealand Ltd. STULZ SWERIGE AB
STULZ Australia Pty. Ltd.
STULZ S.p.A Tel. +64 (9) 360 32 32 Tel. +46 8 12157550
Tel. +61 (2) 96 74 47 00
Tel. +39(045)633 1600 Fax +64 (9) 360 21 80 info@stulzsverige.se
Fax +61 (2) 96 74 67 22
sales@stulz.com.au Fax +39(045)633 1635 sales@stulz.co.nz
info@stulz.it UK
POLAND STULZ U. K. Ltd.
BELGIUM
INDIA STULZ Polska SP. Z O.O. Tel. +44 (1372) 74 96 66
STULZ Belgium BVBA
STULZ-CHSPL (India) Pvt. Ltd. Tel. +48 (22) 883 30 80 Fax +44 (1372) 73 94 44
Tel. +32 (470) 29 20 20
Tel. +91 (22) 56 66 94 46 Fax +48 (22) 824 26 78 sales@stulz.co.uk
info@stulz.be
Fax +91 (22) 56 66 94 48 info@stulz.pl
info@stulz.in USA
BRAZIL
SINGAPORE STULZ AIR TECHNOLOGY
STULZ Brasil
INDONESIA STULZ Singapore Pte Ltd. SYSTEMS (SATS) , INC.
Ar Condicionado Ltda.
PT STULZ AIR TECHNOLOGY Tel. +65 6749 2738 Tel. +1 (301) 620 20 33
Tel. +55 11 4163 4989
INDONESIA Fax +65 6749 2750 Fax +1 (301) 662 54 87
Fax +55 11 2389 6620
Tel. +62 21 2221 3982 andrew.peh@stulz.sg info@stulz-ats.com
comercial@stulzbrasil.com.br
Fax +62 21 2221 3984
info@stulz.id

EN/06.2023 © STULZ GmbH – all rights reserved 36