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A/C UNITS

MINI-SPACE
380-415/3/50

INDEX 20
Issue 6.05

AIR CONDITIONING PRECISION A/C UNITS

OPERATING INSTRUCTIONS
© STULZ GmbH, Hamburg
E/0605/20/2
Contents Page
1. Safety instructions.................................................................................................. 5
2. Type code .............................................................................................................. 7
3. Description ............................................................................................................ 8
3.1 Design/Refrigeration diagram CCD 41-121 A ............................................... 12
3.2 Design/Refrigeration diagram CCD 171-201 A ............................................. 14
3.3 Design/Refrigeration diagram CCU 41-121 G ............................................... 16
3.4 Design/Refrigeration diagram CCU 171-201 G ............................................. 18
3.5 Application ranges ........................................................................................ 20
4. Technical data ...................................................................................................... 21
4.1 Sound data .................................................................................................... 27
4.2 Electrical connected load .............................................................................. 28
4.3 Unit characteristics, air circuit ........................................................................ 29
4.4 Dimensions ................................................................................................... 34
5. Installation and commissioning............................................................................ 35
5.1 Dismantling and disposal .............................................................................. 44
6. Operation and maintenance................................................................................. 45
7. Causes and elimination of faults .......................................................................... 57
8. Refrigerant piping ................................................................................................ 65
9. Options ................................................................................................................ 74
9.1 Steam humidifier ........................................................................................... 74
9.2 Heating .......................................................................................................... 84
9.3 Raised floor stand ......................................................................................... 86
9.4 Refrigerant circuit option ............................................................................... 89
9.5 Air circuit option ............................................................................................. 92
9.6 Control option .............................................................................................. 107
Appendix ............................................................................................................... 109
Customer service .................................................................................................. 110

E/0605/20/3
These operating instructions are to be read carefully and
complied with before installing and operating the A/C unit.

The male triangular wrench and brief operating instructions


are to be displayed in a visible location in the immediate
vicinity of the A/C unit

It is absolutely essential to comply with the measures listed


in the chapter giving safety instructions.

A/C units of types A, G


have an air conditioning system
which contains refrigerant.

Compressor Phase Rotation!


Both the scroll compressor and fan motor are dependent on correct phase rotation. The scroll compressor and
fan motor will be checked at the factory before dispatch. On site, if the fan rotation (as indicated on the fan
housing) is incorrect, the rotating field of the compressor will also be incorrect. The rotating field must be
corrected by changing two phases of the power supply at the isolator.

E/0605/20/4
1. Safety instructions
General
These operating instructions contain basic information which is to be complied with for installation, operation
and maintenance. They must therefore be read and complied with by the fitter and the responsible trained
staff/operators before assembly and commissioning. They must be permanently available at the place where
the system is used.

Freon 407c refrigerants are used in STULZ A/C units. Refrigerants are volatile, or highly volatile fluorinated
hydrocarbons which are liquefied under pressure. They are incombustible and not hazardous to health when
used as intended.

First aid measures


- If health problems occur during or after handling fluorinated hydrocarbons, a doctor is to be consulted
immediately. The doctor is to be informed that the work involved the use of fluorinated hydrocarbons.
- In the case of acute effects, the casualty is to be brought into the fresh air as quickly as possible.
- The casualty must never to be left unsupervised.
- If the casualty is not breathing, initiate mouth-to-mouth resuscitation immediately.
- If the casualty is unconscious or very dazed he or she must not be given any liquid.
- Splashes of fluorinated hydrocarbons in the eyes can be blown out or fanned out by an assistant.
Then rinse with water.
Notes for the doctor:
Do not give any preparations from the adrenalin ephedrine group (nor any
noradrenaline) to treat shock.
Attain further information from the poison accident centres.

Handling refrigerants
The following measures are to be complied with when handling refrigerants:
- Refrigerants have a narcotic effect when inhaled in high concentrations.
- Safety glasses and safety gloves are to be worn.
- Do not eat, drink or smoke at work.
- Liquid refrigerant must not get onto the skin (risk of burns).
- Only use in well ventilated areas.
- Do not inhale refrigerant vapours.
- Warn against intentional misuse.
- It is absolutely essential to comply with the first aid measures if accidents occur.

Installation of refrigerant systems


It is absolutely essential to comply with the following measures when installing refrigerant systems:
- Pressure-test the system with nitrogen
- Eliminate leaks in refrigerant systems immediately.
- Do not allow refrigerant to escape in to the atmosphere during filling and repair work.
- Ensure extraction or good ventilation in enclosed areas.
- The room is to be evacuated immediately if high concentrations of refrigerant suddenly occur. The
room may only be entered again after adequate ventilation.
- If unavoidable work is required in the presence of a high concentration of refrigerant, breathing
apparatus must be worn. This does not mean simple filter masks. Comply with breathing protection
data sheet.

E/0605/20/5
- The refrigerant is to be extracted before soldering and welding work on refrigerant systems.
- Only carry out welding and soldering work on refrigerant systems without refrigerant in properly
ventilated areas.
- If there is a pungent odour, the refrigerant has decomposed due to overheating. Leave the room
immediately. The room may only be entered after proper ventilation or only with a filter mask for
acidic gases.
- Refrigerants containing FCs contribute to the global warming and must be disposed of in accordance
with the regulations, i.e. only by companies specially qualified under § 191 of the water resources
management law and licensed as recognised disposal companies for refrigerants.

Personnel qualification and training


The personnel responsible for operation, maintenance, inspection and assembly must have the appropriate
qualifications for this work.

Hazards resulting from non-compliance with the safety instructions


Non-compliance with the safety instructions can endanger personnel and the system. Non-compliance with
the safety instructions result in the forfeiture of any claims for damage.

Safety-conscious work
The safety instructions listed in these operating instructions, national regulations in force on accident prevention,
as well as company work, operating and safety instructions must be complied with.

Safety instructions on maintenance, inspection and assembly work


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.
Work on the system is only to be carried out when it is shut down. It is absolutely essential to comply with the
procedure for shutting down the system described in the operating instructions.

Before maintenance work, the A/C unit must be switched off at the master switch and a warning sign displayed
to prevent unintentional switching-on.

The master switch must be checked to ensure the A/C unit is in the de-energized state. The preliminary
measures in the "Installing/commissioning" section are to be complied with before recommissioning.

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.

Unacceptable operating methods


The operating safety of the system is only guaranteed when it is used as intended (see operating instructions,
page 8). The limit values stipulated in the technical data must not be exceeded under any circumstances.

E/0605/20/6
2. 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.

Product range

Blow-out direction
Output of unit
Number of refrigeration circuits
Explanation Type of design

C C D 20 1 A

Unit variants
A,G
1
4, 6, 8, 12, 17, 20
D,U

CC = Compact Clima

Page code

E / 0605 / 20 / 7
Page code:
D - German Page
E - English number
F - French Date of issue Index
U - US English month/year number

E/0605/20/7
3. Description
General
This A/C unit is used for the air conditioning of rooms. It is available in various designs, as described under
method of operation. The A/C unit is to be installed in accordance with the "Assembly/commissioning" section.
The A/C unit is only operated via the controller.

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

Design of an A/C unit


The A/C unit is divided into three areas, an air, water and
electrical section.
Electrical
The evaporator, the expansion valve, the fan and the section
optional electrical heating are housed in the air section.
The air to be cooled is drawn in by the fan and flows Air section
through the evaporator.
All the electronics and electrics to control and monitor
the A/C unit are located in the electrical section. All the
wiring of the A/C unit comes together in the electrical
section and is connected here.
Refrigerant
The compressor, collector, condenser and the G-units as
section
well as various fittings and pressure switches are housed
in the low temperature section.

E/0605/20/8
Basic components/function of refrigerant circuit
The refrigeration circuit of the A/C unit consists of a compressor, a condenser, an expansion valve and an
evaporator. These components are connected by pipelines to a sealed refrigerant circuit. The compressor is
used to compress the refrigerant and maintain the refrigerant flow. The heat of the refrigerant is given up in the
condenser. The expansion valve with pressure compensation is used as a throttling component in the refrigerant
circuit. The evaporator extracts the heat from the air flowing through. All components of the refrigerant circuit
are designed for a maximum operating pressure of 25 bar. On air conditioning units of type A (A-units), the
condenser is not in the A/C unit but located externally.

The heat of the room is absorbed by the gaseous low temperature refrigerant in the evaporator. The gaseous
refrigerant is compressed in the compressor and enters the condenser. The condenser gives up the heat
absorbed and liquefies the refrigerant which is under high pressure. The liquid refrigerant enters the expansion
valve and is from there conducted back to the evaporator at low pressure and low temperature. Thus low
pressure and low temperature prevails in the evaporator whilst high pressure and high temperature exist in the
condenser.

Dehumidifying economy circuit


The A/C units of the upper capacity range (17 and 20 kW) are equipped with a dehumidify-ing economy circuit.
Here approx. one third of the evaporator is switched off via a solenoid valve. As a result the evaporation
temperature of the refrigerant is reduced and the air flowing past the evaporator falls below the dew point. The
moisture contained in the air condenses in the evaporator and is carried away.
At the A/C units of the lower capacity range (4 to 12 kW) a dehumidification is achieved by a reduction of the
air flow. The fan speed can be adjusted manually, a precise description of the function can be found in the
section "operation and maintenance" on page 45.

E/0605/20/9
Method of operation of A/C unit
There are the design types A and G in the MINI-SPACE A/C units, the method of operation is as shown below,
in respect of heat flow:

Method of operation of type A A/C unit


Air conditioned room

The room air drawn in by the fan flows


through the evaporator. In this process heat
is drawn from the room air and given up to
the refrigerant. The refrigerant gives up the
Evaporator Condenser heat to the outside air via an external air-
cooled condenser. The A/C unit and the
external condenser are connected with
A/C unit each other by a sealed refrigerant circuit.
Room air
Refrigerant
Outside air

Method of operation of type G A/C unit The room air drawn in by the fan flows
through the evaporator. In this process heat
Air conditioned room is drawn from the room air and given up to
the refrigerant. The refrigerant gives up the
heat to a water/glycol mixture via a
condenser con-tained in the A/C unit. The
cooling water flows through an air-cooled
Drycooler
external dry cooler which gives up the heat
Evaporator
Condenser to the outside air.

Room air
A/C unit
Refrigerant
Cooling water
Outside air

E/0605/20/10
Air flow
A distinction is made between downflow and upflow A/C units. On downflow units the room air is drawn into the
A/C unit from above and passed down into the raised floor. On upflow units the room air is drawn in from the
front of the A/C unit and passed upwards.

Downflow Upflow

Room air/return air Supply air

Room air/return air

Supply air

Preventative safety devices


The A/C units have various safety devices to avoid malfunctions. A non-return valve is fitted in the liquid line
on A-units which prevents backflow of refrigerant into the condenser. In the liquid line of all units there is a filter
drier, a sight glass and a solenoid valve which shuts off the refrigerant flow when the A/C unit is shut down.

Safety devices
The A/C unit is protected against insufficient operating pressure by a low-pressure switch. If the operating
pressure is fallen below, a warning signal appears on the display and the A/C unit is put out of operation. A
high-pressure switch is triggered at an excessive operating pressure of 24.5 bar and switches off the compressor.
A warning signal on the display of the controller appears. A safety valve is fitted on the collector as the last link
in the chain, which opens at a pressure of 27.5 bar.

E/0605/20/11
3.1 Design of CCD 41 - 121 A
(Downflow)

17

11

19

10

18

16

6 15

5 14
12
13
4 3
7

E/0605/20/12
Refrigeration diagram CCD/U 41 - 121 A

14

13

7 12 to external
11 condenser

10 6 5 4

12

3
8 8
1

15 16

1. Fan 10. Expansion valve


2. Motor 11. Evaporator
3. Compressor 12. Shutoff valve
4. Filter drier 13. Safety valve
5. Sight glass 14. Non-return valve (liquid line)
6. Solenoid valve in liquid line 15. Low-pressure pressostat
7. Collector 16. High-pressure pressostat
8. Schrader valve 17. Temp./humidity sensor (behind elec. compart.)
9. - 18. Master switch
19. Electrical compartment

E/0605/20/13
3.2 Design of CCD 171/201 A
(Downflow)

17

9 11

10

19
1

16

15

5
14

4 7
12
3

E/0605/20/14
Refrigeration diagram CCD/U 171/201 A

14 12

13
to external
condenser
7 8
11

10 6 5 4
9

3
8
Rotalock valve
1
only at CCD/U
201

15 16

1. Fan 10. Expansion valve


2. Motor 11. Evaporator
3. Compressor 12. Shutoff valve
4. Filter drier 13. Safety valve
5. Sight glass 14. Non-return valve (liquid line)
6. Solenoid valve in liquid line 15. Low-pressure pressostat
7. Collector 16. High-pressure pressostat
8. Rotalock valve 17. Temp./humidity sensor (behind elec. compart.)
9. Dehumidifier valve 18. Master switch
19. Electrical compartment

E/0605/20/15
3.3 Design of CCU 41 - 121 G
(Upflow)

16

1
18

10

17
9

15

6 14

5 13
12
4 3
7

11

E/0605/20/16
Refrigeration diagram CCD/U 41 - 121 G

12

7 11 19

10
13

9 6 5 4

3
8 8
1

14 15

1. Fan 11. Shutoff valve


2. Motor 12. Safety valve
3. Compressor 13. Condensor
4. Filter drier 14. Low-pressure pressostat
5. Sight glass 15. High-pressure pressostat
6. Solenoid valve in liquid line 16. Temp./humidity sensor (behind elec. compart.)
7. Collector 17. Master switch
8. Schrader valve 18. Electrical compartment
9. Expansion valve 19. Vent valve
10. Evaporator

E/0605/20/17
3.4 Design of CCU 171/201 G
(Upflow)

16

2
1

8 10
18

15

13
4
7
11
3

E/0605/20/18
Refrigeration diagram CCD/U 171/201 G

12

11 19
7

10
13

9 6 5 4
8

1 20 20 Rotalock
valves only at
CCD/U 201

14 15

1. Fan 11. Shutoff valve


2. Motor 12. Safety valve
3. Compressor 13. Condensor
4. Filter drier 14. Low-pressure pressostat
5. Sight glass 15. High-pressure pressostat
6. Solenoid valve in liquid line 16. Temp./humidity sensor (behind elec. compart.)
7. Collector 17. Master switch
8. Dehumidifier valve 18. Electrical compartment
9. Expansion valve 19. Vent valve
10. Evaporator 20. Rotalock valve

E/0605/20/19
3.5 Application Ranges
The STULZ MINI-SPACE units are provided for - Hot water conditions for optional heating coil:
operation within the following ranges: max. inlet water temperature: 110°C
max. water head pressure: 8.5 bar
- Room conditions:
Between 18°C, 45% R.H. and 27°C, 55% R.H. - Max. length of piping between A/C unit and air
cooled condenser: 30m equivalent.
- Outdoor ambient conditions:
lower limit: -10°C - Max. level difference between condenser and
upper limit: 35°C A/C unit: 3m (when condenser is below the
A/C unit).
- Air flow:
nominal values are listed in the tables - Storage conditions: between -20°C and +35°C
on the pages 21-26.
The warranty is invalidated for any possible damage
- Voltage: or malfunction that may occur during or in
400 +/- 10% consequence of operation outside the application
ranges.
- Frequency:
50 Hz +/- 1%

E/0605/20/20
4. Technical Data CCD/U 41

CCD/U 41 CCD/U 41
A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 4.9/4.6 4.9/4.6
With return air at 22°C/50% RH kW 4.4/4.4 4.4/4.4

Fan
Volume flow m³/h 2000 2000
External pressure D/U Pa 50/40 50/40
Motor nominal output kW 0.37 0.37

Compressor
Model Scroll Scroll
Motor nominal output kW 1.5 1.5
Refrigerant charge R407c l 1.0** 2.4

Condenser
Cooling medium Air 30%Glycol
Model KSV 006 B 10x60
Medium inlet temperature °C 32 39
Medium outlet temperature °C - 45
Volume flow m³/h 2400 1.08
Pressure drop, condenser/CW coil and kPa - 1.1
piping

Control valve - 3-way


Size - 3/4''
Pressure drop, valve kPa - 5.5

Filter
Quality EU4 EU4
Design Filter mat Filter mat
Width/Height/Depth - D mm 640/570/20 640/570/20
Width/Height/Depth - U mm 972/395/20 972/395/20

Electrical reheat (option)


Heating capacity kW 2 2
No of stages 1 1

Steam humidifier (option)


Capacity kg/h 1,5-3,0 1,5-3,0

General unit data


Electrical connection V/-/Hz 380-415/3/50/N 380-415/3/50/N
Weight kg 180 185
Width/Height/Depth mm 600 / 1850 / 600 600 / 1850 / 600
* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/21
Technical Data CCD/U 61

CCD/U 61 CCD/U 61
A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 6.8/6.2 6.8/6.2
With return air at 22°C/50% RH kW 6.2/6.0 6.2/6.0

Fan
Volume flow m³/h 2000 2000
External pressure D/U Pa 50/40 50/40
Motor nominal output kW 0.37 0.37

Compressor
Model Scroll Scroll
Motor nominal output kW 1.9 1.9
Refrigerant charge R407c l 1.0** 2.4

Condenser
Cooling medium Air 30%Glycol
Model KSV 008 B 10x60
Output °C 32 39
Medium inlet temperature °C - 45
Medium outlet temperature m³/h 3500 1.4
Volume flow kPa - 1.8
Pressure drop, condenser/CW coil and
piping
- 3-way
Control valve - 3/4''
Size kPa - 9
Pressure drop, valve

Filter EU4 EU4


Quality Filter mat Filter mat
Design mm 640/570/20 640/570/20
Width/Height/Depth - D mm 972/395/20 972/395/20
Width/Height/Depth - U

Electrical reheat (option) kW 2 2


Heating capacity 1 1
No of stages

Steam humidifier (option) kg/h 1,5-3,0 1,5-3,0


Capacity

General unit data V/-/Hz 380-415/3/50/N 380-415/3/50/N


Electrical connection kg 185 190
Width/Height/Depth mm 600 / 1850 / 600 600 / 1850 / 600
* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/22
Technical Data CCD/U 81

CCD/U 81 CCD/U 81
A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 8.9/8.0 8.9/8.0
With return air at 22°C/50% RH kW 8.0/7.6 8.0/7.6

Fan
Volume flow m³/h 2000 2000
External pressure D/U Pa 50/40 50/40
Motor nominal output kW 0.37 0.37

Compressor
Model Scroll Scroll
Motor nominal output kW 2.5 2.5
Refrigerant charge R407c l 1.0** 2.4

Condenser
Cooling medium Air 30%Glycol
Model KSV 012 B 10x60
Medium inlet temperature °C 32 39
Medium outlet temperature °C - 45
Volume flow m³/h 4300 1.78
Pressure drop, condenser/CW coil and kPa - 2.9
piping

Control valve - 3-way


Size - 3/4''
Pressure drop, valve kPa - 15

Filter
Quality EU4 EU4
Design Filter mat Filter mat
Width/Height/Depth - D mm 640/570/20 640/570/20
Width/Height/Depth - U mm 972/395/20 972/395/20

Electrical reheat (option)


Heating capacity kW 2 2
No of stages 1 1

Steam humidifier (option)


Capacity kg/h 1,5-3,0 1,5-3,0

General unit data


Electrical connection V/-/Hz 380-415/3/50/N 380-415/3/50/N
Weight kg 190 195
Width/Height/Depth mm 600 / 1850 / 600 600 / 1850 / 600
* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/23
Technical Data CCD/U 121

CCD/U 121 CCD/U 121


A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 12.4/11.0 12.4/11.0
With return air at 22°C/50% RH kW 11.5/11.0 11.5/11.0

Fan
Volume flow m³/h 3200 3200
External pressure D/U Pa 50/40 50/40
Motor nominal output kW 0.55 0.55

Compressor
Model Scroll Scroll
Motor nominal output kW 2.9 2.9
Refrigerant charge R407c l 1.0** 2.4

Condenser
Cooling medium Air 30%Glycol
Model KSV 016 B 10x60
Medium inlet temperature °C 32 39
Medium outlet temperature °C - 43
Volume flow m³/h 6800 3.49
Pressure drop, condenser/CW coil and kPa - 11
piping

Control valve - 3-way


Size - 3/4''
Pressure drop, valve kPa - 57

Filter
Quality EU3 EU3
Design Filter mat Filter mat
Width/Height/Depth - D mm 640/570/20 640/570/20
Width/Height/Depth - U mm 972/395/20 972/395/20

Electrical reheat (option)


Heating capacity kW 4 4
No of stages 1 1

Steam humidifier (option)


Capacity kg/h 1,5-3,0 1,5-3,0

General unit data


Electrical connection V/-/Hz 380-415/3/50/N 380-415/3/50/N
Weight kg 200 205
Width/Height/Depth mm 600 / 1850 / 600 600 / 1850 / 600
* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/24
Technical Data CCD/U 171
CCD/U 171 CCD/U 171
A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 17.8/17.0 17.8/17.0
With return air at 22°C/50% RH kW 16.6/16.4 16.6/16.4

Fan
Volume flow m³/h 6000 6000
External pressure D/U Pa 70 70
Motor nominal output kW 2.2 2.2

Compressor
Model Scroll Scroll
Motor nominal output kW 4.4 4.4
Refrigerant charge R407c l 2.0** 3.2

Condenser
Cooling medium 30%Glycol
Model KSV 021 B 25x50
Medium inlet temperature °C 32 39
Medium outlet temperature °C - 45
Volume flow m³/h 6500 3.57
Pressure drop, condenser and piping kPa - 21

Control valve - 3-way


Size - 3/4"
Pressure drop, valve kPa - 59

Filter
Quality EU4 EU4
Design Filter mat Filter mat
Width/Height/Depth - D mm 870/970/20 870/970/20
Width/Height/Depth - U mm 975/650/20 975/650/20

Electrical reheat (option)


Heating capacity kW 2x6 2x6
No of stages 2 2

Steam humidifier (option)


Capacity kg/h 1,5-3,0 1,5-3,0

General unit data


Electrical connection V/-/Hz 380-415/3/50/N 380-415/3/50/N
Weight kg 220 225
Width/Height/Depth mm 1000 / 1850 / 810 1000 / 1850 / 810

* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/25
Technical Data CCD/U 201
CCD/U 201 CCD/U 201
A G
Evap. cool. capacity (total/sensible)
With return air at 24°C/50% RH kW 22.6/20.9 22.6/20.9
With return air at 22°C/50% RH kW 20.7/20.1 20.7/20.1

Fan
Volume flow m³/h 7000 7000
External pressure D/U Pa 70 70
Motor nominal output kW 2.2 2.2

Compressor
Model Scroll Scroll
Motor nominal output kW 5.5 5.5
Refrigerant charge R407c l 2.0** 3.4

Condenser
Cooling medium 30%Glycol
Model KSV 036 B 25x50
Medium inlet temperature °C 32 39
Medium outlet temperature °C - 45
Volume flow m³/h 13600 4.34
Pressure drop, condenser and piping kPa - 31

Control valve - 3-way


Size - 3/4"
Pressure drop, valve kPa - 88

Filter
Quality EU4 EU4
Design Filter mat Filter mat
Width/Height/Depth - D mm 870/970/20 870/970/20
Width/Height/Depth - U mm 975/650/20 975/650/20

Electrical reheat (option)


Heating capacity kW 2x6 2x6
No of stages 2 2

Steam humidifier (option)


Capacity kg/h 1,5-3,0 1,5-3,0

General unit data


Electrical connection V/-/Hz 380-415/3/50/N 380-415/3/50/N
Weight kg 230 235
Width/Height/Depth mm 1000 / 1850 / 810 1000 / 1850 / 810

* The electrical power consumption of the fan is to be added to the room load.
** only with running test, otherwise with protective nitrogene filling

E/0605/20/26
4.1 Sound data

Sound level in dB (A)

Unit size CCD CCU Upflow

2000
41 A/G 45 47
M
1000
61 A/G 45 47

81 A/G 45 47

121 A/G 48 50

171 A/G 55 57

201 A/G 57 59 Downflow

2000

M
1000

The data 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
standard unit. The values are due to the noise, which is emitted through the suction opening and the unit
casing.
The noise which is emitted through the discharge opening is not taken into account. It is presupposed that the
discharge noise is muffled by appropriate measures in the raised floor (downflow units) or in the discharge duct
(upflow units).
The data for the upflow units are intended for a mounted discharge duct.
The sound levels stated can be further reduced by suitable attenuation measures determined by individual
site conditions.

E/0605/20/27
4.2 Electrical connected loads
380-415V / 3Ph / 50Hz

Components CCD/U CCD/U CCD/U CCD/U


41 61 81 121
max. current consumption [Amp]
A/G A/G A/G A/G
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
1~ — 3,3 — — 3,3 — — 3,3 — — 5,5 —
3~ 3,3 3,3 3,3 4,3 4,3 4,3 5,9 5,9 5,9 7,3 7,3 7,3
2~ 3,2 — 4,8 3,2 — 4,8 3,2 — 4,8 8,0 — 8,0
1~ — — 12,7 — — 12,7 — — 12,7 — — 12,7

3,3 6,6 3,3 4,3 7,6 4,3 5,9 9,2 5,9 7,3 12,8 7,3
6,5 6,6 8,1 7,5 7,6 9,1 9,1 9,2 10,7 15,3 12,8 15,3
3,3 6,6 16,0 4,3 7,6 17,0 5,9 9,2 18,6 7,3 12,8 20,0

Components CCD/U CCD/U


171 201
max. current consumption [Amp]
A/G A/G

5,1 5,1
12,3 13,4
6 kW 8,7 8,7
2x6 kW 17,3 17,3
4,2 4,2

18,4 19,5
6 kW 27,1 28,2
2x6 kW 35,7 36,8
23,6 24,7

Key: Fan Compressor El. heater Steam humidifier

E/0605/20/28
4.3 Unit characteristics, air circuit
Design example for the fan speed
The units CCD/U 41-121 have a fan which is directly driven by a
motor without a v-belt. The speed and thus the air flow can
exclusively be modified by the speed controller (see page 46).

By means of this example it is explained how the fan speed and


power requirement at the shaft are determined from the fan curve for
a CCD 201 A/G A/C unit.

Given: (A) Air volume 5000 m3/h


(B) p external 75 Pa

Required: (D) Pressure loss of the unit


(E) Overall pressure loss
(F) Fan speed
(G) Power requirement at the shaft

PROCEDURE:

Establish the intersection point (C) of the air volume (A) and the unit
characteristics and determine the pressure loss of the unit:

determined value (D) = 240 Pa

Add the Pressure loss of the unit (D) and the external pressure (B):

(D)+(B)= (E)

determined value (E): 240 + 75 = 315 Pa

The operating point (H) is at the intersection point of air volume (A)
5000 m3/h and the overall pressure loss (E) 315 Pa.

Read off the fan speed (F): 800 rpm

Read off the power requirement at the shaft (G): 0.62 kW

E/0605/20/29
Unit characteristics, air circuit for CCD/U 41-81
(unit characteristics = internal pressure drop in unit) RPM
SP [Pa]
1500
1450

1400
500
1350
1300

1250
1200
1150

400 1100
1050

300

200

mA

5000

4500

4000
100
3500

3000

2500

2000

0 1500
0 1000 2000 3000 Q[m³/h]
0 100 200 300 Pd[Pa]

Factor for dynamic pressure: Downflow = 1.6, Upflow with duct connection = 1.0

E/0605/20/30
Unit characteristics, air circuit for CCD/U 121
(unit characteristics = internal pressure drop in unit)

SP [Pa] RPM
400 1000

950

900

850

800
300

750

Input W
1200

1100

1000

900
200
800

700

600

500

400

mA
6000

100 5500

5000

4500

4000

3500

3000

2500

0 2000
0 1000 2000 3000 4000 Q[m³/h]

0 100 200 300 400 500 600 700 Pd[Pa]

Factor for dynamic pressure: Downflow = 1.6, Upflow with duct connection = 1.0

E/0605/20/31
Unit characteristics, air circuit for CCD 171/201
Fan size: AT 12 - 12
(unit characteristics = internal pressure drop in unit)

Characteristic curve : Air flow range: 3500 - 7500 m³/h

E/0605/20/32
Unit characteristics, air circuit for CCU 171/201
Fan size: AT 12 - 12
(unit characteristics = internal pressure drop in unit)

Characteristic curve : Air flow range: 3500 - 7500 m³/h

E/0605/20/33
4.4 Dimensions
(in mm)
CCD/U 41-121

1850

220
600
600
CCD/U 171/201
1850

370 810
1000

E/0605/20/34
5. Installation and commissioning
Delivery of units
Stulz A/C units are mounted on pallets and packed several times in plastic film. They must always be transported
upright on the palettes.

Construction of protective covering The following information can be found on the packing.
(from inside to outside) 1) Stulz logo
2) Stulz order number
1. Neopole cushioning 3) Type of unit
2. Shrink film 4) Packing piece - contents
3. Additional board in container 5) Warning symbols
shipments
also upon request
6) Gross weight
7) Net weight
8) Dimensions
9) Customer order number
10) Additional customer requirements
When delivery is accepted, the unit is to be checked against the delivery note for
completeness and checked for external damage. The delivery note can be found on the A/
C unit when delivered.

Space required for unit installation


All assembly and maintenance work can be carried out from the front of the A/C unit once the units have been
installed. Observe the clearance required for maintenance as shown below.
1300 mm

1500 mm

700 mm

1100 mm

CCD/U 41 - 121 CCD/U 171/201

E/0605/20/35
Pipelines and cable conduits
All pipelines and electric cables are to be routed through the six openings in the right-hand side-panel of the
unit types 41-121 or six openings in the left-hand side panel of the unit types 171/201. The pipes to be
connected must be soldered on A-type units. On all other versions of the units the pipe connection is designed
as a screwed pipe connection.

CCD/U 41 - 121 A

Unit D3
41 A 285
61 A 285
81 A 285 pressure line
121 A 290
liquid line

D3
condensate line
215

320
295

300

340
H
H
CCD 280 View from behind
50
CCU 170

210

Pressure line Liquid line

CCD/U CCD/U CCD/U


41-81 121 41-121
O 12 16 O 10

E/0605/20/36
CCD/U 171/201 A

pressure line

liquid line

D3

165

150 D2
75
condensate line
D1

Front view

Unit D1 D2 D3
171 A 550 285 270
H 201 A 575 65 525
H CCD 350
CCU 160
50

210
View from behind

50 32
Pressure line Liqid line x x
2 4
CCD/U
70

CCD/U 171-201
171 201
120

O 16 22 O 16

55 70 70

E/0605/20/37
CCD/U 41 - 121 G

Unit E1 E2 E3
41 G 170 70 190
61 G 170 70 190
81 G 170 70 190
121 G 120 70 190

A1 A2 A3
41 G 130 70 125
Inlet
61 G 130 70 125
81 G 130 70 125
121 G 140 65 120 Outlet

E3

A3

E2
A2
condensate line
A1
E1
View from behind

H H
CCD 280
50 CCU 170

210

Inlet/Outlet

Unit D
CCD/U 41-81 22 D
CCD/U 121 28

E/0605/20/38
CCD/U 171/201 G

Inlet

240

120
Outlet
510 175
255
condensate line
600

View from behind

H
H CCD 350
CCU 160
50

210

Inlet/Outlet 50 32
x x
2 4
70

28
120

55 70 70

E/0605/20/39
Installing the A/C unit
Installation sequence

Intake duct 4 Refer to manufacturer's documentation

Louvered flap 3 For assembly, refer to "Louvered flap"


options

A/C unit 2 Described below

Raised floor stand 1 For assembly, refer to "Raised floor


stand" options

Installing the A/C unit


Check the A/C unit to ensure it is complete and not damaged. If the A/C unit is incomplete or damaged, please
contact STULZ customer service.

Transport the complete A/C unit to the installation point.

The A/C unit must only be transported upright.

Transport the complete A/C unit to the installation point or onto the existing raised floor stand (option).

Ensure that all electric cables, condensate-water connections and water connections (on G-units only) are
already routed to the A/C unit or to the individual modules and are ready for connection.

G-Units :
If the water quality is insufficient, we recommend the additional installation of a strainer.
Connect the cooling-water pipes as follows:
Remove the protective caps from the flanges of the water pipes.

Water pipes are only fitted on the G units.

E/0605/20/40
Unit type Thread
41-121 R 1"
171/201 R 1 1/2"

Water remaining from the test run may escape when


the protective caps are removed.

Insert the seals and screw on the flanges of the water pipes.

If any seals have got lost, these may only be replaced


by glycol-resistant rubber seals.

Flanged connection

Insulate the water pipes with the insulating material supplied.

The insulation material required is included with the


respective module as a supplementary pack.

Screw the water pipes of the A/C unit together with the local water pipes
of the dry cooler or the water chiller.
Insulation of water pipes

Fill and bleed the cooling-water circuit.

A filling connection and several schrader valves for


bleeding are fitted to the A/C unit. Refer to refrigeration/
piping diagram.

All Units :
Connect the condensate water drains to the local waste water
33 mm
system.

Comply with the regulations of the local water supply


authority.

E/0605/20/41
A-Units :

Connect the pipelines carrying refrigerant to the external condensor (refer to section on "refrigerant
piping").

The refrigerant-conducting pipelines are only to be connected by an authorised specialist.


Comply with the safety instructions at the start of these operating instructions.

A refrigerant pipe to the external condensor is only


required on A-units.

Connection diameter of the copper pipelines of the A/C unit (in


pressure
mm):
line
Unit types: 41 - 81 121 171 201
Pressure line: 12 16 16 22
Liquid line: 10 10 16 16 liquid line
Fill the refrigerant circuit with refrigerant. (Refer to refrigerant piping
section). For this, the solenoid valve in the liquid line must be
energized (24 V AC).

Position of refrigerant connections

Electrical connection

Ensure that the electric cables are de-energized.


The electric cables are only to be connected by an
authorised specialist.

Route the electric cable into the electrics box from below and connect
them to the master switch in accordance with the wiring diagram
(Appendix).

Electrical connection

E/0605/20/42
Electrical connection
The A/C unit must be installed and connected in
accordance with the chapter on "installation of A/C unit"
before initial commissioning.

Open the electrical compartment door of the A/C unit using the key
provided.

Check whether all power switches and control-circuit fuses in the electrical
section of the A/C unit are switched off.

Power switch OFF

Control-circuit fuses

Master switch

Power switch

Switch on the A/C unit at the master switch.


Electrical compartment
Caution. Electric cables and electrical components of
non calibrated range
the A/C unit are live.

Switch on the control-circuit fuses and the power switches of the fan and
the compressor in sequence as well as the built-in options in accordance
with the wiring diagram. The wiring diagram can be found in the "Appendix".

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.

Power switch ON

E/0605/20/43
If your A/C unit is equipped with additional options,
further measures on initial commissioning are to be
found in the "Options" section.

CompTrol 1002

Switch on the A/C unit at the controller.

Controller C1002
Let the A/C unit operate for approx. 1 hour while paying attention to
any unusual noises.

Check the level of refrigerant in the sight glass on A-type A/C units.

If bubbles are continuously visible in the sight glass,


top up the refrigerant circuit with refrigerant in
accordance with the chapter "refrigerant piping".

G-units are equipped with a sealed refrigerant circuit


in the A/C unit which has been checked and approved
by the factory.

Set the required specified values for room temperature and air humidity
on the controller of the A/C unit. Refer to Controller Manual. Sight glass

5.1 Dismantling and disposal


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

Switch off the A/C unit at the controller and at the master switch.

Disconnect the A/C unit from the de-energized network.

Dispose of the refrigerant in the A/C unit in accordance with the disposal and safety regulations applicable on
site (refer to chapter on refrigerant piping).

If fitted, disconnect the depressurized refrigerant lines, the depressurized cooling water pipes and the condensate
water drainage pipes from the A/C unit.

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 A/C unit basically contains the raw materials aluminium (evaporator), copper
(pipelines, wiring), and iron (panelling, mounting panel).

E/0605/20/44
6. Operation and maintenance
Switching the A/C unit on and off
The A/C unit is only to be switched on when it has been installed in accordance with the
"assembly and commissioning" section, connected correctly and commissioned for the
first time.

The A/C unit is switched on and off by pressing the on/off button
on the controller.
The complete functional sequence of the A/C unit is controlled
and monitored by the controller.
The actual values of room temperature/humidity are shown on the
display when the A/C unit is switched on.
CompTrol 1002

The fan runs on for approx. 3 minutes when the


A/C unit is switched off.

Controller C1002

Switching off the complete A/C unit

The complete A/C unit is switched off via the controller and via
the built-in master switch. To do this, open the electrical
compartment and put the master switch in position "0".

Operating the A/C unit


The A/C unit is operated via the controller. A complete description of the functions of the controller can be
found in the enclosed manual. All alarm and fault signals of the basic A/C unit are also described.

E/0605/20/45
For the operation of the unit variants CCD/U 41 - 121 there is an additional device:

The Fan Speed Control

With the fan speed control you can adapt the fan speed individually to the application domain of the A/C unit.
The speed control is installed in the middle part of the electric box on the terminal strip. You can adjust the fan
speed with two variable resistors which are situated on the printed circuit board of the speed control.
With the variable resistor indicated PHI 1 you adjust the speed for the operation without dehumidification (Non-
dehumidifying speed, N-D speed). With the variable resistor indicated PHI 2 you adjust the speed for the
dehumidification. The speed, adjusted with PHI 2, should be smaller than the N-D speed to make sure that a
dehumidification takes place. Both resistors have got the same range of control from a minimum speed to the
nominal speed.

Consequences, if the speed is too small:

- Icing of the evaporator


- The air flow control can give an alarm.
- Overheating of the electric reheat, the overheat protection is actuated.

Two LEDs on the printed circuit board indicate the state of operation. At a non-dehumidification phase the LED
I1 is illuminated and the fan motor runs at the adjusted speed by PHI 1. At a dehumidification phase the LED
I2 is illuminated and the fan motor runs at the adjusted speed by PHI 2.

adjustable
resistors

LED

Fuse 6A

E/0605/20/46
Maintenance
Safety instructions
All maintenance work is 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.
Maintenance work is only to be carried out on the A/C units by authorised and qualified specialist staff.

Work on the system must always only be carried out when it is shut down. To do this, the
A/C unit must be switched off at the controller and at the master switch. A "DO NOT
SWITCH ON" warning sign must be displayed.

Live electrical components are to be switched to de-energized and checked to ensure that
they are in the de-energized state.

Non-compliance with the safety instructions can endanger people and the environment.
Contaminated parts always result in a loss of performance and, in the case of switching and control units, can
result in the failure of the system.

The built-in filters cannot be washed and the dust cannot be beaten out of them. Therefore
contaminated filters must be replaced regularly, otherwise air output is reduced, energy
consumption increases considerably and the system may fail.

Maintenance measures and intervals


Measure Intervals
in months

General
Checking A/C unit for external damage 12
Cleaning inside of A/C unit and checking for damage 12

Mechanical
Checking fan for satisfactory condition 12
Replacing filter 3
Replacing V-belt 6

Air conditioning
Checking refrigerant circuit 3
Visually inspecting water circuit for leaks 3
Checking compressor for satisfactory condition 3

This table contains all the maintenance measures required for a basic A/C unit. If your A/C unit is equipped
with additional options, the required maintenance measures can be found in the "options" section.
The intervals specified in the table are only reference values, which can vary depending on where the unit is
installed and the degree of contamination.

E/0605/20/47
Maintenance work
Opening the A/C unit

The A/C unit is opened by


opening the electrical
compartment door and by
removing two front panels
The panel in front of the low
temperature section is secured
by ball pins and can be
removed without auxiliary
equipment. To remove the front
panel in front of the air section,
first open the electrical
compartment door using the
male triangular wrench
provided.

All maintenance measures can


be performed from the open
front of the A/C unit.

Checking A/C unit for external damage


- Ensure that the A/C unit is switched on and is in operation.

- Pay attention to unusual noises.

- Check the A/C unit externally for damage, contamination and corrosion.

- Check whether warning information is shown on the display.

E/0605/20/48
Cleaning inside of A/C unit and checking for damage
- Switch the A/C unit off at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Wait until the fan stands still.

- Open the electrical compartment door of the A/C unit using the male
triangular wrench.

- Switch off the A/C unit at the master switch.

- Remove the front panels. Master switch


- Clean the A/C unit with a vacuum cleaner.

- Check the filter for contamination and replace it, if necessary.

- Clean the condensate water tray.

- Clean the fins of the evaporator with a brush.

- Clean the unit components with a cloth.

- Check all built-in unit components for external damage,


contamination and corrosion.
Condensate water tray
- Check the hose connections for damage. Evaporator

- Check the pipeline system for damage.

- Check the cable connections for firm seating and damage.

- Re-install the front panels.

- Switch on the master switch and close the electrical compartment


door.

- Remove the warning sign and put the A/C unit into operation.

E/0605/20/49
Checking fan for satisfactory condition
- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Wait until the fan stands still.

- Open the electrical compartment of the A/C unit using the STULZ
door opener.

- Switch off the A/C unit at the master switch.

- Switch off the power switch of the fan. Master switch

- Remove the front panel in front of the air section.

- Check fan for damage, corrosion and firm seating.

- Turn the fan by hand, checking ease of movement and noting any
running noises from the bearings.

- Check the V-belt for wear and replace it, if necessary.


(only for CCD/U 171/201)

- Check whether the pulleys of the V-belt align.


Aligning the V-belt
- Check the tension of the V-belt. pulleys

The V-belt may yield by a maximum of one V-belt


thickness. The V-belt tension is adjusted by turning the
hexagon shaft on the motor slide.

- Install the front panel in front of the air section.

- Switch on the power switch of the fan.

- Switch on the master switch and close the electrical compartment.

- Remove the warning sign and put the A/C unit into operation.
Tension of the V-belt

E/0605/20/50
Replacing filters
- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Wait until the fan stands still.

- Open the electrical compartment.

- Switch off the A/C unit at the master switch.

- Remove the filters. On a downflow unit the filter is accessible from Master switch
above. On an upflow unit, remove the air section panel in which the
filter is housed.

- Remove contamination from the filter seat.

- Install new filters.

- Re-install the air section panel, if appropriate.

- Switch the master switch on and close the electrical compartment.

- Remove the warning sign and put the A/C unit into operation.
Downflow unit filter

Upflow unit filter

E/0605/20/51
Replacing V-belt (only for CCD/U 171/201)
This measure is only to be performed by an authorised,
trained specialist. We recommend STULZ customer
service.

- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Wait until the fan stands still.

- Open the electrical compartment of the A/C unit.


Master switch
- Switch off the A/C unit at the master switch.

- Remove the air section panel.

- Check the fan by hand for ease of operation.

- Loosen the V-belt by turning the shaft on the motor slide.

- Replace the V-belt.

- Tension the V-belt by turning the shaft on the motor slide.

- Check the tension of the V-belt. Loosening/tensioning


V-belt

The V-belt may yield by a maximum of


one V-belt thickness.

- Check whether the pulleys align.

Remove all tools and repair equipment in the A/C unit.

- Switch on the A/C unit at the master switch.

Caution: Do not reach into the fan when the fan wheel is Aligning the pulleys
running.

! Caution: rotating parts. Do not reach into the V-belt


when it is in operation.

E/0605/20/52
Caution: Current-conducting cables and electrical
components of the A/C unit are live

- Switch on the A/C unit at the controller.

- Check the fan for satisfactory function. Pay particular attention to


running noises from the fan and bearings.

- Switch off the A/C unit at the controller.

- Re-install the air section panel.

- Close the electrical compartment of the A/C unit.

- Remove the warning sign and put the A/C unit into operation.

E/0605/20/53
Checking refrigerant circuit
- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Open the electrical compartment and switch off the A/C unit at the
master switch.

- Remove both front panels.

- Visually inspect the pipelines of the refrigerant circuit for damage.


Sight glass
- Check whether the safety valve has triggered.

Caution: current-conducting cables and electrical


components of the A/C unit are live.

- Switch on the A/C unit at the master switch and at the controller.

- Check the refrigerant quantity at the sight glass during operation.

If bubbles are visible in the sight glass over a long


period, there is insufficient refrigerant in the refrigerant Master switch
circuit.

- Check the pipe connections and connections of the refrigerant circuit


for leaks with leak-detecting spray.

- Switch off the A/C unit at the controller and master switch.

In the case of G-units, the quantity of refrigerant specified


for the unit can be found on the rating plate. If there is
insufficient refrigerant, the refrigerant is to be extracted
and refilled completely.

Location of rating plate

E/0605/20/54
Refrigerant containing fluorinated hydrocarbons damages the
ozone layer and is therefore to be disposed of properly!

- Top up with refrigerant, if there is no leakage and insufficient refrigerant


(refer to the section on "refrigerant piping").

- Re-install the front panels.

- Switch on the master switch and close the electrical compartment door.

- Remove the warning sign and put the A/C unit into operation.

Visually inspecting water circuit for leaks


- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Open the electrical compartment and switch off the A/C unit at the
master switch.

- Remove the low temperature section panel.

- Visually inspect the pipelines of the water circuit for leaks.


Master switch
- Visually inspect the screwed pipe connections for leaks and for
damage.

- Re-install the low temperature section panel.

- Switch on the master switch and close the electrical compartment.

- Remove the warning sign and put the A/C unit into operation.

Screwed pipe
connections

E/0605/20/55
Checking compressor for satisfactory condition
- Switch off the A/C unit at the controller.

- Attach a "DO NOT SWITCH ON" warning sign to the A/C unit.

- Open the electrical compartment and switch off the A/C unit at the
master switch.

- Remove the low temperature section panel.

- Switch off the compressor power switch.

- Check the compressor for external damage and corrosion. Master switch

- Re-install the low temperature section panel.

- Switch on the power switch of the compressor.

- Switch on the A/C unit at the master switch.

- Close the electrical compartment.

- Remove the warning sign and put the A/C unit into operation

Compressor

E/0605/20/56
7. Causes and elimination of faults
All faults which are detected by the A/C-unit are visualized on the display of the controller. On the following
pages the most current faults are documented.

Outputs
1x Fan
1x Humidification (dry contacts)
Inputs 2x Heating
Alarm inputs: 1x Compressor/Valve
Humidification 1x Alarm (dry contacts)
Airflow
Filter Sensors
Heating temperature
Conductivity and humidity
Aux1/water detector

Remote ON/OFF

Display
4-digit LED
CompTrol 1002
4x Status
Operation
4x Alarm
4 keys
4 switch (rear side)

ALARM
HEIZUNG 1
Befeuchter
Fern Ein
Monitor On

RS485 24 V 220 V

TRANS-
FORMER

Program entry: Set values, start values, limit values, hysteresis

E/0605/20/57
Limit value alarms shown on display

Room temperature too high Room temperature too low

Cause of fault Elimination Comments


1 Sensor measures defective Calibrate sensor. To calibrate, check values in the
specified or limit values. controller with external thermo-
meter.
Limit or specified values have Check in the controller the
been exceeded. specified and limit values entered.

Room temperature too high:

2 Filter contaminated. Replace filter. Refer to "Operation/ Before opening the A/C unit, this
Maintenance" section. is to be switched off at the
controller and at the master switch.
3 Expansion valve frozen up. Switch off A/C unit and switch on A "DO NOT SWITCH ON" warning
again after expansion valve has sign is to be attached. Comply with
thawed. the safety instructions at the start
of these operating instruc-tions.
4 Compressor or fan have Check compressor or fan for
failed. satisfactory condition. Refer to
section "Operation/Maintenance".
Inform customer service if
compressor/fan is defective.

Shortage of refrigerant in Check refrigerant circuit. Refer to


refrigerant circuit. "Operation/Maintenance" section.

Room temperature too low:

Compressor does not switch off. Inform customer service.


After the elimination of the
Heating defective. Inform customer service.
fault press the key code
twice.

E/0605/20/58
Room humidity too high Room humidity too low

Cause of fault Elimination Comments


1 Sensor measures defective Calibrate sensor. To calibrate, check values in the
specified or limit values. controller with the external
hygrometer.
Limit or specified values exceeded. Check in the controller the
specified and limit values entered.

Room humidity too high:

2 CCD/U 171/201 A/G : Replace defective solenoid valve. Before opening the A/C unit, this
Solenoid valve for dehumidifying This measure is only to be carried is to be switched off at the
economy circuit defective. out by an authorised specialist or controller and at the master switch.
by STULZ customer service. A "DO NOT SWITCH ON" warning
CCD/U 41 - 121 : sign is to be displayed. Comply
Fan speed on the board is adjusted Turn down the fan speed with PHI with the safety instructions at the
too high. 2 on the circuit board in the electric start of these operating instruc-
Fan speed control is defective. cabinet. tions.
Replace the fan speed control.

Room humidity too low:

Steam humidifier defective. Check function of steam humidifier.

After the elimination of the


fault press the key code
twice.

E/0605/20/59
Air flow failure

Cause of fault Elimination Comments


1 Air flow monitor defective. Check air flow monitor electrically. Work on the electrical systems is
Defective air flow monitors are only only to be carried out by qualified
to be replaced by authorised specialist staff.
specialist staff or by STULZ
customer service. Before opening the A/C unit, this
is to be switched off at the
controller and at the master switch.
2 Hoses to flow monitor Clean hoses and check for kink A "DO NOT SWITCH ON" warning
contaminated or kinked. points. sign is to be displayed. Comply
with the safety instructions at the
start of these operating instruc-
3 Fan defective. Check fan for satisfactory tions.
condition. Refer to "Operation/
Maintenance" section.

4 CCD/U 171/200/201: Replace V-belt. Refer to


V-belt worn. "Operation/maintenance" section.

CCD/U 41-121 :
The fan speed is adjusted too Turn up the fan speed. (page 46)
small.

After the elimination of the


fault press the key code
twice.

E/0605/20/60
Filter alarm

Cause of fault Elimination Comments


1 Filter contaminated Replace filter. Before opening the A/C unit, this
is to be switched off at the
controller and at the master switch.
A "DO NOT SWITCH ON" warning
sign is to be displayed. Comply
with the safety instructions at the
start of these operating instruc-
tions.

2 Filter monitor does not Replace defective filter monitor. Replace defective parts, DO NOT
operate. REPAIR THEM.
Check hoses for contamination
and kink points.

After the elimination of the


fault press the and
key on the C1002.

E/0605/20/61
Low pressure alarm

Cause of fault Elimination Comments


1 Pressure switch defective. Adjust or replace pressure switch. Repairs on components
of the refrigerant circuit
Replace expansion valve. DO NOT and electrical compon-
2 Expansion valve defective. REPAIR IT. ents are only to be carried out
by authorised specialist staff or
3 Solenoid valve in fluid line Replace coil or lower section of by STULZ customer service.
defective. valve.
Before opening the A/C unit, this
Voltage supply of solenoid valve Check electrical actuation with a is to be switched off at the
defective. voltage tester. controller and at the master switch.
A "DO NOT SWITCH ON" warning
sign is to be displayed.
4 Power switch of compressor Check start temperature of the
does not operate. compressor at the controller. Comply with the safety instructions
at the start of these operating
instructions.

Power switch of compressor has Check adjustment value of motor


triggered. protection switch. Measure com-
pressor power consumption.

Shortage of refrigerant in system. Locate and eliminate leaks in


refrigerant system.
Replenish refrigerant on A units.
Replace refrigerant on G units.
After the elimination of the
fault press the key code
twice.

E/0605/20/62
High pressure alarm

Symptom Action Comments


1 Compressor contactor Check adjustment of contactor. Repairs on components of
tripped. Measure power consumption of the refrigerant circuit and
compressor. Replace defective electrical compon-ents are
compressor. only to be carried out by
authorised trained staff or by
Compressor contactor does not Check contactor for satisfactory STULZ customer service.
operate. function.

2 High pressure switch has After elimination of the failure Before opening the A/C unit, this
tripped. press the blue button on the high is to be switched off at the master
pressure switch. switch.
Comply with the notes on safety
Overfilling of the refrigerant Reduce quantity of refrigerant. at the start of these operating
circuit. Surplus refrigerant has to be instructions.
disposed of in accordance with the
regulations.

3 Overheating of compressor Replenish cooling medium.


due to shortage of water in con- Eliminate any leakages. Bleed
denser water circuit. water circuit. Check condenser
water pumps or drycoolers for
satisfactory function.

Overheating of compressor due to Clean the fins of the air cooled


insufficient heat transmission to condenser.
the air cooled condenser.
After the elimination of the
fault press the key code
twice.

E/0605/20/63
Controller fault, Sensor failure

Symptom Action Comments


The controller has detected a Replace the controller. Repairs on electrical
check sum error concerning the components are only to
EPROM. be carried out by
authorised trained staff or by
STULZ customer service.

Before opening the A/C unit, this


is to be switched off at the master
switch. Comply with the notes on
safety at the beginning of this
Sensor failure temperature: Check the actual temperature with manual.
The measured temperature is an external thermometer.
below 3°C or above 50°C. Check the sensor, cable and the
electrical connection, if the
temperature is in between the
measuring range.

Sensor failure humidity: Check the actual humidity with an


The measured humidity is below external hygrostat.
3% r.h. or above 97% r.h. Check the sensor, cable and the
electrical connection, if the
humidity is in between the
measuring range. After the elimination of the
fault press the key code
twice.

E/0605/20/64
8. Refrigerant piping
Notes on refrigerant system installation and filling an air conditioning system

All work on refrigeration systems must only be carried out by authorised specialist staff or
by STULZ customer service

Selection of hot gas and liquid line


- Establish the shortest pipe route from the A/C unit to the condenser. Exceptions only if unnecessary
bends have to be avoided.
- Determine the required pipe fittings and fittings between the A/C unit and condenser.
- With the aid of table No. 1 on P.67, convert the pressure loss of the individual fittings into equivalent
pipe lengths. Look up equivalent pipe lengths for pipe fittings and fittings and add these to the real
pipe lengths.
- Select the pipe dimensions from diagram No. 1 on P.66 appropriate to the calculated overall pipe
length and cooling capacity.

Precautions for hot gas line if the condenser is higher than the A/C unit.
- Ascending pipes are routed with the same dimensions, if oil transportation in accordance with table
No. 2, P.67 is guaranteed even at part load.
- An oil separator must be installed in systems with a pipe length above 25 m.
- Oil elbows (even in the case of the oil separator) are to be installed every 2.5-3.0 m.
- The horizontal lines are always to be routed with a slope towards the condenser.

Precautions for fluid lines:


With fluids, bubbles can form upstream of the expansion valve. This is always the case when the temperature
of the refrigerant upstream of the expansion valve corresponding to the pressure is lower than the ambient
temperature of the fluid line. Therefore insulation with Armaflex or equivalent material with a wall thickness of
9 mm is recommended for the lines outside of the unit. A thicker insulation is not required since the insulating
effect does not significantly increase with wall thickness.

Precautions for hot gas lines:

Hot gas lines can reach a temperature of up to +80°C and should be insulated inside the building at places
where a possibility of contact exists (risk of burn!).

E/0605/20/65
Pipe dimensions and precautions for the routing of refrigerant-
conducting lines
Diagram No. 1 - Diagrams for showing the layout of refrigerant lines for R407c/R22

Liquid lines depending on the


overall pipe lengths and cooling
capacities.
Overall pipe length in m

Ou
tsi
de
dia
. in
m

Cooling capacity in kW

Hot gas lines depending on the


overall pipe lengths and cooling
Ou

capacities.
Overall pipe length in m

tsi
de
dia
. in
mm

Cooling capacity in kW

E/0605/20/66
Table 1: Pressure drop of pipe fittings in meters of equivalent pipe length

Copper pipe Bend Angle T-piece

Outside dia. mm 45° 90° 180° 90°

10 0,16 0,20 0,53 0,32 0,20


12 0,21 0,27 0,70 0,42 0,27
15 0,24 0,30 0,76 0,48 0,30
18 0,26 0,36 0,87 0,54 0,36
22 0,27 0,42 0,98 0,61 0,42
28 0,39 0,51 1,20 0,79 0,51
35 0,51 0,70 1,70 1,00 0,70
42 0,64 0,80 1,90 1,20 0,80

Table 2: Selecting the pipelines

Minimum cooling capacities which are required for oil transportation in rising pipes
of hot gas lines for R407c/R22 at tc (dew point) 48°C.

Pipe diameter 15 18 22 28 35 42

Cooling capacity kW 4,41 5,17 7,14 10,0 16,58 25,9

Route horizontal pipes with a slope towards the condenser.

Position oil bends every 2.5 - 3 m.

Use oil separator for rising pipe longer than 25 m.

E/0605/20/67
Installation instructions
for routing refrigerant-conducting pipes
The following points are to be complied with when routing the pipes:
- The measures listed in the safety instructions chapter are to be complied with when routing refrigerant-
conducting pipelines.

- Routing must be over the shortest routes, (involve a specialist in cases of doubt).

- Bends and angles are to be avoided wherever possible as these result in pressure drops which
reduce the output of the A/C unit. Returns around joists, masonry offsets or the like are to be carried
out with 45° bends wherever possible, in accordance with sketch No. 2, P. 71.

- Horizontal lines must have a slope towards the condenser so that oil and condensed refrigerant
cannot flow into the system when it is shut down. (Hot lines must be insulated. Exceptions are hot
gas lines in the open air which cannot be touched.)

- Upright pressure lines must have an oil bag every 2.5-3 m as well as an oil trap at the highest point,
in accordance with sketch No. 3, P. 71.

- To avoid backflow of condensation, a non-return valve with damping piston must always be installed,
in the pressure line if it is not already installed in the unit on the outlet of the A/C unit or downstream
of the oil separator.

- If an oil separator is installed in the system, this must be filled with the same type of oil as the
compressor in accordance with the manufacturer's specifications.

Never route pipelines through rooms such as conference rooms, rest rooms, offices etc.

Pipe mountings are to be provided at least every 2 m. The pipe mountings are to be insulated against
vibrations. The first pipe mounting behind the A/C unit and upstream of the condenser should be flexible. So
that the pressure lines can expand, the pipe mountings are to be attached at least 1 m from the bend, in
accordance with sketch No. 1, P. 71.

- All copper pipes which lead through masonry are always to be insulated in this area so that the pipes
are not attacked by the masonry and a certain flexibility is retained.

- For routing, only copper pipes are to be used which correspond to country-specific regulations.
Sealing caps or ends added as flux must be meticulously clean and dry and meet the requirements
of refrigeration engineering.

- Before commencing with routing the pipelines, one should ensure that the pipes are dry and clean
inside. Check whether the sealing caps are seated on the pipe ends and if necessary blow through
the pipes with nitrogen. If the sealing caps are no longer seated on the pipe ends, the pipes must be
cleaned inside with a clean non-fraying rag and a spiral and then blown through with nitrogen to
remove the remaining dirt. Furthermore it must be ensured that the remaining pipe is always sealed
with a plug after cutting off pipe ends.

E/0605/20/68
- Pipes for refrigerant must always be cut to length with a pipe cutter and then brought to the correct
inside diameter by slightly expanding or calibrating.

Sawing refrigerant pipes is not permitted as the chips cannot be completely removed and
blockages can result in the control components or the compressor may be irreparably
damaged. The same can also occur as a result of contaminated pipes.

- If copper pipes are flared, the taper of the tube flaring tool must be coated lightly with refrigerator oil
to prevent a burr occurring during the flaring process on the copper pipe which can then enter the
pipe.

- Refrigerant-conducting pipes may only be soldered under inert gas so that no burring occurs on the
inside of the pipes which also contaminates pipelines.

Soldering not carried out by a specialist will render the guarantee invalid.

Nitrogen is used as the inert gas. It is blown through the pipe system under slight pressure without excess
pressure affecting the soldered joint.

Adequate ventilation of the room is to be ensured for welding and soldering work.

Before the final connection is soldered, a screwed connection must be released at the appropriate point so
that no pressure occurs in the pipe system.

After soldering, do not forget to retighten the screwed connection which has been released.

- If the system has finished pipework, it is mandatory that the system is checked for leaks. This must
be carried out as follows:

- The system is initially filled with dry nitrogen to the maximum nominal pressure.

- The system is shut off, the valve in the system is closed and the nitrogen bottle removed.

- Each connection (including screwed connections) is checked for leaks by brushing off. In paral-
lel with this check, a pressure gauge is connected, with which it can be rechecked that the
system has no leaks, the pressure on the pressure gauge being checked for an appropriate
period for the size of the system.

E/0605/20/69
Installation notes for routing refrigerant-conducting pipes

1000
1000

Correct
Mounting the
refrigerant pipes in
corners

Sketch 1
Incorrect

Dealing with obstacles

Sketch 2

gas liquid

Routing pressure lines when


the Condenser is higher than
the compressor.
ca. 2.5 - 3 m Use oil separator for rising
pipe longer than 25m.

Sketch 3

For height differences of


over 3 m the system must
be designed so as to
liquid max. 3 m guarantee additional
gas
subcooling (consult STULZ).

Sketch 4

E/0605/20/70
Basic principles for evacuating refrigerant systems
Vacuum pump
The vacuum pump is used in order to remove as much air as possible in sealed systems, so that the moisture
contained within evaporates and is extracted by the vacuum pump. (With a suitable vacuum, evaporation
already takes place at ambient temperature).
When selecting a vacuum pump this must be adapted to the systems to be evacuated (consult a specialist
company).
Successful evacuation and the associated drying of the system can only be achieved if the vacuum pump
with the associated vacuum meter is in proper working order. In addition the evacuation process must be
monitored continuously by a fitter.

Pressure measurements
The pressure which prevails in the refrigerant circuit, is measured by pressure gauges. Two pressure gauges
are required, one on the suction side for measuring the evaporator pressure and the associated evaporation
temperature, the other for the high pressure side for measuring the condensation pressure and the associated
condensation temperature.
There are two types of pressure display:
- measurement of absolute pressure (gauge pressure + atmospheric pressure)
- measurement of gauge pressure (the pressure gauges only display the gauge pressure).

Condition of equipment for evacuating


For satisfactory evacuation it is essential to use a satisfactory and clean vacuum pump. The connections of
the vacuum pump must always be sealed when it is not being used, because moisture, dirt particles or similar
which enter can result in damage to the vacuum pump so that satisfactory evacuation can no longer be
achieved.

E/0605/20/71
Evacuating instructions
Proceed as follows when it is ensured that the system is sealed

- Let out the test pressure down to 1 bara = 0 barp on the pressure gauge.

- Connect the vacuum pump to the high and low pressure side of the system via a pressure gauge
station.

- Extract from the high and low pressure side down to approx. 0 bar.

- Fill the system with nitrogen (not refrigerant because of environmental pollution) to 1 bar and extract
again down to approx. 0 bar.

This process must be carried out at least 3 times, filling with nitrogen twice. Air and moisture is extracted from
the cooling system due to evacuation
If contaminants and larger quantities of water remain in the system - this may happen if the system has been
open over a long period, or if the pipes to be processed were not sealed - proceed as follows:
- Evacuate the system several times until the pressure gauge stays on 0 bar permanently.
- In addition the system is to be run dry by replacing the drier several times during operation.

For R407c and R134a:


Refer to the special requirements of the refrigerant manufacturer.

Explanatory notes
Absolute pressure [bara] : atmospheric pressure + gauge pressure
Atmospheric pressure: Pressure which is caused by the weight of
the atmosphere (approx. 1 bar)
Gauge pressure [barü] : Pressure which prevails in the cooling system.
Vacuum : Condition of approx. 0.02 - 0 bara, in a sealed system.
The difference to ambient pressure is approx. -0.98 - 1 bar.

E/0605/20/72
Instructions on filling systems with Halogen refrigerants
- Systems without refrigerant collector or sight glass must always be filled according to weight.

- Systems with refrigerant collector should be filled according to weight but can also be filled by
checking the sight glass.

Comply with the safety instructions listed in this section and the country-specific regulations
and safety instructions.

- Before the system is filled with refrigerant, it must be clean and dry inside. (Refer to evacuation
instructions). Then proceed as follows:
The standing refrigerant bottle is connected to the suction side via a pressure gauge station. For
this the bottle stands upright or is suspended on scales. The weight is noted shortly before filling.
The specified amount of refrigerant is now introduced when the system is operating. During filling
the pressure in the refrigerant bottle will adjust to that of the system. Filling is then no longer
possible. This can be seen by the icing up of the bottle or by checking the pressure gauge. The
bottle valve must then be closed until a pressure increase has taken place which is above the
suction pressure of the system. This process can be accelerated if the bottle is wrapped in hot
moist towels or it is placed in a water bath at a maximum temperature of 50°C.

Never heat up the refrigerant bottle with a naked flame as there is a risk of explosion.

The refrigerant bottle must not be stood on its head otherwise any contamination from the bottle enters the
system. When the filling process is complete, the system must be sealed carefully so that no refrigerant can
escape. Only then may the bottle with filling station be removed. Systems with refrigerant collector can be
filled observing the sight glass. The system is correctly filled when no more bubbles can be seen in the sight
glass. Nevertheless scales should also be used here to determine the amount of refrigerant required.

E/0605/20/73
9. Options
9.1 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 power
supply can be found in the electrical diagrams in the appendix.

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
equipped with a water detection system.

9.1.1 Description
The humidifier uses normal mains water for the production of steam. The conductivity of the water should be
within the range of min. 300 to max. 1250 µS/cm. The water is converted directly into steam by means of
electrical energy in a steam cylinder with electrode heating. The steam is introduced into the airflow via the
steam throttle.
Due to the evaporation the water level in the cylinder falls. The current consumption is reduced, as the
electrodes are then immersed less in the water. With a sinking water level the mineral concentration in the
cylinder increases, as the minerals do not evaporate. The current is kept by the control between two limit
values (IN+10%, IN-5%). When the lower limit value is reached, the inlet valve opens. Now fresh water is
mixed with residual water, which has a high mineral concentration. After several evaporation and filling cycles,
the mineral concentration has increased in such a way, that the current reduction due to evaporation and
falling water level takes place quite rapidly. When a certain limit value of current reduction is exceeded, the
drain valve is opened at the moment, when also the lower current limit value is reached, and finally the cylinder
is completely drained.
The filling phase is automatically interrupted if the sensor electrode is contacted due to the high water level in
the steam cylinder. This may happen in the start-up phase with a new steam cylinder.

9.1.2 Technical data


The humidification capacity can be adjusted at a maximum value. The maximum humidification capacities are
shown in the table with the corresponding A/C units.

Steam humidifier

Units: Hum.capacity [kg/h] Nom. current [A] Nom. power [kW]


230V / 1 Ph / 50 Hz
1,5 6,4 1,13
CCD/U 41-121
3 12,7 2,25
400V / 3 Ph / 50 Hz
CCD/U 171/201 3 4,2 2,25

E/0605/20/74
Water requirements

Water properties and ingredients min max


hydrogen ions pH 7 8,5
specific conductivity (at 20°C) s20 µS/cm 300 1250
total dissolved solids TDS mg/l * *
dry residue at 180°C R180 mg/l * *
total hardness mg/l CaCO3 100² 400
iron + manganese mg/l Fe + Mn 0 0,2
chlorides ppm Cl 0 30
silica mg/l SiO2 0 20
residual chlorine mg/l Cl- 0 0,2
Calcium sulphate mg/l CaSo4 0 100
* values depending on specific conductivity; in general: TDS = 0,93 • s20 ; R180 = 0,65 • s20
2 not lower than 200% of chlorides content in mg/l of Cl-

no metallic impurities, no solvents, diluents, soaps, lubricants

9.1.3 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.

Water supply
The water connection is made from the cold water mains and is to be equipped with a shut-off valve. The
humidifier can be connected directly to the mains 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 8 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.

Do not treat the water with softeners !


This could result in corrosion of the electrodes and in the formation of foam with considerable
operational interruptions.
Prevent:
1. the use of well water, process water or water of cooling circuits and generally chemically or
bacteriologically polluted water;
2. the addition of disinfectants or anti-corrosion liquids, as these are very irritating for the
respiratory ducts.

E/0605/20/75
Water drain
The drain is achieved by a plastic hose and is routed out of the unit by means of the openings in the unit
provided for this purpose (refer to 5. Installation - supply connections).
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 directly into an open collector funnel 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 32 mm
is recommended, however the minimum inside diameter should not be less than 25 mm.

9.1.4 Commissioning
As soon as the controller requires the humidifier function, the heating current is switched on; after approx. 30
seconds water is fed into the steam cylinder through the inlet valve which opens and fully automatic operation
begins. A condition is the open shut-off valve in the water supply.

IMPORTANT NOTICE:
After the water pipes have been connected, the supply piping must be flushed for approx. 30 minutes,
where the water is directly conducted into the drain, without letting it flow into the steam humidifier.
This way residues or substances of the installation process are removed, which otherwise could block
the fill valve and cause foam during the boiling process.

Decommissioning the humidifier


The steam cylinder is to be emptied if the humidifier has been out of operation for a longer period (e.g. in
summer, decommissioning the air conditioning system etc.) (see 9.1.6 Maintenance - Drainage).

E/0605/20/76
9.1.5 Operation
The steam humidifier is controlled and monitored by the controller. No further operating measures are required
for continuous operation.
However, you can always vary the humidifier output, by operating the DIP-switches A3/4, which are located on
the humidifier printed circuit board in the electrical section of the A/C unit.
3 4
ON
100 % humidification capacity The humidifier operation is indicated by a green LED.
OFF
From the yellow LED you can see the state of operation
3 4 of the humidifier (see diagram 1,2). The red LED
ON
75 % humidification capacity indicates if an alarm is active (see alarm table).
OFF
You can also manually drain the steam cylinder (see
3 4 9.1.6 Maintenance). The position of the TA RATE-
ON
50 % humidification capacity switches 1-4, the DIP-switches A2 and B2 is not to be
OFF
changed under no circumstances. For this reason the
3 4 switches are sealed.
ON
20 % humidification capacity
OFF

high level/foam
manual drain valve
sensor
Power supply 24 VAC drainage fill valve
G/G0 conductivity sensor

external TAM

green LED
immersed electrodes yellow LED
max. 5A red LED

RS485
fig. 1 remote ON/OFF
alarm relay
humidity sensor external controller

DIP A2: Alarm relay status

1 2 Relay energized (contact closed), when


ON at least 1 alarm is active, otherwise not
OFF energized (contact open).

1 2 Relay not energized (contact open),


ON when at least 1 alarm is active,
OFF otherwise energized (contact closed).

E/0605/20/77
DIP-switch „B“ : Auxiliary functions and automatic drain timings

1 2 3 4 DIP B1: complete drainage after 7 days without any humidification request
ON ON: function disabled
OFF OFF (default): function enabled

1 2 3 4 DIP B2: automatic drainage with electrodes powered/not powered


ON ON: electrodes powered during automatic drainage
OFF OFF (default): elctrodes not powered

1 2 3 4
ON DIP B3: automatic drainage when request is reduced by at least 25%.
OFF
ON: new humidification capacity achieved by steam cycles
OFF (default):
1. new humidification capacity is achieved by steam cycles, if the request
is reduced by less than 25%.
2. automatic drainage, if the request is reduced by at least 25%

DIP B4: disabling of the pre-alarm and the warning for wornout cylinder (see alarm
1 2 3 4 table 2)
ON
ON: warnings are never displayed.
OFF
OFF (default): warnings are displayed when the cylinder is worn out.

DIP B5-6: DIP B7-8:


automatic drainage time evaporation time threshold
5 6 7 8
ON ON
OFF
time = default OFF
threshold = default
5 6 7 8
ON ON
time = default - 30% threshold = default - 30%
OFF OFF

5 6 7 8
ON ON
time = default + 33% threshold = default + 33%
OFF OFF

5 6 7 8
ON ON
time = default + 66% threshold = default + 66%
OFF OFF

Change the default adjustment only after confirmation of the STULZ technical support. The dip-switches serve
to adapt the drain cycle to extreme water conditions beyond the previously described limit values.

E/0605/20/78
Diagram 1: Steam production: yellow LED - transient production "short flashing"

steam
< 1%

time
1-19%

time
20-29%

time

90-99%

time

Diagram 2: Steam production: yellow LED - constant production "long flashing"

steam
< 1%
time
1-19%

time
20-29%
time

90-99%
time
100%
time

The yellow LED stays off when no steam is produced, whereas it stays continuously on at 100% of the
nominal production.

When steam is being produced at a transient production rate while approaching the steady-state production,
the yellow LED is quickly turned on and off to produce 2 Hz-pulse sequences which are related to the actual
steam production as shown in diagram 1.

When the steady-state production is achieved, the yellow LED is slowly turned on and off to produce 0,5 Hz-
pulse sequences which are related to the actual steam production as shown in diagram 2.

Each pulse sequence is separated from the following by a 3-second delay, so that the user can count the
pulse number of a sequence and determine, using the diagram, the actual humidification capacity.

E/0605/20/79
9.1.6 Maintenance

Please switch off the A/C unit at the controller and the main isolator before starting work and
put the power circuit breaker F70 in the electrical box to position 0!

The following work and checks can be carried out:


- check steam hoses, condensate hoses, water hoses and other parts of the humidifier for external effects
or wear.
- Flush out the water drain.

Replacing the steam cylinder


The steam cylinder needs replacing if the electrodes are so highly insulated due to the increasing calcification
or furring that the water level in the steam cylinder constantly touches the sensor electrode.
The specially constructed water filling beaker provides additional safety here, excessive water being routed to
an overflow and being able to drain away there.

Warning note!
The temperature of the discharged water is approx. 60°C during normal operation but can
reach 100°C briefly, if the steam cylinder is emptied manually during maintenance work.

The steam cylinder should be allowed to cool down slightly before removal.
If the alarm code 11x long on the humidifier printed circuit board in the electrical section (also refer to Alarm
table 2) occurs repeatedly, the steam cylinder has worn out and must be replaced. The life of a steam cylinder
depends on the operating period and the hardness of the water.

Manual drainage
By means of a switch on the humidifier board,
you can manually drain the cylinder. After
the drainage the switch must be reset to
position "ON", otherwise no humidification
can take place.

Position "ON" Position "DR"

Switch off the power supply circuits to the humidifier before continuing the work!

The steam cylinder can be unscrewed from the mount after releasing the hose clamp, pulling off the steam
hose and disconnecting the electrical plug on the cylinder.
The new steam cylinder is installed in the reverse sequence. The humidifier is re-started in accordance with
the recommendations of the chapter "9.1.4 Commissioning".

E/0605/20/80
9.1.7 Malfunction causes / Remedy
Alarm: Humidifier defect

In the event of this signal on the controller, please look for the exact cause of the fault on the humidifier printed
circuit board in the electrical section of the A/C unit. If an alarm has been raised, the red light-emitting diode
displays a flashing alarm code. The meaning of the alarm codes can be seen in the alarm table 2.

Repairs to the electrical components are only After the elimination of the
to be carried out by authorized trained staff or fault press the key code
by STULZ Customer Service Department. twice.

Diagram 3: Alarms: red LED - "short flashing"

no alarm

time
1x flashing

time
2x flashing

time

9x flashing

time

Diagram 4: Alarms: red LED - "long flashing"

no alarm
time
1x flashing

time
2x flashing

time

9x flashing

time

E/0605/20/81
Alarm list

Table 1 - Alarm types


Type Description Reset (if alarm cause has Red LED Alarm relay
been removed)

Blocking CP-card stops manual: to restart, turn the The relay is normally open or
humidifier. cp-card off and then on again. normally close depending on
DIP A2.
The relay action is cumulative:
Disabling CP-card stops • automatic • contact is closed (opened), if
humidifier. • manual: at least 1 alarm is active.
to restart, turn the cp-card off Alarm codes: • contact is opened (closed),
and then on again. each code is displayed in if:
sequence. - all alarm causes have been
removed.
Note: the distinction between The codes are displayed - all alarms have been reset,
the automatic and manual even if the alarm causes either manually or
reset is shown in the table have been removed; to stop automatically.
below. displaying them, turn the cp-
card off and then on again. Note: each alarm is not
assigned to the relay (see
Warning CP-card does not • automatic table below)
stop humidifier.

Table 2 - Alarms
Red LED Description & Causes Remedy Type Reset Alarm-
flashes relay
2xshort Electrode over-current 1. Drain part of the water and re-start. blocking manual active
1. water conductivity too high 2. Verify that the drain valve is properly working.
(usually when starting after a 3. Check for any leakage of the fill valve when the humidifier
short stop) is switched off.
2. high water level due to drain
valve malfunction
3. high water level due to fill
valve leakage
4. electrode malfunction

3xshort No voltage at the electrodes: 1. Check the external command signal: type (V or mA)? Value? blocking manual active
with the unit on, no steam is Connections?
produced. 2. Switch off the unit and disconnect it from the mains: check
the internal electrical connections.

4xshort Internal memory error 1. Download the proper default configuration via HumiSet. blocking manual active
2. If the problem persists, contact the STULZ customer
service.

5xshort High conductivity of the supply 1. Switch off the unit and clean the conductivity sensor blocking manual active
water electrodes;
2. If the problem persists, change the source of supply water
or install a suitable treatment system (demineralisation,
even partial).
Note: the problem will not be solved by softening the supply
water.

E/0605/20/82
Table 2 - Alarms (continued)
Red LED Description & Causes Remedy Type Reset Alarm-
flashes relay
2x long Cylinder depleted Do maintenance and/or replace the cylinder. warning manual not
active
3x long Lack of supply water 1. Check that the fill pipe from the mains to the humidifier and disabling manual active
the internal pipe are not blocked or bent and that there is
sufficient supply pressure (1-8 bar).
2. Check that the fill valve is properly working.
3. Check whether the counter-pressure onto the steam hose
is higher than the maximum limit, preventing the entry of
supply water into the cylinder by gravity.
4. Check that the steam outlet pipe is not choked and that
there is no condensate inside.

4x long Excessive reduction of 1. Cylinder completely depleted or excessive foam. Do disabling manual active
steam production maintenance to the cylinder.
5x long Drain malfunction 1. Check the drain circuit and the proper operation of the disabling manual active
drain valve.
6x long User parameter error 1. Download the proper default configuration via HumiSet. blocking manual active
2. If the problem persists, contact the STULZ customer
service.

7x long Supply water high 1. Check the conductivity of the supply water. warning display: not
conductivity pre-alarm 2. If necessary install a suitable demineralizer. automatic active
Note: the problem will not be solved by softening the reset
supply water.

8x long External command signal not 1. Check the connection to the (external) controller. disabling alarm: active
properly connected automat.
(only 2/10V)
9x long Cylinder full with steam with the humidifier switched off: disabling manual active
production not in progress 1. Check for any leaks from the fill valve or the
condensate return pipe.
2. Check that the level sensors are clean.
10xlong Foam inside the cylinder Foam is usually caused by surfactants in the water warning display: not
(lubricants, solvents, detergents, water treatment agents, manual active
softeners) or an excessive concentration of dissolved reset
salts:
1. Drain and clean the water supply pipes.
2. Clean the cylinder.
3. Check for the presence of softeners. (in this case, use
another type of supply water or reduce the softening)

11xlong Cylinder almost completely Do maintenance and/or replace the cylinder. warning display: not
depleted manual active
reset

Note: "manual reset" means one of the following activities


- pulling off and putting on the power supply plug G/G0 (see 10.1.5 operation - fig. 1)
- switching off and on the control fuses F02 (Caution: unit is switched off.)

E/0605/20/83
9.2 Heating
The heater 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 reheat are
available:
- Electrical reheat
- Low pressure hot water reheat (LPHW)
- Refrigerant reheat (RF)

Electrical reheat LPHW reheat RF reheat


CCD/U 171/201

The LPHW reheat is to be The refrigerant reheat is integrated


CCD/U 41-121 connected to an external hot water in the refrigerant circuit in
circuit. The water supply is accordance with the refrigerant dia-
The heater is connected in accord- controlled via an electrically gram in the "Appendix". The
ance with the connection diagram actuated LPHW valve. refrigerant supply is controlled via
(refer to "Appendix"). It is controll- The LPHW valve is controlled via an electrically-actuated 3-way so-
ed and monitored by the controller. the controller. Refer to the C1002 lenoid valve. The solenoid valve
The values for switching on and off manual. is controlled via the controller. Refer
are adjusted on the controller. Refer to the C1002 manual.
to the C1002 manual.

Operation
The reheat is controlled and monitored by the controller. No further measures are required for operation.

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

Installation
The reheats are installed and connected in the A/C unit. The LPHW reheat is to be connected on site to the
external hot water circuit. The pipelines are to be routed out of the A/C unit in accordance with the section
Installation "pipeline and cable ducts". The LPHW reheat is connected via a 22 mm copper pipe.

E/0605/20/84
Electrical Heating Alarm

Symptom Action Comments


1 The overheat protection has Check whether the fins of the Repairs to the electrical
triggered. heating are dirty. components are only to
Raise air flow (at CCD/U 41-121) be carried out by
Mesure the current consumption authorized trained staff or by
of the heating. STULZ Customer Service De-
partment.
2 Power circuit-breaker has for CCD/U 171/201:
triggered. Check power circuit-breakers and The A/C unit is to be switched off
electrical heater for damage. at the master switch before
Replace defective power circuit opening it.
breaker or electrical heater.

for CCD/U 41-121:


In this case there is no display
on the C1002.

3 Cable connection to heater Check cable connection.


open circuit.

After the elimination of the


fault press the key code
twice.

E/0605/20/85
9.3 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 encircling rectangular profile of galvanized steel with adjustable screw sockets. Anti vibration
compound is recommended between concrete floor and base plate.
The delivery volume contains: 4 bars of rectangular profile 70 x 40, 4 mafund plates, 4 adjustable supports,
which can be shortened on site, 8 hammer head screws M8 x 30

CCD 41-121

Connecting the bars


(View from below)

Angle Connection
575

595

Positioning of supports
495

600 Rectangular profile 70 x 40 x 2

Cut out in raised floor


620

CCD 171-201
810

830

Positioning of supports

1000 Rectangular profile 70 x 40 x 2

Cut out in raised floor


1020

E/0605/20/86
Minimum distances and mounting instructions

- the raised floor cutting (notch) should at least be 15°


and must not have any contact to the raised floor
Floor stand Z (min. 30) stand, which could result in bone-conduction.

- the dimensions of the openings in the raised floor (X


Y and Y) are 10 mm longer than the raised floor stand.
The joint must be closed by customers with a
continuous seal.

Z X Z Z (min. 800) - a concrete foundation is recommended in the area


(min. 30) of the raised floor supports.

- the raised floor supports have to be installed on


X/Y = Opening in raised floor vibration dampening material (do not screw down
Z = Limit of distance the supports!).

- prior to installation of the A/C unit, the raised floor


must be installed 7 mm higher than the raised floor
plates, as the mafund plates are compressed by the
weight of the A/C unit.

General design of the raised foor stand

10 mm 10mm
Raised floor
600 mm / connection refer to
1000 mm details on next page

Raised floor
max 500 min 250

Continuous seal Hammer head screw M8 x 30


Raised floor stand Upper support part
Recommended concrete Range of adjustment :
Raised floor support
foundations ± 20mm
Mafund strips
(no (floor) finish) Supporting pipe
Upper edge of
rough floor

E/0605/20/87
Detail of raised floor connection

1 Raised floor stand


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

Sealing detail Sealing detail


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

E/0605/20/88
9.4 Refrigerant Circuit Options

STULZ A/C units of the type A, G are equipped as standard with a refrigerant circuit which can be expanded
with various options.

Description

A/C unit type A with hot gas bypass extension


Air section Low
temperature
section

Collector

Evaporator

Hot gas
bypass
Fan

The refrigerant circuit of your A/C unit is equipped with a compressor which is designed for 12 switching
cycles per hour. The following operating curve for the refrigerant circuit results from these switching on and off
phases.

On 100%
Compressor
Off 0%
In order to reduce the switching rate and thus increase the life of the compressor, the refrigerant circuit can be
enhanced by a hot gas bypass or with a suction throttle. The hot gas bypass has a control range of 50 to
100%.

E/0605/20/89
A/C unit type A with suction throttle extension

Air section Low


temperature
section

Collector

Evaporator

Fan

Suction throttle

The suction throttle has a control range of 40 to 100%.

E/0605/20/90
Adjustable HP/LP switch
The compressor is controlled and monitored by the controller of your A/C unit. Permanently set high-pressure
and low-pressure switches are required as sensors for this. An adjustable version of these HP/LP switches is
supplied in order to individually adapt the switching points for the high pressure and low pressure to the
operating conditions.

Internal condenser

Technical Data

Type of condenser KSI 018 KSI 033


for A/C unit CCD/U CCD/U
41-121 A 171-201 A
Condenser output kW 17.5 32
Air flow m³/h 4000 7500
No. of fans 1 1
Motor power kW 0.55 2.2
Air inlet temperature °C 32 32
Temp. of condensation °C 48 48
Electrical connection V/-/Hz 230/1/50 400/3/50

Dim. KSI 018 KSI 033

A 840 1025
B 400 740
C 120 210
D 100 80
E 361 361
F 329 415
G 72 69
H 136 242,5
J 600 810
K 600 900
L 1850 1950

The internal condenser is an option for A-type units and is installed


on the left side of the A/C unit. It contains a fan with a motor and
a heat exchanger which is connected with the A/C unit by copper
tubes.

E/0605/20/91
9.5 Air Circuit Options
EU5 filter
The EU5 filter is used instead of the standard EU4 filter and cuts down on air contamination to a greater extent.

Condensate pump
The condensate pump extracts the condensate water occurring in the condensate water tray and pumps it
into the local sewage circuit. The condensate water tray is located beneath the filter elements in the A/C unit.
A MARCH AB-1F pump is used which is installed in your A/C unit at the factory. The pump is provided with an
integral float switch. The float switch switches the pump on and off automatically. The 6 m long drain hose (6
mm diameter) is to be connected to the local effluent system. The pump is connected in accordance with the
terminal diagram (refer to "Appendix").

When routing the drain line, ensure that it is not kinked.

Return air suction from behind - Upflow

Dimensions

CCU A B C D

41-121 440 400 80 100


171-201 300 900 50 50

At the return air suction from behind


the air duct has to be fixed at the
back with M8 screws. In this case
the standard filter can not be used.
A special filter has to be installed in
the air duct, instead.

4xM8-nut set up from outside

E/0605/20/92
Air discharge plenum - Upflow
The air discharge plenum is set on the A/C unit without being screwed.

Dimensions

CCU A B C D E H

41-121 572 600 425 525 325 500


171-201 782 1000 625 825 425 500

E/0605/20/93
Unit base for air discharge
The unit base is designed for downflow units which are installed in rooms without a raised floor and serves for
the discharge of the supply air. With upflow units this unit base serves for the return air suction. The room air
to be cooled is sucked in through the air grilles, which are not shown in the illustration.

CCD/U 41-121 35
35
60
0 0
60

50
35
400

325
37.5

.5
37
37
.5

52 5
5 52

Installation

Please note that the unit base has to be bolted to the unit.

E/0605/20/94
Unit base for air discharge for CCD/U 171-201

insulation of foamed

315
material
13
3.5
35

35 51
5

400
315
5
315

41

42.5
60
8.5
8.5

43 5
42.5

6 41
6 00
33
39 10
51 .5
5 .5
39
8.5

78
2
8.5

16 x Ø3.2 13
3.5

E/0605/20/95
Base for duct connection and air damper - Upflow

The base is set on the A/C unit without being screwed. The duct is fixed on the base with 4 M8 screws.

Dimensions

Unit size A B C D E F G H

CCU 41-121 400 400 523 552 40 56 12x9.5 17


CCU 171/201 675 800 738 977 31.5 88.5 26x9.5 20

4xM8-nut set up from above.


(only for CCU 41-121)

E/0605/20/96
Air damper
An air damper can only be provided on the discharge side for downflow and upflow units. The most frequent
use of the air damper is shown, on the discharge side of upflow units. For the installation of an air damper on
the upflow unit a connection plate (see page before) is necessary.

Dimensions

Unit size A B H

CCD/U 41-121 345 400 175


CCD 171/201 500 700 120
CCU 171/201 500 700 120

B
A
H

Continuous
flange, 38 mm wide

E/0605/20/97
Fresh air intake
By means of the fresh air intake outside air is taken in, conducted through a filter into the unit and used to cool
the room air. If the outside temperature is below the room temperature the required cooling capacity is reduced.
The fresh air intake consists of three parts:

1. Collar
2. Filter cartridge
3. Cover

The collar is bolted at the rear wall of the unit. The filter cartridge is put on the collar in the unit and is closed
with the cover. This way the outside air is only taken in via the filter surface.

Unit rear
side
Insulation
Filter cartridge
Dummy
Collar rivet
Cover

We recommend to install an additional fan between the unit and the fresh air intake, to control the fresh air
ratio.

E/0605/20/98
Opening in the unit rear wall - Downflow
CCD 110 CW CCD 200 CW
150 150

120

120
100 mm
100 mm
1850

1850
30

30

600 1000

Opening in the unit rear wall - Upflow


CCU 110 CW CCU 200 CW
600 1000
1850
1850

100 mm
100 mm
320

280
30

30

150 350

E/0605/20/99
Ecocool
With the Ecocool function outside air is used for cooling the room air and is mixed with the return air via
louvers. Two louvers per unit are installed. At the downflow unit the louvers are situated on top and at the upper
part of the rear side, at the upflow unit the louvers are situated at the bottom part of the front and the rear side.
The louvers at the rear allow outside air to come into the unit. The louver on top of the downflow unit and at the
front of the upflow unit allow room air to come into the unit. The louver installed on top of the inside condenser
serves to diminish the exceeding pressure in the room, as a result of the intake of additional outside air. The
surplus room air flows via the opened louver into the inside condenser and through the fan intake and heat
exchanger (which are out of operation) to the outside.
To cut down the dust content of the outside air two filters (EU2 and EU4) are installed upstream the evaporator.
They are part of the delivery volume.
The controller C5000 and a special software are required for the louver control and must be ordered separately.

Actuators and end position switch


Louver actuator NM 24 - SR for fresh or return air

The louver actuator has no end position switch and is overload-proof. When the limit stop of the louver is
attained, the actuator stops automatically.
After switching on the power supply or actuating the push button on the actuator a function test with calibration
is automatically executed. The actuator scans the two end positions and adapts its electrical operating range
of 2-10 V DC and the running time of 150 s to the actual mechanical louver swing angle. The actuator then
adjusts itself on the position which is required by the control signal. The actuators are constantly supplied with
24 V AC. The control is realized with 0-10 V DC. The actuator NM24-SR is mounted on the fresh air louver.

Function test: By pressing the button at the housing the gear shift is released, and the louver can be
operated manually.

Louver actuator NM 24 for return air (option pressure compensation)

The louver actuator has no end position switch and is overload-proof. When the limit stop of the louver is
attained, the actuator stops automatically.
The control is realized by a 24 V AC/DC signal.

Function test: By pressing the button at the housing the gear shift is released, and the louver can be
operated manually.

E/0605/20/100
Configuration of the C5000
To start the A/C unit with the free cooling device, the special software has to be installed. (The EPROMs are
installed by Stulz Hamburg). After the start the software version is displayed at the C5000.

In the menu point "Control/module functions/cooling/ECO-louver the start parameters: start temperature and
gradient can be modified.

In the menu point "Service/equipment/cooling/ECO-louver the unit configuration must be determined (made
by Stulz Hamburg). For the ECO-louver the louver 1 field must be set on "S" ( = proportional).

Control

Two conditions are necessary for enabling the free cooling:

1. The room humidity must be within the limits, at which the unit control neither humidifies nor dehumidifies.

2. The outside temperature value, which can be set in the menu "Control/module functions/cooling/ECO-
damper", must be passed under. The outside temperature is measured by an outside air temperature sensor
connected to the C5000.
The limit value can by adjusted from 0 to 99°C. In practical use the best results are obtained with a value in the
range of 16-20°C.

The free cooling is switched off (and thus the cooling by compressor is switched on), if either the outside
temperature rises above the adjusted value (ECO-off) in the above mentionned menu, or the room humidity is
half of the humidification hysteresis below the value, at which the humidification is turned off (point 1 in the
control diagram) or the room humidity is half of the dehumidification hysteresis above the value, at which the
dehumidification is turned off (point 2 in the control diagram).

The louvers are proportionally controlled. In the same extent, as the outside air louver opens, the room air
louver closes. The louver at the condenser is completely opened, when the free cooling is enabled and competely
closed at compressor operation.

E/0605/20/101
Control Diagram

▲ 1. Condition for enabling the free cooling

1
▲ ▲

0 ▼ ▼


Humidif. Point 1 Humidif. Setpoint Dehumidif. Point 2 Dehumidif. rel. Humidity
Start Stop Stop Start


Humidification Dehumidification
hysteresis hysteresis
2 2

▲ 2. Condition for enabling the free cooling

1

0 ▼

Eco-off outside temp.

Wiring
ECO-louver control
The proportional signal (0-10V) is present to pin X1: 14+15 at the basic I/O-board.

Condenser louver control


The digital signal is present to pin X1: 6 at the extension I/O-board. The louver has to be configured.

Outside temperature sensor


A temperature sensor has to be connected to pin X1: 12 of the controller C5000.

Restrictions
GE-, CW- and dry cooler operation is no longer available. Another louver (e.g. at the discharge) can not be
controlled.

E/0605/20/102
Dimensions - CCD 41 - 121 with Ecocool louvers

front side rear side

63
250
376

63
104 375 104

583
1986

1876

1311

600
642

376
81
110

583

E/0605/20/103
Dimensions - CCU 41 - 121 with Ecocool louvers
Front Left side Rear

1850

63
250
376
376

213

63
49

583 110 599 110 104 375 104

829 583
600

E/0605/20/104
Dimensions - Internal Condenser KSI 010 with Ecocool louvers

front side left side rear side

280
50.5 253 96.5

404
1960

1850

1366.5

122.5

50 50
300
400
131

63
376

250
91

63

129 125 129


383

E/0605/20/105
Dimensions - CCD 171 - 201 with Ecocool louvers

front side rear side

104
125 125 125
583
104
1994

63 125 125 125 125 125 125 63


1874

876
1184

1000
852

583
89
117

876

E/0605/20/106
9.6 Control Options

C5000
Instead of the C1002 controller a C5000 controller can be fitted. For the operation of the C5000 exists a
separate manual.

Remote on/off switch


With this option you can also start your A/C unit from another point other than directly at the C1002 controller.
The switch required for this is also suitable for wall mounting.

Water detector
The water detector consists of two electrodes with a voltage difference of 24 V, which are fitted in the raised
floor. If water appears in the raised floor, a current flows between the electrodes, the C1002 switches off the
humidifier and the signal "LLS" appears on the display.

Fire stat
There are two versions of the fire stat available: provided with a heat detector, it triggers the signal "fire" if there
is excessive heat on the C1002. Equipped with a smoke detector, it reacts in a similar manner when there is
smoke. In both cases the C1002 switches off the A/C unit and closes the louvered flaps (if fitted).

E/0605/20/107
Extension card for C1002

This card is necessary for the complete functionality and a sequencing between two units together with a
water detector and a second heating stage. It is also necessary if an input for a fire stat and/or an input for an
Ultrasonic conductivity alarm in a unit with a compressor is needed.
With the extension card, additional inputs and outputs are provided to the CompTrol 1002, such as a louver
output, a second compressor output, two pressure alarms, an airflow alarm for a second module and an input
for a temperature limit. The extension card is fastened to the CompTrol 1002 by means of the two distance
pieces enclosed. The electric connection to the basic board is made with a 20-channel plug connector.

When you need an extension card for CCD/U 41-201 A/G units :
Fire stat/smoke detect.
OEM humidification
ENS humidification

Temp. limitation
Water detector
Sequencing
Heating 1
Heating 2

Louver

Heating 1 x x x x
Heating 2 x x x x x
OEM humidification x x x
ENS humidification x x x x x x x
Sequencing x x x x x x
Water detector x x x x x
Louver x x x x x x x x
Fire stat/smoke detect. x x x x x x x x
Temp. limitation x x x x x x x x

x = extension card required


= this combination is not possible.

E/0605/20/108
Appendix

The following list contains all documents which are supplied with your unit, apart from the operating instructions.

UNIT-SPECIFIC DOCUMENTS

Test report on unit final inspection ...........................................................................................

Test report on continuous testing .............................................................................................

Test report on final acceptance .................................................................................................

Test certificate for pressure test ................................................................................................

Replacement parts list ...............................................................................................................

Refrigerating diagram ................................................................................................................

Terminal plan for electrical engineering ...................................................................................

Wiring diagram ..........................................................................................................................

E/0605/20/109
Customer service
STULZ customer service ensures optimum operating reliability by means of preventative maintenance and
repair during the entire service life of your A/C units. Customer service is available to you round the clock. You
can contact our customer service at the STULZ branch responsible for you.

VICE
LZ - SER Your partner
STU for
a safe
climate
AIRCONDITIONING

For your service address please look at the back cover of this manual.

E/0605/20/110
STULZ GmbH A/CUNITS
Klimatechnik
Holsteiner Chaussee 283 MINI-SPACE
22457 Hamburg
Telephone: (040) 55 85 0 (switchboard)
Telex:
Telefax:
02 138 68
(040) 55 85 308 AIRCONDITIONING
BRIEF OPERATING INSTRUCTIONS
Your A/C unit originates from the STULZ Compact climate product range and is used to air condition rooms. The
following Frigene refrigerant (CFC) is contained in the refrigerant circuit of your A/C unit at the following system
pressures:
Attention, A-Units
The refrigerant circuits are pre-filled at the works. The complete filling
weight has to be indicated an the maker's plate after the start-up.

Refrigerant : R........ Caution. Only use the refrigerant stated Nominal CFC 25 bar
Quantity : .......... kg on the maker's plate! Perm. water pressure 16 bar

Please obtain the type of your A/C unit from the type code on the maker's plate. Before commissioning the A/C unit,
it is essential to read and follow the operating instructions.

Switching the A/C unit on and off


The A/C unit is switched on and off by pressing an
on/off switch on the controller.

Controller

Switching off the complete A/C unit

The complete A/C unit is switched off


via the controller and via the built-in
master switch. To do this, open the door
of the elctric cabinet and put the master
switch in position "0".

Master switch
First aid measures

- If health problems occur during or after handling - If the casualty is unconscious or very dazed they
fluorinated hydrocarbons, a doctor is to be consulted must not be given any liquid.
immediately. The doctor is to be informed that the - Splashes of fluorinated hydrocarbons in the eyes can
work involved using fluorinated hydrocarbons. be blown out by an assistant or fanned out. Then
- In the case of acute effect, the casualty is to be rinse with water.
brought into the fresh air as quickly as possible. The - Notes for the doctor:
casualty is never to be left unsupervised. Do not give any preparations from the adrenalin
- If the casualty is not breathing, immediately introduce ephedrine group (nor any noradrenaline) to treat shock.
mouth-to-mouth resuscitation. Obtain further information from the poison accident
centres. E/0605/20/111