Stulz Compact CWE Series Owner's manual

(©Aug,2006)
Compact CWE Series Installation, Operation & Maintenance Manual
Installation, Operation
& Maintenance
Chilled Water
Precision Air Conditioners
Compact CWE™ Series
Compact CWE™ Series

(©Aug,2006)
Compact CWE Series Installation, Operation & Maintenance Manual
Compact CWE - Precision Air Conditioners
Nominal Capacity in kW
CC = Compact CW System
D = Down-FlowAirPattern CW = Chilled Water System
CC D-300-CW-E
Number of Refrigeration Circuits
Model Nomenclature
E = EC Fan

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Compact CWE Series Installation, Operation & Maintenance Manual
1.0 Introduction.......................................1-1
1.1 General...................................................... 1-1
1.2 ProductDescription ................................... 1-1
1.3 ProductWarranty ...................................... 1-2
1.4 Safety........................................................ 1-3
1.4.1 General...................................................... 1-3
1.4.2 SafetySummary........................................ 1-3
2.0 Installation .........................................2-1
2.1 ReceivingtheEquipment. .......................... 2-1
2.2 Site Preparation......................................... 2-2
2.3 Rigging ...................................................... 2-2
2.4 Mounting/Placement.................................. 2-2
2.4.1 A/C Unit..................................................... 2-2
2.4.2 OptionalEquipment(Field Installed) .......... 2-3
2.4.2.1 RemoteDisplay ......................................... 2-3
2.4.2.2 RemoteTemperature/HumiditySensor....... 2-3
2.4.2.3 RemoteWaterDetector ............................. 2-4
2.4.2.4 FloorStand ................................................ 2-4
2.4.2.5 PlenumExtension ..................................... 2-4
2.5 AirDistributionConnection ........................ 2-4
2.5.1 DownflowConfigurationAir Patterns........... 2-4
2.6 Piping Connections.................................... 2-4
2.6.1 ChilledWater/HotWater ............................ 2-4
2.6.2 CondensateDrain ...................................... 2-5
2.6.2.1 GravityDrain .............................................. 2-5
2.6.2.2 CondensatePump ..................................... 2-5
2.6.3 Humidifier .................................................. 2-6
2.7 UtilityConnections .................................... 2-6
2.7.1 MainPower ............................................... 2-6
2.7.2 Controls..................................................... 2-7
2.7.3 OptionalEquipment ................................... 2-7
2.7.3.1 RemoteTemperature/HumiditySensor....... 2-7
2.7.3.2 RemoteWaterDetector ............................. 2-8
2.8 System Settings andAdjustments............. 2-8
2.8.1 ChilledWaterCircuit.................................. 2-8
2.8.2 HumidifierAdjustment ................................ 2-8
TABLE OF CONTENTS
3.0 Start-Up/Commissioning..................3-1
3.1 Operation................................................... 3-1
3.2 Step by Step Start-Up Instructions ............. 3-1
3.3 MicroprocessorController
Programming ............................................3-1
4.0 Maintenance/Repairs .......................4-1
4.1 PeriodicGeneralMaintenance ................... 4-1
4.1.1 A/C Unit..................................................... 4-1
4.1.1.1 Filter .......................................................... 4-1
4.1.1.2 Fan .......................................................... 4-1
4.1.1.3 DrainPan .................................................. 4-1
4.1.1.4 Coils .......................................................... 4-1
4.1.1.5 Heat/Reheat .............................................. 4-1
4.1.1.6 Humidifier .................................................. 4-1
4.1.1.7 CondensatePump ..................................... 4-1
4.2 Troubleshooting ...................................... 4-2/3
4.3 FieldService .............................................. 4-4
4.3.1 Piping ........................................................ 4-4
4.3.2 GeneralCommon Repairs/
ComponentReplacement........................... 4-4
4.3.2.1 HumidifierCylinder Replacement ............... 4-4
4.3.2.2 FilterReplacement .................................... 4-4
5.0 Product Support Group ...................5-1
5.1 TechnicalSupport ...................................... 5-1
5.2 Obtaining Warranty Parts .......................... 5-1
5.3 ObtainingSpare/Replacement Parts .......... 5-1
i

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Compact CWE Series Installation, Operation & Maintenance Manual
TABLE OF CONTENTS (Continued)
ii
List of Figures
Figure1 InstallationClearance ............................. 2-1
Figure2 TypicalInstallationDownflow................... 2-3
Figure3 Optional Floor StandInstallation ............. 2-4
Figure4 DownflowConfiguration
TypicalAir Patterns ................................ 2-6
Figure5 Condensate Pump.................................. 2-6
Figure6 SampleNameplate ................................. 2-6
Figure7 Electric Box ........................................... 2-7
AppendixA- Forms
ChecklistforCompletedInstallation .........................A-1
PeriodicGeneral Maintenance
ChecksandServiceChecklist..................................A-2
Appendix B - Glossary
DefinitionofTermsandAcronyms ............................B-1

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Compact CWE Series Installation, Operation & Maintenance Manual
1-1
1.0 INTRODUCTION
1.1 General
Congratulations,theCompactCWE™floormounted
air conditioning system covered by this manual is
designedandmanufacturedbyStulzAirTechnology
Systems, Inc. (SATS) using the latest, state-of-the-art
controltechnology. Recognized as a world leader,
SATSprovides air conditioning systemswith the
highestquality craftsmanship using the finest materi-
alsavailableinthe industry.Theunitwillprovide years
oftroublefreeserviceifinstalledandmaintainedin
accordance with this manual. Damage to the unit from
improperinstallation,operationormaintenanceisnot
coveredbythe warranty.
STUDY the instructions contained in this manual.
Theymustbefollowedto avoid difficulties.Spareparts
areavailable from StulzAir TechnologySystems to
insurecontinuousoperation. Using substitute parts or
bypassing electrical or cooling components in order to
continueoperationisnotrecommendedandwillVOID
THEWARRANTY.Due to technological advance-
ments, components are subject to change without
notice.
All Compact CWE systems are designed to be
installedindoorsunless otherwise noted on the
equipment.
1.2 Product Description
Compact CWE systems are designed to be the most
versatileandflexible floor mounted air conditioning
systems in the industry. Compact CWE units are
availableina down-flow air configurationandutilize
highlyefficient,electronicallycommutated (EC) fans.
The cooling capacity, in kW, will depend on the unit
size, which can range from 30 to 230 kW. (1kW =
3415BTU/Hr).Refertotheunitnameplateto identify
the model number and cooling capacity of your unit.
Compact CWE systems operate with an external
source of chilled water. The chilled water system is a
closed loop circuit in which cold water is circulated
throughthechilled water coil. On demand of cooling
bythemicroprocessor controller, thechilled water
valveopens.Chilledwaterflowstothecoilinpropor-
tiontotheamountofcooling required. The controller
modulatesthevalve opening together with the the fan
speedbasedon the cooling demand. Heat from the
surroundingairisextractedthroughthefinnedtubing
of the coil by the cold water. Water is then recirculated
back to the cold water source.
Compact CWE systems have been designed to supply
air to only one room.
NOTE
CompactCWE systems arestrictlyfornon-resi-
dentialapplications.
Thefunctionalmodesofoperationinadditionto
coolingareheating, humidification and dehumidifica-
tion,whichprovide complete environmental control of a
conditionedspace.
Thereareseveral cabinet sizes based on the type of
systemandcapacity. Regardless of configuration,
Compact CWE systems are compact and versatile.
SeetheInstallationdrawing provided with your unit for
the layout and dimensions of the cabinet.
The Compact CWE unitis provided witha factory
mounted, main power disconnect switch with lockable
handle. The disconnect switch electrically isolates the
unitduringroutinemaintenance.Thesystemincorpo-
rates state of the art component protection with the
use of motor start protectors and circuit breakers.
An operating manual for the system controller is
providedunder separate cover. Refer tothatmanualfor
detailed instructions on operating the system control-
lerprovidedwithyour unit.
The standard controller for Compact CWEA/C units is
theSATSmodelC6000.This microprocessor control-
lerprovidesthe following features: input/output moni-
toringstatus, full integrated control of heating,cooling,
humidificationanddehumidification;multi-unit control
andremotecommunication with building management
systems. The controller is typically factory mounted
on the front hinged access door of the unit.As an
option, the controller may be remotely mounted to a
wallorcontrolpanel.
C6000Controller

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Compact CWE Series Installation, Operation & Maintenance Manual
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1.3 Product Warranty
SATS offers a two year standard limited warranty as stated below:
2-Year Standard Limited Warranty:
Stulz Air Technology Systems, Inc., warrants to the original buyer of its
productsthatthe goods are free from defects inmaterial and workmanship.
Stulz Air Technology Systems, Inc.’s obligation under this warranty is to
repair or replace, at its option, free of charge to the customer, any part or
parts which are determined by StulzAir Technology Systems Inc. to be
defective.Thewarranty is in effect for 24 monthsfrom date of shipment if a
completed Warranty Registration and Start Up Form is submitted to StulzAir
Technology Systems, Inc. within 90 days from shipment. In the event that a
completed start-up form is not received by StulzAir Technology Systems, Inc.
within 90 days from shipment, the company’s obligation will be for a period of
12monthsfromdateofshipment. Parts replaced under warranty are war-
rantedfora period of 90 days from shipmentor for the remainder ofthe unit
warrantyperiod, whichever isgreater.
Stulz Air Technology Systems, Inc.’s warranty does not cover failures caused
by improper installation, abuse, misuse, misapplication, improper or lack of
maintenance,negligence,accident,normaldeteriorationincludingwearandtear,
or the use of improper parts or improper repair as determined by SATS. This
warrantydoesnot include costs for transportation,costsforremovalor reinstal-
lationofequipmentorlabor for repairs or replacement made in the field.
THISOBLIGATIONANDLIABILITYOF STULZAIRTECHNOLOGYSYS-
TEMS,INC. UNDER THIS WARRANTYDOESNOTINCLUDE LOSSES,
DIRECTORINDIRECT,FORINCIDENTALORCONSEQUENTIALDAM-
AGES. THIS WARRANY IS IN LIEU OFALLOTHER WARRANTIES,
EXPRESSORIMPLIED,INCLUDING WARRANTIESOR MERCHANTABIL-
ITYANDFITNESSFORAPARTICULARPURPOSE,ANDTHEREARE NO
WARRANTIESTHATEXTENDBEYONDTHEDESCRIPTION ONTHE FACE
HEREOF.
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


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Compact CWE Series Installation, Operation & Maintenance Manual
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1.4 Safety
1.4.1 General
Stulz Air Technology Systems, Inc. uses NOTES
alongwithCAUTION and WARNING symbols through-
out this manual to draw your attention to important
operationaland safety information.
A bold text NOTE marks a short message in the
information to alert you to an important detail.
A bold text CAUTION safety alert appears with
information that is important for protecting your
equipment and performance. Be especially careful to
read and follow all cautions that apply to your applica-
tion.
Abold text WARNING safety alert appears with
information that is important for protecting you from
harm and the equipment from damage. Pay very
close attention to all warnings that apply to your
application.
A safety alert symbol accompanies a general
WARNINGorCAUTION safetystatement.
A safety alert symbol accompanies an electrical
shockhazardWARNING orCAUTION safetystate-
ment.
1.4.2 Safety Summary
The following statements are general guidelines
followed by warnings and cautions applicable
throughout the manual.
Prior to performing any installation, operation, mainte-
nanceor troubleshooting procedure,readandunder-
stand all instructions, recommendations and guide-
lines contained within this manual.
All maintenance and/or repairs must be performed by
a journeyman, refrigeration mechanic or an air
conditioningtechnician.
Never operate the unit with any cover, guard, screen
panel, etc., removed unless the instructions specifi-
cally state otherwise, then do so with extreme caution
to avoid personal injury.
Never lift any component in excess of 35 pounds
without help. If a lifting device is used to move a unit,
ensure it is capable of supporting the unit.
Whenworkingonelectricalequipment,removeall
jewelry, watches, rings, etc.
Always disconnect the main power supply to the
equipmentatthemain power disconnect switch before
beginningworkonthe equipment.Alock-out tag-out
procedureshouldbefollowedtoensurethatpoweris
notinadvertently reconnected.
Equipment may contain components subject to
Electrostatic Discharge (ESD). Before attempting to
mount or service these electronic devices, ensure
you have no charge built up by touching a ground
source. When possible, use a wrist-grounding strap
when working on or near electronic devices.
Never work on electrical equipment unless another
person who is familiar with the operation and hazards
of the equipment and competent in administering first
aid is nearby.
All personnel working on or near equipment should be
familiar with hazards associated with electrical
maintenance. Safety placards/stickers have been
placed on the unit to call attention to all personal and
equipment damage hazard areas.
Certain maintenance or cleaning procedures may call
for the use and handling of chemicals, solvents, or
cleansers.Always refer to the manufacturer's Material
Safety Data Sheet (MSDS) prior to using these
materials. Clean parts in a well-ventilated area.Avoid
inhalation of solvent fumes and prolonged exposure
of skin to cleaning solvents. Wash exposed skin
thoroughlyaftercontactwithsolvents.
CAUTION
Whentheairconditioner is in the cooling mode,
the return air-intake and discharge (supply)
mustbefree of obstructions. Ensure panels are
secure and latched into position.
CAUTION
Donot usecleaningsolventsnearopen flameor
excessiveheat.Weareyeprotectionwhenblow-
ingsolventfromparts.Thepressure-washshould
notexceed 30 psig. Solventsolutionsshouldbe
disposed of in accordance with local and state
regulatorystatutes.
CAUTION
Units must be kept level and vertical in its nor-
mal installed position.

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Compact CWE Series Installation, Operation & Maintenance Manual
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2.0 INSTALLATION
2.1 Receiving the Equipment
Your Compact CWE system has been tested and
inspected prior to shipment. To ensure that your
equipmenthasbeenreceivedinexcellentcondition,
makeavisual inspection of the equipment immediately
upondelivery. Carefully removetheshippingcontainer
andallprotective packaging. Open the access doors
and thoroughly inspect the unit interior for any signs of
transit-incurreddamage.Ifthereisshippingdamage, it
mustbenotedonthefreightcarrier'sdeliveryforms
BEFORE signingfortheequipment.Anyfreightclaims
MUST bedonethroughthe freight carrier. SATS ships
all equipment FOB. SATS can assist in the claim
filing process with the freight carrier. Should any such
damagebepresent, notify the SATS Product Support
Grouppriorto attempting any repairs. Refer tosection
fiveofthismanualfor instructions.
A Data Package has been sent with your unit. It
containsthismanual, a supplemental microprocessor
controllermanual,systemdrawings,applicable
MSDS’s,othercomponentmanuals,warrantyregistra-
tion and other applicable instructions based on the
configurationandoptionsofyourunit.Thedata
package has been placed in your unit in a clear plastic
envelope.Thesedocumentsneedto be kept with the
unitfor future reference.
NOTE
Items that have been shipped loose, such as
controllers,temperature/humiditysensors, wa-
ter detectors, etc., are shipped inside the air
conditionerunlessspecifiedotherwisebythecus-
tomer.Thefilterbox or plenum box assembly (if
applicable) is shipped separately. Unpack and
storetheseitemsin a safe place unless you are
using them immediately.
40"
(MINIMUM FRONT
CLEARANCE)
Figure 1- Recommended Installation
Clearance
Frontserviceaccess.

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Compact CWE Series Installation, Operation & Maintenance Manual
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2.2 Site Preparation
Compact CWE systems are designed with easy
service access in mind. Component access panels are
locatedonthefrontoftheequipment.Thenumber of
panelsmayvarydependingonsize and configuration.
Each unit has one front hinged access panel housing
the electrical box. In order to have full service access
throughthefrontofunit,no permanent obstructions
can be placed in front of the unit. (See Figure 1.)
NOTE
Workingclearance requirements needtobees-
tablishedpriorto mounting the unit. Refer to lo-
cal and national electrical codes.
Tominimizetheeffects of the conditions surrounding
the conditioned space, certain steps must be taken.
This is especially true for critical/precision room
preparation(computerrooms/labs) requiring a close
toleranceof temperature and humidityvariation.The
conditionedspaceshouldbewell insulated and
includeavaporbarrier.Theinstallershouldensurethat
the proper insulation rating is used based on the
design of the space, which was the basis for the
system selected. The following chart is a recom-
mendedminimumR-value (thermal resistance) to
ensureoptimum equipment operation.
Thevaporbarrieristhesingle most important require-
mentformaintainingenvironmental control in the
conditionedspace.Thevaporbarrier in the ceiling and
walls can be a polyethylene film. Concrete walls and
floorsshould be painted with a rubberor plastic based
paint.Doorsandwindowsshouldbeproperlysealed
and a door sweep used to minimize leakage. Outside
or fresh air should be kept to a minimum (because it
addstothecooling,heating, dehumidification and
humidifyingloads),whilestillmaintainingtherequire-
mentof the IndoorAir Quality (IAQ) standard.Lack of
attention to these factors can cause erratic operation,
unstableroomcontrolandexcessivemaintenance
costs.
2.3 Rigging
The Compact CWE systems are designed to be kept
in a vertical position. Move the unit with a suitable
device such as a forklift, pallet jack or roller bar and
dollies.Weighttables are provided on the installation
drawings. Units are shipped on a skid to facilitate
movingprior to installation. Units should alwaysbe
stored indoors in a dry location prior to installation.
CAUTION
Unitsmustbe kept level and in the verticalposi-
tionwhenlifting to prevent damage to the unit.
2.4 Mounting/Placement
Compact CWE systems that are not ducted are
designed to be located in the conditioned space.
Ducted units may be located inside or outside the
conditioned space, but are designed to supply air to
only one room. Compact CWE systems are front
accessible, which allows the units to be placed in a
cornerorbetween cabinetry. It is recommended that
the unit is positioned in order to optimize air circula-
tion.
NOTE
Placementof the floor or ceilingregisters is im-
portant.Iftheyare too close to the unit, the sup-
ply air will be recirculated back to the unit be-
fore it has circulated throughout the space.
ThedownflowairpatternA/Cunithasbeendesigned
to be located directly on a raised floor. On some raised
floorinstallations,afloorstandisrequired,depending
on the load capacity of the existing raised floor. (See
Figure2).
2.4.1 A/C Unit
The Compact CWE system uses a frame and panel
construction for unit rigidity and full service accessibil-
ity without moving the unit. Ensure the mounting
surface is able to support the weight of equipment.
Beforemountingthe unit, refer to the weight tables
thatareprovidedintheinstallationdrawings.
If a floor stand is used, refer to the installation drawing
provided and cut out the raised floor to match the
unit’s overall base dimension. If a floor stand is not
used, cut out the raised floor to match blower dis-
chargeopening(s) and any required pipingandwiring
holes.Refertothe installation drawing supplied with
theunitfordimensional information.
STRUCTURE R-VALUE
Ceiling R-38
Wall R-21
Floor R-19
Door R-5

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Compact CWE Series Installation, Operation & Maintenance Manual
2-3
NOTE
Equipmentmustbeleveltooperateproperly.
2.4.2 Optional Equipment (Field Installed)
NOTE
Do not mount any optional equipment on unit
access doors.
2.4.2.1 Remote Display
As an option, a factory supplied control panel may be
remotemounted.Formountingandwiring instructions,
refertothe system drawings and the supplemental
manual sent in the data package with your unit.
2.4.2.2 Remote Temperature/Humidity Sensor
Theremotetemperature/humiditysensormustbe
located so that it will properly sense the temperature/
humidityconditions to be controlled.The sensor
shouldnotbemounted near a doorway, near or above
anyheatproducingequipmentoranareawhereit
would be exposed to direct sunlight. Follow the steps
below to mount the sensor. For unit wiring details,
referenceSection2.7, Utility Connections.
Temperature/HumiditySensor
1. Usinga flat headscrewdriver,remove the cover
screw from the top, right corner of the sensor and
removethecover plate from the base.
2. Placethebasetemporarilyover the wire hole
openingin the wall. Levelthe base andmark the
locationthroughthetwoprovidedmountingslots.
3. Drilltheholesandinsert the provided wall an-
chors.
4. Place the base over the wires coming out of the
wallandmountwithscrews provided.
5. Make wiring connections. (See Utility
Connections.)
6. Replaceunit cover.
CAUTION
Donotdamagetheexposedtemperature/humid-
ity sensors on the PC board while screwing in
the cover fastening screw. The sensors can be
damagedif handled improperly.
Figure 2- Typical Installation Downflow
OPTIONAL
FLOOR STAND
HINGED
DOOR
(BOTH SIDES)
SERVICE
SWITCH
CONTROLLER
COVER
SCREW

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Compact CWE Series Installation, Operation & Maintenance Manual
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2.4.2.3 Remote Water Detector
Theremotewater detector is normally placed onthe
sub-floororinafieldsupplied auxiliary drain pan
located beneath the unit. It may be attached using
doublesidedtape. Prepare surface before installing
tape.Apply tape to the water detector and secure in
place.
2.4.2.4 Floor Stand
See Figure 3. Install the floor stand directly on the
sub-floor, ensuring the side withthe "FRONT" label is
facing the same direction as the front of theA/C unit.
Refer to the installation drawing to cut out the raised
floor.Thefloorstandis adjustable. Refer to the floor
standassemblydrawing for the minimum and maxi-
mum height of your floor stand.To adjust height, turn
the floor stand foot in the desired direction to raise or
lower the stand. Ensure top of floor stand is even with
the raised floor and level. Lock the feet in place by
tightening the hex nuts against the floor stand legs.
2.4.2.5 Plenum Extension
The optional plenum extension is typically shipped
loose. To install the plenum extension, place the
assembly on top of the unit.Attach with the supplied
self-tappingscrews.Holesarepre-drilled in the unit
and the plenum extension box.
2.5 Air Distribution Connection
2.5.1 Downflow Configuration Air Patterns
Inadownflowconfiguredunittherearetwobasicair
patterns:topfreereturn and top ducted return. (See
Figure4).Theconditionedsupplyairdischarges
through the bottom of the unit into the raised floor.
Theonlyairdistributionconnectionrequiredona
downflow system is on units that require ducting.
Whendeterminingductingrequirements,always
consult your local or state codes. The duct system
should be designed to allow the air to move as freely
as possible.
Returninletsareprovidedwithaflange on top of the
unitforconnection of the ductwork (refer to the
installationdrawingprovided with the unit). The
connection of the duct to the unit may be made with
eitherpoprivetsorself-tappingscrews.
2.6 Piping Connections
2.6.1 Chilled Water/Hot Water
Theopeningsforthechilledwaterandoptionalhot
water reheat piping are located in the base of the unit.
Generally, the piping terminates inside the unit and
uses sweat connections. See the installation drawing
forthe exact location ofthe openingsand for pipe
connection sizes.
Pipe should not necessarily be the same size as the
unit connection. Piping should be sized to match the
system pressure drop and flow capacity and may
require a reducing fitting to match the connection size
ontheairconditioner.Afilling connection and several
shradervalvesare installedin theA/C unit.Refer to the
pipingdiagramsuppliedwithyourunit
CAUTION
When installing and filling the chilled water and/
or hot water loops, all air must be bled from the
piping system and the piping system must be
cleaned prior to operating the system. Failure to
do so could result in equipment problems.
NOTE
All chilled water lines must be insulated to
preventcondensationfrom forming on the pipes.
2.6.2 Condensate Drain
Figure 3- Optional Floor Stand Installation
ONLY REQUIRED ON 24" OR
TALLER FLOOR STANDS
ONLY REQUIRED ON 24" OR
TALLER FLOOR STANDS
HEX NUT
FOOT

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Compact CWE Series Installation, Operation & Maintenance Manual
2.6.2.1 Gravity Drain
Piping is installed to drain the condensate pan.An “S”
trapis provided at theend ofthe pipingfor the installer
to connect a drain line for directing the water away
fromthe cabinet. This line also drainsthe (optional)
humidifier. The drain line must be located so it will not
beexposedtofreezingtemperatures.Thedrainline
should be the full size of the connection.
2.6.2.2 Condensate Pump (See Figure 5)
Anoptionalcondensate pump may be used for
automaticremovalofcondensatefromthe air condi-
tionerandflushwaterfromthehumidifier. If an optional
field installed condensate pump is selected, a p-trap
mustbeinstalledfor proper condensate drainage. The
height of the trap must be a minimum of 2 inches on
most standard systems to ensure proper water
drainageofthedrainpan.To prevent excessive back
flow to the unit, the condensate pump discharge line
should be 1/2 inch ID maximum copper or vinyl tubing.
2-5
Figure 4- Downflow Configuration Typical Air Patterns
NOTE
Poursomewater into the condensate drain
priortostart-up. This fills the trap and prevents
airfrombeingdrawnupthedrain line.
INLET 7/8" OD
OUTLET 1/2" OD
NOTES:
1. MIMIMUM HEIGHT IN INCHES.
2. P-TRAP MUST BE LOCATED IN THE INLET SIDE OF PUMP WHEN FIELD INSTALLED.
2.00
SEE NOTE 1
SEE NOTE 2
Figure 5- Condensate Pump
RET
U
AIR IN
SU
PPLY
AIR
OU
TLE
T
T
O
P D
UC
TED RET
U
RN
T
O
P FREE RET
U
RN
R
ET
U
RN
AIR INLET
SU
PPLY
A
IR
OU
TLE
T

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Compact CWE Series Installation, Operation & Maintenance Manual
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2.6.3 Humidifier
Compact CWE systems use an electrode steam
cylinderhumidifierrequiring normal tap water for
operation.Thehumidifierrequires a 1/4 inch water
supply line, connected to the compression fitting on
thesideofthe humidifier chassis. The humidifier
empties directly into the condensate pan for the flush/
drain cycle.
2.7 Utility Connections
2.7.1 Main Power
TheCompactCWEproduct offering is available in 208,
460and575voltthree-phaseconfigurations.Itis
imperativethattheunitnameplate be examined to
determinethe operating voltage, frequencyandphase
of the system. (See Figure 6). The nameplate also
providesthe full load amps(FLA), the currentthat the
unitwill draw under full design load,the minimum
circuit ampacity (MCA) for wire sizing, and the maxi-
mumfuseor HACR (Heating,AirConditioning,Refrig-
eration)breakersize(MAXFUSE/CKTBKR)forcircuit
protection. The unit's nameplate is located inside the
cabinet, within the electrical box.
NOTE
If the nameplate states MAX FUSE/CKT BKR,
it is required to utilize fuses or HACR type cir-
cuit breakers to protect the system. Other pro-
tectiondevicesarenotallowedbased upon the
productlisting.
Theunit is provided with terminals for all required field-
wiring connections. Refer to the electrical schematic
suppliedwiththe unit for all power and control field-
wiring connections. It is important to identify the
options that were purchased with the unit in order to
confirmwhichfieldconnections are required.
WARNING
Verifypoweristurnedoffbeforemaking connec-
tions to the equipment.
NOTE
Allwiringmustconformtolocalandnationalelec-
tricalcode requirements.Useof copperconduc-
tors only is required. Wiring terminations may
become loose during transit of the equipment;
therefore, it is required to verify that all wiring
terminationsaresecure.
Figure 6- Sample Nameplate

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Compact CWE Series Installation, Operation & Maintenance Manual
2-7
It is important to verify that the main power supply
coincideswiththevoltage,phaseandfrequency
informationspecifiedonthesystemnameplate.The
supply voltage measured at the unit must be within
±10%of the voltage specified on thesystem name-
plate.
A manual fused disconnect switch or HACR type
circuit breaker must be installed per local and national
electricalcodesforservice of equipment. Do not
mountacustomer supplied manual fused disconnect
switch or HACR type circuit breaker to the surface of
the unit.
Eachunitisprovidedwithopeningsforconnection of
themainpower and control field-wiring. Theseopen-
ings are located at the bottom of the cabinet.Alabel
stating "MAIN POWER INPUT" is in close proximity.
Terminate the main power wires at the line side of the
main power disconnect switch located within the
electric box.Aseparate equipment ground lug is
providedwithintheelectricalboxforterminationofthe
earthground wire.
The number callouts in Figure 7 coincide with the
numbereditemslisted below:
1. Control I/O Board
2. InterfaceTerminals
3. Main Power Disconnect Switch
4. GroundLug
5. Power Switches/Motor Starter Protectors
(Quantity varies by size of A/C unit)
6. Control Circuit Breakers
CAUTION
Improperwireconnectionsmayresultindamage
to the unit.
CAUTION
Priorto unitoperation,anadequateunit-to-earth
ground must be connected to the unit.
2.7.2 Controls
StulzAir Technology Systems offers control features to
solveyourair conditioning control/alarm requirements.
The Compact CWE system is furnished with a C6000
Microprocessor controller. If it is mounted on the unit
(standard), no utility connection is required.As an
option a factory supplid display may be remote
mounted.Asix-conductorcableharnessisprovidedfor
interconnectwiring.Refertotheelectricaldrawing
providedwiththeunitfordetailsoninterconnecting
fieldwiring.
2.7.3 Optional Equipment
Additionalcontrolconductorsmayberequired depend-
ingon the options purchased with theequipment.
Referto the electrical diagram supplied withyour unit
todeterminethetotalnumberof interconnecting
conductors required for your system. It is important to
notethatthe control transformer(s) supplied with the
equipmentaresized and selected based upon the
expected loads for each system.
CAUTION
Do not connect any additional loads to the sys-
temcontrol transformers. Connectingadditional
loadsto the factorysuppliedcontroltransformer
mayresultinoverloadingofthetransformer,which
willcausethetransformer circuit breaker to trip.
NOTE
All wiring must be provided in accordance with
localandnational electrical code requirements.
2.7.3.1 Remote Temperature/Humidity Sensor
Theremotetemperature/humidity sensor requires a
threeconductor shielded cable, withthe shield
terminated at the unit electric box. Both the electric
Figure 7- Electric Box
4
1
3
5
2
6

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Compact CWE Series Installation, Operation & Maintenance Manual
2-8
boxandthe sensor are provided with a terminalstrip
forthewire connections. Refer to the supplied electri-
calschematicforproper wire terminations.
2.7.3.2 Remote Water Detector
Theoptionalremote water detector requires two
conductors to be wired to the control terminal board
within the unit electrical box. The wire insulation must
be rated at 600V. The water detector includes screw
typeterminals for wire connections. Refer tothe
suppliedelectricalschematicforproperwiretermina-
tions.
2.8 System Settings and Adjustments
2.8.1 Chilled Water Circuit
In a chilled waterA/C unit, cooling is maintained by
theliquidflowing through a regulatingvalveonthe
outletofthe cooling coil. The regulatingvalvepropor-
tionally opens to increase liquid flow as the tempera-
ture rises (or closes as the temperature falls). If the
unit is turned off, the valve will return to the closed
position, shutting off liquid flow to the coil. Chilled
Waterregulating valves are availablein2-wayor 3-way
configurations.Referto the piping drawing supplied
withyourunit to determine which type valve ispro-
vided.
Locationandsizeofchilledwatervalvesdifferswith
the size of theA/C unit. The chilled water regulating
valvesarefactorysetforthecorrectoperationand
shouldnotrequirefieldadjustment.
2.8.2 HumidifierAdjustment
The humidifier has a capacity adjustment pot on the
humidifier control circuit board. The capacity pot may
need to be field adjusted if the humidifier is not supply-
ingenoughcapacityfor current room conditions.
It is recommended that if the humidifier capacity pot
requires adjustment, the adjustment is made in small
incrementsandverified. Refer to thehumidifiermanual
sent with your unit for the capacity pot location.
CAUTION
Adjusting the capacity pot too high may result in
condensation within the system.

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Compact CWE Series Installation, Operation & Maintenance Manual
3-1
3.0 START-UP/COMMISSIONING
3.1 Operation
For new installations, ensure the unit is ready to
operatebygoingthroughtheChecklistforCompleted
Installation, located inAppendixA, prior to start-up.
NOTE
AWarrantyRegistrationand Start-UpChecklist
isprovided with theunitdatapackage. It should
becompleted during start-upand senttoSATS.
Thischecklistshould be used as aguidelinefor
itemsthat need tobeconfirmedduring start-up.
Start-up must be performed by a journeyman, refrig-
erationmechanicoran air conditioning technician.
3.2 Step by Step Start-Up Instructions
1. Replaceall equipment removedpriortoperforming
start-up checks.
2. Ensurethatthe control circuit breakers, fanpower
switchandadditionalbuilt in optional equipment
powerswitchesareturnedon.
3. Apply power to start the Compact CWE system
at the main power disconnect switch.
4. Ensurethatallblowersand fans are rotating
correctlyand freely without any unusualnoise.
5. Turn on theA/C unit at the system controller and
setthedesiredvalues(setpoints)forroom
temperatureandhumidity.(Refertotheseparate
controller operation instructions sent in the data
packagewithyour unit.)
6. Testcoolingoperationbyadjustingthetempera-
turesetpointbelowactualroomtemperature.The
chilledwatervalve should open and the fanspeed
shouldincrease.Thedischargeairshouldfeel
coolerthanthereturn air.
7. Testhumidificationoperation.Useanampmeter
todeterminecurrentdrawofthe humidifier.A
visualcheckofhumidity leaving the steam head
or a hot cannister/cylinder bottle can also indicate
if the humidifier is operational. In all cases, 1 to 6
hoursmightbe required to see a desired level or
rise of humidity in the conditioned space. Once
roomconditionshavebeenprogrammedor set, a
repeat visit to the conditioned site may be re-
quiredtoensure the humidifier is meeting the
room'srequirements.
8. Test dehumidificationoperationby creatinga
demand fordehumidification. If necessary,createa
demandforhumidificationbyadjustingthe
setpoint10%belowactual room conditions. (The
setpointmay already be below actualroom
conditions, especially at start-up.Thechilledwater
valveshould opentobeginthedehumidification
process.Whileinthis mode, room temperature
maydecreaseand the reheat function mayacti-
vate.As conditions in the room change, you may
have to readjust the setpoint as you check the
operation.Anadequateheatload withinthespace
isrequired.
9. For Electric Reheat, use an amp meter on the
heatercircuittodetermineifthe heaterisopera-
tional.ForHot Water Reheat ensure that the
controlsignal hasenergizedthecontrolvalve and
thetemperatureofthewaterhasdecreasedasit
passes through the unit. In all cases, 1 to 6 hours
mightbe requiredtoseea desiredlevelor decrease
of humidity in the conditioned space. Once room
conditionshavebeenprogrammedorset,a repeat
visit to the conditioned site may be required to
ensurethe dehumidificationmodeismeeting the
room’srequirements.
3.3 Microprocessor Controller Programming
Themicroprocessorcontroller is factory programmed
basedon the optional features selected.Most applica-
tionsrequirenofieldstart-uporprogramadjustment
beyondsetting the current dateand time. Separate
operatinginstructionsforthecontrollerhavebeensent
withyourunit,including each feature's factory "default"
settingandtheavailableadjustmentrange,ifappli-
cable.

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Compact CWE Series Installation, Operation & Maintenance Manual
4-1
4.0 MAINTENANCE
4.1 Periodic General Maintenance
Systematic,periodicgeneralmaintenance of the
CompactCWE unit is recommended for optimum
systemperformance.General maintenance should
include, but is not limited to the following: replacing
filtersandhumidifiercylinders,tightening electrical
connections, checking the water lines to ensure they
are free of debris, ensuring no air is in the water
line(s), cleaning the interior of the unit and inspecting
the unit’s components visually.
UsecopiesofthePeriodicGeneral Maintenance
Checklist in this manual (seeAppendixA) to record
periodic general maintenance inspections. For
assistance, contact the SATS Product Support Group.
Ensure adherence to all safety statements while
performinganytype of maintenance.
WARNING
Turnoffpower to the unit at the main powerdis-
connectswitch, unless you areperformingtests
that require power. With power and controls en-
ergized,theunitcould beginoperatingautomati-
cally at any time.
Hazardous voltage willstill be present insidethe
electric box at the motor start protectors and at the
heaterandhumidifier circuit breakers even withtheunit
turnedoffat the microprocessor contoller.Toisolate the
unitfor maintenance,turnoff poweratthe mainpower
disconnect switch.
Alwaysdisconnectmainpowerpriorto performing any
serviceorrepairs.To preventpersonal injury, stayclear
ofrotatingcomponentsbecause automatic controls
may start them unexpectedly.
This unit employs high voltage equipment with
rotating components. Exercise extreme care to avoid
accidents and ensure proper operation.
WARNING
Thisequipment should be servicedandrepaired
byajourneyman or a qualified refrigeration
technician only.
4.1.1 A/C Unit
4.1.1.1 Filter
The filter is usually the most neglected item in an air
conditioningsystem.To maintainefficientoperation,
the filter should be checked at least monthly and
replacedas required.
NOTE
Conditions of spaces vary and filters should be
checked based on those conditions.
4.1.1.2 Fan
Periodic checks of the EC fan system should include
checking the fan motor mounts, housing and the
impeller wheel. Check that all mounts are secure and
impellerwheelistightly mounted. The impeller blades
shouldbefreeofdebris.
4.1.1.3 Drain Pan
To ensure proper drainage, inspect the drain pan
regularly. Make sure the drain pan outlets are always
freeofdebris and ensure the drain pandoes not leak.
4.1.1.4 Coils
Thecoil(s)shouldbeinspectedsemi-annuallyand
cleanedasrequired,followingstandard coil cleaning
practices. Using a brush, clean the coil fins of all
debris that will inhibit airflow. This can also be done
with compressed air or with a commercial coil cleaner.
Checkfor bent or damaged coil finsand repair as
necessary. Check all piping lines for signs of leaks.
4.1.1.5 Heat/Reheat
Theheat/reheatequipmentshouldbe inspected semi-
annually to ensure it is operational. If you have electric
heat/reheat,inspectthe heating elements to ensure
theyarefreeofdebris.
4.1.1.6 Humidifier
Because water conditions vary greatly, it is difficult to
establish intervals for changing the cylinder.Achange
cylinder light (red) will illuminate on the humidifier
cabinet when the cylinder requires replacement.
Individualmaintenanceschedules must be determined
foreachlocation,baseduponperiodicexaminationof
thehumidifier.
4.1.1.7 Condensate Pump
Thecondensatepumpshouldbeinspectedsemi-
annually and cleaned. Ensure that the float stem
works freely. Wipe the float with a wet cloth and
detergenttoremove dirt. Clean the bottom tank.
Check that the discharge line is open and water can
pass through it freely.

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Compact CWE Series Installation, Operation & Maintenance Manual
4-2
SYMPTOM PROBABLE CAUSE RECOMMENDATION
4.2 Troubleshooting
WARNING
Turnoffallpowertotheunitbeforeconductinganytroubleshootingprocedures,unlesstheprocedurespecifi-
cally requires the system to operate. For troubleshooting purposes, the system may be operated with the
doors open by using a pair of channel lock pliers to turn the shaft of the main power disconnect switch to the
“on” position. When the switch is turned on, high voltage will be present inside the cabinet. Exercise caution
to prevent injury. Keep hands, clothing and tools clear of the electrical terminals and rotating components.
Ensure that your footing is stable at all times.
Chilled Water Valve Fails a.Temperaturesetpoint too high. Adjust to correct temperature setting.
to Open or Close
b.Nocontrolpowertothevalve. Valve actuatoris wired incorrectly.
Checkwiringschematicand rewire if
required.
c.Actuator failed. Replaceactuator.
EC Fan(s) Fail to Start a.Powerfailure. Check main voltage powersource
inputcable.
b. Motor starterprotector tripped. Reset motor starter protector and check
amperageofmotor. Compareto setting
on motor circuit controller and adjust to
FLA.
c.Control transformer circuit Check for short circuitor ground fault,
breakertripped. if none reset circuit breaker.
d.Defective contactor. Repair orreplace.
e. No control signal to fan(s). Check theControl I/OBoard for a0-10
VDCcontrolsignalto the fan(s). Refer
to the electric drawing to determine the
correctI/Oboardterminalnumbers.(This
must done within 15 seconds of turning
the disconnect switch on or the controller
willgointo“AirProvingAlarm” mode.
Control is Erratic Wiringimproperlyconnectedor Check wiring against schematic
broken. diagram.
System Short of Capacity a. Low Chilled Water flow CheckforleaksRepairand recharge
system.
b.Supplywatertemperaturetoo high Check chilled water supply
c. Reducedairflow. Check filters

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Compact CWE Series Installation, Operation & Maintenance Manual
SYMPTOM PROBABLE CAUSE RECOMMENDATION
4-3
System Short of Capacity d. Dirty Coil Clearcoilfins of debris
(cont.)
Electric Heater a.Circuitbreakertripped. Check for short circuit, reset circuit
Inoperable breaker.
b.Temperaturesetpointtoo low. Increase temperaturesetpoint.
c.Overheatswitchopen. Insufficientairacrossheaterelements.
Check for dirty filters or obstructions
thatmay reduce air flow. Correct or
replaceasneeded.
d.Manualresetoverheatsafety Reset manual overheat safety switch
switchtripped. (Seeitemimmediatelyabove).
e. Heater elementburned out. Check continuity with an ohmmeter.
Replaceheater element.
Hot Water Heater a. Lowhot waterflow. Check hot water flow at supply source.
Inoperable Inspect piping for leaks or obstructions.
b. Hotwater supply temperature too Check hot water supply.
low
c.Temperaturesetpoint too low. Increase temperature setpoint.
d.Control power interrupted. Check for loose or broken wires.
Humidifier Inoperable a. Water supply has been turned Connect and/orturn on watersupply.
Note:SeeHumidifier offornotconnected.
ManualforAdditional Help. b. Electrical connections are loose. Tighten electrical connections.
c.Humidifiercircuitbreakertripped. Checkforovercurrentbythehumidifier
electrodes.Drainwaterfromtankand
refill.Resetcircuit breaker.
d.Relativehumidityisabovesetpoint. Adjust humidity setpoint.
e.Electrode canister change cylinder 1.Consult humidifier manual.
light is on. 2. Water conductivity is too low and
water is at the top of the cylinder
(see next item).
f. Water conductivity is too low. Add a teaspoon of table salt to the water
through the top of the cylinder. Typically
only on initial start-up.

(©Aug,2006)
Compact CWE Series Installation, Operation & Maintenance Manual
4.3 Field Service
NOTE
Do not attempt to make repairs without the
proper tools.
It may be necessary to perform repairs on theA/C
system.If field repairsare necessary,thefollowing
proceduresapply:
1. All electrical connections should be checked to be
surethey are tight andproperly made.
2. Check all circuit breakers, contacts and wiring.
Thecontactershouldbeexaminedandreplacedif
contacts are worn or pitted.
4.3.1 Piping
Whenreplacingcomponents within the cabinet of the
unit,thefollowingconsumablematerialsarerecom-
mended:UseSilfos alloy for copper-to-copper (piping
dischargeorsuctionline repairs).Silversolder(Stay-
Silv#45)andflux are to be used on copper-to-brass or
copper-to-steelrepairs.
Whencomponentreplacementiscomplete,removeall
traces of flux.After any repair, pressure check the
system, checking for leaks prior to recharging the
system.
4.3.2 General Common Repairs/
Component Replacement
4.3.2.1 Humidifier Cylinder Replacement
Afteranextendedperiod of operation a red light will
illuminateon the humidifier cabinet indicatingthat the
cylinder is completely used and a replacement
cylinder must be installed. The cylinder is disposable
andcylinderlife is dependent on water supply condi-
tionsand humidifier usage. The followingprocedures
aretobefollowedwhenreplacingthecylinder.
CAUTION
Failure to replace the cylinder at the end of cyl-
inderlifemayresultin humidifier damage.
NOTE
Decrease the low humidity setpoint below am-
bienthumidityto allow the cylinder to cooldown
beforeremoving thecylinder.
1. Turn offwater supply to thehumidifier.
2. DrainthecylinderbypushingtheAUTO/ON-OFF-
DRAINswitchto the DRAIN position.
4-4
3. Whendrained, push theAUTOON/OFF/DRAIN
switch to the OFF position.
4. Disconnect power to the unit at the main power
disconnect switch.
5. Thepower wiresto the cylinderare attachedby
cylinder plugs to the electrode pins on top of the
cylinder. Pull these plugs vertically off the pins.
CAUTION
The cylinder and steam hose may be hot and
burns may result.
6. Loosen the steam hose clamp(s) and pull the
steamhoseoffvertically.
7. Lift the cylinder straight up to disengage from the
humidifier.
8. Place the new cylinder on the side mounting slots
withinthe unit, ensuring the cylindermounting
stubsareseatedproperly.
9. Replace the cylinder plugs on the pins, ensuring
the white sensor plug goes on the single pin,
which is offset from the others.
10. Ensure the plugs are secured on the pins. If the
fitting plugs are loose, they may be temporarily
squeezedtogether,however, the plugs must be
replacedsincealoose plug could generate
enough heat to melt and destroy the plug.
11. Replace the steam hose and tighten the clamp(s).
12. Turn on main power to the unit at the main power
disconnect switch.
13. Push theAUTO/ON-OFF-DRAINswitch to the
AUTO/ONposition.
14. Turn on the water supplyto the humidifier.
15. Re-adjustthehumidity setpoint.
If the humidifier is to be shut down for an extended
period,alwaysdrainthe cylinder first. Follow the above
steps1through 4 ensuring theAUTO/ON-OFF-DRAIN
switch is in the OFF position. Failure to do this will
drastically shorten the cylinder life.
4.3.2.2 Filter Replacement
The air filters are accessed from inside the cabinet. To
change the filters, open the front doors of the cabinet.
The filters are located inside the cabinet at the top
wherethe label "FILTERACCESS" appears. Remove
the old filters from the trays. Insert the new filter(s)
ensuringthedirectionalairflowarrowsonthefiltersare
correct, then close the front doors.