Stulz Compact CWE User manual

Compact CWE
Installation, Operation and Maintenance Manual
Perimeter Mounted Precision Air Conditioners
30 kW - 360 kW / 60 Hz

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Compact CWE - Precision Air Conditioners
Nominal Capacity in kW
CC = Compact CW System
D = Downflow Air Pattern
U = Upflow Air Pattern
CW = Chilled Water
System
CC D-300-CW-E-UF
0 = Number of Refrigeration
Circuits
Model Nomenclature
E = EC Fan*
*Electronically Commutated (EC) Fan
Highly reliable EC Fans offer considerable energy cost
savings and long life. Using an electronically
commutated permanent magnet DC motor,
AC inverter whine is eliminated. Fan speed is
continuously adjustable via a signal from the
system controller without the use of VFD’s. EC
fans offer energy efficient, quiet, low vibration
operation.
UF = Under Floor
Fan(s)

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1.0 Introduction .......................................1-1
1.1 General......................................................1-1
1.2 Product Description....................................1-1
1.3 Product Warranty.......................................1-2
1.4 Safety.........................................................1-3
1.4.1 General......................................................1-3
1.4.2 Safety Summary ........................................1-3
1.5 General Design..........................................1-5
1.5.1 Electric Box Access....................................1-6
1.5.2 Circuit Breakers/ Motor Start Protectors....1-6
1.5.3 Heaters ......................................................1-6
1.5.4 Coils...........................................................1-6
1.5.5 EC Fans.....................................................1-6
1.5.6 Temperature/ Humidity Sensor ..................1-6
1.6 Optional Equipment ...................................1-6
1.6.1 Humidifier...................................................1-6
1.6.2 Condensate Pump.....................................1-6
1.6.3 Smoke Detector.........................................1-7
1.6.4 Firestat.......................................................1-7
1.6.5 Auto Transfer Switching.............................1-7
2.0 Installation .........................................2-1
2.1 Receiving the Equipment...........................2-1
2.2 Site Preparation.........................................2-1
2.2.1 Conditioned Space.....................................2-1
2.3 Rigging.......................................................2-2
2.4 Mounting/Placement..................................2-2
2.5 Air Distribution Connection ........................2-3
2.5.1 Upflow Configuration Air Patterns..............2-3
2.5.2 Downflow Configuration Air Patterns .........2-4
2.6 Optional Equipment (Field Installed)..........2-5
2.6.1 Floor Stand ................................................2-5
2.6.2 Deploying Underfloor EC Fans..................2-5
2.6.3 Plenum Box................................................2-6
2.6.4 Remote Display..........................................2-7
2.6.5 Condensate Pump.....................................2-7
2.6.6 Remote Temperature/Humidity Sensor......2-7
2.6.6.1 Types of Control.........................................2-7
2.6.7 Remote Water Detector .............................2-8
2.7 Piping Connections....................................2-9
2.7.1 Chilled Water/Hot Water ............................2-9
TABLE OF CONTENTS
2.7.2 Condensate Drain......................................2-9
2.7.2.1 Gravity Drain..............................................2-9
2.7.2.2 Condensate Pump...................................2-10
2.7.3 Humidifier.................................................2-10
2.8 Utility Connections...................................2-11
2.8.1 Main Power..............................................2-11
2.8.2 Controls....................................................2-12
2.8.3 Optional Equipment .................................2-13
2.8.3.1 Remote Temperature/Humidity Sensor....2-13
2.8.3.2 Remote Water Detector ...........................2-13
2.9 System Settings and Adjustments ...........2-13
2.9.1 Chilled Water Circuit ................................2-13
2.9.2 EC Fan(s).................................................2-13
3.0 Start-Up/Commissioning..................3-1
3.1 Operation...................................................3-1
3.2 Step by Step Start-Up Instructions.............3-1
3.3 Microprocessor Controller
Programming .............................................3-1
4.0 Maintenance/Repairs ........................4-1
4.1 Periodic General Maintenance...................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 Drain Pan...................................................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 Condensate Pump.....................................4-2
4.2 Troubleshooting .........................................4-2
4.3 Field Service..............................................4-4
4.3.1 General Common Repairs/
Component Replacement..........................4-4
4.3.1.1 Cooling System..........................................4-4
4.3.1.2 Leaks .........................................................4-4
4.3.1.3 Humidifier Cylinder Replacement ..............4-4
4.3.1.4 Filter Replacement.....................................4-4
5.0 Product Support................................5-1
5.1 Technical Support ......................................5-1
5.2 Obtaining Warranty Parts...........................5-1
5.3 Obtaining Spare/Replacement Parts .........5-1
i

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TABLE OF CONTENTS (Continued)
ii
List of Figures
Figure 1 Typical Internal Layout- Upflow...............1-5
Figure 2 Typical Internal Layout- Downflow..........1-5
Figure 3 Auto Transfer Disconnect Switches........1-7
Figure 4 Preferred Power Selection Switch..........1-7
Figure 5 Recommended Installation Clearance....2-1
Figure 6 Typical Installation Upflow ......................2-2
Figure 7 Typical Installation Downflow..................2-3
Figure 8 Upflow Configuration Air Patterns...........2-3
Figure 9 Downflow Configuration Air Patterns......2-4
Figure 10 Floor Stand Installation...........................2-5
Figure 11 EC Fans Recessed.................................2-5
Figure 12 EC Fans Lowered ..................................2-5
Figure 13 EC Fan Assembly...................................2-6
Figure 14 Plenum Extension Installation.................2-6
Figure 15 Temperature/Humidity Sensor Location..2-7
Figure 16 Condensate Pump................................2-10
Figure 17 Sample Nameplate...............................2-11
Figure 18 Electric Box...........................................2-12
Appendix A - Forms
Checklist for Completed Installation........................ A-1
Periodic General Maintenance
Checks and Service Checklist................................. A-2
Appendix B - Glossary
Definition of Terms and Acronyms........................... B-1
Notice
This document contains information protected by copyright. All rights are reserved. The owner of the equipment for which this
manual is written may photocopy the contents of this manual for internal use only. No part of this document may be photo-
copied, reproduced, or translated into another language for use by anyone other than the owner of the equipment for which
this manual is written without the prior written consent of Stulz Air Technology Systems, Inc. (SATS).
This document contains confidential and proprietary information of Stulz Air Technology Systems, Inc. Distributing or photo-
copying this document for external distribution is in direct violation of U.S. copyright laws and is strictly prohibited without the
express written consent of SATS.
Unpublished — rights reserved under the copyright laws of the United States and of other countries.
Other brands and tradenames are trademarks of their respective owners.
Copyright 2009 by Stulz Air Technology Systems, Inc.
Printed in the United States of America.
All rights reserved.
Stulz Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704
USA

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1.0 INTRODUCTION
1.1 General
The Compact CWE™ floor mounted, precision
air conditioning system covered by this manual is
designed and manufactured by Stulz Air Technology
Systems, Inc. (SATS) and uses the latest, state-of-
the-art control technology. Recognized as a world
leader, SATS provides air conditioning systems with
the highest quality craftsmanship using the fin-
est materials available in the industry. The unit will
provide years of trouble free service if installed and
maintained in accordance with this manual. Damage
to the unit from improper installation, operation or
maintenance is not covered by the warranty.
STUDY the instructions contained in this manual.
They must be followed to avoid difficulties. Spare
parts are available from SATS to insure continuous
operation. Using substitute parts or bypassing
electrical or cooling components in order to continue
operation is not recommended and will VOID THE
WARRANTY. Due to technological advancements,
components are subject to change without notice.
Compact CWE systems are designed to be installed
indoors unless otherwise noted on the equipment.
1.2 Product Description
Compact CWE systems are designed to be the most
versatile and flexible floor mounted air condition-
ing systems in the industry. Compact CWE units are
available in upflow or down flow air configurations and
utilize highly efficient, electronically commutated (EC)
fans. The cooling capacity, in kW, will depend on the
unit size which can range from 30 to 360 kW. (1 kW =
3415 BTU/Hr). Refer to the unit nameplate to 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
through a chilled water coil. On demand for cooling,
the microprocessor controller begins modulating the
chilled water valve open. Chilled water flows to the
coil at a rate that varies proportionally to the amount
of cooling required. The controller modulates the
valve opening together with the fan speed to meet
the user selectable temperature setpoint. Heat from
the surrounding air is transferred through the finned
tubing of the coil into the cold water. Water is then re-
circulated back to the cold water source.
Compact CWE systems are designed to supply air to
only one room.
NOTE
Compact CWE systems are strictly for non-
residential applications.
The functional modes of operation, in addition to
cooling, are heating, humidification, dehumidification
and filtration which provide complete environmental
control of a conditioned space.
There are two air flow pattern configurations, upflow
and downflow, and several cabinet sizes based
on the type of system and capacity. Regardless of
configuration, Compact CWE systems are compact
and versatile. See the Installation drawing provided
with your unit for the layout and dimensions of the
cabinet.
The Compact CWE unit is provided with a factory
mounted, main power disconnect switch with a
lockable handle. The disconnect switch electrically
isolates the unit during routine maintenance. The
system incorporates state of the art component
protection with the use of motor start protectors or
circuit breakers.
The advanced E² microprocessor controller is
provided as a standard for Compact CWE systems.
This controller provides superior features for more
comprehensive control of the unit. These features
include: full alarm system; input/output monitoring
status; full integrated control of heating, cooling,
humidification, and dehumidification; multi-A/C unit
control and remote communication with building man-
agement systems.
The controller user interface display panel is typically
mounted on the front door of the A/C unit. It features
ahigh resolution touch screen display offering
enhanced graphical display capabilities and a round
membrane type keypad to navigate through the
controller menus and adjust operating parameters.
An easy to read, backlit liquid-crystal alphanumeric
display panel is also available as an option.
An operating manual for the E² controller is provided
under separate cover. Refer to that manual for
detailed instructions on operating the system
controller.
Touch Screen Display Liquid-Crystal Display

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1.3 Product Warranty SATS offers a two year standard limited warranty as stated below:
STULZ AIR TECHNOLOGY SYSTEMS, INC.
12 MONTH PRECISION A/C LIMITED WARRANTY /
24 MONTHS PRECISION A/C UPGRADED LIMITED WARRANTY
The 12 month Precision A/C Limited Warranty applies when the Product Support Network
Factory Start-Up is not purchased at the time of order entry.
The 24 Month Precision A/C Upgraded Limited Warranty applies only if Factory Start-Up was
purchased at the time of Order Entry and Start-Up has been validated by Product Support.
The 12 Month Precision A/C Limited Warranty provided by Stulz Air Technology Systems, Inc. (SATS) warrants
your purchase to be free from defects in material and workmanship. SATS’ obligation under this warranty is to
repair or replace, at its option, any part or parts which are determined by SATS to be defective for a period of 12
months from the date of shipment when an accurately completed Factory Start-Up Form has been submitted to
SATS, within 180 days from shipment. Parts repaired or replaced under this warranty are shipped FOB Factory,
and warranted for the balance of the original warranty period or for 90 days from the date of installation, whichever
is greater. If the Factory Start-Up form is not returned to SATS within 180 days from the date of equipment
shipment, the equipment warranty will be terminated on the 181st day from shipment. This limited warranty does
not include labor, freon, or any other expense required to replace the defective component and bring the unit back
to a working status.
The 24 Month Precision A/C, Upgraded Limited, Warranty provided by Stulz Air Technology Systems, Inc. (SATS)
warrants your purchase to be free from defects in material and workmanship for 24 months. SATS obligation under
this warranty is to repair or replace, at its option, any part or parts which are determined by SATS to be defective
for a period of 24 months from the date of start-up. Parts repaired or replaced under this warranty are shipped
FOB factory ground, and warranted for the balance of the original warranty period or for 90 days from the date of
installation, whichever is greater. If the factory is not allowed to start the equipment within 180 days from the date
of shipment, the warranty will commence on the 181st day from equipment shipment. This limited warranty does
not include labor, freon, or any other expense required to replace the defective component and bring the unit back
to a working status.
Stulz Air Technology System’s warranty does not cover failures caused by improper installation, abuse, misuse,
alteration, misapplication, improper or lack of maintenance, negligence, accident, normal deterioration (including
wear and tear), or the use of improper parts or improper repair.
Purchaser’s remedies are limited to replacement or repair of non-conforming materials in accordance with the
written warranty. This warranty does not include costs for transportation, travel expenses, costs for removal or
reinstallation of equipment or labor for repairs or replacements made in the field.
If any sample was shown to the buyer, such sample was merely to illustrate the general type and quality of the
product, and not to represent that the equipment would necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to buyer for commercial or industrial
purposes. The warranty is not enforceable until the invoice(s) is paid in full.
THIS FOREGOING SHALL CONSTITUTE SATS’ ENTIRE LIABILITY AND YOUR EXCLUSIVE
REMEDY. IN NO EVENT SHALL SATS BE LIABLE FOR ANY DEFECT, INDIRECT, SPECIAL,
INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS (EVEN
IF ADVISED OF THE POSSIBILITY THEREOF)ARISING IN ANY WAY OUT OF THE INSTALLATION,
USE OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN LIEU OFALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
This warranty supersedes all other previously printed warranties dated prior to this document.
WARF-1001 Rev. B; 9/20/10
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1.4 Safety
1.4.1 General
Stulz Air Technology Systems, Inc. uses NOTES
along with CAUTION and WARNING symbols
throughout this manual to draw your attention to im-
portant operational and safety information.
A bold text NOTE marks a short message in the infor-
mation to alert you to an important detail.
A bold text CAUTION safety alert appears with infor-
mation that is important for protecting your equipment
and performance. Be especially careful to read and
follow all cautions that apply to your application.
A bold text WARNING safety alert appears with infor-
mation that is important for protecting you from harm
and the equipment from damage. Pay very close at-
tention to all warnings that apply to your application.
A safety alert symbol accompanies a general
WARNING or CAUTION safety statement.
A safety alert symbol accompanies an electrical
shock hazard WARNING or CAUTION safety state-
ment.
1.4.2 Safety Summary
The following statements are general guidelines fol-
lowed by warnings and cautions applicable through-
out the manual.
Prior to performing any installation, operation,
maintenance or troubleshooting procedure, read and
understand all instructions, recommendations and
guidelines contained within this manual.
WARNING
All personnel working on or near equipment
shouldbefamiliar withhazardsassociated with
electricalmaintenance. Safetyplacards/stickers
have been placed on the unit to call attention
to all personal and equipment damage hazard
areas. 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.
WARNING
This equipment should be serviced and re-
paired by a journeyman or a qualified refrigera-
tion technician only.
WARNING
Topreventpersonal injury,stay clearofrotating
components as automatic controls may start
them unexpectedly. Turn off power to the unit
unless you are performing tests that require
power. With power and controls energized, the
unit could begin operating at any time.
WARNING
Whenworkingon electricalequipment,remove
all jewelry, watches, rings, etc.
WARNING
Hazardous voltage will still be present inside
the electric box at the motor start protectors
and circuit breakers, even with the unit turned
off at the microprocessor controller. To isolate
the unit for maintenance, turn off power at the
main power disconnect switch.
WARNING
Always disconnect the main power supply to
the equipment at the main power disconnect
switchbeforebeginningworkontheequipment.
A lock-out tag-out procedure should be fol-
lowed to ensure that power is not inadvertently
reconnected.
CAUTION
Whentheair conditioner is inthe cooling mode,
the return air-intake and discharge (supply)
must be free of obstructions. Ensure panels
are secure and latched into position.
WARNING
Never operate the unit with any cover, guard,
screen panel, etc. removed unless the instruc-
tions specifically state otherwise, then do so
with extreme caution to avoid personal injury.

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CAUTION
If a lifting device is used to move a unit, ensure
itiscapable of supportingtheweight of theunit.
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 thoroughly after contact with solvents.
CAUTION
Do not use cleaning solvents near open flame
or excessive heat. Wear eye protection when
blowingsolvent from parts.The pressure-wash
should not exceed 30 psig. Solvent solutions
should be disposed of in accordance with local
and state regulatory statutes.
CAUTION
Chilled water cooling coils and associated
pipingcircuits are pressurized (up to 100 psi)
andsealed when they leave thefactory.Before
hookingup the interconnectingpiping, observe
appropriate safety precautions and release
the pressure via an available stem valve or
schrader valve prior to uncapping the pipes.
CAUTION
After the customer furnished supply and return
pipingisassembled, the pipingsystemmust be
thoroughly cleaned prior to connecting it to the
unit. Failure to do so will result in equipment
problems.
CAUTION
After the supply and return piping is connected
to the unit, the entire system must be flushed
prior to beginning operation.
CAUTION
Wheninstallingand filling the water/glycol loop,
all air must be bled from the piping system.
WARNING
Do not use chloride based water conditioning
additives in the condensate drain pans. This
will cause corrosion to occur on the coil fins.

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1.5 General Design
The Compact CWE unit is housed in a steel frame type cabinet and is rated for indoor use. The cabinet is coated
with a powder coat finish to protect against corrosion. Hinged doors are located in the front of the cabinet for easy
access to all components. Operator controls are conveniently located on the front of the cabinet.
NOTE
Customer specified nonstandard features or design variations may not be described in this manual. Refer
to the installation and/or electrical drawings supplied with your unit for details on additional feature(s). In
some cases an addendum to this manual may also be included to further describe the feature(s).
Figure 1 depicts a sample internal layout of a CCU (upflow) unit and identifies the major components.
Location of the major components vary depending on CWE model number and options purchased.
Figure 1- Typical Internal Layout- Upflow
(Model CCU-2300-CWE shown for reference)
SUPPLY/RETURN
PIPING
ELECTRIC BOX
CHILLED WATER
VALVE
PREFERRED POWER
SELECTOR SWITCH
(OPTIONAL)
HUMIDIFIER
CONDENSATE PUMP
(LOCATION MAY VARY)
FILTERS
(CUT-AWAY TO
SHOW DETAILS)
FILTER FRAMES
EC FANS
ELECTRIC HEATERS
COILS
SMOKE DETECTOR
(OPTIONAL)
Figure 2 depicts a sample internal layout of a CCD (downflow) unit and identifies the major components.
SUPPLY/RETURN
PIPING
ELECTRIC BOX
CONDENSATE PUMP
(LOCATION MAY VARY)
COIL(S)
CHILLED
WATER VALVE
PREFERRED POWER
SELECTOR SWITCH
(OPTIONAL)
EC FANS
ELECTRIC
HEATERS
HUMIDIFIER
Figure 2- Typical Internal Layout- Downflow
(Model CCD-3600-CWE shown for reference)
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1.5.1 Electric Box Access
The electrical components are protected behind the
hinged front access door on the front of the cabinet.
The access door is safety interlocked with the main
power service disconnect switch, preventing the door
from opening when the switch is in the “On” position.
The switch must be turned “Off” to gain access to the
electrical components.
The service disconnect switch may be used to turn
the unit off for emergency shutdown or during routine
maintenance. The handle of the switch may be locked
in the “Off” position to prevent unintended operation.
1.5.2 Circuit Breakers / Motor Start
Protectors
Individual overload protection is provided by circuit
breaker(s) and motor start protectors. These switches
must be manually reset once the overload condition
is cleared.
1.5.3 Heaters (Optional)
The precision A/C unit incorporates heaters for
re-heating the supply air as required to offset
the sensible cooling of the system during the
dehumidification cycle and for the automatic heating
mode. As a standard, electric resistance heating
elements are factory installed in the supply airstream
to heat the supply air.
As an option, hot water reheat may be selected.
For this option a hot water heating coil is installed
in the supply air stream to heat the supply air. A
modulating valve is provided to control the flow of hot
water through the coil to maintain the correct reheat
temperature.
1.5.4 Coil(s)
The cooling and optional hot water reheating coils are
aluminum finned/copper tube construction. The coils
are leak tested and cleaned before installation by the
factory.
1.5.5 EC Fan(s)
The unit is equipped with high efficiency,
Electronically Commutated (EC) fan(s). EC Fans
utilize a brushless motor equipped with permanent
magnets and permanently lubricated ball bearing.
The Fan impellers are backward curved and
attached to the rotor casing. The fan is balanced and
aerodynamically optimized to minimize vibration.
The fan does not utilize drive belts. The fan speed
is variable via a 0 to 10 VDC signal from the system
controller. The fan motor is equipped with integral
electronics and does not require the addition of
secondary electronics such as thermal protection,
inverters or filters. The fan will not produce AC inverter
whine.
EC fans feature an integrated monitoring function to
protect the motor and electronics against damage
from jamming, phase loss or overheating. If any
of the following failure conditions occur, the motor
automatically stops and an alarm is signaled:
a. Locked rotor(1)
b. Low main supply voltage(1)
c. Loss of a phase(1)
d. Over-heating of electronics(2)
e. Over-heating of motor(2)
(1) Upon correction of these failure conditions, the
motor will automatically reset.
(2) Upon correction of these failure conditions, the
motor must be manually reset by turning off power
for 20 seconds.
1.5.6 Temperature/Humidity Sensor
As a standard, a temperature/humidity (T/H) sensor
is factory mounted in the return air stream for room
air control. The T/H sensor monitors the return
air conditions and provides input signal(s) to the
system controller to manage the operation of the
A/C unit consistent with the set points entered in the
controller. As an option, sensor(s) may be shipped
loose for field installation. Refer to the electrical
drawing supplied with your unit for details specific to
your system. See Section 2.6.6.1 for descriptions of
the types of T/H control methods that may be utilized.
1.6 Optional Equipment
1.6.1 Humidifier
Compact CWE systems may utilize an optional
electrode steam humidifier. For this option a
humidifier is installed inside the air conditioner with
automatic fill and drain valves and associated piping.
Operation of the humidifier’s fill and drain cycles is
based on water conductivity and is maintained by
the humidifier controller. An operating manual for the
humidifier is provided under separate cover. Refer to
that manual for detailed information on the operation
and maintenance of the humidifier.
1.6.2 Condensate Pump
An optional condensate pump may be factory installed.
The pump automatically eliminates condensate and
humidifier flush water (if applicable) from the drain
pan. An internal overflow safety switch is wired to
the system controller to automatically shut down the
precision A/C system should an overflow occur.
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1.6.3 Smoke Detector
Optionally mounted in the return air stream, a
photo-electric smoke detector is used to sense the
presence of smoke and signal the controller when a
smoke alarm condition exists.
1.6.4 Firestat
Optionally mounted in the return air stream, a fire de-
tector senses high return air temperature and signals
the controller when a fire alarm condition exists.
1.6.5 Auto Transfer Switching
An automatic transfer, main power switching system
is optionally available for critical operations. With this
option, two main power service disconnect switches
are provided on the door of the cabinet to connect
two independent power sources (see Figure 3). If the
user selectable main power source is interrupted or,
if a phase loss or imbalance occurs, the automatic
transfer switching circuitry immediately transfers
operation of the precision A/C system to a secondary
power source. If power is transferred, the system
controller provides an alarm signal and the alarm
display indicates which power source failed. When
the primary power source is functionally restored,
the operation of the A/C system is automatically
transferred back to the primary power source.
Figure 3- Auto Transfer Disconnect Switches
OPTIONAL DUAL SERVICE
DISCONNECT SWITCHES
(LOCATION MAY VARY)
INDICATOR LIGHTS
(OPTIONAL)
FRONT DOOR OF
A/C SYSTEM
1.6.5.1 Preferred Power Selector Switch
A preferred power selection switch (Figure 4) is
included with the auto-transfer switching option. It is
either mounted on the front door of the cabinet or it
may be mounted inside the cabinet to the top of the
electric box (see Figure 2). This switch may be used
to manually transfer the power source and/or test the
auto transfer switching function.
Figure 4- Preferred Power Selection Switch
POWER
PREFERRED POWER SWITCH
APOWER B
POWER
SUPPLYA POWER
SUPPLY B
1.6.5.2 Indicator Lights
As an additional option, an indicator light may be
provided above each main power service discon-
nect switch (see Figure 3). A light illuminates above
the switch that’s selected to supply power to theA/C
system whether the unit is running or not, indicating
that power is available at the switch.
1-7

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2.0 INSTALLATION
2.1 Receiving the Equipment
Your Compact CWE system has been inspected and
tested prior to shipment. To ensure your equipment
has been received in excellent condition, perform
immediately inspect the unit for damage which may
have occurred during shipment. If any is found, report
it to the carrier immediately.Any obvious damage
incurred during shipping must be noted on the freight
carrier’s delivery forms BEFORE signing for the
equipment. Freight claims must be done through the
freight carrier. Generally, all equipment ships “FOB
Factory”. SATS can assist in the claim filing process
with the freight company. Refer to section five of this
manual for instructions.
Carefully remove the shipping cover. Remove/open
the access panels, remove any loose parts, and
check the equipment against the packing list to see
if the shipment is complete. Report all discrepancies
to the appropriate authority. Inspect the interior of
the unit for any signs of transit-incurred damage.
Should any damage be present, notify SATS Product
Support prior to attempting any repairs.
A Data Package has been sent with your unit. It
contains this manual, a supplemental microprocessor
controller manual, system drawings, applicable
MSDS’s, warranty registration form and other
component manuals and applicable instructions
based on the configuration and options included with
your unit. The data package has been placed in your
unit inside a clear plastic bag. These documents
should be retained with the unit for future reference.
NOTE
Items that have been shipped loose, such as
controllers, temperature/humidity sensors,
water detectors, etc., are shipped inside the
air conditioner unless specified otherwise by
the customer. The plenum box (if applicable)
is shipped separately. Unpack and store these
itemsina safe placeunless you areusingthem
immediately.
2.2 Site Preparation
Compact CWE systems are designed with easy
service access in mind. Hinged access doors are
located on the front of the cabinet. The number of
doors vary depending on size and configuration
of the unit. Each unit has a door for accessing the
electrical box. In order to have full service access
to internal components, no permanent obstructions
should be placed in front of the unit. See Figure 5 for
the minimum recommended installation clearance in
front of the unit. NOTE
Working clearance requirements need to be
established prior to mounting the unit. Refer to
local and national electrical codes.
When determining the installation location consider
how you’ll route the piping and wiring into the cabinet.
Ensure access is available for routing the piping and
wiring if entering through the side of the cabinet (see
Section 2.7.1). The cabinet may be positioned in a
corner and if necessary a service opening may be cut
into the wall for access to install the piping and wiring
from an adjoining room.
39"
(MINIMUM FRONT
CLEARANCE)
CONTROLLER
SERVICE
DISCONNECT
SWITCH
SEE NOTE
SEE NOTE
NOTE: WHEN INSTALLING UPFLOW UNITS, ALLOW ACCESS FOR PIPINGAND
WIRING IF ROUTING IT THROUGH THE SIDE OF THE CABINET.
Figure 5- Recommended Installation
Clearance
CAUTION
The A/C unit must be installed in a space that
will be air conditioned.
2.2.1 Conditioned Space
Certain steps may be taken to minimize the effects
of the environment surrounding the conditioned
space. This is especially true for critical/precision
room preparation (computer rooms/labs) requiring

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close tolerance control of temperature and humidity.
The conditioned space should be well insulated and
include a vapor barrier. The installer should ensure
that 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
recommended minimum R-value (thermal resistance)
to ensure optimum equipment operation.
STRUCTURE R-VALUE
Ceiling R-38
Wall R-21
Floor R-19
Door R-5
The vapor barrier is the single most important require-
ment for maintaining environmental control in the
conditioned space. The vapor barrier in the ceiling and
walls can be a polyethylene film. Concrete walls and
floors should be painted with a rubber or plastic based
paint. Doors and windows should be properly sealed
and a door sweep used to minimize leakage. Outside
or fresh air should be kept to a minimum (as it adds to
the cooling, heating, dehumidification and humidifying
loads), while still maintaining the requirement of the
Indoor Air Quality (IAQ) standard. Lack of attention to
these factors can cause erratic operation, unstable
room control and excessive maintenance costs.
2.3 Rigging
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.
A weight table is provided on the installation draw-
ing. The unit is shipped on a skid to facilitate moving
prior to installation. The unit should always be stored
indoors in a dry location prior to installation.
CAUTION
When moving the unit, it must be kept level
and in the vertical position to prevent damage.
2.4 Mounting/Placement
Compact CWE systems use a frame and panel
construction for unit rigidity. The cabinet design
allows full service accessibility without moving the
unit. Compact CWE systems that are not ducted
are designed to be located in the space to be
conditioned. 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 unit
to be placed in a corner or between cabinetry. It is
recommended that the unit is positioned to obtain
optimum air circulation.
NOTE
Placement of the floor or ceiling registers is
important. If they are too close to the unit, the
supply air will be recirculated back to the unit
before it has circulated throughout the space.
See Figures 6 & 7. The Compact CWE unit is de-
signed to be located on a raised floor (typically down-
flow) or directly on top of the floor (typically upflow).
Figure 6- Typical Installation Upflow
PLENUM BOX
ASSEMBLY
(OPTIONAL)
HINGED
DOOR
(BOTH SIDES)
NOTE
The equipment must be level to operate
properly.
CAUTION
Ensure the mounting surface is capable of sup-
porting the equipment. Before mounting the unit,
refertotheweighttableprovided ontheinstallation
drawing. On some raised floor installations a floor
stand is required depending on the load capacity
of the existing raised floor (See Figure 7).

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If a floor stand is used (downflow units), see
Section 2.6.1 and refer to the installation drawing
provided. Cut out an opening in the raised floor
slightly larger than the cabinet’s overall base di-
mension so the A/C unit is supported by the stand.
If a floor stand is not selected, use the installation
drawing and only cut out an opening in the raised
floor to match the discharge opening for the blow-
ers and cut out the holes required for installing
piping and wiring through the raised floor.
2.5 Air Distribution Connection
2.5.1 Upflow Configuration Air Patterns
In an upflow configured unit, the conditioned
supply air has two methods of discharge: ducted
or through a 2 or 3-way grilled plenum box (see
Figure 8). The return air pattern is front free return.
The supply air outlet is provided with a flange for
connecting the ductwork (refer to the installation
drawing provided with the unit). The connection of
ductwork to the unit may be made with either pop
rivets or self-tapping screws. If ductwork is to be
used, always consult your state and local codes
when determining ducting requirements. The duct
system should be designed to allow the air to
move with as little resistance as possible.
SUPPLY
AIR OUTLET
RETURN AIR INLET
DUCT
RETURN AIR INLET
SUPPLY AIR OULET PLENUM BOX
ASSEMBLY
(OPTIONAL)
TOP DISCHARGE DUCTED TOP DISCHARGE- 2 OR 3 WAY PLENUM
Figure 8- Upflow Configuration Air Patterns
Figure 7- Typical Installation Downflow
OPTIONAL
FLOOR STAND
HINGED
DOOR
(BOTH SIDES)
OPTIONAL CABLE TYPE
WATER DETECTOR
SECURE WATER DETECTOR CABLE
TO FLOOR WITH J-CLIP, WIRE TIE
w/ ADHESIVE MOUNT, OR MASTICADHESIVE.

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2.5.2 Downflow Configuration Air Patterns
In a downflow configured unit, the conditioned supply air discharges through the bottom of the unit into a raised
floor. There are two basic return air distribution methods: top free return and top ducted return. (See Figure 9).
The return air inlet is provided with a turned in flange on top of the unit for connection of ductwork (refer to the
installation drawing provided with the unit). The connection of ductwork to the unit may be made with either pop
rivets or self-tapping screws.
If ductwork is to be installed, always consult your state and local codes when determining ducting requirements.
The duct system should be designed to allow the air to move with as little resistance as possible.
Figure 9- Downflow Configuration Air Patterns
RETURN
AIR INLET
SUPPLY
AIR OUTLET
TOP DUCTED RETURN
TOP FREE RETURN
RETURN
AIR INLET
SUPPLY
AIR OUTLET

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2.6.2 Deploying Underfloor EC Fans
Compact CCD-2300 & CCD-2800 units may be
optionally equipped with “underfloor” EC plenum fans
which may be lowered beneath a raised floor after
the unit is installed. TheA/C unit is shipped with the
EC fans temporarily recessed inside the cabinet as
shown in Figure 11. The A/C unit must be installed on
a floor stand (purchased separately) with a minimum
height of 24 inches so the fans can be lowered.
Figure 11- EC Fans Recessed
CAUTION
Do not operate the unit with the fans in
the recessed position.
Figure 12- EC Fans Lowered
The fan assemblies are secured with shipping support
brackets as shown in Figure 13. The brackets safely
hold the fans in place during the period the A/C unit is
transported and installed.
NOTE
Onlyremove the shipping supportbrackets after
the A/C unit is mounted in it’s final location.
2.6 Optional Equipment (Field Installed)
NOTE
Do not mount any optional equipment on the
unit access doors.
2.6.1 Floor Stand
Install the optional floor stand directly on the sub-floor,
ensuring the side with the “FRONT” label is facing the
same direction as the front of the precision A/C unit
(see Figure 10). Refer to the floor stand assembly
drawing for the dimensions required to cut the raised
floor. The floor stand is designed with adjustable legs,
allowing for leveling and overall height adjustment.
Refer to the floor stand assembly drawing for mini-
mum and maximum height adjustments. To adjust the
height, first loosen the middle nuts on each leg. Next,
turn the top hex nuts to raise or lower the floor stand.
Once the floor stand is level and even with the raised
floor, lock all feet in place by tightening the middle
hex nuts against the top hex nuts.
Figure 10- Floor Stand Installation
THREADED ROD
MIDDLE HEX NUT
TOP HEX NUT
ISOLATION PAD
FLOOR STAND LEG
"FRONT" LABEL

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2.6.2.1 Lowering the EC fans
After the A/C unit is installed, the EC fans may easily
be lowered to their operating positions below the
cabinet. With the A/C cabinet doors opened, unbolt
the two shipping support brackets from the sides of
each fan assembly where it attaches to the cabinet
frame (see Figure 13). Retain the brackets; they will
be needed to re-secure the fans if the A/C unit is ever
moved. They can also be convenient for holding the
fans in the “up” position if performing maintenance or
service to the unit.
Figure 13- EC Fan Assembly
SHIPPING SUPPORT
BRACKETS TOP PLATE
After the shipping support brackets are removed,
push each fan assembly down by applying pressure
evenly on both sides of the fan at the center of the
top plate. Each fan assembly is supported with two
gas shocks which assist in lowering and raising the
fans. Hold the fan assembly down so the top plate is
on the floor of the cabinet as shown in Figure 12.
Align the two holes in each corner of the top plates
with the threaded inserts in the cabinet floor.
Top Plate
MOUNTING
HOLES 8x
Securely fasten the top plate for each fan assembly
to the cabinet floor using the eight ¼-20 hex bolts
provided. Tighten the bolts securely to prevent them
from vibrating loose. After the first day of operation,
re-check the bolts for tightness.
2.6.3 Plenum Box
If an optional plenum box (plenum extension box or
2 - 3 way air distribution plenum box) is selected it is
typically shipped loose. To install a plenum box, first
apply a strip of sealing foam around the top flange of
the A/C unit or, run a bead of silicone sealant. Place
the plenum assembly on top of the unit (see Figure
14). Attach the plenum with the self-tapping screws
provided. Holes are pre-drilled in the unit and the
plenum box. If mounting a 2 - 3 way air distribution
plenum box (shown in Figure 8), the front grille may
be removed for access to the mounting holes.
Figure 14- Plenum Installation
PLENUM
EXTENSION

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2.6.4 Remote Display
As an option, a factory supplied controller display
may be remotely mounted. For mounting and wiring
instructions, refer to the system drawings and the
supplemental manual sent in the data package with
your unit.
2.6.5 Condensate Pump
An optional, factory installed condensate pump may
be provided for automatically eliminating condensate
and humidifier flush water from the drain pan. The
condensate pump is typically installed by the factory
inside the A/C unit. If an optional, field installed
condensate pump is selected, it should be located
as near as possible to the air conditioning system.
The pump should be positioned so the inlet hole in
the pump is below the drain pan inside the A/C unit.
Secure the pump in place with a mounting clamp or
use an adhesive that’s appropriate for the mounting
surface. Ensure that the pump is level for proper
operation.
2.6.6 Remote Temperature/Humidity Sensor
The remote temperature/humidity (T/H) sensor must
be located so that it will properly sense the tempera-
ture/humidity conditions to be controlled. Depending
on the type of control selected (see Section 2.6.6.1),
the sensor may be factory mounted or shipped loose
for field installation. The T/H sensor should not be
mounted near a doorway or an area where it would be
exposed to direct sunlight. When locating the sensor,
consider the length of wire to be used. As an option,
a 75 foot or 150 foot long cable may be provided by
SATS. Follow the steps below to mount the sensor.
Temperature /Humidity Sensor
1. Remove the cover from the base of the sensor
by squeezing it at the top and bottom.
CAUTION
Take care not to damage the exposed tem-
perature/humidity sensors on the PC board
when the cover is removed. The sensors can
be damaged if handled improperly.
2. Place the base temporarily against the mounting
surface.
3. Level the base. Mark and drill mounting holes
through at least two of the available slotted holes.
4. Run a 3 conductor shielded cable through the
opening in the base, then secure the base with
screws ensuring the word TOP on the PC board
is oriented upward.
5. Make the wiring connections. Refer to Section
2.8, Utility Connections and refer to the wiring
diagram supplied with your unit.
6. Seal the hole in the wall behind the sensor.
7. Replace the cover plate on the base.
CAUTION
The sensor can be damaged if handled
improperly. Take care not to damage the
exposed temperature/humidity sensor on the
PC board. Do not touch the sensor as this will
affect its accuracy.
2.6.6.1 Types of control
Room Air Control (standard)- TheA/C unit is provided
with a temperature and humidity (T/H) sensor, factory
mounted in the return air stream of the A/C unit. The
return air temperature and humidity are monitored by
the system controller and compared to limit values
set at the factory. Control outputs are based on set
points entered into the system controller by the user.
Figure 15- Temperature/Humidity Sensor Location
HEIGHT > 60"
T/H SENSOR FOR
RETURN AIR
T/H SENSOR FOR
ROOM AIR
SUPPLY AIR
T/H SENSOR
FOR SUPPLY AIR
As an alternative to locating the T/H sensor inside
the A/C unit, it may be field installed under a raised
floor for sensing supply air conditions or, on a wall
in the conditioned space for sensing actual room
conditions.

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2.6.7 Remote Water Detector
The remote water detector is normally placed on the
sub-floor or in a field supplied auxiliary drain pan
located beneath the unit. SATS provides 2 types of
water detectors:
Spot type water detector-
Remove the protective cover and connect two control
wires to the terminals on the
base. Run the control wires into
the electric box and connect
them to the control terminal
block as shown in the wiring
diagram provided with your unit.
Replace the cover and place the
water detector(s) on the floor
with the metal electrodes facing down. When water is
present, current will flow between the electrodes. The
base is provided with a mounting hole in the center
which may be used to secure the water detector in
place.
NOTE
Do not place the spot type water detector on
an electrically conductive surface.
Cable type water detector-
Lay the cable water
detector flat across the
sub-floor where water
could collect (see Figure
7). Secure the cable every
12-18 inches with J-clips or cable ties with adhesive
mounting pads when installing it in the airstream.
Secure it at each turn of the cable and when routing
it around obstructions. Do not tie the water detector
cable to the metal floor stand or to pipes.
When a water leak on the floor reaches the cable,
current will flow between the cable wires. A two
conductor wire harness is provided with a quick
connect fitting on the end. The harness mates to
the fitting on the water detector and connects it to
the control terminal block inside the electric box as
shown in the wiring diagram provided with your unit
(see Figure 18).
Supply Air Control- As an option, a field installed
T/H sensor may be used for supply air control. The
sensor is field installed in the supply air stream. The
supply air temperature and humidity are monitored
by the system controller and compared to limit values
set at the factory. Control outputs are based on set
points entered into the system controller by the user.
Room Air Control with Supply Air Limitation- The
controller monitors the T/H sensor located in the
return air stream and a T/H sensor located in the
supply air stream. Control is similar to “Room
Air Control” except, the temperature setpoint is
automatically increased by the controller when the
measured supply air temperature exceeds the Start
Temperature entered by the user. The extent of the
setpoint increase is determined by a factor which
the user enters in the controller as a gradient. A high
gradient significantly corrects the failure to meet
the supply air temperature but has the risk that the
control circuit starts to hunt.
With humidity control, the setpoint shift acts in the
opposite direction. If the starting humidity entered
by the user is exceeded by the measured supply air
humidity, the setpoint is automatically reduced by the
controller. The user may also enter a gradient factor
for humidity control.
Formula:
Newsetpoint = old setpoint+ [gradient • (start value
-actual value)]
Example (temperature): 70.5 = 70 + [0.5 • (61 - 60)]
Example (humidity): 49 = 50 + [0.5 • (70 - 72)]
Supply Air Control with Room Air Limitation- Based
on the same principle as “Room Air Control with
Supply Air Limitation” however, in this case the
setpoint shift works in the opposite direction on the
basis that the supply air is colder than the return air.
The temperature setpoint is automatically reduced by
the system controller when the measured room air
temperature exceeds the Start Temperature entered
by the user. The humidity setpoint is automatically
increased by the system controller when the
measured room humidity drops below the starting
humidity entered by the user.

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with your unit. Provide manual shut-off valves in both
the supply and return lines for servicing the unit and
for emergency isolation.
NOTE
A 60-mesh strainer is recommended to be
installed in the supply line. The strainer screen
should be cleaned periodically.
CAUTION
Chilled water cooling coils and associated
pipingcircuits are pressurized (up to 100 psi)
and sealed when the unit leaves the factory.
Before installing the interconnecting piping,
release the pressure via an available stem
valve or schrader valve prior to uncapping the
pipes.
If newly installed CW supply and return piping is
used, it is recommended that the piping system be
cleaned prior to connecting it to the unit. If solvents/
cleaning solutions are used, ensure they are
completely flushed from the piping before
connecting it. Failure to do so could result in
equipment problems
CAUTION
When installing and filling chilled water and
optional hot water reheat loops, all air must be
bled from the piping system.
NOTE
Chilled water lines should be insulated to
preventcondensation from forming on the pipes
if ambient dew point temperatures are higher
than the fluid temperatures.
2.7.2 Condensate Drain
2.7.2.1 Gravity Drain
A drain line is installed to drain the condensate pan. If
an optional humidifier is used, the drain line from the
humidifier is typically connected to the condensate
drain line. The end of the drain line is clamped inside
the cabinet. The installer must install a customer
supplied drain hose to the end of the drain line to
remove water from the cabinet. See the installation
drawing provided with your unit for the size and
location of the condensate drain line.
2.7 Piping Connections
2.7.1 Chilled Water/Hot Water
Pipe connections for the chilled water and optional
hot water reheat piping are sweat connections. In
most cases, they terminate inside the cabinet except
units which are provided with pipe connections
protruding through the top of the cabinet.
When considering how to route the piping and wiring
for CCU (upflow) units furnished without top piping,
entry holes may be drilled through either the floor
of the cabinet or through a side panel. The SATS
installation drawing (furnished with your unit) shows
a recommended entry location. For special piping
requirements contact SATS for technical assistance.
For CCD (downflow) units, open areas for routing
the piping and wiring are available in the base of the
cabinet. Refer to the installation drawing provided
with your unit for the location of the openings.
If piping is brought into the side of the cabinet, ensure
adequate working space is available on that side or
if necessary cut a service opening into the adjacent
wall if the unit is installed in a corner. After the piping
is installed, seal the gaps between the pipes and the
entrance holes so air won’t leak around the pipes.
For pipe connection sizes, refer to the following table:
INLET/OUTLET PIPE SIZES
Chilled Water Hot Water
Model # (Inches O.D.) (Inches O.D.)
CCU/D-300 1 1/8” 7/8”
CCU/D-600 1 5/8” 7/8”
CCU/D-900 1 5/8” 7/8”
CCU/D-1200 2 1/8” 7/8”
CCU/D-1800 2 1/8” 7/8”
CCU/D-2300 2 1/8” (*or 2 5/8) 7/8”
CCU/D-2800 2 1/8” (*or 2 5/8) 7/8”
CCU/D-3600 3” 7/8”
*Special models requiring high CW flow are equipped with 2 5/8”.
Field piping is not necessarily the same size as the
units’ pipe connections. Piping should be sized to
match the system pressure drop and flow capacity,
and may require reducing fittings to match the
connection size on the air conditioner. An air vent and
several schrader valves are installed in the precision
A/C unit piping. Refer to the piping diagram supplied
2-9