Stulz Tel-Air-2 Series User manual

STULZ the natural choice
Operating instructions
Tel-Air-2
Air conditioner
230/1/50 - 400/3+N/50
Index 35A
Edition 06.18
EN
English

E/0618/35A/3
Table of Contents
1. Safety directions.................................................................................................................6
1.1 Attachments..............................................................................................................6
1.2 General information...................................................................................................7
1.3 Handling refrigerants.................................................................................................8
1.4 Safety and environmental requirements....................................................................8
2. Unit identification..............................................................................................................10
2.1 Intended and non-intended use...............................................................................13
3. Components and operating principle..............................................................................14
3.1 Layout of components.............................................................................................14
3.2 Operating method....................................................................................................19
3.3 Mechanical parts.....................................................................................................20
3.4 Cooling components................................................................................................20
3.5 Motors.....................................................................................................................22
3.6 Control, Monitoring and Safety Components...........................................................23
4. Technical data and drawings...........................................................................................26
4.1 Application limits......................................................................................................26
4.2 Technical data.........................................................................................................26
5. Unpacking and Inspection................................................................................................44
6. Precautions and safety considerations..........................................................................44
6.1 Precautions when handling the unit.........................................................................45
6.2 Precautions when installing and servicing the unit...................................................45
7. Installation.........................................................................................................................45
7.1 Positioning the unit..................................................................................................46
7.2 Hydraulic connections .............................................................................................47
7.3 Electrical Connections.............................................................................................47
8. Start-up..............................................................................................................................52
9. Maintenance......................................................................................................................53
9.1 Preventive maintenance schedule...........................................................................53

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10. Residual Hazards and Emergency Information..............................................................55
10.1 General safety provisions........................................................................................55
10.2 Hazards arising from the product coming into contact with things or persons..........55
10.3 Hazards arising from electrical faults.......................................................................55
10.4 Safety standards to comply with when working on refrigeration circuits...................57
10.5 Hazards arising in case of fire.................................................................................58
10.6 Toxic substances ....................................................................................................58
10.7 Hazardous fluids .....................................................................................................58
11. Uninstalling and disposal of the unit ..............................................................................58
12. Options..............................................................................................................................60
12.1 Protective treatment on coils –TREATT .................................................................60
12.2 Electrical reheat –RSC...........................................................................................60
12.3 Monitoring of phase sequence and phase loss (for 3-phase scroll compressors) –
PSCR......................................................................................................................60
12.4 Refrigerant R134a...................................................................................................60
12.5 Kit for low external temperatures –WINTER KIT.....................................................65
12.6 Main switch - SWT/SWM.........................................................................................65
12.7 Socket connection field –SCF ................................................................................65
12.8 Crankcase heater for compressor –CRA................................................................65
12.9 Soft start for three-phase compressor –SOFTT......................................................66
12.10 Soft start for single-phase compressor –SOFTM....................................................69
12.11 Voltage control device –VCC..................................................................................70
12.12 WIB1000 / WIB1485................................................................................................71
12.13 Seaworthy case packaging - SEAPACK..................................................................71

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Important
Read these operating instructions carefully and observe them before installing and using
this A/C unit.
Keep this manual throughout the lifetime of the product.
This manual reflects the state of the art existing at the time the product is marketed and
shall not be deemed to be inadequate for the sole reason that it has not been updated
following new developments in design and construction methods.
STULZ reserves the right to update the product and relevant manual without being
required to update previous products and manuals other than in exceptional
circumstances. To require or receive any updates of the instructions manual or
amendments thereto, which shall be deemed to be an integral part of the manual, please
contact your local STULZ partner.
Observe the instructions contained in the section entitled
Safety instructions.
For three-phase scroll compressors: take care of correct phase sequence after the
connection of the main power supply.
The sequence is important for the correct sense of rotation of the 3-phase Scroll compressor.
A loud noise coming from the compressor means it is turning in the wrong direction. If this
continues for a few hours, it will overheat and irreparably damage the compressor. Correct
compressor operation can be easily checked by measuring the temperature at the condenser
outlet. If this temperature is noticeably higher than the external temperature, the compressors is
working correctly. Otherwise, the compressor is turning in the wrong direction and the phase
sequence must be changed.

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1. Safety directions
This manual contains the basic instructions which must be respected during installation, use and
maintenance of the unit. Therefore, installer and specialized personnel / user must read and
respect these indications before mounting and commissioning the unit.
Read carefully the whole information on this manual, with particular attention to the
norms marked with the symbol on the left. Failure of conformity to these norms
might cause damages to things, people, ambient and the unit itself.
The manufacturer is not responsible for any misuse of air conditioner, as well as for non-
authorized modifications and for the inobservance of instructions on this manual.
This manual must be kept by the customer and made available to the installation,
commissioning, use and maintenance personnel.
SYMBOLS ON THIS MANUAL
LABELS ON THE UNIT
DANGER
RISK OF INJURY FOR
OPERATOR AND
POSSIBILITY OF
DAMAGING THE UNIT
DANGER:
MOVING
COMPONENTS
ATTENTION
INFORMATION OR
WARNING OF CAUTION
IN CARRYING OUT A
PROCEDURE
DANGER:
HOT
COMPONENTS
INFORMATION
IMPORTANT
INFORMATION
DANGER:
HIGH VOLTAGE
1.1 Attachments
The following documents are attached to this manual, as its integral part:
Use and maintenance manual part 2, which contains the electrical drawing and the
conformity declaration CE of the unit.
User manual of the electronic controller.

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1.2 General information
This air conditioning unit has been designed and built for a professional use according to
applicable regulations. Please check the complete list of applicable regulations to the attached
CE conformity declaration. It has been manufactured with high quality components, tested to
certify its reliability and safety (see attached test report), and provided with warranty.
These operating instructions include the basic directions that must be complied with during
system installation, operation and maintenance. Consequently both the installer and assigned
specialized personnel/operators must read and comply with these directions before proceeding
with installation and start-up. The instruction manual must always be available at the site where
the system is used.
Works have to be carried out by competent staff only.
Observance of regulations for accident prevention.
Stay out of danger when lifting and setting off the unit.
Secure the unit to avoid the risk of overturning.
Do not climb on or enter the air conditioner.
Do not remove protection panels. Safety devices may not be bypassed.
Respect the corresponding EN and IEC standards for the electric connection
of the unit and observe the conditions of power supply companies.
Switch off the voltage from the unit when working on it.
Observe the national regulations of the country where the unit will be
installed.
The refrigerant circuit contains refrigerant and refrigerating plant oil: observe
professional disposal for maintenance and when setting the unit out of
service.
For transport, installation, either ordinary or extraordinary maintenance,
operators and maintenance people must wear individual protection devices
(i.e. gloves, glasses, helmet, shoes), according to the indications of safety
manager and applicable regulations.
The unit may only be used to cool according to the Stulz specification.
Before any maintenance operation, read and follow instructions in the
corresponding chapter.
The manufacturer is not liable for damages caused by either a misuse or
unauthorized modifications of the air conditioner.
Any special opening tools have to be placed in a visible location nearby the
unit.

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1.3 Handling refrigerants
According to EN 378, refrigerants are divided in groups, concerning health and safety.
Refrigerants used in Telecom Line units belongs to group L1 (non-flammable, non-toxic).
Adherence to the regulations by law and guide-lines.
Execution only by competent staff.
Responsibility for correct disposal of refrigerant and system parts is incumbent on the
operator (see chapter 'Uninstalling and disposal of the unit').
Refrigerants have a narcotic effect when inhaled in high concentrations.
The room is to be evacuated immediately if high concentrations of refrigerant suddenly
occur. The room may only be entered again after adequate ventilation.
If unavoidable work is required in presence of a high concentration of refrigerant, breathing
apparatus must be worn. This does not mean simple filter masks. Comply with breathing
protection data sheet.
Safety glasses and safety gloves are to be worn.
Do not eat, drink or smoke at work.
Liquid refrigerant must not get onto the skin.
Only use in well ventilated areas.
Do not inhale refrigerant vapours.
Warn against intentional misuse.
Remove refrigerant from the system before performing any welding or brazing works.
Weld and braze air conditioning systems without refrigerants only in suitably ventilated
rooms.
If the system emits a pungent smell this means that the refrigerant has decomposed due to
overheating. Immediately leave the room and return only after it has been suitably ventilated
or when wearing a gas mask for acid gases.
It is absolutely essential to comply with the first aid measures if accidents occur.
Refrigerants containing FCs contribute to the global warming and with this to climate
changes. The FCs must therefore be disposed of in accordance with the regulations, i.e. only
by companies specially qualified and licensed as recognised disposal companies for
refrigerants (see chapter 'Uninstalling and disposal of the unit').
1.4 Safety and environmental requirements
The following requirements relate to the operation of refrigerating plants within the European
Community.
The used components must correspond to the pressure equipment guide-line 2014/68/EU
and EN 378 part 1-4.
Independent of the design, the equipment and inspection before the delivery, also the
operator of such plants has duties according to EN 378 and national regulations.

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This concerns the installation, the operation and the repeated inspection:
Installation:
according to EN 378
Operation:
Determination of emergency measures (accidents, malfunctions)
Creation of an abbreviated instruction and notification (template page)
a. A unit protocol must be kept
b. To be stored in the proximity of the unit
c. Access for competent staff in case of repairs and repeated
inspection must be ensured.
Repeated inspection:
according to EN 378. The operator is responsible for the execution.
The operator must ensure that all maintenance, inspection and assembly work is carried out by
authorised and qualified specialist staff who have made an in-depth study of the operating
instructions.
It is absolutely essential to comply with the procedure for shutting down the system described in
the operating instructions. Before maintenance work, the unit must be switched off at the main
switch and a warning sign displayed to prevent unintentional switching-on.
Efficiency of safety devices must be kept during the whole life cycle of the unit. In order to
perform this task, please follow the prescription given in Chapter 9.
First aid measures
If health problems occur during or after handling fluorinated hydrocarbons, a doctor is to be
consulted immediately. The doctor is to be informed that the work involved the use of
fluorinated hydrocarbons.
In the case of acute effects, the casualty is to be brought into the fresh air as quickly as
possible.
The casualty must never be left unsupervised.
If the casualty is not breathing, initiate mouth-to-mouth resuscitation immediately.
If the casualty is unconscious or very dazed he or she must not be given any liquid.
Splashes of fluorinated hydrocarbons in the eyes can be removed by an assistant by blowing
air or using a fan. Then rinse with water.
Independent conversion and manufacture of replacement parts.
The system may only be converted or modified after consultation with STULZ. Original
replacement parts and replacement parts/accessories authorized by STULZ are an aid to
safety.
Independent conversion and manufacture of replacement parts
The system may only be converted or modified after consultation with STULZ. Original
replacement parts and replacement parts/accessories authorized by STULZ are an aid to safety.
Unacceptable operating methods
The operating safety of the system is only guaranteed when it is used as intended. The limit
values stipulated in the technical data must not be exceeded under any circumstances.

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2. Unit identification
Technical name-plate
This unit can be correctly identified by
the technical name-plate containing all
the information for its correct use.
The name-plate is attached both to the
external casing of the unit (generally on
one of the sides) and to the door of the
electrical panel.
In addition to the manufacturer's
identification data and the product trade-
marks, the name-plate contains the
following information:
Example of name-plate. Data are purely
an example.
The technical name-plate is embossed
on a plastic support which ensures high
endurance of the text even in particularly
difficult environments.
For any assistance or
information concerning the unit
described in this manual,
knowledge of its serial number
is essential.
*Nominal conditions:
30°C (RH 30%) inside shelter temperature and 35°C ambient temperature

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IP protection degree
IP protection degree is the protection, from the outdoor environment, of the unit
when installed in its normal use.
The IP protection degree of STULZ Tel-Air-2 unit, installed combined with a suitable external
rainproof grille (available as Stulz accessory ACTGRxxTL), is IPX4, therefore the unit is
protected from harmful effects of splashing of water against the enclosure from any direction
(according to EN 60529, considering the prescriptions of EN 60335).
TLF/TLD units:
TLU units:
Indoor
Outdoor
Indoor
Outdoor
Shelter
Shelter
Rainproof
grille
Rainproof
grille

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Code
The table summarises the available options for the Tel-Air-2 family. Some of the options or
combinations are not available on all the products in the family.
Product family
Nominal cooling capacity
Operating method
Type of control system
Application and fans
Main power supply
Compressor - refrigerant
Heating
Combination of options
TLx
40
F
T
1
42
C
0
00
0 = no heating
2 = 1.5 kW
4 = 4.5 kW
1 = alternative compressor + R134a
2 = alternative compressor + R407C
B = scroll compressor + R134a
C = scroll / rotary(1) compressor + R407C
Z = special model(2)
00 = 230V / 1Ph / 50Hz
42 = 400V / 3Ph + N / 50Hz
1 = inside ambient to condition –standard fans
C = with HPFAN option
E = with EVAHPFAN option
J = with HPFAN and EVAHPFAN options
R = electronic board C2020
T = electronic board C2020 + keypad incorporated in the unit
P = customer's external PLC (requires a special code)
V = electronic board C2020 + keypad + WIB1000
Y = electronic board C2020 + keypad + WIB1485
0 = cooling only
F = cooling + free-cooling
H = cooling + free-cooling + emergency ventilation 48VDC
40 = 4 kW
60 = 6 kW
80 = 8 kW
90 = 9 kW
A2 = 12 kW
A4 = 14 kW
TLF = Built-in unit, internal installation, displacement supply
TLD = Built-in unit, internal installation, downflow supply
TLU = Built-in unit, internal installation, upflow supply
(1) rotary compressor is used on single-phase model of TLx40 with R407C.
(2) special models are identified with a Z in the fourth to last digit of the code. The 3
digits following the Z lose their original meaning and act as the progressive
number for special versions.

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2.1 Intended and non-intended use
Intended use
STULZ Tel-Air-2 conditioners are designed to cool rooms containing technological systems,
suitably protected from weather. Their use eliminates the problems caused by high temperatures,
dirt and humidity present in the area where they are installed.
STULZ Tel-Air-2 units are designed to be installed inside a shelter / room whose internal side is
not accessible to the general public (see EN 60335-2-40, paragraph 3.119).
Additionally, STULZ Tel-Air-2 conditioners are designed to operate in an upright position. For all
models the compressor is and must always be in an upright position.
The conditioners may not be used or transported in a position other than that for
which they have been designed. STULZ declines all liability deriving from failure to
observe the above.
Non-intended use
Air conditioner cannot be installed on movable, vibrating, oscillating, tilted (non-levelled) parts.
Generally, air conditioner cannot be installed in the following areas:
with strong heat radiation
with strong magnetic fields
with free flames
with fire risk
with inflammable products
with explosive atmosphere
with saline atmosphere
with aggressive atmosphere
For any doubt, please consult the manufacturer.

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3. Components and operating principle
3.1 Layout of components
TLF –DISPLACEMENT SUPPLY
The internal air return is located in the roof of the unit. Taken in by the radial fan located at the
bottom of the unit behind the supply opening, the air crosses the treatment filter in the centre of
the unit, is blown onto the evaporator coil and leaves from the opening in the lower front panel.
On TLF size 1, the compressor is beside the electrical panel, over the evaporator fan. On TLF
size 2, the compressor is fixed to the base of the unit, under the evaporator coil and beside the
evaporator fan.
The conditioner is controlled by the electronic board in the electrical panel, located behind the
lower front panel and closed by a protective cover. The display indicating operating states and
parameters and used to modify board parameters is located on the upper front panel.
The through holes for the power cables and the electronic board input / output signal connectors
are located on the roof of the unit.
The condensate drainage system is located at the rear.
TLD –DOWNFLOW SUPPLY
Lay-out is the same as TLF units, but cooled air is supplied through an opening on the base of
the unit, not from lower frontal panel.
TLU –UPFLOW SUPPLY
The internal air return is located in the lower frontal panel of the unit. Taken in by the radial fan
located at the top of the unit behind the supply opening, the air crosses the treatment filter in the
centre of the unit, is blown onto the evaporator coil and leaves from the opening in the upper
front panel.
The compressor is fixed to a support in the centre of the unit, in front of the evaporator coil.
The conditioner is controlled by the electronic board in the electrical panel, located behind the
upper front panel and closed by a protective cover. The display indicating operating states and
parameters and used to modify board parameters is located on the upper front panel.
The through holes for the power cables and the electronic board input / output signal connectors
are located on the roof of the unit.
The condensate drainage system is located at the rear.

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Damper block
Air filter
Electrical panel
Condenser
Condenser fan
Display
Evaporator fan
Compressor
Layout of the internal TLF/TLD components
TLF/TLD 40-60
TLF/TLD 80-A4
Water discharge
Evaporator

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Evaporator
Damper block
Air filter
Electrical panel
Condenser
Evaporator fan
Display
Condenser fan
Compressor
Layout of the internal TLU components
Water discharge
Evaporator

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Display
Air flow diagram TLF/TLD units (a unit size 2 is shown in these drawings)
Disposizione componenti interni TLF taglia 1 e taglia 2
COOLING
FREE-COOLING
TLF
TLF
TLD
TLD

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Air flow diagram TLU units (a unit size 2 is shown in these drawings)
COOLING
FREE-COOLING

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3.2 Operating method
Cooling
The shelter air is taken in by the radial fan, filtered and then cooled as it crosses the evaporator
coil. The treated air is then returned to the shelter through the supply air opening. The
compressor operates in order to cool the air.
Free-cooling
There is a damper equipped with servomotor which directs internal and external air flows. The
damper is located in the central part of the conditioner. External air is taken in through an
opening near the damper while the internal air is discharged by overpressure through an opening
located above (TLF/TLD) or below (TLU) the other one.
This damper is proportionally controlled by a modulating signal from the C2020 controller. Its
position can be adjusted from 0 to 100% of fresh air, to regulate free-cooling capacity.
Assisted free-cooling
When the temperature of the external air is low enough to enable the free-cooling mode, but the
effect of this operating mode is not sufficient to keep the internal temperature within the required
range, the compressor is switched on while the free-cooling damper remains open. In this way,
the evaporator cools the external air rather than the internal re-circulating air, combining the
benefits of the free-cooling and the cooling modes.
Emergency ventilation (optional)
When there is a power failure, part of the unit (evaporator fans, control components and the free-
cooling damper motor) is powered by an emergency 48 VDC power supply. In this way,
continuous circulation of air inside the shelter is always assured. This circulation of air is
combined with free-cooling when the conditions required to enable this mode are satisfied.
Units with direct current emergency ventilation always require an external direct
current power line even when mains power is present.
Heating (optional)
With the heating elements option, the units include an electric heating element. When the
temperature is low, the heating coil turns on (compressor off) and the free-cooling damper is in
complete re-circulation position, in order to heat internal air. This mode is controlled by the
C2020 microprocessor.

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3.3 Mechanical parts
Structure
These machines are built using self-supporting panels made of painted galvanised sheet metal to
guarantee good corrosion resistance (not suitable for corrosive and saline environments). They
make the machine easy to inspect and, at the same time, offer adequate protection to its internal
components. The external panels are internally lined with a 3 mm layer of sound-absorbing
material.
The internal components of the unit can be accessed by simply removing the cladding panels.
This is done by undoing their fastening screws.
Air filter
Belonging to class G4, it is designed to prevent large dirt particles present in the environment
from obstructing airflow through the evaporator.
Drip-tray
Made of sheet aluminium, it is located under the evaporator coil to collect the moisture from the
internal air which condenses on the surface of the coil during cooling. It is fitted with a union for
external drainage.
Damper
This damper, fitted in units featuring the free-cooling option, consists of a metal baffle powered
by a servomotor for directing inside and outside air flows. The damper body is made of
galvanised sheet metal.
3.4 Cooling components
The unit comprises a hermetic cooling circuit consisting of a compressor, condenser, refrigerant
filter, thermostatic valve and evaporator. The air inside the shelter is cooled without coming into
contact with the external air in cooling mode.
The system works as follows:
The compressor compresses the refrigerant gas bringing it to a high pressure and temperature.
The hot gas, by going through the condenser, is cooled and liquefied thus releasing heat to the
air in the environment. Pushed through the thermal expansion valve, the liquid refrigerant loses
pressure, which makes it prone to evaporation. This takes place in the evaporator, where the
refrigerant absorbs the heat of the warm air from the shelter, which is therefore cooled.
The circuit components are connected together by copper piping, appropriately welded to ensure
a greater seal. Schrader service valves are fitted internally on the compressor intake and return
lines.
Refrigerant
The refrigerant that is used is R407C (HFC). Optional: R134a.