Stulz DesicAir 1000 Series User manual

STULZ Desicair
DEZ Series 1000
Desiccant Dehumidification System
Installation, Operation and Maintenance Manual

MODEL NOMENCLATURE
DESICAiR Product Identification Number Example
DEZ –600 – 40– E
DEZ = Desicair Series 1000
Nominal Process Airflow
150 CFM
300 CFM
450 CFM
600 CFM
Reactivation Type
E =Electric
Rotor Diameter
35 cm
40 cm
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
photocopied, 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. (STULZ).
This document contains STULZ confidential and proprietary information. Distributing or photocopying this document for
external distribution is in direct violation of U.S. copyright laws and is strictly prohibited without the express written
consent of STULZ.
Unpublished — rights reserved under the copyright laws of theUnited States and of other countries. Other
brands and tradenames are trademarks of their respectiveowners.
Copyright 2017 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

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
i
Table of Contents
1.0 GENERAL INFORMATION ........................ 1
1.1 About this Manual ....................................... 1
1.2 Introduction ................................................. 1
1.2.1 Technical Data Package.......................... 1
1.2.2 Dehumidifier Identification Number ......... 1
1.2.3 Unit Nameplate ........................................ 3
1.3 Safety .......................................................... 3
1.3.1 Warnings and Cautions ........................... 3
1.4 Theory of Operation .................................... 4
1.5 Construction ................................................ 5
1.5.1 Design Features ...................................... 5
1.5.2 Cabinet..................................................... 5
1.5.3 Inlets and Outlets..................................... 6
2.0 INSTALLATION.......................................... 7
2.1 Receipt of Unit............................................. 7
2.2 Rigging ........................................................ 7
2.3 System Location and Clearance................. 7
2.4 Connecting Ductwork.................................. 7
2.5 Utility Connections ...................................... 8
2.6 Installing a Humidistat or Relative Humidity
Transmitter .................................................. 8
3.0 OPERATION............................................... 9
3.1 Installation Checks ...................................... 9
3.2 Start Up ....................................................... 9
3.3 Reactivation Heater Controller.................. 10
3.4 Capacity Control ....................................... 10
3.4.1 D-Stat..................................................... 10
3.4.2 H-Trac .................................................... 10
3.4.3 Dew-Trac ............................................... 10
3.4.4 C-Trol II.................................................. 10
3.4.5 Proportional Reactivation Controls
(H-Trac or Dew-Trac)............................. 11
3.5 Control Panel ............................................ 11
3.5.1 Mode Selector Switch ............................ 12
3.5.2 Hour Meter............................................. 12
3.5.3 Control Panel Lights .............................. 12
3.5.4 Optional Fault Indication Lights ............. 12
3.6 Monitoring Unit Performance .................... 13
4.0 UNIT FEATURES ..................................... 14
4.1 Control Sensor Terminals ......................... 14
4.2 Remote Start/Stop Contact ....................... 14
4.3 Optional Customer Contacts..................... 14
4.4 Sensor Retransmit Terminals ................... 14
4.5 Electrical Disconnect................................. 14
4.6 Emergency Stop ....................................... 15
4.7 Dampers.................................................... 15
4.8 Filter Status ............................................... 15
4.9 Voltage Sensor/Phase Monitor ................. 15
4.10 Process Air Proving .................................. 15
4.11 E2 Controller and Display ......................... 15
5.0 PREVENTIVE MAINTENANCE ................ 16
5.1 Monthly ......................................................16
5.2 Yearly......................................................... 16
5.3 Desiccant Rotor Drive Motor Maintenance16
5.4 Blower Motor Maintenance........................ 16
5.4.1 General Inspection ................................. 16
5.4.2 Lubrication & Bearings ...........................17
5.4.3 Lubrication Procedure ............................18
6.0 TROUBLESHOOTING .............................. 19
7.0 REPAIR PROCEDURES........................... 21
7.1 Rotor Handling Guidelines.........................21
7.2 Replacing the Rotor Drive Belt .................. 21
7.2.1 Removing the Old Belt ...........................22
7.2.2 Installing the New Belt............................ 22
7.3 Removing the Rotor................................... 22
7.4 Replacing Seals.........................................22
7.4.1 Removing Old Seals...............................22
7.4.2 Installing New Seals ............................... 23
7.5 Washing the Rotor.....................................23
7.5.1 Cleaning .................................................23
7.6 Repairing the Rotor ...................................23
8.0 PRODUCT SUPPORT .............................. 25
8.1 Technical Support...................................... 25
8.2 Obtaining Warranty Parts .......................... 25
8.3 Obtaining Spare/Replacement Parts.........25
Appendix A
Installation Checklist ........................................ A-1
Maintenance & Service Checklist .................... A-2
Appendix B
Unit Performance Curves ................................ B-1
Appendix C
Glossary........................................................... C-1

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
ii
Figures
Figure 1 - Sample Nameplate............................................3
Figure 2 - General Theory of Operation Diagram..............5
Figure 3 - Locating a Wall Mounted Control Sensor..........8
Figure 4 - Proportional (Trac) Control Diagram ...............11
Figure 5 - Sample Non-E2Control Panel Layout.............12
Figure 6 - Sample E2Control Panel Layout.....................12
Figure 7 - Differential Pressure Gauges ..........................13
Figure 8 - E2Controller and Display ................................15
Figure 9 - Overheat Safety Switch...................................19
Figure 10 - Rotor Assembly Parts ...................................22
Figure 11 - Rotor Scratch Repair.....................................24
Tables
Table 1 - Blower Motor Lubrication Intervals ...................17
Table 2 - Service Conditions............................................17
Table 3 - Lubrication Interval Multiplier............................17
Table 4 - Bearing Sizes and Types .................................18

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
1
1.0 GENERAL INFORMATION
1.1 About this Manual
This manual provides installation, operation, and
maintenance information for the STULZ DESICAiR®
DEZ Series 1000 dehumidification system. The DEZ
system has several standard options which are
covered in this manual. The exact configuration of
your system is reflected in the Engineering drawings
provided in the Technical Data Package shipped with
your system. It is also described in the Dehumidifier
Identification Number (DIN) sheet and other submittal
package documents for your system. You can use
these documents to determine the sections of this
manual that are relevant to your system.
1.2 Introduction
The DEZ Series 1000 dehumidification system is
designed and manufactured by Stulz Air Technology
Systems, Inc. (STULZ) utilizing the latest, state-of-the-
art control technology. Recognized as a world leader,
STULZ provides dehumidification systems
manufactured with the highest quality craftsmanship
and materials. The unit will provide years of trouble
free service if it is installed, operated and maintained
as described in this manual. Damage to the unit from
improper installation, operation or maintenance is not
covered by the warranty.
Study the instructions in this manual; they must be
followed to avoid difficulties. Spare parts are available
from STULZ to ensure continuous operation. Using
substitute parts or bypassing electrical or other
components in order to continue operation is not
recommended and will void the warranty.
1.2.1 Technical Data Package
This manual is part of the Technical Data Package
provided with your unit. The Technical Data Package
typically includes drawings, Technical Data Sheets, a
Flow Diagram, a Test Report and component part
manufacturer’s manuals containing additional
information about significant components. The
Technical Data Package may also contain related
STULZ manuals (for example, a system controller
manual). These documents should be stored in a safe
place on or near the unit for reference.
A Warranty Registration and Start-up Checklist form is
also included in the Technical Data Package. This
form must be completed during installation and
returned to STULZ Product Support to activate your
warranty.
1.2.2 Dehumidifier Identification Number
The Dehumidifier Identification Number (DIN) defines
specific features that are provided with your unit (see
section 1.2.2.1). The DIN Sheet for this unit is
included for reference in the unit Technical Data
Package. The Technical Data Package also contains
a technical data sheet, a test report (showing
performance information), drawings and this manual.
A manual for the system controller is also provided
under separate cover. These documents should be
stored in a safe place on or near the unit for
reference.

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
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1.2.2.1 Dehumidifier Identification Number (DIN) Sheet
The DIN starts with the model number. The DEZ model number includes the nominal process CFM followed by the
desiccant rotor diameter. (ex: DEZ-600-40). The first 15 digits after the model number (represented by the uppercase
letters A–N below) pertain to the cabinet construction, rotor type, and process and reactivation accessories or
options.
Process CFM Rotor Diameter in Centimeters
DEZ- XXX - XX - AA - B C D E F G H - I J K - L M N
Model Reactivation Cabinet Construction Process Reactivation
Number Type and Rotor Accessories Accessories
The last 17 digits (represented by the lowercase letters a-n below) pertain to the electrical system, unit controls,
control scheme and control panel features.
aa b c - dd ee - f g h i - j k l m n
Power and Capacity Status Other
Wiring Control Contacts
The following is a sample DIN Sheet for a DESICAiR DEZ Series 1000 Desiccant Dehumidifier:

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
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1.2.3 Unit Nameplate
The Unit Nameplate, located on the front or side of
the unit, is a quick source for useful information
about your system, such as the unit model number,
serial number and specific STULZ job number (see
Figure 1 for an example). This data will be required
if you contact STULZ for assistance, warranty
information, or spare parts. The Unit Nameplate
also includes the process and reactivation airflow
targets, along with their corresponding rotor
pressure drops.
Figure 1 - Sample Nameplate
1.3 Safety
Read and understand all instructions,
recommendations, and guidelines in this manual
regarding the installation, maintenance, and
operation of this unit prior to installation and start-
up. All maintenance and repairs should be
conducted by personnel thoroughly trained in the
operation and maintenance of this or like equipment.
The main power supply to the equipment must be shut
off before beginning work on the equipment. Take
extreme care to ensure that every capacitor likely to
hold electrical charge has been grounded. Always
remove all rings, watches, and other jewelry when
working on electrical equipment. Some of the
equipment used may present the hazard of
Electrostatic Discharge (ESD). When working inside
the equipment, always ground all parts before
touching. When working on or near ESD-sensitive
components, use a wrist grounding strap if possible.
Never operate the unit with any cover, screen, guard,
panel, etc., removed unless the instructions
specifically state to do so, and then do so with
extreme caution to avoid personal injury. Never
attempt to lift any component in excess of 35 pounds
without additional help.
Placards and/or stickers have been placed in various
locations on or in the unit. These placards/stickers are
intended to call attention to personal safety and
equipment damage hazards.
Certain maintenance and cleaning procedures may
either recommend or specify the use of solvents,
chemicals, or cleansers. Always refer to the
manufacturer’s Safety Data Sheet (SDS) prior to
handling any of these materials.
1.3.1 Warnings and Cautions
The following is a condensed list of warnings and
cautions that are noted throughout this manual. All
personnel who operate, service and maintain this
equipment should read and understand these
warnings and cautions. All warnings indicate a
potential threat to personnel and all cautions indicate
a potential threat to equipment damage.
Prior to using any chemicals, cleansers, or solvents,
refer to the manufacturers Safety Data Sheets (SDS)
for proper handling and usage of such materials.
Voltages used with this unit can
be deadly. Be careful not to contact high AC
voltage connections when installing or operating
this equipment. Use the services of a qualified
electrician and/or technician to make the electrical
power connections and perform maintenance.
Disconnect main power to the unit
before performing any maintenance or service.
Turning the mode selector switch to the Off
position does not disconnect power to controls or
the unit itself.

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
4
Whenever the nature of the
operation permits, keep one hand away from
the equipment to reduce the hazard of current
flowing through vital organs of the body.
Never work on electrical
equipment unless there is someone nearby
who is both familiar with the operation and
hazards of the equipment and competent to
administer first aid. When operators aid the
technician, the technician must warn them
about dangerous areas.
Do not be misled by the term
"low voltage" which may appear in this manual
or on drawings or documents in the Technical
Data Package. Electrical voltages as low as 50
volts can cause death under certain conditions.
Multiple power sources may be
used in the unit. Ensure power is disconnected
from all sources before servicing powered
components.
Do not touch hot system
components. The design reactivation
temperature range is 250–300 °F. The
components of the reactivation system may be
extremely hot during operation. Be absolutely
certain that the unit and/or reactivation
components are cool before attempting to work
on or near them.
Unless otherwise specifically
instructed, do not operate the equipment
without all grilles, guards, louvers and covers
in place and tightly secured. When instructed
to operate without a grille, guard, louver or
cover in place, do so with care.
Blower motors may start
unexpectedly when the unit is running due to
an automatic resetting of the internal overload
device.
Do not allow anyone under the
equipment while it’s suspended from a lifting
device.
Do not allow the unit to swing
while suspended from a lifting device. Failure
to observe this warning may result in injury to
personnel and damage to the equipment.
!
CAUTION
Ensure that the dehumidifier is
properly phased. Improper phasing can cause severe
damage to the equipment.
!
CAUTION
Air intake and discharge openings
must be completely free of obstructions. Ensure
panels are on and properly secured into position.
!
CAUTION
Do not operate the unit without
filters. It is better to operate the unit with dirty filters
than no filters. Operating the unit without filters may
void the warranty.
1.4 Theory of Operation
The DEZ Series 1000 dehumidification system is
designed to dehumidify a space to a level below that
attainable with a refrigeration-based dehumidification
system. Moisture is removed from the air by being
passed through a desiccant wheel (called the “rotor”)
that is impregnated with a dry desiccant. Process air
(the air being dehumidified) is filtered, dehumidified
and supplied to a conditioned space at a lower relative
humidity and a slightly higher dry bulb temperature
than its inlet condition.
Simultaneously, a second airstream (reactivation air)
is filtered and heated by a reactivation heater system,
then passed through a separate segment of the rotor.
This heated reactivation air removes the previously
adsorbed moisture from the desiccant rotor and
exhausts it to an area other than that being
conditioned. During operation, the desiccant rotor
rotates through the process and reactivation
airstreams of the dehumidifier at a constant speed.
The two airstreams are separated by face and
peripheral seals and by internal fluting in the desiccant
rotor. Process and reactivation airstreams are
counter-flow to maximize the efficiency of the
adsorption process and to help prevent the rotor's
flutes from fouling.
The reactivation heater is sized to raise the
temperature of the reactivation air entering the
desiccant rotor approximately 180 ºF above ambient
(depending upon moisture adsorbed from the process
air and reactivation airflows). The energy from the
heated reactivation air is used to desorb the moisture.
Reactivation discharge air temperature will vary and
can be as high as 150 ºF and moist. Controls are
included in the unit to vary reactivation heat based
upon the amount of moisture adsorbed from the
process airstream.

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
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Electric heat is generated by a heater controlled by
an SSR (solid state relay) or SCR (silicon
controlled rectifier). The SSR cycles the heater on
and off based on signals received from the system
controller to maintain the reactivation discharge air
temperature. An SCR also receives controller
signals, but modulates the percentage of heater
output energy (as opposed to turning the heater on
and off) for tighter temperature control.
There may be more than one heater bank
depending upon the output required. Refer to the
Electrical drawing and technical data sheet for more
detail.
NOTE: The reactivation air temperatures mentioned in
the preceding discussion may vary between DEZ
systems. See the Technical Data Sheet for your unit
for target temperatures.
Figure 2 - General Theory of Operation Diagram
1.5 Construction
This desiccant dehumidifier was manufactured by
STULZ and has passed all Quality Control checks,
including a complete functional testing. Every effort
has been made to ensure the dehumidification system
will perform satisfactorily for many years.
1.5.1 Design Features
Rugged All-Aluminum Cabinet
Continuous or Automatic Operation
Inert, Stable Silica Gel Desiccant
Non-toxic, Non-corrosive Desiccant
Capable of Withstanding 100% RH Without
Adverse Effect
Counterflow Process and Reactivation Air
Patterns
Overheat Safety Protection
Electric Reactivation Heat
Easy Access to Internal Components
Low Operating Cost, Energy Efficient
Dehumidification
Optional Process and Reactivation Inlet Air Filters
For a comprehensive list of the features included,
refer to the DIN Sheet provided specifically for this
unit. The DIN sheet is a listing of all the standard and
optional features that are included (see section 1.2.2).
For particular detail of the features, refer to the
drawings provided with this unit.
1.5.2 Cabinet
This unit is self-contained in an aluminum cabinet
rated for either indoor or outdoor use (see Unit
Nameplate). The exterior of the cabinet is finished
with a durable paint to protect it against corrosion.
Removable access panels are provided for easy
access to all major components for maintenance
and/or service.
The operator controls are conveniently located in the
front of the unit (see the installation drawing provided).
The cabinet houses the desiccant rotor assembly and
drive system, process and reactivation air blowers, a
Process
Air Outlet
Process
75% of rotor
Reactivation
25% of rotor
Desiccant
Rotor
Process
Air Inlet
Reactivation
Air Outlet
Process
Air Filter
Reactivation
Air Blower
Process
Air Blower
Reactivation
Air Filter
Reactivation
Heater(s)
Reactivation
Air Inlet

DEZ SERIES 1000 INSTALLATION,OPERATION AND MAINTENANCE MANUAL
6
reactivation heater system (electric), and electrical
controls.
1.5.3 Inlets and Outlets
Inlets and outlets may be provided with flanged duct
connections or with duct connections for round hard or
round flexible duct. Depending on whether the unit is
intended for indoor or outdoor use, the process and
reactivation inlets and outlets may be equipped with
louvers or hoods to prevent rain and snow from
entering the unit. Screens may be provided to prevent
birds and other small animals from nesting in the
inlets and outlets.
For a comprehensive list of the features, refer to the
DIN sheet provided specifically for this unit (see
section 1.2.2). The DIN sheet is a listing of all the
optional features that are included. For particular
detail of the features, refer to the Installation drawing
provided for this unit.