CeilAiR Series

Supplemental Air Conditioners

3.5 – 35 kW Systems
CeilingMounted,60HzData

Installation, Operation and Maintenance Manual

 CeilAiR IOM Manual

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).
T
his document contains confidential and proprietary information of STULZ Air Technology Systems, Inc.
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Unpublished — rights reserved under the copyright laws of the United States and of other countries. Other
brands and tradenames are trademarks of their respective owners.

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
https://www.stulz-usa.com/en/
 CeilAiR IOM Manual

Table of Contents

1.0 Introduction ................................................ 1 2.4.6 Humidistat/Dehumidistat (Used with

1.1 General.............................................................................. 1 A-Tech1.1/1.2 Thermostat) .................................... 13
1.2 Product Description...................................................... 1 2.4.7 Spot Water Detector.................................................. 14
1.3 Control Devices .............................................................. 1 2.4.8 Cable Type Water Detector ..................................... 14
1.4 Safety ................................................................................ 1 2.5 Air Distribution Connection ..................................... 14
1.4.1 General.............................................................................. 1 2.5.1 Spot Cooler................................................................... 14
1.4.2 Safety Summary ............................................................. 2 2.5.2 Ducted Systems. ......................................................... 14
1.5 General Design ............................................................... 3 2.6 Piping Connections .................................................... 14
1.5.1 Electric Box Access ...................................................... 3 2.6.1 Refrigerant.................................................................... 14
1.5.2 Coil(s) ................................................................................. 4 2.6.1.1 Self-Contained Systems .......................................... 14
1.5.3 Blower ............................................................................... 4 2.6.1.2 Split Systems................................................................ 14
1.5.4 Temperature Sensor ..................................................... 4 2.6.1.3 Remote Air Cooled Condensers (AR Models) .... 17
1.6 Optional Equipment ...................................................... 4 2.6.1.4 Remote Air Cooled Condensing Units
1.6.1 Humidistat/Dehumidistat ........................................... 4 (AHU Models) ............................................................... 17
2.6.2 Chilled Water, Water/Glycol and Hot Water
1.6.2 Temperature/Humidity Sensor................................. 5
Reheat Piping .............................................................. 17
1.6.3 Heaters ............................................................................. 5
2.6.3 Condensate Drain Line ............................................. 18
1.6.4 Humidifier......................................................................... 5
2.6.3.1 Gravity Drain ................................................................. 18
1.6.5 Condensate Pump ........................................................ 5
2.6.3.2 Condensate Pump...................................................... 18
1.6.6 Smoke Detector ............................................................. 5
2.6.4 Humidifier (Optional) .................................................. 18
1.6.7 Firestat .............................................................................. 5
2.7 Utility Connections ..................................................... 18
1.6.8 Water Detector............................................................... 5
2.7.1 Main Power ................................................................... 18
1.7 Free-cooling Operation ............................................... 5
2.7.1.1 Single-Phase Units 208/230V ............................. 19
1.8 AWS Operation. .............................................................. 7
2.7.1.2 Single-Phase Units 277V........................................ 19
2.0 Installation .................................................. 8 2.7.1.3 Three-Phase Units ..................................................... 19
2.1 Receiving the Equipment ............................................ 8 2.7.2 Controls ......................................................................... 20
2.2 Site Preparation ............................................................. 8 2.7.2.1 A-Tech 1.1 Programmable Thermostat ............... 20
2.3 Rigging .............................................................................. 9 2.7.2.2 A-Tech 1.2 Programmable Thermostat ............... 20
2.4 Mounting .......................................................................... 9 2.7.3 Air-Cooled Split Systems ......................................... 20
2.4.1 Indoor Equipment ....................................................... 10 2.7.3.1 Remote Condenser .................................................... 24
2.4.2 Outdoor Equipment ................................................... 10 2.7.3.2 Remote Condensing Unit ......................................... 24
2.4.3 Controls ......................................................................... 10 2.7.4 Water/Glycol Systems............................................... 24
2.4.3.1 A-Tech Programmable Thermostats .................... 10 2.7.5 Remote Shut Down .................................................... 24
2.4.3.2 Advanced STULZ E² Controller ............................. 12 2.7.6 Optional Equipment ................................................... 24
2.4.4 Optional Equipment ................................................... 12 2.7.6.1 Condensate Pump...................................................... 24
2.4.4.1 Condensate Pump (Field Installed) ....................... 12 2.7.6.2 Humidistat/Dehumidistat ........................................ 24
2.4.4.2 Non-Fused Service Switch ..................................... 12 2.7.6.3 Remote Water Detector ........................................... 25
2.4.5 Remote Sensors ......................................................... 12 2.7.6.4 Remote Temperature Sensor (A-Tech) ..................... 25
2.4.5.1 Remote Temperature Sensor (A-Tech) ..................... 12 2.7.6.5 Remote Temperature/Humidity Sensor (E2) ...... 25
2.4.5.2 Remote Temperature/Humidity Sensor (E²) ...... 13 2.8 System Charging Procedures................................. 25

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2.8.1 Water/Glycol Systems .............................................. 25 3.0 Commissioning, Operation And

2.8.1.1 Pump .............................................................................. 25 Decommissioning .................................... 35
2.8.2 DX Unit Charging Requirements ........................... 25 3.1 Commissioning the Unit ............................................ 35
2.8.3 Remote Air-Cooled Systems (AR/AHU) ............... 26 3.1.1 Commissioning Steps................................................ 35
2.8.4 R407C/R410A Refrigerant .................................. 26 3.2 Operating the Unit ...................................................... 36
2.8.5 Estimating Refrigerant Charge .............................. 26 3.2.1 Shutdown Procedure ................................................ 36
2.8.6 Preparing System For Charging ............................ 27 3.2.2 Start-up Procedure .................................................... 36
2.8.6.1 Evacuate the System................................................. 27 3.3 Programming the Thermostat ................................. 36
2.8.7 Refrigerant Charging Procedures ........................ 28 3.3.1 A-Tech Controller ........................................................ 36
2.8.7.1 Initial System Charge ................................................ 28 3.3.2 E² Controller ................................................................. 36
2.8.7.2 Fine Tuning The System Charge ............................ 28 3.4 Decommissioning the Unit ....................................... 36
2.8.7.3 0 ºF Fan Cycling and -20 ºF Variable Speed 3.4.1 Recovering Refrigerant ............................................ 37
Control ........................................................................... 29 3.4.2 Labeling Decommissioned Equipment................ 37
2.9 Refrigerant Characteristics..................................... 30
4.0 Maintenance ............................................. 37
2.9.1 Pressure/Temperature Settings ............................ 30
4.1 Periodic General Maintenance ............................... 37
2.9.2 Saturated Refrigerant Pressure Tables ................. 30
4.1.1 A/C Unit ......................................................................... 38
2.10 System Settings and Adjustments ........................ 31
4.1.1.1 Compressor .................................................................. 38
2.10.1 Low/High Pressure Limit Switch .......................... 31
4.1.1.2 Heater............................................................................. 38
2.10.2 Head Pressure Controls—Air Cooled
Systems ......................................................................... 31 4.1.1.3 Air Filters ........................................................................ 38
2.10.2.1 Condenser Fan Cycling (Condenser Model 4.1.1.4 Blower ............................................................................ 38
SCS-AA, 0 °F) .............................................................. 31 4.1.1.5 Coils................................................................................. 38
2.10.2.2 Condenser Multi-Speed Fan Switch (Model 4.1.1.6 Drain Pan ....................................................................... 38
HES-CAA , 0 °F ) ......................................................... 31 4.1.1.7 Condensate Pump...................................................... 39
2.10.2.3 Variable Condenser Fan Speed (Condenser 4.1.1.8 Humidifier ...................................................................... 39
Model SCS-SA, -20 °F)............................................ 31
4.1.2 Condenser/Condensing Unit ................................. 39
2.10.2.4 Intelligent Control (Condenser Model SCS-EC
4.2 Troubleshooting .......................................................... 40
Only, -20 °F) ................................................................. 31
4.3 Field Service ................................................................. 43
2.10.2.5 Flooded Head Pressure Control (Condenser
Model SCS-AA With Fan Cycling, -30 °F) .......... 32 4.3.1 Leak Detection ............................................................ 43
2.10.2.6 Flooded Head Pressure Control (Condenser 4.3.2 Leak Repair .................................................................. 43
Model HES-CAA , -30 °F) ....................................... 32 4.3.3 Refrigerant Piping ...................................................... 43
2.10.3 Head Pressure Controls—Water/Glycol Cooled 4.3.4 General Common Repairs/Component
Systems ......................................................................... 32 Replacement ................................................................ 43
2.10.4 Humidifier Adjustment .............................................. 32 4.3.4.1 Compressor Failure .................................................... 43
2.10.5 Blower Adjustment .................................................... 33 4.3.4.2 Standard Cleanout Procedure................................ 44
2.10.5.1 Belt Drive Blower ....................................................... 33 4.3.4.3 Burn-Out/Acidic Cleanup Procedure .................. 44
2.10.5.2 EC Fan (Optional)........................................................ 33 4.3.4.4 Humidifier Cylinder Replacement. ........................ 44
2.10.6 Thermal Expansion Valve......................................... 33 4.3.4.5 Air Filter Replacement............................................... 45
2.10.7 Hot Gas Reheat (Optional) ...................................... 34
5.0 Product Support ...................................... 45
2.10.8 Hot Gas Bypass (Optional) ...................................... 34
5.1 Factory Authorized Start Up/Warranty
2.10.8.1 Snap Acting Hot Gas Bypass ................................. 34
Inspection ...................................................................... 45
2.10.8.2 Full Floating Hot Gas Bypass ................................. 34
5.2 Technical Support ....................................................... 45

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5.3 Obtaining Warranty Parts ......................................... 46 Tables

5.4 Obtaining Spare/Replacement Parts .................. 46
Table 1. Pipe Equivalent Lengths....................................15
Appendix A - OHS Preventive Maintenance Table 2. Recommended Discharge Line Sizes For
Inspection Checklist ................................47 R407C Refrigerant .............................................15
Table 3. Recommended Discharge Line Sizes For
Appendix B - Acronyms and Abbreviations ...........50 R410A Refrigerant .............................................15
Table 4. Recommended Liquid Line Sizes For R407C
Refrigerant (Condenser to Receiver ) ............16
Figures Table 5. Recommended Liquid Line Sizes For R410A
Refrigerant (Condenser to Receiver) .............16
Figure 1. A-Tech Digital Thermostats ................................. 1 Table 6. Recommended Suction Line Sizes For R407C
Figure 2. E Microprocessor Controller and Display ..... 1
2 Refrigerant .............................................................16
Figure 3. CeilAiR OHS-032-AR (Access Panels Re- Table 7. Recommended Suction Line Sizes For R410A
moved) ....................................................................... 4 Refrigerant .............................................................16
Figure 4. Free Cooling Diagram ........................................... 6 Table 8. Weight (lb) of Refrigerant per 100 ft of Type L
Figure 5. Alternate Water Source Diagram ...................... 7 Tubing............................................................................. 26
Figure 6. Typical Installation .................................................. 9 Table 9. Weight (lb) of Refrigerant by OHS Model .....27
Figure 7. A-Tech Controller Installation .......................... 10 Table 10. Refrigerant Pressure/Temperature
Settings ...................................................................30
Figure 8. Spot Cooler Grille ................................................ 11
Table 11. Saturated Refrigerant Pressure......................30
Figure 9. Ducted System Typical Air Patterns .............. 11
Table 12. Troubleshooting Table ........................................... 40
Figure 10. Temperature Sensor for A-Tech ...........................12
Figure 11. Temperature/Humidity Sensor for E2
Controller ............................................................... 13
Figure 12. Condensate Pump .............................................. 18
Figure 13. Sample Nameplate ............................................. 19
Figure 14. A-Tech 1.1 (top) and 1.2 (bottom) Controller
Wiring Contacts ................................................... 20
Figure 15. A-Tech 1.1 Control Wiring ................................ 21
Figure 16. A-Tech 1.2 Control Wiring ................................ 21
Figure 17. Interconnection Field Wiring Remote Con-
denser ..................................................................... 22
Figure 18. Interconnection Field Wiring Remote Con-
densing Unit .......................................................... 22
Figure 19. Interconnection Field Wiring Remote Con-
densing Unit with Dual Compressors ........... 23
Figure 20. Interconnection Field Wiring Glycol
Systems .................................................................. 23
Figure 21. Belt Drive Blower ................................................ 33

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Nomenclature
OHS-XXX
XXX--XX
XX--XX
Nominal Capacity
System in 1,000’s of Configuration Options
BTU/Hr
OHS = CeilAiR 012, 018, 024, 032, D( ) = Dual Circuit AHU = Air Handling Unit AWS = Alternate Water Source
Overhead System 040, 048, 060, 072, H( ) = Horizontal Discharge AR = Air-Cooled Remote (Split) FC = Free Cooling
084, 120 (“H-Series”) AS = Air-Cooled Self-Contained LP = Low Profile Configuration
C = Chilled Water System SF = Same-Face Air Pattern
G = Glycol-Cooled SP = Special Configuration *
W = Water Cooled

OHS 040 H G FC

Call 888 520 1266 for additional information.

Example: CHS-040-HG-FC, Overhead System, 40,000 BTU/H Capacity,

Horizontal Discharge, Glycol Cooled with optional Free Cooling OHS-040-G-FC

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1.0 INTRODUCTION The default control device for OHS units is the A-Tech
digital thermostat, which provides basic control of the
1.1 General system. Slightly different wiring is used with the thermostat
in single- and dual-stage units, as shown in Figure 14 on
The CeilAiR® ceiling-mounted air conditioning system page 20. The single-stage version is the A-Tech 1.1.
documented in this manual is designed and manufactured The two-stage version is the A-Tech 1.2. An operating
by STULZ Air Technology Systems, Inc. (STULZ). manual for the thermostat is provided with the unit under
separate cover.
STULZ CeilAiR overhead air conditioning systems (OHS)
are constructed using the finest available materials/com-
ponents, state-of-the-art technology and quality crafts-
manship. 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. Due to
advances in technology, components described herein are
subject to change without notice.

All STULZ CeilAiR OHS systems and CyberAiR centrifugal Figure 1. A-Tech Digital Thermostats
condensers are designed to be installed indoors, unless
otherwise noted on the equipment. Propeller-type con- The advanced STULZ E² microprocessor controller is
densers, condensing units, drycoolers and pump packages also available for OHS systems. This controller provides
are designed for outdoor use. enhanced features for more comprehensive control of
the unit. These features include: full alarm system; input/
output monitoring status; full integrated control of heating,
1.2 Product Description cooling, humidification, and dehumidification and remote
STULZ CeilAiR OHS systems are designed to be the most communication with building management systems. An
versatile and flexible ceiling-mounted air conditioning operating manual for the controller is provided with the unit
systems in the industry. The unit is available in air-cooled, under separate cover.
water-cooled, glycol-cooled and chilled-water configura-
tions. The cooling capacity in BTU/H will depend on the
unit size, which can range from 1 to 10 tons (3.5–35 kW),
and can be either a single stage or dual stage unit.

In addition to cooling, other functional modes of opera-

tion include heating, humidification, dehumidification and
filtration to provide complete environmental control of a
conditioned space. The cabinet configuration is available in
Figure 2. E2 Microprocessor Controller and Display
a 2 ft x 4 ft frame for units ranging from 12,000 to 40,000
BTU/H (spot cooler or ducted) or a larger frame for units
ranging from 48,000 to 120,000 BTU/H (ducted only). 1.4 Safety
For ducted units, there are three basic configurations of
airflow patterns: 90º/right angle, straight-through and in/
1.4.1 General
out-same-face (see Figure 9 on page 11). Refer to the STULZ Air Technology Systems, Inc. uses notes, cautions
installation drawing provided with the unit for the type of and warnings in its manuals to draw attention to important
cabinet configuration and for the layout dimensions. operating and safety information.

A bold text NOTE alerts you to an important detail.

1.3 Control Devices
A bold text CAUTION provides information that is impor-
STULZ offers a variety of control devices for CeilAiR OHS
tant for protecting your equipment and performance. Be
series systems. Control interfaces are typically remotely
especially careful to read and follow all cautions that apply
mounted to a wall or control panel.
to your application.

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 CeilAiR IOM Manual

A bold text WARNING provides information important for

protecting you from harm. Pay very close attention to all WARNING
warnings that apply to your application. To prevent personal injury, stay clear of rotating
components, as automatic controls may start them
precedes a general WARNING or CAUTION safety unexpectedly. Turn off power to the unit unless you
statement. are performing tests that require power. With power
and controls energized, the unit could begin operat-
ing at any time.
precedes an electrical shock hazard WARNING or
CAUTION safety statement.
WARNING
1.4.2 Safety Summary Never lift any component in excess of 35 lb without
The following warnings and cautions appear in this manual. help. If a lifting device is used to move a unit, ensure
Before performing any installation, operation, maintenance it is capable of supporting the wight of the unit.
or troubleshooting procedure, read and understand all
relevant cautions and warnings. Maintenance and/or repair WARNING
procedures must be performed by a journeyman refrigera-
tion mechanic or air conditioning technician. 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
WARNING equipment.
Never work on electrical equipment unless another
person who is familiar with the operation and hazards WARNING
of the equipment and competent in administering
first aid is nearby. Never operate the unit with any cover, guard, screen
panel, etc., removed unless the instructions specifi-
cally state otherwise, then do so with extreme cau-
WARNING tion to avoid personal injury.
All personnel working on or near equipment should
be familiar with hazards associated with electrical WARNING
maintenance. Safety placards/stickers have been
placed on the unit to call attention to all personal Refrigerant is used with this equipment. Death or
and equipment damage hazard areas. serious injury may result if personnel fail to observe
proper safety precautions. Great care must be ex-
ercised to prevent contact of liquid refrigerant or
WARNING refrigerant gas, discharged under pressure, with any
When working on electrical equipment, remove all part of the body. The extremely low temperature re-
jewelry, watches, rings, etc. sulting from the rapid expansion of liquid refrigerant
or pressurized gas can cause sudden and irreversible
WARNING 1 tissue damage.

Hazardous voltage will still be present inside the At a minimum, all personnel should wear thermal
electric box at the motor starter protectors and protective gloves and face-shield/goggles when
circuit breakers, even with the unit turned off at the working with refrigerant. Application of excessive
E2 controller. To isolate the unit for maintenance, heat to any component will cause extreme pressure
turn off power at the main power disconnect switch. and may result in a rupture.
Always disconnect main power prior to performing
any service or repairs. Exposure of refrigerant to an open flame or a very
hot surface may cause a chemical reaction that
WARNING forms hydrofluoric acid or carbonyl fluoride, a highly
poisonous and corrosive gas commonly referred to
A lock-out/tag-out procedure should be followed to as fluorophosgene. In its natural state, refrigerant is
ensure that power is not inadvertently reconnected. a colorless, odorless vapor with no toxic character-

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 CeilAiR IOM Manual

istics. It is heavier than air and will disperse rapidly

in a well-ventilated area. In an unventilated area it CAUTION
presents a danger as a suffocant. After interconnecting piping is installed, the piping
system must be cleaned. If solvents/cleaning solu-
Always review the manufacturer’s Safety Data Sheet tions are used, ensure they are completely flushed
(SDS) provided with the unit before performing work from the piping before connecting it to the unit.
involving refrigerant. Failure to do so will result in equipment problems.

WARNING CAUTION
Do not use cleaning solvents near open flame or When installing and filling a chilled water or water/
excessive heat. Wear eye protection when blow- glycol loop, all air must be bled from the piping
ing solvent from parts. The pressure-wash should system.
not exceed 30 psig. Solvent solutions should be
disposed of in accordance with local and state CAUTION
regulatory statutes.
Do not use chloride-based water conditioning ad-
ditives in the condensate drain pans. They cause
WARNING corrosion to occur on the coil fins.
Certain maintenance or cleaning procedures may
call for the use and handling of chemicals, solvents, CAUTION
or cleansers. Always refer to the manufacturer’s When transporting and installing the A/C unit, it must
Safety Data Sheet (SDS) prior to using these ma- be kept in its normal, horizontally-installed position.
terials. Clean parts in a well-ventilated area. Avoid If the unit is not kept level and horizontal, damage to
inhalation of solvent fumes and prolonged exposure the compressor(s) will result.
of skin to cleaning solvents. Wash exposed skin
thoroughly after contact with solvents.
1.5 General Design
WARNING The CeilAiR unit is housed in an aluminum frame cabinet
and is rated for indoor use. Removable panels are located
When performing soldering or desoldering
on the front and rear of the cabinet for easy access to all
operations, make certain the refrigeration system
components. Additional access may be obtained to some
is fully recovered and purged and dry nitrogen is
components through the bottom of the unit on spot cooler
flowing through the system at the rate of not less
configurations. The unit has an electric box inside the
than 1-2 CFM.
cabinet with a removable panel for accessing the electri-
cal components. Operator controls may be conveniently
WARNING located on a wall within the space to be conditioned.
Cooling coils (and associated piping circuits) are
NOTE
pressurized (up to 100 psi) and sealed when they
leave the factory. Before installing the interconnect- Customer specified, non-standard features or de-
ing piping, observe appropriate safety precautions sign variations may not be described in this manual.
and release the pressure via an available stem valve Refer to the installation and electrical drawings sup-
or Schrader valve prior to uncapping the pipes. plied 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).
CAUTION
When the air conditioner operates in cooling mode 1.5.1 Electric Box Access
the return air intake and discharge (supply) must be Electrical components are protected in an enclosure
free of obstructions. Ensure panels are secure and located in the cabinet behind an access panel. Before
latched into position. opening the access panel, turn off power at the main power
service disconnect switch. This removes power from the E2
controller (if present) and shuts the unit off.

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 CeilAiR IOM Manual

Figure 3. CeilAiR OHS-032-AR (Access Panels Removed)

1.5.2 Coil(s conditions and provides input signal(s) to the thermostat.
)
The cooling and optional hot water reheating coils are alu- The thermostat manages the operation of the A/C unit
minum finned/copper tube construction. The coils are leak consistent with the setpoints entered.
tested and cleaned before installation at the factory. As an option, the temperature sensor may be shipped loose
for field installation in the room to be conditioned. Refer
1.5.3 Blower
to the electrical drawing supplied with your unit for details
The unit is equipped with a centrifugal blower with forward specific to your system.
curved blades. The blower is contained in a double-width,
double-inlet housing. The blower is dynamically and stati-
cally balanced to minimize vibration. The blower motor is 1.6 Optional Equipment
ODP industrial duty and utilizes permanently lubricated ball 1.6.1 Humidistat/Dehumidistat
bearings.
As an option for systems employing an A-Tech 1.1 or
Smaller CeilAiR units (models OHS-012/040) use A-Tech 1.2 thermostat, a room mounted humidistat and/
direct drive blowers (except “H”-series models con- or dehumidistat may be shipped loose for field installation.
figured for horizontal discharge). Larger units (models Each device has an adjustment dial on the front where the
OHS-048/120) and horizontal discharge units (models operator selects the desired setpoint.
OHS-012/040-H), use a belt-driven blower. The belt-driv-
en blower motor is mounted on an adjustable base for belt If an optional humidifier is selected, the humidistat is
tensioning and is furnished with an adjustable pitch sheave included to control its operation. The humidistat controls
to adjust blower speed (see Figure 21 on page 33). the humidifier’s operation independently of the control
thermostat; however, the blower must be on for the humidi-
1.5.4 Temperature Sensor fier to operate.
As a standard for systems utilizing a wall mounted A-Tech If the heat/reheat option is selected, a dehumidistat is provided.
thermostat, the temperature sensor is built into the thermo- If room humidity rises above setpoint when the demand for
stat for room air control. The sensor monitors the room air cooling is satisfied, the dehumidistat signals the compressor

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 CeilAiR IOM Manual

to turn on, removing humidity. At the same time, the heater(s) pan. Should an overflow occur in an E²-based system, the
are turned on to offset the cooling effect, thus maintaining pump overflow safety switch triggers a contact signal to
the temperature of the space to be conditioned. Refer to the the controller that indicates the alarm condition, and the
electrical drawing supplied with your unit for details specific to controller automatically shuts down the compressor and
your system. optional humidifier until the condition is corrected. The
blower(s) will continue to operate. In an A-Tech system, the
1.6.2 Temperature/Humidity Sensor pump safety switch is wired directly to the OHS remote
As a standard for systems that use the E² microprocessor stop/start terminals to cut power to the system.
controller, a temperature/humidity (T/H) sensor is typically
factory mounted in the return airstream for room air control. 1.6.6 Smoke Detector
As an option, the T/H sensor may be shipped loose for field A smoke detector may be mounted in the return airstream
installation. See 2.7.6.5 on page 25 and the electrical to sense the presence of smoke and, when smoke is
drawing supplied with your unit for details specific to your detected, shut down the air conditioner, either via the E²
system. controller or in A-Tech systems via connection to the OHS
remote stop/start terminals.
1.6.3 Heaters
The OHS unit may incorporate heaters for reheating the 1.6.7 Firestat
supply air as required to offset the sensible cooling of the A fire detector (firestat) may be mounted in the return
system during the dehumidification cycle and for the auto- airstream to sense high return air temperature indicative of
matic heating mode. Electric resistance heating elements a fire. The system shuts down, either via the E² controller
are factory installed in the supply airstream to heat the sup- or, in an A-Tech system, via connection to the OHS remote
ply air. The heating elements are protected with line fuses stop/start terminals. Following activation, the firestat must
(manual and/or automatic), thermal fuse links and over- be manually reset using the reset button on the firestat
temperature safety switches which automatically reset. before restarting the unit.

As an option, hot water reheat may be selected for auto- 1.6.8 Water Detector
matic sensible reheating during the dehumidification cycle.
As an option, STULZ offers spot type or strip/cable type
A hot water heating coil is factory installed in the supply air-
water detectors. In units equipped with an E² controller,
stream. A valve is provided to control the flow of hot water
when water is detected the controller turns off cooling and
through the coil to maintain the correct reheat temperature.
humidification, while the blower(s) continue to operate. The
Hot gas reheat may be selected (for CeilAiR units with DX unit will automatically restart when the condition is correct-
cooling only) for automatic sensible reheating during the ed. In units equipped with an A-Tech thermostat, the water
dehumidification cycle. Hot compressor discharge gas detector is wired to the OHS remote stop/start terminals
is diverted from the condenser to a hot gas heating coil and power to the system is cut when water is detected.
mounted in the supply airstream.
1.7 Free-cooling Operation
1.6.4 Humidifier
The free-cooling (FC) configuration illustrated in Figure 4
CeilAiR systems may utilize an optional electrode steam is available to minimize the use of compressor operation
humidifier. The humidifier is factory installed inside the air during low ambient conditions for system energy savings.
conditioner and includes fill and drain valves and associat- An FC system utilizes a remote drycooler to provide water/
ed piping. Operation of the humidifier’s fill and drain cycles glycol coolant to a free-cooling coil positioned within a DX
is based on water conductivity and is maintained by the refrigerant system. If outdoor air temperatures permit free-
humidifier controller. An operating manual for the humidi- cooling operation (adjustable user setpoint), the free-cool-
fier is provided with the unit under separate cover. Refer to ing mode is enabled to take advantage of the low ambient
that manual for detailed information about operating the conditions to provide cooling with partial use or without the
humidifier. use of the system compressor(s). Free-cooling provides
an excellent opportunity for reduced operational cost by
1.6.5 Condensate Pump
reducing the compressor operating hours. The free-cooling
An optional, factory-installed condensate pump may be sequence is enabled if the entering fluid temperature is be-
provided. The pump automatically eliminates condensate low the user adjustable free-cooling-enable setpoint and
and humidifier flush water (if applicable) from the drain the return air temperature rises to the free-cooling setpoint

5
 CeilAiR IOM Manual

plus dead band. The drycooler pump activates and the 3-way control valve directs chilled water/glycol coolant to the FC
coil. The outdoor fluid cooler is controlled by first switching the leaving fluid control setpoint from typical DX heat rejection to
free-cooling control (adjustable setpoint, ambient air) and by controlling the leaving fluid to its user-adjustable setpoint. The
free-cooling control valve opens proportionally to the demand for cooling based on the return air temperature’s deviation
from setpoint.

If the return air temperature continues to rise, the free-cooling valve position eventually reaches 100% open, maximizing the
flow of coolant through the free-cooling coil. Continued operation in this position indicates the A/C unit is unable to lower
the air temperature to the desired setpoint in the free-cooling mode.

Figure 4. Free Cooling Diagram

The compressor activates if the DX cooling stage enable-temperature setpoint has been reached or if the control valve posi-
tion reaches 100% open for 240 seconds (default compressor-on time delay). The free-cooling circuit and the compressor
operate in parallel on dual-circuit units to provide maximum cooling. The 3-way control valve continually modulates the flow
of coolant in response to temperature with the compressor running.

The compressor cycles off based on the normal compressor temperature cut-out settings once the setpoint is maintained.

6
 CeilAiR IOM Manual

As the outside air temperature increases above the ambient air switch-over setting, the fluid cooler controls cycle back to
typical DX heat rejection allowing the leaving fluid control setpoint to increase above the prevailing ambient conditions. The
indoor unit’s inlet fluid temperature sensor monitors the fluid temperature and deactivates the free-cooling mode once the
fluid temperature increases above the user adjustable enable setpoint. The compressor system becomes the primary cool-
ing source and will activate if the return air temperature increases above the setpoint.

1.8 AWS Operation

The AWS (Alternate Water Source) configuration illustrated in Figure 5 utilizes an independent chilled water source to pro-
vide coolant to an AWS cooling coil in the A/C unit. If AWS cooling is unable to handle the load, the separate DX refrigeration
circuit can be utilized to assist. Similar to FC operation (see Section 1.7), when return air temperature rises to the AWS cut-in
temperature setpoint and if the chilled water inlet temperature is 55 °F or less (adjustable), AWS cooling activates (the AWS
control valve opens) and remains on while the activation conditions exist.

Figure 5. Alternate Water Source Diagram

7
 CeilAiR IOM Manual

If the return air temperature rises to the compressor cut-in 2.0 INSTALLATION
setpoint or if the AWS control valve reaches 100% open for
240 seconds (default compressor-on time delay), the com-
pressor turns on and operates in parallel with AWS cooling.
2.1 Receiving the Equipment
The compressor runs until the normal compressor cut-out Your CeilAiR OHS system has been tested and inspected
setpoint temperature is reached provided the minimum run prior to shipment. To ensure the equipment is received in
time expires. excellent condition, visually inspect the equipment im-
mediately upon delivery. Carefully remove the shipping
If the chilled water inlet temperature rises above 55 °F, container and all protective packaging. Remove the access
AWS cooling turns off (the control valve closes). When the panels and thoroughly inspect the unit interior for any signs
DX cooling stage-enable temperature setpoint is reached, of transit-incurred damage. If there is shipping damage, it
the compressor turns on and becomes the primary source must be noted on the freight carrier’s delivery forms before
of cooling. signing for the equipment. Any freight claims must be done
through the freight carrier. STULZ ships all equipment
In the event of loss of water flow during AWS operation, the
Factory FOB. STULZ can assist in the claim filing process
AWS control valve is closed and the compressor system
with the freight carrier. Should any damage be present,
becomes the primary cooling source. It will activate if the
notify STULZ Product Support prior to attempting any
return air temperature increases above the setpoint.
repairs. Refer to section 5.0 on page 45 of this manual
for instructions.

A data package is included with your unit. It contains this

manual, system drawings, applicable material SDS’s, other
component manuals, warranty registration and other appli-
cable instructions based on the configuration and options
provided with the unit. The data package has been placed
in the unit in a clear plastic bag. The documents need to be
retained with the unit for future reference.

NOTE
Items that have been shipped loose, such as remote
sensors, vibration isolators, and so on, are shipped
inside the air conditioner unless specified otherwise
by the customer. Grilles (if applicable) are placed on
top of the air conditioner inside the unit’s carton.
Remove and store these items in a safe place unless
you are using them immediately.

2.2 Site Preparation

CeilAiR systems are designed with easy service access in
mind. Component access panels are located on the front
and rear sides of the equipment. Additional access to some
components may be obtained through the bottom of the
unit on spot cooler configurations. These units can be fully
serviced in the ceiling plenum. In order to have full service
access, the air conditioner must be located so that ad-
equate space is provided in front of all access panels.

NOTE
Working clearance requirements need to be estab-
lished prior to the mounting of the unit. Refer to the
National Electrical Code and local codes.

8
 CeilAiR IOM Manual

To minimize the effects of the environment surrounding a minimum (as it adds to the cooling, heating, dehumidifica-
the conditioned space, certain steps must be taken. This tion and humidifying loads), while maintaining the require-
is especially true for critical/precision room preparation ment of the Indoor Air Quality (IAQ) standard. Lack of these
(computer rooms/labs) requiring close tolerance control of steps can cause erratic operation, unstable room control
temperature and humidity. The conditioned space should and excessive maintenance costs.
be well insulated and include a vapor barrier. The installer
should ensure that the proper insulation rating is used
2.3 Rigging
based on the design of the space that was the basis for the
system selected. The following table is a recommended CeilAiR systems are designed to be kept in a horizontal po-
minimum R-value (thermal resistance) to ensure optimum sition. The unit is shipped on a skid to facilitate moving prior
equipment operation. to installation. A suitable lifting device should be used to lift
the unit from the bottom. A weight table is provided for ref-
STRUCTURE R-VALUE erence on the installation drawing. The unit should always
Ceiling R-38 be stored indoors in a dry location prior to installation.
Wall R-21 CAUTION
Floor R-19 When moving the unit, it must be kept horizontal and
Door R-5 level to prevent damage.
2.4 Mounting
The vapor barrier is the single most important requirement CeilAiR OHS systems are designed for ceiling mounting in
for maintaining environmental control in the conditioned a suspended ceiling grid (spot cooler) or above the sus-
space. The vapor barrier in the ceiling and walls can be
pended ceiling for ducted systems. See Figure 6.
polyethylene film. Concrete walls and floors should be
painted with a rubber or plastic-based paint. Doors and
NOTE: These units use welded frame construction for
windows should be properly sealed and a door sweep used
unit rigidity. The system is designed to be installed on a
to minimize leakage. Outside or fresh air should be kept to
roof curb, which is provided by others and ducted into a
singular space to be conditioned. Ensure the curb is
sealed to prevent air leakage. See the detail drawing
provided with the unit for interface dimensions. These
units are designed to be ducted to a space to be
conditioned and are intended to condition only one room.

(BY OTHERS)

Figure 6. Typical Installation

9
 CeilAiR IOM Manual

NOTES 2.4.3.1 A-Tech Programmable Thermostats

• Do not install the A/C system directly above Mount the thermostat upright on an inside wall within the
electronic equipment that may hinder service- conditioned room at a location that best represents the
ability. average room temperature. In most cases, the thermostat
• Equipment must be level to operate properly should be located near the common return air grille. Mount
the thermostat at least 18 in. from an outside wall and ap-
2.4.1 Indoor Equipment proximately 5 ft above the floor. Follow the steps below for
CeilAiR OHS systems have a frame and panel construction mounting. Instructions for wiring the thermostat are found
for unit rigidity and full service accessibility while the unit in Section 2.7.2 on page 20.
is mounted in place. The unit is lifted from underneath and
1. Open the case with a flathead screwdriver. Place
secured into place using all-thread rods passing through
blade in slot and gently pry forward at the numbered
rubber grommets or a 4 in. x 4 in. neoprene cork pad in the
locations shown in Figure 7.
mounting arms on the sides of the unit. Threaded rods, nuts
and washers (field supplied by others) must be secured so o
they do not loosen. (See Figure 6 on page 9.) n
Before mounting the unit, ensure the mounting structure is
able to support the weight of the equipment. Refer to the
weight table provided on the installation drawing. Secure
the unit via the predrilled mounting bolt holes with suitable
hardware for the application. An auxiliary drain pan is rec-
ommended and can be mounted directly under the cabinet
(only on ducted models; see Figure 9 on page 11).

2.4.2 Outdoor Equipment q p

Install remote condensers/condensing units in a secure
location where the unit cannot be tampered with and the Figure 7. A-Tech Controller Installation
power service switch cannot be inadvertently turned off.
Locate the remote condenser/condensing unit where the 2. Place the base temporarily over the wire hole opening
fan is not likely to draw dirt and debris into the coil fins. in the wall. Level the base and mark the screw loca-
tions through the two provided mounting slots.
There should be at least one equipment-width of clearance
around the condenser to ensure adequate airflow to the CAUTION
coil. Secure the condenser/condensing unit so the system
will not move during operation. Refer to the installation Do not touch the temperature sensor on the bottom
drawing for the non-charged system weight. It is recom- left corner of the thermostat. The sensor can be
mended that the remote condenser/condensing unit be damaged if handled improperly.
mounted with vibration mounts to reduce the amount of
3. If using the supplied anchors, drill two 3/16 in. holes
vibration transmitted to the mounting surface.
and tap in the wall anchors. If only the screws are being
2.4.3 Controls used, drill two 3/32 in. holes.

NOTE 4. Fasten the base to the wall using the supplied screws.
Thermostats and control sensors should not be
5. Connect wiring between the thermostat and equip-
located near a doorway, supply air register or area
ment. See the A-Tech wiring instructions in Section
where they would be exposed to direct sunlight or
other external heat sources. 2.7.2 on page 20.

6. Reinstall thermostat cover to base.

10
 CeilAiR IOM Manual

.75 in/19 mm
THICK
GASKET

Figure 8. Spot Cooler Grille

SUPPLY
AIR OUTLET
IN/OUT
90° / RIGHT ANGLE STRAIGHT-THRU SAME FACE

Figure 9. Ducted System Typical Air Patterns

11
 CeilAiR IOM Manual

2.4.3.2 Advanced STULZ E² Controller during maintenance periods. The switch is typically mount-
If the optional STULZ E² controller is furnished, a separate ed to the A/C cabinet; however, it may be shipped loose
manual is included in the unit data package provided with for field installation. The case has a top keyhole mounting
the unit. The controller user interface display may be field slot and two holes in each bottom corner for mounting. The
mounted to a wall within the conditioned space or it may be hardware for mounting the switch is field supplied. Select
located outside the conditioned space if desired. Refer to suitable fasteners for the intended mounting surface.
the supplemental instructions provided with the mounting
The non-fused service switch can be mounted near the
kit when mounting the controller display. When locating the
unit or in a central location. Non-fused service switches
display panel, consider the length of wire to be used. As an
are rated for either indoor or outdoor use. Ensure that the
option, a 30 ft, 75 ft or 150 ft long cable may be provided
proper type is used for your application.
by STULZ.
NOTE
2.4.4 Optional Equipment
Refer to the National Electrical Code and local codes
NOTE for the appropriate mounting location.
Do not mount any optional equipment on the A/C
unit’s access panels. 2.4.5 Remote Sensors
The remote temperature sensor or temperature/humidity
2.4.4.1 Condensate Pump (Field Installed) (T/H) sensor must be located so that it will properly sense
If the unit was not purchased with the factory-installed con- the temperature and/or humidity conditions to be con-
densate pump option, the shipped-loose condensate pump trolled. The sensor should not be mounted near a doorway
should be mounted as near to the air conditioning system or an area where it would be exposed to direct sunlight.
as possible. The inlet hole in the pump must be below the When locating the sensor, consider the length of wire to be
lowest part of the drain from the A/C unit. The pump has used. As an option, a 75 ft or 150 ft cable may be provided
two mounting supports so it can be hung on an adjacent by STULZ. Refer to the applicable section that follows to
wall. Ensure that the pump is level for proper operation. mount the sensor. For wiring details, refer to Section 2.7.2
on page 20 and to the electrical drawing provided with
CAUTION the unit.
Always follow manufacturer’s instructions when in- 2.4.5.1 Remote Temperature Sensor (A-Tech)
stalling a field-installed condensate pump. If manu-
facturer’s instructions were not provided with the
pump, contact STULZ product support for the pump
documentation. Do not install the pump without first
reading the manufacturer’s instructions. Failure to
exactly follow manufacturer’s instructions may on
rare occasions result in serious damage to the OHS
unit and the surrounding facility.

A P-trap must be installed between the pump and the unit. Figure 10. Temperature Sensor for A-
The height of the trap must be a minimum of 2 in. to exceed Tech NOTE
the total static pressure of the system and ensure proper
water drainage from the drain pan. The remote temperature sensor has a maximum
range of 330 ft.
CAUTION
1. Install shielded or nonshielded two wire twisted cable
Properly size and vent the P-trap according to ap- from the thermostat to the remote sensor location.
plicable codes and best practices.
2. Open the sensor case by grasping the side and pulling
2.4.4.2 Non-Fused Service Switch the two halves apart.
The non-fused service switch may be used to disconnect
main power and isolate the unit during maintenance and
service. The switch has a lockable handle to lock power out

12
 CeilAiR IOM Manual

3. Use the sub-base as a template to mark the mounting ensuring the word TOP on the PC board is oriented
hole locations on the mounting surface. Drill size for upward.
the wall anchors is 1/4 in. Mount the sub-base over
the wires coming out of the wall using the two screws 5. Route the sensor control cable up to the control termi-
and anchors provided. Do not use hex head screws. nal block in the electric box and terminate the control
wire. Refer to section 2.7.6.5 on page 25 and to the
4. Strip 1/4 in. of insulation from the two wires at the wiring diagram supplied with your unit.
remote sensor. Install the wires in the terminals. The
wires can be connected with either polarity. Seal the 6. Seal the hole in the wall behind the sensor.
hole in the wall around the cable to eliminate any draft
7. Replace the cover plate on the base.
that might affect the sensor.

5. Make the wiring connections. Refer to section 2.7.6.4 2.4.6 Humidistat/Dehumidistat (Used
on page 25 and to the wiring diagram supplied with with A-Tech1.1/1.2 Thermostat)
your unit. Mounting the humidistat and/or dehumidistat is performed
in the same manner as described in section 2.4.5.1. It
6. Replace the sensor cover. should be mounted to a wall within the conditioned room at
a location that best represents the average humidity of the
2.4.5.2 Remote Temperature/Humidity Sensor space. In most cases, the humidistat and/or dehumidistat
(E²) should be located near the common return air grille. Mount
the humidistat and dehumidistat at least 18 in. from an
outside wall and approximately 5 ft above the floor.
OPENING FOR Controls may be installed either on a flush switch box or on
CONTROL CABLE
a surface switch box. Follow the steps below for mount-
ing. Instructions for wiring the unit are provided in Section
2.7.6.2 on page 24.
WIRE TERMINALS

1. Pull dial knob off, loosen screw (located at bottom of

unit) and remove cover.
Figure 11. Temperature/Humidity Sensor for E2
2. Make wiring connections according to the wiring dia-
Con-
gram provided with your unit.
troller

1. Remove the cover from the base of the sensor by 3. Mount the base with the two #6 screws provided.
squeezing it at the top and bottom. 4. For external setpoint, reinstall cover, tighten screw, and
replace dial knob.
CAUTION
5. For internal setpoint:
Take care not to damage the exposed temperature/
humidity sensor elements on the PC board when a. Turn dial plate to desired setting and tighten dial
the cover is removed. The sensor elements can be lock screw.
damaged if handled improperly.
b. Break off dial shaft at undercut.
2. Place the base temporarily against the mounting c. Remove insert from cover.
surface.
d. Remove protective backing from adhesive on the
3. Level the base. Mark and drill mounting holes through blank insert provided and press firmly in place on
at least two of the available slotted holes. Also, mark cover.
through the large opening in the base and drill a hole e. Reinstall cover assembly and tighten screw. (If
into the mounting surface for a control cable to pass additional security is required an Allen screw and
through the back of the base. wrench are provided.)
4. Run a three-conductor shielded cable through the f. Remove protective cover from face of cover insert.
opening in the base, then secure the base with screws,

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 CeilAiR IOM Manual

2.4.7 Spot Water Detector NOTE

The spot water detector is normally placed on the floor or in Placement of the grilles is important. The hinged
a field-supplied auxiliary drain pan located beneath the filter grille goes on the return air side of the unit. The
unit. 3-way directional grille goes on the conditioned air
discharge side of the air conditioner. Gasketing is
It may be attached using double sided tape or with the factory-supplied for the air seal between the bot-
mounting holes provided in the flanges tom flange of the air conditioner and the grille. After
(one on each side). Once it’s in place, mounting the air conditioner, attach the gasket to
loosen the screws provided on the the bottom flange, then lower the air conditioner
mounting legs to adjust the height of until the gasket meets the grille, as shown in Figure
the sensing probes. When water is 8 on page 11.
present, current will flow between the
two probes. 2.5.2 Ducted Systems
There are three basic configurations of airflow patterns:
CAUTION 90º/right angle, straight-through and in/out-same-face
The probes must not touch the mounting surface. (see Figure 9). When determining ducting requirements,
Failure to adhere to this may result in improper op- always consult your local and state codes. The duct system
eration of equipment. should be designed to allow the air to move with as little
resistance as possible. Several factors determine ducting
For wiring details, refer to Section 2.7.6.3 on page 25 material and size. These factors are predetermined, refer to
and to the electrical drawing provided with the unit. your ducting system schematic.

2.4.8 Cable Type Water Detector The connection of ducting to the unit is typically accom-
plished with a 1 in. duct flange. Supply air outlet and return
CAUTION air inlet ducts will require a field-provided duct flange (refer
to the installation drawing provided with the unit). The con-
Do not allow the cable water detector to contact nection of ductwork to the unit may be made with either
metal (frame or condensate pan). It must be mounted pop rivets or self-tapping screws.
on the plastic stand-offs provided with the water
detector.
2.6 Piping Connections
Lay the cable water detector across the surface where wa- 2.6.1 Refrigerant
ter could collect. When
water is present, cur- 2.6.1.1 Self-Contained Systems
rent will flow between No refrigeration connections are required for self-con-
the two wires. A two tained air, water or glycol-cooled systems (Models OHS-
conductor wire harness 012/040-AS, OHS-012/120-C and OHS-012/120-
is provided with a quick W/G-( )).
connect fitting on the end. The harness mates to the fitting
on the water detector cable and connects it to the terminal 2.6.1.2 Split Systems
block inside the electric box. Split air-cooled systems will require field refrigeration pip-
ing. All split systems are shipped with a dry nitrogen charge
2.5 Air Distribution Connection of 100 psig. Systems utilizing a remote condenser will
require a copper liquid line and discharge line (see section
2.5.1 Spot Cooler 2.6.1.3). Systems utilizing a remote condensing unit (RCU)
For units that are not ducted (see Figure 9), the air condi- will require a copper liquid line and suction line (see section
tioner should be mounted above the ceiling grid, leaving 2.6.1.4).
sufficient space for the air grilles to rest on the ceiling
All refrigeration piping should be installed with high tem-
T-bar.
perature brazed joints. Use standard refrigeration practices
for piping supports, leak testing, dehydration and charging

14
 CeilAiR IOM Manual

of the refrigeration circuits. The refrigerant piping should NOTE

be isolated by the use of vibration isolating supports. In the following tables:
Provide supports (clamps or hangers) as necessary every
5 to 10 ft along piping runs to minimize vibration and noise • The line sizes represent the correct size for
transmission. To reduce vibration transmission and prevent individual refrigeration circuits. Dual circuit
pipe damage, use a soft flexible material to pack around units, (models 048D to 120D), have two
the piping when sealing openings in walls. separate pairs of refrigeration lines, one per
compressor.
Wrap wet rags around the pipes between the areas to be
soldered and any nearby refrigeration components to keep
• All pipe lengths are “Equivalent Length,” which
excessive heat from traveling through the pipe and causing
accounts for the linear pipe length as well as
damage. Clear all pipe connections of debris and prep con-
equivalent length of valves, elbows and Tee’s as
nections for soldering. Use only “L” or “K” grade refrigerant
shown in Table 1.
copper piping. Be careful not to allow solder/piping debris
to get inside refrigerant lines. Silver solder containing a
minimum of 15% silver is recommended. Dry nitrogen Table 2. Recommended Discharge Line Sizes
should be flowing through the tubing while soldering at a For R407C Refrigerant
rate of not less than 1-2 CFM.
Model No./Total Compressor to Condensor O.D. (inches)
Refrigerant lines for split systems must be sized accord- BTU/H Capacity
50 ft or less 100 ft or 150 ft or
ing to the piping distance between the evaporator and the less less

condenser/condensing unit. Each valve, fitting and bend in 012 / 12,000 1/2 5/8 5/8
the refrigerant line must be considered in this calculation. 018 / 18,000 1/2 5/8 5/8
Pipe sizes are given for “equivalent feet”, not linear feet.
Do not confuse the terminologies. For example, a 7/8 in. 024 / 24,000 5/8 5/8 3/4
standard 90° elbow has an equivalent length of 1.5 ft; a 032 / 32,000 5/8 3/4 3/4
7/8 in. branch Tee has an equivalent length of 3.5 ft. These
corrections must be accounted for when sizing your piping. 040 / 40,000 3/4 3/4 7/8
Refer to the following table for standard equivalent lengths, 048 / 48,000 3/4 7/8 7/8
in feet, of straight pipe.
048D / 48,000 5/8 5/8 3/4
Table 1. Pipe Equivalent Lengths 060 / 60,000 3/4 7/8 1-1/8

Equivalent Length (ft) of Straight Pipe 072D / 72,000 5/8 3/4 3/4

O.D. Glob Angl 90º 45º Tee Tee 084D /84,000 3/4 7/8 7/8
(in.) Line e e Elbo Elbo Line Branc
Size Valve Valve w w h 120D / 120,000 3/4 7/8 1-1/8
1/2 9.0 5.0 0.9 0.4 0.6 2.0
Table 3. Recommended Discharge Line Sizes
5/8 12 6.0 1.0 0.5 0.8 2.5
For R410A Refrigerant
7/8 15 8.0 1.5 0.7 1.0 3.5
Model No./Total Compressor to Condensor O.D. (inches)
1 1/8 22 12 1.8 0.9 1.5 4.5 BTU/H Capacity 50 ft or less 100 ft or 150 ft or
less less
1 3/8 28 15 2.4 1.2 1.8 6.0
012 / 12,000 1/2 5/8 5/8

Oil traps must be included every 20 ft in the vertical risers 018 / 18,000 1/2 5/8 5/8
and the refrigerant lines must be sloped in the horizontal 024 / 24,000 5/8 5/8 5/8
lines to ensure proper oil return to the compressor. An
inverted trap is required on the discharge line of the remote 032 / 32,000 5/8 5/8 3/4
condenser to help prevent oil and liquid from flooding back 040 / 40,000 5/8 3/4 3/4
to the compressor.
048 / 48,000 3/4 3/4 7/8

048D / 48,000 5/8 5/8 5/8

15
 CeilAiR IOM Manual

Model No./Total Receiver to Evaporator O.D. (inches)

Model No./Total Compressor to Condensor O.D. (inches) BTU/H Capacity
50 ft or less 100 ft or 150 ft or
BTU/H Capacity 50 ft or less 100 ft or 150 ft or less less
less less
084D /84,000 5/8 5/8 3/4
060 / 60,000 3/4 7/8 7/8
120D / 120,000 5/8 3/4 3/4
072D / 72,000 5/8 5/8 3/4

084D /84,000 3/4 3/4 7/8

120D / 120,000 3/4 7/8 7/8

Table 6. Recommended Suction Line Sizes
For R407C Refrigerant
Table 4. Recommended Liquid Line Sizes
For R407C Refrigerant (Condenser to Line O.D. (inches)
Model
Receiver ) No./Total
50 ft or less 100 ft or less
Model No./Total Receiver to Evaporator O.D (inches) BTU/H H V H V
BTU/H Capacity Capacity
50 ft or less 100 ft or 150 ft or
less less 012 / 12,000 3/4 3/4 3/4 3/4
012 / 12,000 1/2 1/2 1/2 018 / 18,000 3/4 3/4 3/4 3/4

018 / 18,000 1/2 1/2 1/2 024 / 24,000 3/4 3/4 7/8 7/8
032 / 32,000 7/8 7/8 7/8 3/4
024 / 24,000 1/2 1/2 5/8
040 / 40,000 7/8 7/8 1-1/8 1-1/8
032 / 32,000 1/2 5/8 5/8 048 / 48,000 1-1/8 1-1/8 1-1/8 1-1/8

040 / 40,000 5/8 5/8 5/8 048D / 48,000 3/4 3/4 7/8 7/8
060 / 60,000 1-1/8 1-1/8 1-1/8 1-1/8
048 / 48,000 5/8 5/8 3/4
072D / 72,000 7/8 7/8 7/8 3/4
048D / 48,000 1/2 1/2 5/8 084D /84,000 1-1/8 1-1/8 1-1/8 1-1/8
060 / 60,000 5/8 3/4 3/4 120D / 120,000 1-1/8 1-1/8 1-1/8 1-1/8

072D / 72,000 1/2 5/8 5/8

084D /84,000 5/8 5/8 3/4 Table 7. Recommended Suction Line Sizes
120D / 120,000 5/8 3/4 3/4 For R410A Refrigerant
Line O.D. (inches)
Model No./Total
Table 5. Recommended Liquid Line Sizes BTU/H Capacity
50 ft or less 100 ft or less
For R410A Refrigerant (Condenser to Receiver) H V H V

Model No./Total Receiver to Evaporator O.D. (inches) 012 / 12,000 5/8 5/8 5/8 5/8
BTU/H Capacity 50 ft or less 100 ft or less 150 ft or less 018 / 18,000 5/8 5/8 5/8 5/8
012 / 12,000 1/2 1/2 1/2 024 / 24,000 5/8 5/8 3/4 3/4
018 / 18,000 1/2 1/2 1/2 032 / 32,000 3/4 3/4 3/4 5/8
024 / 24,000 1/2 5/8 5/8 040 / 40,000 3/4 3/4 7/8 7/8
032 / 32,000 1/2 5/8 5/8 048 / 48,000 7/8 7/8 7/8 7/8

040 / 40,000 5/8 5/8 5/8 048D / 48,000 5/8 5/8 3/4 3/4

048 / 48,000 5/8 5/8 3/4 060 / 60,000 7/8 7/8 1-1/8 1-1/8

048D / 48,000 1/2 5/8 5/8 072D / 72,000 3/4 3/4 3/4 5/8
084D /84,000 7/8 7/8 7/8 7/8
060 / 60,000 5/8 3/4 3/4
120D / 120,000 7/8 7/8 1-1/8 1-1/8
072D / 72,000 1/2 5/8 5/8

Suction line sizes are for 50 ºF through 30 ºF suction temp

at 48 through 26 psig.

16
 CeilAiR IOM Manual

migration of liquid refrigerant to the compressor during off

CAUTION cycles.
Do not exceed the maximum line lengths for the
NOTE
system configurations listed below:
Do not exceed 15 ft ofvertical distance when install-
RCU with hot gas bypass 50 ft ing the condensing unit below the evaporator.
Remote condensing unit 100 ft
Remote air cooled condenser 150 ft All suction lines must be insulated to prevent condensa-
tion from forming on the pipes. Refer to the Recommended
Vertical runs are based on a total rise of 30 equivalent ft. Suction Line and Recommended Liquid Line sizing tables.
For longer rises, individual calculations should be made.
Sizes assume the use of single risers; double rises may be 2.6.2 Chilled Water, Water/Glycol and Hot
necessary. Water Reheat Piping
2.6.1.3 Remote Air Cooled Condensers (AR The piping connections for water/glycol, chilled water and
Models) systems with hot water reheat are sweat connections. Pipe
Systems utilizing air cooled condensers must not have sizes may not necessarily be the same as the unit connec-
a refrigerant line pressure drop over 14 psig across the tion. Piping should be sized to match the required system
condenser and the interconnecting piping to the condenser pressure drop and pump capacity (if applicable) and may
sections. require reducing fittings to match the connection size on
NOTE the air conditioner.
Ensure proper condenser selection to maintain CAUTION
reasonable sub-cooling temperatures.

If the condenser is installed above the evaporator, the Fluid coils and associated piping circuits are pres-
discharge line should include a P-trap at the lowest point surized and sealed when they leave the factory.
in the piping. The highest point in the discharge line should When installing and filling water/glycol, chilled water
be above the condenser coil and should include an inverted and optional hot water reheat loops, all air must be
trap to help prevent oil and liquid from flooding back to the
bled from the piping system.
compressor during off cycles.

If the condenser is installed below the evaporator, an CAUTION

inverted trap the height of the evaporator coil is required
on the liquid line to help prevent oil and liquid from flooding
back to the compressor during off cycles. The piping system must be flushed prior to operating
the system. Failure to do so will result in equipment
Refer to the refrigerant-appropriate Recommended Dis- problems.
charge Line Sizes table (Table 2 or Table 3), Recommended
Liquid Line Sizes table (Table 4 or Table 5) and Recom- The recommended ethylene glycol solution ratio is 40%
mended Suction Line Sizes table (Table 6 and Table 7). glycol to 60% water. (STULZ recommends Dowtherm
SR1 manufactured by Dow Chemical Co.) Glycol-cooled
2.6.1.4 Remote Air Cooled Condensing Units systems with a low entering fluid temperature and all chilled
(AHU Models) water systems should have insulated piping.
When installing a remote condensing unit above the evapo-
rator, the suction line should be P-trapped at the evapora- WARNING
tor. Glycol is hazardous. Review the manufacturer’s
SDS before use.
When installing remote condensing units below the evapo-
rator, the suction line should be trapped with an inverted A strainer should be included in the water/glycol, chilled
trap the same height as the evaporator coil. This prevents water and optional hot water reheat line. Once the system
is operational, the fluid runs through the strainer, which

17
 CeilAiR IOM Manual

removes any foreign objects. The strainer screen should be

cleaned periodically.

2.6.3 Condensate Drain Line

2.6.3.1 Gravity Drain
A 7/8 in. O.D. copper (sweat type) line is provided to drain
the condensate drain pan. This line also drains the hu-
midifier, if applicable. A “P” type condensate trap must be
installed. The height of the trap must be at least 2 in. to
exceed the total static pressure of the system and en-
sure proper water drainage from the drain pan. The drain
line must be located so it will not be exposed to freezing
temperatures. The drain line should be the full size of the Figure 12. Condensate
connection. See the installation drawing provided with your Pump NOTE
unit for the size and location of the condensate drain line.
Pour some water into the condensate drain(s) prior
CAUTION to start-up. This fills the trap and prevents air from
being drawn up the drain lines.
Do not use chloride-based water conditioning ad-
ditives in the condensate drain pans. They cause 2.6.4 Humidifier (Optional)
corrosion on the coil fins.
CeilAiR systems may include an optional electrode steam
humidifier. The humidifier empties into the condensate
CAUTION drain pan during the flush/drain cycle. A water supply line
Properly size and vent the P-trap according to ap- must be connected to the humidifier copper tubing inlet
plicable codes and best practices. connection supplied by the factory. Refer to the installation
drawing provided with your unit for the size and location of
NOTE the connection. The humidifier requires normal tap water as
the water supply. If the supply water is high in particulates,
During normal operation the optional humidifier
an external filter may be needed.
drains hot water into the condensate drain line. As
an option, a separate drain line may be provided for
the humidifier.
CAUTION
Do not use demineralized water in the humidifier.
2.6.3.2 Condensate Pump
A condensate pump (Figure 12) is used to automatically Refer to the humidifier operator’s manual supplied with the
remove condensate from the air conditioner and flush OHS unit for complete manufacturer’s information on the
water from the humidifier (if applicable). A P-trap is installed humidifier and for supply water recommendations.
for proper condensate drainage. The height of the trap is
a minimum of 2 in. on most standard systems to ensure 2.7 Utility Connections
proper water drainage of the drain pan. The condensate
pump discharge line should be 1/2 in. I.D. (maximum) vinyl 2.7.1 Main Power
tubing or 1/2 in. O.D. (maximum) copper pipe to prevent CeilAiR units are available in single- or three-phase
excessive back flow to pump. variations and a wide range of voltages. Examine the unit
nameplate, located on the outside of the cabinet in close
proximity of the electric box, to determine the operating
voltage, frequency and phase of the system (see Figure
13). (Note that the unit serial and model numbers are also
found on the nameplate.) Provided power must meet the
listed specifications. The supply voltage measured at the
unit must be within ±10% of the voltage specified on the
system nameplate, with the exceptions noted below.

18
 CeilAiR IOM Manual

The nameplate also provides the full load amps (FLA) the NOTE
unit will draw under full design load, the minimum circuit All wiring must be provided in accordance with Na-
ampacity (MCA) for wire sizing, and the maximum fuse size tional Electrical Code and local code requirements.
(MAX FUSE) for circuit protection. Use copper conductors only. Wiring terminations
may become loose during transit of the equipment;
NOTE
verify all wiring terminations are secure.
If the nameplate states MAX FUSE/CKT BKR,
fuses or an HACR type circuit breaker are required A manual fused disconnect switch must be provided per
to protect the system. Other protection devices are the National Electrical Code and local codes for servicing
not allowed based upon the product listing. the equipment. Do not mount a shipped-loose, non-fused
service switch or customer supplied disconnect switch
The unit is provided with terminals for all required field- to the surface of the unit. If a factory installed, non-fused
wiring. It is important to identify the options that were service switch option was purchased, the main power and
purchased with the unit in order to confirm which field ground connection is located at the switch; otherwise, the
connections are required. Refer to the electrical drawing(s) main power connection is located as stated below.
supplied with the unit for information about power and
control field-wiring. The unit is provided with pilot hole(s) in the main power
and control panel for routing field-wiring. These pilot holes
are located near the electric box and a label stating “MAIN
POWER INPUT” is in close proximity. Terminate the main
power wires at the line side of the main power distribution
block located within the electric box. A separate equipment
ground lug is provided inside the electric box for terminat-
ing an earth ground wire.

NOTE
Prior to operation, an adequate unit-to-Earth ground
must be connected to the unit.

2.7.1.1 Single-Phase Units 208/230V

The supply voltage for units designed to operate at 208V
must be within -5% and +10% tolerance. If the measured
supply voltage is 230V, the unit can operate with a toler-
ance of ±5% if the following change is performed: The
control transformers within the system must have the
primary wire connected to its respective 240V tap instead
of the 208V tap.

2.7.1.2 Single-Phase Units 277V

Single-phase units require that the hot leg of power be
connected to terminal L1 and the neutral wire to terminal
L2 of the main power distribution block.

2.7.1.3 Three-Phase Units

Figure 13. Sample Nameplate Three-phase units are designed to have the L1, L2 and L3
supply wires connected to corresponding L1, L2 and L3
WARNING line terminals of the main power distribution block. The unit
will operate correctly if the supply wires are connected in
Verify power is turned off before making electrical
this manner. A ground lug is provided in each unit near the
connections to the equipment.
distribution block.

19
 CeilAiR IOM Manual

CAUTION A-Tech 1.1 Single-Stage Controller

Improper wire connections will result in reverse

TERMINAL DESIGNATORS
rotation of the blower motors and compressor (if ap- C C - 24VAC Common
plicable) and may eventually result in damage to the R
Y1 R - 24VAC
Y1 - 1st stage cooling
compressor. To correct this problem, exchange any E/W1
W1 - 1st stage heating
two of the incoming main power wires at the main O - Cool active reversing valve
B - Heat active reversing valve
power distribution block. Do not rewire the unit’s OBG G - Fan
individual components.
G

2.7.2 Controls
Y1
R
See OHS Electrical Drawing
for Equivalent Terminal Points
W1
STULZ offers a wide range of control systems to meet C

air conditioning control/alarm requirements. If the unit is B

O
equipped with an A-Tech controller, see the Robertshaw
9701i/9725i2 User’s Manual shipped with the unit for
programming instructions. Wiring contacts on the single- A-Tech 1.2 Two-Stage Controller
and dual-stage versions of the A-Tech controller are shown TERMINAL DESIGNATORS
in Figure 14. If the unit is equipped with an E² controller, C - 24VAC Common
see the STULZ E² Series Microprocessor Controller IOM
C
R R - 24VAC
Y1 Y1 - 1st stage cooling
manual shipped with your unit. For utility connections refer E/W1
W2
E/W1 - 1st stage heating or emergency heat
W2 - 2nd stage heating
to the appropriate manual above and the wiring diagram(s) Y2
L Y2 - 2nd stage cooling
provided with the unit. L - System fault indicator
OBG O - Cool active reversing valve
B - Heat active reversing valve
The unit is provided with a pilot hole for a conduit connection G - Fan
for control wiring. The hole is located near the electric box in C

close proximity to the main power pilot hole. The sizing of the R
Y1
conduit must be per the National Electrical Code and local E/W1

See OHS Electrical Drawing

code requirements. W2
Y2 for Equivalent Terminal Points
L

NOTE G
B

Customer-provided wiring must be in accordance with O

the National Electrical Code and local code require-

ments for Class 2 circuits.
Figure 14. A-Tech 1.1 (top) and 1.2 (bottom)
2.7.2.1 A-Tech 1.1 Programmable Thermostat Controller Wiring Contacts
The thermostat requires four conductors wired to the control
terminal board located within the unit electric box. The 2.7.3 Air-Cooled Split Systems
thermostat has a terminal strip with box type lugs for wire The system interconnecting field wiring illustrations in Fig-
connections. See Figure 14 and refer to the electrical draw- ure 17 through Figure 20 detail the number of conductors
ing for proper wire terminations. required for a typical system. Additional control conductors
may be required depending on the options purchased with
2.7.2.2 A-Tech 1.2 Programmable Thermostat the equipment. Refer to the electrical drawing to determine
The thermostat requires seven conductors wired to the con- the total number of interconnecting conductors required
trol terminal board located within the unit electric box. The for your system. It is important to note that the control
thermostat provides a terminal strip with box type lugs for transformer(s) supplied with the equipment have been
wire connections. See Figure 14 and refer to the supplied sized and selected based upon the expected loads for the
electrical drawing for proper wire terminations. system.

20
 CeilAiR IOM Manual

Figure 15. A-Tech 1.1 Control Wiring

Figure 16. A-Tech 1.2 Control Wiring

21
 CeilAiR IOM Manual

E² CONTROL CONFIGURATION (OPTIONAL)

6 CNDCT. PHONE TYPE 3 CONDUCTOR

NON-SHIELDED CABLE SHIELDED CABLE
SEE NOTE 3

REMOTE TEMPERATURE/
E² CONTROLLER DISPLAY
HUMIDITY SENSOR
E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL)
CONTROLLER INSIDE THE ELECTRIC BOX

THERMOSTAT CONTROL
CONFIGURATION (OPTIONAL)

REMOTE TEMPERATURE
SENSOR (OPTIONAL)
24 VAC (OPTIONAL)

SEE NOTE 3

NOTES:
1. DASHED WIRES ( ) NOT APPLICABLE FOR SINGLE-STAGE UNITS
2. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES
3. OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A/C UNIT TERMINAL BLOCK
4. CONDUCTOR COUNTS IN FIGURE ARE NOTIONAL. SEE UNIT ELECTRICAL DRAWING FOR
ACTUAL NUMBER AND TERMINAL POINTS OF CONDUCTORS

Figure 17. Interconnection Field Wiring Remote Condenser

E² CONTROL CONFIGURATION (OPTIONAL)

6 CNDCT. PHONE TYPE 3 CONDUCTOR

NON-SHIELDED CABLE SHIELDED CABLE
SEE NOTE 3

REMOTE TEMPERATURE/
E² CONTROLLER DISPLAY
HUMIDITY SENSOR
E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL)
CONTROLLER INSIDE THE ELECTRIC BOX

THERMOSTAT CONTROL
CONFIGURATION (W/ OPTIONS)

REMOTE CONDENSING UNIT

SEE NOTE 3

NOTES:
1. DASHED WIRES ( ) NOT APPLICABLE FOR SINGLE-STAGE UNITS
2. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES
3. OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A/C UNIT TERMINAL BLOCK
4. CONDUCTOR COUNTS IN FIGURE ARE NOTIONAL. SEE UNIT ELECTRICAL DRAWING FOR
ACTUAL NUMBER AND TERMINAL POINTS OF CONDUCTORS

Figure 18. Interconnection Field Wiring Remote Condensing Unit

22
 CeilAiR IOM Manual

E² CONTROL CONFIGURATION (OPTIONAL)

6 CNDCT. PHONE TYPE 3 CONDUCTOR

NON-SHIELDED CABLE SHIELDED CABLE
SEE NOTE 3

REMOTE TEMPERATURE/
E² CONTROLLER DISPLAY
HUMIDITY SENSOR
E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL)
CONTROLLER INSIDE THE ELECTRIC BOX

THERMOSTAT CONTROL
CONFIGURATION (W/ OPTIONS)

SEE NOTE 3

REMOTE CONDENSING UNIT

NOTES:
1. DASHED WIRES ( ) NOT APPLICABLE FOR SINGLE-STAGE UNITS
2. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES
3. OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A/C UNIT TERMINAL BLOCK
4. CONDUCTOR COUNTS IN FIGURE ARE NOTIONAL. SEE UNIT ELECTRICAL DRAWING FOR
ACTUAL NUMBER AND TERMINAL POINTS OF CONDUCTORS

Figure 19. Interconnection Field Wiring Remote Condensing Unit with Dual Compressors

E² CONTROL CONFIGURATION (OPTIONAL)

6 CNDCT. PHONE TYPE 3 CONDUCTOR

NON-SHIELDED CABLE SHIELDED CABLE
SEE NOTE 3

REMOTE TEMPERATURE/
E² CONTROLLER DISPLAY
HUMIDITY SENSOR
E² DISPLAY PLUGS DIRECTLY INTO THE (OPTIONAL)
CONTROLLER INSIDE THE ELECTRIC BOX

THERMOSTAT CONTROL
CONFIGURATION (W/ OPTIONS)

SEE NOTE 3

NOTES:
1. DASHED WIRES ( ) NOT APPLICABLE FOR SINGLE-STAGE UNITS
2. PHANTOM WIRES ( ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES
3. OPTIONAL REMOTE MOUNTED DEVICE WIRES DIRECTLY TO A/C UNIT TERMINAL BLOCK
4. CONDUCTOR COUNTS IN FIGURE ARE NOTIONAL. SEE UNIT ELECTRICAL DRAWING FOR
ACTUAL NUMBER AND TERMINAL POINTS OF CONDUCTORS

Figure 20. Interconnection Field Wiring Glycol Systems

23
 CeilAiR IOM Manual

the terminal board within the A/C unit to the pump pack-
CAUTION age electric box. Refer to the electrical drawing(s) supplied
Do not connect any additional loads to the system with your unit to determine the exact number of field wires
control transformers. Connecting additional load to and proper wire terminations required specifically for your
a factory supplied control transformer may result in system.
overloading the transformer.
2.7.5 Remote Shut Down
2.7.3.1 Remote Condenser The unit provides an interface that allows for remote shut
For systems equipped with a remote condenser, the install- down. A normally-closed switch rated at 5 amperes at
er must provide main power wiring to the remote condenser 24VAC is required for this purpose. Two conductors from
control box. A separate equipment ground lug is provided the normally closed switch must be connected to the
within the control box for termination of the earth ground control terminal board located within the unit electric box.
wire. Refer to the electrical drawing supplied with your Refer to the supplied electrical drawing for the appropriate
system and the wiring diagram supplied with the condenser wire terminations.
(typically located in the condenser electric box). NOTE
As an option, control wiring may be installed between the All wiring must be provided in accordance with Na-
A/C system and the condenser for the system controller to tional Electrical Code and local code requirements
enable condenser operation only when the compressor is for Class 2 circuits.
running.
2.7.6 Optional Equipment
You must remove the jumper from the remote condenser
terminal board (see the condenser wiring diagram). Wire 24 2.7.6.1 Condensate Pump
VAC control conductors from the terminal board within the Systems supplied with a field installed condensate pump
A/C unit to the remote condenser terminal board. If control require power and control field wiring. The control wires
wires aren’t installed (and the jumper remains in place), the from the terminal board in the electric box should be run
condenser is always enabled and will turn on and off based through the overflow switch in the condensate pump hous-
on the condenser’s pressure control settings. ing.

2.7.3.2 Remote Condensing Unit After installing the condensate pump, connect two power
conductors from the condensate pump main power termi-
Systems equipped with a remote condensing unit require
nals to the air conditioning unit and a ground wire to the unit
field wiring between the evaporator system and the remote
ground stud located within the unit electric box. Two control
condensing unit. The number of conductors required varies
conductors must be wired to the control terminal board lo-
based upon the options provided. Refer to the electrical
cated within the unit electric box. The condensate pump is
drawing(s) supplied with your unit to determine the exact
provided with pigtail leads for splice-type wire connections
number of field wires and proper wire terminations required
with twist-on connectors (wire caps). Refer to the supplied
specifically for your system.
electrical drawing for proper wire terminations.
Glycol-cooled systems equipped with a pump package
require field wiring between the A/C unit and pump pack- 2.7.6.2 Humidistat/Dehumidistat
age. The installer must wire two control conductors from The humidistat/dehumidistat are mounted in the same
the terminal board within the A/C unit to the pump package manner but are wired differently. The humidistat/dehu-
electric box. Refer to the electrical drawing(s) supplied midistat both require two conductors for connection to the
with your unit to determine the exact number of field wires air conditioning system. The controls have pigtail leads for
and proper wire terminations required specifically for your splice type wire connections with twist on connectors (wire
system. caps). Refer to the supplied electrical schematic for proper
wire terminations.
2.7.4 Water/Glycol Systems
Glycol-cooled systems equipped with a pump package
require field wiring between the A/C unit and pump pack-
age. The installer must wire two control conductors from

24
 CeilAiR IOM Manual

2.7.6.3 Remote Water Detector 2.8 System Charging Procedures

There are two types of water detector available with OHS
units: Spot type and strip/cable type.
2.8.1 Water/Glycol Systems
All self-contained water/glycol cooled units (units that
Spot Type: require no refrigerant field piping) are factory charged with
A remote spot type water detector requires three conduc- refrigerant. No field refrigerant charging is required. The
tors to be wired to the control terminal board in the unit following precautions must be observed when installing
electric box. The wire insulation must be rated at 600V. and filling the water/glycol loop:
The water detector has pig-tail leads for splice type wire • The piping system must be cleaned prior to
connections with twist on connectors (wire caps). Refer to adding water/glycol to the system.
the supplied electrical drawing for proper wire terminations. • Glycol must be mixed with water before it is
added to the system. All air must be bled from
Strip/Cable Type: the piping system. Use only water/glycol solu-
A remote strip/cable type water detector is provided with a tion with inhibitors for corrosion protection.
two conductor cable harness with a quick connect fitting on 1. Open the vent valve at highest point of the system.
the end. The harness mates to the fitting on the water detec-
tor and connects it to the control board inside the electric 2. Fill the system until the solution is discharging from
box. Refer to the electrical drawing supplied with your unit for the vent with minimal signs of foaming due to air in the
proper wire terminations. system.

CAUTION 2.8.1.1 Pump

Do not allow the cable water detector to contact If a pump is used, ensure the system is filled before turning
metal (frame or condensate pan). It must be mounted the pump on. If the pump is not self-priming, it is important
on the plastic stand-offs provided with the water that there is pressure at the suction inlet.
detector.
CAUTION
2.7.6.4 Remote Temperature Sensor (A-Tech) Do not run the pump when dry.
The remote temperature sensor requires a three-conductor
shielded cable with the shield terminated at the thermostat. If the pump has no pressure on the discharge side, leave
Both the thermostat and the sensor are provided with a ter- the discharge valve partially shut to create a back pressure
minal strip with box type lugs for wire connections. Refer to in the pump so that liquid can build up in the impeller hous-
the electrical drawing supplied for proper wire terminations. ing to keep the impeller housing from getting too hot. Make
sure there is always liquid flowing through the pump to cool
2.7.6.5 Remote Temperature/Humidity Sensor (E2) the impeller and housing. If there is no liquid leaving the
The remote temperature/humidity sensor requires a pump, shut the pump off immediately to prevent damage to
shielded cable with the shield terminated at the unit electric the pump. Check for proper rotation of the motor, observ-
box. The number of conductors needed depends on which ing the arrow on the side of the impeller.
system controller is used. Three control conductors are
required for systems using an E² controller. Both the 2.8.2 DX Unit Charging Requirements
electric box and the sensor include a terminal strip with box When performing the specific DX charging procedures in
type lugs for wire connections. Refer to the electrical draw- this section, follow these best practices:
ing supplied with your unit for the number of conductors
required and for the appropriate wire terminations. • Ensure that contamination of different refrig-
erants does not occur when using charging
equipment. Hoses or lines must be as short as
NOTE possible to minimize the amount of refrigerant
contained in them.
All wiring must be provided in accordance with Na-
tional Electrical Code and local code requirements • Keep cylinders upright.
for Class 2 circuits. • Ensure the refrigeration system is grounded
to Earth before charging the system with
refrigerant.

25
 CeilAiR IOM Manual

• Label the system when charging is complete a change in composition and saturation temperature as
(if it is not labeled already). evaporation and condensation occur. Typically, the com-
• Exercise extreme care to avoid overfilling the position of R407C vapor is different than that of R407C
refrigeration system. liquid within a contained system. The composition of liquid
R407C refrigerant remains relatively constant, however,
Before recharging the system, it must be pressure tested
the refrigerant vapor tends to separate into its component
with oxygen-free nitrogen (OFN). The system must be leak
parts even when circulating.
tested upon completion of charging but prior to commis-
sioning. A follow-up leak test must be carried out prior to Refrigerant R410A is similar to R407C in that it is a blend-
leaving the site. ed refrigerant that consists of component parts, however,
the component parts of R410A refrigerant have the same
2.8.3 Remote Air-Cooled Systems (AR/AHU) composition at various operating temperature/pressures in
Remote air-cooled units are provided with a dry nitrogen the liquid phase and gas phase, reducing the temperature
holding charge which must be removed before piping and glide effect experienced with R407C. R410A operates at
charging the unit. higher pressures than R407C, which must be considered
when checking the operating temperatures/pressures
CAUTION while charging or troubleshooting the system.
POE oil is used in systems with R407C or R410A 2.8.5 Estimating Refrigerant Charge
refrigerant. POE oil quickly absorbs moisture when
exposed to air. High POE oil moisture levels react When charging a system with R407C or R410A refrigerant
with refrigerant to form acid which results in system it will be necessary to weigh in the refrigerant and confirm
contamination. Keep the entire system sealed as by checking the superheat and sub-cooling temperatures
much as possible and minimize exposure of the POE (see Section 2.9.1 on page 30). Calculate the minimum
oil to outside air. amount of refrigerant needed by adding the amount of
refrigerant required for the condenser (see the condenser
NOTE manual provided separately) plus the refrigerant piping
(Table 8) plus the refrigerant for the A/C unit (Table 9). The
Refrigerant charging must be performed by a quali- values in Table 9 are the estimated weights for the com-
fied air conditioning technician. pressor circuit. In the case of dual compressor systems, the
values are estimated weights for each compressor circuit.
2.8.4 R407C/R410A Refrigerant The values shown in Table 9 are conservative for the pur-
CeilAiR OHS systems use either R407C or R410A refrig- pose of preventing the system from being overcharged.
erant. Refrigerant charging pressures vary depending on
the type of refrigerant used in the unit. Before charging, Table 8. Weight (lb) of Refrigerant per 100 ft
check the unit nameplate to confirm the type of refrigerant of Type L Tubing
to use. Tables are provided in Section 2.9 on page 30
showing the temperature/pressure characteristics for Line Size (in.) Liquid Line Discharge Line
R407C and R410A.
O.D. I.D. R407C R410A R407C R410A
CAUTION 3/8 0.315 3.42 3.04 0.70 0.80
R407C and R410A can contribute to the green- 1/2 0.43 6.37 5.66 1.30 1.50
house effect if released. Avoid releasing the refriger- 5/8 0.545 10.24 9.09 2.10 2.41
ant into the atmosphere.
7/8 0.785 21.24 18.86 4.35 4.99
1-1/8 1.025 36.21 32.15 7.41 8.51
WARNING
1-3/8 1.265 55.15 48.97 11.29 12.96
R407C and R410A refrigerant released in an en-
closed space can become a suffocant.

R407C and R410A are multi-component blends whose

component parts have different volatilities that result in

26
 CeilAiR IOM Manual

Table 9. Weight (lb) of Refrigerant by OHS 2.8.6 Preparing System For Charging
Model 1. With all the system piping connections made, perform
a dry nitrogen leak detection test on the system. Using
OHS Base Flooded HP dry nitrogen only, pressurize the system to 150 psig.
Model Charge (Per Control Charge Ensure all service and solenoid valves are energized
Number Circuit) Adder open and that no part of the system is isolated from the
Approximate R407C Charge pressurized nitrogen (liquid, suction or discharge lines
and reheat coil).
-012-AR 0.9 8.0
-018-AR 0.9 8.0 2. Since there is no refrigerant in the system to detect
-024-AR 0.9 8.0 at this point, leaks may be detected by observing if
there’s been a change in the standing pressure after
-032-AR 1.9 9.8
12 hours. A significant drop in pressure (>10 psig) in-
-040-AR 1.9 9.8 dicates a leak in the system that needs to be repaired.
-048-AR 3.6 15.3 After the system is determined to be free of leaks, you
may evacuate the system.
-048-DAR 1.0 9.8
-060-AR 3.6 15.3 2.8.6.1 Evacuate the System
-072-DAR 2.5 9.8
-084-DAR 2.5 9.8 CAUTION
-120-DAR 3.9 15.3 A proper vacuum must be drawn on the refrigerant
Approximate R410A Charge system to remove moisture prior to charging. If this
is not done, the refrigerant charge will combine
-012-AR 0.9 7.3 with moisture in the pipes to form an acid that will
-018-AR 0.9 7.3 eventually lead to compressor failure. A triple evacu-
-024-AR 0.9 7.3 ation procedure with dry nitrogen is recommended,
especially for systems with newly installed refriger-
-032-AR 1.9 8.9
ant piping.
-040-AR 1.9 8.9
-048-AR 3.0 13.9 NOTE
-048-DAR 0.7 8.9 A vacuum pump should be used that is capable of
-060-AR 3.0 13.9 evacuating the entire volume of the A/C system,
including newly installed or existing piping. It is es-
-072-DAR 2.0 8.9
sential to use a well maintained pump that is in good
-084-DAR 2.0 8.9 operating condition. Always ensure it contains clean,
-120-DAR 3.0 13.9 fresh oil. You may need to change vacuum pump oil
more than once during the procedure.
Example: Estimate the amount of refrigerant required in
a system using R407C refrigerant consisting of a 5 ton NOTE
(OHS-060-AR) A/C unit with Flooded Head Pressure Use high quality hoses, ensuring they are free of
Control connected with a 1/2 in. x 30 ft liquid line and 7/8” defects and don’t leak. It is recommended to use
x 30 ft discharge line to a STULZ Model SCS-096-SAA copper tubing instead of hoses if possible due to the
condenser: low vacuum that must be attained when evacuating
Condenser = 3.6 lb the system. The use of short, large diameter hoses
helps reduce evacuation time.
+1/2” Liquid Line: 30.0 × 6.37 = 1.911 lb
100 3. After ensuring there are no leaks, relieve pressure and
+ 7/8” Discharge Line: 30.0 × 4.35 = 1.305 lb evacuate the entire system while maintaining all the
100 solenoids (and hot gas reheat valve) open. Pull an initial
+ A/C Unit: (3.6 + 15.3) = 18.9 lb vacuum of 1500 microns or lower using the suction
Estimated Refrigerant Charge = 25.715 lb
Round off to nearest lb = 26 lb

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 CeilAiR IOM Manual

and discharge service ports and the service port of the 26, calculate the minimum amount of refrigerant needed
receiver (if applicable). for your system.

NOTE When charging a system with a blended refrigerant,

When pulling a vacuum, the Schrader valves will maintaining the composition of the refrigerant is essential.
unnecessarily restrict the openings, increasing the To ensure correct composition, introduce the refrigerant
evacuation time. During the evacuation process it is (R407C or R410A) into the system in liquid form rather
recommended to remove the Schrader valve cores than vapor form. Cylinders which are not provided with dip
with a Schrader valve removal tool and draw the tubes should be inverted to allow only liquid refrigerant to
vacuum through the port on the removal tool. charge the system. Keeping the temperature of the cylinder
below 85 °F will help maintain the correct refrigerant com-
4. If you cannot evacuate the system below 1500 position while the cylinder is emptied.
microns, close the vacuum pump isolation valve and
perform a rate-of-rise test by observing the standing WARNING
pressure over time. If the pressure rises slowly (up to If refrigerant gas is released in an enclosed area,
200 microns in 15 minutes), moisture is in the system it may accumulate in low areas and near the floor,
that still needs to be boiled off. Proceed to step #5. If displacing available oxygen. If a major leak occurs,
the pressure rises rapidly up to atmospheric pressure there is a risk of asphyxiation. In such case, imme-
(more than 50 microns per minute), there is a leak that diately evacuate personnel and ventilate the area.
wasn’t detected during step #2. In this case trouble- Personnel should remain away from the area until it
shoot the entire system for leaks and repair them. Then is determined safe.
begin the initial evacuation process again starting at
step #1. 2.8.7.1 Initial System Charge
5. If no leaks are detected after the initial vacuum, Follow the step-by-step instructions below to charge
release the vacuum and pressurize the system with systems using R407C and R410A refrigerant. The initial
2-3 lb of dry nitrogen. Allow the system to stand for charge will be performed by introducing liquid refrigerant
two hours with the dry nitrogen charge. This gives time (R407C or R410A) to the discharge side of the compressor
for the nitrogen molecules to disperse in the system or an available liquid line port with the A/C unit turned Off.
absorbing moisture.
1. Break the vacuum by supplying liquid refrigerant
6. After two hours, release the pressure. Then turn on (R407C or R410A) to the discharge port near the
the vacuum pump and evacuate the system a second compressor until the pressure is equalized. This hold-
time down to 1500 microns or less. Close the vacuum ing charge allows the low pressure switch to “hold,”
pump isolation valve and pressurize the system again enabling the compressor to operate throughout the
with dry nitrogen and allow the system to stand for two process of charging the system.
hours as in step #5.
2.8.7.2 Fine Tuning The System Charge
7. After two hours release the pressure. Turn on the vacu- Once the initial charge is completed, additional refrigerant
um pump and complete the process of evacuating the will need to be added with the unit running.
system, this time with a goal of achieving a 500 micron
vacuum or less. Close the vacuum pump isolation valve.
When you can hold the vacuum at 500 microns or lower
CAUTION
for at least 2 hours with no significant rise in pressure, An adequate heat load must be supplied to ensure
the system is ready to charge. a proper charge.

8. Replace the Schrader valve cores if you removed them 2. Disconnect the refrigerant cylinder from the discharge
during the evacuation steps. You may now introduce side of the compressor and connect it to the suction
the refrigerant charge through the Schrader valves. side.

2.8.7 Refrigerant Charging Procedures 3. Start the A/C system and use the system controller to
R407C and R410A refrigerant must be weighed in when lower the room temperature setpoint 3-5 °F below ac-
performing the charge. Referring to Section 2.8.5 on page

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 CeilAiR IOM Manual

tual room temperature, thus ensuring cooling remains valve must be open to allow refrigerant to flow into the
on as the unit is charged. reheat coil to obtain the proper amount of refrigerant
charge. This can be done using the system controller
When fine tuning the charge on cool days it will be neces- to enable a call for dehumidification (lower the humid-
sary to restrict the airflow across the condenser coil to raise ity setpoint). This process may need to be repeated
the pressure. The fan closest to the header must be run- several times. After cycling the system through the hot
ning. Refrigerant R407C operates at a lower pressure than gas reheat cycle, recheck the system charge with the
R410A. When fine tuning the charge, ensure the pressures system only in the cooling mode.
are correct for the type of refrigerant used. Refer to the
tables in Section 2.9 for the operating temperatures and CAUTION
pressures for the type of refrigerant used in your system.

2.8.7.3 0 ºF Fan Cycling and -20 ºF Variable Remove the blockage to the air intake of the con-
Speed Control denser.
The following instructions are for charging systems with
condenser fan cycling or variable fan speed control using 7. Fill out the applicable sections of Warranty Registra-
R407C or R410A refrigerant. tion and Start-Up Checklist.

1. Partially block the airflow to the condenser with 2.8.7.4 -30 °F Flooded Head Pressure Control
cardboard to raise the discharge pressure. Allow the NOTE
discharge pressure to rise high enough to start the first
For units using flooded head pressure control, a
fan only, then maintain a constant pressure. This will
receiver is used to store the refrigerant during the
lower the possibility of overcharging.
time the condenser is not utilizing the extra refriger-
a. R407C Refrigerant- Allow the discharge pressure ant charge.
to rise to 260-315 psig and hold it constant.
NOTE
b. R410A Refrigerant- Allow the discharge pressure
to rise to 445-480 psig and hold it constant. It is important not to exceed 80% of the total
condenser and receiver volume to allow room for
2. Slowly meter liquid refrigerant through the suction side expansion.
while watching the pressure gauges and monitoring
superheat and sub-cooling temperatures. 1. Fine tune the charge following steps 1–6 in Section
2.8.7.3.
CAUTION
2. The head pressure control valve setting is printed on
Add liquid refrigerant slowly to prevent the refriger- the side of the valve body. This setting is the lowest
ant oil from “washing out” of the compressor. head pressure that will be maintained during system
operation. It may be necessary to add additional refrig-
3. Take a superheat temperature reading near the feeler erant to raise the head pressure to the value printed on
bulb from the thermal expansion valve with the tempera- the valve (225 psig for R407C; 290 psig for R410A).
ture measuring device being well insulated. The ideal
amount of superheat is 12–15 °F. Maximum allowable 3. If a refrigerant level sight glass is included on the side
amount of superheat is 20 °F. of the receiver, it may be used to assist in charging
the air conditioning system. The proper charge can
4. While monitoring the pressure, take a sub-cooling be confirmed by viewing the level of refrigerant in
temperature reading on the output side of the con- the receiver(s) while the unit is running at an elevated
denser. The amount of sub-cooling should be 10–20 discharge pressure.
°F.
4. Add additional refrigerant charge until the refriger-
5. If necessary, (slowly) add liquid refrigerant to the suc- ant level in the receiver rises to the center of the sight
tion side to achieve the sub-cooling temperature. glass, indicating the receiver is 80% filled.
6. If the unit has hot gas reheat (optional), the previ- 5. When the refrigerant in the receiver reaches the center
ous steps are still followed except the hot gas reheat of the sight glass, the unit is fully charged.

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 CeilAiR IOM Manual

2.9.2 Saturated Refrigerant Pressure Tables

CAUTION
The Table 11 refrigerant pressures are provided for refer-
Remove the blockage to the air intake of the con- ence for R407C and R410A refrigerant.
denser.
Table 11. Saturated Refrigerant Pressure
6. Fill out the applicable sections of Warranty Registra-
R410A Refrigerant R407C Refrigerant
tion and Start-Up Checklist.
Pressur Temp. (oF)
Temp. (oF)
e (psig) (psig
2.9 Refrigerant Characteristics Saturated Evaporating Pressur
Temperature
2.9.1 Pressure/Temperature Settings e
20 78.4
The following table is provided to assist with the normal Saturated
22 81.9 Evaporating
settings of the system for R407C and R410A refrigerant.
24 85.5 Temperature
Where applicable, minimum and maximum settings are
20 37.9
given along with normal operating pressures. 26 89.2

28 93.1 22 40.1
NOTE 24 42.3
30 97.0
The operating pressures for R410A refrigerant are 26 44.7
32 101
significantly higher than R407C. 28 47.1
34 105

36 109 30 49.6

38 114 32 52.1
34 54.8 Dew Point
40 118 (Saturated
Table 10. Refrigerant 36 57.5 Vapor)
42 123
Pressure/Temperature 38 60.3
44 128
Settings 40 63.2
46 133
Refrigerant Pressure/Temperature Settings 48 137
42 66.1

Normal Min. Max. 44 69.2

50 143
Sub-cooling °F 10 5 20 46 72.3
55 155
Superheat °F 15 10 20 60 170 48 75.5

Design Condensing Temp. @ 95 °F 125 105 140 65 185 50 78.8

Ambient
70 201 Saturated
Suction Pressure (psig)- R407C 70 55 85 Condensing
75 218 Temperature
Suction Pressure (psig)- R410A 130 105 155 95 209
80 236
Fan Cycling Control- Fan On (psig)- 320 240 340 100 225
R407C 85 255

90 274 105 242

Fan Cycling Control- Fan On (psig)- 440 330 480
R410A 95 295 110 260
Bubble
Fan Speed Control (psig)- R407C 320 - - 100 318 115 279 Point
Fan Speed Control (psig)- R410A 440 - - 105 341 298
120 (Saturate
d
Flooded HP Control Valve (psig)- R407C 205 110 365 Vapor)
125 319
Flooded HP Control Valve (psig)- R410A 295 115 391
130 341
120 418
135 363
125 446

130 477 140 387

135 508

140 541

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 CeilAiR IOM Manual

2.10 System Settings and Adjustments R407C Refrigerant:

Factory setting: On pressure rise, the high fan speed
2.10.1 Low/High Pressure Limit Switch contacts close at 320 psig, increasing the condenser
Air conditioning systems using DX refrigerant are equipped fan speed. A pressure drop to 250 psig will close the low
with hermetically sealed high-pressure and low-pressure fan speed contacts, reducing the fan speed. The setpoint
switches. These switches are pre-set by the manufacturer range is 170 to 400 psig. The differential is nonadjustable
and cannot be adjusted. and set at 70 psi.

R407C Pressure Switch Settings: R410A Refrigerant:

High-pressure switch: opens at 410 psig and has Factory setting: On pressure rise, the high fan speed
a manual reset. contacts close at 440 psig, increasing the condenser
Low-pressure switch: opens at 10 psig (± 4) and fan speed. A pressure drop to 330 psig will close the low
closes at 32 psig (± 5) and has an automatic reset. fan speed contacts, reducing the fan speed. The setpoint
range is 275 to 620 psig. The differential is nonadjustable
R410A Pressure Switch Settings: and set at 110 psi.
High-pressure switch: opens at 630 psig and has
a manual reset. NOTE
Low-pressure switch opens at 10 psig (± 10) and This switch and settings do not apply to units de-
closes at 32 psig (± 10) and has an automatic reset. signed for a power supply greater than 277V.
2.10.2 Head Pressure Controls—Air Cooled
2.10.2.3 Variable Condenser Fan Speed
Sys- tems (Condenser Model SCS-SA, -20 °F)
2.10.2.1 Condenser Fan Cycling (Condenser Used for outdoor installations where ambient temperatures
Model SCS-AA, 0 °F) may fall to -20 °F, a variable speed condenser fan motor
Used for outdoor installations where ambient condenser air control is used to maintain head pressure. The variable
inlet temperatures are 0 °F or higher, this method utilizes a speed motor is located closest to the header end of the
high-pressure differential control switch with SPST (Single condenser. The fan speed control is a continual modula-
Pole, Single Throw) contacts and an automatic reset. The tion of the motor’s speed. The controller is factory installed
switch activates the condenser fan contactor when the dis- in the outdoor condenser/condensing unit. The fan speed
charge pressure reaches a predetermined value to maintain controller requires no adjustment.
the condensing temperature.
The fan speed controller will automatically control the head
See the Head Pressure Controls section of the STULZ SCS pressure at a level to maintain design refrigerant discharge
Series Remote Air Cooled Condensers IOM for informa- pressures. On systems with more than one fan on the
tion about the fan cycling pressure control settings (cut-in condenser, the remaining motors cycle on and off based on
and cut-out pressures) for the supported refrigerants. Note pressure.
that the pressure values vary according to both the refriger-
ant type and the number of fans in the SCS unit. 2.10.2.4 Intelligent Control (Condenser Model SCS-
EC Only, -20 °F)
2.10.2.2 Condenser Multi-Speed Fan Switch Used for outdoor installations where ambient condenser
(Model HES-CAA , 0 °F ) air inlet temperatures may fall to -20 °F, intelligent pres-
Used for indoor installations where ambient condenser sure control is designed to maintain discharge pressure by
air inlet temperatures are 0 °F or higher, the condenser constantly modulating condenser fan speed. SCS outdoor
fan speed switch senses refrigerant discharge pressure condensers are equipped with highly efficient, electroni-
and changes the condenser fan speed to maintain proper cally commutated (EC), axial fan(s). The EC fan speed is
condenser pressures. infinitely variable up to full speed. The control system uses
refrigerant pressure transducer(s) to monitor refrigerant
The condenser fan speed switch changes the fan from low discharge pressure and control the EC fan(s) to the precise
to high speed when pressure rises and returns the fan from speed needed to maintain design refrigerant discharge
high speed to low speed when the pressure lowers. pressures.

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 CeilAiR IOM Manual

2.10.2.5 Flooded Head Pressure Control in Section 2.10.2.5. Instead of cycling the fan on and off,
(Condenser Model SCS-AA With Fan the condenser fan speed is continuous. The head pressure
Cycling, -30 °F) control valve diverts discharge gas to the receiver causing
Used for outdoor installations where ambient condenser air liquid to back up in the condenser, as described in Section
inlet temperatures may fall to -30 °F, flooded head pres- 2.10.2.5, while the fan continues to run.
sure control is designed to maintain head pressure during
low ambient conditions. A head pressure control valve and 2.10.3 Head Pressure Controls—Water /
a receiver are used in the refrigeration circuit to back up Glycol Cooled Systems
liquid refrigerant into the condenser coil. The head pres- In a water/glycol-cooled condenser, condensing tempera-
sure control valve is a 3-way modulating valve controlled by ture is maintained by the liquid flowing through a regulating
discharge pressure. valve and then into a liquid-cooled condenser. The regulat-
ing valve opens to increase the liquid flow as the refrigerant
When the A/C unit begins to operate, the discharge pres- pressure rises and closes as the refrigerant pressure falls.
sure rises (to approximately 320 psig for R407C; 440 The regulating valve is factory set for the correct condens-
psig for R410A) and the condenser fan is cycled on, as ing temperature; however, it can be adjusted to increase or
described in Section 2.10.2.1. When ambient tempera- decrease the condensing temperature.
ture drops, the discharge pressure drops also. When the
discharge pressure drops, the head pressure control valve Head pressure regulating valves are available in 2-way or
diverts discharge gas away from the condenser to the re- 3-way configurations. Refer to the piping diagram to deter-
ceiver. Liquid flow from the condenser is restricted, causing mine which type of valve is provided. The location and size
liquid to back up in the condenser. of regulating valves varies with the size and model of the
A/C unit. Methods for adjusting the valves for condensing
Flooding the condenser reduces the area available for heat pressure differ with the valve types, which can be differen-
transfer. The desired result is to increase the pressure into tiated by the maximum water pressure rating of the valve
the condenser, maintaining a minimum discharge pres- (150, 350, or 450 psig).
sure during low ambient operation, thus ensuring proper
condensing temperature. The head pressure control valve 2.10.3.1 150 psig Pressure Valves
requires no adjustment.
Adjustment is made by turning the slotted square stem on
While the fan is running, the flooded head pressure control top of the valve clockwise to increase the condensing tem-
valve modulates the amount of discharge gas entering the perature or decrease water/glycol flow and counterclock-
receiver. As the pressure increases, the valve diverts more wise to decrease the condensing temperature or increase
discharge gas to the condenser, allowing more liquid to the water/glycol flow. A directional arrow is stamped on the
flow from the condenser to the receiver. metal housing of the valve stem.

When using this method of head pressure regulation 2.10.3.2 350 psig and 450 psig High Pressure Valves
there must be enough refrigerant in the system to ensure Adjustment is made by turning the round-holed knob coun-
adequate charge at the lowest expected ambient tem- terclockwise inside the valve’s metal housing to increase
perature in which the system will be operating. A receiver is condensing pressure or decrease water/glycol flow and
used to store the extra refrigerant when the condenser is clockwise to decrease the condensing temperature or in-
not using it. crease the water/glycol flow. A directional arrow is stamped
on the metal housing of the valve stem.
NOTE
Systems utilizing air cooled condensers must not 2.10.4 Humidifier Adjustment
have a refrigerant line pressure drop greater than 14 The humidifier has a capacity adjustment potentiometer on
psig across the condenser and the interconnecting the humidifier control circuit board. The capacity potenti-
piping to the condenser sections. ometer may need to be field adjusted if the humidifier does
not supply enough capacity for the current room conditions.
2.10.2.6 Flooded Head Pressure Control
(Condenser Model HES-CAA , -30 °F) It is recommended that if the capacity potentiometer
Used for indoor installations where ambient condenser requires adjustment, the adjustment is made and verified in
air inlet temperatures may fall to -30 °F. First, familiarize small increments. Refer to the humidifier manual sent with
yourself with Flooded Head Pressure Control as discussed your unit for the location of the capacity potentiometer.

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 CeilAiR IOM Manual

and motor pulleys when a firm pressure is placed on

CAUTION the side of the blower belt. Adjust the blower belt ten-
Adjusting the capacity potentiometer too high may sion by raising (to tighten) or lowering (to loosen) the
result in condensation within the system. nuts on the adjustment rods of the motor base.

2.10.5 Blower Adjustment CAUTION

2.10.5.1 Belt Drive Blower If the belt tension is too tight, it will cause premature
blower and/or motor bearing failure. If the belt is too
loose, the belt will slip and cause belt squeals and
LOCKNUT eventual belt failure.
MOTOR
MOTOR BASE 9. Restore power to the system.
VARIABLE OR
BLOWER TENSION NUT ADJUSTABLE
PULLY 10. Check the current draw on the blower motor to make
sure it does not exceed the nameplate rating of the
motor.
MOTOR BASE

11. If current draw exceeds the nameplate rating of the

motor, repeat steps 1 through 9 to decrease blower
BELT speed. If the motor pulls too much current, slow the
blower down by opening the adjustable sheave one
half turn at a time until the motor current is at or below
the nameplate FLA.

FIXED PULLEY
12. Check the motor overload on the blower starter to
confirm its setting is correct for the FLA of the motor.

Figure 21. Belt Drive Blower 2.10.5.2 EC Fan (Optional)

The speed of the EC fan is controlled via a 0 to 10 VDC
Systems with belt drive blowers (see Figure 21) are sup- signal from the system controller. The controller is set by
plied with adjustable sheaves to change the blower speed the factory and should not require adjustment. If it is deter-
and adjustable motor bases for belt tensioning. Perform the mined that the air flow needs adjustment, this may be done
following procedure to change the blower speed. using the controller’s programming menu selections. Refer
1. Turn the system off. to the operator’s manual provided under separate cover for
the system controller.
2. Turn off all power to the unit at the non-fused service
switch; use a lock-out/tag-out procedure. 2.10.6 Thermal Expansion Valve
CeilAiR units using DX refrigerant have a thermal expansion
3. Remove the blower belt(s). valve (TEV). The TEV maintains constant superheat of the
refrigerant vapor at the inlet of the evaporator by meter-
4. Loosen the set screw in the side of the sheave with an
ing the flow of refrigerant into the evaporator. Superheat is
Allen wrench.
the difference between the refrigerant vapor temperature
5. Remove the sheave key. and its saturation temperature at a given suction pres-
sure. By controlling superheat, the TEV keeps nearly the
6. Adjust the blower speed by closing the sheave one half entire evaporator surface active while preventing liquid
turn to increase speed or opening the sheave one half refrigerant from returning to the compressor. As a standard,
turn to decrease speed. superheat is factory set at 12–15 °F and should not need
adjustment.
7. Replace the sheave key and tighten the set screw.

8. Proper belt tension is achieved when the belt has a de-

flection of 1/2 in. per foot of span between the blower

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 CeilAiR IOM Manual

2.10.7 Hot Gas Reheat (Optional) The hot gas bypass valve allows refrigerant to flow from the
The hot gas reheat feature incorporates a hot gas reheat discharge line directly to the suction line. Hot gas enter-
solenoid valve and a hot gas reheat coil. Under normal ing the suction side of the compressor would raise the
operation when no reheat is required, the hot gas reheat operating temperature of the compressor to a point where
valve is de-energized and hot gas flows directly from the failure could occur. To prevent this, a small amount of liquid
compressor discharge to the condenser. When there is a refrigerant passes through the quench valve and mixes with
call for reheat, the controller energizes the hot gas reheat the hot gas entering the compressor, maintaining normal
solenoid valve. The hot gas reheat solenoid valve diverts compressor suction pressure and temperature.
hot gas to the reheat coil, mounted directly downstream of The full floating hot gas bypass system provides freeze
the evaporator coil, before it travels to the condenser. No protection for the evaporator coil by limiting the minimum
adjustment to the valve is necessary. refrigerant pressure, preventing the surface temperature of
the evaporator coil from dropping below 32 °F. The hot gas
2.10.8 Hot Gas Bypass (Optional)
(discharge) regulating valve has a normal suction pressure
The two most common systems provided by STULZ for control setting at 75 psig (R407C) and 121 psig (R410A)
hot gas bypass are snap acting and full floating, described read from the suction (low) side of the compressor as it op-
below. erates in full hot gas bypass mode. The valve is factory set
and no adjustment should be necessary. If adjustment is
2.10.8.1 Snap Acting Hot Gas Bypass required, remove the adjustment cap from end of the valve.
The snap acting hot gas bypass system provides for some Using a 5/16 in. Allen wrench, turn clockwise to increase
modulated capacity control and freeze protection. The hot pressure or counterclockwise to lower the pressure.
gas bypass system includes a discharge bypass valve that
allows some hot gas from the compressor discharge line
to pass into the evaporator coil to maintain a preset suc-
CAUTION
tion pressure. The compressor cycles on demand from the Do not exceed 20 °F superheat. Exceeding this
controller. temperature may cause failure of the compressor.

The snap acting hot gas bypass system also provides The normal control setting for the quench valve is 20 °F
freeze protection for the evaporator coil by limiting the superheat (when there is no call for cooling). The valve is
minimum refrigerant pressure, preventing the surface tem- factory set and no adjustment should be necessary. If ad-
perature of the evaporator coil from dropping below 32 °F. justment is required, remove adjustment cap from the valve.
Turn the adjusting stem clockwise to increase superheat
The normal control setting for suction pressure is 75 psig and counterclockwise to decrease the superheat.
(R407C) and 121 psig (R410A) read from the suction (low)
side of the compressor as it operates in full hot gas bypass
operation. The valve is factory set and no adjustment
should be necessary. If adjustment is required, block one
half of the coil and remove the adjustment cap from the end
of the valve. Using a 5/16 in. Allen wrench, turn clockwise
to increase pressure or counterclockwise to lower the
pressure.

2.10.8.2 Full Floating Hot Gas Bypass

A full floating hot gas bypass system is provided for capaci-
ty control and freeze protection. The hot gas bypass system
may include a quench solenoid valve, a quench solenoid
coil, a quench expansion thermal valve, a hot gas (dis-
charge) solenoid valve, a hot gas (discharge) solenoid coil,
and a hot gas bypass valve. To ensure a constant running
compressor, the hot gas and quench solenoid valves open
and the liquid line solenoid valve cycles on the demand of
the controller.

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 CeilAiR IOM Manual

3.0 COMMISSIONING, OPERATION provided with your unit. The compressor(s) should
AND DECOMMISSIONING come on and the discharge air should feel cooler than
the return air.

3.1 Commissioning the Unit NOTE

For new installations, ensure the unit is ready to operate Compressor may have a time delay on start-up.
by going through the Checklist for Completed Installation
provided with the unit, prior to start-up. 5. Test heating operation by setting the temperature set-
point above the actual room temperature. The heater
NOTE will energize to increase the discharge air temperature.
A Warranty Registration and Start-Up Checklist
is provided in the unit data package. It should be 6. Test humidifier operation by creating a demand for
completed during start-up and sent to STULZ. This humidification. Use an amp meter to determine the
checklist should be used as a guideline for items that current draw of the humidifier. Visually check for vapor
need to be confirmed during start-up. leaving the steam head or feel if the cylinder is warm
to verify the humidifier is operational. In all cases, one
Start-up must be performed by a journeyman refrigeration to six hours might be required to see a desired level or
mechanic or air conditioning technician. rise in humidity in the conditioned space. Once room
conditions have been programmed or set, a repeat visit
3.1.1 Commissioning Steps to the conditioned space may be required to ensure
the humidifier is meeting the room’s requirements.
CAUTION
An Operation and Maintenance manual for the humidifi-
For air-cooled outdoor remote condensing units er is provided with your unit under separate cover. Refer
(RCU), apply power to the RCU eight hours before to that manual for detailed information on humidifier
operating the system. This time is required to allow operation.
liquid refrigerant to be driven out of the compressor.
The compressor crank case heater is energized as 7. Test dehumidification operation by creating a demand
long as power is applied to the unit. for dehumidification. If necessary, set the dehumidi-
fication setpoint 10% below actual room conditions.
1. Replace all equipment, access panels and ceiling The cooling circuit(s) will turn on to begin the dehu-
panels that were removed prior to performing start-up midification process. While in this mode, room tem-
checks. perature may decrease and the reheat function may
activate. As conditions in the room change, you may
2. Apply power to start the CeilAiR OHS system at the have to readjust the setpoint as you check operation.
service disconnect switch, then turn the A/C system An adequate heat load within the space is required.
on at the controller.
8. For electric reheat, use an amp meter on the heater
3. Ensure that all blowers/fans are rotating correctly and circuit to determine if the heater is operational. For hot
freely without any unusual noise. Water/Glycol-cooled water reheat, ensure the control signal has energized
units have a head pressure water regulating valve the control valve and the temperature of the water has
that has been factory set. A valve adjustment may be decreased as it passes through the unit. In all cases,
required based on water temperatures or water/glycol one to six hours might be required to see a desired
flow conditions at your site; see section 2.10.3, "Head level or decrease in humidity in the conditioned space.
Pressure Controls—Water / Glycol Cooled Systems". Once room conditions have been programmed or set,
If the system is a dual circuit unit, both refrigeration a repeat visit to the conditioned space may be required
circuits must be tested at start-up. to ensure the dehumidification mode is meeting the
4. Test cooling operation by setting the temperature room’s requirements.
setpoint below the actual room temperature. For dual
compressor systems, the setpoint must be lowered
below the compressor cut-in setpoints for both cooling
circuits. For systems equipped with the E² controller,
refer to the STULZ E² Controller Operation Manual

35
 CeilAiR IOM Manual

3.2 Operating the Unit 3.4 Decommissioning the Unit

This section provides simple instructions for powering an Personnel performing the decommissioning must be com-
OHS unit on and off. The procedures differ depending on pletely familiar with the unit before starting. Best practice
the installed controller. requires all refrigerants be recovered safely; see section
3.4.1 for guidelines. Prior to recovery, an oil and refrigerant
3.2.1 Shutdown Procedure sample should be taken in case analysis is required prior to
1. For E2-equipped units, press and hold the Enter key re-use of the reclaimed refrigerant. Electrical power must
for 3 seconds. be available before decommissioning is started.

2. For all units, turn off power at the unit main power Follow these decommissioning guidelines:
disconnect.
1. Become familiar with the equipment and its operation.
3.2.2 Start-up Procedure 2. Isolate the system electrically.
1. Power on the unit at the main power disconnect.
3. Before attempting the procedure ensure that:
2. A-Tech-equipped units will start automatically. For
E2-equipped units, if the controller is programmed for • Mechanical handling equipment is available,
automatic start, the unit will enter an operational state if required, for handling refrigerant cylinders
automatically; otherwise, a status message will appear • All required personal protective equipment is
stating manual start-up is required. Press the Enter available and used correctly
key to start the unit. • The recovery process is supervised at all times
by competent personnel
3.3 Programming the Thermostat • Recovery equipment and cylinders conform to
the appropriate standards
3.3.1 A-Tech Controller 4. Pump down the refrigerant system, if possible.
The A-Tech controller is a programmable thermostat that
provides: 5. If a vacuum is not possible, make a manifold so that
refrigerant can be removed from various parts of the
• single- and dual-stage cooling control system.
• on/auto/intermittent/off modes of operation
• continuous/auto/residual fan 6. Place the cylinder receiving the refrigerant on the
scale before starting recovery.
• day/time clock
• service reminders 7. Start the recovery machine and operate in accordance
• language and oC / oF display preference with manufacturer’s instructions.
• security features
8. Do not overfill cylinders. (They should contain no more
• temperature setpoint override
than 80 % volume liquid charge).
See the Robertshaw C9701i2 and C9725i2 User’s
Manual that accompanied your unit for programming 9. Do not exceed the maximum working pressure of the
instructions. cylinder, even temporarily.

3.3.2 E² Controller 10. When the cylinders have been filled correctly and the
process completed, make sure that the cylinders and
If the unit employs an E² controller, the controller was fac-
the equipment are removed from site promptly and all
tory programmed based on the model of the A/C unit and
isolation valves on the equipment are closed off.
the optional features selected. Most applications require
no field start-up or program adjustment beyond setting the 11. Recovered refrigerant must not be charged into an-
current date and time. Separate operating instructions for other refrigeration system unless it has been cleaned
the controller have been sent with your unit, including each and checked.
feature’s factory “default” setting and the available adjust-
ment range, if applicable.

36
 CeilAiR IOM Manual

3.4.1 Recovering Refrigerant 4.0 MAINTENANCE

When removing refrigerant from a system, either for
servicing or decommissioning, best practice is to remove 4.1 Periodic General Maintenance
all refrigerants safely. Use the following recommended
guidelines: Systematic, periodic general maintenance of the CeilAiR
unit is required for optimum system performance. General
• When transferring refrigerant into cylinders, ensure maintenance should include, but not be limited to, the fol-
that only appropriate refrigerant recovery cylinders are lowing: Replacing filters and humidifier cylinders; tighten-
employed. Ensure that the correct number of cylinders ing loose fasteners and electrical connections; checking
for holding the total system charge are available and the condensate line to ensure it is free of debris; cleaning
that all cylinders to be used are designated for the the interior of the unit; visually inspecting the units’ compo-
recovered refrigerant and labelled for that refrigerant nents; checking belt tension; checking the level of refriger-
(i.e., special cylinders for the recovery of refrigerant). ant; and ensuring no moisture is in the refrigerant.
Cylinders must be complete with pressure relief valve
and associated shut-off valves in good working order. Use copies of the "OHS Preventive Maintenance Inspection
Empty recovery cylinders must be evacuated and, if Checklist" in Appendix A to record periodic general mainte-
possible, cooled before recovery occurs. nance inspections. For assistance, contact STULZ Product
Support. Follow all safety instructions while performing any
• Recovery equipment must be in good working order type of maintenance.
with a set of instructions concerning the equipment at
hand, and the equipment must be suitable for recover- STULZ recommends a general schedule of quarterly
ing flammable refrigerants. In addition, a set of cali- preventive maintenance inspections. Some items, such as
brated weighing scales must be available and in good filters or coil fins, may need more frequent inspection and
working order. Hoses must be complete and in good maintenance, depending on environmental conditions.
condition with leak-free disconnect couplings. Before
using the recovery machine, check that it is in satisfac- WARNING
tory working order, has been properly maintained and
OHS equipment should be serviced and repaired bya
that any associated electrical components are sealed
journeyman refrigeration mechanic or air condition-
to prevent ignition in the event of a refrigerant release.
ing technician only.
Consult manufacturer if in doubt.

• Recovered refrigerant must be returned to the refrig- WARNING

erant supplier in the correct recovery cylinder, and
If refrigerant gas is released in an enclosed area it
the relevant Waste Transfer Note arranged. Do not
will displace oxygen and act as a suffocant. Always
mix refrigerants in recovery units and especially not in
ensure adequate ventilation during refrigeration
cylinders.
repairs.
• If compressors or compressor oils are to be removed,
Always recover all refrigerant prior to any system
ensure they have been evacuated to an acceptable
repairs. Failure to do so may result in system over
level to make certain flammable refrigerant does not
pressurization and rupture. Follow the guidelines in
remain within the lubricant. The evacuation process
"Recovering Refrigerant" on page 37.
must be carried out prior to returning the compressor
to the suppliers. Only electric heating of the compres-
sor body may be employed to accelerate this process. WARNING
When oil is drained from a system, it must be carried
Turn off power to the unit at the service disconnect
out safely.
switch unless you are performing tests that require
power. With power and controls energized, the unit
3.4.2 Labeling Decommissioned Equipment
could begin operating automatically at any time.
Equipment must be labelled stating that it has been de-
commissioned and emptied of refrigerant. The label must Hazardous voltage will still be present at the
be dated and signed. Ensure that there are labels on the evaporator, condenser, heater/reheater and
equipment stating the equipment contains flammable humidifier, even with the unit turned off at the
refrigerant.

37
 CeilAiR IOM Manual

controller. To isolate the unit for maintenance, turn off • if unit has an oil-level sight glass, verify com-
power at a non-fused service switch. pressor oil level during operation (all compres-
sors)
Always disconnect main power prior to performing any
4.1.1.2 Heater
service or repairs. To prevent personal injury, stay clear
of rotating components because automatic controls Inspect heater items:
may start them unexpectedly. • heater elements for any damage
• heater overloads for damage
WARNING 4.1.1.3 Air Filters
This unit employs high voltage equipment with rotating Air filters are usually the most neglected item in an air con-
components. Exercise extreme care to avoid accidents ditioning system. To maintain efficient operation, the filters
and ensure proper operation. may require inspection monthly. Replace them as required.

4.1.1 A/C Unit NOTE

• Check the refrigerant sight glass on a monthly ba- Conditions of spaces vary and the frequency of
sis while the unit is running. Excessive bubbles in checking air filters should be based on those con-
the sight glass indicates a low refrigerant charge ditions.
or a clogged filter-drier.
• Check for moisture in the refrigerant by viewing 4.1.1.4 Blower
the color of the indicator in the center of the sight The blower motor is provided with permanently lubricated
glass and comparing it to the color scale on the bearings and should not require lubrication for the lifetime
outer ring. If moisture is present, the system must of the unit. Periodic checks of the blower system should
be evacuated and recharged. include checking the wiring, blower motor mounts, hous-
• Check the superheat and sub-cooling tempera- ing bolts and blower wheel set screw. Ensure all electrical
tures semi-annually and ensure they are within connections are tight. Check that all mounts are secure and
the range shown in the refrigerant pressure/ the blower wheel is tightly mounted on the shaft and does
temperature table in Section 2.9.1. If necessary, not rub against the fan housing. The blower vanes should
adjust the refrigerant charge to achieve the cor- be kept free of debris. Inspect motor pulleys and sheaves
rect values. If the refrigerant level is low, check for excessive grooves. Inspect bearings for excessive wear.
the system for leaks. Inspect blower section for any loose parts or debris.
• Inspect electrical items:
* fuses 4.1.1.5 Coils
* internal wiring for discoloration The coil(s) should be cleaned as required following stan-
* check electrical connections are secure dard coil cleaning practices. Using a brush, clean fluid coil
fins of all debris that will inhibit airflow. This can also be
* check low voltage connections
done with compressed air or with a commercial coil cleaner.
* relays and contactors for serviceability, i.e., Check for bent or damaged coil fins and repair as neces-
pitted contacts, weak coils sary. Check all refrigerant lines and capillaries for vibration
• Verify the following: isolation and support if necessary. Check all piping for
* controller operation signs of leaks.
* customer setpoints
Inspect electric heating elements to ensure they are free of
* air safety switch and tubing
debris.
* chilled water valve operation
4.1.1.1 Compressor 4.1.1.6 Drain Pan
Verify compressor operation: To assure proper drainage, inspect the drain pan regularly.
• visually inspect for oil leaks Make sure the drain pan outlet is always free of debris and
ensure the drain pan does not leak. Check the drain pan
• check for excessive vibration
float switch to verify it is free to move.
• check crankcase heater operation

38
 CeilAiR IOM Manual

4.1.1.7 Condensate Pump Also, perform the maintenance operations described in the
The optional condensate pump should be inspected semi- humidifier manual.
annually and cleaned. Ensure that the float works freely.
Wipe the float with a wet cloth and detergent to remove 4.1.2 Condenser/Condensing Unit
dirt. Clean the tank bottom. Check that the discharge line is Maintenance access to the condensing unit is through one
open and water can pass through it freely. or two removable panels (depending on model). Clean the
air-cooled condenser coil of all debris that will inhibit air-
4.1.1.8 Humidifier flow. This can be done with compressed air or with a com-
The optional humidifier’s steam cylinder has a limited mercial coil cleaner. Check for bent or damaged coil fins
lifetime and must be replaced periodically. Because water and repair as necessary. On outdoor units in winter, do not
conditions and humidifier usage rates vary greatly, it is permit snow to accumulate on or around the condensing
difficult to establish intervals for changing the cylinder. unit. Check all refrigerant lines and capillaries for vibration
Individual maintenance schedules must be determined isolation and support as necessary. Check all refrigerant
for each location based upon periodic examination of the and coolant lines for signs of leaks.
humidifier. A yellow LED on the humidifier cabinet repeat-
edly flashes four times to indicate the cylinder should be CAUTION
replaced. If main power is disconnected for a long period, do
not attempt to start a condensing unit until eight
NOTE
hours after applying power. This allows time for all
The yellow LED may illuminate during initial start-up liquid refrigerant to be driven out of the compressor.
but it doesn’t necessarily mean the cylinder needs This is especially important at low ambient tempera-
to be replaced. ture conditions.

Refer to the humidifier operator’s manual supplied under

separate cover for detailed instructions for changing the
cylinder.

39
 CeilAiR IOM Manual

4.2 Troubleshooting
Troubleshooting steps are listed in Table 12. Turn off all power to the unit before conducting any troubleshooting pro-
cedures unless the procedure specifically requires the system to operate. Keep hands, clothing and tools clear of the
electrical terminals and rotating components. Equipment located in the ceiling can pose unusual difficulties. Ensure
that your footing is stable at all times.

Table 12. Troubleshooting Table

Symptom Probable Cause Recommendation

Suction Pressure Too Low a. Loss of refrigerant (excessive bubbles in Locate leak and repair. Recharge system.
sight glass).

b. Expansion valve stuck or obstructed Remove and clean or replace valve.

(short cycle or continuous running).
c. Clogged drier/strainer (feels cold). Replace with new drier/strainer.
d. Dirty air filters. Clean/replace filters.
Chilled Water Valve Fails to a. Temperature setpoint too high/low. Adjust to correct temperature setting.
Open or Close
b. No control power to the chilled water valve Thermostat wired incorrectly. Check wiring
diagram and rewire if required.
c. Actuator failed. Replace actuator.
Evaporator Coil Ices a. Low airflow. 1. Check filters. Replace as needed.
2. Check for and clear any obstructions
across or in the (supply) discharge air-
stream.
3. Check correct rotation of evaporator
blower.
b. Temperature setting too low. Increase temperature setpoint (68 °F
minimum.).
c. Discharge air short cycling back to return. Check discharge grille orientation.
d. Low refrigerant charge. Find leak, repair and recharge system.
Blower Fails to Start a. Power failure. Check main voltage power source input
cable.
b. Control transformer circuit breaker Check for short circuit or ground fault; if
tripped. none, reset circuit breaker.
c. Defective contactor. Repair or replace.
d. Thermal overload tripped. Reset overload and check amperage of
motor. Compare to setting on overload
and adjust to FLA. All direct-drive motors
are internally protected and do not require
overload reset.
Control is Erratic Wiring improperly connected or broken. Check wiring against electrical drawing.

40
 CeilAiR IOM Manual

Symptom Probable Cause Recommendation

Condenser Pressure Too High a. Non-condensable gas or air in system. Recover system and recharge. Replace
drier/strainer. Evacuate to 50 microns and
recharge.
b. Condenser air intake is blocked. Remove debris and clean condenser.
c. Overcharge of refrigerant. Reclaim excess refrigerant from system.
d. Low water flow to water-cooled con- Reset-determine cause and fix.
denser.
e. Condenser fan not operating. Check pressure/temperature operating
switches and motor. Replace as needed.
f. Water/glycol temperature too high. Check flow and operation of drycooler.
g. Condenser pressure regulating valve set- Adjust to obtain correct pressure.
ting too high.
h. Flow of water/glycol too low. 1. Check glycol solution level and concentra-
tion.
2. Valves not open or partially open. Repair/
replace as needed.
3. Air in system - bleed system.
4. Check all strainers and clean if needed.
i. Water/glycol solution not mixed prior to Remove solution and premix. Refill system.
adding to system.
Condenser Pressure Too Low a. Loss of refrigerant (indicated by bubbles Locate and repair leak. Recharge system.
in sight glass).
b. Condenser fan controls not set. Adjust or repair controls.
c. Water regulating valve adjusted too low. R407C - Readjust to 320 psig.
R410A - Readjust to 440 psig.
Noisy Compressor a. Expansion valve stuck in open position Ensure feeder bulb is tight on suction line.
(abnormally cold suction line). Check operation and superheat.
b. Worn or scarred compressor bearings. Replace compressor.
c. Liquid slugging. System overcharged. Reclaim excess
refrigerant.
d. Scroll compressor not properly phased. Phase correctly at main power source. Do
not rewire compressor.
Compressor Fails to Start a. Temperature setpoint too high. Adjust to desired temperature.
b. Compressor internal overload protector Check compressor for short circuit or
is open. ground.
c. Complete loss of refrigerant charge (low Locate and repair leak. Recharge system.
pressure safety switch).
d. Condenser pressure too high (high pres- Check condenser for obstructions.
sure safety switch).
e. Condensate switch open. 1. Ensure unit is level.
2. Check that condensate pan is draining
properly. Clear obstructions.

41
 CeilAiR IOM Manual

Symptom Probable Cause Recommendation

System Short of Capacity a. Low refrigerant (indicated by bubbles in Check for leaks. Repair and recharge
sight glass). system.
b. Expansion valve stuck or obstructed Remove valve and clear obstruction or
(short cycling or continuous running). replace valve.
c. Clogged drier/strainer (feels cold). Replace with new drier/strainer..
d. Reduced airflow. Check belt tension, filters and clear evapo-
rator coil of debris.
Compressor Short Cycles a. Low line voltage causing compressor to Check power source for cause of low line
overheat. voltage.
b. Dirty or iced over evaporator coil. Defrost and/or clean coil.
c. Reduced airflow (when applicable). Check filter and belt tension.
d. Lack of refrigerant. Check for leak. Repair and recharge sys-
tem.
e. Short cycling of conditioned air. 1. Supply and/or return grilles are incorrectly
oriented. Re-orient.
2. Supply and return grilles are too close
together. Move farther apart.
3. Insufficient heat load. Add temporary heat
load to compensate.
f. Thermostat is improperly located. Check for supply registers that may be too
close to thermostat. Relocate if necessary.
Heater Inoperative a. Fuses blown/circuit breaker tripped. Check for short circuit; replace fuses/reset
circuit breaker.
b. Thermostat set too low. Increase temperature setpoint.
c. Overheat switch open due to insufficient Check for dirty filters or obstructions that
airflow across heater elements. . may reduce airflow. Correct or replace as
needed.
d. Fuse link blown. Replace fuse link (see item immediately
above).
e. Heater element burned out. Check continuity with an ohmmeter. Re-
place heater element.
Humidifier a. Water supply has been turned off or not Connect and/or turn on water supply.
Inoperative connected.
b. Humidifier switch is in “Off” position. Turn switch to “Auto/On” position.
Note: See humidifier
manual for additional help. c. Electrical connections are loose. Tighten electrical connections.
d. Humidifier fuses are blown. Check for overcurrent by the humidifier
electrodes. Drain water from tank and refill.
Replace fuses.
e. Relative humidity is above setpoint. Adjust humidistat setpoint.
f. Yellow status LED is flashing. Consult humidifier manual.
g. Water conductivity is too low. Add a teaspoon of table salt to the water
through the top of the cylinder. Typically
only required on initial start-up.

42
 CeilAiR IOM Manual

4.3 Field Service 4.3.4 General Common

Repairs/Component Replacement
NOTE
Do not attempt to make repairs without the proper 4.3.4.1 Compressor Failure
tools. The compressor is the most important component of the
air conditioner. Numerous safety devices are provided to
It may be necessary to perform repairs on the refrigeration protect the compressor from failing.
system. If field repairs are necessary, the following proce-
dures apply: If a compressor failure has occurred, determine whether it
is an electrical or a mechanical failure. An electrical failure
WARNING is indicated by a distinct pungent odor when the system is
been opened. If a burnout has occurred, the oil will be black
If refrigerant gas is released in an enclosed area, and acidic. A mechanical failure will have no burned odor
it will displace oxygen and potentially act as a suf- and the motor will attempt to run. An abnormal or excessive
focant. Always ensure adequate ventilation during noise may be present.
refrigeration repairs.
Analysis of the oil is the only way to determine the proper
WARNING cleaning procedure for the refrigerant system. Acid test
kits are available from several manufacturers for measuring
Always recover all refrigerant prior to any system the acid level in the oil. These are capable of making quite
repairs. Failure to do so may result in system over accurate acid measurements, but if they are not available, a
pressurization and rupture. Follow the guidelines in check of the oil by sight and smell can give a quick indica-
"Recovering Refrigerant" on page 37. tion if contamination remains in the system.

4.3.1 Leak Detection All electrical connections should be checked to ensure

Several methods can be used to detect a leak in the refrig- they are tight and properly made. Check all fuses, contac-
eration system. The most modern and easiest method is to tors and wiring. The contactor should be examined and
use an electronic leak detector. Follow the manufacturer’s replaced if contacts are worn or pitted.
directions and any leak can be quickly located. A second If there is acid in the oil, there has been an electrical failure
method is to use soap bubbles. Apply a solution of soapy that caused the compressor motor to burn out. The acid
water with a brush or sponge to the joints and connec- diffuses throughout the refrigeration system and must be
tions in the refrigeration lines. A leak in the lines will cause removed using a burnout filter kit before a new compres-
bubbles to form. sor is placed in service. The entire refrigeration circuit
must also be cleaned of harmful contaminants left by the
4.3.2 Leak Repair burnout. See Section 4.3.4.3 (4.3.4.3, "Burn-Out/Acidic
When a leak is located, properly reclaim the remaining re- Cleanup Procedure") for the proper procedure.
frigerant charge before beginning repairs. Adjacent piping
must be thoroughly cleaned by removing all paint, dirt and If there is no acid in the oil, there has been a mechanical
oily film. Use a wire brush, sandcloth or sandpaper and wipe failure. See Section 4.3.4.2 (4.3.4.2, "Standard Cleanout
the area with clean, dry cloths. Protect nearby parts from Procedure") for the proper cleaning procedure.
heat damage by wrapping with water-soaked cloths.
CAUTION
4.3.3 Refrigerant Piping
Damage to a replacement compressor caused by
When replacing components within the cabinet of the unit improper system cleaning constitutes abuse under
the following consumable materials are recommended. Use the terms of the warranty. This will void the compres-
Silfos alloy for copper-to-copper (piping discharge or suc- sor warranty. Always consult the factory prior to
tion line repairs). Use silver solder (Stay-Silv #45) and flux replacing the compressor.
on copper-to-brass or copper-to-steel repairs.

When component replacement is complete, remove all CAUTION

traces of flux. After any repair, pressure check the system POE oil is used in systems with R407C and R410A
for leaks prior to recharging the system. refrigerant. If a replacement compressor is provided,
ensure that it is filled with POE oil before installing.

43
 CeilAiR IOM Manual

4.3.4.2 Standard Cleanout Procedure 5. Install a suction line filter-drier designed for acid
removal.
WARNING
6. Remove the liquid line drier and install the appropriate
Avoid touching or contacting refrigerant gas and oil liquid line filter-drier.
with exposed skin. Severe burns will result. Use long
rubber gloves when handling contaminated parts. 7. Check the expansion valve, sight glass and other con-
trols to see if cleaning or replacement is required.
NOTE
8. Evacuate the system according to standard proce-
Cleaning operations must be performed by a jour- dures. Normally, this will include the use of a high-
neyman refrigeration mechanic or air conditioning vacuum pump and a low-vacuum micron gauge for
technician. measuring the vacuum obtained.

1. If your unit is equipped with an E² controller, turn the 9. Recharge the system through the access valve on the
A/C unit off by pressing and holding the Enter key. suction line filter-drier.
2. Turn off power to the unit at the main power discon- 10. Turn on power at the main power disconnect switch
nect switch. and start the system.

3. Remove the old compressor and install the new com- 11. The suction line filter-drier permits small-system
pressor. cleanup to be completed in one service call. The pres-
sure drop across the suction line filter-drier should
4. Remove the liquid line drier and install the appropriate be measured during the first hour of operation. If the
liquid line filter-drier. pressure drop becomes excessive, the suction line
filter-drier should be replaced (See Sporlan Bulletin
5. Evacuate the system according to standard proce-
40-10, for the maximum recommended pressure drop
dures. Normally, this will include the use of a high-
for the suction line filter drier).
vacuum pump and a low-vacuum micron gauge for
measuring the vacuum obtained. 12. In 24 hours, take an oil sample. Observe the color and
test for acidity. If the oil is dirty or acidic, replace the
6. Recharge the system.
suction line filter-drier.
7. Turn on the power at the main power disconnect
13. In two weeks, examine oil to determine if another suc-
switch and start the system.
tion line filter-drier change is necessary.
4.3.4.3 Burn-Out/Acidic Cleanup Procedure
4.3.4.4 Humidifier Cylinder Replacement
NOTE
After an extended period of operation, the yellow LED on
Cleaning operations must be performed by a jour- the humidifier cabinet will repeatedly flash four times indi-
neyman refrigeration mechanic or air conditioning cating that the cylinder is completely used and a replace-
technician. ment cylinder must be installed. The cylinder is disposable
and cylinder life is dependent on water supply conditions
1. These systems should be cleaned using the suction and humidifier usage. Refer to the humidifier operator’s
line filter-drier method. manual supplied under separate cover for detailed instruc-
tions on changing the cylinder. The following procedures
2. If your unit is equipped with an E² controller, turn the
are to be followed when replacing the cylinder.
A/C unit off by pressing and holding the Enter key.

3. Turn off power to the unit at the main power discon- CAUTION
nect switch.
Failure to replace the cylinder at the end of cylinder
4. Remove the burned-out compressor and install the life may result in humidifier damage.
new compressor.

44
 CeilAiR IOM Manual

NOTE 5.0 PRODUCT SUPPORT

Decrease the humidity setpoint below ambient
STULZ Product Support provides aftermarket technical
humidity to allow the cylinder to cool down before
and field support, warranty authorization and part sales to
removing the cylinder.
contractors and end users. Factory authorized services are
available by request and include:
1. If your unit is equipped with an E² controller, turn the
A/C unit off by pressing and holding the Enter key. • Factory Authorized Start-up/Warranty Inspection
• Commissioning Assistance
2. Turn off the water supply to the humidifier.
• Break Fix Repair
3. Turn the main power disconnect switch on the electric • Preventive Maintenance Contracts
box to the Off position. Remove the cover from the • Performance Evaluations
electric box. • Technician and Owner Training
4. Using a pair of vise grips, turn the shaft of the main
power switch to the On position to provide power for
5.1 Factory Authorized Start
the humidifier drain solenoid. Up/Warranty Inspection
STULZ recommends purchasing Factory Authorized Start
5. Follow the steps of the cylinder replacement proce-
Up/Warranty Inspection for all new STULZ precision
dure in the humidifier installation and operation manual
cooling equipment. Factory Authorized Start Up/Warranty
sent under separate cover with your unit.
Inspection ensures that your equipment is installed and op-
6. Replace the cover on the electric box and turn the erating per STULZ recommended guidelines. This essential
main power disconnect switch to the On position. service guarantees that STULZ equipment has the best
warranty coverage available.
7. If your unit is equipped with an E² controller, turn the
A/C unit on by pressing the Enter key. STULZ Upgraded Parts Warranty and the Labor Warranty
applies once Factory Authorized Warranty Inspection/
8. Readjust the humidity to the desired setpoint. Start-Up is performed and Start Up Checklists are returned
and validated by STULZ Product Support.
If the humidifier is to be shut down for an extended period,
follow the steps of the Extended Shutdown procedure in STULZ limited parts-only warranty applies if Factory
the humidifier installation and operation manual. Authorized Start Up/Warranty is not purchased and Start
Up Checklists are received from an unauthorized party and
CAUTION validated by STULZ Product Support.

Failure to perform the recommended Extended The STULZ Product Support coordinates all Factory Au-
Shutdown procedure before a prolonged shut-down thorized Services and ensures only STULZ certified techni-
period will drastically shorten the cylinder life. cians are dispatched to perform your Factory Authorized
Start Up/Warranty Inspection. Please contact the STULZ
4.3.4.5 Air Filter Replacement Product Support with field service requests at (888) 529-
The air filters are located either internal or external to 1266 Monday through Friday from 8:00 a.m. to 5:00 p.m.
the cabinet, depending on the configuration of the unit. EST.
Regardless of location, the filter is accessed through an
access panel labeled “FILTER ACCESS”. Remove the ac- 5.2 Technical Support
cess panel and old filter. Ensuring directional airflow arrows
on filter are correct, insert the new filter and replace the The STULZ Technical Support Department is dedicated
access panel. to the prompt reply and resolution of issues experienced
with supplied equipment. Please contact (888) 529-1266
Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.
After hours support is also available. Please provide your
name and contact information and a support technician will
return your call.

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 CeilAiR IOM Manual

When calling to obtain support, it is important to have the 5.4 Obtaining Spare/Replacement Parts
following information readily available, (information is found
on the unit’s nameplate): Maintaining a recommended spare parts inventory is an in-
dustry best practice for critical facilities. On-site spares kits
• Unit Model Number reduce downtime and can eliminate the cost of expedited
• STULZ Sales Order Number freight charges. Recommended spares and replacement
• Unit Serial Number parts sales are available through Product Support at (888)
• Description of Problem 529-1266.

STULZ accepts Visa and MasterCard. STULZ may extend

5.3 Obtaining Warranty Parts credit to its customers; a credit application must be pre-
All Warranty Parts Authorizations are validated and pared and approved (this process could take one week).
processed through the Technical Support Department at
(888) 529-1266 Monday through Friday from 8:00 a.m. to A 25% minimum restocking charge will be applied on re-
5:00 p.m. EST. A support technician at STULZ will provide turned stocked parts that were sold as spare/replacement
troubleshooting assistance over the telephone. If it can be parts. If the returned part is not a stocked item, a 50%
determined that a part may be defective, a warranty autho- restocking charge may be applied. Additionally, a Return
rization for a replacement part will be processed by STULZ Material Authorization Number is required when returning
Technical Support. The replacement part will then be parts. To receive credit for returned repair/replacement
shipped via UPS ground. If the customer requests that war- parts, the parts must be returned to STULZ within 30 days
ranty part(s) be sent by any other method than UPS ground, of the purchase date. Spare part sales over 30 days old
the customer is responsible for the shipping charges. If will be considered final and the parts will remain the sole
you do not have established credit with STULZ you must property of the ordering party.
provide a freight carrier account number.

A written (or faxed) purchase order is required on warranty

parts and must be received prior to 12:00 p.m. for same
day shipment. The purchase order must contain the follow-
ing items:
• Purchase Order Number
• Date of Order
• STULZ Stated Part Price
• Customer Billing Address
• Shipping Address
• Customer’s Telephone and Fax Numbers
• Contact Name
• Unit Model No. and Serial No
The customer is responsible for the shipping cost incurred
for returning the defective part(s) back to STULZ. Return
of defective part(s) must be within 30 days at which time
an evaluation of the part(s) is conducted and if the part is
found to have a manufacturing defect a credit will be is-
sued.

When returning defective part(s), complete the Return Ma-

terial Authorization Tag and the address label provided with
the replacement part. For prompt processing, please affix
the RMA in a prominent place on the external packaging of
the returned part.

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 CeilAiR IOM Manual

Appendix A OHS Preventive Maintenance Inspection Checklist

Complete a copy of this document for each OHS unit.

Site Name Site Contact

Site Address Site Phone
City, State Service Date
Zip Technician Name
Unit Model Unit Serial

Current Room Conditions

Room Temperature: Room Humidity:

Unit Setpoints
Return Temperature: Return Humidity:
Remote/Supply Temperature: Remote/Supply Humidity:

Electrical Panel (Safety Note: The following should be performed by Stulz Trained Service Personnel only)
Inspect unit disconnect for proper operation:  Pass  Fail  N/A
Inspect internal wire for discoloration:  Pass  Fail  N/A
Inspect fuses:  Pass  Fail  N/A
Inspect for secure electrical connections;  Pass  Fail  N/A
Inspect low voltage connections:  Pass  Fail  N/A
Inspect relays and contactors for serviceability, i.e. pitted contacts, weak coils:  Pass  Fail  N/A

Record Supply Voltage

L1-GND: L2-GND: L3-GND:
L1-L2: L2-L3: L1-L3:

Record Control Voltage

T-1: T-2:

Unit Operation
Verify Control Device Operation:  Pass  Fail  N/A
Verify Customer Setpoints:  Pass  Fail  N/A
Inspect Filter Clog/Air Safety Switches and Tubing:  Pass  Fail  N/A
Chilled Water Valve Operation:  Pass  Fail  N/A
Condensate pump operation:  Pass  Fail  N/A

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 CeilAiR IOM Manual

Blower Section
Inspect motor pulleys and sheaves for excessive grooves:  Pass  Fail  N/A
Inspect bearings for excessive wear:  Pass  Fail  N/A
Inspect Blower Section for any loose parts or debris:  Pass  Fail  N/A
Filter condition:  Replace  Good  N/A
Belt condition:  Replace  Good  N/A

Record Fan Motor Amp Draw

(Fan 1) L1: L2: L3:
(Fan 2) L1: L2: L3:
(Fan 3) L1: L2: L3:

Check Compressor Operation  N/A

Check electrical connections:  Yes  No  N/A
Visual inspect for oil leaks:  Yes  No  N/A
Check for excessive vibration:  Yes  No  N/A
Check crankcase heater operation:  Yes  No  N/A
Compressor 1:  Empty ¼ ½ ¾  Full  N/A
Oil level during operation
Compressor 2:  Empty ¼ ½ ¾  Full  N/A
Circuit 1:  Green  Yellow  N/A
Sight glass
Circuit 2:  Green  Yellow  N/A

Record Compressor Amp Draw

(Compressor 1) L1: L2: L3:
(Compressor 2) L1: L2: L3:

Record Refrigerant Operating Pressures

Discharge Pressure: Suction Pressure:
Discharge Line Temp: Suction Line Temp:
Circuit Liquid Line Temp:
1 Subcooling: Superheat:
EWT: LWT:
Discharge Pressure: Suction Pressure:
Discharge Line Temp: Suction Line Temp:
Circuit Liquid Line Temp:
2 Subcooling: Superheat:
EWT: LWT:

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 CeilAiR IOM Manual

Check Humidifier Operation  N/A

Check electrical connections:  Yes  No  N/A
Canister arching replace:  Yes  No  N/A
Test humidifier drain cycle:  Yes  No  N/A
Inspect humidifier section for water leaks:  Yes  No  N/A
Canister capacity:  Good  Replace

Record Humidifier Amp Draw

L1: L2: L3:

Check Heater Operation  N/A

Check electrical connections:  Yes  No  N/A
Check heater elements for any damage:  Yes  No  N/A
Inspect heater overloads for damage:  Yes  No  N/A

Record Heater(s) Amp Draw

(Heater 1) L1: L2: L3:
(Heater 2) L1: L2: L3:
(Heater 3) L1: L2: L3:

Site Recommendations
1.
2.
3.
4.
5.

Final Verification
Technician Signature: Date:
QA Verification: Date:

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 CeilAiR IOM Manual

Appendix B - Acronyms and Abbreviations

BTU/H- British Thermal Units Per Hour MAX FUSE - Maximum Fuse

CFM - Cubic Feet Per Minute MCA - Minimum Circuit Ampacity

CNDCT - Conductor NEC - National Electric Code

ESD - Electrostatic Discharge NFPA - National Fire Protection Agency

ºF - Degrees Fahrenheit PH - Phase

FLA - Full Load Amps PSI - Pounds Per Square Inch

FOB - Free on Board psig - Pounds Per Square Inch Gauge

HACR - Heating, Air Conditioning, Refrigeration R-Value - Thermal Resistance

HP - Horse Power RLA - Rated Load Amps

Hz - Hertz SDS - Safety Data Sheet

IAQ - Indoor Air Quality SPDT - Single Pole, Double Throw

in - Inches STULZ - STULZ Air Technology Systems, Inc.

in. w.g. - Inches of Water Gauge TEV - Thermal Expansion Valve

kVA - Kilo Volt Amp V- Volt

kW - Kilowatts VAC - Volt, Alternating Current

LRA - Locked Rotor Amps VDC - Volt, Direct Current

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 North American Headquarters

STULZ Air Technology Systems, Inc.

1572 Tilco Drive IFrederick, M[) 21704
301.620.20331 Fax: 301.662.54871 info@stulz-ats.com
Technical Support: 888.529.1266

www.stulz-usa.com

OCH0006D Nov. 2018 © STULZ Air Technology Systems, Inc. • Specifications subject to change without notice.