CeilAiR OHS Series Installation, Operation & Maintenance Manual (©July, 2008) Air Technology Systems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual MODEL NOMENCLATURE OHS-040-G-FC AWS = Alternate Water Source OHS = Overhead System FC = Free Cooling LP = Low Profile Configuration SF = Same-Face Air Pattern SP = Special Configuration AHU = Air Handling Unit Nominal Capacity in 1,000’s of BTU/Hr AR = Air-Cooled Remote (Split) AS = Air-Cooled Self-Contained C = Chilled Water System CAA = Indoor Centrifugal Condenser D( ) = Dual (Two) Circuit System G = Glycol-Cooled H( ) = Hori
CeilAiR OHS Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS 1.0 1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 1.6. Introduction ............................................ 1-1 General .................................................... 1-1 Product Description .................................. 1-1 Controls ................................................... 1-2 Product Warranty ..................................... 1-3 Safety ...................................................... 1-4 General ...
CeilAiR OHS Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS 4.3.4.1 4.3.4.2 4.3.4.3 4.3.4.4 4.3.4.5 Compressor Failure .................................. 4-6 Standard Cleanout Procedure ................... 4-7 Burn-Out/Acidic Cleanup Procedure ......... 4-7 Humidifier Cylinder Replacement .............. 4-7 Filter Replacement ................................... 4-8 5.0 5.1 5.2 5.3 Product Support Group ......................... 5-1 Technical Support ................................
CeilAiR OHS Series Installation, Operation & Maintenance Manual 1.0 Introduction 1.1 General Thank you for your selection of the CeilAiR ceilingmounted air conditioning system made by Stulz Air Technology Systems, Inc. CeilAiR overhead air conditioning systems (OHS) are designed and constructed using the finest available materials/components, state-of-the-art technology and quality craftsmanship to provide years of trouble-free service.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 1.4 Product Warranty SATS offers a two year standard limited warranty as stated on the following pages. Additionally an extended warranty may be purchased on the unit's compressor. Consult the factory to verify if the extended compressor warranty was purchased for your system. The compressor warranty as stated on the next page will be sent with your unit and should be retained for future reference.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Optional Limited Extended Warranty (5 Years Total) Stulz Air Technology Systems, Inc., warrants to the original buyer of its product that the compressor(s) listed below are warranted for parts replacement (not including labor) for extended period of 4 years from the date of expiration of the standard equipment warranty.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 1.5 Safety WARNING 1.5.1 General Stulz Air Technology Systems, Inc. uses notes along with caution and warning symbols throughout this manual to draw your attention to important operational and safety information. To prevent personal injury, stay clear of rotating components as automatic controls may start them unexpectedly. Turn off power to the unit unless you are performing tests that require power.
CeilAiR OHS Series Installation, Operation & Maintenance Manual WARNING WARNING This unit employs high voltage equipment with rotating components. Exercise extreme care to avoid accidents and ensure proper operation. WARNING Hazardous voltage will still be present inside the electric box, even with the unit turned off at the system controller. To isolate the unit for maintenance, turn off power at the main power disconnect switch. Always disconnect main power prior to performing any service or repairs.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 1.6 General Design The CeilAiR unit is housed in an aluminum frame type cabinet and is rated for indoor use. Access panels are located on the front and rear of the cabinet for easy access to all components. Additional access may be obtained to some components through the bottom of the unit on spot cooler configurations. The unit has an electrical box inside the cabinet with a removable panel for accessing the electrical components.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 1.6.5 Optional Equipment 1.6.5.1 Humidistat/Dehumidistat As an option for systems utilizing an A-Tech 1.1 or ATech 1.2 thermostat, a room mounted humidistat and/ or dehumidistat may be shipped loose for field installation. Each device has an adjustment dial on the front where the operator selects the desired setpoint. If an optional humidifier is selected, the humidistat is included to control it’s operation.
CeilAiR OHS Series Installation, Operation & Maintenance Manual NOTE 2.0 Installation 2.1 Receiving the Equipment Your CeilAiR OHS system has been tested and inspected prior to shipment. To ensure that your equipment has been received in excellent condition, make a visual inspection of the equipment immediately upon delivery. Carefully remove the shipping container and all protective packaging. Remove the access panels and thoroughly inspect the unit interior for any signs of transit-incurred damage.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.4.2 Outdoor Equipment CAUTION When moving the unit, it must be kept level and in the horizontal position to prevent damage. 2.4 Mounting CeilAiR OHS systems are designed for ceiling mounting in a suspended ceiling grid (spot cooler) or above the suspended ceiling for ducted systems. NOTE Do not install the A/C system directly above electronic equipment which may hinder serviceability. 2.4.
CeilAiR OHS Series Installation, Operation & Maintenance Manual NOTE SATS supplied thermostats/controls do not contain mercury. Mount the thermostat upright on an inside wall within the conditioned room that best represents the average room temperature. In most cases, the thermostat should be located near the common return air grille. Mount the thermostat at least 18 inches from an outside wall and approximately 5 ft. above the floor. Follow the steps below to mount.
CeilAiR OHS Series Installation, Operation & Maintenance Manual horizontally for ease of making wire connections. Each transformer has keyhole mounting slots for mounting with bolts to desired surface (wall, floor or other structure capable of supporting its weight). 2. Remove the cover by pulling it out and up at the bottom. 2.4.4.2 4. Use the base as a template to mark the mounting holes location on the wall.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.5 Air Distribution Connection CAUTION 2.5.1 Spot Cooler (See Figure 2) The probes must not touch the mounting surface. Failure to adhere to this may result in improper operation of equipment. For units that are not ducted, the air conditioner should be mounted above the ceiling grid, leaving sufficient space for the air grilles to rest on the ceiling T-bar. 2.4.5.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.5.2 Ducted Systems (See Figure 3) There are three basic configurations of airflow patterns: 90º/Right Angle, Straight-Thru and In/Out Same-Face. When determining ducting requirements, always consult your local and state codes. The duct system should be designed to allow the air to move with as little resistance as possible. Several factors determine ducting material and size.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Clear all pipe connections of debris and prep connections for soldering. Use only “L” or “K” grade refrigerant 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 should be flowing through the tubing while soldering at a rate of not less than 1-2 CFM (0.0280.57 M 3/minute).
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.6.2 Chilled Water, Water/Glycol and Hot Water Reheat Piping RECOMMENDED SUCTION LINE SIZES *Equivalent Length Ft. Model No.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.6.3 Condensate Drain Line 2.6.4 Humidifier (Optional) 2.6.3.1 Gravity Drain CeilAiR systems utilize an electrode steam humidifier. The humidifier empties into the condensate drain line during the flush/drain cycle. A water supply line must be connected to the copper tubing connection supplied by the factory. Refer to the installation drawing provided with your unit for the size and location of the connection.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.7 Utility Connections 2.7.1 Main Power The CeilAiR product offering is available in single or three phase variations and a wide range of voltages. It is imperative that the unit nameplate be examined to determine the operating voltage, frequency and phase of the system (see Figure 5).
CeilAiR OHS Series Installation, Operation & Maintenance Manual to the surface of the unit. If the factory installed, nonfused service switch option was purchased, the main power and ground connection shall be located at the non-fused service switch, otherwise, the main power connection shall be located as stated below. 2.7.1.2 Single-Phase Units 277V Each unit is provided with pilot hole(s) in the main power and control panel for connection of the fieldwiring.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Upon examination of the buck/boost transformer, it may be observed that the labeled primary voltage is 120, 240 and/or 480 while the secondary voltage is 12, 16, 24, 32 and/or 48 but not limited to these specific voltages. This transformer is designed as an insulating transformer but if wired in a configuration recommended by the manufacturer it will change its electrical characteristics to those of an autotransformer (buck/boost transformer).
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.7.2.1 A-Tech-1.1 Programmable Thermostat (Single Stage Unit; See Figure 7) Set the dip switches located on the circuit board according to the application needs. Refer to the chart below for factory settings. The thermostat requires four conductors wired to the control terminal board located within the unit electrical box. The thermostat has a terminal strip with box type lugs for wire connections.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.7.2.2 A-Tech-1.2 Programmable Thermostat (Dual Stage Unit; See Figure 8) Set the dip switches located on the circuit board according to the application needs. Refer to the following chart provided for factory settings. The thermostat requires seven conductors wired to the control terminal board located within the unit electrical box. The thermostat provides a terminal strip with box type lugs for wire connections.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Figure 8- A-Tech-1.2 Control Wiring 2.7.3 Optional Equipment NOTE All customer provided wiring must be in accordance with local and national electrical code requirements for Class 2 circuits. connected to the unit ground stud located within the unit electric box. Two control conductors must be wired to the control terminal board located within the unit electric box.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.7.3.3 Remote Water Detector Spot Type: A remote spot type water detector requires three conductors to be wired to the control terminal board within the unit electrical box. The wire insulation must be rated at 600V. The water detector provides pig-tail leads for splice type wire connections with twist on connectors (wire caps). Refer to the supplied electrical diagram for proper wire terminations.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 4 CONDUCTOR NON-SHIELDED CABLE 2 CONDUCTOR SHIELDED CABLE 6 CONDUCTOR PHONE TYPE NON-SHIELDED CABLE 5 CONDUCTOR SHIELDED CABLE mode clock resume 2 CONDUCTOR SHIELDED CABLE A-TECH-20 C-TECH-10 C6000 REMOTE TEMPERATURE/ HUMIDITY SENSOR (OPTIONAL) SEE NOTE 3 REMOTE TEMPERATURE SENSOR (OPTIONAL) SEE NOTE 3 Figure 9- Interconnection Field Wiring Remote Condenser 4 CONDUCTOR NON-SHIELDED CABLE 2 CONDUCTOR SHIELDED CABLE 6 CONDUCTOR
CeilAiR OHS Series Installation, Operation & Maintenance Manual 4 CONDUCTOR NON-SHIELDED CABLE 2 CONDUCTOR SHIELDED CABLE 6 CONDUCTOR PHONE TYPE NON-SHIELDED CABLE 5 CONDUCTOR SHIELDED CABLE mode clock set hold fan resume 2 CONDUCTOR SHIELDED CABLE C-TECH-10 A-TECH-20 C6000 REMOTE TEMPERATURE/ HUMIDITY SENSOR (OPTIONAL) SEE NOTE 3 SEE NOTE 3 REMOTE CONDENSING UNIT 3.
CeilAiR OHS Series Installation, Operation & Maintenance Manual no portion of system has been isolated from the evacuation process (liquid, suction or discharge lines). 2.7.6 Remote Shut Down NOTE All wiring must be provided in accordance with local and national electrical code requirements for Class 2 circuits. Each unit is provided with a means to remotely shut down the air conditioning unit. A normally closed switch rated at 5 amperes at 24VAC is required for this purpose.
CeilAiR OHS Series Installation, Operation & Maintenance Manual ture-measuring device being well insulated. The sub-cooling temperature should be approximately 10-20ºF. NOTE Under cold climate conditions it is recommended to do the following: 6. Block off the intake air to the condenser with cardboard (or reduce the water glycol flow) until a constant discharge pressure (225-280 psig) can be obtained.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 7. Slowly meter R407C liquid refrigerant through the suction side while watching for the sight glass to clear of bubbles. CAUTION POE oil is used in systems with R407C refrigerant. POE oil quickly absorbs moisture when exposed to air. High POE oil moisture levels react with refrigerant to form acid, which results in system contamination. Keep entire system sealed as much as possible and minimize exposure of POE oil to outside air.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.9.2 Head Pressure ControlsAir Cooled Systems denser/condensing unit. The fan speed controller requires no adjustment. 2.9.2.1 Condenser Fan Cycling (Condenser Model SCS-AA, 0°F) The fan speed controller will automatically control the head pressure. On systems with more than one fan on the condenser, the remaining motors cycle on and off based on pressure.
CeilAiR OHS Series Installation, Operation & Maintenance Manual This method of controlling head pressure allows the condenser fan to run continuously. While the fan is running, the flooded head pressure control valve modulates the amount of discharge gas entering the receiver. As the pressure increases, the valve diverts more discharge gas to the condenser, allowing more liquid to flow from the condenser to the receiver.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 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. 12. Check the motor overload on the blower starter to confirm its setting is correct for the FLA of the motor. 2.9.
CeilAiR OHS Series Installation, Operation & Maintenance Manual The normal control setting is 50-55 psig (suction pressure) 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 adjustment cap from end of valve. Using a 5/16 inch Allen wrench, turn clockwise to increase pressure or counterclockwise to lower pressure. 2.9.8.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2.10.2 Saturated Refrigerant Pressure Tables 2.10 Refrigerant Characteristics 2.10.1 Pressure / Temperature Settings The following chart is provided to assist with the normal settings of the system. Where applicable, minimum and maximum settings are given along with normal operating pressures. Pressure/Temperature Settings For R22 & R407C Normal Min. Max.
CeilAiR OHS Series Installation, Operation & Maintenance Manual in a manual mode, refer to the separate Controller Operations Manual sent with your unit. 3.0 Start-Up / Commissioning 3.1 Operation For new installations, ensure the unit is ready to operate by going through the completed installation checklist provided with the unit, prior to start-up. NOTE Warranty Registration and Start-Up Checklist should be completed during start-up and sent to SATS.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 3.3 Thermostat Programming 3.3.1 A-Tech-1.1 (See Figure 14) The A-Tech-1.1 is a programmable thermostat that represents one of the most advanced, solid-state, microcomputer temperature controllers available. The A-Tech-1.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 3.3.1.2 Setback Feature - Setting the Weekday Program Schedule and Heating Temperatures STEP 8 - Repeat programming steps 2 through 7 for each desired event. NOTE STEP 1 - Press and release the MODE button until the word HEAT and the heating symbol display. appears on the STEP 2 - Press and release the PROGRAM button.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 3.3.1.4 Setback Feature - Setting the Weekday and Weekend Cooling Temperatures 3.3.1.5 Since the programmed time schedules are the same for both heating and cooling, you only need to set the cooling temperatures providing you have already programmed the weekday and weekend heating schedules. The cooling temperature must be set at least two degrees higher than the heating temperature.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 3.3.2 A-Tech-1.2 (See Figure 15) The A-Tech-1.2 is a programmable thermostat that represents one of the most advanced, solid-state, microcomputer temperature controllers available. The A-Tech-1.
CeilAiR OHS Series Installation, Operation & Maintenance Manual STEP 2 - Press and release the CLOCK button again. Display will flash the hour (12: _ _) and (AM) or (PM). Press the decrease or increase button until the current hour appears on the display with proper (AM) or (PM) designation. STEP 3 - Press and release the CLOCK button. Display will flash minutes (:00). Press the decrease or increase button until current minutes appear on the display. STEP 4 - Press CLOCK button again.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Program Schedule Thermostat Symbol Event Desired Temperature Setting Time Schedule Mo Tu We Th Fr Sa Su heat = Morning Cool = heat = Day Cool = heat = Evening Cool = heat = Night Cool = 3.3.2.7 Temperature Override 3.3.2.7.1 Temporarily Override the Set Temperature 3.3.2.9 Press and hold the decrease or increase button to change the room set point temperature in 1-degree increments.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 4.0 Maintenance WARNING 4.1 Periodic General Maintenance Systematic, periodic general maintenance of the CeilAiR unit is recommended for optimum system performance.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 4.1.1.5 Condensate Pump 4.1.2 Condensing Unit The optional condensate pump should be inspected semiannually and cleaned. Ensure that the float works freely. Wipe the float with a wet cloth and detergent to remove dirt. Clean the tank bottom. Check that the discharge line is open and water can pass through it freely. Maintenance access to the condensing unit is through one or two removable panels (depending on model).
CeilAiR OHS Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE Evaporator Coil Ices (Cont.) RECOMMENDATION 2. Check for and clear any obstructions across or in the (supply) discharge airstream. 3. Check correct rotation of evaporator blower. Blower Fails to Start b. Temperature setting too low (68°F min.). Increase temperature setpoint. c. Discharge air short cycling back to return. Check discharge grille orientation. d. Low refrigerant charge.
CeilAiR OHS Series Installation, Operation & Maintenance Manual SYMPTOM PROBABLE CAUSE Condenser Pressure Too High (Cont.) RECOMMENDATION 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. Condenser Pressure too Low Noisy Compressor Compressor Fails to Start System Short of Capacity i. Water/glycol solution not mixed prior to adding to system. Remove solution and premix. Refill system. a.
CeilAiR OHS Series Installation, Operation & Maintenance Manual SYMPTOM Compressor Short Cycles PROBABLE CAUSE RECOMMENDATION a. Low line voltage causing compressor to overheat. Check power source for cause oflow line 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 system. e. Short cycling of conditioned air. 1.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 4.3.4 4.3 Field Service NOTE Do not attempt to make repairs without the proper tools. It may be necessary to perform repairs on the refrigeration system. If field repairs are necessary, the following procedures apply: 1. Ensure all electrical connections are tight. 2. Check all fuses, contacts and wiring. Contactors should be replaced if contacts are worn or pitted. 4.3.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 2. Turn off power to the unit at the main power disconnect switch. CAUTION Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty. This will VOID THE COMPRESSOR WARRANTY. Always consult the factory prior to replacing the compressor. CAUTION POE oil is used in systems with R-407C refrigerant.
CeilAiR OHS Series Installation, Operation & Maintenance Manual NOTE Decrease the humidity setpoint below ambient humidity to allow the cylinder to cool down before removing the cylinder. 1. Turn off water supply to the humidifier. 2. Drain the cylinder by pushing the “Auto/On-Off/ Drain” switch to the “Drain” position. 3. When drained, push the “Auto/On-Off/Drain” switch to the “Off” position. 4. Disconnect power at the main power disconnect switch. 5.
CeilAiR OHS Series Installation, Operation & Maintenance Manual 5.0 Product Support Group SATS provides to its customers a Product Support Group (PSG) which not only provides technical support and parts but the following additional services, as requested: performance evaluations, start-up assistance and training. 5.1 Technical Support The SATS Product Support Group (PSG) is dedicated to the prompt reply and solution to any problem encountered with a unit.
CeilAiR OHS Series Installation, Operation & Maintenance Manual NOTES (©July, 2008) Air Technology Systems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Frederick, Maryland USA 21704 Air Technology Systems, Inc. OHS Series Precision Air Conditioner Telephone: (301) 620-2033 Facsimile: (301) 620-1396 Appendix A - Forms Checklist for Completed Installation 1 Proper clearances for service access have been maintained around equipment. 13 Duct work completed or optional plenum installed (if required). 2 Equipment is level and mounting fasteners (if applicable) are tight.
CeilAiR OHS Series Installation, Operation & Maintenance Manual (©July, 2008) Air Technology Systems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Frederick, Maryland USA 21704 Air Technology Systems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual (©July, 2008) Air Technology Systems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual Appendix B – Glossary Definition of Terms and Acronyms SATS - Stulz Air Technology Sytstems, Inc.
CeilAiR OHS Series Installation, Operation & Maintenance Manual (©July, 2008) OCH0006 REVAir Technology Systems, Inc.
