CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

 
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

(© April, 2008)

                                   Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                           MODEL NOMENCLATURE

                               VFS-360-DG-FC-U-EC

                                                                                       EC = *EC Fan

                                                                                  D    = Downflow
                                                                                  U    = Upflow

VFS = Vertical Floor System                                                       AWS = Alternate Water Source
                                                                                  FC    = Free Cooling

                                                                             AR   =    Air Cooled Remote (Split)

Nominal Capacity in                                                          C    =    Chilled Water System

1,000’s of BTU/Hr                                                            G    =    Glycol Cooled
                                                                             S    =    Single Pump
                                                                             W    =    Water Cooled

D ( )=Dual (Two) Circuit System

                    *EC (Electronically Commutated) Fan
                    Highly reliable EC (Electronically Commutated)
                    Fans offer considerable energy cost savings and
                    long life. Using an electronically commutated
                    permanent magnet DC motor, AC inverter whine is
                    eliminated. Fan speed is continuously adjustable
                    via a signal from the system controller without the
                    use of VFD’s. EC fans offer energy efficient, quiet,
                    low vibration operation.

                                                                                                       (© April, 2008)

                                              Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                                          TABLE OF CONTENTS
1.0       Introduction ....................................... 1-1                     2.9         System Charging Procedures .................. 2-13
1.1       General ...................................................... 1-1           2.9.1       R22 Refrigerant Charging Procedures ...... 2-13
1.2       Product Description ................................... 1-1                  2.9.2       R407C Refrigerant Charging Procedures .. 2-14
1.3       Product Warranty ...................................... 1-2                  2.9.3       Water/Glycol Systems ............................ 2-15
1.4       Safety ........................................................ 1-4          2.10        System Settings and Adjustments ........... 2-16
1.4.1     General ...................................................... 1-4           2.10.1      Low/High Pressure Limit Switch .............. 2-16
1.4.2     Safety Summary ........................................ 1-4                  2.10.2      Head Pressure Controls-
1.5       General Design .......................................... 1-6                            Air Cooled Systems ................................. 2-17
1.6       Optional Equipment ................................... 1-8                   2.10.3      Head Pressure Control-
                                                                                                   Water/Glycol-Cooled Systems ................. 2-17
2.0       Installation ......................................... 2-1                   2.10.4      Humidifier Adjustment .............................. 2-17
2.1       Receiving the Equipment. .......................... 2-1                      2.10.5      EC Fan(s) ................................................ 2-17
2.2       Site Preparation ......................................... 2-1               2.10.6      Thermal Expansion Valve ......................... 2-17
2.3       Rigging ...................................................... 2-2           2.10.7      Snap Acting Hot Gas Bypass (Optional) .. 2-18
2.4       Mounting/Placement .................................. 2-2                    2.10.8      Hot Gas Reheat (Optional) ....................... 2-18
2.4.1     Precision A/C Unit ..................................... 2-3                 2.11        Refrigerant Characteristics ....................... 2-18
2.4.2     Outdoor Equipment .................................... 2-3                   2.11.1      Pressure/Temperature Settings ................ 2-18
2.5       Air Distribution Connection ........................ 2-3                     2.11.2      Saturated Refrigerant Pressure Tables ..... 2-18
2.5.1     Downflow Configuration Air Patterns ........... 2-3
                                                                                       3.0         Start-Up/Commissioning .................. 3-1
2.5.2     Upflow Configuration Air Patterns ............... 2-4
                                                                                       3.1         Operation ................................................... 3-1
2.6       Optional Equipment (Field Installed) .......... 2-5
                                                                                       3.2         Step-by-Step Start-Up Instructions ............. 3-1
2.6.1     Floor Stand ................................................ 2-5
                                                                                       3.3         Microprocessor Controller
2.6.2     Remote Display ......................................... 2-6
                                                                                                   Programming ............................................. 3-1
2.6.3     Remote Temperature/Humidity Sensor ....... 2-6
2.6.4     Remote Water Detector ............................. 2-6                      4.0         Maintenance...................................... 4-1
                                                                                       4.1         Periodic General Maintenance ................... 4-1
2.7       Piping Connections .................................... 2-7
                                                                                       4.1.1       Precision A/C Unit ..................................... 4-1
2.7.1     Refrigerant ................................................. 2-7
                                                                                       4.2         Troubleshooting ......................................... 4-2
2.7.2     Water/Glycol ............................................. 2-8
                                                                                       4.3         Field Service .............................................. 4-7
2.7.3     Condensate Drain ...................................... 2-8
                                                                                       4.3.1       Leak Detection .......................................... 4-7
2.7.3.1   Gravity Drain .............................................. 2-8
                                                                                       4.3.2       Leak Repair ............................................... 4-7
2.7.3.2   Condensate Pump ..................................... 2-9
                                                                                       4.3.3       Refrigerant Piping ...................................... 4-7
2.7.4     Humidifier .................................................. 2-9
                                                                                       4.3.4       General Common Repairs/
2.8       Utility Connections .................................... 2-9
                                                                                                   Component Replacement ........................... 4-7
2.8.1     Main Power ............................................... 2-9
                                                                                       4.3.4.1     Compressor Failure ................................... 4-7
2.8.2     Controls ................................................... 2-10
                                                                                       4.3.4.2     Humidifier Cylinder Replacement ............... 4-9
2.8.3     Optional Equipment ................................. 2-10
                                                                                       4.3.4.3     Filter Replacement .................................... 4-9
2.8.3.1   Remote Temperature/Humidity Sensor ..... 2-10
2.8.3.2   Remote Water Detector ........................... 2-10                       5.0         Product Support Group ........................... 5-1
                                                                                       5.1         Technical Support ...................................... 5-1
2.8.4     Interconnecting Field Wiring ...................... 2-11
                                                                                       5.2         Obtaining Warranty Parts .......................... 5-1
2.8.4.1   Air Cooled Split Systems
          with Remote Condenser ............................ 2-11                      5.3         Obtaining Spare/Replacement Parts .......... 5-1
2.8.4.2   Glycol Systems ....................................... 2-12

(© April, 2008)                                                                                                                                                    i

                                                                    Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                           TABLE OF CONTENTS                                                        (Continued)

                       List of Figures                                                               Appendix A - Forms
                                                                                  Checklist for Completed Installation ......................... A-1
Figure 1     Typical Internal Layout - Downflow .......... 1-6                    Periodic General Maintenance
Figure 2     Typical Internal Layout - Upflow ............... 1-7                 Checks and Service Checklist .................................. A-2

Figure 3     Installation Clearance ............................. 2-1
Figure 4     Typical Installation .................................. 2-2                           Appendix B - Glossary
Figure 5     Downflow Configuration                                               Definition of Terms and Acronyms ............................ B-1
             Typical Air Patterns ................................ 2-3
Figure 6     Upflow Configuration
             Typical Air Patterns ................................ 2-4
Figure 7     Optional Floor Stand Installation ............. 2-5
Figure 8     Condensate Pump .................................. 2-9
Figure 9     Sample Nameplate ................................. 2-9
Figure 10 Interconnecting Field Wiring
          Remote Condenser ................................2-11
Figure 11 Interconnecting Field Wiring
          Glycol Systems .................................... 2-12

                                                                      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 docu-
ment 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. (SATS).

This 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 SATS.

Unpublished — rights reserved under the copyright laws of the United States and of other countries.
Other brands and tradenames are trademarks of their respective owners.

Copyright 2007 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

ii                                                                                                                                 (© April, 2008)

                                                                Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

1.0     INTRODUCTION                                                      The functional modes of operation, in addition to
                                                                          cooling, are heating, humidification, dehumidification
 1.1       General                                                        and filtration which provide complete environmental
                                                                          control of a conditioned space.
 Congratulations, the CyberTWO™ floor mounted
 precision air conditioning system covered by this                        There are two air flow pattern configurations, upflow
 manual is designed and manufactured by Stulz Air                         and downflow, and several cabinet sizes based on the
 Technology Systems, Inc. (SATS) using the latest,                        type of system and capacity. Regardless of configura-
 state-of-the-art control technology. Recognized as a                     tion, CyberTWO systems are compact and versatile.
 world leader, SATS provides air conditioning systems                     See the Installation drawing provided with your unit for
 with the highest quality craftsmanship using the finest                  the layout and dimensions of the cabinet.
 materials available in the industry. The unit will provide
 years of trouble free service if installed and maintained                The CyberTWO unit is provided with a main power
 in accordance with this manual. Damage to the unit                       disconnect switch located inside the electric box. The
 from improper installation, operation or maintenance is                  disconnect switch electrically isolates the unit during
 not covered by the warranty.                                             routine maintenance. The system incorporates state-
                                                                          of-the-art component protection with the use of motor
 STUDY the instructions contained in this manual.                         start protectors and circuit breakers.
 They must be followed to avoid difficulties. Spare parts
 are available from SATS to insure continuous opera-                       An operating manual for the system controller is
 tion. Using substitute parts or bypassing electrical or                  provided under separate cover. Refer to that manual for
 refrigeration components in order to continue operation                  detailed instructions on operating the system control-
 is not recommended and will VOID THE WARRANTY.                           ler provided with your unit.
 Due to technological advancements, components are
                                                                          The standard controller for the CyberTWO unit is the
 subject to change without notice.
                                                                          C6000 microprocessor, which provides the following
 All CyberTWO systems and centrifugal condensers                          features: input/output monitoring status, full integrated
 are designed to be installed indoors, unless otherwise                   control of heating, cooling, humidification and dehu-
 noted on the equipment. Propeller-type condensers,                       midification; multi-unit control and remote communica-
 drycoolers and pump packages are designed for                            tion with building management systems. The controller
 outdoor use.                                                             is typically factory mounted on the front hinged access
                                                                          door of the unit. As an option, the controller may be
 1.2       Product Description                                            remotely mounted to a wall or control panel.

 CyberTWO systems are designed to be the most
 versatile and flexible floor mounted air conditioning
 systems in the industry. The unit is available in air
 cooled, water cooled and glycol cooled configurations.
 The cooling capacity, in BTU/Hr, will depend on the
 unit size, which can range from 72,000 to 360,000
 BTU/Hr. CyberTWO systems are designed to operate
 with either R22 or R407C refrigerant. Refer to the unit
 nameplate to identify which refrigerant is used with
 your unit.

                         NOTE

      The CyberTWO systems are designed to sup-                                              C6000 Controller
      ply air to only one room.

(© April, 2008)                                                                                                                1-1

                                                    Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  1.3                                 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 extended compressor warranty as stated on the next page will be
  sent with your unit and should be retained for future reference.

              
      

                                                                                                                                                
                                                                2-Year Standard Limited Warranty:
                                       Stulz Air Technology Systems, Inc., warrants to the original buyer of its products that the goods
                                       are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s
                                       obligation under this warranty is to repair or replace, at its option, free of charge to the customer,
                                       any part or parts which are determined by Stulz Air Technology Systems Inc. to be defective
                                       for a period of 24 months from date of shipment when a completed start-up form has been
                                       submitted to Stulz Air Technology Systems, Inc. within 90 days from shipment. In the event
                                       that a completed start-up form is not received by Stulz Air Technology Systems, Inc. within 90
                                       days from shipment, the company’s obligation will be for a period of 12 months from date of
                                       shipment. Parts repaired or replaced under this warranty are shipped FOB Factory, and
                                       warranted for the balance of the original warranty period or for 90 days from the date of
                                       installation, whichever is greater.

                                       Stulz Air Technology Systems, Inc.’s warranty does not cover failures caused by improper
                                       installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence,
                                       accident, normal deterioration (including wear and tear), or the use of improper parts or improper
                                       repair.

                                       Purchaser’s remedies are limited to replacement or repair of non-conforming materials in
                                       accordance with the written warranty. This warranty does not include costs for transportation,
                                       costs for removal or reinstallation of equipment or labor for repairs or replacement made in the
                                       field.

                                       If any sample was shown to the buyer, such sample was used merely to illustrate the general
                                       type and quality of the product, and not to represent that the equipment would necessarily
                                       conform to the sample.

                                       This is the only warranty given by the seller, and such warranty is only given to buyers for
                                       commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is paid
                                       in full.

                                       THE FOREGOING SHALL CONSTITUTE SATS’S ENTIRE LIABILITY AND YOUR EXCLUSIVE
                                       REMEDY. IN NO EVENT SHALL SATS BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL,
                                       INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS
                                       (EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE
                                       INSTALLATION, USE OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN
                                       LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
                                       MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

              

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                                                                                  Air Technology Systems, Inc.
CyberTWO Series VFS-EC 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.
                                         Stulz Air Technology Systems’ warranty does not cover failures caused by improper
                                         installation, abuse, misuse, misapplication, improper or lack of maintenance, negli-
                                         gence, accident, normal deterioration including normal wear and tear, or the use of
                                         improper parts or improper repair as determined by SATS.

                                         This warranty does not include costs of transportation, cost for removal or reinstallation
                                         of equipment or labor for repairs or replacement made in the field.

                                         The obligation and liability of Stulz Air Technology Systems under this warranty does
                                         not include losses, direct or indirect, for incidental or consequential damages.

                                                         Compressor Serial No.: __________________________________

                                                                  Unit Model No.: __________________________________

                                                                  Unit Serial No.: __________________________________

                                         Stulz Air Technology Systems Job No.: __________________________________

                                                                        End User: __________________________________

                                                                             Date: __________________________________

           

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                                                                              Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  1.4      Safety
                                                                                            WARNING
  1.4.1    General
                                                                              To prevent personal injury, stay clear of rotating
  Stulz Air Technology Systems, Inc. uses NOTES                               components as automatic controls may start
  along with CAUTION and WARNING symbols through-                             them unexpectedly. Turn off power to the unit
  out this manual to draw your attention to important                         unless you are performing tests that require
  operational and safety information.                                         power. With power and controls energized, the
                                                                              unit could begin operating at any time.
  A bold text NOTE marks a short message in the
  information to alert you to an important detail.                      Never operate the unit with any cover, guard, screen
                                                                        panel, etc. removed unless the instructions specifically
  A bold text CAUTION safety alert appears with                         state otherwise, then do so with extreme caution to
  information that is important for protecting your                     avoid personal injury.
  equipment and performance. Be especially careful to
  read and follow all cautions that apply to your applica-              Never lift any component in excess of 35 pounds
  tion.                                                                 without help. If a lifting device is used to move a unit
                                                                        ensure it is capable of supporting the unit.
  A bold text WARNING safety alert appears with
  information that is important for protecting you from                 When working on electrical equipment, remove all
  harm and the equipment from damage. Pay very                          jewelry, watches, rings, etc.
  close attention to all warnings that apply to your
  application.                                                          Always disconnect the main power supply to the
                                                                        equipment at the main power disconnect switch before
  A safety alert symbol  precedes a general WARN-                       beginning work on the equipment. A lock-out tag-out
                                                                        procedure should be followed to ensure that power is
  ING or CAUTION safety statement.
                                                                        not inadvertently reconnected.
  A safety alert symbol precedes an electrical                          Never work on electrical equipment unless another
  shock hazard WARNING or CAUTION safety state-                         person who is familiar with the operation and hazards
  ment.                                                                 of the equipment and competent in administering first
                                                                        aid is nearby.
  1.4.2    Safety Summary
                                                                        All personnel working on or near equipment should be
  The following statements are general guidelines                       familiar with hazards associated with electrical
  followed by warnings and cautions applicable                          maintenance. Safety placards/stickers have been
  throughout the manual.                                                placed on the unit to call attention to all personal and
  Prior to performing any installation, operation, mainte-              equipment damage hazard areas.
  nance or troubleshooting procedure read and under-                    Certain maintenance or cleaning procedures may call
  stand all instructions, recommendations and guide-                    for the use and handling of chemicals, solvents, or
  lines contained within this manual.                                   cleansers. Always refer to the manufacturer's Material
                                                                        Safety Data Sheet (MSDS) prior to using these
                   WARNING                                              materials. Clean parts in a well-ventilated area. Avoid
                                                                        inhalation of solvent fumes and prolonged exposure
      This equipment should be serviced and repaired
                                                                        of skin to cleaning solvents. Wash exposed skin
      by journeyman, refrigeration mechanic or an air
                                                                        thoroughly after contact with solvents.
      conditioning technician.

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                                                   Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                    WARNING                                                                           WARNING
     This unit employs high voltage equipment with                                      When performing soldering or desoldering op-
     rotating components. Exercise extreme care to                                      erations, make certain the refrigeration system
     avoid accidents and ensure proper operation.                                       is fully recovered and purged and dry nitrogen
                                                                                        is flowing through the system at the rate of not
                    WARNING                                                             less than 1-2 CFM (.03 - .06 M³/minute).

     Hazardous voltage will still be present inside the                                               CAUTION
     electric box at the motor start protectors and
     circuit breakers, even with the unit turned off at                                 When the air conditioner is in the cooling mode,
     the microprocessor controller. To isolate the unit                                 the return air-intake and discharge (supply)
     for maintenance, turn off power at the main power                                  must be free of obstructions. Ensure panels are
     disconnect switch. Always disconnect main                                          secure and latched into position.
     power prior to performing any service or repairs.
                                                                                                      CAUTION
                    WARNING
                                                                                        Do not use cleaning solvents near open flame or
     Refrigerant (R22 or R407C) is used with this                                       excessive heat. Wear eye protection when blow-
     equipment. Death or serious injury may result if                                   ing solvent from parts. The pressure-wash should
     personnel fail to observe proper safety precau-                                    not exceed 30 psig. Solvent solutions should be
     tions. Great care must be exercised to prevent                                     disposed of in accordance with local and state
     contact of liquid refrigerant or refrigerant gas, dis-                             regulatory statutes.
     charged under pressure, with any part of the
     body. The extremely low temperature resulting                                                    CAUTION
     from the rapid expansion of liquid refrigerant or
     pressurized gas can cause sudden and irrevers-                                     The unit must be kept in its normal installed po-
     ible tissue damage.                                                                sition. If the unit is not kept level and vertical,
                                                                                        damage to the unit's compressors will result.
     As a minimum, all personnel should wear ther-
     mal protective gloves and face-shield/goggles
     when working with refrigerant. Application of ex-
     cessive heat to any component will cause ex-
     treme pressure and may result in a rupture.

     Exposure of refrigerant to an open flame or a
     very hot surface will cause a chemical reaction
     that will form carbonyl chloride (hydrochloric/hy-
     drofluoric acid); a highly poisonous and corro-
     sive gas commonly referred to as PHOSGENE.
     In its natural state, refrigerant is a colorless, odor-
     less vapor with no toxic characteristics. It is
     heavier than air and will disperse rapidly in a
     well-ventilated area. In an unventilated area, it
     presents a danger as a suffocant.

     Always refer to the manufacturer's MSDS pro-
     vided with the unit.

(© April, 2008)                                                                                                                               1-5

                                                         Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  1.5 General Design                                                                                          NOTE
                                                                                       Customer specified non standard features or de-
  The CyberTWO VFS-EC unit is housed in a steel frame                                  sign variations may not be described in this
  type cabinet and is rated for indoor use. The exterior of                            manual. Refer to the installation and/or electri-
  the cabinet is coated with a powder coat finish to                                   cal drawings supplied with your unit for details
  protect against corrosion. Hinged doors are located in                               on additional feature(s). In some cases, an ad-
  the front of the cabinet for easy access to all compo-                               dendum to this manual may also be included to
  nents. Operator controls are conveniently located on the                             further describe the feature(s).
  front of the cabinet.

 Figure 1 depicts a sample internal layout of a downflow unit and identifies the major components. Location of the
 major components vary depending on VFS model number and options purchased.

  NOTE: CABINET DOORS AND SIDE ACCESS PANEL REMOVED TO SHOW INTERNAL PARTS

      FILTER RACK       T/H SENSOR
                                                                                              FILTER RACKS
                             SMOKE
                             DETECTOR
                                                                                                                          FIRESTAT
                             FIRESTAT
                                                                                                                          ELECTRIC
                                                                                                                          BOX

                                                                                                                         HUMIDIFIER

                                                                                                                         MAIN POWER SERVICE
                              COILS                                                                                      DISCONNECT SWITCH

                                                                                                                         HEAT EXCHANGERS

                             ELECTRIC
                             REHEAT                                                                                      COMPRESSORS
                             FIN TUBE

                                                                                                                         CONDENSATE
                                                                                                                         PUMP

                                                EC FANS
            LEFT SIDE                                                               FRONT

                                         Figure 1 - Typical Internal Layout - Downflow

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                                                            Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

 Figure 2 depicts a sample internal layout of an upflow unit and identifies the major components. Location of the
 major components vary depending on VFS model number and options purchased.

    NOTE: CABINET DOORS AND SIDE ACCESS PANEL REMOVED TO SHOW INTERNAL PARTS

                               ELECTRIC REHEAT
                                       FIN TUBE
                                                                                                  HUMIDIFIER

                                 COILS

                                                                                                                             ELECTRIC
                                                                                                                             BOX

                                                                                                                             MAIN POWER SERVICE
                                                                                                                             DISCONNECT SWITCH

                                FILTER                                                                                       HEAT EXCHANGERS

                                                                                                                             COMPRESSORS

                                                                                                                             CONDENSATE
                                                                                                                             PUMP

                                                  EC FANS                   FIRESTAT                            T/H SENSOR

                                                                                                               SMOKE
            LEFT SIDE                                                                                          DETECTOR
                                                                                     FRONT

                                            Figure 2 - Typical Internal Layout - Upflow

 1.5.1      Electric Box Access                                                   The electric box cover is safety interlocked with the
 The electrical components are protected in an enclo-                             main power service disconnect switch, preventing the
 sure located in the cabinet behind the hinged access                             cover from being removed when the switch is in the
 door with the system controller. Before opening the                              “On” position. The main power service disconnect
 access door, turn the “On/Off” switch beneath system                             switch must be turned “Off” to gain access to the
 controller to the “Off” position. This removes power                             components within the electric box.
 from the system controller and shuts the unit off.                               The main power service disconnect switch may be
                                                                                  used to turn the unit off for emergency shutdown or
                     WARNING                                                      during routine maintenance. The handle of the switch
                                                                                  may be locked in the “Off” position to prevent unin-
     Hazardous voltage will still be present inside the                           tended operation.
     cabinet, even with the unit turned off at the sys-
     tem controller. To isolate the unit for maintenance,
     turn off power at the main power service discon-
                                                                                                         WARNING
     nect switch on the electric box cover.                                                This unit employs high voltage equipment with
                                                                                           rotating components. Exercise extreme care to
                     WARNING                                                               avoid accidents. Always keep hands, clothing
                                                                                           and tools clear of the EC Fan blades when power
     With power and controls energized, the unit could                                     is “On”.
     begin operating at any time. To prevent personal
     injury, stay clear of rotating components as au-
     tomatic controls may start them unexpectedly.

(© April, 2008)                                                                                                                                   1-7

                                                            Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  1.5.2     Circuit Breakers / Motor Start Protectors                      loose for field installation. Refer to the electrical
                                                                           drawing supplied with your unit for details specific to
  Individual overload protection is provided by circuit                    your system.
  breaker(s) and motor start protectors. These switches
  must be manually reset once the overload condition is                    1.5.6     Heaters (Optional)
  cleared.
                                                                           The precision A/C unit incorporates heaters for reheat-
  1.5.3     Coil(s)                                                        ing the supply air as required to offset the sensible
  The cooling and optional hot water reheating coils are                   cooling of the system during the dehumidification cycle
  aluminum finned/copper tube construction. The coils are                  and for the automatic heating mode. As a standard,
  leak tested and cleaned before installation by the factory.              electric resistance heating elements are factory
                                                                           installed in the supply airstream to heat the supply air.
  1.5.4     EC Fan(s)
                                                                           As an option, hot water reheat may be selected. A hot
  The unit is equipped with high efficiency, Electronically                water heating coil is factory installed in the supply air
  Commutated (EC) fan(s). EC Fans utilize a brushless                      stream to heat the supply air. A valve is provided to
  motor equipped with permanent magnets and perma-                         control the flow of hot water through the coil to main-
  nently lubricated ball bearing. The Fan impellers are                    tain the correct reheat temperature.
  backward curved and attached to the rotor casing. The
  fan is balanced and aerodynamically optimized to                         1.6 Optional Equipment
  minimize vibration.
                                                                           1.6.1     Humidifier
  The fan does not utilize drive belts. The fan speed is
  variable via a 0 to 10 VDC signal from the system                        CyberTWO VFS-EC systems may utilize an optional
  controller. The fan motor is equipped with integral                      electrode, steam humidifier. The humidifier is factory
  electronics and does not require the addition of                         installed inside the air conditioner and includes fill and
  secondary electronics such as thermal protection,                        drain valves and associated piping. Operation of the
  inverters or filters. The fan will not produce AC inverter               humidifier’s fill and drain cycles is based on water
  whine.                                                                   conductivity and is maintained by the humidifier
                                                                           controller. An operating manual for the humidifier is
  EC fans feature an integrated monitoring function to
                                                                           provided under separate cover. Refer to that manual for
  protect the motor and electronics against damage from
                                                                           detailed information on operation of the humidifier.
  jamming, phase loss or overheating. If any of the
  following failure conditions occur, the motor automati-                  1.6.2     Condensate Pump
  cally stops and an alarm is signaled:
   a. Locked rotor1                                                        An optional factory installed condensate pump may be
   b. Low main supply voltage1                                             provided. The pump automatically eliminates conden-
    c. Loss of a phase1                                                    sate and humidifier flush water (if applicable) from the
   d. Over-heating of electronics2                                         drain pan. An internal overflow safety switch is wired to
   e. Over-heating of motor2                                               the system controller to automatically shut down the
      1
      Upon correction of these failure conditions, the                     precision A/C system should an overflow occur.
      motor will automatically reset.
      2
                                                                           1.6.3     Smoke Detector
       Upon correction of these failure conditions, the
      motor must be manually reset by turning off power                    Optionally mounted in the return air stream, a photo-
      for 20 seconds.                                                      electric smoke detector is used to sense the presence
                                                                           of smoke and signal the controller when a smoke
  1.5.5     Temperature/Humidity Sensor
                                                                           alarm condition exists.
  As a standard, a temperature/humidity (T/H) sensor is
  factory mounted in the return air stream for room air                    1.6.4     Firestat
  control. The (T/H) sensor monitors the return air
                                                                           Optionally mounted in the return air stream, a fire
  conditions and provides input signal(s) to the system
                                                                           detector senses high retun air temperature and signals
  controller to manage the operation of the A/C unit
                                                                           the controller when a fire alarm condition exists.
  consistent with the setpoints entered in the system
  controller. As an option, sensor(s) may be shipped

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CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

2.0      INSTALLATION                                                                                        NOTE
                                                                                    Working clearance requirements need to be es-
  2.1       Receiving the Equipment                                                 tablished prior to mounting the unit. Refer to lo-
  Your CyberTWO system has been tested and in-                                      cal and national electrical codes.
  spected prior to shipment. To ensure that your equip-
  ment 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. If there is shipping damage, it
  must be noted on the freight carrier's delivery forms
  BEFORE signing for the equipment. Any freight claims
  MUST be done through the freight carrier. SATS ships
  all equipment FOB. SATS can assist in the claim
  filing process with the freight carrier. Should any
  damage be present, notify the SATS Product Support                             30"
  Group prior to attempting any repairs. Refer to section                  (MINIMUM SIDE
                                                                            CLEARANCE)

  five of this manual for instructions.                                                                 40"
                                                                                                  (MINIMUM FRONT
                                                                                                    CLEARANCE)

  A Data Package has been sent with your unit. It                                                                             30"
                                                                                                                        (MINIMUM SIDE
  contains this manual, a supplemental microprocessor                                                                    CLEARANCE)

  controller manual, system drawings, applicable
  MSDS’s, other component manuals, warranty registra-
  tion and other applicable instructions based on the                                      Figure 3 - Installation Clearance
  configuration and options of your unit. The data
  package has been placed in your unit in a clear plastic                  To minimize the effects of the environment surrounding
  envelope. These documents need to be retained with                       the conditioned space, certain steps must be taken.
  the unit for future reference.                                           This is especially true for critical/precision room
                                                                           preparation (computer rooms/labs) requiring close
                           NOTE                                            tolerance control of temperature and humidity. The
                                                                           conditioned space should be well insulated and
      Items that have been shipped loose, such as con-
                                                                           include a vapor barrier. The installer should ensure that
      trollers, temperature/humidity sensors, water
                                                                           the proper insulation rating is used based on the
      detectors, etc., are shipped inside the air condi-
                                                                           design of the space, which was the basis for the
      tioner unless specified otherwise by the customer.
                                                                           system selected. The following chart is a recom-
      Unpack and store these items in a safe place
                                                                           mended minimum R-value (thermal resistance) to
      unless you are using them immediately.
                                                                           ensure optimum equipment operation.
  2.2       Site Preparation
                                                                                           STRUCTURE                R-VALUE
  CyberTWO systems are designed with easy service
  access in mind. Hinged doors are located on the front                                      Ceiling                  R-38
  of the unit and removable access panels are provided                                        Wall                    R-21
  on each side. The number of doors may vary depend-                                          Floor                   R-19
  ing on size and configuration. Each unit has an                                             Door                     R-5
  electrical box inside the cabinet with a removable
  panel for accessing the electrical components. In order
  to have full service access through the front of unit, no                The vapor barrier is the single most important require-
  permanent obstructions can be placed within 40                           ment for maintaining environmental control in the
  inches of the front of unit. Side access panels require                  conditioned space. The vapor barrier in the ceiling and
  a minimum of 30 inches of clearance to remove and                        walls can be a polyethylene film. Concrete walls and
  replace components (see Figure 3).                                       floors should be painted with a rubber or plastic based

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                                                     Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  paint. Doors and windows should be properly sealed                         2.4         Mounting/Placement
  and a door sweep used to minimize leakage. Outside
  or fresh air should be kept to a minimum (as it adds to                    CyberTWO systems that are not ducted are designed
  the cooling, heating, dehumidification and humidifying                     to be located in the conditioned space. Ducted units
  loads), while maintaining the requirement of the Indoor                    may be either inside or outside the conditioned space
  Air Quality (IAQ) standard. Lack of these steps can                        but are designed to supply air to only one room.
  cause erratic operation, unstable room control and                         CyberTWO series systems are 100% front accessible,
  excessive maintenance costs.                                               which allows the units to be placed in a corner or
                                                                             between cabinetry. It is recommended to position the
  2.3       Rigging                                                          unit to obtain optimum air circulation.

  CyberTWO systems are designed to be kept in the                                                        NOTE
  vertical position. Move the unit with a suitable device
                                                                                   Placement of the floor registers is important. If
  such as a forklift, pallet jack or roller bar and dollies.
                                                                                   they are too close to the unit, the supply air will
  For reference, a weight table is provided on the
                                                                                   be recirculated back to the unit before it has
  installation drawing. Units are shipped on a skid to
                                                                                   circulated throughout the space.
  facilitate moving prior to installation. Units should
  always be stored indoors in a dry location prior to                        See Figure 4. The unit is designed to be located
  installation.                                                              directly on top of the floor (typically upflow) or on a
                                                                             raised floor (typically downflow).
                    CAUTION
      Units must be kept level and in the vertical posi-                                         CAUTION
      tion when lifting to prevent damage to the unit.                             Ensure the mounting surface is capable of sup-
                                                                                   porting the equipment. Before mounting the unit,
                                                                                   refer to the weight provided on the installation
                                                                                   drawing. On some raised floor installations a floor
                                                                                   stand is required, depending on the load capac-
                                                                                   ity of the existing raised floor.

                                                                                                                                    HINGED
                                                                                                                                    DOOR

                                                                                                                                    C6000 SERIES
                                                                                                                                    CONTROLLER

                                                                                                                                    ON/OFF
                                                                                                                                    SWITCH

                                                                                                                           FLOOR STAND
                                                                                                                           (OPTIONAL)

                           UPFLOW                                                                 DOWNFLOW
                        CONFIGURATION                                                           CONFIGURATION

                                              Figure 4 - Typical Installation

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CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  2.4.1    Precision A/C Unit                                               Secure the condenser/condensing unit to prevent the
                                                                            system from moving during operation. It is recom-
  CyberTWO systems use a frame and panel construc-                          mended that the remote condenser be mounted with
  tion for unit rigidity and full service accessibility while               field supplied vibration mounts to reduce vibration
  the unit is mounted in place.                                             transmitted to the mounting surface.
  If a floor stand is selected for downflow units, refer to
  the installation drawing provided and cut out the raised
                                                                            2.5      Air Distribution Connection
  floor to match the unit’s overall base dimension. If a                    2.5.1    Downflow Configuration Air Patterns
  floor stand is not selected, use the installation drawing
  and cut out the raised floor to match the discharge                       In a downflow configured unit, the conditioned supply
  opening for the blowers and cut out the holes required                    air discharge is through the bottom of the unit into the
  for piping and wiring through the raised floor.                           raised floor. There are two basic air patterns; top free
                                                                            return and top ducted return (see Figure 5).
                           NOTE
                                                                            If ductwork is to be used, always consult your state
     The equipment must be level to operate properly.                       and local codes when determining ducting require-
                                                                            ments. The duct system should be designed to allow
  2.4.2    Outdoor Equipment
                                                                            the air to move with as little resistance as possible.
  Install remote condensers in a secure location where
  the unit cannot be tampered with and the main power                       The connection of ductwork to the unit is typically
  circuit breaker cannot be inadvertently turned off.                       made to a one-inch collar provided at the top of the
  Locate the remote condenser where the fan is not                          unit (refer to the installation drawing provided with the
  likely to draw dirt and debris into the coil fins. There                  unit). The connection of the duct to the unit may be
  should be at least 24 inches of clearance around the                      made with either pop rivets or self-tapping screws.
  condenser to ensure adequate airflow to the coil.

                                                                                             RETURN
                                                                                             AIR INLET

                                 RETURN
                                 AIR INLET

                                   SUPPLY                                                      SUPPLY
                                 AIR OUTLET                                                  AIR OUTLET

                            TOP FREE RETURN                                                  TOP DUCTED RETURN

                              Figure 5 - Downflow Configuration Typical Air Patterns

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                                                      Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  2.5.2     Upflow Configuration Air Patterns
  In an upflow configured unit, the conditioned supply air has two methods of discharge: ducted or through a 2 or 3-
  way grilled plenum box. The return air pattern is front free return. (See Figure 6.)

  The supply air outlet is provided with a flange for connection of ductwork (refer to the installation drawing provided
  with the unit). The connection of ductwork to the unit may be made with either pop rivets or self-tapping screws.

  If ductwork is to be used, always consult your state and local codes when determining ducting requirements. The
  duct system should be designed to allow the air to move with as little resistance as possible.

                                                      FRONT FREE RETURN

                             SUPPLY                                                                                                      OPTIONAL
                           AIR OUTLET                                                                                                    PLENUM BOX

                                                                           SUPPLY
                                                                         AIR OUTLET

                                                        DUCT

      RETURN AIR                                                                       RETURN
        INLET                                                                         AIR INLET

                   TOP DUCTED DISCHARGE                                                           TOP DISHARGE WITH 2-3 WAY PLENUM BOX

                                    Figure 6 - Upflow Configuration Typical Air Patterns

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                                                      Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

 2.6 Optional Equipment (Field Installed)
 2.6.1     Floor Stand
 Install the floor stand directly on the sub-floor, ensuring the side with the "FRONT" label is facing the same direction
 as the front of the precision A/C unit (see Figure 7). Refer to the floor stand assembly drawing for the dimensions
 required to cut the opening in the raised floor. The optional floor stand is designed with adjustable feet on all the legs,
 allowing for leveling and overall height adjustment. Refer to the floor stand assembly drawing for minimum and
 maximum height adjustability of your floor stand. To adjust the height, first loosen the middle nuts on each leg. Next,
 turn the top hex nuts to raise or lower the floor stand. Once the floor stand is level and even with the raised floor, lock
 all feet in place by tightening the middle hex nuts against the top hex nuts.

                                                                                    TURNING VANES
                                                                                    (OPTIONAL)

                                    "FRONT" LABEL

                                                                                               FLOOR STAND
                                                                                               LEG

                                                                      TOP HEX NUT              THREADED ROD
                                                               MIDDLE HEX NUT

                                                                    ISOLATION PAD

                                   Figure 7 - Optional Floor Stand Installation

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                                                    Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  2.6.2 Remote Display                                                   2.6.4 Remote Water Detector
  The C6000 Microprocessor is the standard controller                    The remote water detector is normally placed on the
  supplied with CyberTWO systems. As an option the                       subfloor or in a field supplied auxiliary drain pan located
  control panel may be remote mounted. For mounting                      beneath the unit. SATS provides 2 types of water
  and wiring instructions, refer to the system drawings                  detectors:
  and the supplemental manual sent in the data pack-                     Spot type water detector-
  age with your unit.
                                                                         Remove the protective cover and connect two control
                                                                         wires to the terminals on the base
  2.6.3 Remote Temperature/Humidity Sensor
                                                                         (terminal lugs are provided). Replace the
  The remote temperature/humidity (T/H) sensor must be                   cover and place the water detector(s) on
  located so that it will properly sense the temperature/                the floor with the metal electrodes
  humidity conditions to be controlled. The T/H sensor                   facing down. When water is present,
  should not be mounted near a doorway or an area                        current will flow between the electrodes. The base is
  where it would be exposed to direct sunlight. Follow the               provided with a mounting hole in the center which may
  steps below to mount the sensor. For unit wiring details,              be used to secure the water detector in place.
  refer to Section 2.8, Utility Connections.                                                      NOTE
                                                                               Do not place the spot type water detector on
                                           COVER
                                           SCREW                               an electrically conductive surface.

                                                                         Cable type water detector-
                                                                         Lay the cable water detector
                                                                         flat across the subfloor
                                                                         where water could collect.
                                                                         When water is present,
             Temperature /Humidity Sensor                                current will flow between the
  1. Using a flat head screwdriver, remove the cover                     two wires. A two conductor wire harness is provided
     plate from the base of the sensor.                                  with a quick connect fitting on the end. The harness
                                                                         mates to the fitting on the water detector and connects
  2. Place the base temporarily over the wire hole                       it to the control board inside the electric box.
     opening in the wall. Level the base and mark the
     mounting hole locations through the two slots.
  3. Drill the mounting holes and insert the provided
     wall anchors.
  4. Run the wires coming out of the wall through the
     opening in the base, then secure the base with the
     screws provided.
  5. Make the wiring connections. See Section 2.8
     Utility Connections and refer to the wiring diagram
     supplied with your unit.
  6. Replace the cover plate on the base.

                   CAUTION
      Take care not damage the exposed tempera-
      ture/humidity sensors on the PC board while
      screwing in the cover fastening screw. The sen-
      sors can be damaged if handled improperly.

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CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

 2.7       Piping Connections                                              Refrigerant lines for split systems must be sized
                                                                           according to the piping distance between the evapora-
 For downflow VFS models, piping is to be routed                           tor and the condenser/condensing unit. Each valve,
 through the bottom of the cabinet. For upflow models,                     fitting and bend in the refrigerant line must be consid-
 the piping is to be routed through the top of the cabinet.                ered in this calculation. Refer to the following chart
 Once the piping is connected to the A/C unit, install 2-                  provided for determining the standard equivalent
 piece, pipe penetration plates (shipped loose) around                     lengths, in feet, of straight pipe.
 the piping to stop air bypass. Mounting holes are
 predrilled in the plates. Self drilling screws are provided
 to attach the plates to the A/C cabinet.                                           Equivalent Length (ft) of Straight Pipe
                                                                          OD (In.) Globe     Angle    90º      45º      Tee      Tee
 2.7.1     Refrigerant                                                   Line Size Valve     Valve   Elbow     Elbow    Line   Branch

 2.7.1.1   Self-Contained Systems                                            1/2       9.0    5.0    0.9      0.4       0.6     2.0
                                                                             5/8       12     6.0    1.0      0.5       0.8     2.5
 No refrigerant connections are required for self-
 contained water or glycol cooled systems (Models                            7/8       15     8.0    1.5      0.7       1.0     3.5
 VFS-[ ]-DW/DG-[ ]).                                                       1-1/8       22     12     1.8      0.9       1.5     4.5
                                                                           1-3/8       28     15     2.4      1.2       1.8     6.0
 2.7.1.2 Split Systems
                                                                           1-5/8       35     17     2.8      1.4       2.0     7.0
 Split air-cooled systems with a remote condenser will
 require field refrigeration piping. All split systems are                 2-1/8       45     22     3.9      1.8       3.0      10
 shipped with a dry nitrogen charge of 50 psig.                            2-5/8       51     26     4.6      2.2       3.5      12
                                                                           3-1/8       65     34     5.5      2.7       4.5      15
 Split systems coupled with a remote condenser will
 require a copper discharge and copper liquid line.                        3-5/8       80     40     6.5      3.0       5.0      17

 All refrigeration piping should be installed with high
 temperature soldered joints. Use standard refrigeration                  When installing remote condenser(s) above the
 practices for piping supports, leak testing, dehydration                 evaporator, the discharge line should include a shallow
 and charging of the refrigeration circuits. The refrigera-               P-trap at the evaporator. The highest point in the
 tion piping should be isolated from the building by the                  discharge line should be above the condenser coil. An
 use of vibration isolating supports. To prevent tube                     inverted trap is required on the discharge line of the
 damage when sealing openings in walls and to reduce                      remote condenser to help prevent oil and liquid refriger-
 vibration transmission, use a soft flexible material to                  ant from flooding back to the compressor.
 pack around the tubes.                                                    Oil traps must be included every 20 feet in the vertical
 Clear all pipe connections of debris and prepare the                      risers and the refrigerant lines must be sloped ¼ inch
 connections for soldering. Use only "L" or "K" grade                      for every 10 feet in the horizontal lines to ensure proper
 refrigerant copper piping. Be careful not to allow                        oil return to the compressor.
 solder/piping debris to get inside refrigerant lines.                     Refer to the following refrigerant line size charts for
 Silver solder containing a minimum of 15% silver is                       recommended line sizing.
 recommended. Dry nitrogen should be flowing through
 the tubing while soldering at a rate of not less than 1-2
 CFM (.03 - .06 M3/minute).

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                                                     Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                                 NOTE                                             2.7.2       Water/Glycol
       In the following charts, the line sizes represent                          Piping connections for water/glycol condensers are
       the sizing for individual refrigeration circuits.                          sweat connections. Field piping may not necessarily
       CyberTWO units have two separate pairs of re-                              be the same size as the unit connection. Piping
       frigeration lines. (One per compressor.)                                   should be sized to match the required system pres-
                                                                                  sure drop and pump capacity, and may require a
              Recommended Liquid Line Sizes                                       reducing fitting to match the connection size on the air
                                                                                  conditioner. Glycol cooled systems with low entering
                (For R22 or R407C Refrigerant)
                                                                                  fluid temperatures should have insulated piping.
      Model No./       Receiver to Evaporator (Equivalent Ft.)*
      Total Unit           50'         100'        150'                           The recommended ethylene glycol solution ratio is
       Capacity          or less     or less     or less
                                                                                  40% glycol to 60% water. (SATS recommends
      072 / 72,000         1/2             1/2        1/2                         Dowtherm SR1 manufactured by Dow Chemical Co.)
                                                                                  Use only ethylene glycol with inhibitors for corrosion
      096 / 96,000         1/2             5/8        5/8
                                                                                  protection.
      120 / 120,000        1/2             5/8        5/8

      180 / 180,000        5/8             7/8        7/8
                                                                                                      WARNING
      240 / 240,000        7/8             7/8        7/8                             Glycol is hazardous. Consult the manufacturer's
                                                                                      MSDS for detailed safety information.
      312 / 312,000        7/8             7/8        7/8

      360 / 360,000        7/8             7/8       1 1/8                                            CAUTION
  *Equivalent Ft. accounts for the linear pipe length as well as                      When installing and filling the water/glycol loop, all
  equivalent length of Valves, Elbows & Tee’s as shown in the                         air must be bled from the piping system and the
  previous chart.                                                                     piping system must be cleaned prior to operating
                                                                                      the system. Failure to do so will result in equip-
           Recommended Discharge Line Sizes                                           ment problems.
              (For R22 or R407C Refrigerant)                                      2.7.3       Condensate Drain
       Model No./              Equivalent Length Ft.*
       Total Unit        50'        100'         150'                             2.7.3.1 Gravity Drain
        Capacity       or less    or less       or less
                                                                                  A 7/8 inch OD copper (sweat type) line is provided to
       072 / 72,000       7/8           7/8          7/8
                                                                                  drain the condensate pan. An “S” trap is installed at
       096 / 96,000       7/8           7/8          7/8                          the end of piping for the installer to connect a 7/8 inch
                                                                                  ID drain line to remove water from the cabinet. This line
       120 / 120,000      7/8           1-1/8       1-1/8
                                                                                  also drains the humidifier.
       180 / 180,000     1-1/8          1-1/8       1-3/8
                                                                                                              NOTE
       240 / 240,000     1-1/8          1-3/8       1-3/8
                                                                                      The humidifier drains (hot) water into the
       312 / 312,000     1-1/8          1-3/8       1-3/8                             condensate drain during normal operation.

       360 / 360,000     1 3/8          1 3/8       1 5/8                         The drain line must be located so it will not be ex-
                                                                                  posed to freezing temperatures. The diameter of the
                           NOTE                                                   drain line should be the full size of the connection.
  Vertical runs are based on a total rise of 30 equivalent
  feet. For longer sizes, individual calculations must be                                                     NOTE
  made. Sizes assume the use of single risers; double                                   Pour some water into the condensate drain pans
  risers may be necessary.                                                              prior to start-up. This fills the trap and prevents
                                                                                        air from being drawn up the drain lines.
  Consult the Copeland applications data guide for more
  detailed information regarding refrigerant line traps and
  line sizing.

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CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

 2.7.3.2 Condensate Pump                                                                             2.8     Utility Connections
 An optional condensate pump is normally factory                                                    2.8.1    Main Power
 installed. The drain connection may be 1/2” ID vinyl
 tubing or 1/2” OD copper sweat connection.                                                         The CyberTWO product offering is available in 208,
                                                                                                    460 and 575 volt three-phase configurations. It is
                                                                                                    imperative that the unit nameplate be examined to
                                                                                                    determine the operating voltage, frequency and phase
                                                        INLET 7/8" OD
                                                                                                    of the system (see Figure 9). The nameplate also
 OUTLET 1/2" OD
                                                                                                    provides the full load amps (FLA), the current the unit
                                                                                                    will draw under full design load, the minimum circuit
                                                                                                    ampacity (MCA) for wire sizing, and the maximum
                                                                                                    fuse or HACR (Heating, Air Conditioning, Refrigeration)
                                                         SEE NOTE 2
                                                                             2.00                   breaker size (MAX FUSE/CKT BKR) for circuit protec-
                                                                             SEE NOTE 1
                                                                                                    tion. The unit's nameplate is located inside the cabinet
                                                                                                    within the electrical box.

 NOTES:
 1. MIMIMUM HEIGHT IN INCHES.
 2. P-TRAP MUST BE LOCATED IN THE INLET SIDE OF PUMP WHEN FIELD INSTALLED.

                   Figure 8 - Condensate Pump

 If an optional field installed condensate pump is used,
 a p-trap must be installed to allow proper condensate
 drainage (see Figure 8). The height of the trap must be
 a minimum of 2 inches on standard systems to ensure
 proper water drainage. The condensate pump dis-
 charge line should be 1/2 inch OD (maximum) copper
 pipe to prevent excessive back flow to the condensate
 pump.

 2.7.4            Humidifier
 CyberTWO 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 connec-
 tion supplied by the factory. Refer to the installation
 drawing provided with your unit for the size and
 location of the connectrion. The humidifier requires
 normal tap water as the water supply. If the supply
 water is high in particulate, an external filter may be
 needed.

                          CAUTION
                  Do not use demineralized water.

 Refer to the humidifier operator’s manual, supplied
 with the equipment, for complete manufacturer’s
 information on the humidifier and the supply water
 recommendations.
                                                                                                             Figure 9 - Sample Nameplate

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                                                                              Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

                             NOTE
                                                                                                 CAUTION
       If the nameplate states MAX FUSE/CKT BKR,
       it is required to use fuses or a HACR type cir-                             Improper wire connections will result in the re-
       cuit breaker to protect the system. Other pro-                              verse rotation of the fans/blower motors and com-
       tection devices are not allowed based upon the                              pressor (if applicable) and may eventually result
       product listing.                                                            in damage to the scroll compressor. To correct
                                                                                   this problem, exchange any two of the incoming
  The unit is provided with terminals for all required field-                      main power wires at the main power disconnect
  wiring. Refer to the electrical schematic supplied with                          switch. Do NOT rewire the unit's individual com-
  the unit for all power and control field-wiring. It is                           ponents.
  important to identify the options that were purchased
  with the unit in order to confirm which field connections                  Prior to unit operation, an adequate unit-to-earth
  are required.                                                              ground must be connected to the unit.

                                                                             2.8.2       Controls
                     WARNING
                                                                             Stulz Air Technology Systems offers a wide range of
       Verify power is turned off before making connec-                      control features to solve your air conditioning control/
       tions to the equipment.                                               alarm requirements. The C6000 Microprocessor is the
                                                                             standard controller for the CyberTWO system. If it is
                            NOTE                                             mounted on the unit (standard), no utility connection is
       All wiring must conform to local and national elec-                   required. As an option the display may be remote
       trical code requirements. Use of copper conduc-                       mounted. A six-conductor cable harness is provided for
       tors only is required. Wiring terminations may                        interconnect wiring. Refer to Figures 10 and 11and the
       become loose during transit of the equipment;                         electrical drawing supplied with your unit for details on
       therefore, it is required to verify that all wiring                   interconnecting the field wiring.
       terminations are secure.
                                                                             2.8.3       Optional Equipment
  It is important to verify that the main power supply                                                  NOTE
  coincides with the voltage, phase and frequency
  information specified on the system nameplate. The                               All wiring must be provided in accordance with
  supply voltage measured at the unit must be within                               local and national electrical code requirements.
  ±10% of the voltage specified on the system name-
  plate.                                                                     2.8.3.1 Remote Temperature/Humidity Sensor
  A manual fused disconnect switch or HACR type                              The remote temperature/humidity sensor requires a
  circuit breaker must be installed per local and national                   three conductor shielded cable with the shield being
  electrical codes for service of equipment. Do not                          terminated at the unit electric box. Both the electric
  mount a customer supplied manual fused disconnect                          box and the sensor include a terminal strip with box
  switch or HACR type circuit breaker to the surface of                      type lugs for wire connections. Refer to the electrical
  the unit.                                                                  schematic supplied with your unit for the number of
                                                                             conductors required and for the appropriate wire
  Each unit is provided with a main power and control                        terminations.
  pilot hole for connection of the field-wiring conduit.
  These pilot holes are located in the floor of the cabinet.                 2.8.3.2 Remote Water Detector
  A label stating "MAIN POWER INPUT" is in close
  proximity. See the installation drawing provided with                      Each remote water detector used will require two
  your unit for pilot hole locations. The main power wires                   conductors to be wired to the control terminal board
  shall be terminated at the line side of the main power                     within the unit electrical box. The wire insulation must
  disconnect switch, located within the electric box. A                      be rated at 600V. Refer to the electrical schematic
  separate equipment ground lug is provided within the                       supplied with your unit for proper wire terminations.
  electrical box for termination of the earth ground wire.

2-10                                                                                                                      (© April, 2008)

                                                        Air Technology Systems, Inc.
CyberTWO Series VFS-EC Installation, Operation & Maintenance Manual

  2.8.4      Interconnecting Field Wiring                                                   2.8.4.1 Air Cooled Split Systems With Remote
                                                                                                    Condenser
 The following system interconnecting field wiring
 sections detail the number of conductors required for a                                    See Figure 10. Systems equipped with a remote
 typical system. Additional control conductors may be                                       condenser will require field wiring between the A/C
 required depending on the options purchased with the                                       system and the remote condenser. Refer to the
 equipment. Refer to the supplied electrical schematic                                      electrical schematic supplied with your unit and the
 to determine the total number of interconnecting                                           wiring diagram supplied with the condenser (typically
 conductors required for your system. It is important to                                    located in the condenser electric box).
 note that the control transformer(s) supplied with the
 equipment have been sized and selected based upon                                          The installer must provide main power wiring to the
 the expected loads for each system.                                                        main power distribution block located within the
                                                                                            remote condenser control box. A separate equipment
                                                                                            ground lug is provided within the electrical box for
                         CAUTION                                                            termination of the earth ground wire.
     Do not connect any additional loads to the sys-
     tem control transformers. Connecting additional                                        The installer must also wire control conductors from
     loads to the factory supplied control transformer                                      the terminal board within the A/C unit to the control
     may result in overloading of the transformer.                                          terminal board within the remote condenser control
                                                                                            box. Refer to the electrical schematic for the correct
                                  NOTE                                                      number of field wires needed and for appropriate wire
     All wiring must be provided in accordance with                                         terminations required for your specific system.
     local and national electrical code requirements.

                                                                                                                                   SEE NOTE 3

                                                                                                                         4 CONDUCTOR NON-
                                                                                                                         SHIELDED CABLE

                                                                                                                           2 CONDUCTOR
                                                                                                                           SHIELDED CABLE
                          MAIN POWER SUPPLY                                                                                                       C6000
                          208-575V/3PH/60Hz
                                                                                                                           3 CONDUCTOR
                                                                                                                           SHIELDED CABLE

                                                                                                                                         REMOTE TEMPERATURE/
     INTERCONNECTING FIELD                                                                                                               HUMIDITY SENSOR
     WIRING (TO BE INSTALLED
     IN ACCORDANCE WITH
      NFPA 70, N.E.C.)
                                                                                              L1

                                                                                              L2
                                                                                                                     MAIN POWER SUPPLY
                                                                                              L3
                                                                                                                     208-575V/3PH/60Hz

                                                                                                                 24VAC

                                                    MODEL VFS-360-DAR SHOWN FOR REFERENCE

                                                                                                                                            AIR COOLED CONDENSER
                                        NOTES:
                                        1. PHANTOM WIRES (       ) NOT APPLICABLE FOR SINGLE PHASE POWER SUPPLIES.
                                        2. NUMBER OF CONDUCTORS VARY DEPENDING ON OPTIONS PROVIDED.                                 INTERCONNECTING FIELD WIRING
                                        3. OPTIONAL REMOTE MOUNTED DEVICES.                                                         (TO BE INSTALLED IN ACCORDANCE
                                                                                                                                    WITH NFPA 70, N.E.C.)
                                                                                                                                    SEE NOTE 1 & 2

                                  Figure 10 - Interconnecting Field Wiring Remote Condenser

(© April, 2008)                                                                                                                                                      2-11

                                                                      Air Technology Systems, Inc.
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