2100_air_cooled_manual 2100 Air Cooled Manual

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INSTALLATION
OPERATION
MAINTENANCE
AND PARTS
MANUAL

SYSTEM 2100
AIR COOLED (CAA)

COMPU-AIRE, INC.

8167 BYRON ROAD, WHITTER,, CA 90606
PHONE: (562) 945-8971 FAX: (562) 696-0724
Website: www.compu-aire.com

E-mail: cs@compu-aire.com

ISO 9002 REGISTERED COMPANY
.

INDEX
DESCRIPTION

PAGES

1. INTRODUCTION, PRE-INSPECTION AND UNCRATING

1 5

2. TECHNICAL AND ELECTRICAL DATA

6 7

3. UNIT DIMENSIONS

8 9

4. SETTING THE AIR COOLED CONDENSER

10 14
-

5. PIPING CONNECTIONS

15 16

6. HUMIDIFIER PIPING CONNECTIONS

17 18

7. EVACUATION AND CHARGING PROCEDURES

18 21

8. HUMIDIFIER

9. ELECTRICAL CONNECTIONS

23 24

10. WIRING

25 29

1.1. START-UP AND TEST PROCEDURE

30 33

12. SYSTEM 2200 PROGRAMMABLE CONTROLLER

13. SERVICE AND MAINTENANCE INSTRUCTIONS

35 44

14. TROUBLE-SHOOTING (HUMIDIFIER)

45 48

15. PARTS

49 56

16. WARRANTY AND WARRANTY CERTIFICATE

57 59

ADDENDUM
CORRECT PHASING OF SCROLL COMPRESSORS:
The scroll compressor is a unidirectional compressor and will only
compress refrigerant in one rotation direction. Therefore, the
proper rotation of the scroll compressor must be checked. The
scroll compressor will run in the reverse direction but it will not
pump refrigerant and will draw substantially reduced current as
compared to listed values, and will result in elevated sound
levels. Scroll compressor will trip on internal protection after
running for some time in the reverse direction.
Verification of the proper rotation of the scroll compressor is
done by observing that suction pressure drops and discharge
pressure rises when the compressor is energized.

WARNING:
EXTENDED IMPROPER ROTATION OPERATION MAY ALSO VOID COMPRESSOR
WARRANTY.

F:\WP\MANUALS\SCROLL.ADD

Contacting Compu-Aire for Technical Assistance

Compu-Aire, Inc. uses the latest in electronic and software
technologies to develop some of the most reliable and cost
efficient air conditioning systems in the world. Since many of our
customer installations are sensitive to down time, we stock nearly
all components for your system ready for same day shipment. In
addition, our service departments can usually diagnose and repair
the electronic components and return them to you within a few days.
Our customer support staff is available should you require
assistance in diagnosing a problem or in setting up your air
conditioning system. During usual business hours, you may call at
(310) 945-8971 between 7:00 AM and 3:30 PM Pacific time, Monday
through Friday except holidays. Or, you may send a facsimile
message at (310) 696-0724 anytime_ Finally, you may write us at
Compu-Aire, Inc., 8167 Byron Road, Whittier, California 90606.
Pl e a s e , d o n o t re t u rn system components without pr ior
authorization from Compu-Aire. Whether repairing or replacement
is required for in warranty or out of warranty parts, Compu-Aire
must know what is being returned and why so that we may keep
proper records of your parts. Call Compu-Aire's service center
for a returned materials authorization number (RMA) and clearly mark
all packages on the outside with the number before sending them to
us.
When contacting the factory, please have information ready as to
the model and size of the air conditioner system and most
important, the job number. Compu-Aire keeps a file on each machine
sold detailing system components using this latter number. All such
information can be found on the Warranty Plate attached to each
machine.

I. CONTROL MONITOR
2, CONTACTOR
3. REHEAT ASSEMBLY
4
COOLING COIL
Z. BLOWER MOTOR

6 BLOWER
7. FILTER RACK
6
NORTEC HUMIDIFIER
9 SOLENOID VALVE
10. DRIER

II. COMPRESSOR
12.
SIGHT GLASS
13.
E X P AN SIO N
VAL
VE
14 DISCONNECT
SWITCH
15. FUSE BLOCK

IS_ POWER PANEL
17. PRESSURE SWITCH
18 RECEIVERS.
19. SUCTION ACCUMULATORS
20. CLOGGED FILTER SWITCH
21. NO AIR FLOW SWITCH
22. N A M E P L A T E

INTRODUCTION
Compu-Aire SYSTEM 2100 is specially designed to simultaneously
cool, heat, humidify, de-humidify and filter the computer room air.
These units are typically down discharge type supplying air in the
computer raised floor.
Standard Air Cooled System 2100 Units are equipped with:
1)
2)
3)
4)

The Base Unit with dual refrigeration system.
Matching Air Cooled Condenser
Low Ambient Control-Variable Speed Type
Control Panel for the Air Cooled Condenser

Features of SYSTEM 2100 Air Conditioner include:
1)
2)
3)
4)
5)
6)
7)

Stainless Steel Condensate Pan
Hermetic Compressors
Disposable Generator Type Humidifier
Disposable 2" filters
Microprocessor Based Control Monitor
Dual Belts Drive Set with an adjustable Motor pulley
Draw Thru Air Flow

OPTIONAL ITEMS WHEN ORDERED
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)

Semi Hermetic Compressors
Up Flow Discharge
Mo u n t i n g S t a n d
Hot Water, Steam, or hot Gas Reheat
Steam, Electric Immersion, or Infra Red Humidifier
Electromechanical Control Panel
Remote Control Panel
4" Filters
1" Pre - filters
Firestat
Smoke Detector
Molded Case Disconnect Switch
Condensate Pump
Low Ambient Control Below -20°F
Co n d e n s a t e O v e r f l o w
Low Voltage Drop Out

PRELIMINARY SURVEY

Prior to installing the unit verify the following requirements:
1) Door Openings
2) Elevator Size if needed to be used.
3) Electrical
a) Voltage and Phase
b) A m p s
c) B r e a k e r S i z e
4) Floor Openings
5) Water Supply for the Humidifier
6) Condensate Drain Connection Point
7) Refrigerant Pipe Routing make sure it does not interfere with
air flow.
8) Air Cooled Condenser
a)
Verify Electrical Service
b)
Location and Structural Integrity
c)
Space allocation for running 2 Liquid Lines and 2 Hot Gas
Lines
d)
F l a s h i n g R e q u irements
e)
Space to Run Electrical Conduit for Interlocking
conductors from the unit to the Air Cooled Condenser.

PRE-INSPECTION
Upon receipt of the units, inspect the items for either visible or
concealed damage.
REPORT ANY DAMAGE TO THE CARRIER. COMPU-AIRE IS NOT RESPONSIBLE
FOR FILING OF ANY CLAIMS. ALL NEEDED INSPECTION AND CLAIM FILING
IS THE RESPONSIBILITY OF THE RECEIVER.
LOCATING THE AIR CONDITIONER
Proper clearance is important for the unit function and access to
various components for adjustment and repair or replacement.
Front*
Left Side
Right Side

36"
36"
36"

*Consult Electrical Codes and provide clearance

UNCRATING
The units are shipped as follows:
1)
2)
3)
4)

SYSTEM 2100 - wrapped with cardboard and wooden crated.
Air Cooled Condenser - wooden crated
Control Panel - corrugated box and shipped separately.
Optional items when ordered such as remote control panel,
water detectors, floor stands, etc. are shipped separately in
its own box.

Extreme care should be exercised in handling these units. SYSTEM
2100 unit is specifically painted to match or contrast the computer
equipment. Exercise care when removing the covers.
Make sure the forks are under the entire unit and protruding on the
far side prior to lifting.

SETTING THE UNIT
If the raised floor is already installed use RUBBER TIRE DOLLIES to move
unit to its location.
If the floor is not installed Mounting Stand may be used to install the
unit.
An alternate method of setting the unit is with the use of leveling
jack stands. The height of the unit can be raised or lowered through the
use of the adjusting rods.
The locknuts must be tightened to assure
rigidity, as shown below.
UPFLOW UNITS - The unit may be placed directly on the sub floor. The
upflow unit has an optional 20" high discharge plenum.

SETTING THE AIR COOLED CONDENSER
Rigging: Move the unit to the installation location using a crane or fork
lift. Each fan section has heavy leg supports with lifting holes at the
top. Do not lift with a choke sling around the unit. Spreader bars are
recommended for lifting multiple fan units. Under no circumstances should
the coil headers or piping be used for lifting the unit.
Leg Assembly: The legs must be unbolted from the shipping position and
extended prior to placing the unit on it's pad. Each leg extends down
approximately 18 inches and reattaches using same bolts.
LOCATING THE CONDENSER
The remote heat exchangers must be located in an area that will ensure
free air flow into and out of the unit. The unit should not be placed
closer than 36 inches from any wall or other obstruction. When two or
more units are used in the same area, space them apart by a minimum of 48
inches.

Heat exchanger piping connections: Piping must be supported within 36
inches of the inlet and outlet connections.
The inlet connection is located on the top header on all units.
outlet connection is located on the bottom header of all unit.

The

INSTALLING THE CONTROL PANEL

Control Panel is shipped separately for field mounting in the control box.
The control panel consists of:
1)
2)
3)
4)
5)

Power Terminal Block
Low Voltage Interlock Terminal Block
Contactors
Control Transformer
Ambient Thermostats

Follow the following steps to install this Control Panel inside this
Control Box :
1)

Remove wires from the terminal block in the Control Box , tag them so
they do not get mixed up.

Install the control panel with sheet metal screws.

Install wires from each conductor as shown on the diagram.

Attach the refrigerant fitting from the SCR controller to the factory
installed schraeder fitting on the liquid lines. Exercise extreme
care so the capillary line is not kinked.

5) Install the bulb(s) of the ambient stats on the side of the Air
Cooled Condenser. Make sure to shield this bulb from direct sun
light.
Standard Air cooled condenser is provided with Fan Speed control type low
ambient control
FAN SPEED CONTROL

Fan speed control provides an infinite number of speed variations on
specially designed permanent split-capacitor motors. Control varies the
quantity of passing air through the air cooled condenser by directly
sensing the refrigerant head pressure.
OPERATION

Fan Speed Control provides air delivery in direct proportion to heat
rejection requirements of the system. This is to maintain optimum system
capacities and pressures in widely varying operating ambient.
As the ambient temperature drops, the head pressure will also drop. As
the head pressure drops, this will sensed by the pressure transducer and
the air quantity will be reduced thereby raising the head pressure and
maintaining the fixed condensing point.
FAN SPEED CONTROL PACKAGE MOUNTING
The Fan Speed Control is provided in a single enclosure package. This
package contains thermostats and a FSC device. The thermostats switches
the condenser fans off on a drop in ambient temperature. The Fan Speed
Control device modulates the speed of the motor closest to the header end
of the condenser.

The FSC package is to be mounted on the right hand side of the condenser
facing the header end. The leads to the motors are brought out to
junction box on the right hand side of the condenser facing the header
end. The leads at this point should be connected to the proper components
in the Pan Speed Control enclosure. (Check the electrical wiring diagram
shipped with the Fan Speed Control enclosure). The thermostat's bulbs are
to be mounted on the exterior of the box so that a representative ambient
temperature is sensed by the bulbs.

FAN SPEED CONTROL REFRIGERANT CONNECTION

The Fan Speed Control requires that the capillary be connected to the hot
gas header through the shraeder fitting provided.
Also enclosed in the Fan Speed Control package are thermostats for each
condenser motor with the exception of the control motor. The thermostats
should be set in accordance with wiring diagram provided with the unit.
NOTE: Fans are numbered starting at the header end of the condenser.

HEAD PRESSURE CONTROL VALVE (OPTIONAL) Low ambient Control Below 20°F
-

This type of low ambient control includes head pressure control valves and
the receiver package. The receivers are installed in the air conditioner
and the valves are shipped separately for field installation on the air
cooled condenser. Upon receipt of this package, these items should be
checked against the packing list and stored inside the building until they
are ready to be installed.
OPERATION OF HEAD PRESSURE CONTROL VALVE

During periods of low ambient temperatures the condensing temperature
falls until it approaches the setting of the head pressure control valve,
which throttles towards a closed setting, thus restricting the flow of the
liquid from the condenser. This causes the refrigerant to back up in the
condenser and reduces the effective condenser surface. The check valve
opens after the head pressure control has offered enough restriction and
then causes the differential between the condensing pressure and the
receiver pressure to exceed 20 psig. The hot gas flowing through the check
valve serves to heat the cold liquid being passed by the limitizer valve.
Thus, the liquid reaches the receiver warm and with sufficient pressure to
assure proper expansion valve operation. The check valve and limitizer
valves modulate the flow automatically to maintain proper condensing
pressures.
INSTALLATION OF HEAD PRESSURE CONTROL VALVE

There is one head pressure control valve on each of the limitizer system.
These control valves, or limitizer valves as they are called, can be
installed in a horizontal or a vertical line, whichever application
permits easy adjustment and accessibility to either valves. Care should
be taken to install the valves with the flow in the proper direction. To
insure fast system start-up, the receiver is mounted inside the air

conditioner. A time delay relay is used to assist start-up in colder
climate. It bypasses the low pressure control valve during start-up. It
is important that head pressure control valve be protected by wrapping the
valve with a wet cloth to keep the body of the valve at a temperature
below 250 degrees F. It is important to keep the flame away from the
valve body, to insure that no-body damage is done to the valve. The valve
should not be subjected to pressures in excess of 250 psig during the leak
testing procedures. The limitizer valves are factory set to maintain 180
psig. The HEAD PRESSURE CONTROL VALVES are hermetically sealed,
therefore, when a valve comes inoperative, it must be replaced. There are
two types of malfunctions that may occur. Failure to open or failure to
close.

If particles of solder are in the system, they can restrict the orifice of
the valve and cause the valve to malfunction. If this occurs, gently tap
the valve, this will possibly allow the particles to flow through the
valve. Since a synthetic material is used in the construction of th e
valve, damage to this will cause hot gas to leak constantly. If this
occurs, the valve must be replaced.

PIPING CONNE CT IONS

All plumbing field piping is brought to the unit through the bottom from
the left hand side of the unit as shown below:

CONDENSATE DRAIN CONNECTION

Two 3/4" copper stubs are provided on each unit for condensate
removal. Primary drain is internally trapped, but the secondary
drain must be field trapped. It is recommended that unions be
installed in each line to permit ready disconnection from the unit
for easy cleaning. Where local codes permit, PVC pipe may be used
for drain lines. It is important that the drain line be installed
with sufficient slope to permit easy draining. Drain lines should
have a pitch away from the unit not less than 1/4" for each 10 feet
of run. DO NOT REDUCE THE SIZE OF THE DRAIN LINE.

A secondary drain connection must be made to the bottom of the
unit. The drain connection is 3/4" stub.
On some applications were a floor sink or other means of condensate
disposal is not available, a condensate pump of adequate size
should be used. There are several small pumps available, complete
with built-in floats for automatic condensate removal. The correct
choice of pump depends greatly on the pressure head(vertical riser)
that must be overcome. In some instances, where the head is higher
than pump head capacity, two pumps piped in series may be
necessary.
A check valve must be installed at the discharge side of all
condensate pumps to reduce short cycling.

NOTE: For units having an automatic flush cycle on the humidifier,
a condensate pump with high temperature plastic sump tank should be
used, due to the high temperature of the water being flushed.
POWER SUPPLY FOR CONDENSATE PUMP SHOULD BE FROM A SEPARATE SOURCE,
USUALLY 115 VOLT OUTLETS, AND MUST NOT IN ANY WAY BE CONNECTED WITH
THE AIR CONDITIONING UNIT.

HUMIDIFIER PIPING CONNECTION
The standard humidifier supplied with Compu Aire units is a
disposable generator type humidifier. A 1/4" compression fitting
is provided for the water supply, a 1/4" O.D. copper tubing should
be used for make-up water.
-

For the optional infra-red humidifier or the electric immersion,
piping connections are identical to the standard humidifier. All
require a 1/4" O.D. tubing.
A water line shut off valve MUST be provided outside the air
conditioner for future disconnection and service. In addition, an
in line water pressure regulator and a strainer should be installed
in the make-up water line. Water pressure should be set between 30
and 50 psig.
For infra-red and electric immersion the float is factory adjusted
to maintain minimum water in the humidifier where the elements are
just submersed in water. For field adjustment, loosen the float
arm, or slightly bend the arm.

REFRIGERANT PIPING
It is of the greatest importance that all refrigerant piping be
cleaned and free from dirt and moisture_ One drop of water in a
refrigerant system will greatly deter the operation and efficiency
of the system. Upon installation, all open ends of piping should
be sealed to prevent condensation from accumulating inside. (If it
is not to be completed during the day). This avoids future
problems, malfunctions and corrosion.

It is suggested that hot gas and liquid return lines be silver
soldered, using one of the many types, such as silfoss, etc.
Absolutely avoid soft solders such as 50/50 or 95/5. Use a flow of
dry nitrogen through the piping while being soldered. (To
eliminate formation of a copper oxide scale on the inside of the
piping).
To reduce noise and pulsations, the air cooled systems are to be
field provided with hot gas mufflers. Extreme care and planning
must be exercised in running the refrigerant lines; they must be
provided with proper isolation by the use of an Arma-Glex or rubber
bushing on the supports. Under no circumstances should hot gas
lines be laid on steel ceilings, or metal supports without a type
of isolation or protection from vibration, which can possibly cause
damage to the refrigerant lines.
EVACUATION PROCEDURES-

CAUTION: PULL ALL FUSES EXCEPT MAIN FAN AND TRANSFORMER FUSES. To
reduce the possibility of non-condensables in the refrigerant
system during charging, the solenoid valves must be open and a
vacuum must be pulled on both the suction side and the discharge
side of the compressor.
PROCEDURE FOR DEHYDRATION - METHODS #1

1)
2)
3)
4)
5)
6)
7)
8)

Open all disconnect switches.
Pull all fuses except main fan and transformer fuses.
Turn disconnect ON
Start the main fan by pushing the main fan switch.
Check amperage on main fan and make sure it does not exceed
FLA (full load amps).
Check fan rotation and correct if necessary.
Set thermostat at 40°F.
Proceed with paragraph #4 in procedure #2.

PROCEDURE FOR DEHYDRATION - METHOD #2
By using a separate control voltage transformer having an output of
24 volts at 40 VA, the solenoid can be energized without starting
the unit.
1)
2)
3)
4)

Turn all power OFF to the unit.
Remove all fuses including main fan and transformer fuses.
Connect the external transformer to the solenoid valves.
Evacuate the system in accordance with t he following
procedure:
Connect the refrigeration gauges on circuits #1 & #2 at both
the suction and discharge service valves.
Start with circuit #1 and open all service valves. Place in
circuit #1, 150 psig of DRY NITROGEN with a tracer of freon
for the purpose of leak checking. With pressure in circuit #1,
open the discharge and suction valve on compressor #2. It
pressure increases in #2, the system is cross circuited and
must be re-checked for proper piping_ If there is no pressure
increase, place 150 psig of DRY NITROGEN with a tracer of
freon in circuit #2 and leak test.
After completion of leak testing, release test pressure & pull
a vacuum on the system. Leav e this pulled down for
approximately 4 hours and re-check the gauge reading. If it
has not changed purge with Freon, pull another vacuum of 250
microns, leave on for 2 hours and re-check the gauge readings.
Purge with Freon and re-pull the vacuum of 250 microns (9.842
in. hg.) or less. After the completion of this step, fill the
system with Freon vapor until pressures have equalized in the
liquid and discharge lines.

CHARGING PROCEDURE
Remove the reheat and humidifier fuses. Check to insure that all
shipping blocks from the compressors, all tags from the electrical
panel, and all tags in the evaporator fan section have been
removed, and that all debris is clear of the unit so that nothing
can be damaged during start-up_
Turn the disconnect "ON" and check the evaporator fan for proper
rotation.
Set the thermostat to 40°F to insure that the solenoid valves are
open during the charging procedure. Connect the refrigerant gauges
to the refrigerant drum purging the hoses to remove non condensable.
Add refrigerant vapor to the suction side of the compressor to
eliminate short cycling of the compressor. The low pressure switch
can be manually energized to expedite the charging.

As the system builds head pressure, the condenser fan will start
rotating slowly. The Fan Speed Control motor will not be energized
until a sufficient head pressure has been developed during the
charging of the unit.
Charge the unit until the sight glasses on the liquid lines in the
compressor section clear_ Watch the sight glasses for a period of
10 minutes to insure that no bubbles re-appear.
A. LIQUID CHARGE

After the final vacuum has been pulled on the systems, liquid
refrigerant may be placed in the receivers. This is accomplished
by the following procedure:
1)
2)
3)
4)
5)
6)
7)

Make sure the unit is off and that the solenoids are closed.
Connect a set of manifold gauges to the refrigerant drum and
to the receiver at the rotolock adapter.
Purge the refrigerant hoses so that no non-condensable will
enter the systems.
Open the refrigerant drum so that the liquid will flow from
the drum to receiver.
Open the roto-lock valve and allow the refrigerant to flow
into the receiver.
Close the roto lock valve and disconnect gauges.
Start the compressor.

B. VAPOR CHARGE

1)
2)
3)

After the dehydration procedures have been followed, replace
the fuses in the condenser fan compressors and transformer
circuits.
Connect hose from drum to suction port of the compressor,
purge hose so that no non-condensable are in the hose.
Start the compressors check the level in the sight glass. If
the level has lowered, add additional Freon to maintain the
sight clear.

After charging is complete, reset the high pressure switch.
Approximate charge required per circuit:
As recommended by ASHRAE MANUAL.
Total Charge = Basic Charge
Liquid Line Based on Hermetic
Compressor Line and Refrigerated Liquid at 100°F.
LEAK TESTING

No installation is complete until the entire system has been
thoroughly checked for leaks. This includes water tubing,
humidifier make-up water, and condensate lines.

HOW TO SAVE REFRIGERANT CHARGE

The process of opening a refrigerant circuit of the Compu-Aire
System 2100 and saving the refrigerant charge of the system to be
opened, requires only a few more minutes than does blowing the
refrigerant charge. Intentionally blowing the charge is illegal.
The procedure for saving the refrigerant charge. is as follows:
1)
2)
3)

Open disconnect switch.
Pull fuses on system not to be opened.
Install manifold on the receiver at each rotolock valve, using
the high pressure gauge and the charging hose.
4) Purge the hoses to remove any con-condensable.
5) Start the unit and set the thermostat at 40 degrees F; this
will start the compressor.
6) Return to the receivers.
7) Backseat the rotolock valves on the system being pumped down.
Open gauge and rotolock valve on the other system.
8) During this procedure, watch the gauge pressure to prevent the
receiver from over-filling. If the gauge pressure starts to
rise, do not let the pressure exceed setting on pressure
relief device located on the receiver.
9) Open the rotolock valve of the system, release vapor pressure
present and make necessary repairs.
10) Evacuate the system. After evacuation is complete, the liquid
can be transferred back into the proper system, through the
manifold gauge.

HUMIDIFIER

The Compu- Aire Humidifier provides the proper amount of
humidification needed through electronic sensing of computer rooms
air moisture content. The humidifier itself is constructed with a
disposable cylinder.
Before starting the unit, be sure that the water supply valve is in
the open position and there is water in the humidifier cylinder.
Periodic checks are required to insure against built up deposits.
The frequency of these checks depends on the hardness of the water.
Under normal conditions these checks should be made at least every
fourth week. An automatic flush system is standard to eliminate the
need for periodic replacement of the humidifier cylinder.
It is important that the humidifier be kept clean for proper
operation. This will provide a long life and efficient operation of
the humidifier.
HUMIDITY CONTROL

This control is pre-set at the factory for 45% and no adjustment
should be necessary, however field adjustment can be made. Refer
to the humidifier section for further details.

ELECTRICAL CONNECTION

The unit is completely factory wired with self-contained controls.
Before proceeding with the electrical connections, make
certain that the volts, hertz and phase correspond to that
specified on the unit rating plate. Also, check to be sure that
service provided by the utility is sufficient to handle the
additional load imposed by this equipment. Refer to the unit rating
plate for equipment electrical requirements. The attached wiring
diagram shows the proper high and low voltage field wiring.
IMPORTANT

Make all electrical connections in accordance with National
Electrical Code and any local code ordinances that may apply. USE
COPPER CONDUCTORS ONLY.
WARNING -- The unit cabinet must have an uninterrupted or unbroken
electrical ground to minimize personal injury if an electrical
fault should occur. It is important that an electrical ground wire
of adequate size can be connected to the ground lug provided inside
the control box.

Supply voltage at the unit must be within + 10% of the voltage
indicated on the nameplate for a dual voltage rating, supply
voltage must be within 5% from the lower nameplate rating and
within 10% from the higher rating. Phase to phase imbalance must
not exceed 3%. Contact your local utility company for correction of
improper line voltage. Improper electrical power supply may cause
premature failures and void unit warranties.

The system cutout termina ls on the terminal strip are for
connection to a "panic button" or remote shut-off if required.
This should only be connected to a switch and NO EXTERNAL SOURCE OF
POWER SHOULD BE INTRODUCED AT THIS POINT. The conductors should be
sized depending on the length of run and the number of control
transformers used in the unit. Maximum voltage drop must not exceed
1 volt. Each control transformer draws approximately 3 amps @ 24 V.
For long runs where the conductor size becomes too large, an
interlocking relay (field provided) should be used.
A dry contact (24 volts rating) is provided for terminals for a
remote alarm connection.
If the control panel includes a condensate probe, make sure it is
mounted below the unit against the floor area where water may
collect. To check the operation of the probe, submerse it in a cup
of water. The condensate alarm should energize.

START-UP AND TEST PROCEDURE
A) With All Power to Unit OFF - Check that All Wiring is Correct

Check that properly sized fuses are installed in the
disconnect switch. Correct fuse size and minimum circuit
ampacity are listed on the unit nameplate. Now, check the
wiring connections in the Main Control Panel to see if they
are tight. It is best that this be checked prior to operating
the machine. After checking, close the Main Control Panel
cover and proceed as follows:
Solid-State Control Panel - With the system switch in the
"OFF" position, apply power to the unit. The "Power On" light
should illuminate.
B) Check for Correct Phasing

The equipment should now be checked for correct phasing
required to make the blower motor turn in the correct
directions. For this test it is necessary to open the front
access panel or the right side doors of the unit to observe
the blower and blower motor. Now, momentarily switch the
system switch to the "ON" position and then back to "OFF".
The blower motor will have started and it is therefore
possible to determine rotation. On Compu-Aire units, the
blower should be rotating in a CLOCKWISE direction in downflow
units and COUNTER CLOCKWISE in upflow units, looking in the
right side of the unit. Heaters and humidifiers are not
affected by phasing.
C) B l o w e r S p e e d Adjustment

Adjustment of the air flow may be desired. The air flow can be
readily adjusted with the variable pitch pulley provided on
the blower motor. After the unit has been started and the air
flow properly adjusted, check the blower motor current to
ensure that the motor is not overloaded. Any time the blower
speed is increased, the blower motor current should be
checked. If a field adjustment is made, the motor should run
for at least one hour at maximum design room temperature to
see if motor trips on internal overload.
D) No Air Flow & Clogged Filter Adjustment

The "No Air Flow" light and alarm should be checked prior to
the completion of the installation. Although the control is
adjusted at the factory, varying local conditions make it
impossible to provide accurate pressure adjustments.
To check the filter pressure switch, let the unit operate on
cooling for about 30 minutes. This will allow the evaporator

Coil surface to become wet. With the cooling unit filters in
place, block off approximately 75% of the air intake. If the
sensing device is correctly adjusted, the "Clogged Filter"
alarm should energize; the sensing device should have JUST
turned on the alarm at the 75% blocked inlet condition. An
Air Flow switch is also provided at t he discharge side of
the blower and will activate the No Air Flow malfunction light
and alarm.

E) Humidifier Operation

Check to see that the unit is securely mounted on a level surface
with the proper drain and water supply. Check for correct voltage
with appropriately sized service. Check that the steam distributor,
steam supply hose and condensate line are correctly installed and
routed back to the unit. Ensure that the external control
humidistat is located in an area to properly sense the relative
humidity to be maintained by the humidifier, and that the interconnecting low voltage wires between the humidistat and unit's
control terminal strip are in accordance with the wiring diagram.
Check all electrical connections for wires which may have been
become loose in shipping. Components burnt due to lose connection
are NOT under warranty.
Check electrode plugs to ensure they are pressed firmly onto the
electrode pins. Important: Loose connections will cause overheating
of the cylinder plugs and probably melting of the plugs and/or
cylinder.
Open the isolating gate valve in the feed water line to the unit.
Make sure the humidistat is set high enough to call for
humidification.

Turn on the main disconnects in the primary service feeding the unit
and check that unit has power at the primary terminal block.
Water will start to enter the cylinder through its bottom port and
rise in the cylinder to a point determined by the solid state
control circuitry.
It is not unusual upon initial start-up for the water to fill the
cylinder an cycle on the red high water level indicator light.
The red light simply acts as a safety to shut off the fill valve
and prevent over fitting. With the red light on, the water in the
cylinder will continue to heat an after a few minutes start to
boil. After the boiling action of the water has lowered the water
level go out and fill solenoid will again open until the cylinder
is again full.
This cycling of the red light and fill valve will continue until
the unit's full output capacity is reached after which the water
level will automatically lower itself in the cylinder. (The
increased concentration allows for lower electrode coverage while
maintaining the same output). When a stabilized condition is
reached the waster will be boiling close to the cylinder seam
level. The solid state circuitry will maintain t he proper
concentration in the cylinder by introducing short drains only when
necessary.
If the cylinder is manually drained, the above process will repeat
itself.
LOW WATER CONDUCTIVITY

Should normalization of the unit be required immediately after
start-up, the installer may speed up the process by artificially
increasing water conductivity. The installer should dissolve half
a teaspoon of table salt(no more) in a cup of water and add it to
the cylinder by means of the fill cup attached to the plumbing
section, during a fill cycle.

To obtain access to this fill cup simply pry open the fill cup
cover plate. (Do not displace the splash diverter underneath).
Excessive amounts of salt will result in erratic operation of the
unit; however, normalization of the unit will be corrected
automatically through the solid state control sequence.
CAPACITY ADJUSTMENT

The M.E.S. series of humidifiers are factory set to cover most
normal conditions. If an extreme situation is encountered notify
the factory for instructions.

SYSTEM 2200 PROGRAMMABLE CONTROLLER:

The System 2200 is a programmable solid state control with
4 Row, 40 Character, back lit, super-twist Liquid Crystal
Display (LCD). Information is displayed and presented in a
format that is viewed and understood.
For detail operational instructions see:

Compu-Aire
System 2200
Programmable Controller
User Guide

SERVICE AND MAINTENANCE INSTRUCTIONS
A. Filters

1) The filters should be checked and changed periodically. When
they become dirty, an alarm is activated by th e filter
pressure switch. If the filters are dirty, they must be
changed for efficient operation of your system. To check the
alarm indicator, cover approximately 75% of the return air
opening; the alarm should energize.
If the alarm energizes prematurely or does not energize when
it should, adjust the filter switch. All doors to machine
should remain closed before determining whether an adjustment
is necessary.
2) Spare filters should be kept in stock. Filters should be
checked monthly and replaced if necessary.
B.

BLOWER DRIVE
Easy access can be made to the drive set by opening the front
right door. This gives a full view of the motor and the drive
set.

Belt tension should be checked every month to assure proper,
efficient operation. If tightening is needed, slightly loosen
the four motor mounting bolts. Then turn the adjusting screw
(located in the front of the motor mounting channel), until
the belt is properly adjusted. RE-TIGHTEN THE FOUR MOUNTING
BOLTS.

BLOWER BEARINGS

Blower bearings are permanently lubricated and do not require
any maintenance. However, in special cases, some units have
bearings that require lubrication at least every six months.
D.

HEATING ELEMENTS

The heating elements are finned type, and there is no
maintenance required. Access to the heater box can be
obtained from the right hand side of the unit.

HUMIDIFIER

Four kinds of humidifiers are used in Compu-Aire Units:
Electric Immersion, Infra-Red, Dry Steam, and Replaceable
Generator.
1.

ELECTRIC IMMERSION
This type humidifier will probably require the most
maintenance. If is necessary to thoroughly clean out the
humidifier pan at regular intervals. The frequency tor this
depends entirely on the nature of the water used, and the
frequency at which the humidifier is called into operation.
To begin with, it is recommended that the humidifier be
checked every two weeks. When excessive scale has formed in
the lower pan and on the heating elements, it will be
necessary to thoroughly clean this pan.
To inspect the humidifier, de-energizes the power to the unit
at the disconnect switch. Open the left front access door.
The humidifier is now fully exposed. Visually inspect the pan
and the heating elements.

If cleaning of the humidifier is required, shut off the water
supply at the valve located on the side of humidifier
assembly. Disconnect the humidifier electrical plug, release
the front pan latch, disconnect the auto flush hose(if used)
and overflow drain connections. Remove the whole humidifier
assembly to a nearby sink for thorough cleaning.
To remove the scale, sulfamic acid scale remover is
recommended (check with your local supply house). Flush out
all free scale, then add scale remover as noted by the
manufacturer of the scale remover to the humidifier pan filled
with water. Empty the pan and rinse. If necessary, repeat the
de-scaling procedure until the pan is clean. NOTE: DO NOT
EMPTY THE RESIDUE FROM EITHER OF THESE OPERATIONS INTO THE
UNIT DRAIN SYSTEM. After cleaning, re-install the humidifier.
Check to ensure that the drain valve is shut, push the
humidifier assembly back into place firmly, engage the latch,
re-connect the electrical plug and piping hoses, then open the
water supply valve.
If the humidifier is equipped with automatic flush cycle,
draining the humidifier can be accomplished by moving the
lever on the flush valve to the manual position. Make sure
that the lever is returned to the auto position when the
cleaning operation is completed.

2. INFRA RED HUMIDIFIER
-

The inspection procedure for the infra-red humidifier is the
same as for the Electric Immersion type described below. If
cleaning is required, remove the humidifier assembly to a
nearby sink for cleaning.
Clean the pan using the method described in I below, again,
using care not to allow scale to clog the drain in the pan or
the unit. Carefully clean the reflector and lamps of any scale

or deposits. BEFORE REPLACING THE LAMPS, WIPE OFF ALL GREASE,
OIL, ETC. WITH A CLEAN DRY CLOTH. ANY GREASE OR OIL MAY CAUSE
A HOT SPOT AND LAMP FAILURE. REMEMBER LAMPS ARE NOT COVERED IN
THE UNIT WARRANTY.

Infra-Red Humidifier

DRY STEAM

When units are equipped with dry steam type humidifiers, the
necessary steam connections are made through additional
connections.
a)
1)

The operation of a steam humidifier is explained below:
The steam supply is taken from the top of the steam main.

2)
Steam passes through a strainer to prevent dirt or scale
from reaching the humidifier.
3)
Incoming steam strikes a baffle to divert any condensate
to the drain.
4)
Steam
fills the body and cap castings.
Casting
temperature will approximate the steam temperature
(approximately 240°F at 10 psig), preventing condensation
and dripping at the outlet when the steam passes through at
atmospheric pressure.

The humidistat actuates the operator to open the
valve for humidity.

6)
Steam enters the re-evaporating chamber through a
tube. Any condensate droplets will fall and
evaporate on contact with hot metal.
7)
Dry steam passes up and out through muffling
asbestos wicking on stainless steel.
8)
The steam is discharged directly in the unit.
b.

Maintenance of a dry steam humidifier is as follows:
1)
Clean the strainer in the supply a few days after
operation, and thereafter at least twice a year or as
required.
2)

If the solenoid valve should stick, touch up the
plunge with fine emery cloth and wipe out the
plunger tube.

Steam enters the re-evaporating chamber through a
tube. Any condensate droplets will fall and
evaporate on contact with hot metal.

Steam Humidifier

Dry steam passes up and out through muffling
asbestos wicking on stainless steel.

The steam is discharged directly in the unit.

Maintenance of a dry steam humidifier is as follows:
1)

Clean the strainer in the supply a few days after
operation, and thereafter at least twice a year or
as required.

If the solenoid valve should stick, touch up the
plunge with fine emery cloth and wipe out the
plunger tube.

Steam Humidifier

If the water reaches top of cylinder before 110% F.L.A. the fill
valve shuts off via the sensor and fill-boil-fill-boil cycle
continues, cycling off the red full cylinder light until the
concentration becomes high enough to reach 100% F.L.A. Then the
following described control process takes over.
WATER SUPPLY AND PLUMBING

The orifice in the fill valve(s) is sized for an extended
water pressure range of 30 to 85 psi.

For water pressure between 15 and 30 psi, notify the factory
and the next larger size of fill valve will be supplied.

For cases below 15 psi, notify the factory and fill valve with
largely oversized orifice will be supplied.

For cases above 85 psi, install a pressure reducing valve in
the water feed line to the unit. Otherwise insufficient
cylinder water will drain when fill and drain mix during the
automatic dilution cycle.

With extremely dirty or muddy water sources, e.g. some well
sources, ensure proper filtration by adding and external
filter to the water line entering the unit. (Consult factory
for accessories such as filters).

DO NOT soften water with Condair unit because it is much too
conductive.

DO NOT use completely de-mineralized water with the Condair
unit as it is the minerals that allow the electrode principle
to work.

DO NOT use a hot water source as it will cause deposits to
eventually block the fill valve orifice.

Water Connection

1) A copper compression olive type coupling for 1/4" soft copper
tubing is provided with unit and requires no soldering for the
water connection to the unit.

An isolating gate valve should ALWAYS be placed in feed water
line allowing service of the fill valve.

Each unit is fitted with a fill solenoid valve located on the
base drain pan. Flow orifices ar designed for water pressures
from 30-85 psi and are protected by the built-in strainer.

For inlet water pressure outside this range, the factory
should be contacted. (See also water supply section)

The Inlet Water Strainer
The fill solenoid is equipped with a built-in serviceable strainer
to prevent foreign particles, such as sand or solder from blocking
the fill orifice.

To clean the strainer, first turn off the unit, close the gate
valve on the water supply line, remove the locking bar located
in the fill solenoid and slide out the strainer.

Rinse the strainer and back flush it thoroughly with tap water
to ensure the removal of all debris.

To re-install strainer, reverse procedure.

Drain Connection
1)

Unit is equipped with a 7/8" O.D. unthreaded drain outlet on
the underside of the base drain pan. Cut a few inches of steam
supply hose, available from the factory, and connect from
drain outlet to 3/4" nominal diameter copper pipe and route to
closest (floor) drain.

Where municipalities, counties or cities require an air gap to
isolate unit from sanitary drainage system, a funnel drain
under the unit should be incorporated.

Drain canal on bottom of unit must be removed and cleaned at
least once a year. Ensure that rubber gasket is re-installed
properly.

4) Drain valve must be disassembled and cleaned each time a
cylinder is replaced. (These three components, i.e. drain
canal, drain valve and cylinder are continually exposed to
concentrated mineral water.
REPLACEMENT OF THE STEAM CYLINDER

Consult factory or agent for replacement. Quote the cylinder model
form the white 3-digit label on the cylinder or quote model,
voltage and serial number from unit specification label.

After an extended period of operation in accordance with life
expectancy information, see Figure 24, the cylin der is completely
used as indicated by a red light illuminated on the face of the
cabinet. When this condition is reached, a new replacement
cylinder is to be installed.

NOTE: Red light may come on during initial start-up but does not

mean cylinder replacement.

Any time that the unit is going to be shut down for an extended
period of time, including summer shutdown, ALWAYS drain down the
cylinder before disconnecting power. Otherwise, the electrodes are
subject to harmful corrosion.
REMOVING THE CYLINDER

1) Turn off the water supply to the unit.
2)

The old cylinder must be drained completely before removing.
This is done by pushing the auto on/off drain switch to the
"drain" position,
3)
When completely drained, push the auto/on/off drain switch to
the "off" position.
4)
Open the main disconnect during the entire cylinder change
operation.

The power wires to the cylinder are attached by cylinder plugs
to the electrode pins on top of the cylinder. Pull these plugs
vertically off the pins.
6)
Using slot screw driver, loosen the steam hose clamp(s) and
pull steam hose off vertically.

The cylinder is , now ready to be lifted out of the unit.

INSTALLING THE NEW CYLINDER
1)

The reverse procedure should be followed to install a new
cylinder. The main disconnect is to be left open until the
cylinder is completely installed an reconnected.

Ensure that the cylinder mounting stubs are seated properly in
the allotted side mounting slots within the unit.

The white cylinder plug on all units is for the sensor
electrode which always goes on the single pin offset from the
others.

NAJGS

4) Ensure that cylinder plugs are very snug on the pins.
5) For loose fitting plugs, squeeze with a pliers before
installing, since loose plugs may generate enough heat to melt
and destroy the plug and cylinder.

TROUBLE-SHOOTING HUMIDIFIER
Auto on/off/drain switch in "on" position-unit will not fill:
When the on/off control circuit is made and the "auto on/off/drain"
switch is pushed to "on", the 24 volt holding coil of the primary
contactor should energize. The resulting magnetic pull closes the
high voltage contacts with a distinct and audible "clunk". If the
contactor will not make, then inspect the following while referring
to the wiring diagram.

1) Check for 24VAC across pins 33 and 39.
2) Jumper contacts 1 & 2 on external control terminal strip. If
contactor operates then control system is at fault.
3) The low voltage 3 amp fuse located on front of the unit.
4) The "on/off" jumper plug connection on the basic unit.
5) The wire ribbon connecting the basic unit to the current
transformer board.
6) The contactor holding coil could be open of shorted.
Recheck that the "auto/on/off drain" switch is still at "on". if
it is, then shut off the main disconnect and check fuses or breaker
of the main disconnect. If they are serviceable, turn power back
on.
To test for a defective "auto/on/off drain" switch, disconnect the
red wire from pin 38 on the main p.c. board (basic unit) and touch
it to pin 39. If the contactor activates, the "on" side of the
switch is defective. If the contactor does not activate, then the
basic unit p.c. board could be defective.
If the 3 amp control fuses blow when the red wire form pin 38 is
touched to pin 39, contactor holding coil could be shorted. After
contactor has been replaced and contactor still will not activate
then the basic unit "on/off" jumper circuit could be burnt. This
can be temporarily bypassed by placing a jumper between terminals
35 and 39 until replacement of the basic unit. Return the red wire
to pin 38.
After the necessary components have been replaced and the
contactors pull in, there is high voltage to the cylinder(s) and
the control sequence can begin.
Approximately 30 seconds after the contactor pulls in, the fill
valve coil should energize. There is also a visible fill relay on
the basic printed circuit board. It is physically located in line
with pin 36. The points on this relay must be touching in order for
the fill valve could be energized.
If the points will not touch after the built-in time delay, then
the sensor input may be interfering. To confirm, remove the red and
black wire sensor input from the male connector on the basic p.c.

board. (It is located 1/2" from the right hand side of the board.)
wait 30 second s and if the fill relay point now touch, then sensor
should be replaced. If they do not touch, then the basic p.c. board
c o u l d b e f a u l t y . To c o n f i r m , d i s c o n n e c t t h e r e d w i r e f r o m p i n 3 8
and touch it to pin 36. If the fill valve coil activates then the
basic p.c. board should be replaced. If it still does not activate
then the fill valve coil should be replaced.
Having changed the necessary co mponents, water sta rts filli ng the
c y l i nd e r a n d b e g i n s to s u b m e r g e t h e e l e c tr o d e s . B e c a u s e o f t he h i g h
voltage across the electrodes, the water can now conduct
electricity.
red Light on- Water at top of cylinder:

Common occurrence on start-up - See previous pages
water level should be at the top of the cylinder - if cylinder is
new this is normal
i f cyl i nder is old , i t i nd ica tes rep lacement ti me (ca n b e o rd ered
from factory

red light on - water NOT at top o f cylinder:
water foaming to top of cylinder to activate red light, also may
b e accomp anied by arcing (flashing) insid e cylind er
indicates abnormal wa ter co ndition(softened) or over
co ncentra ti o n o f co ntai ned wa ter in the cyl i nder ca used b y:
1)
2)
3)
4)
5)
6)
7)

Blocked water filter(clean)
Inoperative fill valve(check)
Inoperative drain valve(check)

Blocked drain valve(disassemble and clean)
Blocked screen at bottom of cylinder(remove and back flush)
Faulty sensor really (remove sensor concentration from p.c.
board and wait 60 seconds)
White sensor plug interchanged with power plug at top of
cylinder (white plug should be on terminal offset from the
others).

Water remains at high level and won't concentrate:

Normal on cold start-up can be accelerated by adding maximum 1
tsp. of salt to the cylinder (thorough the plastic fill cup on
fill cycle. See page 9).
If the unit has been operating extensively, observe for normal
fill, boil, fill, boil, cycle; no drain should be occurring.

Water beyond top of cylinder up into spout:
- red light not on and fill still activated; jump across connection
of sensor on basic unit p.c. board, if fill shuts off, then
sensor was faulty.
If fill remains on when connection is jumped, then basic unit is
faulty.
Consult factory for new part and replacement instructions.
Unit drains continually:

if cylinder almost empty check for magnetic pull on drain
solenoid indicating miss-wiring. If no pull drain actuator is
blocked open, remove, disassemble and clean.
if drain is occurring thorough activated drain valve, valve id
miss-wired or electronics is faulty-consult factory.
if drain is occurring through the overflow on the fill cup, this
is due to an abnormal restriction on the steam line and back
pressure forces water out of the cylinder; therefore water cannot
concentrate and level must stay high; review installation of
steam line to ensure no blockages or excessive static pressure in
air system.
To make service simpler and to check on its normal electronic
functions, an optional solid state pl ug-in check adapter is
available from the factory at cost by ordering BMF-9513.

F. Refrigeration Cycle
1) All systems, except CAA models are factory charged with a
holding charge. After checking system at start-up against
possible shipping and rigging damage, no irregularities should
be experienced except for normal wear.
2) The system should be checked periodically for leaks, oil
charge and dryness of Freon. Bubbles in the sight glass are
generally an indication of a leak except during the pump down
cycle.
3) Any deviation from the above or any head pressure or short
cycling compressor problem should be repaired by a qualified
refrigeration man.
Gr. Cleaning

For cleaning of the panels, a common all-purpose household
cleaner may be used. DO NOT USE SOLVENTS.

Touch-Up

For touch-up of texture vinyl paints, surface should be
lightly sanded, then wiped with a clean cloth saturated with
any good lacquer thinner. Apply touch-up lacquer by spray or
brush.

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