Thermal Edge CS020235 User manual

User & Technical Manual

CS020 50 Hz Series

for Class I, Division 2 Hazardous Locations

Rev 1.6

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 2 |P a g e

Title: CS020 50 Hz Air Conditioner for Class I, Division 2 Hazardous Locations User & Technical Manual

Department: Engineering

Objective: To provide important information for maintenance, diagnostics and advance operations of the

Thermal Edge CS020 Series Air Conditioners.

Revision History:

Rev

Date

Owner

Description of Changes

1.0

10-05-17

B. Slotnick

Initial Release

1.1

05-11-18

B. Slotnick

Updated warranty & RMA procedure

1.2

09-05-18

B. Slotnick

Revised minimum anti-short cycle delay & updated Remote

Controller option description

1.3

10-01-18

B. Slotnick

Updated warranty & unit specifications

1.4

02-20-19

B. Slotnick

Updated mounting instructions, alarm settings & RMA procedure

1.5

04-04-19

B. Slotnick

Added neutral power designation to schematic.

1.6

06-18-19

B. Slotnick

Updated preliminary testing instructions & compressor protection

default setting

Statement of Confidentiality

The Manual and other materials contain proprietary information, comprising Thermal Edge Inc.'s trade secrets.

Please maintain the confidentiality of all proprietary information during and after the term of the use agreement.

Also, please refrain from using this proprietary information in any other manner, including in any other

business, without Thermal Edge Inc.’s written approval.

Thermal Edge Inc. reserves the right to revise and otherwise modify the Manual to reflect changes in the

requirements, standards, and operating recommendations. The Manual is the sole property of Thermal Edge

Inc. It must be returned upon the expiration or the termination of the term of use agreement.

By accepting the Manual you have read and understand the Statement of Confidentiality and will abide by its

terms and conditions.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 3 |P a g e

TABLE OF CONTENTS

Overview 4

Inspecting the Equipment 4

Unpacking the Air Conditioner 4

Moving the Air Conditioner 5

Unit Label 5

Operation 5

Preliminary Testing 8

Mounting the Air Conditioner 9

Unit Specifications 10

Options 12

System Faults 14

Digital Temperature Controller Programming 14

Preventative Maintenance 17

Field Serviceable Parts 18

Safety Information 18

Troubleshooting Guide 19

Physical Dimensions 22

Electrical Schematic 24

Warranty Information 25

Return Material Authorization (RMA) Procedure 26

Appendix A –Power Terminal Block 27

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 4 |P a g e

Overview

Thank you for your purchase of the Thermal Edge Special Purpose Air Conditioner. Our air

conditioning equipment is carefully designed to cool and dehumidify the air in electronic component

enclosures. Thermal Edge has designed air conditioners for all types of electronic equipment

enclosures providing capacity from 1,000 to 20,000 BTUH.

This manual will guide you through the installation, maintenance, diagnostics and advance operations

of the CS020 Series Air Conditioners. This manual contains important information for the end-user

who installs, maintains and/or operates the CS020 Air Conditioner.

Technical Support

By Phone: 972-580-0200 / 888-580-0202

(Monday –Friday, 7:30 am –5:00 pm Central Time)

By Email: support@thermal-edge.com

Our goal is to have continuous improvement for both our equipment and our documentation. We rely

and appreciate your feedback to help us achieve our goal. Our technical support team is glad to work

with you if you require additional technical information not provided in this manual.

Inspecting the Equipment

Thermal Edge air conditioning equipment is designed, manufactured and packed to prevent damage

from normal handling, shock and vibration during shipment. It is necessary to inspect your equipment

upon receipt to ensure that there is no visual or hidden damage.

Upon receipt of the equipment, ensure that it is always top side up as indicated by “THIS SIDE UP”

labels. This ensures that the compressor oil is not displaced.

Note: If the equipment has been on its side it must be put upright for at least 24 hours before installing

or running to ensure the compressor oil has returned to the compressor.

All physical damage to packing or signs of damage to the equipment must be noted on the freight bill

of lading. Packages must be opened after receipt and inspected for any internal or concealed damage

to the equipment and to verify proper count and order fulfillment. Delivery of without the pallet, not top

side up, other freight on top, damaged or wet should be refused.

Unpacking the Air Conditioner

Always keep air conditioner top up as shown by the packaging label and arrows. If the unit is to be

transported after initial unpacking, place air conditioner back in original packing to prevent damage.

For shipment by UPS or freight carrier, repack as received and re-band to the pallet.

Note: Shipping without being strapped to the pallet may result in tipping and damage, this will void the

warranty.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 5 |P a g e

Moving the Air Conditioners

Read this section completely before running or installing your Thermal Edge air conditioning

equipment.

Note: You will need to perform a Preliminary Test before mounting the air conditioner. Refer to the

Preliminary Test section in this manual for instructions on how to run this test. You will also need to

prepare the enclosure that is to be cooled for mounting in accordance with this manual and the

template supplied.

Note: Thermal Edge air conditioning equipment must be mounted vertically with a minimum of 3”air

space for condenser air return and supply. If necessary, equipment may be mounted at up to a 5

degree angle (rotary compressors) without damaging the compressor.

If air conditioner is to be shipped or transported at any time; pack in original packaging and strap to

pallet to prevent damage. Air conditioner must be kept upright at all times. Air conditioners are not

designed to be shipped attached to an equipment enclosure. Air conditioners shipped which have

internal damage due to shipping while attached to enclosures are warranty voided.

Unit Label

Each air conditioner has a unit label, be sure to record the data from the label to the template below

and keep this information in a safe place for warranty and ordering parts. To prevent damage to

equipment, electrical panel and wiring, and to prevent personal injury, assure that the power source is

compatible with the equipment before operating. When recharging, refrigeration type and amount

must be the same as shown on the unit label or air conditioner will not operate properly or may be

damaged and may result in the warranty voided and UL listing voided.

Voltage:_________________ Frequency:__________Hz Phase:__________

Current Rating (A): Cooling:___________ Heat:___________

Max Fuse:____________ Min. Circuit Ampacity:________

Refrigerant:______________ Ounces:_______________

Design Pressure: High Side PSI:__________ Low Side PSI:__________

NEMAType:______ IP:______

Model:________________________________________

S/N:__________________________________________

Operation

Thermal Edge air conditioners will lower (or increase as necessary) the temperature inside an

enclosure to ensure its proper operational temperature. Our air conditioners, when sized properly, will

provide cooling or heating automatically controlled by the temperature digital controller.

Thermal Edge air conditioners operate as a “closed loop” system with no exposure or introduction of

outside air. This ensures that the enclosure is separated from and is not contaminated with ambient

air, dirt, chemicals, dust, moisture or foreign matter so that sensitive enclosure components are

protected and are kept at your required operational temperature.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 6 |P a g e

An air conditioner is designed to dehumidify and extract heat from an area, or provide heat to an area.

The cooling is done using a simple refrigeration cycle. A product of this simple refrigeration cycle is

excess humidity that condenses to a liquid.

Thermal Edge air conditioners are designed using an advanced refrigeration cycle and are equipped

with a Condensate Removal System that changes the excess humidity liquid into a vapor which is then

vented to the atmosphere. In the event of excess water vapor where the enclosure door has been left

open there is an overflow hole on the bottom of every unit. Please contact Thermal Edge Inc. if you

encounter excess water coming from your air conditioner.

THIS APPARATUS IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C AND D

HAZARDOUS LOCATIONS, OR UNCLASSIFIED LOCATIONS ONLY.

WARNING –EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT WHILE THE CIRCUIT

IS LIVE OR UNLESS THE AREA IS KNOW TO BE FREE OF IGNITABLE CONCENTRATIONS.

AVERTISSEMENT –RISQUE D'EXPLOSION - AVANT DE DECONNECTER L'EQUIPEMENT,

COUPER LE COURANT OU S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON

DANGEREUX.

WARNING –SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I,

DIVISION 2.

AVERTISSEMENT –RISQUE D'EXPLOSION –LA SUBSTITUTIOND E COMPOSANTSP EUTR

ENDRE CE MATERIEL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2

WARNING –EXPLOSION HAZARD - DO NOT REPLACE ELECTRICAL COMPONENTS UNLESS

POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS;

AVERTISSEMENT –RISQUE D'EXPLOSION - COUPER LE COURANT OU S'ASSURER QUE

L'EMPLACEMENT EST DESIGNE NON DANGEREUX AVANT DE REPLACER LES

COMPOSANTS ÉLECTRIQUES.

WARNING –EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING PROPERTIES

OF MATERIALS USED IN THE FOLLOWING SEALED DEVICES.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 7 |P a g e

Sealed Device Information:

Sealed Device: Compressor Overload Protector Models B130-135-241A, B170-150*-241C manufactured by

Foshan Tongbao. Model MRA98706 manufactured by Sensata Technologies.

Epoxy: Manufacture of Material –Resinlab L.L.C. Designation of Material –Type EP 1295 Black

Generic Name of Plastic Material –Epoxy Resin

Sealed Device: Low Pressure Switch –HS100-349-0001 manufactured by Wilspec, Oklahoma City.

Sealed Device: High Pressure Switch –HC100-349-0006 manufactured by Wilspec, Oklahoma City.

Epoxy: Manufacture of Material –Suzhou Pochely Electronic Material LTD Designation of Material –Type

HB-5225A/B Generic Name of Plastic Material –Epoxy Resin

Sealed Device: Fan Motor Thermal Protector Model ST-22, manufactured by SEKI Controls Co.

Enclosure: Manufacture of Material –LG Chemical Ltd. Designation of Material –Type GP-2306F

Epoxy: Manufacture of Material - Rhenatech GbmH Designation of Material –Type EP VERGUSSMASSE

5315 Generic Name of Plastic Material –epoxy resin.

Sealed Device: Fan Motor Thermal Protector Type S01, manufactured by Thermik Geraetebau GMBH.

Insulation Cap: Manufacture of Material –E.I. Dupont de Nemours and Co., Inc. Designation of Material –

“Nomex” Type 410 Generic Name of Plastic Material – Aramid Insulating Paper

Epoxy: Manufacture of Material - Rhenatech GbmH Designation of Material –Type EP VERGUSSMASSE

5315 Generic Name of Plastic Material –epoxy resin.

Sealed Device: Relay Cat. No. RY611024, manufactured by Tyco Electronics Austria GmbH.

Relay Cover: Manufacture of Material –E I Dupont De Nemours & Co Inc Designation of Material - "Crastin"

Type CE7931Generic Name of Plastic Material –Polybutylene Terephthalate (PBT)

Relay Base: Manufacture of Material –Evonik Degussa GMBH Designation of Material - "Vestodur" Type

X7212 Generic Name of Plastic Material –Polybutylene Terephthalate (PBT)

Epoxy: Manufacture of Material - Three Bond Co Ltd. Designation of Material - Type 2202C

Generic Name of Plastic Material –Epoxy resin

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 8 |P a g e

Preliminary Testing

Before mounting the air conditioner to the enclosure, test for proper operation. Follow the steps below

prior to installation.

WARNINGS

The air conditioner must sit upright for 24 hours to assure the compressor oil has drained down to the

compressor. Check the unit label to assure the electric power available to the air conditioner is the

proper voltage and phase. Check the electric power source for proper ground wire and neutral wire

installation per 2008 NEC. Assure that the electric power is protected by a circuit protection device;

refer to the Unit Specification section in this manual for proper circuit protection sizing.

Connect a power source to the air conditioner and turn on the power switch. The evaporator

fan will start and the digital controller will power up. If cooling is called for, the compressor will

start in 3 minutes.

If desired, change the cooling set point. Refer to Digital Temperature Controller Programming

section on this manual for details on changing the set point. Factory default settings should be

satisfactory; however you may want to adjust heat, cooling and alarm set points for your

specific application.

The condenser fan is controlled by the refrigerant high heat pressure and will turn on later

when the operating pressure builds up. This feature allows low ambient operation and

reduces current inrush at initial power on.

Run the air conditioner for 15 minutes; during this time the condenser fan will turn on after the

condenser coil warms up. Note: Ambient Temperature must be at least 75°F.

Turn the unit off if the equipment makes any unexpected or hard mechanical noises or

vibrations and refer to the troubleshooting guide in this manual.

The supply cold air should be at least 10°F colder than the return air entering the unit. If it is

not, refer to the troubleshooting guide in this manual;

When you are satisfied that the unit is operating properly, turn unit off, disconnect the power

and mount the unit on the enclosure in accordance with the Mounting the Air Conditioner

section in this manual.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 9 |P a g e

Mounting the Air Conditioner

Using the template supplied, determine where the air conditioner is to be mounted and assure that all

required cuts and holes will not interfere with or damage the enclosure or its contents. Assure that

there is a 3” clearance between walls / obstructions and the air conditioner for the condenser supply

air and return air flow so that it is not restricted. Restricted condenser air flow will affect the air

conditioner’s performance. Mount the air conditioner high on the enclosure in order to cool the hot air

in the top of the enclosure. Position the unit where the cold air can circulate across the width of the

enclosure to cool it all the way across.

Once proper mounting placement is determined, turn the enclosure equipment off, if possible, to

prevent damage. Drill and cut the holes as indicated on the mounting template. Install insulation

gasket as required to ensure an air tight closed loop seal. Be cautious not to let any cutting debris fall

into the enclosure.

Hang the air conditioner on the Easy Mount Flanges and from inside the enclosure use the fasteners

supplied to attach the air conditioner to the enclosure. Screw all fasteners hand tight. Then torque to

96 in-lbs. These fasteners should be checked periodically to ensure that they have not become loose

due to vibration.

The air conditioner is provided with a power cord or a power terminal block. Ensure that the power

supplied is compatible with the air conditioner’s power requirements. Properly connect the unit to a

power circuit that meets the equipment requirements and provide a circuit protection device based on

the Unit Specifications section of this manual. See Appendix A for Phoenix Contact power connector

instructions.

After mounting the air conditioner, replace/close the enclosure door and start air conditioner; test for

air leaks to assure a proper closed air loop seal and run test the unit to assure proper operation after

mounting. If any cold air leaks are found, check for proper mounting and apply silicone-free Lexel seal

if leaks persist. Assure that the air conditioner’s condenser inlet air filter is installed properly and

cleaned regularly.

CAUTION

If mounting the air conditioner to the enclosure door, confirm with the enclosure manufacturer that the

door’s hinges will support the air conditioner’s added weight (see equipment specifications). Ensure

that when the door is fully open that the enclosure will not topple over due to the off-center load.

1800 Hurd Drive ● Irving, Texas 75038 ● (972) 580-0200 ● (888) 580-0202 ● Fax (972) 580-0277

URL: www.thermal-edge.com ● Email: support@thermal-edge.com

SP-ENG-210-000-08 Rev 1.6 10 |P a g e

Unit Specifications

The following table provides electrical and refrigeration specifications for the CS020 Series Air

Conditioners.

CS020 Series

Nominal Capacity Rating: 2,000 BTUH

Maximum Ambient: 118°F

Temperature Classification: T6

Unit Weight: 49 lbs (230V, 50 Hz AC)

Model

Operating

Voltage

Range

(Volts)

Inrush

Current

(Start

Current)

(Amps)

Current

(Running

Current)

(Amps)

SCCR

(Short

Circuit

Current

Rating)

(Amps)

Recommended

Fuse Selection

(Amps)

KVA Rating

Refrigerant

Type

Refrigerant

Amount

(ounces)

Low/High

Unit

Pressures

(psi)

CS020235

207-253

6.64

1.7

3 Amp Class

CC, CCMR

Time Delay *

0.5

R134a

12.00

63 / 200

* HACR Type Circuit Breakers or Time-delay Fuses with the following electrical characteristics are

recommended. Fast-acting fuses are not recommended.

% of Ampere Rating

Opening Time

110 %

15min Minimum

125 %

1hr Maximum

200 %

12sec Minimum

4min Maximum

SCCR rating is based on the SCCR rating for the circuit protection device installed in the panel /

enclosure per UL50 & UL508a to protect the AC unit. Typically 100KA –200KA for Time-Delay Fuses.

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