Related Manuals for Stulz CyberCool
Summary of Contents for Stulz CyberCool
- Page 1 CyberCool Indoor Chiller Original instructions Precision Chillers Index G44 400 V / 3 Ph+N+PE / 50 Hz Issue 9.2017...
- Page 2 CY B E R CO O L I N D O O R C H I L L E R O R I G I N A L I N S T R U C T I O N S A B O U T S T U L Z Since it was founded in 1947, the STULZ company has evolved into one of the world’s leading system suppliers of air-conditioning technology.
- Page 3 Dear customer, thank you for having chosen the CyberCool IndoorChiller from STULZ. STULZ CyberCool indoor chillers have three different systems to ensure that your chilled water supply can respond to demand. Fully automonous, with high availability in the vicinity where supplies are needed, and easy to retrofit.
-
Page 4: Table Of Contents
5.3.2.2 Position of the water piping connections for version GE ....... 32 5.4 Electrical connection ......................34 6. Commissioning ....................37 6.1 Filling the refrigerant circuit ..................... 37 6.2 Filling of the water circuit ....................40 EN/09.2017/G44 © STULZ GmbH – all rights reserved... - Page 5 11.1 Raised floor stand ......................55 11.2 Refrigerant circuit ......................58 11.3 Chilled water circuit ......................59 11.4 Cooling medium circuit (for G units only) ..............61 11.5 C7000 Advanced ......................61 Subject to technical modifications. © STULZ GmbH – all rights reserved EN/09.2017/G44...
-
Page 6: Safety
• Do not inhale refrigerant vapours. • Refrigerants have a narcotic effect when inhaled in high concentrations. • T he room is to be evacuated immediately if high concentrations of refrigerant suddenly occur. • I f unavoidable work is required in the presence of a high concentration of refrigerant, breathing apparatus must be worn. This does not mean simple filter masks. Comply with breathing protection data sheet. • Do not eat, drink or smoke at work. • Warning against intentional misuse. EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 7: Duties Of The Operator
Access for competent staff in case of repairs and repeated inspection must be ensured. • Repeated inspection: according to EN 378 The operator is responsible for the execution. The operator must ensure that all maintenance, inspection and assembly work is carried out by authorised and qualified specialist staff who have made an in-depth study of the operating instructions. independent conversion and manufacture of replacement parts The system may only be converted or modified after consultation with STULZ. Original replacement parts and replacement parts/accessories authorised by STULZ are an aid to safety. © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 8: Transport / Storage
When delivery is accepted, check the unit against the delivery note for completeness and for external damage and record it on the consignment note in the presence of the freight forwarder. • The delivery note can be found on the unit when delivered. • The shipment is made ex works, in case of shipment damages, please assert your claim towards the carrier. • Hidden damage is to be reported in writing within 6 days of delivery. 2.2 transport danger Mortal danger by crushing A defective lifting device can lead to the uncontrolled fall of the unit. Do not stay under suspended loads! The Stulz units can be moved by lifting devices with belts or ropes. • fix the belts or ropes at the pallet, • p rotect the upper unit edges by wooden laths or metal brackets in such a way that they could not be caved EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 9: Storage
You can move the unit still packaged on the pallet with a fork lift. • take care that the centre of gravity is within the fork surface. • take care that the unit is in an upright position at the transport. 2.3 Storage If you put the unit into intermediate storage before the installation, the following measures have to be carried out to protect the unit from damage and corrosion: • t he storage point must not be exposed to direct sunlight. Observe the storage conditions in the chapter “Application limits“. • store the unit packaged to avoid the risk of corrosion. • m ake sure that the water connections are provided with protective hoods. © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 10: Description
Page code EN/09.2017/G17B Date of issue Index number month/year Language: Manufacturing base: EN = English G = Germany DE = German C = China FR = French I = Italy IT = Italian EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 11: Intended Use
Expansion tank in the chilled water circuit (Secondary circuit) electron. expansion valve Sightglass Filter dryer HP switch Frostschutzthermostat TR-1-F-U M26386 Membrandruckausdehnungsgefäß 8l 2,5bar M53268 © STULZ GmbH – all rights reserved EN/09.2017/G44 ND-Schalter Patronendruckschalter-ACB-3-6bar Expansionsventil E3V65SSS10 M74358 1104804 Schauglas Parker SA-17s... -
Page 12: Refrigeration Circuit
A safety valve, which releases refrigerant at 40 bar, is fitted on A-units as further protection. Version A/G Filter dryer Sightglass HP switch Oil sight glass EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 13: Chilled Water Circuit
The cooling medium circuit contains a plate condenser as interface to the refrigerant circuit and a valve for filling and draining. A 2 way or 3 way valve can be optionally installed to control the cooling water flow. © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 14 In the FC- and Mix mode the GE valve controls the water flow in the cooling medium circuit and by this the water temperature in the chilled water circuit. In DX mode this valve is closed. Rear view of version GE Evaporator 3-way valve GE valve GE heat exchanger G valve Condenser EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 15: Operating Modes Of Version Ge
The free cooling valve has completely Heat exchanger for closed the bypass and has opened free cooling Refrigerant circuit the way for the flow through the heat exchanger for free cooling. FC valve Evaporator FZAL © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 16: Fc Mode
The free cooling valve has completely closed the bypass and has opened Heat exchanger for the way for the flow through the heat free cooling Refrigerant circuit exchanger for free cooling. FC valve Evaporator FZAL EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 17: Circuit Scheme
Flow switch / monitor Schrader valve Antifreeze thermostat 3-way motorized valve 2-way motorized valve Electric reheat Solenoid valve Manual stop valve Automatic deventilation valve Electronical expansion valve Stop valve with cap and Schrader valve © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 18: Cooling System A
3.8.1 Cooling system A to the air cooled condenser 2nd compressor only for CSI 661, Chilled water 841 and 981 A Compressor Receiver Pump Expansion tank Evaporator EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 19: Cooling System G
3.8.2 Cooling system G Cooling water Condenser Chilled water 2nd compressor only for CSI 661, 841 and 981 G Compressor Pump Expansion tank Evaporator © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 20: Cooling System Ge
3.8.3 Cooling system GE Cooling medium Condenser Liquid receiver Heat exchanger for free cooling Compressor Chilled water Evaporator Pump Expansion tank EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 21: Technical Data
(400V/3Ph/50 Hz). In this case, see the technical 5 m (when condenser is below the chiller). data by the help of the „Stulz Select“ planning tool. The unit design, the external dimensions, the weight, Chilled water conditions: the position and size of the supply connections are temperature at the unit inlet [°C]:... - Page 22 Auslösung bei releases at automatischer Reset bei automatic reset at Hochdruckschalter High pressure switch Auslösung bei releases at Manueller Reset möglich bei manual reset possible at Sicherheitsventil Safety valve Auslösung bei releases at EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 23: Technical Data - Csi
Betriebsgewicht, Ausführung A Operating weight, A version Transportgewicht, Ausführung G Transport weight, G version Betriebsgewicht, Ausführung G Operating weight, G version The units of the A version contain a protective gas filling under atmospheric pressure. © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 24: Technical Data - Csi
26,1 Leistungsaufnahme - FK-Betrieb Power consumption - FC operation Stromaufnahme, max. Max. current consumption 17,7 33,1 45,4 54,9 65,4 Breite/Höhe/Tiefe Width/Height/Depth 1400 / 1980 / 890 Transportgewicht Transport weight Betriebsgewicht Operating weight EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 25: Dimensional Drawings
4.4 Dimensional drawings Cabinet size 1 (A/G) Cabinet size 2 (GE) Projecting main switch Main switch Side view (for all sizes) /945* © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 26: Installation
• check that the installation site is appropriate for the unit weight, which you can read in the technical data. • take into account the necessary clearances for the maintenance and the air flow. The chiller must be accessible from the front. Maintenance clearance EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 27: Positioning The Unit
• drive the unit by the mounting aids to the installation site. • drop the unit, loosen the belts and pull away the mount- Pallet height ing aids. chiller transport with mounting aids Mounting aids © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 28 • drop the unit, loosen the belts and pull away the mounting aids. 30.06.2017 MU_CSI_982_GES_von_Palette PAGE 1 / 1 NOtICE Place the male triangular wrench in a visible location in the immediate vicinity of the chiller. EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 29: Connection Of The Piping
5.3.1 Refrigerant piping 5.3.1.1 Design To design the piping between the chiller and the condenser follow the instructions in chapter "2. Refrigerant piping" of document "General-DX". This document is available in the e-Stulz area. 5.3.1.2 Position of the refrigerant connections top view... -
Page 30: Strength Pressure Test
At the planning and realisation of the whole system observe the following items: • Protect the Stulz unit against lack of water and thus against dry run by appropriate measures on the installa- tion site. -
Page 31: Position Of The Water Piping Connections For Version A/G
Ein-/Austritt Inlet/outlet 5.3.2.1 Position of the water piping connections for version A/G top view Unit rear side Cooling water outlet safety valve drain Cooling water inlet (G-units) Chilled water inlet Chilled water outlet © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 32: Position Of The Water Piping Connections For Version Ge
• screw the lines of the external system to the lines of the unit respecting the designation at the unit (inlet/ outlet). • insulate the water pipes with the diffusion tight insulating material, to prevent the introduction of ambient air heat and the formation of condensate at the pipes. EN/09.2017/G44 © STULZ GmbH – all rights reserved... - Page 33 • screw the lines of the external system to the lines of the unit respecting the designation at the unit (inlet/ outlet). • insulate the water pipes with the diffusion tight insulating material, to prevent the introduction of ambient air heat and the formation of condensate at the pipes. © STULZ GmbH – all rights reserved EN/09.2017/G44...
-
Page 34: Electrical Connection
• check that the feedthrough openings in the unit are provided with rubber grommets. If the rubber grommets are lacking, the cable insulation can be damaged. ESD NOtE Do not touch electronical components, without taking care of protective ESD measures. Electronical components: - C7000 IO controller (1) EN/09.2017/G44 © STULZ GmbH – all rights reserved... - Page 35 • secure these cables by the pull relief screw. Version A/G Version GE Electrical box insertion for the power supply cable Unit rear side 2. Power supply 1. Power supply Customer control line © STULZ GmbH – all rights reserved EN/09.2017/G44...
- Page 36 Connection of control lines (optional) If the chiller unit shall be connected to other Stulz units by the IO bus, to a BMS or contains opional extensions as louvers, you must route control lines and connect them in the electric box of the chiller.
-
Page 37: Commissioning
• Set the parameter in the column „Value“ of the same line to 100%. C7000IOC: • Enter the command: „eev 1 hand 1“ and Compressor Receiver „eev 1 handon 100“. The expansion valve is now completely open. Evaporator © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 38 • Start the compressor by pressing the I/O button of the C7000 controller if you have filled up 70% of the precalculated refrigerant charge. In some cases, this must be decided by the installer according to the ambi- ent conditions on site. EN/09.2017/G44 © STULZ GmbH – all rights reserved...
- Page 39 • Continue the filling while the compressor is running. • Stop the filling once you see only small bubbles in the sight glass. • Note the weight of the refrigerant bottle and determine the quantity of charged refrigerant. © STULZ GmbH – all rights reserved EN/09.2017/G44...
-
Page 40: Filling Of The Water Circuit
• Fill the cooling medium circuit by means of the filling connections (see refrigerant diagram, part of the unit documents). • Bleed air from the cooling medium circuit by means of the schrader valves for bleeding (see following pages). EN/09.2017/G44 © STULZ GmbH – all rights reserved... - Page 41 During the running-in period the mechanical seal will not seal tight, but will slightly drip! Mechanical seals are expendable parts. The average durability is around 2 to 4 years however extreme condi- tions (as impurities, additives and overheating) may drastically reduce the service life! © STULZ GmbH – all rights reserved EN/09.2017/G44...
- Page 42 Position of deventilation- and filling/drain valves Version GE Chilled water circuit Deventilation valves Rear view: Filling/drain valves a, b Front view: Cooling medium circuit Deventilation valves Filling/drain valve c, d EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 43: Control Of The Electrical Box
• switch on the chiller at the master switch. The controller is now supplied with power, so you can use it for adjustments. • make sure that the heat rejecting system is operating. Version A: air-cooled condenser Version G/GE: drycooler © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 44 • connect a notebook at the service port X15 on the C7000IOC board, to carry out possible configurations (setting the setpoint). • shut the electrical box door. Controller C7000Advanced Terminal, Start/stop-key EN/09.2017/G44 © STULZ GmbH – all rights reserved...
- Page 45 • Check the current consumption of the compressors and the pump comparing it with the values of the e-data sheet. Service port X15 in the e-box. Sight glass Oil sight glasses © STULZ GmbH – all rights reserved EN/09.2017/G44...
-
Page 46: Maintenance
• check to ensure that they are in the de-energized state. 7.2 Maintenance intervals Maintenance interval Component quarterly half-yearly yearly Refrigerant circuit Refrigerant charge HP switch Sight glass Compressor Expansion valve Water circuit Tightness Evaporator Condenser Pump* Unit housing Electrical box Unit interior * The seal ring of the pump must be exchanged every 20,000 operating hours. EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 47: Refrigerant Circuit
A pollution of the filter drier, whose origin task is to clear the refrigerant from impurities and humidity, can be detected by a temperature difference upstream and downstream the filter drier. • Compare the colour indicator in the centre of the sight glass with the outer ring scale. Sight glass © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 48 Oil type: Bitzer BVC32 (factory filling) • Check the oil level at the oil sight glass. expansion valve The refrigerant circuit is equipped with a electronic expansion valve, which controls the superheating in the evaporator.The superheating is adjusted to 5 K at the factory and may not be modified. The expansion valve can freeze, if the humidity in the system is excessive. daNgeR do not thaw by soldering flame, danger of explosion ! Thaw with moist warm cloth. Check the sight glass. EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 49: Water Circuit
At the fan contactor, dangerous voltages occur. Do not open the unit within the first 5 minutes after disconnection of all phases. In units with 2 or 3 fans dangerous charges of >50µC can occur between AC line terminals and PE after disconnection. electrical box • c heck the connection terminals for tight fixation when the unit is installed and once again after an operation time of 30 days. Unit interior Clean pipes simplify the search for leaks. • clean the unit‘s inside with a vacuum cleaner. Vibrations of pipes and circuit components can result in leaks. • check the pipes for a tight seat. Condensing air humidity on cold water pipes means a loss of cooling capacity. • check the insulation of the water piping. © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 50: Malfunction
#: temperature The control module has detect- 1. Cable breakage or faulty contact Check cable and contacts. sensor error ed a malfunction of the temper- ature sensor. 2. Temperature sensor defective. Replace temperature sensor. # stands for a number in case of several components of the same kind. EN/09.2017/G44 © STULZ GmbH – all rights reserved... - Page 51 1. An external device has triggered Depending on the type of message. failure digital input for the external a signal. alarm #. 2. Cable breakage or faulty contact. Check wiring. # stands for a number in case of several components of the same kind. © STULZ GmbH – all rights reserved EN/09.2017/G44...
- Page 52 Water alarm The water detector has Water in the detector area (e.g. rai- Determine the origin of water. triggered. sed floor). Seal leakage. # stands for a number in case of several components of the same kind. EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 53: Dismantling And Disposal
• d isconnect the unit from the external water circuit by closing the shut-off valves and drain the water circuit of the unit. • disconnect the depressurized chilled water pipes of the unit from the external system. • m ove the unit, as described in the chapter „transport“, with a lifting device of sufficient load-carrying capacity. • dispose of the chiller in accordance with the disposal and safety regulations applicable on site. We recommend a recycling company for this. The unit basically contains the raw materials aluminium (heat exchanger), copper (pipelines, wiring), and iron (panelling). © STULZ GmbH – all rights reserved EN/09.2017/G44... -
Page 54: Contents Of The Ce Declaration Of Conformity
In the case of a modification of the equipment not co-ordinated with us this declaration loses its validity. Chiller unit CyberCool ... a / g / ge CSI 221 ... CSI 421 ... CSI 661 ... CSI 841 ... -
Page 55: Options
15° and must not have any contact to the raised floor stand, which could result in • P rior to installation of the chiller, install the raised bone-conduction. floor 7 mm higher than the raised floor plates, as the mafund plates are compressed by the weight • I nstall the raised floor supports on vibration of the chiller. dampening material (Mafund plate) (do not screw down the supports!). © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 56 Raised floor cut out angle Continuous seal profile (use closed-cell material only) Before unit installation Raised floor plate Angled bracket Permanently elastic seal Fixing when distance Z < 100 mm when distance Z > 100 mm EN/09.2017/G44 © STULZ GmbH – all rights reserved...
- Page 57 • l ay at least two securing instruments (e. g. square steel bars) on the stand to avoid a slip-off. • w hen the unit is in the right position take away the securing aids and set down the unit. • n ow pull away the mounting aids under the unit. Mounting aid © STULZ GmbH – all rights reserved EN/09.2017/G44...
-
Page 58: Refrigerant Circuit
A part of the hotgas bypasses the condenser by the hotgas bypass line and is fed upstream the evaporator. This lets the evaporation temperature rise whereas the cooling capacity sinks. Refrigerant circuit of a GE unit Cooling medium circuit Secondary circuit Condenser OPTION HGBP valve Crank case heater Chilled water Evaporator circuit Primary circuit EN/09.2017/G44 © STULZ GmbH – all rights reserved... -
Page 59: Chilled Water Circuit
High efficiency circulating pump with a higher flow water pressure: 3 bar (marked by "7" in the flow scheme) Standby pump High efficiency circulating pump (2 bar flow water pressure) connected in standby (marked by "8" in the flow scheme) Alternative standby pump High efficiency circulating pump (3 bar flow water pressure) connected in standby (marked by "8" in the flow scheme) Strainer delivered loose, to be installed by the customer © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 60 Chilled water circuit for GE unit For the description of options 2-7 see precedent page. GE heat exchanger Evaporator EN/09.2017/G44 © STULZ GmbH – all rights reserved...
-
Page 61: Cooling Medium Circuit (For G Units Only)
The 3 way valve controls the distribution of the water flow through the condenser and the bypass. 11.5 C7000 Advanced The chiller unit can be optionally equipped with a "C7000 Advanced terminal". In this case the right front door of the unit contains the controller with a service display in which actual temperature and pressure values, error messages etc. are indicated. The C7000 AT enables the user to communicate with the chiller control. © STULZ GmbH – all rights reserved EN/09.2017/G44... - Page 62 STULZ Top Service – More than...
Need help?
Do you have a question about the CyberCool and is the answer not in the manual?
Questions and answers