Stulz CyberLab Original Instructions Manual
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Stulz CyberLab Original Instructions Manual

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CyberLab
Original instructions
Precision Air Conditioning Units
400V/50Hz/3Ph/N/PE
Index G17F
Issue 2.2018

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Summary of Contents for Stulz CyberLab

  • Page 1 CyberLab Original instructions Precision Air Conditioning Units Index G17F 400V/50Hz/3Ph/N/PE Issue 2.2018...
  • Page 2 CY B E R L A B 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 CyberLab – Intelligent solution for laboratories, archives and museums Dear customer, we are pleased that you have decided for the Cyberlab from STULZ. Cyberlab is a precision air conditioning unit, which has been developed especially for applications with a low or no heat load, applications however for which temperature and humidity need to be kept precisely constant.
  • Page 4 CY B E R L A B O R I G I N A L I N S T R U C T I O N S EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 5: Table Of Contents

    8. Malfunction ...................... 46 9. Dismantling and disposal ................47 10. Contents of the CE Declaration of Conformity ..........48 11. Options ......................49 11.1 Option external humidifier ..................... 49 Subject to technical modifications. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • 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/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 7: Duties Of The Operator

    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/02.2018/G17F...

  • Page 8: Transport / Storage

    • The delivery note can be found on the A/C 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 A/C unit. Do not stay under suspended loads! The Stulz A/C 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/02.2018/G17F  © 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/02.2018/G17F...

  • Page 10: Description

    L = laboratory unit with speed controlled A = CyberAir compressor Page code EN/02.2018/G17F Date of issue Index number month/year Language: Manufacturing base: DE = German G = Germany EN = English C = China I = Italy EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 11: Intended Use

    The operational conception is designed such as to allow to control up to 19 units from one unit. These units can be installed separately with a maximum control line length of 1000 m. Sight glass Filter dryer © STULZ GmbH – all rights reserved EN/02.2018/G17F...
  • Page 12 The state of the heat exchanger can be checked via the upper revi- sion glasses. The state of the condensate tray can be checked via the lower revision glasses. EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 13: Control

    • humidity control at minimal load We recommend to only operate one active CyberLab unit per room. Several CyberLab units can be installed in the room, but only one of these units may be in operation at a time. This can be achieved by the failure depen- dent change-over of the sequencing function (no time dependent sequencing).

  • Page 14: Technical Data

    (400V/50Hz/3Ph/N/ PE). In this case, see the technical data by the help of the „Stulz Select“ planning tool. The unit design, the external dimensions, the weight, the EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 15: Technical Data

    For electrical data, (compressor and fan power consumption) see e-data sheet. The electrical power consumption of the fans must be added to the room load. Refrigeration scheme Receiver Evaporator Hotgas reheat Compressor Oil separator © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 16: Dimensional Drawings

    4.3 Dimensional drawings Front view Side view Projecting main switch EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 17: Installation

    Mafund strips. The A/C unit must be accessible laterally and from the front. Air outlet area for Upflow units without duct connection Maintenance clearance © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 18: Positioning The Unit

    • drive the unit by the mounting aids to the installation site. • drop the unit, loosen the belts and pull away the mounting aids. Pallet height Mounting aids Chiller transport with mounting aids EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 19 • drive the unit by the mounting aids to the installation site. • drop the unit, loosen the belts and pull away the mounting aids. nOtICe Place the male triangular wrench in a visible location in the immediate vicinity of the A/C unit. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 20: Connection Of The 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 and in the StulzSelect. 5.3.1.2 Position of the refrigerant connections...

  • Page 21: Strength Pressure Test

    Screwed pipe joints can loosen by long transportation distances. Before final commissioning, check all screwed pipe joints in the refrigerant circuit on tightness and retighten if necessary. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 22: Condensate Drain Connection

    = –300 Pa / (1000 kg/m³ ∙ 10 m/s²) area of the A/C unit, which prevents the draining of the h = –3 cm condensate water EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 23 >10 cm Connect the condensate water drains to the local waste water system. unit limit InFORMAtIOn Comply with the regulations of the local water supply authority. possible installation at the custo- mer side: funnel © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 24: Electrical Connection

    Do not touch electronical components, without taking care of protective ESD measures. Electronical components: - C7000 IO controller (1) - µPC circuit board EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 25 (part of the unit documents). • secure these cables by the pull relief screw. Insertion for the power supply cable © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 26: Reheat

    Alarm: Reheat defect All reheat alarms are received by the controller and can be requested according to the equipment. C7000-control system: no display (display only externally) C7000 advanced terminal: indication on the display EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 27: Commissioning

    • Set the parameter in the column „Value“ of the same line to 100%. C7000IOC: • Enter the command: „eev 1 hand 1“ and „eev 1 handon 100“. The expansion valve is now completely open. © STULZ GmbH – all rights reserved EN/02.2018/G17F...
  • Page 28 • 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/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 29 ! Evaporator Hotgas reheat Non-return valve (supplied loose) external installation Oil separator Compressor Oil charge nOtICe The A/C unit is prefilled with 0.6 l oil. Further addition of oil damages the compressor. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 30: Control Of The Electrical Box

    • switch on the A/C unit at the master switch. The controller is now supplied with power, so you can use it for adjustments. • make sure that the air-cooled condenser is operating. EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 31 A/C unit with optional C7000Advanced terminal: • familiarize yourself with the operation of the C7000 con- troller. To do this, there is a separate manual. • adjust the temperature setpoint at the controller. Controller C7000Advanced Terminal, Start/stop-key © STULZ GmbH – all rights reserved EN/02.2018/G17F...
  • Page 32 „Maintenance“. • Check the current consumption of the compressor and the fan comparing it with the values of the e-data sheet. Service port X15 in the e-box. EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 33 "out of operation range" position signal (not used) not used Y2 (0-10V) Compressor speed (not used) not used Y3 (0-10V) Expansion valve opening (not used) not used not used not used not used © STULZ Gmbh – all rights reserved EN/02.2018/G17F...
  • Page 34 ENTER key for access to the selected sub menu, to the modification mode or for confirmation of the adjusted value. After the software update with the Smartkey (description available in the e-Stulz area) some settings must be adapted. For this the connection from the C7000IOC to the µPC must be removed.
  • Page 35 Pc09, Co04, Co05, Co08, Co14, Co15, Ea02 and Eb02. The menu structure helps you to find Pa01 Pb01 Pc01 Ea01 Eb01 Ec01 these windows. Pa04 Pb05 Pc14 Ea09 Eb09 © STULZ Gmbh – all rights reserved EN/02.2018/G17F...
  • Page 36 By the menu eVO Menu' config. and selecting the menu item "b. Regula- tion" you first get to eb01 and then to view eb02 (no picture). In eb02 set the valve opening at start-up on 75%. Now select M06. BLDC means "Brushless direct current" EN/02.2018/G17F  © STULZ Gmbh – all rights reserved...
  • Page 37 1. by closing the expansion valve. 2. by increasing the compressor speed. Set both parameters to "Yes". The configuration is now finished. • De-energize the µPC. • Pull the telephone connector of the PGD1 from block J7. • Re-establish the 0V connection to terminal ID7. • Put the connector of the ModBus® connection onto J8. • Switch on again the µPC. © STULZ Gmbh – all rights reserved EN/02.2018/G17F...
  • Page 38 Reference Description Terminal block for power lines Terminal block for control lines Fastening bracket Cooling fan PE connection Operating status LEDs Terminals for connecting a shunt reactor EN/02.2018/G17F  © STULZ Gmbh – all rights reserved...
  • Page 39 High pressure switch, circuit 1 3-phase voltage supply µPC board terminal Assignation RS485/ModBus® RX+/TX+ connection RX–/TX– PTC input not used 24VDC auxiliary voltage STOa input for HP alarm STOb 1, 2 Relay output not used © STULZ Gmbh – all rights reserved EN/02.2018/G17F...

  • Page 40: Maintenance

    • switch off power conducting cables to the unit and secure them against being switched on again. • 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 Air circuit Heat exchanger Air filter Unit housing Electrical box Unit interior EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 41 Exchange the corresponding filters Check of differential pressure Filtertausch Inspection of the hygienic state Fan section Check on fouling, damage and corrosion Cleaning and repair Cleaning the air conducting fan parts, as well as the condensate drain Heat exchanger Check on fouling, damage and corrosion Cleaning and repair Check of fouling, corrosion and function of the con- densate tray Check of fouling and function of the siphon Inspection of the hygienic state © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 42: Refrigerant Circuit

    A pollution of the filter drier, whose essential 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. Green --> ok. Yellow --> humidity critical. Sight glass EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 43: Compressor

    Expansion valve The refrigerant circuit is equipped with a electronic expansion valve, which controls the superheating in the evaporator.The superheating is adjusted to 7 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. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 44: Air Circuit

    Air filter A filter monitor controls the state of the filter. As soon as the pressure loss exceeds an adjustable value, a filter alarm via the controller is released. The controller can be configured such as to compensate the pressure loss by a higher fan speed, however you should not wait too long for exchanging the filter. The filters can be accessed by the front doors, depending on the cabinet size the number of filter elements varies. The clogged filter elements can not be cleaned with pressurized air, as the filter structure would be destroyed otherwise. When you re-install the filter elements after the exchange, take care that the side with the coloured mark (dirt side) is turned away from the heat exchanger. EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 45: Unit Housing

    • T he cabinet and all associated components are designed for the application of „circulation cooling“ and are arranged in the rear area. Therefore you can assume in case of contamination that this has been caused by the return air. • T he elctric cabinet and all its components must be removed and disinfected in a hermetically sealed room using fumigation, by, for example, a fumigation generator with the disinfectant DIOSOL from DIOP. • T he decontamination may only be carried out by qualified personnel and the use of appropriate means of disinfection and devices. • T he manufacturer cannot accept any responsibility for damage to property and injury to persons caused by failure to comply with the information in this document. © STULZ GmbH – all rights reserved EN/02.2018/G17F...

  • Page 46: Malfunction

    2. sensor cable defective. Check cable on continuity. 3. sensor defective. Check measured value with external thermo- meter, hygrostat, pressure gauge. Depending on the option configured in the controller further alarm messages exist. # stands for a number in case of several components of the same kind. For A/C units with EC compressor exist further alarm messages, which are explained in the C7000 Service manual. EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 47: Dismantling And Disposal

    The ester oil in the compressor must also be disposed of. As it contains dissolved refrigerant, it can not be disposed of like usual oils, but must be returned to the oil manufacturer. • disconnect the depressurized refrigerant pipes 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 A/C unit 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/02.2018/G17F...

  • Page 48: 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. Air conditioning unit Cyber Air ... AL ASU 211 AL National regulation Harmonised EN EC-directives BGR 500 chapter 2.35 EN 378 -1, -2, -3, -4 EC machinery directive 2006/42/EC BGV A3 EN ISO 12100 EC directive for low voltage 2014/35/EU EN ISO 13857 EC EMC directive 2014/30/EU EN 60204 -1 RoHS directive 2011/65/EU EN 61000-6-2 EC pressure equipment directive 2014/68/EU EN 61000-6-4 EN/02.2018/G17F  © STULZ GmbH – all rights reserved...

  • Page 49: Options

    The following installation diagram supports the instructions for the assembly. BNB humidifier Item 3 Leitwertfühler illustr. similar Water supply Item 7 Item 1 PE tube Ion exchanger min. 0,2m Sensor line Control line Power line PE conductor • I nstall the BNB according to the Technical manual for STULZ UltraSonic humidifier BNB, (subsequently named briefly BNB manual) pages 36 - 38. The BNB manual is included with the A/C unit upon delivery and is available as pdf document in the e-Stulz area, section humidifier. The BNB must have a minimum distance of 0.5m to the floor and 0.2m to the CyberLab unit. The length of the electrical supply cables allow an installation in max. 0.6m height for the BNB 5000A (humidifier bottom line). This height decreases with larger distance to the CyberLab unit. The installation diagram on pages 23 and 35, as well as the chapter 6 of the BNB manual are not applicable. © STULZ GmbH – all rights reserved EN/02.2018/G17F...
  • Page 50 • C onnect the water inlet of the ion exchanger and the water Item 6 supply (water tap) by the second hose. connector with internal thread • C onnect the overflow pipe and resp. the waste water pipe at the BNB humidifier according to the instructions on pag- es 40-41 and 44-46 of the BNB manual. Item 2 hose 1.5 m EN/02.2018/G17F  © STULZ GmbH – all rights reserved...
  • Page 51 BNB. A PE line lies reeled up in the lower section of the CyberLab unit. • R oute the PE line through the openings shown below out of the CyberLab unit and connect the line at the external humidifier according to the wirring diagram. Respect the warning notices in the BNB manual on page 49 and 50. All warning notices, which concern the control cabinet as well as the pages 51, 52 and 56 are not applicable. If you want to extend the cables, observe the information in chapter 7.5.2 of the BNB manual. Commissioning To do this, read the pages 57-60 of the BNB manual. operation To do this, read the pages 61-62 of the BNB manual. The pages 63-70 are not applicable. The humidifier is controlled by the humidifier menu of the C7000 controller. © STULZ GmbH – all rights reserved EN/02.2018/G17F...
  • Page 52 STULZ Top Service – More than just quick emergency assistance Technical Manage- Advice...

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