Stulz CyberRow DX CRS-042-W User manual

CyberRow DX
Installation, Operation and Maintenance Manual
Row-Based Precision Air Conditioners
12 kW - 33 kW / 60 Hz

CRS-042-G
C = Chilled Water
G = Glycol Cooled DX
W = Water Cooled DX
A = Air Cooled DX
Notice
This document contains information protected by copyright. All rights are reserved. The owner of the equipment
for which this manual is written may photocopy the contents of this manual for internal use only. No part of this
document may be photocopied, reproduced, or translated into another language for use by anyone other than the
owner of the equipment for which this manual is written without the prior written consent of STULZ Air Technology
Systems, Inc. (STULZ).
This document contains confidential and proprietary information of STULZ Air Technology Systems, Inc.
Distributing or photocopying this document for external distribution is in direct violation of U.S. copyright laws and
is strictly prohibited without the express written consent of STULZ.
Unpublished — rights reserved under the copyright laws of the United States and of other countries.
Other brands and tradenames are trademarks of their respective owners.
Copyright 2016 by STULZ Air Technology Systems, Inc.
Printed in the United States of America.
All rights reserved.
STULZ Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704
USA
MODEL NOMENCLATURE
CRS = CyberRow System
Nominal Capacity in
1,000’s of BTU Hrs

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1.0 Introduction.........................................1-1
1.1 General........................................................1-1
1.2 Product Description.....................................1-1
1.3 Product Warranty.........................................1-2
1.4 Safety ..........................................................1-4
1.4.1 General........................................................1-4
1.4.2 Safety Summary..........................................1-4
1.5 General Design............................................1-6
1.5.1 Electrical Compartment...............................1-7
1.5.2 Circuit Breakers/Motor Start Protectors.......1-7
1.5.3 Compressor.................................................1-7
1.5.4 Coils ............................................................1-7
1.5.5 Condensate Pump.......................................1-7
1.5.6 EC Fans.......................................................1-7
1.5.7 Temperature/Humidity Sensors...................1-8
1.6 Optional Equipment.....................................1-8
1.6.1 Remote Supply Temperature/Humidity
Sensor.........................................................1-8
1.6.2 Water Detector.............................................1-8
1.6.3 Smoke Detector...........................................1-8
1.6.4 Firestat.........................................................1-8
2.0 Installation...........................................2-1
2.1 Receiving the Equipment.............................2-1
2.2 Moving the Equipment.................................2-1
2.3 Site Preparation...........................................2-1
2.4 Mounting/Placement....................................2-2
2.5 Air Distribution.............................................2-3
2.6 Optional Equipment (Field Installed) ...........2-3
2.6.1 Remote Water Detectors.............................2-3
2.6.2 Remote Temperature/Humidity Sensor .......2-4
2.6.3 Outdoor Condensers...................................2-4
2.7 Water-Water/Glycol Cooled DX...................2-5
2.7.1 Piping Connections......................................2-5
2.8 Split Air Cooled Systems.............................2-7
2.8.1 Refrigerant Piping........................................2-7
2.8.2 Remote Air Cooled Condensers..................2-9
2.8.3 Condensate Drain Line................................2-9
2.9 Utility Connections.....................................2-10
2.9.1 Main Power................................................2-10
2.9.2 Optional Equipment...................................2-11
TABLE OF CONTENTS
2.9.2.1 Remote Water Detector.............................2-11
2.9.2.2 Remote Temperature/Humidity Sensor .....2-11
2.9.2.3 Remote On/Off ..........................................2-11
2.9.3 Outdoor Equipment ...................................2-12
2.10 System Charging Procedures....................2-14
2.10.1 Water-Water/Glycol Cooled Systems.........2-14
2.10.2 Remote Air Cooled Systems......................2-14
2.10.3 Refrigerant Characteristics ........................2-18
2.11 Settings & Adjustments..............................2-18
2.11.1 Water- Water/Glycol Circuit .......................2-18
2.11.2 High/Low Pressure Limit Switch................2-18
2.11.3 Thermal Expansion Valve..........................2-18
2.11.4 Hot Gas Bypass.........................................2-19
2.11.5 EC Fans.....................................................2-19
3.0 Start-Up/Commissioning....................3-1
3.1 Initial Operation ...........................................3-1
3.2 Step by Step Start-Up Instructions..............3-1
3.3 Microprocessor Controller Programming.....3-1
4.0 E² Controller.......................................4-1
4.1 General........................................................4-1
4.2 Navigating Controller Display Screens........4-4
4.3 System Operation........................................4-6
4.3.1 Setpoint Adjustment.....................................4-8
4.3.2 Alarms .........................................................4-9
4.4 Controller Operation..................................4-10
4.5 Menu Screens ...........................................4-14
4.5.1 Main Menu.................................................4-14
4.5.2 Information Menu Loop..............................4-15
4.5.3 Alarm Log..................................................4-18
4.5.5 Control Menu Loop....................................4-20
4.5.6 Service Menu Loop....................................4-23
4.6 Communication With The Controller..........4-31
4.6.1 Work Group Set-up....................................4-31
4.6.2 Configuring a Work Group.........................4-32
4.7 BMS Communication.................................4-43
4.8 Troubleshooting the Control I/O Module....4-44
4.9 BMS Modbus Parameters .........................4-45
i

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
TABLE OF CONTENTS (Continued)
ii
5.0 Maintenance........................................5-1
5.1 Periodic General Maintenance....................5-1
5.2 Troubleshooting...........................................5-3
5.3 Field Service................................................5-6
5.3.1 Water-W/G System......................................5-6
5.3.2 DX System...................................................5-6
5.3.3 Refrigeration System Repairs......................5-6
5.3.4 System Repairs/Component Replacement .5-8
6.0 Product Support .................................6-1
6.1 Technical Support........................................6-1
6.2 Obtaining Warranty Parts ............................6-1
6.3 Obtaining Spare/Replacement Parts...........6-1
List of Figures
Figure 1 Typical Internal Layout- CRS-042/084...1-6
Figure 2 Recommended Installation....................2-2
Figure 3a Typical Air Distribution............................2-3
Figure 3b Front Diverted Air Distribution................2-3
Figure 4 Typical W/G Piping Diagram..................2-5
Figure 5 TypicalRemoteAirCooledDX Piping
Diagram................................................2-7
Figure 6 Sample Nameplate ..............................2-10
Figure 7 Field Wiring- Glycol Systems...............2-12
Figure 8 Field Wiring- Remote Condenser ........2-13
Figure 9 Main Display Screen..............................3-1
Figure 10 User Interface Display Panel.................4-2
Figure 11 Controller I/O Module.............................4-3
Figure 12 BMS Interface Ports...............................4-3
Figure 13 Menu Selections ....................................4-4
Figure 14 Control Inputs/Outputs.........................4-10
Figure 15 Dewpoint Control .................................4-12
Figure 16 Compressor On/Off Cycle....................4-12
Figure 17 Service Menu Loop Selections............4-23
Figure 18 Configuring Multiple A/C Units.............4-31
Figure 19 Cleanable Filters....................................5-1
Figure 20 Cartridge filters ......................................5-2
Appendix A - Forms
Checklist for Completed Installation........................ A-1
Periodic General Maintenance Checks
and Service Checklist.............................................. A-2
Appendix B - Glossary
Definition of Terms and Acronyms........................... B-1

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-1
1.0 INTRODUCTION
1.1 General
The CyberRow precision data center air conditioning
system covered by this manual is designed and
manufactured by STULZ Air Technology Systems,
Inc. (STULZ) and uses the latest, state-of-the-art
control technology. Recognized as a world leader,
STULZ provides air conditioning systems using the
finest materials available in the industry. The unit will
provide years of trouble free service if installed and
maintained in accordance with this manual. Damage
to the unit from improper installation, operation or
maintenance is not covered by the warranty.
STUDY the instructions contained in this manual.
They must be followed to avoid difficulties. Spare
parts are available from STULZ to insure continuous
operation. Using substitute parts or bypassing
electrical or refrigeration components in order
to continue operation is not recommended and
will VOID THE WARRANTY. Due to technical
advancements, components are subject to change
without notice.
All STULZ CyberRow systems are designed to be
installed indoors.
1.2 Product Description
STULZ CyberRow systems are available in Water
cooled, Water/Glycol cooled or Air cooled Direct
Expansion (DX) configurations. DX based CyberRow
systems are designed to operate with R410A
refrigerant.
DX based CyberRow cabinets are 12” wide. The
cooling capacity in BTU/Hr will depend on the
compressor size. Refer to the unit nameplate to
identify the capacity of your system.
NOTE
STULZCyberRowsystemshavebeendesigned
to capture and neutralize heat within close-
coupled rack-based environments. Any use
beyond what is described in this manual is
deemedtobe notintended.STULZ isnot liable
for any damage resulting from improper use.
The functional modes of operation are cooling and
dehumidification which provides localized cooling to
offset hot spots in data centers.
The CyberRow system captures high temperature
(hot aisle) discharge air from adjacent rack-based
IT equipment and reintroduces it as conditioned air
through the front of the unit (cold aisle).
The system is equipped with highly reliable EC
(Electronically Commutated) fans which offer
considerable energy cost savings and long life. Using
an electronically commutated permanent magnet DC
motor, AC inverter whine is eliminated. Fan speed is
continuously adjustable via a signal from the system
controller without the use of VFD’s. EC fans offer
energy efficient, quiet, low vibration operation.
An advanced E² series microprocessor controller
is mounted inside the CyberRow electric box. The
controller provides the following features: input/output
monitoring status, full integrated control of cooling
and dehumidification, multi-unit control and remote
communication with a Building Management System
(BMS). The controller may interface directly to a
BMS, allowing the ability to monitor the performance
of the air conditioner and adjust operating
parameters.
The E² user interface display panel is typically
factory mounted on the front access panel of the unit.
Refer Section 4.0 for detailed instructions on
operating the system controller.

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-2
1.3 Product Warranty
See the contract.

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-3
An extended warranty may be purchased on the unit’s compressor. The compressor warranty as stated below
will be sent with your unit if the option is purchased and should be retained for future reference. You may
consult the factory to verify if the extended compressor warranty was purchased for your system.

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-4
1.4 Safety
1.4.1 General
STULZ Air Technology Systems, Inc. uses NOTES
along with CAUTION and WARNING symbols
throughout this manual to draw your attention to im-
portant operational and safety information.
A bold text NOTE marks a short message in the infor-
mation to alert you to an important detail.
A bold text CAUTION safety alert appears with infor-
mation that is important for protecting your equipment
and performance. Be especially careful to read and
follow all cautions that apply to your application.
A bold text WARNING safety alert appears with infor-
mation that is important for protecting you from harm
and the equipment from damage. Pay very close at-
tention to all warnings that apply to your application.
A safety alert symbol precedes a general
WARNING or CAUTION safety statement.
A safety alert symbol precedes an electrical
shock hazard WARNING or CAUTION safety state-
ment.
1.4.2 Safety Summary
The following statements are general guidelines
followed by warnings and cautions applicable
throughout the manual. Prior to performing
any installation, operation, maintenance or
troubleshooting procedure, read and understand
all instructions, recommendations and guidelines
contained within this manual.
CAUTION
All maintenance and/or repairs must be
performed by a journeyman, refrigeration
mechanic or an air conditioning technician.
CAUTION
When moving the unit it must be kept in its
normal installed position. If the unit is not kept
level and vertical, damage to the compressors
will result.
WARNING
Never operate the unit with any cover, guard,
screen panel, etc. removed unless the instruc-
tions specifically state otherwise, then do so
with extreme caution to avoid personal injury.
CAUTION
Never lift any component in excess of 35
poundswithouthelp.Ifa liftingdevice isused to
move a unit, ensure it is capable of supporting
the unit.
WARNING
Whenworkingon electricalequipment, remove
all jewelry, watches, rings, etc.
WARNING
Always turn off the service disconnect switch
and disconnect the main power supply before
beginning work on the equipment. A lock-out
tag-outprocedureshouldbefollowed toensure
that power is not inadvertently reconnected.
WARNING
This unit is fed by incoming power wires. Even
with the service disconnect switch in the “Off”
position, power may still be “live” between
the switch and the main power source. When
performingservice,always ensuremainpower
is disconnected from the unit.
CAUTION
Equipment may contain components subject
to Electrostatic Discharge (ESD). Before
attemptingtomount orservicethese electronic
devices, ensure you have no charge built up
by touching a ground source. When possible,
use a wrist-grounding strap when working on
or near electronic devices.
CAUTION
Never work on electrical equipment unless
another person, who is familiar with the
operation and hazards of the equipment and
competent in administering first aid, is nearby.

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-5
WARNING
All personnel working on or near equipment
should be familiar with hazards associated
with electrical maintenance. Safety placards/
stickers have been placed on the unit to call
attentionto allpersonal andequipment damage
hazard areas.
WARNING
Refrigerant R410A may be used with this
equipment. Death or serious injury may result
if personnel fail to observe proper safety
precautions. Great care must be exercised
to prevent contact of liquid refrigerant or
refrigerant gas, discharged under pressure,
with any part of the body. The extremely low
temperatureresultingfrom therapid expansion
of liquid refrigerant or pressurized gas can
cause sudden and irreversible tissue damage.
As a minimum, all personnel should wear ther-
mal protective gloves and face-shield/goggles
when working with refrigerant. Application of
excessive heat to any component will cause
extreme pressure and may result in a rupture.
Exposure of refrigerant to an open flame or a
very hot surface will cause a chemical reaction
thatwill formcarbonyl chloride(hydrochloric/hy-
drofluoric acid), a highly poisonous and corro-
sivegascommonlyreferredtoasPHOSGENE.
In its natural state, refrigerant is a colorless,
odorless vapor with no toxic characteristics. It
is heavier than air and will disperse rapidly in
a well-ventilated area. In an unventilated area,
it presents a danger as a suffocant.
Always refer to the manufacturer’s MSDS pro-
vided with the unit.
CAUTION
Certain maintenance or cleaning procedures
maycallfor the useandhandling of chemicals,
solvents, or cleansers. Always refer to the
manufacturer’s Material Safety Data Sheet
(MSDS) prior to using these materials. Clean
partsina well-ventilatedarea. Avoidinhalation
of solvent fumes and prolonged exposure of
skin to cleaning solvents. Wash exposed skin
thoroughly after contact with solvents.
CAUTION
Do not use cleaning solvents near open flame
or excessive heat. Wear eye protection when
blowingsolventfrom parts.The pressure-wash
should not exceed 30 psig. Solvent solutions
should be disposed of in accordance with local
and state regulatory statutes.
WARNING
When performing brazing or debrazing
operations, make certain the refrigeration
system is fully recovered and purged and dry
nitrogen is flowing through the system at the rate
of not less than 1-2 CFM (0.03-0.06M³/minute).
CAUTION
The air-intake and discharge areas must be
free of obstructions. Ensure access panels are
secure and latched into position.
CAUTION
Cooling coils (and associated piping circuits)
are pressurized and sealed when they leave
thefactory. Beforeinstallingtheinterconnecting
piping,observeappropriate safety precautions
and release the pressure via an available stem
valve or schrader valve prior to uncapping the
pipes.
CAUTION
After interconnecting piping is installed, the
piping system must be cleaned. If solvents/
cleaning solutions areused, ensure theyare
completely flushed from the piping before
connecting it to the unit. Failure to do so will
result in equipment problems.
CAUTION
When filling the chilled water or water/glycol
loop,all airmustbebledfromthepiping system.
WARNING
Do not use chloride based water conditioning
additives in the condensate drain pans. This
will cause corrosion to occur on the coil fins.

STULZ CyberRow DX Series Installation, Operation & Maintenance Manual
1-6
1.5 General
Design
The STULZ CyberRow unit is housed in a steel frame type cabinet rated for indoor use. The exterior of the cabi-
net is coated with a powder coat finish to protect against corrosion. Removable access panels are located on
the front and rear of the cabinet for easy access to all components. Operator controls are conveniently located
on the front of the cabinet.
NOTE
Customer specified non standard features or design variations may not be described in this manual. Refer
to the installation and/or electrical drawings supplied with your unit for details of additional feature(s). In
some cases, an addendum to this manual may also be included to further describe the feature(s).
Figure 1 depicts a typical internal layout and identifies the major components of a typical CyberRow unit utilizing
Direct Expansion (DX) refrigerant. The location of some components may vary depending on the cooling
configuration selected (Water, Water/Glycol orAir Cooled).
NOTE:
1. CABINETACCESS PANELS REMOVED TO SHOW INTERNAL PARTS.
AIR FILTERS
SWING-OUT
HINGE
EC FAN (3)
ELECTRIC BOX
DISCONNECT
SWITCH
COMPRESSOR
PIPE TRANSITION
PLATE
EVAPORATOR
COIL
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
TEMPERATURE
SENSOR
T/H SENSOR
LEVEL
ADJUSTMENT
SCREW (4)
CASTER
HOUSING (4)
DRAIN PANS
CONDENSER
(CRS-W & CRS-G
UNITS ONLY)
FLOAT SWITCH
ELECTRICAL
KNOCK-OUTS
ELECTRICAL
KNOCK-OUTS (IN
BOTTOM OF BOX)
PIPING/ELECTRICAL
KNOCK-OUTS
(IN FLOOR OF CABINET)
Figure 1- Typical Internal Layout- CRS-042/084