Stulz Split-Air CST 40 User manual

230/1/50 400/3/50
SPLIT-AIR
A/C UNITS
Index 39
Edition 2.04
PRECISION A/C UNITS
AIR CONDITIONING
OPERATING INSTRUCTIONS

E/0204/39/2

E/0204/39/3
Contents Page
Introduction 4
Technical Data 6
Electrical Data 8
Dimensions 10
1. Unpacking and Inspection 16
2. Unit Identificaton 17
3. Operating Principle 18
4. Precautions 24
5. Safety Considerations 24
6. Precautions when handling the Unit 25
7. Vibrations 25
8. Mechanical Parts 25
9. Cooling Components 26
10. Motors 27
11. Control, Monitoring and Safety Components 27
12. Installation 45
13. Electrical Connections 52
14. Start-up 55
15. First Checks after starting the Unit 55
16. Switching off 55
17. Maintenance 55
18. Inactivity 59
19. Options 60
20. Residual Hazards and Emergency Information 71
21. Disassembling the Unit 75
22. Faults, probable Causes, possible Remedies 76
The manufacturer reserves the right to make alterations without notice.

E/0204/39/4
Introduction
Modifications in comparison to edition 4.02
• Technical/electrical data have been changed.
• The operating modes have been extended by a desciption of the mixed mode.
• Chapter 8 "Mechancial Parts" has been extended by a description of the panel insulation and
the fixing brackets.
• Sequencing description in chapter 11 has been added.
• The digital input assignment has slightly been changed.
• The description of the setpoint adjustment has been changed.
• The user setup parameters are listed.
• A description of the sensor calibration has been added.
• Chapter 12 "Installation" has been enriched by a table which shows the pipe diameters of the
connection piping dependent on the pipe length.
• Chapter 13 "Electrical connection" has been extended by some notes.
• In chapter 17 mean operating times for the component exchange are listed.
• The description of nearly all options has been extended by text. All available options are now
described. Beyond this, some options have been changed substantially:
- GRxxSOP this option (previously GRxxS) now includes an overpressure damper which is
fixed at the exhaust air grille.
- SIGC3 the cable layout has changed.
The following options have been added:
- KPDC1010 - Keypad, SERC1010 - serial adapter RS485 for gateway connection, SPLIT-
TER - LAN-Y-plug for sequencing.
The following information is supplied in accordance with Standards:CE73/23,CE93/68,CE89/392:
MANUFACTURER'S NAME AND ADDRESS
STULZ GmbH
Holsteiner Chaussee 283
22480 Hamburg
DATA REGARDING THIS MODEL Air conditioner for telecom application
YEAR OF MANUFACTURE As shown on the technical name plate on the unit
HOW TO CONSULTTHIS MANUAL
This document contains general informations valid for all models of the series.Further
informations like wiring diagrams etc. will be delivered with each unit.
THIS MANUAL IS INTENDED FOR
OWNER OF THE APPLIANCE
PERSON RESPONSIBLE FOR ITS INSTALLATION
PERSON RESPONSIBLE FOR MANAGING THE PRODUCT
PERSON RESPONSIBLE FOR ORDINARY MAINTENANCE
PERSON RESPONSIBLE FOR ITS DISASSEMBLY

E/0204/39/5
PURPOSE OF THE INFORMATION CONTAINED INTHIS MANUAL:
CORRECT HANDLING performed by unskilled personnel
CORRECT INSTALLATION performed by skilled personnel;
CORRECT START-UP performed by personnel trained by STULZ;
CORRECT MANAGEMENT performed by skilled personnel;
CORRECT MAINTENANCE performed by skilled personnel;
CORRECT ORDER FOR SPARE PARTS, made by skilled personnel;
CORRECT DISPOSAL OF THE PRODUCT, made by skilled personnel.
RESTRICTIONSTOTHE USE OFTHIS MANUAL
They apply to any operations that must be performed by highly skilled personnel.
WHERE AND HOWTO STORETHIS MANUAL
Inside the electric cabinet or together with any other literature concerning the equipment which
utilizes the product, provided it is a dry and clean place.
In the event of the manual being misplaced or damaged, the customer may require, for a fee, a
new manual, by quoting the model and serial number shown on the technical name- plate, by
contacting your local STULZ partner.
CURRENT TECHNOLOGY
This manual reflects the state of the art existing at the time the product is marketed and shall not
be deemed to be inadequate for the sole reason that it has not been updated as a result of any
new experience.
UPDATES
STULZ reserves the right to update the product and relevant manual without being required to
update previous products and manuals other than in exceptional circumstances.To require or
receive any updates of the instructions manual or amendments thereto, which shall be deemed
to be an integral part of the manual, please contact your local STULZ partner.
FOR FURTHER INFORMATION
Please contact your local STULZ partner.
Any suggestions or recommendations made by installers or users of the product for the purpose
of improving the product or the contents of this manual, will be greatly appreciated by the
Manufacturer.
IN THE EVENT OF SALE OFTHE PRODUCT
Please advise STULZ GmbH of the address of the new owner so as to enable the dispatch of
any updates to the manual, otherwise STULZ GmbH shall be relieved of any subsequent
liabilities

E/0204/39/6
* Ambient temp. 35°C; Inside cabinet temp. 25°C RH 40%
** measured at 2m distance from the unit front, free field, unit operating in cooling mode at nominal conditions. Referred to type 1.
*** Type 1: with free cooling & emergency ventilation; DC fans;
Type 2: cooling only; with AC fans
Technical Data Split-Air CST 40 / 50
Cooling capacity *
Sensible cooling capacity*
Refrigerant
Refrigerantcharge
Condenserfan
Number/Type
Air flow
External static pressure
Evaporator fan (Type 1)***
Voltage
Number/Type
Air flow
External static pressure
Evaporator fan (Type 2)***
Number/Type
Air flow
External static pressure
EER index (type 2)*
Outsideoperating limit temp. min/max
Shelteroperating limit temp. min/max
Duty cycle
Outdoor unit
Noiselevel**
Weight
Height /Width / Depth
Indoor unit type 1
Noiselevel**
Weight
Height /Width(with brackets) / Depth
Indoor unit type 2
Weight
Height /Width(with brackets) / Depth
kW
kW
kg
m³/h
Pa
V
m³/h
Pa
m³/h
Pa
W/W
°C
°C
%
dB(A)
kg
mm
dB(A)
kg
mm
kg
mm
CST 40
3.8
3.8
R407c
1.95
1 / 315 axial
1900
10
24DC/48DC
1 / 280 radial
1000
60
2 / 220 radial
1000
60
1.88
-20/+45
+20/+40
100
56
60
580/800/350
66
70
310/856/1050
65
310/856/800
CST 50
5.2
4.8
R407c
2.1
1 / 315 axial
2000
5
24DC/48DC
2 / 220 radial
1100
145
2 / 220 radial
1100
35
2.55
-20/+45
+20/+40
100
56
60
580/800/350
72
70
310/856/1050
65
310/856/800

E/0204/39/7
* Ambient temp. 35°C; Inside cabinet temp. 25°C RH 40%
** measured at 2m distance from the unit front, free field, unit operating in cooling mode at nominal conditions. Referred to type 1.
*** Type 1: with free cooling & emergency ventilation; DC fans;
Type 2: cooling only; with AC fans
Technical Data Split-Air CST 60 / 80
Cooling capacity *
Sensible cooling capacity*
Refrigerant
Refrigerantcharge
Condenserfan
Number/Type
Air flow
External static pressure
Evaporator fan (Type 1)***
Voltage
Number/Type
Air flow
External static pressure
Evaporator fan (Type 2)***
Number/Type
Air flow
External static pressure
EER index (type 2)*
Outsideoperating limit temp. min/max
Shelteroperating limit temp. min/max
Duty cycle
Outdoor unit
Noiselevel**
Weight
Height /Width / Depth
Indoor unit type 1
Noiselevel**
Weight
Height / Width(with brackets) / Depth
Indoor unit type 2
Weight
Height / Width(with brackets) / Depth
kW
kW
kg
m³/h
Pa
V
m³/h
Pa
m³/h
Pa
W/W
°C
°C
%
dB(A)
kg
mm
dB(A)
kg
mm
kg
mm
CST 60
6.4
5.6
R407c
2.5
1 / 420 axial
2800
5
24DC/48DC
1 / 310 radial
1400
10
1 / 310 radial
1400
40
2.47
-20/+45
+20/+40
100
56
80
640/950/400
63
90
375/956/1300
85
375/956/1000
CST 80
8.4
7.8
R407c
3.2
1 / 450 axial
3400
5
24DC/48DC
2 / 280 radial
2150
5
2 / 310 radial
2150
60
2.74
-20/+45
+20/+40
100
60
80
640/950/400
69
90
375/956/1300
85
375/956/1000

E/0204/39/8
CST 40 CST 50
Electrical Data Split-Air CST 40 / 50
Outdoor Unit
Power Supply Code
Nominalvoltage
Toleranceon voltage
Phase
Frequency
Toleranceonfrequency
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)*
Controlvoltage
Compressor
Powerconsumption*
Operatingcurrent (OA)*
Max.current (FLA)
Lockedrotor current(LRA)
CondenserFan
Powerconsumption*
Operatingcurrent (OA)*
Indoor UnitType 1**
Voltage
Toleranceon voltage
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
EvaporatorFan
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
Indoor UnitType 2**
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
EvaporatorFan
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
* Ambient temp. 35°C; Inside cabinet temp. 25°C RH 40%
** Type 1: with free cooling & emergency ventilation; DC fans;
Type 2: cooling only; with AC fans
00
230
220-240±10%
1
50
±2%
1.8
8.4
43.6
24
1.73
7.8
11.9
43
42
400
380-420±10%
3+N
50
±2%
1.8
4.2
22.6
24
1.73
3.6
5.4
22
V
V
ph
Hz
kW
A
A
Vac
kW
A
A
A
kW
A
VDC
VDC
kW
A
A
kW
A
A
kW
A
A
kW
A
A
00
230
220-240±10%
1
50
±2%
1.9
8.7
47.6
24
1.74
8.1
11.4
47
42
400
380-420±10%
3+N
50
±2%
1.9
3.8
24.6
24
1.74
3.2
4.2
24
0.11
0.58
24 / 48
22-28/43-56
0.13 / 0.13
6.1 / 3.05
9.25 / 5.42
0.1 / 0.1
4.82 / 2.42
8 / 4.8
0.18
0.82
2 x 0.7
0.18
0.82
2 x 0.7
0.11
0.58
24 / 48
22-28/43-56
0.25 / 0.24
11.75 / 5.66
17.25/ 10.22
0.22 / 0.21
10.5 / 5.04
2 x 8 / 4.8
0.19
0.83
2 x 0.7
0.19
0.83
2 x 0.7

E/0204/39/9
CST 60 CST 80
Electrical Data Split-Air CST 60 / 80
* Ambient temp. 35°C; Inside cabinet temp. 25°C RH 40%
** Type 1: with free cooling & emergency ventilation; DC fans;
Type 2: cooling only; with AC fans
Outdoor Unit
Power Supply Code
Nominalvoltage
Tolerance on voltage
Phase
Frequency
Tolerance onfrequency
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)*
Controlvoltage
Compressor
Powerconsumption*
Operatingcurrent (OA)*
Max.current (FLA)
Lockedrotor current(LRA)
CondenserFan
Powerconsumption*
Operatingcurrent (OA)*
Indoor UnitType 1**
Voltage
Tolerance on voltage
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
EvaporatorFan
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
Indoor UnitType 2**
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
EvaporatorFan
Powerconsumption*
Operatingcurrent (OA)*
Lockedrotor current(LRA)
00
230
220-240±10%
1
50
±2%
2.5
11.3
61.7
24
2.29
10.6
14.8
61
42
400
380-420±10%
3+N
50
±2%
2.5
4.8
32.7
24
2.29
4.1
5.1
32
V
V
ph
Hz
kW
A
A
Vac
kW
A
A
A
kW
A
VDC
VDC
kW
A
A
kW
A
A
kW
A
A
kW
A
A
00
230
220-240±10%
1
50
±2%
2.8
13.0
76.9
24
2.6
12.1
17.3
76
42
400
380-420±10%
3+N
50
±2%
2.8
5.6
40.9
24
2.6
4.7
6,2
40
0.16
0.74
24 / 48
22-28/43-56
0.13 / 0.13
5.73 / 2.98
12.25 / 6.12
0.1 / 0.1
4.48 / 2.35
11 / 5.5
0.14
0.63
1.5
0.14
0.63
1.5
0.19
0.92
24 / 48
22-28/43-56
0.2 / 0.2
9.68 / 4.84
17.25/ 10.23
0.2 / 0.2
9.68 / 4.84
2 x 8 / 4.8
0.28
1.27
2 x 1.5
0.28
1.27
2 x 1.5

E/0204/39/10
A.
B.
A
C
B
C.
Dimensions - Inside Unit CST 40/50 without free cooling
15
320 310
800
856
800
54,5
15
320 80
80

E/0204/39/11
A.
A
C
B
B. C.
Dimensions - Inside Unit CST 40/50 with free cooling
centerpoint
310
800
856
1050
54,5
15 15
320 320 45
45 320
650
255
7838
23 32
363
159.5

E/0204/39/12
A.
B.
A
C
B
C.
Dimensions - Inside Unit CST 60/80 without free cooling
375
900
956
1000
54,5
15
396
15
396 104
104

E/0204/39/13
A.
A
C
B
B. C.
Dimensions - Inside Unit CST 60/80 with free cooling
centerpoint
375
900
956
1300
54,5
15 15
390 390 65
65 390
795
308
78
27
24 43
424.5
197

E/0204/39/14
A. B.
C
B
C.
A
Dimensions - Outside Unit CST 40/50
400
800 350
580
54,5

E/0204/39/15
A. B.
C
B
C.
A


54,5
Dimensions - Outside Unit CST 60/80
450
950 400
640

E/0204/39/16
1. Unpacking and Inspection
STULZ products are shipped ex-works. All units have been individually inspected in all their
parts and carefully packaged.
Immediately inspect the unit upon receipt, making sure it has been shipped in its proper position.
Note improper shipment on the shipping document.
We recommend you accepting merchandise subject to inspection.
Check for damage and, if any, note this immediately on the shipping document. Remove packing
and check that the exterior casing is not scratched, marked or have signs of blows and that no
components are missing and that there are no traces of oil. Before throwing the packaging away
check that it does not contain documents or parts of the machine.
Any damage that is encountered must be notified to the carrier by registered letter within 8 days of
receipt.Thecarrierisresponsibleforanydamagecaused duringshipment.STULZ is notresponsible
fordamage causedto themerchandiseby theshipper butwill doallin itspower toassist customers
in these situations.
N.B.This product may not be returned without prior written approval by STULZ.
For any assistance please contact your local STULZ partner.
NOTE:If installation of the product is not required immediately or the product needs
to be onforwarded to its final destination, replace it in its packing, after inspecting it,
and store it in a safe place.
UP
UP
UP
WARNING! As an environmental concern, we recommend to recycle the
packing cartons and to separate them from any plastic.

E/0204/39/17
This unit can be correctly identified by the
technical name-plate containing all the
information for its correct use.
In addition to the manufacturer's identification
data and the product trade-marks, the name-
plate contains the following information:
The technical name-plate is embossed on a
plastic support which ensures high endurance
of the text even in particularly difficult
environments.
N.B. For any assistance or information
concerning the unit described in this manual,
knowledge of its serial number is essential.
2. Unit Identification
Constructor Trademark
Model
Series
Date
Nominal voltage
Controlvoltage
Phase
Frequency
Start/Runcurrent
Cooling capacity
Powerabsorbed
Circuit breaker,curve type C/ Safety fuse type aM
Insidetemperature
Outsidetemperature
Refrigerantcharge
Typeof refrigerant
Maximum pressure
Shelter side protection IP
Ambient side protection IP
Weight
Dutycycle
This identifies the product family.
Product identification number.
Date on which the product is placed
on the market and date of
commencement of warranty.
Voltage to be supplied to the unit
Working voltage of the auxiliary
circuits if different from the voltage
rating.
Voltage phase
Voltage frequency.
Current absorbed when starting the compressor. /
Current absorption with 25°C (RH40%) inside shelter
temperature and 35°C ambient temperature conditions
Unit cooling capacity with 25°C (RH40%) inside shelter
temperature and 35°C ambient temperature conditions.
Power absorbed by the unit with 25°C (RH40%) inside
shelter temperature and 35°C ambient temperature
conditions.
Rating of the automatic switch/safety fuse to be installed
by the installer.
Minimum and maximum shelter temperature where the
machine works and for which the machine was
designed.
Minimum and maximum ambient temperature where
the machine works and for which the machine was
designed
Quantity of refrigerant contained in the unit's
refrigeration circuit
Brand name of the refrigerant used in the unit's cooling
circuit
Maximum pressure at which the refrigeration circuit
functions
protection level in the direction of the shelter
protection level in the direction of the ambient
Empty weight of the machine
Operational capacity of the unit

E/0204/39/18






Condenser
Condenserfan Evaporatorfan
Antifreeze
thermostat
Regulating
thermostat
Evaporator
HP switch
Compressor
Expansionvalve
3. Operating Principle
Split-Air STULZ conditioners are designed to cool rooms containing technological systems.They
are designed for internal installation. Their use allows to eliminate problems caused by high
temperatures, dirt and humidity which are present in the environment.
The unit, which is basically made up of a sealed cooling circuit where the refrigerant circulates, is
divided into two sections, where the air in the environment and the air in the cabinet are treated
without coming into contact with each other during cooling mode.
The system operates as follows:
The compressor compresses the refrigerant gas bringing it to a high pressure and temperature.
The hot gas, by going through the condenser, is cooled and liquefied thus releasing heat to the air
intheenvironment.Pushedthroughthethermalexpansionvalve,theliquidrefrigerantlosespressure,
which makes it prone to evaporation. This takes place in the evaporator, where the refrigerant
absorbs the heat of the warm air from the cabinet, which is therefore cooled.
LP switch
Filterdryer
Liquidreceiver
Condenser
pressureswitch
valve for
filling valve for
filling
Valve Valve
Valve Valve

E/0204/39/19
ADDITIONAL OPERATING MODES
Standard versions type 1 (with C1010 controller)
Free-cooling mode. On units type 1, there is a damper equipped with servomotor which directs
internal and external air flows. This damper is proportionally controlled by a modulating signal
comingfrom C1010controller(for free-coolinglogic see Chapter11: Control,Monitoringand Safety
Components). Its position can be adjusted from 0 to 100% of fresh air, to regulate free-cooling
capacity.When the free-cooling damper opens, external air is taken from the external environment
and blown directly to the internal ambient.
Mixed mode. When the temperature of the external air is low enough to enable the free-cooling
mode, but the effect of this operating mode is not sufficient to keep the internal temperature within
the admitted range, the compressor is switched ON while the free-cooling damper is still open. In
this way, the evaporator cools external air instead of internal re-circulating air, combining benefit of
free-cooling with cooling mode.
Emergency ventilation. When there is a power failure, units work in emergency ventilation mode,
fed by a back-up battery. During main power supply shortages, the system, including evaporator
fans,control componentsandfree-cooling dampermotor,is energizedbyemergency powersupply.
In this way, continuous circulation of air inside the shelter is always assured.This circulation of air
is combined with free-cooling mode, when the necessary conditions to enable this operation mode
are respected.Versions with 48VDC (standard) and 24 VDC (optional) emergency power supplies
are available.When the power supply is present, the DC components are supplied by the back-up
battery with standard configuration.When the TRAREC option is ordered, the DC power supply is
obtained transforming main power supplied to the unit.
Dehumidification. Units equipped with C1010 include also as standard a mechanical hygrostat.
When humidity inside the shelter is higher than the set value, this hygrostat enables the
dehumidification mode on C1010 controller (for a description of this hygrostat and logic of
dehumidification see Chapter 11: Control, Monitoring and Safety Components).
The dehumidification can also be controlled by a RHC humidity sensor (optional see chapter 19).
Both versions type 1 and type 2 + heating elements option
Heating. With heating elements option (see RSC option on Chapter 19:Options), units include an
electric coil in the evaporator section. When the temperature is low, the heating coil turns on
(compressor off) and the free-cooling damper is in complete re-circulation position, in order to heat
internal air. This mode is controlled by C1010 microprocessor, when present (see Chapter 11:
Control, Monitoring and Safety Components for heating logic). When units are mechanically
controlled, an additional TMC thermostat will be supplied for the heater control (see Chapter 19:
Options).

E/0204/39/20
Airflow - Inside Unit CST - without Free Cooling
Refrigerantconnections Evaporator fan
Filter Evaporator
Horizontal Installation
Vertical Installation
E-box