Stulz CyberCool 2 User manual

CyberCool 2
Original instructions
Precision Chillers
Scroll compressor
400V/50Hz/3Ph/N/PE
Index G42
Issue 6.2018

EN/06.2018/G42 ©STULZ GmbH – all rights reserved
CYBERCOOL 2 SCROLL ORIGINAL INSTRUCTIONS
Editor
STULZ GmbH
Holsteiner Chaussee 283
22457 Hamburg
ABOUT STULZ
Since it was founded in 1947, the STULZ company has
evolved into one of the world’s leading system suppliers of
air-conditioning technology.
Since 1974 the group has seen continual international
expansion of its air conditioning technology business, spe-
cialising in A/C for data centres and telecommunications
installations.
STULZ has seven production plants (Germany, Italy, the
USA, 2 in China, Brazil and India) and seventeen subsi-
diaries (in France, Italy, Great Britain, Belgium, Brazil, the
Netherlands, New Zealand, Mexico, Austria, Poland, Spain,
Singapore, China, India, South Africa, Australia and the
USA).
The company also co-operates with sales and service
partners in over 130 other countries, and therefore boasts
an international network of air-conditioning specialists.

© STULZ GmbH – all rights reserved EN/06.2018/G42
CYBERCOOL 2 SCROLL ORIGINAL INSTRUCTIONS
The high-end chiller
Dear customer,
we are pleased that you have decided for a CyberCool 2 Chiller from STULZ.
The units, which were produced in Hamburg, have been developed especially for use in Data Cen-
ters and industry and satisfy all requirements for efficiency and reliability.
For general inquiries our hotline is available
at [phone]5000
Our service hours are weekdays from 7am – 4pm.
For further information concerning our
products and services visit our website :
www.stulz.com

44 EN/06.2018/G42 ©STULZ GmbH – all rights reserved
CYBERCOOL 2 SCROLL ORIGINAL INSTRUCTIONS

55© STULZ GmbH – all rights reserved EN/06.2018/G42
CYBERCOOL 2 SCROLL ORIGINAL INSTRUCTIONS
Subject to technical modifications.
Contents
1. Safety.................................................................................................................. 6
1.1 Marking...................................................................................................................................... 6
1.2 Safety instructions................................................................................................................. 6
1.3 Handling refrigerants............................................................................................................ 6
1.4 Duties of the operator........................................................................................................... 7
2. Transport / Storage ........................................................................................... 8
2.1 Delivery of units ...................................................................................................................... 8
2.2 Storage...................................................................................................................................... 8
2.3 Transport................................................................................................................................... 9
3. Description....................................................................................................... 18
3.1 Type code............................................................................................................................... 18
3.2 Intended use......................................................................................................................... 19
3.3 Chiller design........................................................................................................................ 19
4. Technical Data.................................................................................................. 23
4.1 Application limits ................................................................................................................. 23
4.2 Technical data....................................................................................................................... 26
4.3 Dimensional drawings ....................................................................................................... 35
5. Installation ....................................................................................................... 37
5.1 Positioning............................................................................................................................. 37
5.2 Weights on the supports................................................................................................... 39
5.3 External water circuit ......................................................................................................... 45
5.4 Electrical connection ........................................................................................................ 51
6. Commissioning ................................................................................................ 56
6.1 Filling of the water circuit.................................................................................................. 56
6.2 Control of the electrical box............................................................................................. 58
6.3 Oil pre-heating..................................................................................................................... 62
6.4 Commissioning of the chilled water circuit................................................................. 62
6.5 Commissioning of the refrigerant circuits................................................................... 63
7. Maintenance..................................................................................................... 65
7.1 Safety instructions.............................................................................................................. 65
7.2 Maintenance intervals ....................................................................................................... 65
7.3 Refrigerant circuit............................................................................................................... 66
7.4 Air circuit................................................................................................................................. 69
7.5 Water circuit.......................................................................................................................... 71
7.6 Unit housing.......................................................................................................................... 72
8. Malfunction ...................................................................................................... 73
9. Dismantling and disposal................................................................................ 76
10. Contents of the CE Declaration of Conformity ............................................ 77
11. Options........................................................................................................... 78
11.1 Option anti vibration mount........................................................................................... 78
11.2 Option AxiTop..................................................................................................................... 80
11.3 Option lateral power supply.......................................................................................... 82
11.4 Option anti-corrosion coating...................................................................................... 84

6EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
1. Safety
1.1 Marking
DANGER threatening danger, grievous bodily harm and death
WARNING dangerous situation, grievous bodily injury
CAUTION dangerous situation, light bodily injury
NOTICE material damage, important information and application notice
ESD NOTE risk of damaging electronical components
1.2 Safety instructions
These operating instructions contain basic information which is to be complied with for installation, operation
and maintenance. They must therefore be read and complied with bythe fitter and the responsible trained
staff/operators before assembly and commissioning. They must be permanently available at the place where
the system is used.
DANGER
 
 
1.3 Handling refrigerants
 
 
 
 
 
 
apparatus must be worn. This does not mean simple filter masks. Comply with breathing protection
data sheet.
 
 
 
 

7© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
1.4 Duties of the operator

 

 

This concerns the installation, the operation and the repeated inspection:
 
  
 
a. A unit protocol must be kept.
b. To be stored in the proximity ofthe unit
c. Access for competent staff in case of repairs and repeated inspection must be ensured.
 
The operator is responsible for the execution.
The operator must ensure that all maintenance, inspection and assembly work is carried out by authorised

Independent conversion and manufacture of replacement parts




 

8EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
2. Transport / Storage
2.1 Delivery of units

NOTICE
The refrigerant circuit is filled with R410A refrigerant ready for use.
The chiller is labelled as follows.





 
gerous goods.
 


NOTICE
consignment papers for completeness
and for external damage and record it on the consignment papers in the presence of the freight
forwarder.
You receive the consignment papers with the delivery of the chiller unit.

2.2 Storage

out to protect the unit from damage and corrosion:
 
“Application limits“.
 
 

9
min. 1400


© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
2.3 Transport
DANGER
Mortal danger by crushing
A defective lifting device can lead to the uncontrolled fall of the chiller unit.

.

Clamps to lock
the rope or belt
Construction sizes 3 and 4

The steel tubes are not delivered and must be provided bythe customer.
Requirements for the steel tubes:
 
 
 
To prevent the ropes from sliding offthe steel tubes, fasten a clamp at
the end of the tubes.



The drawings on the following pages show the dimensions for the sus
pension points and the position of the centre of gravity.

10
S
Sx
S
Sy
min. 1400
min. 5000
Modell Sx[mm] Sy[mm] G [kg]
CSO 541 ASN   
CSO 621 ASN 959  
CSO 801 ASN   
CSO 541 ASF   
CSO 621 ASF 999  
CSO 801 ASF   
CQO 541 ASN   
CQO 621 ASN 959  
CQO 541 ASF   
CQO 621 ASF 999  
EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions


Construction size 3


NOTICE
Consider also the weight of the cross beam when you order the crane.
The rope forces are higher than the weight forces according to the geometry.

Model

11
SSx
Sy
min. 1400
min. 5000
2500
S
A
B
C

Modell Sx[mm] Sy[mm] G [kg]
CSO 1102 ASN   
CSO 1302 ASN   
CSO 1102 ASF   
CSO 1302 ASF   
CQO 802 ASN   
CQO 1102 ASN   
CQO 802 ASF   
CQO 1102 ASF   
© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions


Construction size 4
The ropes or belts named by A, B, C and



Model

12 EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
Construction sizes 5 - 7



The drawings on the following pages show the dimensions for the suspension points and the position of the
centre of gravity.

 
NOTICE
Consider also the weight of the cross beams when you order the crane.
The rope forces are higher than the weight forces according to the geometry.


13


85
1675
S
p3
p2p1 p4
2285
S
3875
2200
min. 5000
A
B
C

1150
S
Modell S [mm] G [kg]
CSO 1602 ASN  
CSO 1902 ASN  
CSO 2402 ASN  
CSO 1602 ASF  
CSO 1902 ASF  
CSO 2402 ASF  
CQO 1302 ASN  
CQO 1602 ASN  
CQO 1902 ASN  
CQO 1302 ASF  
CQO 1602 ASF  
CQO 1902 ASF  
© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
Construction size 5

Model 

The ropes or belts named by A, B, C and


14
210
1910
S
p3
p2
p1 p4
3065
S
4765


2855
min. 5000
A
B
C

1150
S
Modell S [mm] G [kg]
CSO 2802 ASN  
CSO 3702 ASN  
CSO 4002 ASN  
CSO 2802 ASF  
CSO 3702 ASF  
CSO 4002 ASF  
CQO 2402 ASN  
CQO 2802 ASN  
CQO 3702 ASN  
CQO 2402 ASF  
CQO 2802 ASF  
CQO 3702 ASF  
EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
Construction size 6

Model 

The ropes or belts named by A, B, C and


15


200
S
p3
p1 p4
3600
S
5300
p2
1900
3400
min. 6000
A
B
C

1150
S
Modell S [mm] G [kg]
CSO 4202 ASN  
CSO 4202 ASF  
© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
Construction size 6½


Model 

The ropes or belts named by A, B, C and


16


300
S
p4
p1 p6
4500
S
7000
p3
2800
4200

A
B
C

1150
S
Modell S [mm] G [kg]
CSO 4602 ASN  
CSO 5002 ASN  
CSO 5902 ASN  
CSO 4602 ASF  
CSO 5002 ASF  
CSO 5902 ASF  
CQO 4002 ASN  
CQO 4602 ASN  
CQO 5002 ASN  
CQO 4002 ASF  
CQO 4602 ASF  
CQO 5002 ASF  
EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
Construction size 7

Model 

The ropes or belts named by A, B, C and


17© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
Transport protection


unscrewed to remove the polypropylene plates.



Option: Coil protection grille
The spacers are enclosed in the electrical cabinet. 


grille.





18
Typenschild/type plate
plaque d’appareil
S. Nr.
s.-no.
no. serie
Lieferant
manufacturer
vendeur
STULZ GmbH Hamburg
Holsteiner Chaussee 283, D22457 Hamburg
Made in Germany
Typ
type
type
CSO 2802 ASN
Artikel-Nr.
Item-no.
numéro d’article
1300010
Kältemittel
refrigerant
refrigerant
Kommission/Alt
commission/alt
commission/alt
0530111234/01
Baujahr
model
modele
2018
Versorgunsspannung
supply voltage
tension de service
400
50
V  10%
Hz 1%
Max. Betriebsdruck HD
max. operation pressure HP
pression de fonction max. HP
32 bar
Max. Betriebsdruck ND
max. operation pressure LP
pression de fonction max. BP
14 bar
Temperatur min/max
Temperature min/max
Température min/max 10/100 °C
R410A
0098
C S O 280 2 A S N
EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
Free cooling:
N - without "free cooling"
F - with "free cooling", glycol
Outdoor temperature range:
S - standard
Condenser cooling version:
A - air-cooled
Number of refrigerant circuits:
1, 2 - No.
Nominal cooling capacity [kW]
Installation:
O - outside
Sound version:
S - standard
Q - Quiet, low-noise
Chiller type:
C - scroll compressor, DX
3. Description
3.1 Type code
The type code represents the unit variant ofyour chiller unit and can be found on the type plate. The type plate
is located on the inner side of the left the door of the electric cabinet.
internal part no.
Order number
+ alternative
Serial no.
Unit type

19© STULZ GmbH – all rights reserved EN/06.2018/G42
cybercool 2 scroll original insTrUcTions
3.2 Intended use
3.3 Chiller design
View of the right side:
Air inlet zone for
side coils
Air inlet zone
internal coils
compres-
sor cabinet
electric
cabinet
Basic design for construction sizes 5 to 7
Right side view:
Basic design for construction size 3 and 4
Air inlet zone
condenser
circuit 1
condenser
circuit 2
electric
cabinet Access panel for
compressors
circuit 1
Access panel for
compressors
circuit 2
+ opt. pumps
Left side view:
This chiller unit is used for the chilled water production and for the chilled water temperature control. The chill-
er is designed for outdoor installation. Any use beyond this is not deemed to be use as intended. STULZ is not
liable for any damage resulting from such misuse. The operator alone bears the risk.
The chillers of the CyberCool2 series with scoll compressors exist in 5 construction sizes, which differ bytheir
dimensions, design and cooling capacity. An overview of the construction sizes 3 to 7 can be seen on pages
35/36.
The side, on which the electric cabinet is located, is named front side in these operating instructions.
The compressors are installed in a separate cabinet, which can be accessed in the unit sizes 5 - 7 by removing
four panels. Each panel is fixed by eight allen screws.
In the compressor cabinet there are high pressure switches for each compressor and a low pressure switch
with automatic reset function for each refrigerant circuit.

20 EN/06.2018/G42 © STULZ GmbH – all rights reserved
cybercool 2 scroll original insTrUcTions
Refrigerant circuit
The chiller contains two separated refrigerant circuits which are identically composed. Both refrigerant cir-
cuits can be individually operated, which offers the possibility of a capacity grading and which increases the
reliability. The operating hours record of the compressors enables equal utilization of both refrigerant circuits
by sequencing.
An electronic expansion valve is also part of the standard equipment as a filter dryer with replaceable car-
tridge and a sight glass with humidity indication.
Each refrigerant circuit disposes of the following safety devices:
- low pressure switch
- high pressure limiter with reset button
- safety valve
Versions
The standard version for water chillers with scroll compressors has a unit designation, which takes the follow-
ing pattern: CSO _ _ _ _ ASN. There are two more versions which can be combined among each other in
any way.
1. Free cooling version CSO/CQO _ _ _ _ ASF
This version additionally contains a free cooling coil for each refrigerant circuit. The free cooling coils are con-
nected in parallel in the water-side circuit. During free cooling mode, two motor-driven 2-wayvalves (size 3
and 4: one 3-way valve) direct the water volume flow completely through the free cooling coils, before it flows
through the evaporator. If free cooling is not possible due to a high outside temperature, the water volume flow
is directed to the evaporatorvia a bypass line parallel to the free cooling coils.
A control valve is installed in the liquid line and ensures in mixed operation to maintain the condensation pres-
sure, independent of the fan speed.
2. Low noise version CQO _ _ _ _ ASN/ASF
In contrast to the standard chillers of the same construction size, these units work with a reduced air flow.
At approximately the same cooling capacity, a reduction of roughly 10% in sound pressure level is achieved
compared to the standard chillers.
Top view: Component
location of :
circuit 1
circuit 2
The components ofthe first refrigerant circuit are mainly located on the left side of the chiller, the components
of the second refrigerant circuit mainly on the right side.