Stulz CyberCool 2 User manual

CyberCool 2
Original instructions
Precision Chillers
Screw compressor
400V/50Hz/3Ph/N/PE
Index G41
Issue 9.2019

EN/09.2019/G41 © STULZ GmbH – all rights reserved
CYBERCOOL 2 SCREW 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 ten production plants (2 in Germany, Italy,
the USA, Great Britain, Spain, 2 in China, Brazil and India)
and twenty subsidiaries (in Germany, France, Italy, Great
Britain, Belgium, Brazil, the Netherlands, New Zealand,
Mexico, Austria, Poland, Spain, Singapore, China, India,
Indonesia, South Africa, Sweden, Australia and the USA).
The company also co-operates with sales and service
partners in over 140 other countries, and therefore boasts
an international network of air-conditioning specialists.

© STULZ GmbH – all rights reserved EN/09.2019/G41
CYBERCOOL 2 SCREW ORIGINAL INSTRUCTIONS
The high-end chiller
Dear customer,
we are pleased that you have decided for a CyberCool 2 Chillerfrom STULZ.
The units, which were produced in Hamburg, have been developed especiallyfor 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/09.2019/G41 © STULZ GmbH – all rights reserved
CYBERCOOL 2 SCREW ORIGINAL INSTRUCTIONS

55© STULZ GmbH – all rights reserved EN/09.2019/G41
CYBERCOOL 2 SCREW 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....................................................................................................................... 28
4.3 Dimensional drawings ....................................................................................................... 49
5. Installation ....................................................................................................... 51
5.1 Positioning............................................................................................................................. 51
5.2 Weights on the supports................................................................................................... 53
5.3 External water circuit ......................................................................................................... 60
5.4 Electrical connection ........................................................................................................ 64
6. Commissioning ................................................................................................ 68
6.1 Filling of the water circuit.................................................................................................. 68
6.2 Control of the electrical box............................................................................................. 70
6.3 Control of pressure switch setting................................................................................. 74
6.4 Oil pre-heating..................................................................................................................... 74
6.5 Commissioning of the chilled water circuit................................................................. 74
6.6 Commissioning of the refrigerant circuits................................................................... 75
7. Maintenance..................................................................................................... 78
7.1 Safety instructions.............................................................................................................. 78
7.2 Maintenance intervals ....................................................................................................... 78
7.3 Refrigerant circuit............................................................................................................... 79
7.4 Air circuit................................................................................................................................. 85
7.5 Water circuit.......................................................................................................................... 87
7.6 Unit housing.......................................................................................................................... 88
8. Malfunction ...................................................................................................... 89
9. Dismantling and disposal................................................................................ 93
10. Contents of the CE Declaration of Conformity ............................................ 94
11. Options........................................................................................................... 95
11.1 Option anti vibration mount........................................................................................... 95
11.2 Option AxiTop..................................................................................................................... 97
11.3 Option lateral power supply.......................................................................................... 99
11.4 Option anti-corrosion coating................................................................................... 100

6EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw 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 by the 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. Complywith breathing protection
data sheet.
 
 
 
 

7© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw 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 of the 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 assemblywork is carried out by authorized

Independent conversion and manufacture of replacement parts




 

8EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
2. Transport / Storage
2.1 Delivery of units

NOTICE
The refrigerant circuit is filled with R134a 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 ofthe 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© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw original insTrUcTions
2.3 Transport
DANGER
Mortal danger by crushing
A defective lifting device can lead to the uncontrolled fall of the chiller unit.

.


number of lifting lugs varies according to the construction size.
The lifting device must consist of two cross beams.
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.


10
300
S
p2
p1 p3 p4
2000
Sx
5400
3700
3400
1150
S
A
B
C
D
Modell S [mm] G [kg]
ESO 4302 ASN  
ESO 4602 ASN  
ESO 4302 ASF  
ESO 4602 ASF  
ESO 4302 AHN  
ESO 4602 AHN  
ESO 4302 AHF  
ESO 4602 AHF  



EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Construction size 1½

Model 

The ropes or belts named byA, B, C and


11
300
S
p3
p2p1 p4 p6
2800
Sx
7000
p5
4500
4200
1150
S
A
B
C
D



Modell S [mm] G [kg]
ESO 4702 A...N  
ESO 5102 A...N  
ESO 6002 A...N  
ESO 6602 A...N  
ESO 4702 A...F  
ESO 5102 A...F  
ESO 6002 A...F  
ESO 6602 A...F  
Modell S [mm] G [kg]
EQO 3002 A...N  
EQO 3302 A...N  
EQO 3702 A...N  
EQO 4002 A...N  
EQO 3002 ASF  
EQO 3302 ASF  
EQO 3702 ASF  
EQO 4002 ASF  
EQO 3002 AHF  
EQO 3302 AHF  
EQO 3702 AHF  
EQO 4002 AHF  
© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw original insTrUcTions
Construction size 2





Model Model

12
300
S
p6
p3
p2p1 p4 p5
3100
S
4800
7600
4500
1150
S
A
B
C
D



Modell S [mm] G [kg]
ESO 6702 ASN  
ESO 7102 ASN  
ESO 6702 ASF  
ESO 7102 ASF  
ESO 6702 AHN  
ESO 7102 AHN  
ESO 6702 AHF  
ESO 7102 AHF  
EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Construction size 2½



The ropes or belts named byA, B, C and

Model

13
300
S
p6
p3
p2p1 p4 p5
3700
S
5400
8800
5050
1150
S
A
B
C
D
Modell S [mm] G [kg]
ESO 7402 A...N  
ESO 8002 A...N  
ESO 8702 A...N  
ESO 9602 A...N  
ESO 7402 A...F  
ESO 8002 A...F  
ESO 8702 A...F  
ESO 9602 A...F  
Modell S [mm] G [kg]
EQO 4702 A...N  
EQO 5102 A...N  
EQO 6002 A...N  
EQO 6602 A...N  
EQO 4702 ASF  
EQO 5102 ASF  
EQO 6002 ASF  
EQO 6602 ASF  
EQO 4702 AHF  
EQO 5102 AHF  
EQO 6002 AHF  
EQO 6602 AHF  



© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw original insTrUcTions
Construction size 3



Model Model



14
300
S
p6
p3
p2p1 p4 p5
S
4800
5800
p7 p8
10300
5500
1150
S
A
B
C
D
Modell S [mm] G [kg]
ESO 9702 ASN  
ESO 9802 ASN  
ESO 9702 ASF  
ESO 9802 ASF  
ESO 9702 AHN  
ESO 9802 AHN  
ESO 9702 AHF  
ESO 9802 AHF  



EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Construction size 3½



Model


15
300
S
p6
p3
p2p1 p4 p5
S
5400
6240
p7 p8
11340
5940
1150
S
A
B
C
D
Modell S [mm] G [kg]
ESO 10202 A...N  
ESO 11102 A...N  
ESO 11502 A...N  
ESO 12602 A...N  
ESO 10202 A...F  
ESO 11102 A...F  
ESO 11502 A...F  
ESO 12602 A...F  
Modell S [mm] G [kg]
EQO 7402 A...N  
EQO 8002 A...N  
EQO 8702 A...N  
EQO 9602 A...N  
EQO 7402 ASF  
EQO 8002 ASF  
EQO 8702 ASF  
EQO 9602 ASF  
EQO 7402 AHF  
EQO 8002 AHF  
EQO 8702 AHF  
EQO 9602 AHF  



© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw original insTrUcTions
Construction size 4





Model Model

16
200
S
p6
p3
p2p1 p4 p5
S
5300
7000
p7 p8
12100
6525
1150
S
A
B
C
D
Modell S [mm] G [kg]
ESO 13102 A...N  
ESO 14102 A...N  
ESO 13102 A...F  
ESO 14102 A...F  
EQO 10202 A...N  
EQO 11102 A...N  
EQO 10202 ASF  
EQO 11102 ASF  
EQO 10202 AHF  
EQO 11102 AHF  



EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Construction size 5



Model


17© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw 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
ESO 14102 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
24 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
R134A
0098
E S O 740 2 A S F
EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Free cooling:
N - without "free cooling"
F - with "free cooling", glycol
Outdoor temperature range:
S - standard
H - high temperature version
Condenser cooling version:
A - air-cooled
Number of refrigerant circuits:
2 - No.
Nominal cooling capacity [kW]
Installation:
O - outside
Sound version:
S - standard
Q - Quiet, low-noise
Chiller type:
E - screw compressor, DX
3. Description
3.1 Type code
The type code represents the unit variant of your chiller unit and can be found on the type plate. The type plate
is located on the inner side ofthe left the door ofthe electric cabinet.
internal part no.
Order number
+ alternative
Serial no.
Unit type

19© STULZ GmbH – all rights reserved EN/09.2019/G41
cybercool 2 screw original insTrUcTions
3.2 Intended use
3.3 Chiller design
This chiller unit is used for the chilled water production and forthe 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 screw compressors exist in 7 construction sizes, which differ by
their length and cooling capacity. An overview of the construction sizes can be seen on pages 49/50.
The side, on which the electric cabinet is located, is named front side in these operating instructions.
The compressors are installed one upon the other in a separate cabinet, which can be accessed by removing
four panels. Each panel is fixed by eight allen screws.
Behind the panels on the right side there is a set of pressure switches and pressure gauges for each refriger-
ant circuit, as shown below.
View ofthe right side:
Air inlet zone for
side coils
Air inlet zone
internal coils
com-
pressor
cabinet
electric
cabinet
compressor, circuit 1
compressor, circuit 2
High pressure switch with
manual reset button
High pressure switch with
internal manual reset button
Low pressure switch with
automatic reset
Low pressure gauge
High pressure gauge

20 EN/09.2019/G41 © STULZ GmbH – all rights reserved
cybercool 2 screw original insTrUcTions
Refrigerant circuit
The chiller contains two separated refrigerant circuits which are identically composed. Only the two circuit
tube evaporator is a common component of both circuits. Both refrigerant circuits can be individually operat-
ed, which offers the possibility of a capacity grading and which increases the reliability. The operating hours
record ofthe 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 manual reset button at the housing
- safety high pressure limiter with manual reset button in the housing
- safety valve
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.
Versions
The standard version forwater chillers with screw compressors has a unit designation, which takes the follow-
ing pattern: ESO _ _ _ _ 2 ASN. There are three more versions which can be combined among each other in
any way.
1. Free cooling version ESO/EQO _ _ _ _ 2 ASF/AHF
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 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 watervolume flow is directed to the evaporator
via 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 EQO _ _ _ _ 2 ASN/ASF/AHN/AHF
In contrast to the standard chillers of the same construction size, these units contain a smaller compressor
size and work with a reduced air flow. At approximatelythe same cooling capacity, a reduction of roughly 10%
in sound pressure level is achieved compared to the standard chillers.
3. High temperature version ESO/EQO _ _ _ _ 2 AHN/AHF
For outside temperatures higherthan 40°C screw compressors with a larger motor are available for each
capacity size.