Stulz CyberCool User manual

CyberCool Indoor Chiller
Original instructions
Precision Chillers
400 V / 3 Ph+N+PE / 50 Hz
Index G44
Issue 9.2017

EN/09.2017/G44 © STULZ GmbH – all rights reserved
CYBERCOOL INDOOR CHILLER ORIGINAL INSTRUCTIONS
Editor
STULZ GmbH
Holsteiner Chaussee283
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 Indiaand) and seventeen sub-
sidiaries (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/09.2017/G44
CYBERCOOL INDOOR CHILLER ORIGINAL INSTRUCTIONS
Targeted cooling of IT and
medical equipment
Dear customer,
thank you for having chosen the CyberCool IndoorChiller from STULZ.
STULZ CyberCool indoor chillers have three different systems to ensure that your chilled water
supply can respond to demand. Fully automonous, with high availability in the vicinity where supplies
are needed, and easy to retrofit.
For general inquiries our hotline is available
at [phone]
Our service hours are weekdays from 7am – 4pm.
For further information concerning our
products and services visit our website :
www.stulz.com

44 EN/09.2017/G44 © STULZ GmbH – all rights reserved
CYBERCOOL INDOOR CHILLER ORIGINAL INSTRUCTIONS
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 Transport................................................................................................................................... 8
2.3 Storage...................................................................................................................................... 9
3. Description....................................................................................................... 10
3.1 Type code............................................................................................................................... 10
3.2 Intended use......................................................................................................................... 11
3.3 Design..................................................................................................................................... 11
3.4 Refrigeration circuit............................................................................................................ 12
3.5 Chilled water circuit ............................................................................................................ 13
3.6 Cooling medium circuit (G, GE) ....................................................................................... 13
3.7 Operating modes of version GE ..................................................................................... 15
3.7.1 DX mode............................................................................................................................. 15
3.7.2 Mix mode............................................................................................................................ 15
3.7.3 FC mode............................................................................................................................. 16
3.8 Circuit scheme ..................................................................................................................... 17
3.8.1 Cooling system A............................................................................................................. 18
3.8.2 Cooling system G............................................................................................................. 19
3.8.3 Cooling system GE.......................................................................................................... 20
4. Technical Data.................................................................................................. 21
4.1 Application limits ................................................................................................................. 21
4.2 Technical Data - CSI ... A/G.............................................................................................. 23
4.3 Technical Data - CSI ... GE................................................................................................ 24
4.4 Dimensional drawings ....................................................................................................... 25
5. Installation ....................................................................................................... 26
5.1 Selection of the installation site...................................................................................... 26
5.2 Positioning the unit............................................................................................................. 27
5.3 Connection of the piping................................................................................................... 29
5.3.1 Refrigerant piping........................................................................................................... 29
5.3.1.1 Design............................................................................................................................. 29
5.3.1.2 Position of the refrigerant connections ............................................................... 29
5.3.1.3 Strength pressure test............................................................................................... 30
5.3.1.4 Tightness/pressure test............................................................................................ 30
5.3.2 Water piping connection............................................................................................... 30
5.3.2.1 Position of the water piping connections for version A/G ............................. 31
5.3.2.2 Position of the water piping connections for version GE ............................... 32
5.4 Electrical connection ........................................................................................................ 34
6. Commissioning ................................................................................................ 37
6.1 Filling the refrigerant circuit............................................................................................. 37
6.2 Filling of the water circuit.................................................................................................. 40

55© STULZ GmbH – all rights reserved EN/09.2017/G44
CYBERCOOL INDOOR CHILLER ORIGINAL INSTRUCTIONS
Subject to technical modifications.
6.2.1 Chilled water circuit ........................................................................................................ 40
6.2.2 Cooling medium circuit.................................................................................................. 40
6.3 Control of the electrical box............................................................................................. 43
7. Maintenance..................................................................................................... 46
7.1 Safety instructions.............................................................................................................. 46
7.2 Maintenance intervals ....................................................................................................... 46
7.3 Refrigerant circuit ............................................................................................................... 47
7.4 Water circuit.......................................................................................................................... 49
7.5 Unit housing.......................................................................................................................... 49
8. Malfunction ...................................................................................................... 50
9. Dismantling and disposal................................................................................ 53
10. Contents of the CE Declaration of Conformity ............................................ 54
11. Options........................................................................................................... 55
11.1 Raised floor stand............................................................................................................ 55
11.2 Refrigerant circuit ............................................................................................................ 58
11.3 Chilled water circuit ......................................................................................................... 59
11.4 Cooling medium circuit (for G units only).................................................................. 61
11.5 C7000 Advanced............................................................................................................. 61

6EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller 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
• Workshavetobecarriedoutbycompetentstaffonly.
• Safetydevicesmaynotbebypassed.
1.3 Handling refrigerants
• Executiononlybyatrainedrefrigerationtechnician
• Safetyglassesandsafetyglovesaretobeworn.
• Liquidrefrigerantmustnotgetontotheskin(riskofburns).
• Onlyuseinwellventilatedareas.
• Donotinhalerefrigerantvapours.
• Refrigerantshaveanarcoticeffectwheninhaledinhighconcentrations.
• Theroomistobeevacuatedimmediatelyifhighconcentrationsofrefrigerantsuddenlyoccur.
• If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.

7© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
1.4 Duties of the operator
ThefollowingrequirementsrelatetotheoperationofrefrigeratingplantswithintheEuropeanCommunity.
• Theusedcomponentsmustcorrespondtothepressureequipmentguide-lineEC/97/23andEN378part
1-4.
• Independentofthedesign,theequipmentandinspectionbeforethedelivery,alsotheoperatorofsuch
plantshasdutiesaccordingtoEN378andnationalregulations.
This concerns the installation, the operation and the repeated inspection:
• Installation:accordingtoEN378
• Operation: Determinationofemergencymeasures(accidents,malfunctions)
 Creationofanabbreviatedinstructionandnotication(templatepage)
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.
• Repeatedinspection:accordingtoEN378
 Theoperatorisresponsiblefortheexecution.
The operator must ensure that all maintenance, inspection and assembly work is carried out by authorised
andqualied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modiedafterconsultationwithSTULZ.Originalreplacementpartsand
replacementparts/accessoriesauthorisedbySTULZareanaidtosafety.
• Itisabsolutelyessentialtocomplywiththerstaidmeasuresifaccidentsoccur.
• RefrigerantscontainingFCscontributetotheglobalwarmingandwiththistoclimatechanges.The
FCsmustthereforebedisposedofinaccordancewiththeregulations,i.e.onlybycompaniesspe-
ciallyqualiedandlicensedasrecogniseddisposalcompaniesforrefrigerants.
• Responsabilityforcorrectdisposalofrefrigerantandsystempartsisincumbentontheoperator.

8EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
2. Transport / Storage
2.1 Delivery of units
Stulzchillerunitsaremountedonpalletsandpackedseveraltimesinplasticlm.
NOTICE
Version A:
Version G, GE:
The refrigerant circuit is filled with nitrogene up to
atmospheric pressure.
The refrigerant circuit is filled with refrigerant rea-
dy for use.
Construction of protec-
tive covering:
(frominsidetooutside)
The following information can be found on the packing:
1.Neopolenecushioning
2.Shrinklm
3.Additionalboardincon-
tainer shipments
1)Stulzlogo
2)Stulzordernumber
3)Typeofunit
4)Packingpiece-contents
5)Warningsymbols
alsouponrequest
6)Grossweight
7)Netweight
8)Dimensions
9)Customerordernumber
10)Additionalcustomer
requirements
NOTICE
Whendeliveryisaccepted,checktheunitagainstthedeliverynoteforcompletenessand
forexternaldamageandrecorditontheconsignmentnoteinthepresenceofthefreight
forwarder.
•Thedeliverynotecanbefoundonthe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 unit.
Donotstayundersuspendedloads!
TheStulzunitscanbemovedbyliftingdeviceswithbeltsorropes.
•xthebeltsorropesatthepallet,
•protecttheupperunitedgesbywoodenlathsormetalbracketsinsuchawaythattheycouldnotbecaved
in.

9© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
NOTICE
Risk of distorting the frame
Nevermovetheunitonrollersandnevertransportitonaforkliftwithoutpallet.
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:
• the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.
• makesurethatthewaterconnectionsareprovidedwithprotectivehoods.
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.

10
C = CyberCool
S = Standard
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
CSI 221 A
Artikel-Nr.
Item-no.
numéro d’article
B49480
Kältemittel
refrigerant
refrigerant
Kommission/Alt
commission/alt
commission/alt
0530111234/01
Baujahr
model
modele
2017
Versorgunsspannung
supply voltage
tension de service
400
50
V ± 10%
Hz± 1%
Max. Betriebsdruck
max. operation pressure
pression de fonction max.
40 bar
Max. Füllgewicht
max. filling change
charge max. de rempliss.
 kg
C I 1S 22 A
R410A
EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
3. Description
3.1 Type code
The type code represents the unit variant of your chiller and can be found on the rating plate. The
rating plate is located in the door in front of the electrical compartment.
internal part no.
Order number
+ alternative
Serial no.
Unit type
Page code
Explanation
Unit variants
Product range
Installation site
Number of refrigeration circuits
Output of unit in kW
Energy index
Date of issue
month/year
Language:
EN = English
DE = German
FR = French
IT = Italian
Index number
Manufacturing base:
G = Germany
C = China
I = Italy
EN/09.2017/G17B
Cooling system:
A = air-cooled
G = water/glycol cooled
GE = glycol cooled + free cooling
I = Indoor

11
A
HD-Patronendruckschalter ACB 36-29bar
M74360
HD-Patronendruckschalter ACB 36-29bar
M74360
ND-Schalter
Patronendruckschalter-ACB-3-6bar
M74358
Schauglas Parker SA-17s
1103757
Filtertrockner DML 417s
1106182
Membrandruckausdehnungsgefäß 8l 2,5bar
M53268
Frostschutzthermostat TR-1-F-U
M26386
Expansionsventil E3V65SSS10
1104804
A (1 : 5)
ND-Schalter
Patronendruckschalter-ACB-3-6bar
M74358
© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
3.2 Intended use
3.3 Design
In the upper half of the unit, the electric box is situated, which contains the controller C7000IOC, the main
switch and the electric components to control and monitor the chiller. All the wiring comes together in the
electrical section and is connected here.
The chiller unit control is effected by the on board I/O controller. 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.
With a cooling capacity of 60 kW and more, the unit is equipped with two compressors connected in parallel.
Units of version GE always contain two compressors.
Unit of version GE
electron. expansion valve
Sightglass
Filter dryer
HP switch
Expansion tank in the chilled water circuit
(Secondary circuit)
This chiller unit is used to cool water for technical units and A/C units within the application limits stated in
chapter 4.1. The chiller is designed for indoor installation. Any use beyond this is not deemed to be use as
intended.

12
A
HD-Patronendruckschalter ACB 36-29bar
M74360
HD-Patronendruckschalter ACB 36-29bar
M74360
ND-Schalter
Patronendruckschalter-ACB-3-6bar
M74358
Frostschutzthermostat TR-1-F-U
M26386
Expansionsventil E3V65SSS10
1104804
Schauglas Parker SA-17s
1103757
Filtertrockner DML 417s 22mm Löt
1106182
A (1 : 5)
ND-Schalter
Patronendruckschalter-ACB-3-6bar
M74358
EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
3.4 Refrigeration circuit
Filter dryer
Sightglass
HP switch
Oil sight glass
Version A/G
In units of the A version, an external air-cooled condenser must be connected to the open refrigeration circuit
of the unit.
Version A/G:
The unit is eqipped with an electronically controlled hotgas bypass for the proportional capacity control in the
range of 40 to 100% of the nominal cooling capacity. The hotgas bypass valve is commanded and propor-
tionally controlled by the C7000 controller.
Version GE:
The above described capacity control by an HGBP valve can be obtained as an option.
Monitoring devices
The refrigeration circuit is equipped with various safety devices to avoid malfunctions. In the liquid line there
is a filter drier to separate humidity and a sight glass to check the sufficient charge of refrigerant. An oil sight
glass can be consulted to check the state and quantity of the ester oil charge in the compressor.
Safety devices
The refrigerant circuit is protected against insufficient evaporation pressure by a safety pressure limiter
(low-pressure switch). If the operating pressure is fallen below, a warning signal appears on the display and
the unit is put out of operation. A safety pressure cut-out (high-pressure switch) is triggered at 36 bar, switch-
es off the compressor and protects the refrigeration circuit against excessive operating pressure. Simultane-
ously a warning signal on the display of the controller appears.
A safety valve, which releases refrigerant at 40 bar, is fitted on A-units as further protection.

13© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
3.6 Cooling medium circuit (G, GE)
3.5 Chilled water circuit
The chilled water circuit in the unit is open and will only be closed by the connection to the chilled water ring
main on the site. In the unit there is an evaporator as interface to the refrigeration circuit, a (or optionally 2)
centrifugal pump(s), an expansion tank with safety valve, a flow monitor to control the pump function, an anti-
freeze thermostat to protect the evaporator and the system, two ventilating valves and one drainage valve.
A temperature sensor measures the flow water temperature at the unit outlet, this temperature is decisive for
the chiller control. A pressure gauge installed in the unit indicates the flow pressure.
GE units contain an additional heat exchanger for direct cooling (free cooling) and a 3 way valve (free cooling
valve). The free cooling valve conducts the water flow completely through the heat exchanger during free
cooling and mix mode. In the DX mode the valve conducts the water flow completely through a bypass so that
no water flows through through the free cooling heat exchanger.
Version G
The cooling medium circuit contains a plate condenser as interface to the refrigerant circuit and a valve for
filling and draining.
A 2 way or 3 way valve can be optionally installed to control the cooling water flow.

14 EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
Version GE
The cooling medium circuit contains a plate condenser as interface to the refrigerant circuit, a plate heat
exchanger as interface to the chilled water circuit, a 2-way valve (GE valve) to control the water flow through
the heat exchanger for free cooling, a 2-way valve (G valve) to control the condensation pressure in the plate
condenser, a valve for filling and draining and two deventilation valves.
In the DX- and Mix mode the G valve controls the condensation pressure, which is measured by a pressure
sensor upstream the condenser and is compared with a setpoint. In the FC mode (free cooling) this valve is
closed.
In the FC- and Mix mode the GE valve controls the water flow in the cooling medium circuit and by this the
water temperature in the chilled water circuit. In DX mode this valve is closed.
Rear view
of version GE
Evaporator
3-way valve
GE valve
GE heat exchanger
G valve
Condenser

15
TC PI PI
FS
TC PI PI
FS
TT
TT
TT
TT
TT PI
FZAL
PI
TT
TT
TT PI
FZAL
PI
© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
3.7 Operating modes of version GE
3.7.1 DX mode
3.7.2 Mix mode
Chilled water is only cooled by the
refrigerant circuit.
The G valve controls the condensa-
tion pressure. The GE valve is closed.
The free cooling valve has completely
opened the bypass line and closed
the flow through the heat exchanger
for free cooling.
FC valve: free cooling valve
Condenser
Refrigerant circuit
Heat exchanger for
free cooling
GE valve
FC valve
The chilled water is directly cooled on
the one hand and additionally by the
refrigerant circuit.
The G valve controls the condensa-
tion pressure. The GE valve is com-
pletely open.
The free cooling valve has completely
closed the bypass and has opened
the way for the flow through the heat
exchanger for free cooling.
Evaporator
G valve
Condenser
Refrigerant circuit
Heat exchanger for
free cooling
GE valve
FC valve
Evaporator
G valve

16
TC PI PI
FS
TT
TT
TT
TT PI
FZAL
PI
EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
3.7.3 FC mode
The chilled water is directly cooled by
the cooling medium circuit.
The G valve is completely closed.
The GE valve controls the water flow
through the GE heat exchanger.
The free cooling valve has completely
closed the bypass and has opened
the way for the flow through the heat
exchanger for free cooling.
Condenser
Refrigerant circuit
Heat exchanger for
free cooling
GE valve
FC valve
Evaporator
G valve

17© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
Pressure sensor
Temperature sensor
High pressure limiter
Low pressure switch
Pressure gauge
Flow switch / monitor
Antifreeze thermostat
3.8 Circuit scheme
Non-return valve
Filter drier
Sight glass
Rotalock stop valve with cap
Pressure relief valve
Schrader valve
3-way motorized valve
2-way motorized valve
Electric reheat
Solenoid valve
Manual stop valve
Automatic deventilation valve
Electronical expansion valve
Stop valve with cap and Schrader valve
Legend

18
TSL
EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
3.8.1 Cooling system A
Receiver Compressor
Pump
Evaporator Expansion tank
Chilled water
2nd compressor
only for CSI 661,
841 and 981 A
to the air cooled condenser

19
TSL
© STULZ GmbH – all rights reserved EN/09.2017/G44
cybercool indoor chiller original instructions
3.8.2 Cooling system G
Compressor
Pump
Condenser
Evaporator Expansion tank
Cooling water
Chilled water
2nd compressor
only for CSI 661,
841 and 981 G

20
TT
TSL
EN/09.2017/G44 © STULZ GmbH – all rights reserved
cybercool indoor chiller original instructions
3.8.3 Cooling system GE
Compressor
Condenser
Evaporator
Expansion tank
Pump
Cooling medium
Chilled water
Liquid receiver
Heat exchanger
for free cooling