Stulz CyberLab User manual
CyberLab
Original instructions
Precision Air Conditioning Units
400V/50Hz/3Ph/N/PE
Index G17F
Issue 2.2018
EN/02.2018/G17F © STULZ GmbH – all rights reserved
CYBERLAB 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/02.2018/G17F
CYBERLAB ORIGINAL INSTRUCTIONS
CyberLab – Intelligent solution for
laboratories, archives and museums
Dear customer,
we are pleased that you have decided for the Cyberlab from STULZ.
Cyberlab is a precision air conditioning unit, which has been developed
especially for applications with a low or no heat load,
applications however for which temperature and humidity need to be kept
precisely constant.
For general inquiries our hotline is available
at +49 40 5585-5000
Our service hours are weekdays from 7am – 4pm.
For further information concerning our
products and services visit our website :
www.stulz.com
44 EN/02.2018/G17F © STULZ GmbH – all rights reserved
CYBERLAB ORIGINAL INSTRUCTIONS
55© STULZ GmbH – all rights reserved EN/02.2018/G17F
CYBERLAB 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 Transport................................................................................................................................... 8
2.3 Storage...................................................................................................................................... 9
3. Description....................................................................................................... 10
3.1 Type code............................................................................................................................... 10
3.2 Intended use......................................................................................................................... 11
3.3 Function of the A/C unit.................................................................................................... 11
3.4 Control .................................................................................................................................... 13
4. Technical Data.................................................................................................. 14
4.1 Application limits ................................................................................................................. 14
4.2 Technical Data...................................................................................................................... 15
4.3 Dimensional drawings ....................................................................................................... 16
5. Installation ....................................................................................................... 17
5.1 Selection of the installation site...................................................................................... 17
5.2 Positioning the unit............................................................................................................. 18
5.3 Connection of the piping................................................................................................... 20
5.3.1 Refrigerant piping ........................................................................................................... 20
5.3.1.1 Design............................................................................................................................. 20
5.3.1.2 Position of the refrigerant connections ............................................................... 20
5.3.1.3 Strength pressure test............................................................................................... 21
5.3.2 Condensate drain connection..................................................................................... 22
5.4 Electrical connection ........................................................................................................ 24
5.5 Reheat..................................................................................................................................... 26
6. Commissioning ................................................................................................ 27
6.1 Filling the refrigerant circuit............................................................................................. 27
6.2 Control of the electrical box............................................................................................. 30
7. Maintenance..................................................................................................... 40
7.1 Safety instructions.............................................................................................................. 40
7.2 Maintenance intervals ....................................................................................................... 40
7.3 Refrigerant circuit............................................................................................................... 42
7.4 Air circuit................................................................................................................................. 44
7.5 Unit housing.......................................................................................................................... 45
8. Malfunction ...................................................................................................... 46
9. Dismantling and disposal................................................................................ 47
10. Contents of the CE Declaration of Conformity ............................................ 48
11. Options........................................................................................................... 49
11.1 Option external humidifier............................................................................................. 49
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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. Comply with breathing protection
data sheet.
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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 assembly work is carried out by authorised
Independent conversion and manufacture of replacement parts
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2. Transport / Storage
2.1 Delivery of units
NOTICE
The refrigerant circuit is filled with nitrogen with overpressure to atmosphere.
Construction of protec-
tive covering:
The following information can be found on the packing:
tainer shipments
NOTICE
for external damage and record it on the consignment note in the presence of the freight
forwarder.
2.2 Transport
DANGER
Mortal danger by crushing
A defective lifting device can lead to the uncontrolled fall of the A/C unit.
in.
9© STULZ GmbH – all rights reserved EN/02.2018/G17F
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NOTICE
Risk of distorting the frame
2.3 Storage
out to protect the unit from damage and corrosion:
“Application limits“.
You can move the unit still packaged on the pallet with a fork lift.
10
A = CyberAir
U = Upflow
S = Standard
Typenschild/type plate
plaque d’appareil
S. Nr.
s.-no.
no. serie
Lieferant
manufacturer
vendeur
STULZ GmbH Hamburg
Holsteiner Chaussee 283, D22457 Hamburg
Made in Germany
Typ
type
type
ASU 211 AL
Artikel-Nr.
Item-no.
numéro d’article
B99403
Kältemittel
refrigerant
refrigerant
R410A
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
max. operation pressure
pression de fonction max.
40 bar
Max. Füllgewicht
max. filling change
charge max. de rempliss.
kg
A U 1S 21 AL
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Cooling system:
A = air-cooled
L = laboratory unit with speed controlled
compressor
3. Description
3.1 Type code
The type code represents the unit variant of your A/C unit 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
Airflow direction
Number of refrigeration circuits
Output of unit in kW
Energy index
Date of issue
month/year
Language:
DE = German
EN = English
Index number
Manufacturing base:
G = Germany
C = China
I = Italy
EN/02.2018/G17F
11© STULZ GmbH – all rights reserved EN/02.2018/G17F
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3.2 Intended use
This A/C unit is used to control room temperature and air humidity within the application limits stated
in chapter 4.1. The A/C unit is designed for indoor installation. The A/C unit complies with the hygi-
enic requirements according to VDI6022. The unit is also designed for zero-load operation. Any use
beyond this is not deemed to be use as intended.
3.3 Function of the A/C unit
The A/C unit is exclusively operated by the controller in the
front panel and the main switch (operable from outside the
unit) in the electric box.
In the air inlet a temperature/humidity sensor is located which
provides the measured values for the temperature/humidity
control. Cooling is achieved by compressor operation in the
refrigerant circuit.
The unit has an incorporated electric reheat and a hotgas
reheat, to precisely control the temperature in case of a small
thermal load.
To achieve a dehumidification, the electronic expansion
valve is partially closed in the first step. The reduction of the
refrigerant mass flow makes the evaporation temperature
drop, which lets the surface temperature in a part of the
evaporator fall below the dew point of the air. This causes
dehumidification.
For a bigger dehumidification, the fan speed is reduced. With
a constant cooling capacity, the temperature of the air which
flows through the heat exchanger coil, passes below the dew
point. The moisture contained in the air condenses on the
heat exchanger gathers in the condensate pan and is carried
away by the drain.
An external humidifier can optionally be connected and is
powered and controlled by a power and control line coming
from the CyberLab unit.
The A/C unit control is effected by the on board I/O control-
ler. 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.
Electrical
box
Electrical
reheat
Hotgas reheat
Sight glass
Filter dryer
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Composition of the A/C unit
This A/C unit has the following facilities that allow maintenance without opening the A/C unit.
A digital display for the filter pressure loss and an on/off switch for the interior lights are installed in the front door. The
interior light illuminates the front and back of the heat exchanger and can be positioned freely on ferromagnetic metal
surfaces.
Revision glasses, through which the state of pollution in the interior of the air conditioning unit can be checked are integ-
rated in the side panels. The filter positon and the state of the condensate tray can be checked as well.
A service flap in the right side panel allows the cleaning of the condensate tray.
Lateral revision glasses and service flap
Indication of filter pressure loss
optionally in • Pa
• mbar
• inch water column
Interior lights switch
Main switch
CyberLab front view
The state of the condensate tray can
be checked via the lower revision
glasses.
The state of the heat exchanger
can be checked via the upper revi-
sion glasses.
13© STULZ GmbH – all rights reserved EN/02.2018/G17F
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3.4 Control
Temperature control
The temperature is controlled by three components:
1. speed-controlled compressor (EC compressor)
2. electrical reheat
3. hotgas reheat
The speed-controlled compressor is continuously in operation as soon as the A/C unit is switched on. In case
the thermal room load is too low in relation to the cooling capacity, the electrical reheat is switched on.
The electrical reheat as well as the EC compressor are controlled by a PID control.
As soon as the electrical reheat and the EC compressor run simultaneously, the setpoint spread is active. The
setpoint spread is 0,1 K for each component. With an active setpoint spread and a setpoint of e.g. 24°C the
compressor is controlled to achieve 24,1°C and the electrical reheat to achieve 23,9°C.
The hotgas reheat is switched on and off by a start temperature and a hysteresis. If the start temperature is
achieved and if a dehumidification request exists, the hotgas reheat is switched on.
Humidity control
The humidity is controlled by three components:
1. electronical expansion valve
2. speed-controlled compressor (EC compressor)
3. optional external humidifier
If the humidity is smaller than the setpoint humidity, the air is humidified by the optional external humidifier.
If the humidity is bigger than the setpoint humidity, the air is dehumidified by the electronical expansion valve
and by the EC compressor. You can set whether dehumidification is controlled according to the relative humi-
dity or to the dew point.
For the EC compressor a minimum speed for dehumidification can be set.
Control accuracy
The control accuracy (± 0,5 K / ± 3 % r.h.) depends on:
• the positioning of the A/C unit
• the size of the room to be conditioned
• the thermal load
• the air volume ow
• the stability of room conditions
• humidity control at minimal load
We recommend to only operate one active CyberLab unit per room. Several CyberLab units can be installed in
the room, but only one of these units may be in operation at a time. This can be achieved by the failure depen-
dent change-over of the sequencing function (no time dependent sequencing).
A supply air sensor is available as an option and is delivered loose.
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Admissible return air conditions:
Temperature: Lower limit: 18 °C
Upper limit: 35 °C
Humidity: Lower limit: 5 °C dew point
Upper limit: 40 % r. h. at 30 °C and
70 % r. h. at 14 °C
Outdoor ambient conditions:
lower limit: -10°C, depending on selected option down to
–45°C
upper limit: depending on selected condenser
Storage conditions:
Temperature [°C]: -20 - +42
Humidity [% rel. h.]: 5 - 95
Atmosphere pressure [kPa]: 70 - 110
Max. length of piping between A/C unit and
air-cooled condenser:
30 m equivalent
Max. level difference condenser−A/C unit:
10 m (condenser above the A/C unit)
5 m (condenser below the A/C unit)
Voltage:
400V/50Hz/3Ph/N/PE
Voltage tolerancy:
+/- 10 % (not for permanent operation)
Frequency tolerancy: +/- 1 %
The following voltages are also available for this A/C unit
series: 380V/60Hz/3Ph/N/PE
Other voltages on request.
Voltage/frequency tolerances as for
400V/50Hz/3Ph/N/PE.
The cooling capacity, air flow, water flow, pressure loss,
sound pressure level and valve sizes change with a voltage
different from the standard voltage (400V/50Hz/3Ph/N/
PE). In this case, see the technical data by the help of the
„Stulz Select“ planning tool.
The unit design, the external dimensions, the weight, the
position and size of the supply connections are indepen-
dent of the supply voltage and can be found in this manual.
Requirements for UPS systems:
(in case of permanent operation of the EC fans with a UPS
system)
• the output voltage of the UPS system must be groun-
ded neutral (wye).
• the voltage distortions must be within the limits stated
below and no inadmissibly high DC voltage portions
may exist.
• all-pole sinus lters must be provided at the UPS sys-
tem output.
transient peak over-voltage phase to ground:
max. 4 kV (1,2/50µs wave form; Z=12 Ohms in acc. to
ANSI)
transient peak over-voltage phase to phase:
max. 2 kV (1,2/50µs wave form; Z=2 Ohms in acc. to
ANSI)
ripple voltage phase to ground:
dV/dt < 1V/µs (≡1000V/ms)
voltage harmonics: THD(V) < 8%
The warranty is invalidated for any possible damage or
malfunction that may occur during or in consequence of
operation outside the application ranges.
4. Technical Data
4.1 Application limits
Setting of the pressure switch:
HP switch R410A
releases at bar 36,0
manual reset possible at bar 29,0
Safety valve bar 40
15© STULZ GmbH – all rights reserved EN/02.2018/G17F
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Design conditions
Electrical connection: 400V/50Hz/3Ph/N/PE
with an external static pressure: 50 Pa
The sound pressure levels are valid at a height of 1m and
distance of 2m in front of the unit under free field condi-
tions and with nominal data. The values take into account
the effects of all installation and design parts contained in
the standard unit. The values for upflow units assume an
installed discharge duct.
4.2 Technical Data
DX-cooling cap. R410A total
24°C/45% r.h. sensible kW 20,1
20,1
Airflow m³/h 6000
max. external pressure Pa 450
Return air filter class M5
Sound pressure level dBA 57,0
Electrical reheat capacity kW 9
Conrol accuracy - temperature K± 0,5
Control accuracy - humidity % r.h. ± 3
Weight kg 430
Compressor
Receiver
Oil separator
Evaporator
Hotgas reheat
Refrigeration scheme
The units contain a nitrogen filling with overpressure.
For electrical data, (compressor and fan power consumption) see e-data sheet.
The electrical power consumption of the fans must be added to the room load.
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4.3 Dimensional drawings
Front view Side view Projecting main switch
17
0,5 m
1 m 1 m
1 m
© STULZ GmbH – all rights reserved EN/02.2018/G17F
cyberlab original instructions
5. Installation
5.1 Selection of the installation site
The A/C unit is designed for the inside installation on a level base. The A/C unit is not appropriate for opera-
tion in office rooms or other rooms sensitive to noise.
DANGER
Risk of explosion
The unit may not be operated in an explosive atmosphere!
• children, unauthorized persons and animals may not have access to the installation site of the A/C unit.
• check that the installation site is appropriate for the unit weight, which you can read in the technical data.
• take into account the necessary clearances for the maintenance and the air ow.
Vibrations emanate from the A/C unit due to compressor operation. To avoid such vibrations, we recommend
installing the unit on a vibration absorbing base, as it is realized in case of a positioning on a raised floor socket
e.g. by Mafund strips.
Air outlet area for Upflow units without duct connectionThe A/C unit must be accessible laterally and from the front.
Maintenance clearance
18
22
165
EN/02.2018/G17F © STULZ GmbH – all rights reserved
cyberlab original instructions
5.2 Positioning the unit
You will need two mounting aids as shown below.
WARNING
Risk of crushing limbs
A defective lifting device can lead to the uncontrolled fall of the A/C unit.
Do not stay under suspended loads! Wear safety boots.
Mounting aids
Pallet height
Transport with a fork lift
• transport the unit on the pallet as close as possible to the installa-
tion site.
• keep at hand mounting aids at the left and right unit side.
• lift the units with a fork lift by 50mm.
• remove the pallet.
• put the mounting aids at the left and right unit side.
• drop the unit.
• lift the support surface of the mounting aids at a sufcient height
so that the weight of the unit lies on the mounting aids. Secure the
mounting aids by belts around the unit.
• take away the fork lift from under the unit.
• drive the unit by the mounting aids to the installation site.
• drop the unit, loosen the belts and pull away the mounting aids.
Chiller transport with mounting aids
19© STULZ GmbH – all rights reserved EN/02.2018/G17F
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Transport without fork lift
You will need two scantlings of at least 1m length and a height of 150160mm.
WARNING
Risk of crushing by tipping of the unit
Select starting point for pushing not higher than 1m. Do not stay behind the unit. Wear safety
boots.
• lay the scantlings ush against the pallet and secure them against slipping.
• push the unit on the scantlings by two persons.
• put the mounting aids at the left and right unit side.
• lift the support surface of the mounting aids at a sufcient height so that the weight of the unit lies on the
mounting aids. Secure the mounting aids by belts around the unit.
• take away the scantlings from under the unit.
• drive the unit by the mounting aids to the installation site.
• drop the unit, loosen the belts and pull away the mounting aids.
NOTICE
Place the male triangular wrench in a visible location in the immediate vicinity of the A/C unit.
20
125
100
180
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cyberlab original instructions
Connection for refrigerant lines
Upflow unit
Refrigerant line connection diameters
Pressure line 16 mm
Liquid line 16 mm
The refrigerant connections are located near the compressor and
are labelled by the inscriptions „pressure pipe“ and „liquid pipe“. The
lines to be connected have to be soldered.
For the connection of the external pipework note the pipe entrance
area shown on top of the page.
5.3 Connection of the piping
5.3.1 Refrigerant piping
To design the piping between the chiller and the condenser follow the instructions in chapter "2. Refrigerant
piping" of document "General-DX". This document is available in the e-Stulz area and in the StulzSelect.
5.3.1.2 Position of the refrigerant connections
5.3.1.1 Design
Table of contents
