cybercool indoorchiller - find the needle

IT Cooling Solutions

Index G44Issue 11.2016CyberCool IndoorChiller

Precision Chillers380-415/3/50

Original instructions

2 /11.2016/G44EN

Contents1. Safety ...........................................................................................................................3

1.1 Marking ..............................................................................................................................................31.2 Safety instructions .............................................................................................................................31.3 Handling refrigerants .........................................................................................................................31.4 Safety and environmental requirements ............................................................................................4

2. Residual risks .............................................................................................................53. Description ..................................................................................................................7

3.1 Type code ..........................................................................................................................................73.2 Intended use ......................................................................................................................................93.3 Design ...............................................................................................................................................93.4 Refrigeration circuit .........................................................................................................................103.5 Chilled water circuit .........................................................................................................................113.6 Cooling medium circuit (G, GE) .......................................................................................................113.7 Operating modes of version GE ......................................................................................................13

3.7.1 DX mode .................................................................................................................................133.7.2 Mix mode .................................................................................................................................133.7.3 FC mode ..................................................................................................................................14

4. Circuit scheme ..........................................................................................................154.1 Cooling system A ............................................................................................................................164.2 Cooling system G ............................................................................................................................174.3 Cooling system GE ..........................................................................................................................18

5. Technical data ...........................................................................................................195.1 Application limits .................................................................................................................................. 195.2 Technical Data - CSI ... A/G .............................................................................................................205.3 Technical Data - CSI ... GE ..............................................................................................................215.4 Dimensional drawings .....................................................................................................................22

6. Transport / Storage ...................................................................................................236.1 Delivery of units ...............................................................................................................................236.2 Transport ..........................................................................................................................................236.3 Storage ............................................................................................................................................23

7. Installation .................................................................................................................247.1 Positioning .......................................................................................................................................247.2 Connection of the piping ..................................................................................................................25

7.2.1 Pipe entrance area for version A/G .........................................................................................257.2.2 Pipe entrance area for version GE ..........................................................................................267.2.3 Refrigerant piping ....................................................................................................................27

7.2.3.1 Design ..............................................................................................................................277.2.3.2 Filling of the refrigerant circuit ..........................................................................................27

7.2.4 Water connections ...................................................................................................................297.3 Electrical connection ......................................................................................................................33

8. Commissioning .........................................................................................................349. Maintenance ..............................................................................................................36

9.1 Safety instructions ...........................................................................................................................369.2 Maintenance intervals .....................................................................................................................369.3 Refrigerant circuit ............................................................................................................................379.5 Unit in general .................................................................................................................................389.4 Water circuit .....................................................................................................................................38

10. Malfunction .............................................................................................................3911. Dismantling and disposal ......................................................................................4112. Options ....................................................................................................................42

12.1 Raised floor stand .........................................................................................................................4212.2 Refrigerant circuit ..........................................................................................................................4412.3 Chilled water circuit .......................................................................................................................4612.4 Cooling medium circuit (for G units only) ........................................................................... 4712.5 C7000 Advanced ...........................................................................................................................47

Subject to technical modifications.

/11.2016/G44 3EN

1.2 Safety instructionsGeneralThese 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.

This cooling unit contains fluorinated greenhouse gas covered by the Kyoto protocol.

In the chillers of the CyberCool Datachiller series R410A refrigerant is used as standard. Refrigerants are volatile, or highly volatile fluorinated hydrocarbons which are liquefied under pressure. They are incombustible and not haz-ardous to health when used as intended.

- Works have to be carried out by competent staff only- Observance of the regulations for accident prevention- Stay out of danger when lifting and setting off the unit- Secure the unit to avoid the risk of overturning- Safety devices may not be bypassed.- Respect the corresponding VDE-, EN- and IEC standards for the electrical connection of the unit

and observe the conditions of the power supply companies- Switch off the voltage from the unit when working on it.

- Observe the national regulations of the country where the unit will be installed- The refrigerant circuit contains refrigerant and refrigerating plant oil, observe professional dis-

posal for maintenance and when setting the unit out of service.- Cooling water additives have an acidic effect on skin and eyes, wear safety glasses and safety

gloves- Observe personal protective equipment when working on the refrigerant circuit.- The unit may only be used to cool air according to the Stulz specification.

- Respect material compatibility in the whole hydraulic circuit.- The male triangular wrench is to be placed in a visible location in the immediate vicinity of the

unit.

1.3 Handling refrigerants

- Adherence to the regulations by law and guide-lines- Execution only by competent staff

1. Safety1.1 Marking

Danger - threatening danger, grievous bodily harm and death

Attention - dangerous situation, light bodily injury and material damage

Information - important information and application notice

ESD note - risk of damaging electronical components

4 /11.2016/G44EN

- Responsability for correct disposal of refrigerant and system parts is incumbent on the operator.- Refrigerants have a narcotic effect when inhaled in high concentrations.- The room is to be evacuated immediately if high concentrations of refrigerant suddenly occur. The room may only

be entered again after adequate ventilation.- 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.- Safety glasses and safety gloves are to be worn.- Do not eat, drink or smoke at work.- Liquid refrigerant must not get onto the skin (risk of burns).- Only use in well ventilated areas.- Do not inhale refrigerant vapours.- Warn against intentional misuse.- It is absolutely essential to comply with the first 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 specially qualified and licensed as recognised disposal companies for refrigerants.

1.4 Safety and environmental requirementsThe 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 notification (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 qualified specialist staff who have made an in-depth study of the operating instructions.It is absolutely essential to comply with the procedure for shutting down the system described in the operating in-structions. Before maintenance work, the unit must be switched off at the main switch and a warning sign displayed to prevent unintentional switching-on.

Independent conversion and manufacture of replacement parts The system may only be converted or modified after consultation with STULZ. Original replacement parts and re-placement parts/accessories authorised by STULZ are an aid to safety.

Unacceptable operating methodsThe operating safety of the system is only guaranteed when it is used as intended. The limit values stipulated in the technical data must not be exceeded under any circumstances.

/11.2016/G44 5EN

Transport, Installation

Area Cause Danger Safety note

Under the unit Defective lifting device Bruising Keep away from under the unit

Beside the unit Uneven or insufficient foundation or raised floor stand

Bruising by tipping over of the unit

Make sure, the foundation is even and stable and that the raised floor stand is correctly mounted. Wear protective equipment (helmet, gloves, safety shoes).

In the lower part of the unit

Heat by soldering flame,sharp edges, built-in parts

Burns, cuts, concussion damage

Wear safety glasses and gloves, don't put your head into the unit.

Electrical box Connection cable under voltage, sharp edges of the openings for the cable introduction

Electric shock, cable damage at positioning

Check and make sure the unit is de-energized. Stand on isolated ground. Take care that sharp edges are always protected by rubber grommets

Start-up


In the lower part of the unit, refrigerant piping

Defective filling line for refrigerant, leaks in the refrigerant piping, closed stop valves, defective safety valve

Discharge of refrigerant under high pressure,burns in case of contact to the skin, formation of acid vapours with open flames

Open stop valves.Wear safety glasses and gloves, don't put your head into the unit.

In the lower part of the unit, water piping

Leaks in the water lines, closed stop valves

Discharge of water under high pressure, contact with the skin of ethylen glycol, irritation of eyes and respiratory system by glycol vapours, increased risk of electric shock in com-bination with electricity, risk of slipping

Open stop valves.Wear rubber gloves, ethylen glycol is absorbed by the skin. Avoid swallowing water with glycol additives.

Electrical box Short circuit Electric arc, acid vapours Retighten terminal connec-tions,Wear protective gloves

2. Residual risks

Operation



Leaks in the refrigerant piping, defective safe-ty valve/high pressure switch, fire

Discharge of refrigerant under high pressure, explosion of pipe sections, formation of acid vapours with open flames

In case of fire wear protec-tive mask.

Electrical alimen-tation

Falsely dimensioned cab-les or protection devices

Short-circuit, fire, acid vapours Correctly design alimenta-tion cables and protection elements. Wear protective mask.

6 /11.2016/G44EN

Maintenance



Leaks in the refrigerant piping, defective safety valve/high pressure switch

Discharge of refrigerant under high pressure,burns in case of contact to the skin, formation of acid vapours with open flames

Wear safety glasses and gloves, don't put your head into the unit.

Pressure lines, compressor

Heat Burns in case of contact to the skin

Wear safety gloves. Avoid contact to hot unit parts.

Electrical box Live components, sup-posed to be voltage-free

Electric shock Secure master switch against being switched on again.

Dismantling



Soldering off or cutting the refrigerant pipes still under pressure.

Discharge of refrigerant under high pressure,burns in case of contact to the skin.

Depressurize pipes before disconnecting them.Wear safety glasses and gloves, don't put your head into the unit.

In the lower part of the unit, water piping

Unscrewing the water pipes still under pressure.

Discharge of water under high pressure, contact with the skin of ethylen glycol, increased risk of electric shock in com-bination with electricity, risk of slipping

Drain of cooling water by drain valve.Wear rubber gloves.

Electrical box Live electrical alimentati-on cable

Electric shock Check de-energized state of the alimentation before dismantling,Wear safety gloves.

/11.2016/G44 7

C S I 22 1 A

A, G, GE1

22...98

C = CyberCool

B49480

CSI 221 A

---

/ 11.2016 / G44 STULZ GmbHKlimatechnik Holsteiner Chaussee 28322457 HamburgTel: +49 40 55 85-0Fax: +49 40 55 85-404

R410A

40

EN

Explanation

Unit variants

Product range

Installation siteOutput of unit in kW

Number of refrigeration circuitsCooling system:A: air-cooledG: water/glycol cooledGE: glycol cooled + free cooling

Page information

Index number

Date of issuemonth/year

Language:EN - EnglishDA - DanishDE - GermanFR - FrenchIT - ItalianRU - Russian

3. Description

3.1 Type codeThe type code represents the unit variant of your chiller unit and can be found on the rating plate.

Energy index

I - IndoorS - Standard

The rating plate is located in the door in front of the electrical compartment.

Unit type

internal part no.

Order number + alternative

Serial no.

EN

Manufacturing base:G - GermanyC - ChinaI - Italy

Manufacturer address:

8 /11.2016/G44EN

A-systemThe chilled water which is conveyed by the pump flows through the evaporator where the heat load of the water is transferred to the refrigerant. A remotely mounted air-cooled condenser is connected, by specialist installers, to the chiller unit via a sealed refrigeration circuit such that the absorbed refrigerant heat load can be rejected to atmosphere.

G-systemThe glycol/water cooled (G) version utilises the same refrigeration system as the type-A chiller unit. However an internally mounted plate condenser is then used to transfer the water heat load to a glycol solution. This condenser water acts as a secondary heat transfer medium, which is then pumped to a remotely moun-ted air-cooled drycooler or cooling tower where the heat is finally rejected to atmosphere. Generally the condenser water system is in the form of a ring main connected in parallel to a number of stand-alone chiller units mounted in the critical space.

GE-SystemIn summer operation the GE system works like the G system. It additionally contains a heat exchanger for free cooling, which is used in winter operation and a valve system, which distributes the water flows according to the requested operating mode.

Cooling systemThe different versions of the CyberCool Data Chiller product range are defined by the unit capacity and the way of cooling system.

Cabinet sizesThe units are produced in two cabinet sizes. Units of version A and G only exist in cabinet size 1, units of version GE only exist in cabinet size 2.

/11.2016/G44 9EN

3.3 DesignIn 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.

3.2 Intended useThis chiller unit is used to cool water for technical units and A/C units and is exclusively designed for indoor instal-lation. 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.

Unit of version GE

Sightglass

Filter dryer

LP switch

HP switch

electron. expansion valve

Expansion tank in the chilled water circuit (Secondary circuit)

10 /11.2016/G44EN

3.4 Refrigeration circuitIn 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 proportionally controlled by the C6000 controller.

Version GE:The above described capacity control by an HGBP valve can be obtained as an option.

Monitoring devicesThe 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 devicesThe refrigerant circuit is protected against insufficient evaporation pressure by a safety pressure limiter (low-pres-sure 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, switches off the compressor and protects the refrigeration circuit against excessive operating pressure. Simultaneously 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.

Filter dryer

LP switch

HP switch

Oil sight glass

Version A/G

/11.2016/G44 11EN

3.6 Cooling medium circuit (G, GE)Version GThe 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.The 2 way valve is mechanically controlled by the refrigerant pressure via a capillary pipe from the refrigerant pres-sure line and controls the water flow through the condenser this way.The 3 way valve is controlled by the C7000 controller. The C7000 measures the condenser pressure by a pressure sensor. The 3 way valve controls the distribution of the water flow through the condenser and the bypass.

3.5 Chilled water circuitThe 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, 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. The 3 way 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 coo-ling heat exchanger.

12 /11.2016/G44EN

Version GEThe 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 (1) to control the water flow through the heat exchanger for free cooling, a 2-way valve (2) to control the condensation pressure in the plate condenser, a valve for filling and draining (3) and two deventilation valves (4).

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 FC valve controls the water flow in the cooling medium circuit and by this the water temperature n the chilled water circuit. In DX mode this valve is closed.

Rear viewof version GE

Evaporator

3-way valve

GE valve

GE heat ex-changer

G valve

Condenser

/11.2016/G44 13

TC P IPI

FS

TC P IPI

FS

TT

TT

EN

3.7 Operating modes of version GE3.7.1 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.Valve 3 has completely opened the bypass line and closed the flow through the heat exchanger for free cooling.

Condenser

Refrigerant circuitHeat exchanger for free cooling

GE valve

Valve 3

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.Valve 3 has completely closed the bypass and has opened the way for the flow through the heat exchanger for free cooling.

Evaporator

G valve

Condenser


GE valve

Valve 3

Evaporator

G valve

14 /11.2016/G44

TC P IPI

FS

TT

EN

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.Valve 3 has completely closed the by-pass and has opened the way for the flow through the heat exchanger for free cooling.

Condenser


GE valve

Valve 3

Evaporator

G valve

/11.2016/G44 15EN

Pressure sensor

Temperature sensor

High pressure limiter

Low pressure switch

Pressure gauge

Flow switch / monitor

4. Circuit scheme

Legend

Non-return valve

Filter drier

Sight glass

Rotalock stop valve with cap

Schrader valve

Pressure relief 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

16 /11.2016/G44EN

4.1 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

/11.2016/G44 17EN

4.2 Cooling system G

Compressor

Pump

Condenser

Evaporator Expansion tank

Cooling water

Chilled water2nd compressor only for CSI 661, 841 and 981 G

18 /11.2016/G44

TT

EN

4.3 Cooling system GE

Compressor

Condenser

Evaporator

Expansion tank

Pump

Cooling medium

Chilled water

Liquid receiver

Heat exchanger for free cooling

/11.2016/G44 19

Kaltwasser-Volumenstrom 221 421 661 841 981

Standard-Volumenstrom (a) m³/h 3,1 5,9 (6,2)* 9,3 11,8 13,8

Max. Wasservolumenstrom (b) m³/h 4,6 8,9 (9,3)* 14,0 17,8 20,7

Min. Wasservolumenstrom (c) m³/h 2,3 4,4 (4,7)* 7,0 8,9 10,4

EN

5.1 Application limits

5. Technical data

- Chilled / Cooling water pipes: nominal pressure [bar]: 10

- Safety valve trigger pressure [bar]: 6,0

- Voltage: 380 - 415V / 3ph / 50Hz; N; PE- Voltage tolerance: +/- 10% (not for permanent operation)- Frequency tolerance: +/- 1%

The following voltages are also available for this A/C unit series: 460V/3Ph/60Hz; PE

The cooling capacity, water flow, pressure loss, sound pres-sure level and valve sizes change with a voltage different from the standard voltage (400V/3Ph/50 Hz). 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 independent of the supply voltage and can be found in this manual.

The warranty is invalidated for any possible damage or malfunction that may occur during or in consequence of operation outside the application ranges.

- Room conditions: Temperature [°C]: +5 - +40 Humidity [% rel. h.]: 20 - 80 Atmosphere pressure [kPa]: 70 - 110

- 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

- Chilled water conditions: Entering temperature [°C]: +8 - +20 Difference: - at maximum water flow [K]: 4 - at minimum water fow [K]: 8

- Max. length of piping between chiller unit and air cooled condenser: 30m equivalent.

- Max. level difference between condenser and chiller: 5m (when condenser is below the chiller).

Adjustment of the pressure switches:

LP switch: releases at: 3,0 barautomatic reset at: 5,0 bar

HP switch: releases at: 36 barmanual reset possible at: 29 bar

Safety valve: 40 bar

Chilled water volume flow

Standard volume flow (a) m³/h

Max. water volume flow (b) m³/h

Min. water volume flow (c) m³/h

* differing values for GE version in brackets

Chilled water circuit, medium: water

(a) at 18°C/12°C water temperature inlet/outlet(b) at 18°C/14°C water temperature inlet/outlet (min. dTw)(c) at 18°C/10°C water temperature inlet/outlet (max. dTw)

20 /11.2016/G44

Modell 221 421 661 841 981

Kälteleistung kW 21,6 41,2 65,1 82,5 96,3

Kompressor

Leistungsaufnahme kW 5,8 10,5 16,7 20,9 24,3

Stromaufnahme A 10,9 17,1 26,8 34,1 40,7

Stromaufnahme, max. A 15,0 25,7 42,6 51,4 60,4

R410A-Füllmenge (G) kg 2,3 3,5 6,8 7,0 9,0

Kaltwasser-Kreislauf

Wasservolumenstrom m³/h 3,1 5,9 9,3 11,8 13,8

Druckverlust Verdampfer kPa 27 22 31 34 18

Wasservolumen, Verdampfer dm³ 1,9 3,3 4,4 5,6 8,9

Pumpe

Nennleistung kW 0,55 1,1 1,1 1,5 1,85



verfügbarer Pumpendruck kPa 225 228 189 206 235

Kühlmedium-Kreislauf (G)


Druckverlust, Kond.wasserseitig kPa 38 21 40 47 59

Wasservolumen, Kondensator dm³ 2,2 5,0 6,0 7,2 8,4

Gerätedaten


Stromaufnahme A 12,6 20,2 29,6 37,6 45,7


Breite/Höhe/Tiefe mm 950 / 1980 / 890

Gewicht A/G kg 281/296 351/365 450/476 466/493 556/581

EN

5.2 Technical Data - CSI ... A/G

Type

Cooling capacity kW

Compressor

Power consumption kW

Current consumption A

Max. current consumption A

R410A charge (G) kg

Chilled water circuit

Water flow m³/h

Pressure loss, water side kPa

Water volume, evaporator dm³

Pump

Nominal power kW



available pump pressure kPa

Cooling medium circuit (G)

Water flow m³/h

Pressure loss, cond. water side kPa

Water volume, condenser dm³

General unit data


Current consumption A


Width / Height / Depth mm

Weight A/G kg

Design conditions for technical data:

Chilled water circuitMedium:Entering water temperature:Leaving water temperature:Temperature constance:

Refrigerant circuitCondensation temperature:Max. condensation temperature:

Cooling medium circuitCooling fluid:Fluid inlet temperature (G):Fluid outlet temperature (G):

All data is valid for : 400V/3ph/50Hz and refrigerant R410A.

Water18°C12°C± 2K

50°C55°C

30% Glycol39°C45°C

/11.2016/G44 21

Modell 221 421 661 841 981

Kälteleistung kW 21,5 43,4 65,1 82,5 96,3

Kompressor



R410A-Füllmenge kg 6,0 10,7 12,5 12,5 12,6

Kaltwasser-Kreislauf


3-Wege Ventil Zoll 1 1 1/2 1 1/2 2 2

Wasservolumen, Verdampfer dm³ 1,9 3,3 4,4 5,6 8,9

Wasservolumen, Freikühl-Wärmetauscher dm³ 3,4 5,8 8,2 9,4 10,6

Pumpe

Nennleistung kW 0,55 1,1 1,1 1,5 1,85


verfügbarer Pumpendruck kPa 225 229 189 206 235

Kühlmedium-Kreislauf


2-Wege Ventil Zoll 1 1/4 1 1/2 2 2 2

Druckverlust wasserseitig - DX-Betrieb kPa 69 74 81 104 94

Druckverlust wasserseitig - FC-Betrieb kPa 55 66 76 98 84

Wasservolumen, Kondensator dm³ 2,2 5,0 6,0 7,2 8,4

Wasservolumen, Freikühl-Wärmetauscher dm³ 3,6 6,0 8,4 9,6 10,8

Gerätedaten

Schallleistungspegel - DX-Betrieb dB(A) 71,2 75,1 76,3

Schalldruckpegel (2m Abstand) - DX dB(A) 50,9 54,7 56,0

Schallleistungspegel - FC-Betrieb dB(A) 66,5

Schalldruckpegel (2m Abstand) - FC dB(A) 46,1

Leistungsaufnahme - DX-Betrieb kW 6,4 12,6 17,7 22,4 26,1

Leistungsaufnahme - FC-Betrieb kW 0,7 1,4 1,5 2,0 2,4


Breite/Höhe/Tiefe mm 1400 / 1980 / 890

Gewicht kg 455 515 625 699 747

EN

Type

Cooling capacity kW

Compressor



R410A charge kg


Water flow m³/h

3-way valve inch

Water volume, evaporator dm³

Water volume, free cooling heat exchanger dm³

Pump

Nominal power kW


available pump pressure kPa

Cooling medium circuit

Water flow m³/h

2-way valve inch

Pressure loss, water side - DX oper. kPa

Pressure loss, water side - FC oper. kPa

Water volume, condenser dm³

Water volume, free cooling heat exchanger dm³

General unit data

Sound power level - DX operation dB(A)

Sound pressure level (2m distance) DX dB(A)

Sound power level - FC operation dB(A)

Sound pressure level (2m distance) FC dB(A)

Power consumption - DX operation kW

Power consumption - FC operation kW


Width / Height / Depth mm

Weight kg

5.3 Technical Data - CSI ... GE

Design conditions for technical data:

Chilled water circuitMedium:Entering water temperature:Leaving water temperature:Temperature constance:

Refrigerant circuitCondensation temperature:Max. condensation temperature:

Cooling medium circuitCooling fluid:Fluid inlet temperature:Fluid outlet temperature:

Water18°C12°C± 2K

50°C55°C

30% Glycol10°C Winter (FC), 39°C Summer (DX)15°C Winter (FC), 45°C Summer (DX)

All data is valid for : 400V/3ph/50Hz and refrigerant R410A.

22 /11.2016/G44

55

35

/945*

EN

5.4 Dimensional drawings

Cabinet size 1 (A/G) Cabinet size 2 (GE)

Main switch

Projecting main switch

Side view (for all sizes)

* de

pth

incl

udin

g m

ain

switc

h

/11.2016/G44 23EN

6. Transport / Storage

6.1 Delivery of unitsStulz units are mounted on pallets and packed several times in plastic film. They must always be transported upright on the pallets.

Units of the version A are delivered with a nitrogen filling under atmospheric pressure.Units of the version G and GE contain the complete refrigerant charge.

When delivery is accepted, the unit is to be checked against the delivery note for completeness and checked for external damage which is to be recorded 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.

The following information can be found on the packing. 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 number10) Additional customer requirements

Construction of protective covering(from inside to outside)

1. Neopolene cushioning2. Shrink film3. Additional board in container ship-

ments

6.2 TransportThe Stulz chiller units can be moved by lifting devices with ropes, for this the ropes have to be fixed at the pallet, and the upper unit edges have to be protected by wooden laths or metal brackets in such a way that they could not be caved in. You can move the unit still packaged on the pallet with a fork lift, if you 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.

6.3 StorageIf 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:• Make sure that the water connections are provided with protective hoods. If the intermediate storage exceeds 2

months, we recommend filling the pipes with nitrogen.• the temperature at the storage point should not be higher than 42°C, and the site should not be exposed to direct

sunlight.• the unit should be stored packaged to avoid the risk of corrosion.

Never move the unit on rollers and never transport it without pallet on a fork lift, for the risk of distorting the frame.

24 /11.2016/G44

1m

EN

7. Installation

7.1 PositioningCheck that the installation site is appropriated for the unit weight, which you can read in the technical data. The unit is designed for the inside installation on a level base. The solid base frame contributes significantly to an even weight distribution. When selecting the installation site take into account the necessary clearances for the maintenance.

The unit may not be operated in an explosive atmosphere!

Maintenance clearance

/11.2016/G44 25

Gerät 221 421 661 841 981

Druckleitung 16 22 28 28 35

Flüssigkeitsleitung 16 16 22 22 28

Gerät 221 421 661 841 981

Eintritt/Austritt 28 42 54 54 54

Gerät 221 421 661 841 981


EN

7.2 Connection of the piping7.2.1 Pipe entrance area for version A/G

The supply pipes and cables are introduced from the bottom through openings in the base plate.

Unit rear side

Top view

The refrigerant connections are labelled by the inscriptions "pressure pipe" and "liquid pipe".

Connection diameter of refrigerant pipes (mm)

Unit

Pressure line

Liquid line

Pressure line (A-units)

Cooling water outletCooling water inlet(G-units)

Liquid line (A-units)

Chilled water inletChilled water outlet

Connection diameter of the chilled water pipes (mm)

Connection diameter of the cooling water pipes (mm)(only for version G)

Unit

Inlet/outlet

Unit

Inlet/outlet

Customer control line

secondary power supply

Power supply

safety valve drain (A-units)

safety valve drain (G-units)

26 /11.2016/G44

Gerät 221 421 661 841 981


Gerät 221 421 661 841 981


EN

7.2.2 Pipe entrance area for version GE

The supply pipes and cables are introduced from the bottom through openings in the base plate.

Unit rear side

Top view

2. Power supply1. Power supply

Cooling medium:InletOutlet

Chilled waterOutletInlet

safety valve drain

Control lines

Connection diameter of the chilled water pipes (mm)

Connection diameter of the cooling water pipes (mm)

Unit

Inlet/outlet

Unit

Inlet/outlet

/11.2016/G44 27

PS-

PS+

EN

7.2.3.2 Filling of the refrigerant circuit

- Connect the unit electrically as described on top of page 33.- Turn the main switch to the ON position (the C7000 controller should now be in the Stop mode).- Switch on the control-circuit fuses.- Do not switch on neither power switches nor the controller.

C7000AT:- Select the Config menu.- Enter the password.- Go to menu "Components/Manual oper./Cooling/Valves.- Change the parameter in the column "EN" line "EEV 1" from "0" to "1".- Set the parameter in the column "Value" of the same line to 100%.

C7000IOC:- Enter the command:

Compressor

air-cooled condenser

Receiver

EvaporatorChiller

external installation

Stop valveStop valve

"eev 1 hand 1" and "eev 1 handon 100".

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.

7.2.3.1 Design

7.2.3 Refrigerant piping

The expansion valve is now com-pletely open.

- Open the stop valves.- The refrigerant circuit is filled with a

nitrogene filling under atmospheric pressure. Evacuate the refrigerant circuit by the Schrader valves until approximately 0 bar.

28 /11.2016/G44EN

Hazards with incorrectly filled systems

OverfillingOverfilling the system inevitably results in a high condensing pressure. The high pressure switch can trigger as a result.

UnderfillingA system which is insufficiently filled results in the following:Output reduction due to evaporation temperatures which are too low and triggering of the low pressure switch. Excessive superheating temperature which can result in compressor damage.

Recommended superheating: 5 - 8 KRecommended subcooling: > 2 K

- Fill the refrigerant circuit by the Schrader valves with R410A refrigerant.

- Systems with refrigerant receiver should be filled according to weight but can also be filled by checking the sight glass.

Note that R410A is a 2-compound mixture. Take care that you add refrigerant in a liquid state, as the ratio of the refrigerant components changes if one of the two compounds passes over into the gaseous phase.

- Before the system is filled with refrigerant, it must be clean and dry inside.

- Because R410A is a blend, systems should be liquid-charged on both the high and low sides simultaneously to ensure a positive refrigerant pressure is present in the compressor before it runs. The majority of the charge should be placed in the high side of the system to prevent bearing washout during first-time start.

The standing refrigerant bottle is connected to the suction side via a pressure gauge station. The weight is noted shortly before filling. The specified amount of refrigerant is now added when the system is operating. During filling the pressure in the refrigerant bottle will adjust to that of the system. Filling is then no longer necessary.

This can be seen by the icing up of the bottle or by checking the pressure gauge. The bottle valve must then be closed until a pressure increase has taken place which is above the suction pressure of the system. This pro-cess can be accelerated if the bottle is wrapped in hot moist towels or it is placed in a water bath at a maximum temperature of 50°C.

Never heat up the refrigerant bottle with a naked flame as there is a risk of explosion.

/11.2016/G44 29EN

7.2.4 Water connections

Chilled water circuitTo seal the water circuit you must connect the unit to a chilled water ring mains, which contains at least one consumer. If the water quality is insufficient, we recommend the additional installation of a fine mesh strainer.If several consumers are connected, these must be connected in parallel, to eventually equal the pressure losses, caused by different pipe lengths to the consumers, with balancing valves.

At the planning and realisation of the whole system the following items must be observed:

- The Stulz unit should only be installed after all works of soldering and welding have been finished and the pipes have been successfully flushed. Impurities and dirt may cause a malfunction of the pump.

- The circuit system must be designed, so that a good deventilation can easily be achieved.- The Stulz unit must be protected by a fine mesh strainer (mesh width <1 mm) at the water inlet.- The Stulz unit must be protected against lack of water and thus against dry run by appropriate measures on the

installation site.- The pumps in the unit may not be used to fill the water circuit.- The water circuit has to be operated with a filling pressure of at least 1,5 bar.- The glycol content of the system must regularly be checked.

- For connecting the unit to the external system remove the protective caps from of the water pipe screw connec-tions.

Water remaining from the test run may escape when the protective caps are removed.

- The water connections are executed in the shape of a screw connection with a soldering connection.- Solder the part with the external thread of the connection to the external pipes and screw the lines of the external

system to the lines of the unit respecting the designation at the unit.

30 /11.2016/G44EN

The pump has to be separately deventilated by a deventilation screw at the pump housing. The mechanical face seal will be destroyed, if this is not done.

ATTENTION!

During the running-in period the mechanical seal will not seal tight, but will slightly drip!

Mechanical seals are expendable parts. The average durability is around 2 to 4 years however extreme conditions (as impurities, additives and overheating) may drastically reduce the service life!

- Fill and bleed air from the cooling water circuit by means of the filling connections and the schrader valves for bleeding (see below).

Version A/G 1 = Deventilation pipe at expansion tank 2 = Deventilation at the pressure line 3 = Deventilation of the evaporator 4 = Deventilation of the pump

Rear view

pump drain

filling/drain of evaporator

/11.2016/G44 31

1

2

3

4

8

5

a

b

c

6

7d

EN

Cooling medium circuit

Deventilation valves 8Filling/drain valve c, d


Deventilation valves 1-7Filling/drain valves a, b

Position of deventilation- and filling/drain valvesVersion GE

Front view:

Rear view:

32 /11.2016/G44EN

Cooling water circuit (only for version G/GE)Connect the unit to a dry cooler or cooling tower to seal the cooling water circuit which must be provided with a pump and an expansion tank with safety valve to convey the cooling water. If the water quality is insufficient, we recommend the additional installation of a fine mesh strainer.For an efficient protection against corrosion, the anti-freezing agent is mostly sufficient, which should be used if the water temperature passes under 5°C or if the outside temperature is less than 0°C. We recommend to add the following quantities of ethylene glycol (indicated as percentage of weight of the water quantity) :

Water or outside air temperature Ethylene glycol

until -5°C 10% until -10°C 20% until -15°C 28% until -20°C 35% until -25°C 40%

- For connecting the unit to the external system remove the protective caps from of the water pipe screw connec-tions.

Water remaining from the test run may escape when the protective caps are removed.

- The water connections are executed in the shape of a screw connection with a soldering connection. Solder the part with the external thread of the connection to the external pipes and screw the lines of the external system to the lines of the unit respecting the designation at the unit.

If any seals are missing, these must only be replaced by glycol-resistant rubber seals.

/11.2016/G44 33EN

7.3 Electrical connection

Ensure that the electric cables are de-energized.

The electric cables are only to be connected by an authorised specialist.

The unit must dipose of an effective earthing.

The power supply system on site and the pre-fuses must be designed for the total current of the unit (see technical data).

Route the electric cable into the electrics box from below and connect the hree phases to the main switch, the PE conductor at the PE rail and the neutral conductor at the neutral terminal, in accordance with the wiring diagram (part of the unit documents).

Make sure that the phase rotation is correct, the rotating field must turn right !

The scroll compressor and the pump are dependent on correct phase rotation. The sense of rotation will be checked at the factory before dispatch. On site, if the rotating field of the compressor is incorrect, it must be corrected by changing two phases of the power supply at the isolator. An inverse rotating field results in overheating and destruc-tion of the compressor.

For use of leakage-current (FI) circuit breakers, EN 50178 5.2.11.2 must be taken into account. Only type B pulse-current FI circuit breakers are permitted. FI circuit breakers do not provide protection against bodily harm during operation of the unit or frequency converters.

Make sure that the power supply corresponds to the indications on the rating plate and that the tolerances according to the "Application limits" are not exceeded. In addition to this, the asymmetry of phase between the conductors may amount to 2% maximally. The asymmetry of phase is determined by measuring the voltage difference between the phase conductors. The average value of the voltage differences may not exceed 8 V.

insertion for the power supply cable

Electrical box

34 /11.2016/G44EN

The unit must be installed and connected in accordance with the chapter on "installation" before initial commissioning.

• Open the electrical compartment door of the unit using the key provided.

• Make sure that the main switch is off and the unit is de-energized.

• Check whether all power switches and control-circuit fuses in the electrical section of the unit are switched off (position 0).

• Check the the tight connection of the power supply cables and the terminals including the PE-terminals.

• Switch on the unit at the main switch.

• Switch on the control-circuit fuses and the power switches of the pump and the compressor in sequence.

The controller is now supplied with power, so you can use it for adjustments.

Make sure that the heat rejecting system is operating.A - air-cooled condenserG, GE - dry cooler

Switching on power switch

Electrical compartment

Power switch off

Control-circuit fuses

Power switches

Main switch

8. Commissioning

Do not turn the adjustment screw beyond the end of the calibrated scale range, as it may result in overheating and short-circuit at the consumer or in the destruction of the power switch.

non-calibrated range

/11.2016/G44 35EN

Sight glass

• Chiller units of version A: make sure that the shut-off valves are open.

Deventilate the pump by the deventilation screw at the pump housing. The seal ring will be de-stroyed, if this is not done.

• The C7000IO controller can be operated only by typing text commands into a terminal program (e.g. the terminal program "C7000ConfigTermi-nal"). For this you need to connect the laptop to the service port X15 of the I/O controller via a null modem cable. (detailed description see controller manual.)

• Adjust the desired water temperature setpoint by inputting the command "wtctrl settemp ##,#".

• Start the chiller by inputting the command "state start"in the laptop.

• Check after 20 minutes operation, whether bubbles are visible in the sight glass of the liquid line. If this is the case, refrigerant might have escaped by a leak. Check the circuit on leaks, eliminate these and top up the circuit with R410A in regard of the chapter "Maintenance".

• Check the water circuit on leaks also and eliminate these.

• Check the oil level at the compressor in respect of the right level.The oil level should be between the lower quarter and the middle of the sight glass.

• Check the current consumption of the compressors and the pump com-paring it with the values of the technical data.

• Instruct the operational staff how to operate the controller (refer to the controller manual).

Service port X15 in the e-box.

Oil sight glasses

36 /11.2016/G44EN

9. Maintenance

9.1 Safety instructionsAll maintenance work is to be carried out under strict compliance with the national accident prevention regulations. In particular we refer to the accident prevention regulations for electrical installations, refrigerating machines and equipment. Non-compliance with the safety instructions can endanger people and the environment.Maintenance work is only to be carried out on the units by authorized and qualified specialist staff.

Procedure instructions

Work on the system must always only be carried out when it is shut down. To do this, the unit must be switched off at the controller and at the main switch. A „DO NOT SWITCH ON“ warning sign must be displayed.

Live electrical components are to be switched to de-energized and checked to ensure that they are in the de-energized state.

Some verifications must be effected with the unit in operation (measuring the current, pressures, tempera-tures). In such a case the unit must only be switched on at the main switch after all mechanical connections have been carried out. The unit must be switched off immediately after the measuring procedure.

Warning note!

When the main switch is switched on and the controller is stopped the power contactors are live, even if the components are not operating.

Component Maintenance interval

half-yearly yearly

Refrigerant circ.Refrigerant chargeHP/LP switchSight glassCompressorExpansion valve

x

x

x

x

x

Water circuitTightnessEvaporatorCondenserPump *

xxxx

Unit in generalElectricsMechanics

xx

9.2 Maintenance intervals

* The seal ring of the pump must be exchanged every 20,000 operating hours.

/11.2016/G44 37

DR

Y

WE

T

EN

9.3 Refrigerant circuitRefrigerant charge - Tightness, Quantity and Purity

Tightnes of the refrigerant circuitAccording to article 3 of the EC regulation No. 842 / 2006 the operator must check the refrigerant circuit of the chiller every 6 months for leaks. In the chillers described here, no more than 12,6 kg refrigerant R410A are used.

QuantityAn unsufficient charge causes the formation of bubbles in the sight glass or in extreme cases the triggering of the LP-switch. An operation with an unsufficient refrigerant quantity over a longer period leads to a reduction of cooling capacity and to high superheating temperatures, which have a disadvantageous effect on the compressor lifetime. If a leak is detected:

• pump down the refrigerant of a refrigerant circuit resp. a closed off section in a suitable pressure vessel (recycling bottle) down to a pressure of 0 barrel.

• dispose the refrigerant according to the national regulations.• repair the leak.• check the tightness of the refrigerant circuit resp. the closed off section with nitrogen.• the circuit has to be run dry by several fillings and extractings with high-quality nitrogen. • change the filter drier cartridge. evacuate the refrigerant circuit resp. the closed off section by a vacuum pump.• fill with refrigerant circuit with the refrigerant to the weight named on the type plate.

The refrigerant must be charged in a liquid state.

An overfilling of the circuit makes the condensation pressure rise and by that the power consumption of the com-pressor. In the extreme the HP-switch triggers.

After repairing a leak, the refrigeration circuit must be checked on tightness within one month.

The following information must be recorded by the operator in writing:- quantity and type of the used refrigerant- refilled refrigerant quantity- recycled refrigerant quantity

Sight glass

- companies or persons which have carried out maintenance- dates and results of inspections

PurityBubbles in the sight glass indicate that the charge is unsufficient or that the filter drier is clogged.A pollution of the filter drier, whose origin task is to clear the refrigerant from impurities and humidity, can be detected by a temperature difference upstream and downstream the filter drier. Compare the colour indicator in the centre of the sight glass with the outer ring scale.

green ---> ok. yellow ---> humidity critical.

With too much humidity in the circuit, the expansion valve can freeze. In addition to this the ester oil in the compressor, which comes in touch with the refrigerant, takes up humidity and loses its ability to lubricate.In this case the refrigerant must be completely evacuated and recharged according to the above described evacua-tion instruction.

38 /11.2016/G44EN

CompressorIn the compressor there is an ester oil charge, which does not have to be renewed under normal operation conditions and holds out for the unit's lifetime. However, it is possible that the ester oil, as it reacts hygroscopically, has taken up humidity of the air after repeated recharging of the refrigerant circuit due to repair works. The interaction between ester oil and water results in the formation of acid. Owing to a hyperacidity, corrosive processes take place inside the compressor. In this case the ester oil should be exchanged.

Oil levelCheck the oil level at the oil sight glass. During unit idleness the oil level should not be below the lower quarter (bot-tom line) and not rise above the upper line during operation.

Oil type: Bitzer BVC32 (factory filling)

Expansion valveThe refrigerant circuit is equipped with an electronic expansion valve, which controls the superheating in the evaporator.The superheating is adjusted to 5 K at the factory and may not be modified.The expansion valve can freeze, if the humidity in the refrigerant circuit is excessive.

Do not thaw by soldering flame, danger of explosion !

• Thaw the expansion valve with moist warm cloth. • Check the sight glass.

9.4 Water circuit

TightnessCheck the water circuit visually for tightness. Beyond that a level indication at the storage tank, if existant, can give information about changes of the water quantity. A lack of water in the circuit is replaced by air, which reduces the heat capacity of the chilled water circuit and is detrimental to the pump.

EvaporatorCheck the water side pollution of the plate evaporator by comparing the chilled water inlet temperature to the outlet temperature. If the difference is less than 3 K, it indicates a limited heat transmission and thus pollution.Another possibility to verify this consists in the comparison of the outlet temperature with the medium condensation temperature (by measuring the condensation pressure at the high pressure side of the compressor). If this difference exceeds 7 K, the evaporator is probably polluted.In this case the evaporator has to be cleaned chemically.

9.5 Unit in general

ElectricsCheck the connection terminals for tight fixation when the unit is installed and once again after an operation time of 30 days.

MechanicsClean the unit's inside with a vacuum cleaner. Clean pipes simplify the search for leaks. Check the pipes, the com-pressor and the evaporator (also the condenser for version G) for a tight seat. Vibrations of pipes and circuit compo-nents can result in leaks. Check also the insulation of the water piping. Condensing air humidity on cold water pipes means a loss of cooling capacity.

/11.2016/G44 39EN

10. MalfunctionAlarm text Cause for alarm Cause Elimination

High pressure # failure

High pressure switch has triggered.

1. Condenser coil soiled.2. Overcharge of refrigerant

circuit3. Condenser fan defective.4. Electric connection of high

pressure switch loose. Cable defective.

Clean condenser.Discharge and dispose refrigerant.

Check function.Check connection and cable.

Press black release button at HP switch after elimination of error.

Low pressure # failure

Low pressure switch has triggered.

1. Insufficient refrigerant charge/leakage.

2. Electric connection of low pressure switch loose. Cable defective.

3. Trigger point adjusted too high.4. Expansion valve defective.

Refill refrigerant.

Check connection and cable.

Check setting of LP switch.Exchange expansion valve.

Power switch comp. #

Compressor power inter-ruptor has triggered.

1. Current too high. Shortcircuit in the cable. Compressor motor defective.

Check compressor motor on vol-tage continuity and current con-sumption. Check cable.

Compressor # failure

The soft start module (opti-on) or the protection device has detected an error.

- Find the exact cause of error.

EEV #: Pressure sensor error

The control module of the ex-pansion valve has detected a malfunction of the pressure sensor.

1. Cable breakage or faulty contact

2. Pressure sensor defective.

Check cable and contacts.

Replace pressure sensor.

EEV #: Tempe-rature sensor error

The control module has detected a malfunction of the temperature sensor.


2. Temperature sensor defective.


Replace temperature sensor.

EEV #: Stepper motor error

The control module has detected a malfunction of the stepper motor.


2. Stepper motor defective.


Replace expansion valve.

eev# reliability alarm (Carel EVD)

The C7000 controller can not reach the valve by the Modbus connection.

1. Bus connection to the valve faulty.

Check bus connection.

Sensor # failure The tolerance to the average value adjustable in the con-troller has been exceeded.

1. Big difference of measeured values in selected zone.

2. sensor defective.

Check measured value with an external measuring instrument. Maybe raise tolerance parameter.Replace defective sensor.

Sensor # broken The measured voltage/current is outside the range defined in the controller.

1. electrical connection defective.2. sensor cable defective.3. sensor defective.

Check connections.Check cable on continuity.Check measured value with exter-nal thermometer, pressure gauge. Replace defective sensor.

Pump # failure Pump power interruptor (evtl. also the internal pump fault detection) has triggered.

1. Current too high. Shortcircuit in the cable. Pump motor defective.

Check pump motor on voltage continuity and current consumpti-on. Check cable.

# stands for a number in case of several components of the same kind.

40 /11.2016/G44EN

Alarm text Cause for alarm Cause Elimination

watertemp. inlet # too high

The adjusted limit value has been exceeded.

1. Setpoint adjusted too high.2. Thermal load by consumer

is too high (with flow water control).

Check setpoint setting.Check control mode.

watertemp. inlet # too low

The actual value is below the adjusted limit value.

1. Setpoint adjusted too low.2. Thermal load by consumer

is too low (with flow water control).

Check setpoint setting.Check control mode.

watertemp. out-let # too high

The adjusted limit value has been exceeded.

1. Setpoint adjusted too high.2. Evaporator soiled on water

side. (eventually in combinati-on with return water control)

3. Condenser coil soiled on air side. Air inlet temperature too high. (eventually in combinati-on with return water control)

Check setpoint setting.Check heat transmission at the evaporator by checking the temperature difference between flow water temp. and evaporation temperature.Check heat transmission at the condenser by checking the tempe-rature difference between outdoor air temperature and condensation temperature.

watertemp. out-let # too low

The actual value is below the adjusted limit value.

Setpoint adjusted too low. Check setpoint setting.

Phase error Phase monitoring device has detected an error.

Phase failure. Check the voltage supply.

Water flow alarm

The water flow is less than the limit value set in the flow switch for minimum flow.

1. All pumps have failed.2. Leakage in the water circuit. 3. Air in the water circuit.

Check pump operation.Check hydraulic circuit on tightness.Purge the circuit by the vent valves.

Buserror The unit no longer participa-tes in the bus communicati-on.

The bus wiring is defective or in-correctly connected.

Check the bus wiring.

Addressconflict A bus address has been assigned twice.

- One of the two identical bus ad-dresses must be changed.

External alarm in # failure

No voltage is present at the digital input for the external alarm #.

An external device has triggered a signal. Cable breakage or faulty contact.

Depending on the type of message.

Check wiring.

Frost alarm The anti freeze thermostat has triggered and the num-ber of allowed pump starts in the context of frost protec-tion management has been exceeded.

1. Heat load by consumer too low.

1. Determine the heat load of the consumer.

Water alarm The water detector has trig-gered.

Water in the detector area (e.g. raised floor).

Determine the origin of water.Seal leakage.

# stands for a number in case of several components of the same kind.

/11.2016/G44 41EN

11. Dismantling and disposal

The unit can only be dismantled by qualified specialists.

Switch off the unit at the controller and at the main switch. Switch off power conducting cables to the unit and secure them against being switched on again. Disconnect the unit from the de-energized network.

Dispose of the refrigerant in the unit in accordance with the disposal and safety regulations applicable on site

The refrigerant may not be discharged into the atmosphere, but must be returned to the manufac-turer, if it is not reused.

The ester oil in the compressor must also be disposed. As it contains dissolved refrigerant, it can not be disposed like usual oils, but must be returned to the oil manufacturer.

Disconnect the depressurized refrigerant pipes from the external system (version A).

If glycol or similar additives had been used, this liquid also has to be collected and disposed in an appropriate manner and may under no circumstances be introduced in the local waste water system.

Disconnect the unit from the external water circuit by closing the shut-off valves and drain the water circuit of the unit.Disconnect the depressurized cooling water pipes of the unit from the external system.

Move the unit, as described in the chapter "transport", with a lifting device of sufficient load-carrying capacity.

Dispose of the unit in accordance with the disposal and safety regulations applicable on site. We recommend a recy-cling company for this. The unit basically contains the raw materials copper (pipelines, wiring), and iron (evaporator, condenser, panelling, mounting panel).

42 /11.2016/G44

B

X Z

Y

Z (min. 30)

Z (min. 800)Z(min. 30)

865

785

Baugröße 1 2

B mm 910 1360

Stützen Stk 4 4

Rechteckprofile 70 x 40 Stk 4 4

Mafundstreifen Stk 4 4

Schrauben M8 x 30 Stk 8 8

EN

12. Options12.1 Raised floor standThe floor stand is used to adjust the height of the unit to the existing raised floor and consists of an encircling rectan-gular profile of galvanized steel with adjustable screw sockets. Anti vibration compound is recommended between concrete floor and base plate.

Locating the supports

Cabinet size

B mm

Supports n°

Rectangular profiles 70 x 40 n°

Mafund strips n°

Screws M8 x 30 n°

X/Y = Opening in raised floor Z = Limit of distance

- the raised floor cutting (notch) should at least be 15° and must not have any contact to the raised floor stand, which could result in bone-conduction.

- the dimensions of the openings in the raised floor (X and Y) are 10 mm longer than the raised floor stand. The joint must be closed by customers with a continuous seal.

- a concrete foundation is recommended in the area of the raised floor supports.

- the raised floor supports have to be installed on vi-bration dampening material (do not screw down the supports!).

- prior to installation of the unit, the raised floor must be installed 7 mm higher than the raised floor plates, as the mafund plates are compressed by the weight of the unit.

Minimum distances and mounting instructions

Raised floor stand

Angle Connection

Connecting the bars(View from below)

/11.2016/G44 43

Hm

in — H

max

Hmin — Hmax[mm]

995 — 1045

895 — 945

795 — 845

695 — 745

595 — 645

495 — 545

355 — 405

270 — 320

EN

Raised floor standAdjustable support plateAdjusting nutSupport pipeSupport baseMafund stripsRaised floor cut out angleContinuous seal profileBefore unit installationRaised floor plateAngled bracketPermanently elastic sealFixing

Sealing detail when distance Z < 100 mm

Sealing detail when distance Z > 100 mm

Detail of raised floor connection

123456789

10111213

Recommended concrete foundations

(no (floor) finish)Mafund strips

Upper edge of rough floor

Raised floor supportRaised floor stand

Continuous seal

Raised floor

Raised floor connection for details, see below

Hammer head screw M8 x 30

General design of the raised foor stand

Unit width

44 /11.2016/G44EN

12.2 Refrigerant circuitCrank case heaterAround the crank case of the compressor, an electrical heater is installed, which is in operation, when the compressor is switched off, to assure the constant oil lubricity at the compressor start with low ambient temperatures. The power depends on the compressor size from 34 W to 150 W.

Pressure gauge in the refrigerating circuitto indicate the suction pressure and/or the condensation pressure

Winter kit (for A units only)In winter operation, i.e. with very low outside temperatures, the condensation pressure in the air-cooled condenser is falling. In this manner the condenser is filled with refrigerant and the cooling surface is reduced correspondingly. The presence of a condenser pressure control valve prevents the refrigerant from accumulating in the condenser. This valve only opens when a sufficient pressure has been established by the compressor as to ensure the refrigerant flow to start when outside temperatures are extremely low. The receiver pressure control valve adjusts the pressure in the liquid receiver by gradually opening a by-pass to the compressor when the pressure in the condenser is diminishing.

This option consists of the following parts:

1. Liquid receiver Bitzer 25l F 250 H The standard receiver is exchanged 2. Safety valve KSV 28 bar by the liquid receiver named in the list. 3. Condenser pressure control valve KVR 28 4. Receiver pressure control valve KVD 15 5. Non return valve NRV 22 6. Adapter 7. Small parts

air-cooled condenserNon-return valve

Receiver

Pressure line coming from the compressor

Liquid line

/11.2016/G44 45

OPTION

EN

Hotgas Bypass, electronically controlled (for GE units only)The unit can be 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 proportionally controlled by the C7000 controller.A part of the hotgas bypasses the condenser by the hotgas bypass line and is fed upstream the evaporator. This lets the evaporation temperature rise whereas the cooling capacity sinks.

Refrigerant circuit of a GE unit

Chilled water circuitPrimary circuit

Evaporator

Condenser

Cooling medium circuitSecondary circuit

Crank case heater

HGBP valve

46 /11.2016/G44

1 2 3

4

5

6

8

7

EN

12.3 Chilled water circuitPiping / evaporator insulationto avoid the formation of condensate on the pipelines with low flow temperatures and a high ambient humidity.

Water temperature sensorfor the indication of the return water temperature (marked by "1" in the flow scheme)

Pressure gaugefor the indication of the return water pressure (marked by "2" in the flow scheme)

2-way solenoid valveto shut off the chilled water flow, installed at the water inlet, opens with pump operation (marked by "3" in the flow scheme)

Balancing valveto adjust the flow water pressure, installed at the water outlet (marked by "4" in the flow scheme)

Non-return valveinstalled on the pressure side (marked by "5" in the flow scheme)

Shut-off valvefor service, installed on the suction side (marked by "6" in the flow scheme)

Alternative pumpHigh efficiency circulating pump with a higher flow water pressure: 3 bar (marked by "7" in the flow scheme)

Standby pumpHigh efficiency circulating pump (2 bar flow water pressure) connected in standby (marked by "8" in the flow scheme)

Alternative standby pumpHigh efficiency circulating pump (3 bar flow water pressure) connected in standby (marked by "8" in the flow scheme)

Strainerdelivered loose, to be installed by the customer

Ventilating valveto vent pipelines which are temporarily idle. The deairing takes place automatically, however the system pressure dimishes and water must eventually be refilled.

Chilled water circuit for A/G unit

/11.2016/G44 47

7

23

4

5 6

Modell 221 421 661 841 981

Kühlmedium-Kreislauf (G)


Druckverlust, Kond. wasserseitig kPa 38 21 40 47 59

2-Wege Ventilgröße Zoll 1 1/4 1 1/2 2 2 2

Druckverlust Ventil kPa 19 26 26 43 23

EN

12.4 Cooling medium circuit (for G units only)

2-way control valveThe 2 way valve is mechanically controlled by the refrigerant pressure via a capillary pipe from the refrigerant pres-sure line and controls the water flow through the condenser this way.

3-way control valveThe 3 way valve is controlled by the C7000 controller. The C7000 measures the condensation pressure by a pressure sensor. The 3 way valve controls the distribution of the water flow through the condenser and the bypass.

Type

Cooling medium circuit (G)

Water flow m³/h

Pressure loss, water side cond. kPa

2-way valve size inch

Pressure loss, valve kPa

Chilled water circuit for GE unitFor the description of options 2-7 see precedent page.

Evaporator

GE heat exchanger

12.5 C7000 AdvancedThe chiller unit can be optionally equipped with a "C7000 Advanced terminal". In this case the right front door of the unit contains the controller with a service display in which actual temperature and pressure values, error messages etc. are indicated. The C7000 AT enables the user to communicate with the chiller control.

IT Cooling Solutions

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