CyberHandler 2

Air Handling Unit

Installation, Operation and Maintenance manual
CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Contents
1 Information on this manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 components signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Handling refrigerants (units with DX Top-up or DX Redundant) . . . . . . 5
2.4 Safety and environmental requirements . . . . . . . . . . . . . . . . . . . 6

3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Type Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Air Handling Unit design . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Operation limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5 Delivery/Transport/Storage . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 Delivery of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.1 Transport with forklift . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3.2 Transport with crane (via shackles) . . . . . . . . . . . . . . . . . . 14

6 Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6.1 Supplied parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Unit placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Assembly (units in several parts) . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4.2 Adiabatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.4.3 Cooling Coil (version CWT/CWR/DXR) . . . . . . . . . . . . . . . . 23
6.4.4 Refrigerant circuit (version DXT/DXR) . . . . . . . . . . . . . . . . 24

7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Adiabatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3 CW coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.3 Air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.4 Plate heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.5 Plate-fin heat exchangers (Cooling coil, heating coils) . . . . . . . . . . 34
8.6 EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.7 Adiabatic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.8 Refrigerant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
8.9 Unit housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9 Dismantling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 41

10 Contents of the CE declaration of conformity . . . . . . . . . . . . . . . 43

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 CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1 Information on this manual

Read this documentation prior to assembly and commissioning. This is a requirement for safe
work and trouble free handling.

Observe the safety guidelines and warnings in this documentation and on the product itself.

Ensure this manual is available at the place where the unit is installed for any person who is
likely to work on the unit (e.g. maintenance personnel, building technicians, electricians…).

1.1 Safety signs

threatening danger, serious bodily harm and even death

material damage

threatening danger due to electrical components

threatening danger due to suspended load

hand entanglement hazard

important information and application notice

1.2 Components signs

Fan Empty section

Cooling coil Damper

Cooling/heating coil Filter

Heating coil Silencer

Humidifier Controller

Plate heat exchanger Compressor

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

2 Safety

2.1 Intended use

The CyberHandler2 must only be used for ventilation and air conditioning of building.
It includes:
• filtering normally polluted air.
• air cooling.
• air heating.
• air humidifying and/or dehumidifying

Proper use also includes observance of the operation manual and instructions from the manu-
facturer of the individual components, as well as the inspection and maintenance intervals stipu-
lated by Stulz.

Any use other than that described above is considered improper. If necessary, check if your
units are suitable for your intended purpose and application. The manufacturer/supplier is not
liable for any damages arising from improper use. The user alone bears the risk.

Misuse particularly includes:

• Conveying any other gases except air
• Conveying steam or water
• Coarse filtering and/or filtering any other media except air
• Chopping up or reducing size of materials
• Drying out clothing
• The unit is not suitable for handling abrasive media.

The CyberHandler2 unit is intended to be installed in environments with special conditions (for
example: explosive areas, rooms with conductive dust, electromagnetic field or aggressive or
corrosive atmosphere), consult previously STULZ Tecnivel to check the compatibility of the UTA
with these conditions.

The CyberHandler2 unit should not be accessible to the public.

2.2 Safety Instructions
General
These operating instructions contain basic information which is to be complied with for instal-
lation, 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.

INFORMATION
This unit contains fluorinated greenhouse gas covered by the Kyoto protocol

The AHU are to be properly assembled and used under precise observation of our instructions.

If the assembly is performed contrary to our regulations, and the defect/damage which has
occurred is causally associated with inappropriate modification, processing or any other treat-
ment, all claims to damages compensation or warranty are thereby excluded.

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• installation, commissioning, maintenance and operation works have to be carried out by

qualified persons only,
• Observance of the regulations for accident prevention,
• Stay out of danger when lifting and setting off the unit,
• The AHU may only be operated with its revision doors and panels (casing) completely closed
• The air-handling unit must always be operated within the range of operating parameters
stipulated in the technical documentation supplied by STULZ.
• Secure the unit to avoid the risk of overturning
• Safety devices may not be bypassed.
• Prior to all work on the AHU – or opening the revision doors – ensure that:
• power supply is shut off (power off all poles) and safeguarded from unauthorized power-
ing on,
• all moving components - in particular - fan impeller, motor, rotary heat exchanger, control
and shut-off dampers – have come to a standstill: wait at least 5 minutes after deacti-
vating the unit,
• Heat exchangers have cooled down to reach ambient temperature,
• No persons are present in danger areas e.g. inside the unit
• Work performed on the AHU requires personal protective equipment (Personal Protective
Equipment),
• The air handled by the equipment must not contain health-endangering, flammable, explo-
sive, aggressive, corrosive or otherwise hazardous constituents, which would otherwise be
distributed by the ducting system or the building and can have a health-impairing or even
fatal effect on personnel, animals or plants living in the building.

Only trained and qualified electricians are permitted to undertake work on the
electrical system.
Respect the corresponding EN- and IEC standards for the electrical connection of the
unit and observe the conditions of the power supply companies.

2.3 Handling refrigerants (units with DX Top-up or DX Redundant)

According to EN 378, refrigerants are divided in groups in respect of health and safety: R410a
belongs to Group L1.
• Adherence to the regulations by law and guide-lines.
• Execution only by competent staff.
• 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, breath-
ing 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.

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

• 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 compa-
nies specially qualified and licensed as recognized disposal companies for refrigerants.

2.4 Safety and environmental requirements

The following requirements relate to the operation of refrigerating plants within the European
Community.
• The used components must correspond to the pressure equipment guide-line EC/97/23 and
EN 378 part 1-4.
• Independent of the design, the equipment and inspection before the delivery, also the opera-
tor 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. A
 ccess 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 authorized 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 instructions. 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 replace-
ment parts and replacement parts/accessories authorized by STULZ are an aid to safety.

First aid measures

• If health problems occur during or after handling fluorinated hydrocarbons, a doctor is to be
consulted immediately. The doctor is to be informed that the work involved the use of fluori-
nated hydrocarbons.
• In the case of acute effects, the casualty is to be brought into the fresh air as quickly as
possible.
• Splashes of fluorinated hydrocarbons in the eyes can be blown out or fanned out by an assis-
tant. Then rinse with water.

Unacceptable operating methods

The 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.

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3 Residual risks
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 Bruising by tipping over of the unit Make sure, the foundation is even and
foundation stable. Wear protective equipment
(helmet, gloves, safety shoes).
In the lower part of sharp edges, built-in Cuts, concussion damage Wear safety glasses and gloves.
the unit parts
Electrical box Connection cable under Electric shock, cable damage at Check and make sure the unit is
voltage, sharp edges positioning deenergized. Stand on isolated ground.
of the openings for the Take care that sharp edges are always
cable introduction protected by rubber grommets

Start-up

Area Cause Danger Safety note

Water piping Leaks in the water lines, Discharge of water under high pres- Open stop valves.
closed stop valves sure, contact with the skin of ethylen Wear rubber gloves, ethylen glycol is
glycol, irritation of eyes and respiratory absorbed by the skin. Avoid swallowing
system by glycol vapours, increased water with glycol additives.
risk of electric shock in combination
with electricity, risk of slipping
Electrical box Short circuit Electric arc, acid vapours Retighten terminal connections, Wear
protective gloves

Operation

Area Cause Danger Safety note

Refrigerant piping Leaks in the refrigerant Discharge of refrigerant under high In case of fire wear protective mask.
piping, defective safety pressure, explosion of pipe sections,
valve/high pressure formation of acid vapours with open
switch, fire flames
Hot gas line The line can take a Burns in case of contact to the skin Wear safety gloves. Cover lower arms
temperature of up to with clothing.
70°C.
Electrical alimentation Falsely dimensioned Short-circuit, fire, acid vapours Correctly design alimentation cables
cables or protection and protection elements. Wear protec-
devices tive mask.

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Maintenance
Area Cause Danger Safety note
Refrigerant piping Leaks in the refrigerant Discharge of refrigerant under high Wear safety glasses and gloves.
piping, defective safety pressure, burns in case of contact to
valve/high pressure the skin, formation of acid vapours with
switch. open flames
Pressure lines, Heat Burns in case of contact to the skin Wear safety gloves. Avoid contact to
compressor hot unit parts.
Fin heat ex- changer, Sharp edges, fins Injuries by cutting Wear safety gloves.
air side
Electrical box Live components, Electric shock 1. Disconnect mains.
supposed to be 2. Prevent reconnection.
voltage-free. 3. Test for absence of harmful voltages.
4. Ground and short circuit L1-, L2- and
L3 conductor in electric cabinet.
5. Cover or close off nearby live
components.
To energize apply these procedures in
reverse order.

Dismantling

Area Cause Danger Safety note

Refrigerant piping Soldering off or cutting Discharge of refrigerant under high Depressurize pipes before disconnect-
the refrigerant pipes pressure, burns in case of contact to ing them.
still under pressure. the skin. Wear safety glasses and gloves.
Water piping Unscrewing the water Discharge of water under high pres- Drain of cooling water by drain valve.
pipes still under sure, contact with the skin of ethylen Wear rubber gloves.
pressure. glycol, increased risk of electric shock
in combination with electricity, risk of
slipping
Electrical box Live electrical alimenta- Electric shock Check de-energized state of the
tion cable alimentation before dismantling, Wear
safety gloves.

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 CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

4 Description

4.1 Type Code

The type code represents the unit variant of your air handling unit and can be found on the type
plate.

STULZ TECNIVEL SL
C/ Carabaña S/N - 28925 - Alcorcón -Madrid - SPAIN
Tel: +34 915 571 130
E-mail: [email protected]

400 V ± 10 %
Product Air Handling Unit Supply voltage
50 Hz ± 1 %
Model CH2-S1-ADB-SH/RH Cooling capacity 252 Kw

Type R410A

Seria No. CL-000-18 Refrigerant Charge 40 Kg

CO2eq 83,5 T

Year of manufacture 2018 HP 42

bar
Max. operation pressure
Weight 5325 Kg BP 25
bar
Max. Current 276 A
Contains fluorinated greenhouse Made in Spain
gases

CH2 - S1 - ADB - SH/RH

Product range
CyberHandler2

Size
From S1 to S9

Cooling Configuration
ADB: Adiabatic only
CWT: Chilled Water Top-Up Coil
CWR: Chilled Water Redundant Coil
DXT: DX Top-Up integrated system
DXR: DX Redundant system with outdoor condensing unit

Installation Configurations
SH/RH: Supply Horizontal/Return Horizontal (Wall)
SB/RH: Supply Bottom/Return Horizontal (Roof)
SB/RB: Supply Bottom/Return Bottom (Roof)

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CYBERHANDLER 2 INSTALLATION, OPERATION
Climatizadores AND MAINTENANCE
· Condensadores MANUAL· Fan Coils ·Baterias
· Aero-refrigeradores

Air Handlers · Condensers · Dry-Coolers · Air-heaters · Coils

4.2 Air Handling Unit design
4.2 Air Handling Unit design

Customer-specified, non-standard
New text to insert features
in the IOM manual (replacing the or design
current variations may not be described
text, p.10-12):
in this manual. Refer to the installation and/or electrical drawings supplied with your
Customer-specified,
unit for details on additional non-standard features
feature(s). In some or design variationsan
cases, mayaddendum
not be to this manual
described in this manual. Refer to the installation and/or electrical drawings
may be provided tosuppliedfurther describe
with your the
unit for details feature(s).
on additional feature(s). In some cases, an
addendum to this manual may be provided to further describe the feature(s).
General design:
General design:

16 15 14 13 12 11 10

EA RA

OA SA

1 2 3 4a 4b 5 6 7 8 9

Fig 4.1: View of a Fig

CH2-DXT-SH/RH
4.1: View of a CH2-DXT-SH/RH

OA: Outdoor Air SA: Supply Air

OA: Outdoor Air SA: Supply Air
EA: Exhaust Air RA: Return Air
EA: Exhaust Air RA: Return Air

1. Outdoor damper
Frame and blades are made of aluminium.

1. side
2. Filters, outdoor Outdoor damper
Bag filters are Frame
used and bladesaare
ensure made of aluminium.
pressure loss as low as possible.

3. Double Air-to-Air plate heat exchanger

The casing is made of galvanized steel with epoxy coating and the fins are made of aluminium
3 with
a special coating making it more resistant to aggressive water.
4. Adiabatic system
4a: Water pump: centrifugal type.
4b: Spray Nozzles: full water cone type, made of stainless steel.
5. Compressors
Compressors used in Cyberhandler 2 units with DX system (DX Top-up and DX Redundant) are
scroll compressors.
These units are equipped with one inverter compressor and depending on the required cooling
capacity, one or 2 ON/OFF compressors can be added.
6. Cooling coil
The cooling coil can be either a direct expansion coil (DXT and DXR configurations) or a chilled
water coil (CWT/CWR configuration). For the units with ADB configuration, there is no cooling coil
installed inside the unit.

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7. Cooling coil
The CH2 control consists of the C7000 controller and following sensors are mounted as standard:
- Temperature and humidity sensor (outdoor air)
- Temperature and humidity sensor (supply air)
- Temperature and humidity sensor (Return air)
- Pressure switch (Clogged filters alarm, IT room side)
For models equipped with a refrigerant circuit (DXT/DXR), additional sensors are used for refrigerant
circuit control.
For more information about the controller, see the C7000 user’s manual.

8. Electrical cabinet
The electric cabinet is housed inside the unit and is made according to the EN60204-1 IEC
standard.
9. Supply damper
Frame and blades are made of aluminium.

10. Return damper

Frame and blades are made of aluminium.

11. Filters, IT room side

Bag filters are used ensure a pressure loss as low as possible.

12. Supply fans

Supply fans are Electronically Commutated type and mounted in fan wall arrangement.

13. E xhaust fans

Exhaust fans are Electronically Commutated type and mounted in fan wall arrangement.

14. Recirculation damper

Frame and blades are made of aluminium.

15. Condenser coil

Only the model with DX top-up cooling is equipped with a condenser coil.

16. E xhaust damper

Frame and blades are made of aluminium.

Operation

In every unit there is a double plate heat exchanger with an adiabatic cooling system. The noz-
zles spray water directly on the lower plate heat exchanger to ensure the process reaches the
maximum efficiency.

This indirect adiabatic cooling process can be completed by a mechanical cooling system.

This mechanical cooling is provided by either a Chilled water coil (CWT and CWR configurations)
or a DX system (DXT and DXR configurations) with integrated or remote condenser.

The Cyber Handler 2 works in 3 operating modes depending on the outdoor conditions:
• Dry mode: when the outdoor temperature is low enough, the cooling is provided by the plate
heat exchanger only (adiabatic and mechanical cooling OFF),
• Wet mode: when the outdoor temperature is not low enough to allow the plate heat
exchanger to provide the required cooling capacity, the adiabatic system switches on to cool
down the outdoor air.
• Mix mode (not available for units with only adiabatic cooling): when the outdoor temperature
is very high, the mechanical cooling switches on to top-up the indirect adiabatic cooling.

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

The C7000 controller handles the changes between the different operating modes (see C7000
manual)

4.3 Operation limits

• Outdoor ambient conditions:
Lower limit Upper limit
Temperature -15ºC 50ºC

• Return air conditions

Lower limit Upper limit
Temperature 30ºC 45ºC
Humidity - 60% r.h.

• Storage conditions
Lower limit Upper limit
Temperature -10ºC 50ºC
Humidity Dry, non-condensing atmosphere

• Supply voltage:
Voltage: 380 - 415V / 3ph / 50Hz; N; PE
Voltage tolerance: ± 10%
Frequency tolerance: ± 1%
4.4 Technical data
Refer to the order-related documentation for the specific configuration of your CyberHandler 2
unit (unit drawing, electrical diagram, refrigerant circuit diagram, technical data).

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5 Delivery/Transport/Storage
5.1 Delivery of units

The CyberHandler 2 unit is delivered either completely assembled or in separated unit compo-
nents divided as indicated in the unit drawing.

The complete units and individual modules must always be transported upright.

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 con-
signment note in the presence of the freight forwarder.
• You receive the consignment papers with the delivery of the AHU.
• The shipment is made ex works, in case of shipment damages, please assert your
claim directly towards the carrier.

5.2 Storage
If you put the unit into intermediate storage before the installation, the following measures have
to be carried out to protect the unit from damage and corrosion:
• 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 be within the range -10ºC to 50°C, and the site
should be dry and not exposed to direct sunlight.
• the unit should be stored packaged to avoid the risk of corrosion especially of the heat
exchanger fins.

5.3 Transport

Service doors must always be closed during transport

5.3.1 Transport with forklift

When transporting the unit with a forklift truck, make sure that only the base frame or supplied
pallet rest on the forks and not the unit base.

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

5.3.2 Transport with crane (via shackles)

Never stand beneath suspended loads, since there is always a risk that the lifting
gear, shackles, ropes or slings are faulty or damaged

All the local standards and regulations about crane transport must be observed.
The CyberHandler2 unit has several hoisting plates on the baseframe where shackles must be
mounted for craning.

Due to the risk of scratching the panels, we advise not to use chains.
Don’t remove the package until the unit is in its final position

In order to ensure a safe craning of the units, instructions here below must be followed:
• Mount the shackles on the lifting lugs on the base frame.
• Use crossbeams with the appropriate width to prevent the sling to rub against the unit.
• With weatherproof units, make sure the protruding parts of the roof are not damaged by the
lifting gear.
• Do not lift any other loads together with the shipment unit.
• Ensure the suspension angle doesn’t exceed 60°.

Crossbeams

Detail of the
attachment system

Fig. 5-1: Lifting gear

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Crossbeams, shackles and slings/ropes used in the lifting gear are not supplied by
Stulz

To transport a complete unit or several modules joined together, the lifting gear must
be fixed to all lifting lugs of the baseframe

6 Assembly and Installation

6.1 Supplied parts

• M8 x 30 mm socket cap screws with (for fixing element).
• M8 x 30 mm Hex-head cap screws (for base assembly).
• M8 nuts (for module assembly).
• M8 / 125 x 40 mm (units with refrigerant circuit for refrigerant pipes assembly)

6.2 Unit placement

Foundations requirements
• The base on which the unit is to be installed must be level, flat and of adequate load-bearing
capacity.
• The minimum height of the base must correspond to the siphon height (for siphon calculation
see 6.4.2).
• In case of using strip foundations, additional cross supports are required at the beginning and
end of the unit, as well as at the joints between unit sections.
• The whole baseframe of the unit must rest on the base and make full surface contact with it.
• Pad or point contact is not permissible.
The fulfillment of these requirements is essential in order to avoid possible problems
with the unit, such as door jamming.

Structure-borne sound insulation

In order to insulate the supporting structure from the vibrations produced by the unit, it is rec-
ommended to use suitable anti-vibration mounts, such as rubber strip.

Unit’s baseframe

Vibration absorber

Steel beam

Concrete base

Fig. 6-1: Installation on concrete base Fig. 6-2: Installation on steel beam

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Space requirements for installation, maintenance and operation

The minimum space necessary for installation, operation and maintenance is one unit width on
the operator side (see fig. 6-3).

OPERATING SIDE

Fig 6-3: Space requirements

If the unit is to be installed against a wall (fig. 6-4) or back-to-back with another unit (fig. 6-5),
fixing elements for modules connection must be located inside the unit (on the rear side).

OPERATING SIDE

Fig 6-4: Installation against the wall

OPERATING SIDE OPERATING SIDE

Fig 6-5: Installation back-to-back

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If no ductwork is connected, a clearance must be left in front of the outdoor air intake/exhaust
air, as shown on Fig. 6-6 and Fig. 6-7:

AIR
R
OO
TD
OU
Fig 6-6: Clearance in the air intake area (1 wall)

AIR
R
OO
TD
OU

Fig 6-7: Clearance in the air intake area (2 walls)

In order to avoid any air by-pass between outdoor air and exhaust air, the appropriate measure
must be taken to conveniently separate outdoor airflow and exhaust airflow (e.g. duct work on
the exhaust side).

Duct work must be installed by qualified staff

Warning: weatherproof units are not substitute to roof.

It is not allowed to use weatherproof units as supporting surfaces of a building or
similar roof substitutes in accordance to EN 13053

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6.3 Assembly (units in several parts)

Before assembling the modules, check the following points:
• Every module must be placed in its final position according to the unit drawing (Every module
is named after a letter). To ensure a correct tightness between 2 modules, every module is
provided with rubber strip in factory.
• All fixing elements, drilled holes are perfectly placed in order all the modules can be fixed
together.

Assembly sequence:
Aluminium profiles
• Insert first the M8 nuts in the joining element and then insert the M8 x 30 mm socket cap
screw in the other part of the fixing element.
• Tighten the screw with the Allen key

Fixing element

Module 2
Module 1

Fig 6-8: Assembly of modules

• Baseframe:
• Insert first the M8 x 30 mm Hex-head cap screws in the fixing element of the baseframe and
secure it with the M8 nuts.

Screws/nuts

Module 1 Module 2

Fig 6-9: Assembly of baseframe

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• Intermediate baseframe:
• The intermediate baseframe (if existing) of the double deck units must be fixed to the alumin-
ium profiles of the lower modules with screws.

Upper module Intermediate

baseframe

Screw

Lower module

Fig 6-10: Assembly of intermediate baseframe

• Roof (units for outdoor installation):

• Place a rivet in each drilled hole and secure it with a rivet gun

Rivet

Module 2 Module 1

Fig. 6-11: Assembly of roof

Several modules joined together can be transported together only fixing the lifting
gear to all the lifting lugs of the baseframe.

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6.4 Installation
6.4.1 Electrical connection

Before working with electrical wires, make sure they are de-energized. The electric
cables are only to be connected by authorized specialist

Power supply connection

Specifications
Voltage supply: 400 V / 3 Ph / 50 Hz / N / PE / TNS / TNCS
Power supply cable: cable cross section must be chosen according to electrical
data of the unit (available in the technical data sheet on request) and adapted to local
requirements, laying and cable length.

Cable routing and connection:

The electric cable must be introduced into the electrical cabinet from below, passing it
through the hole drilled on the bottom of the unit.

Opening for power

cable insertion

Fig 6-7: Power supply cable insertion in the electrical cabinet

The electric cable must be connected as following:

Cable Connect to
Phase 1/2/3 Main switch L1/L2/L3
PE PE Rail
Neutral Neutral terminal (N)

Once connected, the cables must be secured by the pull relief screw.

Make sure that the phase rotation is correct, the rotating field must turn right!
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.
The power supply system on site and the pre-fuses must be designed for the total
current of the unit (see data sheet of your unit). Make sure that the power supply cor-
responds 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 differ-
ence between the phase conductors.

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The average value of the voltage differences may not exceed 8 V

Modules connection
All modules must be electrically connected
with each other (power, Communication; sen-
sors datas) by the means of the male/female
connectors.

Fig 6-8: electrical connection between 2 modules

6.4.2 Adiabatic system

Spray nozzles are situated in the upper module and the rest of water circuit is situated in the
lower module.

In units delivered in separates modules, the pipe joining the water pump with the spray nozzles
must be connected to the upper module by the mean of the PVC threaded connection (see
drawing below).

The sump of adiabatic system is to be connected to water supply (with or without water treat-
ment) and to water draining as shown on the drawing below.

Brass or copper parts cannot be used for pipe connection between a reverse osmosis
plant and the adiabatic system of the CyberHandler 2 unit.

Make sure the filling water flow is greater than the maximum evaporated waterflow,
available on the technical sheet of your unit.

Water quality requirements

Water quality is a very important parameter to take into account in order the adiabatic system
operates in a safe and reliable way.

For this purpose, the water used must be microbiological drinking water quality (in accordance
to local standard) and the threshold values of the following table must not be exceeded:

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Water cuality Circulation water max

Material in contact with water • Stainless steel

• Aluminum
• Epoxy coating
• Plastics
Appearance - Clear, colourless, without
sediment
Climatizadores · Condensadores · Aero-refrigeradores · Fan Coils ·Baterias
pH value - 7.5 to 8.5
Total saltAir Handlers
content · Condensers · Dry-Coolers
g/m3 · Air-heaters · Coils
<1400
Electrical conductivity (25 ºC) µS/cm <1600
Hardness KH ºdH <1
Chloride CL- g/m3 <100
Sulphate SO42- g/m 3
<280
Cu-ionen CU2+ g/m3 < 0,05

6.4.2.KMnO4
Adiabatic system g/m 3
< 50

New sketch to insert in the IOM manual (replacing the current sketch, p.21):

Cooling Coil:
Adiabatic system: Water draining (O 1.’’ GAS)
water connection of
upper module

Adiabatic system: Adiabatic system:

Water filling Water draining
(Ø 3/4" GAS) (Ø 11/2" GAS)

Fig 6-9: water connection

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Siphon calculation
The siphon height H (mm) must be enough to overcome the static pressure inside the unit

The minimum height of the siphon must be equal to 2H, calculating H according to the following
formula:

P(Pa)
H (mm)= 10

P: total pressure (positive or negative) of the unit fan

Fig. 6-13: Siphon for positive pressure Fig. 6-14: Siphon for negative pressure

In order the siphon work properly, do not connect several water outlets to the same
siphon.

6.4.3 Cooling Coil (version CWT/CWR/DXT/DXR)

The CyberHandler2 unit can be equipped with chilled water coil (CWT/CWR) or direct expansion
coil (DXT/DXR).

Chilled water coils (for CWR and CWT models) are to be connected to a cool water production
system (e.g. chiller) according to table here below.

Inlet/Outlet Draining
Coils connections (examples)
Diameter Connection Diameter Connection

Up to 2,5” Thread GAS ¾” Thread GAS Water

outlet
Air Air
direct direct
io n io n

Greater than
Flanges ¾” Thread GAS
2,5”

Water
Thread inlet Flanges

We recommend to insulate the pipes of the external system, if they come into contact with
external air, to prevent the introduction of heat from the ambient air as well as possible

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Anti-freezing agent
An anti-freezing agent should be used if the water temperature passes under 5°C or if the out-
side temperature is less than 0°C. We recommend to add the following quantities of ethylengly-
col (indicated as percentage of weight of the water quantity):

Water or outside air temperature Ethylenglycol

until -5°C 10%

until -10°C 20%

until -15°C 28%

until -20°C 35%

until -25°C 40%

For DX coil connected to a remote condenser (DXR) external pipe must be welded.

The connection piping must be connected to the CH2 free of mechanical stress.

Condensate tray (CW coil and DX coil) are to be connected to water draining, provided with a
siphon (see siphon calculation in 4.4.2).

6.4.4 Refrigerant circuit (version DXT/DXR)

All work on refrigeration systems may only be carried out by competent staff or by
STULZ customer service

Piping connection of 2 modules

Each part of the refrigerant circuit is filled with dry nitrogen in factory. When removing the pro-
tective caps, the gas shall escape emitting a hissing noise.
If not, there is a leakage in the circuit and Stulz technical service must be informed.

For units delivered in several modules refrigerant pipes of each module has to be joined.
For this purpose, each pipe is equipped with a fixing part at the connection end. To join 2 parts
of a pipe, put the 2 fixing parts together (ensuring the O-ring is in the right position) and secure
it with the 4 M8 /125 x 40 screws (pre-positioned in the fixing parts)

O-ring

Fig. 6-12: refrigerant pipes connection

For units with redundant refrigerant circuit (DXR), a remote condenser must be connected to the
open refrigerant circuit of the unit.

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The pipe diameter must be chosen according to the following diagrams:

Liquid lines
depending on the overall pipe lengths and
refrigeration outputs with a permissible
pressure loss of: 15 kPa

Pressure lines
depending on the overall pipe lengths and
refrigeration outputs with a permissible
pressure loss of: 30 kPa

Further conditions:
tc = 45°C
to = 3°C
Subcooling: 3K
Superheating: 7K

This cooling capacity is at least required for oil transportation in rising pipes of pressure lines at
tc (dew point) 45 °C, to 10 °C and hot gas temperature 70 °C.
Pipe diameter mm 15 18 22 28 35 42
R410A Refrig. capacity kW 1.48 2.47 4.32 7.56 14.04 22,92

The units contain an oil separator which is installed at the hot gas side of the compressor and
serves to recuperate oil in all operating states. The separated oil is injected on the suction side
of the compressor.

For the liquid line we recommend to install a non-return valve near the condenser, this avoids
the return flow of refrigerant in to the condenser and a possible low pressure error at the unit
start.

For the hot gas line we recommend to install a non-return valve as close as possible to the Air
Handling Unit. The non-return valve avoids the return flow of liquid refrigerant from the con-
denser when the AHU is not in operation.

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Measures to take with hot gas pipes if the condenser is positioned higher than the Air
handling unit (for total pipe length up to 45m or total pipe height up to 15m)
• Ascending pipes must have oil traps every 5 m (see drawing).
• Install an oil trap at the end of horizontal gas pipes whenever the following pipe is an ascend-
Climatizadores · Condensadores · Aero-refrigeradores · Fan Coils ·Baterias
ing pipe (see drawing)
Air Handlers · Condensers · Dry-Coolers · Air-heaters · Coils

For installation with total pipe length greater than 15m or total pipe height greater
than 15m,
New sketch consult
to insert Stulz
in the IOM manual (replacing the current sketch, p.25):

Inverted Oil Trap

(higher than upper
header of the

Max. 15m
Max. 5m

Oil Trap

Fig 6-13: Condenser located higher than the Air handling unit
13

Once the refrigerant pipes are correctly connected, the circuit tightness must be checked
according to the following procedure, in order to ensure there is no refrigerant leak.

Do not subject the compressor to dry air. Otherwise you risk a bearing malfunction!

• Fill the circuit with dry nitrogen until the rated maximum pressure is reached.
• Wait for 10 minutes and check the pressure value.
• If the pressure keeps constant, tightness is OK.
• If the pressure has dropped, the circuit must be checked for a possible leak, using a soapy
solution.

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Connection points of the refrigerant circuit must be carefully checked, because most
of the leaks are located in these areas.

• Repair all the detected leaks and check the circuit again until the tightness is OK.

Vacuum and filling of refrigerant circuit

Fig 6-14: refrigerant circuit diagram

Before filling the compressor with refrigerant, make sure the unit is connected to
power supply
The nitrogen used the for tightness test must be removed from the refrigerant circuit

Evacuating refrigeration circuit:

• Connect a vacuum pump and manometer to the refrigeration circuit.
• Operate the vacuum pump until the pressure value of 70 mbar is reached.
• Wait for 30 minutes and check if the pressure keeps constant. If the pressure has increased,
it indicates there is a possible leak in the circuit. In this case, the leak must be detected and
repaired and the evacuation procedure must be started again.
• If the pressure keeps constant, fill refrigerant (R410A) until the pressure value of 0.98 bar is
reached (to break the vacuum)
• Wait for 5 minutes and remove the refrigerant from the circuit.
• Operate the vacuum pump again in order to realize a last evacuation.

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When the vacuum operation has been completed the refrigerant circuit must be filled by the
Schrader valve with the rated quantity of R410A refrigerant (available on the unit nameplate),
following the general rules here below:
• Before the system is filled with refrigerant, it must be clean and dry inside.
• Because R410A is blend and scrolls have discharge check valves, 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
process 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.

R410A is a binary blend. 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.

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7 Commissioning
The unit must be installed and connected in accordance with the chapter on
“installation” before initial commissioning.

• Make sure that the master switch is off and the unit is de-energized.
• Open the electrical compartment door of the unit using the key provided.
• Check whether all power switches and control-circuit fuses in the electrical section of the unit
are switched off.
• Retighten all screw connections in the electric cabinet.
• Verify the smooth function of the contactors.

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.

• Adjustment of the power switches according to electrical data sheet.

• Switch on the control-circuit fuses and the power switches of the fan and the compressor in
sequence.
• Close all doors of the Air handling unit.
• Switch on the CyberHandler2 unit at the master switch.

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

Make sure that the heat rejecting system is operating.

DXR: Condenser
CWT/CWR: Chiller

The doors can only be opened with the key provided and represent a protective
device. During operation the doors may not be opened and the rear panels may not be
removed.
• Adjust the desired return air temperature at the controller.

7.1 Refrigerant circuit

Oil dilution! Bearing malfunction!

• It is important to ensure that new compressors are not subjected to liquid abuse. If the
compressor is equipped with a crankcase heater, turn it on 12 hours before starting the
compressor.
• Start the A/C unit by pressing the Start/Stop-key on the controller.
• 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 refrigerant in regard of the chapter “Maintenance”.
• 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.

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There is no oil sight glass in A/C units with speed controlled compressor.
• Check the current consumption of the compressors and the fans comparing it with the values
of the e-data sheet.
• Instruct the operational staff of the controller manipulation (refer to the controller manual).

7.2 Adiabatic System

In order to reduce legionella risks and increase the useful life of the plate heat
exchanger and adiabatic system, Stulz recommends using water treated by reverse
osmosis.
Check if your Cyberhandler2 unit must comply with local regulation about control of
legionella bacteria in water.

Water sump filling

Before filling the water sump, the system must be rinsed in order to remove possible bodies
from the pipes.
The water sump must be checked and cleaned if necessary.

Filling the water sump:

Before water filling the unit must be energized.
The water sump must be filled with water up to the maximum level. When the maximum level is
reached, the water supply will be automatically stopped.

Water pressure adjusting

Once the water sump is filled with water, the water pressure must be checked with the pressure
gauge located on the water pipe connecting the pump and the spray nozzles (see fig. 6-1).
In order the adiabatic system works properly, the value must be between 2 and 2,5 bar.
If necessary, water pressure can be adjusted, changing the opening of the ball valve (see fig.
7-1)

Pressure gauge

Ball valve

Fig 7-1: water pressure adjustment

Siphon must be filled with water.

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7.3 CW coil
The system must be rinsed prior to filling, in
order to remove any solid particle or dirt.
The system must be filled with the fluid named Venting screw
in the design data sheet to the correct concen-
tration.
It is important to vent carefully the system to
ensure there is no air left inside which lead to a
reduction in capacity.
For this purpose, open the venting screw
located at the highest point of the cooling coil
(or open a separate one).

Coil Draining

Fig 7-1: Venting of coil

Siphon must be filled with water.

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8 Maintenance

8.1 Safety instructions

All maintenance work is to be carried out under strict compliance with the country-specific
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.

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 master 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.

8.2 Periodic maintenance

Maintenance Interval
Activity Action, if required 1 3 6 12
month month month mont
DAMPERS
Check for contamination, damage and
Clean and repair x
corrosion
Check mechanical function Repair x
Check actuators Repair / replace x

AIR FILTERS

Check for damage, corrosion and odors Replace the filter(s) if needed x

Check if the maximal pressure drop across

the filter stage is exceeded (alarm on the Replace the filter x*
controller)
*filters must be replaced when the clogged filter alarm is showed and at least every 6 months

AIR/AIR PLATE HEAT EXCHANGER

Check for contamination, damage and
Clean and repair x
corrosion

COOLING / HEATING COIL

Check for contamination, damage and
Clean and repair x
corrosion
Check Drip tray (cooling and evaporator
Clean x
coils)

Check water inlet/outlet (water coils) Clean x

Check Siphon function and water level of

Clean and top-up x
siphon (Cooling and evaporator coils)
Check flow control valves (water coils) Clean and repair/replace x

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Maintenance Interval
Activity Action, if required 1 3 6 12
month month month mont
EC FANS
Check Blades and housing for con-tamina-
Clean and replace x
tion, damage and corrosion
Check impeller for wear/deposits/corrosion
Clean and replace x
and damage
Check bearings for noise Replace x
Vibration test Clean/rebalance impeller/replace x

ADIABATIC SYSTEMa
Check regulating and control devices (valves,
Repair / Replace x
sensors…) for function
Check automatic drainage system for
Repair / Replace x
function
Check all components for contamination,
Clean/ Repair / Replace x
damage and corrosionb
Check plate heat exchanger for dirt, scaling
Microbiological testing / Cleaning x
and biofouling
Check spray nozzles for dirt, scaling and
Microbiological testing / Cleaning x
biofouling

Check sump for dirt, scaling and biofouling Microbiological testing / Cleaning x

Check piping for dirt, scaling and biofouling Microbiological testing / Cleaning x
Check recirculation pump for dirt, scaling
Microbiological testing / Cleaning x
and biofouling
Check pump bearings for noise and
Repair / replace x
vibrationsc
Check water level control for function Repair x
Check Siphon function and water level of
Clean and top-up x
siphon
Check water filter for dirt, scaling and
Microbiological testing / Cleaning x
biofouling
a Maintenance to be carried out when adiabatic system is in use only. Maintenance intervals are given when RO treatment is used. If no
RO treatment is used, maintenance intervals must be divided by 2. If no water treatment is used, maintenance interval must be shortened
b this checking must be performed before the winter season (when adiabatic system is not in use) and during the season with the most
common demand.
c Internal parts of the pump are maintenance-free. In particular motor has greased-for-life bearings

REFRIGERANT CIRCUIT
Check circuit for leakage Check circuit for leakage x
Check sight glass for refrigerant quan-tity Check sight glass for refrigerant quan-tity and
x
and quality quality
Check HP/LP switch function Check HP/LP switch function x
Check compressor for damage and corrosion Check compressor for damage and corrosion x
Check pressure relief valve of com-pressors Check pressure relief valve of com-pressors x
Check check valve of compressor Check check valve of compressor x
Check roller bearing for noise Check roller bearing for noise x
Check crankcase heater Check crankcase heater x
Check oil level Check oil level x
Check mechanical function of expan-sion Check mechanical function of expan-sion
valve valve
Check control module of the valve Check control module of the valve x

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Maintenance Interval
Activity Action, if required 1 3 6 12
month month month mont
UNIT HOUSING
Check for contamination, damage and
Clean and repair x
corrosion
Check for water formation (condensa-tion,
Clean and determination of cause x
leaks)
Check function of drains Clean x
Check flexible connections for leaks x

ELECTRICS

Retighten electrical connection x

8.3 Air filters

Filters are equipped with a pressure switch. When the maximum allowed differential pressure
across the filter is exceeded because of clogging an alarm message is showed on Controller’s
display and filters must be replaced.

Procedure for filters replacement

• Open the access door to the filters.
• Open clamping device by pulling it out by means of the loose removal lever provided.
• Remove the filters to be changed pulling them out of the frame individually.
• Clean filter seals, check and replace damaged seals as needed.
• Put new filters.
• Close clamping device

8.4 Plate heat exchanger

Plate heat exchangers have no moving parts, hence mechanical maintenance is unnecessary.

If there are dirt and dust deposits in the heat exchangers, these can be easily removed, using
one of the following methods:
• with compressed air, in the case of dusty surfaces if there is a lot of dirt, but it is not firmly
attached, at the same time taking care not to damage the plates and seals;
• hot water or by using a detergent spray (e.g., Decade, ND-150, Chem Zyme, Primasept, Poly-
Det, Oakite 86M or the like) to remove greasy deposits, if there is a lot of firmly attached dirt.

Strongly alkaline or other substances corrosive to the fins or the seal should obviously be
avoided.

8.5 Plate-fin heat exchangers (Cooling coil, heating coils)

Use protection gloves to avoid injuries caused by sharp edges during maintenance
and cleaning process.

Do not use high pressure water to clean coils, risk of damage to the unit

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Plate-fin heat exchangers are static elements inside the unit and there is no special mainte-
nance required.

It’s necessary keep coils clean in order to ensure its capacity is maximum.

The fins can be cleaned using:

• Compressed air, directing the airstream against airflow direction and perpendicularly to the
fins.
• Low pressure Hot water, eventually adding neutral soap, to avoid any damages or corrosion
troubles.
• Vacuum extraction

Condensate pans (cooling coils only) must be cleaned with a neutral soap.

8.6 EC fans

Disconnect main power supply and wait five minutes before opening the device

The fans have an overrun time after the unit is stopped ! (Risk of injury)
The electronics housing of the fan motor can get hot.
It is recommended to perform a vibration test every 6 months in order to check correct balanc-
ing of impeller.

The testing procedure is as following:

• Place vibration sensors on the motor support plate as indicated on the drawing here below

1 1: v ibration sensor towards

motor’s axis of rotation

2 2: v ibration sensor perpendicular

to motor’s axis of rotation

Fig 8-1: Positionning of the vibration sensors

• Check vibration severity is lower than 3.5 mm/s

Cleaning of fans:
Use a soft cloth and water with a neutral soap to clean the fan (housing, impeller)

Do not use high pressure water to clean the device

Do not use alkaline or corrosive substance to clean the device
Do not use any pointed or sharp-edged objects for cleaning

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8.7 Adiabatic system

In general, hygienic guidelines and standards relative to evaporative cooling installations (e.g
VDI2047-2, HSG274 part1, LCEP29, AI-32). must be observed.

In particular, the VDI 2047-2 regulation requires microbiological tests to be done by an

authorized and independent laboratory at least every three months.

Specific maintenance operation on the adiabatic system is required only in the periods when the
adiabatic system is in use and maintenance frequencies depend on the type of water treatment
used.

The recommended maintenance frequencies are given in the table of the chapter 8.2. periodic
maintenance and are partially based on the VDI 2047-2 regulation.

Depending on local regulations (in particular related to legionella control), it might be necessary
to adopt specific maintenance measures and intervals.

Make sure you are aware of the local regulations and apply them correctly.

General cleaning and disinfection

Disinfection must be carried out by qualified personnel only.

When handling disinfectant, following safety instructions must be observed:
• Wear personal protective equipment (safety glasses, protective gloves,
protective clothes)
• Avoid direct contact with the disinfectant
• Follow the instructions on the safety data sheet of the product
• Do not drink, eat or smoke in the work area.

The cleaning and disinfection process must be as following:

• 1. Before applying disinfectant on surfaces, they must previously be perfectly cleaned, using a
soft cloth and fresh water, eventually adding neutral soap, in order to remove all dirt particles.
• 2. Rinse the surface with fresh water and dry it.
• 3. Apply disinfectant on all the surfaces with a spray or a rub-wipe, exercising slight pressure.
• 4. Rinse the surfaces with clean water.
Additional recommendation for cleaning and disinfection process:
• Apply the disinfectant evenly to the surfaces, without scrubbing or brushing.
• In case of using wiping utensils, choose materials that don’t excessively absorb the
disinfectant and don’t leave particles on the surfaces.
• After applying disinfectant, all utensils must be cleaned and dried.
• Follow the manufacturer’s instructions for dosing and using the product and use the suitable
dosing device.
• Prepare a new solution before every use. Do not store ready-to-use solution and use it for one
working day at most.
• When using alcohol-based disinfectant, adequate measures, must be taken to prevent
explosion and fire hazards:
- The prepared solution should not exceed 50 ml/m2
- Max. coverage should not exceed 2 m2 at any one time
- In case of large scale utilisation, working area should be enough ventilated

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 CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

• Following criterias should be considered for the disinfectant selection:

- Effectiveness in microorganism elimination
- No corrosive for materials to desinfect.
- As health friendly as possible (not irritant, no allergenic, mutagenic or carcinogenic effects,
no unpleasant odor if possible)

Cleaning of plate heat exchanger

See section 8.4 for cleaning instructions of the plate heat exchanger.

Cleaning of water sump

The dirt particles can be removed from the surface of the sump using a high pressure steam
cleaner or scrubbing with a cloth with detergent and clean water.

Make sure that all edges and corners are perfectly clean

Cleaning of piping and pump housing

Pipes, pump housing can be cleaned with a soft cloth and fresh water, eventually adding neutral
soap.

Cleaning of spray nozzles

For cleaning the nozzles, unscrew them and clean them with a commercially available descaling
agent.

8.8 Refrigerant circuit

Maintenance work must only be carried out by a qualified expert

Refrigerant charge – Quantity and Purity

Quantity - Check the sight glass and the LP switch (there is no LP switch in units with EC
compressor).

An insufficient charge causes the formation of bubbles in the sight glass or in extreme cases
the triggering of the LP-switch. An operation with an insufficient 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:
• let out the refrigerant in a collecting device down to a pressure of 1 barabsolut
• connect a vacuum pump via a pressure gauge station on the high and low pressure side
• extract the refrigerant by the vacuum pump (not by the compressor !) to approx. 0 barabsolut.
• dispose the refrigerant according to the national regulations
• fill the circuit with nitrogen to 1 barabsolut
• repair the leak
• the circuit has to be run dry by several (at least 3x) fillings and extractings of nitrogen,
eventually change the filter drier.
• fill with R410A according to weight (see type plate)

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Quantity – Check the HP switch

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

Purity – Check the sight glass and the filter drier.

Bubbles in the sight glass indicate that the charge is insufficient 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 compres-
sor, 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.

Sight glass

Compressor

In 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.
The oil level can be checked by looking at the sight glass of the compressor.

Units with a speed controlled compressor are not equipped with an oil sight glass. For
these units it is not allowed to recharge oil in case of refilling a refrigeration circuit
after a leakage. In such cases the compressor has to be exchanged.

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Inverter (EC compressor driver)

According to a signal from the μPC controller, the inverter modulates the rotation speed of
compressor, in order to adjust cooling capacity to the actual thermal load.

A: Terminal block for power lines

B: Terminal block for control
lines
C: Fastening bracket
D: Cooling fan
E: PE connection
F: Operating status LEDs
G: Terminals for connecting a
shunt reactor

µPC Board

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Terminal Assignation Use

3 0V
RS485/ModBus®
4 RX+/TX+
connection
5 RX–/TX–
6 PTC input not used
7 24VDC
auxiliary voltage
8 0V
9 STOa
input for HP alarm
10 STOb
1,2 Relay output not used

In case of μPC electronic board replacement or updating of the software the inverter must be
configured according to a specific procedure (available on request).

Inverter configuration must be realized by trained personal only.

Expansion valve

The refrigerant circuit is equipped with an electronic expansion valve, which controls the
superheating in the evaporator.
The superheating is adjusted to 7 K at the factory and may not be modified. The expansion
valve can freeze, if the humidity in the system is excessive.

Do not thaw by soldering flame, danger of explosion! Thaw with moist warm cloth.
Check the sightglass.

8.9 Unit housing

Clean the unit casing with a microfiber cloth with lukewarm water (possibly add a neutral soap
solution). Panels can be removed for replacement.

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9 Dismantling and disposal

The air handling unit can only be dismantled by qualified specialists.

Switch off the unit at the controller and at the master switch. Switch off power con-
ducting cables to the unit and secure them against being switched on again. Discon-
nect the chiller 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 manufacturer, if it is not reused.
The ester oil in the compressor must also be disposed. As it contains dissolved
refrigerant, it cannot be disposed like usual oils, but must be returned to the oil
manufacturer.

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.

Move the unit, as described in the chapter “transport”, with a lifting device of sufficient load-car-
rying capacity.

Dispose of the air handling unit in accordance with the disposal and safety regulations applica-
ble on site. We recommend a recycling company for this. The unit basically contains the follow-
ing raw materials:
• Aluminium (profiles, heat exchanger coils, plate heat exchanger).
• Stainless steel (condensing tray, adiabatic sump).
• Galvanized steel (frames, panels, roof).
• Zinc aluminium (panels).
• Copper (pipelines, wiring)

The electrical and electronical components installed in the electric cabinet must be separately
disposed of according to the European directive 2012/19/EU. The concerned components are
marked by the symbol of the crossed-out wheeled bin.

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CYBERHANDLER 2 INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Alarm message Cause for alarm Cause Elimination

C7000: High pressure switch 1. outside temperature too high Install bigger condenser
Compressor # has triggered or
error 2. cooling water temperature too Check drycooler.
high
3. condenser fan defective Check function.
4. condenser pressure switch adjusted Modify setting
too high
5. condenser coil soiled. Clean condenser.
6. overcharge of refrigerant circuit
7. electric connection of high pressure Check connection and cable.
switch loose. Cable defective.
8. trigger point adjusted too low. Check setting of high pressure switch.
Press blue release button at HP switch
after elimination of error.

Compressor power 1. compressor motor defective Check compressor motor on voltage

interruptor continuity and current consumption.
has triggered.
2. feeding voltage too low. Check alimentation under load.

C7000: Low pressure switch 1. condenser pressure switch Modify setting.

Low pressure # has triggered.
adjusted too low.
error
(not for units 2. Insufficient refrigerant charge Refill refrigerant.
with EC compressor) 3. electric connection of low Check connection and cable.
pressure switch loose. Cable
defective.
4. trigger point adjusted too high. Check setting of low pressure switch.
5. Expansion valve defective. Exchange expansion valve.
6. Solenoid valve in liquid line defective Check electric alimentation with
voltage meter.
C7000: The tolerance to the 1. Big difference of measured Check room on Hotspots or chilled
Sensor # error average value adjust- values in selected zone. air zones, moist zones.
able in the controller
2. sensor defective. Check measured value with an
has been exceeded.
external measuring instrument
C7000: The measured 1. electrical connection defective. Check connections.
Sensor # defective voltage/current
2. sensor cable defective. Check cable on continuity.
is outside the range
defined in the 3. sensor defective Check measured value with
controller. external thermometer, hygrostat,
pressure gauge.
Depending on the option configured in the controller further alarm messages exist, which are explained in the C7000 Service
manual.

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

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0918_V0 - © STULZ Tecnivel, S.L.
STULZ Top Service – More than
just quick emergency assistance

Technical Manage-
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For general inquiries about our products and services, our hotline is available
at +49 40 5585-5000. Our service hours are weekdays from 7 am – 4 pm.
Or directly contact our representative in your area:

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