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Table of Contents
Related Manuals for ATS CyberChiller Series
Summary of Contents for ATS CyberChiller Series
- Page 1 CyberChiller Series Installation, Operation & Maintenance Manual (©October, 2006)
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Page 2: Model Nomenclature
CyberChiller Series Installation, Operation & Maintenance Manual MODEL NOMENCLATURE OHS = Overhead System CCH = CyberChiller System VFS = Vertical Floor System FCS = Floor Console System GPS = Glycol Pump System COS = CyberONE System MCS = Modular Cyber System Nominal Capacity in 1,000’s of BTU/Hr... -
Page 3: Table Of Contents
CyberChiller Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS Introduction ... 1-1 General ... 1-1 Product Description ... 1-1 1.2.1 Capabilities and Features ... 1-1 1.2.2 Application Ranges ... 1-1 1.2.3 General Design ... 1-2 1.2.4 Safety Features ... 1-3 Product Warranty ... - Page 4 CyberChiller Series Installation, Operation & Maintenance Manual List of Figures Figure 1- Typical Layout ... 1-2 Figure 2- Typical Installation ... 2-1 Figure 3- Typical Piping Air Cooled Systems ... 2-3 Figure 4- Typical Piping Water/Glycol Cooled Systems ... 2-5 Figure 5- Sample Nameplate ...
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Page 5: Introduction
CyberChiller Series Installation, Operation & Maintenance Manual INTRODUCTION General Congratulations, the CyberChiller™ floor mounted liquid chiller system covered by this manual is de- signed and manufactured by Stulz Air Technology Systems, Inc. (SATS) using the latest, state-of-the-art control technology. Recognized as a world leader,... -
Page 6: Figure 1- Typical Layout
CyberChiller Series Installation, Operation & Maintenance Manual 1.2.3 General Design The CyberChiller is divided into 3 areas; a pump section, a refrigeration section and an electrical section. The housing is a frame type construction. Figure 1 depicts the internal layout of the unit and the location of the major components. -
Page 7: Safety Features
CyberChiller Series Installation, Operation & Maintenance Manual cycle, one scroll remains stationary while the other scroll orbits around the first. As this motion occurs, gas is drawn into the scrolls and moved in increasingly smaller pockets toward the center. At this point, the gas, now compressed to a high pressure, is dis- charged from a port in the center if the fixed scroll. -
Page 8: Product Warranty
CyberChiller Series Installation, Operation & Maintenance Manual Product Warranty SATS offers a two year standard limited warranty as stated below. Additionally an extended warranty may be purchased on the unit's compressors. Consult the factory to verify if the extended compressor warranty was purchased for your system. - Page 9 CyberChiller Series Installation, Operation & Maintenance Manual Optional Limited Extended Warranty (5 Years Total) Stulz Air Technology Systems, Inc., warrants to the original buyer of its product that the compressor(s) listed below are warranted for parts replacement (not including labor) for extended period of 4 years from the date of expiration of the standard equipment warranty.
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Page 10: Safety
CyberChiller Series Installation, Operation & Maintenance Manual Safety 1.4.1 General Stulz Air Technology Systems, Inc. uses NOTES along with CAUTION and WARNING symbols through- out this manual to draw your attention to important operational and safety information. A bold text NOTE marks a short message in the information to alert you to an important detail. - Page 11 CyberChiller Series Installation, Operation & Maintenance Manual CAUTION All personnel working on or near equipment should be familiar with hazards associated with electrical maintenance. Safety placards/stick- ers have been placed on the unit to call atten- tion to all personal and equipment damage haz- ard areas.
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Page 12: Figure 2- Typical Installation
CyberChiller Series Installation, Operation & Maintenance Manual INSTALLATION Receiving the Equipment Your CyberChiller system has been tested and inspected prior to shipment. To ensure that your equipment has been received in excellent condition, make a visual inspection of the equipment immedi- ately upon delivery. -
Page 13: Indoor Equipment
CyberChiller Series Installation, Operation & Maintenance Manual The following general requirements should be consid- ered during installation: NOTE Equipment must be level to operate properly. 2.4.1 Indoor Equipment The CyberChiller system uses a frame and panel construction for unit rigidity and full service accessibil- ity while the unit is mounted in place. -
Page 14: Figure 3- Typical Piping Air Cooled Systems
CyberChiller Series Installation, Operation & Maintenance Manual Piping Connections 2.5.1 Process Supply Fluid Lines Coolant fluid supply and return lines are connected from the equipment being cooled to the CyberChiller via copper sweat fittings provided in the pump section. 2.5.2 Refrigerant 2.5.2.1... -
Page 15: Water/Glycol Fluid Cooled Systems
CyberChiller Series Installation, Operation & Maintenance Manual NOTE In the following (3) charts, the line sizes repre- sent the sizing for individual refrigeration circuits. CyberChiller units have two separate pairs of re- frigeration lines. (One per compressor.) Equivalent Length (ft) of Straight Pipe OD (In.) -
Page 16: Figure 4- Typical Piping Water/Glycol Cooled Systems
CyberChiller Series Installation, Operation & Maintenance Manual AIRTROL FITTING REMOTE DRYCOOLER AQUASTAT VALVE SHUT-OFF VALVE STRAINER Figure 4- Typical Piping Water/Glycol Cooled System WARNING Glycol is hazardous. Consult the manufacturer's MSDS for detailed safety information. CAUTION When installing and filling the water/glycol loop all... -
Page 17: Figure 5- Sample Nameplate
CyberChiller Series Installation, Operation & Maintenance Manual Figure 5- Sample Nameplate (©October, 2006) CKT BKR) for circuit protection. The unit's nameplate is located inside the cabinet within the electrical box. NOTE If the nameplate states MAX FUSE/CKT BKR, it is required to utilize fuses or HACR type cir- cuit breakers to protect the system. -
Page 18: Figure 6- Electric Box
CyberChiller Series Installation, Operation & Maintenance Manual Each unit is provided with main power and control terminal positions for connection of the field-wiring. The opening for the conduit is located in the floor of the cabinet. A label stating "MAIN POWER INPUT" is in close proximity. -
Page 19: Figure 7- Interconnecting Field Wiring Remote Condenser
CyberChiller Series Installation, Operation & Maintenance Manual MAIN PO 208-575V INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) Figure 7- Interconnecting Field Wiring Remote Condenser 2.6.4.1 Air-Cooled Split System Remote Condenser See Figure 7. Systems equipped with a remote condenser require field wiring between the evaporator system and the remote condenser. -
Page 20: Figure 8- Interconnecting Field Wiring Glycol Systems
CyberChiller Series Installation, Operation & Maintenance Manual MAIN POWER SUPPLY 208-575V/3PH/60Hz INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) Figure 8- Interconnecting Field Wiring Glycol Systems System Settings and Adjustments 2.7.1 Chilled Water Supply Charging Procedures (Evaporator Side) 2.7.1.1 Pump Start-Up... -
Page 21: Outdoor Heat Exchanger Glycol Charging Procedures
CyberChiller Series Installation, Operation & Maintenance Manual 2. Open the vent valve at highest point of the system. 3. Open the water source and run until the water solution is discharging from the vent with minimal signs of foaming due to air in the system. -
Page 22: R407C Refrigerant Charging Procedures
CyberChiller Series Installation, Operation & Maintenance Manual CAUTION A proper vacuum must be drawn on the refriger- ant system prior to charging. If this is not done the refrigerant will combine with the moisture in the pipes to form an acid that will eventually cause compressor failure. - Page 23 CyberChiller Series Installation, Operation & Maintenance Manual CAUTION POE oil is used in systems with R-407C refrigerant. POE oil quickly absorbs moisture when exposed to air. High POE oil moisture levels react with refrigerant to form acid, which results in system contamination. Keep entire system sealed as much as possible and minimize exposure of POE oil to outside air.
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Page 24: Head Pressure Controls
CyberChiller Series Installation, Operation & Maintenance Manual 2.7.6 Head Pressure Controls 2.7.6.1 Air-Cooled Systems 2.7.6.1.1 Condenser Fan Speed Remote air-cooled condensers use variable speed condenser motor control to maintain head pressure. The variable speed motor is located closest to the header end of the condenser. -
Page 25: Refrigerant Characteristics
CyberChiller Series Installation, Operation & Maintenance Manual Refrigerant Characteristics 2.8.1 Pressure/Temperature Settings The following chart is provided to assist with the normal settings of the system for R-22 and R407C refrigerant. Where applicable, minimum and maximum settings are given along with normal operating pres- sures. -
Page 26: Start-Up/Commissioning
CyberChiller Series Installation, Operation & Maintenance Manual START-UP/COMMISSIONING Operation For new installations, ensure the unit is ready to operate by going through the Checklist for Completed Installation, located in Appendix A, prior to start-up. NOTE A Warranty Registration and Start-Up Checklist is provided with the unit data package. -
Page 27: Microprocessor Controller Programming
CyberChiller Series Installation, Operation & Maintenance Manual supplied to the equipment. The flow switch senses the coolant flow in the system. When the pump is operat- ing, the coolant flow in the piping actuates the flow switch. The switch will signal the system controller to disable compressors and expansion valves and close the hot gas valves if the coolant flow rate drops. -
Page 28: Maintenance/Repairs
CyberChiller Series Installation, Operation & Maintenance Manual MAINTENANCE/REPAIRS Periodic General Maintenance Systematic, periodic general maintenance of the CyberChiller unit is recommended for optimum system performance. General maintenance should include, but is not limited to the following: tightening electrical connections, cleaning the interior of the unit, inspect- ing the unit’s components visually. -
Page 29: Troubleshooting
CyberChiller Series Installation, Operation & Maintenance Manual Troubleshooting Turn off all power to the unit before conducting any troubleshooting procedures, unless the procedure specifi- cally requires the system to operate. Keep hands, clothing and tools clear of the electrical terminals and rotating components. - Page 30 CyberChiller Series Installation, Operation & Maintenance Manual SYMPTOM Condenser Pressure a. Non-condensable gas or air in the too High system. b. Condenser air intake is blocked. c. Overcharge of refrigerant. d. Condenser fan not operating. e. Condenser pressure regulating valve setting too high.
- Page 31 CyberChiller Series Installation, Operation & Maintenance Manual SYMPTOM Head Pressure is too Low a. Loss of refrigerant (indicated by bubbles in the sight glass). Suction Pressure too Low a. Expansion valve stuck in the open position (indicated by abnormally cold suction line).
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Page 32: Field Service
CyberChiller Series Installation, Operation & Maintenance Manual Field Service It may be necessary to perform repairs on the refrig- eration system. If field repairs are necessary, the following procedures apply: NOTE Do not attempt to make repairs without the proper tools. - Page 33 CyberChiller Series Installation, Operation & Maintenance Manual harmful contaminants left by the burnout. See section 4.3.4.1.2 (Burn-Out/Acidic Cleanup) for the proper cleaning procedure. CAUTION Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty. This will VOID THE COMPRESSOR WARRANTY.
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Page 34: Product Support Group
CyberChiller Series Installation, Operation & Maintenance Manual PRODUCT SUPPORT GROUP SATS provides to its customers a Product Support Group (PSG) which not only provides technical support and parts but the following additional services, as requested: performance evaluations, start-up assistance and training. -
Page 35: Appendix A - Forms
Control wiring connections completed to evaporator and condenser/condensing unit (if required), including wiring to wall mounted control panel and optional controls. (©October, 2006) CyberChiller Series Stulz Air Technology Systems Inc. Frederick, Maryland USA 21704 Checklist for Completed Installation ❏ Foreign materials have been removed from... - Page 36 CyberChiller Series Installation, Operation & Maintenance Manual NOTES (©October, 2006)
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Page 37: Periodic General Maintenance Checks And Service Checklist
*** If factory assistance is required for any reason, provide the model number, serial number, and SATS item number found on the unit nameplate. This will speed the process and ensure accuracy of information. *** (©October, 2006) CyberChiller Series Prepared By: ___________________________ Serial Number: __________________________... - Page 38 CyberChiller Series Installation, Operation & Maintenance Manual NOTES (©October, 2006)
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Page 39: Appendix B- Glossary
CyberChiller Series Installation, Operation & Maintenance Manual SATS - Stulz Air Technology Systems, Inc. BTU/Hr - British Thermal Units Per Hour CNDCT - Conductor ESD - Electrostatic Discharge º F - Degrees Fahrenheit FLA - Full Load Amps FOB -... - Page 40 CyberChiller Series Installation, Operation & Maintenance Manual (©October, 2006)
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