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CyberChiller Series Installation, Operation & Maintenance Manual
(©October, 2006)
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CyberChiller Series Installation, Operation & Maintenance Manual MODEL NOMENCLATURE CCH-330-D-AR OHS = Overhead System AR = Air-Cooled Remote (Split) CCH = CyberChiller System W/G = Water/Glycol Cooled 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 D ( ) = Dual (Two) Circuit System (©October, 2006)
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CyberChiller Series Installation, Operation & Maintenance Manual TABLE OF CONTENTS 2.7.1 Chilled Water Supply Charging 1.0 Introduction ....................................... 1-1 Procedures (Evaporator Side) .................... 2-9 1.1 General ...................................................... 1-1 2.7.2 Outdoor Heat Exchanger Glycol Charging 1.2 Product Description ................................... 1-1 Procedures .............................................. 2-10 1.2.1 Capabilities and
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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 ................................. 2-6 Figure 6- Electric Box ..........
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CyberChiller Series Installation, Operation & Maintenance Manual Refer to the installation drawing supplied with your unit 1.0 INTRODUCTION for layout and dimensions of the cabinet. The CyberChiller unit is provided with a factory mounted 1.1 General service disconnect switch with a lockable handle. The Congratulations, the CyberChiller™ floor mounted service disconnect switch isolates the unit during liquid chiller system covered by this manual is de- routine maintenance. The system incorporate
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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. ELECTRIC BOX AIR VENT AIR SEPARATOR EXPANSION TANK (BEHIND PUMP #2) HEAT EXCHANGERS PUMP #2 (EVAPORATORS) (OPTIONAL) HEAT EXCHANGERS (CONDENSERS- NOTE 1) RECEIVERS (BEHI
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CyberChiller Series Installation, Operation & Maintenance Manual cycle, one scroll remains stationary while the other Each scroll compressor comes equipped with a scroll orbits around the first. As this motion occurs, crankcase heater, used to evaporate any liquid that gas is drawn into the scrolls and moved in increasingly may have migrated to the compressor during extended smaller pockets toward the center. At this point, the periods on non-operation (>12 hours). The crankcase gas, now compres
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CyberChiller Series Installation, Operation & Maintenance Manual 1.3 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. The compressor warranty as stated on the next page will be sent with your unit and should be retained for future reference. 2-Year Standar
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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. Stulz Air Technology Systems' warranty does not cover failures caused by impr
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CyberChiller Series Installation, Operation & Maintenance Manual 1.4 Safety CAUTION 1.4.1 General Do not allow the unit to swing while suspended from a lifting device. Failure to observe this warn- Stulz Air Technology Systems, Inc. uses NOTES ing may result in injury to personnel and dam- along with CAUTION and WARNING symbols through- age to the equipment. out this manual to draw your attention to important operational and safety information. CAUTION A bold text NOTE marks a short message in
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CyberChiller Series Installation, Operation & Maintenance Manual CAUTION WARNING All personnel working on or near equipment Avoid skin contact or inhaling fumes from any should be familiar with hazards associated with acid formed by burn out of oil and refrigerant. electrical maintenance. Safety placards/stick- Wear gas mask if area is not thoroughly venti- ers have been placed on the unit to call atten- lated. Wear protective goggles or glasses to tion to all personal and equipment damage haz-
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CyberChiller Series Installation, Operation & Maintenance Manual NOTE 2.0 INSTALLATION Working clearance requirements need to be es- 2.1 Receiving the Equipment tablished prior to the mounting of the unit. Refer to local and national electrical codes. Your CyberChiller system has been tested and inspected prior to shipment. To ensure that your 2.3 Rigging equipment has been received in excellent condition, make a visual inspection of the equipment immedi- The CyberChiller systems are designed to
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CyberChiller Series Installation, Operation & Maintenance Manual 2.4.3 Pump Package Installation (Water - The following general requirements should be consid- ered during installation: Glycol Systems NOTE Install the pump in general accordance with the piping diagram provided with the unit. The pump should be at Equipment must be level to operate properly. least 3 feet below the height of the expansion tank. Do not form piping loops adjacent to the pump. Avoid 2.4.1 Indoor Equipment piping very
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CyberChiller Series Installation, Operation & Maintenance Manual Clear all pipe connections of debris and prepare the 2.5 Piping Connections connections for soldering. Use only "L" or "K" grade 2.5.1 Process Supply Fluid Lines refrigerant copper piping. Be careful not to allow solder/piping debris to get inside refrigerant lines. Coolant fluid supply and return lines are connected Silver solder containing a minimum of 15% silver is from the equipment being cooled to the CyberChiller recommended.
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CyberChiller Series Installation, Operation & Maintenance Manual NOTE Recommended Discharge Line Sizes In the following (3) charts, the line sizes repre- (For R-22 or R-407C Refrigerant) sent the sizing for individual refrigeration circuits. Equivalent Length Ft.* CyberChiller units have two separate pairs of re- Model No./ Total Unit 50' 100' 150' frigeration lines. (One per compressor.) Capacity or less or less or less Equivalent Length (ft) of Straight Pipe 120 / 120,000 7/8 1-
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~ CyberChiller Series Installation, Operation & Maintenance Manual EXPANSION TANK (MUST BE INSTALLED AT THE HIGHEST POINT IN THE SYSTEM.) AIRTROL FITTING VALVE SHUT-OFF WATER/GLYCOL COOLED REMOTE DRYCOOLER CONDENSER SHUT-OFF SHUT-OFF FLOW BYPASS VALVE REGULATOR AQUASTAT PUMP PACKAGE SHUT-OFF VALVE CHECK SHUT-OFF UNION VALVE VALVE UNION STRAINER PUMP Figure 4- Typical Piping Water/Glycol Cooled System 2.5.3.2 Discharge Side Piping WARNING Install a concentric reducer at the pump discharge Glycol
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CyberChiller Series Installation, Operation & Maintenance Manual 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. Other pro- tection devices are not allowed based upon the product listing. Each unit is provided with terminals for all required field-wiring connections, (supplied by others). Refer to the
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CyberChiller Series Installation, Operation & Maintenance Manual Each unit is provided with main power and control 2.6.2 Controls terminal positions for connection of the field-wiring. Stulz Air Technology Systems offers the C6000 The opening for the conduit is located in the floor of Microprocessor as the standard controller for the the cabinet. A label stating "MAIN POWER INPUT" is CyberChiller system. If it is mounted on the unit in close proximity. The main power wires are termi- (standard),
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CyberChiller Series Installation, Operation & Maintenance Manual MAIN PO 208-575V INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) MAIN POWER SUPPLY 208-575V/3PH/60Hz 24VAC AIR COOLED CONDENSER INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) Figure 7- Interconnecting Field Wiring Remote Condenser 2.6.4.2 Glycol Systems With Outdoor Fluid 2.6.4.1 Air-Cooled Split System Remote Pump Package Condenser See Figure 8. Systems equippe
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CyberChiller Series Installation, Operation & Maintenance Manual MAIN POWER SUPPLY 208-575V/3PH/60Hz MAIN POWER SUPPLY 208-575V/3PH/60Hz INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) DRYCOOLER (GLYCOL UNITS ONLY) INTERCONNECTING FIELD WIRING (TO BE INSTALLED IN ACCORDANCE WITH NFPA 70, N.E.C.) 24VAC BOX GPS PUMP PACKAGE (GLYCOL UNITS ONLY) Figure 8- Interconnecting Field Wiring Glycol Systems there is no flow shut the pump off immediately to 2.7 System Settin
