ATS CyberChiller CCH-330-D-AR, Operation & Maintenance Manual

Page 1: ... October 2006 CyberChiller Series Installation Operation Maintenance Manual ...

Page 2: ...RE CCH 330 D AR 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 AR Air Cooled Remote Split W G Water Glycol Cooled D Dual Two Circuit System ...

Page 3: ...ms with Outdoor Fluid Pump Package 2 8 2 7 System Settings and Adjustments 2 9 TABLE OF CONTENTS 2 7 1 Chilled Water Supply Charging Procedures Evaporator Side 2 9 2 7 2 Outdoor Heat Exchanger Glycol Charging Procedures 2 10 2 7 3 R 22 Refrigerant Charging Procedures 2 11 2 7 4 R 407C Refrigerant Charging Procedures 2 11 2 7 5 Low High Pressure Limit Switch 2 12 2 7 6 Head Pressure Controls 2 13 2...

Page 4: ... Figure 4 Typical Piping Water Glycol Cooled Systems 2 5 Figure 5 Sample Nameplate 2 6 Figure 6 Electric Box 2 7 Figure 7 Interconnecting Field Wiring Remote Condenser 2 8 Figure 8 Interconnecting Field Wiring Glycol Systems 2 9 Appendix A Forms Checklist for Completed Installation A 1 Periodic General Maintenance Checks and Service Checklist A 2 Appendix B Glossary Definition of Terms andAcronyms...

Page 5: ... which can range from 120 000 to 330 000 BTU Hr CyberChiller systems are designed to operate with either R22 or R407C refrigerant Refer to the unit nameplate to identify which refrigerant is used with your unit NOTE The CyberChiller systems are strictly for non residential applications Refer to the installation drawing supplied with your unit for layout and dimensions of the cabinet The CyberChill...

Page 6: ...y circuit breaker s and motor start protectors These switches must be manually re set once the overload condition is cleared 1 2 3 3 Pumps Multi stage centrifugal pumps are located in the right side of the unit to circulate the coolant through the system A hinged access door is located on the right side of the unit This door may be opened to gain access to the pump section 1 2 3 4 Expansion Tank A...

Page 7: ...he compressor prevents the compressor from running backwards for more than a second or two This normal direction reversal of the scrolls at shut down has no effect on compressor reliability Each scroll compressor comes equipped with a crankcase heater used to evaporate any liquid that may have migrated to the compressor during extended periods on non operation 12 hours The crankcase heaters are eq...

Page 8: ...reater Stulz Air Technology Systems Inc s warranty does not cover failures caused by improper installation abuse misuse misapplication improper or lack of maintenance negligence accident normal deterioration including wear and tear or the use of improper parts or improper repair as determined by SATS This warranty does not include costs for transportation costs for removal or reinstal lation of eq...

Page 9: ...ccident normal deterioration including normal wear and tear or the use of improper parts or improper repair as determined by SATS This warranty does not include costs of transportation cost for removal or reinstallation of equipment or labor for repairs or replacement made in the field The obligation and liability of Stulz Air Technology Systems under this warranty does not include losses direct o...

Page 10: ...per formed by a journeyman refrigeration mechanic or an air conditioning technician CAUTION Never lift any component in excess of 35 pounds without help If a lifting device is used to move a unit ensure it is capable of supporting the unit CAUTION Do not allow the unit to swing while suspended from a lifting device Failure to observe this warn ing may result in injury to personnel and dam age to t...

Page 11: ...ith no toxic characteristics It is heavier than air and will disperse rapidly in a well ventilated area In an unventilated area it presents a danger as a suffocant Always refer to the manufacturer s MSDS pro vided with the unit WARNING Avoid skin contact or inhaling fumes from any acid formed by burn out of oil and refrigerant Wear gas mask if area is not thoroughly venti lated Wear protective gog...

Page 12: ...he data package has been placed in your unit in a clear plastic envelope These documents need to be kept with the unit for future reference NOTE Items that have been shipped loose such as controllers temperature sensors water detec tors etc are shipped inside the air conditioner unless specified otherwise by the customer Unpack and store these items in a safe place unless you are using them immedi...

Page 13: ...pplied vibration mounts to reduce the amount of vibration transmitted to the mounting surface Refer to the wiring diagram for electrical connections and to the refrigeration diagram for piping details 2 4 3 Pump Package Installation Water Glycol Systems Install the pump in general accordance with the piping diagram provided with the unit The pump should be at least 3 feet below the height of the e...

Page 14: ...igerant lines Silver solder containing a minimum of 15 silver is recommended Dry nitrogen should be flowing through the tubing while soldering at a rate of not less than 1 2 CFM 03 06 M3 minute Refrigerant lines for split systems must be sized according to the piping distance between the evapora tor and the condenser Each valve fitting and bend in the refrigerant line must be considered in this ca...

Page 15: ...ly be the same as the unit connec tion Piping should be sized to match the system pressure drop and pump capacity and may require a reducing fitting to match the connection size on the pump package and CyberChiller Copper is adequate for closed loop systems and ground water which is not high in mineral content and is pH neutral In situations where scaling could be heavy or where biological growth ...

Page 16: ...discharge piping at least one 1 size larger than the diameter of the discharge outlet Install a check valve in the discharge line to prevent back flow that may damage the pump on shut down Install a ball valve in the discharge line for maintenance purposes 2 6 Utility Connections 2 6 1 Main Power The CyberChiller product offering is available in 208 230 VAC single phase or 460 VAC three phase conf...

Page 17: ...is equipment Death on contact may result if personnel fail to observe safety precautions WARNING Verify power is turned off before making connec tions to the equipment NOTE All wiring must conform to local and national elec trical code requirements Use of copper conduc tors only is required Wiring terminations may become loose during transit of the equipment therefore it is required to verify that...

Page 18: ... If it is mounted on the unit standard no utility connection is required As an option a factory supplied display may be remote mounted Asix conductor cable harness is provided for interconnect wiring Refer to the electrical drawings supplied with your unit for details on interconnecting field wiring 2 6 3 Optional Equipment NOTE All wiring must be provided in accordance with local and national ele...

Page 19: ... the terminal board within the evaporator unit to the control terminal board within the remote condenser control box Refer to the supplied electrical schematic for proper wire terminations 2 6 4 2 Glycol Systems With Outdoor Fluid Pump Package See Figure 8 Systems equipped with a glycol system pump package require field wiring between the drycooler unit and pump package The installer must wire two...

Page 20: ...the pump to cool the impeller and housing If there is no flow shut the pump off immediately to prevent damage to the pump Check for proper rotation of the motor observing the arrow on the side of the impeller CAUTION The pumping system of the CyberChiller is designed for use with a positive suction head At no point should the system be operated for an extended period of time with less than 5 to 10...

Page 21: ...e Y strainer and pull the screens out 4 Wash the screens thoroughly to remove the collected particulate 5 Reinstall the screens in the strainer housing and replace the brass fitting 6 Re open isolation valves 7 Resume unit operation Repeat steps 1 6 every 30 minutes for first 3 hours operation 2 7 2 Outdoor Heat Exchanger Glycol Charging Procedures In glycol cooled units the refrigerant system is ...

Page 22: ...condenser with the tempera ture measuring device being well insulated The 2 11 sub cooling temperature should be approximately 10 20 ºF NOTE Under cold climate conditions it is recommended to do the following 6 Block off the intake air to the condenser with cardboard or reduce the water glycol flow until a constant discharge pressure 225 280 psig can be obtained This will lower the possibility of ...

Page 23: ...estrict the airflow across the condenser or reduce the water glycol flow to raise the pressure 7 Slowly meter R 407C liquid refrigerant through the suction side while watching the sight glass to clear ofbubbles CAUTION Addliquidrefrigerant slowlytopreventtherefrigerant oil from washing out of the compressor 8 While monitoring the sight glass take a sub cooling temperature reading on the output sid...

Page 24: ...method for adjusting the valves for condensing pres sure differs with the valve types To increase the condensing temperature decrease water glycol flow To decrease the condensing temperature increase the water glycol flow A directional arrow is stamped on the metal housing of the valve stem 2 7 7 Thermal Expansion Valve CyberChiller units utilize a thermal expansion valve TEV to control the flow o...

Page 25: ... 34 53 5 36 56 2 38 58 9 40 61 7 42 64 6 44 67 6 46 70 7 48 73 8 50 77 1 Sub cooling 95 206 100 222 105 239 110 257 115 275 120 294 125 315 130 336 135 358 140 381 Bubble Point Dew Point Pressure Temperature Settings For R 22 R407C Normal Min Max Sub cooling F 10 5 20 Superheat F 15 10 20 Condensing Temperature Air Cooled F 125 105 140 Condensing Temperature Water Cooled F 105 105 140 Condensing T...

Page 26: ...rigerant that is not in circulation 5 The refrigerant drier strainer removes any moisture water vapor or impurities that may be carried by the liquid refrigerant 6 The refrigerant then flows through the liquid sight glass This device indicates the presence of moisture and state of refrigerant in the system 7 The liquid line solenoid valve controls the flow of refrigerant before going to expansion ...

Page 27: ...the drycooler fan ON to maintain 85 F glycol temperature 3 2 1 4 1 Dual Pump Packages A field installed flow switch shipped loose from the factory must be installed in the main glycol line If flow is not established the flow switch closes the 24 VAC control circuit to a switch over relay and turns off the primary pump contactor after a time delay and turns on the secondary pump The manual Primary ...

Page 28: ... particulate Clean as required Monthly Examine all wiring for signs of chafing loose connections or other obvious damage Quarterly Examine brackets motor mounts and hardware for loose or missing parts or other damage Quarterly Clean accumulations of dust and dirt from all interior and exterior surfaces Quarterly 4 1 2 Compressor The refrigerant compressor and its drive motor are hermetically seale...

Page 29: ...ow a Loss of refrigerant bubbles in Locate leak and repair Recharge sight glass system b Expansion valve stuck or obstructed Remove and clean or replace valve short cycle or continuous running c Clogged drier strainer feels cold Replace with new drier strainer Evaporator Coil Ices a Temperature setting too low Increase temperature setpoint b Low refrigerant charge Find leak repair and recharge sys...

Page 30: ...ondenser fan controls not set Adjust or repair controls properly Noisy Compressor a Expansion valve stuck in open Ensure feeder bulb is tight on suction position abnormally cold suction line line Check operation and superheat b Broken compressor valve Replace compressor compressor knocking suction pressure rises faster than 2lbs min after shutdown c Worn or scarred compressor Replace compressor be...

Page 31: ...r Fails to Start a Temperature setpoint too high Adjust to desired temperature b Compressor internal protector Check compressor for short circuit or is open ground c Complete loss of refrigerant charge Locate and repair leak Recharge low pressure safety switch system d Condenser pressure too high high Check condenser for obstructions pressure safety switch e Minimum off time has not expired Wait f...

Page 32: ...pressor Failure The compressor is the most important component of the air conditioner Numerous safety devices are provided to protect the compressor from failing If a compressor failure has occurred determine whether it is an electrical or a mechanical failure An electrical failure will be indicated by the distinct pungent odor once the system has been opened If a burnout has occurred the oil will...

Page 33: ...ower at the main power disconnect switch and start the system 4 3 4 1 2 Burn Out Acidic Cleanup Procedure NOTE Cleaning operations must be performed by a jour neyman refrigeration mechanic or air condition ing technician 1 These systems should be cleaned using the suction line filter drier method 2 Turn off power to the unit at the main power disconnect switch 3 Remove the burned out compressor an...

Page 34: ...u do not have established credit with SATS you must provide a freight carrier account number A written or faxed purchase order is required on warranty parts and must be received prior to 12 00 p m for same day shipment The purchase order must contain the following items Purchase Order Number Date of Order SATS Stated Part Price obtained from PSG Customer BillingAddress ShippingAddress Customer s T...

Page 35: ...rant charge added if required 6 Incoming line voltage matches equipment nominal nameplated rating tolerances 7 Main power wiring connections to the equipment including earth ground have been properly installed 8 Customer supplied main power circuit breaker HACR type or fuses have proper ratings for equipment installed 9 All wiring connections are tight 10 Control wiring connections completed to ev...

Page 36: ... October 2006 CyberChiller Series Installation Operation Maintenance Manual NOTES ...

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Page 38: ... October 2006 CyberChiller Series Installation Operation Maintenance Manual NOTES ...

Page 39: ...orse Power Hz Hertz KVA Kilo Volt Amps kW Kilowatt LRA Locked RotorAmps MAX CKT BKR Maximum Circuit Breaker MAX FUSE Maximum Fuse MCA Minimum Circuit Ampacity MSDS Material Safety Data Sheet NEC National Electric Code NFPA National Fire ProtectionAgency PH Phase PSG Product Support Group PSI Pounds per Square Inch PSIG Pounds per Square Inch Gauge RLA Run LoadAmps R Value Thermal Resistance R 22 R...

Page 40: ... October 2006 CyberChiller Series Installation Operation Maintenance Manual ...