CyberChiller Series Installation, Operation & Maintenance Manual
1.0INTRODUCTION
1.1General
Congratulations, the CyberChiller™ floor mounted
liquid chiller system covered by this manual is designed and manufactured by Stulz Air Technology
Systems, Inc. (SATS) using the latest, state-of-the-art
control technology . Recognized as a world leader,
SATS provides precision cooling systems with the
highest quality craftsmanship using the finest materials available in the industry . The unit will provide years
of trouble free service if installed and maintained in
accordance with this manual. Damage to the unit from
improper installation, operation or maintenance is not
covered by the warranty .
This manual contains information for installation,
operation, maintenance, troubleshooting and repair .
STUDY the instructions contained in this manual.
They must be followed to avoid difficulties. Sp are part s
are available from Stulz Air T echnology Systems to
insure continuous operation. Using substitute parts or
bypassing electrical or refrigeration components in
order to continue operation is not recommended and
will VOID THE WARRANTY. Due to technological
advancements, components are subject to change
without notice.
CyberChiller systems are designed to precisely control
leaving fluid temperature for fluid cooled equipment
such as server racks, MRI’s, precision cooling units or
other devices. Any use beyond this is deemed to be
not intended. SA TS is not liable for any damage
resulting from improper use. All CyberChiller systems
are designed to be installed indoors unless otherwise
noted on the equipment. Propeller-type condensers
and fluid coolers are designed for outdoor use.
1.2Product Description
CyberChiller systems are designed to meet the needs
and technical requirements of individual customers.
Each individual module or unit can be supplied with
remote air-cooled condensers (AR) or optional water/
glycol (W/G) cooled heat rejection configurations. The
cooling capacity, in BTU/Hr, will depend on the unit
size, 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 nonresidential applications.
Refer to the installation drawing supplied with your unit
for layout and dimensions of the cabinet. The
CyberChiller unit is provided with a factory mounted
service disconnect switch with a lockable handle. The
service disconnect switch isolates the unit during
routine maintenance. The system incorporates state of
the art component protection with the use of motor
start protectors and circuit breakers.
An operating manual for the system controller is
provided under separate cover . Refer to that manual for
detailed instructions on operating the system controller provided with your unit.
The standard controller for the CyberChiller unit is the
C6000 microprocessor, which provides the following
features: input/output monitoring status, full integrated
control of cooling, multi-unit control and remote
communication with building management systems.
The controller is typically factory mounted on the front
hinged access door of the unit. As an option the
controller display may be factory supplied for remote
mounting to a wall or control panel.
1.2.1Capabilities and Features
Dual Refrigeration Circuits
Constant Running Compressor
Vibration Isolation of Compressor
Electronic Hot Gas Bypass
(With control based on the chilled water supply
temperature.)
Heavy Gauge Cabinet Construction
High Density Sound & Thermal Insulation
1.2.2Application Ranges
The SA TS CCH Modular Line Chiller Units are designed for operation within the following ranges:
Room Temperature Range: 35ºF to 95ºF, non-condensing
environment.
Cold Water Conditions: Between 45ºF and 65ºF.
Voltage Tolerances: 460VAC +/-10%; 208VAC +/-10%.
Frequency: 60 Hz. (as noted on unit nameplate).
Max. Piping Length; Chiller to Air Cooled Condenser:
200 ft equivalent length.
Max. Level Drop; Chiller to Condenser: 20 ft (when
condenser is below the chiller).
Storage Conditions: 35ºF to 95ºF.
NOTE
Damage or malfunctions to the unit due to
storage or operation outside of these ranges
will VOID THE WARRANTY.
CyberChiller Series Installation, Operation & Maintenance Manual
1.2.3General 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
HEAT EXCHANGERS
(EVAPORATORS)
HEAT EXCHANGERS
(CONDENSERS- NOTE 1)
RECEIVERS
(BEHIND COMPRESSORS)
SCROLL COMPRESSORS
NOTE 1: PROVIDED WITH
WATER/GLYCOL COOLED UNITS.
Figure 1- Typical Layout
1.2.3.1Electric Box Access
The electrical components are protected behind dual
hinged access doors located on the left side of the
unit. The access doors are safety interlocked with the
service disconnect switch preventing the doors from
opening when the switch in the “On” position. The
switch must be turned “Off” to gain access to the
electrical components.
1.2.3.2Circuit Breakers/ Motor Start Protectors
Individual overload protection is provided by circuit
breaker(s) and motor start protectors. These switches
must be manually re-set once the overload condition is
cleared.
1.2.3.3Pumps
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.
AIR VENT
AIR SEPARATOR
EXPANSION TANK
(BEHIND PUMP #2)
PUMP #2
(OPTIONAL)
PUMP #1
1.2.3.4Expansion T ank
An expansion tank has been provided on the chilled
water side of the unit to compensate for thermal
expansion of the coolant. An air vent is mounted on
top of the fluid separator .
1.2.3.5Heat Exchangers
Constructed of 316 stainless steel with brazed plate fin
construction, the evaporator heat exchangers are for
the exchange of heat from the process water/glycol
coolant to the refrigerant.
1.2.3.6Receivers
Receivers are provided for each refrigeration circuit for
storage of excess refrigerant in the refrigeration cycle.
1.2.3.7Compressors
The compressors used in this unit are scroll compressors mounted inside the unit on vibration absorbers to
eliminate noise and vibration during operation. The
scroll compressor is designed around two identical
spirals or scrolls that, when inserted together, form
crescent shaped pockets. During a compression
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 discharged from a port in the center if the fixed scroll.
During each orbit, several pockets of gas are compressed simultaneously , creating smooth, nearly
continuous compression.
Due to the design of the scroll compressor, the internal
compression components always start unloaded even
if the system pressures are not balanced. In addition,
since internal compressor pressures are always
balanced at start-up, low voltage starting characteristics are excellent for scroll compressors
With fewer moving parts, the
scroll compressor sets the
industry standard for reliability among one and a half to
twelve horsepower compressors. The compressor’s
simple design and proven
day-to-day performance
means less maintenance
calls for field personnel.
The scroll compressor has
demonstrated superior
durability . Its axial and radial
compliance make the scroll
compressor more tolerant to liquid refrigerant and
debris - two of the most common causes of system
failure.
The scroll compressor is quiet, but not silent. On
average, the compressor is up to five decibels quieter
than standard piston compressors. A scroll compressor, however , has different sound characteristics from
reciprocating compressors. These sounds do not
affect system reliability or performance.
Upon shut-down of a normal run cycle, the compressor
will run backwards for one or two seconds as the
scrolls internal pressures are equalized. A short
reverse rotation “burp” will result. This sound is normal.
A check valve in the discharge tube of the 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 equipped with over current protection.
CAUTION
Prior to initial start-up (only when main power
has been disconnected for 12 hours or longer),
allow at least ten (10) minutes (two (2) hours is
recommended) with main power reconnected.
This will allow sufficient time for the crankcase
heaters to evaporate any liquid that may have
migrated to the compressor crankcase. When
this procedure is completed, the CyberChiller is
ready to be run.
Automatic, staged starting of the compressors is
provided to prevent an in rush of current to the
CyberChiller. High and low pressure safety switches
prevent operation of the compressor during high or low
pressure conditions.
1.2.3.8Strainer
A “Y” strainer is included to remove any debris that
may be circulated to the chiller.
1.2.4Safety Features
Low and high-pressure switches are provided for each
refrigeration circuit. The pressure switches are nonadjustable encapsulated control switches. If a high
pressure switch is tripped for any reason, it must be
manually reset. The cause for tripping of the high
pressure switch must be determined. The low pressure
switches are reset automatically . These pressure
switches are installed as safety devices and will help
prevent compressor failure or other serious damage to
the system.
A flow switch is provided which will disable the refrigeration circuits if the coolant flow drops below a preset limit.
A blocked flow bypass valve is recommended for field
installation to ensure proper return flow to the chiller at
all times.
Manual reset circuit breakers will open to de-energize
a failed component if electrical overload conditions are
encountered.
CyberChiller Series Installation, Operation & Maintenance Manual
1.3Product Warranty
SA TS offers a two year standard limited warranty as st ated 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 S tandard Limited Warranty:
Stulz Air Technology Systems, Inc., warrant s to the original buyer of it s
products that the goods are free from defects in material and workmanship.
Stulz Air Technology Systems, Inc.’s obligation under this warranty is to
repair or replace, at its option, free of charge to the customer , any part or
parts which are determined by S tulz Air Technology Systems Inc. to be
defective. The warranty is in effect for 24 months from date of shipment if a
completed Warranty Registration and S t art Up Form is submitted to S tulz Air
T echnology Systems, Inc. within 90 days from shipment. In the event that a
completed start-up form is not received by S tulz Air Technology Systems, Inc.
within 90 days from shipment, the company’s obligation will be for a period of
12 months from date of shipment. Parts replaced under warranty are warranted for a period of 90 days from shipment or for the remainder of the unit
warranty period, whichever is greater.
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 reinstallation of equipment or labor for repairs or replacement made in the field.
THIS OBLIGA TION AND LIABILITY OF STULZ AIR TECHNOLOGY SYSTEMS, INC. UNDER THIS WARRANTY DOES NOT INCLUDE LOSSES,
DIRECT OR INDIRECT , FOR INCIDENT AL OR CONSEQUENTIAL DAMAGES. THIS WARRANY IS IN LIEU OF ALL OTHER W ARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OR MERCHANT ABILITY AND FITNESS FOR A P ARTICULAR PURPOSE, AND THERE ARE NO
WARRANTIES THA T EXTEND BEYOND THE DESCRIPTION ON THE F ACE
HEREOF.
CyberChiller Series Installation, Operation & Maintenance Manual
Optional Limited Extended Warranty (5 Y ears T otal)
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 improper
installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence, accident, normal deterioration including normal wear and tear, or the use of
improper parts or improper repair as determined by SA TS.
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 or indirect, for incidental or consequential damages.
Compressor Serial No.: __________________________________
Unit Model No.: __________________________________
Unit Serial No.: __________________________________
Stulz Air T echnology Systems Job No.: __________________________________
CyberChiller Series Installation, Operation & Maintenance Manual
1.4Safety
1.4.1General
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.
A bold text CAUTION safety alert appears with
information that is important for protecting your
equipment and performance. Be especially careful to
read and follow all cautions that apply to your application.
A bold text WARNING safety alert appears with
information that is important for protecting you from
harm and the equipment from damage. Pay very
close attention to all warnings that apply to your
application.
A safety alert symbol
WARNING or CAUTION safety statement.
A safety alert symbol accompanies an electrical
shock hazard WARNING or CAUTION safety state-
ment.
accompanies a general
1.4.2Safety Summary
The following statements are general guidelines
followed by warnings and cautions applicable
throughout the manual.
Prior to performing any installation, operation, maintenance or troubleshooting procedure read and understand all instructions, recommendations and guidelines contained within this manual.
CAUTION
All maintenance and/or repairs must be performed 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 warning may result in injury to personnel and damage to the equipment.
CAUTION
Do not allow anyone under the equipment suspended from a lifting sling.
W ARNING
High voltage is used in the operation of this
equipment. Death on contact may result if
personnel fail to observe safety precautions.
CAUTION
When working on electrical equipment, remove
all jewelry , watches, rings, etc. Keep one hand
away from the equipment to reduce the hazard
of current flowing through vital organs of the body .
CAUTION
Always disconnect the main power supply to
the equipment at the main power disconnect
switch before beginning work on the equipment.
A lock-out tag-out procedure should be followed
to ensure that power is not inadvertently reconnected.
CAUTION
Equipment may contain components subject to
Electrostatic Discharge (ESD). Before attempting to mount or service these electronic devices,
ensure you have no charge built up by touching
a ground source. When possible, use a wristgrounding strap when working on or near electronic devices.
CAUTION
Never work on electrical equipment unless another person who is familiar with the operation
and hazards of the equipment and competent in
administering first aid is nearby .
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/stickers have been placed on the unit to call attention to all personal and equipment damage hazard areas.
CAUTION
Ensure the unit is properly phased. Improper
phasing can cause severe damage to the compressor.
W ARNING
Refrigerant (R-22 or R-407C) is used with this
equipment. Death or serious injury may result if
personnel fail to observe proper safety precautions. Great care must be exercised to prevent
contact of liquid refrigerant or refrigerant gas, discharged under pressure, with any part of the
body . The extremely low temperature resulting
from the rapid expansion of liquid refrigerant or
pressurized gas can cause sudden and irreversible tissue damage.
As a minimum, all personnel should wear thermal protective gloves and face-shield/goggles
when working with refrigerant. Application of excessive heat to any component will cause extreme pressure and may result in a rupture.
Exposure of refrigerant to an open flame or a
very hot surface will cause a chemical reaction
that will form carbonyl chloride (hydrochloric/hydrofluoric acid); a highly poisonous and corrosive gas commonly referred to as PHOSGENE.
In its natural state, refrigerant is a colorless, odorless vapor with 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 provided with the unit.
W ARNING
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 ventilated. Wear protective goggles or glasses to
protect eyes. Wear rubber gloves to protect
hands. Use care to avoid spilling compressor
burnout sludge. If sludge is spilled , clean area
thoroughly.
W ARNING
When performing soldering or desoldering operations, make certain the refrigeration system
is fully recovered and purged and dry nitrogen is
flowing through the system at the rate of not
less than 1-2 CFM (.03 - .06 M³/minute).
CAUTION
Certain maintenance or cleaning procedures
may call for the use and handling of chemicals,
solvents, or cleansers. Always refer to the
manufacturer's Material Safety Data Sheet
(MSDS) prior to using these materials. Clean
parts in a well-ventilated area. Avoid inhalation
of solvent fumes and prolonged exposure of skin
to cleaning solvents. Wash exposed skin thoroughly after contact with solvents.
CAUTION
Do not use cleaning solvents near open flame or
excessive heat. Wear eye protection when blowing solvent from parts. The pressure-wash should
not exceed 30 psig. Solvent solutions should be
disposed of in accordance with local and state
regulatory statutes.
CAUTION
Units must be kept in its normal installed position. If the unit is not kept level and vertical,
damage to the unit's compressors will result.
CyberChiller Series Installation, Operation & Maintenance Manual
2.0INSTALLATION
2.1Receiving the Equipment
Your CyberChiller system has been tested and
inspected prior to shipment. T o ensure that your
equipment has been received in excellent condition,
make a visual inspection of the equipment immediately upon delivery . Carefully remove the shipping
container and all protective packaging. Open the
access doors and thoroughly inspect the unit interior
for any signs of transit-incurred damage. If there is
shipping damage, it must be noted on the freight
carrier's delivery forms BEFORE signing for the
equipment. Any freight claims MUST be done through
the freight carrier. SATS ships all equipment FOB
factory . SA TS is not liable for any equipment damage
while in transit. SA TS can assist in the claim filing
process with the freight carrier. Should any such
damage be present, notify the SA TS Product Support
Group prior to attempting any repairs. Refer to section
five of this manual for instructions.
Check the equipment against the packing slip to see if
the shipment is complete. Report all discrepancies to
appropriate authority .
A Data Package has been sent with your unit. It
contains this manual, a supplemental microprocessor
controller manual, system drawings, applicable
MSDS’s, other component manuals, warranty registration and other applicable instructions based on the
configuration and options of your unit. The 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
Working clearance requirements need to be established prior to the mounting of the unit. Refer
to local and national electrical codes.
2.3Rigging
The CyberChiller systems are designed to be kept in
the vertical position. Move the unit with a suitable
device such as a forklift, pallet jack or roller bar and
dollies. Weight tables are provided on the installation
drawings. Units are shipped on a skid to facilitate
moving prior to installation. Units should always be
stored indoors in a dry location prior to installation.
CAUTION
Units must be kept level and in the vertical position when lifting to prevent damage to the unit.
2.4Mounting/Placement
Position unit in the desired location. CyberChiller
systems are 100% front accessible, which allows the
units to be placed in a corner or between cabinetry .
(See Figure 2.)
NOTE
Allow access to the unit for routine operation,
servicing and for necessary maintenance.
NOTE
Items that have been shipped loose, such as
controllers, temperature sensors, water detectors, 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 immediately .
2.2Site Preparation
CyberChiller systems are designed with easy service
access in mind. Component access doors are located
on the front of the unit.
In order to have full service access through the front,
no permanent obstructions should be placed within 40
inches of the front of unit.