CyberChiller Series Installation, Operation & Maintenance Manual

TABLE OF CONTENTS

1.0

Introduction .......................................

1-1

1.1

General ......................................................

1-1

1.2

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

1.3

Product Warranty ......................................

1-4

1.4

Safety ........................................................

1-6

1.4.1

General ......................................................

1-6

1.4.2

Safety Summary ........................................

1-6

2.0

Installation .........................................

2-1

2.1

Receiving the Equipment. ..........................

2-1

2.2

Site Preparation .........................................

2-1

2.3

Rigging ......................................................

2-1

2.4

Mounting/Placement ..................................

2-1

2.4.1

Indoor Equipment .......................................

2-2

2.4.2

Outdoor Equipment ....................................

2-2

2.4.3Pump Package Installation (Water - Glycol

 

Systems ....................................................

2-2

2.4.4

Optional Equipment (Field Installed) ..........

2-2

2.4.4.1

Remote Display .........................................

2-2

2.4.4.2

Remote Water Detector .............................

2-2

2.5

Piping Connections ....................................

2-3

2.5.1

Process Supply Fluid Lines .......................

2-3

2.5.2

Refrigerant .................................................

2-3

2.5.2.1

Split Air Cooled Systems ...........................

2-3

2.5.2.2

Water/Glycol Fluid Cooled Systems ..........

2-4

2.5.3

Pump Package ..........................................

2-5

2.6

Utility Connections ....................................

2-5

2.6.1

Main Power ...............................................

2-5

2.6.2

Controls .....................................................

2-7

2.6.3

Optional Equipment ...................................

2-7

2.6.3.1

Remote Water Detector .............................

2-7

2.6.4

Interconnecting Field Wiring .......................

2-7

2.6.4.1Air-Cooled Split Systems

Remote Condenser ....................................

2-8

2.6.4.2Glycol Systems with Outdoor Fluid Pump

 

Package ....................................................

2-8

2.7

System Settings and Adjustments .............

2-9

2.7.1Chilled Water Supply Charging

Procedures (Evaporator Side) ....................

2-9

2.7.2Outdoor 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

2.7.6.1

Air-Cooled Systems .................................

2-13

2.7.6.2

Water/Glycol Cooled Systems .................

2-13

2.7.7

Thermal Expansion Valve .........................

2-13

2.7.8

Hot Gas Bypass ......................................

2-13

2.8

Refrigerant Characteristics .......................

2-14

2.8.1

Pressure/Temperature Settings ................

2-14

2.8.2

Saturated Refrigerant Pressure Tables .....

2-14

3.0

Start-Up/Commissioning ..................

3-1

3.1

Operation ...................................................

3-1

3.2

Step by Step Start-Up Instructions .............

3-1

3.2.1

Operational Description..............................

3-1

3.3Microprocessor Controller

 

Programming .............................................

3-2

4.0

Maintenance/Repairs .......................

4-1

4.1

Periodic General Maintenance ...................

4-1

4.1.1

General ......................................................

4-1

4.1.2

Compressor ...............................................

4-1

4.1.3

Outdoor Condenser/Fluid Cooler ................

4-1

4.2

Troubleshooting .........................................

4-2

4.3

Field Service ..............................................

4-5

4.3.1

Leak Detection ..........................................

4-5

4.3.2

Leak Repair ...............................................

4-5

4.3.3

Refrigerant Piping ......................................

4-5

4.3.4General Common Repairs/

Component Replacement ...........................

4-5

4.3.4.1 Compressor Failure ...................................

4-5

5.0

Product Support Group ...................

5-1

5.1

Technical Support ......................................

5-1

5.2

Obtaining Warranty Parts ..........................

5-1

5.3

Obtaining Spare/Replacement Parts ..........

5-1

(©October, 2006)

 

 

 

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