ATS CyberChiller Series 40

CyberChiller Series Installation, Operation & Maintenance Manual

(©October, 2006)

Contents

Page AR = Air-CooledRemote (Split) CCH = CyberChiller System Nominal Capacity in 1,000’s of BTU/Hr D ( ) = Dual (Two) Circuit System Introduction Installation Start-Up/Commissioning Maintenance/Repairs Product Support Group List of Figures Appendix A- Forms Appendix B - Glossary 1.2.1Capabilities and Features 1.2.2Application Ranges 1.2.3General Design 1.2.4Safety Features 1.3Product Warranty 2-YearStandard Limited Warranty: Optional Limited Extended Warranty (5 Years Total) 1.4.1General 1.4.2Safety Summary Page 2.0INSTALLATION 2.1Receiving the Equipment BEFORE MUST 2.2Site Preparation 2.4.1Indoor Equipment 2.4.3Pump Package Installation (Water - Glycol Systems 2.4.2Outdoor Equipment 2.4.4Optional Equipment (Field Installed) 2.5.1Process Supply Fluid Lines 2.5.2Refrigerant Equivalent Length (ft) of Straight Pipe Recommended Liquid Line Sizes (For R-22or R-407CRefrigerant) Recommended Discharge Line Sizes (For R-22or R-407CRefrigerant) 2.5.2.2Water/Glycol Fluid Cooled Systems 2.5.3Pump Package 2.6.1Main Power Figure 5- Sample Nameplate 2.6.2Controls 2.6.3Optional Equipment 2.6.4Interconnecting Field Wiring Figure 7- Interconnecting Field Wiring Remote Condenser 2.6.4.1Air-CooledSplit System Remote Condenser 2.6.4.2Glycol Systems With Outdoor Fluid Pump Package 2.7.1Chilled Water Supply Charging Procedures (Evaporator Side) 2.7.2Outdoor Heat Exchanger Glycol Charging Procedures 2.7.3R-22Refrigerant Charging Procedures 2.7.4R407C Refrigerant Charging Procedures 2.7.5High/Low Pressure Limit Switch 2.7.6Head Pressure Controls 2.7.7Thermal Expansion Valve 2.7.8Hot Gas Bypass 2.8.1Pressure/Temperature Settings 2.8.2Saturated Refrigerant Pressure Tables 3.2.1Operational Description 3.2.1.4Water/Glycol Outdoor Fluid Cooler 3.3 Microprocessor Controller Programming 4.1.2Compressor 4.1.3Outdoor Condenser/Fluid Cooler 4.1.1General 4.2Troubleshooting SYMPTOM PROBABLE CAUSE RECOMMENDATION Unit Fails to Start Condenser Pressure too High too Low Noisy Compressor DO NOT REWIRE COMPRESSOR Head Pressure is too Low Suction Pressure too Low Compressor Fails to Start System Short of Capacity Compressor Short Cycles 4.3.1Leak Detection 4.3.2Leak Repair 4.3.3Refrigerant Piping 4.3.4General Common Repairs/ Component Replacement VOID THE COMPRESSOR WARRANTY 4.3.4.1.1Standard Cleanout Procedure 4.3.4.1.2Burn-Out/AcidicCleanup Procedure 5.0PRODUCT SUPPORT GROUP 5.1 Technical Support 5.2 Obtaining Warranty Parts 5.3 Obtaining Spare/Replacement Parts CyberChiller Series Checklist for Completed Installation Page CyberChiller Series Periodic General Maintenance Checks and Services Checklist Monthly Miscellaneous Semi-Annually Page Definition of Terms and Acronyms SATS MSDS BTU/Hr NEC