ATS CyberChiller Series Manual

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
MODEL NOMENCLATURE
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

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CyberChiller Series Installation, Operation & Maintenance Manual
1.0 Introduction.......................................1-1
1.1 General...................................................... 1-1
1.2 ProductDescription ................................... 1-1
1.2.1 CapabilitiesandFeatures .......................... 1-1
1.2.2 ApplicationRanges.................................... 1-1
1.2.3 GeneralDesign .......................................... 1-2
1.2.4 SafetyFeatures ......................................... 1-3
1.3 ProductWarranty ...................................... 1-4
1.4 Safety........................................................ 1-6
1.4.1 General...................................................... 1-6
1.4.2 SafetySummary........................................ 1-6
2.0 Installation .........................................2-1
2.1 Receivingthe Equipment. .......................... 2-1
2.2 SitePreparation......................................... 2-1
2.3 Rigging ...................................................... 2-1
2.4 Mounting/Placement.................................. 2-1
2.4.1 IndoorEquipment....................................... 2-2
2.4.2 OutdoorEquipment.................................... 2-2
2.4.3 Pump Package Installation (Water - Glycol
Systems.................................................... 2-2
2.4.4 OptionalEquipment(Field Installed) .......... 2-2
2.4.4.1 RemoteDisplay ......................................... 2-2
2.4.4.2 RemoteWater Detector ............................. 2-2
2.5 PipingConnections.................................... 2-3
2.5.1 Process Supply Fluid Lines ....................... 2-3
2.5.2 Refrigerant ................................................. 2-3
2.5.2.1 SplitAir Cooled Systems ........................... 2-3
2.5.2.2 Water/Glycol Fluid Cooled Systems .......... 2-4
2.5.3 PumpPackage .......................................... 2-5
2.6 Utility Connections .................................... 2-5
2.6.1 MainPower ............................................... 2-5
2.6.2 Controls..................................................... 2-7
2.6.3 OptionalEquipment ................................... 2-7
2.6.3.1 RemoteWater Detector ............................. 2-7
2.6.4 InterconnectingFieldWiring....................... 2-7
2.6.4.1 Air-Cooled Split Systems
RemoteCondenser .................................... 2-8
2.6.4.2 Glycol Systems with Outdoor Fluid Pump
Package .................................................... 2-8
2.7 System Settings and Adjustments............. 2-9
TABLE OF CONTENTS
2.7.1 ChilledWaterSupplyCharging
Procedures(EvaporatorSide) .................... 2-9
2.7.2 OutdoorHeatExchanger Glycol Charging
Procedures .............................................. 2-10
2.7.3 R-22RefrigerantChargingProcedures ......2-11
2.7.4 R-407CRefrigerantChargingProcedures ..2-11
2.7.5 Low/HighPressure Limit Switch .............. 2-12
2.7.6 HeadPressureControls........................... 2-13
2.7.6.1 Air-CooledSystems................................. 2-13
2.7.6.2 Water/Glycol Cooled Systems................. 2-13
2.7.7 ThermalExpansionValve......................... 2-13
2.7.8 Hot Gas Bypass ...................................... 2-13
2.8 RefrigerantCharacteristics....................... 2-14
2.8.1 Pressure/TemperatureSettings................ 2-14
2.8.2 SaturatedRefrigerantPressureTables ..... 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 OperationalDescription.............................. 3-1
3.3 MicroprocessorController
Programming ............................................. 3-2
4.0 Maintenance/Repairs .......................4-1
4.1 PeriodicGeneralMaintenance ................... 4-1
4.1.1 General...................................................... 4-1
4.1.2 Compressor ............................................... 4-1
4.1.3 OutdoorCondenser/FluidCooler ................ 4-1
4.2 Troubleshooting ......................................... 4-2
4.3 FieldService .............................................. 4-5
4.3.1 LeakDetection .......................................... 4-5
4.3.2 LeakRepair ............................................... 4-5
4.3.3 RefrigerantPiping ...................................... 4-5
4.3.4 GeneralCommonRepairs/
ComponentReplacement........................... 4-5
4.3.4.1 CompressorFailure ................................... 4-5
5.0 Product Support Group ...................5-1
5.1 TechnicalSupport ...................................... 5-1
5.2 Obtaining WarrantyParts .......................... 5-1
5.3 ObtainingSpare/ReplacementParts .......... 5-1
i

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CyberChiller Series Installation, Operation & Maintenance Manual
ii
List of Figures
Figure1- TypicalLayout ........................................ 1-2
Figure2- TypicalInstallation .................................. 2-1
Figure3- Typical PipingAir Cooled Systems ......... 2-3
Figure4- Typical Piping Water/GlycolCooled
Systems ................................................ 2-5
Figure5- SampleNameplate ................................. 2-6
Figure6- Electric Box ........................................... 2-7
Figure7- InterconnectingFieldWiring
RemoteCondenser................................. 2-8
Figure8- InterconnectingFieldWiring
Glycol Systems...................................... 2-9
AppendixA- Forms
Checklistfor Completed Installation .........................A-1
PeriodicGeneralMaintenance
Checksand Service Checklist..................................A-2
Appendix B - Glossary
DefinitionofTerms andAcronyms ............................B-1

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CyberChiller Series Installation, Operation & Maintenance Manual
1-1
1.0 INTRODUCTION
1.1 General
Congratulations,the CyberChiller™ floormounted
liquid chiller system covered by this manual is de-
signed 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 materi-
als 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. Spare parts
are available from Stulz Air Technology 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
leavingfluid temperature forfluidcooled equipment
such as server racks, MRI’s, precision cooling units or
other devices. Any use beyond this is deemed to be
not intended. SATS 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.
1.2 Product 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 non-
residential 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
providedunder separate cover. Refertothat manual for
detailed instructions on operating the system control-
ler provided with your unit.
The standard controller for the CyberChiller unit is the
C6000microprocessor, which providesthe 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.
1.2.1 Capabilities and Features
DualRefrigeration Circuits
ConstantRunning Compressor
Vibration Isolation of Compressor
Electronic Hot Gas Bypass
(With control based on the chilled water supply
temperature.)
HeavyGauge Cabinet Construction
High Density Sound & Thermal Insulation
1.2.2 Application Ranges
The SATS CCH Modular Line Chiller Units are de-
signed 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.

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
1.2.3 General Design
TheCyberChiller isdivided into 3areas; apump section, a refrigeration sectionand 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.
PUMP #2
(OPTIONAL)
SCROLL COMPRESSORS
HEAT EXCHANGERS
(EVAPORATORS)
ELECTRIC BOX
RECEIVERS
(BEHIND COMPRESSORS)
EXPANSION TANK
(BEHIND PUMP #2)
AIR VENT
HEAT EXCHANGERS
(CONDENSERS- NOTE 1)
NOTE 1: PROVIDED WITH
WATER/GLYCOL COOLED UNITS.
PUMP #1
AIR SEPARATOR
Figure 1- Typical Layout
1.2.3.1 ElectricBox Access
Theelectrical components areprotectedbehind dual
hinged access doors located on the left side of the
unit. The access doors are safety interlocked with the
servicedisconnectswitch preventing thedoorsfrom
openingwhen theswitch in the“On” position.The
switch must be turned “Off” to gain access to the
electricalcomponents.
1.2.3.2 CircuitBreakers/MotorStart Protectors
Individualoverloadprotectionisprovided by circuit
breaker(s)and motor startprotectors. Theseswitches
mustbe manuallyre-set oncethe overload condition is
cleared.
1.2.3.3 Pumps
Multi-stagecentrifugal pumpsare located inthe right
side of the unit to circulate the coolant through the
system.Ahinged 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
Anexpansion tank hasbeen providedon the chilled
water side of the unit to compensate for thermal
expansion of the coolant.An air vent is mounted on
topof the fluidseparator.
1.2.3.5 Heat Exchangers
Constructed of 316 stainless steel with brazed plate fin
construction,theevaporator heat exchangersarefor
theexchange ofheat from theprocess water/glycol
coolantto the refrigerant.
1.2.3.6 Receivers
Receiversareprovidedforeachrefrigerationcircuit for
storageof excess refrigerantin therefrigerationcycle.
1.2.3.7 Compressors
The compressors used in this unit are scroll compres-
sorsmounted inside theunit onvibration absorbers to
eliminatenoiseandvibrationduring operation. The
scrollcompressor isdesigned around twoidentical
spirals or scrolls that, when inserted together, form
crescentshaped pockets.During acompression
1-2

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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 dis-
charged from a port in the center if the fixed scroll.
Duringeach orbit, several pockets ofgas are com-
pressedsimultaneously, creating smooth,nearly
continuouscompression.
Due to the design of the scroll compressor, the internal
compressioncomponentsalways start unloadedeven
if the system pressures are not balanced. In addition,
sinceinternal compressor pressuresare always
balancedat start-up, lowvoltage starting characteris-
tics are excellent for scroll compressors
Withfewer moving parts,the
scroll compressor sets the
industrystandardfor reliabil-
ity among one and a half to
twelvehorsepowercompres-
sors.The compressor’s
simpledesignandproven
day-to-dayperformance
meansless maintenance
callsfor field personnel.
Thescroll compressor has
demonstratedsuperior
durability. Its axial and radial
compliance make the scroll
compressormoretolerant to liquidrefrigerant and
debris - two of the most common causes of system
failure.
The scroll compressor is quiet, but not silent. On
average,the compressor isup to fivedecibelsquieter
than standard piston compressors. Ascroll compres-
sor,however,has differentsoundcharacteristics from
reciprocatingcompressors. These soundsdo not
affectsystem reliability orperformance.
Uponshut-down ofa normal runcycle, thecompressor
will run backwards for one or two seconds as the
scrolls internal pressures are equalized. Ashort
reverserotation “burp” willresult. This soundis normal.
Acheck valve in the dischargetube of thecompressor
preventsthecompressorfrom running backwards for
morethan a second or two. This normal direction
reversal of the scrolls at shut down has no effect on
compressorreliability.
Each scroll compressor comes equipped with a
crankcaseheater, usedto evaporateany liquid that
mayhave migrated tothecompressor during extended
periodsonnon-operation (>12 hours). Thecrankcase
heatersareequipped with over currentprotection.
CAUTION
Prior to initial start-up (only when main power
hasbeen disconnectedfor 12 hoursor 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
thisprocedureis completed, theCyberChilleris
ready to be run.
Automatic, staged starting of the compressors is
providedto prevent anin rush ofcurrentto the
CyberChiller.High and lowpressure safety switches
preventoperationof the compressorduringhighor low
pressureconditions.
1.2.3.8 Strainer
A “Y” strainer is included to remove any debris that
may be circulated to the chiller.
1.2.4 Safety Features
Lowandhigh-pressureswitches are providedforeach
refrigerationcircuit. The pressureswitchesare non-
adjustableencapsulated control switches. If ahigh
pressure switch is tripped for any reason, it must be
manuallyreset. The cause for trippingof the high
pressureswitch must bedetermined. Thelowpressure
switchesare resetautomatically. These pressure
switches are installed as safety devices and will help
preventcompressorfailure or otherseriousdamageto
the system.
Aflow switch isprovided which willdisable therefrig-
eration circuits if the coolant flow drops below a pre-
set limit.
Ablockedflow bypass valveisrecommended for field
installationto ensure proper return flow to thechiller at
all times.
Manual reset circuitbreakers will opento de-energize
afailed component ifelectricaloverload conditions are
encountered.
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CyberChiller Series Installation, Operation & Maintenance Manual
1-4
2-Year StandardLimited Warranty:
StulzAir Technology Systems, Inc., warrants to the original buyer of its
productsthat thegoods are freefrom defectsin material andworkmanship.
StulzAir 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 StulzAirTechnology Systems Inc. to be
defective.The warrantyis in effectfor 24months from dateof shipmentif a
completed Warranty Registration and Start Up Form is submitted to StulzAir
Technology Systems, Inc. within 90 days from shipment. In the event that a
completed start-up form is not received by StulzAir Technology Systems, Inc.
within 90 days from shipment, the company’s obligation will be for a period of
12months from dateof shipment. Partsreplaced under warrantyare war-
rantedfor aperiod of 90days fromshipment or forthe remainderof the unit
warrantyperiod,whicheverisgreater.
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,normaldeteriorationincludingwearandtear,
or the use of improper parts or improper repair as determined by SATS. This
warrantydoesnot include costs fortransportation,costsfor removal orreinstal-
lationof equipment orlabor for repairsor replacementmadein thefield.
THISOBLIGATIONANDLIABILITYOFSTULZAIRTECHNOLOGYSYS-
TEMS,INC.UNDERTHIS WARRANTY DOES NOTINCLUDELOSSES,
DIRECTORINDIRECT, FORINCIDENTALORCONSEQUENTIALDAM-
AGES. THIS WARRANYIS IN LIEU OFALL OTHER WARRANTIES,
EXPRESSORIMPLIED,INCLUDINGWARRANTIESORMERCHANTABIL-
ITYANDFITNESSFORAPARTICULARPURPOSE,ANDTHEREARE NO
WARRANTIESTHATEXTENDBEYONDTHEDESCRIPTIONONTHEFACE
HEREOF.
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1.3 Product Warranty
SATS offers a two year standard limited warranty as stated below.Additionally an extended warranty may be
purchasedon theunit's compressors. Consultthe factoryto verify if the extendedcompressor warrantywas
purchased for your system. The compressor warranty as stated on the next page will be sent with your unit and
shouldberetainedforfuture reference.

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CyberChiller Series Installation, Operation & Maintenance Manual
1-5
OptionalLimitedExtended Warranty(5Years Total)
Stulz Air Technology Systems, Inc., warrants to the original buyer of its product that
thecompressor(s)listedbelowarewarrantedforpartsreplacement(notincluding
labor)forextendedperiodof4yearsfromthedateofexpirationofthestandard
equipmentwarranty.
Stulz Air Technology Systems' warranty does not cover failures caused by improper
installation, abuse, misuse, misapplication, improper or lack of maintenance, negli-
gence, accident, normal deterioration including normal wear and tear, or the use of
improperpartsorimproper repairas determined bySATS.
Thiswarranty does notinclude costs oftransportation, cost forremoval 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.: __________________________________
StulzAir Technology Systems Job No.: __________________________________
End User: __________________________________
Date: __________________________________
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CyberChiller Series Installation, Operation & Maintenance Manual
1-6
1.4 Safety
1.4.1 General
StulzAir Technology Systems, Inc. uses NOTES
alongwith CAUTION and WARNING symbolsthrough-
out this manual to draw your attention to important
operationalandsafetyinformation.
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 applica-
tion.
Abold 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 accompanies a general
WARNINGor CAUTION safety statement.
A safety alert symbol accompanies an electrical
shock hazard WARNING or CAUTION safety state-
ment.
1.4.2 Safety Summary
The following statements are general guidelines
followed by warnings and cautions applicable
throughout the manual.
Prior to performing any installation, operation, mainte-
nance or troubleshooting procedure read and under-
stand all instructions, recommendations and guide-
lines contained within this manual.
CAUTION
All maintenance and/or repairs must be per-
formedbyajourneyman,refrigerationmechanic
oran air conditioning technician.
CAUTION
Neverliftanycomponentin excess of35pounds
withouthelp.If aliftingdevice is usedtomove a
unit ensure it is capable of supporting the unit.
CAUTION
Do not allow the unit to swing while suspended
fromaliftingdevice.Failuretoobservethiswarn-
ing may result in injury to personnel and dam-
ageto the equipment.
CAUTION
Do not allow anyone under the equipment sus-
pendedfrom a liftingsling.
WARNING
High voltage is used in the operation of this
equipment. Death on contact may result if
personnelfailtoobservesafetyprecautions.
CAUTION
Whenworking on electricalequipment,remove
all jewelry, watches, rings, etc. Keep one hand
away from the equipment to reduce the hazard
ofcurrentflowingthroughvitalorgansofthebody.
CAUTION
Always disconnect the main power supply to
the equipment at the main power disconnect
switchbeforebeginningworkontheequipment.
Alock-outtag-outprocedureshouldbefollowed
toensure that poweris not inadvertentlyrecon-
nected.
CAUTION
Equipmentmay contain componentssubject to
ElectrostaticDischarge (ESD). Beforeattempt-
ingtomountorservicetheseelectronicdevices,
ensureyou have nochargebuilt up bytouching
a ground source. When possible, use a wrist-
grounding strap when working on or near elec-
tronicdevices.
CAUTION
Never work on electrical equipment unless an-
other person who is familiar with the operation
andhazardsoftheequipmentand competent in
administering first aid is nearby.

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CyberChiller Series Installation, Operation & Maintenance Manual
1-7
CAUTION
All personnel working on or near equipment
shouldbe familiar withhazardsassociated with
electrical maintenance. Safety placards/stick-
ers have been placed on the unit to call atten-
tiontoallpersonal and equipment damagehaz-
ardareas.
CAUTION
Ensure the unit is properly phased. Improper
phasingcan cause severedamage tothe com-
pressor.
WARNING
Refrigerant (R-22 or R-407C) is used with this
equipment.Death or seriousinjury may resultif
personnelfail toobserve proper safetyprecau-
tions. Great care must be exercised to prevent
contactofliquidrefrigerantorrefrigerantgas,dis-
charged under pressure, with any part of the
body. The extremely low temperature resulting
fromthe rapidexpansion of liquid refrigerant or
pressurizedgascancausesuddenandirrevers-
ibletissue damage.
As a minimum, all personnel should wear ther-
mal protective gloves and face-shield/goggles
whenworkingwithrefrigerant.Application of ex-
cessive heat to any component will cause ex-
treme pressure and may result in a rupture.
Exposure of refrigerant to an open flame or a
very hot surface will cause a chemical reaction
thatwillformcarbonylchloride(hydrochloric/hy-
drofluoric acid); a highly poisonous and corro-
sivegascommonly referred to asPHOSGENE.
Initsnaturalstate,refrigerantisacolorless,odor-
less vapor with no toxic characteristics. It is
heavier than air and will disperse rapidly in a
well-ventilated area. In an unventilated area, it
presentsa dangeras a suffocant.
Always refer to the manufacturer's MSDS pro-
videdwith 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 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.
WARNING
When performing soldering or desoldering op-
erations, make certain the refrigeration system
isfullyrecoveredandpurgedanddrynitrogenis
flowing through the system at the rate of not
less than 1-2 CFM (.03 - .06 M³/minute).
CAUTION
Certain maintenance or cleaning procedures
maycall forthe useand handlingof 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
ofsolventfumesandprolonged exposureofskin
to cleaning solvents. Wash exposed skin thor-
oughlyafter contact with solvents.
CAUTION
Donotusecleaningsolventsnearopenflameor
excessiveheat.Weareyeprotectionwhenblow-
ingsolventfromparts.Thepressure-washshould
notexceed30psig. Solvent solutions shouldbe
disposed of in accordance with local and state
regulatorystatutes.
CAUTION
Units must be kept in its normal installed posi-
tion. If the unit is not kept level and vertical,
damage to the unit's compressors will result.

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CyberChiller Series Installation, Operation & Maintenance Manual
2-1
2.0 INSTALLATION
2.1 Receiving the Equipment
Your CyberChiller system has been tested and
inspected prior to shipment. To ensure that your
equipment has been received in excellent condition,
make a visual inspection of the equipment immedi-
ately upon delivery. Carefully remove the shipping
containerand all protectivepackaging.Open the
access doors and thoroughly inspect the unit interior
forany signs oftransit-incurred damage.If there is
shipping damage, it must be noted on the freight
carrier'sdeliveryformsBEFORE signingfor the
equipment.Anyfreight claimsMUST be done through
the freight carrier. SATS ships all equipment FOB
factory. SATS is not liable for any equipment damage
while in transit. SATS can assist in the claim filing
process with the freight carrier. Should any such
damagebe present,notify the SATS ProductSupport
Groupprior toattempting any repairs.Refer tosection
fiveof this manualfor instructions.
Check the equipment against the packing slip to see if
the shipment is complete. Report all discrepancies to
appropriateauthority.
A Data Package has been sent with your unit. It
containsthis manual, a supplemental microprocessor
controllermanual, system drawings,applicable
MSDS’s,other component manuals,warranty registra-
tion and other applicable instructions based on the
configurationand options ofyourunit. Thedata
package has been placed in your unit in a clear plastic
envelope.These documents needto be keptwith the
unitforfuturereference.
NOTE
Items that have been shipped loose, such as
controllers, temperature sensors, water detec-
tors,etc., areshipped inside theair conditioner
unless specified otherwise by the customer.
Unpack and store these items in a safe place
unless you are using them immediately.
2.2 Site Preparation
CyberChillersystems are designedwith easyservice
access in mind. Component access doors are located
on the front of the unit.
Inorder to havefull service accessthrough the front,
nopermanent obstructions shouldbe placedwithin 40
inches of the front of unit.
NOTE
Workingclearancerequirementsneedto be es-
tablishedpriorto the mountingoftheunit. Refer
to local and national electrical codes.
2.3 Rigging
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 onthe installation
drawings. Units are shipped on a skid to facilitate
movingprior toinstallation. Units should always be
stored indoors in a dry location prior to installation.
CAUTION
Unitsmustbe kept levelandin the verticalposi-
tionwhen liftingto prevent damageto theunit.
2.4 Mounting/Placement
Positionunit inthe desired location. CyberChiller
systems are 100% front accessible, which allows the
units to be placed in a corner or between cabinetry.
(SeeFigure2.)
NOTE
Allow access to the unit for routine operation,
servicingandfor necessary maintenance.
Figure 2- Typical Installation

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-2
Thefollowinggeneralrequirements should be consid-
eredduringinstallation:
NOTE
Equipmentmust be levelto operate properly.
2.4.1 Indoor Equipment
TheCyberChiller systemuses a frameand panel
construction for unit rigidity and full service accessibil-
ity while the unit is mounted in place. The unit is
designed to be located directly on top of the floor or on
araised floor installation.Ensure themounting surface
isable tosupport theequipment. Beforemounting the
unit,refer tothe appropriate weighttables that are
providedinthe installation drawing.
2.4.2 Outdoor Equipment
Installthe remote condenser or fluid cooler ina secure
locationwhere the unit cannot betampered with and
themain power circuitbreakercannot beinadvertently
turnedoff. If possible,make use ofterrain features
suchas treesand buildingsto providea shaded
location. This will minimize the solar load on the unit.
Locatethe remote condenseror fluid coolerwhere the
coils are not likely to draw dirt and debris into the coil
fins. The clearance around the unit should be at least
1 times (1x) the unit’s width to ensure adequate airflow
to the coil.
Secure the condenser or fluid cooler so that the
systemwill not move during operation.Refer to the
installationdrawing for thenon-chargedsystem
weight.It isrecommended that theremote condenser/
fluidcoolerbe mounted withfieldsupplied vibration
mountsto reduce theamount of vibrationtransmitted
tothe mounting surface.
Referto the wiringdiagram for electricalconnections
andto the refrigerationdiagramfor piping details.
2.4.3 Pump Package Installation (Water -
Glycol Systems
Installthe pump in general accordancewith the piping
diagramprovided with theunit. The pumpshouldbe at
least 3 feet below the height of the expansion tank.
Do not form piping loops adjacent to the pump. Avoid
pipingvery rigid lines.
If the pump will be operated at reduced capacity,
a by-pass must be provided around the pump
suction and discharge connections to prevent
damage to the pump seals. Damage would result
frominsufficient liquid passingthroughthe pumpand
theheat of thepump vaporizing thebrine solutiondue
to the motor’s heat and the friction of the impeller
housing.
It is a good idea to install a pressure gauge in the
discharge line to check the pressure.
2.4.4 Optional Equipment (Field Installed)
NOTE
Do not mount any optional equipment on unit
access doors.
2.4.4.1 Remote Display
TheC6000 Microprocessor isthestandard controller
supplied with the CyberChiller systems.As an option a
factorysupplied controlpanel may beremotely
mounted.For mounting andwiring instructions, referto
thesystem drawings and the supplementalmanual
sent in the data package with your unit.
2.4.4.2 Remote Water Detector
Theoptional remote waterdetector(s) is normally
placedon thesub-floor or in a fieldsupplied auxiliary
drain pan located beneath the unit. It may be attached
usingdoublesided tape. Preparesurfacebefore
installing tape.Apply tape to the water detector and
secure in place.

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-3
2.5 Piping Connections
2.5.1 Process Supply Fluid Lines
Coolantfluid supply andreturn lines areconnected
fromthe equipment beingcooledto the CyberChiller
viacopper sweat fittingsprovided in thepump section.
2.5.2 Refrigerant
2.5.2.1 Split Air Cooled Systems
Split air-cooled systems with a remote condenser will
requirefield refrigeration piping.(SeeFigure 3.)All split
systems are shipped with a dry nitrogen charge of 50
psig.
Split systems coupled with a remote condensing unit
willrequire a copperdischarge anda copper liquidline.
Allrefrigeration piping shouldbe installed withhigh
temperaturesolderedjoints.Use standard refrigeration
practicesfor pipingsupports, leak testing,dehydration
andchargingofthe refrigeration circuits.Therefrigera-
tion piping should be isolated from the building by the
useofvibration isolating supports.To preventtube
damagewhen sealing openingsin walls andto reduce
vibrationtransmission, usea soft flexible material to
packaround the tubes.
Clearall pipe connectionsof debris andprepare the
connections for soldering. Use only "L" or "K" grade
refrigerantcopper piping. Becarefulnot to allow
solder/pipingdebris to getinside refrigerant lines.
Silversolder containing a minimum of15% silver is
recommended.Drynitrogenshould be flowingthrough
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
accordingtothe piping distancebetweenthe evapora-
torand the condenser.Each valve, fittingand bend in
the refrigerant line must be considered in this calcula-
tion.Referto the followingchartsfor standard equiva-
lent lengths, in feet, of straight pipe.
Oil traps must be included in the discharge line every
20feet in the vertical risersand the refrigerantlines
must be sloped ¼ inch for every 10 feet in the horizon-
tal lines to ensure proper oil return to the compressor.
Aninverted trap is required onthe discharge line of the
remotecondenser to helppreventoil and liquidfrom
floodingback tothe compressor.
VALVE
R
O
T
O
L
OCK
ROTOLOCK
S
ERVI
C
E P
O
R
T
S
ERVI
C
E P
O
R
T
RELIEF VALVE
PRE
SSU
R
E
(
OPTIONAL
)
S
EE N
O
TE
2
VALVE
ELE
C
TR
O
NI
C
H
O
T
G
A
S
BYPA
SS
EQ
UALIZER LINE
VALVE
EXPAN
S
I
ON
SO
LEN
O
ID VALV
E
LI
Q
UID LIN
E
S
I
G
HT
G
LA
SS
DRIER
/S
TRAINE
R
S
ERVI
CE
P
O
R
T
RE
C
EIVE
R
CO
NTR
OL
FAN
S
PEE
D
CO
NDEN
S
E
R
CS
INTER
CO
NNE
C
TIN
G
FIELD PIPIN
G
BY
O
THER
S
INTER
CO
NNE
C
TIN
G
FIELD PIPIN
G
BY
O
THER
S
H
O
T
G
A
S
SO
LEN
O
ID VALV
E
C
HE
CK
SC
HRADE
R
H
I
G
H PRE
SSU
R
E
LIMIT
S
WIT
CH
H
P
LO
W PRE
SSU
R
E
L
IMIT
S
WIT
CH
EVAP
2
)
PRESSURE RELIEF VALVE MUST BE PIPED TO EXIT THE CABINET
.
1
)
LOCATE AUTOMATIC AIR VENT AT HIGHEST POINT OF SYSTEM
.
N
O
TE
S:
INLET
OU
TLE
T
Figure 3- Typical Piping Air Cooled System

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-4
NOTE
In the following (3) charts, the line sizes repre-
sentthesizingforindividual refrigerationcircuits.
CyberChillerunitshavetwoseparatepairsofre-
frigerationlines.(One per compressor.)
*Equivalent Ft. accounts for the linear pipe length as well as
equivalent length of Valves, Elbows & Tee’s as shown in the
previous chart.
Equivalent Length (ft) of Straight Pipe
OD (In.) Globe Angle 90º 45º Tee Tee
Line Size Valve Valve Elbow Elbow Line Branch
1/2 9.0 5.0 0.9 0.4 0.6 2.0
5/8 12 6.0 1.0 0.5 0.8 2.5
7/8 15 8.0 1.5 0.7 1.0 3.5
1-1/8 22 12 1.8 0.9 1.5 4.5
1-3/8 28 15 2.4 1.2 1.8 6.0
1-5/8 35 17 2.8 1.4 2.0 7.0
2-1/8 45 22 3.9 1.8 3.0 10
2-5/8 51 26 4.6 2.2 3.5 12
3-1/8 65 34 5.5 2.7 4.5 15
3-5/8 80 40 6.5 3.0 5.0 17
NOTE
Vertical runs are based on a total rise of 30 equivalent
feet. For longer sizes, individual calculations must be
made. Sizes assume the use of single risers; double
risers may be necessary.
*Equivalent Ft. accounts for the linear pipe length as well as
equivalent length of Valves, Elbows & Tee’s as shown in the
previous charts.
2.5.2.2 Water/Glycol Fluid Cooled Systems
Pipingconnections for thewater/glycol fluidcoolers
are sweat connections. (See Figure 4.) Pipe sizes
may not necessarily be the same as the unit connec-
tion. Piping should be sized to match the system
pressuredrop and pump capacity andmay require a
reducing fitting to match the connection size on the
pumppackageandCyberChiller.
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, orwhere biologicalgrowth will be present, a
closed loop system is recommended. Untreated water
in the unit heat exchangers may cause, over a period
of time, a loss of heat exchange capacity due to a
mineraldeposit build-up inside the exchanger. Onlya
qualifiedservice mechanicshould cleanthese.
Glycol-cooledsystems with lowentering fluidtempera-
turesshouldhaveinsulated piping. Therecommended
ethylene glycol solution ratio is 40% glycol to 60%
water. (SATSrecommends Dowtherm SR1 manufac-
tured by Dow Chemical Co.) Use only ethylene glycol
withinhibitors for corrosionprotection.
Recommended Liquid Line Sizes
(For R-22 or R-407C Refrigerant)
Model No./ Receiver to Evaporator (Equivalent Ft.)*
Total Unit 50' 100' 150'
Capacity or less or less or less
120 / 120,000 1/2 5/8 5/8
210 / 210,000 5/8 7/8 7/8
260 / 260,000 7/8 7/8 7/8
320 / 320,000 7/8 7/8 7/8
Recommended Discharge Line Sizes
(For R-22 or R-407C Refrigerant)
Model No./ Equivalent Length Ft.*
Total Unit 50' 100' 150'
Capacity or less or less or less
120 / 120,000 7/8 1-1/8 1-1/8
210 / 210,000 1-1/8 1-1/8 1-3/8
260 / 260,000 1-1/8 1-3/8 1-3/8
330 / 330,000 1-1/8 1-3/8 1-3/8

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-5
WARNING
Glycolis hazardous. Consultthe manufacturer's
MSDSfor detailed safetyinformation.
CAUTION
When installing and filling the water/glycol loop all
air must be bled from the piping system and the
piping system must be cleaned prior to operating
the system. Failure to do so will result in equip-
mentproblems.
2.5.3 Pump Package
2.5.3.1 Suction Side Piping
Install a concentric reducer at the pump suction
openingand makeall suctionpiping atleast one-(1)
size larger than the diameter of the suction inlet. If
necessary, install a suction strainer with a net area 2-3
timeslarger than thesuction piping. Thepiping leaving
the drycooler should enter the pump suction port.
Installa ball valvein thesuction line formaintenance
purposes.
2.5.3.2 Discharge Side Piping
Install a concentric reducer at the pump discharge
openingand make alldischarge piping atleast one-(1)
size larger than the diameter of the discharge outlet.
Installa check valvein thedischarge line toprevent
back flow that may damage the pump on shut down.
Installa ball valvein the dischargelinefor maintenance
purposes.
2.6 Utility Connections
2.6.1 Main Power
TheCyberChillerproduct offering is available in208-
230VACsingle-phaseor 460 VAC three-phase
configurations.It is imperativethat theunit nameplate
beexaminedto determine theoperatingvoltage,
frequency and phase of the system. (See Figure 5.)
Thenameplate also providesthefull load amps(FLA),
the current that the unit will draw under full design
load, the minimum circuit ampacity (MCA) for wire
sizing, and the maximum fuse or HACR (Heating,Air
Conditioning,Refrigeration)breakersize (MAX FUSE/
A
Q
UASTA
T
VALVE
S
TRAINER
U
NI
O
N
FL
O
W BYPA
SS
VALVE
P
U
MP PA
C
KA
G
E
R
EM
O
TE DRY
COO
LER
AIR
TR
O
L
FITTIN
G
WATER/GLYCOL COOLED
CO
NDEN
S
E
R
C
HE
CK
VALVE
U
NI
O
N
RE
GU
LAT
O
R
VALVE
P
U
M
P
S
H
U
T-
O
F
F
VALVE
S
H
U
T-
O
F
F
S
H
U
T-
O
F
F
S
H
U
T-
O
F
F
S
H
U
T-
O
F
F
EXPAN
S
I
O
N TAN
K
(
MUST BE INSTALLED AT THE
HIGHEST POINT IN THE SYSTEM.
)
~
Figure 4- Typical Piping Water/Glycol Cooled System

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-6
CKTBKR) for circuitprotection. The unit'snameplate
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-
tectiondevices are notallowed based uponthe
productlisting.
Eachunit is providedwith terminals forall required
field-wiringconnections, (supplied byothers).Refer to
the electrical schematic supplied with the unit for all
powerand control field-wiringconnections. It is
importantto identifythe options thatwere purchased
with the unit in order to confirm which field connections
arerequired.
WARNING
High voltage is used in the operation of this
equipment. Death on contact may result if
personnelfailtoobservesafetyprecautions.
WARNING
Verify power is turnedoffbeforemakingconnec-
tions to the equipment.
NOTE
Allwiringmustconformtolocalandnationalelec-
tricalcoderequirements.Useofcopperconduc-
tors only is required. Wiring terminations may
become loose during transit of the equipment;
therefore, it is required to verify that all wiring
terminationsare secure.
It is important to verify that the main power supply
coincideswith the voltage,phaseand frequency
informationspecified on thesystem nameplate. The
supply voltage measured at the unit must be within
±10%of thevoltage specified onthe systemname-
plate.
A manual fused disconnect switch or HACR type
circuit breaker must be installed per local and national
electricalcodes forservice ofequipment. Do not install
a customer supplied manual fused disconnect switch
or HACR type circuit breaker to the surface of the unit.
Figure 5- Sample Nameplate

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-7
Eachunit is providedwith mainpower and control
terminalpositions for connectionofthe field-wiring.
Theopening forthe conduitis located in the floor of
the cabinet.Alabel stating "MAIN POWER INPUT" is
in close proximity. The main power wires are termi-
nated at the line side of the service disconnect switch
located within the electric box. (See Figure 6.) A
separateequipmentground lug isprovidedwithinthe
electricalbox for terminationof the earthground wire.
Terminals areavailable as aninterface toadry
contact, (N.O./N.C.), relay for a remote alarm status
signal.
Figure 6- Electric Box
The number call outs in Figure 6 coincide with the
numbereditems listed below.
1. PowerSwitches/Motor Starter Protectors
2. ControlCircuitBreakers
3. ServiceDisconnect Switch
4. GroundLug
5. ControlI/OBoard
6. InterfaceTerminals
CAUTION
Improper wire connections will result in the re-
verserotation of thepumps andcompressor(if
applicable) and may eventually result in dam-
age to the scroll compressor. To correct this
problem,exchangeanytwooftheincomingmain
power wires at the main power circuit breaker.
DoNOTrewirethe unit'sindividualcomponents.
Priorto unit operation,anadequate unit-to-earth
ground must be connected to the unit.
2.6.2 Controls
StulzAir Technology Systems offers the C6000
Microprocessoras the standardcontroller forthe
CyberChiller system. 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 cableharnessis provided for
interconnectwiring. Refer tothe electrical drawings
suppliedwith yourunit for detailson interconnecting
fieldwiring.
2.6.3 Optional Equipment
NOTE
All wiring must be provided in accordance with
localandnational electrical coderequirements.
2.6.3.1 Remote Water Detector
Theoptionalremote water detectorrequirestwo
conductors to be wired to the control terminal board
within the unit electrical box. The wire insulation must
be rated at 600V. The water detector includes screw
typeterminals forwire connections. Refer to the
suppliedelectrical schematic forproper wire termina-
tions.
2.6.4 Interconnecting Field Wiring
Thefollowingsystem interconnecting fieldwiring
sections detail the wiring required for a typical system.
Additionalcontrol conductors mayberequired depend-
ingon theoptions purchased with the equipment.
Referto the suppliedelectrical drawings todetermine
thetotal number ofinterconnecting conductors
required for your system. It is important to note that
thecontrol transformer(s) suppliedwiththe equipment
are sized and selected based upon the expected loads
for each system.
CAUTION
Do not connect any additional loads to the sys-
temcontroltransformers.Connectingadditional
loadstothefactorysuppliedcontrol transformer
mayresultinoverloadingofthetransformer,which
willcausethe transformer circuitbreakerto trip.
NOTE
All wiring must be provided in accordance with
localandnational electrical coderequirements.
1
2
3
4
5
6

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-8
2.6.4.1 Air-Cooled Split System Remote
Condenser
See Figure 7. Systems equipped with a remote
condenserrequirefieldwiringbetweentheevaporator
systemand theremote condenser. Referto thewiring
diagramsupplied with thecondenser (typicallylocated
in the condenser electric box).
Theinstaller must providemainpower wiringtothe
mainpower distributionblock locatedwithin the
remotecondenser control box.Aseparateequipment
groundlug is providedwithin the electricalbox for
terminationofthe earth groundwire.
The installer must also wire two control conductors
fromthe terminal boardwithinthe evaporator unitto
thecontrol terminal boardwithin the remotecondenser
control box. Refer to the supplied electrical schematic
forproperwireterminations.
2.6.4.2 Glycol Systems With Outdoor Fluid
Pump Package
See Figure 8. Systems equipped with a glycol system
pumppackagerequire field wiring betweenthe
drycoolerunit andpump package. Theinstaller must
wiretwo control conductorsfrom the terminalboard
within the drycooler to the pump package electrical
box. Refer to the supplied electrical schematic for
properwireterminations.
Figure 7- Interconnecting Field Wiring Remote Condenser
AIR
COO
LED
CO
NDEN
S
E
R
WITH NFPA 70, N.E.C.
)
INTER
CO
NNE
C
TIN
G
FIELD WIRIN
G
(
T
O
BE INSTALLED IN ACC
O
RDANC
E
24VA
C
2
08
-
5
7
5
V
/3
PH
/60
H
z
MAIN P
O
WER
SU
PPLY
2
08
-
5
7
5V
M
AIN P
O
IN A
CCO
RDAN
C
E WIT
H
INTER
CO
NNE
C
TIN
G
FIELD
WIRING
(
TO BE INSTALLE
D
NFPA 70, N.E.C.
)

(©October,2006)
CyberChiller Series Installation, Operation & Maintenance Manual
2-9
2.7 System Settings and Adjustments
2.7.1 Chilled Water Supply Charging
Procedures (Evaporator Side)
2.7.1.1 Pump Start-Up
Fill the system with potable water before turning the
pump on. These pumps are not self-priming, so it is
important that there is a pressure on the suction inlet.
CAUTION
Do not run the pump dry.
If the pump has no pressure on the discharge side,
leavethe discharge valvepartially shut tocreatea
back pressure in the pump so that liquid volume can
build up in the impeller housing to keep the impeller
housing from getting too hot. Make sure there is
always liquid leaving the pump, indicating that there is
flow in the pump to cool the impeller and housing. If
there is no flow shut the pump off immediately to
preventdamageto the pump.Checkfor proper rotation
ofthe motor observing the arrowon the sideof the
impeller.
CAUTION
Thepumping system of the CyberChilleris
designedfor use with a positivesuction head.
At no point should the system be operated for
an extended period of time with less than 5 to
10 psig at the pump inlet pressure fitting.
NOTE
The piping system must be clean prior to
operatingthe system
1. Connectthe water sourcetothe drainvalvehose
bib.
Figure 8- Interconnecting Field Wiring Glycol Systems
(
TO BE INSTALLED IN ACCORDANC
E
(
GLYCOL UNITS ONLY
)
24VA
C
G
P
S
P
U
MP PA
C
KA
GE
B
OX
WITH NFPA 70, N.E.C.
)
INTER
CO
NNE
C
TIN
G
FIELD WIRIN
G
M
AIN P
O
WER
SU
PPLY
2
08
-
5
7
5
V
/3
PH
/60
H
z
(
GLYCOL UNITS ONLY
)
DRY
COO
LE
R
2
08
-
5
7
5
V
/3
PH
/60
H
z
M
AIN P
O
WER
SU
PPLY
IN A
CCO
RDAN
C
E WIT
H
INTER
CO
NNE
C
TIN
G
FIELD
WIRING
(
TO BE INSTALLE
D
NFPA 70, N.E.C.
)