SCS Installation, Operation & Maintenance Manual

1 SCS installation , Operation & Maintenance Manual ( Sept, 2007). Air Technology Systems, Inc. SCS installation , Operation & Maintenance Manual MODEL NOMENCLATURE. SCS-060-SAA. AA = 0 F Fan Cycling/Fan Speed/-30 F. SCS Series Flooded Head Pressure Control SA = -20 F Variable Speed Control EC = Intelligent Control Nominal Capacity in S = Single Circuit 1,000's of BTU/H D = Dual Circuit Notice This document contains information protected by copyright. All rights are reserved. The owner of the equipment for which this Manual is written may photocopy the contents of this Manual for internal use only. No part of this docu- ment may be photocopied, reproduced, or translated into another language for use by anyone other than the owner of the equipment for which this Manual is written without the prior written consent of Stulz Air Technology Systems, Inc. (SATS). This document contains confidential and proprietary information of Stulz Air Technology Systems, Inc.

2 Distributing or photocopying this document for external distribution is in direct violation of copyright laws and is strictly prohibited without the express written consent of SATS. Unpublished rights reserved under the copyright laws of the United States and of other countries. Other brands and tradenames are trademarks of their respective owners. Copyright 2007 by Stulz Air Technology Systems, Inc. Printed in the United States of America. All rights reserved. Stulz Air Technology Systems, Inc. 1572 Tilco Drive Frederick, MD 21704. USA. 09/07. ( Sept, 2007). Air Technology Systems, Inc. SCS installation , Operation & Maintenance Manual TABLE OF CONTENTS. Introduction .. 1-1 Start-Up/Commissioning .. 3-1. General .. 1-1 Operation .. 3-1. Product Description .. 1-1 Step by Step Start-Up Instructions .. 3-1. Capabilities and Features .. 1-1 Operational Description .. 3-1. Application Ranges .. 1-1. Safety Features .. 1-2 Maintenance /Repairs.

3 4-1. General Design .. 1-2 Periodic General Maintenance .. 4-1. Product Warranty .. 1-3 General .. 4-1. Safety .. 1-4 Troubleshooting .. 4-2. General .. 1-4 Field Service .. 4-3. Safety Summary .. 1-4 Leak Detection .. 4-3. Leak Repair .. 4-3. installation .. 2-1 Refrigerant Piping .. 4-3. Receiving the Equipment.. 2-1 Electrical System .. 4-3. Site Preparation .. 2-1. Rigging .. 2-1 Product Support Group .. 5-1. Mounting/Placement .. 2-1 Technical Support .. 5-1. Piping Connections .. 2-2 Obtaining Warranty Parts .. 5-1. Refrigerant Line Sizing .. 2-3 Obtaining Spare/Replacement Parts .. 5-1. Discharge Line .. 2-3. Liquid Line .. 2-4 List of Figures Weight of refrigerant .. 2-4. Figure 1- Typical Layout .. 1-2. Utility Connections .. 2-5. Figure 2- Ground Mounting .. 2-2. Main Power/Control Wiring .. 2-5. Figure 3- Side Clearance .. 2-2. System Settings and Adjustments .. 2-7. R-22 Refrigerant Charging Procedures .. 2-7 Figure 4- Walled Areas or Pits.

4 2-3. R-407C Refrigerant Charging Procedures .. 2-8 Figure 5- Piping installation .. 2-4. Head Pressure Controls .. 2-10 Figure 6- Dual Riser Piping .. 2-4. Condenser Fan Cycling .. 2-10 Figure 7- Field Wiring .. 2-5. Variable Condenser Fan Speed .. 2-10 Figure 8- Sample Nameplate .. 2-6. Flooded Head Pressure Control .. 2-11 Figure 9- Flooded Head Pressure Control Diagram .. 2-11. Refrigerant Characteristics .. 2-12. Pressure/Temperature Settings .. 2-12. Appendix A - Forms Saturated Refrigerant Pressure Tables .. 2-12. Checklist for Completed installation .. A-1. Standard Refrigerant Charge .. 2-13. Periodic General Maintenance Refrigerant Charge Correction Factors .. 2-13. Checks and Service Checklist .. A-2. Appendix B - Glossary Definition of Terms and Acronyms .. B-1. ( Sept, 2007) i Air Technology Systems, Inc. SCS installation , Operation & Maintenance Manual INTRODUCTION which refrigerant is continuously circulated by the pressure differential created by a compressor.

5 The General compressor increases refrigerant pressure to a level sufficiently high for it to be cooled and condensed into The Remote Air Cooled Condenser covered by this liquid by the effect of ambient air being drawn over the Manual is designed and manufactured by Stulz Air condenser coil. SATS condensers are designed to Technology Systems, Inc. (SATS). Recognized as a operate with either R22 or R407C refrigerant. world leader, SATS provides precision cooling systems with the highest quality craftsmanship using the finest Outdoor air cooled condensers use fan cycling for low materials available in the industry. The unit will provide ambient head pressure control down to 0 F. Variable years of trouble free service if installed and maintained fan speed control is used for Operation in low ambient in accordance with this Manual . Damage to the unit temperatures down to -20 F. Flooded head pressure from improper installation , Operation or Maintenance is control is used with fan cycling for low ambient not covered by the warranty.

6 Temperatures down to -30 F. This Manual contains information for installation , NOTE. Operation , Maintenance , troubleshooting and repair. SATS condensers are strictly for non-residen- STUDY the instructions contained in this Manual . tial applications. They must be followed to avoid difficulties. Spare parts are available from SATS to insure continuous opera- Operation of the condenser is controlled by a 24 VAC. tion. Using substitute parts or bypassing electrical or input signal from a system controller provided with the refrigeration components in order to continue opera- indoor evaporator section or, it can be configured for tion is not recommended and will VOID THE WAR- independant, stand-alone Operation . RANTY. Due to technological advancements, compo- Capabilities and Features nents are subject to change without notice. All Aluminum Cabinet Construction SATS Air Cooled Condensers are designed to reject Aluminum Fin Copper Tube Coil Construction heat from refrigerant based cooling equipment.

7 Any Mounting Legs use beyond this is deemed to be not intended. SATS. is not liable for any damage resulting from improper Direct driven axial fan(s) equipped with use. The unit is designed to be installed outdoors external rotor motors unless otherwise noted on the equipment nameplate. Unit Mounted, Weather Resistant Control Enclosure with Lockable Service Disconnect Switch Product Description Application Ranges SATS Remote Air Cooled Condensers are designed to be the most efficient and reliable condensers in the SATS remote air cooled condensers are designed for industry. The unit is an air-cooled, heat rejection Operation within the following ranges: condenser with a vertical air discharge pattern. Outdoor Temperature Range: The unit is self contained in a light weight, corrosion Fixed Fan Cycling Control .. 0 F or higher resistant aluminum cabinet designed for mounting to Variable Fan Speed Control .. -20 F or higher a horizontal surface.

8 The cabinet houses the con- Flooded Head Pressure Control .. -30 F or higher denser coil(s) and fan assembly(s). The electrical controls are in an integrally mounted, weather proof Operating Voltage: enclosure which is isolated from the rest of the VAC Input per unit nameplate +/- 10%. equipment. There are several cabinet sizes based on Max. Piping Length; Indoor Evaporator to Condenser: the capacity of the unit. Refer to the installation 150 ft equivalent length. drawing supplied with your unit for the layout and Max. Level Drop; Indoor Evaporator to Condenser: dimensions of your cabinet. 20 ft (when condenser is below the evaporator). The total heat rejection in BTU/Hr will depend on the Storage Conditions: .. -30 F to 105 F. unit size which can range from 12,000 to 683,000. BTU/Hr. Refer to the unit nameplate to identify the NOTE. model number of your unit. The system will consist of Damage or malfunction to the unit due to a single circuit or dual circuit coil.

9 The coil is a storage or Operation outside of these ranges closed-loop refrigerant condensing heat exchanger in will VOID THE WARRANTY. 1-1 ii ( Sept, 2007). Air Technology Systems, Inc. SCS installation , Operation & Maintenance Manual Safety Features Fan Assembly The remote air-cooled condenser is provided with a For outdoor applications the condenser is equipped factory mounted, service disconnect switch as stan- with high efficiency axial type, impeller fan(s). The dard. The service disconnect switch electrically quantity of fans varies depending upon the capacity of isolates the unit during routine Maintenance . The the unit. The fan(s) utilize corrosion resistant, multi- handle of the switch may be locked in the Off blade impellers designed for high aerodynamic position to prevent unauthorized Operation . Finger efficiency which results in lower power consumption, guard grilles are provided on each fan to protect the lower noise levels and longer life.

10 Each fan utilizes a operator from injury and to keep large tools or other direct driven motor with Maintenance free bearings. objects from falling into the fan. The fan motors are internally protected from overload. General Design Electric Box The remote condenser is housed in an aluminum The electrical components are protected in a weather frame type cabinet and is rated for outdoor use. Figure resistant enclosure located at the header end of the 1 depicts a typical layout of a remote air cooled unit. The electric box has a removable front access condenser and identifies the major components. panel which is safety interlocked with the service disconnect switch, preventing the panel from being Condenser Coil removed when the switch is in the On position. The switch must be turned Off to gain access to the Each condenser coil is a copper tube, aluminum electrical components. finned coil. The capacity of the condenser indicated by the unit model number, is based on the rated capacity of the coil.