Stulz CyberWall CAH Installation, Operation And Maintenance Manual

664 kw chilled water system

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CyberWall

™

Model CAH-XXXX-XXXX

664 kW Chilled Water System

Floor Mounted, 3-Phase/460Vac/60 Hz

Installation, Operation and Maintenance Manual

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Summary of Contents for Stulz CyberWall CAH

Page 1 CyberWall ™ Model CAH-XXXX-XXXX 664 kW Chilled Water System Floor Mounted, 3-Phase/460Vac/60 Hz Installation, Operation and Maintenance Manual...
Page 2 CY B E R WA L L™ I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N UA L A B O U T S T U L Z Since it was founded in 1947, the STULZ company has evolved into one of the world’s leading system suppliers of computer room air conditioners and air handlers.
Page 3 Inc. Distributing or photocopying this document for external distribution is in direct violation of U.S. copyright laws and is strictly prohibited without the express written consent of STULZ. Unpublished rights reserved under the copyright laws of the United States and of other countries.
Page 4: Table Of Contents
CY B E R WA L L™ I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N UA L Contents Nomenclature ..............................5 Introduction ..............................6 Installation ..............................12 Start-Up/Commissioning ........................26 Maintenance ..............................27 Product Support ............................34 Appendix A - Checklists .........................36 11.8.22 © STULZ USA – all rights reserved...
Page 5: Nomenclature
(CFM) Cooling Connections 045K CyberWall 0664 C = Chilled Water 0 = None L = Left Hand 060K Horizontal Example: 664 kW capacity, 45,000 CFM airflow, chilled water coil, horizontal air pattern: CAH-0664-045K-C0HL © STULZ USA – all rights reserved 11.8.22 ...
Page 6: Introduction
NOTE A Warranty Registration and Start-Up Checklist is provided with the unit data package. Complete it during start-up and return it to STULZ. This checklist should be used as a guideline for items that need to be confirmed during start-up.
Page 7 A lock-out tag-out procedure should be followed to ensure that power is not inadvertently reconnected. WARNING Do not use chloride based water conditioning additives in the condensate drain pans. This will cause corrosion to occur on the coil fins. © STULZ USA – all rights reserved 11.8.22 ...
Page 8 Ensure panels are secure and latched into position. For optimal performance and to ensure continuous operation, only use STULZ spare parts. Product Support provides spare and replacement parts by fax, phone and email. Refer to “Product Support” on page 34 for guidance on contacting STULZ support.
Page 9 Figure 2 shows the major mechanical and control interfaces on the unit. CHILLED WATER CONNECTIONS LIFTING EYES (4 PL) AUXILIARY ELECTRICAL BOX DOOR GRAPHIC TERMINAL POWER DISCONNECT SWITCHES MAIN ELECTRICAL BOX DOOR Figure 2. Unit Cabinet Features © STULZ USA – all rights reserved 11.8.22 ...
Page 11 SUPPLY RETURN AUXILIARY ELECTRONICS BOX DOOR GRAPHIC TERMINAL REMOVABLE POWER DISCHARGE DISCONNECT GRILLE SWITCHES (6 PL) MAIN ELECTRONICS BOX DOOR FRONT VIEW WITH FLOORSTAND REAR VIEW WITH FLOORSTAND Figure 4. Unit Cabinet Features © STULZ USA – all rights reserved 11.8.22 ...
Page 12: Installation
Freight claims must be filed through the freight carrier. Generally, all equipment ships FOB Factory. In the event of damage during shipment, STULZ can assist in the claim filing process with the freight company. Refer to section 5.0 Product Support for instructions.
Page 13 (top module). No permanent obstructions should be placed in front of the fan grilles, and the minimum clearances shown in Figure 5 on page 14 should be maintained for the doors and to permit maintenance from the supply side of the cabinet. © STULZ USA – all rights reserved 11.8.22 ...
Page 14 The unit is shipped on a skid to facilitate moving prior to installation. The unit should always be stored indoors in a dry location prior to installation. 11.8.22 © STULZ USA – all rights reserved...
Page 15 The installation drawing furnished with your unit shows the piping and wiring locations. Ensure access is available for routing the piping and wiring. © STULZ USA – all rights reserved 11.8.22 ...
Page 16 Connect the P-trap to the internal and external condensate drain lines using flexible couplings (PN194315). Install two drain cover plates (PN 207779) to floor plate using #14 X 1 hex head self-tapping screws (PN112914). 11.8.22 © STULZ USA – all rights reserved...
Page 18 PIPE CLAMP (207756) (W/ NO SHIMS) 60-INCH COPPER TUBE SECTION A-A PIPE CLAMP (207756) FLEXIBLE GROMMET (W/3X SHIMS) COUPLING DRAIN ACCESS SECTION H-H PANELS P-TRAP SECTION G-G BOTTOM MODULE Figure 7. Attaching Condensate Drain 11.8.22 © STULZ USA – all rights reserved...
Page 19 INSULATION FOAM ROLL GROOVE INSULATION COUPLING FOAM COPPER FOAM INSULATION TUBING INSULATION APPLY ADHESIVE TO SEAMS. BUTT END OF INSULATION AGAINST COUPLING. FOAM TUBING LENGTH AS REQUIRED. Figure 8. Connecting Internal Water Lines © STULZ USA – all rights reserved 11.8.22 ...
Page 20 If solvents/cleaning solutions are used, ensure they are completely flushed from the piping before connecting it. Failure to do so could result in equipment problems. NOTE Chilled water lines should be insulated to prevent condensation from forming on the pipes. 11.8.22 © STULZ USA – all rights reserved...
Page 21 (see Figure 10). 3. Use a screw drive to hand-tighten the hose clamps to make them water tight. 4. Connect a facility drain line to the bottom of the condensate pipe. © STULZ USA – all rights reserved 11.8.22 ...
Page 22 Hot Water or Steam Pressure: - psig ELECTRICAL DOOR OF LOWER Minimum Installation Clearance: 0.0 in. MODULE. Remote Condenser Type: - Suitable for Indoor: Outdoor: Use Date of Manufacture: 9/22 SATS Q.A. Acceptance: Figure 10. Example CyberWall™ Nameplate 11.8.22 © STULZ USA – all rights reserved...
Page 23 Refer to the electrical drawing supplied with your unit to determine the total number of interconnecting conductors required for your system. It is important to note that control transformer(s) supplied with the equipment are sized and selected based upon the expected loads for each system. © STULZ USA – all rights reserved 11.8.22 ...
Page 24 Return Temperature and Humidity sensor. If the humidity sensor fails in the unit, then the value will go to 0% RH, and the unit will not allow dehumidification. 11.8.22 © STULZ USA – all rights reserved...
Page 25 BMS. If the BMS Keep Alive goes into alarm if the unit is commanded off by the BMS it will turn on and go into operation until the BMS keep alive point is updated. © STULZ USA – all rights reserved 11.8.22 ...
Page 26: Start-Up/Commissioning
A Warranty Registration and Start-Up Checklist is provided with the unit data package. It should be completed during start-up and sent to STULZ. This checklist should be used as a guideline for items that need to be confirmed during start-up.
Page 27: Maintenance
Use copies of the Periodic General Maintenance Checklist in this manual (see Appendix A) to record periodic general maintenance inspections. For assistance, contact STULZ Product Support. Heed all safety directives when performing any type of maintenance.
Page 28 To ensure proper drainage, inspect the drain pans in the top and bottom modules regularly. Make sure the drain pan outlets are free of debris and ensure the drain pans do not leak. Ensure that the condensation drain lines are clear properly attached. To clean drain pans: 11.8.22 © STULZ USA – all rights reserved...
Page 29 When the main power disconnect switch is On, high voltage is present inside the cabinet. Exercise caution to prevent injury. Keep hands, clothing and tools clear of the electrical terminals and rotating components. Ensure that your footing is stable at all times. © STULZ USA – all rights reserved 11.8.22 ...
Page 30 Field Service NOTE Do not attempt to make repairs without the proper tools. It may be necessary to perform repairs on the A/C system. If field repairs are necessary, the following procedures apply: 11.8.22 © STULZ USA – all rights reserved...
Page 31 5. Refer to Figure 12. Attach chain-fall or hoist from top fan removal eye (3) to motor lifting eyes (4) leaving some slack in the system. 6. Unbolt four M8 hex bolts (5) at fan pedestal bottom. © STULZ USA – all rights reserved 11.8.22 ...
Page 32 If the Chilled Water system isn’t cooling or if cooling is reduced, check for leaks in the system. Check for clogged water lines. If strainers are installed in the CW lines, check the condition of the strainers. Clean or replace the strainers if necessary. 11.8.22 © STULZ USA – all rights reserved...
Page 33 3. Slide new filters into the rack. Start by sliding in first new filter to the bottom of the rack, then slide the second filter into the top rack and place in middle filter last. © STULZ USA – all rights reserved 11.8.22 ...
Page 34: Product Support
UPS ground. If the customer requests that warranty part(s) be sent by any other method than UPS ground the customer is responsible for the shipping charges. If you do not have established credit with STULZ you must give a freight carrier account number.
Page 35 • Unit Model No. and Serial No. The customer is responsible for the shipping cost incurred for returning the defective part(s) back to STULZ. Return of defective part(s) must be within 30 days at which time an evaluation of the part(s) is conducted and if the part is found to have a manufacturing defect a credit will be issued.
Page 36: Appendix A - Checklists
(if required) … 12. Foreign materials have been removed from inside and around all installed equipment (shipping materials, construction materials, tools, etc.) … 13. Inspect all piping connections for leaks during initial operation 11.8.22 © STULZ USA – all rights reserved...
Page 37 Notes: Signature: *** If factory assistance is required, provide the model number, serial number, and STULZ item number from the unit nameplate. This will speed up the process and ensure the accuracy of information. *** © STULZ USA – all rights reserved 11.8.22 ...
Page 38 First Quarter, Paulo-SP, CEP 04708-010 Al. Jerozolimskie 162 Blenheim Rd. Epsom 02 – 342 Warszawa Surrey KT 19 9 QN www.stulz-usa.com ONA0247 11/8/2022 © STULZ USA – Specifications subject to change without notice. 11.8.22 © STULZ USA – all rights reserved...