Sterling 30RA010-055 manual Contents, General

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CONTENTS

CONTENTS

Page

SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3

MAJOR SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . .3,4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Main Base Board (MBB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Scrolling Marquee Display . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Energy Management Module (EMM). . . . . . . . . . . . . . . . . 3

Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . . . . 3

Emergency On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Control Module Communication . . . . . . . . . . . . . . . . . . . . 3 Sterlco Comfort Network Interface . . . . . . . . . .. . . . . . . . 3

OPERATING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

•T1 — COOLER LEAVING FLUID SENSOR

•T2 — COOLER ENTERING FLUID SENSOR

•T7,T8 — COMPRESSOR RETURN GAS TEMPERATURE SENSOR (ACCESSORY)

•T9 — OUTDOOR-AIR TEMPERATURE SENSOR

•T10 — REMOTE SPACE TEMPERATURE SENSOR OR

DUAL LEAVING WATER TEMPERATURE SENSOR

Energy Management Module . . . . . . . . . . . . . . . . . . . . . . . 17

Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . . . . 17

Thermostatic Expansion Valves (TXV) . . . . . . . . . . . . . 17

Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

•MINUTES LEFT FOR START

•MINUTES OFF TIME

•LEAD/LAG DETERMINATION

•CAPACITY CONTROL OVERRIDES

Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation of Machine Based on Control Method and Cooling Set Point Selection Settings . . . . . . . . 22

Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Marquee Display Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Optional Factory-Installed Hydronic Package . . . . . . 24

Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cooler Pump Sequence of Operation . . . . . . . . . . . . . . 24

Configuring and Operating Dual Chiller Control. . . . 26

Temperature Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

•DEMAND LIMIT (2-Stage Switch Controlled)

•EXTERNALLY POWERED DEMAND LIMIT (4 to 20 mA Controlled)

•DEMAND LIMIT (SCN Loadshed Controlled)

Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . . . . . . 45 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-57 Complete Unit Stoppage and Restart . . . . . . . . . . . . . . 46

•GENERAL POWER FAILURE

•UNIT ENABLE-OFF-REMOTE CONTACT SWITCH IS OFF

•CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN

•OPEN HIGH-PRESSURE SWITCH(ES)

•OPEN COMPRESSOR INTERNAL THERMAL PROTECTION

•OPEN 24-V CONTROL CIRCUIT BREAKERS

•COOLING LOAD SATISFIED

•THERMISTOR FAILURE

•LOW SATURATED SUCTION

Alarms and Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-73

Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

• CONTROL COMPONENTS

Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 58

Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

•BRAZED-PLATE COOLER HEAT EXCHANGER REPLACEMENT

•BRAZED-PLATE COOLER HEAT EXCHANGER CLEANING

Check Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Page

Condenser Section and Coils . . . . . . . . . . . . . . . . . . . . . . 60

•COIL CLEANING

•CLEANING E-COATED COILS

•CONDENSER SECTION

Check Refrigerant Feed Components . . . . . . . . . . . . . . 61

•THERMOSTATIC EXPANSION VALVE (TXV)

•FILTER DRIER

•MOISTURE-LIQUID INDICATOR

•MINIMUM LOAD VALVE

•PRESSURE RELIEF DEVICES

Compressor and Unit Protective Devices . . . . . . . . . . 62

•MANUAL STARTER

•COMPRESSOR INTERNAL THERMAL PROTECTION

Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

•HIGH-PRESSURE SWITCH

•PRESSURE TRANSDUCERS

•COOLER FREEZE-UP PROTECTION

•HEATER CABLE

•WINTER SHUTDOWN

Thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Motormaster® V Controller . . . . . . . . . . . . . . . . . . . . . . . . 68

•GENERAL OPERATION

•SET POINTS

•INSTALLATION

•PROGRAMMING

•EPM CHIP

•LIQUID LINE PRESSURE SET POINT ADJUSTMENT

•LOSS OF SCN COMMUNICATIONS

•REPLACING DEFECTIVE MODULES

Hydronic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Recommended Maintenance Schedule . . . . . . . . . . . . 74

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . .74-76

Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Check Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 75

Operating Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

•TEMPERATURES

•LOW AMBIENT OPERATION

•VOLTAGE — ALL UNITS

OPERATION SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 76 APPENDIX A — SCN TABLES. . . . . . . . . . . . . . . . . . . .77-88

APPENDIX B — FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP AND MANUAL STARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89,90

APPENDIX C — BUILDING INTERFACE . . . . . . . . . .91,92

START-UP CHECKLIST FOR 30RA LIQUID CHILLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CL-1-CL-8

GENERAL

This publication contains Controls Start-Up, Service, Oper- ation, and Troubleshooting information for the 30RA AquaSnap® air-cooled chillers. See Table 1. These chillers are equipped with ComfortLink™ controls and conventional thermostatic expansion valves (TXVs).

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out or bypass components or otherwise depart from recom- mended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the board or electrical component.

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Contents SAFETY CONSIDERATIONS CONTENTS GENERALSterlco Comfort Network SCN Interface — MAJOR SYSTEM COMPONENTSControl Module Communication Table 1 — Unit SizesTable 2 — Thermistor Designations Table 3 — Status SwitchesTable 5 - SCN Communication Bus Wiring Table 4 - Output RelaysLEGEND FOR FIG. Page Page Fig. 3 — Wiring Schematic 30RA010-018 30RA010-018AQUA SNAPSEE NOTE SEE NOTE AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATICFig. 3 - Wiring Schematic 30RA010-018cont Fig. 4 - Wiring Schematic 30RA022-030 30RA022-030AQUA SNAPFig. 4 - Wiring Schematic 30RA022-030cont AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATICFig. 5 — Wiring Schematic 30RA032-040 30RA032-040AQUA SNAPFig. 5 — Wiring Schematic 30RA032-040cont AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATICFig. 6 — Wiring Schematic 30RA042-055 30RA042-055AQUA SNAPFig. 6 — Wiring Schematic 30RA042-055cont AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATICREMOTE CONTACT SW1 OFF ENABLE OFF SW2 ON Fig. 7 — Main Base BoardESCAPEENTER MODEFig. 9 — Typical Space Temperature Sensor Wiring Fig. 11 - Energy Management Module CEPL130351100/100 Fig. 12 — Deadband Multiplier Fig. 14 — 30RA Condenser Fan Sequence Fig. 13 — Operating Envelope forR-22Maneurop Compressor Cooling Set Point Select Table 8 — Control Methods and Cooling Set Points Service Test See Table 11 — Both main powerand control circuit power must be on Fig. 16 — Scrolling Marquee DisplayOptional Factory-InstalledHydronic Package — •Cooler Pump Control CPC Configuration, OPT1 ON Fig. 17 — Dual Chiller Thermistor Location Table 9 — Marquee Display Menu StructureTable 10 — Run Status Mode and Sub-ModeDirectory SUB-MODE Table 12 - Temperature Mode and Sub-ModeDirectory Table 15 — Inputs Mode and Sub-ModeDirectory Table 13 — Pressure Mode and Sub-ModeDirectoryTable 14 — Set Point and Sub-ModeDirectory KEYPAD Table 16 — Outputs Mode and Sub-ModeDirectorySUB-MODE DISPLAYITEM SUB-MODEKEYPAD DISPLAYITEM SUB-MODEKEYPAD DISPLAYTable 18 — Time Clock Mode and Sub-ModeDirectory PER.3 SUB-MODE Table 20 — Alarms Mode and Sub-ModeDirectory Table 19 — Operating Mode and Sub-ModeDirectoryKEYPAD ENTRY SUB-MODEITEM DISPLAYRSET DISP Table 23 — Operating Modes Table 24 — Example of Reading and Clearing Alarms Table 25A — 4-20mA ResetTable 26B — Configuring Return Temperature Reset Fig. 19 — Outdoor-AirTemperature Reset Fig. 18 — Standard Chilled FluidTemperature Control — No Reset Fig. 20 — Space Temperature ResetFig. 21A — 4- to 20-mADemand Limiting Fig. 21B — Cooling Set Point 4 to 20 mATROUBLESHOOTING Table 27 — Configuring Demand Limitand fluid tubing Table 28 — TroubleshootingRecommended that system be filled with an appro Fig. 22 — Component Arrangement — 30RA010-030 FU — Fuse GND — GroundFig. 23 — Component Arrangement — 30RA032-040 FU — Fuse GND — GroundFig. 24 — Component Arrangement — 30RA042-055 FU — Fuse GND — GroundNOTES LEGEND Table 29 — Alarm and Alert Codes Table 29 - Alarm and Alert Codes cont Table 29 — Alarm and Alert Codes cont ALARMTable 29 — Alarm and Alert Codes cont ALARMTable 29 — Alarm and Alert Codes cont ALARMTable 30 - Unit Torque Specification SERVICECompressor Replacement Refer to Fig Electronic ComponentsFig. 29 — Compressor Location — 30RA010-030 Fig. 28 — Compressor WiringFig. 27 — Typical Compressor Mounting — All Sizes Fig. 30 — Compressor Location — 30RA032-055Condenser Section and Coils Table 31 - Oil ChargeFig. 32 — Condenser-FanMounting Fig. 31 — 30RA Access PanelsCheck Refrigerant Feed Components Fig. 33 — Condenser-FanPosition Standard FanCompressor and Unit Protective Devices Table 32 — Factory Settings, High-PressureSwitch Fixed Check Unit SafetiesCOOLER FREEZE-UPPROTECTION TEMP TEMP For Thermistor T10 For Thermistor T10 Fig. 36 — Thermistor Connections to Main Base Board, J8 ConnectorFig. 35 — Fluid-SideTemperature Sensors T1 and T2 PROGRAMMING Mode •P51: SOFTWARE version Table 37 - Fault Codes•P50: FAULT HISTORY — Last 8 faults PARAMETERS Table 39 — Replacement Modules PRE-START-UP MAINTENANCEMinimum Loop Volume System CheckOperating Limitations Standard 30RA Units OPERATION SEQUENCETable 41 — Temperature Limits for CIRCADIO Circuit A Discrete Inputs/Outputs APPENDIX ASCN Tables A_UNIT General Unit Parameters CIRCA_AN Circuit A Analog ParametersOPTIONS Unit Parameters CIRCBDIO Circuit B Discrete Inputs/OutputsCIRCB_AN Circuit B Analog Parameters DUALCHIL Dual Chiller Configuration Settings ALARMDEF Alarm Definition TableDISPLAY Marquee Display SETUP BRODEFS Broadcast POC Definition TableOPTIONS1 Options 1 Configuration OPTIONS2 Options 2 ConfigurationSETPOINT SCHEDOVR Timed Override SetupRESETCON Temperature Reset and Demand Limit MAINTENANCE ALARMS: Maintenance DisplayUNIT CURRMODS: Maintenance Display DUALCHIL: Maintenance DisplayLEARNFNS Maintenance Display LOADFACT: Maintenance DisplayPM-STRN Maintenance Display PM-COIL:Maintenance DisplayPM-PUMP:Maintenance Display RUNTEST: Maintenance Display VERSIONS: Maintenance Display STRTHOUR Maintenance DisplayTESTMODE: Maintenance Display WSMDEFME: Maintenance Display AND MANUAL STARTERS FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMPAPPENDIX B AND MANUAL STARTERS cont FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMPAPPENDIX C DataPort, DataLink, BAClink Object DefinitionOPTIONS SETPOINTII. Preliminary Equipment Check START-UPCHECKLIST FOR 30RA LIQUID CHILLERRemove and use for Job File I.Project Information Design InformationIII. Unit Start-Up Start and Operate Machine. Complete the FollowingCL-3 CL-4 Record Software Versions MODE — RUN STATUSCOMMENTS III.Unit Start-Upcont UNIT Configuration SettingsOPTIONS1 Options Configuration III.Unit Start-Upcont OPTIONS2 Options ConfigurationRSET Reset Configuration Settings CL-6SETPOINT SLCT Setpoint and Ramp Load ConfigurationIII.Unit Start-Upcont CL-7Service Test Mode and Sub-ModeDirectory III.Unit Start-Upcont
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