Sterling 30RA010-055 manual Optional Factory-InstalledHydronic Package

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Optional Factory-Installed Hydronic Package —

Optional Factory-Installed Hydronic Package —

If the chiller has factory-installed chilled fluid pumps, specific steps should be followed for proper operation.

The pump(s) in the hydronic package come factory pre-wired into the main unit power supply/starter. In order to check proper pump rotation, use the Service Test function to test the condenser fans and observe them for proper rotation (counter clockwise when viewed from the top). If fans turn correctly, the pumps will rotate correctly. Clockwise rotation of the pump motor cooling fans can also be used to determine that pumps are rotating correctly.

Operation of pump in wrong direction, even for a few seconds, can cause irreversible damage to pump impeller and housing. Always verify correct wiring/pump rotation before operation.

Use Service Test function to test operation of pumps. Verify that the flow switch input is made when the pump is running. For dual pump hydronic systems, the control only uses one pump at a time. Consult the Installation Instructions supplied with this chiller and use the circuit setter balancing valve installed in hydronic package to adjust fluid flow rate.

Cooler Pump Control — The 30RA AquaSnap® ma- chines equipped with a factory installed pump package are configured with the Cooler Pump Control (CPC) [Configura- tion, OPT1] ON.

Machines not equipped with a pump package are config- ured with the cooler pump control OFF. It is recommended that the machine control the chilled water pump. If not, a 5-minute time delay is required after the command to shut the machine down is sent before the chilled water pump is turned off. This is required to maintain water flow during the shutdown period of the machine.

With or without this option enabled, the cooler pump relay will be energized when the machine enters an ON status (i.e., On Local, On SCN, On Time). An A207 - Cooler Freeze Protection Alarm, will energize the cooler pump relay also, as an override. The cooler pump relay will remain energized if the machine is in MODE 10 – Minimum Off Time.

Cooler Pump Sequence of Operation — At any- time the unit is in an ON status, as defined by the one of the following conditions, the cooler pump relay will be enabled.

1.The Enable-Off-Remote Switch in ENABLE, (CTRL=0).

2.Enable-Off-Remote Switch in REMOTE with a Start-Stop remote contact closure, (CTRL=0).

3.An Occupied Time Period from an Occupancy Schedule in combination with items 1 or 2, (CTRL=2).

4.A SCN Start-Stop Command to Start in combination with items 1 or 2, (CTRL=3).

As stated before, there are certain alarm conditions and Operating Modes that will turn the cooler pump relay ON. This sequence will describe the normal operation of the pump control algorithm.

When the unit cycles from an “On” state to an “Off” state, the cooler pump output will remain energized for the Cooler Pump Shutdown Delay (PM.DY) [Configuration, OPT1]. This is configurable from 0 to 10 minutes. The factory default is 1 minute. If the pump output was deenergized during the transi- tion period, the pump output will not be energized.

NO INTEGRAL PUMP — SINGLE EXTERNAL PUMP CONTROL — With a single external pump, the following options must be configured:

•Cooler Pump Control (CPC) [Configuration, OPT1] OFF.

•Cooler Pump 1 Enable (PM1E) [Configuration, UNIT] NO.

•Cooler Pump 2 Enable (PM2E) [Configuration, UNIT] NO.

The maximum load allowed for the Chilled Water Pump Starter is 5 VA sealed, 10 VA inrush at 24 volts. The starter coil is powered from the chiller control system. The starter should be wired between TB5-11 and TB5-13. If equipped, the field- installed chilled water pump starter auxiliary contacts should be connected in series with the chilled water flow switch.

The Cooler Pump Relay will be energized when the machine is “On.” The chilled water pump interlock circuit consists of a chilled water flow switch and a field-installed chilled water pump interlock. If the chilled water pump inter- lock circuit does not close within five (5) minutes of starting, an A200 — Cooler Flow/Interlock failed to close at Start-Up alarm will be generated and chiller will not be allowed to start.

If the chilled water pump interlock or chilled water flow switch opens for at least three (3) seconds after initially being closed, an A201 — Cooler Flow/Interlock Contacts Opened During Normal Operation Alarm will be generated and the ma- chine will stop.

NO INTEGRAL PUMP — DUAL EXTERNAL PUMP CONTROL — With two external pumps, the following options must be configured:

•Cooler Pump Control (CPC) [Configuration, OPT1] ON.

•Cooler Pump 1 Enable (PM1E) [Configuration, UNIT] YES.

•Cooler Pump 2 Enable (PM2E) [Configuration, UNIT] YES.

The maximum load allowed for the Chilled Water Pump Starters is 5 VA sealed, 10 VA inrush at 24 volts. The starter coil is powered from the chiller control system. The starter for Chilled Water Pump 1 should be wired between TB5-11 and TB5-13. The starter for Chilled Water Pump 2 should be wired between TB5-15 and TB5-13. A field-installed chilled water pump interlock for each pump must be connected to each pump’s interlock points on the Main Base Board. The Chilled Water Pump 1 Interlock, CWP1, must be connected to MBB- J7-1 and –2. The Chilled Water Pump 2 Interlock, CWP2, must be connected to MBB-J7-3 and –4. The chilled water pump interlock contacts should be rated for dry circuit application capable of handling 5 vdc at 2 mA.

SINGLE INTEGRAL PUMP CONTROL — With a single pump, the following options must be configured:

•Cooler Pump Control (CPC) [Configuration, OPT1] ON.

•Cooler Pump 1 Enable (PM1E) [Configuration, UNIT] YES.

•Cooler Pump 2 Enable (PM2E) [Configuration, UNIT] NO.

With a single integral pump, the Cooler Pump Starter will be energized when the machine is occupied. As part of the factory-installed package, an auxiliary set of contacts is wired to the MBB to serve as Chilled Water Pump Interlock. When the mechanical cooling is called for, the pump interlock and flow switch is checked. If the circuits are closed, the machine starts its capacity routine. If the auxiliary contact interlock does not close within 25 seconds of the ON command, a T190 — Cooler Pump 1 Aux Contacts Failed to Close at Start-Up Alert will be generated and the pump shut down. The unit will not be allowed to start. If the chilled water flow switch does not close within one (1) minute, two alarms will be generated. A T192 — Cooler Pump 1 Failed to Provide Flow at Start-Up Alert and an A200 – Cooler Flow/Interlock failed to close at Start-Up will be generated and chiller will not be allowed to start.

If the chilled water flow switch opens for at least 3 seconds after initially being closed, a T196 — Flow Lost While Pump 1 Running Alert and an A201 — Cooler Flow/Interlock Contacts

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Contents SAFETY CONSIDERATIONS CONTENTS GENERALMAJOR SYSTEM COMPONENTS Control Module CommunicationSterlco Comfort Network SCN Interface — Table 1 — Unit SizesTable 3 — Status Switches Table 5 - SCN Communication Bus WiringTable 2 — Thermistor Designations Table 4 - Output RelaysLEGEND FOR FIG. Page Page Fig. 3 — Wiring Schematic 30RA010-018 30RA010-018AQUA SNAPAQUA-SNAPLOW VOLTAGE CONTROL SCHEMATIC Fig. 3 - Wiring Schematic 30RA010-018contSEE NOTE SEE NOTE 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 SCHEMATICFig. 7 — Main Base Board ESCAPEENTERREMOTE CONTACT SW1 OFF ENABLE OFF SW2 ON MODEFig. 9 — Typical Space Temperature Sensor Wiring Fig. 11 - Energy Management Module CEPL130351100/100 Fig. 12 — Deadband Multiplier Fig. 13 — Operating Envelope for R-22Maneurop CompressorFig. 14 — 30RA Condenser Fan Sequence Cooling Set Point Select Service Test See Table 11 — Both main power and control circuit power must be onTable 8 — Control Methods and Cooling Set Points 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 13 — Pressure Mode and Sub-ModeDirectory Table 14 — Set Point and Sub-ModeDirectoryTable 15 — Inputs Mode and Sub-ModeDirectory Table 16 — Outputs Mode and Sub-ModeDirectory SUB-MODEKEYPAD DISPLAYSUB-MODE KEYPADITEM DISPLAYSUB-MODE KEYPADITEM 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-ModeDirectorySUB-MODE ITEMKEYPAD ENTRY 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. 18 — Standard Chilled Fluid Temperature Control — No ResetFig. 19 — Outdoor-AirTemperature 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 LimitTable 28 — Troubleshooting Recommended that system be filled with an approand fluid tubing 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 ALARMSERVICE Compressor Replacement Refer to FigTable 30 - Unit Torque Specification Electronic ComponentsFig. 28 — Compressor Wiring Fig. 27 — Typical Compressor Mounting — All SizesFig. 29 — Compressor Location — 30RA010-030 Fig. 30 — Compressor Location — 30RA032-055Condenser Section and Coils Table 31 - Oil ChargeFig. 31 — 30RA Access Panels Check Refrigerant Feed ComponentsFig. 32 — Condenser-FanMounting Fig. 33 — Condenser-FanPosition Standard FanTable 32 — Factory Settings, High-Pressure Switch FixedCompressor and Unit Protective Devices Check Unit SafetiesCOOLER FREEZE-UPPROTECTION TEMP TEMP For Thermistor T10 For Thermistor T10 Main Base Board, J8 Connector Fig. 35 — Fluid-SideTemperature Sensors T1 and T2Fig. 36 — Thermistor Connections to PROGRAMMING Mode Table 37 - Fault Codes •P50: FAULT HISTORY — Last 8 faults•P51: SOFTWARE version PARAMETERS Table 39 — Replacement Modules MAINTENANCE Minimum Loop VolumePRE-START-UP System CheckOperating Limitations OPERATION SEQUENCE Table 41 — Temperature Limits forStandard 30RA Units APPENDIX A SCN Tables A_UNIT General Unit ParametersCIRCADIO Circuit A Discrete Inputs/Outputs CIRCA_AN Circuit A Analog ParametersCIRCBDIO Circuit B Discrete Inputs/Outputs CIRCB_AN Circuit B Analog ParametersOPTIONS Unit Parameters ALARMDEF Alarm Definition Table DISPLAY Marquee Display SETUPDUALCHIL Dual Chiller Configuration Settings BRODEFS Broadcast POC Definition TableOPTIONS1 Options 1 Configuration OPTIONS2 Options 2 ConfigurationSCHEDOVR Timed Override Setup RESETCON Temperature Reset and Demand LimitSETPOINT ALARMS: Maintenance Display UNITMAINTENANCE CURRMODS: Maintenance Display DUALCHIL: Maintenance DisplayLEARNFNS Maintenance Display LOADFACT: Maintenance DisplayPM-COIL:Maintenance Display PM-PUMP:Maintenance DisplayPM-STRN Maintenance Display RUNTEST: Maintenance Display STRTHOUR Maintenance Display TESTMODE: Maintenance DisplayVERSIONS: Maintenance Display WSMDEFME: Maintenance Display FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP APPENDIX BAND MANUAL STARTERS AND MANUAL STARTERS cont FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMPAPPENDIX C DataPort, DataLink, BAClink Object DefinitionOPTIONS SETPOINTSTART-UPCHECKLIST FOR 30RA LIQUID CHILLER Remove and use for Job File I.Project InformationII. Preliminary Equipment Check Design InformationIII. Unit Start-Up Start and Operate Machine. Complete the FollowingCL-3 Record Software Versions MODE — RUN STATUS COMMENTSCL-4 UNIT Configuration Settings OPTIONS1 Options ConfigurationIII.Unit Start-Upcont OPTIONS2 Options Configuration RSET Reset Configuration SettingsIII.Unit Start-Upcont CL-6SLCT Setpoint and Ramp Load Configuration III.Unit Start-UpcontSETPOINT CL-7Service Test Mode and Sub-ModeDirectory III.Unit Start-Upcont
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