Sterling 30RA010-055 manual •Cooler Pump Control CPC Configuration, OPT1 ON

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Opened During Normal Operation Alarm will be generated and the machine will stop.

If the control detects the chilled water pump interlock open for 25 seconds after initially being closed, a T194 — Cooler Pump 1 Contacts Opened During Normal Operation Alert is generated and the unit is shut down.

If the control detects the chilled water flow switch circuit closed for at least 5 minutes with the pump output OFF, an A202 — Cooler Pump Interlock Closed When Pump is Off Alarm will be generated and the unit will not be allowed to start.

If the control detects that the chilled water pump auxiliary contacts are closed for at least 25 seconds while the pump is OFF, a T198 — Cooler Pump 1 Aux Contacts Closed While Pump Off Alert is generated. The chiller will not be allowed to start.

If the control starts a pump and the wrong interlock circuit closes for at least 20 seconds, an A189 — Cooler Pump and Aux Contact Input Miswire Alarm will be generated. The unit will be prevented from starting.

As part of a pump maintenance routine, the pump can be started to maintain lubrication of the pump seal. To utilize this function, Cooler Pmp Periodic Start (PM.P.S) [Configuration, UNIT] must be set to YES. This option is set to NO as the fac- tory default. With this feature enabled, if the pump is not oper- ating, it will be started and operated for 2 seconds starting at 14:00 hours. If the pump is operating, this routine is skipped. If the pump has failed and an Alarm/Alert condition is active, the pump will not start that day.

DUAL INTEGRAL PUMP CONTROL — With a dual inte- gral pump package, 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

Pump Start Selection is a field-configurable choice. Cooler Pump Select (PM.SL) [Configuration, UNIT] is factory de- faulted to 0 (Automatic). This value can be changed to 1 (Pump 1 Starts First) or 2 (Pump 2 Starts First). If PM.SL is 0 (Auto- matic), the pump selection is based on two criteria: the alert status of a pump and the operational hours on the pump. If a pump has an active Alert condition, it will not be considered for the lead pump. The pump with the lowest operational hours will be the lead pump. A pump is selected by the control to start and continues to be the lead pump until the Pump Changeover Hours (PM.DT) [Configuration, UNIT] is reached. The Lead Pump (LD.PM) [Run Status, VIEW] indicates the pump that has been selected as the lead pump: 1 (Pump 1), 2 (Pump 2), 3 (No Pump). The Pump Changeover Hours is factory defaulted to 500 hours. Regardless of the Cooler Pump Selection, any pump that has an active alert will not be allowed to start.

With the dual integral pump package, the Cooler Pump Starter will be energized when the machine is in an occupied period. As part of the factory-installed package, an auxiliary set of contacts is wired to the MBB to serve as Chilled Water Pump Interlock, one set for each pump to individual channels on the MBB. With a call for mechanical cooling, the specific pump interlock and flow switch are checked. If the circuits are closed, the machine starts its capacity routine. If Pump 1 starts and 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 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. In either fault case listed above, Pump 2 will be commanded to start once Pump 1 has failed.

If Pump 2 starts and the auxiliary contact interlock does not close within 25 seconds of the ON command, a T191 — Cooler Pump 2 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 T193

—Cooler Pump 2 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. In either fault case listed above, Pump 1 will be commanded to start once Pump 2 has failed.

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 or T197 — Flow Lost While Pump 2 Running Alert for the appropriate pump and an A201 — Cooler Flow/ Interlock Contacts Opened During Normal Operation Alarm will be generated and the machine will stop. If available, the other pump will be started. If flow is proven, the machine will be allowed to restart.

If the chilled water pump interlock opens for 25 seconds after initially being closed is detected by the control, the appro- priate T194 – Cooler Pump 1 Contacts Opened During Normal Operation Alert or T195 – Cooler Pump 2 Contacts Opened During Normal Operation Alert is generated and the unit is shut down. If available, the other pump will be started. If flow is proven, the machine will be allowed to restart.

If the control detects that the chilled water flow switch circuit is closed for at least 5 minutes with the pump output OFF, an A202 – Cooler Pump Interlock Closed When Pump is Off Alarm will be generated and the unit will not be allowed to start.

If the control detects that the chilled water pump auxiliary contacts are closed for at least 25 seconds while the pump is OFF, the appropriate T198 – Cooler Pump 1 Aux Contacts Closed While Pump Off or Alert T199 – Cooler Pump 2 Aux Contacts Closed While Pump Off Alert is generated. The chiller will not be allowed to start.

If the control starts a pump and the wrong interlock circuit closes for at least 20 seconds, an A189 – Cooler Pump and Aux Contact Input Miswire Alarm will be generated. The unit will be prevented from starting.

The control will allow for pump changeover. Two methods will change the pump sequence. Before the changeover can occur, the unit must be at Capacity Stage 0. During changeover the chilled water flow switch input is ignored for 10 seconds to avoid a nuisance alarm.

With Cooler Pump Select (PM.SL) [Configuration, UNIT] set to 0 (Automatic) and when the differential time limit Pump Changeover Hours (PM.DT) [Configuration, UNIT] is reached, the lead pump will be turned OFF. Approximately one (1) sec- ond later, the lag pump will start. Manual changeover can be ac- complished by changing Rotate Cooler Pump Now (ROT.P) [Configuration, UNIT] to YES only if the machine is at Capac- ity Stage 0 and the differential time limit Pump Changeover Hours (PM.DT) [Configuration, UNIT] is reached. If the PM.DT is not satisfied, the changeover will not occur. With the machine at Capacity Stage 0, the pumps would rotate automati- cally as part of the normal routine.

With Cooler Pump Select (PM.SL) [Configuration, UNIT] set to 1 (Pump 1 Starts First) or 2 (Pump 2 Starts First), a manual changeover can be accomplished by changing PM.SL only. The machine Remote-Off-Enable Switch must be in the OFF posi- tion to change this variable. The Rotate Cooler Pump Now (ROT.P) [Configuration, UNIT] feature does not work for these configuration options.

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Contents SAFETY CONSIDERATIONS GENERAL CONTENTSControl Module Communication MAJOR SYSTEM COMPONENTSSterlco Comfort Network SCN Interface — Table 1 — Unit SizesTable 5 - SCN Communication Bus Wiring Table 3 — Status SwitchesTable 2 — Thermistor Designations Table 4 - Output RelaysLEGEND FOR FIG. Page Page 30RA010-018AQUA SNAP Fig. 3 — Wiring Schematic 30RA010-018Fig. 3 - Wiring Schematic 30RA010-018cont AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATICSEE NOTE SEE NOTE 30RA022-030AQUA SNAP Fig. 4 - Wiring Schematic 30RA022-030AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATIC Fig. 4 - Wiring Schematic 30RA022-030cont30RA032-040AQUA SNAP Fig. 5 — Wiring Schematic 30RA032-040AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATIC Fig. 5 — Wiring Schematic 30RA032-040cont30RA042-055AQUA SNAP Fig. 6 — Wiring Schematic 30RA042-055AQUA-SNAPLOW VOLTAGE CONTROL SCHEMATIC Fig. 6 — Wiring Schematic 30RA042-055contESCAPEENTER Fig. 7 — Main Base BoardREMOTE CONTACT SW1 OFF ENABLE OFF SW2 ON MODEFig. 9 — Typical Space Temperature Sensor Wiring CEPL130351 Fig. 11 - Energy Management Module100/100 Fig. 12 — Deadband Multiplier R-22Maneurop Compressor Fig. 13 — Operating Envelope forFig. 14 — 30RA Condenser Fan Sequence Cooling Set Point Select and control circuit power must be on Service Test See Table 11 — Both main powerTable 8 — Control Methods and Cooling Set Points Fig. 16 — Scrolling Marquee DisplayOptional Factory-InstalledHydronic Package — •Cooler Pump Control CPC Configuration, OPT1 ON Table 9 — Marquee Display Menu Structure Fig. 17 — Dual Chiller Thermistor LocationTable 10 — Run Status Mode and Sub-ModeDirectory SUB-MODE Table 12 - Temperature Mode and Sub-ModeDirectory Table 14 — Set Point and Sub-ModeDirectory Table 13 — Pressure Mode and Sub-ModeDirectoryTable 15 — Inputs Mode and Sub-ModeDirectory SUB-MODE Table 16 — Outputs Mode and Sub-ModeDirectoryKEYPAD DISPLAYKEYPAD SUB-MODEITEM DISPLAYKEYPAD SUB-MODEITEM DISPLAYTable 18 — Time Clock Mode and Sub-ModeDirectory PER.3 SUB-MODE Table 19 — Operating Mode and Sub-ModeDirectory Table 20 — Alarms Mode and Sub-ModeDirectoryITEM SUB-MODEKEYPAD ENTRY DISPLAYRSET DISP Table 23 — Operating Modes Table 25A — 4-20mA Reset Table 24 — Example of Reading and Clearing AlarmsTable 26B — Configuring Return Temperature Reset Temperature Control — No Reset Fig. 18 — Standard Chilled FluidFig. 19 — Outdoor-AirTemperature Reset Fig. 20 — Space Temperature ResetFig. 21B — Cooling Set Point 4 to 20 mA Fig. 21A — 4- to 20-mADemand LimitingTable 27 — Configuring Demand Limit TROUBLESHOOTINGRecommended that system be filled with an appro Table 28 — Troubleshootingand fluid tubing FU — Fuse GND — Ground Fig. 22 — Component Arrangement — 30RA010-030FU — Fuse GND — Ground Fig. 23 — Component Arrangement — 30RA032-040FU — Fuse GND — Ground Fig. 24 — Component Arrangement — 30RA042-055NOTES LEGEND Table 29 — Alarm and Alert Codes Table 29 - Alarm and Alert Codes cont ALARM Table 29 — Alarm and Alert Codes contALARM Table 29 — Alarm and Alert Codes contALARM Table 29 — Alarm and Alert Codes contCompressor Replacement Refer to Fig SERVICETable 30 - Unit Torque Specification Electronic ComponentsFig. 27 — Typical Compressor Mounting — All Sizes Fig. 28 — Compressor WiringFig. 29 — Compressor Location — 30RA010-030 Fig. 30 — Compressor Location — 30RA032-055Table 31 - Oil Charge Condenser Section and CoilsCheck Refrigerant Feed Components Fig. 31 — 30RA Access PanelsFig. 32 — Condenser-FanMounting Fig. 33 — Condenser-FanPosition Standard FanSwitch Fixed Table 32 — Factory Settings, High-PressureCompressor and Unit Protective Devices Check Unit SafetiesCOOLER FREEZE-UPPROTECTION TEMP TEMP For Thermistor T10 For Thermistor T10 Fig. 35 — Fluid-SideTemperature Sensors T1 and T2 Main Base Board, J8 ConnectorFig. 36 — Thermistor Connections to PROGRAMMING Mode •P50: FAULT HISTORY — Last 8 faults Table 37 - Fault Codes•P51: SOFTWARE version PARAMETERS Table 39 — Replacement Modules Minimum Loop Volume MAINTENANCEPRE-START-UP System CheckOperating Limitations Table 41 — Temperature Limits for OPERATION SEQUENCEStandard 30RA Units SCN Tables A_UNIT General Unit Parameters APPENDIX ACIRCADIO Circuit A Discrete Inputs/Outputs CIRCA_AN Circuit A Analog ParametersCIRCB_AN Circuit B Analog Parameters CIRCBDIO Circuit B Discrete Inputs/OutputsOPTIONS Unit Parameters DISPLAY Marquee Display SETUP ALARMDEF Alarm Definition TableDUALCHIL Dual Chiller Configuration Settings BRODEFS Broadcast POC Definition TableOPTIONS2 Options 2 Configuration OPTIONS1 Options 1 ConfigurationRESETCON Temperature Reset and Demand Limit SCHEDOVR Timed Override SetupSETPOINT UNIT ALARMS: Maintenance DisplayMAINTENANCE DUALCHIL: Maintenance Display CURRMODS: Maintenance DisplayLOADFACT: Maintenance Display LEARNFNS Maintenance DisplayPM-PUMP:Maintenance Display PM-COIL:Maintenance DisplayPM-STRN Maintenance Display RUNTEST: Maintenance Display TESTMODE: Maintenance Display STRTHOUR Maintenance DisplayVERSIONS: Maintenance Display WSMDEFME: Maintenance Display APPENDIX B FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMPAND MANUAL STARTERS FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP AND MANUAL STARTERS contDataPort, DataLink, BAClink Object Definition APPENDIX CSETPOINT OPTIONSRemove and use for Job File I.Project Information START-UPCHECKLIST FOR 30RA LIQUID CHILLERII. Preliminary Equipment Check Design InformationStart and Operate Machine. Complete the Following III. Unit Start-UpCL-3 COMMENTS Record Software Versions MODE — RUN STATUSCL-4 OPTIONS1 Options Configuration UNIT Configuration SettingsIII.Unit Start-Upcont RSET Reset Configuration Settings OPTIONS2 Options ConfigurationIII.Unit Start-Upcont CL-6III.Unit Start-Upcont SLCT Setpoint and Ramp Load ConfigurationSETPOINT CL-7III.Unit Start-Upcont Service Test Mode and Sub-ModeDirectory
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