Sterling 30RA010-055 manual Replacement Modules

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Table 39 — Replacement Modules

REPLACING DEFECTIVE MODULES — The Comfort- Link™ replacement modules are shown in Table 39. If the Main Base Board (MBB) has been replaced, verify that all configura- tion data is correct. Follow the Configuration mode table and verify that all items under sub-modes UNIT, OPT1 and OPT2 are correct. Any additional field-installed accessories or op- tions (RSET, SLCT sub-modes) should also be verified as well as any specific time and maintenance schedules.

Refer to the Start-Up Checklist for 30RA Liquid Chillers (completed at time of original start-up) found in the job folder. This information is needed later in this procedure. If the check- list does not exist, fill out the current information in the Config- uration mode on a new checklist. Tailor the various options and configurations as needed for this particular installation.

Electrical shock can cause personal injury. Disconnect all electrical power before servicing.

1.Check that all power to unit is off. Carefully disconnect all wires from the defective module by unplugging its connectors.

2.Remove the defective module by removing its mounting screws with a Phillips screwdriver, and removing the module from the control box. Save the screws later use.

3.Verify that the instance jumper (MBB) or address switch- es (all other modules) exactly match the settings of the defective module.

NOTE: Handle boards by mounting standoffs only to avoid electrostatic discharge.

4.Package the defective module in the carton of the new module for return to Sterling.

5.Mount the new module in the unit’s control box using a Phillips screwdriver and the screws saved in Step 2.

6.Reinstall all module connectors. For accessory Navigator replacement, make sure the plug is installed at TB3 in the LEN connector.

7.Carefully check all wiring connections before restoring power.

8.Verify the ENABLE/OFF/REMOTE CONTACT switch is in the OFF position.

9.Restore control power. Verify that all module red LEDs blink in unison. Verify that all green LEDs are blinking and that the Scrolling Marquee or Navigator display is communicating correctly.

10.Verify all configuration information, settings, set points and schedules. Return the ENABLE/OFF/REMOTE CONTACT switch to its previous position.

Table 39 — Replacement Modules

MODULE

REPLACEMENT PART

REPLACEMENT PART

NO. (with Software)

NO. (without Software)

 

Main Base

30RA501102

HK50AA029

Board (MBB)

 

 

Scrolling

 

 

Marquee

HK50AA031

HK50AA030

Display

 

 

Energy

 

 

Management

30GT515218

HK50AA028

Module

 

 

(EMM)

 

 

Navigator

HK50AA033

N/A

Display

 

 

Hydronic Package — If the unit is equipped with a factory-installed hydronic package, consult the information be- low for proper maintenance and service. In addition to this

information, each factory-installed hydronic package is sup- plied with a packet of information supplied by the manufactur- er, Bell & Gossett. Sterling/Sterlco strongly recommends that this information be thoroughly reviewed prior to operation of the chiller.

PUMP PERFORMANCE CHECK — The factory-installed pumps in the 30RA units are shipped with a single impeller size available for that pump. The pump was selected based on the flow and head requirements as provided to Sterling. It is not uncommon for actual pump duty to be different than what was anticipated at time of selection. In many cases, it may be desir- able to make some field modifications to obtain optimum pump performance.

Before any pump modifications are made, it is recommend- ed that actual pump performance be verified and compared to the applicable pump curve. See base unit installation instruc- tions. This can be done in a variety of ways:

1.If pump impeller diameter is known:

a.Connect a differential pressure gage across the pump at the ports provided on the pump volutes.

b.Read GPM from applicable impeller curve.

2.If pump impeller diameter is not known:

If pump impeller diameter has been trimmed and the size is not known, it is necessary to determine which impeller curve to read.

The easiest way to confirm pump performance is to “dead-head” the pump and read the differential pressure across the pressure ports on the pump. “Dead-heading” can be done by shutting the circuit setter valve on the dis- charge side of the pump.

NOTE: Although not all pumps can be safely “dead- headed”, centrifugal pumps (such as on the 30RA units) can be “dead-headed” for short amounts of time. It is rec- ommended to keep the time short due to excessive heat build-up in the pump.

Since the “dead-head” condition is a no-flow condition, the head will correspond to the intersection of an impel- ler curve with the vertical axis of the pump chart. The correct impeller diameter is that which corresponds to the measured head.

3.Once the impeller diameter is known, proceed as in Step 1.

4.Water flow rate can be determined by using a differential pressure gage with the Bell & Gossett circuit setter bal- ance valve calculator. (This information is also provided in the installation instructions.) This method will not di- rectly measure pressure differential seen by the pump, but can be used to “double-check” the pump measurement.

5.Verify that cable connections at the switch and at the ter- minal block are secure.

6.For factory-installed hydronic system, verify that:

•All air has been purged from the system.

•Circuit setter balance valve has been correctly set.

7.Pump impeller has been improperly trimmed and is not providing sufficient flow.

8.Wrong pump motor rotation. Pump must rotate clockwise when viewed from motor end of pump.

PUMP MODIFICATIONS AND IMPELLER TRIMMING

— See applicable section in the Installation instructions.

RESET OF CHILLER WATER FLOW — See applicable sec- tion in the Installation instructions.

CHANGING OF PUMP SEALS — See Bell & Gossett ser- vice instruction manual provided with the hydronic package.

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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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