Sterling 30RA010-055 manual Maintenance, Pre-Start-Up, System Check, Minimum Cooler Flow Rates and

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MAINTENANCE

MAINTENANCE

Recommended Maintenance Schedule — The fol- lowing are only recommended guidelines. Jobsite conditions may dictate that maintenance schedule is performed more often than recommended.

Routine:

For machines with E-coat Condenser Coils:

•Check condenser coils for debris, clean as necessary with Sterling approved coil cleaner.

•Periodic clean water rinse, especially in coastal and industrial applications.

Every month:

•Check condenser coils for debris, clean as necessary with Sterling approved coil cleaner.

•Check moisture indicating sight glass for possible refrig- erant loss and presence of moisture.

Every 3 months (for all machines):

•Check refrigerant charge.

•Check all refrigerant joints and valves for refrigerant leaks, repair as necessary.

•Check chilled water flow switch operation.

•Check condenser coils for debris, clean as necessary with Sterling approved coil cleaner.

•Check all condenser fans for proper operation.

•Check compressor oil level.

•Check crankcase heater operation.

Every 12 months (for all machines):

•Check all electrical connections, tighten as necessary.

•Inspect all contactors and relays, replace as necessary.

•Check accuracy of thermistors, replace if greater than

± 2° F (1.2° C) variance from calibrated thermometer.

•Obtain and test an oil sample. Change oil only if necessary.

•Check to be sure that the proper concentration of anti- freeze is present in the chilled water loop, if applicable.

•Verify that the chilled water loop is properly treated.

•Check refrigerant filter driers for excessive pressure drop, replace as necessary.

•Check chilled water strainers, clean as necessary.

•Check cooler heater operation, if equipped.

•Check condition of condenser fan blades and that they are securely fastened to the motor shaft.

•Perform Service Test to confirm operation of all components.

•Check for excessive cooler approach (Leaving Chilled Water Temperature — Saturated Suction Temperature) which may indicate fouling. Clean cooler vessel if necessary.

PRE-START-UP

IMPORTANT: Before beginning Pre-Start-Up or Start-Up, complete Start-Up Checklist for 30RA Liquid Chiller at end of this publication (page CL-1 to CL-8). The Checklist assures proper start-up of a unit, and provides a record of unit condition, application requirements, system informa- tion, and operation at initial start-up.

Do not attempt to start the chiller until following checks have been completed.

System Check

1.Check all auxiliary components, such as chilled fluid pumps, air-handling equipment, or other equipment to which the chiller supplies liquid. Consult manufacturer's instructions. Verify that any pump interlock contacts have been properly installed. If the unit If the unit has

field-installed accessories, be sure all are properly in- stalled and wired correctly. Refer to unit wiring diagrams.

2.Use the Scrolling Marquee display to adjust the Cooling Set Point.

3.Fill chilled fluid circuit with clean water (with recom- mended inhibitor added) or other non-corrosive fluid to be cooled. Bleed all air out of the high points of the sys- tem. If chilled water is to be maintained at a temperature below 40 F (4.4 C) or outdoor temperatures are expected to be below 32 F (0° C), a brine of sufficient concentra- tion must be used to prevent freeze-up at anticipated suction temperatures. See Table 40.

4.Check tightness of all electrical connections.

5.Oil should be visible in the compressor sightglass(es). See Fig. 39. An acceptable oil level in the compressors is from ¼ to ¾ of sight glass. Adjust the oil level as re- quired. See Check Oil Charge section on page 60 for Sterling approved oils.

6.Electrical power source must agree with unit nameplate.

7.All condenser fan and factory installed hydronic package pump motors are three phase. Check for proper rotation of condenser fans first BEFORE attempting to start pumps or compressors. To reverse rotation, interchange any two of the main incoming power leads.

8.Be sure system is fully charged with refrigerant (see Check Refrigerant Charge section on page 75).

9.If unit is a brine unit, check to ensure proper brine con- centration is used to prevent freezing.

10.Verify proper operation of cooler and hydronic package heaters (if installed). Heaters operate at the same voltage as the main incoming power supply and are single phase. Heater current is approximately .4 amps for 380, 400, 460 and 575 v units. Heater current is approximately .8 amps for 230 v units.

Table 40 — Minimum Cooler Flow Rates and

Minimum Loop Volume

UNIT SIZE

COOLER MINIMUM

MINIMUM COOLER

 

FLOW

LOOP VOLUME

30RA

 

Gpm

 

L/s

Gal.

L

 

 

010

12

 

.76

40

151.2

015

16

 

1.01

55

207.9

018

19

 

1.20

48

181.4

022

26

 

1.64

65

245.7

025

29

 

1.83

71

268.3

030

33

 

2.08

82

309.3

035

42

 

2.65

102

393.1

040

45

 

2.80

113

449.8

042

48

 

3.02

119

427.1

045

52

 

3.28

129

487.6

050

57

 

3.59

142

536.6

055

65

 

4.10

163

616.1

START-UP AND OPERATION

NOTE: Refer to Start-Up Checklist on pages CL-1 to CL-8.

Actual Start-Up — Actual start-up should be done only under supervision of a qualified refrigeration mechanic.

1.Be sure all service valves are open.

2.Using the Scrolling Marquee display, set leaving-fluid set point (CSP.1) [Set Point, COOL]. No cooling range ad- justment is necessary.

3.Start chilled fluid pump (if not configured for cooler pump control).

4.Turn ENABLE/OFF/REMOTE CONTACT switch to ENABLE position.

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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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