Sterling 30RA010-055 manual Contents, General

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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