Sterlco AquaSnap 30RA010, Operation And Service Manual

Page 1: ...r death Misuse can be fatal Vapor is heavier than air and reduces the amount of oxygen available for breathing Product causes eye and skin irritation Decomposition products are hazardous DO NOT attempt to unbraze factory joints when servicing this equipment Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines Cut lines with a tubing cutter a...

Page 2: ...nents 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 PRESS...

Page 3: ...outputs from these modules will be turned off Board Addresses The Main Base Board MBB has a 3 position Instance jumper that must be set to 1 All other boards have 4 position DIP switches All switches are set to On for all boards Control Module Communication RED LED Proper operation of the control boards can be visually checked by looking at the red status LEDs light emitting diodes When operating ...

Page 4: ...SOR RETURN GAS TEMPERA TURE SENSOR ACCESSORY A well for this sensor is factory installed in each circuit s suction line If desired a 5 kΩ thermistor Sterling part number HH79NZ029 can be installed in this well and connected to the Main Base Board as shown in Table 2 Use the Scrolling Marquee display to con figure the sensor Configuration mode sub mode OPT1 enable item RG EN T9 OUTDOOR AIR TEMPERAT...

Page 5: ...ture sensor terminal block 3 Insert and secure the white ground wire to terminal 4 of the space temperature sensor 4 Insert and secure the black wire to terminal 2 of the space temperature sensor 5 Connect the other end of the communication bus cable to the remainder of the SCN communication bus T10 Dual Leaving Water Temperature Sensor For dual chiller applications parallel only are supported con...

Page 6: ...6 Fig 1 Typical Control Box for 30RA010 030 022 030 Shown ...

Page 7: ...7 Fig 2 Typical Control Box for 30RA032 055 042 055 Shown ...

Page 8: ...8 Fig 3 Wiring Schematic 30RA010 018 30RA010 018 AQUA SNAP ...

Page 9: ...9 SEE NOTE 8 SEE NOTE 8 Fig 3 Wiring Schematic 30RA010 018 cont AQUA SNAP LOW VOLTAGE CONTROL SCHEMATIC 010 018 ...

Page 10: ...10 Fig 4 Wiring Schematic 30RA022 030 30RA022 030 AQUA SNAP ...

Page 11: ...11 Fig 4 Wiring Schematic 30RA022 030 cont AQUA SNAP LOW VOLTAGE CONTROL SCHEMATIC 022 030 ...

Page 12: ...12 Fig 5 Wiring Schematic 30RA032 040 30RA032 040 AQUA SNAP ...

Page 13: ...13 Fig 5 Wiring Schematic 30RA032 040 cont AQUA SNAP LOW VOLTAGE CONTROL SCHEMATIC 032 040 ...

Page 14: ...14 Fig 6 Wiring Schematic 30RA042 055 30RA042 055 AQUA SNAP ...

Page 15: ...15 Fig 6 Wiring Schematic 30RA042 055 cont AQUA SNAP LOW VOLTAGE CONTROL SCHEMATIC 042 055 ...

Page 16: ...tatus Service Test Temperature Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Alarm Status ENTER MODE ESCAPE SW1 OFF ENABLE REMOTE CONTACT OFF SW2 ON CB2 CB1 TB3 ENABLE OFF REMOTE CONTACT SWITCH SCN COMMUNICATIONS EMERGENCY ON OFF SWITCH LEN SCN CN SHIELD COM Fig 7 Main Base Board Fig 8 LEN SCN Interface Enable Off Remote Contact Switch and Emergency On Off Swit...

Page 17: ...next If no compressors have been running for more than 30 minutes and the leaving fluid temperature is greater than the saturated condensing temperature the wear factor is still used to determine which compressor to start next If the leaving fluid temperature is less than the saturated condensing temperature then the control will start either compressor A1 or compressor B1 first depending on the u...

Page 18: ...Hz 1 25 A1 40 B1 2 60 A1 A2 65 A1 B1 3 100 A1 A2 B1 100 A1 A2 B1 035 50 Hz 1 33 A1 33 B1 2 67 A1 A2 67 A1 B1 3 100 A1 A2 B1 100 A1 A2 B1 040 1 32 A1 37 B1 2 63 A1 A2 68 A1 B1 3 100 A1 A2 B1 100 A1 A2 B1 042 045 50 Hz 050 055 1 25 A1 25 B1 2 50 A1 B1 50 A1 B1 3 75 A1 A2 B1 75 A1 B1 B2 4 100 A1 A2 B1 B2 100 A1 A2 B1 B2 045 60 Hz 1 22 A1 22 B1 2 44 A1 B1 44 A1 B1 3 72 A1 A2 B1 72 A1 B1 B2 4 100 A1 A2...

Page 19: ... 1 2 3 39 50 100 A1 A1 A1 A2 032 1 2 3 4 15 25 60 100 A1 A1 A1 A2 A1 A2 B1 30 40 65 100 B1 B1 A1 B1 A1 A2 B1 035 50 60 Hz 1 2 3 4 16 25 25 33 60 67 100 A1 A1 A1 A2 A1 A2 B1 32 25 40 33 65 67 100 B1 B1 A1 B1 A1 A2 B1 040 1 2 3 4 24 32 63 100 A1 A1 A1 A2 A1 A2 B1 29 37 68 100 B1 B1 A1 B1 A1 A2 B1 042 1 2 3 4 5 18 25 50 75 100 A1 A1 A1 B1 A1 A2 B1 A1 A2 B1 B2 18 25 50 75 100 B1 B1 A1 B1 A1 B1 B2 A1 A...

Page 20: ...events the capacity stages from being changed when the leaving fluid temperature is close to the set point within an adjustable deadband and moving towards the set point Ramp Loading CRMP Configuration SLCT Limits the rate of change of leaving fluid temperature If the unit is in a Cooling mode and configured for Ramp Loading the control makes 2 comparisons before deciding to change stages of ca pa...

Page 21: ...equipped with the Motormaster V head pressure controller option or accessory The control will automatically raise the head pressure set point by 5 F 2 8 C when Motormaster control is configured The controller is energized with the first fan stage and adjusts fan speed to maintain a liquid pressure of 135 psig 931 kPa For sizes 010 018 and Circuit B of sizes 032 040 the two speed fan is wired for h...

Page 22: ...variable is Start Table 8 illustrates how the control method and cooling set point select variables direct the operation of the chiller and the set point to which it controls The illustration also shows the ON OFF state of the machine for the given combinations Cooling Set Point Select SINGLE Unit operation is based on Cooling Set Point 1 CSP1 Set Point COOL DUAL SWITCH Unit operation is based on ...

Page 23: ...t modes are password protected The display will flash PASS and WORD when required Use the and arrow keys to enter the 4 digits of the password The default password is 1111 Changing item values or testing outputs is accomplished in the same manner Locate and display the desired item Press to stop the display at the item value Press the key again so that the item value flashes Use the arrow keys to ...

Page 24: ...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...

Page 25: ...rt 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...

Page 26: ...s be configured for CTRL 0 Switch If the chillers are to be controlled by Remote Contacts both Master and Slave chillers should be enabled together Two separate relays or one relay with two sets of contacts may control the chillers The Enable Off Remote Contact switch should be in the Remote Contact position on both the Master and Slave chillers The Enable Off Remote Contact switch should be in th...

Page 27: ...MS ALERTS TIME XX XX TIME OF DAY 00 00 23 59 MNTH XX MONTH OF YEAR 1 January 2 February etc DATE XX DAY OF MONTH 01 31 YEAR XX YEAR OF THE CENTURY RUN HRS U XXXX HRS MACHINE OPERATING HOURS STR U XXXX MACHINE STARTS HR P1 XXXX X PUMP 1 RUN HOURS HR P2 XXXX X PUMP 2 RUN HOURS HOUR HRS A XXXX HRS CIRCUIT A RUN HOURS HRS B XXXX HRS CIRCUIT B RUN HOURS See Note HR A1 XXXX HRS COMPRESSOR A1 RUN HOURS H...

Page 28: ...RS STRAINER SRVC COUNTDOWN S T MN YES NO STRAINER MAINT DONE User Entry ST DT STRAINER MAINT DATES S T M0 MM DD YY HH MM S T M1 MM DD YY HH MM S T M2 MM DD YY HH MM S T M3 MM DD YY HH MM S T M4 MM DD YY HH MM COIL COIL MAINTENANCE SI CL XXXX HRS COIL SRVC INTER C L DN XXXX HRS COIL SERVICE COUNTDOWN C L MN YES NO COIL MAINT DONE User Entry CL DT COIL MAINTENANCE DATES C L M0 MM DD YY HH MM C L M1 ...

Page 29: ...TE ALARM RELAY CMPA CIRCUIT A COMPRESSOR TEST CC A1 ON OFF COMPRESSOR A1 RELAY CC A2 ON OFF COMPRESSOR A2 RELAY MLV ON OFF MINIMUM LOAD VALVE RELAY CMPB CIRCUIT B COMPRESSOR TEST See Note CC B1 ON OFF COMPRESSOR B1 RELAY CC B2 ON OFF COMPRESSOR B2 RELAY MLV ON OFF MINIMUM LOAD VALVE RELAY SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT UNIT ENT AND LEAVE UNIT TEMPS CEWT XXX X F COOLER EN...

Page 30: ...SURE SETPOINTS HD P A XXX X F CALCULATED HP SETPOINT A Default 113 F Read Only HD P B XXX X F CALCULATED HP SETPOINT B Default 113 F Read Only FRZ BRINE FREEZE SETPOINT BR FZ XXX X F BRINE FREEZE POINT Default 34 F SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT GEN I GENERAL INPUTS STST STRT STOP START STOP SWITCH FLOW ON OFF COOLER FLOW SWITCH PM F 1 OPEN CLSE COOLER PUMP 1 INTERLOCK L...

Page 31: ...RESSOR B2 RELAY SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT DISP DISPLAY CONFIGURATION TEST ON OFF TEST DISPLAY LEDS METR ON OFF METRIC DISPLAY Off English On Metric LANG X LANGUAGE SELECTION Default 0 0 English 1 Espanol 2 Francais 3 Portuguese PAS E ENBL DSBL PASSWORD ENABLE PASS xxxx SERVICE PASSWORD UNIT UNIT CONFIGURATION SZA 1 XX COMPRESSOR A1 SIZE Unit Size 60 Hz 50 Hz 010 015...

Page 32: ...Control SCNA XXX SCN ADDRESS Default 1 Range 1 to 239 SCNB XXX SCN BUS NUMBER Default 0 Range 0 to 239 BAUD X SCN BAUD RATE Default 9600 1 2400 2 4800 3 9600 4 19 200 5 38 400 LOAD X LOADING SEQUENCE SELECT Default Equal 1 Equal 2 Staged LLCS X LEAD LAG CIRCUIT SELECT Default Automatic 1 Automatic 2 Circuit A Leads 3 Circuit B Leads LCWT XX X F HIGH LCW ALERT LIMIT Default 60 Range 2 to 60 F DELY ...

Page 33: ...efault Disable MSSL SLVE MAST MASTER SLAVE SELECT Default Master SLVA XXX SLAVE ADDRESS Default 2 Range 0 to 239 LLBL X LEAD LAG BALANCE SELECT Default Master Leads 0 Master Leads 1 Slave Leads 2 Automatic LLBD XXX LEAD LAG BALANCE DELTA Default 168 hours Range 40 to 400 hours LLDY XXX LAG START DELAY Default 5 minutes Range 0 to 30 minutes PARA YES PARALLEL CONFIGURATION Default YES CANNOT BE CHA...

Page 34: ...nge 0 99 SCH N XX SCHEDULE NUMBER Default 1 Range 1 99 SCH L LOCAL OCCUPANCY SCHEDULE PER 1 OCCUPANCY PERIOD 1 OCC 1 XX XX PERIOD OCCUPIED TIME Military 00 00 23 59 UNC 1 XX XX PERIOD UNOCCUPIED TIME Military 00 00 23 59 MON 1 YES NO MONDAY IN PERIOD TUE 1 YES NO TUESDAY IN PERIOD WED 1 YES NO WEDNESDAY IN PERIOD THU 1 YES NO THURSDAY IN PERIOD FRI 1 YES NO FRIDAY IN PERIOD SAT 1 YES NO SATURDAY I...

Page 35: ...PERIOD TUE 4 YES NO TUESDAY IN PERIOD WED 4 YES NO WEDNESDAY IN PERIOD THU 4 YES NO THURSDAY IN PERIOD FRI 4 YES NO FRIDAY IN PERIOD SAT 4 YES NO SATURDAY IN PERIOD SUN 4 YES NO SUNDAY IN PERIOD HOL 4 YES NO HOLIDAY IN PERIOD PER 5 OCCUPANCY PERIOD 5 OCC 5 XX XX PERIOD OCCUPIED TIME Military 00 00 23 59 UNC 5 XX XX PERIOD UNOCCUPIED TIME Military 00 00 23 59 MON 5 YES NO MONDAY IN PERIOD TUE 5 YES...

Page 36: ... YES NO THURSDAY IN PERIOD FRI 7 YES NO FRIDAY IN PERIOD SAT 7 YES NO SATURDAY IN PERIOD SUN 7 YES NO SUNDAY IN PERIOD HOL 7 YES NO HOLIDAY IN PERIOD PER 8 OCCUPANCY PERIOD 8 OCC 8 XX XX PERIOD OCCUPIED TIME Military 00 00 23 59 UNC 8 XX XX PERIOD UNOCCUPIED TIME Military 00 00 23 59 MON 8 YES NO MONDAY IN PERIOD TUE 8 YES NO TUESDAY IN PERIOD WED 8 YES NO WEDNESDAY IN PERIOD THU 8 YES NO THURSDAY...

Page 37: ...SET MD15 ON OFF DEMAND SOUND LIMITED MD16 ON OFF COOLER FREEZE PROTECTION MD17 ON OFF LOW TEMPERATURE COOLING MD18 ON OFF HIGH TEMPERATURE COOLING MD19 ON OFF MAKING ICE MD20 ON OFF STORING ICE MD21 ON OFF HIGH SCT CIRCUIT A MD22 ON OFF HIGH SCT CIRCUIT B MD23 ON OFF MINIMUM COMP ON TIME MD24 ON OFF PUMP OFF DELAY TIME MD25 ON OFF LOW SOUND MODE MD26 ON OFF SHORT LOOP OVERRIDE FSM Flotronic System...

Page 38: ...HILLER ENABLE 15 ITEMS LLEN DSBL SCROLLING STOPS DSBL VALUE FLASHES ENBL SELECT ENBL LLEN ENBL LEAD LAG CHILLER ENABLE CHANGE ACCEPTED LLEN MSSL MASTER SLAVE SELECT MSSL MAST MASTER SLAVE SELECT DEFAULT MAST MSSL SLVA SLAVE ADDRESS SLVA 0 SCROLLING STOPS 0 VALUE FLASHES 2 SELECT 2 SLVA 2 SLAVE ADDRESS CHANGE ACCEPTED SLVA LLBL LEAD LAG BALANCE SELECT LLBL 0 SCROLLING STOPS 0 VALUE FLASHES 2 SELECT...

Page 39: ...UB MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS RSET LLBL 2 LEAD LAG BALANCE SELECT CHANGE ACCEPTED LLBL LLBD LEAD LAG BALANCE DELTA LLBD 168 LEAD LAG BALANCE DELTA DEFAULT 168 LLBD LLDY LAG START DELAY LLDY 5 SCROLLING STOPS 5 VALUE FLASHES 10 SELECT 10 LLDY 10 LAG START DELAY CHANGE ACCEPTED LLDY RSET PARA YES MASTER COMPLETE ENTER ESCAPE ENTER ESCAPE ENTER ENTER ENTER ESCAPE ESCAPE EN...

Page 40: ...RESS SCROLLING STOPS 1 VALUE FLASHES 2 SELECT 2 SEE NOTE 1 SCNA 2 SCN ADDRESS CHANGE ACCEPTED SCNA SCNB SCNB 0 SCN BUS NUMBER DEFAULT 0 SEE NOTE 2 SCNB OPT2 RSET PROCEED TO SUBMODE RSET RSET CRST COOLING RESET TYPE LLEN LEAD LAG CHILLER ENABLE 15 ITEMS LLEN DSBL SCROLLING STOPS DSBL VALUE FLASHES ENBL SELECT ENBL LLEN ENBL LEAD LAG CHILLER ENABLE CHANGE ACCEPTED LLEN MSSL MASTER SLAVE SELECT MSSL ...

Page 41: ...be modified based on return fluid outdoor air temperature space temperature or 4 to 20 mA signal 15 DEMAND SOUND LIMITED Demand limit is in effect This indicates that the capacity of the chiller is being limited by demand limit control option Because of this limitation the chiller may not be able to pro duce the desired leaving fluid temperature Demand limit can be controlled by switch inputs or a...

Page 42: ...S NO Alarms alerts clear YES changes to NO SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT RSET CRST 1 COOLING RESET TYPE 0 no reset 1 4 to 20 mA input 2 Outdoor air temp 3 Return Fluid 4 Space Temperature CRT1 4 0 NO COOL RESET TEMP Default 125 F 51 7 C Range 0 to 125 F CRT2 20 0 FULL COOL RESET TEMP Default 0 F 17 8 C Range 0 to 125 F DGRC 5 0 F 2 8 C DEGREES COOL RESET Default 0 F 0 C...

Page 43: ...amount of reset desired To use Return reset four variables must be configured In the Configuration mode under the sub mode RSET items CRST RT NO RT F and RT DG must be properly set See Table 26B Configuring Return Temperature Reset This ex ample provides 5 0 F 2 8 C chilled water set point reset at MODE RED LED KEYPAD ENTRY SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT Outdoor Air Spac...

Page 44: ...uce the capacity if required NOTE The 2 stage switch control and 4 to 20 mA input sig nal types of demand limiting require the Energy Management Module EMM To use Demand Limit select the type of demand limiting to use Then configure the Demand Limit set points based on the type selected DEMAND LIMIT 2 Stage Switch Controlled To con figure Demand Limit for 2 stage switch control set the Demand Limi...

Page 45: ...the leaving fluid temperature set point Connect the signal to TB6 3 5 See Table 27 for instructions to enable the function Figure 21B shows how the 4 to 20 mA sig nal is linearly calculated on an overall 10 F to 80 F range for fluid types FLUD 1 or 2 Configuration OPT1 The set point will be limited by the fluid FLUD type Be sure that the chilled water loop is protected at the lowest temperature Ca...

Page 46: ...shuts down when cooling load has been satisfied Unit restarts when required to satisfy leaving fluid temperature set point THERMISTOR FAILURE If a thermistor fails in either an open or shorted condition the unit will be shut down Replace T1 T2 or T9 as required Unit restarts automatically but must be reset manually by resetting the alarm with the Scrolling Marquee as shown in Table 24 LOW SATURATE...

Page 47: ...ge system Condenser scaled dirty Clean condenser Condenser water pump or fans not operating Start pump repair or replace if defective System overcharged with refrigerant Reduce charge Unit Operates Too Long or Continuously Low refrigerant charge Add refrigerant Control contacts fused Replace control Air in system Purge system Partially plugged or plugged expansion valve or filter drier Clean or re...

Page 48: ...WP Chilled Water Pump EMM Energy Management FC Fan Contactor FIOP Factory Installed Option FU Fuse GND Ground MBB Main Base Board MM Motormaster MMPT Motormaster Pressure Transducer MS Manual Starter NEC National Electrical Code SW Switch TB Terminal Block TRAN Transformer Factory Wiring Field Wiring Accessory or Option Wiring ...

Page 49: ...WP Chilled Water Pump EMM Energy Management FC Fan Contactor FIOP Factory Installed Option FU Fuse GND Ground MBB Main Base Board MM Motormaster MMPT Motormaster Pressure Transducer MS Manual Starter NEC National Electrical Code SW Switch TB Terminal Block TRAN Transformer Factory Wiring Field Wiring Accessory or Option Wiring ...

Page 50: ...WP Chilled Water Pump EMM Energy Management FC Fan Contactor FIOP Factory Installed Option FU Fuse GND Ground MBB Main Base Board MM Motormaster MMPT Motormaster Pressure Transducer MS Manual Starter NEC National Electrical Code SW Switch TB Terminal Block TRAN Transformer Factory Wiring Field Wiring Accessory or Option Wiring ...

Page 51: ...lled water pump 1 CWP1 starter Terminals 13 and 15 of TB5 are for control of chilled water pump 2 CWP2 starter The maximum load allowed for the chilled water pump relay is 5 va sealed 10 va inrush at 24 v Field power supply is not required 6 Terminals 12 and 13 of TB5 are for an alarm relay The maximum load allowed for the alarm relay is 5 va sealed 10 va inrush at 24 v Field power supply is not r...

Page 52: ... water pump 1 CWP1 starter Terminals 13 and 15 of TB5 are for control of chilled water pump 2 CWP2 starter The maximum load allowed for the chilled water pump relay is 5 va sealed 10 va inrush at 24 v Field power supply is not required 6 Terminals 12 and 13 of TB5 are for an alarm relay The maximum load allowed for the alarm relay is 75 va sealed 360 va inrush at 115 v Field power supply is not re...

Page 53: ... wiring error A061 Alarm Cooler Entering Fluid Thermistor Failure T2 Thermistor outside range of 40 to 245 F 40 to 118 C Chiller shutdown immediately Automatic Thermistor failure damaged cable wire or wiring error T068 None Circuit A Return Gas Thermistor Failure If return gas sensors are enabled RG EN and thermistor is outside range of 40 to 245 F 40 to 118 C None Automatic Thermistor failure dam...

Page 54: ...estart after first daily occurrence Manual restart thereafter Faulty expansion valve faulty suction pressure transducer faulty suction gas thermistor circuit overcharged T116 Alert Circuit A Low Cooler Suction Temperature Mode 7 caused the com pressor to unload 6 consecu tive times with less than a 30 minute interval between each circuit shutdown Circuit shut down Manual Faulty expansion valve low...

Page 55: ...igured with EMM and input less than 2 mA or greater than 22 mA Set point function disabled Chiller controls to CSP1 Automatic Faulty signal generator wiring error or faulty EMM T176 Alert 4 to 20 mA Temperature Reset Input Failure If configured with EMM and input less than 2 mA or greater than 22 mA Reset function disabled Chiller returns to normal set point control Automatic Faulty signal generat...

Page 56: ...Cooler Pump Interlock Closed When Pump is Off If configured for cooler pump control and flow switch input is closed for 5 minutes while pump output s are off Chiller shut down Automatic when aux contacts open Wiring error faulty pump contactor welded contacts T203 Alert Loss of Communication with slave chiller Master chiller MBB loses communication with slave chiller MBB Dual chiller control disab...

Page 57: ...e been received by the MBB within 5 minutes of last transmission WSM forces removed Chiller runs under own control Automatic Failed module wiring error failed transformer loose connection plug wrong address T951 Alert Loss of Communication with Flotronic System Manager No communications have been received by the MBB within 5 minutes of last transmission FSM forces removed Chiller runs under own co...

Page 58: ...ions and high pressure switch internal thermostat wiring as on the old com pressor Refer to Fig 27 30 Following the installation of the new compressor tighten all hardware to the following specifi cations See Table 30 Table 30 Unit Torque Specification Cooler BRAZED PLATE COOLER HEAT EXCHANGER RE PLACEMENT Brazed plate heat exchangers cannot be repaired if they develop a leak If a leak refrigerant...

Page 59: ...P A1 COMP A2 COMP B1 COMP B2 COMP A1 COMP A2 Fig 27 Typical Compressor Mounting All Sizes Fig 28 Compressor Wiring Fig 29 Compressor Location 30RA010 030 Fig 30 Compressor Location 30RA032 055 LEGEND HPS High Pressure Switch ...

Page 60: ...ompletely removed prior to using low velocity clean water rinse Periodic Clean Water Rinse A periodic clean water rinse is very beneficial for coils that are applied in coastal or industrial environments However it is very important that the water rinse is made with very low velocity water stream to avoid damaging the fin edges Monthly cleaning as described below is recommended Routine Cleaning of...

Page 61: ... sizes units have 1 filter drier per circuit MOISTURE LIQUIDINDICATOR The indicator is located immediately ahead of the TXV to provide an indication of the refrigerant moisture content It also provides a sight glass for refrigerant liquid Clear flow of liquid refrigerant at full unit loading indicatessufficient chargeinthesystem Bubblesin the sightglass atfullunitloading indicate anunderchargedsys...

Page 62: ... pressure conditions See Table 32 for high pressure switch settings The high pressure switch is mounted in the discharge side of each compressor A snubber is provided between the com pressor discharge manifold and the high pressure switch to pre vent pressure pulsations from damaging the switch The high pressure switch is mounted in the discharge line of each compressor If an unsafe high pressure ...

Page 63: ...e sensor tem perature from Tables 33 36 3 To check thermistor accuracy measure temperature at probe location with an accurate thermocouple type tem perature measuring instrument Insulate thermocouple to avoid ambient temperatures from influencing reading Temperature measured by thermocouple and temperature determined from thermistor voltage reading should be close 5 F 3 C if care was taken in appl...

Page 64: ...5 1 361 4 096 86 1 340 4 000 87 1 319 3 906 88 1 298 3 814 89 1 278 3 726 90 1 257 3 640 91 1 237 3 556 92 1 217 3 474 93 1 198 3 395 94 1 179 3 318 95 1 160 3 243 96 1 141 3 170 97 1 122 3 099 98 1 104 3 031 99 1 086 2 964 100 1 068 2 898 101 1 051 2 835 102 1 033 2 773 103 1 016 2 713 104 0 999 2 655 105 0 983 2 597 106 0 966 2 542 107 0 950 2 488 108 0 934 2 436 109 0 918 2 385 110 0 903 2 335 ...

Page 65: ...1 22 1 666 5 710 23 1 623 5 461 24 1 580 5 225 25 1 538 5 000 26 1 497 4 786 27 1 457 4 583 28 1 417 4 389 29 1 378 4 204 30 1 340 4 028 31 1 302 3 861 32 1 265 3 701 33 1 229 3 549 34 1 194 3 404 35 1 160 3 266 36 1 126 3 134 37 1 093 3 008 38 1 061 2 888 39 1 030 2 773 40 0 999 2 663 41 0 969 2 559 42 0 940 2 459 43 0 912 2 363 44 0 885 2 272 45 0 858 2 184 46 0 832 2 101 47 0 807 2 021 48 0 782...

Page 66: ...69 88 2 173 7 685 89 2 144 7 507 90 2 115 7 333 91 2 087 7 165 92 2 059 6 999 93 2 030 6 838 94 2 003 6 683 95 1 975 6 530 96 1 948 6 383 97 1 921 6 238 98 1 894 6 098 99 1 867 5 961 100 1 841 5 827 101 1 815 5 698 102 1 789 5 571 103 1 763 5 449 104 1 738 5 327 105 1 713 5 210 106 1 688 5 095 107 1 663 4 984 108 1 639 4 876 109 1 615 4 769 110 1 591 4 666 111 1 567 4 564 112 1 544 4 467 113 1 521...

Page 67: ...5 10 449 25 2 500 10 000 26 2 445 9 571 27 2 391 9 164 28 2 337 8 776 29 2 284 8 407 30 2 231 8 056 31 2 178 7 720 32 2 127 7 401 33 2 075 7 096 34 2 025 6 806 35 1 975 6 530 36 1 926 6 266 37 1 878 6 014 38 1 830 5 774 39 1 784 5 546 40 1 738 5 327 41 1 692 5 117 42 1 648 4 918 43 1 605 4 727 44 1 562 4 544 45 1 521 4 370 46 1 480 4 203 47 1 439 4 042 48 1 400 3 889 49 1 362 3 743 50 1 324 3 603 ...

Page 68: ...efault The set point is displayed in speed as Hz and is configured by the start command jumper as detailed in Fig 38 Motormaster V control can also be configured to follow an external control system to perform the PI control functions See configuration section for details The real time feedback signal liquid line pressure in volts is displayed by viewing parameter 69 The real time output fre quenc...

Page 69: ...password To disable automatic control mode and enter manual speed control mode 1 Change P05 to 01 keypad 2 Push UP and DOWN arrow key to set manual speed 3 Set P05 to 05 R22 to restore automatic control To provide manual start stop control With power removed from VFD remove start command jumper and install a switch between the appropriate start termi nals as required in Fig 37 EPM CHIP The drive u...

Page 70: ...otormaster V Mode Buttons and Mode Display At 208 v the drive can run in either mode MODE NOMINAL VOLTAGE Hz CONTROL INPUT PIN 5 START JUMPER SETPOINT JUMPER REFRIGERANT 1 208 230 460 575 60 Internal PI control 0 5V feedback TB1 TB2 None R 22 2 208 230 60 Internal PI control 0 5V feedback TB13A TB2 None 3 230 50 Internal PI control 0 5V feedback TB13B TB2 None 4 380 415 50 Internal PI control 0 5V...

Page 71: ...requency to reduce the output current If the drive remains in CURRENT LIMIT too long it can trip into a CURRENT OVERLOAD fault PF Check for loose electrical connections Check for faulty condenser fan motor Check Parameter P25 from Table 38 is set cor rectly GF Data Fault User data and OEM defaults in the EPM are corrupted Restore factory defaults P48 see section above If that does not work replace...

Page 72: ...0 Hz 60 60 50 50 P28 Fixed boost 0 5 at low frequencies 0 5 0 5 0 5 0 5 P29 Accel boost 0 0 0 0 0 P30 Slip compensation 0 0 0 0 0 P31 Preset spd 1 speed if loss of control signal 57 57 47 47 P32 Preset spd 2 0 0 0 0 0 P33 Preset spd 3 0 0 0 0 0 P34 Preset spd 4 default R22 set point TB12 2 open 18 0 18 0 18 0 18 0 P35 Preset spd 5 default R134a set point TB12 2 closed 12 6 12 6 12 6 12 6 P36 Prese...

Page 73: ...ead 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 uni...

Page 74: ...ll 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 tempera...

Page 75: ...s required to reach this temperature range Add refrigerant un til the system subcooling SCT A or SCT B minus liquid line temperature entering TXV is approximately 15 to 17 F 9 4 to 8 3 C Refrigerant VAPOR only may be added to a circuit through the 1 4 in suction Schraeder connection on the com pressor This connection is located in line and to the left of the compressor junction box for the SM110 c...

Page 76: ...n the unit receives a call for cooling either from the internal control or SCN network command or remote con tact closure the unit stages up in capacity to maintain the leav ing fluid set point The first compressor starts 11 2 to 3 minutes after the call for cooling The lead circuit can be specifically designated on all models or selected based on compressor run hours and starts depend ing on fiel...

Page 77: ...tes MIN_LEFT N PUMPS Cooler Pump Relay 1 Off On COOLPMP1 N Cooler Pump Relay 2 Off On COOLPMP2 N Cooler Pump 1 Interlock Open Close PMP1_FBK N Cooler Pump 2 Interlock Open Close PMP2_FBK N Cooler Flow Switch Open Close COOLFLOW N Rotate Cooler Pumps Now No Yes ROT_PUMP Heat Cool Select Heat Cool HC_SEL N DESCRIPTION VALUE UNITS POINT NAME FORCEABLE CIRC A DISCRETE OUTPUTS Compressor A1 Relay On Of...

Page 78: ... F TMP_SCTB N Saturated Suction Temp snnn n F TMP_SSTB N Compr Return Gas Temp snnn n F TMP_RGTB N Suction Superheat Temp snnn n F SH_B N DESCRIPTION VALUE UNITS POINT NAME FORCEABLE FANS Fan 1 Relay Off On FAN_1 N Fan 2 Relay Off On FAN_2 N Cooler Pump Heater Off On COOL_HTR N UNIT ANALOG VALUES Cooler Entering Fluid snnn n F COOL_EWT N Cooler Leaving Fluid snnn n F COOL_LWT N Lead Lag Leaving Fl...

Page 79: ...Start Month 1 to 12 4 STARTM Week 1 to 5 1 STARTW Day 1 to 7 7 STARTD Minutes to Add 0 to 99 60 min MINADD Daylight Savings Stop Month 1 to 12 10 STOPM Week 1 to 5 5 STOPW Day 1 to 7 7 STOPD Minutes to Subtract 0 to 99 60 min MINSUB DESCRIPTION VALUE DEFAULT UNITS POINT NAME Service Password nnnn 1111 PASSWORD Password Enable Enable Disable Enable PASS_EBL Metric Display Off On Off DISPUNIT Langua...

Page 80: ...INT NAME Control Method 0 Switch 2 Occupancy 3 SCN 0 CONTROL Loading Sequence Select 1 Equal Loading 2 Staged Loading 1 SEQ_TYP Lead Lag Circuit Select 0 Automatic 1 Circuit A Leads 2 Circuit B Leads 0 LEAD_TYP Cooling Setpoint Select 0 Single 1 Dual remote switch controlled 2 Dual SCN occupancy 3 4 20 mA input 0 CLSP_TYP Ramp Load Select Enable Dsable Enable RAMP_EBL Heat Cool Select Cool Heat Co...

Page 81: ... DEMAND LIMIT Demand Limit Select 0 None 1 External switch input 2 4 20 mA input 3 Loadshed 0 DMD_CTRL Demand Limit at 20 mA 0 to 100 100 DMT20MA Loadshed Group Number 0 to 99 0 SHED_NUM Loadshed Demand Delta 0 to 60 0 SHED_DEL Maximum Loadshed Time 0 to 120 60 minutes SHED_TIM Demand Limit Switch 1 0 to 100 80 DLSWSP1 Demand Limit Switch 2 0 to 100 50 DLSWSP2 DESCRIPTION VALUE DEFAULT UNITS POINT...

Page 82: ...2 040 4 Four Fans 042 055 FAN_TYPE DESCRIPTION VALUE POINT NAME Active Alarm 1 Axxx or Txxx ALARM01C Active Alarm 2 Axxx or Txxx ALARM02C Active Alarm 3 Axxx or Txxx ALARM03C Active Alarm 4 Axxx or Txxx ALARM04C Active Alarm 5 Axxx or Txxx ALARM05C Active Alarm 6 Axxx or Txxx ALARM06C Active Alarm 7 Axxx or Txxx ALARM07C Active Alarm 8 Axxx or Txxx ALARM08C Active Alarm 9 Axxx or Txxx ALARM09C Act...

Page 83: ..._23 Pump Off Delay Time On Off MODE_24 Low Sound Mode On Off MODE_25 Short Loop Override On Off MODE_26 DESCRIPTION VALUE UNITS POINT NAME Dual Chiller Link Good Yes No DC_LINK Master Chiller Role Stand Alone Lead Chiller Lag Chiller MC_ROLE Slave Chiller Role Stand Alone Lead Chiller Lag Chiller SC_ROLE Lead Chiller Ctrl Point snnn n F LEAD_CP Lag Chiller Ctrl Point snnn n F LAG_CP Control Point ...

Page 84: ...GM for Compressor A2 nn n SAGA2M SAGP for Compressor B1 nn n SAGB1P SAGM for Compressor B1 nn n SAGB1M SAGP for Compressor B2 nn n SAGB2P SAGM for Compressor B2 nn n SAGB2M DESCRIPTION VALUE UNITS POINT NAME CAPACITY CONTROL Load Unload Factor snnn n SMZ Control Point snnn n F CTRL_PNT Entering Fluid Temp snnn n F EWT Leaving Fluid Temp snnn n F LWT Ramp Load Limited On Off MODE_5 Slow Change Over...

Page 85: ...CDOWN Pump 2 Maintenance Done Yes No P2_MAINT Pump 1 Maintenance Date mm dd yy hh mm PMP1_PM0 Pump 1 Maintenance Date mm dd yy hh mm PMP1_PM1 Pump 1 Maintenance Date mm dd yy hh mm PMP1_PM2 Pump 1 Maintenance Date mm dd yy hh mm PMP1_PM3 Pump 1 Maintenance Date mm dd yy hh mm PMP1_PM4 Pump 2 Maintenance Date mm dd yy hh mm PMP2_PM0 Pump 2 Maintenance Date mm dd yy hh mm PMP2_PM1 Pump 2 Maintenance...

Page 86: ...B Calculated HP Setpoint B nnn n F HSP_B Saturated Condensing Tmp nnn n F TMP_SCTB Saturated Suction Temp nnn n F TMP_SSTB Compr Return Gas Temp nnn n F TMP_RGTB Suction Superheat Temp nnn n F SH_B Compressor B1 Relay On Off K_B1_RLY Compressor B2 Relay On Off K_B2_RLY Minimum Load Valve Relay On Off MLV_RLY Compressor B1 Feedback On Off K_B1_FBK Compressor B2 Feedback On Off K_B2_FBK Fan 1 Relay ...

Page 87: ...tarts nnnnnn CY_A2 Circuit B Starts nnnnnn CY_CIRB Compressor B1 Starts nnnnnn CY_B1 Compressor B2 Starts nnnnnn CY_B2 PUMP HOURS Pump 1 Run Hours nnnnnn hours HR_PUMP1 Pump 2 Run Hours nnnnnn hours HR_PUMP2 DESCRIPTION VALUE UNITS POINT NAME Service Test Mode On Off NET_CTRL Compressor A1 Relay On Off S_A1_RLY Compressor A2 Relay On Off S_A2_RLY Compressor B1 Relay On Off S_B1_RLY Compressor B2 R...

Page 88: ...CRIPTION VALUE UNITS POINT NAME WSM Active Yes WSMSTAT Chilled water temp snn n F CHWTEMP Equipment status On CHLRST Commanded state Enable Dsable None CHLRENA CHW setpoint reset value nn n F CHWRVAL Current CHW setpoint snn n F CHWSTPT ...

Page 89: ... 7 018 575 3 60 100 13 6 13 6 3 6 1 8 1 9 2 5 2 5 3 6 380 3 60 200 21 21 5 5 1 8 2 9 3 7 3 7 5 4 230 3 60 400 31 9 31 9 9 1 2 5 4 8 6 2 6 2 8 9 208 230 3 60 500 35 4 35 4 10 1 2 5 5 3 7 0 7 0 9 8 460 3 60 600 16 9 16 9 4 6 1 8 2 8 3 1 3 1 4 4 230 3 50 800 33 7 33 7 7 6 2 5 3 4 4 8 4 8 6 1 380 415 3 50 900 18 7 18 7 4 6 1 8 2 0 2 9 2 9 3 7 022 575 3 60 100 14 6 19 9 2 3 1 8 1 9 2 5 2 5 3 6 380 3 60...

Page 90: ... 380 3 60 200 31 7 31 7 36 1 5 5 3 5 1 8 3 7 5 4 9 1 230 3 60 400 44 44 52 6 9 1 5 8 2 5 6 2 8 9 15 1 208 230 3 60 500 49 49 58 4 10 1 7 0 2 5 7 0 9 8 16 7 460 3 60 600 24 2 24 2 28 6 4 6 2 9 1 8 3 1 4 4 7 6 042 230 3 50 800 40 9 40 9 40 9 40 9 4 6 2 5 4 8 6 1 10 4 380 415 3 50 900 23 8 23 8 23 8 23 8 3 7 1 8 2 9 3 7 6 4 045 575 3 60 100 15 5 19 9 15 5 19 9 2 3 1 8 2 5 3 6 6 0 380 3 60 200 24 2 31...

Page 91: ...f On Off On Open Close Open Close Off On 0 1 2 No Yes Heat Cool F C F C F C F C Minutes STAT OCC CHIL_S_S LSACTIVE ALM DEM_LIM MODE CAP_T STAGE SP CTRL_PNT EWT LWT EMSTOP MIN_LEFT COOLPMP1 COOLPMP2 PMP1_FBK PMP2_FBK COOLFLOW LEADPUMP ROT_PUMP HC_SEL RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RW RO RO RW RO RO RO RO RW RO RO RW RO RO RO RO RO RO RO RO RO RO RO RW NA ...

Page 92: ... RO RO RO RO RO RO RO RO RW RW RO RO RO RO RO RO RO RO RO RO NA RO RO NA RO NA NA RO NA NA RO NA NA NA NA SETPOINT COOLING Cooling Setpoint 1 Cooling Setpoint 2 Ice Setpoint RAMP LOADING Cooling Ramp Loading Brine Freeze Point 20 to 70 28 8 to 21 1 20 to 70 28 8 to 21 1 20 to 32 28 8 to 0 0 0 2 to 2 0 0 1 to 1 1 20 to 34 28 8 to 1 1 F C F C F C dF dC F C CSP1 CSP2 CSP3 CRAMP BRN_FRZ NA NA NA NA NA...

Page 93: ...IT MODEL ______________________________ SERIAL ________________________________ II Preliminary Equipment Check IS THERE ANY PHYSICAL DAMAGE YES NO DESCRIPTION ____________________________________________________________________________ ________________________________________________________________________________________ 1 UNIT IS INSTALLED LEVEL AS PER THE INSTALLATION INSTRUCTIONS YES NO 2 POW...

Page 94: ...ATE RANGE YES NO 5 CONTROL TRANSFORMER PRIMARY CONNECTION SET FOR PROPER VOLTAGE YES NO 6 CONTROL TRANSFORMER SECONDARY VOLTAGE 7 CHECK VOLTAGE IMBALANCE A B A C B C AVERAGE VOLTAGE A B A C B C 3 MAXIMUM DEVIATION FROM AVERAGE VOLTAGE VOLTAGE IMBALANCE ____________ MAX DEVIATION AVERAGE VOLTAGE X 100 VOLTAGE IMBALANCE LESS THAN 2 YES NO DO NOT START CHILLER IF VOLTAGE IMBALANCE IS GREATER THAN 2 C...

Page 95: ...SATURATED CONDENSING TEMP SCT A SCT B SATURATED SUCTION TEMP SST A SST B LIQUID LINE TEMPERATURE DISCHARGE LINE TEMPERATURE RETURN GAS TEMPERATURE COOLER EWT EWT COOLER LWT LWT OUTDOOR AIR TEMPERATURE OAT CONTROL POINT CTPT PERCENT TOTAL CAPACITY CAP LEAD LAG LEAVING FLUID DLWT Dual Chiller Control Only COMPRESSOR MOTOR CURRENT L1 L2 L3 COMPRESSOR A1 COMPRESSOR A2 COMPRESSOR B1 COMPRESSOR B2 CONDE...

Page 96: ..._________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ ______...

Page 97: ...MPRESSOR B2 SIZE SH SP XX X F SUPERHEAT SETPOINT REFG X REFRIGERANT FAN S X FAN STAGING SELECT SUBMODE ITEM DISPLAY DESCRIPTION VALUE OPT1 UNIT OPTIONS 1 HARDWARE FLUD X COOLER FLUID MLV S YES NO MINIMUM LOAD VALVE SELECT MMR S YES NO MOTORMASTER SELECT RG EN ENBL DSBL RETURN GAS SENSOR ENABLE CPC ON OFF COOLER PUMP CONTROL PM1E YES NO COOLER PUMP 1 ENABLE PM2E YES NO COOLER PUMP 2 ENABLE PM P S Y...

Page 98: ... LS ND 00 00 LOW SOUND END TIME LS LT XXX LOW SOUND CAPACITY LIMIT SUBMODE ITEM DISPLAY DESCRIPTION VALUE RSET RESET COOL TEMP CRST X COOLING RESET TYPE MA DG XX X F 4 20 DEGREES RESET RM NO XXX X F REMOTE NO RESET TEMP RM F XXX X F REMOTE FULL RESET TEMP RM DG XX X F REMOTE DEGREES RESET RT NO XXX X F RETURN NO RESET TEMP RT F XXX X F RETURN FULL RESET TEMP RT DG XX X F RETURN DEGREES RESET DMDC ...

Page 99: ...ION INFORMATION BELOW SETPOINT SUBMODE ITEM DISPLAY DESCRIPTION VALUE SLCT SETPOINT AND RAMP LOAD CLSP X COOLING SETPOINT SELECT RL S ENBL DSBL RAMP LOAD SELECT CRMP X X COOLING RAMP LOADING SCHD XX SCHEDULE NUMBER Z GN X X DEADBAND MULTIPLIER SUBMODE ITEM DISPLAY DESCRIPTION VALUE COOL COOLING SETPOINTS CSP 1 XXX X F COOLING SETPOINT 1 CSP 2 XXX X F COOLING SETPOINT 2 CSP 3 XXX X F ICE SETPOINT H...

Page 100: ...AIN SO OFF FLASHES PRESS THE UP ARROW KEY AND ENTER TO ENABLE THE MANUAL MODE PRESS ESCAPE AND DISPLAY NOW SAYS TEST ON REFER TO THE TABLE BELOW Service Test Mode and Sub Mode Directory NOTE If the unit has a single circuit the Circuit B items will not appear in the display except the ability to configure circuit B will be displayed SUB MODE KEYPAD ENTRY ITEM DISPLAY ITEM EXPANSION COMMENT Complet...