Sterling SCW Series Bedienungsanleitung

Operation and Installation Manual SCW Series Central Chilling Stations Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. A0551795 Bulletin No. SC3-635.1[...]

Page 2 of 77 SCW Series Central Chilling Stations Write down your unit serial number(s) ________________ ________________ here for future reference _______________ _ ________________ ______ __________ ________________ ______ __________ ________________ Sterling is committed to a continuing program of product improvement. Specifications, appearance,[...]

SCW Series Central Chilling Stations Page 3 of 77 Safety Considerations Sterling SCW Series central chilling stations a re designed to provide safe and reliable opera tion when installed and operated within design specifications, fo llowing national and local safety codes. To avoid possible personnel injury or equipment damage when installing, oper[...]

Page 4 of 77 SCW Series Central Chilling Stations Table of Contents 1 General Information ................................................. 8 ; 1-1 Introduction ....... 8 ; 1-2 Necessary Documents 8 ; 1-3 Models Covered 9 ; 1-4 Standard Features 9 ; 1-5 Available Options 10 2 Shipping Info rmation ............................................. 16 ; [...]

SCW Series Central Chilling Stations Page 5 of 77 ; 4-6 Refrigeration Circuit 29 ; 4-7 Freezestat Control 29 ; 4-8 High Pressure Cutout 31 ; 4-9 Low Pressure Cutout 31 ; 4-10 Flow Switch ....... 31 ; 4-11 Control Nipple ... 32 ; 4-12 Control Probe .... 32 ; 4-13 Chilled Water Manifold 32 ; 4-14 Optional Condenser Water Manifold 32 5 Startup Checkli[...]

Page 6 of 77 SCW Series Central Chilling Stations 8-5 Viewing and Operating Chiller Pumps ................. 55 ; 8-6 Viewing Active Alarms and Handling Alarm Conditions 59 ; 8-7 Viewing and Setting System Temperatures 61 9 Routine Main tenance ............................................. 64 ; 9-1 Lubrication......... 64 ; 9-2 Condenser Maintenance[...]

SCW Series Central Chilling Stations Page 7 of 77 Charts and Figures 1 Typical Two-Circuit 60-195 Ton Water Cooled Chiller 11 2 Typical Two-Circuit 60-195 Ton Remote Air Cooled Chiller 13 3 Freezing Protection Curve 29 4 SCW Series Standard Control Panel 39 5 SCW Series Advanced Control Panel 40 6 SCW Series Standard Control Panel 44 7 SCW Series A[...]

Page 8 of 77 SCW Series Central Chilling Stations 1 General Information 1-1 Introduction Sterling SCW Series central water ch illing stations are available in water-cooled and remote air-cool ed designs. They differ only in the condensing media used. The SC W Series units are configured with two independent circuits using multiple co mpressors for [...]

SCW Series Central Chilling Stations Page 9 of 77 1-3 Models Covered This manual provides operation, installation, and maintenance instructions for the SCW Seri es central chilling stations. Model numbers are listed on the serial tag. A model number followed by Q indicates a specially cons tructed unit, and no t all information in this manual m ay [...]

Page 10 of 77 SCW Series Central Chilling Stations 1-5 Available Options SCW Series central chillers are av a ilable with options to tailor the unit to your requirements. Some are factory installed; som e can be retro-fitted in the field. C onsult Sterling sales for more information. Available SCW Series options include: • Advanced control packag[...]

SCW Series Central Chilling Stations Page 11 of 77 Model Number Nomeclature SCW W 060 SCW – Screw Compressor Central Chill er Condenser Type R – Remote Air Cooled W – Water Cooled (Nominal Unit Size) 060 115 075 145 090 165 100 195[...]

Page 12 of 77 SCW Series Central Chilling Stations Figure 1 Typical Two-Circuit 60-195 Ton Water Cooled Chiller SCWW-xxx Model 60 75 90 100 Cooling Capacit y (tons) @ 50°F LWT c 60.4 74.9 88.8 102.2 Capacity stages Infinite Unloadi ng EER (BTUH/W) 15. 2 15.1 15.7 15.5 Evaporator d 145 180 213 245 Nominal water flow (gpm) Condensers e 181 225 266 3[...]

SCW Series Central Chilling Stations Page 13 of 77 SCWW-xxx Model 115 145 165 195 Cooling Capacit y (tons) @ 50°F LWT c 116.3 146.0 166.3 193.1 Capacity stages Infinite Unloadi ng EER (BTUH/W) 15. 5 16.2 15.9 16.2 Evaporator d 279 350 399 463 Nominal water flow (gpm) Condensers e 349 438 499 579 Condenser connection (no manifol d) Flange Conn. (in[...]

Page 14 of 77 SCW Series Central Chilling Stations Figure 2 Typical Two-Circuit 60-195 T on Remote Air Cooled Chiller SCWR-xxx Model 60 75 90 100 Cooling Capacit y (tons) @ 50°F LWT 53.8 67.1 79.1 91.2 Capacity stages Infinite Unloadi ng EER (BT UH/W) 9.4 9.9 9.8 10 Nominal water flow (gpm) Evaporator 129 161 190 219 Evaporator manifold connecti o[...]

SCW Series Central Chilling Stations Page 15 of 77 SCWR Series Remote Condenser Models Fan(s) Refrigeration d Each Connections Charge Model Dia. Motor A mps Air flow Discharge Liquid R-134a Number in. hp c 460V Fans cfm e ODS(in.) ODS (in.) lbs. e SCWR60 30 1 ½ hp 3 ø 11.0 3 34,800 2 1 / 8 2 1 / 8 19 SCWR75 30 1 ½ hp 3 ø 11.0 3 32,900 2 1 / 8 2[...]

Page 16 of 77 SCW Series Central Chilling Stations 2 Shipping Information 2-1 Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that m ight have occurred in transit, such as broken or loose wiring and components, loose hardware and m ounting screws, etc. 2-2 In the[...]

SCW Series Central Chilling Stations Page 17 of 77 2-3 If the Shipment is Not Complete Check the packing list as back-ordered items are noted on the packing list. In addition to th e equipment itself, you should have: ; ................. Bill of lading ; ................. Packing list ; ................. Operating and Installation packet ; ........[...]

Page 18 of 77 SCW Series Central Chilling Stations 2-6 Uncrating Your New Chiller ! WARNING ! DUE TO THE SIZE AND WEIGHT OF SCW SERIES CHILLERS, STERLING RECOMMENDS USIN G BONDED PROFESSIONAL MILLWRIGHTS TO UNLOAD AND MOVE SCW SERIES CHILLERS. Rig the chiller from the frame only, using spreader bars to prevent load transfer to any chiller compone n[...]

SCW Series Central Chilling Stations Page 19 of 77 - Notes -[...]

Page 20 of 77 SCW Series Central Chilling Stations 3 Installation 3-1 Installation Location Considerations As with all equipment installations, follow all ap plicable codes and regulations. ; Locate close to the process to reduce piping expense. ; Locate adjacent to drain and city water sources. ; Consult a structural engineer to assure that the fl[...]

SCW Series Central Chilling Stations Page 21 of 77 ! DANGER Improper electrical connections will damage the unit and cause serious operator injury or death! Compressor damage will occur if compressors are run backwards. Bring properly sized power l eads and ground from a fused disconnect (installed by your electr ician) to the unit. Provide externa[...]

Page 22 of 77 SCW Series Central Chilling Stations Note: • Never switch contactor leads or motor leads for reversing rotation. • Do not use contactor or motor leads for phase matching. • Compressor damage will occur if the compressor is run in reverse. The compressor motor prote ctor checks for correct phasing and will not allow it to start i[...]

SCW Series Central Chilling Stations Page 23 of 77 From Process The chilled water return for wate r returning back to the ch iller from the process to be cooled and recirculated. Adjust the butterfly valve for the pressure drop that corresponds to the model number of the chiller. Pressure drop is equal to supply pressure minus return pressure Model[...]

Page 24 of 77 SCW Series Central Chilling Stations 3-6 Water Connection Sizing Considerations Important! • Run all external chilled water connect ions with adequate size to the process. • Provide the largest possible openings and passages for the flow of chilled water through platens, dies, mold s, or other pieces of equipment. • Minimum exte[...]

SCW Series Central Chilling Stations Page 25 of 77 Two connections are made to each SCW Series unit: Condenser Water In The city or tower water supply inlet is located at the side or rear of the chiller. • Water pressure ≥ 25 psi ( ≥ 172.4 kPa/ ≥ 1.72 bars) • Water temperature ≤ 85°F ( ≤ 29ºC) Condenser Water Out The return outlet, [...]

Page 26 of 77 SCW Series Central Chilling Stations • No steam, hot air or fume exhausts drawn into the condenser coils. • Service accessibility. SCW Series condensing pressure with 95ºF (35ºC) condenser air R-134a = 171 psi (1,179 kPa/11.79 bars) Note: Due to the variables involved in remote air-cooled condenser in stallations, no set or stan[...]

SCW Series Central Chilling Stations Page 27 of 77 Condenser Fan On SCW Series remote air-cool ed units, air should be drawn through the condenser and disc harge up from the condenser. Changing fan rotation direction • Disconnect and lock out power at the fused disconnect. • If all fans are going backwards, reverse any two main power leads. •[...]

Page 28 of 77 SCW Series Central Chilling Stations 4 Sequence Of Operation 4-1 Staging 1. The system uses a PID control algorithm to regulate the chilled water temperature. As the required control effort increases or decreases, the system compressors are infinitely unloaded or turned on/off to keep the temperature at the specified set-point. 2. Com[...]

SCW Series Central Chilling Stations Page 29 of 77 4-5 Chilled Water Circuit If your central chilling station is equipped with the optional integral pump tank, make the pr ocess cooling water supply connection at the P1 manifold at the left side of the pum p tank at the exposed connection. Bring the process cooling water return connection to the Ho[...]

Page 30 of 77 SCW Series Central Chilling Stations If you want lower chilled water te mperatures, you’ll need to mix process water with industrial- ( not automotive) grade ethylene or propylene glycol with rust inhibito r to provide protection down to 20°F (12ºC) below the operating temperature you want. Figure 3 below shows the proper mixtures[...]

SCW Series Central Chilling Stations Page 31 of 77 4-8 High Pressure Cutout This electro-mechanical safety f eature opens the c ontro l circuit if the system condensing pressure exceeds a safe level. High pressure cutout setting Model psi kPa bars SCW Series water-cooled and re mote air-cooled chilling stations 290 psi 2,000 kPa 20 bars Important! [...]

Page 32 of 77 SCW Series Central Chilling Stations 4-11 Control Nozzle All SCW Series chilling station evaporators have two control nozzles. The flow switch, freezestat, and flush port are located in the control nozzle. Pressure gages are mounted in the control nozzles to aid in achieving proper flow through the evaporator and balancing flows. Pres[...]

SCW Series Central Chilling Stations Page 33 of 77 - Notes -[...]

Page 34 of 77 SCW Series Central Chilling Stations 5 Startup Checklists 5-1 Introduction Important! These lists assume the installation information in this manual has been read and followe d. Have new chillers started up and checked by a qualified refrigeration service technician. Sterling offers factory startup for SCW Series chilling stations. Ca[...]

SCW Series Central Chilling Stations Page 35 of 77 ; Complete all piping leadi ng to and from the pump tank. Observe all applicable codes. ; Complete all electrical wiring. Observe all applicable codes. ; Prepare all related equipment in the system for operation. ; Check for proper compressor rota tion direction. T o confirm proper rotation: 1. Con[...]

Page 36 of 77 SCW Series Central Chilling Stations 2. Close the gauge cock leading to the pump suction and open the gauge cock leading to the pump discharge. 3. Close the discharge butterfl y valve, crack it open, then start the pump and observe the gauge. • If the gauge indicates within 15 psi (103.4 kPa/1.03 bars) below the pump curve, pump rot[...]

SCW Series Central Chilling Stations Page 37 of 77 7. Operate the chiller, looking for leaks and listening for unusual noises or vibrations th at could indicate improper operation. 5-4 Remote Air-Cooled SCW Series Startup Checklist ; Check the shipping papers agains t the serial tag to be sure chiller size, type and voltage is correct for the proce[...]

Page 38 of 77 SCW Series Central Chilling Stations 2. Connect a refrigerant gauge to the suction service valve. Fully front seat the service valve and open one full turn. 3. Bump start the compressor by switching off then on quickly 0.5 to 1 second. If th e rotation is correct, the suction pressure will drop imme diately. A rise in pressure will in[...]

SCW Series Central Chilling Stations Page 39 of 77 ; Check the water level in the pump tank to be sure the pump does not run dry while the system piping is be ing filled. ; Check your work and proceed to the Startup procedure in the following section. 5-5 Remote Air-Cooled SCW Series Startup 1. Start the chiller by pushing the Start button on the c[...]

Page 40 of 77 SCW Series Central Chilling Stations 5-6 Determining Flow Rate To determine flow: 1. Close the gauge cock leading to the pump suction side and open the gauge cock leading to the pump discharge. 2. Start the pump and make note of the discharge pressure in psi (kPa/bars). 3. Check the pump curve for the appropriate hors epower pump at t[...]

SCW Series Central Chilling Stations Page 41 of 77 6 Graphic Panel Devices 6-1 Indicator Lights and Control Switches (MMI) System On The green System On indicator lights when the main power switch is on and the contro l circuit is energized. Start The Start push-button lets you energize the unit. Stop The Stop push-button lets you de -energize the [...]

Page 42 of 77 SCW Series Central Chilling Stations -Notes-[...]

SCW Series Central Chilling Stations Page 43 of 77 Using the Standard 7 Operator Interface 7-1 Operator Interface Introduction The Standard touchscreen interface lets you control your SCW Series central chilling station. You can do such things as: • Control compressors and optional pumps • View current statuses of ope ration, such as pressures,[...]

Page 44 of 77 SCW Series Central Chilling Stations Figure 6 SCW Series Standard Control Panel 7-2 Using the SCW Series Standard Operator Interface[...]

SCW Series Central Chilling Stations Page 45 of 77 7-3 Getting Started on the SCW Series Standard Operator Interface 7-4 Viewing and Operating Chiller Compressors V iewing Compressor S t atus Operating the chiller compressors Setting Compressor Lead/Lag T i mes and Activating Compressor Lead/Lag Operation V iewing Compressor Run Times 7-5 Viewing a[...]

Page 46 of 77 SCW Series Central Chilling Stations 7-6 Viewing Active Alarms and Handling Alarm Conditions ! CAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910.147 standards. All electrical connections mu st be done by a qualified electrician. ! WARNING Disconnect all [...]

SCW Series Central Chilling Stations Page 47 of 77 Setting System T emperatures[...]

Page 48 of 77 SCW Series Central Chilling Stations Using the Advanced 8 Touchscreen Interface 8-1 Touchscreen Interface Introduction (MMI) The Advanced touchscreen interfaces let you control your SCW Series central chilling station. You can do such things as: • Control compressors and optional pumps • View current statuses of ope ration, such a[...]

SCW Series Central Chilling Stations Page 49 of 77 Figure 7 SCW Series Advanced Control Panel 8-2 Using the SCW Series Advanced Touchscreen Interface[...]

Page 50 of 77 SCW Series Central Chilling Stations 8-3 Getting Started on the SCW Series Advanced Touchscreen Interface Figure 8 Main Menu Screen The Main Menu screen lets you gain access to: • “ Active Alarms ” contains the current alarm(s) of the system • “ Al;arm History ” contains the last thirty (30) alarm s that were activated. ?[...]

SCW Series Central Chilling Stations Page 51 of 77  Press the Up or Down buttons on th e right side of the screen to highlight “ System Information ”  Press ↵ The chiller status screen displays: Figure 9 Chiller Status Screen The Chiller Status screen shows the status for co mpressors within the system. Only compressors that a re includ[...]

Page 52 of 77 SCW Series Central Chilling Stations be shown on this screen. Compressors will display one of the following states: 1. OFFLINE – This indicates that the compressor has been tu rned off in the compressor enable/disable screen. The com pressor will not be called to operate until it has been r e-enabled. The color code for this indicat[...]

SCW Series Central Chilling Stations Page 53 of 77  Touch the screen corresponding with the compressor you want to bring On-Line or Off-Line. The background color of the square turns green for On-Line and black for Off-line. Setting Compressor Lead/Lag T i mes and Activating Compressor Lead/Lag Operation While in the Configuration Menu, the comp[...]

Page 54 of 77 SCW Series Central Chilling Stations V iewing Compressor Run Times From the Main Menu, use the Up or Down buttons to highlight the “ Compressor Hourmeters ” menu. Scroll to select the compressors. Then press ↵ to display the hourmeters. Note: This is a complete list of all co mpressors that may be included in the system. Any com[...]

SCW Series Central Chilling Stations Page 55 of 77 Two hourmeters are kept for each compressor in the system. The first is a lifetime m eter. This measures the total tim e that the compressor has been operational in the lifetim e of the chiller. The second is a resettable hourmeter. This hourmeter can be cleared to monitor run time on specific inte[...]

Page 56 of 77 SCW Series Central Chilling Stations  Press the Up or Down butt ons to highlight either “ System Information ”.  Press ↵ The Pump Status Screen appears Figure 12 Pump Status Screen Only pumps that are included in the s ystem will be shown on this screen. Pumps will display one of the following states: 1. OFFLINE – This i[...]

SCW Series Central Chilling Stations Page 57 of 77 3. RUNNING – Pump is currently running. The color code for this indication is green. 4. FAULT – A safety on the pump i ndicates a fault condition and the pump has been deactivated. Once the problem is remedied, the pump will return to a READY state unless it is put in the OFFLINE state. The col[...]

Page 58 of 77 SCW Series Central Chilling Stations toggle the state of the pump fr om the ON-LINE to OFF-LINE state. Setting Pump Lead/Lag T imes a nd Activating Pump Lead/Lag Operation While in the Configuration Menu, the pump lead/lag (rotation) can be enabled or disabled. Simply press the Process or Recirculation Pump Interval button on the scre[...]

SCW Series Central Chilling Stations Page 59 of 77 Two hourmeters are kept for each pump in the system. The first is a lifetime meter. This measures the total tim e that the pump has been operational in the lifetime of the chiller. The second is a resettable hourmeter. This hourmeter can be cleared to m onitor run time on specific intervals. In ord[...]

Page 60 of 77 SCW Series Central Chilling Stations  Chilled Water Circuit High Pressure (One per ch illed water circuit)  Chilled Water Circuit L ow Pressure (One per chilled water circuit)  Pump motor overload (One per system pum p) If an alarm condition occurs, the follow screen is displayed: Figure 15 Alarm Condition Screen To acknowled[...]

SCW Series Central Chilling Stations Page 61 of 77 Once a device has gone offline you w ill need to contact a licensed professional (electrician or refrig eration sevice company) to bring the device back online. ! CAUTION Never attempt to service a unit until a qualified electrician has opened and locked out the main disconnect using OSHA 1910.147 [...]

Page 62 of 77 SCW Series Central Chilling Stations  Use the Up or Down arrows to highlight “ System Information ”  Press ↵ The system status displays: Figure 16 System Status Screen Note: If you have a metric version of the SCW Series controller, the screens display in converted metric values. Setting System T emperatures The chiller se[...]

SCW Series Central Chilling Stations Page 63 of 77  Press the Up or Down buttons to highlight “ Chiller Configuration ”  Press ↵  Touch the “Process Set-point” button The input display screen appears: Figure 17 Temperature Input Display Screen[...]

Page 64 of 77 SCW Series Central Chilling Stations 9 Routine Maintenance 9-1 Lubrication Grease all fan bearings, fan motors , and pump motors that do not have permanently sealed bearings . Remove the grease relief plug (motors only) before adding grease. Failure to d o so may dislodge the bearing grease retainer w hich will eventually cause bearin[...]

SCW Series Central Chilling Stations Page 65 of 77 9-3 Evaporator Maintenance The evaporator(s) may be accessed for back-flus hing by removal of the 2” plug (approx. 51 mm) in the return contro l nipple and the flow switch in the supply contro l nipple. If the suggested piping recommendations have been followed, one circ uit of a multiple circuit[...]

Page 66 of 77 SCW Series Central Chilling Stations 9-7 Preventive Maintenance Service A systematic preventive maintenance program helps avoid costly down time. Call the Service Depar t ment at Sterling to arrange a schedule of inspections. This service, described in Sterling Bulletin No. 10-106.3 , is tailored to fit your maintenance requirements. [...]

SCW Series Central Chilling Stations Page 67 of 77 - Notes -[...]

Page 68 of 77 SCW Series Central Chilling Stations 10 Troubleshooting Problem Possible Cause Solution No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage must be within plus or minus ten percent (±10%) of nameplate rating. Defective On/Off switch. Replace switch. Control circuit fuse blow[...]

SCW Series Central Chilling Stations Page 69 of 77 Problem Possible Cause Solution Allow time to cool and reset. Check for high/low voltage. Voltage must be within plus or minus ten percent (±10%) of nameplate rating. Check for poor compressor electrical connections. Compressor internal overload open. Check compressor rotation on scroll compressor[...]

Page 70 of 77 SCW Series Central Chilling Stations Problem Possible Cause Solution Pump is running in reverse. Verify proper rotation; if incorrect, see Changing Rotation Direction on Page 25 for more information. Pump pressure is too low. Check for foreign matter. Clean the system. You may also have to pull the pump and inspect the impeller. Check[...]

SCW Series Central Chilling Stations Page 71 of 77 Service Notes[...]

Page 72 of 77 SCW Series Central Chilling Stations I Index Ala rm s Advanced Controls , 59 Standard Controls , 46 Available options, 10 Checking Motor Direction , 26 Chiller Pumps Advanced Controls , 55 Chiller Shutdown , 40 Circuit Alarm Sequence , 28 Compressor Lead-L ag , 28 Compressor Staging Sequence , 28, 32 Condenser Maintena nce , 64 Copyri[...]

SCW Series Central Chilling Stations Page 73 of 77 Ala rm s , 46 Getting Started , 45 Introduction , 43 Operating Chiller Compressors , 45 Water Connection Sizing Consideration, 24 Water Cooled Startup , 36 Water Cooled Startup Checklist , 34 Water Treatment Considerations , 24 Water-Cooled Condenser Connections , 24[...]

Page 74 of 77 SCW Series Central Chilling Stations Service Notes[...]

SCW Series Central Chilling Stations Page 75 of 77 Service Notes[...]

Page 76 of 77 SCW Series Central Chilling Stations Service Notes[...]

SCW Series Central Chilling Stations Page 77 of 77 Technical Assistance Parts Department Call toll-free 7am–5pm CST or call [800] 423-3183, [262] 641-8610, or fax to [262] 64 1-86 53 The ACS Customer Service Group will provide your company with genu ine OEM quality parts manufactured to engi neering design specifications, which will maximize your[...]