Sterling AquaSnap 30RA010-055 manual

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificat ions or des igns without notice an d withou t inc urring obligation s. PC 9 03 Cata log N o . 533- 000 47 Printe d in U .S . A. F o rm 30RA- 2T Pg 1 1-03 Repl ace s: 3 0RA- 1T Book 2 Ta b 5 c Controls, Star t-Up , Operation, Ser vice , and T roub l eshooting S[...]

2 CONTENTS Page SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,3 MAJOR SYSTEM COMPO NENTS . . . . . . . . . . . . . . . . . . . 3,4 Gene ral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

3 Table 1 — Unit Sizes *60 Hz only . †50 Hz o nly . MAJOR SYSTEM COMPONENTS General — The 30RA air- cooled reciprocating chill ers contain the Comfort Link™ electronic control system that controls and monitors all opera tions of the chiller . The control system is composed o f several components as listed in the sections below . See Fig. 1 [...]

4 At each system el ement, the shie lds of its communic ation bus cables must be tied together . If the communic ation bus is entirely within one building, th e resulting continuous shield must be connected to a ground at one point only . If the commu- nication bus cable exits from one building and enters another, the shields must be connected to g[...]

5 T10 — REMOTE S P ACE TEMPERA TURE S ENSOR O R DUAL LEA VING W A TER TEMPERA TURE SENSOR — One of two inputs can be connected to TB5-5 and TB5-6. See appropriate sensor below . T10 — Remote Space T emperature Sensor — Sensor T10 (part no. 33ZCT55SP T) is an acce ssory sensor that is rem otely mounted in the controlled space and used for sp[...]

6 Fig. 1 — T ypical Con trol Box for 30RA010 -030 (022-030 S hown)[...]

7 Fig. 2 — Typical Control Bo x for 30RA 032-0 55 (042-055 Shown )[...]

8 Fig. 3 — Wirin g Schemat ic 30RA 010-018 30RA010-01 8 AQUA SNAP[...]

9 SEE NOTE 8 SEE NOTE 8 Fig. 3 — W iring Sch ematic 30 RA010-018 (cont) AQUA-SNAP LOW VOLTAGE CONTROL SC HEMATIC ( 010-018)[...]

10 Fig. 4 — Wiring Schematic 30RA022-030 30RA022-030 AQ UA SNAP[...]

11 Fig. 4 — Wiring S chematic 30RA022 -030 (c ont) AQUA-SNAP LOW VOLTAGE CONTROL SC HEMATIC ( 022-030)[...]

12 Fig. 5 — Wiring Schematic 30RA032-040 30RA032-040 AQ UA SNAP[...]

13 Fig. 5 — W iring Sch ematic 30 RA032-040 (cont) AQUA-SNAP LOW VOLTAGE CONTROL SC HEMATIC ( 032-040)[...]

14 Fig. 6 — Wirin g Schemat ic 30RA 042-055 30RA042-055 AQ UA SNAP[...]

15 Fig. 6 — Wiring Schematic 30RA042-055 (cont) AQUA-SNAP LOW VOLTAGE CONTROL SC HEMATIC ( 042-055)[...]

16 CEPL130346-01 ST A TUS LEN J1 J2 J4 J3 J5 J6 J7 J8 J9 J10 S CN RED LED - ST A TUS GREEN LED - LEN (LOCAL EQUIPMENT NETWORK) YELLOW LED - S CN ( STERLCO COMFO R T NETWORK) INST ANCE JUMPER K1 1 K10 K9 K8 K7 K6 K5 K4 K3 K2 K1 Run Status Service T est T emperature Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Al[...]

17 Ener gy Mana gement Modul e (Fig. 11) — This factory-installed option (FIOP) or field-installed acce ssory is used for the following types of temper ature reset, dem and limit, and/or i ce feat ures: • 4 to 20 mA leaving flui d temperatur e reset (requir es field-su pplied 4 to 20 mA generator) • 4 to 20 mA coo ling set poin t reset (req u[...]

18 Table 6 — Part Load Data Percent Displacement, Standard Units without M inimum Load Valve NO TE : These capacity steps ma y v ary due to diff erent capacity staging sequences. 30RA UNIT SIZE CONTROL STEPS LO ADING SEQ A LO ADING SEQ B % Displacement Compressor % Displacement Compressor 010,015 (60 Hz) 1 100 A1 —— 015 (50 Hz), 018 15 0 A 1 [...]

19 Table 7 — Part Load Data Per cent Displace ment, Standard Unit s with Minimum Load V alve *Minimum Load V alve energized. NO TE : These capacity steps may v ar y due to different capacity staging sequences. 30RA UNIT SIZE CONTR OL STEPS LO ADING SEQ A LO ADING SEQ B % Displacement Compressor % Displacement Com pressor 010 (50/60 Hz) 1 2 69/ 71[...]

20 MINUTES LEF T FOR ST AR T — Th i s va lu e is di spl aye d only in the network display tables (using Service T ool, ComfortVIEW™ or ComfortWORKS® software) and represents the amount of time to elapse before the unit will start its initialization routine. This value can be zero without the machine running in many situations. This can in clud[...]

21 Head Pressure Contr ol — The Main Base Bo a rd (MBB) controls the condenser fans to maintain the lowest condensing temperature possible, and thus the highest unit efficiency . The MBB uses the sat urated condensing tempera- ture input from the discha rge pressure transducer to control the fans. Head pressure control is maintained through a cal[...]

22 Operation of Mac hine B ased on Contr ol Method and Cool ing Set P oint Se lection Set - tings — Mac hine On/Of f contro l is de termined by the configuration of the control method (CTRL) [Configuration, OP T2] and cooling set point select (CLSP) [Configuration, SLCT] variables. All mode ls are fa ctory configured with cool - ing set point sel[...]

23 Table 8 — Control Methods and Cooling Set P oints *Dual set point s witch input used. CSP1 used when s witch input is open. CSP2 used when s witch input is closed. † Cooling set point det erm ined from 4 to 20 m A input to Energ y Managem ent Module (EMM) to terminals TB6-3,5. HE A T IN G O PE R A T I ON — The chi ller can be used for pump[...]

24 Opt ional F act ory- Insta lled Hy dron ic P ac kage — If the chiller has factory-installed chilled fluid pumps, specific steps should be followed for proper operation. The pump(s) in t he hydronic packa ge come factory pre-wired into the main unit power supply/starter . In order to check proper pump rotation, use the Service T est function to[...]

25 Opened During Normal Ope ration Alarm will be generat ed and the machine will stop. If the control detects the chi lled water pump i nterlock open for 25 seconds after initially being closed, a T194 — Cool er Pump 1 Conta cts Op ened During Normal Operat ion Al ert is generated and the unit i s shut down. If the contr ol detects t he chil led [...]

26 As part of a pump mai ntenance routine, the pumps can be star ted to maint ain lubric ation to the pump seal. T o utili ze thi s function, Cooler Pmp Periodic Start (PM.P .S) [Confi gura tion, UNIT ] mu st b e se t t o YE S. Th is option i s se t to N O a s th e f a c- tory default. If feature is ena bled and t he pump(s) are not operating, then[...]

27 Table 10 — Run Status Mode and Sub-Mode Directory NO TE : If the unit ha s a single circ uit, the Circuit B items will n ot appear in t he display , except the ability to configure cir cu it B will be display ed . SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y SUB- ITEM DI SPLA Y SUB-ITEM DISPLA Y ITEM EXP AN SION COMMENT VIEW EWT XXX.X ° F ENTERING F[...]

28 Table 10 — Run Status Mode and Sub-Mode Dire ctory (cont) *Press and simul taneousl y to obtain version number. SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y SUB- ITEM DISPLA Y SUB-ITEM D ISPLA Y ITE M EXP AN SION COMMENT PM (c ont) PMDT PUMP MAINTENANCE DA TES P .1.M0 MM/DD/YY HH:M M P .1.M1 MM/DD/YY HH:M M P .1.M2 MM/DD/YY HH:M M P .1.M3 MM/DD/YY HH[...]

29 Table 11 — Service Test Mode and Sub-Mode Directory NO TE : If the unit ha s a single circuit, t he Circuit B items will n ot appear in t he display , except the ability to con figure cir cu it B will be display ed . Table 12 — Temperature Mode a nd Sub-Mode Directory NO TE : If the unit ha s a single circuit, t he Circuit B items will n ot [...]

30 Table 13 — Pressure Mode and Sub- M ode Directory NO TE : If the unit ha s a single circuit, t he Circuit B items will n ot appear in t he display , except the ability to con figure cir cu it B will be display ed . Table 14 — Set Point and Sub-Mode Direc tory Table 15 — Inputs Mode and Sub-Mode Directory SUB-MODE KEYP AD ENTR Y ITEM DISPLA[...]

31 Tab le 1 6 — Outputs Mode and Sub-Mode Directory NO TE: If the unit has a single circuit, the Circu it B items will not appe ar in the displa y , excep t the ability to configure cir cuit B will be displa yed. Table 17 — Configuration Mode and Sub-Mode Directory NO TE: If the unit has a single circuit, the Circu it B items will not appe ar i[...]

32 Table 17 — Configuration Mode and Sub-M ode Directory (cont) SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y ITEM EXP ANSION COMMENT OPT1 UNIT OPTIONS 1 HARDW ARE FLUD X COOLER FL UID Default: W ater 1 = W ater 2 = Medium T em perature Brine ML V . S YES/NO M INIMUM LOAD V AL VE SELECT MMR.S YES/NO MO TORMASTER SELECT RG.EN ENBL/DSBL RETURN GAS SENSOR E[...]

33 Table 17 — Configuration Mode and Sub-M ode Directory (cont) SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y ITEM EXP ANSION COMMENT RSET (cont) RM.F XXX.X ° F REMOTE - FULL RESET TEMP Default: 0.0 ° F (-17.8 C) Range: 0 ° to 125 F RM.DG XX.X ° F REMO TE - DE GREES RESET Default: 0.0 ° F Range: – 30 to 30 F RT .NO XXX .X ∆ F RETURN - NO RESET T[...]

34 Table 18 — Time Clock Mode and Sub-Mode Directory SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y SUB- ITEM DISPLA Y ITEM EXP ANSION COMMENT TIME TIME OF DA Y HH.MM XX.XX HOUR AND MINUTE M ilitar y (00:00 – 23:5 9) DA T E MONTH,D A TE,DA Y AND YEAR MNTH XX MONTH OF YEAR 1-12 (1 = Januar y , 2 = Februar y , e tc) DOM XX D A Y OF M ONTH Range: 0 1-31 DA[...]

35 Table 18 — Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y SUB- ITEM DISPLA Y ITEM EXP ANSION COMMENT SCH .L (co nt) PER.3 OCCUP ANCY PERIO D 3 OCC.3 XX:XX PERIOD OCCUPIED TIME Militar y (00:00 – 2 3:59) UNC.3 XX.XX PERIOD UNOCCUPIED TIME Militar y (00:00 – 2 3:59) MON.3 YES/NO MONDA Y IN PERIOD TUE.3 YE[...]

36 Table 18 — Time Clock Mode and Sub-Mode Directory (cont) SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y SUB- ITEM DISPLA Y ITEM EXP ANSION COMMENT SCH .L (co nt) THU .6 YES/NO THURSD A Y IN PERIOD FRI.6 YES/NO FRID A Y IN PERIOD SA T .6 YES/NO SA TURD A Y IN PERIOD SUN.6 YES/NO SUND A Y IN PERIOD HOL.6 YES/NO HOLID A Y IN PERIOD PER.7 OCCUP ANCY PERIO [...]

37 Tab le 1 9 — Operating Mode and Sub-Mode Directory LEGEND Table 20 — Alarms Mode and Sub-Mode Directory SUB-MODE KEYP AD ENTR Y ITEM DISPLA Y ITEM EXP AN SION COM MENT MODE MODES CONTROLLING UNIT MD01 ON/OFF FSM CONTROLLING CHILLER MD02 ON/O FF WSM CONTROLLING CHILLER MD03 ON/OFF M ASTER/SLA VE CONTROL MD05 ON/O FF RAMP LOAD LIMIT ED MD06 ON[...]

38 Table 21 — Dual Chiller Confi guration (Master Chil ler Exa mple) SUB-MODE ITEM KEYP AD ENTRY DISPLA Y ITEM EXP ANSIO N COMMENTS DISP UNIT OPT1 OPT2 CTRL CONTROL METHOD CTRL 0 SWITCH DEF A UL T 0 CTRL S CNA S CNA 1 S CN ADDRESS DE F A U L T 1 S CNA S CNB S CNB 0 S CN BUS NU M BER DE F A U L T 0 S CNB OPT2 RSET PR OCEED T O SUBMODE RESET RSET C[...]

39 Tab le 2 1 — Dual Chiller Configuration (Master Chille r Exam ple) (cont) NO TES: 1 . M a st e r C o n t r o l M e t h o d ( C T R L ) c a n b e c o n f i g u r e d a s 0 - Switc h , 2 - Occ u pa n cy o r 3 - S CN. 2. Parallel Con figuration (P ARA) ca nnot be chang ed. SUB-MODE ITEM KEYP AD ENTRY DISPLA Y ITEM EXP ANSION COMMENTS RSET LLBL 2 [...]

40 Ta b l e 2 2 — D ual Chiller C onfiguration (Slave Chiller E xample) NO TES: 1 . S l a v e C on t rol M e t hod ( C T R L) must be con f i gu r ed f or 0. 2 . Sl a v e S CN A d d r e ss ( S CNA) m u st b e d i f f e r e n t t h a n M a s t e r . 3 . Sl a v e S CN B u s N u m b e r ( S CNB) m u st b e t h e s a m e a s M a st e r 4. Sl av e doe[...]

41 Table 23 — Operating Modes MODE NO . ITEM EXP ANSION DESCRIPTION 01 FSM CONTROLLING CHILLER F lotronic ™ System Ma nager (FSM) is controlling the chiller . 02 WSM CONTROLLING CHILLER W a ter System Manager (WSM) is controlling the chiller . 03 MASTER/SLA VE CONTROL Dual Chiller c ontrol is enab led. 05 RAMP L OAD LIMITED Ramp load (pull-down[...]

42 Table 24 — Example of Reading and Clearing Alarms Table 25 A — 4-20 mA Re set NO TE : The e xample abov e shows how to configure the chiller for 4-20 mA reset. No reset will occur at 4.0 mA input, and a 5.0 F reset will occur at 20. 0 mA. An EMM is required. Table 25B — Menu Configuration of 4 to 20 mA Cooling Set Point Control SUB-MODE KE[...]

43 Table 26A — Configuring Outdoor Air and Space Temperature Reset *4 items sk ipped in this example. Table 26B — Configuring Return Temperature Reset *4 items sk ipped in this example. T emperature Reset — The control system is capable of handling leaving-fluid temperature reset based on return cooler fluid temperature. Because the change i [...]

44 2.0 F (1.1 C) cooler ∆ T and 0° F (0° C) reset a t 10.0 F (5.6 C) cooler ∆ T . The va riable R T .NO should be set t o the cooler temperature differen ce ( ∆ T) wh ere no chil led w ater tem per a- ture reset should occur . The variable R T .F should be set to the cooler temper atur e difference w h ere the maxi mum chil le d wa- ter tem[...]

45 DEMAND LIM I T ( S C N L o a d s h ed C on t r o lle d ) — T o c on - f i gure D e mand L i m i t for S C N Lo a d s h e d con t rol set t h e D e - mand Limit Select (DMDC) [Configuration, RSET] to 3. Then configure the Loadshe d Group Number (SHNM), L oadshed Demand Delta ( SHDL), and M aximum Loadshed T im e (SHTM) [Configuration, RSET]. Se[...]

46 Table 27 — Configuring Demand Limit *Sev en items skipped in this e xample. TROUBLESHOO TING Complete Unit Stoppage and Restart — Poss i- ble causes for unit stoppage a nd rese t methods are shown be- low . (See T able 28 also. ) Refer to Fig. 22-26 for Component Arrangement and Control Wiring Diagrams. GE N E R A L P OW E R F A I LU R E —[...]

47 Table 28 — Troubleshooting SYMPTOMS CA USE RE MED Y Cooler Cir culating Pump Does Not Run P ower line open Reset circuit breaker . Control fuse or circuit break er open Check control circuit f or ground or shor t. Reset breaker and replace fuse. Compressor over temperature sensor open (06D) F ind cause of high temperature and reset con trols. [...]

48 Fig. 22 — Component Ar rangement — 30RA010-03 0 LEGEN D C — Contactor , Compressor CB — Circuit Breaker CHC — Cooler /Pump He ater Co ntactor CWP — Chilled Wa ter Pump EMM — Energy Mana gement FC — F an Conta ctor FIOP — Factory- Installed Opt ion FU — Fuse GND — Ground MBB — Main B ase Board MM — Motor ma ster ® MMPT [...]

49 Fig. 23 — Component Arrangement — 30RA032-0 40 LEGEN D C — Contactor , Compressor CB — Circuit Breaker CHC — Cooler /Pump He ater Co ntactor CWP — Chilled Wa ter Pump EMM — Energy Mana gement FC — F an Conta ctor FIOP — Factory- Installed Opt ion FU — Fuse GND — Ground MBB — Main B ase Board MM — Motor ma ster ® MMPT ?[...]

50 Fig. 24 — Component Arrangement — 30RA042-0 55 LEGEN D C — Contactor , Compressor CB — Circuit Breaker CHC — Cooler /Pump He ater Co ntactor CWP — Chilled Wa ter Pump EMM — Energy Mana gement FC — F an Conta ctor FIOP — Factory- Installed Opt ion FU — Fuse GND — Ground MBB — Main B ase Board MM — Motor ma ster ® MMPT ?[...]

51 Fig. 25 — Control and Field Power Wiring Diagram — 30RA010- 030 NO TES: 1. F a ctor y wir ing i s in a ccordan ce with U L 1995 standar ds. Field modific ations or ad diti on s m ust be in compl ianc e with al l ap plicab le code s. 2. Wir ing for main field supply must be rated 75 C mini mum. Use cop per for all unit s. Max imum in coming w[...]

52 Fig. 26 — Control and Field Power Wiring Diagram — 30RA032-0 55 NO TES: 1. F act or y wi ri ng is in accor dance w ith UL 199 5 standar ds. Field modi fication s or additions must be in c ompliance with all app licable codes. 2. Wir ing for main fi eld supp ly must be rate d 75 C minimum. Us e copper for all units. Maximum incoming wire size[...]

53 Alarms and Al er ts — These are warnings of abnormal or fault conditions, and may cause either one circuit or the whole unit to shut dow n. They are a ssigned code numbers as described in T able 29. Automatic al arms will reset without opera tor intervention if the condition corrects itself. The following met hod must be used to reset manual a[...]

54 Table 29 — Alar m and Ale rt Cod es (con t) ALARM/ ALERT CODE ALARM OR ALERT DESCRIPTION WHY W AS THIS ALARM GENERA TED? A CTION T AKEN BY CONTROL RESET METHO D PROB ABLE CA USE T093 Aler t Circuit B Suction Pressure T ransdu cer F ailure V oltage rat io more than 99.9% o r less than .5%. Circuit B shu t down A uto matic T ra nsducer f ailure,[...]

55 Table 29 — Alar m and Ale rt Cod es (con t) ALARM/ ALERT CODE ALARM OR ALERT DESCRIPTION WHY W AS TH IS ALARM GENERA TED? ACT IO N T AKEN BY CONTROL RESET METHOD PROB ABLE CA USE A140 Aler t Re verse Rotation Detected Incoming chiller power lead s not phas ed cor rectl y Chiller not allowed to star t. Manual Reverse any two inc oming pow er le[...]

56 Table 29 — Alar m and Ale rt Cod es (con t) ALARM/ ALERT CODE ALARM OR ALERT DESCRIPTION WHY W AS THIS ALARM GENERA TED? ACT I O N T A K E N BY CONTROL RESET METH OD PROB ABLE CA USE T196 Aler t Flow Lost While P ump 1 Running Cooler flow switch contacts open for 3 seco nds aft er initially made All c ompr essors shut down. Pu mp 1 turn ed off[...]

57 Table 29 — Alar m and Ale rt Cod es (con t) LEGEN D ALARM/ ALERT CODE ALARM OR ALERT DESCRIPTION WHY W AS THIS ALARM GENERA TED? A CTION T AKEN BY CONTROL RESET METHO D PROB ABLE CA USE T301 Ale r t Co ol er Pu mp 2 Schedul ed Maintenance Due Pump 2 Ser v ic e Countdown ( P .2.DN) e xpired. Complete pump 2 mai ntenance and enter 'YES&apos[...]

58 SER VICE Electr onic Components CO N TR O L CO MP O N E N T S — Unit uses an advanced e lec- tronic control system that normally doe s not require service. For details on controls refe r to Operating Da ta section. Access to the compressors is through latched panels from beneath the control box on all models or from opposite the coil side (siz[...]

59 BASE COMPRESSOR COMP A1 COMP A2 COMP B1 COMP B2 COMP A1 COMP A2 Fig. 27 — Typic al Compressor Mounting — All Si zes Fig. 28 — Com presso r Wiri ng Fig. 29 — Compr essor Locatio n — 30RA010 -030 Fig. 30 — Compressor Loc ation — 30RA032-055 LEGEND HPS — High-Pressure Switch[...]

60 Chec k Oil Charge — Compressors are factory charged with oil as shown in T able 31. Table 31 — Oil Charge If oil is visible in the c ompressor sight glass, check unit for operating readiness as de scribed in Pre-Start-Up, System Check section (page 74), the n start the unit. Observe oil level and add oil if required, to bring oil level in co[...]

61 • Thoroughly r inse all surfaces with low veloc i ty clean water using downward ri nsing motion of wa ter spray nozzle. Protect fins from damage fr om the spray nozzle. CO N D E NS E R S ECT I O N — Condenser fan motors and fans can be serviced by removal of out let grilles or si de panels. See Fig. 31. Be sure the wire fan guard is in place[...]

62 The amount of capacity reduction achieved by the mini- mum l oad valve is not adj ustable. T he tot al unit capa city with the minimum load valve i s shown in T able 7. PR E S SU R E R EL I E F D E V I C E S — All units have one pres- sure relief device per circui t located in the liquid line w hich re- lieves at 210 F (100 C). Compressor and [...]

63 COOLER FREEZE-UP PROTECTION The Main Base Board (MBB) monitors leaving fluid tem- perature at all t imes. The MBB w ill rapidly remove stages of capacity as necessary to pre vent fr eezing condi tions due to t he rapid loss of load or low cooler fluid flow . When the cooler is exposed to lower ambient temperat ures (34 F [1° C] or be low), free[...]

64 Table 33 — 5K Thermistor Temperatu res ( ° F) vs. R esistance/V oltage D rop (Voltage Drop for Ent ering, Leaving Water and Outside-Air Thermistors T1 , T2, T9) TEMP (F) VO LT AG E DROP (V) RESIST ANCE (Ohms) – 25 3.699 9 8,010 – 24 3.689 9 4,707 – 23 3.679 9 1,522 – 22 3.668 8 8,449 – 21 3.658 8 5,486 – 20 3.647 8 2,627 – 19 3.[...]

65 Table 34 — 5K Thermistor Temperatures ( ° C) vs. Re sistance/V oltage Drop (Voltage Drop for Ent ering, Leaving Water and Outside-Air Thermistors T1 , T2, T9) TEMP (C) VO LT AG E DROP (V) RESIST ANCE (Ohms) – 32 3.705 100 ,260 – 31 3.687 94 ,165 – 30 3.668 88 ,480 – 29 3.649 83 ,170 – 28 3.629 78 ,125 – 27 3.608 73 ,580 – 26 3.5[...]

66 Table 35 — 10K Thermistor Tempe rature ( ° F) vs. Resis tance/Vo ltage D rop (For Thermistor T10) TEMP (F) VO LT AG E DROP (V) RESIST ANCE (Ohm s) – 25 4.7 58 196, 45 3 – 24 4.7 50 189, 69 2 – 23 4.7 41 183, 30 0 – 22 4.7 33 177, 00 0 – 21 4.7 24 171, 07 9 – 20 4.7 15 165, 23 8 – 19 4.7 05 159, 71 7 – 18 4.6 96 154, 34 4 – 1[...]

67 Table 36 — 10K Thermistor Temperature ( ° C) vs. Re sistanc e/Voltage Dr op (For Thermistor T10) TEMP (C) VO LT AG E DROP (V) RESIST ANCE (Ohms) – 32 4.762 200 ,510 – 31 4.748 188 ,340 – 30 4.733 177 ,000 – 29 4.716 166 ,342 – 28 4.700 156 ,404 – 27 4.682 147 ,134 – 26 4.663 138 ,482 – 25 4.644 130 ,402 – 24 4.624 122 ,807 ?[...]

68 Strainer — Periodic fact ory-installed s trainer cl eaning is required. Pressure drop across st rainer in excess of 3 psi (21 kPa) indicates the need for c leaning. Normal (clean) pres- sure drop is approximately 1 psi (6.9 kPa). Open the factory- installed blowdown valve to clean the strainer . If requi red, shut the chiller dow n and remove [...]

69 PROGRAMMING Motormaster V cont rol is complet ely configured accordi ng to the inputs provided. No additi onal programming is necessary . The dr iv e can dis play 7 1 pr ogra m par ame ters . P arame ter s 50-60 are m onitor func tions and c annot be changed. Th e remainde r of the parameters can be changed af ter entering a passw ord. T o enter[...]

70 L1 L2 L3 Mode DANGER T1 T2 T3 B+ B- DISPLA Y BUTTONS Mode MMV TERMINAL BLOCK 12 5 6 1 1 12 2 14 13A 13B 13C 15 25 2 30 31 TXA TXB COM +5V MMV TERMINAL BLOCK Fig. 38 — Pressure Transducer and St art Command Jumper Wiring Fig. 37 — Motormas ter ® V Mo de Buttons and Mode Display *At 20 8 v , the d r iv e can run in either mo de. MODE NOMINAL [...]

71 Table 37 — Fault Codes Manual Reset — If fault condition has been removed, cycle powe r to th e chil ler to rese t the V FD. T roublesho oting — Troubleshooting the Motormaster® V control requires a combination of observi ng system operation and VFD information. The drive provides 2 kinds of t rouble- shooting modes: a st a tus matrix usi[...]

72 Table 38 — Motormaster ® V Progra m Parameters for Ope rating Mode s LEG END P ARAME TERS DESCRIPTION MODE 1 MODE 2 MODE 3 MODE 4 P01 Line V oltage: 01 = lo w line, 02 = high li n e 01 02 01 02 P02 Sterlco F r eq: 01 = 4 k H z, 02 = 6 kH z , 03 = 8 k H z 01 01 01 01 P03 Star tup mode: f lying restar t 06 06 06 06 P04 Stop mode: c oast to stop[...]

73 REPLACIN G DEFECTIVE MODUL ES — Th e Comfort - Link ™ replacement modules are shown in T able 39. If t he Main Base Board (MBB) has be en replaced, verify that all configura- tion data is correct. Follow the Configuration mode table and verify that all items under sub-modes UNIT , OP T1 and OP T2 are correct. Any additional field-installed a[...]

74 MAINTENANCE Recommended Maintenance Schedule — The fol- lowing are only recommended guidelines. Jobsite conditions may dictate that maintenance schedule is performed more oft en than recommended. Routine: For machines with E-coat Condenser C oils: • Check condense r coils for debris, clean as necessary with Sterling app r oved coil cleane r [...]

75 5. Allow unit to operate and confirm that everything is func- tioning properly . Check to see that leaving fluid tempera- ture agrees with leaving set point (CSP .1 or C SP .2), or if reset is used, with the control point (CTP T) [Run Status, VIEW]. 6. Check th e c oo l er leavi n g c h il le d water te mp e r at ure to see that it remains well [...]

76 Table 41 — Temperature Limi ts for Standard 30RA Unit s LEGEND *F or sus tained operation, EWT should not e xceed 85 F (29.4 C). † Unit requires modification below t his temperature. LOW-AMBIENT OPE RA TION — If operating temperat ures below 45 F (7 C) for sizes 010-030 or below 32 F (0° C) for sizes 032-055 are expected, accessory Motorm[...]

77 APPENDIX A S CN T a bl e s A_UNIT (General Unit Para meters) CIRCADIO (Circuit A D iscrete Inputs/Outputs) CIRCA_AN (Circuit A Anal og Parameters) DESCRIPTION V ALUE UNITS POINT NAM E FORCEABLE Control Mode 0 = T est 1 = Local Off 2 = S CN O f f 3 = Clock Off 4 = Emergency Stop 5 = Local On 6 = S CN On 7 = Clock On 8 = Heat Enabled 9 = Pump D el[...]

78 CIRCBDIO (Circuit B D iscrete Inputs/Outputs) CIRCB_AN (Circuit B Anal og Parameters) OPTIONS ( Unit Parame te rs) DESCRIPTION V ALUE UNITS POINT NAM E FORCEABLE CIRC . B DISCRETE OUTPUTS Compressor B1 Relay On/Off K_B1_RL Y N Compressor B2 Relay On/Off K_B2_RL Y N Minimum Load V alve Rela y On/Off ML V_R L Y N CIRC . B DISCRETE INPUTS Compresso[...]

79 ALARMDEF (Alarm Definition Table) BRODEFS (Broadcast POC Definition Table) DISPLAY (Marquee Display SETUP) DUALCHIL (Dual Chiller C onfiguration Settings) DESCRIPTION V ALUE DE F A UL T UNITS POINT NAME Alarm Routing Control 00000000 00000000 ALRM_CNT Equipment Pr ior ity 0 to 7 4 EQP _TYPE Comm F ailure Retr y Time 1 to 2 40 10 min RETR Y_TM Re[...]

80 OPTIONS1 (Options 1 Configuration) OPTIONS2 (Options 2 Configuration) DESCRIPTION V ALUE DEF A UL T UNITS POINT NAME Cooler Fluid 1 = W ater 2 = Med. Br ine 1F L U I D T Y P Minimum Load Vlv S elect No/ Y es No ML V_FLG Retur n Gas Sensor Enable Dsable/Enab le Dsable RGT_ENA Motormaster Sel e ct No /Y es No MTR_TY PE Cooler Pump Control Off/On O[...]

81 RESETCON (Temperature Reset and Demand Limit) SCHEDOVR ( Timed Override Setup) SETPO INT DESCRIPTION V ALUE DEF A UL T UNITS POINT NAME COOLING RE SET Cooling Reset T ype 0 = No Reset 1 = 4-20 mA input 2 = External temp – OA T 3 = Retur n Fluid 4 = Exter nal temp - SPT 0 CRST_TYP 4-20 MA RESET 4-20 – Degrees Reset – 30 to 30 0.0 ∆ ∆ ?[...]

82 UNIT MAINTENANCE ALARMS: Maintenanc e Display DESCRIPTION V ALUE DEF A UL T UN ITS POINT NAME Compressor A1 Size 8 to 15 60 Hz: 010-10; 015-1 5; 018-9; 022-9 ; 025- 13; 030-15 ; 035- 9; 040-13 ; 045-10 ; 050- 13; 05 5-15 50 Hz: 010- 11; 01 5-7; 018-9; 022-1 1; 025 -13; 032-8; 035-1 3; 042 -11; 045-1 3 SIZE_ A 1 Compressor A2 Size 0 to 15 60 Hz: [...]

83 CURRMODS: Maintenance Display DUALCHIL: Maintenance Displa y DESCRIPTION V ALUE POINT NAME FSM controlling Chiller On/Off MODE_1 WSM controlling Chiller On/Off MODE_2 Master/Slav e control On/Off MODE_3 Ramp Load Limit ed O n/Off MODE_5 Timed Override in eff ect On/Off MODE_6 Low Cooler Suction T empA On/Off MO DE_7 Low Cooler Suction T empB On/[...]

84 LEARNFNS: Maintenance Display LOADFACT: Maintenance Dis play OCCUPANCY SUPERVISO RY (OCCDEFM): Mainte nance Display DESCRIPTION V ALUE UNITS POINT NAME F an 1 Delta SCT point 1 snnn.n ° ° ° ° FF 1 D L T A 1 F an 1 Delta SCT point 2 snnn.n ° ° ° ° FF 1 D L T A 2 F an 1 Delta SCT point 3 snnn.n ° ° ° ° FF 1 D L T A 3 F an 1 Delta SCT p[...]

85 PM-COIL: Maintenance Display PM-PUM P: Mainte nance Display PM-STRN: Maintenance Display DESCRIPTION V ALUE UNITS POINT NAME Coil Cleaning Sr vc Inter nnnnnn hours S I_COIL Coil Service Countdown nnnnnn hours CL_CDOWN Coil Cleaning Maint.Done Y es/No CL_MAINT Coil Cleaning Maint.Date mm /dd/yy hh:mm COIL_PM0 Coil Cleaning Maint.Date mm /dd/yy hh[...]

86 RUNTEST: Maintenance Display DESCRIPTION V ALUE UNITS POINT NAME P ercent T otal C apacity nnn % CAP A_T P ercent Av ailable Cap . nnn % CAP A_A Discharge Press ure nnn.n psig DP_A Suction Pressure nnn.n psig SP_A Calculated HP Setpoint A nnn.n ° ° ° ° FH S P _ A Saturated Condensing Tmp nnn.n ° ° ° ° FT M P _ S C T A Saturated Suction T[...]

87 STRTHOUR: Maintenance Di splay TESTMO DE: Mai ntenance D isplay VERSIONS: Maintenance Display DESCRIPTION V ALUE UNITS POINT NAME Machine Operating Hours nnnnnn hours HR_MACH Machine Star ts nnnnnn CY_MA CH Circuit A Run Hours nnnnnn hours HR_C IRA Compressor A 1 Run Hours nnnnnn hours HR_A1 Compressor A 2 Run Hours nnnnnn hours HR_A2 Circuit B [...]

88 WSMDEF ME: Ma intenance Display DESCRIPTION V ALUE UNITS POINT NAME WSM Act ive ? Y e s WSMST A T Chilled water temp snn.n ° F CHWTEMP Equipment status On CHLRST Commanded s tate Enable Dsable None CHLRENA CHW setpoint reset value nn.n ^ F CHW R V A L Current CHW setpoint snn.n ° F CHW STPT[...]

89 APPENDIX B FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP, AND MANUAL STARTERS UNIT SIZE 30RA VO LT A G E V- P H - H z VO LT A G E SERIES O VERLO AD RELA Y (CA1) SETTING FOR COMPRESSOR A1 O VERLO AD RELA Y (CA2) SETTING FOR COMPRESSOR A2 MANU AL ST ARTER SETTING F O R F ANS FC-HS/LS MANU AL ST ARTER SETTING FOR F ANS FC-A 1/A2 MANU AL ST ARTER SETTI[...]

90 FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP, AND MANUAL S TARTERS (cont) UNIT SIZE 30RA VO LT A G E V- P H - H z VO LT A G E SERIES O VERLO AD RELA Y (CA1) SETTING FOR COMPRESSOR A1 O VERLO AD RELA Y (CA2) SETTING FOR COMPRESSOR A2 O VERLO AD RELA Y (CB1) SETTING FOR COMPRESSOR B1 O VERLO AD RELA Y (CB2) SETTING FOR COMPRESSOR B2 MANU AL ST ARTER[...]

91 APPENDIX C Building Interf ace — The 30RAN chil ler can be inte r- faced with multi-vendor control systems through 3 l evels of inter-operability using BA Clink, DataPort™, or D ataLink™ controls. BAClink controls function as a gate way between a SCN and a B A Cne t ™ sys t e m t o f a c i l i t a t e t he pas s i ng of da t a from t h e[...]

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificati ons or des igns without notice an d withou t inc urring obligation s. PC 9 03 Cata log No . 533-0 0047 Printe d in U .S .A. F orm 30RA -2T Pg 92 1-03 Repl aces: 3 0RA- 1T Book 2 Ta b 5 c C o p y r i g h t 2 0 03 Sterling DataPort, DataLink, BAClink Obj ect De[...]

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificat ions or designs without notice an d wit hout in c urring obligation s. PC 903 Catalog No . 533-0 0047 Printed i n U.S.A. Form 3 0RA-2T Pg C L-1 1-03 Replaces: 30 RA-1T Book 2 Ta b 5 c ST AR T -UP CHECKLIST FOR 30RA LIQUID CHILLER (Remove and use f or Job File)[...]

CL-2 5. CHILLED W A TER P UMP ST AR TER IN TERLOCKED WI TH CHILLER. YES NO 6. CHILLED W A TER FLO W SWITCH IS OPER A T I ONAL. YES NO 7. W A TE R LOOP V OLUME GREA TE R THAN MINIMUM REQUIREMENTS. (See T able 40). YES NO 8. PROPER LO OP FRE EZE PRO TECTIO N PRO VIDED TO _____ ° F ( ° C). YES NO ANTIFR EEZE TY PE _____ _______ ______ ___ CONCEN TRA[...]

CL-3 OPERA TING D A T A: RECORD THE FOLLOW ING INFORMA TION FR OM THE PRESSURE S AND TEMPERA TURES MODES WHEN MA CHINE IS IN A S T A BLE OPERA TING CONDITION: PRESSURE/TEMPERA TURE *Readi ngs taken w ith a dig ital ther m ometer. Compressor Run ning Current — Al l readi ngs taken at ful l load. CIRCUIT A CIRCUIT B DISCHARGE PRES SURE D P .A DP .B[...]

CL-4 Recor d S oftware V ersi ons MODE — RUN S T A TUS (PRE SS EN TER & ESCA PE SIM UL T A NEOU SL Y TO OBT AIN SOF TW ARE VERSIONS) COMMENTS: _________ _______ ______ ______ _______ ______ _______ _________ _______ ______ _______ ______ ______ _________ _______ ______ ______ _______ ______ _______ _________ _______ ______ _______ ______ ____[...]

CL-5 III. Unit Start-Up (cont) RECORD CONFIGURA TION SETTINGS UNIT (Configuration Settings) PRESS ESCAPE KEY T O DISPLA Y ‘ UNIT ’ . PRE SS DO WN ARR O W KEY T O DISP LA Y ‘ OPT1 ’ . PRESS ENTER KEY . RECORD CONFIGURA TION INFORMA TION B ELO W: OPTIONS1 (Options Configura tion) SUBMODE ITEM DISPLA Y DESCRIPTION V ALUE UNIT UNIT CONFIGURA TI[...]

CL-6 III. Unit Start-Up (cont) PRESS ESCAPE KEY T O DISPLA Y ‘ OPT1 ’ . PRESS D OWN A RRO W KEY T O DISPLA Y ‘ OPT2 ’ . PRESS ENTER KEY . RECORD CONFIGURA TION INFORMA TION BELOW . OPTIONS2 (Options Configura tion) RSET (Reset Configuration Settings) SUBMODE ITEM DISPLA Y DESCRIPTION V ALUE OPT2 UNIT OPTIONS 2 CONTRO LS CTRL X CONTROL M ETH[...]

CL-7 III. Unit Start-Up (cont) PRESS ESCAPE KEY T O DISPLA Y ‘ RSET ’ . PRESS DO WN ARR O W KEY T O DISPLA Y ‘ SLCT ’ . PRESS ENTER KEY . RECORD CONFIGURA TION INFORMA TION BELOW: SLCT (Setpoint and Ramp Load Configuration) PRESS ESCAPE KEY SEVERAL TIMES T O GET T O THE MODE LE VEL (BLANK DI SPLA Y). USE TH E ARR OW KEYS T O SCRO LL T O THE[...]

Manufactu rer reser ves the rig ht to dis continue , or chan ge at a ny time, spec ificati ons or des igns without notice an d withou t inc urring obligation s. PC 903 Catalo g No. 533-00047 Printe d in U.S.A. F o r m 30RA- 2T Pg CL-8 1-03 Repla ces: 30 RA-1T Book 2 Ta b 5 c C o p y r i g h t 2 0 03 Sterling - - - - - - - - - - - - - - - - - - - - [...]