Sterling AquaSnap 30RA010-055 - Manual (Page 2)

2
CONTENTS
Page
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3
MAJOR SYSTEM COMPONENTS. . . . . . . . . . . . . . . . . . .3,4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main Base Board (MBB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Scrolling Marquee Display . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Energy Management Module (EMM) . . . . . . . . . . . . . . . . . 3
Enable/Off/Remote Contact Switch. . . . . . . . . . . . . . . . . . 3
Emergency On/Off Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Board Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control Module Communication . . . . . . . . . . . . . . . . . . . . 3
Sterlco Comfort Network Interface . . . . . . . . . .. . . . . . . . 3
OPERATING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
•
T1 — COOLER LEAVING FLUID SENSOR
• T2 — COOLER ENTERING FLUID SENSOR
• T7,T8 — COMPRESSOR RETURN GAS
TEMPERATURE SENSOR (ACCESSORY)
• T9 — OUTDOOR-AIR TEMPERATURE SENSOR
• T10 — REMOTE SPACE TEMPERATURE SENSOR OR
DUAL LEAVING WATER TEMPERATURE SENSOR
Energy Management Module . . . . . . . . . . . . . . . . . . . . . . . 17
Loss-of-Cooler Flow Protection . . . . . . . . . . . . . . . . . . . . 17
Thermostatic Expansion Valves (TXV) . . . . . . . . . . . . . 17
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
•
MINUTES LEFT FOR START
• MINUTES OFF TIME
• LEAD/LAG DETERMINATION
• CAPACITY CONTROL OVERRIDES
Head Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation of Machine Based on Control Method
and Cooling Set Point Selection Settings . . . . . . . . 22
Cooling Set Point Select . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Marquee Display Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Service Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Optional Factory-Installed Hydronic Package . . . . . . 24
Cooler Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cooler Pump Sequence of Operation . . . . . . . . . . . . . . 24
Configuring and Operating Dual Chiller Control. . . . 26
Temperature Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Demand Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
•
DEMAND LIMIT (2-Stage Switch Controlled)
• EXTERNALLY POWERED DEMAND LIMIT
(4 to 20 mA Controlled)
• DEMAND LIMIT (SCN Loadshed Controlled)
Cooling Set Point (4 to 20 mA) . . . . . . . . . . . . . . . . . . . . . 45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-57
Complete Unit Stoppage and Restart . . . . . . . . . . . . . . 46
•
GENERAL POWER FAILURE
• UNIT ENABLE-OFF-REMOTE CONTACT SWITCH IS
OFF
• CHILLED FLUID PROOF-OF-FLOW SWITCH OPEN
• OPEN HIGH-PRESSURE SWITCH(ES)
• OPEN COMPRESSOR INTERNAL THERMAL
PROTECTION
• OPEN 24-V CONTROL CIRCUIT BREAKERS
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
• LOW SATURATED SUCTION
Alarms and Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-73
Electronic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
•
CONTROL COMPONENTS
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
•
BRAZED-PLATE COOLER HEAT EXCHANGER
REPLACEMENT
• BRAZED-PLATE COOLER HEAT EXCHANGER
CLEANING
Check Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Page
Condenser Section and Coils . . . . . . . . . . . . . . . . . . . . . . 60
•
COIL CLEANING
• CLEANING E-COATED COILS
• CONDENSER SECTION
Check Refrigerant Feed Components . . . . . . . . . . . . . . 61
•
THERMOSTATIC EXPANSION VALVE (TXV)
• FILTER DRIER
• MOISTURE-LIQUID INDICATOR
• MINIMUM LOAD VALVE
• PRESSURE RELIEF DEVICES
Compressor and Unit Protective Devices . . . . . . . . . . 62
•
MANUAL STARTER
• COMPRESSOR INTERNAL THERMAL PROTECTION
Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
•
HIGH-PRESSURE SWITCH
• PRESSURE TRANSDUCERS
• COOLER FREEZE-UP PROTECTION
• HEATER CABLE
• WINTER SHUTDOWN
Thermistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Motormaster® V Controller . . . . . . . . . . . . . . . . . . . . . . . . 68
•
GENERAL OPERATION
• SET POINTS
• INSTALLATION
• PROGRAMMING
• EPM CHIP
• LIQUID LINE PRESSURE SET POINT ADJUSTMENT
• LOSS OF SCN COMMUNICATIONS
•
REPLACING DEFECTIVE MODULES
Hydronic Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Recommended Maintenance Schedule . . . . . . . . . . . . 74
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
START-UP AND OPERATION . . . . . . . . . . . . . . . . . . . . .74-76
Actual Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Check Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 75
Operating Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
•
TEMPERATURES
• LOW AMBIENT OPERATION
• VOLTAGE — ALL UNITS
OPERATION SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 76
APPENDIX A —
SCN TABLES. . . . . . . . . . . . . . . . . . . .77-88
APPENDIX B — FACTORY SETTINGS FOR
COMPRESSOR, FAN, PUMP AND MANUAL
STARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89,90
APPENDIX C — BUILDING INTERFACE . . . . . . . . . .91,92
START-UP CHECKLIST FOR 30RA LIQUID
CHILLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CL-1-CL-8
GENERAL
This publication contains Controls Start-Up, Service, Oper-
ation, and Troubleshooting information for the 30RA
AquaSnap® air-cooled chillers. See Table 1. These chillers are
equipped with ComfortLink™ controls and conventional
thermostatic expansion valves (TXVs).
This unit uses a microprocessor-based electronic control
system. Do not use jumpers or other tools to short out or
bypass components or otherwise depart from recom-
mended procedures. Any short-to-ground of the control
board or accompanying wiring may destroy the board or
electrical component.