Page 2 - CONTENTS; Sterlco; GENERAL
2 CONTENTS Page SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,3 MAJOR SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . .3,4 General . . . . . . . . . . . . . . . . . . . . . ...
Page 3 - Table 1 — Unit Sizes; UNIT
3 Table 1 — Unit Sizes *60 Hz only. †50 Hz only. MAJOR SYSTEM COMPONENTS General — The 30RA air-cooled reciprocating chillers contain the ComfortLink™ electronic control system thatcontrols and monitors all operations of the chiller. The control system is composed of several components as listed in ...
Page 4 - Sensors —
4 At each system element, the shields of its communication bus cables must be tied together. If the communication bus isentirely within one building, the resulting continuous shieldmust be connected to a ground at one point only. If the commu-nication bus cable exits from one building and enters ano...
Page 16 - ENTER; MODE; ESCAPE; Fig. 7 — Main Base Board
16 CEPL130346-01 STATUS LEN J1 J2 J4 J3 J5 J6 J7 J8 J9 J10 S CN RED LED - STATUS GREEN LED -LEN (LOCAL EQUIPMENT NETWORK) YELLOW LED - S CN ( STERLCO COMFORT NETWORK) INSTANCE JUMPER K11 K10 K9 K8 K7 K6 K5 K4 K3 K2 K1 Run Status Service Test Temperature Pressures Setpoints Inputs Outputs Configurati...
Page 17 - Capacity Control —; Fig. 9 — Typical Space Temperature; CN Communications Bus Wiring
17 Energy Manag ement Module (Fig. 11) — This factory-installed option (FIOP) or field-installed accessory isused for the following types of temperature reset, demandlimit, and/or ice features:• 4 to 20 mA leaving fluid temperature reset (requiresfield-supplied 4 to 20 mA generator) • 4 to 20 mA coo...
Page 18 - TEST; Fig. 11 — Energy Management Module
18 Table 6 — Part Load Data Percent Displacement, Standard Units without Minimum Load Valve NOTE: These capacity steps may vary due to different capacity staging sequences. 30RA UNIT SIZE CONTROL STEPS LOADING SEQ A LOADING SEQ B % Displacement Compressor % Displacement Compressor 010,015 (60 Hz) 1 ...
Page 20 - LWT —; Fig. 12 — Deadband Multiplier
20 MINUTES LEFT FOR START — This value is displayedonly in the network display tables (using Service Tool,ComfortVIEW™ or ComfortWORKS® software) andrepresents the amount of time to elapse before the unit will startits initialization routine. This value can be zero without themachine running in many...
Page 21 - Head Pressure Control —; The Main Base Board; Fig. 13 — Operating Envelope for; FAN ARRANGEMENT; Fig. 14 — 30RA Condenser Fan Sequence
21 Head Pressure Control — The Main Base Board (MBB) controls the condenser fans to maintain the lowestcondensing temperature possible, and thus the highest unitefficiency. The MBB uses the saturated condensing tempera-ture input from the discharge pressure transducer to control thefans. Head pressu...
Page 22 - Cooling Set Point Select
22 Operation of Machine Based on ControlMethod and Cooling Set Point Selection Set-tings — Machine On/Off control is determined by the configuration of the control method (CTRL) [Configuration,OPT2] and cooling set point select (CLSP) [Configuration,SLCT] variables. All models are factory configured...
Page 23 - Table 8 — Control Methods and Cooling Set Points; Both main power; CONTROL; Fig. 16 — Scrolling Marquee Display
23 Table 8 — Control Methods and Cooling Set Points *Dual set point switch input used. CSP1 used when switch input is open. CSP2 used when switch input is closed. †Cooling set point determined from 4 to 20 mA input to Energy Management Module (EMM) to terminals TB6-3,5. HEATING OPERATION — The chill...
Page 26 - Table 9 — Marquee Display Menu Structure*; Fig. 17 — Dual Chiller Thermistor Location
26 As part of a pump maintenance routine, the pumps can be started to maintain lubrication to the pump seal. To utilize thisfunction, Cooler Pmp Periodic Start (PM.P.S) [Configuration,UNIT] must be set to YES. This option is set to NO as the fac-tory default. If feature is enabled and the pump(s) ar...
Page 27 - Table 10 — Run Status Mode and Sub-Mode Directory
27 Table 10 — Run Status 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 SUB-ITEM DISPLAY SUB-ITEM DISPLAY ITEM EXPANSION COMMENT VI...
Page 34 - Table 18 — Time Clock Mode and Sub-Mode Directory
34 Table 18 — Time Clock Mode and Sub-Mode Directory SUB-MODE KEYPAD ENTRY ITEM DISPLAY SUB-ITEM DISPLAY ITEM EXPANSION COMMENT TIME TIME OF DAY HH.MM XX.XX HOUR AND MINUTE Military (00:00 – 23:59) DATE MONTH,DATE,DAY AND YEAR MNTH XX MONTH OF YEAR 1-12 (1 = January, 2 = February, etc) DOM XX DAY OF...
Page 38 - Table 21 — Dual Chiller Configuration (Master Chiller Example)
38 Table 21 — Dual Chiller Configuration (Master Chiller Example) SUB-MODE ITEM KEYPAD ENTRY DISPLAY ITEM EXPANSION COMMENTS DISP UNIT OPT1 OPT2 CTRL CONTROL METHOD CTRL 0 SWITCH DEFAULT 0 CTRL S CNA S CNA 1 S CN ADDRESS DEFAULT 1 S CNA S CNB S CNB 0 S CN BUS NUMBER DEFAULT 0 S CNB OPT2 RSET PROCEED...
Page 40 - Table 22 — Dual Chiller Configuration (Slave Chiller Example)
40 Table 22 — Dual Chiller Configuration (Slave Chiller Example) NOTES: 1. Slave Control Method (CTRL) must be configured for 0.2. Slave S CN Address ( S CNA) must be different than Master. 3. Slave S CN Bus Number ( S CNB) must be the same as Master 4. Slave does not require SLVA, LLBL, LLBD, or LL...
Page 41 - Table 23 — Operating Modes
41 Table 23 — Operating Modes MODE NO. ITEM EXPANSION DESCRIPTION 01 FSM CONTROLLING CHILLER Flotronic™ System Manager (FSM) is controlling the chiller. 02 WSM CONTROLLING CHILLER Water System Manager (WSM) is controlling the chiller. 03 MASTER/SLAVE CONTROL Dual Chiller control is enabled. 05 RAMP ...
Page 42 - Table 24 — Example of Reading and Clearing Alarms
42 Table 24 — Example of Reading and Clearing Alarms Table 25A — 4-20 mA Reset NOTE: The example above shows how to configure the chiller for 4-20 mA reset. No reset will occurat 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 C...
Page 43 - Temperature Reset —; The control system is capable of
43 Table 26A — Configuring Outdoor Air and Space Temperature Reset *4 items skipped in this example. Table 26B — Configuring Return Temperature Reset *4 items skipped in this example. Temperature Reset — The control system is capable of handling leaving-fluid temperature reset based on return cooler...
Page 44 - Demand Limit —; Fig. 18 — Standard Chilled Fluid; Fig. 20 — Space Temperature Reset
44 2.0 F (1.1 C) cooler ∆ T and 0° F (0° C) reset at 10.0 F (5.6 C) cooler ∆ T. The variable RT.NO should be set to the cooler temperature difference ( ∆ T) where no chilled water tempera- ture reset should occur. The variable RT.F should be set to thecooler temperature difference where the maximum ...
Page 45 - EMM
45 DEMAND LIMIT (SCN Loadshed Controlled) — To con-figure Demand Limit for SCN Loadshed control set the De-mand Limit Select (DMDC) [Configuration, RSET] to 3. Thenconfigure the Loadshed Group Number (SHNM), LoadshedDemand Delta (SHDL), and Maximum Loadshed Time(SHTM) [Configuration, RSET]. See Tabl...
Page 46 - Table 27 — Configuring Demand Limit; TROUBLESHOOTING
46 Table 27 — Configuring Demand Limit *Seven items skipped in this example. TROUBLESHOOTING Complete Unit Stoppage and Restart — Possi- ble causes for unit stoppage and reset methods are shown be-low. (See Table 28 also.) Refer to Fig. 22-26 for ComponentArrangement and Control Wiring Diagrams.GENE...
Page 47 - Table 28 — Troubleshooting
47 Table 28 — Troubleshooting SYMPTOMS CAUSE REMEDY Cooler Circulating Pump DoesNot Run Power line open Reset circuit breaker. Control fuse or circuit breaker open Check control circuit for ground or short. Reset breaker and replace fuse. Compressor over temperature sensor open (06D) Find cause of h...
Page 53 - Alarms and Alerts —; Table 29 — Alarm and Alert Codes
53 Alarms and Alerts — These are warnings of abnormal or fault conditions, and may cause either one circuit or thewhole unit to shut down. They are assigned code numbers asdescribed in Table 29. Automatic alarms will reset without operator intervention if the condition corrects itself. The following...
Page 58 - Table 30 — Unit Torque Specification; Cooler; FASTENER
58 SERVICE Electronic Components CONTROL COMPONENTS — Unit uses an advanced elec-tronic control system that normally does not require service.For details on controls refer to Operating Data section. Access to the compressors is through latched panels from beneath the control box on all models or fro...
Page 59 - HPS —
59 BASE COMPRESSOR COMP 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 - Check Oil Charge —; Table 31 — Oil Charge; Condenser Section and Coils; COMPRESSOR
60 Check Oil Charge — Compressors are factory charged with oil as shown in Table 31. Table 31 — Oil Charge If oil is visible in the compressor sight glass, check unit for operating readiness as described in Pre-Start-Up, SystemCheck section (page 74), then start the unit. Observe oil leveland add oi...
Page 61 - Check Refrigerant Feed Components; The valve is factory-set to maintain between 8 and 12 F; Fig. 31 — 30RA Access Panels
61 • Thoroughly rinse all surfaces with low velocity cleanwater using downward rinsing motion of water spraynozzle. Protect fins from damage from the spray nozzle. CONDENSER SECTION — Condenser fan motors and fanscan be serviced by removal of outlet grilles or side panels. SeeFig. 31. Be sure the wi...
Page 62 - The amount of capacity reduction achieved by the mini-; Compressor and Unit Protective Devices; Manual starters are factory set field adjustment should not; Check Unit Safeties; The high-pressure switch is mounted in the discharge side; Table 32 — Factory Settings, High-Pressure; Clear the alarm using the Scrolling Marquee display as de-; Fig. 34 — Mounting Locations for TXV Sensing Bulb
62 The amount of capacity reduction achieved by the mini- mum load valve is not adjustable. The total unit capacity withthe minimum load valve is shown in Table 7.PRESSURE RELIEF DEVICES — All units have one pres-sure relief device per circuit located in the liquid line which re-lieves at 210 F (100...
Page 68 - Strainer —; Periodic factory-installed strainer cleaning is; Motormaster® V Controller —; When the ambient air temperature drops, a fan running at; Fig. 36 — Thermistor Connections to
68 Strainer — Periodic factory-installed strainer cleaning is required. Pressure drop across strainer in excess of 3 psi(21 kPa) indicates the need for cleaning. Normal (clean) pres-sure drop is approximately 1 psi (6.9 kPa). Open the factory-installed blowdown valve to clean the strainer. If requir...
Page 70 - Mode; Fig. 38 — Pressure Transducer and Start Command Jumper Wiring
70 L1 L2 L3 Mode DANGER T1 T2 T3 B+ B- DISPLAY BUTTONS Mode MMVTERMINALBLOCK 1 2 5 6 11 12 2 14 13A 13B 13C 15 25 2 30 31 TXA TXB COM +5V MMVTERMINALBLOCK Fig. 38 — Pressure Transducer and Start Command Jumper Wiring Fig. 37 — Motormaster® V Mode Buttons and Mode Display *At 208 v, the drive can run...
Page 71 - FAULT CODE
71 Table 37 — Fault Codes Manual Reset — If fault condition has been removed, cyclepower to the chiller to reset the VFD.Troubleshooting — Troubleshooting the Motormaster® Vcontrol requires a combination of observing system operationand VFD information. The drive provides 2 kinds of trouble-shooting...
Page 72 - Table 38 — Motormaster® V Program Parameters for Operating Modes
72 Table 38 — Motormaster® V Program Parameters for Operating Modes LEGEND PARAMETERS DESCRIPTION MODE 1 MODE 2 MODE 3 MODE 4 P01 Line Voltage: 01 = low line, 02 = high line 01 02 01 02 P02 Sterlco Freq: 01 = 4 kHz, 02 = 6 kHz, 03 = 8 kHz 01 01 01 01 P03 Startup mode: flying restar t 06 06 06 06 P04...
Page 73 - Table 39 — Replacement Modules; Hydronic Package —
73 REPLACING DEFECTIVE MODULES — The Comfort-Link ™ replacement modules are shown in Table 39. If the Main Base Board (MBB) has been replaced, verify that all configura-tion data is correct. Follow the Configuration mode table andverify that all items under sub-modes UNIT, OPT1 and OPT2are correct. ...
Page 74 - Table 40 — Minimum Cooler Flow Rates and
74 MAINTENANCE Recommended Maintenance Schedule — The fol- lowing are only recommended guidelines. Jobsite conditionsmay dictate that maintenance schedule is performed more oftenthan recommended.Routine:For machines with E-coat Condenser Coils:• Check condenser coils for debris, clean as necessarywi...
Page 75 - Check Refrigerant Charge —; All 30RA units are; Operating Limitations; Fig. 39 — Compressor Connections and Oil Sight Glass Location
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 CSP.2), or ifreset is used, with the control point (CTPT) [Run Status,VIEW]. 6. Check the cooler leaving chilled water temperature t...
Page 76 - OPERATION SEQUENCE; UNIT SIZE 30RA
76 Table 41 — Temperature Limits for Standard 30RA Units LEGEND *For sustained operation, EWT should not exceed 85 F (29.4 C).†Unit requires modification below this temperature. LOW-AMBIENT OPERATION — If operating temperaturesbelow 45 F (7 C) for sizes 010-030 or below 32 F (0° C) forsizes 032-055 ...
Page 77 - APPENDIX A; CN Tables
77 APPENDIX A S CN Tables A_UNIT (General Unit Parameters) CIRCADIO (Circuit A Discrete Inputs/Outputs) CIRCA_AN (Circuit A Analog Parameters) DESCRIPTION VALUE UNITS POINT NAME FORCEABLE Control Mode 0 = Test1 = Local Off2 = S CN Off 3 = Clock Off4 = Emergency Stop5 = Local On6 = S CN On 7 = Clock ...
Page 79 - DUALCHIL (Dual Chiller Configuration Settings)
79 ALARMDEF (Alarm Definition Table) BRODEFS (Broadcast POC Definition Table) DISPLAY (Marquee Display SETUP) DUALCHIL (Dual Chiller Configuration Settings) DESCRIPTION VALUE DEFAULT UNITS POINT NAME Alarm Routing Control 00000000 00000000 ALRM_CNT Equipment Priority 0 to 7 4 EQP_TYPE Comm Failure R...
Page 82 - MAINTENANCE; ALARMS: Maintenance Display
82 UNIT MAINTENANCE ALARMS: Maintenance Display DESCRIPTION VALUE DEFAULT UNITS POINT NAME Compressor A1 Size 8 to 15 60 Hz: 010-10; 015-15; 018-9; 022-9; 025-13; 030-15; 035-9; 040-13; 045-10; 050-13; 055-15 50 Hz: 010-11; 015-7; 018-9; 022-11; 025-13; 032-8; 035-13; 042-11; 045-13 SIZE_A1 Compress...
Page 86 - RUNTEST: Maintenance Display; DESCRIPTION
86 RUNTEST: Maintenance Display DESCRIPTION VALUE UNITS POINT NAME Percent Total Capacity nnn % CAPA_T Percent Available Cap. nnn % CAPA_A Discharge Pressure nnn.n psig DP_A Suction Pressure nnn.n psig SP_A Calculated HP Setpoint A nnn.n °°°° F HSP_A Saturated Condensing Tmp nnn.n °°°° F TMP_SCTA Sa...
Page 88 - WSMDEFME: Maintenance Display
88 WSMDEFME: Maintenance Display DESCRIPTION VALUE UNITS POINT NAME WSM Active? Yes WSMSTAT Chilled water temp snn.n ° F CHWTEMP Equipment status On CHLRST Commanded state EnableDsable None CHLRENA CHW setpoint reset value nn.n ^F CHWRVAL Current CHW setpoint snn.n ° F CHWSTPT
Page 89 - APPENDIX B; AND MANUAL STARTERS
89 APPENDIX B FACTORY SETTINGS FOR COMPRESSOR, FAN, PUMP, AND MANUAL STARTERS UNIT SIZE 30RA VOLTAGE V-PH-Hz VOLTAGE SERIES OVERLOAD RELAY (CA1) SETTING FOR COMPRESSOR A1 OVERLOAD RELAY (CA2) SETTING FOR COMPRESSOR A2 MANUAL STARTER SETTING FOR FANS FC-HS/LS MANUAL STARTER SETTING FOR FANS FC-A1/A2 ...
Page 91 - The 30RAN chiller can be inter-; DataPort, DataLink, BAClink Object Definition; CIRCADIO
91 APPENDIX C Building Interface — The 30RAN chiller can be inter- faced with multi-vendor control systems through 3 levels ofinter-operability using BAClink, DataPort™, or DataLink™controls. BAClink controls function as a gateway between aSCN and a BACnet™ system to facilitate the passing of datafr...
Page 92 - OPTIONS
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 903 Catalog No. 533-00047 Printed in U.S.A. Form 30RA-2T Pg 92 1-03 Replaces: 30RA-1T Book 2 Tab 5c Copyright 2003 Sterling DataPort, DataLink, BAClin...
Page 93 - START-UP CHECKLIST FOR 30RA LIQUID CHILLER; Design Information; II. Preliminary Equipment Check; Chilled Water System Check
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 903 Catalog No. 533-00047 Printed in U.S.A. Form 30RA-2T Pg CL-1 1-03 Replaces: 30RA-1T Book 2 Tab 5c START-UP CHECKLIST FOR 30RA LIQUID CHILLER (Remo...
Page 94 - Start and Operate Machine. Complete the Following:; YES
CL-2 5. CHILLED WATER PUMP STARTER INTERLOCKED WITH CHILLER. YES NO 6. CHILLED WATER FLOW SWITCH IS OPERATIONAL. YES NO 7. WATER LOOP VOLUME GREATER THAN MINIMUM REQUIREMENTS. (See Table 40). YES NO 8. PROPER LOOP FREEZE PROTECTION PROVIDED TO _____ °F (°C). YES NO ANTIFREEZE TYPE __________________...
Page 95 - Compressor Running Current —
CL-3 OPERATING DATA: RECORD THE FOLLOWING INFORMATION FROM THE PRESSURES AND TEMPERATURES MODES WHENMACHINE IS IN A STABLE OPERATING CONDITION: PRESSURE/TEMPERATURE *Readings taken with a digital thermometer. Compressor Running Current — All readings taken at full load. CIRCUIT A CIRCUIT B DISCHARGE...
Page 97 - RECORD CONFIGURATION SETTINGS
CL-5 III. Unit Start-Up (cont) RECORD CONFIGURATION SETTINGS UNIT (Configuration Settings) PRESS ESCAPE KEY TO DISPLAY ‘UNIT’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT1’.PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW: OPTIONS1 (Options Configuration) SUBMODE ITEM DISPLAY DESCRIPTION VALUE UNIT ...
Page 98 - RECORD CONFIGURATION INFORMATION BELOW.
CL-6 III. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘OPT1’. PRESS DOWN ARROW KEY TO DISPLAY ‘OPT2’.PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW. OPTIONS2 (Options Configuration) RSET (Reset Configuration Settings) SUBMODE ITEM DISPLAY DESCRIPTION VALUE OPT2 UNIT OPTIONS 2 CONTROLS ...
Page 99 - RECORD CONFIGURATION INFORMATION BELOW:; SLCT (Setpoint and Ramp Load Configuration)
CL-7 III. Unit Start-Up (cont) PRESS ESCAPE KEY TO DISPLAY ‘RSET’. PRESS DOWN ARROW KEY TO DISPLAY ‘SLCT’.PRESS ENTER KEY. RECORD CONFIGURATION INFORMATION BELOW: SLCT (Setpoint and Ramp Load Configuration) PRESS ESCAPE KEY SEVERAL TIMES TO GET TO THE MODE LEVEL (BLANK DISPLAY). USE THEARROW KEYS TO...
Page 100 - COMPONENT TEST; Service Test Mode and Sub-Mode Directory
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. PC 903 Catalog No. 533-00047 Printed in U.S.A. Form 30RA-2T Pg CL-8 1-03 Replaces: 30RA-1T Book 2 Tab 5c Copyright 2003 Sterling - - - - - - - - - - - - ...
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