Sterling SCW Series - Manuals

Page 8 of 77 SCW Series Central Chilling Stations 1 General Information 1-1 Introduction Sterling SCW Series central water chilling stations are available in water-cooled and remote air-cooled designs. They differ only in the condensing media used. The SCW Series units are configured with two indepe...

SCW Series Central Chilling Stations Page 9 of 77 1-3 Models Covered This manual provides operation, installation, and maintenance instructions for the SCW Series central chilling stations. Model numbers are listed on the serial tag. A model number followed by Q indicates a specially constructed uni...

Page 10 of 77 SCW Series Central Chilling Stations 1-5 Available Options SCW Series central chillers are available with options to tailor the unit to your requirements. Some are factory installed; some can be retro-fitted in the field. Consult Sterling sales for more information. Available SCW Serie...

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

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 might have occurred in transit, such as broken or loose wiring and components, loo...

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 the equipment itself, you should have: ; ................. Bill of lading ; ................. Packing list ; ................

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 USING BONDED PROFESSIONAL MILLWRIGHTS TO UNLOAD AND MOVE SCW SERIES CHILLERS. Rig the chiller from the frame only, using spreader bars ...

Page 20 of 77 SCW Series Central Chilling Stations 3 Installation 3-1 Installation Location Considerations As with all equipment installations, follow all applicable codes and regulations. ; Locate close to the process to reduce piping expense. ; Locate adjacent to drain and city water sources. ; Co...

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 leads and ground from a fused disconnect (installed b...

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 protector checks for corre...

SCW Series Central Chilling Stations Page 23 of 77 From Process The chilled water return for water returning back to the chiller 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 equa...

Page 24 of 77 SCW Series Central Chilling Stations 3-6 Water Connection Sizing Considerations Important! • Run all external chilled water connections with adequate size to the process. • Provide the largest possible openings and passages for the flow of chilled water through platens, dies, molds, or...

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) Conde...

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-coo...

SCW Series Central Chilling Stations Page 27 of 77 Condenser Fan On SCW Series remote air-cooled units, air should be drawn through the condenser and discharge up from the condenser. Changing fan rotation direction • Disconnect and lock out power at the fused disconnect. • If all fans are going back...

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 ...

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 process cooling water supply connection at the P1 manifold at the left side of the pump tank at the exposed connection. Bring the p...

Page 30 of 77 SCW Series Central Chilling Stations If you want lower chilled water temperatures, you’ll need to mix process water with industrial- (not automotive) grade ethylene or propylene glycol with rust inhibitor to provide protection down to 20°F (12ºC) below the operating temperature you wan...

SCW Series Central Chilling Stations Page 31 of 77 4-8 High Pressure Cutout This electro-mechanical safety feature opens the control circuit if the system condensing pressure exceeds a safe level. High pressure cutout setting Model psi kPa bars SCW Series water-cooled and remote air-cooled chilling ...

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 flo...

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 followed. Have new chillers started up and checked by a qualified refrigeration service technician. Sterling offers fac...

SCW Series Central Chilling Stations Page 35 of 77 ; Complete all piping leading 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 rotatio...

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 butterfly valve, crack it open, then start the pump and observe the gauge. • If the gauge indicates within 15 psi (103....

SCW Series Central Chilling Stations Page 37 of 77 7. Operate the chiller, looking for leaks and listening for unusual noises or vibrations that could indicate improper operation. 5-4 Remote Air-Cooled SCW Series Startup Checklist ; Check the shipping papers against the serial tag to be sure chiller...

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 being filled. ; Check your work and proceed to the Startup procedure in the following section. 5-5 Remote Air-Cooled SCW Series Startup 1. Start...

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 pu...

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 control circuit is energized. Start The Start push-button lets you energize the unit. Sto...

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 curr...

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 Viewing Compressor Status Operating the chiller compressors Setting Compressor Lead/Lag Times and Activating Compressor Lead/Lag Operatio...

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 must be done by a...

SCW Series Central Chilling Stations Page 47 of 77 Setting System Temperatures

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...

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 thirt...

SCW Series Central Chilling Stations Page 51 of 77 „ Press the Up or Down buttons on the 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 compressors within the sys...

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 turned off in the compressor enable/disable screen. The compressor will not be called to operate until it has bee...

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 Times and Activating Compressor Lead/Lag Opera...

Page 54 of 77 SCW Series Central Chilling Stations Viewing 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 compressors t...

SCW Series Central Chilling Stations Page 55 of 77 Two hourmeters are kept for each compressor in the system. The first is a lifetime meter. This measures the total time that the compressor has been operational in the lifetime of the chiller. The second is a resettable hourmeter. This hourmeter can ...

Page 56 of 77 SCW Series Central Chilling Stations „ Press the Up or Down buttons to highlight either “ System Information ”. „ Press ↵ The Pump Status Screen appears Figure 12 Pump Status Screen Only pumps that are included in the system will be shown on this screen. Pumps will display one of the f...

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 indicates a fault condition and the pump has been deactivated. Once the problem is remedied, the pump will return to a READY state u...

Page 58 of 77 SCW Series Central Chilling Stations toggle the state of the pump from the ON-LINE to OFF-LINE state. Setting Pump Lead/Lag Times and 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...

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 time that the pump has been operational in the lifetime of the chiller. The second is a resettable hourmeter. This hourmeter can be cleared t...

Page 60 of 77 SCW Series Central Chilling Stations „ Chilled Water Circuit High Pressure (One per chilled water circuit) „ Chilled Water Circuit Low Pressure (One per chilled water circuit) „ Pump motor overload (One per system pump) If an alarm condition occurs, the follow screen is displayed: Figu...

SCW Series Central Chilling Stations Page 61 of 77 Once a device has gone offline you will need to contact a licensed professional (electrician or refrigeration sevice company) to bring the device back online. ! CAUTION Never attempt to service a unit until a qualified electrician has opened and loc...

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 do so may dislodge the bearing grea...

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 Department at Sterling to arrange a schedule of inspections. This service, described in Sterling Bulletin No. 10-106.3 , is...

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 ...

SCW Series Central Chilling Stations Page 71 of 77 Service Notes

Page 72 of 77 SCW Series Central Chilling Stations I Index Alarms 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-Lag , 28 Compressor Staging Seque...

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] 641-8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering des...