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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.