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SterlingTEK A0551797 User's Manual

1. SSCW xxx 30 4 5 6 Cooling Capacity tons 50 F 10 C LWT Capacity stages qty 2 EER BTUH W 14 91 15 35 Nominal water flow gpm 78 295 3 99 374 8 120 454 2 156 590 5 lom 97 367 2 124 469 4 1511571 6 194 734 4 2 21 2 85 215 9 Dimensions in om 689 5 861 8 961 6 1224 7 730 3 911 7 1025 1 1301 8 STERLCOS SSC Series Central Chilling Stations Page 11 of 86 SSCW xxx 70 8 amp i Capacity stages qty 4 EER BTUH W 15 15 14 63 14 90 15 16 l Evaporator 75 662 4 196 741 9 217 821 4 38 900 9 Nominal water flow gpm DA 829 0 923 6 1025 8 1128 1 100 Cooling Capacity tons 50 F 10 C LWT aa ae ce 4 2 298 Condenser connection no manifold Flange Conn in 2 21 2 2 21 2 21 2 3 Evaporator manifold connection Victaulic Amp draw nameplate 460 3 60 V 174 Height 75 190 5 Dimensions in cm Width 94 238 8 115 292 1 Depth 45 114 3 1360 8 1496 9 1623 9 1759 9 1541 5 1596 6 1737 3 1886 9 Based on 50 F 10 C chilled water supply temperature and 85 F 29 C tower water Based on 2 4 gpm per ton 9 1 lpm per 3 517 kW Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 1 2 for 380 3 60 amperages multiply
2. 4 3 4 4 Staging Alarms 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 turned on or off to keep the temperature at the specified set point 2 Compressor anti recycle time is three 3 minutes If a fault occurs that compressor or circuit is deactivated The load will automatically shift to any other compressors that are currently ON LINE but not running Lead Lag rotation will continue to function Compressors that are faulted will be removed from the rotation order Lead Lag Compressors The system automatically rotates the compressor order to generate a Lead Lag rotation Any time a compressor is faulted or manually taken OFF LINE it will be removed from the Lead Lag rotation Once the fault is cleared or manually put ON LINE the compressor is returned to the Lead Lag rotation at the end of the rotation order Lead Lag Pumps The system automatically rotates the pump order to generate a Lead Lag rotation Any time a pump is faulted or manually taken OFF LINE it will be removed from the Lead Lag rotation Once the fault is cleared or manually put ON LINE the pump is returned to the Lead Lag rotation at the end of the rotation order STERLCOS SSC Series Central Chilling Stations Page 27 of 86 4 5 Chilled Water Circuit If your central chilling station 1s equipped with the optional integral p
3. Sterling offers factory startup for SSC Series Series chilling stations Call the Sterling Service Department at 1 800 233 4819 for more details 5 2 Water Cooled SSC Series Startup Checklist M Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process M Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using M The voltage at the main power connection must be within plus or minus ten percent 10 of the voltage listed on the serial tag M Phase imbalance must be less than two percent lt 2 M Electrical connections must conform to all applicable codes M Complete the chilled water TO and FROM PROCESS connections M The optional or field installed chilled water supply and return valves on the chiller must be open M Be sure the pump tank and chilled water circuit are filled with a water glycol mixture that provides freeze protection to 20 F 12 C below the leaving water temperature you want M Complete the tower or city condenser WATER IN and WATER OUT connections Provide an adequate condenser water supply 2 gpm per ton for city water or 3 gpm per ton for tower water operation M Remove all tools foreign matter and debris from the pump tank reservoir and piping qaip SSC Series Central Chilling Stations Page 33 of 86 Page 34 of 86 M Complete all piping leading to and from the pu
4. 10 C STERLCOS SSC 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 12 C below the operating temperature you want Figure 3 below shows the proper mixtures needed to provide protection to 20 F 12 C below the operating temperature you want You can then reset the freezestat cutout temperature to a temperature 10 F 6 C below the operating temperature you selected Caution Make sure all freezestat adjustments are performed by a qualified refrigeration service technician The Sterling product warranty does not cover system freeze up Figure 3 Freezing Protection Curve Ethylene glycol required for evaporator freeze protection mT heed le a stttt tt Psat ttt ttt ttt ttt LS Ee ee E ot ttt tt tt tt PANE E oan zest a TS y percent by ey volume 20 T R DR EE OA E D M E D A a E R rer NII e A T E a E NS C o tt ttt ttt tt tt tte te et tT TN 50 F 40 F 30 F 20 F 10 OF 10 20 30 409 50 60 469C 40 C 349 299C 23 18 12C 729C 1C 4 10 16 Chilled water operating temperature F 9C STERLCOS SSC Series Central Chilling Stations Page 29 of 86 4 8 High Pressure Cutout This electro mechanical safety feature opens the control circuit if the system condensing pressure exceeds a safe level High pr
5. A AB Alien Bradiey Panelvier 1000 RC Series Central Chiller Main Menu Chilled Water Recirc Pump Hourmeters Chiller Configuration 4 Chilled Water Pump Tank Configuration PanelView Utilities System Information WACS Service Alarm Silence Active Alarms l Alarm History Compressor Hourmeters Chilled Water Process Pump Hourmeters The Main Menu screen lets you gain access to e Active Alarms contains the current alarm s of the system e AljarmHistory contains the last thirty 30 alarms that were activated qa SSC Series Central Chilling Stations Page 59 of 86 e Compressor Hour meter s contains the lifetime and resettable hour meters to show the number of hours that the compressors have been running e If the chiller was configured to operate the chilled water pump tank there are three screens to configure and view the pump tank setup The configuration screen allows for the user to turn on or off any of the pumps as well as configuring the lead lag rotation if multiple pumps were configured e Chiller Configuration shows the configuration of the chiller itself including the chiller temperature setpoint temperature alarm settings as well as setting up the lead lag rotation and the ability to turn on and off the compressors e PanelView Utilities and ACS Service are both password protected sections of the PLC that are used to configure the display and the initial
6. Check main disconnect No power fuses wiring and power lead to unit Voltage must be within plus mong NONAJE SUPPER or minus ten percent 10 unit of nameplate rating Replace fuse check transformer check wiring for loose wires check for shorted coils on contactors and Unit does not run solenoids check crankcase heater Defective control transformer Replace Flow switch circuit is open Check pump for proper rotation Pump motor off on overload Reset and test motor Check that the chiller pump is running Unit is off on flow switch or Check that all valves are pressure switch open Check for defective flow switch or pressure switch Lower freeze control setting to 10 F 6 C below the leaving temperature you want Air cooled units Check and clean air filters Check condenser fans for proper rotation Check for dirty Pump runs condenser Check for compressor does not condenser air obstruction High pressure refrigerant Check for tripped motor cutout switch contacts open overload blown fuses or bad condenser fan motor Water cooled units Check for water valves turned on Check for dirty condenser Check water flow through condenser Control circuit fuse blown Freeze control set higher than temperature of liquid in system STERLCOS SSC Series Central Chilling Stations Page 77 of 86 Possible Cause _ Solution _ Allow time to cool and reset Check for high lo
7. to run However the current loading does not require the compressor to be running This compressor will be automatically started when needed 3 RUNNING Compressor is currently running 4 FAULT A safety on the compressor indicates a fault condition and the compressor has been deactivated Once the problem is remedied the compressor will return to a READY state unless it is put in the OFFLINE state Operating the chiller compressors To enable or disable the individual compressors start at the Main Menu then E Press the ty or 9 buttons on the right side of the screen to highlight CONFIGURATION MENU M Press the el button The configuration menu screen displays CIR 1 COMP ENABLES ch TEMP SETPOINT CH TEMP HIGH LIMIT Chiller Configuration Screen mM Press the te or 7 button to highlight either CIR 1C0MP ENABLES or CIR 2 COMP ENABLES mM Press the gl STERLCOS SSC Series Central Chilling Stations Page 47 of 86 The compressor enable screen displays 4 COMP 1A COMP 16 ON LINE OFF LINE F1 TOGGLE Compressor Enable Screen These screens allow the customer to toggle the compressors between ON LINE and OFF LINE As the operator presses the F1 or F2 button the corresponding compressor state changes between ON LINE and OFF LINE Setting Compressor Lead Lag Times and Activating Compressor Lead Lag Operation While in the Configuration Menu the compressor lead lag screen allows t
8. 2 Electrical connections 19 Electrical wiring schematics 20 Evaporator Maintenance 74 Freezestat Control 28 Galvanic Corrosion Considerations 23 General information Available options 9 Models covered 8 Necessary documents 7 Standard features 8 Graphic Panel Devices 41 Indicator Lights and Control Switches 41 Incomplete shipment 16 Incorrect shipment 16 Installation information 19 25 Checking Motor Direction 25 Connection Sizing Considerations 23 Electrical connections 19 Galvanic Corrosion Considerations 23 Location considerations 19 Piping Considerations 21 Process Water Connections 21 Remote Air Cooled Condensers 24 Tank Piping Connections 22 Water Treatment Considerations 23 Water Cooled Condenser Connections 23 Location considerations 19 Makeup Valve Maintenance 74 Models covered 8 Motors Checking Direction 25 Necessary documents 7 Operating Compressors Advanced Controls 60 Standard Controls 46 Options 9 Piping Considerations 21 Process Water Connections 21 Pump Lead Lag 27 Pump Seal Maintenance 74 Pump Tank Piping Connections 22 SSCR Condenser Specifications 14 SSCR drawing 13 SSCR specifications 13 SSCW drawing 11 SSCW specifications 12 Remote Air Cooled Condenser Installation 24 Remote Air Cooled Startup 37 Remote Air Cooled Startup Checklist 35 Returns 16 Revision number 2 Routine Maintenance 73 75 Condensers 73
9. 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 e If the gauge indicates within 15 psi 103 4 kPa 1 03 bars below the pump curve pump rotation 1s correct Pump rotation is clockwise opposite the shaft end e If the gauge indicates 20 psi 137 9 kPa 1 38 bars or more below the pump curve the pump is running backwards Reverse rotation by interchanging any two power mains to the pump motor or starter e Recheck the pressure to be sure it increased M Check the water level in the pump tank to be sure the pump does not run dry while the system piping is being filled M Check your work and proceed to the Startup procedure in the following section 5 5 Remote Air Cooled SSC Series Startup l Start the chiller by pushing the Start button on the control panel of the unit The touchscreen will display the Main Menu screen If your chiller has been setup to control the pump tank the recirculation pump will turn on first then after 5 seconds the process pump will turn on If configured with a standby pump the lead lag will control which pump turns on Fifteen 15 seconds after the last pump turns on the first compressor will turn on Based on the temperature of the water the controller will turn on compressors every 15 seconds Adjust the Freezestat cut out locate
10. 30 Operation and Installation Manual SSC Series Central Chilling Stations Important Read Carefully Before Attempting to Install or Operate Equipment Part No A0551797 Revision NEW Bulletin No SC3 630 Write down your unit serial number s here for future reference Sterling is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling 2006 All rights reserved Effective 8 16 2006 Part No A0551797 Revision NEW Bulletin No SC3 630 Page 2 of 86 SSTER LCOS SSC Series Central Chilling Stations Safety Considerations Sterling central chilling stations are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M N Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment Follow all local SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the chiller Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL
11. AEA A aleea basen AA RR 16 2 6 Uncrating Your New Chiller c ce ceccceececeeeeeeeeeeeeeeeeeeeeaeeesaeeens 17 3 JNSlalallON sarrin eni eA O EARNAN 19 3 1 Installation Location Considerations cccseceeseeeeeeeeeeeeeaeeeens 19 3 2 Making Electrical CONNECTIONS qssrarssssssneiaaa 19 S23 PIPING CONSIGESATIONS aenn a 21 3 4 Making Process Water COnnectiOns ccccsececeeceeeeeeeeeeeeaeeeens 21 3 5 Making Tank Piping CONNECTIONS cccceececeeeeeeeeeeeeeeeaeeeeaeeens 22 3 6 Water Connection Sizing Considerations cccccccceececsseeeeeeeees 23 3 7 Galvanic Corrosion Considerations cccccccseceeseeeeeeeeeeeeesaeeeeas 23 3 8 Water Treatment Considerations ccccsccecseceeeeeeeeeeetaeeetaeeeeas 23 3 9 Making Water Cooled Condenser Connections 0cceeeees 23 3 10 Installing the Remote Air Cooled Condenser ccccseeeeseeeees 24 3 11 GNeECKING Motor Directo Nerea we cseddirideddecedeens 25 4 Sequence Of Operation sscccscccccssccnsscecssncenssenssees 26 AW Otag aee 27 A ANO a e 27 4 3 Lead Lag COMPSeSSOSS cccscccssecceseeceseeceueeceueeseueeseueeseueeseueeees 27 4A Leaditag PUMDScsrsnereso na 27 4 5 GnileG Water GIPON inrsin A 28 4 6 Refrigeration CirCult cccccccccccceccceecceeceeeeseeeseeeeseeeseeeseueeeeeesaes 28 4 7 Freezestat COntrol sss a 28 4 8 AiGh Pressure CUTOUT ananin anana ANAA eee ea 30 429 OW P
12. Cooled Startup 35 Page 81 of 86 Water Cooled Startup Checklist Water Treatment Water Cooled Condenser 33 Considerations 23 Connections 23 Page 82 of 86 STERLCOS SSC Series Central Chilling Stations Service Notes STERLCOS SSC Series Central Chilling Stations Page 83 of 86 Service Notes Page 84 of 86 STERLCOS SSC Series Central Chilling Stations Service Notes STERLCOS SSC Series Central Chilling Stations Page 85 of 86 Parts Department Call toll free 7am 6pm CST 800 423 3183 or call 262 641 8653 The Parts Department at Sterling is ready to provide the parts to keep your systems up and running Sterling replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8600 Emergencies after 50m CST call 800 423 3183 Sterling has a qualified service department ready to help Service contracts are available for most Sterling products Sales Department Call 262 641 8600 Monday Friday 8am 5pm CST Sterling products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8600 Monday Friday 8am 5pm CST Let Sterling
13. Patno Part description Quantity A0550190 1 per pump A0102396 Float valve 1 approx 25 mm 1 per tank 1 er tank p A0102394 Float rod 10 25 cm 1 per tank Call Sterling Pump seal and casing gasket per pump Parts A0069538 Plastic ball float 6 approx 152 mm Check your Customer Information Packet for a complete list of spare parts and part numbers for your SSC Series chilling station STERLCOS SSC 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 tailored to fit your maintenance requirements Inspections include N NS KA RKR ARKNRKAKRKRRKNARKRK qi SSC Series Central Chilling Stations Check refrigerant suction and discharge pressures Check safety and operating controls Check voltage and amperage of all motors Check all electrical connections Check quantity of refrigerant Check compressor oil level Check lubrication of motor and pump bearings Check circulating pump operation Check flow through heat exchangers Check compressor efficiency Check noise levels Check cleanliness of equipment area Page 75 of 86 Notes Page 76 of 86 STERLCOS SSC Series Central Chilling Stations 10 Troubleshooting Possible Cause gt Solution ___
14. by 0 8 for 575 3 60 amperages OOO Page 12 of 86 SSTER LCOS SSC Series Central Chilling Stations Figure 2 Typical Two Circuit 60 100 Ton Remote Air Cooled Chiller SSCR xxx 30 OT 5 _ Cooling Capacity tons 50 F LWT Capacity stages gty _ O O OOO 2 2 4 8 Capacity stages aty 8 4 eo L a EER BTUH W 11 36 10 84 11 29 Nominal water flow gpm 72 D 111 iam Evaporator 272 5 348 3 420 2 0 7 e No of condenser fans per condenser 3 2 2 Chiller 56e 7 8 Amp draw nameplate condenser Dimensions in cm of 85 215 9 chiller 45 114 3 Dimensions in cm of each condenser 42 5 108 0 607 8 694 0 784 7 961 6 condenser 249 5 349 3 358 3 539 8 Ibs kg 612 3 703 1 798 3 975 2 Condensers per 845 945 condenser 276 6 383 3 428 6 644 1 7 8 amp 10 Cooling Capacity tons 50 F LWT Capacity stages qty A 6 9 Evaporator manifold connection Victaulic 3 O A o ee 2 2 T Capacity stages qty 4 EER BTUH W 10 84 10 64 10 93 11 19 lom p 613 2 685 2 757 1 832 8 5 1 Evaporator manifold connection Victaulic 3 3 4 4 4 O See ee ee ee eee ee O No of condenser fans per condenser oo n aa A A A O Chiller Amp draw nameplate 460 3 60 V Condensers per 10 5 14 14 condenser l 3 5 4 4 Dimensions in cm of 75 190 5 chiller Width 86 218 4 45 114 3 Dimensions in cm of Height 50 127 0 each condenser Wi
15. contactor leads or motor leads for reversing rotation e Do not use contactor or motor leads for phase matching e Compressor noise from reverse rotation is noticeable Do not run in this mode for more than ten 10 seconds The compressor shuts off if it is run longer in this mode e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws will be lower than normal e If you discover that compressor rotation is reversed correct it by switching any two main power leads into the disconnect switch or distribution block on the unit Check your work and proceed to the following Piping Considerations section 3 3 Piping Considerations Piping systems vary with process application and pump tank configuration Typical system configuration drawings are provided in this manual the details may or may not apply to your application Piping systems must be designed by a person knowledgeable in piping system design and configuration Sterling s Contracting Department can design and install a piping system tailored to your process e All piping returning to the pump tank must be equipped with an inverted trap with a vacuum breaker at the high point of the system to prevent mains from siphoning into the pump tank e Run mains full size in order to reduce pressure drop in the system and provide maximum pressures at the ends of the mains 3 4 Making Process Water Connections All Models All SSC Series c
16. e ALARMHISTORY contains the last twenty five 25 alarms that were activated STERLCOS SSC Series Central Chilling Stations Page 45 of 86 e CONFIGURATION MENU contains the chiller setup parameters i e chiller setpoint and high and low temperature alarm setpoints The following sections in this chapter list the information you need to navigate through these screens for operating and monitoring your SSC Series central chilling station with the Standard Control Package 7 4 Viewing and Operating Chiller Compressors Viewing Compressor Status Page 46 of 86 To view the status of the chiller compressors start at the Main Menu screen then E Press the ty or y buttons on the right side of the screen to highlight COMPRESSOR STATUS E Press The compressor status screen displays CHILLER STATUS COMP READY COMP RUNNING COMP 2A READY COMP 2B PROC SUPPLY 55 F Compressor Status Screen The Compressor Status screen shows the status for compressors within the system Only compressors that are included in the system will 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 been re enabled STERLCOS SSC Series Central Chilling Stations 2 READY Indicates that the compressor is enabled and ready
17. install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations fh Sterling QU 2900 S 160 Street e 2 New Berlin WI 53151 A 262 641 8610 Fax 262 641 8653 Page 86 of 86 STERLCOS SSC Series Central Chilling Stations
18. must be preformed in order to allow the chiller to fully run Should a compressor or pump turn off from an alarm condition the remaining will shut down and display FAULT in the status screen for the device 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 locked out the main disconnect using OSHA 1910 147 standards All electrical connections must be done by a qualified electrician WARNING Disconnect all power to the unit let the unit cool down and turn off the water prior to any servicing Failure to do so can result in SERIOUS INJURY OR DEATH Page 54 of 86 STERLCOS SSC Series Central Chilling Stations 7 7 Viewing and Setting System Temperatures To view the actual process temperature select any of the status screens from the main menu The process temperature is located on the bottom of the screen For example the compressor status displays READY RUNNING READY BE T SUPPLY 55 F Compressor Status Screen Note If you have a metric version of the SSC Series controller the screens display in converted metric values Setting System Temperatures The chiller setpoints are set through the configuration menu Starting from the Main Menu E Press the te or 9 buttons to highlight CONFIGURATION ME
19. refrigeration service technician Washing from the outside will only make matters worse Proper water treatment will greatly reduce cleaning intervals Remove dirt in the condenser tubes with a nylon tube brush Mineral deposits can be removed by circulating Sterling Liquid De Scaling Solution Sterling Model Number A0502600 through the water side of the condenser Follow the directions on the container The refrigerant side is sealed and requires no routine maintenance GGT ssc Series Central Chilling Stations Page 73 of 86 9 3 Evaporator Maintenance The evaporator s may be accessed for back flushing by removal of the 2 plug approx 51 mm in the return control nipple and the flow switch in the supply control nipple If the suggested piping recommendations have been followed one circuit of a multiple circuit chiller may be back flushed without shutting down the entire system Check Y strainer for any clogging 9 4 Pump Motor Seal Pump seals require water for lubrication so the pump s must never be run dry Always fill the tank before attempting to operate the pump s Seal failures usually follow a period of dry operation of the pump 9 5 Makeup Valve Periodically inspect the water makeup valve assembly for proper operation If the valve no longer shuts off completely or reliably replace it The plastic ball float should be buoyant for proper operation 9 6 Recommended Pump Tank Spare Parts Page 74 of 86
20. 4 070 70 040 40 140 6 080 80 281 2 050 50 175 7 090 90 316 3 060 60 210 9 100 100 351 5 246 0 Page 10 of 86 SSTER LCOS SSC Series Central Chilling Stations Figure 1 Typical Two Circuit 60 100 Ton Water Cooled Chiller CONDENSER WATER MUI C Ier PANGE Ce PLACES INDENSER WATER IN J L AH 2 1 2 FPT 2 PLACES y h a P 2e a pa CHILLED WATE Ca i cr i 3 VICTAULIC Ro AJ is 4 4 ii 3 i ae weil elim CHILLED WATER MUI ENSER CONNEC TINS Se 3 VICTAULIC
21. 4 kPa 1 03 bars below the pump curve pump rotation 1s correct Pump rotation is clockwise opposite the shaft end e If the gauge indicates 20 psi 137 9 kPa 1 38 bars or more below the pump curve the pump is running backwards Reverse rotation by interchanging any two power mains to the pump motor or starter e Recheck the pressure to be sure it increased STERLCOS SSC Series Central Chilling Stations M Check the water level in the pump tank to be sure the pump does not run dry while the system piping is being filled M Check your work and proceed to the Startup procedure 5 3 Water Cooled SSC Series Startup l Start the chiller by pushing the Start button on the control panel of the unit The touchscreen will display the Main Menu screen If your chiller has been setup to control the pump tank the recirculation pump will turn on first then after 5 seconds the process pump will turn on If configured with a standby pump the lead lag will control which pump turns on Fifteen 15 seconds after the last pump turns on the first compressor will turn on Based on the temperature of the water the controller will turn on compressors every 15 seconds Adjust the Freezestat cut out located in the main electrical enclosure to 10 F 6 C below the process temperature set point you want Note If the recirculation pump does not turn on or that the flow switch is not satisfied the compressors will not be allowed to turn
22. 6 Setting System Temperatures The chiller setpoints are set through the compressor configuration menu Starting from the Main Menu E Press the Up or Down buttons to highlight Chill er Configuration E Press l M Touch the Process Set point button The input display screen appears Figure 17 Temperature Input Display Screen AB Ahen Bradiey Pansivier 000 AEC Appelication Engineering Chilled Water Process Supply Set Point Degrees Current HAHHH HEHH High Limit Page 72 of 86 qa SSC 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 grease retainer which will eventually cause bearing failure Lubricate components regularly based only on the component manufacturer s specifications for frequency and lubricant Compressors require a special scroll oil Suniso 3GSA or equivalent failure to use this oil when lubricating will void the warranty 9 2 Condenser Maintenance Remote Air Cooled Water Cooled Dirty condenser heat exchange surfaces reduce system capacity Inspect and clean as needed Brush or vacuum light dirt accumulations Avoid bending or damaging the fins Heavy soil accumulations on the coil require professional steam cleaning by a qualified
23. Chilling Stations Figure 4 SSC Series Standard Control Panel Sana Ca ololators A airia T TE re age Tae Terra otal Figure 5 SSC Series Advanced Control Panel Wer aoe Paneler CO ce w Sylen Is SSTERLCO SSC Series Central Chilling Stations Page 39 of 86 Notes Page 40 of 86 STERLCOS SSC Series Central Chilling Stations 6 Graphic Panel Devices 6 1 Indicator Lights and Control Switches MMI System On Start Stop Touchscreen Interface The green System On indicator lights when the main power switch is on and the control circuit is energized The Start push button lets you energize the unit The Stop push button lets you de energize the unit The color touchscreen interface gives you control over the chilling station It has an easy to use control menu that lets you quickly change or adjust chiller settings and also gives you all the operation information you need to control the unit effectively See Chapter 7 on Page 42 for more information on the Standard touchscreen interface operation See Chapter 8 on Page 57 for more information on the Advanced touchscreen interface operation STERLCOS SSC Series Central Chilling Stations Page 41 of 86 Notes Page 42 of 86 STERLCOS SSC Series Central Chilling Stations Using the Standard 7 Touchscreen Interface 7 1 Touchscreen Interface Introduction MMI The Standard touchscreen interfaces let you control your SSC Seri
24. Chilling Stations Two hourmeters are kept for each compressor 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 to monitor run time on specific intervals In order to clear the resettable hourmeter press the F1 button as prompted on the screen 7 6 Viewing Active Alarms and Handling Alarm Conditions These two screens let you view any active alarm conditions as well as the alarm history for the entire history The list of system alarms that are tracked are as follows Chilled Water High Temperature Alarm Chilled Water Low Temperature Alarm Compressor Motor Protector Fault One for each compressor Chilled Water Circuit Low Flow One per chilled water circuit Chilled Water Circuit Freezestat One per chilled water circuit Chilled Water Circuit High Pressure One per chilled water circuit E Chilled Water Circuit Low Pressure One per chilled water circuit E Pump motor overload One per system pump If an alarm conditions occurs the follow screen is displayed Alarm Condition Screen qa SSC Series Central Chilling Stations Page 53 of 86 To acknowledge the alarm press F1 to clear the alarm It will then appear in the alarm history screen Except for High and Low Water Temperature and Low Refrigerant Pressure these alarms are considered fatal and maintenance
25. DISCONNECTS before working on equipment Sterling recommends following OSHA Lock Out Tag Out Standard 29 CFR 1910 147 Make sure the unit is properly GROUNDED before switching power on When welding or brazing in or around this equipment be sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment etc and chiller and related equipment have been removed STERLCOS SSC Series Central Chilling Stations Page 3 of 86 Table of Contents 1 General INFOMATION csccssceecenecnncneennsnsennsnesensennsenes 7 Mod HTPOGIIG UG as t35 4anctasaaashnasndaanvansdestuasacantuoandeatcesncesesssecasevasacassnssateaste 7 t2 INCCeSSaky DOCUMEN S eranen aaan 7 13 Mod ls Covered onai a a a E AAA A 8 ee Sola Cala ES a N 8 to Avala be ONOS esens S 9 2 Shipping INFOLFMAtION 1cccscceeccnecennenenennsennsennenees 15 2 1 Unpacking and Inspection cccccccceecceeeeceseeceeeceeecseeseeseeeeenees 15 2 2 Inthe Event of Shipping Damages ccccseeeeceeeeseeeesaeeeseeeesees 15 2 3 Ifthe Shipment is Not Complete ccccssccsssseeecsseeseeeeeseeees 16 2 4 Ifthe Shipment is Not Correct cccccccccceseeeeseeeeeeseeeseeeeeseaeees 16 7 ROWS enren aise atactue tasiatenasis
26. ENABLES E Press E Highlight the pump you want to operate The Pump Enables Screen appears PROCESS PUMP 1 OM LINE Fi TOGGLE Pump Enables Screen Any pump that is disabled to the OFF LINE position will not be called to operate Simply toggle the F1 key on the enable disable screen to 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 screen allows the customer to enable or disable the Lead Lag rotation of compressors While viewing the screen for the applicable rotation pressing F1 will toggle the rotation function On or Off Pressing the F2 button will present an entry screen which will allow the entry of a rotation interval Acceptable range is 50 200 hours STERLCOS SSC Series Central Chilling Stations Page 51 of 86 The compressor lead lag screen displays COMPRESSOR ROTATION Fi ROTATION OFF F2 INTERUWAL 188 Pump Lead Lag Screen Viewing Pump Run Times From the Main Menu use the te or 9 buttons to highlight the HOURMETERS menu Scroll to select the pump Then press e to display the hourmeter Note this is a complete list of all pumps that may be included in the system Any pump that is not included in the system will not accumulate time The Pump Run Time screen displays Pump Run Time Display Screen Page 52 of 86 STERLCOS SSC Series Central
27. Evaporators 74 Lubrication 73 Makeup Valve 74 Pump Seals 74 Safety considerations 3 Sequence of Operation 25 31 Alarms 27 Chilled Water Circuit 28 Chilled Water Manifold 31 Compressor Staging 27 Condenser Water Manifold 31 Control Nipple 31 Control Probe 31 Flow Switch 30 Freezestat Control 28 STERLCOS SSC Series Central Chilling Stations High Pressure Cutout 30 Lead lag Compressors 27 Lead Lag Pumps 27 Low Pressure Cutout 30 Refrigeration Circuit 28 Shipping damages 15 Shipping information 15 17 Incomplete shipment 16 Incorrect shipment 16 Returns 16 Shipping damages 15 Uncrating 17 Unpacking and inspection 15 Specifications SSCR 13 SSCR Condensers 14 SSCW 12 Standard Controls Touchscreen 44 58 Standard features 8 Startup Checklist 33 39 Chiller Shutdown 38 Determining Flow Rate 38 Introduction 33 Remote Air Cooled 35 Remote Air Cooled Startup 37 Water Cooled 33 Water Cooled Startup 35 System Temperatures Advanced Controls 71 Troubleshooting 73 75 Uncrating 17 Unpacking and inspection 15 Using the Advanced Touchscreen Interface 57 72 Alarms 68 Chiller Pumps 64 Getting Started 59 Introduction 57 Operating Chiller Compressors 60 System Temperatures 71 Using the Standard Touchscreen Interface 44 43 56 58 Alarms 53 Getting Started 45 Introduction 43 Operating Chiller Compressors 46 Water Connection Sizing Consideration 23 Water
28. Make sure that you know the model number serial number and operating voltage of your chiller if you contact Sterling 1 4 Standard Features e Two independent refrigeration circuits e High efficiency scroll compressors e Stainless steel brazed plate evaporators e Cleanable shell and tube condensers water cooled models e Two way water regulating valve water cooled models e 2 remote single circuit condensers with variable speed lead fans and fan cycling air cooled models e NEMA 12 electrical enclosure e Allen Bradley Micrologix 1500 PLC control with Panel View 300 Micro monochrome key pad interface e High and low refrigerant pressure safeties e Touch safe branch circuit fusing e Evaporator water piping manifold Condenser manifold optional e HCFC 22 refrigerant e Digital low temperature freezestat e Liquid line solenoid and shut off valves e Chilled water flow switches e Auto Manual control mode switch for emergency operation e year warranty on parts and labor e 3 year warranty on controller Page 8 of 86 AIID ssc series Central Chilling Stations 1 5 Available Options SSC 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 SSC Series options include Advanced control package including AB SLC 5 04 PLC with PanelView 1000 color touch screen cont
29. NU E Press al Highlight CWTEMP SETPOINT CWTEMP HIGH LIMIT or CW TEMP LOW LIMIT Press eal While on the parameter screen simply press the F1 button to make the parameter change A numeric entry screen will appear Use the lt and gt buttons to select the digit and the and e buttons to increase and decrease that digit STERLCOS SSC Series Central Chilling Stations Page 55 of 86 Once the value is correct press the e button to make the change In the event that the value is outside the range specified by MAX or MIN the value entered will be the corresponding MAX or MIN Page 56 of 86 STERLCOS SSC Series Central Chilling Stations Using the Advanced 8 Touchscreen Interface 8 1 Touchscreen Interface Introduction MMI The Advanced touchscreen interfaces let you control your SSC Series central chilling station You can do such things as e Control compressors and optional pumps e View current statuses of operation such as pressures temperatures and capacities e Handle alarm conditions The sections in this chapter list special instructions for operating either touchscreen interfaces Note The screens shown in this chapter are sample screens Actual screen representations may be slightly different in appearance but are no different in operation Also the PLC is configured based on options and system configuration at the time of order These screens are the basic ones to sta
30. Page 70 of 86 pump turn off from an alarm condition the remaining will shut down and display FAULT in the status screen for the device 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 locked out the main disconnect using OSHA 1910 147 standards All electrical connections must be done by a qualified electrician WARNING Disconnect all power to the unit let the unit cool down and turn off the water prior to any servicing Failure to do so can result in SERIOUS INJURY OR DEATH STERLCOS SSC Series Central Chilling Stations 8 7 Viewing and Setting System Temperatures To view the actual process temperature start at the Main Menu and E Use the Up or Down arrows to highlight System Information mM Press si The system status displays Figure 16 System Status Screen AB Allen Braaiey Pansi Vier 090 Chilled Water System Status Chilled Water System Pumps Compressors Recire 1 Comp 1A Comp ZA Running Running Ready tecirec 2 omp Comp 2B Offline ine Offline Outside Ambient Winter Kooler Pump Ready rocess Return Note If you have a metric version of the SSC Series controller the screens display in converted metric values qa SSC Series Central Chilling Stations Page 71 of 8
31. backwards reverse any two main power leads at the incoming terminal block Remove all tools foreign matter and debris from the pump tank reservoir and piping 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 Note e Never switch contactor leads or motor leads for reversing rotation e Do not use contactor or motor leads for phase matching e Compressor noise from reverse rotation is noticeable Do not run in this mode for more than ten 10 seconds The compressor shuts off if run longer in this mode e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws are lower than normal e If you discover that compressor rotation is reversed correct it by switching any two main power leads into the disconnect switch or distribution block on the unit Open the 1 approx 25 mm makeup water valve and allow the tank to fill until the automatic float valve shuts off The float level should be adjusted so the standing water level is 8 20 cm from the top of the tank STERLCOS SSC Series Central Chilling Stations M Check for proper pump rotation direction To confirm proper rotation 1 Observe a pump pressure gauge connected to the suction and discharge sides of the pump casing through two 4 approx 6 4 mm gauge cocks
32. configuration of the chiller and system The following sections in this chapter list the information you need to navigate through these screens for operating and monitoring your SSC Series central chilling station with the Standard Control Package 8 4 Viewing and Operating Chiller Compressors Viewing Compressor Status To view the status of the chiller compressors start at the Main Menu screen then E Press the Up or Down buttons on the right side of the screen to highlight System Information mM Press El The chiller status screen displays Page 60 of 86 AIID ssc Series Central Chilling Stations Figure 9 Chiller Status Screen AB A fey ie l ra ne Y ga anel Wi T TH g Chilled Water System Status Chilled Water System Pumps Compressor Recirce 2 Comp 1A Comp 2A Running Running Ready tecire 2 Comp d Comp 2B Offline Offline Offline Outside Ambient Winter Kooler Pump Ready rocess Return The Chiller Status screen shows the status for compressors within the system Only compressors that are included in the system will 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 been re enabled The color code for this indication is black 2 READY Indicates that the compressor is enabled and ready to
33. cseceeseeeeeeeeees 46 7 5 Viewing and Operating Chiller PUMPS cccceceeeeeeeeeeeeeeeeees 50 7 6 Viewing Active Alarms and Handling Alarm Conditions 53 7 7 Viewing and Setting System Temperatures cccceccseeeeeeeeees 55 8 Using the Advanced Touchscreen Interface 57 8 1 Touchscreen Interface Introduction MMI ccccseeeseeeeeeeeees 57 8 2 Using the SSC Series Advanced Touchscreen Interface 58 8 3 Getting Started on the SSC Series Advanced Touchscreen WAC Ciao du AEEA antes tu AAE A E AEN nada E A EE 59 8 4 Viewing and Operating Chiller COMPreSSOMS ccceceeeeeeeeeeeees 60 8 5 Viewing and Operating Chiller PUMPS ccccsececseeeeeeeeeeeeeees 64 8 6 Viewing Active Alarms and Handling Alarm Conditions 68 8 7 Viewing and Setting System Temperatures cccccceeseeeeeeeeees 71 9 Routine MaintOnanCe ccscccecceceecennennsnnsnesenseenens 73 SF EUDE CUON aren een nner er mn eer Meier eet eee em eer mney eee Mera eE Mee Ten mee Terre 73 9 2 Condenser Maintenance ce cececceeceeeeeeeeeeeeeeeaneeeeeeeeeeaneeeeeens 73 9 9 EVOL ALOR Mantenan CE isn a te alee lee A 74 OAs PUNIM o Sali 74 O25 WaKeCUD VAIN Grenn a A 74 9 6 Recommended Pump Tank Spare Pats cc cccceseeeeseeeeeeeeees 74 9 7 Preventive Maintenance Service ccccceeeeceeeeeeeeeseeeeteeeesaeeens 75 10 TFOUDICSAOOUNG secv
34. d in the main electrical enclosure to 10 F 6 C below the process temperature set point you want qa SSC Series Central Chilling Stations Page 37 of 86 Note If the recirculation pump does not turn on or that the flow switch is not satisfied the compressors will not be allowed to turn on 6 Check the pump s amp draws and pressures The amp draws must be within the pump s running load and service factor amps Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation Check condenser fans for pressure switch settings as shown in the table below Seton CSetOff psi kPa bars psi kPa bars not applicable Fan 1 is a variable speed fan 654 5 6 Determining Flow Rate To determine flow 5 7 Shutdown Page 38 of 86 Close the gauge cock leading to the pump suction side and open the gauge cock leading to the pump discharge Start the pump and make note of the discharge pressure in psi kPa bars Check the pump curve for the appropriate horsepower pump at the discharge pressure psi Project this point down to find the flow in gpm lpm 5 Process pumps can be left wide open if running amps are a ge I below full load amps Ready process and related equipment for shut down Turn off main power Close the water make up valve If the system is to be drained open the 2 drain valve STERLCOS SSC Series Central
35. dth 42 5 108 0 Depth 180 457 2 235 596 9 1070 5 1179 3 1301 8 1437 9 condenser 539 8 716 7 116 7 716 7 748 4 148 4 Ibs kg 1088 6 1197 5 1320 0 1460 6 condenser 644 1 818 7 818 7 818 7 859 6 859 6 Based on 50 F 10 C chilled water supply temperature and 95 F 35 C ambient air Based on 2 4 gpm per ton 9 1 Ipm per 3 517 kW Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 1 2 for 380 3 60 amperages multiply by 0 8 for 575 3 60 amperages oO STERLCOS SSC Series Central Chilling Stations Page 13 of 86 SSCR Series Remote Condenser Models Charge cfm ODS in ODS in Ibs il 21 AK O EN O 3 NIN DID NO i 8 b p 14 0 42 400 2 8 27 SSCR100 30 1 2hp3 14 0 4 42 400 21 21 27 represents electrical phase all motors are 1 140 rom Multiply hp by 0 746 to convert to kW Refrigeration charge is for remote condenser only To convert cfm to cmh multiply by 1 699 To convert lbs to Kg multiply by 0 454 No oO Page 14 of 86 SSTER LCOS SSC Series Central Chilling Stations 2 Shipping Information 2 1 Unpacking and Inspection You should inspect your central chilling station for possible shipping damage If the container and packing materials are in re usable condition save them for reshipment if necessary Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and co
36. ed 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 other pieces of equipment Minimum external pressure drop is critical for proper operation 3 Galvanic Corrosion Considerations Water circuit piping components are primarily ferrous iron and react electro chemically with non ferrous metallic materials such as copper Some water has dissolved minerals that will greatly accelerate the reaction between dissimilar metals Use PVC or ferrous piping to minimize galvanic action If piping must be copper use dielectric unions at the chiller 3 8 Water Treatment Considerations Water treatment is important in any piping system In some locations raw water may be used in the system without problem in other locations it will result in large deposits of scale and corrosion Sterling offers a complete line of water treatment equipment Contact your Sterling sales representative for water testing and treatment options 3 9 Making Water Cooled Condenser Connections SSC Series water cooled chilling stations use city or tower water as a cooling medium All external condenser supply and discharge piping and connections should be of adequate size STERLCOS SSC Series Central Chilling Stations Page 23 of 86 Two connections are made to each SSC Series unit Condenser Water In The city or tower water supply inlet
37. ents and make sure your electrical service conforms before making any electrical connections Total running amps for the SSC Series systems are listed on the nameplate Customer connections can be run to the supply terminals from either side of the unit Make sure that all three phases are wired correctly If not wired properly the unit will run backwards Again check the unit nameplate for correct voltage and amperage qaip SSC Series Central Chilling Stations Page 19 of 86 DANGER Improper electrical connections can damage the unit and cause serious operator injury or death Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Provide external overcurrent protection to the unit using circuit breakers or fuses If you use fuses make sure that they are dual element time delay fuses sized according to your electrical code Make sure that all electrical connections are tight Important 1 Electrical connections must comply with all applicable electrical codes 2 The chiller must be grounded in accordance with NEC Article 250 3 Voltage must be within plus or minus ten percent 10 of the nameplate rating Make sure your installer provides external protection Check the electrical wiring schematic provided in your Customer Information packet for additional information Page 20 of 86 STERLCOS SSC Series Central Chilling Stations Note e Never switch
38. eries Central Chilling Stations Page 65 of 86 2 READY Indicates that the pump is enabled and ready to run However the current number of pumps specified to run does not require this pump to operate The color code for this indication is yellow 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 unless it is put in the OFFLINE state The color code for this indication is red Operating Chiller Pumps To turn on and off the pumps start from the Main Menu then E Press the Up or Down buttons to highlight either Chilled Water Pump Tank Configuration M Press a The Pump Enables Screen appears Figure 13 Pump Enables Screen AB Aller Bradie y Panalview 020 AEG Application Engineering Chilled Water Pump Tank Configuration Purp Requirements Process Recire CW Purnp Pumps Pumps Rotation Required Required Interval Pumps Pumps Hours Page 66 of 86 STERLCOS SSC Series Central Chilling Stations Any pump that is disabled to the OFF LINE position will not be called to operate Simply press the button of the desired pump to 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 la
39. es central chilling station You can do such things as e Control compressors and optional pumps e View current statuses of operation such as pressures temperatures and capacities e Handle alarm conditions The sections in this chapter list special instructions for operating either touchscreen interfaces Note The screens shown in this chapter are sample screens Actual screen representations may be slightly different in appearance but are no different in operation On all screens in this controller the F4 button is reserved for the previous screen function Some screens such as the chiller status screen do not have sufficient space to display a prompt that the F4 performs this function However the F4 button will always move to the previous screen and will eventually return to the Main Menu STERLCOS SSC Series Central Chilling Stations Page 43 of 86 Figure 6 SSC Series Standard Control Panel Berg tt h oe aj Oleleloi 7 2 Using the SSC Series Standard Touchscreen Interface Page 44 of 86 The SSC Series Standard touchscreen interface is the manager of your SSC Series central chilling station The screen contains screen buttons you can press to control system operation For example if you need to resolve an alarm condition press the or Vv buttons on the right side of the screen to highlight ACTIVE ALARM LIST The screen will tell you what alarm is active and you may clear the alarm b
40. essor Lead Lag Operation Viewing Compressor While in the Configuration Menu the compressors can be setup in a lead lag configuration using interval hours By pressing the Compressor Rotation Interval button a numeric keypad will be displayed and allow the user to change the timeframe of the interval To activate the Lead Lag operation touch the Compressor Rotation button The status of the button will change to Enabled green background or Disabled black background Run Times From the Main Menu use the Up or Down buttons to highlight the Compressor Hour meters menu Scroll to select the compressors Then press e to display the hourmeters Note this is a complete list of all compressors that may be included in the system Any compressor that is not included in the system will not accumulate time The Compressor Run Time screen displays STERLCOS SSC Series Central Chilling Stations Page 63 of 86 Figure 11 Compressor Run Time Display Screen AB Alien Braciey Panalview A System Hour Meters Compressor 1A 88H H Hours Compressor 1B FHHHH Hours Compressor 24 HHHH Hours Compressor 2B HH HHHHH Hours Compressor 14 H HH8HHHHR Hours Resetable Compressor 1B HHHHH Hours Resetable Compressor 2A H HHHHHHR Hours Resetable Compressor 2B H HHHHH Hours Resetable Two hourmeters are kept for each compressor in the system The first 1
41. essure cutout setting Pi kPa bars SSC Series water cooled chilling stations 2 000 kPa SSC Series remote air cooled chilling stations 375 psi 2 586 kPa Important The high pressure cutout is a manual reset control so you should reset it once lf the problem persists call a refrigeration service technician to analyze the problem and to reset the control 4 9 Low Pressure Cutout This encapsulated switch safety feature prevents the compressor suction pressure from dropping below a pre set point It is factory set to open the control circuit when pressure drops below a safe level The chiller will need to be restarted when the suction pressure reaches above 65 psi 448 2 kPa 4 5 bars ae O Opens control circuit Resets control circuit _psi kPa bars psi_ bars SSC Series water cooled chilling stations 15 psi 103 4 kPa 30 psi 206 9 kPa SSC Series remote air cooled chilling 15 psi 103 4 kPa 6 9 kPa stations 4 10 Flow Switch The flow switch shuts down the chiller if the evaporator water flow falls below a safe operating gallons per minute liters per minute flow rate Page 30 of 86 AIID ssc Series central Chilling Stations 4 11 Control Nipple All SSC Series chilling station evaporators have two control nipples The flow switch freezestat and flush port are located in the control nipple Optional pressure gages can be mounted in the control nipples to aid in achieving proper flow through the e
42. g rotation can be enabled or disabled Simply press the Process or Recirculation Pump Interval button on the screen to toggle between Enabled and Disabled The interval between rotating pumps may also be setup in this screen Press the CW Pump Rotation Interval button to bring up the time entry screen Acceptable range is 50 200 hours Viewing Pump Run Times From the Main Menu use the Up or Down buttons to highlight either the Chilled Water Process Pump Hour meters or Chilled Water Recirc Pump Hour meters menu Then press H to display the hourmeters Note this is a complete list of all pumps that may be included in the system Any pump that is not included in the system will not accumulate time The Pump Run Time screen displays STERLCOS SSC Series Central Chilling Stations Page 67 of 86 Figure 14 Pump Run Time Display Screen AB Alen Bragiey Compressor 1A SEBERE Hours Compressor 1B H HHHHH Hours Compressor 2A H HHHH Hours Hour M Compressor 14 8HHHH8H Hours Resetable Compressor 1B HSHH Hours Resetable Compressor zA HHHHHHHR Hours Resetable Panelyiew AO eters Compressor 2B Compressor 2B H HHHHHHH Hours H HHHHH Hours Resetable Two hourmeters are kept for each compressor in the system The first 1s 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 Th
43. ge Caution Due to the weight of these units use extreme caution when moving and placing SSC Series chillers STERLCOS SSC Series Central Chilling Stations Page 17 of 86 Notes Page 18 of 86 STERLCOS SSC Series Central Chilling Stations 3 Installation 3 1 Installation Location Considerations As with all equipment installations follow all applicable codes and regulations M Locate close to the process to reduce piping expense M Locate adjacent to drain and city water sources M Consult a structural engineer to assure that the floor mounting pad or structural steel support is of adequate strength M Allow for required service clearances necessary for condenser maintenance and easy access to all components 3 2 Making Electrical Connections SSC Series systems are designed for three phase voltage operation Refer to the unit nameplate for proper voltage and amperage requirements Make sure you provide a correctly sized and protected supply of electrical power to the unit Important Refer to National Electric Code NEC Article 430 24 through 430 26 for proper feeder conductor and supply disconnect sizing Maintain a safe ground and disconnect the power supply before servicing the unit A qualified electrician should make electrical connections and disconnect and lock out electricity using OSHA 29CFR 1910 147 standards when you need a service call Check serial tag voltage and amperage requirem
44. he customer to enable or disable the Lead Lag rotation of compressors While viewing the screen for the applicable rotation pressing F1 will toggle the rotation function On or Off Pressing the F2 button will present an entry screen which will allow the entry of a rotation interval Acceptable range is 50 200 hours The compressor lead lag screen displays COMPRESSOR ROTATION Fi ROTATION OFF F2 INTERUAL 168 Compressor Lead Lag Screen Page 48 of 86 STERLCOS SSC Series Central Chilling Stations Viewing Compressor Run Times From the Main Menu use the ti or y buttons to highlight the HOURMETERS menu Scroll to select the compressors Then press e to display the hourmeter Note this is a complete list of all components that may be included in the system Any component that is not included in the system will not accumulate time The Compressor Run Time screen displays Compressor Run Time Display Screen 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 be cleared to monitor run time on specific intervals In order to clear the resettable hourmeter press the F1 button as prompted on the screen STERLCOS SSC Series Central Chilling Stations Page 49 of 86 7 5 Viewing and Operating Chiller Pumps If your chi
45. hilling stations have two chilled water connections per unit and on water cooled models one more set of water connections for condenser water STERLCOS SSC Series Central Chilling Stations Page 21 of 86 To Process The chilled water supply outlet leading to the process being controlled From Process The chilled water return for water returning back to the chiller from the process to be cooled and recirculated 3 5 Making Tank Piping Connections If you have purchased the SSC Series central chilling station with the integral pump tank please proceed with this section Return Bring the chilled water returning from the process to the pump tank warm From Process side This line is sized according to the flow rate from the process to the pump tank See Section 3 3 on Page 21 for more information on piping considerations Important Do not use the SSC Series unit to support piping Makeup Connect a city water source to maintain water level in the pump tank Overflow Connect the OVERFLOW outlet to an approved trapped drain to permit excess water in the pump tank to overflow to the drain The overflow line is sized according to the size of the pump tank To Drain Connect to a 1 line approx 63 mm leading to an approved trapped drain You can drain the pump tank if necessary Page 22 of 86 STERLCOS SSC Series Central Chilling Stations 3 6 Water Connection Sizing Considerations Important Run all external chill
46. is hourmeter can be cleared to monitor run time on specific intervals In order to clear the resettable hourmeter press the appropriate Hour Meter Reset button as prompted on the screen 8 6 Viewing Active Alarms and Handling Alarm Conditions Page 68 of 86 These two screens let you view any active alarm conditions as well as the alarm history for the entire history The list of system alarms that are tracked are as follows E Chilled Water High Temperature Alarm E Chilled Water Low Temperature Alarm SSTERLCO SSC Series Central Chilling Stations Compressor Motor Protector Fault One for each compressor Chilled Water Circuit Low Flow One per chilled water circuit Chilled Water Circuit Freezestat One per chilled water circuit Chilled Water Circuit High Pressure One per chilled water circuit E Chilled Water Circuit Low Pressure One per chilled water circuit E Pump motor overload One per system pump If an alarm condition occurs the follow screen is displayed Figure 15 Alarm Condition Screen AB Ajen Braciey Paneivier 000 To acknowledge the alarm press the alarm silence button to clear it It will then appear in the alarm history screen Except for High and Low Water Temperature and Low Refrigerant Pressure these alarms are considered fatal and maintenance must be preformed in order to allow the chiller to fully run Should a compressor or SSC Series Central Chilling Stations Page 69 of 86
47. is located at the side or rear of the chiller e Water pressure 225 psi 2172 4 kPa 21 72 bars e Water temperature lt 85 F lt 29 C Condenser Water Out The return outlet located at the chiller side or rear is connected to a cooling tower inlet a sewer or other approved discharge receiver e A water regulating valve is a standard feature in the condenser water out line Caution The water regulating valve is set at the factory It must not be adjusted except by a qualified refrigeration technician 3 10 Installing the Remote Air Cooled Condenser SSC Series models use the surrounding air to cool the remote condenser All models have variable speed fans and low ambient controls to allow proper operation down to 20 F 29 C outdoor air temperature Install the remote air cooled condenser where there 1s e Greater than or equal to 20 F 29 C air temperature e Free passage of air for condensing e Adequate structural support e Protection from strong winds and drifting snow e Provisions for removal of heated air from the area e No steam hot air or fume exhausts drawn into the condenser coils e Service accessibility Page 24 of 86 STERLCOS SSC Series Central Chilling Stations SSC Series condensing pressure with 95 F 35 C condenser air R 22 260 psi 1 793 kPa 17 93 bars Note Due to the variables involved in remote air cooled condenser installations no set or standard piping procedure ex
48. ists Each installation must be designed and installed by qualified persons Follow the instructions supplied with the condenser 3 11 Checking Motor Direction Compressor Note e Never switch contactor leads or motor leads for reversing rotation e Do not use contactor or motor leads for phase matching e Compressor noise from reverse rotation is noticeable Do not run in this mode for more than ten 10 seconds The compressor shuts off if run longer in this mode e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws will be lower than normal e If you discover that compressor rotation 1s reversed correct it by switching any two main power leads into the disconnect switch or distribution block on the unit Water Pump A positive pressure of 20 to 30 psi 137 9 to 206 8 kPa 1 38 to 2 07 bars on the TO PROCESS line indicates correct pump rotation Condenser Fan On SSC Series remote air cooled units air should draw through the condenser and discharge up from the condenser Changing fan rotation direction e Disconnect and lock out power at the fused disconnect e If all fans are going backwards reverse any two main power leads e If only some of the fans are going backwards switch any two of their respective motor leads STERLCOS SSC Series Central Chilling Stations Page 25 of 86 Notes Page 26 of 86 STERLCOS SSC Series Central Chilling Stations Sequence Of Operation
49. lled water processes These dual well models hold hot and cold water before and after it is pumped through the chiller Tanks have recirculation pump s to send return water to the chiller and process pump s to pump cooled water directly to process Standby pumps may be utilized to distribute pump service or to allow uninterrupted chiller operation during pump maintenance Properly installed operated and maintained SSC Series chilling stations provide many years of reliable operation To get the most satisfaction from your new chiller read and follow the instructions in this manual 1 2 Necessary Documents The following documents are necessary for the operation installation and maintenance of Sterling SSC Series central chillers Additional copies are available from Sterling Familiarize the appropriate personnel with these documents M This manual M The schematic and connection diagram in the control enclosure M Operation and installation manuals for accessories and options selected by the customer M The Customer Parts List included in the information packet STERLCOS SSC Series Central Chilling Stations Page 7 of 86 1 3 Models Covered This manual provides operation installation and maintenance instructions for the SSC Series central chilling stations Model numbers are listed on the serial tag A model number followed by Q indicates a specially constructed unit and not all information in this manual may apply
50. ller system was configured to operate the pump s of the chilled water pump tank the user may view the status of the process and recirculation pumps Viewing Chiller Pump Status To view the status of the pumps start from the Main Menu then E Press the te or 7 buttons to highlight either PROC PUMP STATUS or RECIRC PUMP STATUS mM Press zl The Pump Status Screen appears PROCESS PUMP STATUS PROCESS 1 READY Sw FPROCESS 2 RUNNING PROCESS 3 Pump Status Screen Only pumps that are included in the system will be shown on this screen Pumps will display one of the following states 1 OFFLINE This indicates that the pump has been turned off in the pump enable disable screen The pump will not be called to operate until it has been re enabled 2 READY Indicates that the pump is enabled and ready to run However the current number of pumps specified to run does not require this pump to operate RUNNING Pump is currently running 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 unless it is put in the OFFLINE state oS Page 50 of 86 STERLCOS SSC Series Central Chilling Stations Operating Chiller Pumps To turn on and off the pumps start from the Main Menu then E Press the ty or buttons to highlight either CONFIGURATION MENU T Press E Highlight PUMP
51. mp tank Observe all applicable codes M Complete all electrical wiring Observe all applicable codes M Prepare all related equipment in the system for operation Note e Never switch contactor leads or motor leads for reversing rotation e Do not use contactor or motor leads for phase matching e Compressor noise from reverse rotation is noticeable Do not run in this mode for more than ten 10 seconds The compressor shuts off if run longer in this mode e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws are lower than normal e If you discover that compressor rotation is reversed correct it by switching any two main power leads into the disconnect switch or distribution block on the unit M Open the 1 approx 25 mm makeup water valve and allow the tank to fill until the automatic float valve shuts off The float level should be adjusted so the standing water level is 8 20 cm from the top of the tank M Check for proper pump rotation direction To confirm proper rotation 1 Observe a pump pressure gauge connected to the suction and discharge sides of the pump casing through two 4 approx 6 4 mm gauge cocks 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 e If the gauge indicates within 15 psi 103
52. mponents loose hardware and mounting screws etc In case of breakage damage shortage or incorrect shipment refer to the following sections 2 2 Inthe Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment M Notify the transportation company s local agent if you discover damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid contact Sterling at 414 354 0970 for a receipted transportation bill M Advise Sterling regarding your request for replacement and to obtain an RMA return material authorization number qaip SSC Series Central Chilling Stations Page 15 of 86 2 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have Sterling SSC Series central chilling station Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component in
53. n Direction on Page 25 for more information Clean the system You may also have to pull the pump and inspect the impeller Check for foam in the water circuit add anti foam if needed Isolate evaporator thaw out check for leaks Check Process water pressure low Evaporator frozen coolant solution Coolant pressure at pump high solution should be good for at least 10 F 6 C below leaving water temperature Restricted condenser air flow Clean air filters clean condenser check water flow Check superheat on Refrigerant not feeding expansion valve Improper water glycol Make HTE that coolant mixture protection is right for solution Unit runs continuously but the process not enough cooling Poor heat transfer in power evaporator evaporator evaporator of 2 4 gpm ton Unit Undersized ior Call sales representative application p l Pump is running in reverse Pump pressure is too low Check for foreign matter qa SSC Series Central Chilling Stations Page 79 of 86 Service Notes Page 80 of 86 GID ssc series central Chilling Stations Index Alarms Advanced Controls 68 Standard Controls 53 Available options 9 Checking Motor Direction 25 Chiller Pumps Advanced Controls 64 Chiller Shutdown 38 Circuit Alarm Sequence 27 Compressor Lead Lag 27 Compressor Staging Sequence 2 31 Condenser Maintenance 73 Copyright information 2 Determining Flow Rate 38 Disclaimer information
54. on 6 Check the pump s amp draws and pressures The amp draws must be within the pump s running load and service factor amps Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation 5 4 Remote Air Cooled SSC Series Startup Checklist M Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process M Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using M The voltage at the main power connection must read within plus or minus ten percent 10 of the voltage listed on the serial tag M Phase imbalance must be less than two percent lt 2 STERLCOS SSC Series Central Chilling Stations Page 35 of 86 Page 36 of 86 Electrical connections must conform to all applicable codes Complete the chilled water TO and FROM PROCESS connections The optional or field installed chilled water supply and return valves must be open Be sure the tank and chilled water circuit piping are filled with a water glycol mixture The water glycol mix should provide freeze protection to 20 F below the leaving water temperature you ve selected The air cooled condenser should have an adequate supply of air for proper operation Connect the main power to the unit and bump start it to check for proper rotation direction If the fans are operating
55. ressure G l anreisen aa 30 Aao FON OWO a AAA 30 4 11 Contool NDIDE ennenen 31 Aek Control Probe crassior aa 31 4 13 Chilled Water Manifold ccc cccceccsseeseeeeeteeeseeeeeenseeeeeteeeeeeess 31 4 14 Condenser Water Manifold cccccccseccceseeceeeeteeeeseeeetaeetaeeeas 31 Page 4 of 86 SSTER LCOS SSC Series Central Chilling Stations Table of Contents 5 Startup Checklists scecssesecevecenetinceenevdesseustecesesecesscess 33 SA JINWMOOUCTION Svsseassseseuesetesusaetseetaesestenclectavtesnfasetasntasshacaetasdestecstaradess 33 5 2 Water Cooled SSC Series Startup Checklist ccccceeeeeeeeeees 33 5 3 Water Cooled SSC Series Startup ccccccseeeeeseseeeeeeeeeeeeeeaeees 35 5 4 Remote Air Cooled SSC Series Startup Checklist 008 35 5 5 Remote Air Cooled SSC Series Startup ccceccesseeeeseeeeeeeeees 37 S6 Determining FOW TALS arassa aa E eN eea 38 Df ONUOWN nossas aea a 38 6 Graphic Panel Devices 1 cc1scccccsecesesensssensnenennees 41 6 1 Indicator Lights and Control Switches MMI cccsseeeeseeeees 41 7 Using the Standard Touchscreen Interface 43 7 1 Touchscreen Interface Introduction MMI ccccseeeseeeeeeeeees 43 7 2 Using the SSC Series Standard Touchscreen Interface 44 7 3 Getting Started on the SSC Series Standard Touchscreen Interface45 7 4 Viewing and Operating Chiller COMPreSSOIMS c
56. rol of up to nine additional chillers cooling tower system water treatment system and DH communication capabilities General Fault audible visual alarm with elevated light stack Non fused rotary thru the door disconnect switches Electrical operation available in 208 460 and 575 volts 60 Hz 200 380 and 415 volts 50 Hz UL cUL listed electrical subpanel Water cooled condenser manifold Onsite startup Standard Features on Remote Condensers Direct drive 3 phase fan motors with ball bearings and internal overload protection Electronic variable speed control of lead fan and fan cycling for constant condenser head pressure control Fans are 30 76 cm in diameter and have PVC coated steel fan guards 1 2 hp 1 12 kW variable speed fans are 26 66 cm in diameter Internal baffles between fan cells UL listed in the United States and Canada Patented floating tube coil to eliminate tube sheet leaks Copper tube condenser coils have corrugated aluminum fins Weather proof control panel with factory mounted door interrupt switch High efficiency condenser coil designed for optimum performance Aluminum housing provides corrosion protection for outdoor applications STERLCOS SSC Series Central Chilling Stations Page 9 of 86 Model Number Nomeclature SSC 060 SSC Scroll Compressor Central Chiller Condenser Type R Remote Air Cooled W Water Cooled Nominal Unit Size Tons kW 030 30 105
57. rtup the chiller STERLCOS SSC Series Central Chilling Stations Page 57 of 86 Figure 7 SSC Series Advanced Control Panel e salem tiw 8 2 Using the SSC Series Advanced Touchscreen Interface Page 58 of 86 The SSC Series Advanced touchscreen interface is the manager of your SSC Series central chilling station This screen contains screen buttons you can press to control system operation For example if you need to resolve an alarm condition press the Up or Down arrow buttons on the right side of the screen to highlight ACTIVE ALARMS The screen will tell you what alarm is active and you may clear the alarm by touching the F1 button located on the lower left of the terminal To return to the Main Menu screen at this point press the Main Menu button on the screen located in the lower right corner The Main Menu screen then displays Some screens let you directly control the operation of the chilling station while others are for information purposes and are display only screens This chapter distinguishes between operation and display screens STERLCOS SSC Series Central Chilling Stations 8 3 Getting Started on the SSC Series Advanced Touchscreen Interface To start the SSC Series Standard touchscreen interface M Push the ON OFF button on the cabinet The SSC Series control panel energizes and the System On indicator turns on The Main Menu screen displays Figure 8 Main Menu Screen
58. run However the current loading does not require the compressor to be running This compressor will be automatically started when needed The color code for this indication is yellow 3 RUNNING Compressor is currently running The color code for this indication is green 4 FAULT A safety on the compressor indicates a fault condition and the compressor has been deactivated Once the problem is remedied the compressor will return to a READY qa SSC Series Central Chilling Stations Page 61 of 86 state unless it is put in the OFFLINE state The color code for this indication is red Operating the chiller compressors To enable or disable the individual compressors start at the Main Menu then E Press the Up or Down buttons on the right side of the screen to highlight Chiller Configuration M Press the al button The configuration menu screen displays Figure 10 Chiller Configuration Screen AB Allen Bradley PanetView 1090 AEC Application Engineering Chilled Water Compressor Contiguration Chilled Water Process Set point High Low Process Temperature Temperature Set point Alarm Alarm HHHH F HAH F AHHH F 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 Page 62 of 86 SSTERLCO SSC Series Central Chilling Stations Setting Compressor Lead Lag Times and Activating Compr
59. s 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 be cleared to monitor run time on specific intervals In order to clear the resettable hourmeter press the Hour Meter Reset button as prompted on the screen 8 5 Viewing and Operating Chiller Pumps If your chiller system was configured to operate the pump s of the chilled water pump tank the user may view the status of the process and recirculation pumps SSTERLCO SSC Series Central Chilling Stations Page 64 of 86 Viewing Chiller Pump Status To view the status of the pumps start from the Main Menu then E Press the Up or Down buttons to highlight either ys tem Information E Press a The Pump Status Screen appears Figure 12 Pump Status Screen AB 1 Allen Bradley Panelview 1090 Chilled Water System Status Chilled Water System Pumps Compressors Recire 1 Comp 1A Comp 2A Running Running Ready Outside Ambient Winter Kooler Pump Ready KRRB F rocess Return HEHH OF Only pumps that are included in the system will be shown on this screen Pumps will display one of the following states 1 OFFLINE This indicates that the pump has been turned off in the pump enable disable screen The pump will not be called to operate until it has been re enabled The color code for this indication is black qa SSC S
60. siensictiveutvencienedeniierveenvensisnevenines 77 l HOOK cercvonsvanececivanccieeereowstbocencccnevasressedenecennssnveceaeanece 81 qa SSC Series Central Chilling Stations Page 5 of 86 Charts and Figures 1 Typical Two Circuit 60 100 Ton Water Cooled Chiller 11 2 Typical Two Circuit 60 100 Ton Remote Air Cooled Chiller 13 3 Freezing Protection Curve 29 4 SSC Series Standard Control Panel 39 5 SSC Series Advanced Control Panel 39 6 SSC Series Standard Control Panel 44 SSC Series Advanced Control Panel 58 8 Main Menu Screen Advanced Control Panel 59 9 Chiller Status Screen Advanced Control Panel 61 1 0 Chiller Configuration Screen Advanced Control Panel 62 1 1 Compressor Run Time Display Screen Advanced Control Panel 64 12 Pump Status Screen 65 1 3 Pump Enables Screen 66 1 4 Pump Run Time Display Screen 68 15 Alarm Condition Screen 69 1 6 System Status Screen 71 1 Temperature Input Display Screen 72 Page 6 of 86 STERLCOS SSC Series Central Chilling Stations 1 General Information 1 1 Introduction Sterling SSC Series central water chilling stations are available in water cooled and remote air cooled designs They differ only in the condensing media used The SSC Series units are configured with two independent circuits using multiple compressors for each circuit This manual lists information for these units SSC Series chilling stations may be configured with stainless steel pump tanks for use as reservoirs for chi
61. struction manuals Parts list NS AKARNAK Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify Sterling immediately of the shortage 2 4 If the Shipment is Not Correct If the shipment is not what you ordered contact Sterling immediately Include the order number and item Hold the items until you receive shipping instructions 2 5 Returns Important Do not return any damaged or incorrect items until you receive shipping instructions from Sterling Page 16 of 86 STERLCOS SSC Series Central Chilling Stations 2 6 Uncrating Your New Chiller WARNING DUE TO THE SIZE AND WEIGHT OF SSC SERIES CHILLERS STERLING RECOMMENDS USING BONDED PROFESSIONAL MILLWRIGHTS TO UNLOAD AND MOVE SSC SERIES CHILLERS Rig the chiller from the frame only using spreader bars to prevent load transfer to any chiller components Rig the frame from at least four points and balance the load before lifting to clear the skid Use a forklift of adequate size when lifting the chiller by the fork pockets Insert the forks all the way into the pockets and be sure to balance the load before lifting the chiller to clear the skid Lift only as high as necessary Use a pry bar to free the skid if necessary Lower slowly Retain the crating in case reshipment is necessary due to hidden shipping dama
62. ump 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 process cooling water return connection to the Hot well of the tank on the right side at the flanged connection Warm coolant water and ethylene glycol mixture returns from the process to the tank then gets pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle 4 6 Refrigeration Circuit e SSC Series chilling station air and water cooled unit refrigeration cycles differ only in the way the compressed gas is condensed to a liquid e Liquid refrigerant from the condenser passes through a shut off valve into a filter dryer e The refrigerant then passes through the sight glass and solenoid valves into the thermal expansion valve which regulates flow the valve lowers pressure and boiling point Heat from the fluid causes the refrigerant to boil off into a vapor e The refrigerant vapor flows through the suction line back into the compressor e The refrigerant gives up heat as it re condenses to a liquid in the condenser 4 7 Freezestat Control Page 28 of 86 The freezestat shuts down the compressor if the chilled water temperature approaches the freezing point The chilled water pump on the system will continue to run It is factory set at 40 F 4 C or 10 F 6 C below the rated capacity operating temperature of 50 F
63. vaporator and balancing flows Coupling mounts for customer installed pressure gauges are included on both control nipples Pressure drop between evaporator entering water pressure and evaporator leaving water pressure can be converted to gallons per minute using the pressure drop charts provided 4 12 Control Probe Two control probes sense temperatures One probe measures the temperature of the hot well and the other does the same for the cold well of the reservoir These temperatures are used by the PLC controller to sequence the compressors based on load 4 13 Chilled Water Manifold The chilled water manifold allows one point connections of TO PROCESS piping The Sch 40 steel piping includes butterfly valves at each evaporator for flow balancing and circuit isolation optional pressure gauges can be installed 4 14 Condenser Water Manifold The condenser water manifold allows one point connection of TO TOWER drain and FROM TOWER city water piping Sch 40 steel include butterfly valves for each condenser Drain points are at the bottom of the header STERLCOS SSC Series Central Chilling Stations Page 31 of 86 Notes Page 32 of 86 STERLCOS SSC 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
64. w voltage Voltage must be within plus Compressor internal overload or minus ten percent 10 p of nameplate rating electrical connections on scroll compressors holding coil open Pump runs compressor does not contd Replace Sight glass should be clear Low refrigerant pressure while comperssor runs Call switch contact open for service if bubbling or foaming Defective pump motor interlock to compressor Repair or replace control circuit Broken wire in the Locate and repair compressor control circuit Lower set point to 10 F 6 Freezestat control setting is below the leaving water too high temperature you want with at Pump runs compressor least 15 degrees differential cycles at short intervals Check refrigeration charge check refrigerant sight glass for bubbles or a level in the glass TEER lca Be sure the antifreeze Ae JY mixture protection is right for Leaving water temperature is l the process not at set point Defective freezestat control Refrigerant charae is low Refrigerant charge is iow Gal service to find and a eae Refrigerant charge is ow j the leak Add eae Check for partially closed Pump pressure is too high Restricted water flow valves etc Be sure all lines are properly sized Refrigerant is too low Page 78 of 86 STERLCOS SSC Series Central Chilling Stations Possible Cause _ Solution _ Verify proper rotation if incorrect see Changing Rotatio
65. y touching the F1 button located to the lower left of the terminal To return to the Main Menu screen at this point press the F4 button of the terminal located in the lower right corner The Main Menu screen then displays Some screens let you directly control the operation of the chilling station while others are for information purposes and are display only screens This chapter distinguishes between operation and display screens STERLCOS SSC Series Central Chilling Stations 7 3 Getting Started on the SSC Series Standard Touchscreen Interface To start the SSC Series Standard touchscreen interface E Push the ON OFF button on the cabinet The SSC Series control panel energizes and the System On indicator turns on The Main Menu screen displays Main Menu Screen The Main Menu screen lets you gain access to e COMPRESSOR STATUS contains the compressor status display screen e If the chiller was configured to operate the chilled water pump tank the PROC PUMP STATUS is displayed This screen contains the process pump status e RECIRC PUMP STATUS contains the recirculation pump status if the chiller was configured to operate the chilled water pump tank e ACTIVE ALARM LIST shows all of the active alarms Those alarms which are currently preventing the chiller from functioning if fatal alarm or those that show a condition which needs to be looked at in a short period of time

SterlingTEK A0551797 User's Manual

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