NumberOne
Airconditioning
Maker
Carrier Parkwav • Syracuse NY 13221
Reciprocating Liquid Chillers (60 Hz)
All 208/230-volt units have extended-voltage compressor motors.
All units have suction-cutoff unloading system.
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CONTENTS |
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SAFETY CONSIDERATIONS............................................. |
I |
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INSTALLATION.................................................................. |
1-6 |
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Step 1 — Inspect Shipment.................................................... |
1 |
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Step 2 — Rig and Place Unit................................................. |
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RIGGING |
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PLACEMENT |
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Step 3 — Check Compressor Mounting |
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and Connections.................................................................. |
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SERVICE ACCESS |
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Step 4 — Make Piping Connections ...................................... |
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CONDENSER DESCRIPTION |
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CONDENSER PIPING |
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COOLER DESCRIPTION |
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COOLER PIPING |
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Step 5 — Make Electrical Connections .................................. |
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•ELECTRICAL BOX, CONTROL SECTION
•UNBALANCED 3-PHASE SUPPLY VOLTAGE
•ELECTRICAL BOX, POWER SECTION
START-UP AND SERVICE.................................................. |
6 |
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Initial Check............................................................................ |
6 |
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Check Refrigerant Charge..................................................... |
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LIQUID CHARGING METHOD |
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Check Oil Charge................................................................... |
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TO ADD OIL |
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TO REMOVE OIL |
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START-UP............................................................................ |
7-10 |
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Check Refrigerant Feed Components................................... |
7 |
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•THERMOSTATIC EXPANSION VALVE
•FILTER DRIER
•MOISTURE-LIQUID INDICATOR
•LIQUID-LINE SERVICE VALVE
•LIQUID-LINE SOLENOID VALVE
•PRESSURE RELIEF DEVICES
•CHECK VALVE
Check Compressor Protection Devices_
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UNIT OPERATION........................................................... |
10-11 |
Control Power....................................................................... |
10 |
Control Sequence.................................................................. |
11 |
Unit Stoppage and Restart.................................................. |
11 |
SERVICING COOLER..................................................... |
11-13 |
Tube Plugging ....................................................................... |
12 |
Retubing ................................................................................ |
12 |
Tightening Cooler Head Bolts ............................................. |
12 |
•GASKET PREPARATION
•BOLT TORQUES
•BOLT TIGHTENING SEQUENCE
TROUBLESHOOTING GUIDE....................................... |
14,15 |
SAFETY CONSIDERATIONS
Installation, start-up and servicing of this equipment can be hazardous due to system pres sures, electrical components and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start-up and service this equipment.
When working on the equipment, observe pre cautions in the literature, tags, stickers and labels attached to the equipment and any other safety precautions that apply.
•Follow all safety codes.
•Wear safety glasses and work gloves.
•Use care in handling, rigging and setting bulky equipment.
INSTALLATION
Step 1 — Inspect Shipment
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CIRCUIT BREAKER |
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Inspect unit for damage or missing parts. If dam |
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MOTOR OVERTEMPERATURE |
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age is detected, or if shipment is incomplete, file a |
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THERMOSTAT |
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claim immediately with the shipping company. |
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CRANKCASE HEATER |
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Step 2 — Rig and Place Unit |
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TIME GUARD® CONTROL |
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• FOUR-FUNCTION TIMER |
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RIGGING |
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OIL PRESSURE SAFETY |
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On each end of cooler, a steel loop is provided for |
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SWITCH (OPS) |
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Check Unit Safety Devices........................ |
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the preferred method of lifting unit. Use spreader |
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SAFETY THERMOSTAT |
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bars to keep cables away from compressor enclo*- |
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HIGH-PRESSURE SWITCH |
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sure and control box. If unit is to be moved by fork |
• LOW-PRESSURE SWITCH |
10 |
truck, use the following methods: |
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Check Capacity Control System............... |
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DESCRIPTION |
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1. From front or rear, lift under the cooler rails. |
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3-STEP TEMPERATURE |
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Unit can be either on or off skid. |
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CONTROLLER |
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2. When moving from ends, leave unit on skid. Lift |
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DESIGN SET POINT ADJUSTMENT |
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CYLINDER UNLOADING SYSTEM |
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from under skid. |
© Carrier Corporation 1983 |
Form 30HK.HL-10SI |
Table 1 — Weight Distribution (ib)
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UM!T |
APPROX |
HK |
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HL |
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OPERWT |
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30( )-- |
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HK |
HL |
A I B |
C |
D |
A |
B |
C |
D |
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015 |
1637 |
1016 |
142j 201 |
755 |
539 |
266 |
266 |
242 |
242 |
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020 |
1787 |
1136 |
182| 240 |
790 |
575 |
296 |
296 |
272 |
272 |
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025 |
1980 |
1310 |
3031 205 |
592 |
880 |
367 |
285 |
285 |
373 |
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030 |
1985 |
1334 |
3031 205 |
592 |
885 |
377 |
290 |
290 |
377 |
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Location of mounting holes: |
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WATER |
1 |
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INLET |
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PLAN VIEW |
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END |
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FRONT |
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To ensure safe moving, unit should remain on shipping skid until final placement. If unit is moved on rollers, use minimum of 3. Unit can also be dragged into final position (must be on skid).
When rolling or dragging, apply force to the skid, not the unit. Use care to avoid damage to piping and control box.
PLACEMENT
When unit is in final position, remove skid, level unit with a spirit level and bolt to floor or pad.
SCLF-ILOCKINÖ |
SNOb&ER Ft.ANo>--0 |
WASHER |
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0OLT |
NEOPHENE |
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— |
SNUSSKR |
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'COMPRESSOR FOOT |
J_
ISfL A'lON S-RING
Fig. 2 — Compressor Mounting
These units are not suitable for unprotected outdoor use.
Carrier recommends that these units be located in the basement or on the ground floor. However, if it is necessary to locate unit on an upper floor, be sure the structure has been designed to support the weight. If necessary, add structural support to floor. Also, be sure surface for installation is level. Refer to Fig. I for space requirements and Table 1 for weight distribution.
1090
Table 2 — Physical Data
UNIT AND COMPRESSOR
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UNIT 30HK.HL |
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015 |
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020 |
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025 |
030 |
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APPROXIMATE |
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HK |
1637 |
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1787 |
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1980 |
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1985 |
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OPERATING WT (lb) |
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HL |
1016 |
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1136 |
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1310 |
1334 |
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REFRIGERANT(R-22) |
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HK |
34 |
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38 |
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40 |
45 |
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CHARGE (lb) |
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HL |
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Holding Charge |
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COMPRESSOR 06* |
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HK |
DC537 |
E2150 |
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E7265 |
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E7175 |
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HL |
DC537 |
E2250 |
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E7265 |
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E7275 |
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No. Cylinders |
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6 |
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4 |
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6 |
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6 |
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Oil Charge (pt)t |
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8.5 |
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14 |
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19 |
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19 |
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No. of Unioaders |
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2 |
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1 |
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2 |
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2 |
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Cap. Control Steps |
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3 |
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3 |
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3 |
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3 |
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CONDENSER. 09RP (HK) |
022 |
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027 |
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MAX DESIGN WORKING |
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PRESSURE (psig) |
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Water |
Side |
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150 |
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Cooler i „ , - .< Refrig Side |
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235 |
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„ . f Water Side |
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250 |
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Condenser Side |
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385 |
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COOLER |
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COOLER10HA400 |
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774 |
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784 |
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UNIT 30HK.HL |
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015,020 |
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025,030 |
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SHELL, Net Vol. (Gal.)t |
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6.8 |
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9.9 |
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TUBES (Copper) |
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Internal Fins, |
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Number |
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5/8-in. OD X0.020 wall |
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81 |
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81 |
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Length (in.) |
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62.5 |
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85.5 |
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Eff. Outside Surface (sq ft) |
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66.3 |
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91.7 |
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REFRIGERANT CIRCUITS |
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1 |
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1 |
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CONNECTIONS (in.) |
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2 |
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2 |
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Water 1 |
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3/4 |
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3/4 |
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^ ( Drain (MPT) |
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Refrig |
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I 1.125 |
1.125 |
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< Suction |
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1.625 ODM |
2.125 ODM |
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WEIGHTS (lb) |
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Cooler (Net) |
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354 |
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446 |
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Water |
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75 |
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100 |
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Refrigerant |
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8 |
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12 |
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Total |
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437 |
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558 |
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CONDENSER |
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09RP |
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022 |
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027 |
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TUBES |
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Copper, Integral Fins |
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OD (in.) |
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3/4 |
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Wall Thickness (in.) |
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Plain End |
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0.043 |
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Finned Section |
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0.028 |
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Length (in.) |
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10^7 |
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Fins/in. |
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40 |
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Number" |
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36 |
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44 |
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Surface Area (sq ft) i .! Outside |
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32.9 |
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40 2 |
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133.6 |
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163.4 |
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NO. WATER PASSES |
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CONNECTIONS (in.) |
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... , ( In (IPS) |
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2/2 Sched 40 |
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^ f Out (IPS) |
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2/2 Sched 40 |
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Relief Valve Outlet (SAE) |
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Ув |
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Water Regulating Valve |
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/4 |
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Liquid Outlet (ODF) |
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/в |
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Hot Gas (ODF) |
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13/в |
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'Prefix; |
2 |
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1 electric |
unloader; C, 7 |
= 2 electric unloaders. |
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tSee Check Oil Charge for Carrier-approved oil. + lncludes nozzles.
"Includes 5 subcooler tubes.
Only electrical power connections and water con nections for condenser and cooler are required for HK installation. Installation of HL units varies only in field piping required for the remote condenser.
Step 3 — Check Compressor Mounting and Connections
As shipped, compressor is held down by special self-locking bolts and plain lock washers. After unit is installed, remove self-locking bolts one at a time and reassemble with flanged washers and neoprene snubbers as shown in Fig. 2. Special flanged washers and neoprene snubbers are shipped in a cloth bag tied to one of the compressor feet. Tighten all 4 bolts. Then loosen each until flanged washer can be moved sideways with finger pressure.
t’.-M "! ION: iie sure mierconnecting piping and electrical condu■'.^ aic suspended Irec oi contact with any adjacent wails, and be sure unit capil- k;:;cs are nol rur'-.nmg aguinst ;i::>thing.
SERVICE ACCESS
Remove combination top and back cover over compressor. Servicing can be performed from either top or back. For rear access, allow approximately 3 ft of clear space behind unit.
Step 4 — Make Piping Connections
CONDENSER DESCRIPTION
The condenser is a sheli-and-tube type with removable heads for easy tube servicing. Condenser has an internal subcooler designed for 1215 F total liquid subcooling at average tower water conditions. For further condenser data refer to Table 2, Physi cal Data.
CONDENSER PIPING
Provide a means for draining system in winter and for maintenance.
1MP(.)R 1 ,-\N i ; L -.mdeu.sc: v>a*.cr ntust enter at ho:tom I;.;- proper operation ot the intcrual .subcooler in condenser bottom (Fig. I).
Keep water supply lines as short as possible. Si/e lines according to available head pressure, rather than by connection size, especially on cooling tower applications. Use flexible connections to reduce vibration transmission. Refer to Carrier System Design Manual, Part 3, Piping Design.
The 30HL units using air-cooled or evaporative condenser should have adequate means for head pressure control when operating below 60 F outdoor ambient temperature.
A water regulating valve must be installed on cooling tower application when any of the following conditions exists:
1.Low outdoor ambient temperatures affect head pressure.
2.Entering chilled water temperature is below 70 F.
1090
3. A specific head pressure must be maintained.
Set water regulating valve to maintain design head pressure. Do not adjust to compensate for high head pressures caused by fouled condenser tubes, excess refrigerant or the presence of non-con densables. Due to changes in water temperature, it may be necessary to adjust valve seasonally. After adjusting for design head pressure, shut unit down. Water regulating valve should shut off flow of water in a few minutes. If it does not, raise head pressure setting. Make sure that capillary tube from water regulating valve is connected to condenser purge valve.
Instead of water regulating valve(s), a bypass arrangement may be used. This permits leaving condenser water to mix with condenser supply water, in order to maintain entering chilled water temperature above 70 F or an appropriate tem perature necessary to maintain a specific head pressure.
CAl ;'A;\; keliglr.e:: ali condenser ixuui bolts before filling system with water. Torque bolts to a maximum of 45 ft-lb.
Water leaving condenser is under pressure and should not be connected directly into sewer lines. Check local codes. A 3/ 8-in. drain plug is located in the head at each condenser end.
Refer to PRESSURE RELIEF DEVICES and CHECK VALVE, page 8, concerning piping con nections for these components.
COOLER DESCRIPTION
The cooler is a direct-expansion type with removable heads and is partitioned for multi-pass refrigerant flow. Water flow across the tube bundle is directed by baffles designed for minimum waterpressure drop. The tubes have integral internal fins for maximum heat transfer efficiency.
Viewed from unit front, the return chilled water enters at left end of cooler and leaves at right end. The sensing bulb for the water temperature con troller is in the return-water nozzle, the returnwater temperature being the control point. The sensor for the low water-temperature cutout is located in the leaving-water nozzle.
The cooler is insulated with a flexible, closed cell plastic foam insulation of suitable thickness. Water vapor cannot penetrate the cellular structure to condense either within cells or on the cooler shell. Thus, the insulation itself is a vapor barrier. Because of the toughness of insulation, a protective sheet metal covering is not necessary.
The standard cooler can be used for all glycol brines down to -20 F. However, for calcium or sodium chloride brines, it is improtant that the proper inhibitors be carefully selected for protection of the copper tubes. Refer to publications of the
Calcium Institute or the Mutual Chemical Division of Allied Chemical Corporation for information on corrosion control in calcium or sodium chloride systems.
COOLER PIPING
Plan piping for minimum number of changes in elevation. Install manual or automatic vent valve at high points in line. Maintain system pressure by using a pressure tank or combination relief and reducing valve.
See Carrier System Design Manual, Part 3, Piping Design, for chilled-water piping details.
Install thermometers in entering and leaving water lines. Provide drain connections at all low points to permit complete drainage of system. Connect shutoff valve to drain line before oper ating unit. Install shutoff valves near entering and leaving water connections. Use flexible connections to reduce vibration transmission.
Insulate piping after leak testing to prevent heat transfer and sweating. Cover insulation with moisture seal.
A chilled water flow switch is factory installed in the line entering the cooler. Sec Table 3 for min imum recommended cooler and condenser flow rates and loop volume.
^ Table 3 — Minimum Cooler and Condenser Water Flow Rates and Minimum Loop Volume
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MINIMUM FLOW |
T |
PRESSURE DROP |
MINIMUM |
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UNIT |
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(GPM) |
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(ftwg) |
VOLUME! |
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Cooler |
ContSenser*I |
Cooler |
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Condenser |
(Gal) |
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30HK,HL015 |
'~25~ |
34 |
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3,2 |
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2,1 |
47 |
020 |
32 |
34 |
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5.1 |
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2,1 |
60 |
025 |
38 |
41 |
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5,5 |
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2,1 |
81 |
030 |
38 |
41 |
I, |
5.5 |
2.1 |
88 |
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'Applicable to 30HK units only. |
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tMlnimum system water volumes: |
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Gallons = V X ARi Capacity in Tons |
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APPLICATION |
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Normal Air Conditioning |
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Process Type Cooling'
Low Ambient Operation
NOTE: Minimum condenser water flow based on 3 ft/sec to minimize condenser fouling. Flow rates below 3 ft/sec may require more frequent tube cleaning.
Step 5 — Make Electrical Connections
All field wiring must conform with local code requirements. Control circuit is 115 volts on all 60-Hertz units. Control power is supplied from a separate source, thru a !5-amp fused disconnect.
Inside the control box, provisions are made to connect the ground wires which must be installed with each field power supply.
The 30HK,HL015 units are factory supplied with across-the-line start at all voltages and cannot
be converted to part-winding start. The 30HK, HL020,025,030 units are factory supplied with part winding start at 208/230 volts and across-the-line start at 460,575 volts.
1090
Refer to Tables 4 and 5 for electrical data on indi vidual compressors and complete units. Compressor usage is given in Tables 2 and 5.
ELECTRICAL BOX, CONTROL SECTION Inside this section are relays, highand low-
pressure cutouts, low water-temperature cutout, timer, terminal strips and a 3-step temperature controller. On the outside (control panel) are con trol circuit ON-OEF switch, partial load switch (DLS), compressor run light, safety trip lights and control circuit fuse. The control panel is hinged to provide easy access to the controls inside.
^ Table 4 — Unit Voltage and Model Number*
VOLTS |
UNIT 30HK.HL |
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015,020,025,030 |
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208/230 |
5-- |
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460 |
6-- |
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575 |
1-- |
'Compiete number has 10 digits. Example: 30HK020530.
UNBALANCED 3-PHASE SUPPLY VOLTAGE
Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the follow ing formula to determine the % voltage imbalance:
% Voltage Imbalance =
100 X-max voltage deviation from average voltage * * average voltage
Example: Supply voltage is 240-3-60.
* ^ |
AB = 243 volts |
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BC = 236 volts |
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AC = 238 volts |
Average Voltage |
243 + 236 + 238 |
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717
3
Determine maximum deviation from average voltage:
(AB) 243 - 239 = 4 volts
(BC) 239 |
236 |
3 volts |
(AC) 239 |
238 |
1 volt |
Maximum deviation is 4 volts.
Determine % voltage imbalance:
A
% Voltage Imbalance = 100 x 239 = 1.7%
This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.
IMPOR 1 .-XN'l : li the ■'UppU \oliagc phase im balance is more than 2((', contact \our h>cal electric uulits cornpain immcdiateU.
LQUIP GND
Control circuit power is from separate source, Incoming wires are
connected directly to terminals and on TB2.
EQUIPGMD — Equipment Ground
Fig. 3 — Wiring Schematic — Unit and
Control Power Supply
ELECTRICAL BOX, POWER SECTION
The main electrical power supply is brought in thru the top of the electrical box, on the left-hand side (see Fig. 1). The hole accommodates up to a 3-in. conduit. Pressure-lug connections on terminal block are suitable for copper, copper-clad alumi num or aluminum wire, unless otherwise noted on a label near the terminal block.
The power section contains: main power terminal block, compressor circuit breaker with calibrated magnetic trip (for compressor motor overload and locked rotor protection), and compressor motor contactors. The panel over this section is secured with screws as a safety measure against casual entry for purposes other than service.
1090
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