Carrier 30H User Manual
Carrier Parkway • Syracuse NY 13221
Reciprocating Heat Reclaim Units
Page
INSTALLATION ...................................................................1
Step 1 — Inspect the Shipment
Step 2 — Rig and Place the Unit......................................1
RIGGING......................................................................1
PLACEMENT...............................................................1
Step 3 — Check Compressor Mounting &
Connections
SERVICE ACCESS
Step 4 — Make Piping Connections.................................3
CONDENSER DESCRIPTION
TOWER CONDENSER PIPING
HEAT RECLAIM CONDENSER PIPING .. 3
COOLER DESCRIPTION...........................................4
COOLER PIPING
Step 5 — Make Electrical Connections
ELECTRICAL BOX, CONTROL SECTION . 5
ELECTRICAL BOX, POWER SECTION ... 5
START-UP AND SERVICE.................................................5
INITIAL CHECK..................................................................5
Check Refrigerant Charge................................................6
LIQUID CHARGING METHOD
Check Oil Charge
TO ADD OIL.................................................................6
TO REMOVE OIL........................................................6
START-UP AND OPERATION CHECKS
Check Refrigerant Feed Components
THERMOSTATIC EXPANSION VALVE
FILTER-DRIER
MOISTURE-LIQUID INDICATOR
LIQUID-LINE SERVICE VALVE
PRESSURE RELIEF DEVICES
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60-Hertz
CONTENTS
1
1,2
3
3
3
4
4
6
6
6
Page
Check Compressor Protection Devices ....
CIRCUIT BREAKER
DISCHARGE TEMPERATURE
THERMOSTAT
CRANKCASE HEATER
TIME GUARD® CONTROL
FOUR FUNCTION TIMER
OIL PRESSURE SAFETY SWITCH (OPS) .8
Check Unit Safety Devices
SAFETY THERMOSTAT
HIGH-PRESSURE SWITCH
LOW-PRESSURE SWITCH
Check Capacity Control System
DESCRIPTION .............................................................9
4-STEP TEMPERATURE CONTROLLER .. 9
DESIGN SETPOINT ADJUSTMENT
CYLINDER UNLOADING SYSTEM
UNIT OPERATION ............................................................. 11
Control Power.................................................................. 11
Control Sequence............................................................. 11
Stoppage and Restart...................................................... 11
SERVICING THE COOLER
Tube Plugging................................................................... 12
Retubing
Tightening Cooler Head Bolts......................................... 12
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GASKET PREPARATION
BOLT TORQUES
BOLT TIGHTENING SEQUENCE
TROUBLESHOOTING GUIDE
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8
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11,12
12
12
12
13
14,15
INSTALLATION
Step 1 — Inspect the Shipment
Inspect the unit for damage or missing parts. If
damage is detected, or if shipment is incomplete,
file a claim immediately with the shipping company.
Step 2 — Rig and Place the Unit
RIGGING
On each end of the cooler, a steel loop is pro
vided for the preferred method of lifting the unit.
Use spreader bars to keep cables away from the
compressor enclosure and control box. If unit is to
be moved by fork truck, use the following methods:
1. From the front or rear, lift under the cooler rails.
Unit can be either on or off the skid.
2. When moving from the ends, leave the unit on the
skid. Lift from under the skid.
If unit is to be dragged or rolled into final posi
tion, leave it on the skid; apply force only to the skid,
not the unit. When rolling, use a minimum of 3
rollers.
© Carrier Corporation 1979
PLACEMENT
When the unit is in final position, remove the
skid, level the unit with a spirit level and bolt to
the floor or pad.
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 the unit on an upper floor, be
sure the structure has been designed to support the
weight. If necessary, add structural support to the
floor. Also, be sure the surface for installation is
level. Refer to Fig. 1 for space requirements and
Table 1 for weight distribution.
Only electrical power connections and water con-„
nections for condensers and cooler are required for
installation.
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 the self-
Form 30H-1S1
UNIT DIMENSIONS
DIMENSION
LENGTH 1 toe. CHILLED WATER CONN.
8«stc Unit
With Cond. Manifolds
WIDTH B
HEIGHT
BETWEEN MTG HOLES
Length
Width
BETWEEN LIFT ANGLES
A
8 - 1-7/16 8
A’ 9 1-3/4
2 - 11-3/8
6 - 7-3/16 6 7-3/16 i REMOVAL (Either End)
c
30H
040 050,060 040
9 2-1/8
2
11-3/8 SPACE FOR COOLER TUBE
1 DIMENSION
7
1 Inlet
1 Outlet H
1 LOG. COOLER DRAIN
G 1 - 6
0-111
J 7 - 6
1 - 2-1
K
050,060
1 - 11-1/2
1 - 5
SPACE REQUiRED
FOR REMOVABLE
OF COOLER TUBES
\ (EITHER END)
O'-iij DIA
r TUBE
I
BUNDLE
(COOLER)
LEFT SIDE VIEW
Fig. 1 — Unit Dimensions {30H050,060 shown} f\
Table 1 — Weight Distribution (lb)
UNIT
30H
040
050
060
LOCATION OF MOUNTING HOLES;
APPROXIMATE
OPERATING WT
3930
4310
4440 1110
WATER-
INLET
END - + - A
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 the flanged washer can be moved sideways
with finger pressure.
APPROXIMATE LOAD
AT EACH MTG HOLE
{A, B, C, D)
983
l078“
FRONT
- DiA MTG HOLES (8)
FRONT VIEW
Fig. 2 — Compressor Mounting
Tabie 2 — Physical Data
COMPLETE UNIT
UNIT ЗОН
APPROX OPER WT (lb)
REFRIG CHG, R-22 (lb) Ckt 1
COMPRESSOR 06E Ckt 1
Cylinders/Compressor
Unloaders/Compressor
Oil Chg Per Compressor (pt) Ckt 1 14
Capacity Control Steps
TOWER CONO, 09RP Ckt 1 022 027 027
HEAT RECLAIM COND, 09RP Ckt 1 022
MAX DESIGN WORK. PRESS, (psig)
Cooler 1
Tower Condensers j
Water Side 150
Refrig Side
Water Side
Refrig Side
040 050 060
4310 4440
:3930
■ 62 62
Ckt 2
Ckt 2
Ckt 1
Ckt 2 : 4 4 6
Ckt 1
Ckt 2 ' 1 1 1
Ckt 2
Ckt 2 022
Ckt 2 022
52
52 : 52
J275 J275
B250
B250 B250
4
^ 1 1 1
' 14 14 19
: 4 4 4
; 022 027
J275
6 6
19 19
235
250
385
62
COOLER
COOLER, 10HA400
unît зон
SHELL, Net Volume (gal.)
TUBES
00 X Wall Thickness (in.)
Number 129
Length (in.) 74.5 5
Effective Outside Surface Area (sq ft) i
REFRIG CIRCUITS
CONNECTIONS (in.)
X (In and Out
Water ir-. •
(Drain
1^
040
13.1
iCopper, Internai Fins
126.6 )
2 2
3
3/4
1.125
1.625
050, 060
5/8 X 0.025
154
129
85.5
146.0
3
3/4
1.125
2.125
CONDENSERS
CONDENSER 09RP (See Note)
TUBES Copper, Interna! Fins
OD (in.)
Wall Thickness (in.)
Plain End .042
Finned Section
Length (in.)
Fins/in. 40
Number Tubes*
Surface Area (sq ft)
NO. WATER PASSES
CONNECTIONS (in.)
I Inlet (IPS)
1 Outlet (IPS)
Relief Valve Outlett (SAE) 5/8
Liquid Outlet (OOF)
Hot Gas (OOF) 1-3/8
*!n Tower condensers, 5 of the tubes are n subcooling section.
tNot on Heat Reclaim Condensers.
NOTE: Heat Reclaim Condensers same as Tower Condensers
except where noted. The bottom outlet of each Heat Reclaim
Condenser is same size as Hot Gas connection.
1 Inside
iOutside
t
022
027
3/4
.028
70-5/32
36 ! 44
32.9 ‘ 40.2
133.6 163.4
3
2-1/2
2-1/2
7/8
C .'\r flON; He Mire ip-lcreunnuciiti!: pipi,ni.;ind
electrical conduits are suspended free of contact
with ar.y adiacent walls and be sure taiit capil
laries are not rubbing against anything.
SERVICE ACCESS
Remove the combination top and back cover over
each compressor. Servicing can be performed from
either top or back. For rear access, allow approxi
mately 3 ft of clear space behind unit.
Step 4 — Make Piping Connections
CONDENSER DESCRIPTION
In the 4-condenser bundle, the lower 2 are Tower
and the upper 2 are Heat Reclaim. All are shell and
tube type with removable heads for easy tube servic
ing. Each Tower condenser has an internal sub
cooler designed to provide 12 F to 15 F total
liquid subcooling at average tower water condi
tions. The Heat Reclaim condensers do not require
subcooling, therefore, the subcooler baffling is
removed. For further condenser data, refer to
Table 2 — Physical Data.
TOWER CONDENSER PIPING
Provide means for draining system in winter and
..
for maintenance.
iMPOR r.\N 1 ; Ci):!üc!>er wa'.ur nvj'.t a;
the bottom for proper operation of the internal .
subcooler, which is in the bottom of the con
denser (Fig. 1).
Water supply lines should be sized according to
the required flow rate for operation at design con
ditions (not necessarily connection size). Use flexi
ble connections to reduce vibration transmission.
A cooling tower bypass valve is usually used to
regulate the temperature of the water entering the
condensers. This may be controlled by sensing either
outdoor air temperature or temperature of water
leaving the Heat Reclaim condensers. For further
information on Systems Controls, refer to the Engi
neering Guide for Reciprocating Chiller Heat
Reclaim Systems.
HEAT RECLAIM CONDENSER PIPING
Normally, the piping is for series water flow thru
the condensers. Piping to and from the condensers is
connected to the heating system of the building.
Piping for parallel water flow thru the condensers is
used only when the cooling load is constant at all
times. For further piping information, refer to the
Engineering Guide for Reciprocating Chiller Heat
Reclaim Systems.
Figure 1 shows connections for series piping thru
the Heat Reclaim condensers.
CAUTION; Retìghten all condenser head bolts
before filling system with water. Torque bolts
to 150-170 Ib-ft.
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 end of the condenser.
Refer to Pressure Relief Devices concerning con
nections for these components.
COOLER DESCRIPTION
The cooler is a direct-expansion type with remov
able heads and is partitioned for multi-pass refrig
erant flow. The 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 the front of the unit, the chilled
water enters (returns) at the left end of the cooler and
leaves at the right end. The sensing bulb for the
factory-set water temperature controller is located
in the return-water nozzle; the return-water tem
perature 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 the cells or on the cooler
shell. Thus, the insulation itself is a vapor barrier.
Because of the toughness of the insulation, a pro
tective 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 important 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 detials.
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 operating
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 mois
ture seal.
Step 5 — Make Electrical Connections
All field wiring must conform with local code
requirements. Control circuit is 115 volts on all
60-Hertz units. Accessory transformer package is
available to allow 115 volts to be taken directly from
unit terminal block (see Fig. 3). Installation instruc
tions are furnished with the accessory package. Con
trol power may also be supplied from a separate
source thru a 15-amp fused disconnect.
Inside the control box, provision is made to
connect the ground wire which must be installed
with each field power supply.
All units are factory supplied with across-the-line
start at all voltages.
Refer to Table 4 for electrical data on individual
compressors and complete units and compressor
usage.
LABEL DIAGRAMS
The applicable Label Diagrams for the 30H040,
050,060 Heat Reclaim units are the same as for the
standard 30HK040,050,060 units.
Table 3 — Unit Voltage and Model Number
UNIT
30H
200
.....
040 ! 420
050 i 420
060 420 520 I 620 120
*Last 3 digits of complete mode! number.
EQUIP GND
WHEN CONTROL CIRCUIT POWER IS FROM SEPARATE SOURCE
INCOMING WIRES ARE CONNECTED DIRECTLY TO
TERMINALS
CONNECTED TO NEUTRAL (GROUND) POTENTIAL.
CB — Circuit Breaker
EQUIP GIMD — Equipment Ground
TB — Terminal Board
*Appropriate transformer terminal depends on unit voltage,
instructions with accessory transformer package. H2 = 200 v;
H3 = 230 v; H4 = 460 v.
NOTE: For grounding 1 1 5-voit control circuit when transformer is
used, see instructions with accessory transformer package.
LL! AND
: 520 1
LL2
230 i
ON TB2.
VOLTS
Model*
520 ‘
460
620 120
620 > 120
±2 MUST BE
575
Fig. 3 — Wiring Schematic — Unitand Control
Power Supply
VOLTS
Nameplate
Supply Range"
UNIT 30 MKW
040 50.4
H 050
060 71.8 259 350
UNIT 30
; 040 250 (2) 25 2 86 345
П L/OU
060 275 (2) 35.9 115 506
61.1 230
COMPR
nctr KW
06 E
275 (L) 35.9 11 5 506
250 (R) 25.2 86 345
MCA
194
RLA LRA ; MTA
Table 4 — Electrical Data; 3-Phase, 60-Hertz
COMPLETE UNIT
200 230 460
180-229
Max
Fuse
Amps
250
300
207-264 414-528
Max Max
MCA
167 225
207 300
239
Fuse MCA
Amps Amps
104
300 120 150 97
84
INDIVIDUAL COMPRESSORS
200 V
; eo..; 74 300
' 80 "
Í" 80" 106 440
230 V
RLA LRA MTA RLA
102
106 440
"i 72
..........
74 300 ; 102 37 150 50 30
1
......
''
72 ' 1 53 220 73 43 176 : 58
575
518-660
Fuse MCA Fuse
110 68 90 B250 B250
150
37 150 50 30 120 42
53 220 73 43 176 58
84
460 V
LRA
Max
Amps
125
125
MTA RLA LRA MTA
06E COMPR
l' (l(^''' 2'{R) /^
I
J275 B250
J275 ; J275
...
575
USAGEt
Cl rcuit
........................
; 120 42
6-Pole Breakers: values shown are for each 3-poie
KW — Maximum Power Input (compressor)
LRA — Locked Rotor Amps
MCA — M inimum Circuit Amps. Complies with National Elec
MKW — Unit Power Input at operating conditions of 50 F Leaving
section.
trical Code (NEC), Section 430-24.
Chilled Water Temperature (44 F Saturated Suction
Temperature) and 145 F Saturated Discharge
Temperature.
ELECTRICAL BOX CONTROL SECTION
Inside this section are: relays, high- and lowpressure cut-outs, low water-temperature cut-out,
timer, terminal strips and a 4-step temperature
controller. On the outside (control panel) are: con
trol circuit ON-OFE switch, partial load switch,
compressor transfer switch, compressor run light,
safety trip lights and control circuit fuse. The control
panel is hinged to provide easy access to the controls
inside.
ELECTRICAL BOX, POWER SECTION
The main electrical power supply is brought in
START-UP AND SERVICE
MTA — Must Trip Amps (Factory-installed circuit breaker)
RLA — Rated Load Amps
*Untts are suitable for use on electrical systems where voltage
supplied to the unit terminals is not below or above the range
limits shown.
fPrefix: B, J = 1 electric unloader.
thru the top of the electrical box, on the left-hand
side (see Fig. 1). The hole is suitable for accommo
dating 3-in. conduit. Pressure-lug connections on
the terminal block are suitable for copper, copperclad aluminum or aluminum wire.
In this section are: main power terminal block,
compressor circuit breakers with calibrated mag
netic trip (for compressor motor overload and
locked rotor protection) and compressor motor con
tactors. The panel over this section is secured with
screws as a safety measure against casual entry for
purposes other than service.
WARNING: Shut off all power to the unit
before proceeding with any service work.
INITIAL CHECK
Do not start the liquid chiller even momentarily
until the following steps have been completed.
1. Check all auxiliary components such as chilled
liquid circulating pump, cooling tower if used,
air handling equipment, or other equipment to
which the chiller supplies liquid. Consult the
manufacturer’s instructions.
2. Check safety thermostat. See Safety
Thermostat.
3. Determine if there is a refrigerant charge in the
system. See Check Refrigerant Charge.
4. Backseat (open) compressor suction and dis
charge shutoff valves.
5. Open liquid line shutoff valves.
6. Fill chilled liquid circuit completely with clean
water or other noncorrosive fluid to be cooled.
Bleed all air out of high points of system.
7. Fill cooling tower for condenser cooling water.
8. Set temperature controller.
9. Check tightness of all electrical connections..
10. Check compressor oil (should be visible in
bull’s-eye). Refer to Check Oil Charge.
11. Be sure crankcase of each compressor is warm
(heaters should be on for 24 hours before
starting compressors).
12. Be sure compressors are floating freely. See
INSTALLATION, Step 3.
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