Carrier 30HK User Manual

Page 1
Number One 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

CONTENTS

Page

SAFETY CONSIDERATIONS

INSTALLATION..................................................................1-6
Step 1 — Inspect Shipment.................................................... 1

Step 2 — Rig and Place Unit

• RIGGING
• PLACEMENT
Step 3 — Check Compressor Mounting
and Connections.................................................................. 3
• SERVICE ACCESS
Step 4 — Make Piping Connections
• CONDENSER DESCRIPTION
• CONDENSER PIPING
• COOLER DESCRIPTION
• COOLER PIPING
Step 5 — Make Electrical Connections ..................................4
• ELECTRICAL BOX, CONTROL SECTION
• UNBALANCED 3-PHASE SUPPLY VOLTAGE
• ELECTRICAL BOX, POWER SECTION
START-UP AND SERVICE.................................................. 6
Initial Check............................................................................ 6
Check Refrigerant Charge..................................................... 6
• LIQUID CHARGING METHOD
Check Oil Charge
• TO ADD OIL
• TO REMOVE OIL
START-UP............................................................................7-10
Check Refrigerant Feed Components................................... 7
• 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
• CIRCUIT BREAKER
• MOTOR OVERTEMPERATURE
THERMOSTAT
• CRANKCASE HEATER
• TIME GUARD® CONTROL
• FOUR-FUNCTION TIMER
• OIL PRESSURE SAFETY SWITCH (OPS)
Check Unit Safety Devices
• SAFETY THERMOSTAT
• HIGH-PRESSURE SWITCH
• LOW-PRESSURE SWITCH
Check Capacity Control System............... 10
DESCRIPTION 3-STEP TEMPERATURE CONTROLLER DESIGN SET POINT ADJUSTMENT CYLINDER UNLOADING SYSTEM
...................................................................
.............................................
.................................................
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_
........................
I
1
3
7
Page
UNIT OPERATION...........................................................10-11
Control Power
Control Sequence.................................................................. 11
Unit Stoppage and Restart SERVICING COOLER
Tube Plugging ....................................................................... 12
Retubing ................................................................................ 12
Tightening Cooler Head Bolts
• GASKET PREPARATION
• BOLT TORQUES
• BOLT TIGHTENING SEQUENCE
TROUBLESHOOTING GUIDE
.......................................................................
..................................................
.....................................................
.............................................
.......................................
10
11
11-13
12
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

Inspect unit for damage or missing parts. If dam age is detected, or if shipment is incomplete, file a claim immediately with the shipping company.
Step 2 — Rig and Place Unit
RIGGING
On each end of cooler, a steel loop is provided for
the preferred method of lifting unit. Use spreader
bars to keep cables away from compressor enclo*­sure and control box. If unit is to be moved by fork
truck, use the following methods:
1. From front or rear, lift under the cooler rails. Unit can be either on or off skid.
2. When moving from ends, leave unit on skid. Lift
from under skid.
© Carrier Corporation 1983
Form 30HK.HL-10SI
Page 2
Table 1 — Weight Distribution (ib)
UM!T
30( )--
015 020 025 030
Location of mounting holes:
APPROX
OPERWT
HK HL A I B C
1637
1016
1787
1136
1980
1310 3031 205 1334
1985
HK
142j 201 755 182| 240
3031 205
HL
D A B
539 790 575 296 296 272 592 880 592 885 377
266 266
367
C
242
285 373
285 290 290
242 272
377
SClF-IlOCKINö
0OLT
D
J
_
SNOb&ER Ft.ANo>--0 WASHER
NEOPHENE
SNUSSKR
'COMPRESSOR FOOT
i
WATER
INLET
END
1
PLAN VIEW
FRONT
i
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.
1090
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.
Page 3
Table 2 — Physical Data
UNIT AND COMPRESSOR
UNIT 30HK.HL
APPROXIMATE
OPERATING WT (lb)
REFRIGERANT(R-22) CHARGE (lb)
COMPRESSOR 06*
No. Cylinders
Oil Charge (pt)t No. of Unioaders Cap. Control Steps
CONDENSER. 09RP (HK) 022 MAX DESIGN WORKING
PRESSURE (psig)
_ , ( Water Side
Cooler i „ , - . „ . f Water Side
Condenser Side
COOLER10HA400 UNIT 30HK.HL 015,020 SHELL, Net Vol. (Gal.)t 6.8 9.9 TUBES (Copper) Internal Fins,
Number 81 Length (in.) Eff. Outside Surface (sq ft)
REFRIGERANT CIRCUITS
CONNECTIONS (in.)
Water 1 ^ ( Drain (MPT)
Refrig
WEIGHTS (lb)
Cooler (Net) Water
Refrigerant 8 12
Total
09RP 022 TUBES Copper, Integral Fins
OD (in.) 3/4 Wall Thickness (in.)
Length (in.) Fins/in. Number"
Surface Area (sq ft) i .
NO. WATER PASSES
CONNECTIONS (in.)
^ f Out (IPS)
Relief Valve Outlet (SAE)
Water Regulating Valve /4
Liquid Outlet (ODF) /в Hot Gas (ODF)
'Prefix; 2 = 1 electric unloader; C, 7 = 2 electric unloaders. tSee Check Oil Charge for Carrier-approved oil. + lncludes nozzles.
"Includes 5 subcooler tubes.
< Refrig Side
< Suction
Plain End Finned Section
... , ( In (IPS)
015
1637
HK
1016
HL
HK
HL
HK DC537
HL DC537 E2250 E7265 E7275
COOLER
CONDENSER
! Outside
020 025 030
1787
1136 1310
34
Holding Charge
E2150 E7265 E7175
6
8.5 14 2 1 2 2 3
774 784
5/8-in. OD X 0.020 wall
62.5 85.5
66.3 91.7 1 1
2 2
3/4
I 1.125 1.125
1.625 ODM
354
75
437 558
1980 1985
38 40
4
3 3
133.6
6
19 19
150 235
250 385
2.125 ODM
0.043
0.028
10^7
40
36 44
32.9
2/2 Sched 40 2/2 Sched 40
Ув
13/в
1334
027
025,030
81
3/4
446 100
027
40 2
163.4
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
45
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
6
and reassemble with flanged washers and neoprene snubbers as shown in Fig. 2. Special flanged washers
3
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 capil­k;:;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 12- 15 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 .sub-
cooler 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
Page 4
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
MINIMUM FLOW
UNIT
30HK,HL015 '~25~
020 025 38 030
'Applicable to 30HK units only. tMlnimum system water volumes:
Gallons = V X ARi Capacity in Tons
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.
(GPM)
34
32 38
34 41 41
PRESSURE DROP
T
(ftwg)
Condenser
3,2
5.1 5,5
5.5
I,
APPLICATION
Normal Air Conditioning Process Type Cooling' Low Ambient Operation
MINIMUM
VOLUME!
2,1 47 2,1 60 2,1
2.1 88
(Gal)Cooler ContSenser*ICooler
81
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
Page 5
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, high- and low­pressure 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
208/230
460 575
'Compiete number has 10 digits.
Example: 30HK020530.
UNIT 30HK.HL
015,020,025,030
5-­6-­1--
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
* *
Maximum deviation is 4 volts. Determine % voltage imbalance:
% Voltage Imbalance = 100 x
A
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
Example: Supply voltage is 240-3-60.
* ^ AB = 243 volts
BC = 236 volts AC = 238 volts
Average Voltage
243 + 236 + 238
717
= 239 volts
3
Determine maximum deviation from average
voltage:
(AB) 243 - 239 = 4 volts (BC) 239 (AC) 239
236 238
3 volts 1 volt
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
Page 6
VOLTS
UNIT 30
HK
HL
Table 5 — Electrical Data; 3-Phase, 60-Hertz
COMPLETE UNIT
Nameplate 208/230* Supply Ränget 187-253
MKW
015 020 21.8 025 29.0 103 175 030
015 19.1 020 025 31.8 115 200 030
015 0537** 020 2150 21.8 63 283 88 025
030
015 0537** 19.1
020 2250
025
030
7265 7175
7265 7275
16.4
31.0 115 200
25.2 90 150
35.9 140 250
COMPRESSOR
06t
MCA
69 79
80 125
Kw
16.4
29.0
31.0
25.2 72
31.8 92 446
35.9
RLA LRA
55 266 77
82 446 114 92 446
64
112 506
Max
Fuse
Amps
110 34 125 36
INDIVIDUAL COMPRESSORS
208/230V*
MTA
128 40 223 56
266 89 345 100
128 40 223 56 36 164 50 156
460
414-508
MCA
50 50
38 60 30 42 50 62 110
Max
Fuse
Amps
60
60 34
90 45
90 49
70 38
90 45
460 V 575 V
RLA LRA MTA
27 120 37 29 40 223 56
30 120 33 173
49 253 68 42 176 58
142
575
518 632
MCA
29 50
53
Max
Fuse
Amps
60 80 80
50 60 80 90
RLA LRA
40 27 98
41
45 30 120
COMPRESSOR
06E USAGES
0537** 2150 7265 7175
C537** 2250 7265 7275
MTA
23
36 39
24
96 31
164 50 164
96
37
54 33
42
KW — Maxi mum Power Input (compressor)
LRA — Locked Rotor Am.ps MCA -- Mm imum Circuit Amps (for wire sizing). Complies with
National Electrical Code (NEC) Section 430-24.
MKW — Unit power input at operating conditions of 50 F Leaving
Chilled Water Temperature (44 F Saturated Suction Temperature) and 120F (FIK) or 145F (HL) Saturated Discharge Temperature.
MTA — Must Trip Amps (factory-installed circuit breaker) RLA — Rated Load Amps
START-UP AND SERVICE
WAk\lN(j; Shut oil all powur to unit hdorc proceeding with any ^cr\!ce woik.
Initial Check
Do not attempt to 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 chiller supplies liquid. Consult manu facturer’s instructions.
2. Checksafety thermostat. See Safety Thermostat.
3. Determine if there is a refrigerant charge in the system. Refer to Check Refrigerant Charge.
4. Backseat (open) compressor suction and dis charge shutoff valves.
5. Open liquid line shutoff valves.
6. Open valves to capillaries of water-regulating valve (when used).
’Compressors in ail models have extended voltage motor.
tUnits are suitable for use on electrical systems where voltage
supplied to the unit terminals is not below or above the range limits shown.
fPrefix: 2 = 1 electric unloader; C, 7 = 2 electric unloaders.
”30FIK,HL015 models use 06D compressor instead
of 06E compressors.
7. Fill chilled liquid circuit with clean water or other noncorrosive fluid to be cooled. Bleed all air out of high points of system.
8. Open supply valve (or fill cooling tower if used) for condenser cooling water.
9. Set temperature controller. Check tightness of all electrical connections.
10.
Be sure compressor is floating freely on the
11.
isolation springs. See installation. Step 3.
Check compressor oil (should be visible in
12.
bull’s-eye). Refer to Check Oil Charge. Be sure crankcase of each compressor is warm
13. (heaters should be on for 24 hours before start ing compressors).
Check Refrigerant Charge
IMPORI AN'l; Do not open liquid \al\e or compressor discharge \al\e until there is a charge in remainder ol system. .A positive pres sure will indicate a eharue in svstem.
1090
Page 7
The ЗОН К units are shipped with a full refrigerant charge (see Table 2). However, if it is necessary to add refrigerant, operate the unit for some time at full capacity and then add charge until the sight glass
is clear of bubbles. For maximum liquid subcooling, liquid level should be up to condenser liquid level test cock located on shell, near condenser end. This
usually requires additional refrigerant charge
beyond amount to clear sight glass.
30HL units (condenserless) are shipped with a holding charge only. After chiller assembly is com pleted in the field, system must be fully charged. While unit is running at full capacity, add refrigerant until sight glass is clear.
If there is no refrigerant vapor pressure in the system, the entire system must be leak tested. After repair of leaks, evacuate system before recharging.
See Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants, for leak testing, evacuation and charging procedures.
6. To ensure maximum subcooler performance on 30HK units, check liquid level in condenser by means of test cock located on condenser shell near right end tube sheet. Liquid discharge from
test cock indicates fully charged subcooler.
Check on Charge — All units are factory charged
with oil. If oil is visible in sight glass, check unit for operating readiness as described in the section, Initial Check; then start compressor. Observe level and add oil, if required, to bring level in crankcase
1/8 to 3/8 of bull’s-eye during steady operation. To add or remove oil, see Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants.
Use only Carrier-approved compressor oil:
Witco Chemical Co lexaco, Inc
........................................
................................
Capella WF-32
Suniso 3GS
Do not reuse oil that has been drained and do
not use oil that has been exposed to atmosphere.
CAU TION; When adjusting relrigcrant charge, circulate water thru the condenser and cooler at all times to prevent free/ing. Freezing damage is considered abuse and may affect the Carrier
The liquid charging method is recommended for complete charging or when additional charge is required.
LIQUID CHARGING METHOD
C.'M 1 ION; Be careful nut to overcharge sys tem. (.)\ercharging results in higher dischaige
pres.sure wiih higher cooling water consump
tion. possible compressor damage, and higher
power cemsumption.
Charge thru 1/4-in. flare connection on liquid
line shutoff valve. Never charge liquid into low-
pressure side of system.
1. Frontseat (close) liquid line shutoff valve.
2. Connect a refrigerant cylinder loosely to charg ing valve connection. Purge charging line and tighten connections.
3. Open liquid line shutoff valve.
4. If system has been dehydrated and is under vacuum, break vacuum with refrigerant (gas
charge). Build up system pressure to 58psi for
R-22 (32 F). Invert refrigerant cylinder so that
liquid refrigerant will be charged.
5. a. For complete charge, see Charging in Carrier Standard Service Techniques Manual, Chap ter 1, Refrigerants. Follow Charging By Weight procedure. (When charge is nearly full, complete process by observing sight glass for clear liquid flow.)
b. For complete charge where refrigerant cyl
inder cannot be weighed, or for adding refrig
erant, follow the procedure Charging By Sight Glass in manual.
TO ADD OIL
Close suction shutoff valve and pump down crankcase to 2 psig (low-pressure cutout must be bypassed with a jumper). Wait a few minutes and
repeat as needed until pressure remains at 2 psig. Close discharge shutoff valve. Remove oil fill plug
above bull’s-eye, add oil thru plug hole and replace
plug. Reopen suction and discharge valves. Run
compressor for about 20 minutes and check oil level.
TO REMOVE OIL
Pump down compressor to 2 psig. Close suction and discharge valves. Loosen the 1/4-in. pipe plug in compressor base and allow oil to seep out past plug threads. The crankcase will be under slight
pressure. Be careful not to remove plug; the entire
oil charge may he lost. Small amounts of oil can be
removed thru oil pump discharge connection while compressor is running.
START-UP
Start-up should be performed only under super vision of experienced refrigeration mechanic. Be
sure crankcase heaters have been energized for 24 hours.
!. Open all system valves that may have been
closed during or after charging.
2. Check air handling equipment, chilled water and
condenser water pumps, and any other equip ment connected to chiller.
3. Start unit by firmly pushing ON button.
4. Check all controls for proper operation. Refer to
Check Unit Safety Devices.
5. Adjust water-regulating valve (if used) to most
economical head pressure (based on relative cost of water and electricity). Head pressure is nor mally 200 to 230 psi for R-22.
1090
Page 8
6. Check leaving chilled water temperature to see that it remains well above freezing.
7. Recheck compressor oil level. See Check Oil Charge.
Check Refrigerant Feed Components
THERMOSTATIC EXPANSION VALVE (TXV)
This valve controls refrigerant flow. Valve is activated by a temperature sensing bulb clamped to suction line. The valve is factory set to maintain a superheat of 8 F to 10 F. Do not change setting
unless absolutely necessary.
FILTER DRIER
The 30HK,HL015 thru 030 units (single com pressor) have sealed-type driers. When a drier must be changed, the entire drier must be replaced. The function of the filter drier is to maintain a clean, dry system. The moisture indicator (below) can indi cate any need to change filter drier.
MOISTURE-LIQUID INDICATOR
The indicator is located immediately ahead of the TXV to provide a constant indication of refrig erant moisture content. It also provides a sight glass for refrigerant liquid. Clear flow of liquid refrigerant indicates sufficient charge in system.
Bubbles indicate under-charged system or presence of noncondensables. Moisture in the system, measured in parts per million (ppm), will change
color of indicator.
Unit must be in operation at least 12 hours
before moisture indicator will give an accurate
reading. With unit running, indicating element must be in contact with liquid refrigerant to give true moisture indication.
At first sign of moisture in the system, change the filter drier. The tables below indicate when the change is required.
30HK,HL01 5,020
COLOR
Green Chartreuse Yellow
COLOR CONDITION
Blue Light violet Pink
Dry; moisture is below 45 ppm Caution: 45 ppm
Wet; above 130 ppm
30HK,HL025,030
Safe, dry First sign of moisture Dangerous moisture level
CONDITION
PRESSURE RELIEF DEVICES
On HK units, a high-side pressure-relief valve is factory installed on the condenser. The valve is set to open at a maximum pressure of 385 psig (maxi mum design working pressure of the condenser).
For ЗОНЕ units, pressure relief device, designed to relieve at 450 psig, is field supplied and installed in the discharge line after the muffler according to ANSI.B9.1 code requirements.
Additional pressure relief valves, properly se lected, must be field installed to protect field-
installed high-side equipment as may be required by applicable codes.
A fusible plug is factory installed on the suction
line for low-side protection. This plug will relieve on temperature rise to 170 F.
Most local codes require that a relief valve be
vented directly to outdoors. The vent line must not
he smaller than the relief valve outlet (518-in. SAE).
CHECK VALVE
A discharge-line check valve is supplied with each
condenseriess (HL) unit as standard equipment.
This valve should be located downstream from, but
close to, the hot gas muffler. The valve can be
mounted in either horizontal or vertical position.
The valve prevents migration of refrigerant from condenser to compressor and cooler during off­cycle of compressor.
Check Compressor Protection Devices
CIRCUIT BREAKER
The compressor is protected against an over
current condition by a manual-reset calibrated-trip
circuit breaker.
IMPOR LAN I l'>o not bypass connections or increase brcakci si/c ti> correct trouble. Deter
mine the cause and correct before resetting
breaker.
MOTOR OVERTEMPERATURE
THERMOSTAT
On size 015 units, a sensor embedded in motor
windings protects against overtemperature.
On all other sizes, a sensor in the discharge side
of the compressor reacts to excessively high dis
charge gas temperature and shuts off the com
pressor. A high discharge gas temperature indicates an overtemperature condition in motor windings.
LIQUID-LINE SERVICE VALVE
This valve provides a refrigerant charging port and, in combination with the compressor discharge service valve, allows the refrigerant to be pumped into the high side.
LIQUID-LINE SOLENOID VALVE (HL only)
The solenoid valve closes when its circuit is in operative, either from capacity control or from any safety trip.
1090
CRANKCASE HEATER
The heater prevents absorption of liquid refrig
erant by oil when compressor is not operating.
On size 015 units, the heater is secured by a clip;
on all other sizes, it is held in place by a bracket.
t. AU l ION; The hcatci must be light to prevent il from backing out ot the crankcase. I he heater will burn out if exposed to aii for an extended
Page 9
The electric heater is wired into the 115-volt control circuit thru normally closed contacts of control relay in such a way that it is energized only when compressor is not operating.
All heaters are 125 watts.
C .\L 1 ION: Never open an\ >witeh or discon nect that will de-encrgi/e crankcase healer un
less unit IS being serviced or will be shut down
tor a prolonged period. .Alter such service or
prrdonged shutdown, energize crankcase heater lor 24 hours before starting compressor.
TIME GUARD® CONTROL
This control protects compressor against short
cycling (Switch A on four-function timer). FOUR-FUNCTION TIMER
Refer to Fig. 4 — Timer Cycle. The functions are
as follows: Switch A (Contacts A-Al, A-A2) runs timer motor.
This provides a minimum of 5-1/2 minutes after compressor stops before it can restart, to prevent
short cycling (Time Guard control). Switch B (Contacts B-Bl, B-B2) provides 1-second
time delay for part-winding start and also provides a lock-out function.
Switch D (Contacts D-D 1) provides a 2-1 / 2 minute bypass of the low-pressure switch at start-up to prevent nuisance trips under cold-start conditions.
Switch E (Contacts E-El) provides a 35-second by pass of the oil safety switch (OPS) at compressor start-up (when OPS is used), if sufficient oil pressure does not build up in this time, compressor stops.
SWITCH POSITION
Close on rise 9 - 12 psi diff Open on fall
PRESSURE SETTING
4 - 6 psi diff
The oil pressure safety switch is wired in parallel with Switch E of the 4-function timer. This arrange ment allows approximately 35 seconds for oil pres sure to reach normal operating level after com pressor starts. If the oil safety switch does not close within 35 seconds, the compressor shuts down.
To restart the compressor, the control circuit ON-OFF switch must be pressed to OFF and then to ON. The timer will start and after approximately
5-1/2 minutes compressor will start. If normal oil pressure is established within the next 35 seconds, the compressor continues to run. If, however, the oil pressure does not reach a safe level, the compressor
stops at the end of the 35 seconds and locks out.
(’.ли I ION; Di' not attempt to restart the com pressor tor a second time until the problem has been determined and corrected.
REMOVE ORANGE Wl RE
0 OR 8 MiN.
1 BBi
____Щ_______
7 SEC±4 —И h
S DDI
NOTE: BLACK DENOTES CLOSED CONTACTS
POSITION DURING UNIT OPERATION-
1 1
I . ............................................. 1
COMPRESSOR STARTS
H 1—-1 SEC±05
H^SSECiZ
■«
............^----------
40SEC15
1--------------------------1
Fig. 4 — Timer Cycle
OIL PRESSURE SAFETY SWITCH (OPS)
This control is standard on ЗОНЕ (condenserless) units (020-030) and is available as an accessory for 30HK units (020-030). Refer to Fig. 5 for field wiring connections. It is not available for the 015 unit.
The pressure switch is factory set at the following
pressures and should not be adjusted in the field.
OPS — Oil Pressure Safety Switch TB — Terminal Board
Fig. 5 — Oil Pressure Safety Switch to
Control Box Wiring Connections
(020-030 Only)
LOW LIMIT STOP TAB
5
Fig. 6 — Safety Thermostat
(No. HH22CC050 Shown)
1090
Page 10
Check Unit Safety Devices
SAFETY THERMOSTAT (Fig. 6)
The low water temperature cutout (LWTC) pro tects the unit against freeze-up due to operating mal function. The sensing bulb is inserted into a well
located in the leaving water nozzle. As installed, the standard control is factory set to open at 36 ± 2 F, breaking the control circuit and locking out unit. The contacts remake at 5 ± 2 F above cutout point, but the control circuit switch must be pressed to OFF and then to ON for unit restart. This action re energizes the control circuit and starts the timer under Time Guard® control.
The thermostat cuts out in a range down to -30 F,
but to obtain this range, the low-limit stop tab on the
underside of dial must be either cut or bent. Make
this adjustment only if necessary (when cooling
glycols or brines).
HIGH-PRESSURE SWITCH (HPS)
The HPS settings are nonadjuslable. Table 6
shows factory settings for this switch.
If HPS cuts out while unit is in normal operation (2-1/2 minutes or more after compressor start-up), compressor will stop and lock out. To restart com pressor, the ON-OFF control circuit switch must be manually pressed to OFF and then to ON. The timer will start, and after approximately 5-1/2 min utes, the compressor will start under Time Guard control. If the pressure has not dropped to the HPS cut-in point (see Table 6), the compressor will stop again immediately and again lock out. Do not
attempt to restart until trouble is found and
corrected. Unless control circuit swdtch is pressed to
OFF at this time, timer will continue to run.
Table 6 — Pressure Switch Specifications
UNIT 30 HK HL
PRESSURE RANGE (psig)
DIFFERENTIAL SETTING (psi)
FACTORY SETTING (psig)
High
Low High Low
High Low
Fixed
10 to 90
96 ± 17 (Fixed) | 1 03 ± 19 (Fixed)
1 3 to 50 Adjustable
Cutout
260 ± 10
Cut-in
29 ± 4 44 ± 4
Adjustable
Cutout
335+10
29 ± 4
Fixed
Cut-in
44 ± 4
LOW-PRESSURE SWEICH (EPS)
The EPS is bypas.sed for 2-1/2 minule.s after compressor start on all start-ups. The EPS has an adjustable range from 10 to 90 psig and a differential of 13 to 50 psi. See Fig. 7. Table 6 shows factory settings for this switch.
If EPS cuts out while unit is in normal operation (any time after 2-1/2 minutes from compressor start-up) timer starts and runs for approximately 5-1/2 minutes. The compressor then starts, by passing the EPS for 2-1/2 minutes under Time Guard control. If the EPS cut-in pressure is reached
within 2-1/2 minutes, compressor continues to run; if, on the other hand, the required pressure has not built up, compressor stops at end of 2-1 /2 minutes and locks out.
Do not attempt to restart unit until trouble has
been found and corrected. The LPS contacts must
be closed before compressor can be restarted after lockout.
, RANGE ADJ SCREW
/ TURN CLOCKWISE TO RAISE
J BOTH CUT-IN AND CUTOUT
7
/
(RIGHT SIDE OF CONTROL BOX, VIEWED FROM TOP)
^^G7PSI PER TURN)
aiWFFERENTIAL ADJ SCREW
TURN CLOCKWISE TO DECREASE (8 PSI PER TURN). ONLY CUTOUT CHANGES
Fig. 7 — Low-Pressure Switch (LPS)
Adjustment
Check Capacity Control System
DESCRIPTION
Capacity control is a system which loads and unloads compressor cylinders and starts and stops compressor to maintain load requirements. System includes a 3-step temperature controller and cyl inder unloaders (see Table 2). Table 7 shows ca pacity control steps.
Table 7 — Capacity Control Steps
UNIT
30HK,
30HL
015
020
025, 030
'Uses hot gas bypass.
CONTROL
STEPS
1 2 67 3 100
1 35 2 50 3 100 4
1 2 3
%
CAP.
33
33 67
100
OPER
CYL
2 4 6
2* 2
2 4 6
3-STEP TEMPERATURE CONTROLLER
This controller consists of 3 load switches actu ated by pressures developed in a temperature sensing bulb located in return water line of chilled water system. The controller is factory set to control from return water temperature thru a cooling range of 10 F. Sequence switches are factory calibrated and sealed and should not require any field changes.
IMPOR 1 .\N 1. It a dilferent reiurn-waler cool ing range or leaving-water control is specified, or if brine below 10 L' is to be used, controller must be changed. Consult local Carrier repre sentative for proper control device.
10
Page 11
The return water temperature at which the last step of capacity unloads is indicated by the leaving water temperature design set point on the adjustable dial (Fig. 8).
Example: Design set point is at 44 F. On a reduction in load,
the capacity of the unit will be reduced to zero when
return water temperature drops to 44 F, and unit
will cycle off.
W.ARNlNCj; .Anj, alteration ol factory settings, except design set point, without t. arrier authori zation, mav \oid the (.'arricr Warianix
DESIGN SET POINT ADJUSTMENT
When unit IS ready for operation, insert small screwdriver in adjusting slot (Fig. 8) and rotate to turn dial (dial may also be turned by hand). Rotate until design set point for installation appears direct ly under pointer. Insert a thermometer in the return chilled water connection and allow unit to run thru a cycle. .At instant the last step of capacity unloads (switch no. 1 opens), read temperature. If it is not same as dial reading, variation can be compensated by shifting control point slightly.
UNIT OPERATION
Control Power (115 volts) can be from a separate
source, thru a 15-amp fused disconnect or can be taken from the main unit power source, thru a field-supplied transformer shown on wiring label.
Control Sequence — At initial start-up, assume
all safety devices are satisfied and the chilled water temperature controller switches are all in position for maximum cooling capacity.
Close compressor circuit breaker and press con trol circuit ON-OFF switch to ON. The timer starts and, depending on position of timer the compressor starts in approximately 12 seconds to 8 minutes. At compressor start-up, D-Dl contacts (see Four-
Function Timer and Fig. 4) are closed, bypassing low-pressure switch for 2-1/2minutes. In addition, the E-El contacts are closed, bypassing the oil safety switch (if used) for approximately 35 seconds. Both these bypass functions protect against compressor continuing to run under conditions that could cause damage to the compressor. Barring any malfunc tion, when timer contacts A-A2 dose, approxi
mately 2-1/2 minutes after start-up, unit is in normal
operation. The timer stops when A-A2 contacts close and holds in this position while the tempera ture controller regulates the cooling capacity by
loading and unloading compressor cylinders, and by
stopping and starting the compressor, under Time
Guard® control, in response to load requirements.
t \i I loN. Di' :.o: ^■..p. 1 c.iu ^au'c .1,"^ .1- pi'.m ami dama.---
Fig. 8 — Set Point Adjustment
CYLINDER UNLOADING SYSTEM
Each unloading device is the cylinder head suction cutoff type, which unloads 2 cylinders (one bank) when the control solenoid is energized. Load
switches in the temperature controller energize and
de-energize the cylinder unloaders.
Unit Stoppage and Restart — After each descrip
tion of a possible cause for unit stoppage is a short description of the normal method of restart.
1. CONTROL POWER INTERRUPTION (IN CLUDES BLOWN FUSE).
After power is restored, or fuse replaced, restart is automatic thru normal timer cycle.
2. CONTROL CIRCUIT ON-OFF SWITCH IS OPENED.
The timer motor starts automatically, runs for approximately 5-1/2 minutes, and then stops.
To restart, press ON-OFF switch to ON. Com pressor will start in approximately 12 seconds.
3. CONTACTS OF ANY AUXILIARY INTER LOCK ARE OPEN. After trouble has been corrected, restart is automatic thru the normal timer cycle.
4. LOW WATER TEMPERATURE CUTOUT CONTACTS ARE OPEN. Allow time for water temperature to rise 5 F; then press the control circuit ON-OFF switch to
OFF, and back to ON. This restarts timer. Unit restarts automatically on the normal timer cycle.
5. CONTROL CIRCUIT FUSE BLOWS. Refer to Stoppage Cause No. ! above for normal
restart description.
Page 12
6. ANY SAFETY DEVICE TRIPS. If device is low-pressure switch, reset is automatic
and unit restart is thru normal timer cycle. In the case of low, or lost, refrigerant charge, charge must be increased to normal level before restart.
If device is one of the following, high-pressure switch, overtemperature switch or oil pressure safety switch, press control circuit ON-OFF switch to OFF, then to ON. Restart occurs thru normal timer cycle.
If chilled water flow has stopped, locate and correct cause, restart water flow. Unit will restart automatically thru normal timer cycle.
IMi’Oxl .ANl; И sU;ppage b\ ;; •.aic;;. deuce
rcpca.s -..nee. do attempt am/ti'cr restart
unt.. IS ds
titted and cotijcted
Refer also to Troubleshooting section for addi
tional information on unit malfunctions.
SERVICING COOLER
When cooler heads and partition plates are
removed, tube sheets are exposed showing tube
ends shown in Fig. 9.
C.-M I'lON; Four lubes m the bun-.iie .ue 'Ci,tired
inside cooler at baffles and cannot he removed. These are identified on the tube sheets by a drill mark horizontally adjacent to each of the 4
lubes. !; iruku^te o; ^ oi ou\ - V4 m!>< s.
Jc.M r:;>eJ i:ihler Inhe
Tube Plugging — Leaky tube(s) can be plugged
until retubing can be done. The number of plugged tubes determines how soon cooler must be retubed.
If several tubes require plugging, check with your local Carrier representative to find out how number and location will affect unit capacity.
Figure 10 shows an Elliott tube plug and a cross­sectional view of a plug in place. Table 8 lists the components for plugging.
C.Ai'ilON; Use e.vtreme caie when mslalling plugs to prevent damaging the lube sheet sec tions between holes.
Clean parts with Loequie "N" and apply a few drops of Loctite #75 to obtain a tight seal without
using too much force to set pin.
Usually plugs can be removed by heating pro
jecting end of pin to approximately 1000 F and
chilling quickly with water. Apply heating flame to side of the pin to prevent overheating tube sheet.
Table 8 — Plugs and Tubes
UNIT 30HK.HL j
COMPONENTS FOR i
PLUGGING i
For Tubes i Brass Pin Brass Ring
For Holes without Tubes | Brass Pin ' Brass Ring i 853002 631 '
Loctite i
Loequie i
‘Order directly from Elliott Tube Co.
Dayton, Ohio.
tCan be obtained locally.
015.020 025,030
PART NUMBER
853103-500‘
853002-570*
853103-1*
No. 75t
-N"t
c
‘Four fixed tubes (cannot be removed) identified by adjacent drill
points.
Fig. 9 — Typical Tube Sheet
1090
Retubing (See Table 8) — When retubing is to be done, obtain service of qualified personnel exper ienced in boiler maintenance and repair. Most standard procedures can be followed when retubing the lOHA coolers. A (i% crush is recommended when rolling replacement tubes into the tube sheet. A 6% crush can be achieved by setting the torque on the gun at 48 to 50 in. lbs.
The following Elliott Co. tube rolling tools are
required:
В3400 Expander Assembly B3401 Cage В 3405 Mandrel B3408 Rolls
Place one drop of Loctite No. 67541, or
equivalent, on top of tube prior to rolling.
12
Page 13
Tube information:
(mm) (16.03) (15.87)
(14.76 to
14.94)
Tube sheet hole diameter Tube OD
...............................
......
Tube ID after rolling.............
(includes expansion due
to clearance)
in.
.... 0.631
.... 0.625
.... 0.581
to
0.588
NOTE: Tubes next to gasket webs must be flush
with tube sheet (both ends).
Tightening Cooler Head Bolts
GASKET PREPARATION
When reassembling, use new gaskets. Com pressed asbestos neoprene gaskets. Carrier Material Specification ZAOO-24, are to be momentarily dipped in compressor break-in oil prior to assembly. Do nut soak gaskets in oil as gasket deterioration results. Use dipped gaskets within 30 minutes to prevent deterioration.
BOLT TIGHTENING SEQUENCE (Fig. 11)
The following is a recommended bolt tightening
sequence:
Step 1 — Tighten moderately (without torquing) all the flange bolts in sequence shown.
Step 2 — Repeat Step 1, tightening bolts to speci fied torque.
BOLT TORQUES
Apply the following torques during bolt tighten
ing sequence described below:
1/2-in. diameter flange bolts
..............
70 - 90 lb ft
Fig. 10 — Elliott Tube Plug
Fig. 11 — Tightening Sequence,
Cooler Head Bolts
Tuet SHEET
13
1090
Page 14
TROUBLESHOOTING GUIDE
SYMPTOMS
Compressor does not run !
Compressor cycles on low-
pressure control
Compressor loses oil
Frosted suction line
Compressor cycles on high­pressure control
Unit operates long or continuously
PROBABLE CAUSE
1
Power line open Control circuit breaker tripped
!
s
j Safety tripped
1
Tripped power breaker
REMEDY
Reset circuit breaker. Check control circuit for ground or
short.
Reset breaker. Reset. Check the controls. Find cause of
trip and reset breaker.
Condenser circulating pump not Power off — restart.
1
j
running
Pump binding — free pump. Incorrect wiring — rewire. Pump motor burned out — replace.
Loose terminal connection
Check connections. Improperly wired controls Check wiring and rewire. Low line voltage
1
Check line voltage — determine
location of voltage drop and
remedy deficiency. Compressor motor defective
Check motor winding for open or
short. Replace compressor, if
j
;
Seized compressor Replace compressor.
i
Low-pressure control erratic in Raise differential setting.
i
action
1
necessary.
Check capillary for pinches.
Replace control. Compressor suction valve leaking Replace valve plate. Compressor suction shutoff valve
Open valve.
partially closed Low refrigerant charge
Plugged compressor suction
Add refrigerant.
Clean strainer or replace. strainer
Leak in system Mechanical damage (blown piston
or broken discharge valve)
Oil trapped in line Crankcase heaters not energized
during shutdown
Repair leak.
Repair damage or replace
compressor.
Check piping for oil traps.
Check wiring and crankcase
heater relay. Replace heater if
necessary.
Expansion valve admitting excess refrigerant
High-pressure control erratic in
action
Compressor discharge valve
Adjust expansion valve. Replace
valve if defective.
Check capillary tube for pinches.
Set control as required.
Open valve, or replace if defective.
partially closed Air in system Purge.
Condenser scaled Condenser water pump or fans not
operating Low refrigerant charge Control contacts fused Air in system
Partially plugged or plugged
Clean condenser.
Start pump — repair or replace if
defective.
Add refrigerant.
Replace control. Purge. Clean or replace.
expansion valve or strainer
Defective insulation Service load too high Inefficient compressor
Replace or repair. Keep doors and windows closed. Check valves, replace if necessary.
!4
Page 15
TROUBLESHOOTING GUIDE (cont)
SYMPTOM 1 PROBABLE CAUSE System noises | Piping vibration
Freeze-up
Hot liquid line Frosted liquid line
Compressor will not unload
Compressor will not load
REMEDY
Support piping as required. Check for loose pipe connectors.
Expansion valve hissing
Compressor noisy
improper charging Make sure that a full quantity of
Improperly set safety thermostat
Operating with safety thermostat bypassed
Improper circulation of chilled
water
System not drained for winter shutdown
Shortage of refrigerant due to leak Repair leak and recharge. Restricted filter drier
Burned-out coil Defective capacity control valve Replace valve. Miswired solenoid
Weak, broken or wrong valve body spring
Miswired solenoid Defective capacity control valve Replace valve. Plugged strainer (high side) Stuck or damaged unloader piston
or piston rings.
Add refrigerant. Check for plugged liquid line
strainer. Check valve plates for valve noise. Replace compressor (worn
bearings). Check for loose compressor
holddown bolts. water is flowing thru the cooler
while charging and that suction pressure in cooler is equal to or greater than that corresponding to 32 F (58 psig for Refrigerant 22).
Check safety thermostat for proper setting at beginning of each season.
If thermostat was bypassed for checking, be sure it is back in the circuit before starting the unit.
Use ample size cleanable strainer
in the chilled water circuit. Make sure strainer is clean. It may some times be necessary to chemically treat the water to prevent forma tion of deposits.
Remove drain plugs at end of
cooling season. Blow out any
residual water. Instead of drain
ing, a suitable antifreeze may be
added to the water. Damage to the
chiller due to freezing is considered abuse and may affect the warranty.
Remove restriction or replace
filter drier core.
Replace coil.
Rewire correctly.
Replace spring. Rewire correctly.
Clean or replace strainer.
Clean or replace necessary parts.
15
Page 16
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book |2 Form 30HK.HL-1 OSI Supersedes 30HK,HL-8SI Printed in U.S.A. 1090 3-83 PC 1 11 Catalog No. 533-064 Tab|5c
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