Carrier 30HK User Manual
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
system.
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
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.
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
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
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
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