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
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.HL015,020
SHELL, Net Vol. (Gal.)t6.89.9
TUBES (Copper)Internal Fins,
'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 DC537E2250E7265E7275
COOLER
CONDENSER
! Outside
020025030
1787
11361310
34
Holding Charge
E2150E7265E7175
6
8.514
2122
3
774784
5/8-in. OD X 0.020 wall
62.585.5
66.391.7
11
22
3/4
I 1.1251.125
1.625 ODM
354
75
437558
19801985
3840
4
33
133.6
6
1919
150
235
250
385
2.125 ODM
0.043
0.028
10^7
40
3644
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
02538
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!
2,147
2,160
2,1
2.188
(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
Nameplate208/230*
Supply Ränget187-253
MKW
015
02021.8
02529.0103175
030
01519.1
020
02531.8115200
030
0150537**
020215021.86328388
025
030
0150537**19.1
0202250
025
030
7265
7175
7265
7275
16.4
31.0115200
25.290150
35.9140250
COMPRESSOR
06t
MCA
69
79
80125
Kw
16.4
29.0
31.0
25.272
31.892446
35.9
RLALRA
5526677
82446114
92446
64
112506
Max
Fuse
Amps
11034
12536
INDIVIDUAL COMPRESSORS
208/230V*
MTA
1284022356
26689
345100
12840223563616450
156
460
414-508
MCA
50
50
386030
42
50
62110
Max
Fuse
Amps
60
6034
9045
9049
7038
9045
460 V575 V
RLALRAMTA
2712037
29
4022356
30120
33173
49253684217658
142
575
518 632
MCA
2950
53
Max
Fuse
Amps
60
80
80
50
60
80
90
RLALRA
402798
41
4530120
COMPRESSOR
06E USAGES
0537**
2150
7265
7175
C537**
2250
7265
7275
MTA
23
36
39
24
9631
16450
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
COLORCONDITION
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 rise9 - 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.
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 30HKHL
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
267
3100
135
250
31004
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 i853002 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.
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 systemPurge.
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 chargingMake 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 leakRepair leak and recharge.
Restricted filter drier
Burned-out coil
Defective capacity control valveReplace valve.
Miswired solenoid
Weak, broken or wrong valve body
spring
Miswired solenoid
Defective capacity control valveReplace 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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