Reciprocating Liquid Chillers
Installation, Start-Up and
Service Instructions
30HK040-060
30HL050,060
30HW018-040
50/60 Hz
CONTENTS
Page
GENERAL ....................................2
SAFETY CONSIDERATIONS .....................2
INSTALLATION ..............................3-25
Location ......................................3
Step 1 — Inspect Shipment .....................3
Step 2 — Rig the Unit ..........................3
• 30HK,HL UNITS
• 30HW UNITS
Step 3 — Place the Unit
30HK,HL UNITS
•
• 30HW UNITS
Step 4 — Check Compressor Mounting and
Connections
Step 5 — Make Piping Connections .............13
• 30HK,HWC,HWS CONDENSER DESCRIPTION
• 30HL,HWA SYSTEM CONDENSER
• 30HWB CONDENSER DESCRIPTION
• 30HK,HWC,HWS CONDENSER(S)
• 30HWB CONDENSER
• 30HK,HWB,HWC,HWS UNITS
• COOLER DESCRIPTION
• COOLER PIPING
Step 6 — Make Electrical Connections
• 30HK,HL UNITS
• 30HW UNITS
• ALL UNITS
PRE-START-UP
Initial Check .................................25
Check Refrigerant Charge .....................26
• LIQUID CHARGING METHOD
Check Oil Charge
• TO ADD OIL
• TO REMOVE OIL
START-UP AND OPERATION ..................27-30
Operation Checks ............................27
Operating Limitations .........................27
• HIGH COOLER LEAVING CHILLED WATER (FLUID)
TEMPERATURES (LCWT)
• LOW COOLER LCWT
• MAIN POWER SUPPLY
Check Refrigerant Feed Components
• THERMOSTATIC EXPANSION VALVE (TXV)
• FILTER DRIER
• MOISTURE-LIQUID INDICATOR
• LIQUID LINE SERVICE VALVE
• DISCHARGE LINE CHECK VALVE
• HOT GAS BYPASS VALVE
• LIQUID LINE SOLENOID VALVE (30HL ONLY)
• PRESSURE RELIEF DEVICES
Compressor and Unit Protective Devices
• CIRCUIT BREAKER
..................................3
.............................25-27
........................3
...........19
.............................27
............27
.........28
• COMPRESSOR INTERNAL THERMAL PROTECTION
• CRANKCASE HEATER
• OIL PRESSURE SAFETY SWITCH (OPS)
Check Unit Safeties
CONTROL MODULE
•
• HIGH-PRESSURE SWITCH
• LOW-PRESSURE SWITCH
• CHILLED FLUID TEMPERATURE CONTROLLER
• FREEZE-UP PROTECTION
• LOSS-OF-COOLER-FLOW PROTECTION
• COMPRESSOR GROUND FAULT SENSOR
UNIT OPERATION
Capacity Control and Operating Sequence .......30
• 30HK,HL UNITS
• 30HW UNITS
SERVICE
Compressor Replacement ......................32
Circuit Breaker(s) .............................32
Brazed-Plate Cooler and Condenser
Heat Exchanger Replacement .................32
Brazed-Plate Cooler and Condenser
Heat Exchanger Cleaning .....................32
Shell-and-Tube Condenser Cleaning .............32
Thermistor ...................................33
• THERMISTOR REPLACEMENT, 30HK,HL UNITS
• THERMISTOR REPLACEMENT, 30HW UNITS
SERVICING COOLER (30HK,HL ONLY)
Tube Plugging ...............................36
• RETUBING
Tightening Cooler Head Bolts
• GASKET PREPARATION
• BOLT TORQUES
TROUBLESHOOTING
Complete Unit Stoppage and Restart ............37
• GENERAL POWER FAILURE
• UNIT ON-OFF SWITCH IS OPEN
• CONTACTS OF ANY AUXILIARY INTERLOCKS ARE
OPEN
• CHILLED FLUID PROOF-OF-FLOW SWITCH(ES) OPEN
• OPEN LOW-PRESSURE SWITCH
• TEMPERATURE CONTROLLER SHUTS UNIT DOWN ON
OUT-OF-RANGE
• OPEN HIGH-PRESSURE SWITCH(ES)
• OPEN COMPRESSOR INTERNAL THERMAL
PROTECTION
• OPEN OIL PRESSURE SWITCH
• OPEN CONTACTS ON COMPRESSOR GROUND-
CURRENT SENSOR(S) (Accessory)
• OPEN 24-V CONTROL CIRCUIT BREAKER(S)
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
START-UP CHECKLIST FOR
CHILLER SYSTEMS
..................................32-35
...........................28
...........................30-32
.........36,37
..................36
........................37-39
...................CL-1 to CL-4
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg 1 11-98 Replaces: 30H-8SI
GENERAL
These installation instructions cover the 30HK, HL, HWA,
HWB, HWC, and HWS units. The HL and HWA are condenserless units, and the HK, HWB, HWC, and HWS units
are all fluid cooled. In addition, the 30HK and HWC units
have a standard mechanically cleanable condenser and the
30HWS unit has a mechanically cleanable condenser specifically designed for sea coast applications.
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment
(Fig. 1-3) can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated
structures, etc.).
Only trained, qualified installers and service technicians
should install, start up, and service this equipment.
When working on the equipment, observe precautions in
the literature and on tags, stickers, and labels attached to the
equipment.
• Follow all safety codes.
• Wear safety glasses and work gloves.
• Use care in handling, rigging, and setting bulky
equipment.
Be sure all power to equipment is shut off before performing maintenance or service. There may be more than
one disconnect. Tag all disconnects to alert others not to
turn on power until work is completed.
Fig. 2 — 30HWA,B Unit
Fig. 1 — 30HK,HL Unit (30HK Shown)
Fig. 3 — 30HWC,S Unit
2
INSTALLATION
Location—
because of sensitive control mechanisms and electronic
devices. Locate unit indoors. See Fig. 4-8 for unit dimensional details.
Allow 36 in. (914 mm) in front of the unit for control box
access door. Compressor can be removed from either side or
the front of the unit. Prior to installation determine which
direction compressor will be removed, and leave 3 to 4 ft
(914 to 1219 mm) clearance for removal.
On 30HK,HL units leave 7
9 ft (2.7 m) (for 050,060 units) clearance on one side for
cooler tube removal. Leave 2 ft (610 mm) clearance on the
other side for making fluid connections to cooler and water
connections to condenser. See Fig. 4 and 5.
On 30HWA,B units, leave 2 ft (610 mm) on one side for
making fluid connections to cooler and water connections to
condenser,accessing the thermostatic expansion valve (TXV),
and replacing heat exchanger(s) if necessary. See Fig. 6
and 7.
On 30HWC,S units, leave 75 in. (1905 mm) on one side
for condenser tube removal and 2 ft (610 mm) on the other
side for making fluid connections to cooler and water connections to condenser,accessing the TXV, and replacing heat
exchanger(s) if necessary. See Fig. 8.
The floor must be strong enough to support the unit operating weight (see Tables 1A-2B and Fig. 9 and 10). If necessary, add a supporting structure (steel beams or reinforced
concrete slabs) to the floor to transfer weight to nearest beams.
Additional weights of factory-installed options (30HW only)
are:
Sound enclosure — 75 lb (34 kg)
Hot gas bypass — 15 lb (7 kg)
80-amp non-fused disconnect — 15 lb (6.8 kg)
100-amp non-fused disconnect — 25 lb (11.3 kg)
200-amp non-fused disconnect — 70 lb (31.8 kg)
Be sure interconnecting piping and electrical conduits
are suspended freely, and are not in contact with any
adjacent walls. Be sure unit capillaries are not rubbing
against anything.
Do not store units in an area exposed to weather
1
⁄2ft (2.3 m) (for 040 units) or
Step 1 — Inspect Shipment — Inspectunit for dam-
age or missing parts. If damaged, or if shipment is incomplete, file a claim immediately with the shipping company.
Step 2 — Rig and Place Unit
30HK,HL UNITS — 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 enclosure and
control box. If unit is to be moved by forklift truck, use one
of the following two methods:
1. From front or rear, lift under the cooler rails. Unit can be
either on or off skid.
2. When moving from the ends, leave unit on the skid. Lift
from under the skid.
If unit is to be dragged into final position, or moved on
rollers, it is recommended that it be left on the skid. When
dragging or rolling, apply force only to the skid, not to the
unit. Lift from above, using the lifting angles provided, to
remove unit from the skid.
30HW UNITS
NOTE: If accessory mobility package (Carrier part no.
30HW900008) is to be used, install this accessory after bringing unit into building and before moving the unit to its final
location per installation instructions provided with the
accessory.
Units Equipped WithFactory-Installed Unit Wheels —This
factory-installed option consists of 4 swivel-type wheels
mounted to the legs of the unit. See Fig. 11. For units equipped
with this option, leave the skid on until the unit is in the
building. Once in the building, remove the skid, and wheel
the unit to its final location.
NOTE: The wheels are equipped with a thumb-screw brake.
Units Not Equipped With Factory-Installed Unit Wheels —
Do not remove the skid until the unit has been moved to its
final location. The unit may be moved by means of rollers
under the skid, a forklift truck, or rig and slings.
Step 3 — Place the Unit
30HK,HL UNITS — When unit is in final position, remove
skid, level the unit (using a level), and bolt the unit to floor
or pad.
NOTE: These units are not suitable for unprotected outdoor
use.
Carrier recommends that these units be located in the basement or on the ground floor. However, if it is necessary to
locate the unit on an upper floor, be sure the structure has
been designed to support the unit weight. If necessary, add
structural support to floor. Also, be sure the surface for installation is level. Refer to Fig. 4 and 5 for space requirements and Fig. 9 for weight distribution.
Only electrical power connections, water connections for
condenser, and fluid connections for cooler are required for
30HK installation. Installation of 30HL units varies only in
field piping required for the remote condenser.
30HW UNITS — When the unit is in its final position, remove the skid (from units not equipped with factorymounted wheels), or remove the wheels (if equipped). Re-
3
⁄8-in. wheel nuts to remove wheels from unit legs.
move
Level the unit (using a level), and bolt the unit to the floor
or pad.
If unit is to be mounted on unit external vibration isolators, follow the mounting instructions included with the accessory vibration isolator (Carrier part numbers 30HW900001 and -002).
Step 4 — Check Compressor Mounting and
Connections—
by special self-locking nuts (Fig. 12). After unit is installed,
loosen the self-locking nuts one at a time until compressor
floats freely. Do not remove nuts, as they are self-locking
and will hold their locked position.
As shipped, the compressor is held down
3
TOP VIEW
FRONT VIEW RIGHT SIDE VIEW
UNIT
30HK
040
050,060
DIMENSIONS — in. (mm)
ABCD
1
5
⁄
4
(133)90(2286)
3
10
⁄
4
(273)
108
(2743)
149⁄
(370)
1
20
(510)
16
715⁄
(202)
⁄
16
9
13
(344)
LEGEND
COMP — Compressor
K.O. — Knockout
MTG — Mounting
SAE — Society of Automotive Engineers (U.S.A.)
NOTES:
1. Standard unit shown with the sound enclosure
accessory.
2. Dimensions are in inches unless otherwise
indicated.
Dimensions in ( ) are in millimeters.
3. Service clearance for the control box is 36-in.
Fig. 4 — 30HK040-060 (Fluid Cooled)
16
⁄
16
LEFT SIDE VIEW
4
TOP VIEW
FRONT VIEW RIGHT SIDE VIEW
LEGEND
CLY — Cylinder
COMP — Compressor
CONN — Connection
K.O. — Knockout
NOTES:
1. Standard unit shown withthesoundenclosure accessory.
2. Dimensions are in inches unless otherwiseindicated.Dimensions in ( ) are
in millimeters.
LEFT SIDE VIEW
Fig. 5 — 30HL050,060 (Condenserless)
5
LEFT SIDE VIEW
REAR VIEW
UNIT
30HWA
018
025
028
035
040
DISCONNECT
(Amps)
DISC. — Disconnect
K.O. — Knockout
ABCDEFG
12.58
(320)
12.82
(326)
12.64
(321)
12.87
(327)
12.66
(322)
80
100
200
LEGEND
DIMENSIONS — in. (mm)
19.20
(488)
18.98
(482)
18.31
(465)
18.62
(473)
18.64
(473)
20.48
(520)
20.57
(522)
20.73
(527)
20.81
(529)
21.30
(541)
33.85
(860)
33.85
(860)
33.85
(860)
33.85
(860)
34.15
(867)
11.72
(298)
11.72
(298)
11.72
(298)
11.72
(298)
11.34
(288)
5.75
(146)
5.75
(146)
5.75
(146)
5.75
(146)
8.22
(209)
17.95
(456)
17.95
(456)
17.95
(456)
17.95
(456)
17.36
(441)
RIGHT SIDE VIEW
LOCATION — in. (mm) MODEL 30HWA (See Table Below)
J K L M 018--- 025--- 028--- 035--- 040---
3.33
(85)
4.33
(110)
7.46
(189)
2.98
(76)
4.98
(126)
11.19
(284)
NOTES:
1. Denotes center of gravity.
2. Denotes accessory or factory-installed option.
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.
14.44
(367)
14.82
(376)
15.82
(402)
46.50
(1181)
47.50
(1207)
54.50
(1384)
100,200,
600,800,900
500 500,800 800 200,800
— — 500 500 500,800
100,200,
600,900
100,200,
600,900
100,600,900 —
MODEL VOLT-Hz
100 575-60
200 380-60
500 208/230-60
600 460-60
800 230-50
900 400-50
100,200,
600,900
Fig. 6 — 30HWA018-040 (Condenserless)
6
LEFT SIDE VIEW
REAR VIEW
UNIT
30HWB
018
025
028
035
040
DISCONNECT
COND — Condenser
DISC. — Disconnect
K.O. — Knockout
ABCDEFGHJ
13.14
18.72
(334)
(475)
13.22
18.25
(336)
(464)
13.18
17.71
(335)
(450)
13.45
17.98
(342)
(457)
13.27
17.75
(337)
(451)
(Amps)
80
100
200
LEGEND
DIMENSIONS — in. (mm)
22.02
33.85
11.72
5.75
12.29
17.95
(559)
22.10
(561)
22.39
(569)
22.68
(576)
23.44
(595)
(860)
33.85
(860)
33.85
(860)
33.85
(860)
34.15
(867)
(298)
11.72
(298)
11.72
(298)
11.72
(298)
11.34
(288)
(146)
5.75
(146)
5.75
(146)
5.75
(146)
8.22
(209)
(312)
12.29
(312)
12.29
(312)
12.29
(312)
12.38
(314)
(456)
17.95
(456)
17.95
(456)
17.95
(456)
17.36
(441)
9.28
(236)
9.28
(236)
9.28
(236)
9.28
(236)
8.22
(209)
RIGHT SIDE VIEW
LOCATION — in. (mm) MODEL 30HWB (See Table Below)
K L M N 018--- 025--- 028--- 035--- 040---
3.33
(85)
4.33
(110)
7.46
(189)
2.98
(76)
4.98
(126)
11.19
(284)
14.44
(367)
14.82
(376)
15.82
(402)
46.50
(1181)
47.50
(1207)
54.50
(1384)
100,200,300,
600,800,900
500 500,800 500,800 800
— — — 500 500,800
100,200,
600,900
NOTES:
1. Denotes center of gravity.
2. Denotes accessory or factory-installed option.
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.
100,200,
600,900
MODEL VOLT-Hz
100,200,
600,900
100 575-60
200 380-60
500 208/230-60
600 460-60
800 230-50
900 400-50
600,900
Fig. 7 — 30HWB018-040 (Fluid Cooled)
100
200,
7
LEFT SIDE VIEW FRONT VIEW
UNIT
30HWC,S
018
025
028
035
040
DISCONNECT
(Amps)
LEGEND
D. — Diameter
Disc. — Disconnect
K.O. — Knockout
SCH.40 — Schedule 40 Pipe
ABCDEFG
80
100
200
47.50
(1206)
48.30
(1227)
48.00
(1219)
48.20
(1224)
47.80
(1214)
9.90
(251)
9.90
(251)
10.00
(254)
10.00
(254)
10.00
(254)
(1971)
(2022)
(2127)
DIMENSIONS — in. (mm)
14.00
(356)
15.50
(394)
15.80
(401)
15.90
(404)
15.90
(404)
LOCATION — in. (mm) MODEL 30HWC,S (See Table Below)
J K L 018--- 025--- 028--- 035--- 040---
77.61
79.61
83.74
NOTES:
1. Denotes center of gravity.
2. Denotes accessory or factory-installed option.
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.
4.38
(111)
5.00
(127)
10.00
(254)
18.15
(461)
18.15
(461)
18.15
(461)
18.15
(461)
18.45
(469)
17.95
(456)
17.95
(456)
17.95
(456)
17.95
(456)
17.36
(441)
3.33
(85)
4.33
(110)
7.46
(189)
6.69
(170)
6.69
(170)
6.69
(170)
6.69
(170)
6.40
(163)
34.20
(869)
34.20
(869)
34.20
(869)
34.20
(869)
32.94
(837)
100,200,
600,800,900
500 500,800 500,800 800
— — — 500 500,800
100,200,
600,900
RIGHT SIDE VIEW
100,200,
600,900
100,200,
600,900
MODEL VOLT-Hz
100 575-60
200 380-60
500 208/230-60
600 460-60
800 230-50
900 400-50
Fig. 8 — 30HWC,S018-040 (Fluid Cooled)
100
200,
600,900
8
WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 60 HZ UNITS
MOUNTING HOLES
UNIT
SIZE
040 710322712323705320703319————————
050 787 357 789 358 782 355 780 354 519 235 521 236 516 234 514 233
060 838 380 840 381 832 377 830 376 534 242 536 243 531 241 529 240
NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions.
ABCDABCD
Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg
30HK 30HL
WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 50 HZ UNITS
MOUNTING HOLES
UNIT
SIZE
040 721327723328716325715325————————
050 838 380 840 381 832 377 830 376 534 242 526 238 531 241 529 240
060 853 387 855 388 847 384 845 383 550 249 551 250 545 247 544 247
NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions.
ABCDABCD
Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg
30HK 30HL
LOCATION OF MOUNTING HOLES
Fig.9—Weight Distribution and Mounting Hole Location; 30HK,HL Units
30HWA,B 30HWC,S
WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE — Lb (kg)
UNIT
30HW
A018 185 (83.9) —
A025 220 (99.8) —
A028 240 (108.9) —
A035 244 (110.7) —
A040 270 (122.5) —
B018 199 (90.3) —
B025 238 (108.0) —
B028 266 (120.7) —
B035 271 (122.9) —
B040 328 (148.8) —
C,S018 171 (77.6) 136 (61.7)
C,S025 196 (88.9) 144 (65.3)
C,S028 211 (95.7) 160 (72.6)
C,S035 216 (98.0) 161 (73.0)
C,S040 240 (108.9) 185 (83.9)
12345678
MOUNTING HOLE NO.
Fig. 10 — Mounting Hole Weight Distribution; 30HW Units
9
Table 1A — Physical Data; 30HK, HWB, HWC, and HWS Fluid-Cooled Units — English
UNIT 30 HW-018* HW-025* HW-028* HW-035* HW-040* HK040 HK050 HK060
OPERATING WT (Approximate) − lb
HWB 795 950 1065 1085 1310 — — —
HWC,S 1231 1358 1484 1508 1702 — — —
HK —————
REFRIGERANT — lb R-22
HWB 12.5 15.0 17.5 18.5 23.2 — — —
HWC,S 35.0 37.0 42.0 42.0 47.0 — — —
HK — Ckt 1 —————35/40† 45/45† 45/45†
HK − Ckt 2 —————35/35† 35/45† 45/45†
COMPRESSOR
Model No. 06DG537 06E2150** 06E7265 06E7175** 06E7299 06E2150
Nominal Hp 15 20 25 30 35 20 (ea) 20,30 30 (ea)
Quantity 11111 21(ea) 2
Cylinders Per Compressor 646664(ea) 6,4 6 (ea)
Capacity Control — Standard
No. of Steps 32333 4 4 4
Minimum Step Capacity (%) 33 50 33 33 33 25 20†† 33
Capacity Control — With Optional
Hot Gas Bypass
No. of Steps 43444 5 5 5
Minimum Step Capacity (%) 10 10 10 10 10 10 10 10
Relief Valve Flow Rate — lb air/min — 15.1 15.1 15.1 15.1 15.1 15.1 15.1
COOLER
Part No. LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664 10HA400664
Dry Weight — lb 69 81 105 105 145 657 726 726
Fluid Side — psig 300 300 300 300 300 150 150 150
Refrigerant Side — psig 430 430 430 430 430 235 235 235
Net Fluid Volume — Gal. 1.4 1.6 2.1 2.1 3.3 13.1 15.2 15.2
(includes nozzles)
Fluid Connections — in. Grooved End
Inlet 1
Outlet 1
CONDENSER
30HWB (Water Cooled)
Part No. LL01S- D001 D002 D003 D004 E004 — — —
Dry Weight — lb 48 62 79 87 153 — — —
Water Side — psig 300 300 300 300 300 — — —
Refrigerant Side — psig 430 430 430 430 430 — — —
Net Water Volume — Gal. 0.9 1.2 1.6 1.8 3.3 — — —
(includes nozzles)
Water Connections — in. Grooved End
Inlet 1
Outlet 11⁄
30HWC (Water Cooled)
Part No. 09RW- 400007 400007 400011 400011 400009 — — —
Dry Weight — lb 532 532 560 560 624 — — —
Water Side — psig 300 300 300 300 300 — — —
Refrigerant Side — psig 365 365 365 365 365 — — —
Net Water Volume — Gal. 2.6 2.6 4.0 4.0 7.3 — — —
Relief Valve Flow Rate — lb air/min 24.6 24.6 24.6 24.6 24.6 − — —
Water Connections — in. Weld
Inlet 2
Outlet 21⁄
30HWS (Water Cooled)
Part No. 09RW- 400017 400017 400019 400019 400018 — — —
Dry Weight — lb 532 532 560 560 624 — — —
Water Side — psig 300 300 300 300 300 — — —
Refrigerant Side — psig 335 335 335 335 335 — — —
Net Water Volume — Gal. 2.6 2.6 4.0 4.0 7.3 — — —
Relief Valve Flow Rate — lb air/min 22.6 22.6 22.6 22.6 22.6 − — —
Water Connections — in. Weld
Inlet 2
Outlet 21⁄
30HK (Water Cooled)
Part No. 09RP- —————022/022† 022/027† 027/027†
Dry Weight — lb —————1000 1095 1190
Water Side — psig —————250250250
Refrigerant Side — psig —————385385385
Net Water Volume — Gal. —————4.4/4.4† 4.4/5.2† 5.2/5.2†
(includes nozzles)
Relief Valve Flow Rate — lb air/min —————25.9 25.9 25.9
Water Connections — in. Weld
Inlet —————2
Outlet —————2
LEGEND
ODS — Outside Diameter, Sweat
*Unless otherwise noted, data is for HWB, HWC, and HWS units.
†60 Hz/50 Hz units.
**For 025 50 Hz units, compressor number is 06E2250, for 035 50 Hz units
compressor number is 06E7275.
††Withtransferswitch set tocompressor no. 2 position;40% with transfer switch
set to compressor no. 1 position.
1
⁄
2
1
⁄
2
1
⁄
2
2
1
⁄
2
2
1
⁄
2
2
11⁄
11⁄
11⁄
11⁄
21⁄
21⁄
21⁄
21⁄
2
2
2
2
2
2
2
2
11⁄
2
11⁄
2
11⁄
2
11⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
11⁄
2
11⁄
2
11⁄
2
11⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
NOTES:
1. Operating weight includes refrigerant operating charge and weight of fluid
in the heat exchangers.
2. 30HK,HWB,HWC, and HWS units are shipped with full operating charge.
21⁄
21⁄
21⁄
21⁄
21⁄
21⁄
21⁄
21⁄
2
2
2
2
2
2
2
2
2830/
2875†
333
333
———
———
———
———
———
———
1
⁄
2
1
⁄
2
3138/
3340†
06E6175,
06E2150
1
2
⁄
2
1
2
⁄
2
3340/
3400†
06E6175
1
2
⁄
2
1
2
⁄
2
10
Table 1B — Physical Data; 30HK, HWB, HWC, and HWS Fluid-Cooled Units — SI
OPERATING WT (Approximate) − kg
UNIT 30 HW-018* HW-025* HW-028* HW-035* HW-040* HK040 HK050 HK060
HWB 360 431 483 492 594 — — —
HWC,S 554 611 668 679 766 — — —
HK —————
REFRIGERANT — kg R-22
HWB 5.7 6.8 7.9 8.4 10.5 — — —
HWC,S 15.9 16.8 19.1 19.1 21.3 — — —
HK — Ckt 1 —————15.9/18.1† 20.4/20.4† 20.4/20.4†
HK — Ckt 2 —————15.9/15.9† 15.9/20.4† 20.4/20.4†
COMPRESSOR
Model No. 06DG537 06E2150** 06E7265 06E7175** 06E7299 06E2150
Nominal kW 11.1 14.9 18.7 22.4 26.1 14.9 (ea) 14.9,22.4 22.4 (ea)
Quantity 11111 21(ea) 2
Cylinders Per Compressor 646664(ea) 6,4 6 (ea)
Capacity Control — Standard
No. of Steps 32333 4 4 4
Minimum Step Capacity (%) 33 50 33 33 33 25 20†† 33
Capacity Control — With Hot Gas Bypass
No. of Steps 43444 5 5 5
Minimum Step Capacity (%) 10 10 10 10 10 10 10 10
Relief Valve Flow Rate — kg air/min — 6.8 6.8 6.8 6.8 6.8 6.8 6.8
COOLER
Part No. LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664 10HA400664
Dry Weight — kg 31.3 36.7 47.6 47.6 65.7 297 330 330
Fluid Side — kPa 2069 2069 2069 2069 2069 1034 1034 1034
Refrigerant Side — kPa 2965 2965 2965 2965 2965 1620 1620 1620
Net Fluid Volume — L 5.3 6.1 8.0 8.0 12.5 49.9 57.5 57.5
(includes nozzles)
Fluid Connections — in. Grooved End
Inlet 1
Outlet 11⁄
CONDENSER
30HWB (Water Cooled)
Part No. LL01S- D001 D002 D003 D004 E004 — — —
Dry Weight — kg 21.8 28.1 35.8 39.5 69.4 — — —
Water Side — kPa 2069 2069 2069 2069 2069 — — —
Refrigerant Side — kPa 2965 2965 2965 2965 2965 — — —
Net Water Volume — L 3.4 4.5 6.1 6.8 12.5 — — —
(includes nozzles)
Water Connections — in. Grooved End
Inlet 1
Outlet 1
30HWC (Water Cooled)
Part No. 09RW- 400007 400007 400011 400011 400009 — — —
Dry Weight — kg 241 241 254 254 283 — — —
Water Side — kPa 2069 2069 2069 2069 2069 — — —
Refrigerant Side — kPa 2517 2517 2517 2517 2517 — — —
Net Water Volume — L 9.8 9.8 15.4 15.4 27.6 — — —
Relief Valve Flow Rate — kg air/min 11.2 11.2 11.2 11.2 11.2 — — —
Water Connections — in. Weld
Inlet 2
Outlet 2
30HWS (Water Cooled)
Part No. 09RW- 400017 400017 400019 400019 400018 — — —
Dry Weight — kg 241 241 254 254 283 — — —
Water Side — kPa 2069 2069 2069 2069 2069 — — —
Refrigerant Side — kPa 2310 2310 2310 2310 2310 — — —
Net Water Volume — L 9.8 9.8 15.4 15.4 27.6 — — —
Relief Valve Flow Rate — kg air/min 10.3 10.3 10.3 10.3 10.3 — — —
Water Connections — in. Weld
Inlet 2
Outlet 2
30HK (Water Cooled)
Part No. 09RP- —————022/022† 022/027† 027/027†
Dry Weight — kg —————454497540
Water Side — kPa —————1724 1724 1724
Refrigerant Side — kPa —————2655 2655 2655
Net Water Volume — L —————17/17† 17/20† 20/20†
(includes nozzles)
Relief Valve Flow Rate — kg air/min —————11.711.711.7
Water Connections — in. Weld
Inlet —————2
Outlet —————2
LEGEND
ODS — Outside Diameter, Sweat
*Unless otherwise noted, data is for HWB, HWC, and HWS units.
†60 Hz/50 Hz units.
**For 025 50 Hz units, compressor number is 06E2250, for 035 50 Hz units
compressor number is 06E7275.
††Withtransferswitch set tocompressor no. 2 position;40% with transfer switch
set to compressor no. 1 position.
1
⁄
2
2
1
⁄
2
1
⁄
2
1
⁄
2
1
⁄
2
1
⁄
2
1
⁄
2
11⁄
2
11⁄
2
11⁄
2
11⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
11⁄
2
11⁄
2
11⁄
2
11⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
11⁄
2
11⁄
2
11⁄
2
11⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
NOTES:
1. Operating weight includes refrigerant operating charge and weight of fluid
in the heat exchangers.
2. 30HK,HWB,HWC, and HWS units are shipped with full operating charge.
21⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
21⁄
2
1284/
1305†
333
333
———
———
———
———
———
———
1
⁄
2
1
⁄
2
1424/
1514†
06E6175,
06E2150
1
2
⁄
2
1
2
⁄
2
1514/
1542†
06E6175
1
2
⁄
2
1
2
⁄
2
11
Table 2A — Physical Data; 30HL, HWA Condenserless Units — English
UNIT 30 HWA018 HWA025 HWA028 HWA035 HWA040 HL050 HL060
OPERATING WT (Approximate) − lb 740 880 960 975 1080
REFRIGERANT† — lb R-22
1.6 2.0 2.4 2.4 3.0 6.3/4.2** 5.3/5.3**
COMPRESSOR
Model No. 06DG537 06E2250 06E7265 06E7275 06E7299
Nominal Hp 15 20 25 30 35 25,20 30 (ea)
Quantity 111111(ea) 2
Cylinders Per Compressor 646666,4 6
Capacity Control — Standard
No. of Steps 32333 4 4
Minimum Step Capacity (%) 33 50 33 33 33 20†† 33
Capacity Control — With Optional
Hot Gas Bypass
No. of Steps 43444 5 5
Minimum Step Capacity (%) 10 10 10 10 10 10 10
Relief Valve Flow Rate — lb air/min — 15.1 15.1 15.1 15.1 15.1 15.1
COOLER
Part No. LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664
Dry Weight — lb 69 81 105 105 145 726 726
Fluid Side — psig 300 300 300 300 300 150 150
Refrigerant Side — psig 430 430 430 430 430 235 235
Net Fluid Volume — Gal. 1.4 1.6 2.1 2.1 3.3 13.1 15.2
(includes nozzles)
Fluid Connections — in. Grooved End
Inlet 1
Outlet 11⁄
CONDENSER CONNECTIONS
Refrigerant Connections — in.
Liquid Line ODS
Discharge Line ODS 11⁄
LEGEND
ODS — Outside Diameter, Sweat
*60 Hz/50 Hz units.
†30HWA and HL units (condenserless) are shipped with a refrigerant holding
charge. Approximate cooler operating charge is shown.
**Ckt 1/Ckt 2.
††Withtransferswitch set tocompressor no. 2 position;40% with transfer switch
set to compressor no. 1 position.
1
⁄
2
2
7
⁄
8
8
11⁄
11⁄
11⁄
2
2
7
⁄
8
8
11⁄
2
11⁄
2
7
⁄
8
13⁄
8
NOTE: Operating weight includes refrigerant operating charge and weight of
fluid in the heat exchangers.
11⁄
2
11⁄
2
7
⁄
8
13⁄
8
21⁄
2
21⁄
2
7
⁄
8
15⁄
8
2070/
2120*
06E6275,
06E2250
33
33
7
⁄
8
13⁄
8
2130/
2190*
06E6275
7
⁄
8
13⁄
8
Table 2B — Physical Data; 30HL, HWA Condenserless Units — SI
UNIT 30 HWA018 HWA025 HWA028 HWA035 HWA040 HL050 HL060
OPERATING WT (Approximate) − kg 335 399 435 442 490
REFRIGERANT† — kg R-22
0.7 0.9 1.1 1.1 1.4 2.9/1.9** 2.4/2.4**
COMPRESSOR
Model No. 06DG537 06E2250 06E7265 06E7275 06E7299
Nominal kW 11.2 14.9 18.7 22.4 26.1 18.7,14.9 22.4 (ea)
Quantity 111111(ea) 2
Cylinders Per Compressor 646666,4 6
Capacity Control — Standard
No. of Steps 32333 4 4
Minimum Step Capacity (%) 33 50 33 33 33 20†† 33
Capacity Control — With Optional Hot Gas Bypass
No. of Steps 43444 5 5
Minimum Step Capacity (%) 10 10 10 10 10 10 10
Relief Valve Flow Rate — kg air/min — 6.8 6.8 6.8 6.8 6.8 6.8
COOLER
Part No. LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664
Dry Weight — kg 31.3 36.7 47.6 47.6 65.7 330 330
Fluid Side — kPa 2069 2069 2069 2069 2069 1034 1034
Refrigerant Side — kPa 2965 2965 2965 2965 2965 1620 1620
Net Fluid Volume — L 5.3 6.1 8.0 8.0 12.5 49.9 57.5
(includes nozzles)
Fluid Connections — in. Grooved End
Inlet 1
Outlet 1
CONDENSER CONNECTIONS
Refrigerant Connections — in.
Liquid Line ODS
Discharge Line ODS 11⁄
LEGEND
ODS — Outside Diameter, Sweat
*60 Hz/50 Hz units.
†30HWA and HL units (condenserless) are shipped with a refrigerant holding
charge. Approximate cooler operating charge is shown.
**Ckt 1/Ckt 2.
††Withtransferswitch set tocompressor no. 2 position;40% with transfer switch
set to compressor no. 1 position.
1
⁄
2
1
⁄
2
11⁄
2
11⁄
2
7
⁄
8
8
11⁄
2
11⁄
2
NOTE: Operating weight includes refrigerant operating charge and weight of
fluid in the heat exchangers.
11⁄
2
11⁄
2
7
⁄
8
13⁄
8
21⁄
21⁄
15⁄
2
2
7
⁄
8
8
938/
961†
06E6275,
06E2250
33
33
7
⁄
8
13⁄
8
966/
993†
06E6175
7
⁄
8
13⁄
8
12
THUMB-SCREW
BRAKE
Fig. 11 — Factory-Installed Unit Wheels (4)
Fig. 12 — Compressor Mounting
Step 5 — Make Piping Connections — See
Fig. 13 and 14 for typical piping applications.
30HK, HWC, HWS CONDENSER DESCRIPTION — All
30HWC and HWS units use a shell-and-tube condenser with
removable heads for easy tube servicing. Refrigerant is contained within the shell, and water flows through the tubes.
The 30HK and HWC units use a steel shell condenser(s) with
steel tube sheets and copper tubes. The 30HWS units are
designed for sea coast applications and use a steel shell condenser with cupronickel tube sheets and tubes. In addition,
the 30HWS water heads utilize ‘‘sacrificial’’ zinc anodes for
condenser corrosion protection.
IMPORTANT:Inspect the zinc anodes every 3 months
for deterioration and replace as needed. Galvanic protection of the condenser is lost if the anodes are not
replaced prior to complete deterioration.
The number of tubes in the condenser(s) varies depending
on the unit size.The condensers have internal subcoolers which
provide approximately 8 F (4.4 C) for 30HK, HL units or 13 F
(7.2 C) for 30HW units subcooling at ARI (Air Conditioning and Refrigeration Institute, U.S.A.) rating conditions.
30HL, HWA SYSTEM CONDENSER — For detailed condenser piping installation instructions for 30HL and HWA
systems, refer to separate instructions packaged with the remote condenser unit(s).
Condenser refrigerant piping for 30HLandHWAunitsshould
be sized to minimize the amount of refrigerant required.
The 30HL and HWA units that use an air-cooled evaporative condenser(s) must have adequate means for head pressure control when operating below 60 F (15.6 C).
Carrier recommends that a field-supplied pressure relief
device be installed after the muffler in each discharge line.
Most local codes require the relief valve to be vented directly to the outdoors. The vent must not be smaller than the
relief valve outlet.
30HWB CONDENSER DESCRIPTION —All 30HWB units
use a brazed-plate heat-exchanger-type condenser. These heat
exchangers are made of embossed plates of acid-resistant stainless steel. Every other plate is reversed so that the ridges of
the herringbone pattern intersect one another on adjacent plates,
forming a lattice of contact points. These plates are vacuumbrazed together to form a compact and pressure-resistant heat
exchanger.
After brazing, the impressions in the plates form 2 separate systems of channels where the refrigerant and water flows
are counter-current. The number of plates varies depending
on unit tonnage. The condensers provide approximately 14°
to 18° F (8° to 10° C) liquid subcooling at the standard
Air Conditioning and Refrigeration Institute (ARI) rating
condition.
30HK, HWC, HWS CONDENSER(S) — When facing the
front of the unit, the condenser(s) is in the uninsulated shell(s)
located across the bottom of the unit. The water connections
are such that the water inlet is located on the left-hand side
(30HK) or right-hand side (30HW) of the unit. The water
inlet mustALWAYS be on the bottom of the condenser(s) to
provide the proper subcooling. The water outlet is located
on the right-hand side (30HK) or left-hand side (30HW) of
the unit. The water connections can be reversed by rotating
the heads and gaskets 180 degrees ON BOTH ENDS OF
THE CONDENSER(S).
IMPORTANT: THE WATER INLET MUST ALWAYS BE ON THE CONDENSER HEAD(S) THAT
HAS THE NOZZLE CONNECTION AT THE BOTTOM OF THE HEAD. Incorrect inlet connection will
result in poor system performance due to incorrect
subcooling.
The LIQUID-IN and LIQUID-OUT labels indicate water
connections AS SUPPLIED FROM THE FACTORY.
It is recommended that strainer with a minimum of 20 mesh
be installed ahead of the condenser water inlet(s) to prevent
debris from clogging or damaging the heat exchanger(s).
There is a pressure-relief device on the condenser(s) of all
30HK, HWC, and HWS units. Most local codes require that
this relief be vented directly to the outdoors.
NOTE: The relief line must not be smaller than the relief
valve outlet. Be sure to provide a way of draining and servicing the unit.
13
LEGEND
Airflow Through Condenser
Airflow Through Air
Handling Unit
Power Wiring
Control Wiring
Chilled Water Piping
ST — Field-Supplied Starter
Flow Switch
FD — Field-Supplied Disconnect
FS — Field-Supplied Differential
*Field Supplied.
14
to maintain proper compressor oil return.
levelly
2. Wiring and piping shown are general points-of-connection guides only and are not intended for a specific installation. Wiring and piping
NOTES:
1. Chiller must be installed
shown are for a quick overview of system and are not in accordance with recognized standards.
of Heating, Refrigeration, and Air Conditioning Engineers) handbook for details.
3. All wiring must comply with applicable local and national codes.
4. All piping must follow standard piping techniques. Refer to Carrier System Design Manual or appropriate ASHRAE (American Society
Fig. 13 — Typical Piping with Fluid-Cooled 30HWB Unit Shown
volume.
5. See Table 3 on page 17 for minimum system fluid volume. This system may require the addition of a holding tank to ensure adequate
NOTES:
1. Chiller must be installed
sor oil return.
2. Wiring andpipingshown are general points-of-connectionguides
only and are not intended for a specific installation. Wiring
and piping shown are for a quick overview of system and are
not in accordance with recognized standards.
3. All wiring must complywithapplicablelocaland national codes.
4. All piping must follow standard piping techniques. Refer to
Carrier System Design Manual part 3, Carrier E20-IIT software Refrigerant Piping program, or appropriate ASHRAE
(American Society of Heating, Refrigeration, and Air ConditioningEngineers)handbookfordetailsonproperpipingsizes
and design.
5. See Table 3 on page 17 for minimum system fluid volume.
This system may require the addition of a holding tank to ensure adequate volume.
6. Hot gas lines should rise above refrigerant level in condenser
circuit. Double riser may be required; check compressor minimum capacity.
7. Trap should be installed on hot gas lines to prevent condenser oil and refrigerant vapor migration from accumulating
on compressor heads during off cycle.
8. Pitch all horizontal lines downward in the direction of refrigerant flow.
9. For piping lengths greater than 50 ft, provide support to liquid
and gas lines near the connections to the condenser coil.
10. For pressure relief requirements, see latest revision of
ASHRAE Standard 15, Safety Code for Mechanical
Refrigeration.
levelly
to maintain proper compres-
Fig. 14 — Typical Piping with Air-Cooled 30HWA with Remote 09DK Unit Shown
15
30HWB CONDENSER — When facing the back of the unit,
the condenser is the uninsulated heat exchanger located on
the right-hand side. The water connections are on the righthand side of the heat exchanger with the LIQUID-IN connection at the bottom, and the LIQUID-OUT connection at
the top.
A strainer with a minimum of 20 mesh must be installed
ahead of the condenser water inlet to prevent debris from
clogging or damaging the heat exchanger.
To install the grooved end coupling (see Fig. 15):
1. Lubricate the gasket lips and stretch the gasket over
the end of the pipe. Avoid twisting the gasket when
installing.
2. Bring the pipe and heat exchanger coupling ends together into alignment. Slide the gasket so that it is centered over the ends. Apply a light film of lubricant to the
gasket, or to the gasket recess of the coupling housing.
Avoid twisting the gasket during installation.
3. Seat the coupling halves over the gasket and install the
nuts and bolts. Tighten the nuts equally on both sides.
4. Alternately tighten the nuts with a wrench to draw
the coupling halves together uniformly. The joint is now
complete.
30HK, HWB, HWC, HWS UNITS — In order to minimize
the water pressure drop in the system, use as few bends as
possible in the field water piping, and run the lines as short
as possible. Size the water lines according to the available
pump pressure (not necessarily the connection size), especially on cooling tower applications. See Carrier System Design Manual, Part 3, Piping Design. See Fig. 16 for condenser
pressure drops.
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 noncondensables. Due to changes in water
temperature, it may be necessary to adjust the valve seasonally.After adjusting for design head pressure, shut unit down.
The water regulating valve should shut off the flow of water
in a few minutes. If it does not, raise head pressure setting.
Make sure that the capillary tube from each water regulating
valve is connected to the proper condenser purge valve.
Provide a means for draining the system in the winter (if
not used) and for maintenance.
Accessory steel manifold packages for inlet and outlet condenser water are available for 30HK units. Each manifold is
furnished in 2 sections, to be field welded as shown in
Fig. 4. Manifolds should not be used where regulating valves
are required because separate valves must be used on each
condenser circuit.
Retighten all condenser head bolts before filling system
with water. Torque bolts to a maximum of 40 to
45 ft-lb.
Water leaving the 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 Discharge Line Check
Valve sections on page 28, concerning piping connections
for these components.
COOLER DESCRIPTION
30HK, HL Units — The cooler is a direct-expansion type
with removable heads and is partitioned for multi-pass refrigerant flow. Fluid flow across the tube bundle is directed
by baffles designed for minimum fluid-pressure drop. The
tubes have integral internal fins for maximum heat transfer
efficiency.
Viewed from unit front, the return chilled fluid enters at
the left end of the cooler and leaves at the right end. The
sensing bulb for the factory-supplied fluid temperature controller is in the leaving-fluid nozzle; the leaving-fluid temperature being the control point.
The cooler is insulated with a flexible, closed-cell plastic
foam insulation of suitable thickness. Fluid 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.
Special modification may be necessary for brine chillers.
Contact your Carrier representative for details. For calcium
or sodium chloride brines, it is important that the proper inhibitors be carefully selected for protection of the copper tubes.
Refer to the publications of the Calcium Institute or the
Mutual Chemical Division of Allied Chemical Corporation
for information on corrosion control for calcium or sodium
chloride systems.
30HW Units — All 30HW units use a brazed-plate heatexchanger type cooler.The heat exchanger is constructed essentially the same as the brazed-plate condenser used on
30HWB units. See 30HWB Condenser Description section
on page 13 for more details. Similar to the condenser, the
cooler can only be chemically cleaned.
COOLER PIPING — Plan cooler fluid piping for minimum
number of changes in elevation, and for the fewest number
of bends as possible. Install manual or automatic vent valve
at high points in the line. Maintain system pressure by using
a pressure tank or a combination or relief and reducing valves.
A strainer with a minimum of 20 mesh must be installed
ahead of the cooler fluid inlet to prevent debris from clogging or damaging the heat exchanger.
See Carrier System Design Manual, Part 3, Piping
Design, for chilled fluid piping details.
Fig. 15 — Installed Coupling Fastening Grooved
Pipe Ends
16
The cooler fluid inlet and outlet connections are groovedend. On 30HW units, the fluid enters at the top connection
and leaves at the bottom connection. Procedures for making
the grooved-end connections are the same as for the 30HWB
condensers. See 30HWB Condenser section on page 16 for
more details.
Run the pump for 10 minutes, then clean the strainer before starting the unit.
A cooler flow switch must be field-installed on all units.
This should be a differential pressure switch that is installed
between the cooler fluid inlet and outlet. The switch should
be set to open when the cooler fluid flow drops below the
values shown in Table 3. Use the cooler water pressure drop
curves (Fig. 16) to determine correct setting for each unit
size. Use Carrier accessory flow switch, part number
30HW900003. See Table 3 for Minimum Flow rates and loop
volumes.
See Step 6 — Make Electrical Connections section on
page 19 for flow switch wiring details.
30HK, HL Units — The thermistor used for sensing fluid
temperature is factory-installed in the cooler leaving fluid
line.
30HW Units — The thermistor used for sensing the fluid
temperature is inside the cooler leaving-water cavity.
Table 3 — Minimum Cooler and Condenser Flow
Rates Minimum Loop Volume
UNIT SIZE
30HK040 56.0 3.5 67 4.23 120 454.2
30HK,HL050 68.0 4.3 76 4.79 148 560.2
30HK,HL060 68.0 4.3 83 5.24 174 658.6
30HW018 22.5 1.4 22.5 1.4 44 167
30HW025 30.0 1.9 30.0 1.9 59 223
30HW028 37.5 2.4 37.5 2.4 76 288
30HW035 45.0 2.8 45.0 2.8 85 322
30HW040 57.0 3.6 57.0 3.6 113 428
ARI — Air Conditioning and Refrigeration Institute
N—Liters per kW
V—Gallons per ton
*30HK, HWB, HWC and HWS only.
†Minimum system fluid volumes.
NOTES:
Gallons=VxARIcapacity in tons.
Liters=NxARIcapacity in kW.
Normal Air Conditioning 3 3.25
Process Type Cooling 6 to 10 6.5 to 10.8
Low Ambient Operation 6 to 10 6.5 to 10.8
COOLER CONDENSER*
Gal./Min L/s Gal./Min L/s Gal. L
LEGEND
APPLICATION V N
MINIMUM COOLER
LOOP VOLUME†
COOLER PRESSURE DROP — 30HW UNITS COOLER PRESSURE DROP — 30HK, HL UNITS
NOTE: Ft of water = 2.31 x change in psig.
Fig. 16 — Cooler and Condenser Water Pressure Drop
17
CONDENSER PRESSURE DROP —
30HK UNITS
CONDENSER PRESSURE DROP —
30HWB UNITS
NOTE:Ftof water = 2.31xchange
in psig.
CONDENSER PRESSURE DROP —
30HWC AND 30HWS UNITS
Fig. 16 — Cooler and Condenser Water Pressure Drop (cont)
18
Step6 — Make Electrical Connections— All field
wiring must comply with local code requirements. Electrical
data for the complete unit and for the compressors is shown
in Tables 4A and 4B. See Fig. 17 and 18 for field wiring
connections.Afield-supplied branch circuit disconnect switch
that can be locked in either OPEN or OFF position must be
installed.
30HK, HL UNITS — On all 60 Hz units, a fused (15 amp
maximum), 115 v control circuit must be supplied by either
a separate power source or by using a minimum 300 va transformer. On 208/230 and 460 v units, control circuit power
can be supplied by accessory transformer part no. 07EA900051.
Check to be sure that installation of the 115 v control power
source meets all local codes.
On all 50 Hz units, a fused (15 amp maximum), 230 v
control circuit must be field supplied. On 200-3-50 units, power
for the control circuit can be supplied by connecting a fieldsupplied fuse (15 amp maximum) between TB1 and TB2 for
L1 overcurrent protection. On 400-3-50 units, power for the
control circuit can be supplied by connecting a fieldsupplied fuse (15 amp maximum) between TB1 and a neutral leg from TB2 for L1 overcurrent protection. On all units,
check to be sure that installation of the 230 v control power
source meets all local codes.
30HW UNITS — Control circuit power is 24 v and 115 v
on all units, and is supplied by factory-installed control
transformers.
ALL UNITS — Inside the control box are terminals for field
power and ground (earth) wiring, as well as a terminal for a
neutral wire when needed (380-3-60 and 400-3-50 units only).
A ground wire must be installed with each field power supply.Compressor are wired standard from the factory for acrossthe-line start. As a factory-installed option, all 025-060 sizes
are available wired for part-wind start (special order option
on 30HK, HL unit).
Refer to Tables 4A and 4B for electrical data.
Flow Switch — A cooler flow switch is required for all units,
and must be field-installed. The Carrier flow switch accessory (part number 30HW900003), is available for this purpose. Flow switch wiring terminals are located in the field
wiring compartment of the control box. The flow switch should
be wired between terminals TB3-1 and TB3-7 for 30HK, HL
units or between terminals TB2-7 and TB2-13 for 30HW units.
The factory jumper wire between these 2 terminals must be
removed for proper operation of the flow switch.
Control Box, Power Section — The electrical power supply
is brought in through the top left-hand side (30HK, HL) or
right-hand side (30HW) of the control box (see Fig. 19 and
20). The knockout accepts up to a 3-in. (76 mm) conduit for
30HK, HL units, and a 13⁄4-to21⁄2-in. (44 to 64 mm) conduit
for 30HW units. Pressure-lug connections on the terminal
blocks are suitable for copper, copper-clad aluminum, or aluminum conductors.
The control box power section contains the following
components:
• power terminal block
• compressor circuit breaker(s)
• compressor contactor(s)
• high-voltage transformer (30HW units only)
• control-circuit circuit breaker for 24-v circuit
• unit ON-OFF switch
• unit service light
• ground lug
• neutral terminal (380-3-60 and 400-3-50 units)
• terminal block for ground current sensing accessory
Control Box, Controls Section — The control box controls
section contains the following components:
• temperature controller
• control relay(s)
• control module(s)
• low-voltage control transformer(s)
• terminal block for ground current sensing accessory
Control Box, Field Control Wiring Section — Inside this
section is a 10-terminal (30HK, HL) or 14-terminal (30HW),
low-voltage, field-wiring terminal strip. All low-voltage fieldwiring connections are made to this terminal block. Seven
3
⁄4-in. (19 mm) knockouts are provided for field wiring in
this section. Connections for chilled fluid flow switch, chilled
fluid pump interlock, condenser pump interlock, remote alarm
output, and ground current sensor accessory are made at this
location. The remote condenser relay connections are made
to a separate 4-terminal (30HK, HL) or 3-terminal (30HW)
field wiring strip. See Fig. 17-20 for specific location of
connections.
Unbalanced 3-Phase Supply Voltage — Never operate a com-
pressor where a phase imbalance in the supply voltage is
greater than 2%. Use the following formula to determine
the percent voltage imbalance:
% Voltage Imbalance =
max voltage deviation from average voltage
100 x
average voltage
Example: Supply voltage is 240-3-60
AB = 243 v
BC = 236 v
AC = 238 v
Average Voltage =
243 + 236 + 238
3
= 239 v
Determine maximum deviation from average voltage:
(AB) 243 - 239=4v
(BC) 239 - 236=3v
(AC) 239 - 238=1v
Maximum deviation is 4 v.
Determine percent voltage imbalance:
% Voltage Imbalance = 100 x
4
239
= 1.7%
This amount of phase imbalance is satisfactory as it is below
the maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance
is more than 2%, contact your local utility company
immediately.
19
Table 4A — Electrical Data — 30HK, HWB, HWC, HWS Fluid-Cooled Units
UNIT SIZE
30-
HK040
HK050
HK060
HWB,C,S018
HWB,C,S025
HWB,C,S028
HWB,C,S035
HWB,C,S040
UNIT COMPRESSOR (ea)
Volts Voltage*
Nameplate (3 ph) Hz Min Max PW XL PW XL PW XL
208/230 60 187 253 129 † 340 175 150 57 † 283 † 89
460 60 414 518 59 † 168 80 70 26 † 142 † 40
575 60 518 632 54 † 122 70 60 24 † 98 † 42
220 50 198 253 142 † 390 200 175 75/48** † 342/201** † 116/74**
400 50 342 440 71 † 249 100 90 36/26** † 223/142** † 56/40**
208/230 60 187 253 161 † 503 225 200 83/57** † 446/283** † 89/64**
460 60 414 518 75 † 249 110 90 39/26** † 223/142** † 56/40**
575 60 518 632 73 † 188 110 90 39/24** † 164/ 88** † 54/37**
220 50 198 253 169 † 417 225 200 75 † 342 † 116
400 50 342 440 81 † 259 110 100 36 † 223 † 56
208/230 60 187 253 187 † 529 250 225 83 † 446 † 64
460 60 414 518 88 † 262 125 100 39 † 223 † 56
575 60 518 632 88 † 203 125 100 39 † 164 † 54
220 50 198 253 225 † 600 300 250 100 † 545 † 156
400 50 342 440 131 † 403 175 150 58 † 345 † 90
208/230 60 187 253 62 — 266 110 80 49 — 266 — 89
380 60 342 418 35 — 145 60 45 28 — 145 — 40
460 60 414 508 28 — 120 50 35 23 — 120 — 33
575 60 518 632 24 — 96 40 30 19 — 96 — 25
230 50 198 253 58 — 200 100 70 46 — 200 — 63
380/415 50 342 440 34 — 115 60 45 27 — 115 — 41
208/230 60 187 253 72 170 283 125 90 57 170 283 88 88
380 60 342 418 43 85 142 70 60 34 85 142 52 52
460 60 414 508 34 85 142 60 45 27 85 142 40 42
575 60 518 632 28 59 98 45 35 22 59 98 33 33
230 50 198 253 67 150 250 110 80 53 150 250 80 80
380/415 50 342 440 38 104 173 60 45 30 104 173 44 44
208/230 60 187 253 89 268 446 150 110 71 268 446 104 104
380 60 342 418 54 134 223 90 70 43 134 223 66 66
460 60 414 508 44 134 223 70 60 35 134 223 50 52
575 60 518 632 35 98 164 60 45 28 98 164 41 42
230 50 198 253 85 205 342 150 110 68 205 342 98 98
380/415 50 342 440 54 134 223 90 70 43 134 223 60 60
208/230 60 187 253 102 268 446 175 125 81 268 446 120 120
380 60 342 418 59 134 223 100 80 47 134 223 70 70
460 60 414 508 48 134 223 80 60 38 134 223 52 57
575 60 518 632 39 98 164 60 50 31 98 164 42 42
230 50 198 253 94 220 366 150 125 75 220 366 112 112
380/415 50 342 440 54 152 253 90 70 43 152 253 66 66
208/230 60 187 253 145 414 690 250 175 116 414 690 180 180
380 60 342 418 84 207 345 150 110 67 207 345 98 98
460 60 414 508 69 207 345 110 90 55 207 345 78 84
575 60 518 632 55 165 276 90 70 44 165 276 63 66
230 50 198 253 135 327 545 225 175 108 327 545 166 166
380/415 50 342 440 78 207 345 125 100 62 207 345 98 98
MCA
ICF
MFA
Rec
Fuse
RLA
LRA MTA
20
UNIT SIZE
30-
HL050
HL060
HWA018
HWA025
HWA028
HWA035
HWA040
Table 4B — Electrical Data — 30HL and HWA Condenserless Units
Nameplate (3 ph) Hz Min Max PW XL PW XL PW XL
Volts Voltage*
208/230 60 187 253 190 † 571 250 225 100/65** † 506/315** † 78/50**
460 60 414 518 84 † 282 125 100 44/29** † 253/173** † 68/45**
575 60 518 632 75 † 203 110 90 38/27** † 176/128** † 58/42**
200 50 198 253 187 † 449 250 225 83 † 366 † 128
400 50 342 440 99 † 297 125 110 44 † 253 † 68
208/230 60 187 253 225 † 606 300 250 100 † 506 † 78
460 60 414 518 99 † 297 125 110 44 † 253 † 68
575 60 518 632 86 † 214 110 100 38 † 176 † 58
200 50 198 253 261 † 616 350 300 116 † 545 † 180
400 50 342 440 138 † 406 175 175 61 † 345 † 95
208/230 60 187 253 72 — 266 125 90 57 — 266 — 89
380 60 342 418 40 — 145 70 50 32 — 145 — 45
460 60 414 508 34 — 120 60 45 27 — 120 — 41
575 60 518 632 28 — 96 45 35 22 — 96 — 33
230 50 198 253 58 — 200 100 70 46 — 200 — 63
380/415 50 342 440 34 — 115 60 45 27 — 115 — 41
208/230 60 187 253 79 207 345 125 100 63 207 345 98 98
380 60 342 418 47 104 173 80 60 37 104 173 52 52
460 60 414 508 38 104 173 60 45 30 104 173 42 45
575 60 518 632 30 72 120 50 40 24 72 120 33 37
230 50 198 253 67 150 250 110 80 53 150 250 80 80
380/415 50 342 440 38 104 173 60 45 30 104 173 44 44
208/230 60 187 253 107 268 446 175 150 85 268 446 124 124
380 60 342 418 60 134 223 100 80 48 134 223 70 70
460 60 414 508 54 134 223 90 70 43 134 223 52 60
575 60 518 632 42 98 164 70 50 33 98 164 42 52
230 50 198 253 85 205 342 150 110 68 205 342 98 98
380/415 50 342 440 54 134 223 90 70 43 134 223 60 60
208/230 60 187 253 119 304 506 200 150 95 304 506 144 144
380 60 342 418 67 152 253 110 80 53 152 253 80 80
460 60 414 508 54 152 253 90 70 43 152 253 66 66
575 60 518 632 44 106 176 70 60 35 106 176 50 52
230 50 198 253 94 220 366 150 125 75 220 366 112 112
380/415 50 342 440 54 152 253 90 70 43 152 253 66 66
208/230 60 187 253 167 414 690 300 200 133 414 690 204 204
380 60 342 418 95 207 345 150 125 76 207 345 106 106
460 60 414 508 78 207 345 125 100 62 207 345 95 98
575 60 518 632 63 165 276 110 80 50 165 276 73 76
230 50 198 253 135 327 545 225 175 108 327 545 166 166
380/415 50 342 440 78 207 345 125 100 62 207 345 98 98
UNIT COMPRESSOR (ea)
MCA
ICF
MFA
Rec
Fuse
RLA
LRA MTA
LEGEND FOR TABLES 4A AND 4B
ICF — Maximum instantaneous current flow during starting. For these
kcmil — Thousand circular mils
LRA — Locked rotor amps. First value is for part-wind start. Larger value
MCA — Minimum circuit amps (for wire sizing). Complies with NEC,
MFA — Maximum fuse amps (225% of compressor RLA). Size down to
MTA — Must-trip amps (compressor circuit breaker).
NEC — National Electrical Code (U.S.A.)
1. All units have one field power terminal block.
2. Maximum incoming wire size:
3. Any field modification of factory wiring must be in compliance with all ap-
4. Usecopper,copper-clad aluminum, oraluminum conductors for field wiring.
5. For all30HW units, control circuit power supplyis 115-v singlephase for 50-
6. Across-the-line start is standard on all units. Part-wind start is available as
single-compressor units, ICF is the compressor LRA.
is the full LRA.
Section 430-24.
the next standard fuse size.
NOTES FOR TABLES 4A AND 4B
a. 350 kcmil for unit sizes 040-060; 208/230-3-60, 230-3-50, and 400-3-50
voltages.
b. 2/0 for all other unit sizes; all voltages.
plicable codes. Field-installed power wires must be rated 75 C minimum.
and 60-Hz units. Control power is supplied by the factory-installed control
transformer.Additional control circuit power is not required for 30HW units.
a factory-installed option on 025-060 sizes (not available on 018 size; special order option on 30HK,HL units).
PW — Part wind
Rec Fuse — Recommended dual element fuse amps (150% of
RLA — Rated load amps
XL — Across the line
*Supply Range — Units are suitable for use on electrical systems where volt-
age suppliedto the unit terminalsis not below or abovethe listed range limits.
†Contact your local Carrier representative for part-wind details.
**Compressor no. 1/Compressor no. 2.
7. For all 30HK,HL units, control circuit MCA is 7.2, and control circuit MFA is
15. For 30HK,HL 60 Hz units, a separately-fused (15 amp maximum) 115v,
single-phase, 60 Hz, power supply or accessory transformer is required.
For 30HK,HL50 Hz units, a field-supplied, separately fused (15ampsmaximum), 230 v, single-phase, 50 Hz power supply is required.
compressor RLA). Size up to the next standard fuse size.
(30HK, HL, HWA, HWB, (30HK, HL, HWA, HWB,
HWC 60 Hz Only) HWC 60 Hz Only)
21
FIELD POWER WIRING, 60 Hz UNITS FIELD CONTROL WIRING, 50 Hz UNITS
COM — Common
CR — Compressor Relay
CWP — Chilled Water Pump
DLS — Demand Limit Switch
GCS — Ground Current Sensing
NC — Normally Closed
NO — Normally Open
TB — Terminal Block
TC — Temperature Control
NOTE: Manual lead/lag selector switch must
be disconnected when using automatic lead/
lag accessory.
FIELD ACCESSORY WIRING
Fig. 17 — Field Wiring Diagram; 30HK, HL Units
22
LEGEND
Field Wiring
Factory Wiring
Accessory
NOTE: Factory wiring is in accordance with the National Electrical
Code (U.S.A.). Any field modifications or additions must be in com-
pliance with all applicable codes. Field installed power wires must be
rated 75° C minimum.
LEGEND
A—Alarm
C—Contactor, Compressor
COM — Common
EQUIP — Equipment
GND — Ground
NC — Normally Closed
NO — Normally Open
R—Relay
TB — Terminal Block
TOR — Torroid,Accessory Ground Fault
Interrupt
Field Wiring
Factory Wiring
Fig. 18 — Field Wiring Diagram; 30HW Units
23
PRI — Primary (Transformer)
S—Suction
LEGEND
GCS — Ground Current Sensing
GND — Ground
SEC — Secondary (Transformer)
SW — Switch
T—Thermistor
TB — Terminal Block
TC — Temperature Control
HGS — Hot Gas Solenoid
HPS — High-Pressure Switch
LLSV — Liquid Line Solenoid Valve
LPS — Low-Pressure Switch
NC — Normally Closed
TDR — Time Delay Relay
THERM — Thermistor
TRAN — Transformer
NEC — National Electrical Code (U.S.A.)
NO — Normally Open
OPS — Oil Pressure Switch
TSW — Transfer Switch
U—Unloader
PL — Plug
Fig. 19 — 30HK, HL Control Box
24
A—Alarm
C—Contactor
CB — Circuit Breaker
CH — Crankcase Heater
CM — Control Module
COM — Common
COMP — Compressor
CWFS — Chilled Water (Fluid) Flow Switch
CWP — Chilled Water (Fluid) Pump
D—Discharge
DLS — Demand Limit Switch
C—Contactor
CB — Circuit Breaker
CM — Control Module
COM — Common
CR — Control Relay
Fig. 20 — 30HW Control Box Components Label
GCS — Ground Current Sensor
GND — Ground
NC — Normally Closed
NEUT — Neutral
NO — Normally Open
LEGEND
SW — Switch
TB — Terminal Block
TDR — Time Delay Relay
THERM — Termistor
TRAN — Transformer
PRE-START-UP
IMPORTANT: Before beginning Start-Up, complete
Start-Up Checklist on pages CL-1 to CL-4. This checklist assures proper start-up of a unit, and provides a
record of unit condition, application requirements, system information, and operation at initial start-up.
ELECTRIC SHOCK HAZARD
Open all disconnects before servicing this
equipment. There may be more than one
disconnect.
Initial Check
IMPORTANT: Electrical power source must agree
with unit nameplate rating. Do not start the chiller, even
momentarily, until the following checks have been
completed.
1. Check all auxiliary components, such as cooling tower
(if used), chilled liquid and condenser water pumps, airhandling equipment, or other equipment to which
the chiller supplies liquid. Consult manufacturer’s
instructions.
2. Be sure flow switch is properly installed and set. See
instructions packaged with flow switch accessory.
3. Set the temperature controller deadband as specified in
Tables 5 and 6. Set point should be at the desired cooler
leaving fluid temperature. Refer to Chilled Fluid Temperature Controller section on page 29 for additional deadband setting information.
4. Backseat (open) compressor suction and discharge shutoffvalves. Crack open valves (one turn in) to allow some
pressure to each test gage (if installed).
5. Backseat (open) liquid line shutoff valve(s).
6. Open valve to capillaries from fluid regulating valve (when
used).
7. Fill chilled fluid liquid circuit with clean water or other
noncorrosive fluid to be cooled. Bleed all air out of the
high points of the system. Set flow rate according to job
requirements. See Table 3. If the chilled water is to be
maintained at a temperature below 40 F (4.4 C), a brine
of sufficientconcentration must be used to prevent freeze-up
at anticipated suction temperatures.
8. Open supply valve (or fill cooling tower, if used) for
condenser water.
9. Check tightness of all electrical connections.
25
Table5—Typical Deadband Requirements
UNIT
CAPACITY
STEPS
2 1.3 (0.7) 2.5 (1.4) 3.8 (2.1)
3 0.8 (0.4) 1.7 (0.9) 2.5 (1.4)
4 0.6 (0.3) 1.3 (0.7) 1.9 (1.1)
COOLER DESIGN RANGE, F (C)
5.0 (2.8) 10.0 (5.6) 15.0 (8.3)
If there is no refrigerant vapor pressure in the system, the
entire system must be leak tested.After repairing leaks, evacuate the system before recharging. Follow approved evacuation procedures when removing refrigeration. Release remaining pressure to an approved evacuated cylinder.
The liquid charging method is recommended for complete charging or when additional charge is required.
Table 6 — Deadband Setting
MIN. REQUIRED DEADBAND
FC
0.5 to 1.5 0.28 to 0.83 1.0
2.0 1.11 2.0
2.5 1.39 2.5
3.0 1.67 2.8
3.5 1.94 3.0
4.0 2.22 3.7
4.5 2.50 4.0
DEADBAND SETTING (F)
10. Check compressor oil charge (should be visible in
oil sight glass). Refer to Check Oil Charge section on
page 27.
11. Be sure the compressor crankcase heater is warm (heater
should be on for 24 hours before starting the compressor). The crankcase heater must be firmly locked into
the compressor crankcase.
12. Be sure the compressor is floating freely on the compressor springs (see Step 4 — Check Compressor Mounting and Connections section on page 3).
13. For 30HL and HWAunits with remote condenser, check
the condenser fans for correct rotation. See instructions
shipped with the condenser.
14. Be sure the unit is fully charged with refrigerant (see
Check Refrigerant Charge section below).
15. If unit is a brine unit, check to ensure proper brine concentration is used to prevent freezing.
Check Refrigerant Charge
When adding or removing refrigerant charge, circulate
water through condenser and cooler at all times to prevent freezing. Freezing damage is considered abuse and
is not covered by Carrier warranty.
The 30HK, HWB, HWC, and HWS units are shipped with
a full refrigerant charge (see Tables 1A-2B). 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 end (30HK, HWC, HWS units
only). This usually requires additional refrigerant charge beyond the amount to clear sight glass.
The 30HL and HWAunits (condenserless) are shipped with
a refrigerant holding charge only. After chiller assembly is
completed in the field, system must be fully charged. While
the unit is running at full capacity, add refrigerant until the
sight glass is clear. R-22 is the normal refrigerant.
Do not open the liquid valve or the compressor discharge
valve until there is a charge in remainder of system. A posi-
tive pressure indicates a charge in system. With the unit operating at full load, check liquid line sight glass to be sure
the unit is fully charged (bubbles in the sight glass indicate
the unit is not fully charged).
Be careful not to overcharge the system. Overcharging
results in higher discharge pressure with higher cooling
water consumption, possible compressor damage, and
higher power consumption.
LIQUID CHARGING METHOD — Add charge to the unit
through the liquid line service valve. Never charge liquid
into the low-pressure side of the system.
1. Frontseat (close) condenser liquid line shutoff valve.
2. Connect a refrigerant cylinder loosely to the charging valve
connection of the liquid line shutoffvalve. Purge the charging hose and tighten the connections.
3. Open the charging valve.
4. If the system has been dehydrated and is under vacuum,
break the vacuum with refrigerant gas. For R-22, build
up system pressure to 58 psig and 32 F (400 kPa and
0° C). Invert the refrigerant cylinder so that the liquid
refrigerant will be charged.
5. a. For complete charge of 30HK, HWB, HWC, and HWS
units, follow charging by weight procedure. When charge
is nearly full, complete the process by observing the
sight glass for clear liquid flow. The use of sight glass
charging is valid only when unit is operating at full
capacity (no unloaders energized).
b. For complete charge of 30HL and HWAunits or where
refrigerant cylinder cannot be weighed, follow charging by sight glass procedure. The use of sight glass
charging is valid only when unit is operating at full
capacity (no unloaders energized).
6. a. The 30HL and HWA condenserless units are shipped
with a holding charge only.After installation with the
field-supplied system high side, the complete system
should be charged until the sight glass is clear (with
the unit running at full capacity). To achieve maximum system capacity, add additional charge equal to
the difference between the condenser optimal charge
and the condenser minimum charge, which can be obtained from the charge data provided in the condenser
installation instructions.
b. To ensure maximum performance of 30HWB units,
raise the compressor saturated discharge temperature
(SDT) to approximately 105 F (40.6 C) by throttling
the condenser water intake. Add charge until there is
approximately 15 to 17° F (8.3 to 9.4° C) of system
subcooling (SDT minus actual temperature entering the
thermostatic expansion valve).
c. Toensure maximum performance of 30HK, HWC, and
HWS units, raise the compressor saturated discharge
temperature (SDT) to approximately 103 F (39.4 C)
by throttling the condenser water intake. Add charge
until there is approximately 8 to 10° F (4.4 to 5.6° C)
for 30HK units or 12 to 14° F (6.7 to 7.8° C) for 30HWC,
HWS units of system subcooling (SDT minus actual
temperature entering the thermostatic expansion valve).
26
Check Oil Charge — The compressor(s) is factory-
charged with oil. If oil is visible in the compressor sight
glass(es), check the unit for operating readiness as described
in Initial Check section (page 25), then start the unit. Observe oil level and add oil, if required, to bring the oil level
in the compressor crankcase(s) to between1⁄8and3⁄8of the
sight glass(es) during steady operation.
TO ADD OIL
1. Close the suction shutoff valve and pump the compressor
crankcase down to between zero and 2 psig (zero to
13.8 kPa) (the low-pressure switch must be jumpered).
Wait a few minutes and repeat as needed until the pressure remains between zero and 2 psig (zero to 13.8 kPa).
2. Close the discharge shutoff valve.
3. Remove the oil-fill plug above the compressor sight glass,
add oil through the plug hole, and replace the plug.
4. After opening the suction and discharge service valves,
remove low-pressure switch jumper, run the compressor
for about 20 minutes, and check the oil level.
Use only Carrier-approved compressor oil:
Petroleum Specialties, Inc. ................Cryol 150*
Texaco, Inc. .........................Capella WF-32
Witco Chemical Co. .....................Suniso 3GS
*Factory charge.
Do not reuse drained oil, and do not use any oil that has
been exposed to the atmosphere.
TO REMOVE OIL
The crankcase will be under slight pressure. Be careful
not to lose the entire oil charge. Gloves and eye protection must be worn.
Pump down the compressor to between zero and 2 psig
(zero to 13.8 kPa). Loosen the oil drain valve located in the
compressor base to allow the oil to seep out past plug threads.
Be careful not to remove plug; the entire oil charge may be
lost. Small amounts of oil can be removed through oil pump
discharge connection.
START-UP AND OPERATION
OperationChecks —
under supervision of an experienced refrigeration technician. Refer to Start-Up Checklist on pages CL-1 to CL-4.
Remove and save the checklist for future reference.
1. Crankcase heater must be energized for at least 24 hours
before the chiller is started.
2. Open all system valves that may have been closed during
or after charging.
3. Check air-handling equipment, chilled water (fluid) and
condenser pumps, and any other equipment connected to
the chiller.
4. Start the unit by moving the ON-OFF switch to the ON
position.
5. Check all controls for proper operation. Follow Start-Up
Checklist procedures in these instructions.
6. Adjust the water regulating valve (where used) to obtain
the most economical head pressure (based on the relative
cost of water and electricity). Head pressure is normally
200 to 230 psig (1379 to 1586 kPa) for 30HK,HL units,
and 195 to 226 psig (1344 to 1558 kPa) for 30HW units
when using R-22 refrigerant.
7. Check the cooler leaving chilled water temperature to see
that it remains well above 32 F (0° C), or the brine freezing point if the unit is a medium temperature brine unit.
Start-up should be performed only
8. Recheck compressor oil level (see Check Oil Charge section on this page). Add or remove oil to achieve the level
required during steady operation.
Operating Limitations
Do not operate with cooler leaving chiller water (fluid)
temperature (LCWT) below 40 F (4.5 C) for the standard units, or below 15 F (−9.4 C) for units factory built
for medium temperature brine.
HIGH COOLER LEAVING CHILLED WATER (FLUID)
TEMPERATURES (LCWT) — During start-up with cooler
LCWT above approximately 60 F (16 C), the unit expansion
valve will limit suction pressure to approximately 90 psig
(620 kPa) to avoid overloading the compressor.
LOW COOLER LCWT — For standard units, the LCWT
must be no lower than 40 F (4.5 C). If the unit is the factoryinstalled optional medium temperature brine unit, the cooler
LCWT can go down to 15 F (−9.4 C).
MAIN POWER SUPPLY — Minimum and maximum acceptable supply voltages are listed in Tables 4A and 4B.
Unbalanced 3-Phase Supply Voltage — Never operate a mo-
tor where a phase imbalance between phases is greater than
2%. To determine percent voltage imbalance, see Unbal-
anced 3-Phase Supply Voltage section on page 19.
Check Refrigerant Feed Components
THERMOST ATICEXPANSION VALVE(TXV) — The TXV
controls the flow of liquid refrigerant to the cooler by maintaining constant superheat of vapor leaving the cooler. There
is one valve per refrigerant circuit. The valve(s) is activated
by a temperature-sensing bulb(s) strapped to the suction line(s).
The valve(s) is factory-set to maintain between 8° and
10° F (4.4° and 5.6° C) of superheat leaving the cooler. Check
the superheat during operation after conditions have stabilized. If necessary, adjust the superheat to prevent refrigerant floodback to the compressor.
FILTER DRIER — The function of the filter drier is to maintain a clean, dry system. The moisture indicator (described
below) indicates any need to change the filter drier. The filter drier is a sealed-type drier. When the drier needs to be
changed, the entire filter drier must be replaced.
NOTE: The 30HK, HL units have 2 filter driers; one per
circuit.
MOISTURE-LIQUID INDICATOR — The indicator is located immediately ahead of the TXV to provide an indication of the refrigerant moisture content. It also provides a
sight glass for refrigerant liquid. Clear flow of liquid refrigerant (at full unit loading) indicates sufficient charge in the
system. Bubbles in the sight glass (at full unit loading) indicate an undercharged system or the presence of noncondensables. Moisture in the system, measured in parts per million
(ppm), changes the color of the indicator as follows:
Blue (safe) — Moisture is below 45 ppm
Light Violet (caution) — 45 to 180 ppm
Pink (wet) — above 180 ppm
The unit must be in operation at least 12 hours before the
moisture indicator gives an accurate reading, and must be in
contact with liquid refrigerant. At the first sign of moisture
in the system, change the corresponding filter drier.
NOTE: The 30HK, HL units have 2 indicators; one per
circuit.
LIQUID LINE SERVICE VALVE — This valve provides a
refrigerant charging port and, in combination with the compressor discharge service valve(s), allows the refrigerant to
be pumped into the high side of the system.
27
DISCHARGE LINE CHECK VAL VE— On all 30HL, HWA
units, a factory-supplied check valve is shipped with the unit
(two valves are provided for 30HL units). The check valve(s)
should be installed in the discharge line(s) downstream from,
but close to, the compressor muffler. Install the valve in any
position except bonnet down.
The check valve(s) prevents backwards-migration of refrigerant from the condenser(s) to the compressor(s) and cooler
during the compressor off cycle.
HOT GAS BYPASS VALVE — On units equipped with the
factory-installed capacity reduction option (30HW only), a
hot gas bypass valve is located between the discharge line
and the cooler entering-refrigerant line. A solenoid valve is
installed in the equalizer line of the hot gas valve to allow
the temperature control to cycle the hot gas bypass function.
The amount of capacity reduction achieved by the hot gas
bypass valve may be altered by adjusting the spring tension
of the hot gas bypass valve. The total unit capacity should
not be reduced below 10% of the nominal rating.
LIQUID LINE SOLENOID VALVE (30HL ONLY) — The
solenoid valve closes when its circuit is inoperative, either
from capacity control or from any safety trip.
PRESSURE RELIEF DEVICES — All 30HK, 30HL, and
30HW units are equipped with a compressor pressure relief
valve located on the crankcase of the 06E compressor units
(except for the 30HW018 units which have a compressor
displacement less than 50 cfm). The pressure relief valve opens
at 450 psig (3103 kPa).
The 30HK,HWC, and HWS units are also equipped with
a high-side refrigerant pressure relief valve on the shell and
tube condenser. The valve is set to open at the working pressure of the condenser, as shown in Table 7.
The 30HWB does not have a condenser pressure relief
valve, because the brazed-plate condenser is not considered
a pressure vessel, as defined in ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigerating, and Air Conditioning Engineers) safety
code requirements.
For 30HL and HWA condenserless units, pressure relief
devices designed to relieve at 450 psig (3103 kPa), must be
field-supplied and installed in the discharge line piping after
the muffler in accordance with ANSI/ASHRAE 15 safety code
requirements. Additional pressure relief valves, properly selected, must be field-supplied and installed to protect high
side equipment and may be required by applicable codes.
Most codes require that a relief valve be vented directly
to the outdoors. The vent line must not be smaller than the
relief valve outlet. The condenser relief valves have a
5
⁄8-in.
SAE (Society of Automotive Engineers, U.S.A.) flare connection. The compressor relief valves have a3⁄8-in. SAE Flare
connection. Consult ANSI/ASHRAE 15 for detailed infor-
mation concerning layout and sizing of relief vent lines.
All units have a factory-installed fusible plug in the suction line which relieves on a temperature rise at 170 F
(77 C) and one in the liquid line which relieves at 210 F (99 C).
Table 7 — Pressure Relief Valve Settings
UNIT
30HK 385 2655
30HWC 365 2517
30HWS 335 2310
PRESSURE RELIEF VALVE SETTINGS
Psig kPa
Compressor and Unit Protective Devices
CIRCUIT BREAKER — There is a single circuit breaker
per compressor in each unit. The circuit breaker(s) protects
the compressor(s) against overloading, locked rotor conditions, and primary single phasing. If the circuit breaker(s)
trips, determine the cause and correct it before resetting the
breaker(s).
COMPRESSOR INTERNAL THERMALPROTECTION —
On the 30HW018 units, there is a sensor imbedded in
the compressor windings to detect an overtemperature
condition.
The thermostat opens and shuts off the compressor if the
discharge gas temperature exceeds 295 ± 5° F (146 ± 2.8° C).
The thermostat will reset when the temperature drops to approximately 250 F (121 C). However, the control module
will keep the unit locked off until control power is manually
cycled off, then back on.
NOTE: Compressor overtemperature protection for 30HK,
HL units is accomplished by high and low pressure switches
and circuit breakers which are external to the compressors.
CRANKCASE HEATER
Never open or disconnect any switch that energizes the
crankcase heater, unless the unit is being serviced or will
be shut down for an extended period. After service or
shutdown, energize the crankcase heater for 24 hours
before starting the compressor.
IMPORTANT: The crankcase heater is located in the
bottom corner of the compressor and held in place by
a bracket. The heater must be tight to prevent it from
backing out of the heater well. The heater eventually
burns out if exposed to the air for an extended period.
The heater in each compressor prevents absorption of liquid refrigerant by the compressor oil when the compressor
is not operating. The heater is wired into the normally closed
contacts of the compressor control relay so that it energizes
only when the compressor is not operating. The heater is
125 w, 115 v on all 60 Hz units; 230 v on 50 Hz 30HK, HL
units; and 115 v on 50 Hz 30HW units.
OILPRESSURE SAFETY SWITCH (OPS) — One OPS per
compressor is standard on all 30HL and HWA units, and on
all units equipped with the medium temperature brine option. One is located in each compressor terminal box with
capillaries to the crankcase and oil pump. The switch is also
offeredasan accessory (part number 30HW900006) for standard 30HK, HWB, HWC, and HWS units. When used, the
OPS is monitored by the unit control module. If at any time
after the compressor is started, the OPS is open for more
than 2 minutes, the compressor shuts down and is locked off
until control power is manually cycled to OFF, then back to
the ON position. The OPS cuts out at5±1psig (34.5 ±
6.9 kPa), and has a maximum cut-in of 9.5 psig (65.5 kPa).
Check Unit Safeties
CONTROL MODULE — The unit control module is located in the control section of the control box. See Fig. 19
and 20. It performs several functions. The control module
has a built-in compressor anti-short-cycle timer which will
not allow a compressor to restart until 5 minutes have elapsed
since the previous shutdown.
On 30HL and HWA units (and 30HK, HWB, HWC, and
HWS units equipped with the oil pressure safety switch [OPS]
accessory), the compressor oil pressure and low-pressure
switch(es) (LPS) are monitored through the control module.
The unit is allowed to remain operational as long as the OPS
and/or LPS have not been open for more than 2 minutes after a compressor has started.After start-up, if the OPS and/or
LPS are open for more than 2 minutes, the control module
shuts down the compressor and places the unit in a lockout
condition. The control module activates the fault indication
circuit, and the unit service lamp is illuminated. The unit
cannot be restarted until control power is manually cycled to
OFF, then to ON.
28
The control module also monitors the high-pressure
switch(es) and compressor internal thermal protection (30HW).
If at any time one or both of these switches opens, the control module shuts down the compressor and places the unit
in a lockout condition. The control module activates the fault
indication circuit, and the unit service lamp is illuminated.
The unit cannot be restarted until control power is manually
cycled to OFF, then to ON.
If the unit shuts down on an automatic reset switch, such
as the temperature controller, the compressor will be allowed to restart when the switch closes and the control module anti-short-cycle time has elapsed.
For Servicing Only — To speed up the 5-minute anti-short
cycle, a jumper may be placed between terminals T1 and T6
of the control module.
This jumper must be removed after servicing is complete.
Failure to remove this jumper is considered abusive treatment and will void the Carrier warranty.
HIGH-PRESSURE SWITCH — A high-pressure switch is
provided to protect each compressor and refrigeration system from unsafe high pressure conditions. See Table 8 for
high-pressure switch settings.
The high-pressure switch is mounted in the discharge side
of each compressor.A snubber is provided between the compressor discharge manifold and the high-pressure switch to
prevent pressure pulsations from damaging the switch.
If an unsafe, high-pressure condition should exist, the switch
opens and shuts off the affectedcompressor.The unit control
module prevents the unit from restarting. The unit will not
restart until control power is manually cycled off, then on.
To check operation of the switch, slowly close the compressor discharge shutoff valve until the compressor shuts
down. The switch should open at the pressure corresponding
to the appropriate switch setting as shown in Table 8.
Table 8 — Factory Settings, High-Pressure Switch
(Fixed)
UNIT
30
HK, HWS 280 ± 10 1931 ± 69 180 ± 20 1241 ± 138
HL, HWB, HWC 375 ± 10 2585 ± 69 275 ± 20 1896 ± 138
HWA 395 ± 10 2723 ± 69 298 ± 20 2054 ± 138
CUTOUT CUT-IN
Psig kPa Psig kPa
Reopen the compressor discharge shutoff valve, and cycle
the unit ON-OFF switch to OFF, then ON. The unit should
restart after the compressor anti-short-cycle delay, built into
the unit control module, expires.
LOW-PRESSURESWITCH —Alow-pressure switch is provided to protect each compressor and system from a loss of
refrigerant. The low-pressure switch(es) also provides freeze
protection for the cooler. The low-pressure switch(es) is nonadjustable. See Table 9 for low-pressure switch settings. One
switch is used for standard units, and a different switch is
used for units with the brine option.
Table 9 — Factory Settings, Low-Pressure Switch
(Fixed)
T ocheckoperation of the low-pressure switch, slowly close
the suction service valve and allow the affected compressor
to pump down. The compressor should cut out when the suction pressure falls below the low-pressure switch cutout setting. Open the suction service valve. The compressor should
restart after the low-pressure switch closes, and the compressor anti-short-cycle delay expires.
CHILLED FLUID TEMPERATURECONTROLLER — All
units are equipped with a temperature controller (see
Fig. 21) which is capable of controlling up to 4 steps of capacity. A thermistor installed inside the cooler supplies the
input to the controller. The temperature controller can operate a system with cooling ranges (entering cooler fluid temperature minus leaving cooler fluid temperature) of 5° to
15° F (2.8° to 8.3° C), and with a range of set points from
40 to 60 F (4.4 to 15.5 C) for standard units, and 15 to
39 F (−9.4 to 3.9 C) for units with the medium temperature
brine option.
The set point of the temperature controller should be adjusted to the desired leaving cooler fluid temperature, and
verified by using a thermometer placed in the leaving-cooler
piping. The amount of deadband around the set point value
is adjusted through the use of the deadband adjustment knob
on the temperature controller.See Tables 5 and 6 for the correct setting of the deadband.
The unit should then control the average leaving-fluid temperature to this setting. If the leaving-fluid temperature does
not correspond to the desired set point, slightly readjust the
controller set point knob until the desired leaving-fluid temperature is obtained. The temperature controller has an adjustable 30-second (HI position) to 3-minute (LO position)
sample rate knob. The sample rate knob should always be
set at LO position (fully clockwise) for 30HK, HL units, and
at HI position (fully counterclockwise) for 30HW units.
Do not force the knob dials past the stops. This
could cause loss of control point and damage to the
controller.
UNIT
TYPE
STANDARD 42±3 290±21 57±5 393±34
BRINE 27±3 186±21 44±5 303±34
CUTOUT CUT-IN
Psig kPa Psig kPa
LEGEND
COM — Common
NC — Normally Closed
NO — Normally Open
Fig. 21 — Temperature Controller
29
If rapid cycling of the capacity steps occurs, the deadband
setting is too low and should be raised to the point that rapid
cycling will cease.
If a cooler design range other than those shown in
Table 5 is desired, determine the setting by using the following formula and Table 6:
Minimum Required Unit Deadband:
Minimum Deadband = (Cooler Design Dt÷
(2 x no. of Capacity Steps)
= F (C)
The lights on the temperature controller will indicate the
status of the control. If the green light labeled ABOVE SET
POINT is illuminated, the controller will add steps of capacity, if additional steps are available. If the yellow light
labeled BELOW SET POINT is illuminated, the controller
removes steps of capacity.
The temperature controller also has a red light labeled OUT
OF RANGE that indicates the system load was reduced faster
than the controller could remove stages. If this occurs, the
unit shuts down to avoid cooler freeze-up.
Once the temperature rises back into the control band, the
unit restarts automatically. This also occurs if the thermistor fails in the open mode. In the case of a thermistor failure, the unit does not restart until the thermistor is replaced.
FREEZE-UP PROTECTION
On medium temperature brine units, the brine must be
properly mixed to prevent freezing at a temperature of
at least 15 F (8.3 C) below the leaving-fluid temperature
set point. Failure to provide the proper brine mixture is
considered abuse and may void the Carrier warranty.
All units have the following 2 modes of freeze-up
protection.
1. Thetemperature controller protects the system from freeze-up
due to rapid loss of load and from low fluid flow by rapidly removing all steps of capacity and shutting down the
compressor if an out-of-range condition exists. This normally occurs if the leaving-fluid temperature drops 6 to
7° F (3.3 to 3.9° C) below the temperature controller set
point. Set point range is 40 to 60 F (4.4 to 15.6 C) for
standard units and 15 to 39 F (−9.4 to 3.9 C) for units
with medium temperature brine option.
2. The low-pressure switch provides a back-up cooler freeze-up
protection system. The low-pressure switch shuts down
the unit when the suction temperature drops to a point
where the cooler will freeze up.
LOSS-OF-COOLER-FLOW PROTECTION — A proof-ofcooler-flow device (accessory flow switch) must be used with
all 30HK, HL, HW chillers. The device should be a differential pressure type device and should be set to shut the unit
off if cooler gpm drops below 1.5 times the nominal unit
tonnage. Carrier accessory flow switch, part number
30HW900003 is available for this purpose. See page 19 and
Fig. 17 and 18.
COMPRESSOR GROUND FAULTSENSOR— The ground
fault sensor accessory (Part No. 30HW900004) monitors all
phases of the 3-phase power supply to the compressor. If a
short to ground is sensed by the sensor, the compressor automatically shuts down. This prevents contamination of the
refrigeration system from acid formation. The compressor
shuts down when a 2.5 ± 2 amps ground current is sensed by
a toroid installed around the compressor power leads. The
unit control module locks the compressor off until the circuit
power is cycled to OFF, and then ON. For installation details, see the instructions included with the accessory
package.
NOTE: Two accessory packages are required for 30HK, HL
units.
UNIT OPERATION
Capacity Control and Operating Sequence —
The 30HW units have a multiple-step temperature controller, factory set to maintain capacity control through leaving
chilled fluid temperature. The controller has 4 capacity steps.
All 30HK, HL units have 4 capacity steps as standard. The
30HW018 and 028-040 units have 3 steps as standard, with
a fourth step available as a factory-installed option. The
30HW025 units have 2 steps of capacity as standard with a
third step available as a factory-installed option. All units
have electric solenoid operated unloaders. See Tables10 and
11 for capacity control steps of each unit.
At initial start-up, assume that all safety devices are sat-
isfied and there is a call for cooling.
30HK,HL UNITS — Close the compressor circuit breaker
and turn the ON-OFF switch to the ON position.
In approximately 5 minutes, the lead compressor starts and
the unloaders are energized (compressor unloads when compressor unloader solenoid is energized). On 30HL units, the
liquid line solenoid valve will remain closed for the first
10 seconds of compressor operation. The low-pressure and
oil pressure switches are bypassed for 2 minutes. At the end
of the 2-minute bypass period, the low-pressure and oil pressure switches are active in the control circuit.
Approximately 30 seconds (high setting) or 3 minutes (low
setting) later, depending on the sample rate setting, the lag
compressor starts and the unloaders are energized (compressor unloads when compressor unloader solenoid is energized). On 30HL units, the liquid line solenoid valve will
remain closed for the first 10 seconds of compressor operation. The low-pressure and oil-pressure switches are bypassed for 2 minutes. At the end of the 2-minute bypass period, the low-pressure and oil-pressure switches are active in
the control circuit.
Approximately 30 seconds (high setting) or 3 minutes (low
setting) later, depending on the sample rate setting, the lead
compressor is loaded (unloader solenoids deenergized).
Approximately 30 seconds (high setting) or 3 minutes (low
setting) later, depending on the sample rate setting, the lag
compressor is loaded (unloader solenoids deenergized).
When the load is satisfied and the leaving fluid temperature falls below the set point, the last stage activated is dropped
immediately. If the leaving fluid temperature still remains
below the set point, then the control drops an additional stage
every 30 (high setting) or 180 (low setting) seconds, depending on the sample rate setting.
30
Once the compressor is shut off, the control system prevents the compressor from restarting within 5 minutes of when
it was last shut down. Once this period has elapsed and the
leaving fluid temperature rises above the set point, the compressor will start within 5 seconds.
If the unit is equipped with field-installed hot gas bypass,
the hot gas bypass valve opens only when stage 1 is active.
If the unit trips out on high pressure, low pressure, ground
current (accessory), or low oil pressure, the control module
locks the unit off and must be manually reset (turn the ONOFF switch to OFF and then back to ON). If the unit trips
out on low fluid temperature, chilled fluid flow switch, or
chilled fluid pump switch, it restarts automatically when the
condition is corrected.
30HW UNITS — Close the compressor circuit breaker and
move ON-OFF switch to the ON position. The switch should
light up. In approximately 3 seconds, the compressor starts
unloading. For 2 minutes the low-pressure switch is
bypassed and the unloaders are energized (compressor unloads when compressor unloader solenoid is energized). At
end of 2-minute bypass period, the low-pressure switch activates the control circuit and the temperature controller regulates the capacity steps based on leaving cooler fluid temperature, set point and deadband settings on the temperature
controller.
Table 10 — Capacity Control Steps — 30HK, HL Standard Units
If system load drops to the point where the unit is fully
unloaded and the fluid temperature is below the lower deadband limit, the compressor shuts off and is not able to restart
until the 5-minute anti-short cycle has expired. If during normal operation, the fluid temperature rises above the upper
deadband limit, the temperature controller adds a step of capacity (assuming a step is left to be added).
On condenserless units (30HWA),or on fluid-cooled units
(30HWB,C, and S) equipped with the accessory oil safety
switch, the control module provides a 2-minute bypass of
the oil safety switch.
If the unit is equipped with hot gas bypass option, the hot
gas bypass valve closes before unloaders are deactivated.
If the unit trips out on high pressure, ground current (accessory), or low oil pressure, the control module locks the
unit off and must be manually reset (by turning the ON-OFF
switch to OFF, then back to ON). If the unit trips out on low
pressure, low fluid temperature, the chilled fluid flow switch,
or the chilled fluid pump switch, it restarts automatically when
the condition is corrected.
UNIT
30HK040
30HK,HL050
30HK,HL060
LEGEND
Ckt — Circuit
Disp. — Displacement
CONTROL
TRANSFER SWITCH COMPRESSOR
STEPS
1 25 2 2 — 25 2 — 2
2 50 4 2 2 50 4 2 2
3 75 6 4 2 75 6 2 4
4 100 8 4 4 100 8 4 4
1 40 4 4 — 20 2 — 2
2 60 6 4 2 60 6 4 2
3 80 8 6 2 80 8 4 4
4 100 10 6 4 100 10 6 4
1 33 4 4 — 33 4 — 4
2 66 8 4 4 66 8 4 4
3 8810 6 4 8810 4 6
4 100 12 6 6 100 12 6 6
%
Disp.
NO. 1 POSITION*
Operating Cylinder
Total Ckt 1 Ckt 2 Total Ckt 1 Ckt 2
*Manually operated.
NOTE: Circuits are designated from left to right when viewed from
front of unit.
TRANSFER SWITCH COMPRESSOR
%
Disp.
NO. 2 POSITION*
Operating Cylinder
31
Table 11 — Capacity Control Steps —
30HW Standard Units
UNIT CAPACITY CONTROL CAPACITY OPERATING
30HW STEPS* % CYLINDERS
018
025
028
035
040
*Factory-installed hot gas bypass option adds an additional capacity
step to that shown in this table.
1 33.3 2
2 66.7 4
3 100.0 6
1 50.0 2
2 100.0 4
1 33.3 2
2 66.7 4
3 100.0 6
1 33.3 2
2 66.7 4
3 100.0 6
1 33.3 2
2 66.7 4
3 100.0 6
SERVICE
ELECTRIC SHOCK HAZARD
To avoid the possibility of electrical shock,
turn off all power to unit before servicing.
Do not attempt to bypass, short-out, or modify the control circuit or electronic boards in any way to correct a
problem. This could result in component failures or a
hazardous operating condition.
Compressor Replacement — If a replacement
6-cylinder compressor has a center-bank cylinder head with
discharge valve pad facing the pump end, remove head and
install reverse flange head from original compressor (discharge valve pad toward the motor end). Center-bank cyl-
inder head cannot be rotated 180 degrees.
Be sure all the hardware from the old compressor is
removed and installed on the new compressor, including
the high-pressure switch snubber, the discharge gas thermostat (30HW025-040), the oil pressure safety switch (if equipped),
and the low-pressure switch.
The compressor can be removed from either the front or
the sides of the unit, depending on where clearance space
was allowed during unit installation. The compressor and mounting hardware are mounted on a plate which is screwed down
to the unit basepan. Remove the 4 screws holding the plate
to the basepan and the plate should easily slide out of the
unit. Mount the replacement compressor to the plate, slide
the plate back into the unit and secure with the 4 screws.
CircuitBreaker(s) — The breaker(s) provides 3-leg over-
load protection. Do not bypass connections or increase the
size of the circuit breaker(s) to correct trouble. Determine
the cause of the trouble and correct it before resetting the
breaker(s).Atripped breaker must be manually reset by moving the circuit breaker handle to OFF, then ON position. See
Tables 4A and 4B for must-trip amps (MTA).
NOTE: One circuit breaker is provided per compressor.
Brazed-Plate Cooler and Condenser Heat Exchanger Replacement —
ers cannot be repaired if they develop a leak. If a leak (refrigerant or water) develops, the heat exchanger must be
replaced. To replace a brazed plate heat exchanger:
1. Disconnect the liquid-in and liquid-out connections at the
heat exchanger.
2. Check that the replacement heat exchanger is the same as
the original heat exchanger. For the condensers, compare
part numbers on the heat exchangers. For the coolers, insulation covers the manufacturer’s part number.Make sure
the depths of the replacement and original cooler heat exchangers are the same.
3. Reclaim the refrigerant from the system, and unsolder the
refrigerant-in and refrigerant-out connections.
1
4. Remove the four
to the brackets. Save the nuts.
5. Install the replacement heat exchanger in the unit and
attach to the bracket using the four
in Step 4.
6. Carefully braze the refrigerant lines to the connections on
the heat exchanger.Lines should be soldered using silver
as the soldering material with a minimum of 45% silver.
Keep the temperature below 1472 F (800 C) under normal soldering conditions (no vacuum) to prevent the copper solder of the brazed plate heat exchanger from changing
its structure. Failure to do so can result in internal or
external leakage at the connections which cannot be
repaired.
7. Reconnect the water/brine lines.
8. Dehydrate and recharge the unit. Check for leaks.
⁄2-in. nuts holding the heat exchanger
Brazed-plate heat exchang-
1
⁄2-in. nuts removed
Brazed-Plate Cooler and Condenser Heat ExchangerCleaning —
be cleaned chemically.Aprofessional cleaning service skilled
in chemical cleaning should be used. Use a weak acid (5%
phosphoric acid, or if the heat exchanger is cleaned frequently,5% oxalic acid). Pump the cleaning solution through
the exchanger, preferably in a backflush mode. After cleaning, rinse with large amounts of fresh water to dispose of all
the acid. Cleaning materials must be disposed of properly.
The mesh screens in front of the water/brine inlets of the
heat exchangers should be cleaned periodically, depending
on condition of the chiller water/brine.
Brazed-plate heat exchangers must
Shell-and-Tube Condenser Cleaning— The shell-
and-tube condenser tubes can be cleaned either mechanically or chemically. To clean them chemically, follow the
procedure described in Brazed-Plate Cooler and Condenser
Heat Exchanger Cleaning section above.
To clean the condenser tubes manually:
1. Order tubing brushes (Carrier part no. KC21AH105).
2. Close the valves on the condenser and relieve condenser
water pressure. BE SURE TO PROVIDE DRAINAGE
TO PREVENT WATER DAMAGE.
3. Remove the condenser heads and brush the tubes clean,
removing scale and other deposits.
4. Inspect the head gaskets and replace if necessary.
5. Clean all gasket surfaces prior to reassembly.
6. Replace the water heads and torque the head bolts to
90 ft-lb (122 N-m). Allow the gaskets to set overnight
and re-torque the bolts to ensure proper sealing.
32
Thermistor— The resistance at various temperatures for
the thermistor are given in Tables 12A and 12B.
THERMISTOR REPLACEMENT, 30HK, HL UNITS
Thermistors are installed directly in fluid circuit. Drain
fluid before removing.
Proceed as follows (see Fig. 22):
1. Remove and discard original thermistor and coupling.
IMPORTANT:Do not diassemble new coupling. Install as received.
2. Apply pipe sealant to1⁄4-in. NPT threads on replacement
coupling and install in place of original. Do not use a packing nut to tighten coupling. This damages the ferrules (see
Fig. 22).
3. Insert thermistor T1 into coupling body to its full depth.
Tighten packing nut finger tight to position ferrules, then
tighten 1
1
⁄4turns more using a back-up wrench. Ferrules
are not attached to the sensor, which can be withdrawn
from coupling for service.
THERMISTOR REPLACEMENT, 30HW UNITS — To replace the thermistor, follow these steps:
1. Disconnect the existing thermistor from the S1 and S2
terminals of the temperature controller (located in the control section of the control box).
2. Remove the thermistor from the well in the cooler leavingfluid cacity.
3. Insert the replacement thermistor into the thermistor well.
4. Run thermistor wires into the control box and connect to
the S1 and S2 terminals of the temperature controller.
Fig. 22 — Thermistor
33
Table 12A — Sensor Temperature (F) vs Resistance
TEMPERATURE RESISTANCE
(F) (OHMS)
-25 98,010
-24 94,707
-23 91,522
-22 88,449
-21 85,485
-20 82,627
-19 79,871
-18 77,212
-17 74,648
-16 72,175
-15 69,790
-14 67,490
-13 65,272
-12 63,133
-11 61,070
-10 59,081
-9 57,162
-8 55,311
-7 53,526
-6 51,804
-5 50,143
-4 48,541
-3 46,996
-2 45,505
-1 44,066
0 42,678
1 41,339
2 40,047
3 38,800
4 37,596
5 36,435
6 35,313
7 34,231
8 33,185
9 32,176
10 31,201
11 30,260
12 29,351
13 28,472
14 27,624
15 26,804
16 26,011
17 25,245
18 24,505
19 23,789
20 23,096
21 22,427
22 21,779
23 21,153
24 20,547
25 19,960
26 19,392
27 18,843
28 18,311
29 17,796
30 17,297
31 16,814
32 16,346
33 15,892
34 15,453
35 15,027
36 14,614
37 14,214
38 13,826
39 13,449
40 13,084
41 12,730
42 12,387
43 12,053
44 11,730
45 11,416
46 11,111
47 10,816
48 10,529
49 10,250
50 9,979
51 9,717
52 9,461
53 9,213
54 8,973
55 8,739
56 8,511
57 8,291
58 8,076
59 7,868
60 7,665
61 7,468
62 7,277
TEMPERATURE RESISTANCE
(F) (OHMS)
63 7,091
64 6,911
65 6,735
66 6,564
67 6,399
68 6,237
69 6,081
70 5,929
71 5,781
72 5,637
73 5,497
74 5,361
75 5,229
76 5,101
77 4,976
78 4,855
79 4,737
80 4,622
81 4,511
82 4,403
83 4,298
84 4,195
85 4,096
86 4,000
87 3,906
88 3,814
89 3,726
90 3,640
91 3,556
92 3,474
93 3,395
94 3,318
95 3,243
96 3,170
97 3,099
98 3,031
99 2,964
100 2,898
101 2,835
102 2,773
103 2,713
104 2,655
105 2,598
106 2,542
107 2,488
108 2,436
109 2,385
110 2,335
111 2,286
112 2,238
113 2,192
114 2,147
115 2,103
116 2,060
117 2,018
118 1,977
119 1,937
120 1,898
121 1,860
122 1,822
123 1,786
124 1,750
125 1,715
126 1,680
127 1,647
128 1,614
129 1,582
130 1,550
131 1,519
132 1,489
133 1,459
134 1,430
135 1,401
136 1,373
137 1,345
138 1,318
139 1,291
140 1,265
141 1,239
142 1,214
143 1,189
144 1,165
145 1,141
146 1,118
147 1,095
148 1,072
149 1,050
150 1,028
TEMPERATURE RESISTANCE
(F) (OHMS)
151 1,007
152 986
153 965
154 945
155 925
156 906
157 887
158 868
159 850
160 832
161 815
162 798
163 782
164 765
165 749
166 734
167 719
168 705
169 690
170 677
171 663
172 650
173 638
174 626
175 614
176 602
177 591
178 581
179 570
180 560
181 551
182 542
183 533
184 524
185 516
186 508
187 501
188 494
189 487
190 480
191 473
192 467
193 461
194 456
195 450
196 444
197 439
198 434
199 429
200 424
201 419
202 415
203 410
204 405
205 401
206 396
207 391
208 386
209 382
210 377
211 372
212 366
213 361
214 356
215 350
216 344
217 338
218 332
219 325
220 318
221 311
222 304
223 297
224 289
225 282
34
Table 12B — Sensor Temperature (C) vs Resistance
TEMPERATURE RESISTANCE
(C) (OHMS)
-32.0 100 049
-31.5 97 006
-31.0 94 061
-30.5 91 209
-30.0 88 449
-29.5 85 777
-29.0 83 191
-28.5 80 687
-28.0 78 264
-27.5 75 918
-27.0 73 648
-26.5 71 451
-26.0 69 324
-25.5 67 265
-25.0 65 272
-24.5 63 344
-24.0 61 477
-23.5 59 670
-23.0 57 921
-22.5 56 228
-22.0 54 589
-21.5 53 003
-21.0 51 467
-20.5 49 980
-20.0 48 541
-19.5 47 148
-19.0 45 799
-18.5 44 492
-18.0 43 228
-17.5 42 003
-17.0 40 817
-16.5 39 668
-16.0 38 556
-15.5 37 478
-15.0 36 435
-14.5 35 424
-14.0 34 444
-13.5 33 495
-13.0 32 576
-12.5 31 685
-12.0 30 821
-11.5 29 984
-11.0 29 173
-10.5 28 386
-10.0 27 624
- 9.5 26 884
- 9.0 26 168
- 8.5 25 472
- 8.0 24 798
- 7.5 24 144
- 7.0 23 509
- 6.5 22 893
- 6.0 22 296
- 5.5 21 716
- 5.0 21 153
- 4.5 20 606
- 4.0 20 076
- 3.5 19 561
- 3.0 19 061
- 2.5 18 575
- 2.0 18 103
- 1.5 17 645
- 1.0 17 199
- 0.5 16 766
0.0 16 346
0.5 15 937
1.0 15 539
1.5 15 153
2.0 14 777
2.5 14 412
3.0 14 057
3.5 13 711
4.0 13 375
4.5 13 048
5.0 12 730
5.5 12 420
6.0 12 119
6.5 11 826
7.0 11 541
7.5 11 263
8.0 10 992
8.5 10 729
9.0 10 472
9.5 10 223
10.0 9 979
10.5 9 742
11.0 9 512
11.5 9 287
12.0 9 068
12.5 8 855
13.0 8 647
13.5 8 444
14.0 8 247
14.5 8 055
15.0 7 868
15.5 7 685
TEMPERATURE RESISTANCE
(C) (OHMS)
16.0 7507
16.5 7334
17.0 7165
17.5 7000
18.0 6840
18.5 6683
19.0 6531
19.5 6382
20.0 6237
20.5 6096
21.0 5959
21.5 5825
22.0 5694
22.5 5566
23.0 5442
23.5 5321
24.0 5203
24.5 5088
25.0 4976
25.5 4867
26.0 4760
26.5 4656
27.0 4555
27.5 4457
28.0 4360
28.5 4267
29.0 4175
29.5 4086
30.0 4000
30.5 3915
31.0 3832
31.5 3752
32.0 3674
32.5 3597
33.0 3523
33.5 3450
34.0 3379
34.5 3310
35.0 3243
35.5 3177
36.0 3113
36.5 3051
37.0 2990
37.5 2931
38.0 2873
38.5 2816
39.0 2761
39.5 2707
40.0 2655
40.5 2603
41.0 2553
41.5 2504
42.0 2457
42.5 2410
43.0 2364
43.5 2320
44.0 2276
44.5 2234
45.0 2192
45.5 2152
46.0 2112
46.5 2073
47.0 2035
47.5 1997
48.0 1961
48.5 1925
49.0 1890
49.5 1856
50.0 1822
50.5 1789
51.0 1757
51.5 1725
52.0 1694
52.5 1663
53.0 1634
53.5 1604
54.0 1575
54.5 1547
55.0 1519
55.5 1492
56.0 1465
56.5 1438
57.0 1412
57.5 1387
58.0 1362
58.5 1337
59.0 1313
59.5 1289
60.0 1265
60.5 1242
61.0 1219
61.5 1197
62.0 1175
62.5 1153
63.0 1132
63.5 1111
TEMPERATURE RESISTANCE
(C) (OHMS)
64.0 1090
64.5 1070
65.0 1050
65.5 1030
66.0 1011
66.5 992
67.0 973
67.5 955
68.0 937
68.5 919
69.0 902
69.5 885
70.0 868
70.5 852
71.0 836
71.5 820
72.0 805
72.5 790
73.0 775
73.5 761
74.0 746
74.5 733
75.0 719
75.5 706
76.0 693
76.5 681
77.0 669
77.5 657
78.0 645
78.5 634
79.0 623
79.5 613
80.0 602
80.5 592
81.0 583
81.5 573
82.0 564
82.5 556
83.0 547
83.5 539
84.0 531
84.5 524
85.0 516
85.5 509
86.0 502
86.5 496
87.0 489
87.5 483
88.0 477
88.5 472
89.0 466
89.5 461
90.0 456
90.5 451
91.0 446
91.5 441
92.0 436
92.5 432
93.0 427
93.5 423
94.0 419
94.5 415
95.0 410
95.5 406
96.0 402
96.5 398
97.0 393
97.5 389
98.0 385
98.5 380
99.0 376
99.5 371
100.0 367
100.5 362
101.0 357
101.5 352
102.0 346
102.5 341
103.0 335
103.5 330
104.0 324
104.5 318
105.0 312
105.5 305
106.0 299
106.5 292
107.0 285
35
SERVICING COOLER (30HK,HL ONLY)
NOTE: The cooler on 30HW units is not serviceable.
When cooler heads and partition plates are removed, tube
sheets are exposed showing tube ends as shown in Fig. 23.
Four tubes in the bundle are secured inside cooler at baffles
and cannot be removed. These are identified on the tube
sheets by a drill mark horizontally adjacent to each of
the 4 tubes. See Fig. 23. If leakage occurs in any of these
tubes, plug as described in Tube Plugging section
below.
Tube Plugging — Leaky tube(s) can be plugged until
retubing can be done. The number of plugged tubes determines how soon the 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 24 shows an Elliott tube plug and a cross-sectional
view of a plug in place. Table 13 lists the components for
plugging.
Use extreme care when installing plugs to prevent damaging the tube sheet sections between holes.
Clean parts with Locquic ‘‘N’’solution (or equivalent) and
apply a few drops of Loctite No. 675 sealant (or equivalent)
to obtain a tight seal without using too much force to set the
pin.
Usually plugs can be removed by heating the projecting
end of pin to approximately 1000 F (538 C) and chilling quickly
with water.Apply heating flame to side of the pin to prevent
overheating tube sheet.
RETUBING (See Table 13) — When retubing is to be done,
obtain the service of qualified personnel experienced in boiler
maintenance and repair.Most standard procedures can be followed when retubing the 10HA coolers. A 6% crush is recommended when rolling replacement tubes into the tube sheet.
A6% crush can be achieved by setting the torque on the gun
at 48 to 50 in.-lb (780 to 815 N-m).
*
*
The following Elliott Co. tube rolling tools are required:
B3400 Expander Assembly
B3401 Cage
B3405 Mandrel
B3408 Rolls
Place one drop of Loctite No. 675 sealant (or equivalent)
on top of the tube prior to rolling.
Tube information:
in. mm
• Tube sheet hole diameter ............0.631 16.03
•TubeOD ......................0.625 15.87
• Tube ID after rolling ..............0.581 14.76
(includes expansion due to to
to clearance) 0.588 14.94
IMPORTANT:Tubes next to gasket webs must be flush
with tube sheet (both ends).
Tightening Cooler Head Bolts
GASKET PREPARATION — When reassembling, use
new gaskets. Compressed non-asbestos/neoprene gaskets
(Carrier Material Specification ZA00-32) are to be momentarily dipped in compressor break-in oil prior to assembly.
Do not soak gaskets in oil, as gasket deterioration results.
Use dipped gaskets within 30 minutes to prevent deterioration.
BOLT TORQUES — Apply the following torques during bolt
tightening sequence described below:
5
⁄8-in. 16-mm) diameter flange
bolts .............150to170ft-lb (203 to 230 N-m)
1
⁄2-in. (13-mm) diameter center-stud
nuts ................70to90ft-lb (95 to 122 N-m)
Bolt Tightening Sequence (Fig. 25) — The recommended
bolt tightening sequence is:
Step 1 — Tighten all
1
⁄2-in. (13-mm) center nuts finger tight.
Step 2 — Following sequence shown in Fig. 25, tighten the
bolts and nuts to approximately 50% of specified torque.
Step 3 — Starting at top (12 o’clock) tighten flange bolts to
specified torque (see Bolt Torques section on this page) consecutively in a clockwise direction.
Step 4 — Tighten center nuts to specified torque.
Step 5 — No less than one hour later, retighten center nuts.
Step 6 — After refrigerant is restored to cooler, check center
studs and exposed gasket edges for refrigerant leaks with
soap solution or a Halide device.
Table 13 — Plugs and Tubes
5
⁄8-in. (16-mm) flange bolts and
*
*Fourfixedtubes(cannot be removed) identified by adjacentdrillpoints.
Fig. 23 — Typical Tube Sheet
*
COMPONENTS FOR
PLUGGING
For Tubes
Brass Pin 853103-500*
Brass Ring 853002-570*
For Holes without Tubes
Brass Pin 853103-1*
Brass Ring 853002-631*
Loctite No. 675†
Locquic ‘‘N’’†
*Order directly from Elliott Tube Co., Dayton, Ohio.
†Can be obtained locally.
36
PART NUMBER
Fig. 24 — Elliott Tube Plug
HEAD BOLT TIGHTENING SEQUENCE
Fig. 25 — Typical Tube Sheet
TROUBLESHOOTING
Complete Unit Stoppage and Restart —
sible causes for unit stoppage and reset methods are (also
see Table 14):
GENERAL POWER FAILURE — After power is restored,
restart is automatic through the normal timer cycle.
UNIT ON-OFF SWITCH IS OPEN — When the switch is
opened, the unit stops immediately. If the switch is closed
immediately after it was opened, the unit restarts automatically after the 5-minute timer cycle is completed. If the switch
is closed after an extended off-period, the unit restarts automatically in approximately 3 seconds.
CONTACTS OF ANY AUXILIARY INTERLOCKS ARE
OPEN — After the problem has been corrected, restart is
automatic after completion of the 5-minute timer cycle.
CHILLED FLUID PROOF-OF-FLOW SWITCH(ES) OPEN
— After the problem causing the loss of flow has been corrected, restart is automatic after completion of the 5-minute
timer cycle.
OPEN LOW-PRESSURESWITCH— If a low-pressure switch
remains open for more than 2 minutes during unit operation,
the compressor(s) shuts down and is locked off.The unit service light is illuminated. Determine and correct the cause of
the failure. The switch automatically resets, but the unit must
be manually reset by cycling the unit control power (move
the ON-OFF switch to OFF, then to ON). The unit restarts
Pos-
after completion of the 5-minute timer cycle unless the refrigerant charge is either very low or lost. If this is the case,
determine the cause of the loss of charge, correct the problem, and recharge the unit before restarting.
TEMPERATURE CONTROLLER SHUTS UNIT DOWN
ON OUT-OF-RANGE (See Fig. 21) — Check the thermistor for an open circuit failure. See Tables 12A and 12B
for temperature-resistance values. If thermistor is damaged,
replace it. If thermistor is not damaged, the unit restarts
automatically after completion of the 5-minute timer cycle,
and after the leaving cooler chilled fluid temperature
rises above the upper deadband limit of the temperature
controller.
OPEN HIGH-PRESSURE SWITCH(ES) — The unit service light is illuminated. Determine and correct the cause of
the failure. The switch(es) automatically resets but the unit
must be manually reset by cycling the control power (move
ON-OFF switch to OFF, then back to ON). The unit restarts
after completion of 5-minute timer cycle.
OPEN COMPRESSOR INTERNALTHERMAL PROTECTION (30HW UNITS) — This is compressor overtemperature protector on 30HW018 units and the discharge gas thermostat (DGT) on 30HW025-040 units. The unit service light
is illuminated. Determine and correct cause of problem. The
switch resets automatically but unit must be reset by cycling
the control power (move ON-OFF switch to OFF, then back
to ON). The unit restarts after completion of 5-minute timer
cycle.
OPEN OIL PRESSURE SWITCH — If oil pressure switch(es)
opens for more than 2 minutes during unit operation, the unit
shuts down and is locked off. The unit service light is illuminated. Determine and correct cause of failure. Unit must
be reset by cycling the control power (move ON-OFF switch
to OFF, then back to ON). Unit restarts after completion of
5-minute timer cycle.
OPEN CONTACTS ON COMPRESSOR GROUNDCURRENT SENSOR(S) (Accessory) — The light-emitting
diode (LED) on the ground current accessory board (located
in field control wiring section of control box) is illuminated.
See Fig. 17-20. Unit service light is also illuminated. Check
the compressor motor windings for a short to ground.
Determine and correct cause of the failure. The unit must be
reset by cycling the control power (move ON-OFF switch to
OFF, then back to ON). Unit restarts after completion of the
5-minute timer cycle.
OPEN 24-V CONTROL CIRCUIT BREAKER(S) — Determine the cause of the failure and correct. Reset circuit
breaker(s). Restart is automatic after completion of 5-minute
timer cycle.
37
COOLING LOAD SATISFIED — Unit shuts down if cooling load is satisfied. Unit restarts if required after completion of 5-minute timer cycle.
THERMISTORFAILURE— If thermistor fails in open mode,
the temperature controller shuts down the unit in an out-ofrange condition. Replace the thermistor. Unit restarts automatically after completion of a 5-minute timer cycle, and
when the leaving cooler chilled fluid temperature rises above
the upper deadband limit of the temperature controller.
Table 14 — Troubleshooting
SYMPTOMS CAUSE REMEDY
Compressor does
not run
Compressor cycles
off on loss of
charge
Compressor cycles
off on out of range
condition
Compressor cycles control
steps rapidly
Compressor shuts
down on highpressure control
Unit operates too long
or continuously
Unusual or loud system
noises
Power line open Reset circuit breaker.
Control fuse or circuit breaker opens Check control circuit for ground or short. Reset breaker
Compressor overtemperature sensor open Find cause of high temperature and reset controls.
Tripped power breaker Check the controls. Find the cause of trip and
Condenser circulating pump not running Power off — restart.
Loose terminal connection Check connections.
Improperly wired controls Check wiring and rewire if necessary.
Low line voltage Check line voltage — determine location of voltage drop
Compressor motor defective Check motor winding for open or short. Replace
Seized compressor Replace compressor.
Loss of charge control erratic in action Repair leak and recharge.
Low refrigerant charge Add refrigerant.
Low suction temperature Raise cooler leaving fluid temperature set point.
Compressor suction valve leaking Replace valve plate.
Plugged compressor suction strainer Clean or replace strainer.
Compressor suction shutoff valve partially closed Open valve.
Thermistor failure Replace thermistor.
System load was reduced faster than
controller could remove stages
Temperature controller deadband setting is
too low
High-pressure control acting erratically Replace control.
Compressor discharge valve partially closed Open valve or replace (if defective).
Air in system Purge system.
Condenser scaled/dirty Clean condenser.
Receiver not properly vented — refrigerant
backs up into evaporator condenser
Condenser water pump or fans not operating Start pump — repair or replace if defective.
System overcharged with refrigerant Reduce charge.
Low refrigerant charge Add refrigerant.
Control contacts fused Replace control.
Air in system Purge system.
Partially plugged or plugged expansion valve
or filter drier
Defective insulation Replace or repair as needed.
Service load Keep doors and windows closed.
Inefficient compressor Check valves, and replace if necessary.
Piping vibration Support piping as required.
Expansion valve hissing Add refrigerant.
Compressor noisy Check valve plates for valve noise.
NOTE: If the thermistor fails in closed mode, the temperature controller keeps trying to load up.
If unit stoppage occurs more than once as a result of
any of the safety devices listed, determine and correct
cause before attempting another restart.
and replace fuse.
reset breaker.
Pump binding — free pump.
Incorrect wiring — rewire.
Pump motor burned out — replace.
and remedy deficiency.
compressor if necessary.
Replace control.
Unit will restart after fluid temperature rises back into the
control band. Avoid rapidly removing system load.
Raise deadband setting.
Repipe as required to provide adequate venting.
Clean or replace as needed.
Check for loose pipe connections.
Check for plugged liquid line filter drier.
Replace compressor (worn bearings).
Check for loose compressor holddown bolts.
38
Table 14 — Troubleshooting (cont)
SYMPTOMS CAUSE REMEDY
Compressor
loses oil
Hot liquid line Shortage of refrigerant due to leak Repair leak and recharge.
Frosted liquid line Shutoff valve partially closed or restricted Open valve or remove restriction.
Frosted suction line Expansion valve admitting excess refrigerant Adjust expansion valve. Replace valve if defective.
Compressor will
not unload
Compressor will
not load
System noises Piping vibration Support piping as required.
Freeze-up Improper charging Make sure a full quantity of fluid is flowing through the
Leak in system Repair leak.
Mechanical damage (blown piston or broken
discharge valve)
Oil trapped in line Check piping for oil traps.
Crankcase heater not energized
during shutdown
Restricted filter drier Replace filter drier.
Burned-out coil Replace coil.
Defective capacity control valve Replace valve.
Miswired solenoid Rewire correctly.
Weak, broken, or wrong valve body spring Replace spring.
Miswired solenoid Rewire correctly.
Defective capacity control valve Replace valve.
Plugged strainer (high side) Clean or replace strainer.
Stuck or damaged unloader piston or piston ring(s) Clean or replace the necessary parts.
Expansion valve hissing Add refrigerant.
Compressor noisy Check valve plates for valve noise.
Improperly set safety thermostat Check safety thermostat for proper setting at beginning of
Operating with safety thermostat bypassed If thermostat was bypassed for checking, be sure it is back
Improper circulation of condenser water Use adequately sized cleanable strainer in the condenser
System not drained for winter shutdown Remove drain plugs at end of cooling season. Blow out any
Loose Thermistor Tighten thermistor to pipe and reinsulate (30HW).
Repair damage or replace compressor as needed.
Check wiring and crankcase heater contacts on the
temperature controller, and replace heater if necessary.
Check for loose pipe connectors.
Check for plugged liquid line strainer.
Replace compressor (worn bearings).
Check for loose compressor holddown bolts.
cooler while charging, and suction pressure in cooler is
equal to or greater than pressure corresponding to 32 F
(0° C) (58 psig [400 kPa] for Refrigerant 22).
each season.
in circuit before starting unit.
water circuit. Make sure strainer is clean. It may sometimes
be necessary to chemically treat the water to prevent formation of deposits.
residual water. Instead of draining, a suitable anti-freeze
may be added to the water.
ing is considered abuse and is not covered by warranty.
Damage to chiller due to freez-
39
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Installation Overview
A large selection of product, theory, and skills programs are available, using popular video-based formats and materials. All include video and/or slides, plus companion book.
Classroom Service Training which includes ‘‘hands-on’’ experience with the products in our labs can
mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks.
Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training [ ] Classroom Service Training
• Maintenance
• Operating Sequence
Copyright 1998 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg 40 11-98 Replaces: 30H-8SI
START-UP CHECKLIST FOR CHILLER SYSTEMS
(Remove and use for job file)
A. Preliminary Information
JOB NAME
LOCATION
INSTALLING CONTRACTOR
DISTRIBUTOR
START-UP PERFORMED BY
EQUIPMENT: Chiller: MODEL # SERIAL #
COMPRESSORS:
CIRCUIT #1 CIRCUIT #2 (30HK,HL ONLY)
MODEL #
SERIAL # SERIAL #
MOTOR # MOTOR #
CONDENSER (30HK, HWB, HWC, HWS ONLY):
MODEL #
SERIAL #
COOLER:
MODEL #
SERIAL # DATE
MANUFACTURED BY
MODEL #
AIR-HANDLING EQUIPMENT:
MANUFACTURER
MODEL # SERIAL #
ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES
B. Preliminary Equipment Check (YES or NO)
IS THERE ANY SHIPPING DAMAGE?
WILL THIS DAMAGE PREVENT UNIT START-UP?
CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?
HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)
ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)
HAS THE GROUND WIRE BEEN CONNECTED?
ARE ALL TERMINALS TIGHT?
ON 30HW UNITS, IS THE THERMISTOR SECURELYSTRAPPED TO THE COOLER LEAVING CHILLED FLUID LINE, AND
IS IT PROPERLY INSULATED?
ON 30HW UNITS, IS YELLOW WIRE GOING TO TRANSFORMER 1 (POWER TRANSFORMER) ON THE CORRECT
TERMINAL (TERMINAL H2 FOR 208 V AND 575 V; TERMINAL H3 FOR 230 V, 380 V, AND 400 V, TERMINAL H4
FOR 460 V)?
IF UNIT IS A MEDIUM TEMPERATURE BRINE UNIT, IS TEMPERATURE CONTROLLER SET FOR BRINE AND NOT
FOR WATER? IF UNIT IS NOT A BRINE UNIT, IS TEMPERATURE CONTROLLER SET FOR WATER AND NOT FOR
BRINE?
HAVE TEMPERATURE CONTROLLER, CONTROL MODULE AND CONTROL RELAY CONNECTIONS BEEN CHECKED
FOR TIGHTNESS?
IF SO, WHERE
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg CL-1 11-98 Replaces: 30H-8SI
B. Preliminary Equipment Check (YES or NO) (cont)
HAVE POWER SIDE ELECTRICAL COMPONENT CONNECTIONS BEEN CHECKED FOR TIGHTNESS?
ON 30HK,HL UNITS, IS THE PROPER CONTROL VOLTAGE SUPPLIED TO TB2-1 AND TB2-3?
ON 30HK,HL 50 HZ UNITS, IS THE BLACK WIRE GOING TO TRAN1 AND TRAN2 CONNECTED TO THE RED LEAD FROM
THE TRANSFORMER?
CHECK AIR SYSTEMS (YES OR NO)
ARE ALL AIR HANDLERS OPERATING?
ARE ALL CHILLED FLUID VALVES OPEN?
IS THE FLUID PIPING CONNECTED PROPERLY?
HAS ALL AIR BEEN VENTED FROM THE COOLER LOOP?
IS THE CHILLED WATER (FLUID) PUMP (CWP) OPERATING?
IS THE CWP ROTATION CORRECT?
CWP MOTOR AMPERAGE: Rated
(refer to air-handling equipment Installation and Start-Up Instructions)
Actual
C. Unit Start-Up (insert check mark as each item is completed)
HAS THE CHILLER BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CONDENSER
WATER PUMP STARTER?
ASSURE THAT UNIT IS SUPPLIED WITH CORRECT CONTROL VOLTAGE POWER.
ASSURE CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF 24 HOURS PRIOR TO
START-UP.
ASSURE COMPRESSOR OIL LEVEL IS CORRECT.
ASSURE LIQUID LINE SERVICE VALVE(S) IS BACKSEATED.
ASSURE COMPRESSOR DISCHARGE SERVICE VALVE(S) IS BACKSEATED.
ASSURE COMPRESSOR SUCTION SERVICE VALVE(S) IS BACKSEATED.
LOOSEN COMPRESSOR SHIPPING ISOLATOR LOCKNUTS.
OPEN GAGE PANEL SERVICE VALVES.
BE SURE TEMPERATURE CONTROLLER DEADBAND AND SAMPLE RATE SETTINGS ARE SET.
SET POINT SHOULD BE ADJUSTED TO THE DESIRED COOLER LEAVING FLUID TEMPERATURE. (refer to installation
instructions)
LEAK CHECK THOROUGHLY: COMPRESSOR(S), CONDENSER FITTINGS, TXV(s), SOLENOID VALVE(S), FILTER
DRIER(S), FUSIBLE PLUG(S), AND COOLER HEAD(S), WITH GENERAL ELECTRIC H-10-B ELECTRONIC LEAK
DETECTOR.
LOCATE, REPAIR, AND REPORT ANY R-22 LEAKS.
CHECK VOLTAGE IMBALANCE: AB AC BC
AB + AC + BC (divided by 3) = AVERAGE VOLTAGE = V
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE =
VOLTAGE IMBALANCE = x 100 = % VOLTAGE IMBALANCE
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER!
CALL LOCAL POWER COMPANY FOR ASSISTANCE.
ASSURE THAT INCOMING POWER VOLTAGE TO CHILLER IS WITHIN RATED UNIT VOLTAGE RANGE.
SYSTEM FLUID VOLUME IN LOOP: TYPE SYSTEM:
AIR CONDITIONING — MINIMUM 3 GAL. (3.25 L) PER NOMINAL TON (kW) =
PROCESS COOLING — MINIMUM 6 GAL. (6.5 L) PER NOMINAL TON (kW) =
(MAX. DEVIATION)
AVERAGE VOLTAGE
GAL. (L)
GAL. (L)
CL-2
C. Unit Start-Up (cont)
COOLER LOOP PROTECTION IF REQUIRED:
GALLONS (LITERS) OF BRINE ADDED:
PIPING INCLUDES ELECTRIC TAPE HEATERS.
CHECK PRESSURE DROP ACROSS COOLER.
FLUID ENTERING COOLER:
FLUID LEAVING COOLER:
(PSIG DIFFERENCE) x 2.31 = FT OF FLUID PRESSURE DROP =
(kPa DIFFERENCE) x .335 = FT OF FLUID PRESSURE DROP =
PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (LOCATED IN PRODUCT DATA LITERATURE)TO
DETERMINE TOTAL GPM (L/s).
TOTAL GPM (L/s) =
GPM (L/s) PER TON = UNIT’S RATED MIN. PRESSURE DROP =
JOB’S SPECIFIED GPM (L/s) (if available)
NOTE: IF UNIT HAS LOW FLUID FLOW,FIND SOURCE OF PROBLEM: CHECK FLUID PIPING, IN-LINE FLUID STRAINER,
SHUT-OFF VALVES, CHILLED FLUID PUMP ROTATION, ETC.
COOLER LOOP PROTECTION:
GAL. (L) OF BRINE ADDED (IF REQUIRED).
IN-LINE WATER STRAINER INSTALLED ADJACENT TO COOLER FLUID INLET. (REQUIRED FOR 30HW COOLERS.)
PSIG (kPa)
PSIG (kPa)
UNIT’S RATED MIN. GPM (L/s) =
(Refer to product data literature.)
YES NO
CONDENSER PROTECTION:
IN-LINE MINIMUM 20-MESH STRAINER INSTALLEDADJACENT TO THE CONDENSER WATER INLET.
YES
TO START THE CHILLER: (insert check mark as each item is completed)
PLACE ON-OFF SWITCH IN THE ON POSITION.
ASSUMING THERE IS A CALL FOR CHILLED FLUID, THE COMPRESSOR WILL START UNLOADED AFTER A6-SECOND
TO 5-MINUTE DELAY (DEPENDING ON THE TIMING LOGIC).
THE LOW-PRESSURE SWITCH (ALL UNITS)AND OIL-PRESSURE SWITCH (30HL, HWAUNITS — ACCESSORYON 30HK,
HWB, HWC, HWS UNITS) ARE BYPASSED FOR 2 MINUTES.
IF ADDITIONAL CAPACITY IS REQUIRED AFTER THE 2-MINUTE PERIOD, COMPRESSOR WILL LOAD UP.
MEASURE THE FOLLOWING: WHILE MACHINE IS IN STABLE OPERATING CONDITION.
SUCTION PRESSURE
SUCTION LINE TEMP.
SUCTION SUPERHEAT
DISCHARGE PRESSURE
DISCHARGE LINE TEMP.
DISCHARGE SUPERHEAT
NO
CHECK AND ADJUST SUCTION SUPERHEAT (9 to 11 F [5 to 6 C]).
CL-3
NOTES:
Copyright 1998 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg CL-4 11-98 Replaces: 30H-8SI
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