Carrier Ecologic Series 3 Controls, Start-Up, Operation, Service, And Troubleshooting page 59

9. Remove the four M14 bolts securing the discharge line
flange to the compressor. Two of the bolts also secure the
mounting bracket for the external oil filter. Support the oil
line to prevent damage to the line while the compressor is
being changed. For 30GX units, place temporary protec-
tion over coils to prevent fin and tube damage.
10. Move lifting apparatus into place and attach to the 2 lifting
rings on the compressor. Apply minimal tension to hold
the compressor while the remaining bolts are removed.
3
11. Remove the / -in. holddown bolt securing the foot at the
8
discharge end of the compressor to the mounting bracket
on the cooler. A foot bracket will be mounted to the
replacement compressor.
12. Remove the 4 lockwashers and nuts securing the compres-
sor to the suction flange of the cooler. The compressor is
held in place using four M14 x 2 studs through the suction
nozzle of the cooler. The studs have an E-12 external Torx
drive head. If possible, remove studs; if studs hit the cooler
insulation, leave them in place — they will not interfere
with compressor removal or installation. Save all the hard-
ware as it will be needed to install the replacement
compressor.
13. After checking to ensure all lines, wires, conduits, etc. are
free and out of the way, remove compressor from cooler.
Apply a light film of O-ring grease to new O-ring and
place back into groove in mounting flange of compressor.
If the new compressor is the A1/A2 (30HX units), A2
(30GX205-265 units) or B2 (30GX281-350 units) com-
pressor, remove the compressor junction box and rotate
it 180 degrees. Tighten screws to 6.8 to 9.5 N-m (5 to
7 ft-lb). The A1 and A2 compressors are on the right side
of the unit when facing the unit control box.
14. Remove suction cover plate and bolts from new compres-
sor and set compressor on unit flange. Thread the studs all
the way back into the compressor. Install the 4 lockwash-
ers and nuts finger-tight. Tighten bolts in a crossing pattern
to a range of 81.4 to 135.6 N-m (60 to 100 ft-lb). Do NOT
overtighten as damage may result to O-ring. Install and
tighten holddown bolt in mounting foot.
15. Remove motor cooling/economizer and discharge line
cover plates from new compressor.
16. Apply a light film of O-ring grease to motor cooling/econo-
mizer and discharge line O-rings, place back into grooves
and install flange bolts. Tighten discharge line bolts in a
crossing pattern to a range of 81.4 to 135.6 N-m (60 to
100 ft-lb). Tighten motor cooling/economizer bolts to a
range of 81.4 to 108.5 N-m (60 to 80 ft-lb). Do NOT over-
tighten as damage may result to O-rings.
17. Reconnect the oil filter to the shutoff valve and oil line to
the compressor. Install oil line straight into fitting until fer-
rule seats against fitting. Thread packing nut onto fitting
and tighten finger tight. Use a backup wrench to finish
tightening the nut. Do not overtighten.
18. Reinstall the loader and oil solenoids, high-pressure switch,
and oil pressure transducer. Make sure the loader solenoids
are installed on the correct number loader.
19. Reconnect conduits back into compressor junction box.
Reconnect all wiring that was removed in Steps 4, 5, and
7. Temporarily install the reverse rotation low pressure
switch that is supplied with the replacement compressor.
Connect the switch to the second high pressure port using
1
a standard / -in. service hose. The switch will not reset
4
until 10 psig of pressure is present on the switch. Tempo-
rarily wire the reverse rotation low pressure switch in
series with the compressor's high pressure switch as
shown in Fig. 21.
20. Leak check compressor and refrigerant lines with nitrogen.
Repair any leaks found. Remove nitrogen from system.
Evacuate compressor and refrigerant lines. Refer to the
Refrigerant and Oil Charging sections on pages 56 and 57
for recharging procedures.
21. Open all shutoff valves and leak check the circuit and all
fittings and joints. Repair any leaks found.
22. Reset the reverse rotation low pressure switch.
23. Restore main and control power to the machine. Using the
HSIO, enter the quick test function by pressing
(for compressor A1 or A2 replacement) or
compressor B1 replacement). Test the operation of the
solenoids. Press
use the key to find the motor cooling and oil solenoids
and test them in the same manner. Pressing the
after each output turns the solenoid off (or press
It is important that the loaders are located properly (loader
1 on right hand side when viewed from side opposite con-
trol box on 30HX units, on left hand side when reaching
over compressor to far side on 30GX units).
24. Start the compressor using the Manual mode. Press
at the HSIO. Press
ual mode. When display changes to "Enable," switch the
Local-Off-Remote switch to the Local position. Select the
desired compressor using the down arrow key. Press
to start the compressor. Use the down arrow key
ENTER
and press
ENTER
stabilize with both loaders energized. Refer to the Refrig-
erant and Oil Charging sections of this document for
recharging procedures and performance criteria.
25. Once proper rotation has been verified disconnect and
lockout the power to the chiller. The reverse rotation low
pressure switch can now be removed from the compressor
and high pressure switch circuit.
Fig. 19 — Compressor Component Diagram
59
to test each loader solenoid, then
ENTER
to enable the Man-
ENTER
to energize both loaders. Let the circuit
(for
key
).
ENTER