Carrier 60 Installation And Service Instructions Manual
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Carrier 60 Installation And Service Instructions Manual

Reciprocating liquid chillers 50/60 hz
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CONTENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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30HK,HL UNITS
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30HW UNITS
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30HL,HWA SYSTEM CONDENSER
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30HK,HWC,HWS CONDENSER(S)
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30HWB CONDENSER
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30HK,HWB,HWC,HWS UNITS
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ALL UNITS
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TEMPERATURES (LCWT)
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MAIN POWER SUPPLY
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DISCHARGE LINE CHECK VALVE
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HOT GAS BYPASS VALVE
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PRESSURE RELIEF DEVICES
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CIRCUIT BREAKER
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
PC 903
Tab
5c
Installation, Start-Up and
Service Instructions
Page
. . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . 13
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. . . . . . . . . . . . . . . . . . 27-30
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. . . . . . . . . 28
Catalog No. 533-070
Printed in U.S.A.
Reciprocating Liquid Chillers
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OIL PRESSURE SAFETY SWITCH (OPS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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LOW-PRESSURE SWITCH
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. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-35
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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RETUBING
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GASKET PREPARATION
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. . . . . . . . . . . . . . . . . . . . . . . . 37-39
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GENERAL POWER FAILURE
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UNIT ON-OFF SWITCH IS OPEN
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OPEN
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OPEN LOW-PRESSURE SWITCH
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OPEN HIGH-PRESSURE SWITCH(ES)
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PROTECTION
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CURRENT SENSOR(S) (Accessory)
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COOLING LOAD SATISFIED
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THERMISTOR FAILURE
START-UP CHECKLIST FOR
. . . . . . . . . . . . . . . . . . . CL-1 to CL-4
CHILLER SYSTEMS
Form 30H-10SI
Pg 1
30HK040-060
30HL050,060
30HW018-040
50/60 Hz
. . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . 32
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. . . . . . . . . 36,37
. . . . . . . . . . . . . . . . . . 36
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11-98
Replaces: 30H-8SI

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Summary of Contents for Carrier 60

  • Page 1: Table Of Contents

    ..28 CHILLER SYSTEMS Printed in U.S.A. Form 30H-10SI 30HK040-060 30HL050,060 30HW018-040 50/60 Hz ......28 .

  • Page 2: General

    GENERAL These installation instructions cover the 30HK, HL, HWA, HWB, HWC, and HWS units. The HL and HWA are con- denserless 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 spe- cifically designed for sea coast applications.

  • Page 3: Installation

    ⁄ ft (2.3 m) (for 040 units) or 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.
  • Page 4 2. Dimensions are in inches unless otherwise indicated. Dimensions in ( ) are in millimeters. 3. Service clearance for the control box is 36-in. TOP VIEW ⁄ (202) ⁄ (344) Fig. 4 — 30HK040-060 (Fluid Cooled) RIGHT SIDE VIEW LEFT SIDE VIEW...
  • Page 5 NOTES: 1. Standard unit shown with the sound en- closure accessory. 2. Dimensions are in inches unless oth- erwise indicated. Dimensions in ( ) are in millimeters. TOP VIEW Fig. 5 — 30HL050,060 (Condenserless) RIGHT SIDE VIEW LEFT SIDE VIEW...
  • Page 6 LEFT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HWA 12.58 19.20 20.48 33.85 (320) (488) (520) 12.82 18.98 20.57 33.85 (326) (482) (522) 12.64 18.31 20.73 33.85 (321) (465) (527) 12.87 18.62 20.81 33.85 (327) (473) (529) 12.66 18.64 21.30 34.15 (322) (473)
  • Page 7 LEFT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HWB 13.14 18.72 22.02 33.85 11.72 (334) (475) (559) (860) (298) 13.22 18.25 22.10 33.85 11.72 (336) (464) (561) (860) (298) 13.18 17.71 22.39 33.85 11.72 (335) (450) (569) (860) (298) 13.45 17.98 22.68 33.85...
  • Page 8 LEFT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HWC,S 47.50 9.90 14.00 (1206) (251) (356) 48.30 9.90 15.50 (1227) (251) (394) 48.00 10.00 15.80 (1219) (254) (401) 48.20 10.00 15.90 (1224) (254) (404) 47.80 10.00 15.90 (1214) (254) (404) LOCATION — in. (mm) DISCONNECT (Amps) 77.61...
  • Page 9 WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 60 HZ UNITS 30HK UNIT SIZE NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions. WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 50 HZ UNITS 30HK UNIT SIZE NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions. Fig.
  • Page 10 Table 1A — Physical Data; 30HK, HWB, HWC, and HWS Fluid-Cooled Units — English UNIT 30 HW-018* OPERATING WT (Approximate) − lb HWC,S REFRIGERANT — lb HWC,S HK — Ckt 1 HK − Ckt 2 COMPRESSOR Model No. 06DG537 Nominal Hp Quantity Cylinders Per Compressor Capacity Control —...
  • Page 11 Table 1B — Physical Data; 30HK, HWB, HWC, and HWS Fluid-Cooled Units — SI UNIT 30 OPERATING WT (Approximate) − kg HWC,S REFRIGERANT — kg HWC,S HK — Ckt 1 HK — Ckt 2 COMPRESSOR Model No. Nominal kW Quantity Cylinders Per Compressor Capacity Control —...
  • Page 12 Table 2A — Physical Data; 30HL, HWA Condenserless Units — English UNIT 30 OPERATING WT (Approximate) − lb REFRIGERANT† — lb COMPRESSOR Model No. Nominal Hp Quantity Cylinders Per Compressor Capacity Control — Standard No. of Steps Minimum Step Capacity (%) Capacity Control —...

  • Page 13: Step 5 - Make Piping Connections

    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 di- rectly to the outdoors.
  • Page 15 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 part 3, Carrier E20-II soft- ware Refrigerant Piping program, or appropriate ASHRAE (American Society of Heating, Refrigeration, and Air Condi- tioning Engineers) handbook for details on proper piping sizes and design.

  • Page 16: Cooler Description

    Size the water lines according to the available pump pressure (not necessarily the connection size), espe- cially on cooling tower applications. See Carrier System De- sign Manual, Part 3, Piping Design. See Fig. 16 for condenser pressure drops.
  • Page 17 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.
  • Page 18 CONDENSER PRESSURE DROP — CONDENSER PRESSURE DROP — 30HK UNITS 30HWB UNITS CONDENSER PRESSURE DROP — 30HWC AND 30HWS UNITS NOTE: Ft of water = 2.31 x change in psig. Fig. 16 — Cooler and Condenser Water Pressure Drop (cont)

  • Page 19: Step 6 - Make Electrical Connections

    A ground wire must be installed with each field power sup- ply. Compressor are wired standard from the factory for across- the-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).
  • Page 20 Table 4A — Electrical Data — 30HK, HWB, HWC, HWS Fluid-Cooled Units UNIT SIZE Volts Nameplate (3 ph) 208/230 HK040 208/230 HK050 208/230 HK060 208/230 HWB,C,S018 380/415 208/230 HWB,C,S025 380/415 208/230 HWB,C,S028 380/415 208/230 HWB,C,S035 380/415 208/230 HWB,C,S040 380/415 UNIT Voltage* †...
  • Page 21 Additional control circuit power is not required for 30HW units. 6. Across-the-line start is standard on all units. Part-wind start is available as a factory-installed option on 025-060 sizes (not available on 018 size; spe- cial order option on 30HK,HL units).
  • Page 22 FIELD POWER WIRING, 60 Hz UNITS Fig. 17 — Field Wiring Diagram; 30HK, HL Units FIELD CONTROL WIRING, 50 Hz UNITS FIELD ACCESSORY WIRING LEGEND COM — Common — Compressor Relay CWP — Chilled Water Pump — Demand Limit Switch GCS —...

  • Page 25: Pre-Start-Up

    — Contactor — Circuit Breaker — Control Module COM — Common — Control Relay Fig. 20 — 30HW Control Box Components Label PRE-START-UP IMPORTANT: Before beginning Start-Up, complete Start-Up Checklist on pages CL-1 to CL-4. This check- list assures proper start-up of a unit, and provides a record of unit condition, application requirements, sys- tem information, and operation at initial start-up.

  • Page 26: Check Refrigerant Charge

    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...

  • Page 27: Check Oil Charge

    20 minutes, and check the oil level. Use only Carrier-approved compressor oil: Petroleum Specialties, Inc....Cryol 150* Texaco, Inc.

  • Page 28: Liquid Line Solenoid Valve (30Hl Only)

    DISCHARGE LINE CHECK VALVE — 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.

  • Page 29: High-Pressure Switch

    This jumper must be removed after servicing is complete. Failure to remove this jumper is considered abusive treat- ment and will void the Carrier warranty. HIGH-PRESSURE SWITCH — A high-pressure switch is provided to protect each compressor and refrigeration sys- tem from unsafe high pressure conditions.

  • Page 30: Freeze-Up Protection

    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.
  • Page 31 Once the compressor is shut off, the control system pre- vents 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 com- pressor will start within 5 seconds.

  • Page 32: 30Hw Units

    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.

  • Page 33: Thermistor

    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.
  • Page 34 3,170 3,099 3,031 2,964 2,898 2,835 2,773 2,713 2,655 2,598 2,542 2,488 2,436 2,385 2,335 2,286 2,238 2,192 2,147 2,103 2,060 2,018 1,977 1,937 1,898 1,860 1,822 1,786 1,750 1,715 1,680 1,647 1,614 1,582 1,550 1,519 1,489 1,459 1,430 1,401...
  • Page 35 Table 12B — Sensor Temperature (C) vs Resistance TEMPERATURE RESISTANCE (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...

  • Page 36: Servicing Cooler (30Hk,Hl Only)

    The number of plugged tubes deter- mines how soon the cooler must be retubed. If several tubes require plugging, check with your local Carrier representa- tive to find out how number and location will affect unit capacity.

  • Page 37: Troubleshooting

    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 —...
  • Page 38 COOLING LOAD SATISFIED — Unit shuts down if cool- ing load is satisfied. Unit restarts if required after comple- tion of 5-minute timer cycle. THERMISTOR FAILURE — If thermistor fails in open mode, the temperature controller shuts down the unit in an out-of- range condition.
  • Page 39 SYMPTOMS Compressor Leak in system loses oil Mechanical damage (blown piston or broken discharge valve) Oil trapped in line Crankcase heater not energized during shutdown Hot liquid line Shortage of refrigerant due to leak Frosted liquid line Shutoff valve partially closed or restricted Restricted filter drier Frosted suction line Expansion valve admitting excess refrigerant...
  • Page 40 Course descriptions and schedules are in our catalog. [ ] Packaged Service Training 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 PC 903 Catalog No.
  • Page 41 START-UP CHECKLIST FOR CHILLER SYSTEMS A. Preliminary Information JOB NAME LOCATION INSTALLING CONTRACTOR DISTRIBUTOR START-UP PERFORMED BY EQUIPMENT: Chiller: MODEL # COMPRESSORS: CIRCUIT #1 MODEL # SERIAL # MOTOR # CONDENSER (30HK, HWB, HWC, HWS ONLY): MODEL # SERIAL # COOLER: MODEL # SERIAL #...
  • Page 42 B. Preliminary Equipment Check 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?
  • Page 43 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...
  • Page 44 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 PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg CL-4 11-98...

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