Carrier 30HK040-060 manual

Installation, Start-Up and Service Instructions CONTENTS Page GENERAL ....................................2 SAFETY CONSIDERA TIONS .....................2 INST ALLA TION .............................. 3-25 Location ......................................3 Step 1 — Inspect Shipment .....................3 Step 2 — Rig the Unit .....................[...]

GENERAL These installation instructions cover the 30HK, HL, HW A, HWB, HWC, and HWS units. The HL and HW A 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- cificall[...]

INST ALLA TION Location — Do not store units in an area exposed to weather because of sensitive control mechanisms and electronic devices. Locate unit indoors. See Fig. 4-8 for unit dimen- sional 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. P[...]

TOP VIEW FRONT VIEW RIGHT SIDE VIEW LEFT SIDE VIEW UNIT 30HK DIMENSIONS — in. (mm) AB C D 040 5 1 ⁄ 4 (133) 90 (2286) 14 9 ⁄ 16 (370) 7 15 ⁄ 16 (202) 050,060 10 3 ⁄ 4 (273) 108 (2743) 20 1 ⁄ 16 (510) 13 9 ⁄ 16 (344) LEGEND COMP — Compressor K.O. — Knockout MTG — Mounting SAE — Society of Automotive Engineers (U.S.A.) NOTES: 1.[...]

TOP VIEW FRONT VIEW RIGHT SIDE VIEW LEFT SIDE VIEW LEGEND CL Y — Cylinder COMP — Compressor CONN — Connection K.O. — Knockout 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. Fig. 5 — 30HL050,060 (Condenserless) 5[...]

UNIT 30HW A DIMENSIONS — in. (mm) ABCDE F G 018 12.58 (320) 19.20 (488) 20.48 (520) 33.85 (860) 1 1.72 (298) 5.75 (146) 17.95 (456) 025 12.82 (326) 18.98 (482) 20.57 (522) 33.85 (860) 1 1.72 (298) 5.75 (146) 17.95 (456) 028 12.64 (321) 18.31 (465) 20.73 (527) 33.85 (860) 1 1.72 (298) 5.75 (146) 17.95 (456) 035 12.87 (327) 18.62 (473) 20.81 (529) [...]

UNIT 30HWB DIMENSIONS — in. (mm) ABCDE F GHJ 018 13.14 (334) 18.72 (475) 22.02 (559) 33.85 (860) 1 1.72 (298) 5.75 (146) 12.29 (312) 17.95 (456) 9.28 (236) 025 13.22 (336) 18.25 (464) 22.10 (561) 33.85 (860) 1 1.72 (298) 5.75 (146) 12.29 (312) 17.95 (456) 9.28 (236) 028 13.18 (335) 17.71 (450) 22.39 (569) 33.85 (860) 1 1.72 (298) 5.75 (146) 12.29[...]

UNIT 30HWC,S DIMENSIONS — in. (mm) A BCDEFG 018 47.50 (1206) 9.90 (251) 14.00 (356) 18.15 (461) 17.95 (456) 6.69 (170) 34.20 (869) 025 48.30 (1227) 9.90 (251) 15.50 (394) 18.15 (461) 17.95 (456) 6.69 (170) 34.20 (869) 028 48.00 (1219) 10.00 (254) 15.80 (401) 18.15 (461) 17.95 (456) 6.69 (170) 34.20 (869) 035 48.20 (1224) 10.00 (254) 15.90 (404) 1[...]

WEIGHT DISTRIBUTION A T EACH MOUNTING HOLE, 60 HZ UNITS UNIT SIZE MOUNTING HOLES 30HK 30HL ABCDABCD Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg 040 7 1 0 3 2 2 7 1 2 3 2 3 7 0 5 3 2 0 7 0 3 3 1 9 ———————— 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 2[...]

T able 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 OPERA TING WT (Approximate) − lb HWB 795 950 1065 1085 1310 — — — HWC,S 1231 1358 1484 1508 1702 — — — HK ————— 2830/ 2875† 3138/ 3340† 3340/ 3400† REFRIGERANT — lb R-[...]

T able 1B — Physical Data; 30HK, HWB, HWC, and HWS Fluid-Cooled Units — SI UNIT 30 HW-018* HW -025* HW-028* HW-035* HW-040* HK040 HK050 HK060 OPERA TING WT (Approximate) − kg HWB 360 431 483 492 594 — — — HWC,S 554 61 1 668 679 766 — — — HK ————— 1284/ 1305† 1424/ 1514† 1514/ 1542† REFRIGERANT — kg R-22 HWB 5.7 6[...]

T able 2A — Physical Data; 30HL, HW A Condenserless Units — English UNIT 30 HW A018 HWA025 HW A028 HW A035 HWA040 HL050 HL060 OPERA TING WT (Approximate) − lb 740 880 960 975 1080 2070/ 2120* 2130/ 2190* 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 06E6275, 06E[...]

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 con- tained within the shell, and water flows through the tubes. The 30HK and HWC units use a steel s[...]

Fig. 13 — T ypical Piping with Fluid-Cooled 30HWB Unit Shown NOTES: 1. Chiller must be installed levelly to maintain proper compressor oil return. 2. Wiring and piping shown are general points-of-connection guides only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system and are not in acco[...]

Fig. 14 — T ypical Piping with Air-Cooled 30HW A with Remote 09DK Unit Shown NOTES: 1. Chiller must be installed levelly to maintain proper compres- sor oil return. 2. Wiring and piping shown are general points-of-connection guides only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system a[...]

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 right- hand side of the heat exchanger with the LIQUID-IN con- nection at the bottom, and the LIQUID-OUT connection at the top. A strainer with a minimum of 20 mesh must be installed [...]

The cooler fluid inlet and outlet connections are grooved- end. 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 [...]

CONDENSER PRESSURE DROP — 30HK UNITS CONDENSER PRESSURE DROP — 30HWB UNITS NOTE: Ft of water = 2.31 x change in psig. Fig. 16 — Cooler and Condenser W ater Pressure Drop (cont) CONDENSER PRESSURE DROP — 30HWC AND 30HWS UNITS 18[...]

Step 6 — 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 T ables 4A and 4B. See Fig. 17 and 18 for field wiring connections. A field-supplied branch circuit disconnect switch that can be locked in either OPEN or OFF position must[...]

T able 4A — Electrical Data — 30HK, HWB, HWC, HWS Fluid-Cooled Units UNIT SIZE 30- UNIT COMPRESSOR (ea) V olts V oltage* MCA ICF MFA Rec Fuse RLA LRA MT A Nameplate (3 ph) Hz Min Max PW XL PW XL PW XL HK040 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 [...]

T able 4B — Electrical Data — 30HL and HW A Condenserless Units UNIT SIZE 30- UNIT COMPRESSOR (ea) V olts V oltage* MCA ICF MFA Rec Fuse RLA LRA MT A Nameplate (3 ph) Hz Min Max PW XL PW XL PW XL HL050 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** 57[...]

LEGEND COM — Common CR — Compressor Relay CWP — Chilled W ater Pump DLS — Demand Limit Switch GCS — Ground Current Sensing NC — Normally Closed NO — Normally Open TB — T erminal Block TC — T emperature Control Field Wiring Factory Wiring Accessory NOTE: Manual lead/lag selector switch must be disconnected when using automatic lead[...]

LEGEND A— Alarm C— Contactor , Compressor COM — Common EQUIP — Equipment GND — Ground NC — Normally Closed NO — Normally Open R— Relay TB — T erminal Block TOR — T orroid, Accessory Ground Fault Interrupt Field Wiring Factory Wiring NOTE: Factory wiring is in accordance with the National Electrical Code (U.S.A.). Any field modi[...]

A— Alarm C— Contactor CB — Circuit Breaker CH — Crankcase Heater CM — Control Module COM — Common COMP — Compressor CWFS — Chilled W ater (Fluid) Flow Switch CWP — Chilled W ater (Fluid) Pump D— Discharge DLS — Demand Limit Switch Fig. 19 — 30HK, HL Control Box GCS — Ground Current Sensing GND — Ground HGS — Hot Gas So[...]

PRE-ST ART -UP IMPOR T ANT : 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. ELECTRIC SHOCK HAZARD Open all disconnects before servicing this eq[...]

T a b l e5—T ypical Deadband Requirements UNIT CAP ACITY STEPS COOLER DESIGN RANGE, F (C) 5.0 (2.8) 10.0 (5.6) 15.0 (8.3) 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) T able 6 — Deadband Setting MIN. REQUIRED DEADBAND DEADBAND SETTING (F) FC 0.5 to 1.5 0.28 to 0.83 1.0 2.0 1.1 1 2.0 2.5 1.39 2.[...]

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. Ob- serve oil level and add oil, if required, to bring the oil level in the compressor crankcase(s) to between 1 ⁄ 8 [...]

DISCHARGE LINE CHECK V AL VE — On all 30HL, HW A 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 muf f ler . Install the valve in any position except bonnet down. The check valve(s)[...]

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 con- trol 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 illumi[...]

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 T able 5 is desired, determine the setting by using the fol- lowing formula and T able 6: Minimum Required Unit Deadband: Minimum Deadband = (Cooler Design[...]

Once the compressor is shut of f, 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. If the unit is equipped with field-installed hot gas bypass, the hot [...]

T able 1 1 — Capacity Control Steps — 30HW Standard Units UNIT CAP ACITY CONTROL CAP ACITY OPERA TING 30HW STEPS* % CYLINDERS 018 1 33.3 2 2 66.7 4 3 100.0 6 025 1 50.0 2 2 100.0 4 028 1 33.3 2 2 66.7 4 3 100.0 6 035 1 33.3 2 2 66.7 4 3 100.0 6 040 1 33.3 2 2 66.7 4 3 100.0 6 *Factory-installed hot gas bypass option adds an additional capacity [...]

Thermistor — The resistance at various temperatures for the thermistor are given in T ables 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. IMPOR T ANT : Do not diassemb[...]

T able 1 2A — Sensor T emperature (F) vs Resistance TEMPERA TURE RESIST ANCE (F) (OHMS) -2 5 98,010 -2 4 94,707 -2 3 91,522 -2 2 88,449 -2 1 85,485 -2 0 82,627 -1 9 79,871 -1 8 77,212 -1 7 74,648 -1 6 72,175 -1 5 69,790 -1 4 67,490 -1 3 65,272 -1 2 63,133 -1 1 61,070 -1 0 59,081 -9 57,162 -8 55,31 1 -7 53,526 -6 51,804 -5 50,143 -4 48,541 -3 46,9[...]

T able 1 2B — Sensor T emperature (C) vs Resistance TEMPERA TURE RESIST ANCE (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[...]

SERVICING COOLER (30HK,HL ONL Y) 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 horizonta[...]

TROUBLESHOOTING Complete Unit Stoppage and Restart — Pos- sible causes for unit stoppage and reset methods are (also see T able 14): GENERAL POWER F AILURE — 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[...]

COOLING LOAD SA TISFIED — Unit shuts down if cool- ing load is satisfied. Unit restarts if required after comple- tion of 5-minute timer cycle. THERMISTOR F AILURE — If thermistor fails in open mode, the temperature controller shuts down the unit in an out-of- range condition. Replace the thermistor . Unit restarts auto- matically after comple[...]

T able 14 — T roubleshooting (cont) SYMPTOMS CAUSE REMEDY Compressor loses oil Leak in system Repair leak. Mechanical damage (blown piston or broken discharge valve) Repair damage or replace compressor as needed. Oil trapped in line Check piping for oil traps. Crankcase heater not energized during shutdown Check wiring and crankcase heater contac[...]

SERVICE TRAINING Packaged Service T raining programs are an excellent way to increase your knowledge of the equip- ment discussed in this manual, including: • Unit Familiarization • Installation Overview • Maintenance • Operating Sequence A large selection of product, theory , and skills programs are available, using popular video-based for[...]

ST ART -UP CHECKLIST FOR CHILLER SYSTEMS (Remove and use for job file) A. Preliminary Information JOB NAME LOCA TION INST ALLING CONTRACTOR DISTRIBUTOR ST ART -UP PERFORMED BY EQUIPMENT : Chiller: MODEL # SERIAL # COMPRESSORS: CIRCUIT #1 CIRCUIT #2 (30HK,HL ONL Y) MODEL # MODEL # SERIAL # SERIAL # MOTOR # MOTOR # CONDENSER (30HK, HWB, HWC, HWS ONL[...]

B. Preliminary Equipment Check (YES or NO) (cont) HA VE POWER SIDE ELECTRICAL COMPONENT CONNECTIONS BEEN CHECKED FOR TIGHTNESS? ON 30HK,HL UNITS, IS THE PROPER CONTROL VOL T AGE SUPPLIED T O TB2-1 AND TB2-3? ON 30HK,HL 50 HZ UNITS, IS THE BLACK WIRE GOING TO TRAN1 AND TRAN2 CONNECTED T O THE RED LEAD FROM THE TRANSFORMER? CHECK AIR SYSTEMS (YES OR [...]

C. Unit Start-Up (cont) COOLER LOOP PROTECTION IF REQUIRED: GALLONS (LITERS) OF BRINE ADDED: PIPING INCLUDES ELECTRIC T APE HEA TERS. CHECK PRESSURE DROP ACROSS COOLER. FLUID ENTERING COOLER: PSIG (kPa) FLUID LEA VING COOLER: PSIG (kPa) (PSIG DIFFERENCE) x 2.31 = FT OF FLUID PRESSURE DROP = (kPa DIFFERENCE) x .335 = FT OF FLUID PRESSURE DROP = PLOT[...]

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 Ta b 5 c PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg CL-4 1 1-98 Replaces: 30H-8SI[...]