Carrier 30HK040-060 User Manual
Installation, Start-Up and
Service Instructions
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
. . . . . . . . . . . . . . . . . . . . . . . . 3
•
30HK,HL UNITS
•
30HW UNITS
Step 4 — Check Compressor Mounting and
Connections
Connections
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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
. . . . . . . . . . . 19
•
30HK,HL UNITS
•
30HW UNITS
•
ALL UNITS
PRE-START-UP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-27
Initial Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check Refrigerant Charge
. . . . . . . . . . . . . . . . . . . . . 26
•
LIQUID CHARGING METHOD
Check Oil Charge
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
•
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)
TEMPERATURES (LCWT)
•
LOW COOLER LCWT
•
MAIN POWER SUPPLY
Check Refrigerant Feed Components
. . . . . . . . . . . . 27
•
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
. . . . . . . . . 28
•
CIRCUIT BREAKER
•
COMPRESSOR INTERNAL THERMAL PROTECTION
•
CRANKCASE HEATER
•
OIL PRESSURE SAFETY SWITCH (OPS)
Check Unit Safeties
. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
•
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Capacity Control and Operating Sequence
. . . . . . . 30
•
30HK,HL UNITS
•
30HW UNITS
SERVICE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-35
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)
. . . . . . . . . 36,37
Tube Plugging
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
•
RETUBING
Tightening Cooler Head Bolts
. . . . . . . . . . . . . . . . . . 36
•
GASKET PREPARATION
•
BOLT TORQUES
TROUBLESHOOTING
. . . . . . . . . . . . . . . . . . . . . . . . 37-39
Complete Unit Stoppage and Restart
. . . . . . . . . . . . 37
•
GENERAL POWER FAILURE
•
UNIT ON-OFF SWITCH IS OPEN
•
CONTACTS OF ANY AUXILIARY INTERLOCKS ARE
OPEN
OPEN
•
CHILLED FLUID PROOF-OF-FLOW SWITCH(ES) OPEN
•
OPEN LOW-PRESSURE SWITCH
•
TEMPERATURE CONTROLLER SHUTS UNIT DOWN ON
OUT-OF-RANGE
OUT-OF-RANGE
•
OPEN HIGH-PRESSURE SWITCH(ES)
•
OPEN COMPRESSOR INTERNAL THERMAL
PROTECTION
PROTECTION
•
OPEN OIL PRESSURE SWITCH
•
OPEN CONTACTS ON COMPRESSOR GROUND-
CURRENT SENSOR(S) (Accessory)
CURRENT SENSOR(S) (Accessory)
•
OPEN 24-V CONTROL CIRCUIT BREAKER(S)
•
COOLING LOAD SATISFIED
•
THERMISTOR FAILURE
START-UP CHECKLIST FOR
CHILLER SYSTEMS
CHILLER SYSTEMS
. . . . . . . . . . . . . . . . . . . CL-1 to CL-4
30HK040-060
30HL050,060
30HW018-040
Reciprocating Liquid Chillers
50/60 Hz
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab
Tab
5c
PC 903
Catalog No. 533-070
Printed in U.S.A.
Form 30H-10SI
Pg 1
11-98
Replaces: 30H-8SI