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Carrier 60 User Manual

Carrier 60
44 pages
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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
..................................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)
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
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
...................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 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg 1 11-98 Replaces: 30H-8SI

Table of Contents

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Carrier 60 Specifications

General IconGeneral
CapacityUnknown
TypeUnknown
Energy Star CertifiedUnknown
Defrost TypeUnknown
Number of DoorsUnknown

Summary

General Unit Information

Safety Considerations for Installation and Service

Hazards and precautions during installation, start-up, and servicing.

Installation Procedures

Unit Location Requirements

Guidelines for indoor placement, ventilation, and clearances for controls.

Inspect Shipment

Procedure for checking unit for damage or missing parts upon delivery.

Rig and Place Unit

Instructions for lifting and positioning 30HK, HL, and 30HW units.

Place the Unit

Final placement, leveling, and securing of the unit to the floor or pad.

Check Compressor Mounting and Connections

Procedure to check compressor mounting and self-locking nuts.

Make Piping Connections

30HK, HWC, HWS Condenser Description

Details on shell-and-tube condensers, tube servicing, and zinc anodes.

30HL, HWA System Condenser

Instructions for remote condensers and head pressure control.

30HWB Condenser Description

Description of brazed-plate condensers and their construction.

30HWB Condenser Servicing

Cooler Description

Details on direct-expansion and brazed-plate coolers.

Cooler Pressure Drop Analysis

Make Electrical Connections

Field Wiring Compliance and Data

Requirements for field wiring, electrical data, and compressor wiring.

Flow Switch Installation and Wiring

Instructions for installing and wiring the cooler flow switch accessory.

Control Box Power and Controls Sections

Description of components within the control box power and controls sections.

Unbalanced 3-Phase Supply Voltage Check

Procedure to check for and calculate phase voltage imbalance.

Pre-Start-Up Procedures

Electrical Shock Hazard Warning

Critical safety warning to open all disconnects before servicing.

Initial Check Procedures

Steps for initial electrical checks before starting the unit.

Check Refrigerant Charge Procedure

Start-Up and Operation Checks

Check Compressor Oil Charge

Procedure for checking and adjusting compressor oil level.

Operation Checks

Steps to perform during initial start-up and operation.

Operating Limitations

Safe operating temperature and voltage limits for the unit.

Compressor and Unit Protective Devices

Pressure Relief Devices

Information on pressure relief valve settings and locations.

Compressor Internal Thermal Protection

Details on compressor overtemperature protection for 30HW units.

Oil Pressure Safety Switch (OPS)

Description and function of the oil pressure safety switch.

Check Unit Safeties

High-Pressure Switch Operation

How the high-pressure switch protects the compressor.

Low-Pressure Switch Operation

How the low-pressure switch protects the cooler and compressor.

Chilled Fluid Temperature Controller

Details on the temperature controller settings and operation.

Unit Operation and Capacity Control

Freeze-Up Protection Measures

Systems to prevent unit damage from freezing conditions.

Loss-of-Cooler-Flow Protection

Use of flow switch for protection against low fluid flow.

Compressor Ground Fault Sensor

Description of the accessory ground fault sensor.

Capacity Control and Operating Sequence

How the unit controls capacity and its start-up sequence.

Service Procedures

Compressor Replacement

Steps for replacing a compressor unit.

Circuit Breaker Function

Explanation of circuit breaker protection and reset.

Brazed-Plate Heat Exchanger Replacement

Procedures for replacing brazed-plate coolers and condensers.

Brazed-Plate Heat Exchanger Cleaning

Method for chemically cleaning brazed-plate heat exchangers.

Shell-and-Tube Condenser Cleaning

Manual and chemical cleaning procedures for shell-and-tube condensers.

Thermistor Service and Replacement

Thermistor Replacement (30HK, HL)

Instructions for replacing thermistors in 30HK and HL units.

Thermistor Replacement (30HW)

Instructions for replacing thermistors in 30HW units.

Servicing Cooler (30HK,HL Only)

Tube Plugging Procedure

Method for plugging leaky cooler tubes.

Retubing Cooler Tubes

Procedures for retubing cooler heat exchangers.

Tightening Cooler Head Bolts

Bolt torques and tightening sequence for cooler heads.

Troubleshooting Unit Stoppage and Restart

General Power Failure

Unit restart after power restoration.

Unit ON-OFF Switch Open

Unit behavior when the ON-OFF switch is opened.

Auxiliary Interlocks Open

Restart after correcting open auxiliary interlock contacts.

Chilled Fluid Flow Switch Open

Restart after correcting loss of cooler fluid flow.

Open Low-Pressure Switch

Troubleshooting and restart after low-pressure switch trip.

Temperature Controller Out-of-Range

Unit shutdown due to temperature controller out-of-range condition.

Open High-Pressure Switch

Troubleshooting and restart after high-pressure switch trip.

Open Compressor Internal Thermal Protection

Troubleshooting for 30HW units with thermal protection trip.

Open Oil Pressure Switch

Troubleshooting and restart after oil pressure switch trip.

Open Compressor Ground-Current Sensor

Troubleshooting for ground fault sensor activation.

Open 24-V Control Circuit Breaker

Resetting circuit breakers for control circuit failures.

Troubleshooting Common Symptoms

Cooling Load Satisfied

Unit shutdown when cooling load is met.

Thermistor Failure

Troubleshooting steps for thermistor failures.

Start-Up Checklist for Chiller Systems

Preliminary Information Section

Fields for job name, location, contractor, and equipment details.

Preliminary Equipment Check

Pre-start checks for shipping damage, power supply, and wiring.

Unit Start-Up Procedures

Preliminary Equipment Check (Continued)

Continued checks for electrical connections and air systems.

Unit Start-Up Procedures (Continued)

Cooler Loop Protection

Requirements for cooler loop protection and brine.

Check Pressure Drop Across Cooler

How to check and determine cooler pressure drop.

Condenser Protection

Requirements for condenser water inlet strainers.

To Start the Chiller

Step-by-step instructions to start the chiller.

Measure Operating Parameters

Key parameters to measure during stable operation.

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