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30HK040-060
30HL050,060
30HW018-040
Reciprocating Liquid Chillers
50/60 Hz
Installation, Start-Up and
Service Instructions
• COMPRESSOR INTERNALTHERMAL PROTECTION
CONTENTS
• CRANKCASE HEATER
Page
• OIL PRESSURE SAFETY SWITCH (OPS)
GENERAL ....................................2
Check Unit Safeties ...........................28
• CONTROL MODULE
SAFETY CONSIDERATIONS .....................2
• HIGH-PRESSURE SWITCH
INSTALLATION ..............................3-25
• LOW-PRESSURE SWITCH
Location..........
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GENERAL Theseinstallationinstructionscoverthe30HK,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. SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment (Fig. 1-3) can be hazardous due to system pressu
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If unit is to be dragged into final position, or moved on INSTALLATION rollers, it is recommended that it be left on the skid.When Location— Donotstoreunitsinanareaexposedtoweather draggingorrolling,applyforceonlytotheskid,nottothe because of sensitive control mechanisms and electronic unit. Lift from above, using the lifting angles provided, to devices. Locate unit indoors. See Fig. 4-8 for unit dimen- remove unit from the skid. sional details. 30HW UNITS Allow36in.(914mm)infrontoftheunitforcont
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TOP VIEW FRONT VIEW RIGHT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HK AB C D 1 9 15 5 ⁄4 90 14 ⁄16 7 ⁄16 040 (133) (2286) (370) (202) 3 1 9 10 ⁄4 108 20 ⁄16 13 ⁄16 050,060 (273) (2743) (510) (344) LEGEND COMP — Compressor K.O. — Knockout MTG — Mounting SAE — Society ofAutomotive Engineers (U.S.A.) NOTES: 1. Standard unit shown with the sound enclosure accessory. 2. Dimensions are in inches unless otherwise indicated. Dimensions in ( ) are in millimeters. 3. Service clearance for the control box is
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TOP VIEW FRONT VIEW RIGHT SIDE VIEW LEGEND CLY — Cylinder COMP — Compressor CONN — Connection K.O. — Knockout NOTES: 1. Standardunitshownwiththesounden- closure accessory. 2. Dimensions are in inches unless oth- erwiseindicated.Dimensionsin( )are in millimeters. LEFT SIDE VIEW Fig. 5 — 30HL050,060 (Condenserless) 5
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REAR VIEW LEFT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HWA ABCD E F G 12.58 19.20 20.48 33.85 11.72 5.75 17.95 018 (320) (488) (520) (860) (298) (146) (456) 12.82 18.98 20.57 33.85 11.72 5.75 17.95 025 (326) (482) (522) (860) (298) (146) (456) 12.64 18.31 20.73 33.85 11.72 5.75 17.95 028 (321) (465) (527) (860) (298) (146) (456) 12.87 18.62 20.81 33.85 11.72 5.75 17.95 035 (327) (473) (529) (860) (298) (146) (456) 12.66 18.64 21.30 34.15 11.34 8.22 17.36 040 (322) (473) (541) (867) (288) (209) (4
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REAR VIEW LEFT SIDE VIEW DIMENSIONS — in. (mm) UNIT 30HWB ABCD E F G H J 13.14 18.72 22.02 33.85 11.72 5.75 12.29 17.95 9.28 018 (334) (475) (559) (860) (298) (146) (312) (456) (236) 13.22 18.25 22.10 33.85 11.72 5.75 12.29 17.95 9.28 025 (336) (464) (561) (860) (298) (146) (312) (456) (236) 13.18 17.71 22.39 33.85 11.72 5.75 12.29 17.95 9.28 028 (335) (450) (569) (860) (298) (146) (312) (456) (236) 13.45 17.98 22.68 33.85 11.72 5.75 12.29 17.95 9.28 035 (342) (457) (576) (860) (298) (146) (312)
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LEFT SIDE VIEW FRONT VIEW DIMENSIONS — in. (mm) UNIT 30HWC,S A BCD EF G 47.50 9.90 14.00 18.15 17.95 6.69 34.20 018 (1206) (251) (356) (461) (456) (170) (869) 48.30 9.90 15.50 18.15 17.95 6.69 34.20 025 (1227) (251) (394) (461) (456) (170) (869) 48.00 10.00 15.80 18.15 17.95 6.69 34.20 028 (1219) (254) (401) (461) (456) (170) (869) 48.20 10.00 15.90 18.15 17.95 6.69 34.20 035 (1224) (254) (404) (461) (456) (170) (869) 47.80 10.00 15.90 18.45 17.36 6.40 32.94 040 (1214) (254) (404) (469) (441) (1
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WEIGHT DISTRIBUTIONAT EACH MOUNTING HOLE, 60 HZ UNITS MOUNTING HOLES 30HK 30HL UNIT SIZE ABCDABCD Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg Lb Kg 040 710 322 712 323 705 320 703 319 ———————— 050 787 357 789 358 782 355 780 354 519 235 521 236 516 234 514 233 060 838 380 840 381 832 377 830 376 534 242 536 243 531 241 529 240 NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions. WEIGHT DISTRIBUTIONAT EACH MOUNTING HOLE, 50 HZ UNITS MOUNTING HOLES 30HK 30HL UNIT SIZE ABCDABCD Lb Kg
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Table 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 OPERATING WT (Approximate) − lb HWB 795 950 1065 1085 1310 — — — HWC,S 1231 1358 1484 1508 1702 — — — 2830/ 3138/ 3340/ HK ———— — 2875† 3340† 3400† REFRIGERANT — lb R-22 HWB 12.5 15.0 17.5 18.5 23.2 — — — HWC,S 35.0 37.0 42.0 42.0 47.0 — — — HK — Ckt 1 ———— — 35/40† 45/45† 45/45† HK − Ckt 2 ———— — 35/35† 35/45† 45/45† COMPRESSOR 06E6175, Model No. 06DG5
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Table 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 OPERATING WT (Approximate) − kg HWB 360 431 483 492 594 — — — HWC,S 554 611 668 679 766 — — — 1284/ 1424/ 1514/ HK ———— — 1305† 1514† 1542† REFRIGERANT — kg R-22 HWB 5.7 6.8 7.9 8.4 10.5 — — — HWC,S 15.9 16.8 19.1 19.1 21.3 — — — HK — Ckt 1 ———— — 15.9/18.1† 20.4/20.4† 20.4/20.4† HK — Ckt 2 ———— — 15.9/15.9† 15.9/20.4† 20.4/20.4† COMPRESSOR 06E6175, Model No
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Table 2A — Physical Data; 30HL, HWA Condenserless Units — English UNIT 30 HWA018 HWA025 HWA028 HWA035 HWA040 HL050 HL060 2070/ 2130/ OPERATING WT (Approximate) − lb 740 880 960 975 1080 2120* 2190* REFRIGERANT† — lb R-22 1.6 2.0 2.4 2.4 3.0 6.3/4.2** 5.3/5.3** COMPRESSOR 06E6275, Model No. 06DG537 06E2250 06E7265 06E7275 06E7299 06E6275 06E2250 Nominal Hp 15 20 25 30 35 25,20 30 (ea) Quantity 1111 1 1 (ea) 2 Cylinders Per Compressor 6466 6 6,4 6 Capacity Control — Standard No. of Steps 3233 3 4
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Thenumberoftubesinthecondenser(s)variesdepending ontheunitsize.Thecondensershaveinternalsubcoolerswhich provideapproximately8F(4.4C)for30HK,HLunitsor13F (7.2 C) for 30HW units subcooling atARI (Air Condition- ing and Refrigeration Institute, U.S.A.) rating conditions. 30HL,HWASYSTEMCONDENSER—Fordetailedcon- denser piping installation instructions for 30HL and HWA systems,refertoseparateinstructionspackagedwiththere- mote condenser unit(s). Condenserrefrigerantpipingfor30HLandHWAunitsshould be si
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14 LEGEND Airflow Through Condenser Airflow ThroughAir Handling Unit Power Wiring Control Wiring Chilled Water Piping ST — Field-Supplied Starter FD — Field-Supplied Disconnect FS — Field-Supplied Differential Flow Switch *Field Supplied. NOTES: 1. Chiller must be installed levelly to maintain proper compressor oil return. 2. Wiringandpipingshownaregeneralpoints-of-connectionguidesonlyandarenotintendedforaspecificinstallation.Wiringandpiping shown are for a quick overview of system and are not in a
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NOTES: 1. Chillermustbeinstalled levelly tomaintainpropercompres- sor oil return. 2. Wiringandpipingshownaregeneralpoints-of-connectionguides only and are not intended for a specific installation. Wiring andpipingshownareforaquickoverviewofsystemandare not in accordance with recognized standards. 3. Allwiringmustcomplywithapplicablelocalandnationalcodes. 4. All piping must follow standard piping techniques. Refer to Carrier System Design Manual part 3, Carrier E20-IIT soft- ware Refrigerant Pipin
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30HWBCONDENSER—Whenfacingthebackoftheunit, Provide a means for draining the system in the winter (if the condenser is the uninsulated heat exchanger located on not used) and for maintenance. the right-hand side.The water connections are on the right- Accessorysteelmanifoldpackagesforinletandoutletcon- hand side of the heat exchanger with the LIQUID-IN con- denserwaterareavailablefor30HKunits.Eachmanifoldis nection at the bottom, and the LIQUID-OUT connection at furnished in 2 sections, to be fiel
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Thecoolerfluidinletandoutletconnectionsaregrooved- Table 3 — Minimum Cooler and Condenser Flow end. On 30HW units, the fluid enters at the top connection Rates Minimum Loop Volume andleavesatthebottomconnection.Proceduresformaking MINIMUM COOLER COOLER CONDENSER* thegrooved-endconnectionsarethesameasforthe30HWB LOOP VOLUME† UNIT SIZE condensers. See 30HWB Condenser section on page 16 for Gal./Min L/s Gal./Min L/s Gal. L more details. 30HK040 56.0 3.5 67 4.23 120 454.2 Run the pump for 10 minutes,
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CONDENSER PRESSURE DROP — CONDENSER PRESSURE DROP — 30HK UNITS 30HWB UNITS CONDENSER PRESSURE DROP — 30HWCAND 30HWS UNITS NOTE:Ftofwater = 2.31xchange in psig. Fig. 16 — Cooler and Condenser Water Pressure Drop (cont) 18
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ControlBox,ControlsSection —Thecontrolboxcontrols Step6—MakeElectricalConnections— Allfield wiringmustcomplywithlocalcoderequirements.Electrical section contains the following components: dataforthecompleteunitandforthecompressorsisshown • temperature controller in Tables 4A and 4B. See Fig. 17 and 18 for field wiring • control relay(s) connections.Afield-suppliedbranchcircuitdisconnectswitch • control module(s) thatcanbelockedineitherOPENorOFFpositionmustbe • low-voltage control transformer(s) in
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Table 4A — Electrical Data — 30HK, HWB, HWC, HWS Fluid-Cooled Units UNIT COMPRESSOR (ea) UNIT SIZE Volts Voltage* ICF LRA MTA Rec 30- MCA MFA RLA Fuse Nameplate (3 ph) Hz Min Max PW XL PW XL PW XL 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 24 † 98 † 42 HK040 220 50 198 253 142 † 390 200 175 75/48** † 342/201** † 116/74** 400 50 342 440 71 † 249 100 90 36/26** † 223/142** † 56/40** 208/230 60 187 253 161 † 503 225 2
