Carrier 30HK Chiller Manual: Installation, Start-Up, and Service Instructions
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30HK040-060 30HL050,060 30HW018-040

Reciprocating Liquid Chillers 50/60 Hz

Installation, Start-Up and

Service Instructions

CONTENTS

Page

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 1 Ð Inspect Shipment . . . . . . . . . . . . . . . . . . . . . 3

Step 2 Ð Rig the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3

·30HK,HL UNITS

·30HW UNITS

Step 3 Ð Place the Unit . . . . . . . . . . . . . . . . . . . . . . . . 3

·30HK,HL UNITS

·30HW UNITS

Step 4 Ð Check Compressor Mounting and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 5 Ð 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 Ð 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

Manufacturer reserves the right to discontinue, or change at any time, speci®cations 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 1

11-98

Replaces: 30H-8SI

Tab

5c

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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Contents Contents Installation, Start-Up Service InstructionsGeneral Safety ConsiderationsRig and Place Unit InstallationPlace the Unit 30HW UnitsLeft Side View TOP ViewUnit SAETOP View Front View Right Side View 30HL050,060 CondenserlessRear View Left Side View 30HWB 30HWB018-040 Fluid Cooled30HWC,S Left Side View Front ViewWeight Distribution AT Each Mounting HOLE, 50 HZ Units Weight Distribution AT Each Mounting HOLE, 60 HZ UnitsLocation of Mounting Holes 30HWA,B 30HWC,SHWC,S HWBCompressor CoolerRefrigerant Ð kg Ð Physical Data 30HL, HWA Condenserless Units Ð SI Ð Physical Data 30HL, HWA Condenserless Units Ð EnglishCondenser Connections Factory-Installed Unit Wheels Typical Piping with Fluid-Cooled 30HWB Unit Shown Page Cooler Description Installed Coupling Fastening Grooved Pipe EndsUnit Size Cooler Condenser Minimum Cooler Loop VOLUME² Minimum Cooler and Condenser Flow Rates Minimum Loop VolumeCooler Pressure Drop Ð 30HW Units Cooler Pressure Drop Ð 30HK, HL UnitsCondenser Pressure Drop Ð Page Unit Size Ð Electrical Data Ð 30HK, HWB, HWC, HWS Fluid-Cooled UnitsICF LRA MTAÐ Electrical Data Ð 30HL and HWA Condenserless Units CWP Field Accessory WiringDLS GCSEquip COMGND TORHGS PRISEC HPSInitial Check PRE-START-UPElectric Shock Hazard NeutCheck Refrigerant Charge Deadband SettingTypical Deadband Requirements Operating Limitations START-UP and OperationCheck Refrigerant Feed Components To ADD OILCompressor and Unit Protective Devices Pressure Relief Valve SettingsCheck Unit Safeties Crankcase HeaterFactory Settings, Low-Pressure Switch Fixed Factory Settings, High-Pressure Switch FixedCapacity Control and Operating Sequence Ð Unit OperationFREEZE-UP Protection Capacity Control Steps Ð 30HK, HL Standard Units Transfer Switch Compressor Unit Control No Position StepsCapacity Control Steps Ð 30HW Standard Units ServiceUnit Capacity Control Operating Steps CylindersThermistor Thermistor REPLACEMENT, 30HK, HL UnitsTemperature Resistance Ohms Ð Sensor Temperature F vs ResistanceÐ Sensor Temperature C vs Resistance Tightening Cooler Head Bolts Servicing Cooler 30HK,HL onlyPlugs and Tubes Components for Part Number PluggingChilled Fluid PROOF-OF-FLOW Switches Open TroubleshootingHead Bolt Tightening Sequence Symptoms Cause Remedy TroubleshootingCompressor Call for Free Catalog Service TrainingRemove and use for job le Preliminary Information START-UP Checklist for Chiller SystemsPreliminary Equipment Check YES or no Voltage Imbalance LOCATE, REPAIR, and Report ANY R-22 LeaksFluid Entering Cooler Unit Start-UpFluid Leaving Cooler Units Rated MIN. Pressure Drop =Book Catalog No Form 30H-10SI Pg CL-4 11-98

30HK040-060, 060, 30HL050, 30HW018-040 specifications

The Carrier 30HW018-040, 30HL050, 060, and 30HK040-060 series represents a range of advanced rooftop units designed to meet the diverse heating and cooling needs of commercial buildings. Renowned for their efficiency and performance, these units incorporate cutting-edge technologies to improve operational effectiveness and reduce energy consumption.

One of the standout features of the Carrier 30HW series is its high-efficiency scroll compressors, which are engineered to provide exceptional cooling capacity while minimizing energy usage. These compressors operate quietly and ensure smooth performance across varying loads. Additionally, the units utilize advanced microprocessor controls that enhance system efficiency by enabling precise temperature regulation and optimizing energy consumption based on real-time weather conditions.

Another important aspect of the 30HL series is its ability to provide reliable heating and cooling capabilities even in extreme weather conditions. With robust heat exchangers and a range of variable-speed fans, these units can efficiently circulate air while maintaining optimal indoor comfort levels. Variable-speed technology not only enhances comfort but also improves energy savings, as the system can adjust its output based on occupancy and external temperature fluctuations.

The 30HK series, specifically designed for high-performance applications, features enhanced filtration systems which improve indoor air quality. These systems are capable of accommodating various filter types, ensuring that airborne contaminants are effectively captured. This makes the 30HK a suitable choice for environments where air quality is a priority, such as schools, hospitals, and commercial offices.

Moreover, all units in the 30HW, 30HL, and 30HK series are designed with ease of maintenance in mind. Removable panels and easy access points allow for quick servicing and reduces downtime. The compact design also ensures that installation is straightforward, making them a preferred choice for many contractors.

In summary, Carrier's 30HW018-040, 30HL050, 060, and 30HK040-060 series are integral solutions in the HVAC market, combining energy efficiency, advanced controls, and superior air quality features. These rooftop units are tailored for commercial applications, providing reliable heating and cooling solutions while prioritizing comfort and sustainability. Through continuous innovation, Carrier remains at the forefront of HVAC technology, ensuring that their products meet the evolving demands of the industry.
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