Carrier Refrigerator 060 User Manual
30HK040-060  
30HL050,060  
30HW018-040  
Reciprocating Liquid Chillers  
50/60 Hz  
Installation, Start-Up and  
Service Instructions  
• COMPRESSOR INTERNAL THERMAL PROTECTION  
CONTENTS  
• CRANKCASE HEATER  
Page  
• OIL PRESSURE SAFETY SWITCH (OPS)  
Check Unit Safeties . . . . . . . . . . . . . . . . . . . . . . . . . . . 28  
• CONTROL MODULE  
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . 2  
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25  
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Step 1 — Inspect Shipment . . . . . . . . . . . . . . . . . . . . . 3  
Step 2 — Rig the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
• 30HK,HL UNITS  
• HIGH-PRESSURE SWITCH  
• LOW-PRESSURE SWITCH  
• CHILLED FLUID TEMPERATURE CONTROLLER  
• FREEZE-UP PROTECTION  
• LOSS-OF-COOLER-FLOW PROTECTION  
• COMPRESSOR GROUND FAULT SENSOR  
• 30HW UNITS  
Step 3 — Place the Unit . . . . . . . . . . . . . . . . . . . . . . . . 3  
• 30HK,HL UNITS  
UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32  
Capacity Control and Operating Sequence . . . . . . . 30  
• 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  
• 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  
• 30HK,HWB,HWC,HWS UNITS  
• COOLER DESCRIPTION  
• COOLER PIPING  
Step 6 — Make Electrical Connections . . . . . . . . . . . 19  
• 30HK,HL UNITS  
SERVICING COOLER (30HK,HL ONLY) . . . . . . . . . 36,37  
Tube Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
• RETUBING  
Tightening Cooler Head Bolts . . . . . . . . . . . . . . . . . . 36  
• GASKET PREPARATION  
• BOLT TORQUES  
• 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  
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  
• 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  
START-UP CHECKLIST FOR  
CHILLER SYSTEMS . . . . . . . . . . . . . . . . . . . CL-1 to CL-4  
Manufacturer reserves the right to discontinue, or change at any time, specifications 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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If unit is to be dragged into final position, or moved on  
rollers, it is recommended that it be left on the skid. When  
dragging or rolling, apply force only to the skid, not to the  
unit. Lift from above, using the lifting angles provided, to  
remove unit from the skid.  
INSTALLATION  
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. Prior to installation determine which  
direction compressor will be removed, and leave 3 to 4 ft  
(914 to 1219 mm) clearance for removal.  
On 30HK,HL units leave 71⁄2 ft (2.3 m) (for 040 units) or  
9 ft (2.7 m) (for 050,060 units) clearance on one side for  
cooler tube removal. Leave 2 ft (610 mm) clearance on the  
other side for making fluid connections to cooler and water  
connections to condenser. See Fig. 4 and 5.  
On 30HWA,B units, leave 2 ft (610 mm) on one side for  
making fluid connections to cooler and water connections to  
condenser, accessing the thermostatic expansion valve (TXV),  
and replacing heat exchanger(s) if necessary. See Fig. 6  
and 7.  
On 30HWC,S units, leave 75 in. (1905 mm) on one side  
for condenser tube removal and 2 ft (610 mm) on the other  
side for making fluid connections to cooler and water con-  
nections to condenser, accessing the TXV, and replacing heat  
exchanger(s) if necessary. See Fig. 8.  
The floor must be strong enough to support the unit op-  
erating weight (see Tables 1A-2B and Fig. 9 and 10). If nec-  
essary, add a supporting structure (steel beams or reinforced  
concrete slabs) to the floor to transfer weight to nearest beams.  
30HW UNITS  
NOTE: If accessory mobility package (Carrier part no.  
30HW900008) is to be used, install this accessory after bring-  
ing unit into building and before moving the unit to its final  
location per installation instructions provided with the  
accessory.  
Units Equipped With Factory-Installed Unit Wheels — This  
factory-installed option consists of 4 swivel-type wheels  
mounted to the legs of the unit. See Fig. 11. For units equipped  
with this option, leave the skid on until the unit is in the  
building. Once in the building, remove the skid, and wheel  
the unit to its final location.  
NOTE: The wheels are equipped with a thumb-screw brake.  
Units Not Equipped With Factory-Installed Unit Wheels —  
Do not remove the skid until the unit has been moved to its  
final location. The unit may be moved by means of rollers  
under the skid, a forklift truck, or rig and slings.  
Step 3 — Place the Unit  
30HK,HL UNITS — When unit is in final position, remove  
skid, level the unit (using a level), and bolt the unit to floor  
or pad.  
NOTE: These units are not suitable for unprotected outdoor  
use.  
Carrier recommends that these units be located in the base-  
ment or on the ground floor. However, if it is necessary to  
locate the unit on an upper floor, be sure the structure has  
been designed to support the unit weight. If necessary, add  
structural support to floor. Also, be sure the surface for in-  
stallation is level. Refer to Fig. 4 and 5 for space require-  
ments and Fig. 9 for weight distribution.  
Additional weights of factory-installed options (30HW only)  
are:  
Sound enclosure — 75 lb (34 kg)  
Hot gas bypass — 15 lb (7 kg)  
80-amp non-fused disconnect — 15 lb (6.8 kg)  
100-amp non-fused disconnect — 25 lb (11.3 kg)  
200-amp non-fused disconnect — 70 lb (31.8 kg)  
Only electrical power connections, water connections for  
condenser, and fluid connections for cooler are required for  
30HK installation. Installation of 30HL units varies only in  
field piping required for the remote condenser.  
Be sure interconnecting piping and electrical conduits  
are suspended freely, and are not in contact with any  
adjacent walls. Be sure unit capillaries are not rubbing  
against anything.  
30HW UNITS — When the unit is in its final position, re-  
move the skid (from units not equipped with factory-  
mounted wheels), or remove the wheels (if equipped). Re-  
3
move ⁄8-in. wheel nuts to remove wheels from unit legs.  
Step 1 — Inspect Shipment — Inspect unit for dam-  
age or missing parts. If damaged, or if shipment is incom-  
plete, file a claim immediately with the shipping company.  
Level the unit (using a level), and bolt the unit to the floor  
or pad.  
If unit is to be mounted on unit external vibration isola-  
tors, follow the mounting instructions included with the ac-  
cessory vibration isolator (Carrier part numbers 30HW900-  
001 and -002).  
Step 2 — Rig and Place Unit  
30HK,HL UNITS — On each end of cooler, a steel loop is  
provided for the preferred method of lifting unit. Use spreader  
bars to keep cables away from compressor enclosure and  
control box. If unit is to be moved by forklift truck, use one  
of the following two methods:  
1. From front or rear, lift under the cooler rails. Unit can be  
either on or off skid.  
Step 4 — Check Compressor Mounting and  
Connections — As shipped, the compressor is held down  
by special self-locking nuts (Fig. 12). After unit is installed,  
loosen the self-locking nuts one at a time until compressor  
floats freely. Do not remove nuts, as they are self-locking  
and will hold their locked position.  
2. When moving from the ends, leave unit on the skid. Lift  
from under the skid.  
3
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TOP VIEW  
FRONT VIEW  
RIGHT SIDE VIEW  
DIMENSIONS — in. (mm)  
UNIT  
30HK  
A
B
C
D
715⁄16  
(202)  
51⁄4  
(133)  
90  
(2286)  
149⁄16  
(370)  
040  
103⁄4  
(273)  
108  
(2743)  
201⁄16  
(510)  
139⁄16  
(344)  
050,060  
LEGEND  
COMP  
—
—
—
—
Compressor  
Knockout  
Mounting  
K.O.  
MTG  
SAE  
Society of Automotive 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 36-in.  
LEFT SIDE VIEW  
Fig. 4 — 30HK040-060 (Fluid Cooled)  
4
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TOP VIEW  
FRONT VIEW  
RIGHT SIDE VIEW  
LEGEND  
CLY  
—
—
—
—
Cylinder  
COMP  
CONN  
K.O.  
Compressor  
Connection  
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.  
LEFT SIDE VIEW  
Fig. 5 — 30HL050,060 (Condenserless)  
5
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REAR VIEW  
LEFT SIDE VIEW  
DIMENSIONS — in. (mm)  
UNIT  
30HWA  
A
B
C
D
E
F
G
12.58  
(320)  
19.20  
(488)  
20.48  
(520)  
33.85  
(860)  
11.72  
(298)  
5.75  
17.95  
(456)  
018  
025  
028  
035  
040  
(146)  
12.82  
(326)  
18.98  
(482)  
20.57  
(522)  
33.85  
(860)  
11.72  
(298)  
5.75  
(146)  
17.95  
(456)  
12.64  
(321)  
18.31  
(465)  
20.73  
(527)  
33.85  
(860)  
11.72  
(298)  
5.75  
(146)  
17.95  
(456)  
12.87  
(327)  
18.62  
(473)  
20.81  
(529)  
33.85  
(860)  
11.72  
(298)  
5.75  
(146)  
17.95  
(456)  
12.66  
(322)  
18.64  
(473)  
21.30  
(541)  
34.15  
(867)  
11.34  
(288)  
8.22  
(209)  
17.36  
(441)  
RIGHT SIDE VIEW  
LOCATION — in. (mm)  
MODEL 30HWA (See Table Below)  
DISCONNECT  
(Amps)  
J
K
L
M
018---  
025---  
028---  
035---  
040---  
3.33  
(85)  
2.98  
(76)  
14.44  
(367)  
46.50  
100,200,  
100,200,  
600,900  
100,200,  
600,900  
80  
100  
200  
100,600,900  
—
(1181)  
600,800,900  
4.33  
(110)  
4.98  
(126)  
14.82  
(376)  
47.50  
(1207)  
100,200,  
600,900  
500  
—
500,800  
—
800  
500  
200,800  
500  
7.46  
(189)  
11.19  
(284)  
15.82  
(402)  
54.50  
(1384)  
500,800  
NOTES:  
LEGEND  
MODEL  
VOLT-Hz  
DISC.  
K.O.  
—
—
Disconnect  
Knockout  
1.  
2.  
Denotes center of gravity.  
Denotes accessory or factory-installed option.  
100  
200  
500  
600  
800  
900  
575-60  
380-60  
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.  
208/230-60  
460-60  
230-50  
400-50  
Fig. 6 — 30HWA018-040 (Condenserless)  
6
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REAR VIEW  
LEFT SIDE VIEW  
DIMENSIONS — in. (mm)  
UNIT  
30HWB  
A
B
C
D
E
F
G
H
J
13.14 18.72 22.02 33.85 11.72 5.75 12.29 17.95 9.28  
(334) (475) (559) (860) (298) (146) (312) (456) (236)  
018  
025  
028  
035  
040  
13.22 18.25 22.10 33.85 11.72 5.75 12.29 17.95 9.28  
(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  
(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  
(342) (457) (576) (860) (298) (146) (312) (456) (236)  
13.27 17.75 23.44 34.15 11.34 8.22 12.38 17.36 8.22  
(337) (451) (595) (867) (288) (209) (314) (441) (209)  
RIGHT SIDE VIEW  
LOCATION — in. (mm)  
MODEL 30HWB (See Table Below)  
DISCONNECT  
(Amps)  
K
L
M
N
018---  
025---  
028---  
035---  
040---  
3.33  
(85)  
2.98  
(76)  
14.44  
(367)  
46.50  
(1181)  
100,200,300,  
600,800,900  
100,200,  
600,900  
100,200,  
600,900  
100,200,  
600,900  
80  
100  
4.33  
4.98  
14.82  
(376)  
47.50  
200,  
100  
200  
500  
—
500,800  
—
500,800  
—
800  
500  
(110)  
(126)  
(1207)  
600,900  
7.46  
(189)  
11.19  
(284)  
15.82  
(402)  
54.50  
(1384)  
500,800  
LEGEND  
NOTES:  
MODEL  
VOLT-Hz  
COND  
DISC.  
K.O.  
—
—
—
Condenser  
Disconnect  
Knockout  
1.  
2.  
Denotes center of gravity.  
Denotes accessory or factory-installed option.  
100  
200  
500  
600  
800  
900  
575-60  
380-60  
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.  
208/230-60  
460-60  
230-50  
400-50  
Fig. 7 — 30HWB018-040 (Fluid Cooled)  
7
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LEFT SIDE VIEW  
FRONT VIEW  
DIMENSIONS — in. (mm)  
UNIT  
30HWC,S  
A
B
C
D
E
F
G
47.50  
9.90  
14.00  
(356)  
18.15  
(461)  
17.95  
(456)  
6.69  
34.20  
(869)  
018  
025  
028  
035  
040  
(1206)  
(251)  
(170)  
48.30  
(1227)  
9.90  
(251)  
15.50  
(394)  
18.15  
(461)  
17.95  
(456)  
6.69  
(170)  
34.20  
(869)  
48.00  
(1219)  
10.00  
(254)  
15.80  
(401)  
18.15  
(461)  
17.95  
(456)  
6.69  
(170)  
34.20  
(869)  
48.20  
(1224)  
10.00  
(254)  
15.90  
(404)  
18.15  
(461)  
17.95  
(456)  
6.69  
(170)  
34.20  
(869)  
47.80  
(1214)  
10.00  
(254)  
15.90  
(404)  
18.45  
(469)  
17.36  
(441)  
6.40  
(163)  
32.94  
(837)  
RIGHT SIDE VIEW  
LOCATION — in. (mm)  
K
MODEL 30HWC,S (See Table Below)  
DISCONNECT  
(Amps)  
J
L
018---  
025---  
028---  
035---  
040---  
77.61  
4.38  
3.33  
100,200,  
100,200,  
600,900  
100,200,  
600,900  
100,200,  
600,900  
80  
100  
200  
100  
(1971)  
(111)  
(85)  
600,800,900  
79.61  
(2022)  
5.00  
(127)  
4.33  
(110)  
200,  
600,900  
500  
—
500,800  
—
500,800  
—
800  
500  
83.74  
(2127)  
10.00  
(254)  
7.46  
(189)  
500,800  
LEGEND  
NOTES:  
MODEL  
100  
VOLT-Hz  
D.  
—
—
—
—
Diameter  
1.  
2.  
Denotes center of gravity.  
Denotes accessory or factory-installed option.  
575-60  
380-60  
Disc.  
K.O.  
SCH.40  
Disconnect  
Knockout  
200  
Schedule 40 Pipe  
3. Dimensions are in inches. Dimensions in ( ) are in millimeters.  
500  
208/230-60  
460-60  
600  
800  
230-50  
900  
400-50  
Fig. 8 — 30HWC,S018-040 (Fluid Cooled)  
8
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WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 60 HZ UNITS  
MOUNTING HOLES  
30HK  
Kg  
30HL  
UNIT  
SIZE  
A
B
C
D
A
B
C
D
Lb  
Kg  
322  
357  
380  
Lb  
Lb  
Kg  
320  
355  
377  
Lb  
Kg  
319  
354  
376  
Lb  
—
Kg  
—
Lb  
—
Kg  
—
Lb  
—
Kg  
—
Lb  
—
Kg  
—
040  
050  
060  
710  
787  
838  
712  
789  
840  
323  
358  
381  
705  
782  
832  
703  
780  
830  
519  
534  
235  
242  
521  
536  
236  
243  
516  
531  
234  
241  
514  
529  
233  
240  
NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions.  
WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE, 50 HZ UNITS  
MOUNTING HOLES  
30HK  
Kg  
30HL  
UNIT  
SIZE  
A
B
C
D
A
B
C
D
Lb  
Kg  
327  
380  
387  
Lb  
Lb  
Kg  
325  
377  
384  
Lb  
Kg  
325  
376  
383  
Lb  
—
Kg  
—
Lb  
—
Kg  
—
Lb  
—
Kg  
—
Lb  
—
Kg  
—
040  
050  
060  
721  
838  
853  
723  
840  
855  
328  
381  
388  
716  
832  
847  
715  
830  
845  
534  
550  
242  
249  
526  
551  
238  
250  
531  
545  
241  
247  
529  
544  
240  
247  
NOTE: See Fig. 4 and 5 for specific mounting hole location dimensions.  
LOCATION OF MOUNTING HOLES  
Fig. 9 — Weight Distribution and Mounting Hole Location; 30HK,HL Units  
30HWA,B  
30HWC,S  
WEIGHT DISTRIBUTION AT EACH MOUNTING HOLE — Lb (kg)  
MOUNTING HOLE NO.  
UNIT  
30HW  
1
2
3
4
5
6
7
8
A018  
A025  
185 (83.9)  
220 (99.8)  
240 (108.9)  
244 (110.7)  
270 (122.5)  
199 (90.3)  
238 (108.0)  
266 (120.7)  
271 (122.9)  
328 (148.8)  
171 (77.6)  
196 (88.9)  
211 (95.7)  
216 (98.0)  
240 (108.9)  
—
—
A028  
—
A035  
—
—
A040  
B018  
—
B025  
—
B028  
—
B035  
—
B040  
—
C,S018  
C,S025  
C,S028  
C,S035  
C,S040  
136 (61.7)  
144 (65.3)  
160 (72.6)  
161 (73.0)  
185 (83.9)  
Fig. 10 — Mounting Hole Weight Distribution; 30HW Units  
9
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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  
1484  
1085  
1508  
1310  
1702  
—
—
—
—
3340/  
3400†  
HWC,S  
1231  
1358  
—
—
2830/  
2875†  
3138/  
3340†  
HK  
—
—
—
—
—
REFRIGERANT — lb  
HWB  
R-22  
12.5  
35.0  
—
15.0  
37.0  
—
17.5  
42.0  
—
18.5  
42.0  
—
23.2  
47.0  
—
—
—
—
HWC,S  
—
—
—
HK — Ckt 1  
HK − Ckt 2  
35/40†  
35/35†  
45/45†  
35/45†  
45/45†  
45/45†  
—
—
—
—
—
COMPRESSOR  
Model No.  
06E6175,  
06E2150  
20,30  
06DG537  
06E2150**  
06E7265  
06E7175**  
06E7299  
06E2150  
06E6175  
Nominal Hp  
Quantity  
Cylinders Per Compressor  
Capacity Control — Standard  
No. of Steps  
Minimum Step Capacity (%)  
Capacity Control — With Optional  
Hot Gas Bypass  
No. of Steps  
Minimum Step Capacity (%)  
Relief Valve Flow Rate — lb air/min  
15  
1
6
20  
1
4
25  
1
6
30  
1
6
35  
1
6
20 (ea)  
2
4 (ea)  
30 (ea)  
2
6 (ea)  
1 (ea)  
6,4  
3
33  
2
50  
3
33  
3
33  
3
33  
4
25  
4
20††  
4
33  
4
10  
—
3
4
4
4
5
5
5
10  
10  
10  
10  
10  
10  
10  
15.1  
15.1  
15.1  
15.1  
15.1  
15.1  
15.1  
COOLER  
Part No.  
LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664 10HA400664  
Dry Weight — lb  
Fluid Side — psig  
Refrigerant Side — psig  
Net Fluid Volume — Gal.  
(includes nozzles)  
Fluid Connections — in.  
Inlet  
69  
300  
430  
1.4  
81  
300  
430  
1.6  
105  
300  
430  
2.1  
105  
300  
430  
2.1  
145  
300  
430  
3.3  
657  
150  
235  
13.1  
726  
150  
235  
15.2  
726  
150  
235  
15.2  
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
3
3
3
3
3
3
Outlet  
CONDENSER  
30HWB (Water Cooled)  
Part No. LL01S-  
Dry Weight — lb  
Water Side — psig  
Refrigerant Side — psig  
Net Water Volume — Gal.  
(includes nozzles)  
Water Connections — in.  
Inlet  
D001  
48  
300  
430  
0.9  
D002  
62  
300  
430  
1.2  
D003  
79  
300  
430  
1.6  
D004  
87  
300  
430  
1.8  
E004  
153  
300  
430  
3.3  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HWC (Water Cooled)  
Part No. 09RW-  
400007  
532  
400007  
532  
400011  
560  
400011  
560  
400009  
624  
—
—
—
—
—
−
—
—
—
—
—
—
—
—
—
—
—
—
Dry Weight — lb  
Water Side — psig  
Refrigerant Side — psig  
Net Water Volume — Gal.  
Relief Valve Flow Rate — lb air/min  
Water Connections — in.  
Inlet  
300  
300  
300  
300  
300  
365  
365  
365  
365  
365  
7.3  
2.6  
2.6  
4.0  
4.0  
24.6  
24.6  
24.6  
24.6  
24.6  
Weld  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HWS (Water Cooled)  
Part No. 09RW-  
400017  
532  
400017  
532  
400019  
560  
400019  
560  
400018  
624  
—
—
—
—
—
−
—
—
—
—
—
—
—
—
—
—
—
—
Dry Weight — lb  
Water Side — psig  
Refrigerant Side — psig  
Net Water Volume — Gal.  
Relief Valve Flow Rate — lb air/min  
Water Connections — in.  
Inlet  
300  
300  
300  
300  
300  
335  
335  
335  
335  
335  
7.3  
2.6  
2.6  
4.0  
4.0  
22.6  
22.6  
22.6  
22.6  
22.6  
Weld  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HK (Water Cooled)  
Part No. 09RP-  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
022/022†  
1000  
022/027†  
1095  
027/027†  
1190  
Dry Weight — lb  
Water Side — psig  
Refrigerant Side — psig  
Net Water Volume — Gal.  
(includes nozzles)  
Relief Valve Flow Rate — lb air/min  
Water Connections — in.  
Inlet  
250  
250  
250  
385  
4.4/4.4†  
385  
4.4/5.2†  
385  
5.2/5.2†  
—
—
—
—
—
25.9  
25.9  
25.9  
Weld  
—
—
—
—
—
—
—
—
—
—
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
Outlet  
LEGEND  
NOTES:  
1. Operating weight includes refrigerant operating charge and weight of fluid  
in the heat exchangers.  
ODS  
—
Outside Diameter, Sweat  
*Unless otherwise noted, data is for HWB, HWC, and HWS units.  
†60 Hz/50 Hz units.  
2. 30HK,HWB,HWC, and HWS units are shipped with full operating charge.  
**For 025 50 Hz units, compressor number is 06E2250, for 035 50 Hz units  
compressor number is 06E7275.  
††With transfer switch set to compressor no. 2 position; 40% with transfer switch  
set to compressor no. 1 position.  
10  
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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  
554  
431  
611  
483  
668  
492  
679  
594  
766  
—
—
—
HWC,S  
—
—
—
1284/  
1305†  
1424/  
1514†  
1514/  
1542†  
HK  
—
—
—
—
—
REFRIGERANT — kg  
HWB  
R-22  
8.4  
5.7  
15.9  
—
6.8  
16.8  
—
7.9  
19.1  
—
10.5  
21.3  
—
—
—
—
HWC,S  
19.1  
—
—
—
—
HK — Ckt 1  
HK — Ckt 2  
15.9/18.1†  
15.9/15.9†  
20.4/20.4†  
15.9/20.4†  
20.4/20.4†  
20.4/20.4†  
—
—
—
—
—
COMPRESSOR  
Model No.  
06E6175,  
06E2150  
14.9,22.4  
1 (ea)  
06DG537  
06E2150**  
06E7265  
06E7175**  
06E7299  
06E2150  
06E6175  
Nominal kW  
Quantity  
Cylinders Per Compressor  
Capacity Control — Standard  
No. of Steps  
Minimum Step Capacity (%)  
Capacity Control — With Hot Gas Bypass  
No. of Steps  
Minimum Step Capacity (%)  
Relief Valve Flow Rate — kg air/min  
11.1  
1
6
14.9  
1
4
18.7  
1
6
22.4  
1
6
26.1  
1
6
14.9 (ea)  
2
4 (ea)  
22.4 (ea)  
2
6 (ea)  
6,4  
3
33  
2
50  
3
33  
3
33  
3
33  
4
25  
4
20††  
4
33  
4
10  
—
3
10  
6.8  
4
10  
6.8  
4
10  
6.8  
4
10  
6.8  
5
10  
6.8  
5
10  
6.8  
5
10  
6.8  
COOLER  
Part No.  
LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664 10HA400664  
Dry Weight — kg  
Fluid Side — kPa  
Refrigerant Side — kPa  
Net Fluid Volume — L  
(includes nozzles)  
Fluid Connections — in.  
Inlet  
31.3  
2069  
2965  
5.3  
36.7  
2069  
2965  
6.1  
47.6  
2069  
2965  
8.0  
47.6  
2069  
2965  
8.0  
65.7  
2069  
2965  
12.5  
297  
1034  
1620  
49.9  
330  
1034  
1620  
57.5  
330  
1034  
1620  
57.5  
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
3
3
3
3
3
3
Outlet  
CONDENSER  
30HWB (Water Cooled)  
Part No. LL01S-  
Dry Weight — kg  
Water Side — kPa  
Refrigerant Side — kPa  
Net Water Volume — L  
(includes nozzles)  
Water Connections — in.  
Inlet  
D001  
21.8  
2069  
2965  
3.4  
D002  
28.1  
2069  
2965  
4.5  
D003  
35.8  
2069  
2965  
6.1  
D004  
39.5  
2069  
2965  
6.8  
E004  
69.4  
2069  
2965  
12.5  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HWC (Water Cooled)  
Part No. 09RW-  
400007  
241  
400007  
241  
400011  
254  
400011  
254  
400009  
283  
2069  
2517  
27.6  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Dry Weight — kg  
Water Side — kPa  
Refrigerant Side — kPa  
Net Water Volume — L  
Relief Valve Flow Rate — kg air/min  
Water Connections — in.  
Inlet  
2069  
2517  
9.8  
2069  
2517  
9.8  
2069  
2517  
15.4  
2069  
2517  
15.4  
11.2  
11.2  
11.2  
11.2  
11.2  
Weld  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HWS (Water Cooled)  
Part No. 09RW-  
400017  
241  
400017  
241  
400019  
254  
400019  
254  
400018  
283  
2069  
2310  
27.6  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Dry Weight — kg  
Water Side — kPa  
Refrigerant Side — kPa  
Net Water Volume — L  
Relief Valve Flow Rate — kg air/min  
Water Connections — in.  
Inlet  
2069  
2310  
9.8  
2069  
2310  
9.8  
2069  
2310  
15.4  
2069  
2310  
15.4  
10.3  
10.3  
10.3  
10.3  
10.3  
Weld  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
—
—
—
—
—
—
Outlet  
30HK (Water Cooled)  
Part No. 09RP-  
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
022/022†  
454  
022/027†  
497  
027/027†  
540  
Dry Weight — kg  
Water Side — kPa  
Refrigerant Side — kPa  
Net Water Volume — L  
(includes nozzles)  
Relief Valve Flow Rate — kg air/min  
Water Connections — in.  
Inlet  
1724  
1724  
1724  
2655  
17/17†  
2655  
17/20†  
2655  
20/20†  
—
—
—
—
—
11.7  
11.7  
11.7  
Weld  
—
—
—
—
—
—
—
—
—
—
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
21⁄2  
Outlet  
LEGEND  
NOTES:  
1. Operating weight includes refrigerant operating charge and weight of fluid  
in the heat exchangers.  
ODS  
—
Outside Diameter, Sweat  
*Unless otherwise noted, data is for HWB, HWC, and HWS units.  
†60 Hz/50 Hz units.  
2. 30HK,HWB,HWC, and HWS units are shipped with full operating charge.  
**For 025 50 Hz units, compressor number is 06E2250, for 035 50 Hz units  
compressor number is 06E7275.  
††With transfer switch set to compressor no. 2 position; 40% with transfer switch  
set to compressor no. 1 position.  
11  
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Table 2A — Physical Data; 30HL, HWA Condenserless Units — English  
UNIT 30  
HWA018  
HWA025  
HWA028  
HWA035  
HWA040  
HL050  
HL060  
2070/  
2120*  
2130/  
2190*  
OPERATING WT (Approximate) − lb  
REFRIGERANT† — lb  
740  
880  
960  
975  
1080  
R-22  
2.4  
1.6  
2.0  
2.4  
3.0  
6.3/4.2**  
5.3/5.3**  
COMPRESSOR  
Model No.  
06E6275,  
06E2250  
25,20  
06DG537  
06E2250  
06E7265  
06E7275  
06E7299  
06E6275  
Nominal Hp  
Quantity  
Cylinders Per Compressor  
Capacity Control — Standard  
No. of Steps  
Minimum Step Capacity (%)  
Capacity Control — With Optional  
Hot Gas Bypass  
No. of Steps  
Minimum Step Capacity (%)  
Relief Valve Flow Rate — lb air/min  
15  
1
6
20  
1
4
25  
1
6
30  
1
6
35  
1
6
30 (ea)  
2
6
1 (ea)  
6,4  
3
33  
2
50  
3
33  
3
33  
3
33  
4
20††  
4
33  
4
10  
—
3
4
4
4
5
5
10  
10  
10  
10  
10  
10  
15.1  
15.1  
15.1  
15.1  
15.1  
15.1  
COOLER  
Part No.  
LL01SB006  
LL01SB007  
LL01SB009  
105  
LL01SB009  
105  
LL01SC005  
145  
10HA400654  
726  
10HA400664  
726  
Dry Weight — lb  
Fluid Side — psig  
Refrigerant Side — psig  
Net Fluid Volume — Gal.  
(includes nozzles)  
Fluid Connections — in.  
Inlet  
69  
81  
300  
430  
1.4  
300  
430  
1.6  
300  
300  
300  
150  
150  
430  
2.1  
430  
2.1  
430  
3.3  
235  
13.1  
235  
15.2  
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
3
3
3
3
Outlet  
CONDENSER CONNECTIONS  
Refrigerant Connections — in.  
Liquid Line ODS  
7
7
7
7
7
7
7
⁄
8
⁄
8
⁄
8
⁄
8
⁄
8
⁄
8
⁄
8
Discharge Line ODS  
11⁄8  
11⁄8  
13⁄8  
13⁄8  
15⁄8  
13⁄8  
13⁄8  
LEGEND  
NOTE: Operating weight includes refrigerant operating charge and weight of  
fluid in the heat exchangers.  
ODS  
—
Outside Diameter, Sweat  
*60 Hz/50 Hz units.  
†30HWA and HL units (condenserless) are shipped with a refrigerant holding  
charge. Approximate cooler operating charge is shown.  
**Ckt 1/Ckt 2.  
††With transfer switch set to compressor no. 2 position; 40% with transfer switch  
set to compressor no. 1 position.  
Table 2B — Physical Data; 30HL, HWA Condenserless Units — SI  
UNIT 30  
HWA018  
HWA025  
HWA028  
HWA035  
HWA040  
HL050  
HL060  
938/  
966/  
OPERATING WT (Approximate) − kg  
REFRIGERANT† — kg  
335  
399  
435  
442  
490  
961†  
993†  
R-22  
1.1  
0.7  
0.9  
1.1  
1.4  
2.9/1.9**  
2.4/2.4**  
COMPRESSOR  
Model No.  
06E6275,  
06E2250  
18.7,14.9  
1 (ea)  
06DG537  
06E2250  
06E7265  
06E7275  
06E7299  
06E6175  
Nominal kW  
Quantity  
Cylinders Per Compressor  
Capacity Control — Standard  
No. of Steps  
Minimum Step Capacity (%)  
Capacity Control — With Optional Hot Gas Bypass  
No. of Steps  
Minimum Step Capacity (%)  
Relief Valve Flow Rate — kg air/min  
11.2  
1
6
14.9  
1
4
18.7  
1
6
22.4  
1
6
26.1  
1
6
22.4 (ea)  
2
6
6,4  
3
33  
2
50  
3
33  
3
33  
3
33  
4
20††  
4
33  
4
10  
—
3
10  
6.8  
4
10  
6.8  
4
10  
6.8  
4
10  
6.8  
5
10  
6.8  
5
10  
6.8  
COOLER  
Part No.  
LL01SB006 LL01SB007 LL01SB009 LL01SB009 LL01SC005 10HA400654 10HA400664  
Dry Weight — kg  
Fluid Side — kPa  
Refrigerant Side — kPa  
Net Fluid Volume — L  
(includes nozzles)  
Fluid Connections — in.  
Inlet  
31.3  
2069  
2965  
5.3  
36.7  
2069  
2965  
6.1  
47.6  
2069  
2965  
8.0  
47.6  
2069  
2965  
8.0  
65.7  
2069  
2965  
12.5  
330  
1034  
1620  
49.9  
330  
1034  
1620  
57.5  
Grooved End  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
11⁄2  
21⁄2  
21⁄2  
3
3
3
3
Outlet  
CONDENSER CONNECTIONS  
Refrigerant Connections — in.  
Liquid Line ODS  
7
7
7
7
7
⁄
8
⁄
8
⁄
8
⁄
8
⁄
8
Discharge Line ODS  
11⁄8  
13⁄8  
15⁄8  
13⁄8  
13⁄8  
LEGEND  
NOTE: Operating weight includes refrigerant operating charge and weight of  
fluid in the heat exchangers.  
ODS  
—
Outside Diameter, Sweat  
*60 Hz/50 Hz units.  
†30HWA and HL units (condenserless) are shipped with a refrigerant holding  
charge. Approximate cooler operating charge is shown.  
**Ckt 1/Ckt 2.  
††With transfer switch set to compressor no. 2 position; 40% with transfer switch  
set to compressor no. 1 position.  
12  
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The number of tubes in the condenser(s) varies depending  
on the unit size. The condensers have internal subcoolers which  
provide approximately 8 F (4.4 C) for 30HK, HL units or 13 F  
(7.2 C) for 30HW units subcooling at ARI (Air Condition-  
ing and Refrigeration Institute, U.S.A.) rating conditions.  
30HL, HWA SYSTEM CONDENSER — For detailed con-  
denser piping installation instructions for 30HL and HWA  
systems, refer to separate instructions packaged with the re-  
mote condenser unit(s).  
Condenser refrigerant piping for 30HL and HWAunits should  
be sized to minimize the amount of refrigerant required.  
The 30HL and HWA units that use an air-cooled evapo-  
rative condenser(s) must have adequate means for head pres-  
sure control when operating below 60 F (15.6 C).  
Carrier recommends that a field-supplied pressure relief  
device be installed after the muffler in each discharge line.  
Most local codes require the relief valve to be vented di-  
rectly to the outdoors. The vent must not be smaller than the  
relief valve outlet.  
30HWB CONDENSER DESCRIPTION —All 30HWB units  
use a brazed-plate heat-exchanger-type condenser. These heat  
exchangers are made of embossed plates of acid-resistant stain-  
less steel. Every other plate is reversed so that the ridges of  
the herringbone pattern intersect one another on adjacent plates,  
forming a lattice of contact points. These plates are vacuum-  
brazed together to form a compact and pressure-resistant heat  
exchanger.  
THUMB-SCREW  
BRAKE  
Fig. 11 — Factory-Installed Unit Wheels (4)  
After brazing, the impressions in the plates form 2 sepa-  
rate systems of channels where the refrigerant and water flows  
are counter-current. The number of plates varies depending  
on unit tonnage. The condensers provide approximately 14°  
to 18° F (8° to 10° C) liquid subcooling at the standard  
Air Conditioning and Refrigeration Institute (ARI) rating  
condition.  
30HK, HWC, HWS CONDENSER(S) — When facing the  
front of the unit, the condenser(s) is in the uninsulated shell(s)  
located across the bottom of the unit. The water connections  
are such that the water inlet is located on the left-hand side  
(30HK) or right-hand side (30HW) of the unit. The water  
inlet must ALWAYS be on the bottom of the condenser(s) to  
provide the proper subcooling. The water outlet is located  
on the right-hand side (30HK) or left-hand side (30HW) of  
the unit. The water connections can be reversed by rotating  
the heads and gaskets 180 degrees ON BOTH ENDS OF  
THE CONDENSER(S).  
Fig. 12 — Compressor Mounting  
IMPORTANT: THE WATER INLET MUST AL-  
WAYS BE ON THE CONDENSER HEAD(S) THAT  
HAS THE NOZZLE CONNECTION AT THE BOT-  
TOM OF THE HEAD. Incorrect inlet connection will  
result in poor system performance due to incorrect  
subcooling.  
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 shell condenser(s) with  
steel tube sheets and copper tubes. The 30HWS units are  
designed for sea coast applications and use a steel shell con-  
denser with cupronickel tube sheets and tubes. In addition,  
the 30HWS water heads utilize ‘‘sacrificial’’ zinc anodes for  
condenser corrosion protection.  
The LIQUID-IN and LIQUID-OUT labels indicate water  
connections AS SUPPLIED FROM THE FACTORY.  
It is recommended that strainer with a minimum of 20 mesh  
be installed ahead of the condenser water inlet(s) to prevent  
debris from clogging or damaging the heat exchanger(s).  
There is a pressure-relief device on the condenser(s) of all  
30HK, HWC, and HWS units. Most local codes require that  
this relief be vented directly to the outdoors.  
NOTE: The relief line must not be smaller than the relief  
valve outlet. Be sure to provide a way of draining and ser-  
vicing the unit.  
IMPORTANT: Inspect the zinc anodes every 3 months  
for deterioration and replace as needed. Galvanic pro-  
tection of the condenser is lost if the anodes are not  
replaced prior to complete deterioration.  
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vley  
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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 and are  
not in accordance with recognized standards.  
3. All wiring must comply with applicable local and national codes.  
4. All piping must follow standard piping techniques. Refer to  
Carrier System Design Manual part 3, Carrier E20-IIா soft-  
ware Refrigerant Piping program, or appropriate ASHRAE  
(American Society of Heating, Refrigeration, and Air Condi-  
tioning Engineers) handbook for details on proper piping sizes  
and design.  
5. See Table 3 on page 17 for minimum system fluid volume.  
This system may require the addition of a holding tank to en-  
sure adequate volume.  
6. Hot gas lines should rise above refrigerant level in condenser  
circuit. Double riser may be required; check compressor mini-  
mum capacity.  
7. Trap should be installed on hot gas lines to prevent con-  
denser oil and refrigerant vapor migration from accumulating  
on compressor heads during off cycle.  
8. Pitch all horizontal lines downward in the direction of refrig-  
erant flow.  
9. For piping lengths greater than 50 ft, provide support to liquid  
and gas lines near the connections to the condenser coil.  
10. For pressure relief requirements, see latest revision of  
ASHRAE Standard 15, Safety Code for Mechanical  
Refrigeration.  
Fig. 14 — Typical Piping with Air-Cooled 30HWA with Remote 09DK Unit Shown  
15  
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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  
ahead of the condenser water inlet to prevent debris from  
clogging or damaging the heat exchanger.  
Provide a means for draining the system in the winter (if  
not used) and for maintenance.  
Accessory steel manifold packages for inlet and outlet con-  
denser water are available for 30HK units. Each manifold is  
furnished in 2 sections, to be field welded as shown in  
Fig. 4. Manifolds should not be used where regulating valves  
are required because separate valves must be used on each  
condenser circuit.  
To install the grooved end coupling (see Fig. 15):  
1. Lubricate the gasket lips and stretch the gasket over  
the end of the pipe. Avoid twisting the gasket when  
installing.  
Retighten all condenser head bolts before filling system  
with water. Torque bolts to a maximum of 40 to  
45 ft-lb.  
2. Bring the pipe and heat exchanger coupling ends to-  
gether into alignment. Slide the gasket so that it is cen-  
tered over the ends. Apply a light film of lubricant to the  
gasket, or to the gasket recess of the coupling housing.  
Avoid twisting the gasket during installation.  
Water leaving the condenser is under pressure and should  
not be connected directly into sewer lines. Check local codes.  
A 3/8-in. drain plug is located in the head at each condenser  
end.  
3. Seat the coupling halves over the gasket and install the  
nuts and bolts. Tighten the nuts equally on both sides.  
4. Alternately tighten the nuts with a wrench to draw  
the coupling halves together uniformly. The joint is now  
complete.  
Refer to Pressure Relief Devices and Discharge Line Check  
Valve sections on page 28, concerning piping connections  
for these components.  
COOLER DESCRIPTION  
30HK, HL Units — The cooler is a direct-expansion type  
with removable heads and is partitioned for multi-pass re-  
frigerant flow. Fluid flow across the tube bundle is directed  
by baffles designed for minimum fluid-pressure drop. The  
tubes have integral internal fins for maximum heat transfer  
efficiency.  
Viewed from unit front, the return chilled fluid enters at  
the left end of the cooler and leaves at the right end. The  
sensing bulb for the factory-supplied fluid temperature con-  
troller is in the leaving-fluid nozzle; the leaving-fluid tem-  
perature being the control point.  
The cooler is insulated with a flexible, closed-cell plastic  
foam insulation of suitable thickness. Fluid vapor cannot pen-  
etrate the cellular structure to condense either within cells or  
on the cooler shell. Thus, the insulation itself is a vapor bar-  
rier. Because of the toughness of insulation, a protective sheet  
metal covering is not necessary.  
Special modification may be necessary for brine chillers.  
Contact your Carrier representative for details. For calcium  
or sodium chloride brines, it is important that the proper in-  
hibitors be carefully selected for protection of the copper tubes.  
Refer to the publications of the Calcium Institute or the  
Mutual Chemical Division of Allied Chemical Corporation  
for information on corrosion control for calcium or sodium  
chloride systems.  
30HK, HWB, HWC, HWS UNITS — In order to minimize  
the water pressure drop in the system, use as few bends as  
possible in the field water piping, and run the lines as short  
as possible. Size the water lines according to the available  
pump pressure (not necessarily the connection size), espe-  
cially on cooling tower applications. See Carrier System De-  
sign Manual, Part 3, Piping Design. See Fig. 16 for condenser  
pressure drops.  
Set water regulating valve to maintain design head pres-  
sure. Do not adjust to compensate for high head pressures  
caused by fouled condenser tubes, excess refrigerant, or  
the presence of noncondensables. Due to changes in water  
temperature, it may be necessary to adjust the valve season-  
ally. After adjusting for design head pressure, shut unit down.  
The water regulating valve should shut off the flow of water  
in a few minutes. If it does not, raise head pressure setting.  
Make sure that the capillary tube from each water regulating  
valve is connected to the proper condenser purge valve.  
30HW Units — All 30HW units use a brazed-plate heat-  
exchanger type cooler. The heat exchanger is constructed es-  
sentially the same as the brazed-plate condenser used on  
30HWB units. See 30HWB Condenser Description section  
on page 13 for more details. Similar to the condenser, the  
cooler can only be chemically cleaned.  
COOLER PIPING — Plan cooler fluid piping for minimum  
number of changes in elevation, and for the fewest number  
of bends as possible. Install manual or automatic vent valve  
at high points in the line. Maintain system pressure by using  
a pressure tank or a combination or relief and reducing valves.  
A strainer with a minimum of 20 mesh must be installed  
ahead of the cooler fluid inlet to prevent debris from clog-  
ging or damaging the heat exchanger.  
See Carrier System Design Manual, Part 3, Piping  
Design, for chilled fluid piping details.  
Fig. 15 — Installed Coupling Fastening Grooved  
Pipe Ends  
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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.  
Table 3 — Minimum Cooler and Condenser Flow  
Rates Minimum Loop Volume  
MINIMUM COOLER  
LOOP VOLUME†  
COOLER CONDENSER*  
UNIT SIZE  
Gal./Min L/s Gal./Min L/s  
Gal.  
120  
148  
174  
44  
L
30HK040  
30HK,HL050  
30HK,HL060  
30HW018  
30HW025  
30HW028  
30HW035  
30HW040  
56.0  
68.0  
68.0  
22.5  
30.0  
37.5  
45.0  
57.0  
3.5  
4.3  
4.3  
1.4  
1.9  
2.4  
2.8  
3.6  
67  
4.23  
4.79  
5.24  
1.4  
454.2  
560.2  
658.6  
167  
Run the pump for 10 minutes, then clean the strainer be-  
fore starting the unit.  
76  
83  
A cooler flow switch must be field-installed on all units.  
This should be a differential pressure switch that is installed  
between the cooler fluid inlet and outlet. The switch should  
be set to open when the cooler fluid flow drops below the  
values shown in Table 3. Use the cooler water pressure drop  
curves (Fig. 16) to determine correct setting for each unit  
size. Use Carrier accessory flow switch, part number  
30HW900003. See Table 3 for Minimum Flow rates and loop  
volumes.  
22.5  
30.0  
37.5  
45.0  
57.0  
1.9  
59  
223  
2.4  
76  
288  
2.8  
85  
322  
3.6  
113  
428  
LEGEND  
ARI  
N
V
—
—
—
Air Conditioning and Refrigeration Institute  
Liters per kW  
Gallons per ton  
See Step 6 — Make Electrical Connections section on  
page 19 for flow switch wiring details.  
*30HK, HWB, HWC and HWS only.  
†Minimum system fluid volumes.  
NOTES:  
30HK, HL Units — The thermistor used for sensing fluid  
temperature is factory-installed in the cooler leaving fluid  
line.  
30HW Units — The thermistor used for sensing the fluid  
temperature is inside the cooler leaving-water cavity.  
Gallons = V x ARI capacity in tons.  
Liters = N x ARI capacity in kW.  
APPLICATION  
V
N
Normal Air Conditioning  
Process Type Cooling  
Low Ambient Operation  
3
3.25  
6.5 to 10.8  
6.5 to 10.8  
6 to 10  
6 to 10  
COOLER PRESSURE DROP — 30HW UNITS  
COOLER PRESSURE DROP — 30HK, HL UNITS  
NOTE: Ft of water = 2.31 x change in psig.  
Fig. 16 — Cooler and Condenser Water Pressure Drop  
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CONDENSER PRESSURE DROP —  
30HK UNITS  
CONDENSER PRESSURE DROP —  
30HWB UNITS  
CONDENSER PRESSURE DROP —  
30HWC AND 30HWS UNITS  
NOTE: Ft of water = 2.31 x change  
in psig.  
Fig. 16 — Cooler and Condenser Water Pressure Drop (cont)  
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Control Box, Controls Section — The control box controls  
section contains the following components:  
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 Tables 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 be  
installed.  
• temperature controller  
• control relay(s)  
• control module(s)  
• low-voltage control transformer(s)  
• terminal block for ground current sensing accessory  
30HK, HL UNITS — On all 60 Hz units, a fused (15 amp  
maximum), 115 v control circuit must be supplied by either  
a separate power source or by using a minimum 300 va trans-  
former. On 208/230 and 460 v units, control circuit power  
can be supplied by accessory transformer part no. 07EA900051.  
Check to be sure that installation of the 115 v control power  
source meets all local codes.  
On all 50 Hz units, a fused (15 amp maximum), 230 v  
control circuit must be field supplied. On 200-3-50 units, power  
for the control circuit can be supplied by connecting a field-  
supplied fuse (15 amp maximum) between TB1 and TB2 for  
L1 overcurrent protection. On 400-3-50 units, power for the  
control circuit can be supplied by connecting a field-  
supplied fuse (15 amp maximum) between TB1 and a neu-  
tral leg from TB2 for L1 overcurrent protection. On all units,  
check to be sure that installation of the 230 v control power  
source meets all local codes.  
Control Box, Field Control Wiring Section — Inside this  
section is a 10-terminal (30HK, HL) or 14-terminal (30HW),  
low-voltage, field-wiring terminal strip. All low-voltage field-  
wiring connections are made to this terminal block. Seven  
3
⁄4-in. (19 mm) knockouts are provided for field wiring in  
this section. Connections for chilled fluid flow switch, chilled  
fluid pump interlock, condenser pump interlock, remote alarm  
output, and ground current sensor accessory are made at this  
location. The remote condenser relay connections are made  
to a separate 4-terminal (30HK, HL) or 3-terminal (30HW)  
field wiring strip. See Fig. 17-20 for specific location of  
connections.  
Unbalanced 3-Phase Supply Voltage — Never operate a com-  
pressor where a phase imbalance in the supply voltage is  
greater than 2%. Use the following formula to determine  
the percent voltage imbalance:  
% Voltage Imbalance =  
30HW UNITS — Control circuit power is 24 v and 115 v  
on all units, and is supplied by factory-installed control  
transformers.  
max voltage deviation from average voltage  
100 x  
average voltage  
ALL UNITS — Inside the control box are terminals for field  
power and ground (earth) wiring, as well as a terminal for a  
neutral wire when needed (380-3-60 and 400-3-50 units only).  
A ground wire must be installed with each field power sup-  
ply. Compressor are wired standard from the factory for across-  
the-line start. As a factory-installed option, all 025-060 sizes  
are available wired for part-wind start (special order option  
on 30HK, HL unit).  
Example: Supply voltage is 240-3-60  
AB = 243 v  
BC = 236 v  
AC = 238 v  
Refer to Tables 4A and 4B for electrical data.  
243 + 236 + 238  
Average Voltage =  
Flow Switch — A cooler flow switch is required for all units,  
and must be field-installed. The Carrier flow switch acces-  
sory (part number 30HW900003), is available for this pur-  
pose. Flow switch wiring terminals are located in the field  
wiring compartment of the control box. The flow switch should  
be wired between terminals TB3-1 and TB3-7 for 30HK, HL  
units or between terminals TB2-7 and TB2-13 for 30HW units.  
The factory jumper wire between these 2 terminals must be  
removed for proper operation of the flow switch.  
Control Box, Power Section — The electrical power supply  
is brought in through the top left-hand side (30HK, HL) or  
right-hand side (30HW) of the control box (see Fig. 19 and  
20). The knockout accepts up to a 3-in. (76 mm) conduit for  
30HK, HL units, and a 13⁄4- to 21⁄2-in. (44 to 64 mm) conduit  
for 30HW units. Pressure-lug connections on the terminal  
blocks are suitable for copper, copper-clad aluminum, or alu-  
minum conductors.  
3
= 239 v  
Determine maximum deviation from average voltage:  
(AB) 243 - 239 = 4 v  
(BC) 239 - 236 = 3 v  
(AC) 239 - 238 = 1 v  
Maximum deviation is 4 v.  
Determine percent voltage imbalance:  
4
% Voltage Imbalance = 100 x  
239  
= 1.7%  
This amount of phase imbalance is satisfactory as it is below  
the maximum allowable 2%.  
The control box power section contains the following  
components:  
• power terminal block  
• compressor circuit breaker(s)  
• compressor contactor(s)  
IMPORTANT: If the supply voltage phase imbalance  
is more than 2%, contact your local utility company  
immediately.  
• high-voltage transformer (30HW units only)  
• control-circuit circuit breaker for 24-v circuit  
• unit ON-OFF switch  
• unit service light  
• ground lug  
• neutral terminal (380-3-60 and 400-3-50 units)  
• terminal block for ground current sensing accessory  
19  
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Table 4A — Electrical Data — 30HK, HWB, HWC, HWS Fluid-Cooled Units  
UNIT  
Voltage*  
Nameplate (3 ph) Hz Min Max  
COMPRESSOR (ea)  
LRA  
XL  
UNIT SIZE  
30-  
Volts  
ICF  
PW  
MTA  
XL  
Rec  
Fuse  
MCA  
MFA  
RLA  
XL  
PW  
PW  
208/230  
460  
575  
60 187  
60 414  
60 518  
253  
518  
632  
129  
59  
54  
†
†
†
340  
168  
122  
175  
80  
70  
150  
70  
60  
57  
26  
24  
†
†
†
283  
142  
98  
†
†
†
89  
40  
42  
HK040  
HK050  
HK060  
220  
400  
50 198  
50 342  
253  
440  
142  
71  
†
†
390  
249  
200  
100  
175 75/48**  
90 36/26**  
†
†
342/201**  
223/142**  
†
†
116/74**  
56/40**  
208/230  
460  
575  
60 187  
60 414  
60 518  
253  
518  
632  
161  
75  
73  
†
†
†
503  
249  
188  
225  
110  
110  
200 83/57**  
90 39/26**  
90 39/24**  
†
†
†
446/283**  
223/142**  
164/ 88**  
†
†
†
89/64**  
56/40**  
54/37**  
220  
400  
50 198  
50 342  
253  
440  
169  
81  
†
†
417  
259  
225  
110  
200  
100  
75  
36  
†
†
342  
223  
†
†
116  
56  
208/230  
460  
575  
60 187  
60 414  
60 518  
253  
518  
632  
187  
88  
88  
†
†
†
529  
262  
203  
250  
125  
125  
225  
100  
100  
83  
39  
39  
†
†
†
446  
223  
164  
†
†
†
64  
56  
54  
220  
400  
50 198  
50 342  
253  
440  
225  
131  
†
†
600  
403  
300  
175  
250  
150  
100  
58  
†
†
545  
345  
†
†
156  
90  
208/230  
380  
60 187  
60 342  
60 414  
60 518  
253  
418  
508  
632  
62  
35  
28  
24  
—
—
—
—
266  
145  
120  
96  
110  
60  
80  
45  
35  
30  
49  
28  
23  
19  
—
—
—
—
266  
145  
120  
96  
—
—
—
—
89  
40  
33  
25  
460  
50  
HWB,C,S018  
HWB,C,S025  
HWB,C,S028  
HWB,C,S035  
HWB,C,S040  
575  
40  
230  
50 198  
50 342  
253  
440  
58  
34  
—
—
200  
115  
100  
60  
70  
45  
46  
27  
—
—
200  
115  
—
—
63  
41  
380/415  
208/230  
380  
460  
575  
60 187  
60 342  
60 414  
60 518  
253  
418  
508  
632  
72 170 283  
125  
70  
60  
45  
90  
60  
45  
35  
57  
34  
27  
22  
170  
85  
85  
59  
283  
142  
142  
98  
88  
52  
40  
33  
88  
52  
42  
33  
43  
34  
28  
85 142  
85 142  
59  
98  
230  
380/415  
50 198  
50 342  
253  
440  
67 150 250  
38 104 173  
110  
60  
80  
45  
53  
30  
150  
104  
250  
173  
80  
44  
80  
44  
208/230  
380  
460  
575  
60 187  
60 342  
60 414  
60 518  
253  
418  
508  
632  
89 268 446  
54 134 223  
44 134 223  
150  
90  
70  
60  
110  
70  
60  
45  
71  
43  
35  
28  
268  
134  
134  
98  
446  
223  
223  
164  
104  
66  
50  
41  
104  
66  
52  
42  
35  
98 164  
230  
380/415  
50 198  
50 342  
253  
440  
85 205 342  
54 134 223  
150  
90  
110  
70  
68  
43  
205  
134  
342  
223  
98  
60  
98  
60  
208/230  
380  
460  
575  
60 187  
60 342  
60 414  
60 518  
253  
418  
508  
632  
102 268 446  
59 134 223  
48 134 223  
175  
100  
80  
125  
80  
60  
50  
81  
47  
38  
31  
268  
134  
134  
98  
446  
223  
223  
164  
120  
70  
52  
42  
120  
70  
57  
42  
39  
98 164  
60  
230  
380/415  
50 198  
50 342  
253  
440  
94 220 366  
54 152 253  
150  
90  
125  
70  
75  
43  
220  
152  
366  
253  
112  
66  
112  
66  
208/230  
380  
460  
575  
60 187  
60 342  
60 414  
60 518  
253  
418  
508  
632  
145 414 690  
84 207 345  
69 207 345  
55 165 276  
250  
150  
110  
90  
175  
110  
90  
116  
67  
55  
44  
414  
207  
207  
165  
690  
345  
345  
276  
180  
98  
78  
63  
180  
98  
84  
66  
70  
230  
380/415  
50 198  
50 342  
253  
440  
135 327 545  
78 207 345  
225  
125  
175  
100  
108  
62  
327  
207  
545  
345  
166  
98  
166  
98  
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Table 4B — Electrical Data — 30HL and HWA Condenserless Units  
UNIT  
COMPRESSOR (ea)  
LRA  
UNIT SIZE  
30-  
Volts  
Voltage*  
Min Max  
ICF  
MTA  
Rec  
Fuse  
MCA  
MFA  
RLA  
Nameplate (3 ph)  
Hz  
PW  
XL  
PW  
XL  
PW  
XL  
208/230  
460  
575  
60  
60  
60  
187  
414  
518  
253  
518  
632  
190  
84  
75  
†
†
†
571  
282  
203  
250  
125  
110  
225  
100  
90  
100/65**  
44/29**  
38/27**  
†
†
†
506/315**  
253/173**  
176/128**  
†
†
†
78/50**  
68/45**  
58/42**  
HL050  
HL060  
200  
400  
50  
50  
198  
342  
253  
440  
187  
99  
†
†
449  
297  
250  
125  
225  
110  
83  
44  
†
†
366  
253  
†
†
128  
68  
208/230  
460  
575  
60  
60  
60  
187  
414  
518  
253  
518  
632  
225  
99  
86  
†
†
†
606  
297  
214  
300  
125  
110  
250  
110  
100  
100  
44  
38  
†
†
†
506  
253  
176  
†
†
†
78  
68  
58  
200  
400  
50  
50  
198  
342  
253  
440  
261  
138  
†
†
616  
406  
350  
175  
300  
175  
116  
61  
†
†
545  
345  
†
†
180  
95  
208/230  
380  
60  
60  
60  
60  
187  
342  
414  
518  
253  
418  
508  
632  
72  
40  
34  
28  
—
—
—
—
266  
145  
120  
96  
125  
70  
90  
50  
45  
35  
57  
32  
27  
22  
—
—
—
—
266  
145  
120  
96  
—
—
—
—
89  
45  
41  
33  
460  
60  
HWA018  
HWA025  
HWA028  
HWA035  
HWA040  
575  
45  
230  
50  
50  
198  
342  
253  
440  
58  
34  
—
—
200  
115  
100  
60  
70  
45  
46  
27  
—
—
200  
115  
—
—
63  
41  
380/415  
208/230  
380  
460  
575  
60  
60  
60  
60  
187  
342  
414  
518  
253  
418  
508  
632  
79  
47  
38  
30  
207  
104  
104  
72  
345  
173  
173  
120  
125  
80  
60  
50  
100  
60  
45  
40  
63  
37  
30  
24  
207  
104  
104  
72  
345  
173  
173  
120  
98  
52  
42  
33  
98  
52  
45  
37  
230  
380/415  
50  
50  
198  
342  
253  
440  
67  
38  
150  
104  
250  
173  
110  
60  
80  
45  
53  
30  
150  
104  
250  
173  
80  
44  
80  
44  
208/230  
380  
460  
575  
60  
60  
60  
60  
187  
342  
414  
518  
253  
418  
508  
632  
107  
60  
54  
42  
268  
134  
134  
98  
446  
223  
223  
164  
175  
100  
90  
150  
80  
70  
50  
85  
48  
43  
33  
268  
134  
134  
98  
446  
223  
223  
164  
124  
70  
52  
42  
124  
70  
60  
52  
70  
230  
380/415  
50  
50  
198  
342  
253  
440  
85  
54  
205  
134  
342  
223  
150  
90  
110  
70  
68  
43  
205  
134  
342  
223  
98  
60  
98  
60  
208/230  
380  
460  
575  
60  
60  
60  
60  
187  
342  
414  
518  
253  
418  
508  
632  
119  
67  
304  
152  
152  
106  
506  
253  
253  
176  
200  
110  
90  
150  
80  
70  
60  
95  
53  
43  
35  
304  
152  
152  
106  
506  
253  
253  
176  
144  
80  
66  
50  
144  
80  
66  
52  
54  
44  
70  
230  
380/415  
50  
50  
198  
342  
253  
440  
94  
54  
220  
152  
366  
253  
150  
90  
125  
70  
75  
43  
220  
152  
366  
253  
112  
66  
112  
66  
208/230  
380  
460  
575  
60  
60  
60  
60  
187  
342  
414  
518  
253  
418  
508  
632  
167  
95  
78  
63  
414  
207  
207  
165  
690  
345  
345  
276  
300  
150  
125  
110  
200  
125  
100  
80  
133  
76  
62  
50  
414  
207  
207  
165  
690  
345  
345  
276  
204  
106  
95  
204  
106  
98  
73  
76  
230  
380/415  
50  
50  
198  
342  
253  
440  
135  
78  
327  
207  
545  
345  
225  
125  
175  
100  
108  
62  
327  
207  
545  
345  
166  
98  
166  
98  
LEGEND FOR TABLES 4A AND 4B  
ICF  
—
Maximum instantaneous current flow during starting. For these  
single-compressor units, ICF is the compressor LRA.  
Thousand circular mils  
PW  
—
—
Part wind  
Rec Fuse  
Recommended dual element fuse amps (150% of  
kcmil  
LRA  
—
—
compressor RLA). Size up to the next standard fuse size.  
Rated load amps  
Across the line  
Locked rotor amps. First value is for part-wind start. Larger value  
is the full LRA.  
RLA  
XL  
—
—
MCA  
MFA  
—
—
Minimum circuit amps (for wire sizing). Complies with NEC,  
Section 430-24.  
*Supply Range — Units are suitable for use on electrical systems where volt-  
age supplied to the unit terminals is not below or above the listed range limits.  
†Contact your local Carrier representative for part-wind details.  
**Compressor no. 1/Compressor no. 2.  
Maximum fuse amps (225% of compressor RLA). Size down to  
the next standard fuse size.  
MTA  
NEC  
—
—
Must-trip amps (compressor circuit breaker).  
National Electrical Code (U.S.A.)  
NOTES FOR TABLES 4A AND 4B  
1. All units have one field power terminal block.  
7. For all 30HK,HL units, control circuit MCA is 7.2, and control circuit MFA is  
15. For 30HK,HL 60 Hz units, a separately-fused (15 amp maximum) 115 v,  
single-phase, 60 Hz, power supply or accessory transformer is required.  
For 30HK,HL 50 Hz units, a field-supplied, separately fused (15 amps maxi-  
mum), 230 v, single-phase, 50 Hz power supply is required.  
2. Maximum incoming wire size:  
a. 350 kcmil for unit sizes 040-060; 208/230-3-60, 230-3-50, and 400-3-50  
voltages.  
b. 2/0 for all other unit sizes; all voltages.  
3. Any field modification of factory wiring must be in compliance with all ap-  
plicable codes. Field-installed power wires must be rated 75 C minimum.  
4. Use copper, copper-clad aluminum, or aluminum conductors for field wiring.  
5. For all 30HW units, control circuit power supply is 115-v single phase for 50-  
and 60-Hz units. Control power is supplied by the factory-installed control  
transformer. Additional control circuit power is not required for 30HW units.  
6. Across-the-line start is standard on all units. Part-wind start is available as  
a factory-installed option on 025-060 sizes (not available on 018 size; spe-  
cial order option on 30HK,HL units).  
(30HK, HL, HWA, HWB,  
HWC 60 Hz Only)  
(30HK, HL, HWA, HWB,  
HWC 60 Hz Only)  
21  
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FIELD POWER WIRING, 60 Hz UNITS  
FIELD CONTROL WIRING, 50 Hz UNITS  
LEGEND  
COM  
CR  
—
—
—
—
—
—
—
—
—
Common  
Compressor Relay  
Chilled Water Pump  
Demand Limit Switch  
Ground Current Sensing  
Normally Closed  
Normally Open  
CWP  
DLS  
GCS  
NC  
NO  
TB  
Terminal Block  
Temperature Control  
TC  
Field Wiring  
Factory Wiring  
Accessory  
NOTE: Manual lead/lag selector switch must  
be disconnected when using automatic lead/  
lag accessory.  
FIELD ACCESSORY WIRING  
Fig. 17 — Field Wiring Diagram; 30HK, HL Units  
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LEGEND  
C
—
—
—
—
—
Contactor  
GCS  
GND  
NC  
NEUT  
NO  
—
—
—
—
—
Ground Current Sensor  
SW  
—
—
—
—
—
Switch  
CB  
CM  
COM  
CR  
Circuit Breaker  
Control Module  
Common  
Ground  
TB  
Terminal Block  
Time Delay Relay  
Termistor  
Normally Closed  
Neutral  
Normally Open  
TDR  
THERM  
TRAN  
Control Relay  
Transformer  
Fig. 20 — 30HW Control Box Components Label  
2. Be sure flow switch is properly installed and set. See  
instructions packaged with flow switch accessory.  
3. Set the temperature controller deadband as specified in  
Tables 5 and 6. Set point should be at the desired cooler  
leaving fluid temperature. Refer to Chilled Fluid Tem-  
perature Controller section on page 29 for additional dead-  
band setting information.  
PRE-START-UP  
IMPORTANT: 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.  
4. Backseat (open) compressor suction and discharge shut-  
off valves. Crack open valves (one turn in) to allow some  
pressure to each test gage (if installed).  
5. Backseat (open) liquid line shutoff valve(s).  
6. Open valve to capillaries from fluid regulating valve (when  
used).  
ELECTRIC SHOCK HAZARD  
Open all disconnects before servicing this  
equipment. There may be more than one  
disconnect.  
Initial Check  
7. Fill chilled fluid liquid circuit with clean water or other  
noncorrosive fluid to be cooled. Bleed all air out of the  
high points of the system. Set flow rate according to job  
requirements. See Table 3. If the chilled water is to be  
maintained at a temperature below 40 F (4.4 C), a brine  
of sufficient concentration must be used to prevent freeze-up  
at anticipated suction temperatures.  
8. Open supply valve (or fill cooling tower, if used) for  
condenser water.  
9. Check tightness of all electrical connections.  
IMPORTANT: Electrical power source must agree  
with unit nameplate rating. Do not start the chiller, even  
momentarily, until the following checks have been  
completed.  
1. Check all auxiliary components, such as cooling tower  
(if used), chilled liquid and condenser water pumps, air-  
handling equipment, or other equipment to which  
the chiller supplies liquid. Consult manufacturer’s  
instructions.  
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Table 5 — Typical Deadband Requirements  
If there is no refrigerant vapor pressure in the system, the  
entire system must be leak tested. After repairing leaks, evacu-  
ate the system before recharging. Follow approved evacu-  
ation procedures when removing refrigeration. Release re-  
maining pressure to an approved evacuated cylinder.  
The liquid charging method is recommended for com-  
plete charging or when additional charge is required.  
UNIT  
CAPACITY  
STEPS  
COOLER DESIGN RANGE, F (C)  
5.0 (2.8)  
10.0 (5.6)  
15.0 (8.3)  
2
3
4
1.3 (0.7)  
0.8 (0.4)  
0.6 (0.3)  
2.5 (1.4)  
1.7 (0.9)  
1.3 (0.7)  
3.8 (2.1)  
2.5 (1.4)  
1.9 (1.1)  
Table 6 — Deadband Setting  
Be careful not to overcharge the system. Overcharging  
results in higher discharge pressure with higher cooling  
water consumption, possible compressor damage, and  
higher power consumption.  
MIN. REQUIRED DEADBAND  
DEADBAND SETTING (F)  
F
0.5 to 1.5  
2.0  
C
0.28 to 0.83  
1.11  
1.0  
2.0  
2.5  
2.8  
3.0  
3.7  
4.0  
2.5  
1.39  
LIQUID CHARGING METHOD — Add charge to the unit  
through the liquid line service valve. Never charge liquid  
into the low-pressure side of the system.  
3.0  
1.67  
3.5  
1.94  
4.0  
2.22  
1. Frontseat (close) condenser liquid line shutoff valve.  
4.5  
2.50  
2. Connect a refrigerant cylinder loosely to the charging valve  
connection of the liquid line shutoff valve. Purge the charg-  
ing hose and tighten the connections.  
10. Check compressor oil charge (should be visible in  
oil sight glass). Refer to Check Oil Charge section on  
page 27.  
11. Be sure the compressor crankcase heater is warm (heater  
should be on for 24 hours before starting the compres-  
sor). The crankcase heater must be firmly locked into  
the compressor crankcase.  
3. Open the charging valve.  
4. If the system has been dehydrated and is under vacuum,  
break the vacuum with refrigerant gas. For R-22, build  
up system pressure to 58 psig and 32 F (400 kPa and  
0° C). Invert the refrigerant cylinder so that the liquid  
refrigerant will be charged.  
12. Be sure the compressor is floating freely on the com-  
pressor springs (see Step 4 — Check Compressor Mount-  
ing and Connections section on page 3).  
13. For 30HL and HWA units with remote condenser, check  
the condenser fans for correct rotation. See instructions  
shipped with the condenser.  
5. a. For complete charge of 30HK, HWB, HWC, and HWS  
units, follow charging by weight procedure. When charge  
is nearly full, complete the process by observing the  
sight glass for clear liquid flow. The use of sight glass  
charging is valid only when unit is operating at full  
capacity (no unloaders energized).  
14. Be sure the unit is fully charged with refrigerant (see  
Check Refrigerant Charge section below).  
15. If unit is a brine unit, check to ensure proper brine con-  
centration is used to prevent freezing.  
b. For complete charge of 30HL and HWA units or where  
refrigerant cylinder cannot be weighed, follow charg-  
ing by sight glass procedure. The use of sight glass  
charging is valid only when unit is operating at full  
capacity (no unloaders energized).  
Check Refrigerant Charge  
6. a. The 30HL and HWA condenserless units are shipped  
with a holding charge only. After installation with the  
field-supplied system high side, the complete system  
should be charged until the sight glass is clear (with  
the unit running at full capacity). To achieve maxi-  
mum system capacity, add additional charge equal to  
the difference between the condenser optimal charge  
and the condenser minimum charge, which can be ob-  
tained from the charge data provided in the condenser  
installation instructions.  
When adding or removing refrigerant charge, circulate  
water through condenser and cooler at all times to pre-  
vent freezing. Freezing damage is considered abuse and  
is not covered by Carrier warranty.  
The 30HK, HWB, HWC, and HWS units are shipped with  
a full refrigerant charge (see Tables 1A-2B). However, if it  
is necessary to add refrigerant, operate the unit for some time  
at full capacity and then add charge until the sight glass is  
clear of bubbles. For maximum liquid subcooling, liquid level  
should be up to condenser end (30HK, HWC, HWS units  
only). This usually requires additional refrigerant charge be-  
yond the amount to clear sight glass.  
The 30HL and HWA units (condenserless) are shipped with  
a refrigerant holding charge only. After chiller assembly is  
completed in the field, system must be fully charged. While  
the unit is running at full capacity, add refrigerant until the  
sight glass is clear. R-22 is the normal refrigerant.  
Do not open the liquid valve or the compressor discharge  
valve until there is a charge in remainder of system. A posi-  
tive pressure indicates a charge in system. With the unit op-  
erating at full load, check liquid line sight glass to be sure  
the unit is fully charged (bubbles in the sight glass indicate  
the unit is not fully charged).  
b. To ensure maximum performance of 30HWB units,  
raise the compressor saturated discharge temperature  
(SDT) to approximately 105 F (40.6 C) by throttling  
the condenser water intake. Add charge until there is  
approximately 15 to 17° F (8.3 to 9.4° C) of system  
subcooling (SDT minus actual temperature entering the  
thermostatic expansion valve).  
c. To ensure maximum performance of 30HK, HWC, and  
HWS units, raise the compressor saturated discharge  
temperature (SDT) to approximately 103 F (39.4 C)  
by throttling the condenser water intake. Add charge  
until there is approximately 8 to 10° F (4.4 to 5.6° C)  
for 30HK units or 12 to 14° F (6.7 to 7.8° C) for 30HWC,  
HWS units of system subcooling (SDT minus actual  
temperature entering the thermostatic expansion valve).  
26  
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8. Recheck compressor oil level (see Check Oil Charge sec-  
tion on this page). Add or remove oil to achieve the level  
required during steady operation.  
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  
Operating Limitations  
1
3
in the compressor crankcase(s) to between ⁄8 and ⁄8 of the  
sight glass(es) during steady operation.  
Do not operate with cooler leaving chiller water (fluid)  
temperature (LCWT) below 40 F (4.5 C) for the stan-  
dard units, or below 15 F (−9.4 C) for units factory built  
for medium temperature brine.  
TO ADD OIL  
1. Close the suction shutoff valve and pump the compressor  
crankcase down to between zero and 2 psig (zero to  
13.8 kPa) (the low-pressure switch must be jumpered).  
Wait a few minutes and repeat as needed until the pres-  
sure remains between zero and 2 psig (zero to 13.8 kPa).  
2. Close the discharge shutoff valve.  
3. Remove the oil-fill plug above the compressor sight glass,  
add oil through the plug hole, and replace the plug.  
HIGH COOLER LEAVING CHILLED WATER (FLUID)  
TEMPERATURES (LCWT) — During start-up with cooler  
LCWT above approximately 60 F (16 C), the unit expansion  
valve will limit suction pressure to approximately 90 psig  
(620 kPa) to avoid overloading the compressor.  
LOW COOLER LCWT — For standard units, the LCWT  
must be no lower than 40 F (4.5 C). If the unit is the factory-  
installed optional medium temperature brine unit, the cooler  
LCWT can go down to 15 F (−9.4 C).  
4. After opening the suction and discharge service valves,  
remove low-pressure switch jumper, run the compressor  
for about 20 minutes, and check the oil level.  
Use only Carrier-approved compressor oil:  
MAIN POWER SUPPLY — Minimum and maximum ac-  
ceptable supply voltages are listed in Tables 4A and 4B.  
Petroleum Specialties, Inc. . . . . . . . . . . . . . . . .Cryol 150*  
Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . .Capella WF-32  
Witco Chemical Co. . . . . . . . . . . . . . . . . . . . . .Suniso 3GS  
*Factory charge.  
Do not reuse drained oil, and do not use any oil that has  
been exposed to the atmosphere.  
Unbalanced 3-Phase Supply Voltage — Never operate a mo-  
tor where a phase imbalance between phases is greater than  
2%. To determine percent voltage imbalance, see Unbal-  
anced 3-Phase Supply Voltage section on page 19.  
TO REMOVE OIL  
Check Refrigerant Feed Components  
THERMOSTATIC EXPANSION VALVE (TXV) — The TXV  
controls the flow of liquid refrigerant to the cooler by main-  
taining constant superheat of vapor leaving the cooler. There  
is one valve per refrigerant circuit. The valve(s) is activated  
by a temperature-sensing bulb(s) strapped to the suction line(s).  
The crankcase will be under slight pressure. Be careful  
not to lose the entire oil charge. Gloves and eye pro-  
tection must be worn.  
The valve(s) is factory-set to maintain between 8° and  
10° F (4.4° and 5.6° C) of superheat leaving the cooler. Check  
the superheat during operation after conditions have stabi-  
lized. If necessary, adjust the superheat to prevent refriger-  
ant floodback to the compressor.  
Pump down the compressor to between zero and 2 psig  
(zero to 13.8 kPa). Loosen the oil drain valve located in the  
compressor base to allow the oil to seep out past plug threads.  
Be careful not to remove plug; the entire oil charge may be  
lost. Small amounts of oil can be removed through oil pump  
discharge connection.  
FILTER DRIER — The function of the filter drier is to main-  
tain a clean, dry system. The moisture indicator (described  
below) indicates any need to change the filter drier. The fil-  
ter drier is a sealed-type drier. When the drier needs to be  
changed, the entire filter drier must be replaced.  
START-UP AND OPERATION  
Operation Checks — Start-up should be performed only  
under supervision of an experienced refrigeration techni-  
cian. Refer to Start-Up Checklist on pages CL-1 to CL-4.  
Remove and save the checklist for future reference.  
1. Crankcase heater must be energized for at least 24 hours  
before the chiller is started.  
2. Open all system valves that may have been closed during  
or after charging.  
3. Check air-handling equipment, chilled water (fluid) and  
condenser pumps, and any other equipment connected to  
the chiller.  
NOTE: The 30HK, HL units have 2 filter driers; one per  
circuit.  
MOISTURE-LIQUID INDICATOR — The indicator is lo-  
cated immediately ahead of the TXV to provide an indica-  
tion of the refrigerant moisture content. It also provides a  
sight glass for refrigerant liquid. Clear flow of liquid refrig-  
erant (at full unit loading) indicates sufficient charge in the  
system. Bubbles in the sight glass (at full unit loading) in-  
dicate an undercharged system or the presence of noncon-  
densables. Moisture in the system, measured in parts per million  
(ppm), changes the color of the indicator as follows:  
Blue (safe) — Moisture is below 45 ppm  
Light Violet (caution) — 45 to 180 ppm  
Pink (wet) — above 180 ppm  
4. Start the unit by moving the ON-OFF switch to the ON  
position.  
5. Check all controls for proper operation. Follow Start-Up  
Checklist procedures in these instructions.  
6. Adjust the water regulating valve (where used) to obtain  
the most economical head pressure (based on the relative  
cost of water and electricity). Head pressure is normally  
200 to 230 psig (1379 to 1586 kPa) for 30HK,HL units,  
and 195 to 226 psig (1344 to 1558 kPa) for 30HW units  
when using R-22 refrigerant.  
7. Check the cooler leaving chilled water temperature to see  
that it remains well above 32 F (0° C), or the brine freez-  
ing point if the unit is a medium temperature brine unit.  
The unit must be in operation at least 12 hours before the  
moisture indicator gives an accurate reading, and must be in  
contact with liquid refrigerant. At the first sign of moisture  
in the system, change the corresponding filter drier.  
NOTE: The 30HK, HL units have 2 indicators; one per  
circuit.  
LIQUID LINE SERVICE VALVE — This valve provides a  
refrigerant charging port and, in combination with the com-  
pressor discharge service valve(s), allows the refrigerant to  
be pumped into the high side of the system.  
27  
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DISCHARGE LINE CHECK VALVE — On all 30HL, HWA  
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 muffler. Install the valve in any  
position except bonnet down.  
The check valve(s) prevents backwards-migration of re-  
frigerant from the condenser(s) to the compressor(s) and cooler  
during the compressor off cycle.  
COMPRESSOR INTERNAL THERMAL PROTECTION —  
On the 30HW018 units, there is a sensor imbedded in  
the compressor windings to detect an overtemperature  
condition.  
The thermostat opens and shuts off the compressor if the  
discharge gas temperature exceeds 295 ± 5° F (146 ± 2.8° C).  
The thermostat will reset when the temperature drops to ap-  
proximately 250 F (121 C). However, the control module  
will keep the unit locked off until control power is manually  
cycled off, then back on.  
HOT GAS BYPASS VALVE — On units equipped with the  
factory-installed capacity reduction option (30HW only), a  
hot gas bypass valve is located between the discharge line  
and the cooler entering-refrigerant line. A solenoid valve is  
installed in the equalizer line of the hot gas valve to allow  
the temperature control to cycle the hot gas bypass function.  
The amount of capacity reduction achieved by the hot gas  
bypass valve may be altered by adjusting the spring tension  
of the hot gas bypass valve. The total unit capacity should  
not be reduced below 10% of the nominal rating.  
NOTE: Compressor overtemperature protection for 30HK,  
HL units is accomplished by high and low pressure switches  
and circuit breakers which are external to the compressors.  
CRANKCASE HEATER  
Never open or disconnect any switch that energizes the  
crankcase heater, unless the unit is being serviced or will  
be shut down for an extended period. After service or  
shutdown, energize the crankcase heater for 24 hours  
before starting the compressor.  
LIQUID LINE SOLENOID VALVE (30HL ONLY) — The  
solenoid valve closes when its circuit is inoperative, either  
from capacity control or from any safety trip.  
PRESSURE RELIEF DEVICES — All 30HK, 30HL, and  
30HW units are equipped with a compressor pressure relief  
valve located on the crankcase of the 06E compressor units  
(except for the 30HW018 units which have a compressor  
displacement less than 50 cfm). The pressure relief valve opens  
at 450 psig (3103 kPa).  
IMPORTANT: The crankcase heater is located in the  
bottom corner of the compressor and held in place by  
a bracket. The heater must be tight to prevent it from  
backing out of the heater well. The heater eventually  
burns out if exposed to the air for an extended period.  
The 30HK,HWC, and HWS units are also equipped with  
a high-side refrigerant pressure relief valve on the shell and  
tube condenser. The valve is set to open at the working pres-  
sure of the condenser, as shown in Table 7.  
The 30HWB does not have a condenser pressure relief  
valve, because the brazed-plate condenser is not considered  
a pressure vessel, as defined in ANSI/ASHRAE 15 (Ameri-  
can National Standards Institute/American Society of Heat-  
ing, Refrigerating, and Air Conditioning Engineers) safety  
code requirements.  
The heater in each compressor prevents absorption of liq-  
uid refrigerant by the compressor oil when the compressor  
is not operating. The heater is wired into the normally closed  
contacts of the compressor control relay so that it energizes  
only when the compressor is not operating. The heater is  
125 w, 115 v on all 60 Hz units; 230 v on 50 Hz 30HK, HL  
units; and 115 v on 50 Hz 30HW units.  
OIL PRESSURE SAFETY SWITCH (OPS) — One OPS per  
compressor is standard on all 30HL and HWA units, and on  
all units equipped with the medium temperature brine op-  
tion. One is located in each compressor terminal box with  
capillaries to the crankcase and oil pump. The switch is also  
offered as an accessory (part number 30HW900006) for stand-  
ard 30HK, HWB, HWC, and HWS units. When used, the  
OPS is monitored by the unit control module. If at any time  
after the compressor is started, the OPS is open for more  
than 2 minutes, the compressor shuts down and is locked off  
until control power is manually cycled to OFF, then back to  
the ON position. The OPS cuts out at 5 ± 1 psig (34.5 ±  
6.9 kPa), and has a maximum cut-in of 9.5 psig (65.5 kPa).  
For 30HL and HWA condenserless units, pressure relief  
devices designed to relieve at 450 psig (3103 kPa), must be  
field-supplied and installed in the discharge line piping after  
the muffler in accordance withANSI/ASHRAE 15 safety code  
requirements. Additional pressure relief valves, properly se-  
lected, must be field-supplied and installed to protect high  
side equipment and may be required by applicable codes.  
Most codes require that a relief valve be vented directly  
to the outdoors. The vent line must not be smaller than the  
relief valve outlet. The condenser relief valves have a 5⁄8-in.  
SAE (Society of Automotive Engineers, U.S.A.) flare connec-  
3
Check Unit Safeties  
tion. The compressor relief valves have a ⁄8-in. SAE Flare  
connection. Consult ANSI/ASHRAE 15 for detailed infor-  
mation concerning layout and sizing of relief vent lines.  
All units have a factory-installed fusible plug in the suc-  
tion line which relieves on a temperature rise at 170 F  
(77 C) and one in the liquid line which relieves at 210 F (99 C).  
CONTROL MODULE — The unit control module is lo-  
cated in the control section of the control box. See Fig. 19  
and 20. It performs several functions. The control module  
has a built-in compressor anti-short-cycle timer which will  
not allow a compressor to restart until 5 minutes have elapsed  
since the previous shutdown.  
Table 7 — Pressure Relief Valve Settings  
On 30HL and HWA units (and 30HK, HWB, HWC, and  
HWS units equipped with the oil pressure safety switch [OPS]  
accessory), the compressor oil pressure and low-pressure  
switch(es) (LPS) are monitored through the control module.  
The unit is allowed to remain operational as long as the OPS  
and/or LPS have not been open for more than 2 minutes af-  
ter a compressor has started. After start-up, if the OPS and/or  
LPS are open for more than 2 minutes, the control 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 illuminated. The unit  
cannot be restarted until control power is manually cycled to  
OFF, then to ON.  
PRESSURE RELIEF VALVE SETTINGS  
UNIT  
Psig  
385  
365  
335  
kPa  
2655  
2517  
2310  
30HK  
30HWC  
30HWS  
Compressor and Unit Protective Devices  
CIRCUIT BREAKER — There is a single circuit breaker  
per compressor in each unit. The circuit breaker(s) protects  
the compressor(s) against overloading, locked rotor condi-  
tions, and primary single phasing. If the circuit breaker(s)  
trips, determine the cause and correct it before resetting the  
breaker(s).  
28  
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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 illuminated.  
The unit cannot be restarted until control power is manually  
cycled to OFF, then to ON.  
If the unit shuts down on an automatic reset switch, such  
as the temperature controller, the compressor will be al-  
lowed to restart when the switch closes and the control mod-  
ule anti-short-cycle time has elapsed.  
To check operation of the low-pressure switch, slowly close  
the suction service valve and allow the affected compressor  
to pump down. The compressor should cut out when the suc-  
tion pressure falls below the low-pressure switch cutout set-  
ting. Open the suction service valve. The compressor should  
restart after the low-pressure switch closes, and the com-  
pressor anti-short-cycle delay expires.  
CHILLED FLUID TEMPERATURE CONTROLLER — All  
units are equipped with a temperature controller (see  
Fig. 21) which is capable of controlling up to 4 steps of ca-  
pacity. A thermistor installed inside the cooler supplies the  
input to the controller. The temperature controller can op-  
erate a system with cooling ranges (entering cooler fluid tem-  
perature minus leaving cooler fluid temperature) of 5° to  
15° F (2.8° to 8.3° C), and with a range of set points from  
40 to 60 F (4.4 to 15.5 C) for standard units, and 15 to  
39 F (−9.4 to 3.9 C) for units with the medium temperature  
brine option.  
The set point of the temperature controller should be ad-  
justed to the desired leaving cooler fluid temperature, and  
verified by using a thermometer placed in the leaving-cooler  
piping. The amount of deadband around the set point value  
is adjusted through the use of the deadband adjustment knob  
on the temperature controller. See Tables 5 and 6 for the cor-  
rect setting of the deadband.  
The unit should then control the average leaving-fluid tem-  
perature to this setting. If the leaving-fluid temperature does  
not correspond to the desired set point, slightly readjust the  
controller set point knob until the desired leaving-fluid tem-  
perature is obtained. The temperature controller has an ad-  
justable 30-second (HI position) to 3-minute (LO position)  
sample rate knob. The sample rate knob should always be  
set at LO position (fully clockwise) for 30HK, HL units, and  
at HI position (fully counterclockwise) for 30HW units.  
For Servicing Only — To speed up the 5-minute anti-short  
cycle, a jumper may be placed between terminals T1 and T6  
of the control module.  
This jumper must be removed after servicing is complete.  
Failure to remove this jumper is considered abusive treat-  
ment and will void the Carrier warranty.  
HIGH-PRESSURE SWITCH — A high-pressure switch is  
provided to protect each compressor and refrigeration sys-  
tem from unsafe high pressure conditions. See Table 8 for  
high-pressure switch settings.  
The high-pressure switch is mounted in the discharge side  
of each compressor. A snubber is provided between the com-  
pressor discharge manifold and the high-pressure switch to  
prevent pressure pulsations from damaging the switch.  
If an unsafe, high-pressure condition should exist, the switch  
opens and shuts off the affected compressor. The unit control  
module prevents the unit from restarting. The unit will not  
restart until control power is manually cycled off, then on.  
To check operation of the switch, slowly close the com-  
pressor discharge shutoff valve until the compressor shuts  
down. The switch should open at the pressure corresponding  
to the appropriate switch setting as shown in Table 8.  
Table 8 — Factory Settings, High-Pressure Switch  
(Fixed)  
Do not force the knob dials past the stops. This  
could cause loss of control point and damage to the  
controller.  
CUTOUT  
Psig kPa  
280 ± 10 1931 ± 69 180 ± 20 1241 ± 138  
CUT-IN  
UNIT  
30  
Psig  
kPa  
HK, HWS  
HL, HWB, HWC 375 ± 10 2585 ± 69 275 ± 20 1896 ± 138  
HWA 395 ± 10 2723 ± 69 298 ± 20 2054 ± 138  
Reopen the compressor discharge shutoff valve, and cycle  
the unit ON-OFF switch to OFF, then ON. The unit should  
restart after the compressor anti-short-cycle delay, built into  
the unit control module, expires.  
LOW-PRESSURE SWITCH — A low-pressure switch is pro-  
vided to protect each compressor and system from a loss of  
refrigerant. The low-pressure switch(es) also provides freeze  
protection for the cooler. The low-pressure switch(es) is non-  
adjustable. See Table 9 for low-pressure switch settings. One  
switch is used for standard units, and a different switch is  
used for units with the brine option.  
Table 9 — Factory Settings, Low-Pressure Switch  
(Fixed)  
CUTOUT  
CUT-IN  
kPa  
LEGEND  
UNIT  
TYPE  
Psig  
kPa  
Psig  
COM  
NC  
NO  
—
—
—
Common  
Normally Closed  
Normally Open  
STANDARD  
BRINE  
42 ± 3  
27 ± 3  
290 ± 21  
186 ± 21  
57 ± 5  
44 ± 5  
393 ± 34  
303 ± 34  
Fig. 21 — Temperature Controller  
29  
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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  
Table 5 is desired, determine the setting by using the fol-  
lowing formula and Table 6:  
phases of the 3-phase power supply to the compressor. If a  
short to ground is sensed by the sensor, the compressor au-  
tomatically shuts down. This prevents contamination of the  
refrigeration system from acid formation. The compressor  
shuts down when a 2.5 ± 2 amps ground current is sensed by  
a toroid installed around the compressor power leads. The  
unit control module locks the compressor off until the circuit  
power is cycled to OFF, and then ON. For installation de-  
tails, see the instructions included with the accessory  
package.  
Minimum Required Unit Deadband:  
Minimum Deadband  
=
(Cooler Design ⌬t  
÷
(2 x no. of Capacity Steps)  
F (C)  
=
NOTE: Two accessory packages are required for 30HK, HL  
units.  
The lights on the temperature controller will indicate the  
status of the control. If the green light labeled ABOVE SET  
POINT is illuminated, the controller will add steps of ca-  
pacity, if additional steps are available. If the yellow light  
labeled BELOW SET POINT is illuminated, the controller  
removes steps of capacity.  
The temperature controller also has a red light labeled OUT  
OF RANGE that indicates the system load was reduced faster  
than the controller could remove stages. If this occurs, the  
unit shuts down to avoid cooler freeze-up.  
UNIT OPERATION  
Capacity Control and Operating Sequence —  
The 30HW units have a multiple-step temperature control-  
ler, factory set to maintain capacity control through leaving  
chilled fluid temperature. The controller has 4 capacity steps.  
All 30HK, HL units have 4 capacity steps as standard. The  
30HW018 and 028-040 units have 3 steps as standard, with  
a fourth step available as a factory-installed option. The  
30HW025 units have 2 steps of capacity as standard with a  
third step available as a factory-installed option. All units  
have electric solenoid operated unloaders. See Tables 10 and  
11 for capacity control steps of each unit.  
Once the temperature rises back into the control band, the  
unit restarts automatically. This also occurs if the therm-  
istor fails in the open mode. In the case of a thermistor fail-  
ure, the unit does not restart until the thermistor is replaced.  
At initial start-up, assume that all safety devices are sat-  
isfied and there is a call for cooling.  
FREEZE-UP PROTECTION  
30HK,HL UNITS — Close the compressor circuit breaker  
and turn the ON-OFF switch to the ON position.  
On medium temperature brine units, the brine must be  
properly mixed to prevent freezing at a temperature of  
at least 15 F (8.3 C) below the leaving-fluid temperature  
set point. Failure to provide the proper brine mixture is  
considered abuse and may void the Carrier warranty.  
In approximately 5 minutes, the lead compressor starts and  
the unloaders are energized (compressor unloads when com-  
pressor unloader solenoid is energized). On 30HL units, the  
liquid line solenoid valve will remain closed for the first  
10 seconds of compressor operation. The low-pressure and  
oil pressure switches are bypassed for 2 minutes. At the end  
of the 2-minute bypass period, the low-pressure and oil pres-  
sure switches are active in the control circuit.  
Approximately 30 seconds (high setting) or 3 minutes (low  
setting) later, depending on the sample rate setting, the lag  
compressor starts and the unloaders are energized (compres-  
sor unloads when compressor unloader solenoid is ener-  
gized). On 30HL units, the liquid line solenoid valve will  
remain closed for the first 10 seconds of compressor opera-  
tion. The low-pressure and oil-pressure switches are by-  
passed for 2 minutes. At the end of the 2-minute bypass pe-  
riod, the low-pressure and oil-pressure switches are active in  
the control circuit.  
Approximately 30 seconds (high setting) or 3 minutes (low  
setting) later, depending on the sample rate setting, the lead  
compressor is loaded (unloader solenoids deenergized).  
Approximately 30 seconds (high setting) or 3 minutes (low  
setting) later, depending on the sample rate setting, the lag  
compressor is loaded (unloader solenoids deenergized).  
When the load is satisfied and the leaving fluid tempera-  
ture falls below the set point, the last stage activated is dropped  
immediately. If the leaving fluid temperature still remains  
below the set point, then the control drops an additional stage  
every 30 (high setting) or 180 (low setting) seconds, de-  
pending on the sample rate setting.  
All units have the following 2 modes of freeze-up  
protection.  
1. The temperature controller protects the system from freeze-up  
due to rapid loss of load and from low fluid flow by rap-  
idly removing all steps of capacity and shutting down the  
compressor if an out-of-range condition exists. This nor-  
mally occurs if the leaving-fluid temperature drops 6 to  
7° F (3.3 to 3.9° C) below the temperature controller set  
point. Set point range is 40 to 60 F (4.4 to 15.6 C) for  
standard units and 15 to 39 F (−9.4 to 3.9 C) for units  
with medium temperature brine option.  
2. The low-pressure switch provides a back-up cooler freeze-up  
protection system. The low-pressure switch shuts down  
the unit when the suction temperature drops to a point  
where the cooler will freeze up.  
LOSS-OF-COOLER-FLOW PROTECTION — A proof-of-  
cooler-flow device (accessory flow switch) must be used with  
all 30HK, HL, HW chillers. The device should be a differ-  
ential pressure type device and should be set to shut the unit  
off if cooler gpm drops below 1.5 times the nominal unit  
tonnage. Carrier accessory flow switch, part number  
30HW900003 is available for this purpose. See page 19 and  
Fig. 17 and 18.  
COMPRESSOR GROUND FAULT SENSOR — The ground  
fault sensor accessory (Part No. 30HW900004) monitors all  
30  
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Once the compressor is shut off, 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 gas bypass valve opens only when stage 1 is active.  
If system load drops to the point where the unit is fully  
unloaded and the fluid temperature is below the lower dead-  
band limit, the compressor shuts off and is not able to restart  
until the 5-minute anti-short cycle has expired. If during nor-  
mal operation, the fluid temperature rises above the upper  
deadband limit, the temperature controller adds a step of ca-  
pacity (assuming a step is left to be added).  
On condenserless units (30HWA), or on fluid-cooled units  
(30HWB,C, and S) equipped with the accessory oil safety  
switch, the control module provides a 2-minute bypass of  
the oil safety switch.  
If the unit is equipped with hot gas bypass option, the hot  
gas bypass valve closes before unloaders are deactivated.  
If the unit trips out on high pressure, ground current (ac-  
cessory), or low oil pressure, the control module locks the  
unit off and must be manually reset (by turning the ON-OFF  
switch to OFF, then back to ON). If the unit trips out on low  
pressure, low fluid temperature, the chilled fluid flow switch,  
or the chilled fluid pump switch, it restarts automatically when  
the condition is corrected.  
If the unit trips out on high pressure, low pressure, ground  
current (accessory), or low oil pressure, the control module  
locks the unit off and must be manually reset (turn the ON-  
OFF switch to OFF and then back to ON). If the unit trips  
out on low fluid temperature, chilled fluid flow switch, or  
chilled fluid pump switch, it restarts automatically when the  
condition is corrected.  
30HW UNITS — Close the compressor circuit breaker and  
move ON-OFF switch to the ON position. The switch should  
light up. In approximately 3 seconds, the compressor starts  
unloading. For 2 minutes the low-pressure switch is  
bypassed and the unloaders are energized (compressor un-  
loads when compressor unloader solenoid is energized). At  
end of 2-minute bypass period, the low-pressure switch ac-  
tivates the control circuit and the temperature controller regu-  
lates the capacity steps based on leaving cooler fluid tem-  
perature, set point and deadband settings on the temperature  
controller.  
Table 10 — Capacity Control Steps — 30HK, HL Standard Units  
TRANSFER SWITCH COMPRESSOR  
NO. 1 POSITION*  
TRANSFER SWITCH COMPRESSOR  
NO. 2 POSITION*  
CONTROL  
STEPS  
UNIT  
Operating Cylinder  
Ckt 1  
Operating Cylinder  
%
%
Disp.  
Disp.  
Total  
Ckt 2  
Total  
Ckt 1  
Ckt 2  
1
2
3
4
25  
50  
2
4
6
8
2
2
4
4
—
2
25  
50  
2
4
6
8
—
2
2
2
4
4
30HK040  
75  
2
75  
2
100  
4
100  
4
1
2
3
4
40  
60  
4
6
4
4
6
6
—
2
20  
60  
2
6
—
4
2
2
4
4
30HK,HL050  
80  
8
2
80  
8
4
100  
10  
4
100  
10  
6
1
2
3
4
33  
66  
4
8
10  
12  
4
4
6
6
—
4
33  
66  
4
8
10  
12  
—
4
4
4
6
6
30HK,HL060  
88  
4
88  
4
100  
6
100  
6
LEGEND  
*Manually operated.  
NOTE: Circuits are designated from left to right when viewed from  
front of unit.  
Ckt  
Disp.  
—
—
Circuit  
Displacement  
31  
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Table 11 — Capacity Control Steps —  
30HW Standard Units  
Brazed-Plate Cooler and Condenser Heat Ex-  
changer Replacement — Brazed-plate heat exchang-  
ers cannot be repaired if they develop a leak. If a leak (re-  
frigerant or water) develops, the heat exchanger must be  
replaced. To replace a brazed plate heat exchanger:  
1. Disconnect the liquid-in and liquid-out connections at the  
heat exchanger.  
2. Check that the replacement heat exchanger is the same as  
the original heat exchanger. For the condensers, compare  
part numbers on the heat exchangers. For the coolers, in-  
sulation covers the manufacturer’s part number. Make sure  
the depths of the replacement and original cooler heat ex-  
changers are the same.  
UNIT  
CAPACITY CONTROL  
STEPS*  
CAPACITY  
%
OPERATING  
CYLINDERS  
30HW  
1
2
3
33.3  
66.7  
100.0  
2
4
6
018  
025  
028  
1
2
50.0  
100.0  
2
4
1
2
3
33.3  
66.7  
100.0  
2
4
6
1
2
3
33.3  
66.7  
100.0  
2
4
6
035  
040  
3. Reclaim the refrigerant from the system, and unsolder the  
refrigerant-in and refrigerant-out connections.  
1
2
3
33.3  
66.7  
100.0  
2
4
6
1
4. Remove the four ⁄2-in. nuts holding the heat exchanger  
to the brackets. Save the nuts.  
*Factory-installed hot gas bypass option adds an additional capacity  
step to that shown in this table.  
5. Install the replacement heat exchanger in the unit and  
1
attach to the bracket using the four ⁄2-in. nuts removed  
in Step 4.  
6. Carefully braze the refrigerant lines to the connections on  
the heat exchanger. Lines should be soldered using silver  
as the soldering material with a minimum of 45% silver.  
Keep the temperature below 1472 F (800 C) under nor-  
mal soldering conditions (no vacuum) to prevent the cop-  
per solder of the brazed plate heat exchanger from changing  
its structure. Failure to do so can result in internal or  
external leakage at the connections which cannot be  
repaired.  
SERVICE  
ELECTRIC SHOCK HAZARD  
To avoid the possibility of electrical shock,  
turn off all power to unit before servicing.  
7. Reconnect the water/brine lines.  
8. Dehydrate and recharge the unit. Check for leaks.  
Do not attempt to bypass, short-out, or modify the con-  
trol circuit or electronic boards in any way to correct a  
problem. This could result in component failures or a  
hazardous operating condition.  
Brazed-Plate Cooler and Condenser Heat Ex-  
changer Cleaning — Brazed-plate heat exchangers must  
be cleaned chemically. A professional cleaning service skilled  
in chemical cleaning should be used. Use a weak acid (5%  
phosphoric acid, or if the heat exchanger is cleaned fre-  
quently, 5% oxalic acid). Pump the cleaning solution through  
the exchanger, preferably in a backflush mode. After clean-  
ing, rinse with large amounts of fresh water to dispose of all  
the acid. Cleaning materials must be disposed of properly.  
Compressor Replacement — If a replacement  
6-cylinder compressor has a center-bank cylinder head with  
discharge valve pad facing the pump end, remove head and  
install reverse flange head from original compressor (dis-  
charge valve pad toward the motor end). Center-bank cyl-  
inder head cannot be rotated 180 degrees.  
Be sure all the hardware from the old compressor is  
removed and installed on the new compressor, including  
the high-pressure switch snubber, the discharge gas thermo-  
stat (30HW025-040), the oil pressure safety switch (if equipped),  
and the low-pressure switch.  
The compressor can be removed from either the front or  
the sides of the unit, depending on where clearance space  
was allowed during unit installation. The compressor and mount-  
ing hardware are mounted on a plate which is screwed down  
to the unit basepan. Remove the 4 screws holding the plate  
to the basepan and the plate should easily slide out of the  
unit. Mount the replacement compressor to the plate, slide  
the plate back into the unit and secure with the 4 screws.  
The mesh screens in front of the water/brine inlets of the  
heat exchangers should be cleaned periodically, depending  
on condition of the chiller water/brine.  
Shell-and-Tube Condenser Cleaning — The shell-  
and-tube condenser tubes can be cleaned either mechani-  
cally or chemically. To clean them chemically, follow the  
procedure described in Brazed-Plate Cooler and Condenser  
Heat Exchanger Cleaning section above.  
To clean the condenser tubes manually:  
1. Order tubing brushes (Carrier part no. KC21AH105).  
2. Close the valves on the condenser and relieve condenser  
water pressure. BE SURE TO PROVIDE DRAINAGE  
TO PREVENT WATER DAMAGE.  
Circuit Breaker(s) — The breaker(s) provides 3-leg over-  
load protection. Do not bypass connections or increase the  
size of the circuit breaker(s) to correct trouble. Determine  
the cause of the trouble and correct it before resetting the  
breaker(s). A tripped breaker must be manually reset by mov-  
ing the circuit breaker handle to OFF, then ON position. See  
Tables 4A and 4B for must-trip amps (MTA).  
3. Remove the condenser heads and brush the tubes clean,  
removing scale and other deposits.  
4. Inspect the head gaskets and replace if necessary.  
5. Clean all gasket surfaces prior to reassembly.  
6. Replace the water heads and torque the head bolts to  
90 ft-lb (122 N-m). Allow the gaskets to set overnight  
and re-torque the bolts to ensure proper sealing.  
NOTE: One circuit breaker is provided per compressor.  
32  
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3. Insert thermistor T1 into coupling body to its full depth.  
Tighten packing nut finger tight to position ferrules, then  
tighten 11⁄4 turns more using a back-up wrench. Ferrules  
are not attached to the sensor, which can be withdrawn  
from coupling for service.  
Thermistor — The resistance at various temperatures for  
the thermistor are given in Tables 12A and 12B.  
THERMISTOR REPLACEMENT, 30HK, HL UNITS  
THERMISTOR REPLACEMENT, 30HW UNITS — To re-  
place the thermistor, follow these steps:  
1. Disconnect the existing thermistor from the S1 and S2  
terminals of the temperature controller (located in the con-  
trol section of the control box).  
2. Remove the thermistor from the well in the cooler leaving-  
fluid cacity.  
3. Insert the replacement thermistor into the thermistor well.  
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.  
IMPORTANT: Do not diassemble new coupling. In-  
stall as received.  
4. Run thermistor wires into the control box and connect to  
the S1 and S2 terminals of the temperature controller.  
2. Apply pipe sealant to 1⁄4-in. NPT threads on replacement  
coupling and install in place of original. Do not use a pack-  
ing nut to tighten coupling. This damages the ferrules (see  
Fig. 22).  
Fig. 22 — Thermistor  
33  
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Table 12A — Sensor Temperature (F) vs Resistance  
TEMPERATURE  
(F)  
RESISTANCE  
(OHMS)  
TEMPERATURE  
(F)  
RESISTANCE  
(OHMS)  
TEMPERATURE  
(F)  
RESISTANCE  
(OHMS)  
- 25  
- 24  
- 23  
- 22  
- 21  
- 20  
- 19  
- 18  
- 17  
- 16  
- 15  
- 14  
- 13  
- 12  
- 11  
- 10  
98,010  
94,707  
91,522  
88,449  
85,485  
82,627  
79,871  
77,212  
74,648  
72,175  
69,790  
67,490  
65,272  
63,133  
61,070  
59,081  
57,162  
55,311  
53,526  
51,804  
50,143  
48,541  
46,996  
45,505  
44,066  
42,678  
41,339  
40,047  
38,800  
37,596  
36,435  
35,313  
34,231  
33,185  
32,176  
31,201  
30,260  
29,351  
28,472  
27,624  
26,804  
26,011  
25,245  
24,505  
23,789  
23,096  
22,427  
21,779  
21,153  
20,547  
19,960  
19,392  
18,843  
18,311  
17,796  
17,297  
16,814  
16,346  
15,892  
15,453  
15,027  
14,614  
14,214  
13,826  
13,449  
13,084  
12,730  
12,387  
12,053  
11,730  
11,416  
11,111  
10,816  
10,529  
10,250  
9,979  
63  
64  
7,091  
6,911  
6,735  
6,564  
6,399  
6,237  
6,081  
5,929  
5,781  
5,637  
5,497  
5,361  
5,229  
5,101  
4,976  
4,855  
4,737  
4,622  
4,511  
4,403  
4,298  
4,195  
4,096  
4,000  
3,906  
3,814  
3,726  
3,640  
3,556  
3,474  
3,395  
3,318  
3,243  
3,170  
3,099  
3,031  
2,964  
2,898  
2,835  
2,773  
2,713  
2,655  
2,598  
2,542  
2,488  
2,436  
2,385  
2,335  
2,286  
2,238  
2,192  
2,147  
2,103  
2,060  
2,018  
1,977  
1,937  
1,898  
1,860  
1,822  
1,786  
1,750  
1,715  
1,680  
1,647  
1,614  
1,582  
1,550  
1,519  
1,489  
1,459  
1,430  
1,401  
1,373  
1,345  
1,318  
1,291  
1,265  
1,239  
1,214  
1,189  
1,165  
1,141  
1,118  
1,095  
1,072  
1,050  
1,028  
151  
152  
153  
154  
155  
156  
157  
158  
159  
160  
161  
162  
163  
164  
165  
166  
167  
168  
169  
170  
171  
172  
173  
174  
175  
176  
177  
178  
179  
180  
181  
182  
183  
184  
185  
186  
187  
188  
189  
190  
191  
192  
193  
194  
195  
196  
197  
198  
199  
200  
201  
202  
203  
204  
205  
206  
207  
208  
209  
210  
211  
212  
213  
214  
215  
216  
217  
218  
219  
220  
221  
222  
223  
224  
225  
1,007  
986  
965  
945  
925  
906  
887  
868  
850  
832  
815  
798  
782  
765  
749  
734  
719  
705  
690  
677  
663  
650  
638  
626  
614  
602  
591  
581  
570  
560  
551  
542  
533  
524  
516  
508  
501  
494  
487  
480  
473  
467  
461  
456  
450  
444  
439  
434  
429  
424  
419  
415  
410  
405  
401  
396  
391  
386  
382  
377  
372  
366  
361  
356  
350  
344  
338  
332  
325  
318  
311  
304  
297  
289  
282  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
-
-
-
-
-
-
-
-
-
9
8
79  
80  
7
81  
6
82  
5
83  
4
84  
3
85  
2
86  
1
87  
0
88  
1
89  
2
90  
3
91  
4
92  
5
93  
6
94  
7
95  
8
96  
9
97  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
116  
117  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
137  
138  
139  
140  
141  
142  
143  
144  
145  
146  
147  
148  
149  
150  
9,717  
9,461  
9,213  
8,973  
8,739  
8,511  
8,291  
8,076  
7,868  
7,665  
7,468  
7,277  
34  
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Table 12B — Sensor Temperature (C) vs Resistance  
TEMPERATURE  
(C)  
RESISTANCE  
(OHMS)  
TEMPERATURE  
(C)  
RESISTANCE  
(OHMS)  
TEMPERATURE  
(C)  
RESISTANCE  
(OHMS)  
-32.0  
-31.5  
-31.0  
-30.5  
-30.0  
-29.5  
-29.0  
-28.5  
-28.0  
-27.5  
-27.0  
-26.5  
-26.0  
-25.5  
-25.0  
-24.5  
-24.0  
-23.5  
-23.0  
-22.5  
-22.0  
-21.5  
-21.0  
-20.5  
-20.0  
-19.5  
-19.0  
-18.5  
-18.0  
-17.5  
-17.0  
-16.5  
-16.0  
-15.5  
-15.0  
-14.5  
-14.0  
-13.5  
-13.0  
-12.5  
-12.0  
-11.5  
-11.0  
-10.5  
-10.0  
- 9.5  
- 9.0  
- 8.5  
- 8.0  
- 7.5  
- 7.0  
- 6.5  
- 6.0  
- 5.5  
- 5.0  
- 4.5  
- 4.0  
- 3.5  
- 3.0  
- 2.5  
- 2.0  
- 1.5  
- 1.0  
- 0.5  
0.0  
100 049  
97 006  
94 061  
91 209  
88 449  
85 777  
83 191  
80 687  
78 264  
75 918  
73 648  
71 451  
69 324  
67 265  
65 272  
63 344  
61 477  
59 670  
57 921  
56 228  
54 589  
53 003  
51 467  
49 980  
48 541  
47 148  
45 799  
44 492  
43 228  
42 003  
40 817  
39 668  
38 556  
37 478  
36 435  
35 424  
34 444  
33 495  
32 576  
31 685  
30 821  
29 984  
29 173  
28 386  
27 624  
26 884  
26 168  
25 472  
24 798  
24 144  
23 509  
22 893  
22 296  
21 716  
21 153  
20 606  
20 076  
19 561  
19 061  
18 575  
18 103  
17 645  
17 199  
16 766  
16 346  
15 937  
15 539  
15 153  
14 777  
14 412  
14 057  
13 711  
13 375  
13 048  
12 730  
12 420  
12 119  
11 826  
11 541  
11 263  
10 992  
10 729  
10 472  
10 223  
9 979  
16.0  
16.5  
17.0  
17.5  
18.0  
18.5  
19.0  
19.5  
20.0  
20.5  
21.0  
21.5  
22.0  
22.5  
23.0  
23.5  
24.0  
24.5  
25.0  
25.5  
26.0  
26.5  
27.0  
27.5  
28.0  
28.5  
29.0  
29.5  
30.0  
30.5  
31.0  
31.5  
32.0  
32.5  
33.0  
33.5  
34.0  
34.5  
35.0  
35.5  
36.0  
36.5  
37.0  
37.5  
38.0  
38.5  
39.0  
39.5  
40.0  
40.5  
41.0  
41.5  
42.0  
42.5  
43.0  
43.5  
44.0  
44.5  
45.0  
45.5  
46.0  
46.5  
47.0  
47.5  
48.0  
48.5  
49.0  
49.5  
50.0  
50.5  
51.0  
51.5  
52.0  
52.5  
53.0  
53.5  
54.0  
54.5  
55.0  
55.5  
56.0  
56.5  
57.0  
57.5  
58.0  
58.5  
59.0  
59.5  
60.0  
60.5  
61.0  
61.5  
62.0  
62.5  
63.0  
63.5  
7507  
7334  
7165  
7000  
6840  
6683  
6531  
6382  
6237  
6096  
5959  
5825  
5694  
5566  
5442  
5321  
5203  
5088  
4976  
4867  
4760  
4656  
4555  
4457  
4360  
4267  
4175  
4086  
4000  
3915  
3832  
3752  
3674  
3597  
3523  
3450  
3379  
3310  
3243  
3177  
3113  
3051  
2990  
2931  
2873  
2816  
2761  
2707  
2655  
2603  
2553  
2504  
2457  
2410  
2364  
2320  
2276  
2234  
2192  
2152  
2112  
2073  
2035  
1997  
1961  
1925  
1890  
1856  
1822  
1789  
1757  
1725  
1694  
1663  
1634  
1604  
1575  
1547  
1519  
1492  
1465  
1438  
1412  
1387  
1362  
1337  
1313  
1289  
1265  
1242  
1219  
1197  
1175  
1153  
1132  
1111  
64.0  
64.5  
65.0  
65.5  
66.0  
66.5  
67.0  
67.5  
68.0  
68.5  
69.0  
69.5  
70.0  
70.5  
71.0  
71.5  
72.0  
72.5  
73.0  
73.5  
74.0  
74.5  
75.0  
75.5  
76.0  
76.5  
77.0  
77.5  
78.0  
78.5  
79.0  
79.5  
80.0  
80.5  
81.0  
81.5  
82.0  
82.5  
83.0  
83.5  
84.0  
84.5  
85.0  
85.5  
86.0  
86.5  
87.0  
87.5  
88.0  
88.5  
89.0  
89.5  
90.0  
90.5  
91.0  
91.5  
92.0  
92.5  
93.0  
93.5  
94.0  
94.5  
95.0  
95.5  
96.0  
96.5  
97.0  
97.5  
98.0  
98.5  
99.0  
99.5  
100.0  
100.5  
101.0  
101.5  
102.0  
102.5  
103.0  
103.5  
104.0  
104.5  
105.0  
105.5  
106.0  
106.5  
107.0  
1090  
1070  
1050  
1030  
1011  
992  
973  
955  
937  
919  
902  
885  
868  
852  
836  
820  
805  
790  
775  
761  
746  
733  
719  
706  
693  
681  
669  
657  
645  
634  
623  
613  
602  
592  
583  
573  
564  
556  
547  
539  
531  
524  
516  
509  
502  
496  
489  
483  
477  
472  
466  
461  
456  
451  
446  
441  
436  
432  
427  
423  
419  
415  
410  
406  
402  
398  
393  
389  
385  
380  
376  
371  
367  
362  
357  
352  
346  
341  
335  
330  
324  
318  
312  
305  
299  
292  
285  
0.5  
1.0  
1.5  
2.0  
2.5  
3.0  
3.5  
4.0  
4.5  
5.0  
5.5  
6.0  
6.5  
7.0  
7.5  
8.0  
8.5  
9.0  
9.5  
10.0  
10.5  
11.0  
11.5  
12.0  
12.5  
13.0  
13.5  
14.0  
14.5  
15.0  
15.5  
9 742  
9 512  
9 287  
9 068  
8 855  
8 647  
8 444  
8 247  
8 055  
7 868  
7 685  
35  
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The following Elliott Co. tube rolling tools are required:  
SERVICING COOLER (30HK,HL ONLY)  
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.  
B3400 Expander Assembly  
B3401 Cage  
B3405 Mandrel  
B3408 Rolls  
Place one drop of Loctite No. 675 sealant (or equivalent)  
on top of the tube prior to rolling.  
Tube information:  
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 horizontally adjacent to each of  
the 4 tubes. See Fig. 23. If leakage occurs in any of these  
tubes, plug as described in Tube Plugging section  
below.  
in.  
mm  
• Tube sheet hole diameter . . . . . . . . . . . . 0.631 16.03  
• Tube OD . . . . . . . . . . . . . . . . . . . . . . 0.625 15.87  
• Tube ID after rolling . . . . . . . . . . . . . . 0.581 14.76  
(includes expansion due  
to clearance)  
to  
to  
Tube Plugging — Leaky tube(s) can be plugged until  
retubing can be done. The number of plugged tubes deter-  
mines how soon the cooler must be retubed. If several tubes  
require plugging, check with your local Carrier representa-  
tive to find out how number and location will affect unit  
capacity.  
0.588 14.94  
IMPORTANT: Tubes next to gasket webs must be flush  
with tube sheet (both ends).  
Figure 24 shows an Elliott tube plug and a cross-sectional  
view of a plug in place. Table 13 lists the components for  
plugging.  
Tightening Cooler Head Bolts  
GASKET PREPARATION — When reassembling, use  
new gaskets. Compressed non-asbestos/neoprene gaskets  
(Carrier Material Specification ZA00-32) are to be momen-  
tarily dipped in compressor break-in oil prior to assembly.  
Do not soak gaskets in oil, as gasket deterioration results.  
Use dipped gaskets within 30 minutes to prevent deteriora-  
tion.  
Use extreme care when installing plugs to prevent dam-  
aging the tube sheet sections between holes.  
Clean parts with Locquic ‘‘N’’solution (or equivalent) and  
apply a few drops of Loctite No. 675 sealant (or equivalent)  
to obtain a tight seal without using too much force to set the  
pin.  
Usually plugs can be removed by heating the projecting  
end of pin to approximately 1000 F (538 C) and chilling quickly  
with water. Apply heating flame to side of the pin to prevent  
overheating tube sheet.  
BOLT TORQUES — Apply the following torques during bolt  
tightening sequence described below:  
5
⁄
8-in. 16-mm) diameter flange  
bolts . . . . . . . . . . . . . 150 to 170 ft-lb (203 to 230 N-m)  
1
⁄2-in. (13-mm) diameter center-stud  
nuts . . . . . . . . . . . . . . . . 70 to 90 ft-lb (95 to 122 N-m)  
Bolt Tightening Sequence (Fig. 25) — The recommended  
RETUBING (See Table 13) — When retubing is to be done,  
obtain the service of qualified personnel experienced in boiler  
maintenance and repair. Most standard procedures can be fol-  
lowed when retubing the 10HA coolers. A 6% crush is rec-  
ommended when rolling replacement tubes into the tube sheet.  
A 6% crush can be achieved by setting the torque on the gun  
at 48 to 50 in.-lb (780 to 815 N-m).  
bolt tightening sequence is:  
5
Step 1 — Tighten all  
⁄8-in. (16-mm) flange bolts and  
1
⁄
2-in. (13-mm) center nuts finger tight.  
Step 2 — Following sequence shown in Fig. 25, tighten the  
bolts and nuts to approximately 50% of specified torque.  
Step 3 — Starting at top (12 o’clock) tighten flange bolts to  
specified torque (see Bolt Torques section on this page) con-  
secutively in a clockwise direction.  
Step 4 — Tighten center nuts to specified torque.  
Step 5 — No less than one hour later, retighten center nuts.  
Step 6 — After refrigerant is restored to cooler, check center  
studs and exposed gasket edges for refrigerant leaks with  
soap solution or a Halide device.  
*
*
*
Table 13 — Plugs and Tubes  
COMPONENTS FOR  
PART NUMBER  
PLUGGING  
For Tubes  
Brass Pin  
Brass Ring  
For Holes without Tubes  
Brass Pin  
853103-500*  
853002-570*  
*
853103-1*  
853002-631*  
No. 675†  
‘‘N’’†  
Brass Ring  
Loctite  
Locquic  
*Order directly from Elliott Tube Co., Dayton, Ohio.  
†Can be obtained locally.  
*Four fixed tubes (cannot be removed) identified by adjacent drill points.  
Fig. 23 — Typical Tube Sheet  
36  
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Fig. 24 — Elliott Tube Plug  
after completion of the 5-minute timer cycle unless the re-  
frigerant charge is either very low or lost. If this is the case,  
determine the cause of the loss of charge, correct the prob-  
lem, and recharge the unit before restarting.  
TEMPERATURE CONTROLLER SHUTS UNIT DOWN  
ON OUT-OF-RANGE (See Fig. 21) — Check the ther-  
mistor for an open circuit failure. See Tables 12A and 12B  
for temperature-resistance values. If thermistor is damaged,  
replace it. If thermistor is not damaged, the unit restarts  
automatically after completion of the 5-minute timer cycle,  
and after the leaving cooler chilled fluid temperature  
rises above the upper deadband limit of the temperature  
controller.  
OPEN HIGH-PRESSURE SWITCH(ES) — The unit ser-  
vice light is illuminated. Determine and correct the cause of  
the failure. The switch(es) automatically resets but the unit  
must be manually reset by cycling the control power (move  
ON-OFF switch to OFF, then back to ON). The unit restarts  
after completion of 5-minute timer cycle.  
HEAD BOLT TIGHTENING SEQUENCE  
Fig. 25 — Typical Tube Sheet  
OPEN COMPRESSOR INTERNAL THERMAL PROTEC-  
TION (30HW UNITS) — This is compressor overtempera-  
ture protector on 30HW018 units and the discharge gas ther-  
mostat (DGT) on 30HW025-040 units. The unit service light  
is illuminated. Determine and correct cause of problem. The  
switch resets automatically but unit must be reset by cycling  
the control power (move ON-OFF switch to OFF, then back  
to ON). The unit restarts after completion of 5-minute timer  
cycle.  
TROUBLESHOOTING  
Complete Unit Stoppage and Restart — Pos-  
sible causes for unit stoppage and reset methods are (also  
see Table 14):  
GENERAL POWER FAILURE — After power is restored,  
restart is automatic through the normal timer cycle.  
OPEN OIL PRESSURE SWITCH — If oil pressure switch(es)  
opens for more than 2 minutes during unit operation, the unit  
shuts down and is locked off. The unit service light is illu-  
minated. Determine and correct cause of failure. Unit must  
be reset by cycling the control power (move ON-OFF switch  
to OFF, then back to ON). Unit restarts after completion of  
5-minute timer cycle.  
UNIT ON-OFF SWITCH IS OPEN — When the switch is  
opened, the unit stops immediately. If the switch is closed  
immediately after it was opened, the unit restarts automati-  
cally after the 5-minute timer cycle is completed. If the switch  
is closed after an extended off-period, the unit restarts au-  
tomatically in approximately 3 seconds.  
CONTACTS OF ANY AUXILIARY INTERLOCKS ARE  
OPEN — After the problem has been corrected, restart is  
automatic after completion of the 5-minute timer cycle.  
OPEN CONTACTS ON COMPRESSOR GROUND-  
CURRENT SENSOR(S) (Accessory) — The light-emitting  
diode (LED) on the ground current accessory board (located  
in field control wiring section of control box) is illuminated.  
See Fig. 17-20. Unit service light is also illuminated. Check  
the compressor motor windings for a short to ground.  
Determine and correct cause of the failure. The unit must be  
reset by cycling the control power (move ON-OFF switch to  
OFF, then back to ON). Unit restarts after completion of the  
5-minute timer cycle.  
CHILLED FLUID PROOF-OF-FLOW SWITCH(ES) OPEN  
— After the problem causing the loss of flow has been cor-  
rected, restart is automatic after completion of the 5-minute  
timer cycle.  
OPEN LOW-PRESSURE SWITCH — If a low-pressure switch  
remains open for more than 2 minutes during unit operation,  
the compressor(s) shuts down and is locked off. The unit ser-  
vice light is illuminated. Determine and correct the cause of  
the failure. The switch automatically resets, but the unit must  
be manually reset by cycling the unit control power (move  
the ON-OFF switch to OFF, then to ON). The unit restarts  
OPEN 24-V CONTROL CIRCUIT BREAKER(S) — De-  
termine the cause of the failure and correct. Reset circuit  
breaker(s). Restart is automatic after completion of 5-minute  
timer cycle.  
37  
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COOLING LOAD SATISFIED — Unit shuts down if cool-  
ing load is satisfied. Unit restarts if required after comple-  
tion of 5-minute timer cycle.  
NOTE: If the thermistor fails in closed mode, the tempera-  
ture controller keeps trying to load up.  
THERMISTOR FAILURE — 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 completion of a 5-minute timer cycle, and  
when the leaving cooler chilled fluid temperature rises above  
the upper deadband limit of the temperature controller.  
If unit stoppage occurs more than once as a result of  
any of the safety devices listed, determine and correct  
cause before attempting another restart.  
Table 14 — Troubleshooting  
SYMPTOMS  
CAUSE  
REMEDY  
Compressor does  
not run  
Power line open  
Reset circuit breaker.  
Control fuse or circuit breaker opens  
Check control circuit for ground or short. Reset breaker  
and replace fuse.  
Compressor overtemperature sensor open  
Tripped power breaker  
Find cause of high temperature and reset controls.  
Check the controls. Find the cause of trip and  
reset breaker.  
Condenser circulating pump not running  
Power off — restart.  
Pump binding — free pump.  
Incorrect wiring — rewire.  
Pump motor burned out — replace.  
Check connections.  
Loose terminal connection  
Improperly wired controls  
Low line voltage  
Check wiring and rewire if necessary.  
Check line voltage — determine location of voltage drop  
and remedy deficiency.  
Compressor motor defective  
Check motor winding for open or short. Replace  
compressor if necessary.  
Seized compressor  
Replace compressor.  
Compressor cycles  
off on loss of  
charge  
Loss of charge control erratic in action  
Repair leak and recharge.  
Replace control.  
Low refrigerant charge  
Add refrigerant.  
Low suction temperature  
Raise cooler leaving fluid temperature set point.  
Replace valve plate.  
Compressor suction valve leaking  
Plugged compressor suction strainer  
Clean or replace strainer.  
Compressor suction shutoff valve partially closed Open valve.  
Compressor cycles  
off on out of range  
condition  
Thermistor failure  
Replace thermistor.  
System load was reduced faster than  
controller could remove stages  
Unit will restart after fluid temperature rises back into the  
control band. Avoid rapidly removing system load.  
Compressor cycles control Temperature controller deadband setting is  
Raise deadband setting.  
steps rapidly  
too low  
Compressor shuts  
down on high-  
pressure control  
High-pressure control acting erratically  
Compressor discharge valve partially closed  
Air in system  
Replace control.  
Open valve or replace (if defective).  
Purge system.  
Condenser scaled/dirty  
Clean condenser.  
Receiver not properly vented — refrigerant  
backs up into evaporator condenser  
Repipe as required to provide adequate venting.  
Condenser water pump or fans not operating  
System overcharged with refrigerant  
Low refrigerant charge  
Start pump — repair or replace if defective.  
Reduce charge.  
Unit operates too long  
or continuously  
Add refrigerant.  
Control contacts fused  
Replace control.  
Air in system  
Purge system.  
Partially plugged or plugged expansion valve  
or filter drier  
Clean or replace as needed.  
Defective insulation  
Service load  
Replace or repair as needed.  
Keep doors and windows closed.  
Check valves, and replace if necessary.  
Support piping as required.  
Inefficient compressor  
Piping vibration  
Unusual or loud system  
noises  
Check for loose pipe connections.  
Add refrigerant.  
Expansion valve hissing  
Compressor noisy  
Check for plugged liquid line filter drier.  
Check valve plates for valve noise.  
Replace compressor (worn bearings).  
Check for loose compressor holddown bolts.  
38  
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Table 14 — Troubleshooting (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 contacts on the  
temperature controller, and replace heater if necessary.  
Hot liquid line  
Shortage of refrigerant due to leak  
Shutoff valve partially closed or restricted  
Restricted filter drier  
Repair leak and recharge.  
Open valve or remove restriction.  
Replace filter drier.  
Frosted liquid line  
Frosted suction line  
Expansion valve admitting excess refrigerant  
Burned-out coil  
Adjust expansion valve. Replace valve if defective.  
Replace coil.  
Compressor will  
not unload  
Defective capacity control valve  
Miswired solenoid  
Replace valve.  
Rewire correctly.  
Weak, broken, or wrong valve body spring  
Miswired solenoid  
Replace spring.  
Compressor will  
not load  
Rewire correctly.  
Defective capacity control valve  
Plugged strainer (high side)  
Stuck or damaged unloader piston or piston ring(s)  
Piping vibration  
Replace valve.  
Clean or replace strainer.  
Clean or replace the necessary parts.  
Support piping as required.  
Check for loose pipe connectors.  
Add refrigerant.  
System noises  
Expansion valve hissing  
Compressor noisy  
Check for plugged liquid line strainer.  
Check valve plates for valve noise.  
Replace compressor (worn bearings).  
Check for loose compressor holddown bolts.  
Freeze-up  
Improper charging  
Make sure a full quantity of fluid is flowing through the  
cooler while charging, and suction pressure in cooler is  
equal to or greater than pressure corresponding to 32 F  
(0° C) (58 psig [400 kPa] for Refrigerant 22).  
Improperly set safety thermostat  
Check safety thermostat for proper setting at beginning of  
each season.  
Operating with safety thermostat bypassed  
Improper circulation of condenser water  
If thermostat was bypassed for checking, be sure it is back  
in circuit before starting unit.  
Use adequately sized cleanable strainer in the condenser  
water circuit. Make sure strainer is clean. It may sometimes  
be necessary to chemically treat the water to prevent for-  
mation of deposits.  
System not drained for winter shutdown  
Loose Thermistor  
Remove drain plugs at end of cooling season. Blow out any  
residual water. Instead of draining, a suitable anti-freeze  
may be added to the water. Damage to chiller due to freez-  
ing is considered abuse and is not covered by warranty.  
Tighten thermistor to pipe and reinsulate (30HW).  
39  
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SERVICE TRAINING  
Packaged Service Training 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-  
mats and materials. All include video and/or slides, plus companion book.  
Classroom Service Training which includes ‘‘hands-on’’ experience with the products in our labs can  
mean increased confidence that really pays dividends in faster troubleshooting and fewer callbacks.  
Course descriptions and schedules are in our catalog.  
CALL FOR FREE CATALOG 1-800-962-9212  
[
] Packaged Service Training  
[
] Classroom Service Training  
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  
PC 903  
Catalog No. 533-070  
Printed in U.S.A.  
Form 30H-10SI  
Pg 40  
11-98  
Replaces: 30H-8SI  
Tab 5c  
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START-UP CHECKLIST FOR CHILLER SYSTEMS  
(Remove and use for job file)  
A. Preliminary Information  
JOB NAME  
LOCATION  
INSTALLING CONTRACTOR  
DISTRIBUTOR  
START-UP PERFORMED BY  
EQUIPMENT:  
Chiller:  
MODEL #  
SERIAL #  
COMPRESSORS:  
CIRCUIT #1  
CIRCUIT #2 (30HK,HL ONLY)  
MODEL #  
SERIAL #  
MOTOR #  
MODEL #  
SERIAL #  
MOTOR #  
CONDENSER (30HK, HWB, HWC, HWS ONLY):  
MODEL #  
SERIAL #  
COOLER:  
MODEL #  
SERIAL #  
MANUFACTURED BY  
DATE  
AIR-HANDLING EQUIPMENT:  
MANUFACTURER  
MODEL #  
SERIAL #  
ADDITIONAL AIR-HANDLING UNITS AND ACCESSORIES  
B. Preliminary Equipment Check (YES or NO)  
IS THERE ANY SHIPPING DAMAGE?  
IF SO, WHERE  
WILL THIS DAMAGE PREVENT UNIT START-UP?  
CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT?  
HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)  
ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (refer to Installation Instructions)  
HAS THE GROUND WIRE BEEN CONNECTED?  
ARE ALL TERMINALS TIGHT?  
ON 30HW UNITS, IS THE THERMISTOR SECURELY STRAPPED TO THE COOLER LEAVING CHILLED FLUID LINE, AND  
IS IT PROPERLY INSULATED?  
ON 30HW UNITS, IS YELLOW WIRE GOING TO TRANSFORMER 1 (POWER TRANSFORMER) ON THE CORRECT  
TERMINAL (TERMINAL H2 FOR 208 V AND 575 V; TERMINAL H3 FOR 230 V, 380 V, AND 400 V, TERMINAL H4  
FOR 460 V)?  
IF UNIT IS A MEDIUM TEMPERATURE BRINE UNIT, IS TEMPERATURE CONTROLLER SET FOR BRINE AND NOT  
FOR WATER? IF UNIT IS NOT A BRINE UNIT, IS TEMPERATURE CONTROLLER SET FOR WATER AND NOT FOR  
BRINE?  
HAVE TEMPERATURE CONTROLLER, CONTROL MODULE AND CONTROL RELAY CONNECTIONS BEEN CHECKED  
FOR TIGHTNESS?  
Manufacturer reserves the right to discontinue, or change at any time, specifications 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 CL-1  
11-98  
Replaces: 30H-8SI  
Tab 5c  
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B. Preliminary Equipment Check (YES or NO) (cont)  
HAVE POWER SIDE ELECTRICAL COMPONENT CONNECTIONS BEEN CHECKED FOR TIGHTNESS?  
ON 30HK,HL UNITS, IS THE PROPER CONTROL VOLTAGE SUPPLIED TO TB2-1 AND TB2-3?  
ON 30HK,HL 50 HZ UNITS, IS THE BLACK WIRE GOING TO TRAN1 AND TRAN2 CONNECTED TO THE RED LEAD FROM  
THE TRANSFORMER?  
CHECK AIR SYSTEMS (YES OR NO)  
ARE ALL AIR HANDLERS OPERATING? (refer to air-handling equipment Installation and Start-Up Instructions)  
ARE ALL CHILLED FLUID VALVES OPEN?  
IS THE FLUID PIPING CONNECTED PROPERLY?  
HAS ALL AIR BEEN VENTED FROM THE COOLER LOOP?  
IS THE CHILLED WATER (FLUID) PUMP (CWP) OPERATING?  
IS THE CWP ROTATION CORRECT?  
CWP MOTOR AMPERAGE:  
Rated  
Actual  
C. Unit Start-Up (insert check mark as each item is completed)  
HAS THE CHILLER BEEN PROPERLY INTERLOCKED WITH THE AUXILIARY CONTACTS OF THE CONDENSER  
WATER PUMP STARTER?  
ASSURE THAT UNIT IS SUPPLIED WITH CORRECT CONTROL VOLTAGE POWER.  
ASSURE CRANKCASE HEATERS HAVE BEEN ENERGIZED FOR A MINIMUM OF 24 HOURS PRIOR TO  
START-UP.  
ASSURE COMPRESSOR OIL LEVEL IS CORRECT.  
ASSURE LIQUID LINE SERVICE VALVE(S) IS BACKSEATED.  
ASSURE COMPRESSOR DISCHARGE SERVICE VALVE(S) IS BACKSEATED.  
ASSURE COMPRESSOR SUCTION SERVICE VALVE(S) IS BACKSEATED.  
LOOSEN COMPRESSOR SHIPPING ISOLATOR LOCKNUTS.  
OPEN GAGE PANEL SERVICE VALVES.  
BE SURE TEMPERATURE CONTROLLER DEADBAND AND SAMPLE RATE SETTINGS ARE SET.  
SET POINT SHOULD BE ADJUSTED TO THE DESIRED COOLER LEAVING FLUID TEMPERATURE. (refer to installation  
instructions)  
LEAK CHECK THOROUGHLY: COMPRESSOR(S), CONDENSER FITTINGS, TXV(s), SOLENOID VALVE(S), FILTER  
DRIER(S), FUSIBLE PLUG(S), AND COOLER HEAD(S), WITH GENERAL ELECTRIC H-10-B ELECTRONIC LEAK  
DETECTOR.  
LOCATE, REPAIR, AND REPORT ANY R-22 LEAKS.  
CHECK VOLTAGE IMBALANCE:  
AB  
AC  
BC  
V
AB + AC + BC (divided by 3) = AVERAGE VOLTAGE =  
MAXIMUM DEVIATION FROM AVERAGE VOLTAGE  
(MAX. DEVIATION)  
=
VOLTAGE IMBALANCE =  
x 100 =  
% VOLTAGE IMBALANCE  
AVERAGE VOLTAGE  
IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START CHILLER!  
CALL LOCAL POWER COMPANY FOR ASSISTANCE.  
ASSURE THAT INCOMING POWER VOLTAGE TO CHILLER IS WITHIN RATED UNIT VOLTAGE RANGE.  
SYSTEM FLUID VOLUME IN LOOP:  
TYPE SYSTEM:  
AIR CONDITIONING — MINIMUM 3 GAL. (3.25 L) PER NOMINAL TON (kW) =  
PROCESS COOLING — MINIMUM 6 GAL. (6.5 L) PER NOMINAL TON (kW) =  
GAL. (L)  
GAL. (L)  
CL-2  
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C. Unit Start-Up (cont)  
COOLER LOOP PROTECTION IF REQUIRED:  
GALLONS (LITERS) OF BRINE ADDED:  
PIPING INCLUDES ELECTRIC TAPE HEATERS.  
CHECK PRESSURE DROP ACROSS COOLER.  
FLUID ENTERING COOLER:  
PSIG (kPa)  
PSIG (kPa)  
FLUID LEAVING COOLER:  
(PSIG DIFFERENCE) x 2.31 = FT OF FLUID PRESSURE DROP =  
(kPa DIFFERENCE) x .335 = FT OF FLUID PRESSURE DROP =  
PLOT COOLER PRESSURE DROP ON PERFORMANCE DATA CHART (LOCATED IN PRODUCT DATA LITERATURE) TO  
DETERMINE TOTAL GPM (L/s).  
TOTAL GPM (L/s) =  
UNIT’S RATED MIN. GPM (L/s)  
=
GPM (L/s) PER TON =  
UNIT’S RATED MIN. PRESSURE DROP =  
(Refer to product data literature.)  
JOB’S SPECIFIED GPM (L/s) (if available)  
NOTE: IF UNIT HAS LOW FLUID FLOW, FIND SOURCE OF PROBLEM: CHECK FLUID PIPING, IN-LINE FLUID STRAINER,  
SHUT-OFF VALVES, CHILLED FLUID PUMP ROTATION, ETC.  
COOLER LOOP PROTECTION:  
GAL. (L) OF BRINE ADDED (IF REQUIRED).  
IN-LINE WATER STRAINER INSTALLED ADJACENT TO COOLER FLUID INLET. (REQUIRED FOR 30HW COOLERS.)  
YES  
NO  
CONDENSER PROTECTION:  
IN-LINE MINIMUM 20-MESH STRAINER INSTALLED ADJACENT TO THE CONDENSER WATER INLET.  
YES  
NO  
TO START THE CHILLER: (insert check mark as each item is completed)  
PLACE ON-OFF SWITCH IN THE ON POSITION.  
ASSUMING THERE IS A CALL FOR CHILLED FLUID, THE COMPRESSOR WILL START UNLOADED AFTER A 6-SECOND  
TO 5-MINUTE DELAY (DEPENDING ON THE TIMING LOGIC).  
THE LOW-PRESSURE SWITCH (ALL UNITS) AND OIL-PRESSURE SWITCH (30HL, HWA UNITS — ACCESSORY ON 30HK,  
HWB, HWC, HWS UNITS) ARE BYPASSED FOR 2 MINUTES.  
IF ADDITIONAL CAPACITY IS REQUIRED AFTER THE 2-MINUTE PERIOD, COMPRESSOR WILL LOAD UP.  
MEASURE THE FOLLOWING: WHILE MACHINE IS IN STABLE OPERATING CONDITION.  
SUCTION PRESSURE  
SUCTION LINE TEMP.  
SUCTION SUPERHEAT  
DISCHARGE PRESSURE  
DISCHARGE LINE TEMP.  
DISCHARGE SUPERHEAT  
CHECK AND ADJUST SUCTION SUPERHEAT (9 to 11 F [5 to 6 C]).  
CL-3  
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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  
PC 903  
Catalog No. 533-070  
Printed in U.S.A.  
Form 30H-10SI  
Pg CL-4  
11-98  
Replaces: 30H-8SI  
Tab 5c  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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