Filter
Top Products
Installation, Start-Up and
Service Instructions
CONTENTS
Page
GENERAL ....................................2
SAFETY CONSIDERATIONS .....................2
INSTALLATION ..............................3-25
Location ......................................3
Step 1 — Inspect Shipment .....................3
Step 2 — Rig the Unit ..........................3
• 30HK,HL UNITS
• 30HW UNITS
Step 3 — Place the Unit
........................3
•
30HK,HL UNITS
• 30HW UNITS
Step 4 — Check Compressor Mounting and
Connections
..................................3
Step 5 — Make Piping Connections .............13
• 30HK,HWC,HWS CONDENSER DESCRIPTION
• 30HL,HWA SYSTEM CONDENSER
• 30HWB CONDENSER DESCRIPTION
• 30HK,HWC,HWS CONDENSER(S)
• 30HWB CONDENSER
• 30HK,HWB,HWC,HWS UNITS
• COOLER DESCRIPTION
• COOLER PIPING
Step 6 — Make Electrical Connections
...........19
• 30HK,HL UNITS
• 30HW UNITS
• ALL UNITS
PRE-START-UP
.............................25-27
Initial Check .................................25
Check Refrigerant Charge .....................26
• LIQUID CHARGING METHOD
Check Oil Charge
.............................27
• TO ADD OIL
• TO REMOVE OIL
START-UP AND OPERATION ..................27-30
Operation Checks ............................27
Operating Limitations .........................27
• HIGH COOLER LEAVING CHILLED WATER (FLUID)
TEMPERATURES (LCWT)
• LOW COOLER LCWT
• MAIN POWER SUPPLY
Check Refrigerant Feed Components
............27
• THERMOSTATIC EXPANSION VALVE (TXV)
• FILTER DRIER
• MOISTURE-LIQUID INDICATOR
• LIQUID LINE SERVICE VALVE
• DISCHARGE LINE CHECK VALVE
• HOT GAS BYPASS VALVE
• LIQUID LINE SOLENOID VALVE (30HL ONLY)
• PRESSURE RELIEF DEVICES
Compressor and Unit Protective Devices
.........28
• CIRCUIT BREAKER
• COMPRESSOR INTERNAL THERMAL PROTECTION
• CRANKCASE HEATER
• OIL PRESSURE SAFETY SWITCH (OPS)
Check Unit Safeties
...........................28
•
CONTROL MODULE
• HIGH-PRESSURE SWITCH
• LOW-PRESSURE SWITCH
• CHILLED FLUID TEMPERATURE CONTROLLER
• FREEZE-UP PROTECTION
• LOSS-OF-COOLER-FLOW PROTECTION
• COMPRESSOR GROUND FAULT SENSOR
UNIT OPERATION
...........................30-32
Capacity Control and Operating Sequence .......30
• 30HK,HL UNITS
• 30HW UNITS
SERVICE
..................................32-35
Compressor Replacement ......................32
Circuit Breaker(s) .............................32
Brazed-Plate Cooler and Condenser
Heat Exchanger Replacement .................32
Brazed-Plate Cooler and Condenser
Heat Exchanger Cleaning .....................32
Shell-and-Tube Condenser Cleaning .............32
Thermistor ...................................33
• THERMISTOR REPLACEMENT, 30HK,HL UNITS
• THERMISTOR REPLACEMENT, 30HW UNITS
SERVICING COOLER (30HK,HL ONLY)
.........36,37
Tube Plugging ...............................36
• RETUBING
Tightening Cooler Head Bolts
..................36
• GASKET PREPARATION
• BOLT TORQUES
TROUBLESHOOTING
........................37-39
Complete Unit Stoppage and Restart ............37
• GENERAL POWER FAILURE
• UNIT ON-OFF SWITCH IS OPEN
• CONTACTS OF ANY AUXILIARY INTERLOCKS ARE
OPEN
• CHILLED FLUID PROOF-OF-FLOW SWITCH(ES) OPEN
• OPEN LOW-PRESSURE SWITCH
• TEMPERATURE CONTROLLER SHUTS UNIT DOWN ON
OUT-OF-RANGE
• OPEN HIGH-PRESSURE SWITCH(ES)
• OPEN COMPRESSOR INTERNAL THERMAL
PROTECTION
• OPEN OIL PRESSURE SWITCH
• OPEN CONTACTS ON COMPRESSOR GROUND-
CURRENT SENSOR(S) (Accessory)
• OPEN 24-V CONTROL CIRCUIT BREAKER(S)
• COOLING LOAD SATISFIED
• THERMISTOR FAILURE
START-UP CHECKLIST FOR
CHILLER SYSTEMS
...................CL-1 to CL-4
30HK040-060
30HL050,060
30HW018-040
Reciprocating Liquid Chillers
50/60 Hz
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 533-070 Printed in U.S.A. Form 30H-10SI Pg 1 11-98 Replaces: 30H-8SI