Reciprocating Flotronic™ Liquid Chillers 50 Hz & 60 Hz, Domestic and Export CONTENTS Page el SAFETY CONSIDERATIONS . INSTALLATION ... Step 1 — Rig and Place the Unit . ‘Step 2 — Check Compressor Mounting . ‘Step 3 — Make Chilled Water and Drain jing Connections ... © WATER TREATMENT © PREPARATION FOR WINTER Step 4 — Make Electrical Connections ... 2 © POWER SUPPLY © FIELD POWER CONNECTION Step 5 — Install Accessories ELECTRICAL © WIND BAFFLES PRE-START-UP .. 9 System Check (Steps 1-9) +9 Quick Test (Step 10) .... 212 START-UP AND OPERATION “7 igital Display 7 Actual Start-Up 7 Operating Limitations . Operation Sequence ... SERVICE iagnostics and Troubleshooting . Refrigerant Circuit . Electronic Components . Compressors .. Cooler ... : Condenser Coils - Condenser Fans Refrigerant Feed Components: Thermistors Safety Devices Relief Devices ...... Other Safeties -- © Carrier Corporation 1984 SAFETY CONSIDERATIONS Installation, start-up and servicing of this equip- ment can be hazardous due to system pressures, electrical components and equipment location (roofs, elevated structures, etc.) Only trained, qualified installers and service mechanics should install, start-up and service this, equipment. Untrained personnel can perform basic mainte- nance functions of cleaning coils, All other opeta- tions should be performed by trained service personnel When working on the equipment, observe pre- cautions in the literature, tags, stickers and labels attached to the equipment and any other safety precautions that apply. © Follow all safety codes, © Wear safety glasses and work gloves. © Use care in handling, rigging and setting bulky equipment, INSTALLATION Step 1 — Rig and Place the Unit — These units are designed for overhead rigging and it isimportant that this method be used. Holes are provided in the frame base channels, marked for rigging see rigging label on unit). It is recommended that field-supplied pipes be passed through these holes, extending beyond the frame enough to attach cables or chains on both sides. Use spreader bars or frame to keep cables or chains clear of the unit sides. As a further precaution, sheets of plywood placed along the coils will provide additional protection. For shipping, the unit is mounted on wood rails which are under the lengthwise members of the frame base. These can be removed before the unit is moved to the installation-area. Lift from above to remove rails. Form 3068-1381If overhead equipment is not available, the unit can be moved on rollers or skidded. When unit is moved on rollers, the shipping rails must be re- moved. To lift the unit, use jacks at the rigging points. Use a minimum of 3 rollers to distribute the load. If unit is to be skidded, lift as prescribed above and place a pad under the base. When dragging, apply force 10 the pad, not the unit The placement area must be level and strong enough to support the operating weight of the unit (sce Tables 1 and 2). Unit must have clearances as listed in Fig. 1, 2, 3 and 4. When in final position, level the unit with a spirit level and bolt at points shown. Step 2 — Check Compressor Mounting — In each circuit, the compressors are mounted on rails. Each rail is mounted on springs, one at each end and one between each 2 compressors. For shipping, the rails are secured to the frame base at each support On some units, compressor feet are spring mounted. AL installation, remove the nut at each mounting spring to be sure that the compressor-rail assembly floats freely on the springs. Figures 5 and 6 show the front and rear views of the compressor mounting, ‘Step 3— Make Chilled Water and Drain Piping Connections — When facing the cooler side of unit, the inlet (return) chilled water connection is at the right (nearest to the main control box) and. the leaving (supply) water connection is at the left. At installation, holes must be cut in the metal sereen for field piping and insulation To isolate the cooler for servicing, shutoff valves should be installed in the leaving and return chilled water lines as near the cooler as possible. At the highest point in the chilled water circuit, install an air-trap vent. After field piping has been completed, all piping that is exposed to low ambient temperature should bbe wrapped with electric heating tape with a rating auitable for the area ambients, and covered with a suitable thickness of closed cell insulation, Bring the power for the heating tape(s) from a separate fused disconnect. Identify the disconnect as the power source for the pipe heater(s), with emphasis that it must never be turned off except when the unit is being serviced. A drain connection is located at the leaving-water end of the cooler (see Fig. I, 2, 3 and 4), WATER TREATMENT If the unit is on year-round operation, add sufficient ethylene glycol to the chilled water to prevent freezing under the operating ambient conditions. Consult the local water authority on the char- acteristics of the area water and add a recommended inhibitor to the chilled water. PREPARATION FOR WINTER Do not shut off control power disconnect during off-season shutdown, At the efad of she cooling season, drain the water from the system. Replace the drain plug and put 2 gallons (8 liters) of ethylene glycol in the cooler to prevent freezing of residual water. Remove the plug on top of the leaving chilled water nozzle to add the glycol. At the beginning of the next cooling season, refill the cooler and add the recommended inhibitor, Step 4 — Make Electrical Connections POWER SUPPLY Blectrical characteristics of available power supply must agree with unit nameplate rating, Supply voltage must be within the limits shown in Tables 3 and 4 Refer to Operation Limitations section for information on power supply. FIELD POWER CONNECTIO! All power wiring must comply with applicable local and national codes. Install field-supplied branch circuit fused disconnect(s) of a type that can be locked OFF or OPEN. Disconnect(s) must be located within sight from and readily ac sible from the unit in compliance with NEC Article 440-14 All field power enters the unit through control box at left end when unit is viewed facing the com- pressors. This is the main control box on 30GBI10- 200 (the only box on 30GBO75-100). Entrance into the unit is through holes in corner post (see Fig. 1, 2, 3 and 4), Refer to Fig. 7 for field wiring details, Main Power — All units have single-point power connection to simplify field-power wiring (all power enters unit at oneend). The maximum wire size these units can accept per terminal block is 500 MCM. Main power conductors for 208/230-volt 30GB200 units must be copper-only to meet National Elec~ trical Code (NEC) requirements, All other units may use copper, copper-clad aluminum or aluminum conductors at all voltages. For units requiring larger than 500. MCM con- ductors, power must be supplied as follows (see Fig. 7) 208-230/3/60 Units 30GBO75-100 — Unit has 2 terminal blocks and requires 6 parallel conductors from the fused disconnect 30GB110-200 — Unit has 3 terminal blocks and requires 9 parallel conductors from the fused disconnect 380/360 Units 30GBO75-100 — Unit has one terminal block and has 3 conductors from the fused disconnect. 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