90RMC050-D-610_REV- Carrier Operation and Maintenance Manual.pdf

90RMC050-D-6

Sea Water Cooled Condenser, Reciprocating Liquid Chillers With ComfortLink™ Controls

Operating & Maintenance Manual

CARRIER TRANSICOLD MODEL

90RMC050-D-610

R-134A SEAWATER COOLED CHILLER

50 TONS (175.8 kW) NOMINAL

COOLING CAPACITY

CARRIER TRANSICOLD DIVISION

CARRIER CORPORATION

MARINE SYSTEMS GROUP

CARRIER PARKWAY BLDG TR-20

P.O. BOX 4805

SYRACUSE, NY 13221

UNIT Model: 90RMC050-D-610

UNIT Serial No: J38366CH22061

CTD JOB NO.: 131-J38-366

CUSTOMER: HILL MARINE

MANUAL #974 REV. - RELEASED, 5/2/2024

WARNING -- This document contains technical data the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations (EAR), 15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export, reexport, transfer or re-transfer of this technical data to any other company, entity, person, or destination, or for any use or purpose other than that for which the technical data was originally provided by Carrier, is prohibited without prior written approval from Carrier and authorization under applicable export control laws.

EAR Export Classification: ECCN 1B999.d

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment. When working on this equipment, observe precautions in the literature, and on 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 this equipment, and in handling all electrical components.

WARNING

Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service. There may be more than one disconnect switch. Tag all disconnects locations to alert others not to restore power until work is completed.

WARNING

DO NOT attempt to un-braze factory joints when servicing this equipment. Compressor oil is flammable and there is no way to detect how much oil may be in any of the refrigerant lines. Cut lines with a tubing cutter as required when performing service. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to system. DO NOT re-use compressor oil. Do NOT leave refrigerant system open to air any longer than necessary. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed

WARNING

To prevent potential damage to heat exchanger tubes always run fluid through heat exchangers when adding or removing refrigerant charge. Use appropriate brine solutions in cooler loop to prevent the freezing of heat exchangers when the equipment is exposed to temperatures below 32 o F (0 o C).

DO NOT VENT refrigerant relief valves within a building. Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE (American National Standards Institute/American Society of Heating, Refrigeration and Air Conditioning Engineers) 15 (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas.

Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing.

Product causes eye and skin irritation.

Decomposition products are hazardous.

WARNING

This unit uses a microprocessor-based electronic control system. Do not use jumpers or other tools to short out components, or to bypass or otherwise depart from recommended procedures. Any short-to-ground of the control board or accompanying wiring may destroy the electronic modules or electrical components.

PROVIDE ADEQUATE VENTILATION in accordance with ANSI/ASHRAE 15 or any applicable ships registration society. Inhalation of high concentrations of vapor is harmful and may case heart irregularities, unconsciousness, or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize equipment for any purpose. Oxygen reacts violently with oil, grease and other common substances.

Subject to the export control restrictions on the first page of this document.

NEVER EXCEED SPECIFIED TEST

PRESSURES, verify the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate. A table providing refrigerant temperature - pressure data is provided immediately following this safety consideration listing. Information on the refrigerant used in this application is provided in Appendix B.

DO NOT USE AIR FOR LEAK TESTING. Use only refrigerant or dry nitrogen.

DO NOT VALVE OFF ANY SAFETY DEVICE.

BE SURE THAT ALL PRESSURE RELIEF

DEVICES ARE PROPERLY INSTALLED AND

FUNCTIONING before operating equipment.

RISK OF INJURY OR DEATH BY

ELECTROCUTION. High voltage is present in motor leads even though the motor is not running when a solid-state or inside-delta mechanical starter is used. Open the power supply disconnect before touching motor leads or terminals.

WARNING

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed. Traces of vapor should be displaced with nitrogen and the work area should be well ventilated.

Refrigerant in contact with an open flame produces toxic gases.

DO NOT use eyebolt holes to rig unit sections or the entire assemblies.

WARNING

DO NOT work on high-voltage equipment unless you are a qualified electrician.

DO NOT work on electrical components, including control panel, switches, starters, or oil heater until you are sure all power is off and no residual voltage can leak from capacitors or solid-state components.

LOCK OPEN AND TAG electrical circuits during servicing. If work is interrupted, confirm that all circuits are de-energized before resuming work.

DO AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. Use safety goggles.

Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, immediately flush eyes with water and consult a physician.

NEVER APPLY AN OPEN FLAME OR LIVE

STEAM TO A REFRIGERANT CYLINDER.

Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110ºF [43ºC] ) water.

DO NOT REUSE DISPOSABLE

(NONRETURNABLE) CYLINDERS or attempt to refill them. It is dangerous and illegal. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar and unscrew and discard the valve stem. Do not incinerate.

CHECK THE REFRIGERANT TYPE BEFORE

ADDING REFRIGERANT. The introduction of the wrong refrigerant can cause damage or malfunction. Operation of this equipment with refrigerants other than those cited herein is not to be allowed. Information on the refrigerant used in this application is provided in Major Component Specifications. Contact Carrier for information on use of this equipment with other refrigerants.

DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while equipment is under pressure or while equipment is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief devices, rupture discs, and other relief devices at least once a year. If equipment operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR

RECONDITION ANY RELIEF DEVICE when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the device.

DO NOT install relief devices in series or backwards.

CAUTION

DO NOT step on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury

DO NOT climb on equipment. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements can engage the starter, or pumps. Open disconnect ahead of the starter, or pumps.

USE only repair or replacement parts that meet the code requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

PROVIDE A REMOVABLE DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rainwater.

During Piping Connecting. Applying current to the grounded side of this machine could cause damage to electronic devices such as temperature sensors, pressure transducers sensitive electronic boards and other microprocessor devices. If weld repairs are necessary, all electronic devices mentioned should be removed or isolated from the machine. It is recommended that welded components such as piping flanges be unbolted and welded away from the machine then re-bolted to the machine.

REFRIGERANT LINE BREAKAGE.

In the unlikely event of a refrigerant line break, operators should evacuate all personnel from the affected space. Refrigerant in enclosed spaces will displace air and could lead to oxygen deficiency, which could cause asphyxiation. Area should be sealed off. Air in this space should be exhausted to outdoors and fresh make-up air should be piped in. The area should not be entered until it has been deemed safe by authorized personnel.

CONTENTS

SAFETY CONSIDERATIONS

CONTENTS

FIGURES

Tables

GENERAL

MAJOR SYSTEM COMPONENTS

General Main Base Board (MBB) Scrolling Marquee Display Compressor Expansion Board (CXB) Start Interlock Switch, SW3 Enable/Off/Remote Contact Switch, SW1.8 Emergency On/Off Switch, SW2 Board Addresses Control Module Communication Compressor Cooler Assembly Condenser Assembly Oil Safety Switch Compressor Ground Fault Sensor Non-Fused Disconnect Water Regulating Valve Carrier Comfort Network (CCN) Interface...10

MAJOR COMPONENT SPECIFICATIONS ...13

Chiller Compressor Cooler Assembly Condenser Assembly High Pressure Switch Low Pressure Switch Oil Safety Switch Pressure Relief Valve, Condenser Rupture Disc, Condenser Compressor Contactor (C-A1 & C-B1) Compressor Circuit Breaker (CB-A1 & CB- B1) Non – Fused Disconnect Switch Solenoid Coil (LLSV-A & LLSV-B) Solenoid Coil (UL1-A1, UL1-B1, UL2-A1 &

UL2-B1)

Zinc Anodes, Condenser Transformer (TRANS1, TRANS2 & TRANS4) Transformer (TRANS3) Thermal Expansion Valve (TXV-A,TXV-B) .16

Assembly and Installation instructions

GENERAL

SAFETY CONSIDERATIONS

Location Inspect Shipment Rigging the Components Place the Condenser Assembly Assembly of Modular Chiller Final Check Compressor Mounting and Connections

Make Piping Connections

CONDENSER DESCRIPTION

90RMC050 CONDENSERS

COOLER DESCRIPTION

COOLER PIPING

COOLER FLOW SWITCH

MAKE ELECTRICAL CONNECTIONS

CONTROL BOX, POWER SECTION

CONTROL BOX, CONTROLS SECTION

CONTROL BOX, FIELD CONTROL WIRING

SECTION

UNBALANCED 3-PHASE SUPPLY

VOLTAGE

OPERATING DATA

Sensors T1-Cooler Leaving Fluid Sensor T2-Cooler Entering Fluid Sensor T3-Suction Temperature, Circuit–A1 T4-Suction Temperature, Circuit–B1 SPT-A- Suction Pressure Transducer Circuit -A SPT-B— Suction Pressure Transducer Circuit -B DPT-A— Discharge Pressure Transducer Circuit -A DPT-B— Discharge Pressure Transducer Circuit -B Loss-of-Cooler Flow Protection Compressor Ground Fault Sensor Thermostatic Expansion Valves (TXV) Compressor Control Relay (CR) Capacity Control

MINUTES LEFT FOR START

LOADING SEQUENCE

LEAD/LAG DETERMINATION

CAPACITY SEQUENCE DETERMINATION

CAPACITY CONTROL OVERRIDES

Operation of Machine Based On Control Method and Cooling Set Point Selection Settings Enable/Off/Remote Contact (CTRL=0)

7-DAY SCHEDULE (CTRL=1)

OCCUPANCY SCHEDULE (CTRL=2)

CCN SCHEDULE (CTRL=3)

Pumpout Marquee Display Usage (See Figure 12 and Tables 9-27)

EMERGENCY OPERATION

Pumping down the plant Emergency Operation

POWER FAILURE

SHORT TERM POWER OUTAGE (LESS

THAN 30 MINUTES)

Long Term Power Outage (longer than 30 Minutes)

TROUBLESHOOTING

Complete Unit Stoppage and Restart

GENERAL POWER FAILURE

UNIT ENABLE-OFF-REMOTE CONTACT

SWITCH IS OFF

CHILLED FLUID PROOF-OF-FLOW

SWITCH OPEN

OPEN LOW-PRESSURE SWITCH

OPEN HIGH-PRESSURE SWITCH(es)

OPEN OIL PRESSURE SWITCH

OPEN CONTACTS ON COMPRESSOR

GROUND-CURRENT SENSOR (S)

OPEN 24-V CONTROL CIRCUIT BREAKER

(S)

COOLING LOAD SATISFIED

THERMISTOR FAILURE

Alarms and Alerts

SERVICE

Electronic Components

Control Components Compressor Replacement 90RMC050 Condenser

GASKET REPLACEMENT

TUBE SIDE LEAKS

PROCEDURE FOR PLUGGING TUBES

WITHOUT REMOVING TUBES

PROCEDURE FOR REPLACING

CONDENSER TUBES

RE-ROLLING PROCEDURE

90RMC050 Cooler Assembly

TUBE PLUGGING

TIGHTENING COOLER HEAD BOLTS

Check Oil Charge To Add Oil To Remove Oil Check Refrigerant Feed Components

THERMOSTATIC EXPANSION VALVE

(TXV)

FILTER DRIER

MOISTURE-LIQUID INDICATOR

LIQUID LINE SERVICE VALVE

LIQUID LINE SOLENOID

PRESSURE RELIEF DEVICES

COMPRESSOR AND UNIT PROTECTIVE

DEVICES

CIRCUIT BREAKER

CRANKCASE HEATER

OIL PRESSURE SAFETY SWITCH (OPS) 65

Check Unit Safeties

HIGH-PRESSURE SWITCH

LOW-PRESSURE SWITCH

COOLER FREEZE-UP PROTECTION

THERMISTORS

REPLACING THERMISTORS T1, T2, T3 &

T4

THERMISTOR/TEMPERATURE SENSOR

CHECK

PRESSURE TRANSDUCERS

TROUBLESHOOTING

PRE-START-UP

System Check

START-UP AND OPERATION

Actual Start-Up Check Refrigerant Charge

Operating Limitations

TEMPERATURES

VOLTAGE

Main Power Supply Control Circuit Power

OPERATION SEQUENCE

Component and Assembly Parts List

Parts List

APPENDIX A

Appendix B

REFRIGERANT TEMPERATURE -

PRESSURE CHART

Appendix C Additional Vendor Information Sheets

C-1, Johnson Controls Water Regulating Valve C-2, McDonnell & Miller Fluid Flow Switch (Cooler Water) C-3, Ketema Water – Cooled Condenser96 C-4, Henry Rupture Disc Assembly and Pressure Gauge C-5, Henry Safety Relief Valves C-6, Liquid Line Solenoid Valve Assembly C-7, Alco Thermo Expansion Valve Assembly C-8, Carlyle Compressor Assembly C-9, Sight Glass, (Liquid Line) C-10, Compressor Contactor C-11, Compressor Circuit Breaker C-12, Cooler Assembly C-13, Transformers C-14, Filer Drier Core

APPENDIX D

Unit Reference Drawings

90RMC050-D-6_Sh1 90RMC050-D-6_Sh2 90RMC050-D-6_Sh3 90RMC050-D-6_Sh4 90RMC050-D-6_Sh5 90RMC050-D-6_Sh6 90RMC050-D-6_Sh7 90RMC050-D-6_Sh8 90RMC050-D-6_Sh9 90RMC050-D-6_Sh10

APPENDIX E

Unit Disassembly Instructions

FIGURES

Figure 1, Main Base Board Figure 2, LEN/CNN Interface, Enable /

Off/Remote Contact Switch Figure 5, Power Wiring Connection Figure 6, Low Voltage Field Wiring Connection

Figure 7, Leaving Cooler Nozzle T1 Figure 8, Suction Temperature Sensors T3

(bottom) & T4 (top) Figure 9, Compressor –B Transducer location SPT-B (bottom) and DPT-B (top) Figure 13, Dual Chiller Thermistor Location.29 Figure 14, Tube Rolling Tool Figure 15, Typical Tube Sheet Figure 16, Head Tightening Sequence Figure 17, Elliott Tube Plug Figure 18, Filter Drier Assembly Figure 19, Thermister and Well Figure 20, Thermistor and Transducer

Connection to Main Base Board… ….66 Figure 21, Compressor Connections……….70 Figure 22, Condenser Assembly…………..E-1 Figure 23, Cooler Assembly………………..E-1 Figure 24, Liquid Line Flange………………E-2 Figure 25, Mounting Bolts, Cooler…………E-2 Figure 26, Mounting Filter Drier Assembly..E-2 Figure 27, Line Flange Figure 28, Unit Base Pan…………………..E-3 Figure 29, Compressor Rails………………E-4 Figure 30, Compressor Base Pan…………E-4 Figure 31, Compressor Pump End………..E-5 Figure 32, Compressor Vent Line…………E-6 Figure 33, TXV Equalization Line………….E-6 Figure 34, TXV Sensing Bulb………………E-6 Figure 35, Compressor Conduit……………E-7 Figure 36, Compressor B1………………….E-7 Figure 37, Compressor Contactors………..E-8 Figure 38, Compressor Conduits………….E-8 Figure 39, Back of Control Panel………….E-9 Figure 40, LLSV Conduits………………...E-10 Figure 41, Wiring LLSV ……………...……E-10 Figure 42,Transducer / Thermistor…….…E-11 Figure 43, Pressure Transducer………….E-11 Figure 44, Pressure Transducer………….E-11 Figure 45, Thermistor T1………………….E-12 Figure 46, Thermistor Routing……………E-12 Figure 47, T3 & T4 Thermistor Location…E-13

TABLES

Table 1– Thermistor Designations Table 2 – Status Switches Table 3 – Pressure Transducers Table 4 – Output Relays Table 5 – CCN Communication Bus Wiring .11

Table 6 – Minimum Cooler and Condenser Flow Rates Minimum Loop Volume

Table 7 – Part Load Data Percent Displacement

Table 8— Control Methods and Cooling Set Points

Table 9 Marquee Display Menu Structure Table 10— Run Status Mode and Sub-Mode

Directory Table 11— Service Test Mode and Sub-Mode

Directory Table 12— Temperature Mode and Sub-Mode

Directory Table 13— Pressure Mode and Sub-Mode

Directory Table 14— Set Point Mode and Sub-Mode

Directory Table 15— Reading and Changing Chilled

Fluid Set Point Table 16— Inputs Mode and Sub-Mode

Directory Table 17— Outputs Mode and Sub-Mode

Directory Table 18— Configuration Mode and Sub-Mode

Directory Table 19— Example of Temperature Reset

(Return Fluid) Configuration Table 20— Example of Configuring Dual Chiller

Control Table 21— Example of Compressor Lead/Lag

Configuration Table 22— Time Clock Mode and Sub-Mode

Directory Table 23— Setting an Occupied Time Schedule

Table 24— Operating Mode and Sub-Mode

Directory Table 25— Operating Modes Table 26— Alarms Mode and Sub-Mode

Directory Table 27— Example of Reading and Clearing

Alarms Table 28— Troubleshooting Table 29 - Alarm and Alert Codes Table 30, Plugs and Tubes Table 31 - Acceptable POE Oils Table 32— 5K Thermistor Temperatures (°F) vs Resistance/Voltage Drop (Voltage Drop for Entering and Leaving Condenser Water Thermistors T1, T2, T3 and T4)

Table 33– Minimum Cooler and Condenser Flow Rates and Minimum Loop Volume70

Table 34- Provisioning Technical Document – (PTD) Components and Assembly Parts List

Table 35 -Provisioning Technical Document – (PTD) Depot Level Spare Parts – (2) Year

GENERAL

This publication contains Start-Up, Installation, Service, Controls, Operation, and Troubleshooting information for the 90RMC050 seawater-cooled chiller.

This liquid chiller is equipped with ComfortLink controls, conventional (non-electronic) thermostatic expansion valves (TXVs) and Reciprocating Compressors with 2 unloader heads per compressor. They are also equipped with liquid line solenoid valves (LLSV) for pump down at start up.

MAJOR SYSTEM COMPONENTS

General The 90RMC050 seawater-cooled reciprocating chillers contain the ComfortLink™ electronic control system that controls and monitors all operations of the chiller.

The control system is composed of several components as listed in the sections below.

The drawings for the control panel are as follows:

See Drawing 90RMC050-D-6-Sheet 10 for Control Box Component Arrangement drawing.

See Drawing 90RMC050-D-6-Sheet 8 for Power and Control Schematics.

See Drawing 90RMC050-D-6-Sheet 9 for Low Voltage Schematics.

Main Base Board (MBB) See Figure 1. The MBB is the heart of the ComfortLink control system. It contains the major portion of operating software and controls the operation of the machine. The MBB continuously monitors input/output channel information received from its inputs and from all other modules. The MBB receives inputs from Thermistors T1, T2, T3, and T4.

The MBB also receives the feedback inputs from compressors A1 and B1 and other status switches. See Table 2. The MBB also controls several outputs.

Relay outputs controlled by the MBB are shown in Table 4. Information is transmitted between modules via a 3-wire communication bus or LEN (Local Equipment Network). The CCN (Carrier Comfort Network) bus is also supported. Connections to both LEN and CCN buses are made at TB3. See Figure 2.

Scrolling Marquee Display This device is the keypad interface used for accessing chiller information, reading sensor values, and testing the chiller. The marquee display is a 4-key, 4-character, 16-segment LED (light-emitting diode) display. Eleven mode LEDs are located on the display as well as an Alarm Status LED. See Marquee Display Usage section on page 28 for further details.

Compressor Expansion Board (CXB) The compressor expansion board (CXB) receives the feedback inputs from compressors A1 and B1. See Table 2. The CXB board communicates the status to the MBB and controls the outputs for these compressors.

Start Interlock Switch, SW3 The Start Interlock Switch is a momentary switch with an illuminated lens. This switch will need to be depressed after power has been applied to the control panel. Then the SW3 is depressed, power will energize the switch and Relay (R-1). The normally open contacts 8 and 4 on R-1 will close completing the holding circuit on this momentary switch. The green lens will now be energized; also the normally open contacts 5 and 1 on R-1 will close allowing power from SW1 to energize the MBB.

To de-energize SW3 control panel power will need to be shut-down.

Enable/Off/Remote Contact Switch, SW1 The Enable/Off/Remote Contact switch is a 3-position switch used to control the chiller. When switched to the Enable position the chiller is under its own control. Move the switch to the off position to shut the chiller down. Move the switch to the Remote Contact position and a field installed dry contact can be used to start the chiller. The contacts must be rated for dry circuit application capable of handling a 5-vdc, 1- to 20-mA load. In the Enable and Remote Contact (dry contacts closed) positions, the chiller is allowed to operate and respond to the scheduling configuration, CCN configuration and set point data. See Figure No. 2.

Emergency On/Off Switch, SW2 The Emergency On/Off switch should only be used when it is required to shut the chiller off immediately. Power to MBB, and marquee display is interrupted when this switch is off and all out-puts from this module will be turned off.

Board Addresses The Main Base Board (MBB) has a 3-position Instance jumper that must be set to ‘1.’ The Compressor Expansion Board has a 4-position DIP switch. All switches are set to ‘On’.

Control Module Communication RED LED — Proper operation of the control boards can be visually checked by looking at the red status LEDs (light-emitting diodes).

When operating correctly, the red status LEDs should be blinking in unison at a rate of once every 2 seconds. If the red LEDs are not blinking in unison, verify that correct power is being supplied to all modules. Be sure that the Main Base Board (MBB) Is supplied with the current software. If necessary, reload current software. If the problem still persists, replace the MBB. A board LED that is lit continuously or blinking at a rate of once per second or faster indicates that the board should be replaced.

GREEN LED — The MBB has one green LED.

The Local Equipment Network (LEN) LED should always be blinking whenever power is

on. All other boards have a LEN LED, which should be blinking whenever power is on.

Check LEN connections for potential communication errors at the board J3 and/or J4 connectors. A 3-wire sensor bus accomplishes communication between modules. These 3 wires run in parallel from module to module.

The J4 connector on the MBB provides both power and communication directly to the marquee display only.

YELLOW LED — The MBB has one yellow LED. The Carrier Comfort Network (CCN) LED will blink during times of network communication.

Compressor The Compressor is a Reciprocating, serviceable, semi-hermetic type. Equipped with an automatically reversible oil pump, operating oil charge, suction and discharge shutoff valves, oil sight glass, and a refrigerant suction gas-cooled motor.

Each shall be mounted on spring vibration isolators with an isolation efficiency of no less than 95%.

Each compressor shall have a crankcase heater, muffler, and suction cutoff unloaders.

Speed not to exceed 1750 rpm (29.2 r/s).

Cooler Assembly Single-pass, shell-and-tube type with removable heads and multiple internal polypropylene baffles. Seamless copper tubes shall be rolled into tube sheets.

Direct-expansion type, positioned for multi-pass refrigerant flow. Baffles are designed for minimum fluid-pressure drop direct fluid flow across the tube bundle. 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 controller is in the leaving-fluid nozzle; the leaving-fluid temperature being the control point. The cooler is insulated with ¾” (19 mm) closed-cell plastic foam insulation of suitable thickness. Water vapor cannot penetrate the cellular structure to condense either within cells or on the cooler shell. Thus, the insulation itself is a vapor barrier. Because of the toughness of insulation, a protective sheet metal covering is not necessary.

The Water Connections are 3” raised Face ANSI Flange.

Cooler shall be tested and stamped according to ASME code (U.S.A.) for working pressures of 235 psig (1620 kPa) on the refrigerant side.

Cooler shall have a maximum of 150 psig (1034 kPa) fluid-side working pressure.

Condenser Assembly The Shell is Steel pipe to ASME specification.

Shells are shot blasted and cleaned prior to assembly. Tubes are 90/10 Copper-Nickel high performance enhanced design roller expanded into grooved tube sheet. Tube sheet - 90/10 Copper-Nickel to ASME specifications. Tube Supports - Quality steel manufactured to close tolerance to minimize vibration. The Heads are Cast bronze to withstand the corrosive effects of seawater duty. The Water Connections are 2-1/2” raised Face ANSI Flange. Refrigerant connections are steel and bored to ODS of copper tubing. Relief, vent and drain connections are provided. Codes - The refrigerant side is constructed to the latest edition of the ASME Section VIII Div 1 code and stamped. Refrigerant side dual-rated for 450 psi at 150°F or 305 psi at 250°F. Water side design pressure is 150°F at 150 psi. Both circuits are tested at 1.25 times the design pressure.

Oil Safety Switch The Oil Safety Switch is Standard on 90RMC050 units. This switch senses differential oil pressure and prevents unit operation at low oil pressures.

Compressor Ground Fault Sensor Ground-current sensing shall de-energize the Compressor on sensing of a 2.5 ± 2 amps current imbalance from primary to ground to prevent formation of acids from motor burnout.

Non-Fused Disconnect The non-fused disconnect shall be factory installed and shall disconnect all power to the unit (including control circuit power).

Water Regulating Valve Metrex valves control water flow in response to pressure changes. Pressure actuated values modulate the water flow in response to a pressure signal and are primarily used to stabilize the refrigerant head pressure in the water cooled air conditioning systems.

Carrier Comfort Network (CCN) Interface (Not supplied with the 90RMC050) The 90RMC050 chiller unit can be connected to the CCN if desired. The communication bus wiring is a shielded, 3-conductor cable with drain wire and is supplied and installed in the field. See Table 5. The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system elements on either side of it. This is also required for the negative and signal ground pins of each system element. Wiring connections for CCN should be made at TB3.

Consult the CCN Contractor’s Manual for further information. NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper.

Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene.

An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –20 C to 60 C is required.

Wire manufactured by Alpha (2413 or 5463), American (A22503), Belden (8772), or Columbia (02525) meets the above-mentioned requirements. It is important when connecting to a CCN communication bus that a color-coding scheme be used for the entire network to simplify the installation. It is recommended that red be used for the signal positive, black for the signal negative, and white for the signal ground. Use a similar scheme for cables containing different colored wires. At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to a ground at one point only. If the communication bus cable exits from one building and enters another, the shields must be connected to grounds at the lightning suppressor in each building where the cable enters or exits the building (one point per building only). To connect the unit to the network:

Turn off power to the control box.

Cut the CCN wire and strip the ends of the red (+), white (ground), and black (–) conductors.

(Substitute appropriate colors for different colored cables.)

Connect the red wire to (+) terminal on TB3 of the plug, the white wire to COM terminal, and the black wire to the (–) terminal.

The RJ14 CCN connector on TB3 can also be used, but is only intended for temporary connection (for example, a laptop computer running Service Tool).

IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent the unit from starting. If abnormal conditions occur, unplug the connector. If conditions return to normal, check the CCN connector and cable. Run new cable if necessary. A short in one section of the bus can cause problems with all system elements on the bus.

Table 1– Thermistor Designations Thermistor Designation Pin Connection Point Thermistor Input T1 J8-13, 14 (TB5) Cooler Leaving Fluid T2 J8-11, 12 (TB5) Cooler Entering Fluid T3 J8-5, 6 (TB5) Circuit A, Suction Temp T4 J8-7, 8 (TB5) Circuit B, Suction Temp

Table 2 – Status Switches Status Switch Connection Point Designation Compressor-A1 Fault Signal J9-11, 12 (MBB) CR-A1 Compressor-B1 Fault Signal J9-8, 12 (MBB) CR-B1 Oil Pressure Circuit-A J7-1, 2 (MBB) OPS-A Oil Pressure Circuit-B J7-3, 4 (MBB) OPS-B Remote ON / OFF TB5-9, 10 Field Installed Relay Closure Chilled Water Flow Switch / Chilled Water Pump Interlock

TB5-1, 2 Field Installed

Table 3 – Pressure Transducers Transducer Designation

Connection Point Transducer Input

SPT-A J8-24, 25, 26 (TB5) Circuit A, Suction Pressure DPT-A J8-21, 22, 23 (TB5) Circuit A, Discharge Pressure SPT-B J8-18, 19, 20 (TB5) Circuit B, Suction Pressure DPT-B J8-15, 16, 17 (TB5) Circuit B, Discharge Pressure

Table 4 – Output Relays Relay No. Description K1 Relay R1, Energize Compressor -A1 K2 Relay R3, Energize Compressor -B1 K3 Energize Unloader UL1-A1 (MBB) K4 Energize Unloader UL1-B1 (MBB) K5 Energize Liquid Line Solenoid LLSV-A K6 Energize Liquid Line Solenoid LLSV-B K7 Alarm K8 Energize Chilled Water Pump Relay K9 Energize Condenser Pump Relay

Table 5 – CCN Communication Bus Wiring Manufacturer Regular Wiring – P/N Plenum Wiring- P/N Alpha 1895 - American A21451 A48301 Belden 8205 884421 Columbia D6451 - Manhattan M13402 M64430 Quabik 6130 -

Figure 1, Main Base Board

Figure 2, LEN/CNN Interface, Enable/Off/Remote Contact Switch And Emergency On/Off Switch Location

MAJOR COMPONENT SPECIFICATIONS

Chiller The 90RMC050 seawater-cooled chiller has been rated at the following conditions; Saturated Suction Temperature of 37.0 Deg. F., and Condensing Temperature of 104.0 Deg. F. the Chiller has a Capacity of 50.1 Tons of Cooling.

Manufacture Carrier Air Conditioning Model Number 90RMC050-D-610 Capacity 50.0 TONS Power Input 175.8 KW

MCA 76.3 AMPS

MOCP 110 AMPS

Recommended Circuit Breaker 110 AMPS Power Supply 460-3-60 Refrigerant Type R – 134a Refrigerant Charge, Circuit – A 45 LBS. (20.4 KG) Refrigerant Charge, Circuit – B 45 LBS. (20.4 KG) Oil Charge / Circuit 2.38 GALS (9.0 L) Oil Type SW68 CASTROL ICEMATIC Carrier Part Number, Oil PP23BZ – 103 Expansion Valve TXV TYPE Controls Comfortlink Microprocessor Capacity Control – No. Of Steps 6 Minimum Step Capacity (%) 16

Compressor The 90RMC050 has (2) Compressors that are designated as COMP-A1 and COMP-B1. Both Compressors are the same Carrier Model number.

Manufacture Carlyle Production Model Number 06E7199611G Saturated Suction Temp 37.0 F (2.8 C) Displacement 99 CFM (46.7 L/S) Nominal Motor Hp 35 Condensing Temp 104.0 F (40.0 C) Run Load Amps 33.9 Lock Rotor Amps 283 Motor Rpm 1750 Drive Type SEMI – HERMETIC Cylinders Per Compressor 6

Cooler Assembly The cooler assembly is shell in tube, direct expansion type with integral internal Fin tubes.

Manufacture Carrier Air Conditioning Model number 90RM410236 Fluid Type FRESH WATER Fluid Flow Rate (Nominal) 120 GPM (7.57 L/S) Fluid Pressure Drop 11.3 FT. WG (33.8 KPA) Fluid Flow Rate (Max) 250 GPM (1577 L/S) Water Inlet Temp 54 F (12.2 C) Water Outlet Temp 44 F (6.7C) Max Water Side Pressure 150 PSIG (1034 KPA) Max Refrigerant Side Pressure 235 PSIG (1620.3 KPA) Water Connection Inlet 3 IN (73.5 MM) ANSI FLANGE Water Connection Outlet 3 IN (73.5 MM) ANSI FLANGE Number Of Passes 4 Number Of Tubes 129

Length Of Tubes 85.5 IN (2171.17 MM) Head Material H.R. STEEL Tube H.R. STEEL Tube Material COPPER (ASME SB-75) Fouling Factor 0.0001

Condenser Assembly The Condenser Assembly is for Seawater applications. Equipped with Bronze Heads and the Tubes are 90/10 Copper – Nickel high performance Enhanced.

Manufacture Ketema LP Carrier Part Number (*Left) 90C02-6342-01 Carrier Part Number (*Right) 90C02-6342-02 Fluid Type SEA WATER Fluid Flow Rate (Each) 111.5 GPM (7.03 L/S) Fluid Pressure Drop 8.8 FT. WG (26.20 KPG) Fluid Velocity 6.0 FT/S (1.97 M/S) Water Inlet Temp 90 F (50 C) Water Outlet Temp 97.0 F (36.1 C) Max Water Side Pressure 150 PSIG (1034 KPA) Max Refrigerant Side Pressure 350 PSIG (2413 KPA) Pump Down Capacity (Max) 76 LBS. (34.7 KG) (Each Condenser Asy.)

Water Connection Inlet 2.5 IN (61.3 MM) ANSI FLANGE Water Connection Outlet 2.5 IN (61.3 MM) ANSI FLANGE Number Of Passes 2 Number Of Tubes 52 Length Of Tubes 59.75 IN (1517.7 MM) Head Material BRONZE Tube Sheet Material 90/10 CU. NI. CLAD Tube Material 90/10 CU. NI Fouling Factor 0.0005 Required Pressure Relief Vent Rate (Cr) 5.75 LBS-AIR/ MIN.

* Left and Right Condenser Assemblies are determined by facing the Condenser End that has the Liquid Shut off Valve.

High Pressure Switch The High Pressure Switch is Normally Closed at operating pressure and the contacts will open on pressure rise. This switch is automatic reset and is non–adjustable.

Manufacture Texas Instruments OEM Part Number TI-PS80-01-0132 Carrier Part Number HK02ZA440 Close Pressure 135 +/- 10 PSIG Open Pressure 191 +/- 7 PSIG

Low Pressure Switch The Low Pressure Switch is Normally Closed at operating pressure and the contacts will open on pressure fall. This switch is automatic reset and is non-adjustable.

Manufacture Texas Instruments OEM Part Number PS80-02-F0611 Carrier Part Number HK02ZB022 Close Pressure 45 +/- 10 PSIG Open Pressure 20 +/- 5 PSIG

Oil Safety Switch This Switch is Normally Open at operating pressure and the contacts will close on pressure differential fall. This switch is automatic reset and is non-adjustable. Pressure ratings are Pressure differential, not actual pressures.

Manufacture Robertshaw Controls Co.

OEM Part Number LS101010 Carrier Part Number HK06UB011 Cut-Out Pressure 11.0 +/- 1.5 PSI Cut-In Pressure 16. 5 PSI

Pressure Relief Valve, Condenser The pressure relief is factory set for the stamped pressure relief setting and are suitable for R-134a refrigerant. They are of “Straight Thru”, Positive Pressure Relief Type; with 5/8” Flare connection for vent line connection. (Note if vent is used, Line sizing must comply with ASHREA Standard 15- 1994 of the Mechanical Refrigeration Handbook).

Manufacture Henry Valve Products OEM Part Number 5232-350

Carrier Part Number 90C02-6233-20 Opens @ 350 PSIG CV Rating 11.2 lbs. Air/min

Rupture Disc, Condenser The Rupture Disc Assembly is factory sealed and the material is brass.

Manufacture Henry Valve Products OEM Part Number 5526-350

Carrier Part Number 90C02-6462-01 Opens @ 350 PSIG

Compressor Contactor (C-A1 & C-B1) Manufacture General Electric Co. or Furnas

Electric Co.

Carrier Part Number HN53CB115 OEM Part Number 55-B36A or 75D70152-001

Contact Voltage 480 – Volts Coil Voltage 120 – Volts Full Load Amps 25 Lock Rotor Amps 100

Compressor Circuit Breaker (CB-A1 & CB-B1) Manufacture Heineman Electric or Airpax

Electronics Carrier Part Number HH83XE626 OEM Part Number CF6-Z3-10 or 219-6-26010626

Voltage 600 – Volts Must Hold Amps 22 Must Trip Amps 26 Lock Rotor Amps Poles 1,2,3 = 100-A

Poles 4,5,6 = 82-A

Non – Fused Disconnect Switch The Disconnect Switch is mounted in the Control Panel. The Disconnect Handle is attached to the Panel Door and Door Clutch Mates with Disconnect inside Panel Box. Two-position OFF-ON switch for connect and disconnect of inductive load.

Manufacturer ABB Carrier Part Number 90C02-10332-01 (Disconnect) OEM Part Number OT200U03 (Disconnect) Carrier Part Number 90C02-10332-02 (Handle) OEM Part Number OHB65L6 (Handle) Max. Load Amps 200 Number of poles 3

Solenoid Coil (LLSV-A & LLSV-B) Manufacture Sporlan Valve Co..

Carrier Part Number 90C02-6472-01 OEM Part Number MKC-2-120_50/60_CAM_124 Nominal Voltage 120 –Volts Inrush Current .60 - Amps Holding Current .26 - Amps

Solenoid Coil (UL1-A1, UL1-B1, UL2-A1 & UL2-B1) Manufacture Alco Controls Co.

Carrier Part Number EF19ZE024 OEM Part Number FS1487 Nominal Voltage 24 –Volts Inrush Current 2.07 - Amps Holding Current 1.04 - Amps

Zinc Anodes, Condenser Manufacture Ketema Carrier Part Number 90C02-8162-01 OEM Part Number PLUG0003332 Plug Diameter 3/8” MNPT Anode Length 1”

Transformer (TRANS1, TRANS2 & TRANS4) Step down NEC Class 2, type Transformer. 50/60 Hz.

Manufacture Balser or Products Unlimited Carrier Part Number HT01BD118 OEM Part Number BE27650-001 or PU-4001-277J41AR28 Rating 75 VA Primary Voltage 115 - Volts Secondary Voltage 24 - Volts

Transformer (TRANS3) Class F, 115 Deg. C Rise over 40 Deg. C Ambient.

Manufacture Square D Carrier Part Number HT01BE218 OEM Part Number 9070K350Q34674 Rating 350 VA Primary Voltage 460 - Volts Secondary Voltage 115 - Volts

Thermal Expansion Valve (TXV-A,TXV-B) Replaceable cage and power element assembly. R-134a compatible.

Manufacture Alco Carrier Part Number 90C02-6352-01 OEM Part Number TRAE+30MW 10 Capacity 30 Tons Pressure Limiting 50 Deg. MOP

ASSEMBLY AND INSTALLATION

INSTRUCTIONS

GENERAL

This assembly and installation instruction covers the 90RMC050 unit with ComfortLink controls. These units are Seawater Cooled and have mechanically cleanable condenser that is specifically designed for seawater applications.

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service technicians should install, start up, and service this equipment.

When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.

Follow all safety codes.

Wear safety glasses and work gloves.

Use care in handling, rigging, and setting bulky equipment.

WARNING

Be sure all power to equipment is shut off before performing maintenance or service.

There may be more than one disconnect. Tag all disconnects to alert others not to turn on power until work is completed.

Location Do not store units in an area exposed to weather because of sensitive control mechanisms and electronic devices. Locate unit indoors. See Drawing 90RMC050-D-6- Sheet 5 for assembled unit dimensional details.

Allow 36 in. (914 mm) in front of the unit for control box access door. Prior to installation determine which direction compressor will be removed, and leave 3 to 4 ft (914 to 1219 mm) clearance for removal.

On the 90RMC050-D-610 units leave 7.2 ft.

(2180 mm) 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 Drawing 90RMC050-D-6-Sheet 5. The floor must be strong enough to support the unit operating weight (see Drawing 90RMC050-D-6- Sheet 5). If necessary, add a supporting structure (steel beams or reinforced concrete slabs) to the floor to transfer weight to nearest beams.

WARNING

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.

Inspect Shipment Inspect unit for damage or missing parts. Refer to Drawings 90RMC050-D-6-Sheet 1 (Modular Components), 90RMC050-D-6-Sheet 2 (Piping Assemblies), and 90RMC050-D-6-Sheet 3 (Mounting Hardware). If damaged, or if shipment is incomplete, file a claim immediately with the shipping company.

Rigging the Components See drawing 90RMC050-D-6-Sheet 1 (Modular Components) for the lifting point that have be identified for each of the Components. The weights are also listed on the same drawing. If components are to be moved by forklift truck, when moving from the ends, leave components on the skid. Lift from under the skid. If components are 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 components. Lift from above, using the lifting points provided, to remove components from the skid.

Place the Condenser Assembly The base of the Condenser Assembly will be moved into final position, remove skid, level the unit (using a level), and bolt the unit to floor or pad. NOTE: 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 installation is level.

Refer to Drawing 90RMC050-D-6-Sheet 5 for space requirements and weights. Electrical power connections, water connections for condenser, and fluid connections for cooler are required for Installation.

Assembly of Modular Chiller Follow the Assembly Instruction outline in Steps #1 – 46 that detail the step-by-step Assembling of the 90RMC050-D-6 Seawater Modular Chiller. See Appendix Section E for

“Unit Assembly Instructions of the 90RMC050- D-6 Modular Chiller”.

Final Check Compressor Mounting and Connections

Self-locking nuts for shipping hold down the compressor mounting springs. After unit has been assembled and new nuts from hardware bag #2 have been installed, (see Assembly Instructions Steps 16A, 16B and 16C) tighten the self-locking nuts until compressor floats freely, (Fig. 27). Do not over tighten nuts, as they are self-locking and will hold their locked position.

Make Piping Connections See Drawing 90RMC050-D-6-Sheet 5 and 90RMC050-D-6-Sheet 6 for typical piping connections. All piping must follow standard piping techniques. Refer to Carrier System Design Manual part 3, Carrier E20-II Software Refrigeration piping Program or appropriate ASHREA (American Society of Heating, Refrigeration, and Air Conditioning Engineers) handbook for details on proper pipe sizing and design.

CONDENSER DESCRIPTION

These units use a shell-and-tube condenser with removable heads for easy tube servicing.

Refrigerant is contained within the shell, and water flows through the tubes. These units have a steel shell condenser with 90/10 Copper-Nickel tube sheets and 90/10 Copper- Nickel tubes. In addition, the water heads utilize “sacrificial” zinc anodes for condenser corrosion protection.

IMPORTANT

Inspect the zinc anodes every 3 months for deterioration and replace as needed. Galvanic protection of the condenser is lost if the anodes are not replaced prior to complete deterioration.

There are (2) zinc anodes on each condenser assembly located in the head assembly, opposite nozzle end of the condenser. They are 3/8” NPT. See Figure 4 for location.

90RMC050 CONDENSERS

When facing the front of the unit, the condensers are in the un-insulated shells located across the bottom of the unit. The water connections are such that the water inlet is located on the end of the unit. There are (2) inlets (one for each condenser assembly) water inlet must ALWAYS be on the bottom of the condensers to provide the proper sub-cooling.

The water outlets are also located of the same end of unit. Rotating the heads and gaskets 180 degrees ON BOTH ENDS OF THE CONDENSERS can reverse the water connections.

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 exchangers. See Appendix C-1 for Installation Instructions for the Water Regulating Valve.

Low Flow Protection is achieved by connecting the normally open condenser pump auxiliary contacts to TB5-3 and TB5-4. When the condenser pump is operating, the auxiliary contacts will close, completing the circuit.

Figure 3, Compressor Mounting

Figure 4, Zinc Anodes location. Typical, both sides of the head

There is a pressure-relief device on the condensers. 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 servicing the unit.

IMPORTANT

THE WATER INLET MUST ALWAYS BE ON

THE CONDENSER HEADS THAT HAS THE

NOZZLE CONNECTION AT THE BOTTOM

OF THE HEAD. Incorrect inlet connection will result in poor system performance due to incorrect sub-cooling.

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). See Drawing 90RMC050- D-6-Sheet 7 (Piping Diagram) for piping connection. See Carrier System Design Manual, Part 3, Piping Design. See Condenser Specs listed on page 14 system design pressure drops.

Set water-regulating valve to maintain design head pressure. Do not adjust to compensate for high head pressures caused by fouled condenser tubes, excess refrigerant, or the presence of non-condensables. Due to changes in water temperature, it may be necessary to adjust the valve seasonally. 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.

Provide a means for draining the system for maintenance.

CAUTION

Retighten all condenser head bolts before filling system with water. Torque bolts to a maximum of 40 to 45 ft-lb.

COOLER DESCRIPTION

The cooler is a direct-expansion type with removable heads and is partitioned for multi-pass refrigerant flow. Baffles designed for minimum fluid-pressure drop direct fluid flow across the tube bundle. 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 controller is in the leaving-fluid nozzle; the leaving-fluid temperature being the control point.

The cooler is insulated with a flexible, closed-cell plastic foam insulation of suitable thickness. Water vapor cannot penetrate the cellular structure to condense either within cells or on the cooler shell. Thus, the insulation itself is a vapor barrier. Because of the toughness of insulation, a protective sheet metal covering is not necessary.

COOLER PIPING

Plan cooler fluid piping for minimum number of changes in elevation, and for the fewest number of bends possible. Install manual or automatic vent valve at high points in the line.

Maintain system pressure by using a pressure tank or a combination of relief and reducing valves.

A strainer with a minimum of 40 mesh must be installed ahead of the cooler fluid inlet to prevent debris from clogging or damaging the heat exchanger.

See Drawing 90RMC050-D-6-Sheet 7 (Piping Diagram) for piping connection. See Carrier System Design Manual, Part 3, Piping Design, for chilled fluid piping details.

The cooler fluid inlet and outlet connections are ANSI Raised Flange 150 lbs type connections.

Run the pump for 10 minutes, and then clean the strainer before starting the unit.

COOLER FLOW SWITCH

A cooler flow switch is required for all units, and must be field-installed. The Carrier flow switch, part number HR81LG005 has been shipped loose.

Flow switch wiring terminals are located on Terminal Block TB5 of the control box. The flow switch should be wired between terminals TB5- 1 and TB5-2.

The ship loose switch Carrier Part Number HR81LG005 is McDonnell & Miller Part Number FS8-WG; refer to Installation & Maintenance Instructions in Appendix Section C-2 for final installation. This will be a Paddle Type switch that is installed in the pump suction line. The following are items that need to be followed for correct operation of the flow switch.

The flow switch should be located in a horizontal section of pipe where there is a straight horizontal run of at least 5 pipe diameters on each side of the flow switch. The flow switch may be installed in a vertical pipe if the flow is in the upward direction.

The flow switch must be installed in the…