(089)controlledenviroment-refsys.pdf

FRV40-226-089-010

REV 1

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Refrigeration System Controlled Environment Room Model: 90YK12NBD3CA1Z9Z

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-089-010

REV 1

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Refrigeration System Controlled Environment Room Model: 90YK12NBD3CA1Z9Z

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

05 JULY 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

Revision “1”

9/30/03

Manual Revised in it’s entirety.

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-089-010

TITLE OF MANUAL: Refrigeration System Controlled Environment Room

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-089-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND, LLC

Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Refrigeration System Controlled Environment Room

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-226 Refrigeration System Controlled Environment Room. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Refrigeration System Controlled Environment Room. The text is broken down as follows:

Section 1- Introduction / Safety Considerations

Section 2- Installation And Start- Up Instructions

Section 3- Electrical Wiring / Controls

Section 4- Unit Performance Summary

Section 5- Unit Configuration Summary

Section 6- Unit Dimensions And Piping

Section 7- Component Information Service Instructions

Section 8- Component Parts List

Section 9- Maintenance And Troubleshooting

Section 10- Ship Loose Items

CARRIER TRANSICOLD DIVISION, CARRIER CORPORATION, MARINE SYSTEMS

CARRIER PARKWAY BLDG TR-20, P.O. BOX 4805, SYRACUSE, NY 13221

TECHNICAL MANUAL

CARRIER TRANSICOLD 90YK12NBD3CA1Z9Z

1.6-TON R-134A CONDENSING UNIT

FOR REFRIGERATION DUTY

CONTROLLED ENVIRONMENTAL ROOM

CTD JOB NO: 331-K42-218

CUSTOMER: BAILEY N.O.

PROJECT: NOAA FRV REEFER

UNIT MODEL: 90YK12NBD3CA1Z9Z

APPROVAL SIGNATURES:

DAVID WAUGH (MANAGER, APPLICATIONS ENGINEERING)

CHARLES KRAFT (MANAGER, SERVICE ENGINEERING)

ii

TABLE OF CONTENTS

SUMMARY

1 INTRODUCTION

Safety Considerations ......................................................................................................................1-1 Refrigerant Temperature-Pressure Chart...........................................................................................1-5

2 INSTALLATION, AND STARTUP INSTRUCTIONS .......................................................................2-1 Step 1 Prepare for Installation........................................................................................................2-1 Step 2 Receive Unit ......................................................................................................................2-1 Step 3 Install Unit..........................................................................................................................2-1 Step 4 Assemble Refrigerant Piping and Components.....................................................................2-2 Step 5 Make Electrical Connections ...............................................................................................2-2 Step 6 Check Compressor/Motor Alignment ...................................................................................2-2 Step 7 Assemble Water Piping ......................................................................................................2-3 Step 8 Prepare Lubrication System ................................................................................................2-3 Step 9 Evacuate, Dehydrate and Leak Test ....................................................................................2-3 Step 10 Refrigerant Charging ..........................................................................................................2-3 Step 11 Preliminary Steps ...............................................................................................................2-3 Step 12 Capacity Control ................................................................................................................2-4 Step 13 Start Compressor .....................................2-4

3 CONTROL CIRCUIT SEQUENCE OF OPERATION

Sequence of Operation Unit Control / Power Wiring Diagram.

Component Arrangement Notes and Legend Pressure Switch Information

4 UNIT PERFORMANCE SUMMARY

5 UNIT CONFIGURATION SUMMARY

Refrigerant and Oil Used Compressor Data Control Settings Estimated Weights

6 UNIT APPENDIX

Unit Dimensional / Interface Drawing. (AS BUILT) Unit Piping Diagram Refrigerant Piping Guide

7 COMPONENT APPENDIX / SERVICE INSTRUCTIONS

Compressor Oil Specification Sheet Condenser Information (05K)Compressor (Operation/Service Instructions) Soenoid Valve Information LPE Unit Cooler Information Oil Separator Information Digital Thermostat Instructions ( 50-90 deg operating range) Vibration Mount Information iii

TABLE OF CONTENTS (Cont’d)

8 UNIT AND MAJOR COMPONENT PARTS LIST

Seahorse Condensing Unit Parts List Recommended ABS Spare Parts List Compressor Service Parts List

9 MAINTENANCE AND TROUBLESHOOTING

Seahorse Scheduled Maintenance Log Sheet Troubleshooting Guide

10 SHIP LOOSE ITEMS APPENDIX

iv

SUMMARY

This manual contains information for installation and startup of the Carrier Transicold 90Y Seahorse condensing unit. These units are provided with 2KAB compressors. These are 2-cylinder compressor from the 5K-compressor family.

When referencing these compressors refer to 5K with 2 cylinders. Also included are unit performance summary, unit/component parts list, and troubleshooting guide.

The following nameplate information will be useful when ordering spare and replacement parts from your Carrier Transicold Marine dealer. You’re nearest Carrier Transicold Marine Dealer can be found on the Internet at www.marinesystems.carrier.com/.

Vessel Name:

Hull Number:

Seahorse Nameplate Information:

Condensing Unit A :

Model No.: 0YK12NBD3CA1Z9Z

Unit S/N: DC03658

Compressor Model: 2KAB001B3032 (5K Family 2 CYC.)

Compressor S/N: 0803J01512

Motor S/N 30B2550012

SECTION 1

INTRODUCTION / SAFETY CONSIDERATIONS

1-1

1 INTRODUCTION

This manual contains installation, operation & service instructions and parts listing information for the Sea Horse marine condensing unit supplied by Carrier Transicold. Sea Horse units are Carrier compressor based packaged condensing units outfitted for a particular marine application. Standard Carrier Transicold Sea Horse units consist of a compressor water-cooled condenser with double drains, liquid outlet with a shutoff valve, condenser pressure relief valve, and control box.

Scope of supply includes the condensing unit and may include factory-installed accessories, field installed ship loose items and/or low side equipment. A listing of the ship loose items is provided in section 8 while information on interconnection is provided on the electrical schematic in section 3 or unit diagrammatic in section 6. For detailed information on the condensing unit, see the unit drawing and piping diagram supplied in section 6. Refer to shipbuilder system manuals for information on equipment not supplied by Carrier Transicold.

Listing of manual sections with general content description is as follows:

Section 2, General guidelines for installation and startup of the unit. Additional installation, application, service and start up information on major components is provided in Section 7.

Section 3, Controller sequence of operation (with schematic diagram) and integrally mounted refrigeration pressure switch information.

Section 4, Unit Performance Summary, with design condition parameters and operational performance characteristics.

Section 5, Unit Configuration Summary, providing a list of the refrigerant, oil, compressor and control set point data.

Section 6, Unit drawing with dimensional & interface information and piping diagrammatic.

Section 7. Major component application, start up, service and operation data.

Section 8, Unit parts list and major component parts listing.

Section 9 Troubleshooting guide.

Section 10 Product information on ship loose and or low side equipment supplied by Carrier Transicold.

1-2

SAFETY CONSIDERATIONS

Installation, start-up and servicing of this equipment can be hazardous due to system pressures, electrical components and equipment location. Only trained, qualified installation and service personnel should ins tall, start-up or service this equipment. When working on this equipment, observe precautions in the literature, tags, stickers and labels attached to the equipment and any other safety precautions that apply. A listing of general safety considerations is as follows. Be sure you understand and adhere to the following procedures.

DANGER

DO NOT VENT REFRIGERANT RELIEF VALVES WITHIN A SHIP. Outlet from rupture disc or relief valve must be vended overboard in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/ American Society of Heating, Refrigeration, and Air Conditioning Engineers.) or any applicable ships registration society. The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

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.

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 Section 5

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.

1-3

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.

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

DO NOT work on electrical components, including control panels, 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 (110 F [43 C] ) 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 Section 5. 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.

1-4

WARNING (Continued)

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.

USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.

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 the 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.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.

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 DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

1-5

REFRIGERANT TEMPERATURE - PRESSURE CHART

(See following sheet for higher temperature data)

R134a

F C PSIG* kPa* BAR*

-30 -34 9.7 * 246.4 ** 0.67 ***

-28 -33 8.6 * 218.4 ** 0.59 *** -26 -32 7.4 * 188.0 ** 0.53 *** -24 -31 5.5 * 139.7 ** 0.43 *** -22 -30 4.9 * 124.5 ** 0.34 *** -20 -29 3.6 * 91.4 ** 0.25 ***

-18 -28 2.2 * 55.9 ** 0.16 *** -16 -27 0.7 * 17.8 ** 0.06 *** -14 -26 0.4 2.8 0.03

-12 -24 1.2 8.3 0.08

-10 -23 2.0 13.8 0.14

-8 -22 2.8 19.3 0.19

-6 -21 3.7 25.5 0.25

-4 -20 4.6 31.7 0.31

-2 -19 5.5 37.9 0.37

0 -18 6.5 44.8 0.44

2 -17 7.5 51.7 0.51

4 -16 8.6 59.3 0.59

6 -14 9.7 66.9 0.66

8 -13 10.8 74.5 0.73

10 -12 12.0 82.7 0.82

12 -11 13.2 91.0 0.90

14 -10 14.4 99.3 0.98

16 -9 15.7 108.3 1.07

18 -8 17.1 117.9 1.16

20 -7 18.4 126.9 1.25

22 -6 19.9 137.2 1.35

24 -4 21.4 147.6 1.46

26 -3 22.9 157.9 1.56

28 -2 24.5 168.9 1.67

30 -1 26.1 180.0 1.78

32 0 27.8 191.7 1.89

34 1 29.5 203.4 2.01

36 2 31.3 215.8 2.13

38 3 33.1 228.2 2.25

40 4 35.0 241.3 2.38

42 6 37.0 255.1 2.52

44 7 39.0 268.9 2.65

46 8 31.1 214.4 2.12

48 9 43.2 297.9 2.94

50 10 45.4 313.0 3.09

NOTE: (*) Figures with * are inches of mercury (**) Figures with ** are millimeters of mercury.

(***) Figures with *** are bar – vacuum.

1-6

REFRIGERANT TEMPERATURE - PRESSURE CHART

(See preceding sheet for lower temperature data) R134a

F C PSIG kPa BAR

52 11 47.7 328.9 3.25

54 12 50.0 344.8 3.40

56 13 52.4 361.3 3.57

58 14 54.9 378.5 3.74

60 16 57.4 395.8 3.91

62 17 60.0 413.7 4.08

64 18 62.7 432.3 4.27

66 19 65.4 450.9 4.45

68 20 68.2 470.2 4.64

70 21 71.1 490.2 4.84

72 22 74.1 510.9 5.04

74 23 77.1 531.6 5.25

76 24 80.2 553.0 5.46

78 26 83.4 575.0 5.67

80 27 86.7 597.8 5.90

82 28 90.0 620.6 6.12

84 29 93.5 644.7 6.36

86 30 97.0 668.8 6.60

88 31 100.6 693.6 6.84

90 32 104.3 719.1 7.10

92 33 108.1 745.3 7.36

94 34 112.0 772.2 7.62

96 36 115.9 799.1 7.89

98 37 120.0 827.4 8.16

100 38 124.1 855.7 8.44

102 39 128.4 885.3 8.74

104 40 132.7 915.0 9.03

106 41 137.2 946.0 9.34

108 42 141.7 977.0 9.64

110 43 146.4 1009.4 9.96

112 44 151.1 1041.8 10.28

114 46 155.9 1074.9 10.61

116 47 160.9 1109.4 10.95

118 48 166 1144.6 11.29

120 49 171.1 1179.7 11.64

SECTION 2

INSTALLATION AND START-UP INSTRUCTIONS

2-1

2 INSTALLATION AND STARTUP INSTRUCTIONS

ATTENTION

The following instructions are to be followed along with or in addition to any other applicable requirements provided in Sections 1 through 10 of the technical manual.

Study the entirety of the technical manual before attempting any service or installation of the subject equipment. Use appropriate refrigeration service practices and comply with all applicable rules and regulations.

INSTALLATION

Step 1 Prepare for Installation

PREPARE EQUIPMENT ROOM Locate condensing unit in a well-ventilated area per applicable code requirements. If natural ventilation is inadequate, provide forced ventilation through ductwork. Refer to SAFETY CONSIDERATIONS in section one for additional equipment room requirements.

Provide freeze-up protection for water-cooled condensers, water lines and accessories if freezing temperatures can occur during winter shutdown periods.

Provide sufficient clearance for removal of compressor cylinder heads and valve plates. Allow space on the oil pump end for crankshaft removal. Provide space equal to condenser length for tube removal and cleaning.

For equipment installation data see drawings provided in section 6

To reduce bearing wear caused by gyroscopic action induced by vessel movement the unit is to be installed with compressor crankshaft fore and aft.

Step 2 Receive unit.

BEFORE UNLOADING Check unit nameplates against model and serial numbers recorded in job specifications. Check all items against shipping list, and examine items carefully for any shipping damage. If damage is found or any major component has torn loose from its anchorage, have transportation inspectors examine it before unloading. Units are shipped with a 5 to 15 pound nitrogen charge. If unit is damaged, check that the holding charge was not lost.

File claim immediately with shipping company for any loss or damage.

RIG UNIT CAREFULLY Check that rigging equipment can safely handle the equipment weight (refer to Section 5).

Rig and move unit carefully to prevent damage to mounting brackets, refrigerant piping or connections.

2-2

Step 3 Install Unit

TO MOUNT UNIT ON DECK OR BASE Prepare the foundation to properly support unit weight. Mount unit on deck or vibration isolators as required. Shim under mounting so as to not spring bases.

Step 4 Assemble Refrigerant Piping and Components

THERMAL EXPANSION VALVES - (AIR CONDITIONING PLANTS) - condenser and motors are sized for use with thermal expansion valves with standard maximum operating pressure (MOP) feature. To prevent condenser and motor overload ensure thermal expansion valves are supplied with a 54°F MOP, (R-22 = 90 psig, R-134a = 50 psig).

PIPING ACCESSORIES may not be supplied as part of the order. Check Section 5 for a listing of ship loose items. Carrier Transicold recommends a replaceable-core filter drier, especially for systems that operate below atmospheric pressure. If the filter drier is not part of Carrier Transicold supply, it should be field supplied and installed in the liquid line along with a by-pass valve arrangement so that the filter drier can be isolated and the core replaced without shutting the machine down. Drier core(s) for units with Carrier Transicold supplied drier(s) are shipped strapped to the unit frame. Do not install the drier core(s) at this time, core(s) are to be installed after leak test, (see Step 9).

Accessories, such as oil separator, suction line accumulator, auxiliary liquid-suction heat exchanger, and receiver should be reviewed by the system engineer. Proper design of the field installed refrigerant piping must ensure the following conditions:

• oil return to the compressor

• subcooled refrigerant liquid entering thermal expansion valve, (provide 1/2° per foot of rise).

• superheat at suction of compressor not exceeding safe limits

• line pressure loss effect on the unit capacity within 2 -3%

• minimal line heat gain

Step 5 Make Electrical Connections

GENERAL NOTES

1. Factory wiring complies with National Electrical Code (NEC). Any field modifications or additions must comply with applicable codes.

2. For control circuit information refer to Section 3.

3. Open control-power disconnect only when servicing the unit. Crankcase heaters must remain energized when unit is not operating.

4. Factory wiring is for single pumpout control.

FIELD WIRING Install all necessary wiring and field supplied components in compliance with the wiring diagram provided in Section 3.

2-3

Step 6 Check Compressor/Motor Alignment (Open-Drive Units)

Compressor drive is factory installed and aligned. Once unit is operational check belt tension or perform hot check of coupling alignment and dowel motor to base as described in Section 7. Dowel pins and excess shims are supplied in a cloth bag attached to the unit. Align so that parallel (Hub O.D. to HUB O.D.) and angular (Hub face to Hub face) do not exceed .010 T.I.R. (total indicator reading).

Rotate compressor and motor shafts the same amount and direction while obtaining readings.

Step 7 Assemble Water Piping

Refer to the unit drawing in Section 6 for details on condenser water connections.

Condenser flow and pressure drop data for use in system design is provided in Section 4. Excess flow will cause rapid erosion of heat exchanger tubes, tube sheets and heads. Measures are to be taken in the shipbuilder design of water distribution system to maintain flows at design water pressure drop, (+/- 2%). If a water-regulating valve is not part of Carrier Transicold supply, a field-supplied valve should be installed. Set water regulating valve to maintain design saturated condensing pressure provided in Section 5. . Inlet strainers with a maximum of 16 mesh baskets are required in all seawater condenser installations. Failure to install proper strainers on seawater condensers may negate warranty on heat exchanger.

Step 8 Prepare Lubrication System

Equipment that is required for lubrication system to function properly is normally supplied with the unit. Any field supplied oil coolers, oil filters or oil separators must be approved by Carrier Transicold.

CHECK OIL LEVEL Check that oil level is between ½ & ¾ compressor sight glass at start up. Compressors that use optional equipment such as oil filter, oil cooler and oil separator or any other oil management systems will require a greater oil charge than listed in Section 5. Recheck oil level after operating compressor. Add or remove oil as needed.

RECOMMENDED OILS When additional oil or a complete oil change is required, use only Carrier Transicold approved oils refer to Section 5.

PREPARE FOR INITIAL START-UP

Step 9 Leak Test and Evacuate, Dehydrate

WARNING

Never use oxygen to build up system pressure. When using nitrogen guard against dangerously high system pressure. Use a pressure regulator on cylinder

2-4

CAUTION

Do not use compressor to build up pressure.

Leak Test Remove shipping pressure and charge system to 10 psig with refrigerant to be used for final charge. Add dry nitrogen until system pressure is 150 psig. Check for leaks with an electronic leak detector.

Installation of Filter Drier Core(s) Remove unit pressure and install the filter drier core(s).

Evacuation and Dehydration Use a two stage vacuum pump capable of reducing the absolute pressure 500 microns. Evacuate the system until the absolute pressure is approximately 1000 microns. Valve off the unit and check for pressure rise, if the pressure rises continue to evacuate to ensure that all moisture is removed. If the pressure continues to rise, check for leaks.

Step 10 Refrigerant Charging

Charge the system to a clear liquid line sight glass at design saturated condensing pressure and saturated suction pressure. Minimum refrigerant charge held in condenser during normal operation is given in Section 5. To estimate total system charge, add up refrigerant held in the piping, evaporator, and any other system component that may be used (receiver, accumulator, etc.).

START-UP

Step 11 Preliminary Steps

Energize crank case heater at least 24 hours before starting unit.

1. Make sure power is provided to the control circuit.

2. If required (5F & 5H Compressors Only) install felt sock filter for the first 50 hours of operation. Refer to Section 7 for details on felt sock filter installation and removal.

3. Check direction of motor rotation (5F & 5H Compressor Only) and verify that the compressor oil pump is configured properly. Refer to compressor data in Section 7 for oil pump details.

4. Check compressor oil level. Refer to Section 7 for recommended oil level.

5. Open condenser water supply valves.

6. Open pressure line of water regulating valve if used.

7. Backseat (open) compressor suction and discharge valves.

8. Open liquid line shutoff valve.

9. Start evaporator fan, or chilled water pump.

10. Set all other valves as required for normal operation (Refer to system design data for information on components not supplied by Carrier Transicold).

11. Set high and low pressure switches in accordance with application requirements. Standard factory settings are provided in Section 5. More

2-5 detailed procedures can be found in compressor data provided in Section 7 while information on the actual switches is provided in Section 3. If any other adjustable control devices are supplied by Carrier Transicold (temperature controller, safety switch, etc.), their settings are listed in Section 5.

Step 12 Capacity Control

Capacity control may be one of two types: electrical or pressure actuated. Refer to compressor data (Section 5) for type of unloading used on the unit if any.

Electric unloaders require a device to control power to the solenoid coil. Often, pressure switch or thermostat is used. Capacity control is set by adjusting their settings. Pressure unloaders are adjusted using the adjustment screws provided.

For more details on pressure unloader adjustment see compressor data in Section 7.

Step 13 Start Compressor

Close main power switch that supplies power to the compressor motor. Place On/Off switch in ON position. The control circuit is fitted with a timer to prevent short cycling. Start may be delayed up to 5 minutes. Immediately recheck oil level and check oil pressure. If correct pressure is not reached in 10-12 seconds and the unit continues to run, stop compressor by placing On/Off switch in OFF position and check oil pump.

SECTION 3

ELECTRICAL WIRING / CONTROLS

3-1

SEQUENCE OF OPERATION – 90YK12NBD3CA1Z9Z

Reference Drawing – 90YK12NBD3CA1Z9Z

CONTROL BOX

All controls other than the thermostat and the unit cooler defrost controls are located in the condensing unit control box. The field-supplied and installed thermostat will be located in the space to be cooled. The unit cooler defrost controls will be located in the unit cooler. All field wiring should be in accordance with N.E.C. (National Electric Code) any applicable local codes.

The control box contains the following components:

1. Power Terminal Block for 460 Volt Power (TB3) – This terminal block is for the field connection of 460-volt single-phase power for powering the unit cooler.

2. Compressor Contactor (C1) – Used to start and stop the compressor.

3. Unit Cooler Fan Motor Contactor (C2) – Used to start and stop the Unit Cooler fan motors.

4. Unit Cooler Defrost Heater Contactor (C3) – Used to start and stop the Unit Cooler defrost heater.

5. Fuses 4 and 5 (and Terminal Block) – Fuses protecting the Unit Cooler fan motors.

6. Fuses 6 and 7 (and Terminal Block) – Fuses protecting the Unit Cooler defrost heater.

7. Fuses 1 and 2 (and Terminal Block) – Fuses protecting the primary of the condensing unit control transformer (TRAN 1).

8. Terminal Block 4 (TB4) – This terminal block is for running 460-1-60 power from the condensing unit control box to the Unit Cooler.

9. Compressor Motor Overload (OL) – Provides over-current protection for the compressor motor.

10. Control Transformer (TRAN 1) – Steps the 575-volt three-phase field power wiring down to control power of 115-v single phase.

11. Control Relays (CHR, AR, AC, POR, R1 and R2) – These relays are used to control various aspect of the system operation.

12. Fuse 3 (and Terminal Block) – Fuse protecting the control voltage side of TRAN 1.

13. Switch 1 (SW1) – Manual On-Off switch to shut off power to most of the 115-volt control circuit. With the switch in the open position, there is still 115-volt power supplied to the compressor crankcase heater (CH).

14. Compressor Safeties (HPS, OPS and LPS) – The condensing unit has a high-pressure switch (HPS), a low-pressure switch (LPS) and an oil safety switch (OPS) to provide protection to the compressor.

15. Control Power Terminal Block (TB2) – This terminal block is used for factory and field 115-volt wiring connections.

16. Timer (TM) – This timer is used to prevent short cycling of the compressor. The compressor can only restart after a minimum four minute and forty-five second off time.

17. Compressor On Light (GRN) – This light is located on the control box cover and when it is lit it indicates that there is power to the compressor contactor and the unit should be running.

18. Alarm Light (RED) – This light is located on the control box cover and is lit whenever the high-pressure switch (HPS), oil safety switch (OPS) or compressor overloads (OL) are tripped. It is not lit when the low-pressure switch (LPS) opens since the condensing unit opens on low-pressure switch after it pumps down during a normal shut down.

19. Defrost Timer (DFT) – This timer is used to place the system into and out of defrost.

FIELD WIRING CONNECTIONS

Drawing 90YK12NBD3CA1Z9Z, Page 3 shows the required field control (115-volt) wiring connections. Drawing 90YK12NBD3CA1Z9Z, Page 4 shows the required field power (460 and 575-volt) wiring connections.

3-2

POWER WIRING

1. 575-3-60 power must be run to the field-supplied and installed fused disconnect. Power must then be run from the load side of the fused disconnect to the line side of the compressor contactor (C1) inside the condensing unit control box. The compressor rated load amp (RLA) value is 6.1 amps. The compressor locked rotor (LRA) value is 36.6 amps. The minimum circuit amps (MCA) for the condensing unit are 7.6 amps; the maximum over-current protection (MOCP) amps for the condensing unit are 10 amps. The minimum gage for field power wiring for the condensing unit is 14 AWG.

2. 460-1-60 power must be run to a field-supplied and installed fused disconnect. Power must then be run from the line side of the fused disconnect to terminal block 3 (TB3) in the condensing unit control box. The 460 -1-60 power wire must then be run from terminals 1 and 2 on terminal block 4 (TB4) to terminals H1 and H2 on terminal block 7 (TB7) in the Unit Cooler. This is for the Unit Cooler fan motors. The 460-1-60-power wiring must be run from terminals 3 and 4 on terminal block 4 (TB4) in the condensing unit control box to terminals H1 and H2 on TB3 in the Unit Cooler. This is for the defrost heater.

CONTROL WIRING

1. Run two 115-volt wires from the field-supplied and installed thermostat in the Unit Cooler.

Wires are to be connected between terminal 8 and 9 on terminal block 2 (TB2).

2. Run four 115-volt wires from terminal block 2 (TB2) in the condensing unit control box to terminal block 3 (TB3) in the Unit Cooler. Run one wire from TB2-15 to TB3-3; run another wire from TB2-16 to TB3-4; run another wire from TB2-17 to TB3-X and run the fourth wire from TB2-19 to TB3-N.

3. There are also two sets of alarm contacts (AC) - one set is normally open (NO) and the other is normally closed (NC). These are dry contacts. To use the normally open contacts run wires between TB2-15 and TB2-17. To use the normally closed contacts run wires between TB2-15 and TB2-16. In an alarm situation, the normally open contacts will close and the normally closed contacts will open.

SEQUENCE OF OPERATION

Following is a description of the operation of the system in the following modes:

1. Call for Cooling - Cooling Mode

2. Cooling Load Satisfied.

3. Defrost Mode

4. Alarm Mode

A. Call for Cooling - Cooling Mode

1. Power is applied with switch 1 (SW1) open. The compressor crankcase heater (CH) will be energized through the crankcase heater relay (CHR) normally closed (NC) 4-5 contacts.

2. Close switch 1 (SW1) and assume all the safeties are closed.

3. Unit Cooler thermostat closes.

4. The pumpout relay (POR) coil is energized.

5. The alarm relay (AR) coil is energized.

6. Alarm relay (AR) normally closed (NC) contacts 1-2 open. This prevents the alarm contactor (AC) from being energized and keeps the red alarm light from being lit (it is possible that during the initial start-up the red alarm light may blink on until the alarm relay (AR) is energized).

7. Pumpout relay (POR) normally open (NO) 1-3 contacts close.

8. Timer motor (TM) is energized through the A2, B2 and B contacts on the timer.

9. Timer relay (TR) is energized through the A2 and A contacts on the timer.

3-3

10. Timer relay (TR) normally open (NO) contacts 1-3 close. Timer relay (TR) normally closed (NC) 4-5 contacts open.

11. Timer motor (TM) on the defrost timer (DFT) is energized.

12. Unit Cooler fan contactor (C2) is energized, starting the fans in the Unit Cooler.

13. After approximately 15 seconds, the contacts on the condensing unit timer switch from A-A2 to A-A1 and from B-B2 to B-B1.

14. The condensing unit timer motor (TM) is de-energized via the open timer relay 4-5 contacts.

15. The green Compressor On light is energized.

16. Compressor contactor (C1) is energized. C1 three normally open contacts close allowing the compressor to start.

17. Relay R2 is energized.

18. Relay R2 normally open (NO) 1-3 contacts close, energizing the liquid line solenoid valve (LLSV).

19. Crankcase heater relay (CHR) coil is energized.

20. Crankcase heater relay (CHR) normally closed (NC) 4-5 contacts open, de-energizing the compressor crankcase heater (CH).

21. Crankcase heater relay (CHR) normally open (NO) 1-3 contacts (in parallel with the pumpout relay (POR) 1-3 contacts close.

22. System is now operating in the cooling mode.

B. Cooling Load Satisfied

1. System is operating at full cooling load. Unit Cooler is at the desired temperature.

2. The Unit Cooler thermostat opens

3. The liquid line solenoid valve (LLSV) is de-energized shutting off refrigerant flow to the unit cooler.

4. The pumpout relay (POR) is de-energized.

5. Pumpout relay (POR) normally open (NO) 1-3 contacts open.

6. The unit continues to operate until the low-pressure switch (LPS) opens.

7. The timer relay (TR) is de-energized.

8. The timer relay (TR) normally open (NO) 1-3 contacts open.

9. The timer relay (TR) normally closed (NC) 4-5 contacts close.

10. The green Compressor On light is de-energized.

11. The compressor contactor (C1) is de-energized. The C1 three normally open (NO) contacts open, shutting down the compressor.

12. Relay R2 is de-energized.

13. Relay R2 normally open (NO) 1-3 contacts open.

14. Crankcase heater relay (CHR) coil is de-energized.

15. Crankcase heater relay (CHR) normally closed (NC) contacts 4-5 close. Compressor crankcase heater (CH) is energized.

16. Crankcase heater relay (CHR) normally open (NO) contacts 1-3 open.

17. The condensing unit timer motor (TM) is energized through the timer relay (TR) normally closed (NC) 4-5 contacts.

18. After approximately four minutes and forty-five seconds, the contacts on the condensing unit timer switch from A-A1 to A-A2 and from B-B1 to B-B2. This shuts off all power to the timer. The four minute and forty-five second time delay is to prevent short cycling of the compressor.

19. The condensing unit is now off. The defrost timer motor (TM) is still energized and the Unit Cooler fan motors continue to operate as long as the unit does not go into defrost.

20. The sequence will repeat once there is a sufficient demand for cooling.

C. Defrost Mode

1. Unit operating in the normal cooling mode.

2. The defrost timer (DFT) switches to the defrost mode.

3. Relay R1 is energized.

3-4

4. Relay R1 normally closed (NC) 4-5 contacts open.

5. The liquid line solenoid valve (LLSV) is de-energized, closing the liquid line solenoid and shutting off refrigerant flow to the Unit Cooler. The condensing unit proceeds to shut down normally as described above.

6. Assuming the defrost heater high temperature safety (HS) is closed, the defrost heater contactor (C3) is energized. The two C3 normally open (NO) contacts close, energizing the defrost heater.

7. The Unit Cooler fan contactor (C2) is de-energized. The C2 normally open (NO) contacts open, shutting off the Unit Cooler fans.

8. The heater remains energized until the defrost termination thermostat (DT) closes.

9. The timer reset solenoid (SOL) is energized.

10. The defrost timer (DFT) switches back to the normal operating mode.

11. The defrost heater contactor coil (C3) is de-energized. The two C3 normally open contacts open, shutting off the defrost heater.

12. Relay R1 coil is de-energized.

13. Relay R1 normally closed (NC) contacts 4-5 close.

14. Assuming the Unit Cooler thermostat is calling for cooling, the system goes through a normal start.

15. When the fan delay thermostat (FD) closes, the Unit Cooler fan motor contactor (C2) is energized. The two C2 normally open (NO) contacts close, energizing the Unit Cooler fan motors. The fan delay is used to ensure that the coil is cold so that warm air is not blown into the conditioned space.

D. Alarm Mode:

The ALARM LIGHT will energize if any of the following safety devices open.

Safety devices include COMPRESSOR MOTOR OVERLOADS, oil pressure safety switch (OPS) and the high-pressure switch (HPS). Opening any of these safeties will remove power from Alarm Relay Coil (AR). This will cause the alarm relay (AR) contacts 1 /2 to return to their normally closed state. This will energize the alarm light, After a short delay (TDR) the alarm contactor (AC) coil will also energize. This will cause the normally open (NO) alarm contactor (AC) contacts 1/3 to close. A holding circuit is then provided to keep the red alarm light energized. A manual reset (turn switch SW1 off then on again) will be required to break the holding circuit and de-energized the alarm light. The cause of the ALARM must be investigated and corrected prior to resetting the alarm circuit.

A set of dry contacts is provided for field wiring if a signal needs to be sent elsewhere in the ship when there is an alarm. One set of normally open (NO) contacts and one set of normally closed (NC) contacts are provided. When the alarm contactor (AC) is energized, normally open (NO) alarm contactor (AC) contacts 4/6 close and normally open (NC) contacts 4/5 open. For the normally open (NO) contacts 4/6, field wiring would be betweenTB2-20 and TB2-22. For the normally closed (AC) contacts 4/5, field wiring would be betweenTB2-20 and TB2-21.

Installation Sheets Manual 121 Pressure Controls Section

Technical Bulletin P70, P72 Issue Date 1190

© 1990 Johnson Controls, Inc. 1 Code No. LIT-121463 Part No. 997-203, Rev. F

CARRIER TRANSICOLD PRESSURE SWITCH DATA

High Press. S. #HK02UA300, Low Press. S. #HK02UB050

Application

The P70 single pole and P72 two pole controls incorporate a load-carrying contact structure which provides direct control of AC motors within the control rating. (See cover label for the electrical rating.) The P72 heavy duty controls provide direct control of motors having integral line-interrupting overload protectors up to 3 hp, 240 V single phase. No starter is needed.

The controls with “all-range” construction can be used with R-12, R-22, R-500 and R-502 refrigerants. Specific models for ammonia applications are also available.

! WARNING: On ammonia installations the ammonia pressure control must be mounted separately from the electrical cabinet.

All Series P70 and P72 pressure controls are designed for use only as operating controls. Where an operating control failure would result in personal injury and/or loss of property, it is the responsibility of the installer to add devices (safety, limit controls) or systems (alarm, supervisory systems) that protect against, or warn of, control failure.

Certain models of the P70 and P72 controls are supplied as pressure limiting devices for refrigeration or air conditioning equipment. Contact Johnson Controls Inc., Control Products Division for specific model identification for refrigeration pressure limiting applications.

Operation

The P70 and P72 controls are available with either CLOSE high -- OPEN low or OPEN high -- CLOSE low contact action.

The snap-acting contacts operate from the pressure actuated bellows. On P70 controls with auxiliary contact, the auxiliary contact closes to actuate a signal or other auxiliary circuit at the same time the main contact opens. (See Fig. 10.)

Installation

Mounting

Unless equipped with an outdoor enclosure, the control must be located in areas protected from the weather. Mount the control on a flat surface or panel board by two screws or panel board by two screws or bolts through the holes in the back of the case.

The control should be mounted above the element connections to provide drainage from the sensing elements. The pressure connection should be above the liquid level of the equipment on which the control is used. This reduces possible accumulation of foreign matter inside the bellows by providing drainage from the sensing elements.

Fig. 1 -- Single function high pressure control.

! CAUTION: Do not mount the control in a position where dirt, sediment or oil will affect the operation of the control.

Universal mounting bracket No. 271-51 is available, if required. (Note: Use only mounting screws supplied with the control to avoid damage to internal components.)

Fig. 2 -- Part No. 271-51 standard mounting bracket.

Do not install this control where the ambient temperature falls below -40°F (-40°C) or exceeds 140°F (60°C).

2 P70, P72 Technical Bulletin

General Instructions

1. Avoid sharp bends or kinks in capillary tubing.

2. Be sure pressure controls installed on ammonia systems are built for ammonia service.

3. Purge all tubing and lines before connecting pressure controls.

4. Make sure the control is not installed on equipment to handle a load in excess of the switch’s electrical rating.

5. Coil and secure excess capillary length to avoid vibration but allow some slack in the capillary to avoid “violin string” vibration which can cause tubing to break. Do not allow tubing to rub against metal surfaces where friction can damage capillary.

6. Do not expose the control to pressure in excess of overrun pressure rating.

See Overrun Pressure Rating table.

Fig. 3 -- Manual reset button on independent high or independent low pressure cutout controls. Button must be pushed in and released to restart after lockout occurs.

Fig. 4 -- If lockout is supplied on cutout mechanism of “dual” controls, the reset button provides for manual reset after operation of high pressure cutout.

Fig. 5 -- Where it is desirable for the user to increase or decrease the DIFFERENTIAL ONLY, external adjusting knob is supplied on differential screw as shown above. Knob is provided with stops and factory assembled to permit change only within specified limits.

Fig. 6 -- External adjusting knob may be placed on range screw as shown where it is necessary for the user to raise or low both

CUT-IN and CUTOUT points (differential remains constant).

Knob is provided with stops and factory assembled to permit adjustments within specified limits.

Note: Knob is usually factory assembled in either position as shown in Figs. 5 or 6, depending upon specifications of original buyer. However, knob may be changed in the field from the differential to the range screw or vice versa by loosening set screw, removing knob and indicator plate and reversing their positions. Assuming that knob is factory assembled on range screw (Fig. 6) and set to limit adjustment to 20 PSIG (140kPa), this adjustment will become approximately 10 PSIG (69 kPa) if knob is placed on differential screw (Fig. 5).

Fig. 7 -- Interior view of an open low pressure control.

Fig. 8 -- Interior view of an open high pressure control.

Fig. 9 -- Interior view of dual control.

P70, P72 Technical Bulletin 3

Wiring

! CAUTION: Disconnect power supply before wiring connections are made to avoid possible electrical shock or damage to equipment. On multiple circuit units more than one circuit may have to be disconnected. Use terminal screws furnished in the contact block (8-32 x 1/4 in.). Longer terminal screws can interfere with switch mechanism and damage the switch.

Make all wiring connections using copper conductors only, and in accordance with the National Electrical Code and local regulations. For maximum electrical rating of the control, see cover label on inside of control cover.

Adjustments

The controls have a single “sight-set” calibrated scale which shows both the cut-in and cutout settings. Adjustments can be made without removing the control cover. (See Figs. 7, 8 and 9.)

If the control is equipped with lockout, the contacts must be reset manually after lockout occurs. (See Figs. 3 and 4.)

Checkout Procedure

The operating point(s) of the control should be confirmed by an accurate pressure gage.

Before leaving the installation, observe at least three complete operating cycles to be sure that all components are functioning correctly.

Repairs and Replacement

Field repairs must not be made except for replacement of the cover or knob. For a replacement control, cover or knob, contact the nearest Johnson Controls wholesaler.

Main contacts (Line-M2) open on fall or rise (depending on model selected).

Auxiliary contacts (Line-M1) close simultaneously.

Fig. 10 -- Typical wiring diagram for P70 with auxiliary contact.

4 P70, P72 Technical Bulletin

Notes

Controls Group 507 E. Michigan Street P.O. Box 423 Printed in U.S.A.

Milwaukee, WI 53202

SECTION 4

UNIT PERFORMANCE SUMMARY

4-1

4 UNIT PERFORMANCE SUMMARY

Design Conditions: 90YK12NBB3ND6Z9Z (HOLDING/PULLDOWN) Parameter Units U.S. IMPERIAL SI METRIC Condenser Water Temperature In F° (C°) 95 35 Condenser Leaving Temperature F° (C°) 105.8 36.7/38.2 Saturated Condensing Temperature* F° (C°) 98.7/103.5 37.0/39.7 Saturated Suction Temperature F° (C°) -20.0/8.0 -28.9/-13.3

* Water Regulating Valve to be Set to Maintain Saturated Condensing Temperature (SCT).

Holding -20°F sst Performance Characteristic Units U.S. IMPERIAL SI METRIC Cooling Capacity Ton (kW) 0.56 2.25 Power Input hp (kW) 1.67 2.24 Condenser Water Flow Gpm (l/s) 3.1 0.20 Condenser Water Pressure Drop Psid(kPa) 3.3 22.7

Pulldown 8°F sst Performance Characteristic Units U.S. IMPERIAL SI METRIC Cooling Capacity Ton (kW) 1.40 4.91 Power Input hp (kW) 3.27 2.44 Note: Exceeding maximum allowable pressure drops on condenser may cause condenser erosion. Carrier Transicold Warranty does not apply to any equipment operated at excessive flow rates as deemed by CTD.

SECTION 5

UNIT CONFIGURATION SUMMARY

5-1

5 UNIT CONFIGURATION SUMMARY :

Refrigerant and Oil Used (Refer to SAFETY CONSIDERATIONS in section one, Refrigerant Pressure Temperature chart)

Type Description Units Value Refrigerant R-134a Minimum condenser charge Lbs(kg) 2.3 (1.0) Oil SEE OIL SPEC

SHEET

Initial charge pts(l) 4.0pts (1.9L)

Compressor Data

UNLOADER TYPE – NONE

Performance Characteristic Units Value Notes Rotational speed Rotations/min 1750 Number of cylinders quantity 2 Number of cylinders with unloaders quantity 0

Control Settings

R-134A Refrigeration A/C Component Type Setting Units Value Value High pressure switch Adjustable Cut-out psig (kPa) 185 (1275) •

Cut-in psig (kPa) 135 (930) • Low pressure switch Adjustable Cut-out In Hg

(mm Hg)

3.7 (91.4) •

Cut-in psig (kPa) 15 (103) • Oil pressure switch Fixed Cut-in psid (kPad) 8.8 (60.6) •

Manual reset Cut-out psid (kPad) 6 (41.3) •

• Not used for A/C

ESTIMATED WEIGHTS

DESCRIPTION NOTES

US

IMPERIAL

(Lbs.)

SI

METRIC

(kg)

1 90Y CONDENSING UNIT TOTAL UNIT (DRY SHIP WT.) 476 216.3

2 COMPRESSOR DRY SHIP WT. 84 38

3 CONDENSER DRY SHIP WT. 35 15.9

4. CONDENSER PUMP DOWN

CAPACITY MAXIMUM STORAGE CAPACITY 14 6.35

SECTION 6

UNIT DIMENSIONS AND PIPING

SECTION 7

COMPONENT INFORMATION

SERVICE INSTRUCTIONS

7-1

OIL SPECIFICATION SHEET:

This unit is equipped with 2KA compressors. These compressors are of the 5K family of compressors, 2K indicating that they are 2 cyclinder. The system is designed for use with R-134A and refrigeration duty. The following oils have been approved for use in this application:

RCG P/N PP23BZ108

Castrol Icematic SW68C ICI Emkarate RL68H Mobil Artic EAL-68

7-2 co n d e n s e r s

CONDENSER INSTA…