Carrier AQUASNAP 30RAP010-150 Start Up & Operation Manual

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Carrier AQUASNAP 30RAP010-150 Start Up & Operation Manual Manual pdf 50 page image

50Compressor Replacement (Fig. 34-36) — Allmodels contain scroll compressors and have from one to sixcompressors. The size 010-030 units are a single refrigerationcircuit while sizes 035-150 are dual circuit. A compressor ismost easily removed from the front of the unit, depending onwhere clearance space was allowed during unit installation.Remove the junction box cover bolts and disconnect thecompressor power and ground connections. Remove the cablefrom the compressor junction box. Remove the connectionsfrom the high-pressure switch. Knock the same holes out of thenew compressor junction box and install the cable connectorsfrom the old compressor.The compressors are bolted to rails, which are in turn boltedto the unit basepan for all sizes except 010 and 015 which aredirectly bolted to the basepan. Remove the 4 bolts holding thecompressor to the rail on the basepan. Save the mounting hard-ware for use with the new compressor. Carefully cut the com-pressor suction and discharge lines with a tubing cutter as closeto the compressor as feasible. Remove high-pressure switchand pressure transducer(s) if required for compressor removal.Lift one corner of the compressor at a time and remove all therubber mounting grommets (single compressor circuits) orsteel spacers (dual compressor circuits). Remove the old com-pressor from the unit.Slide the new compressor in place on the basepan. Liftingone side of the compressor at a time, replace all of the compres-sor mounting grommets. Using new tubing as required, recon-nect compressor suction and discharge lines. Using hardwaresaved, reinstall the mounting bolts and washers through thecompressor feet. Using proper techniques, braze suction anddischarge lines and check for leaks. Reconnect oil equalizationline on dual compressor circuit models.Reconnect the compressor power connections and high-pressure switch wiring as on the old compressor. Refer toFig. 34-36. Following the installation of the new compressor,tighten all hardware to the following specifications. (SeeTable 23.)Table 23 — Unit Torque SpecificationCoolerBRAZED-PLATE COOLER HEAT EXCHANGER RE-PLACEMENT — Brazed-plate heat exchangers cannot berepaired if they develop a leak. If a leak (refrigerant or water)develops, the heat exchanger must be replaced. To replace abrazed-plate heat exchanger:1. Check that the replacement heat exchanger is the same asthe original heat exchanger. The unit insulation covers themanufacturer’s part number. Make sure the depths of thereplacement and original cooler heat exchangers are thesame.2. Disconnect the liquid-in and liquid-out connections at theheat exchanger.3. Recover the refrigerant from the system, and unsolder therefrigerant-in and refrigerant-out connections.4. Remove the old heat exchanger. The replacement heat ex-changer is supplied fully insulated. It also includes a cool-er heater. Use of the heater is not required unless the orig-inal cooler contained a factory-installed heater.5. Install the replacement heat exchanger in the unit and at-tach the mounting bracket hardware to the fan uprights(sizes 010-030) or to the bottom bracket (sizes 035-150)using the hardware removed in Step 4. Reconnect thecooler heater if required. For sizes 010-025, torque thebolts to 7-10 ft-lb. For sizes 030-150, torque the bolts to30-50 ft-lb.6. Carefully braze the refrigerant lines to the connections onthe heat exchanger. Lines should be soldered using silveras the soldering material with a minimum of 45% silver.Keep the temperature below 1472 F (800 C) under nor-mal soldering conditions (no vacuum) to prevent the cop-per solder of the brazed plate heat exchanger from chang-ing its structure. Failure to do so can result in internal orexternal leakage at the connections which cannot be re-paired. Braze the liquid lines with a heat sink around theexpansion valve to protect it from excess heat.7. Reconnect the water/brine lines.8. Dehydrate and recharge the unit. Check for leaks.BRAZED-PLATE COOLER HEAT EXCHANGERCLEANING — Brazed-plate heat exchangers must becleaned chemically. A professional cleaning service skilled inchemical cleaning should be used. Use a weak acid (5% phos-phoric acid, or if the heat exchanger is cleaned frequently, 5%oxalic acid). Pump the cleaning solution through theexchanger, preferably in a backflush mode. After cleaning,rinse with large amounts of fresh water to dispose of all theacid. Cleaning materials must be disposed of properly.The factory-installed strainer screen in front of the water/brine inlets of the heat exchangers should be cleaned periodi-cally, depending on condition of the chiller water/brine.Oil ChargePuron refrigerant systems use a polyol ester (POE) oil. Useonly Carrier-approved compressor oil. Oil should be visible incompressor oil sight glass. An acceptable oil level is from 1/8 to3/8 of sight glass for unit size 010-090, and 3/4 to 7/8 of sightglass for unit size 100-150. All compressors must be off whenchecking oil level. Recommended oil level adjustment methodis as follows:ADD OIL — Recover charge from the unit. Add oil to suctionline Schrader valve on tandem compressors sets and the com-pressor Schrader on the three-compressor circuits and single-compressor circuits. (See Fig. 34-36.) When oil can be seen atthe bottom of the sight glass, add oil in 5 oz increments whichis approximately 1/8 in oil level. Run all compressors for 20minutes then shut off to check oil level. Repeat procedure untilacceptable oil level is present.NOTE: Use only Carrier-approved compressor oil.• Oil Type. . . . . . . . . . . . . . . . Inhibited polyol ester-basedsynthetic compressor lubricant.• ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . . . . . 32Approved sources are:UNIT SIZES 010-090MANUFACTURER OILTotaline . . . . . . . . . . . . . . . . . . . . . . 3MAF POE, P903-1601Mobil . . . . . . . . . . . . . . . . . . . . . . . . . . .EAL Arctic 32-3MAUniqema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RL32-3MAFFASTENER RECOMMENDED TORQUECompressor MountingBolts7 to 10 ft-lb (9.5 to 13.5 N-m)Compressor PowerConnections24 to 28 in.-lb (2.7- to 3.2 N-m)Compressor GroundTerminal Connections14 to 18 in.-lb (1.6 to 2.0 N-m)CAUTIONThe compressor in a Puron® refrigerant (R-410A) systemuses a polyol ester (POE) oil. This is extremely hygro-scopic, meaning it absorbs water readily. POE oils canabsorb 15 times as much water as other oils designed forHCFC and CFC refrigerants. Take all necessary precau-tions to avoid exposure of the oil to the atmosphere. Failureto do so could result in possible equipment damage.