30HZ Carrier Water Cooled
30HZ Carrier Water Cooled
30HZ Carrier Water Cooled
Water-Cooled/Condenserless
Liquid Chillers
Nominal cooling capacity 30HZ: 134-783 kW
Nominal cooling capacity 30HZV: 126-735 kW
50 Hz
1 - INTRODUCTION ....................................................................................................................................................................... 4
1.1 - Installation safety considerations .............................................................................................................................................. 4
1.2 - Equipment and components under pressure .............................................................................................................................. 4
1.3 - Maintenance safety considerations ............................................................................................................................................ 4
1.4 - Repair safety considerations ...................................................................................................................................................... 5
The cover illustration is for illustrative purposes only and is not part of any offer for sale or contract.
2
CONTENTS (cont’d)
7 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA FOR STANDARD UNITS ........................................... 24
7.1 - Compressors ............................................................................................................................................................................. 24
7.2 - Lubricant .................................................................................................................................................................................. 24
7.3 - Pressure vessels ........................................................................................................................................................................ 24
7.4 - Electronic expansion device (EXV) ........................................................................................................................................ 25
7.5 - Refrigerant ............................................................................................................................................................................... 25
7.6 - High-pressure safety switch ..................................................................................................................................................... 25
7.7 - Moisture indicator .................................................................................................................................................................... 25
7.8 - Filter drier ................................................................................................................................................................................ 25
9 - MAINTENANCE ...................................................................................................................................................................... 27
9.1 - Soldering and welding ............................................................................................................................................................. 27
9.2 - Maintenance of the refrigerant circuit ..................................................................................................................................... 27
9.3 - Electrical maintenance ............................................................................................................................................................. 28
9.4 - Evaporator maintenance .......................................................................................................................................................... 29
9.5 - Corrosion control ..................................................................................................................................................................... 30
3
1 - INTRODUCTION The safety valves must be connected to discharge pipes.
These pipes must be installed in a way that ensures that
Prior to the initial start-up of the 30HZ/HZV units, the people people and property are not exposed to refrigerant leaks.
involved in the on-site installation, start-up, operation, and These fluids may be diffused in the air, but far away from any
maintenance of this unit should be thoroughly familiar with these building air intake, or they must be discharged in a quantity
instructions and the specific project data for the installation site. that is appropriate for a suitably absorbing environment.
The 30HZ/HZV liquid chillers are designed to provide a very Periodic check of the globe valves: See paragraph
high level of safety during installation, start-up, operation and “Maintenance safety considerations”.
maintenance. They will provide safe and reliable service when
operated within their application range. Provide a drain in the discharge circuit, close to each valve,
to avoid an accumulation of condensate.
This manual provides the necessary information to familiarize
yourself with the control system before performing start-up Ensure good ventilation, as accumulation of refrigerant in
procedures. The procedures in this manual are arranged in the an enclosed space can displace oxygen and cause
sequence required for machine installation, start-up, operation asphyxiation or explosions.
and maintenance.
Inhalation of high concentrations of vapour is harmful and
Be sure you understand and follow the procedures and safety may cause heart irregularities, unconsciousness, or death.
precautions contained in the instructions supplied with the Vapour is heavier than air and reduces the amount of oxygen
machine, as well as those listed in this guide. available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
1.1 - Installation safety considerations
1.2 - Equipment and components under pressure
After the unit has been received, when it is ready to be
installed or reinstalled, and before it is started up, it must be These products incorporate equipment or components under
inspected for damage. Check that the refrigerant circuit(s) is pressure, manufactured by Carrier or other manufacturers. We
(are) intact, especially that no components or pipes have shifted recommend that you consult your appropriate national trade
(e.g. following a shock). If in doubt, carry out a leak tightness association or the owner of the equipment or components under
check and verify with the manufacturer that the circuit pressure (declaration, re-qualification, retesting, etc.). The
integrity has not been impaired. If damage is detected upon characteristics of this equipment/these components are given
receipt, immediately file a claim with the shipping company. on the nameplate or in the required documentation, supplied
with the products.
Do not remove the skid or the packaging until the unit is in
its final position. These units can be moved with a fork lift 1.3 - Maintenance safety considerations
truck, as long as the forks are positioned in the right place
and direction on the unit. Engineers working on the electric or refrigeration components
must be authorized, trained and fully qualified to do so
The units can also be lifted with slings, using only the desig- (electri-cians trained and qualified in accordance with IEC
nated lifting points marked on the unit. 60364 Classification BA4).
These units are not designed to be lifted from above. Use All refrigerant circuit repairs must be carried out by a trained
slings with the correct capacity, and always follow the lifting person, fully qualified to work on these units. He must have
instructions on the certified drawings supplied with the unit. been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
Safety is only guaranteed, if these instructions are carefully qualified specialists.
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel. Any manipulation (opening or closing) of a shut-off valve
must be carried out by a qualified and authorised engineer.
Never cover any safety devices. These procedures must be carried out with the unit shut-down.
This applies to the globe valve in the water circuit and the NOTE: The unit must never be left shut down with the liquid
globe valve(s) in the refrigerant circuit(s). line valve closed, as liquid refrigerant can be trapped
between this valve and the expansion device. (This valve is
Ensure that the valves are correctly installed, before situated on the liquid line before the filter drier box.)
operating the unit.
During any handling, maintenance and service operations
In certain cases the globe stops are installed on ball valves. the engineers working on the unit must be equipped with
These valves are factory-supplied lead-sealed in the open safety gloves, glasses, shoes and protective clothing.
position. This system permits isolating and removing the
globe stop for checking and replacing. The globe stops are Never work on a unit that is still energized.
designed and installed to ensure protection against fire risk.
Removing the globe stops is only permitted if the fire risk is
fully controlled and the responsibility of the user.
4
Never work on any of the electrical components, until the Ensure that you are using the correct refrigerant type before
general power supply to the unit has been cut using the recharging the unit (see unit name plate).
disconnect switch(es) in the control box(es).
Charging any refrigerant other than the original charge type
If any maintenance operations are carried out on the unit, will impair machine operation and can even lead to a
lock the power supply circuit in the open position ahead of destruction of the compressors.
the machine.
Do not use oxygen to purge lines or to pressurize a machine
If the work is interrupted, always ensure that all circuits are for any purpose. Oxygen gas reacts violently with oil, grease,
still deenergized before resuming the work. and other common substances.
ATTENTION: Even if the unit has been switched off, the Never exceed the specified maximum operating pressures.
power circuit remains energized, unless the unit or circuit Verify the allowable maximum high- and low-side test
disconnect switch is open. Refer to the wiring diagram for pressures by checking the instructions in this manual and the
further details. Attach appropriate safety labels. pressures given on the unit name plate.
Protection of electronic boards : If the boards need to be Do not use air for leak testing. Use only refrigerant or dry
handled wear anti-static gloves to avoid exposing the electronic nitrogen.
components to a destructive voltage. Only unpack the boards
from their anti-static bag when they need to be installed. Do not unweld or flamecut the refrigerant lines or any refri-
gerant circuit component until all refrigerant (liquid and
Once a year check that the high-pressure safety switch is vapour) has been removed from chiller. Traces of vapour
correctly connected and that it cuts out at the correct value. should be displaced with dry air nitrogen. Refrigerant in
contact with an open flame produces toxic gases.
Operating checks: During the life-time of the system,
inspection and tests must be carried out in accordance with The necessary protection equipment must be available, and
national regulations. appropriate fire extinguishers for the system and the refrigerant
type used must be within easy reach.
The information on operating inspections given in annex C
of standard EN278-2 can be used if no similar criteria exist Do not siphon refrigerant.
in the national regulations.
Avoid spilling liquid refrigerant on skin or splashing it into
Safety device checks (annex C6 – EN378-2): The safety the eyes. Use safety goggles. Wash any spills from the skin
devices must be checked on site once a year for safety devices with soap and water. If liquid refrigerant enters the eyes,
(high-pressure switches), and every five years for external immediately and abundantly flush the eyes with water and
overpressure devices (safety globe valves). consult a doctor.
Check manual “30HZ/HZV Pro-Dialog Plus control” for a Never apply an open flame or live steam to a refrigerant
detailed explanation of the high-pressure switch test method. container. Dangerous overpressure can result. If it is
necessary to heat refrigerant, use only warm water.
At least once a year thoroughly inspect the protection devices
(valves). If the machine operates in a corrosive environment, During refrigerant removal and storage operations follow
inspect the protection devices more frequently. applicable regulations. These regulations, permitting condition-
ing and recovery of halogenated hydrocarbons under opti-
Regularly carry out leak tests and immediately repair any leaks. mum quality conditions for the products and optimum safety
conditions for people, property and the environment are
1.4 - Repair safety considerations described in standard NFE 29795.
All installation parts must be maintained by the personnel in Any refrigerant transfer and recovery operations must be
charge, in order to avoid material deterioration and injuries to carried out using a transfer unit. A 3/8” SAE connector on
people. Faults and leaks must be repaired immediately. The the manual liquid line valve is supplied with all units for
authorized technician must have the responsibility to repair the connection to the transfer station. The units must never be
fault immediately. Each time repairs have been carried out to modified to add refrigerant and oil charging, removal and
the unit, the operation of the safety devices must be re-checked. purging devices. All these devices are provided with the units.
Please refer to the certified dimensional drawings for the units.
If a leak occurs or if the refrigerant becomes polluted (e.g. by a
short circuit in a motor) remove the complete charge using a Do not re-use disposable (non-returnable) cylinders or attempt
recovery unit and store the refrigerant in mobile containers. to refill them. It is dangerous and illegal. When cylinders are
empty, evacuate the remaining gas pressure, and move the
Repair the leak detected and recharge the circuit with the total cylinders to a place designated for their recovery. Do not
R407C or R22 charge, as indicated on the unit name plate. incinerate.
Only charge liquid refrigerant R407C or R22 at the liquid line
(see chapter “Refrigerant charge”).
5
Do not attempt to remove refrigerant circuit components or 2 - PRELIMINARY CHECKS
fittings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 kPa before removing 2.1 - Check equipment received
components or opening a circuit.
• Inspect the unit for damage or missing parts. If damage is
Do not attempt to repair or recondition any safety devices detected, or if shipment is incomplete, immediately file a
when corrosion or build-up of foreign material (rust, dirt, claim with the shipping company.
scale, etc.) is found within the valve body or mechanism. If • Confirm that the unit received is the one ordered. Compare
necessary, replace the device. Do not install safety valves in the name plate data with the order.
series or backwards. • The unit name plate must include the following
information:
ATTENTION: No part of the unit must use feet, racks or - Version number
supports during operation. Periodically monitor and repair - Model number
or if necessary replace any component or piping that shows - CE marking
signs of damage. - Serial number
- Year of manufacture and test date
The refrigerant lines can break under the weight and release - Refrigerant used and refrigerant class
refrigerant, causing personal injury. - Refrigerant charge per circuit
- Containment fluid to be used
Do not climb on a machine. Use a platform, or staging to - PS: Min./max. allowable pressure (high and low
work at higher levels. pressure side)
- TS: Min./max. allowable temperature (high and low
Use mechanical lifting equipment (crane, hoist, winch, etc.) pressure side)
to lift or move heavy components. For lighter components, - Globe valve cut-out pressure
use lifting equipment when there is a risk of slipping or - Pressure switch cut-out pressure
losing your balance. - Unit leak test pressure
- Voltage, frequency, number of phases
Use only original replacement parts for any repair or compo- - Maximum current drawn
nent replacement. Consult the list of replacement parts that - Maximum power input
corresponds to the specification of the original equipment. - Unit net weight
Do not drain water circuits containing industrial brines, High pressure Low pressure
without informing the technical service department at the Min. Max. Min. Max.
PS (bar) -0.9 32 -0.9 21
installation site or a competent body first. TS (°C) -20 74 -20 55
Pressure switch cut-out pressure (bar) 21.8 -
Close the entering and leaving water shutoff valves and Valve cut-out pressure (bar) 30 21
Test pressure, unit leak test (bar) 15
purge the unit hydronic circuit, before working on the
components installed on the circuit (screen filter, pump,
water flow switch, etc.). • Confirm that all accessories ordered for on-site installation
have been delivered, and are complete and undamaged.
Periodically inspect all valves, fittings and pipes of the
refrigerant and hydronic circuits to ensure that they do not The unit must be checked periodically during its whole
show any corrosion or any signs of leaks. operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, the damaged parts
must be repaired or replaced. See also chapter “Maintenance”.
2.2.1 - Moving
See chapter 1.1 "Installation safety considerations".
6
CAUTION: Only use slings at the designated lifting points • Verify the accessibility for maintenance or repair and to
which are marked on the unit. check the piping.
• Verify the status of the valves.
Before siting the unit check that: • Verify the quality of the thermal insulation and of the
• the permitted loading at the site is adequate or that vapour barriers.
appropriate strenghtening measures have been taken.
• the unit is installed level on an even surface (maximum 2.2.3 - Check compressor mountings
tolerance is 5 mm in both axes). Before any start-up of the unit proceed as follows:
• there is adequate space above the unit to ensure access to
the components for maintenance. For 30HZ/HZV 043-065 units
• the number of support points is adequate and that they are
in the right places.
• the location is not subject to flooding.
CAUTION: Lift and set down the unit with great care. Tilting
and jarring can damage the unit and impair unit operation.
7
3 - DIMENSIONS, CLEARANCES
2200
600
4
3
C
750
600
1
B
2550
800
3 4
C800
800
8
3.3 - 30HZ/HZV 250-280
2750
850
3 4
C
1000
800
Legend:
30HZ - units with condenser A B C
043 2452 1520 915 1 Evaporator
052 2750 1505 915
065 2750 1505 915
2 Condensers
091 2630 1915 950
101 2940 1915 950
111 2940 1915 950 3 Clearances required for operation and maintenance
121 2940 1915 950
141 3550 1915 950
161 3550 1915 950 4 Clearances recommended for heat exchanger tube removal
195 4255 1950 950
225 4255 1950 950
250-280 4070 2150 1275 Power supply
30HZV - units without condenser A B C
043 2452 1260 904
Water inlet
052 2750 1245 904
065 2750 1245 904
091 2630 1300 950
Water outlet
101 2940 1300 950
111 2940 1300 950
121 2940 1300 950
141 3550 1300 950
161 3550 1300 950
195 4255 1340 950
225 4255 1340 950
250-280 4070 1680 1275
Dimensions in mm
NOTE:
Non-contractual drawings. Certified dimensional drawings, available on
request.
FLOOR MOUNTING
For the positioning of the fixing points, weight distribution and centre of gravity coordinates, refer to the certified drawings.
9
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22)
30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280
Net nominal cooling capacity* kW
30HZ 134 153 199 230 270 300 316 371 415 533 626 719 783
30HZV 126 144 194 216 260 278 297 352 388 500 588 677 735
Operating weight** kg
30HZ 1090 1183 1252 2039 2370 2460 2510 2730 2830 3505 3805 4470 4900
30HZV 880 968 1018 1672 1960 2000 2040 2260 2300 2975 3267 3780 4106
Refrigerant charge*** kg R-407C
Circuit A 15.7 17.5 21.0 38.2 29.5 34.5 33.5 38.0 42.0 54.0 54.0 62.5 62.5
Circuit B 15.7 17.5 21.0 19.5 29.5 29.5 33.5 38.0 42.0 46.5 54.0 60.5 62.5
Compressors 06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s
Quantity - Circuit A 1 1 1 2 2 2 2 2 2 3 3 4 4
Quantity - Circuit B 1 1 1 1 2 2 2 2 2 2 3 3 4
Capacity control PRO-DIALOG Plus control
No. of control steps 4 4 4 6 11 11 11 11 11 5 6 7 8
Minimum step capacity % 40 33 33 22 20 18 16 19 16 20 16 14 12
Evaporator One, direct expansion, multi-tube shell
Net water volume l 55 63 63 92 154 154 154 199 199 242 242 276 276
No. of refrigerant circuits 2 2 2 2 2 2 2 2 2 2 2 2 2
Water connections
Inlet/outlet 3” gas threaded PN16DN100 PN16DN125 PN16DN150
NFE 03005 NFE 29203 NFE 29203 NFE29203
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Shell and multi-tube
Quantity 2 2 2 2 2 2 2 2 2 2 2 2 2
Net water volume l
Circuit A 10 10 12 25 18 25 25 25 30 37 37 51 51
Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51
Water connections in Gas threaded Flat flange, brazed
Inlet/outlet, circuit A 1-1/2 1-1/2 2 2-1/2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Inlet/outlet, circuit B 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Notes:
* Nominal Eurovent conditions:
- evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C
- evaporator and condenser fouling factor = 0.000044 m2 K/W
- condensing temperature dew point 45°C
- fluid temperature = condensing temperature at dew point - refrigerant glide - 5 K subcooling.
- Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)
** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.
*** The 30HZV units have a nitrogen holding charge only.
30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280
Power wiring
Nominal power supply V-ph-Hz 400-3-50
System voltage range V 360-440
Control circuit power supply The control circuit is supplied via a factory-installed transformer.
Nominal operating power input* kW
30HZ 38.5 48.9 68 69 78 86 92 112 131 165 201 239 270
30HZV 38.5 48.6 65 70 77 86 94 112 135 165 200 234 266
Nominal operating current* A
30HZ 63.8 81.1 112 114 129 142 152 185 217 273 333 396 448
30HZV 63.8 80.6 108 116 127 142 156 185 224 273 332 388 441
Maximum operating power input** kW
30HZ – circuit A and B 45 55 77 82 90 100 109 132 155 194 232 - -
30HZ – circuit A - - - - - - - - - - - 155 155
30HZ – circuit B - - - - - - - - - - - 116 155
30HZV – circuit A and B 54 65 90 98 107 119 130 155 180 225 270 - -
30HZV – circuit A - - - - - - - - - - - 180 180
30HZV – circuit B - - - - - - - - - - - 135 180
Maximum operating current (Un-10%)*** A
30HZ – circuit A and B 87 105 150 158 174 192 211 255 299 374 449 - -
30HZ – circuit A - - - - - - - - - - - 299 299
30HZ – circuit B - - - - - - - - - - - 224 299
30HZV – circuit A and B 101 123 170 185 203 224 246 293 340 425 509 - -
30HZV – circuit A - - - - - - - - - - - 340 340
30HZV – circuit B - - - - - - - - - - - 255 340
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.
Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).
** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12°C, saturated condensing temperature (dew point) = 52°C
(30HZ)/66°C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
† Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest
compressor).
‡ Current and power inputs not included in the values above.
10
4.2 - Electrical data (R407C) - (continued)
30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280
Maximum operating current (Un)*** A
30HZ – circuit A and B 78 95 135 142 157 173 190 230 269 336 404 - -
30HZ – circuit A - - - - - - - - - - - 269 269
30HZ – circuit B - - - - - - - - - - - 202 269
30HZV – circuit A and B 91 111 153 166 182 202 221 264 306 382 458 - -
30HZV – circuit A - - - - - - - - - - - 306 306
30HZV – circuit B - - - - - - - - - - - 229 306
Maximum unit starting current (Un)† A
30HZ – circuit A and B 182 198 273 245 227 275 291 330 404 470 536 - -
30HZ – circuit A - - - - - - - - - - - 404 404
30HZ – circuit B - - - - - - - - - - - 338 404
30HZV – circuit A and B 188 207 283 263 251 299 318 360 436 513 589 - -
30HZV – circuit A - - - - - - - - - - - 436 436
30HZV – circuit B - - - - - - - - - - - 360 436
30HZ Ratio max. starting current/max. current, circ. A A 2.33 2.09 2.03 1.72 1.45 1.59 1.53 1.44 1.50 1.40 1.33 1.50 1.50
30HZ Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.68 1.50
30HZV Ratio max. starting current/max. current, circ. A A 2.06 1.87 1.85 1.58 1.37 1.48 1.44 1.37 1.43 1.34 1.28 1.43 1.43
30HZV Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.57 1.43
Holding current for three-phase short circuits kA
30HZ – circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -
30HZ – circuit A - - - - - - - - - - - 25 25
30HZ – circuit B - - - - - - - - - - - 25 25
30HZV – circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -
30HZV – circuit A - - - - - - - - - - - 25 25
30HZV – circuit B - - - - - - - - - - - 25 25
Customer unit standby power for evaporator and
condenser pump connections‡ A
Circuit A 6 8 10 10 10 10 10 12 15 24 32 25 32
Circuit B - - - - - - - - - - - 20 20
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.
Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).
** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12°C, saturated condensing temperature (dew point) = 52°C
(30HZ)/66°C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
† Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest
compressor).
‡ Current and power inputs not included in the values above.
30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280
Net nominal cooling capacity* kW
30HZ 144 166 215 250 292 323 342 402 447 578 677 779 847
30HZV 136 157 208 234 280 300 321 380 417 538 633 729 792
Operating weight** kg
30HZ 1090 1183 1252 2039 2370 2460 2510 2730 2830 3505 3805 4470 4900
30HZV 880 968 1018 1672 1960 2000 2040 2260 2300 2975 3267 3780 4106
Refrigerant charge*** kg R22
Circuit A 13.5 14 16.2 33.5 25.5 30 30 34 40 48 48 59 59
Circuit B 13.5 14 15.3 17.5 25.5 25.5 30 34 40 43.5 50 47 56
Compressors 06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s
Quantity - Circuit A 1 1 1 2 2 2 2 2 2 3 3 4 4
Quantity - Circuit B 1 1 1 1 2 2 2 2 2 2 3 3 4
Capacity control PRO-DIALOG Plus control
No. of control steps 4 4 4 6 11 11 11 11 11 5 6 7 8
Minimum step capacity % 40 33 33 22 20 18 16 19 16 20 16 14 12
Evaporator One, direct expansion, multi-tube shell
Net water volume l 55 63 63 92 154 154 154 199 199 242 242 276 276
No. of refrigerant circuits 2 2 2 2 2 2 2 2 2 2 2 2 2
Water connections
Inlet/outlet 3” gas threaded PN16DN100 PN16DN125 PN16DN150
NFE 03005 NFE 29203 NFE 29203 NFE29203
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Shell and multi-tube
Quantity 2 2 2 2 2 2 2 2 2 2 2 2 2
Net water volume l
Circuit A 10 10 12 25 18 25 25 25 30 37 37 51 51
Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51
Water connections in Gas threaded Flat flange, brazed
Inlet/outlet, circuit A 1-1/2 1-1/2 2 2-1/2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Inlet/outlet, circuit B 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* Nominal Eurovent conditions:
- evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C
- evaporator and condenser fouling factor = 0.000044 m2 K/W
- condensing temperature 45°C (30HZV)
- fluid temperature = condensing temperature - 5 K subcooling (30HZV)
- Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)
** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.
*** The 30HZV units have a nitrogen holding charge only.
11
4.4 - Electrical data (R22)
30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280
Power wiring
Nominal power supply V-ph-Hz 400-3-50
System voltage range V 360-440
Control circuit power supply The control circuit is supplied via a factory-installed transformer.
Nominal operating power input* kW
30HZ 35.8 45.5 64 64 72 80 85 104 122 154 189 224 253
30HZV 38.1 48 65 69 76 85 93 111 133 164 198 233 264
Nominal operating current* A
30HZ 59.4 75.5 106 106 119 133 141 172 202 255 313 372 418
30HZV 63.2 79.6 108 114 126 141 154 184 221 272 328 387 438
Maximum operating power input** kW
30HZ – circuit A and B 46 55 79 83 91 101 111 134 158 198 237 - -
30HZ – circuit A - - - - - - - - - - - 158 158
30HZ – circuit B - - - - - - - - - - - 119 158
30HZV – circuit A and B 54 65 90 98 107 119 130 155 180 225 270 - -
30HZV – circuit A - - - - - - - - - - - 180 180
30HZV – circuit B - - - - - - - - - - - 135 180
Maximum operating current (Un-10%)*** A
30HZ – circuit A and B 88 107 153 161 177 195 214 260 305 382 458 - -
30HZ – circuit A - - - - - - - - - - - 305 305
30HZ – circuit B - - - - - - - - - - - 229 305
30HZV – circuit A and B 101 123 170 185 203 224 246 293 340 425 509 - -
30HZV – circuit A - - - - - - - - - - - 340 340
30HZV – circuit B - - - - - - - - - - - 255 340
Maximum operating current (Un)*** A
30HZ – circuit A and B 79 96 137 145 159 176 193 234 275 343 412 - -
30HZ – circuit A - - - - - - - - - - - 275 275
30HZ – circuit B - - - - - - - - - - - 206 275
30HZV circuit A and B 91 111 153 166 182 202 221 264 306 382 458 - -
30HZV circuit A - - - - - - - - - - - 306 306
30HZV circuit B - - - - - - - - - - - 229 306
Maximum unit starting current (Un)† A
30HZ – circuit A and B 183 199 274 246 229 277 293 333 408 475 542 - -
30HZ – circuit A - - - - - - - - - - - 408 408
30HZ – circuit B - - - - - - - - - - - 341 408
30HZV – circuit A and B 188 207 283 263 251 299 318 360 436 513 589 - -
30HZV – circuit A - - - - - - - - - - - 436 436
30HZV – circuit B - - - - - - - - - - - 360 436
30HZ Ratio max. starting current/max. current, circ. A A 2.3 2.07 1.99 1.7 1.44 1.57 1.52 1.43 1.49 1.38 1.32 1.49 1.49
30HZ Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.66 1.49
30HZV Ratio max. starting current/max. current, circ. A A 2.06 1.87 1.85 1.58 1.37 1.48 1.44 1.37 1.43 1.34 1.28 1.43 1.43
30HZV Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.57 1.43
Holding current for three-phase short circuits kA
30HZ – circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -
30HZ – circuit A - - - - - - - - - - - 25 25
30HZ – circuit B - - - - - - - - - - - 25 25
30HZV – circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -
30HZV – circuit A - - - - - - - - - - - 25 25
30HZV – circuit B - - - - - - - - - - - 25 25
Customer unit standby power for evaporator and
condenser pump connections‡ A
Circuit A 6 8 10 10 10 10 10 12 15 24 32 25 32
Circuit B - - - - - - - - - - - 20 20
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.
Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).
** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12°C, saturated condensing temperature (dew point) = 53°C
(30HZ)/68°C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
† Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest
compressor).
‡ Current and power inputs not included in the values above.
12
4.5 - Power supply 4.6 - Voltage phase imbalance (%)
The power supply must conform to the specification on the 100 x max. deviation from average voltage
chiller nameplate. The supply voltage must be within the range Average voltage
specified in the electrical data table. For connections refer to
the wiring diagrams. Example:
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages
WARNING: Operation of the chiller with an improper supply were measured to be:
voltage or excessive phase imbalance constitutes abuse which
will invalidate the Carrier warranty. If the phase imbalance AB = 406 V ; BC = 399; AC = 394 V
exceeds 2% for voltage, or 10% for current, contact your
local electricity supply at once and ensure that the chiller is Average voltage = (406 + 399 + 394)/3 = 1199/3
not switched on until corrective measures have been taken. = 399.7 say 400 V
1. The operating environment for the 30HZ/HZV chillers is specified below: * The protection level required to conform to this class is IP21B (according to
a. Environment* - Environment as classified in IEC 60364 § 3: reference document IEC 60529). All 30HZ/HZV units are protected to IP23C
- ambient temperature range: +5°C to +40°C, class AA4 and fulfil this protection condition.
- humidity range (non-condensing)*:
50% relative humidity at 40°C
90% relative humidity at 20°C
- altitude: £ 2000 m
13
4.7 - Recommended wire sections 4.7.1 - Field control wiring
Refer to the 30HZ/HZV Pro-Dialog Plus Controls IOM and the
Wire sizing is the responsibility of the installer, and depends certified wiring diagram supplied with the unit for the field
on the characteristics and regulations applicable to each control wiring of the following features:
installation site. The following is only to be used as a • Evaporator pump interlock (mandatory)
guideline, and does not make Carrier in any way liable. After • Remote on/off switch
wire sizing has been completed, using the certified • Remote heat/cool switch
dimensional drawing, the instal-ler must ensure easy • Demand limit external switch 1
connection and define any modifications necessary on site. • Remote dual set point
• Alarm report by circuit
The connections provided as standard for the field-supplied • Evaporator pump control
power entry cables to the general disconnect/isolator switch • Condenser pump control
are designed for the number and type of wires, listed in the • Remote set point reset or outside air temperature sensor
table below. reset (0-10 V)
4.7.2 - Selection table of minimum and maximum wire sections for connection by phase to 30HZ/HZV units
14
5 - APPLICATION DATA 5.2 - Minimum chilled water flow
5.1 - Unit operating range The minimum chilled water flow is shown in the table on the
next page. If the flow is less than this, the evaporator flow can
Evaporator Minimum Maximum be recirculated, as shown in the diagram. The temperature of
Entering water temperature at start-up °C 6.8* 30 the mixture leaving the evaporator must never be less than
Leaving water temperature during operation °C 4** 10†
2.8 K lower than the chilled water entering temperature.
Condenser Minimum Maximum
Entering water temperature °C 15 ‡
Leaving water temperature °C 20 45 For minimum chilled water flow rate
Notes:
* For application requiring operation at less than 6.8°C, contact Carrier s.a. for 1
unit selection using the Carrier electronic catalog.
** For operation between 4°C and -15°C, the unit must be equipped with option 5
or 6, and the use of anti-freeze is required.
† For an application, requiring operation up to +15°C leaving water temperature,
contact Carrier for the selection of the unit.
‡ Depends on the maximum condenser flow rate.
Maximum outside temperature: For transport and storage of the 30HZ/HZV 2
units the minimum and maximum allowable temperatures are –20°C and
+50°C. It is recommended that these temperatures are used for transport by
container.
Legend
45 1 Evaporator
44 2 Recirculation
D
42 5.3 - Maximum chilled water flow
Leaving condenser water temperature °C
40 B
39
The maximum chilled water flow is limited by the maximum
36 permitted pressure drop in the evaporator. It is provided in the
35
table on the next page. If the flow exceeds the maximum value,
two solutions are possible:
30 E C A a - Select a non-standard evaporator (-2 baffles) which will
allow a higher maximum water flow rate.
b - Bypass the evaporator as shown in the diagram to obtain a
25 highter temperature difference with a lower evaporator
flow rate.
-15 -10 -6 -5 0 5 10 1
Leaving evaporator water temperature °C
Legend:
A 30HZ
B 30HZ with option 150 (high condensing temperature)
C 30HZ with option 5
2
D 30HZ with option 150 + 5
E 30HZ with option 6
Notes:
1. Evaporator and condenser ,T = 5 K
Legend
1 Evaporator
2 Bypass
15
5.4 - Variable flow evaporator It is often necessary to add a buffer water tank to the circuit in
order to achieve the required volume. The tank must itself be
Variable evaporator flow can be used in standard chillers. The internally baffled in order to ensure proper mixing of the
chillers maintain a constant leaving water temperature under liquid (water or brine). Refer to the examples below.
all flow conditions. For this to happen, the minimum flow rate
must be higher than the minimum flow given in the table of NOTE: The compressor must not restart more than 6 times in
permissible flow rates and must not vary by more than 10% per an hour.
minute.
If the flow rate changes more rapidly, the system should contain
a minimum of 6.5 liters of water per kW instead of 3.25 l/kW.
5 6 7
100
Pressure drop, kPa
10
1 2
4
3
1 10 100
16
5.7 - Condenser water flow rates 5.8 - Condenser water flow restrictor
30HZ/HZV Passes Minimum flow rate, l/s* Maximum flow rate, l/s** CAUTION: To ensure correct operation of the units, these
Closed loop Open loop restrictors must be installed. The restrictor is supplied with
043 2 1.20 3.60 14.8
052 2 1.20 3.60 14.8
the machine, inside the control box.
065 2 1.40 4.20 17
091 2 2.47 7.42 30 30HZ/HZV Passes* OD, mm Location
101 2 2.60 7.64 31
111 2 3.04 9.13 37 043 2 31 Condenser 09RS 022 circuit B - water outlet
121 2 3.54 10.62 43 091 2 47 Condenser 09RS 054 - water outlet
141 2 3.54 10.62 43 111 2 47 Condenser 09RS 054 - water outlet
161 2 3.54 10.62 43 195 2 47 Condenser 09RS 070 - water outlet
195 2 4.00 12.00 48.00 250 2 56 Condenser 09RS 084 - water outlet
225 2 4.46 13.40 54 Legend:
250 2 5.04 15.14 61 * No. of passes
280 2 5.62 16.88 68
Legend:
* Based on a water velocity of 0.3 m/s in closed-loop and 0.9 m/s in open-loop
systems.
** Based on a water velocity of 3.6 m/s
4 5 6
100
3
1
2
Pressure drop, kPa
11
10
1 7 8 9 10 10 100
17
6 - WATER CONNECTIONS Carrier s.a. recommendations on heat exchange fluids:
1. No NH4+ ammonium ions in the water, they are very
For size and position of the heat exchanger water inlet and detrimental for copper. This is one of the most important
outlet connections refer to the certified dimensional drawings factors for the operating life of copper piping. A content
supplied with the unit. of several tenths of mg/l will badly corrode the copper
over time.
The water pipes must not transmit any radial or axial force to 2. Cl- Chloride ions are detrimental for copper with a risk of
the heat exchangers nor any vibration. perforations by corrosion by puncture. If possible keep
below 10 mg/l.
The water supply must be analysed and appropriate water 3. SO42- sulphate ions can cause perforating corrosion, if
treatment elements installed: (filters, additives, intermediate their content is above 30 mg/l.
heat exchangers, purges, vents, shut-off valves, etc) to prevent 4. No fluoride ions (<0.1 mg/l).
corrosion, fouling and deterioration of the pump fittings. Consult 5. No Fe2+ and Fe3+ ions with non negligible levels of
either a water treatment specialist or appropriate literature on dissolved oxygen must be present. Dissolved iron < 5 mg/
the subject. l with dissolved oxygen < 5 mg/l.
6. Dissolved silicon: silicon is an acid element of water and
6.1 - Operating precautions can also lead to corrosion risks. Content < 1mg/l.
7. Water hardness: TH >2.8 K. Values between 10 and 25
The water circuit should be designed to have the least number can be recommended. This will facilitate scale deposit
of elbows and horizontal pipe runs at different levels. Below that can limit corrosion of copper. TH values that are too
the main points to be checked for the connection: high can cause piping blockage over time. A total
• Comply with the water inlet and outlet connections alkalimetric titre (TAC) below 100 is desirable.
shown on the unit. 8. Dissolved oxygen: Any sudden change in water oxygen-
• Install manual or automatic air purge valves at all high ation conditions must be avoided. It is as detrimental to
points in the circuit. deoxygenate the water by mixing it with inert gas as it is
• Use an expansion device to maintain pressure in the to over-oxygenate it by mixing it with pure oxygen. The
circuit and install a safety valve as well as an expansion disturbance of the oxygenation conditions encourages
tank. destabilisation of copper hydroxides and enlargement of
• Install thermometers in both the entering and leaving particles.
water connections. 9. Specific resistance – electric conductivity: the higher the
• Install drain connections at all low points to allow the specific resistance, the slower the corrosion tendency.
whole circuit to be drained. Values above 3000 Ohm/cm are desirable. A neutral
• Install stop valves, close to the entering and leaving water environment favours maximum specific resistance
connections. values. For electric conductivity values in the order of
• Use flexible connections to reduce the transmission of 200-6000 S/cm can be recommended.
vibrations. 10. pH: Ideal case pH neutral at 20-25°C
• Insulate all pipework, after testing for leaks, both to 7 < pH < 8
reduce thermal leaks and to prevent condensation. - If the water circuit must be emptied for longer than
• Cover the insulation with a vapour barrier. one month, the complete circuit must be placed
• Where there are particles in the fluid that could foul the under nitrogen charge to avoid any risk of corrosion
heat exchanger, a screen filter should be installed ahead by differential aeration.
of the pump. The mesh size of the filter must be 1.2 mm - Charging and removing heat exchange fluids should
(see ‘Typical water circuit’ diagram on the right). be done with devices that must be included on the
• Before the system start-up verify that the water circuits water circuit by the installer. Never use the unit heat
are connected to the appropriate heat exchangers (e.g. no exchangers to add heat exchange fluid.
reversal between evaporator and condenser).
• Do not introduce any significant static or dynamic
pressure into the heat exchange circuit (with regard to the
design operating pressures).
• Before any start-up verify that the heat exchange fluid is
compatible with the materials and the water circuit
coating.
18
6.2 - Water connections Potentiometer adjustment
1 2 2
4 5
9
12
10
11
6
8
7
Legend
1 Control valve 1
2 Air vent
3 Flow switch for the evaporator
4 Flexible connection
5 Heat exchanger Legend
6 Pressure tap 1 Setting potentiometer sensitivity
7 Thermostat sleeve 2 Chain of LEDs
8 Drain - red LED lights: the unit is not adjusted
9 Buffer tank - yellow LED lights: the output is switched
10 Filter (mesh size: 1.2 mm = 20 mesh) - green LED lights: the unit is adjusted
11 Expansion tank
12 Fill valve
6.4 - Condenser connections
6.3 - Flow control
The condenser is of the multi-tube shell and tube type with
6.3.1 - Evaporator flow switch and chilled water pump removable water boxes to facilitate cleaning of the tubes.
interlock
6.4.1 - Before making water connections
IMPORTANT: On 30HZ/HZV units, the unit chilled water Tighten the bolts in both heads to the lower torque shown,
flow switch must be energised, and the chilled water pump following the method described. Tighten in the pairs and
interlock must be connected. Failure to follow this sequence indicated according to the size of bolt (see below)
instruction will void the Carrier guarantee. using a torque value at the low end of the range given.
The flow switch is supplied, installed on the evaporator Water box tightening sequence
entering water pipe and factory-set to the minimum water flow
1
rate. If adjustment is necessary: 5
7
1. Switch on the unit. Set it to constant flow (preset value).
The yellow LED is illuminated, and the output is
switched for approximately 20 seconds (power-on delay 4 3
time).
2. Turn the potentiometer until one green LED is illuminated. 8
6
The further the green LED is from the yellow LED, the
2
safer the adjustment (standby capacity in case of flow or
temperature fluctuations). Sequence 1: 1 2 3 4
3. After the adjustment attach the label supplied to the Sequence 2: 5 6 7 8
potentiometer, in order to protect it against unauthorised
Bolt size M12 - 71-87 Nm
tampering. Bolt size M16 - 171-210 Nm
Bolt size M20 - 171-210 Nm
Terminals 34 and 35 are provided for field installation of the
chilled water pump interlock (auxiliary contact for pump
operation to be wired on site).
19
6.4.2 - Pipe connections 6.6 - Refrigerant line connections (30HZV)
After welding the pipes to the flanges previously removed
from the water boxes: 6.6.1 - Recommendations for the installation of liquid
1. Reinstall the pipes and tighten lightly to a torque at the chillers with remote condensers
low end of the range. To guarantee optimum and reliable performance of the 30HZV
2. Fill the system with water. units (split units for connection to condensers) it is necessary
3. Wait for 10 minutes and check for minor leaks to comply with the regulations described below, when these
- at the water box joints units are connected to remote condensers.
- at the flange joints
4. Drain the system. 1. Install a valve in the discharge piping (valves are factory-
5. Disconnect the pipework. installed in sizes 043-063, and supplied non-installed in
6. Tighten the head bolts to their final torque (middle of the sizes 091-280).
range) in the sequence illustrated. 2. Size the discharge and liquid line piping according to the
7. Reconnect the water pipes, tightening the flange bolts to recommendations in the following paragraphs (if neces-
the mid-range torque value. sary, install a double riser to ensure correct oil circulation
8. Refill the system with water. in the refrigerant circuit).
9. Pressurize the system. 3. Depending on the layout and the routing of the discharge
piping it may be necessary to install additional silencers
6.5 - Frost protection (to reduce pulsations and noise emission) between the
liquid chiller and the condenser.
The 30HZ and 30HZV units are designed to be installed under 4. Select a condenser with an integrated subcooler to obtain
cover at outside temperatures between +5°C and +40°C. a minimum of 3 K subcooling at the inlet to the expansion
Therefore they do not include anti-freeze protection, as standard. device.
5. Keep the condensing pressure as stable as possible
If the water piping is in an area where the ambient temperature (pressostat staging or fan control via Pro-Dialog Plus). A
can fall below 0°C it is recommended to install a trace heater on speed controller may be required for the first fan stage for
the piping and to add an antifreeze solution to protect the unit operation at low ambient temperature and partial load.
and the water piping to a temperature of 10 K below the lowest 6. If the system can have several operating modes (summer/
temperature likely to be reached at the installation site. Use winter, dual set point etc.), it is necessary to install a tank
only antifreeze solutions, approved for heat exchanger duty. If (or receiver) to absorb the variations in charge.
the system is not protected by an antifreeze solution and will
not be used during the freezing weather conditions, draining of 6.6.2 - General
the cooler and outdoor piping is mandatory. Damage due to Refrigerant pipe sizing must be carried out, taking account of
freezing is not covered by the warranty. the following constraints:
IMPORTANT: Depending on the climatic conditions in your Oil return to the compressor must be ensured for the majority of
area you must: applications. Oil return is ensured by entrainment. A minimum
- Add ethylene glycol with an adequate concentration to refrigerant velocity is required to ensure entrainment. This
protect the installation up to a temperature of 10 K velocity depends on the pipe diameter, the refrigerant and oil
below the lowest temperature likely to occur at the temperature (these are treated as being the same in most
installation site. cases). A reduction of the pipe diameter permits an increase of
- If the unit is not used for an extended period, it is the refrigerant velocity. The problem of a minimum
recommended to drain it, and as a safety precaution add entrainment velocity does not exist for the pipes that carry
ethylene glycol to the heat exchanger, using the water liquid refrigerant as the oil is fully miscible here.
entering purge valve connection.
At the start of the next season, refill the unit with water The pressure drop at the compressor discharge (pipes linking
and add an inhibitor. the compressor outlet with the condenser inlet) must be limited
- For the installation of auxiliary equipment, the installer to avoid system performance losses (the compressor power
must comply with basic regulations, especially for input inceases, and the cooling capacity decreases).
minimum and maximum flow rates, which must be
between the values listed in the operating limit table As a first estimate and for standard air conditioning applica-
(application data). tions, a one degree Celsius pressure drop on the discharge side
decreases the cooling capacity 2% and increases the compres-
sor power input by 3%. Increasing the pipe diameter permits
limiting the pressure drops.
20
6.6.3 - Use of pipe sizing diagrams Special attention must be paid to the liquid line sizing when
On page 21 of this document two pipe sizing diagrams are the expansion device ist positioned higher than the condenser.
shown. They allow an estimate of the cooling capacity, corres- It may now be necessary to increase the pipe diameter to com-
ponding to 1.5 K pressure drop for different pipe diameters, pensate for the additional pressure of the liquid refrigerant
based on the pipe length. column. If the liquid refrigerant head ist very high, it may even
be necessary to increase the subcooling to prevent an phase
The following procedure can be used for pipe sizing: change in the liquid line. This can be done e.g. by a liquid-
1. Measure the length (in metres) of the piping under vapour heat exchanger or an additional coil.
consideration.
2. Add 40 to 50% to take account of special characteristics. At 45°C the volume mass of refrigerant R407C in the liquid
3. Multiply this length by the appropriate correction factor phase is approximately 1050 kg/m3. A pressure of 1 bar
from Table 1 (this correction factor depends on the corresponds to a liquid head of: 100 000/(1050 x 9.81) = 9.7 m.
saturated suction and discharge temperatures).
4. Read the pipe size from diagrams “Discharge piping” and
“Liquid line piping”.
5. Calculate the equivalent lengths for parts included in the
piping under consideration (such as valves, filters,
connections).
The equivalent lengths are normally available from the
component supplier. Add these lengths to the length
caculated in step 3.
6. Repeat steps 4 and 5 is necessary.
21
Table 1 - R-407C correction factors for copper tube
Legend
S Suction
HG Hot gas
L Liquid
Table 2 - Minimum capacity for oil entrainment in the discharge piping (kW) for R407C copper tube
22
Discharge piping
200
100
Equivalent length (m)
50
40
30
20
Legend
1 1/2"
10 2 3/8"
3 3/4"
4 7/8"
5 5 1 1/8"
4 6 1 3/8"
3 1 2 3 4 5 6 7 8 7 1 5/8"
8 2 1/8"
2
Liquid piping
200
100
50
Equivalent length (m)
40
30
20
Legend
10 1 3/8"
2 1/2"
5 3 5/8"
4 4 3/4"
5 7/8"
3 1 2 3 4 5 6 7 6 1 1/8"
2 7 1 3/8"
3 4 5 10 20 30 40 50 100 200 300 400 1000
23
6.7 - Operation of two units in master/slave mode 7 - MAJOR SYSTEM COMPONENTS AND
OPERATION DATA FOR STANDARD UNITS
The control of a master/slave assembly is in the entering water
and does not require any additional sensors (standard configura- 7.1 - Compressors
tion). It can also be located in the leaving water. In this case
two additional sensors must be added on the common piping. 30HZ/HZV units use reciprocating, semi-hermetic compressors.
As standard, each compressor is equipped with:
All parameters, required for the master/slave function must be • a discharge valve
configured using the Service Configuration menu. All remote • a suction valve
controls of the master/slave assembly (start/stop, set point, • an oil crankcase heater with a safety device that shuts off
load shedding etc.) are controlled by the unit configured as the compressor in case of a fault
master and must only be applied to the master unit. • a discharge line muffler
• anti-vibration mounts
Each unit controls its own water pump. If there is only one
common pump, in cases with variable flow, isolation valves With options 5 and 6 (low leaving brine temperature) each
must be installed on each unit. They will be activated at the compressor is equipped with a thermostat controlling the
opening and closing by the control of each unit (in this case discharge gas temperature. This sensor is activated, if the
the valves are controlled using the dedicated water pump temperature exceeds the safety limit and shuts off the
outputs). See the 30HZ/HZV Pro-Dialog Plus Control IOM for compressor (cut-out: 146°C - cut-in: 115°C).
a more detailed explanation.
7.2 - Lubricant
30HZ/HZV with configuration: leaving water control
The compressors installed in these units have an oil charge (9
l) to ensure their correct operation.
Check that the oil level is between 1/8 and 3/8 up the sight
glass before start-up and after normal unit operation.
NOTE: Use only oils which have been approved for the
compressors. Never use oils which have been exposed to air.
1 2
Recommended oils:
• R407C compressors:
- Carrier specification: PP 47 26
- Mobiloil EAL 68 (original charge)
• R22 compressors:
- Mineral oil, Carrier specification: PP 33 26
- Gargoyle Artic (Mobil Oil, original charge)
- Suniso 3 GS (Sun Oil Co.)
Legend
- Capella WF 32-150
1 Master unit - Clavus G32 (Shell Oil Co.)
2 Slave unit
Control boxes of the master and slave units CAUTION: R407C oils are absolutely not compatible with
R22 oils.
Water inlet
Water outlet
7.3 - Pressure vessels
Water pumps for each unit (included as standard for units with hydronic
module)
7.3.1 - Condensers (30HZ units)
Additional sensors for leaving water control, to be connected to channel 1 of The condensers (one per circuit) are shell-and-tube
the slave boards of each master and slave unit
condensers. They have been tested and stamped in accordance
CCN communication bus with the applicable pressure code for a maximum refrigerant-
side operating pressure of 3200 kPa and for a water-side
Connection of two additional sensors
operating pressure of 1000 kPa.
24
7.3.2 - Evaporator - 710000 cycles (start-ups) with a maximum difference of
The evaporator is a shell-and-tube type with two refrigerant 6 K between two neighbouring points in the container,
circuits. It has been tested and stamped in accordance with based on 6 start-ups per hour over 15 years at a usage
applicable pressure codes for a maximum operating pressure rate of 90%.
of 2100 kPa refrigerant-side and 1000 kPa water-side. The
seam-less copper tubes are finned on the refrigerant side and Excess corrosion thickness
expanded onto the tube sheets. Gas side: 0 mm
Heat exchange fluid side: 1 mm for tubular plates in lightly
The heat exchanger shell has a thermal insulation of 19 mm alloyed steels, 0 mm for stainless steel plates or plates with
polyurethane foam, and is equipped with a water drain and copper-nickel or stainless steel protection.
purge.
7.4 - Electronic expansion device (EXV)
The products that may be added for thermal insulation of the
containers during the water piping connection procedure must These are an option for sizes 30HZ/HZV 043-065.
be chemically neutral in relation to the materials and coatings
to which they are applied. This is also the case for the products The microprocessor controls the EXD through the EXV board
originally supplied by Carrier s.a. module. Inside this EXV is a linear actuator stepper motor.
NOTES: Monitoring during operation, re-qualification, re- The stepper motor moves in increments and is controlled
testing and re-testing dispensation: directly by the processor module. As the stepper motor rotates,
- Follow the regulations on monitoring pressurised motion is transferred into linear movement by the lead screw.
equipment. Through the stepper motor and lead screws, 1500 discrete
- It is normally required that the user or operator sets up steps of motion are obtained. The large number of steps and
and maintains a monitoring and maintenance file. long stroke result in very accurate control of refrigerant flow.
- Follow the control programmes of EN 378-2, annexes A, At initial start-up, the EXV position is at zero. After that, the
B, C and D. microprocessor keeps accurate track of the valve position in
- If they exist follow local professional recommendations. order to use this information as input for the other control
- Regularly inspect the condition of the coating (paint) to functions. It does this by initializing the EXV’s at startup. The
detect blistering resulting from corrosion. To do this, processor sends out enough closing pulses to the valve to move
check a non-insulated section of the container or the it from fully open to fully closed, then resets the position
rust formation at the insulation joints. counter to zero. From this point on, until the initialization, the
- Regularly check for possible presence of impurities (e.g. processor counts the total number of open and closed steps it
silicon grains) in the heat exchange fluids. These impuri- has sent to each valve.
ties maybe the cause of the wear or corrosion by puncture.
- Filter the heat exchange fluid check and carry out 7.5 - Refrigerant
internal inspections as described in EN 378-2, annex C.
- In case of re-testing take possible maximum pressure 30HZ/HZV standard units operate with refrigerant R407C.
differences, as indicated in (2) above into consideration. Optionally (option 7A) the units can use R22.
- The reports of periodical checks by the user or operator
must be included in the supervision and maintenance 7.6 - High-pressure safety switch
file.
30HZ/HZV units are equipped with a high-pressure safety
Repair switch, calibrated to 2700 kPa for 30HZ units and 2900 kPa for
Any repair or modification, including the replacement of 30HZV units.
moving parts:
- must follow local regulations and be made by qualified This switch is located on the central block of each lead com-
operators and in accordance with qualified procedures, pressor.
including changing the heat exchanger tubes
- must be made in accordance with the instructions of the 7.7 - Moisture indicator
original manufacturer. Repair and modification that
necessitate permanent assembly (soldering, welding, Located on the liquid line, permits control of the unit charge
expanding etc.) must be made using the correct and indicates moisture in the circuit. The presence of bubbles
procedures and by qualified operators. in the sight-glass indicates an insufficient charge or non-
- An indication of any modification or repair must be condensables in the system. The presence of moisture changes
shown in the monitoring and maintenance file. the colour of the indicator paper in the sight-glass.
25
8 - MAIN OPTIONS AND ACCESSORIES 8.7 - Additional capacity step 30HZ/HZV 043 to 065
(option 94)
Depending on the applications for which the units are selected,
they can be equipped with options. This chapter describes the Compressor B1 of the 30HZ 043-065 units is equipped with a
main components that require special information for correct capacity reduction that increases the available capacity steps
start-up and maintenance of these units, except where this is to five steps.
contained in a separate document.
8.8 - Evaporator pump starter (options 84 and 84D)
8.1 - Units for low evaporator outlet temperature
applications (options 5 and 6) Option 84: single evaporator pump
Option 84D: dual evaporator pump
Compressors (option 5 or 6) The unit control boxes are equipped with a disconnect-
The capacity reductions are suppressed. The number of contactor assembly (2 for option 84D) that allows control of
capacity stages is the same as the number of compressors. the evaporator pump.
Each compressor is equipped with a temperature sensor 8.9 - Condenser pump starter (option 84R)
located in the discharge block which permits control of the
discharge gas temperature. The unit control boxes are equipped with a disconnect-
contactor assembly that allows control of the condenser pump.
Expansion devices (option 5 or 6)
The expansion devices are chosen in accordance with the
operating conditions supplied when the unit was ordered.
Evaporator (option 6)
This is designed and made of special materials, and permits
operation down to -15°C fluid-side. The evaporator shell has
double thermal insulation of polyurethane foam (2 x 19 mm).
Condensers (option 6)
Because the thermal heat rejection is less important, the
condensers are down-graded by one size.
26
9 - MAINTENANCE 9.2 - Maintenance of the refrigerant circuit
During the unit operating life the service checks and tests must • Keep the unit itself and the space around it clean and free
be carried out in accordance with applicable national of obstructions. Remove all rubbish such as packing
regulations. materials, as soon as the installation is completed.
• Regularly clean the exposed pipework to remove all dust
If there are no similar criteria in local regulations, the and dirt. This makes detection of water leaks easier, and
information on checks during operation in annex C of standard they can be repaired before more serious faults develop.
EN 378-2 can be used. • Confirm that all screwed and bolted connections and
joints are secure. Secure connections prevent leaks and
External visual checks: annex D of standard EN 378-2. These vibration from developing.
controls must be carried out: • Check that all insulation joints are securely closed and
- After an intervention that is likely to affect the resistance that all insulation is firmly in place. Check all heat
or a change in use or change of high-pressure refrigerant, exchangers and all pipework.
or after a shut down of more than two years. Components
that do not comply, must be changed. Test pressures 9.2.1 - Verification of the refrigerant charge
above the respective component design pressure must not
be applied (annex B and D). CAUTION: The 30HZ/HZV units are supplied with a precise
- After repair or significant modifications or significant refrigerant charge (see Physical Data table).
system or component extension (annex B)
- After re-installation at another site (annexes A, B and D) To verify the correct system charge prodeed as follows:
- After repair following a refrigerant leak (annex D). The Ensure that no bubbles appear in the sight-glass, when operat-
frequency of refrigerant leak detection can vary from ing the unit at full load for a while. Under these conditions the
once per year for systems with less than 1% leak rate per apparent subcooling which is equal to the saturated
year to once a day for systems with a leak rate of 35% per condensing temperature (1 - on the saturated dew point curve)
year or more. The frequency is in proportion with the leak minus the liquid refrigerant temperature (3) ahead of the
rate. expansion device must be between 12 and 14°C. This
corresponds to an actual subcooling temperature of between 5
NOTE: High leak rates are not acceptable. The necessary and 7 K at the condenser outlet, depending on the unit type.
steps must be taken to eliminate any leak detected. Actual subcooling is equal the saturated liquid temperature (2
- on the saturated bubble point curve) minus the liquid
NOTE 2: Fixed refrigerant detectors are not leak detectors, refrigerant temperature (3) ahead of the expansion device. Use
as they cannot locate the leak. the pressure tap supplied on the liquid piping to charge
refrigerant and to find out the pressure of the liquid refrigerant.
9.1 - Soldering and welding If the subcooling value is not correct, i.e. lower than the
specified values, a leak detection test must be carried out on
Component, piping and connection soldering and welding the unit, as it no longer contains its original charge.
operations must be carried out using the correct procedures
and by qualified operators. Pressurised containers must not be WARNING: To ensure proper operation of 30HZ/HZV units
subjected to shocks, nor to large temperature variations during there must be at least 12 K of subcooling as the liquid
maintenance and repair operations. refrigerant enters the expansion valve.
Any technician attending the machine for any purpose must be The 30HZ/HZV units use refrigerant. For your information,
fully qualified to work on refrigerant and electrical circuits. we are reproducing here some extracts from the official
publication dealing with the design, installation, operation
WARNING: Before doing any work on the machine ensure and maintenance of air conditioning and refrigeration
that the power is switched off. If a refrigerant circuit is systems and the training of people involved in these activities,
opened, it must be evacuated, recharged and tested for leaks. agreed by the air conditioning and refrigeration industry.
Before any operation on a refrigerant circuit, it is necessary
to remove the complete refrigerant charge from the unit with
a refrigerant charge recovery group.
27
Apparent and actual subcooling 9.2.3 - Recharging liquid refrigerant
Refrigeration installations must be inspected and maintained Find the leak and completely drain the system with a refrigerant
regularly and rigorously by specialists. Their activities must be recovery unit. Carry out the repair, leak test and then recharge
overseen and checked by properly trained people. To minimise the system.
discharge to the atmosphere, refrigerants and lubricating oil
must be transferred using methods which reduce leaks and IMPORTANT: After the leak has been repaired, the circuit
losses to a minimum. must be tested, without exceeding the maximum low-side
• Leaks must be repaired immediately operating pressure shown on the unit name plate.
• All units are equipped with two special connections on
the suction and liquid line, which permit the connection The refrigerant must always be recharged in the liquid phase
of quick-connect recovery valves without loss of into the liquid line.
refrigerant. The refrigerant cylinder must always contain at least 10% of
• If the residual pressure is too low to make the transfer its initial charge. For the refrigerant quantity per circuit, refer
alone, a purpose-built refrigerant recovery unit must be to the data on the unit name plate.
used.
• Compressor lubricating oil contains refrigerant. Any oil 9.2.5 - Characteristics of R407C
drained from a system during maintenance must See the table on the following page.
therefore be handled and stored accordingly. Saturated bubble point temperatures (bubble point curve)
• Refrigerant under pressure must never be discharged to Saturated dew point temperatures (dew point curve)
the atmosphere.
9.3 - Electrical maintenance
28
Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew
(relative) point temp. point temp. (relative) point temp. point temp. (relative) point temp. point temp.
1 -28.55 -21.72 10.5 23.74 29.35 20 47.81 52.55
1.25 -25.66 -18.88 10.75 24.54 30.12 20.25 48.32 53.04
1.5 -23.01 -16.29 11 25.32 30.87 20.5 48.83 53.53
1.75 -20.57 -13.88 11.25 26.09 31.62 20.75 49.34 54.01
2 -18.28 -11.65 11.5 26.85 32.35 21 49.84 54.49
2.25 -16.14 -9.55 11.75 27.6 33.08 21.25 50.34 54.96
2.5 -14.12 -7.57 12 28.34 33.79 21.5 50.83 55.43
2.75 -12.21 -5.7 12.25 29.06 34.5 21.75 51.32 55.9
3 -10.4 -3.93 12.5 29.78 35.19 22 51.8 56.36
3.25 -8.67 -2.23 12.75 30.49 35.87 22.25 52.28 56.82
3.5 -7.01 -0.61 13 31.18 36.55 22.5 52.76 57.28
3.75 -5.43 0.93 13.25 31.87 37.21 22.75 53.24 57.73
4 -3.9 2.42 13.5 32.55 37.87 23 53.71 58.18
4.25 -2.44 3.85 13.75 33.22 38.51 23.25 54.17 58.62
4.5 -1.02 5.23 14 33.89 39.16 23.5 54.64 59.07
4.75 0.34 6.57 14.25 34.54 39.79 23.75 55.1 59.5
5 1.66 7.86 14.5 35.19 40.41 24 55.55 59.94
5.25 2.94 9.11 14.75 35.83 41.03 24.25 56.01 60.37
5.5 4.19 10.33 15 36.46 41.64 24.5 56.46 60.8
5.75 5.4 11.5 15.25 37.08 42.24 24.75 56.9 61.22
6 6.57 12.65 15.5 37.7 42.84 25 57.35 61.65
6.25 7.71 13.76 15.75 38.31 43.42 25.25 57.79 62.07
6.5 8.83 14.85 16 38.92 44.01 25.5 58.23 62.48
6.75 9.92 15.91 16.25 39.52 44.58 25.75 58.66 62.9
7 10.98 16.94 16.5 40.11 45.15 26 59.09 63.31
7.25 12.02 17.95 16.75 40.69 45.71 26.25 59.52 63.71
7.5 13.03 18.94 17 41.27 46.27 26.5 59.95 64.12
7.75 14.02 19.9 17.25 41.85 46.82 26.75 60.37 64.52
8 14.99 20.85 17.5 42.41 47.37 27 60.79 64.92
8.25 15.94 21.77 17.75 42.98 47.91 27.25 61.21 65.31
8.5 16.88 22.68 18 43.53 48.44 27.5 61.63 65.71
8.75 17.79 23.57 18.25 44.09 48.97 27.75 62.04 66.1
9 18.69 24.44 18.5 44.63 49.5 28 62.45 66.49
9.25 19.57 25.29 18.75 45.17 50.02 28.25 62.86 66.87
9.5 20.43 26.13 19 45.71 50.53 28.5 63.27 67.26
9.75 21.28 26.96 19.25 46.24 51.04 28.75 63.67 67.64
10 22.12 27.77 19.5 46.77 51.55 29 64.07 68.02
10.25 22.94 28.56 19.75 47.29 52.05 29.25 64.47 68.39
Plug
When the evaporator heads and manifolds are removed, the
outer tube end plates will be visible. Ring
Six or eight evaporator tubes are swaged into the end plate and
cannot be removed. A dot punch mark in the end plate opposite Components Part number
each one identifies each of them. If any of them develop a Tube brass plug ---T-853--103500S-*
leak, the tube must be plugged, as described below. Tube brass ring ---T-853--002570S-*
29
9.4.3 - Replacing cooler tubes
Retubing must be done only by a properly trained service Bolt size M12 - 71-87 Nm
Bolt size M16 - 171-210 Nm
engineer. Most standard practices can be applied, but for Bolt size M20 - 171-210 Nm
Stage 1
cooler tubes a 5% crush allowance is made for tube expansion
Stage 2
and twisting (15.87 mm diameter tubes are used in these 7
coolers). 1
5
The table below gives the specification of the materials used.
4 3
Example:
6
Tube sheet hole diameter 16.00 mm 2
Tube outside diameter 15.87 mm 8
Clearance 0.13 mm
Tube inside diameter before rolling 14.27 mm
Tube inside diameter after rolling 14.48 mm
9.5 - Corrosion control
NOTE: Tubes next to the gasket webs must be flush with the
All metallic parts of the unit (chassis, casing panels, control
tube sheets at either end of the cooler.
boxes, heat exchangers etc.) are protected against corrosion by
a coating of powder or liquid paint. To prevent the risk of
9.4.4 - Preparation of gaskets
blistering corrosion that can appear when moisture penetrates
When rebuilding the cooler, new gaskets must always be used.
under the protective coatings, it is necessary to carry out
They must conform to the Carrier specification for compressed
periodic checks of the coating (paint) condition.
gaskets.
• Clean the gasket and its place on the tube sheet.
• Cover the two matching surfaces (gasket and tube sheet)
with adhesive, and stick them together.
• Let the joint dry for 5 minutes.
• Moisten the joint with a small amount of compressor oil.
• Reinstall the evaporator head within 30 minutes.
30
10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS (USE FOR JOB FILE)
Preliminary information
Job name: ................................................................................................................................................................................................
Location:.................................................................................................................................................................................................
Installing contractor: ..............................................................................................................................................................................
Distributor: .............................................................................................................................................................................................
Start-up preformed by: ...........................................................................................................................................................................
Compressors
Model: ............................................................................................ S/N ..............................................................................................
Compresseurs
Circuit A Circuit B
1. Model # ...................................................................................... 1. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
Mtr # ........................................................................................... Mtr # ...........................................................................................
Cooler
Model # ........................................................................................... Manufactured by .........................................................................
S/N .................................................................................................. Date .............................................................................................
Condensers
Manufacturer ..........................................................................................................................................................................................
Model # ........................................................................................... S/N ..............................................................................................
31
Unit start-up
CWP starter has been properly interlocked with the chiller
Oil heaters have been energized for at least 24 hours
Oil level is correct
All discharge, suction and liquid valves are open
Unit has been leak checked (including fittings)
Locate, repair, and report any refrigerant leaks
................................................................................................................................................................................................................
................................................................................................................................................................................................................
................................................................................................................................................................................................................
WARNING: Do not start chiller if voltage imbalance is greater than 2%. Contact local power company for assistance.
WARNING: Plot cooler pressure drop on performance data chart (in product data literature) to determine total liters per
second (l/s) and find unit's minimum flow rate.
32
Perform TEST function (indicate positive result):
WARNING: Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the TEST
function instructions in the Controls and Troubleshooting literature (follow the procedure in the Controls IOM).
Be sure all service valves are open before beginning the compressor test section.
Examine and register the configuration at the installation site <2> <SRVC>
WARNING: Be sure that all service valves are open, and all pumps are on before attempting to start this machine. Once all
checks have been made, move the switch to "LOCAL" or "REMOTE" from "OFF".
WARNING: Once the machine has been operating for a while and the temperatures and pressures have stabilized, record the
following:
Compressor oil pressure A1* ......................................................... Compressor oil pressure B1* .....................................................
A2* ......................................................... B2* .....................................................
A3* ......................................................... B3* .....................................................
A4* ......................................................... B4* .....................................................
* if installed
NOTES:
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
33
Order No: 13412-76, 03.2003. Supersedes order No: 13412-76, 08.2002 Manufacturer: Carrier s.a., Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on chlorine-free paper.