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30RA 040 - 240
30RA 040-140 NEE (high-ambient)
Air-Cooled Liquid Chillers with
Integrated Hydronic Module
Nominal cooling capacity 40-250 kW
50 Hz
AQUASNAP
Carrier is participating in the
Eurovent Certification Programme.
Products are as listed in the
Eurovent Directory of Certified
Products.
For the operation of the control please refer
to the Pro-Dialog Plus Control manual for
the 30RA/RY - RH/RYH series
Installation, operation and maintenance instructions
The cover image is for illustrative purposes only and is not part of any offer for sale or contract.
2
Table of contents
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
2 - PRELIMINARY CHECKS .......................................................................................................................................................... 6
2.1 - Check equipment received ........................................................................................................................................................... 6
2.2 - Moving and siting the unit ............................................................................................................................................................ 6
3 - DIMENSIONS/CLEARANCES .................................................................................................................................................. 7
4 - LIFTING WITH SLINGS ............................................................................................................................................................ 9
5 - PHYSICAL DATA ....................................................................................................................................................................... 10
6 - ELECTRICAL DATA ................................................................................................................................................................. 11
7 - APPLICATION DATA ................................................................................................................................................................ 12
7.1 - Unit operating range ................................................................................................................................................................... 12
7.2 - Minimum and maximum evaporator water flows ...................................................................................................................... 12
7.3 - Minimum water flow rate ........................................................................................................................................................... 12
7.4 - Maximum evaporator water flow rate ........................................................................................................................................ 12
7.5 - Water loop volume ..................................................................................................................................................................... 12
7.6 - Unit operating range at full and part load. .................................................................................................................................. 13
7.7 - Pressure drop in the plate heat exchangers ................................................................................................................................. 14
8 - ELECTRICAL CONNECTION ................................................................................................................................................ 15
8.1 - Power supply .............................................................................................................................................................................. 16
8.2 - Voltage phase imbalance (%) ..................................................................................................................................................... 16
9 - RECOMMENDED WIRE SECTIONS .................................................................................................................................... 18
9.1 - Field control wiring .................................................................................................................................................................... 18
10 - WATER CONNECTIONS ........................................................................................................................................................ 19
10.1 - Operating precautions .............................................................................................................................................................. 19
10.2 - Hydronic connections ............................................................................................................................................................... 19
10.3 - Frost protection ........................................................................................................................................................................ 19
11 - NOMINAL SYSTEM WATER FLOW CONTROL .............................................................................................................. 21
11.1 - Water flow control procedure ................................................................................................................................................... 21
11.2 - Pump curve and water flow control as a function of the system pressure drops ..................................................................... 21
11.3 - Pump pressure/flow rate curves ............................................................................................................................................... 22
11.4 - Available static system pressure ............................................................................................................................................... 22
12 - START-UP .................................................................................................................................................................................. 23
12.1 - Preliminary checks ................................................................................................................................................................... 23
12.2 - Actual start-up .......................................................................................................................................................................... 23
12.3 - Operation of two units in master/slave mode ........................................................................................................................... 23
13 - MAINTENANCE ...................................................................................................................................................................... 24
13.1 - Maintenance of the refrigerant circuit ...................................................................................................................................... 24
13.2 - Electrical maintenance ............................................................................................................................................................. 25
13.3 - Condenser coil .......................................................................................................................................................................... 26
13.4 - Replacement of motor and pump impeller sub-assembly on the hydronic module ................................................................. 26
14 - START-UP CHECKLIST FOR 30RA LIQUID CHILLERS (USE FOR JOB FILE) ........................................................ 28
3
1 - INTRODUCTION
Prior to the initial start-up of the 30RA units, the people
involved in the on-site installation, start-up, operation, and
maintenance of this unit should be thoroughly familiar with
these instructions and the specific project data for the
installation site.
The 30RA liquid chillers are designed to provide a very high
level of safety during installation, start-up, operation and
maintenance. They will provide safe and reliable service when
operated within their application range.
This manual provides the necessary information to familiarize
yourself with the control system before performing start-up
procedures. The procedures in this manual are arranged in the
sequence required for machine installation, start-up, operation
and maintenance.
Ensure that no refrigerant can escape at the safety valves into
the building interior. The outlet from relief valves must be
vented outdoors. Accumulation of refrigerant in an enclosed
space can displace oxygen and cause asphyxiation or
explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
1.2 - Equipment and components under pressure
Be sure you understand and follow the procedures and safety
precautions contained in the instructions supplied with the
machine, as well as those listed in this guide.
These products incorporate equipment or components under
pressure, manufactured by Carrier or other manufacturers.
We recommend that you consult your appropriate national
trade association or the owner of the equipment or components under pressure (declaration, re-qualification, retesting,
etc.). The characteristics of this equipment/these components are given on the nameplate or in the required documentation, supplied with the products.
1.1 - Installation safety considerations
1.3 - Maintenance safety considerations
After the unit has been received, when it is ready to be installed
or reinstalled, and before it is started up, it must be inspected
for damage. Check that the refrigerant circuit(s) is (are) intact.
Ensure especially that no components or pipes have shifted
(e.g. following a shock). If in doubt, carry out a leak tightness
check and verify with the manufacturer that the circuit integrity
has not been impaired. If damage is detected upon receipt,
immediately file a claim with the shipping company.
Engineers working on the electric or refrigeration components must be authorized and fully qualified to do so (electricians trained and qualified in accordance with IEC 60364
Classification BA4).
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
truck, as long as the forks are positioned in the right place
and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked at the four corners at the
unit base.
These units are not designed to be lifted from above. Use
slings with the correct capacity, and always follow the lifting
instructions on the certified drawings supplied with the unit.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
Never cover any safety devices.
This applies to the valve in the hydronic circuit and the
valve(s) in the refrigerant circuit(s) .
Ensure that the valve(s) (if used in the refrigerant circuit)
are correctly installed, before operating the unit (the
valves are not systematically installed on the units, but may
be required by certain national safety codes, depending on
the destination country).
Provide a drain in the discharge circuit, close to each valve,
to avoid an accumulation of condensate or rain water.
4
All refrigerant circuit repairs must be carried out by a trained
person, fully qualified to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualified specialists.
Never work on a unit that is still energized.
Never work on any of the electrical components, until the
general power supply to the unit has been cut using the
disconnect switch in the control box.
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead of
the machine.
If the work is interrupted, always ensure that all circuits are
still deenergized before resuming the work.
ATTENTION: Even if the unit has been switched off, the
power circuit remains energized, unless the unit or circuit
disconnect switch is open. Refer to the wiring diagram for
further details. Attach appropriate safety labels.
Once a year check that the high-pressure safety switch is
correctly connected and that it cuts out at the correct value
(cut-out between 2820 and 2900 kPa, relative for standard
units and between 3000 and 3100 kPa for 30RA NEE units.
At least once a year thoroughly inspect the protection devices
(valves and fuses). If the machine operates in a corrosive
environment, inspect the protection devices more frequently.
Regularly carry out leak tests and immediately repair any
leaks.
1.4 - Repair safety considerations
All installation parts must be maintained by the personnel
in charge, in order to avoid material deterioration and
injuries to people. Faults and leaks must be repaired
immediately. The authorized technician must have the
responsibility to repair the fault immediately. Each time
repairs have been carried out to the unit, the operation of
the safety devices must be re-checked.
If a leak occurs, evacuate all refrigerant, repair the leak
detected and recharge the circuit with the total R407C charge,
as indicated on the unit name plate. Never top up the charge.
Only charge liquid refrigerant R407C at the liquid line.
Ensure that you are using the correct refrigerant type before
recharging the unit.
Charging any refrigerant other than the original charge type
(R407C) will impair machine operation and can even lead to
a destruction of the compressors. The compressors operating
with this refrigerant type are charged with a synthetic
polyolester oil.
These units have a hermetic refrigerant circuit and the
original charge need not be topped up.
Do not use oxygen to purge lines or to pressurize a machine
for any purpose. Oxygen gas reacts violently with oil, grease,
and other common substances.
Never exceed the specified maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and the
pressures given on the unit name plate.
Do not use air for leak testing. Use only refrigerant or dry
nitrogen.
Do not unweld or flamecut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid and
vapour) has been removed from chiller. Traces of vapour
should be displaced with dry air nitrogen. Refrigerant in
contact with an open flame produces toxic gases.
Do not attempt to remove refrigerant circuit components or
fittings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 kPa before removing
components or opening a circuit.
Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install safety valves in
series or backwards.
CAUTION
Do not step on refrigerant lines. The lines can break under
the weight and release refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, etc.) to lift or
move heavy components such as compressors or plate heat
exchangers. For lighter components, use lifting equipment
when there is a risk of slipping or losing your balance.
Use only original replacement parts for any repair or
component replacement. Consult the list of replacement parts
that corresponds to the specification of the original
equipment.
Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body first.
Close the entering and leaving water shutoff valves and
purge the unit hydronic circuit, before working on the
components installed on the circuit (screen filter, pump, water
flow switch, etc.).
Periodically inspect all valves, fittings and pipes of the
refrigerant and hydronic circuits to ensure that they do not
show any corrosion or any signs of leaks.
The necessary protection equipment must be available, and
appropriate fire extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles. Wash any spills from the skin
with soap and water. If liquid refrigerant enters the eyes,
immediately and abundantly flush the eyes with water and
consult a doctor.
Never apply an open flame or live steam to a refrigerant
container. Dangerous overpressure can result. If it is
necessary to heat refrigerant, use only warm water.
Do not re-use disposable (non-returnable) cylinders or
attempt to refill them. It is dangerous and illegal. When
cylinders are empty, evacuate the remaining gas pressure,
and move the cylinders to a place designated for their
recovery. Do not incinerate.
5
2 - PRELIMINARY CHECKS
2.1 - Check equipment received
•
•
•
Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately file a
claim with the shipping company.
Confirm that the unit received is the one ordered.
Compare the name plate data with the order.
Confirm that all accessories ordered for on-site installation
have been delivered, and are complete and undamaged.
2.2 - Moving and siting the unit
2.2.1 - Moving
See chapter 1.1 " Installation safety considerations "
2.2.2 - Siting the unit
Always refer to the chapter " Dimensions and clearances " to
confirm that there is adequate space for all connections and
service operations. For the centre of gravity coordinates, the
position of the unit mounting holes, and the weight distribution points, refer to the certified dimensional drawing
supplied with the unit.
CAUTION:
Only use slings at the designated lifting points which are
marked on the unit.
Before siting the unit check that :
•
•
•
•
•
•
6
the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
the surface is horizontal, flat and intact.
there is adequate space above the unit for air flow.
there are adequate support points and that they are in the
right places.
the location is not subject to flooding.
where heavy snowfall is likely and long periods of subzero temperatures are normal, provision has been made to
prevent snow accumulating by raising the unit above the
height of drifts normally experienced.
Baffles may be necessary to deflect strong winds and to
prevent snow from blowing directly into the unit. They
must not restrict air flow into the unit.
CAUTION:
Before lifting the unit, check that all casing panels are
securely fixed in place. Lift and set down the unit with great
care. Tilting and jarring can damage the unit and impair unit
operation.
The 30RA units can be hoisted with rigging. Coils should
always be protected against crushing while a unit is being
moved. Use struts or spreader bars to spread the slings above
the unit. Do not tilt a unit more than 15°.
WARNING:
Never push or lever on any of the enclosure panels of the
unit. Only the base of the unit frame is designed to withstand
such stresses.
3 - DIMENSIONS/CLEARANCES
30RA 040-080
1081
1329
2071
1000
1000
1
2
1000
1
2
1000
30RA 090-160
2071
1000
1329
2278
1
1
2
2
1
1000
1
1000
1000
7
30RA 200-240
3351
1000
1674
2279
1
2
1
2
2
1
1000
Legend:
All dimensions are given in mm
Power supply
Water inlet
Water outlet
Required clearances for air flow
Recommended clearances for maintenance
Air outlet, do not obstruct
Power cable entry
NOTE:
A
Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation.
For the location of fixing points, weight distribution and coordinates of
the centre of gravity refer to the certified dimensional drawings.
B
In multiple-chiller installations (maximum four units), the side clearance
between the units should be increased from 1000 to 2000 mm.
C
The height of the solid surface must not exceed 2 m.
8
1000
1
2
1000
Multiple chiller installation
NOTE: If the walls are higher than 2 m, contact the factory.
Solid surface
1000
1000
2000
2000
2000
Solid surface
1000
2000
1000
1000
4 - LIFTING WITH SLINGS
30RA 040 - 080
30RA 090 - 160
30RA 200 - 240
M
3500
M
3000
4000
M
Z
Z
Y
X
Y
Y
X
120
80
80
Z
X
50
50
(a)
50.5
(a)
(a)
(a)
Maintenance shackle, field-supplied
X mm
30RA 040
30RA 050
30RA 060
30RA 070
30RA 080
30RA 090
Y mm
Z mm
Weight kg
1030
930
930
930
930
980
540
610
610
610
610
1190
570
570
570
570
570
570
536
595
610
625
642
1100
X mm
30RA 100
30RA 120
30RA 140
30RA 160
30RA 200
30RA 240
Y mm
Z mm
Weight kg
980
980
930
930
1460
1435
1240
1250
1140
1140
1170
1136
570
570
570
570
702
691
1112
1157
1224
1262
2223
2395
These illustrations should only be used as guidelines. Before lifting the unit, always refer to the certified dimensional
drawings or maintenance labels on the unit.
9
5 - PHYSICAL DATA
30RA
Net nominal cooling capacity*
30RA
040
050
060
070
080
090
100
120
140
160
200
240
kW
38.6
49.4
58
67
79
89
98
118
135
158
206
248
Operating weight
with hydronic module
kg
536
595
610
625
642
1100
1112
1157
1224
1262
2133
2305
Operating weight
without hydronic module
kg
502
560
573
587
605
1062
1075
1107
1174
1210
1996
2106
kg
kg
R-407C
10
13
-
14
-
12.5
-
18
-
10
13
10
14
10
18
12.5
12.5
18
18
21
28
28
28
%
Hermetic, scroll
A1
A1+A2
1
2
100
46
A1+A2
2
50
A1+A2
2
50
A1
B1+B2
3
25
A1
B1+B2
3
25
A1
B1+B2
3
33
A1+A2
B1+B2
4
25
A1+A2
B1+B2
4
25
A1+A2
A1+A2+A3
B1+B2+B3 B1+B2+B3
5
6
20
16.5
Welded, direct-expansion plate heat exchanger
3.6
4.6
5.9
6.5
7.6
8.2
9.5
11.2
13
15.2
22
26
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
kPa
300
300
300
300
300
300
300
300
300
300
400
400
in
mm
Threaded male conical gas connection
2
2
2
2
2
60.3
60.3
60.3
60.3
60.3
2
60.3
2
60.3
2-1/2
76.1
2-1/2
76.1
2-1/2
76.1
3
88.9
3
88.9
Refrigerant charge
Circuit A
Circuit B
Compressors
Quantity, circuit A
Quantity, circuit B
Number of capacity steps
Minimum capacity
Control type
Evaporator
Water volume
Max. water-side operating pressure
without hydronic module
Max. water-side operating pressure
with hydronic module
Water connection type
Gas thread diameter
Outside tube diameter
48.3 r/s
A1+A2
2
42
PRO-DIALOG Plus
l
kPa
Condensers
Grooved copper tubes and aluminium fins
Fans
Quantity
Air flow (high speed)
Speed (high/low)
Axial FLYING-BIRD fans, with rotating shroud
1
1
1
1
1
2
2
2
2
2
4
3945
3780
4220
5150
5800
7725
8165
9745
10300 11600 17343
11.5/5.8 11.5/5.8 11.5/5.8 15.6/7.8 15.6/7.8 11.5/5.8 11.5/5.8 15.6/7.8 15.6/7.8 15.6/7.8 11.5/5.8
l/s
r/s
Hydronic module
Pump
Quantity
Expansion tank volume
*
l
4
20908
15.6/7.8
Pump, screen filter, safety valve, expansion tank, pressure gauges, purge valves, flow switch and flow
control valve.
Single, centrifugal monocell pump, 48.3 r/s
1
1
1
1
1
1
1
1
1
1
1
1
12
12
12
12
12
35
35
35
35
35
50
50
Standard EUROVENT conditions: evaporator entering/leaving water = 12°C/7°C, outdoor air temperature = 35°C
Net nominal cooling capacity based on Eurovent conditions = gross cooling capacity plus the capacity corresponding to the available pressure (flow x pressure/0.3)
30RA NEE
40
50
60
70
90
100
120
140
Nominal cooling capacity*
kW
41.7
50
59
68
92
100
117
136
Operating weight
with hydronic module
kg
551
616
610
716
1136
1127
1196
1406
Operating weight
without hydronic module
kg
517
581
573
678
1098
1090
1146
1356
kg
kg
R-407C
12
-
14.3
-
14
-
13.5
-
12
14.3
12
14
14
14
13.5
13.5
%
Hermetic, scroll 48.3 r/s
1
2
2
1
2
2
100
46
42
2
2
50
1
2
3
25
1
2
3
25
2
2
4
21
2
2
4
25
2
10950
15.6/7.8
2
11600
15.6/7.8
2
12800
24.6/12.3
Refrigerant charge
Circuit A
Circuit B
Compressors
Quantity, circuit A
Quantity, circuit B
Number of capacity steps
Minimum capacity
Control type
PRO-DIALOG Plus
Condensers
Grooved copper tubes and aluminium fins
Fans
Quantity
Air flow (high speed)
Speed (high/low)
l/s
r/s
Axial fans,
1
5150
15.6/7.8
l
Welded, direct-expansion plate heat exchanger
3.6
4.6
5.9
6.5
8.2
9.5
12.2
13
kPa
1000
1000
1000
1000
Evaporator
Water volume
Max. water-side operating pressure
(option without hydronic module)
with rotating shroud
1
1
5800
5800
15.6/7.8 15.6/7.8
1000
1000
1
2
6400
10950
24.6/12.3 15.6/7.8
1000
1000
Hydronic module
Pump, screen filter, safety valve, expansion tank, pressure gauges, purge valves, flow switch and
flow control valve
Pump
Quantity
Expansion tank volume
Max. water-side operating pressure
with hydronic module
Water connection
(with and without hydronic module)
Gas thread diameter
Outside tube diameter
l
Single, centrifugal monocell pump, 48.3 r/s
1
1
1
1
12
12
12
12
1
35
1
35
1
35
1
35
kPa
300
300
300
300
300
in
mm
Threaded male conical gas connection
2
2
2
2
60.3
60.3
60.3
60.3
2
60.3
2
60.3
2-1/2
76.1
2-1/2
76.1
300
300
300
* Based on the following conditions: evaporator entering/leaving water = 12°C/7°C, outdoor air temperature = 35°C
10
6 - ELECTRICAL DATA
30RA
040
Power circuit
Nominal voltage
Voltage range
V-ph-Hz
V
Control circuit supply
Maximum unit power input*
Nominal unit current draw**
Maximum unit current draw***
Maximum unit current draw****
Maximum start-up current*****
Standard unit†
Unit with electronic starter (option)‡
050
060
070
080
090
100
120
140
160
200
240
69.2
104.6
132.1
118.9
80.8
114.9
149.9
134.9
101.85
151.0
195.5
176.3
119.42
179.1
232.3
209.1
400-3-50
360-440
The control circuit is supplied via the transformer installed on
21.1
25.4
29.7
34.7
40.5
44.6
48.9
31.3
36.9
43.5
52.3
57.5
64.8
71.4
40.3
48.8
56.2
66.1
75.0
85.3
92.8
36.3
43.9
50.6
59.5
67.5
76.8
83.5
kW
A
A
A
A
the unit
61.4
88.7
115.2
103.7
182
121
160
113
169
122
213
152
222
-
229
-
249
-
228
-
280
-
321.5
-
354.6
-
10
Three-phase short-circuit holding current kA
154
109
10
10
10
10
10
10
10
10
10
10
10
*
Power input, compressor(s) + fan(s) + pump, at max. unit operating conditions (water entering/leaving temperature = 15°C/10°C and a maximum air entering temperature of 45°C ±
1 K depending on the unit size and at a nominal voltage of 400 V (values given on the unit name plate).
**
Nominal unit operating current draw at standard Eurovent conditions: evaporator entering/leaving water = 12°C/7°C, outdoor air temperature = 35°C. The current values are given for a
nominal voltage of 400 V.
*** Maximum unit operating current at maximum unit power input and 360 V.
**** Maximum unit operating current at maximum unit power input and 400 V (data shown on the unit name plate).
***** Maximum instantaneous start-up current (max. operating current of the smallest compressor(s) + fan current + pump current + locked rotor current of the largest compressor).
†
Maximum instantaneous starting current at 400 V nominal voltage (maximum operating current of the smallest compressors + fan current + pump current + locked rotor current of the
largest compressor).
‡
Maximum instantaneous starting current at 400 V nominal voltage and with compressor with electronic starter (maximum operating current of the smallest compressor(s) + fan current +
pump current + reduced start-up current of the largest compressor).
COMPRESSOR
30RA
Reference code
I Nom
I Max
LRA
Circuit
DQ 12 CA 001EE
14
19.1
130
DQ 12 CA 002EE
16.2
22.1
130
DQ 12 CA 003EE
14.8
20.3
120
DQ 12 CA 005EE
21.9
28.3
135
A
B
A
B
A
B
A
B
A
B
DQ 12 CA 006EE
24.5
32.8
175
040
050
060
070
080
090
100
120
140
160
200
240
A1+A2
B1+B2
A1+A2
B1+B2+B3
A1+A2+A3
B1+B2+B3
A1
B1
A2
B2
A1
B1
A2
A1+A2
A1
A1+A2
A1
B2
A1
A1+A2
B1+B2
A1
B1+B2
Legend:
I Nom Nominal current draw at Eurovent conditions (see definition of conditions under nominal unit current draw), A
I Max Maximum operating current at 360 V, A
LRA Locked rotor current, A
30RA NEE
Power circuit
Nominal voltage
Voltage range
Control circuit supply
Maximum unit power input*
Nominal unit current draw**
Nominal unit current draw***
Maximum start-up current
Standard unit†
Unit with electronic starter (option)‡
Three-phase short-circuit holding current
*
**
***
†
‡
40
V-ph-Hz
V
50
60
70
90
100
120
140
400-3-50
360-440
The control circuit is supplied via the transformer installed on the unit
22.5
26.8
31.1
37.65
47.4
51.7
62
33
38.6
45.2
60
68.2
74.8
90.3
38
45.6
52.3
67.2
80.2
86.9
104.5
75
120
134.3
A
A
184
122
156
110
162
115
177
129
225
-
232
-
214
-
244
-
kA
10
10
10
10
10
10
10
10
kW
A
A
Power input, compressor(s) + fan(s) + pump, at max. unit operating conditions depending on the unit size and at a nominal voltage of 400 V (values given on the unit name plate).
Nominal unit operating current draw at the following conditions: evaporator entering/leaving water = 12°C/7°C, outdoor air temperature = 35°C. The current values are given for a nominal
voltage of 400 V (values given on the unit name plate).
Maximum unit operating current at maximum unit power input and 400 V (data shown on the unit name plate).
Maximum instantaneous starting current at 400 V nominal voltage (maximum operating current of the smallest compressors + fan current + pump current + locked rotor current of the largest
compressor).
Maximum instantaneous starting current at 400 V nominal voltage and with compressor with electronic starter (maximum operating current of the smallest compressor(s) + fan current +
pump current + reduced start-up current of the largest compressor).
11
7 - APPLICATION DATA
7.5 - Water loop volume
7.1 - Unit operating range
7.5.1 - Minimum water loop volume
The minimum water loop volume, in litres, is given by the
following formula:
Volume = CAP (kW) x N* = litres, where CAP is the nominal
cooling capacity at nominal operating conditions.
7.1.1 - 30RA units
Evaporator
Minimum °C
Maximum °C
Water entering temp. (at start-up)
Water leaving temp. (in operation)
Water entering temp. (at shut down)
7.8 *
5 **
-
30
15
55
-10
46
Evaporator
Minimum °C
Maximum °C
Water entering temp. (at start-up)
Water leaving temp. (in operation)
Water entering temp. (at shut down)
7.8 *
5 **
-
40
15
55
-10
50
Condenser
Entering air temp.
7.1.2 - 30RA NEE units
Condenser
Entering air temp.
Notes
*
For a system requiring operation below 7,8°C, contact Carrier SA.
** For a system requiring operation below 5°C, anti-freeze must be added to
the unit.
7.2 - Minimum and maximum evaporator water flows
30RA
Evaporator water flows
Min. flow rate
l/s
040
050
060
070
080
090
100
120
140
160
200
240
Max. flow rate*
l/s
3.8
4.5
5.2
5.5
5.9
6.1
7.5
10
10.8
11.3
15.7
23.9
3.5
2.5
(See note)
NOTE:
For industrial process cooling applications, where high
stability of the water temperature levels must be achieved, the
values above must be increased.
This volume is required to obtain temperature stability and
precision.
To achieve this volume, it may be necessary to add a storage
tank to the circuit. This tank should be equipped with baffles to
allow mixing of the fluid (water or brine). Please refer to the
examples below.
3.8
4.7
6
6.6
7.4
8.3
9.1
11
13.1
14.9
18.6
23.5
Bad
7.3 - Minimum water flow rate
If the installation flow rate is below the minimum flow rate,
recirculation of the evaporator water flow may take place,
leading to the risk of excessive fouling.
Good
7.5.2 - Maximum water loop volume
Units with hydronic module incorporate an expansion tank that
limits the water loop volume. The table below gives the
maximum loop volume for pure water or ethylene glycol
with various concentrations.
7.4 - Maximum evaporator water flow rate
This is limited by the permitted evaporator pressure drop.
Also, a minimum evaporator ∆T of 2.8 K must be guaranteed,
which corresponds to a water flow rate of 0.9 l/s per kW.
Good
Bad
Legend
*
Maximum flow rate at an available pressure of 50 kPa (unit with
hydronic module).
** Maximum flow rate at a pressure drop of 100 kPa in the plate heat
exchanger (unit without hydronic module).
30RA 040-080
(in litres)
Pure water
EG 10%
EG 20%
EG 35%
30RA 090-160
(in litres)
30RA 200-240
(in litres)
600
450
400
300
1500
1200
1000
800
2000
1600
1400
1000
EG: Ethylene glycol
12
N*
Max. flow rate**
l/s
1.2
1.2
1.5
1.7
2.0
2.2
2.5
2.9
3.4
3.9
6.3
7.6
Application
Air conditioning
30RA 040
30RA 050 to 240
Industrial process cooling
30RA 040 to 240
7.6 - Unit operating range at full and part load
7.6.1 - Standard 30RA units
7.6.2 - 30RA NEE units
˚C
˚C
46
53
45
44.5
44
Entering air temperature
50
-10
0
0
-10
0
1
2
3
4
5
6
7
8
9
10
˚C
Evaporator water leaving temperature
1
2
Evaporator ∆T = 5 K
The evaporator and the hydronic circuit pump are frost protected down to -10°C
outside air temperature.
1
2
5
Evaporator water leaving temperature
10
˚C
Evaporator ∆T = 5 K
The evaporator and the hydronic circuit pump are frost protected down to -10°C
outside air temperature.
Operating range with required anti-freeze solution and special ProDialog control configuration
Operating range with required anti-freeze solution and special Pro-Dialog control
configuration
Exceptional unit operation is authorised in this air temperature range.
Based on the operating conditions (leaving water temperature and thermal
load) the unit control system can automatically unload one or two capacity
stages, in order to maintain the condensing pressure within an acceptable
range. This system prevents high-pressure shutdowns of the unit and
ensures chilled water production at part load, even at very high outside
temperatures. For unit cooling capacities at unloaded conditions refer to
the capacity table.
Notes:
Correct unit operation at high air entering temperatures is linked to
the cleanliness of the condenser. It is therefore strongly recommended to maintain it regularly.
13
7.7 - Pressure drop in the plate heat exchangers
Pressure drop, kPa
100
10
1
11
5
2
3
4
6
12
7
8
9
10
1
1
2
3
4
5
Water flow rate, l/s
Legend
1
2
3
4
5
6
7
8
9
10
11
12
14
30RA 040
30RA 050
30RA 060
30RA 070
30RA 080
30RA 090
30RA 100
30RA 120
30RA 140
30RA 160
30RA 200
30RA 240
6
7
8
9 10
20
8 - ELECTRICAL CONNECTION
30RA 040 - 080
Control box
X
33
33
81
143
A
S
1
L1 L2 L3
A
Y
PE
X
30RA 040 - 080
30RA 090 - 160
30RA 200 - 240
Control box
Y
227
1408
1408
30RA 090 - 240
809
809
1154
X
39
39
295
1257
S
L1 L2 L3
1
B
B
Legend
1 Main disconnect switch
PE Earth connection
S Power supply cable section (see table " Recommended wire sections " ).
X Disconnect switch position referred to the unit side
Y Control box position referred to the unit base
Y
PE
NOTES
The 30RA 040-240 units have only one power
connection point located at the main disconnect switch.
Before connecting electric power cables, it is imperative to
check the correct order of the 3 phases (L1 - L2 - L3).
Non-certified drawings.
Refer to the certified drawings supplied with the unit or
available on request.
15
8.1 - Power supply
The power supply must conform to the specification on the
chiller name plate. The supply voltage must be within the range
specified in the electrical data table.
For connections refer to the wiring diagrams.
WARNING:
Operation of the chiller with an improper supply voltage or
excessive phase imbalance constitutes abuse which will
invalidate the Carrier warranty. If the phase imbalance
exceeds 2% for voltage, or 10% for current, contact your
local electricity supply source at once and ensure that the
chiller is not switched on until corrective measures have been
taken.
8.2 - Voltage phase imbalance (%)
100 x max. deviation from average voltage
Average voltage
Example:
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages
were measured to be:
AB = 406 V ; BC = 399 ; AC = 394 V
Average voltage = (406 + 399 + 394)/3 = 1199/3
= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average:
(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
Motor
The maximum deviation from the average is 6 V. The greatest
percentage deviation is:100 x 6/400 = 1.5 %
This is less than the permissible 2% and is therefore acceptable.
16
-
Electrical data notes 30RA:
•
•
•
•
30RA 040-240 units have a single power connection point located at
the main switch.
The control box includes the following standard features:
- a main disconnect switch, starter and motor protection devices for
each compressor, the fan and the pump
- the control devices
Field connections:
All connections to the system and the electrical installations must be
in full accordance with all applicable local codes.
The Carrier 30RA units are designed and built to ensure
conformance with these codes. The recommendations of European
standard EN 60204-1 (machine safety - electrical machine
components - part 1: general regulations - corresponds to IEC
60204-1) are specifically taken into account, when designing the
electrical equipment.
NOTES:
• Generally the recommendations of IEC 60364 are accepted as
compliance with the requirements of the installation directives.
Conformance with EN 60204 is the best means of ensuring
compliance with the Machines Directive § 1.5.1.
• Annex B of EN 60204-1 describes the electrical characteristics used
for the operation of the machines.
1. The operating environment for the 30RA units is specified below:
a. Environment* - Environment as classified in EN 60721
(corresponds to IEC 60721):
- outdoor installation*
Electrical data notes 30RA NEE units:
•
•
•
•
30RA 040-240 NEE units have a single power connection point
located at the main switch.
The control box includes the following standard features:
- a main disconnect switch, starter and motor protection devices for
each compressor, the fan and the pump
- the control devices
Field connections:
All connections to the system and the electrical installations must be
in full accordance with all applicable local codes.
The Carrier 30RA NEE units are designed and built to ensure
conformance with these codes. The recommendations of standard
IEC 60204-1 (machine safety - electrical machine components - part
1: general regulations) are specifically taken into account, when
designing the electrical equipment.
NOTES:
• The recommendations of IEC 60364 (standards issued by the
International Electrotechnical Commission) are accepted as
compliance with the requirements of the installation directives.
• Annex B of EN 60204-1 describes the electrical characteristics used
for the operation of the machines.
1. The environment conditions for these units are specified below:
- outdoor installation(1)
- ambient temperature range: -10°C to +50°C ± 1 K depending on
the unit
- altitude: ≤ 2000 m
- presence of hard solids: significant dust present*
- presence of corrosive and polluting substances: negligible**
- vibration and shock: negligible
- Minimum competence level of personnel: instructed personnel***
(1)
2.
3.
4.
5.
6.
ambient temperature range: -10°C to +46°C, class 4K3*
altitude: ≤ 2000 m
presence of hard solids, class 4S2 (no significant dust present)
presence of corrosive and polluting substances, class 4C2
(negligible)
- vibration and shock, class 4M2
b. Competence of personnel, class BA4* (trained personnel - IEC
60364)
Power supply frequency variation: ± 2 Hz.
The neutral (N) conductor must not be connected directly to the unit
(if necessary use a transformer).
Overcurrent protection of the power supply conductors is not
provided with the unit.
The factory-installed disconnect switch(es)/circuit breaker(s) is (are)
of a type suitable for power interruption in accordance with EN
60947.
The units are designed for connection to TN networks (IEC 60364).
For IT networks the earth connection must not be at the network
earth. Provide a local earth, consult competent local organisations to
complete the electrical installation.
Caution: If particular aspects of an actual installation do not
conform to the conditions described above, or if there are other
conditions which should be considered, always contact your local
Carrier representative.
*
The required protection level for this class is IP43BW (according to
reference document IEC 60529). All 30RA units are protected to
IP44CW and fulfil this protection condition.
2. Power supply frequency variation: ± 2 Hz.
3. The neutral (N) conductor must not be connected directly to the unit
(if necessary use a transformer).
4. Overcurrent protection of the power supply conductors is not
provided with the unit.
5. The factory-installed disconnect switch(es)/circuit breaker(s) is (are)
of a type suitable for power interruption in accordance with EN
60947‡.
6. The units are designed for connection to TN networks (IEC 60364).
For IT networks the earth connection must not be at the network
earth. Provide a local earth, consult competent local organisations to
complete the electrical installation.
If particular aspects of an actual installation do not conform to
the conditions described above, or if there are other conditions
which should be considered, always contact your local Carrier
representative.
Notes:
* During operation the maintenance programme must take into
account the dust in the environment.
** In case of condensation in the control box, ensure tropicalisation of
the control boxes.
*** Trained personnel: Personnel trained by a specialist, to ensure that
he/she avoids any possible danger and risk in using electricity (IEC
60364 BA4 – classification of competence of personnel)
† Corresponds to IEC 60529 (IP codes correspond to the protection
degree of the unit enclosure).
‡ IEC 60947-3 (low-capacity control and regulation units – Part 3: for a
unit, associated disconnect switches, circuit breakers, disconnect
buttons and fuses).
The required protection level for this class is IP43BW†. All 30RA
units are protected to IP44CW† (electrical compartment protected
against intrusion of hard solids or liquid splashes), and fulfil this
protection condition.
17
9 - RECOMMENDED WIRE SECTIONS
9.1 - Field control wiring
Wire sizing is the responsibility of the installer, and depends on
the characteristics and regulations applicable to each installation
site. The following is only to be used as a guideline, and does
not make Carrier in any way liable. After wire sizing has been
completed, using the certified dimensional drawing, the installer must ensure easy connection and define any modifications
necessary on site. The connections provided as standard for the
field-supplied power entry cables to the general disconnect/
isolator switch are designed for the number and type of wires,
listed in the table below.
For the field control wiring of the following elements refer
to the Controls IOM " Pro-Dialog Plus control, 30RA/RH
series " and the certified wiring diagram supplied with the
unit:
-
Unit start/stop
Heating/cooling selection
Set-point selection
Customer interlock - (example: auxiliary contact of the
chilled water pump contactor)
- General alarm reporting, circuit A and circuit B
The calculations are based on the maximum machine current
(see electrical data tables) and the standard installation
practises, in accordance with IEC 60364, table 52C.
- For 30RA units, installed outside, the following standard
installation practises have been maintained:
No.17: suspended aerial lines, and No. 61: buried
conduit with a derating coefficient of 20.
The calculation is based on PVC or XLPE insulated
cables with copper core.
A maximum ambient temperature of 46°C has been
taken into consideration.
The given wire length limits the voltage drop to
& lt; 5% (length L in metres - see table below).
IMPORTANT: Before connection of the main power cables
(L1 - L2 - L3) on the terminal block, it is imperative to check
the correct order of the 3 phases before proceeding to the
connection on the main disconnect/isolator switch.
Units
30RA 040
30RA 050
30RA 060
30RA 070
30RA 080
30RA 090
30RA 100
30RA 120
30RA 140
30RA 160
30RA 200
30RA 240
S
18
S Min. (mm2)
by phase
1x 6
1x 6
1x 10
1x 10
1x 16
1x 16
1x 25
1x 25
1x 35
1x 50
1x 70
1x 70
1x 70
Cable type
L (m)
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
XLPE Cu
90
80
110
100
125
115
145
135
150
180
180
180
180
S Max. (mm2)
by phase
1x 16
1x 25
1x 25
1x 35
1x 50
1x 70
1x 70
1x 95
1x 120
1x 150
1x 240
1x 150
1x 185
Power supply cable section (see the diagram in chapter: " Electrical connection " )
Cable type
L (m)
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
PVC Cu
XLPE Cu
XLPE Cu
245
300
300
310
350
380
380
410
435
450
480
335
345
10 - WATER CONNECTIONS
10.2 - Hydronic connections
For size and position of the unit water inlet and outlet connections refer to the certified dimensional drawings supplied with
the unit. The water pipes must not transmit any radial or axial
force to the heat exchangers nor any vibration.
The diagram on the next page shows a typical hydronic
installation.
The components numbered 1 to 12 are part of units with
hydronic module.
The components numbered 13 to 18 are part of the actual
installation.
The water supply must be analysed and appropriate filtering,
treatment, control devices, shutoff and bleed valves and circuits
built in, to prevent corrosion, fouling and deterioration of the
pump fittings. Consult either a water treatment specialist or
appropriate literature on the subject.
10.1 - Operating precautions and recommendations
The water circuit should be designed to have the least number
of elbows and horizontal pipe runs at different levels. Below
the main points to be checked for the connection:
•
Comply with the water inlet and outlet connections shown
on the unit.
•
Install manual or automatic air purge valves at all high
points in the circuit.
•
Use an expansion device to maintain pressure in the
system and install a safety valve as well as an expansion
tank.
Units with a hydronic module include the safety valve and
the expansion tank.
•
Install thermometers in both the entering and leaving
water connections.
•
Install drain connections at all low points to allow the
whole circuit to be drained.
•
Install stop valves, close to the entering and leaving water
connections.
•
Use flexible connections to reduce the transmission of
vibrations.
•
Include an electric trace heater for the installation pipework up to the unit. The pipes of units with hydronic
module are protected down to -10°C.
For units without hydronic module, include an electric
trace heater for the internal pipes up to the plate heat
exchanger.
•
Insulate all pipework, after testing for leaks, both to
reduce thermal leaks and to prevent condensation.
•
If the external unit water pipes are in an area, where the
ambient temperature is likely to fall below 0°C, add an
electric trace heater up to the unit.
NOTE: For units not equipped with a hydronic module a
screen filter must be installed as close to the heat exchanger
as possible, in a position that is easily accessible for removal
and cleaning.
The mesh size of the filter must be 1.2 mm. The unit with
hydronic module is already equipped with this type of filter.
10.3 - Frost protection
The plate heat exchangers, the piping and the hydronic module
pump can be damaged by frost, despite the built-in anti-freeze
protection of these units.
The frost protection of plate heat exchanger and all hydronic
module components is guaranteed down to -10°C by
automatically energized heaters.
Never switch off the evaporator and hydronic circuit heaters.
For this reason the main unit disconnect switch (QS101) as
well as the auxiliary protection switch (QF101) for the heaters
must always be left closed (for location of QS and QF 101 see
wiring diagram).
If the external unit water piping is in an area where the ambient
temperature can fall below 0°C it is recommended to add an
antifreeze solution to protect the unit and the water piping to a
temperature of 10 K below the lowest temperature likely to
occur at the installation site. Use only antifreeze solutions,
approved for heat exchanger duty. If the system is not protected
by an antifreeze solution and will not be used during the
freezing weather conditions, draining of the cooler and outdoor
piping is mandatory. Damage due to freezing is not covered by
the warranty.
IMPORTANT
Depending on the atmospheric conditions in your area you
must:
- Add ethylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 K below
the lowest temperature likely to occur at the installation
site.
- If the unit is not used for an extended period, it is
recommended to drain it, and as a safety precaution
introduce ethylene glycol in the heat exchanger, using the
water entering purge valve connection.
At the start of the next season, refill the unit with water and
add an inhibitor.
- For the installation of auxiliary equipment, the installer
must comply with basic regulations, especially for minimum and maximum flow rates, which must be between the
values listed in the operating limit table (application data).
The plate heat exchanger can foul up quickly at the initial
unit start-up, as it complements the filter function, and the
unit operation will be impaired (reduced water flow rate due
to increased pressure drop).
19
Typical hydronic circuit diagram
6
2
5
17
14
18
10
13
15
4
11
1
3
12
6
18
5
8
9
15
13
14
7
16
Legend
Components of the hydronic module
Installation components
1
2
3
4
5
13
14
15
16
17
18
Shutoff valve
Thermometer sleeve
Flexible connection
Charge valve
Air vent
Pressure gauges
---
Hydronic module (unit with hydronic module)
Screen filter
Expansion tank
Safety valve
Available pressure pump
Purge valve (circuit and pressure gauge) and shutoff valve (pressure
gauge)
6 Pressure gauges to measure the plate heat exchanger pressure drop (to
be shut off with valve 5 if not used) - In this kind of unit: evaporator
7 Drain plug
8 Flow switch
9 Flow control valve
10 Plate heat exchanger - In this kind of unit: evaporator
11 Anti-freeze heater of the hydronic module
12 Evaporator anti-freeze heater
20
Note:
Units without hydronic module are equipped with a flow switch.
11 - NOMINAL SYSTEM WATER FLOW CONTROL
The water circulation pumps of the 30RA units have been sized
to allow the hydronic modules to cover all possible configurations based on the specific installation conditions, i.e. for
various temperature differences between the entering and the
leaving water (∆T) at full load, which can vary between 3 and
10°C.
This required difference between the entering and leaving
water temperature determines the nominal system flow rate.
It is above all absolutely necessary to know the nominal system
flow rate to allow its control via a manual valve provided in the
water leaving piping of the module (item 9 in the typical
hydronic circuit diagram).
With the pressure loss generated by the control valve in the
hydronic system, the valve is able to impose the system
pressure/flow curve on the pump pressure/flow curve, to obtain
the desired operating point (see example for 30RA 100).
The pressure drop reading in the plate heat exchanger is used to
control and adjust the nominal system flow rate.
The pressure drop is measured with the two pressure gauges
installed in the heat exchanger water inlet and outlet.
Use this specification for the unit selection to know the system
operating conditions and to deduce the nominal air flow as well
as the plate heat exchanger pressure drop at the specified
conditions. If this information is not available at the system
start-up, contact the technical service department responsible
for the installation to get it.
When the circuit is cleaned, read the pressures at the two
pressure gauges (entering water pressure - leaving water
pressure), expressed in bar and convert this value to kPa
(multiply by 100) to find out the evaporator pressure drop.
Compare the value obtained with the theoretical selection
value. If the pressure drop measured is higher than the value
specified this means that the flow rate in the evaporator (and
thus in the system) is too high. The pump supplies an excessive
flow rate based on the global pressure drop of the application.
In this case close the control valve one turn and read the new
pressure difference.
Proceed by successively closing the control valve until you
obtain the specific pressure drop that corresponds to the
nominal flow rate at the required unit operating point.
- If the system has an excessive pressure drop in relation to the
available static pressure provided by the pump, the resulting
water flow rate will de reduced and the difference between
entering and leaving water temperature of the hydronic
module will be increased.
To reduce the pressure drops of the hydronic system, it is
necessary:
- to reduce the individual pressure drops as much as
possible (bends, level changes, accessories, etc.)
- to use a correctly sized piping diameter.
- to avoid hydronic system extensions, wherever possible.
11.2 - Pump curve and water flow control as a
function of the system pressure drops
These characteristics can be obtained from the technical
literature using the unit performance tables for a ∆T of 5 K at
the evaporator or with the Electronic Catalogue selection
program for all ∆T conditions other than 5 K in the range of 3
to 10 K.
As the total system pressure drop is not known exactly at the
start-up, the water flow rate must be adjusted with the control
valve provided to obtain the specific flow rate for this application.
4
175
3
150
1
Pressure drop, kPa
11.1 - Water flow control procedure
200
125
100
75
2
50
Proceed as follows:
Open the valve fully (approximately 9 turns counter-clockwise).
25
0
Start-up the pump using the forced start command (refer to the
controls manual) and let the pump run for two consecutive
hours to clean the hydronic circuit of the system (presence of
solid contaminants).
Read the evaporator pressure drop by taking the difference
between the two pressure gauge readings, and comparing this
value after two hours of operation. If the pressure drop has
increased, this indicates that the screen filter must be removed
and cleaned, as the hydronic circuit contains solid particles.
In this case close the shutoff valves at the water inlet and outlet
and remove the screen filter after emptying the hydronic
section of the unit.
2
4
6
8
10
Water flow rate, l/s
Legend
1
2
3
4
Pump curve, 30RA 100
Plate heat exchanger pressure drop (to be measured with the pressure
gauges installed at the water inlet and outlet)
Installation pressure drop with control valve wide open
Installation pressure drop after valve control to obtain nominal flow rate
Example: 30RA 100 at Eurovent conditions of 4,8 l/s
Renew, if necessary, to ensure that the filter is not contaminated.
21
11.3 - Pump pressure/flow rate curves
300
290
280
270
Pressure supplied, kPa
260
250
240
230
220
210
200
190
3
180
170
160
150
140
1
130
Legend
1
2
3
18
16
14
12
10
8
6
4
2
0
2
24
22
20
Water flow rate, l/s
30RA 040 to 100
30RA 120 to 160
30RA 200 to 240
11.4 - Available static system pressure
11.4.2 - 30RA NEE units
11.4.1 - 30RA Standard units
275
200
250
Available static pressure, kPa
175
Available static pressure, kPa
225
200
175
150
125
100
75
50
1
2
3 456
7
8
9 10
11
12
25
125
100
75
50
1 2 34
5
6 7 8
25
0
0
0
0
2
4
6
8
10
12
14
16
18
20
22
24
Water flow rate, l/s
Legend
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
30RA 040
30RA 050
30RA 060
30RA 070
30RA 080
30RA 090
30RA 100
30RA 120
30RA 140
30RA 160
30RA 200
30RA 240
2
4
6
Water flow rate, l/s
Legend
22
150
30RA 040
30RA 050
30RA 060
30RA 070
30RA 090
30RA 100
30RA 120
30RA 140
8
10
12
12 - START-UP
12.1 - Preliminary checks
- Never be tempted to start the chiller without reading fully,
and understanding, the operating instructions and without
having carried out the following pre-start checks:
- Check the chilled water circulation pumps, air handling units
and all other equipment connected to the evaporator.
- Refer to the manufacturer's instructions.
- For units without hydronic module, the water pump overheat
protection device must be connected in series with the pump
contactor power supply. If the pump is not supplied with the
unit (unit without hydronic module), verify that the power
input of the field-installed pump does not exceed the rating
of the standard pump contactor, supplied in the control box
(max. 3 kW for sizes 040 to 160 and max. 5.5 kW for
sizes 200 and 240).
- Refer to the wiring diagram supplied with the unit.
- Ensure that there are no refrigerant leaks.
- Confirm that all pipe securing bands are tight.
- Confirm the the electrical connections are secure.
Depending on the installation and control type, each unit can
control its own water pump. If there is only one common pump
for the two units, the master unit can control this. In this case
shut-off valves must be installed on each unit. They will be
activated at the opening and closing by the control of each unit
(and the valves will be controlled using the dedicated water
pump outputs).
30RA 040 to 240 (standard configuration: return
water control)
2
1
12.2 - Actual start-up
IMPORTANT
• Commissioning and start-up of the chiller must be
supervised by a qualified refrigeration engineer.
• Start-up and operating tests must be carried out with a
thermal load applied and water circulating in the
evaporator.
• All set-point adjustments and control tests must be carried
out before the unit is started up.
• Please refer to the controls section of this manual.
30RA 090 to 240 (with configuration: leaving water
control)
The unit should be started up in Local ON mode.
Ensure that all safety devices are satisfied, especially the high
pressure switches.
1
2
12.3 - Operation of two units in master/slave mode
The control of a master/slave assembly is in the entering water
and does not require any additional sensors (standard configuration). It can also be located in the leaving water. In this case
two additional sensors must be added on the common piping.
All parameters, required for the master/slave function must be
configured using the Service Configuration menu. All remote
controls of the master/slave assembly (start/stop, set point, load
shedding etc.) are controlled by the unit configured as master and
must only be applied to the master unit.
IMPORTANT:
The two units must be equipped with option No. 155 - CCN
time scheduling and communications “Clock Board”.
Legend
1
2
Master unit
Slave unit
Additional CCN board (one per unit, with connection via communication
bus)
Control boxes of the master and slave units
Water inlet
Water outlet
Water pumps for each unit (included as standard for units with hydronic
module)
Additional sensors for leaving water control, to be connected to channel 1
of the slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors
23
13 - MAINTENANCE
Any technician attending the machine for any purpose must be
fully qualified to work on refrigerant and electrical circuits.
WARNING
Before doing any work on the machine ensure that the power is
switched off. If a refrigerant circuit is opened, it must be
evacuated, recharged and tested for leaks. 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.
WARNING
To ensure proper operation of 30RA units there must be at
least 12 K of subcooling as the liquid refrigerant enters the
expansion valve.
The 30 RA units use refrigerant. For your information, we
are reproducing here some extracts from the official publication dealing with the design, installation, operation and
maintenance of air conditioning and refrigeration systems
and the training of people involved in these activities, agreed
by the air conditioning and refrigeration industry.
13.1.2.2 - Apparent and actual subcooling
13.1 - Maintenance of the refrigerant circuit
5
3
Pressure
13.1.1 - General maintenance
•
Keep the unit itself and the space around it clean and
free of obstructions. Remove all rubbish such as
packing materials, as soon as the installation is
completed.
•
Regularly clean the exposed pipework to remove all dust
and dirt. This makes detection of water leaks easier, and
they can be repaired before more serious faults develop.
•
Confirm that all screwed and bolted connections and
joints are secure. Secure connections prevent leaks and
vibration from developing.
•
Check that all insulation joints are securely closed and that
all insulation is firmly in place. Check all heat exchangers
and all pipework.
L
4
2
1
6
V
L+V
13.1.2 - Refrigerant charge
13.1.2.1 - Verification of the charge
Enthalpy
Legend
CAUTION
The 30RA units are supplied with a precise refrigerant charge
(see Physical Data table).
To verify the correct system charge prodeed as follows:
Ensure that no bubbles appear in the sight-glass, when operating the unit at full load for a while, at a saturated condensing
temperature of between 55 and 57°C. If necessary cover a section of the coil surface to obtain this condensing temperature.
Under these conditions the apparent subcooling which is equal
to the saturated condensing temperature (1 - on the saturated
dew point curve) minus the liquid refrigerant temperature (3)
ahead of the expansion device must be between 12 and 14°C.
This corresponds to an actual subcooling temperature of
between 5 and 7 K at the condenser outlet, depending on the
unit type. Actual subcooling is equal the saturated liquid
temperature (2 - on the saturated bubble point curve) minus the
liquid refrigerant temperature (3) ahead of the expansion
device. Use the pressure tap supplied on the liquid piping to
charge refrigerant and to find out the pressure of the liquid
refrigerant. If the subcooling value is not correct, i.e. lower
than the specified values, a leak detection test must be
carried out on the unit, as it no longer contains its original
charge.
In order to measure the liquid refrigerant pressure and temperature ahead of the expansion device, an access port must be
opened on the expansion device which causes a slight air bypass
on the condenser. Wait until unit operation has stabilized before
carrying out pressure and temperature measurements.
24
1
2
3
4
5
6
7
8
L
L+V
V
Saturated condensing temperature at the dew point
Saturated liquid temperature at the bubble point
Liquid refrigerant temperature
Saturation curve at the dew point
Saturation curbe at the bubble point
Isotherms
Apparent subcooling (1 - 3)
Real subcooling (2 - 3)
Liquid
Liquid + vapour
Vapour
13.1.2.3 - Principles
Refrigerant guidelines
Refrigeration installations must be inspected and maintained
regularly and rigorously by specialists. Their activities must be
overseen and checked by properly trained people. To minimise
discharge to the atmosphere, refrigerants and lubricating oil
must be transferred using methods which reduce leaks and
losses to a minimum.
•
Leaks must be repaired immediately
•
All units are equipped with two special connections on the
suction and liquid line, which permit the connection of
quick-connect recovery valves without loss of refrigerant.
•
If the residual pressure is too low to make the transfer
alone, a purpose-built refrigerant recovery unit must be
used.
•
Compressor lubricating oil contains refrigerant. Any oil
drained from a system during maintenance must therefore
be handled and stored accordingly.
•
Refrigerant under pressure must never be discharged to
the atmosphere.
13.1.3 - Recharging liquid refrigerant
CAUTION
30RA units are charged with liquid HFC-407C refrigerant.
This non-azeotropic refrigerant blend consists of 23% R-32,
25% of R-125 and 52% R-134a, and is characterised by the
fact that at the time of the change in state the temperature of
the liquid/vapour mixture is not constant, as with azeotropic
refrigerants. All checks must be pressure tests, and the
appropriate pressure/temperature ratio table must be used to
determine the corresponding saturated temperatures
(saturated bubble point curve or saturated dew point curve).
Leak detection is especially important for units charged with
refrigerant R-407C. Depending on whether the leak occurs in
the liquid or in the vapour phase, the proportion of the
different components in the remaining liquid is not the same.
NOTE: Regularly carry out leak checks and immediately
repair any leak found.
13.1.4 - Undercharge
If there is not enough refrigerant in the system, this is indicated
by gas bubbles in the moisture sight glass.
If the undercharge is significant, large bubbles appear in the
moisture sight glass, and the suction pressure drops. The
compressor suction superheat is also high. The machine must
be recharged after the leak has been repaired.
IMPORTANT
After the leak has been repaired, the circuit must be tested,
without exceeding the maximum low-side operating pressure
shown on the unit name plate.
The refrigerant must always be recharged in the liquid phase
into the liquid line.
The refrigerant cylinder must always contain at least 10% of its
initial charge.
For the refrigerant quantity per circuit, refer to the data on the
unit name plate.
13.1.5 - Characteristics of R407C
See the table below.
Saturated bubble point temperatures (bubble point curve)
Saturated dew point temperatures (dew point curve)
13.2 - Electrical maintenance
When working on the unit comply with all safety precautions
decribed in section “Maintenance safety considerations”.
- It is strongly recommended to change the fuses in the units
every 15000 operating hours or every 3 years.
- It is recommended to verify that all electrical connections are
tight:
a. after the unit has been received at the moment of
installation and before the first start-up,
b. one month after the first start-up,when the electrical
components have reached their nominal operating
temperatures,
c. then regularly once a year.
Find the leak and completely drain the system with a
refrigerant recovery unit. Carry out the repair, leak test and
then recharge the system.
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
1
1.25
1.5
1.75
2
2.25
2.5
2.75
3
3.25
3.5
3.75
4
4.25
4.5
4.75
5
5.25
5.5
5.75
6
6.25
6.5
6.75
7
7.25
7.5
7.75
8
8.25
8.5
8.75
9
9.25
9.5
9.75
10
10.25
-28.55
-25.66
-23.01
-20.57
-18.28
-16.14
-14.12
-12.21
-10.4
-8.67
-7.01
-5.43
-3.9
-2.44
-1.02
0.34
1.66
2.94
4.19
5.4
6.57
7.71
8.83
9.92
10.98
12.02
13.03
14.02
14.99
15.94
16.88
17.79
18.69
19.57
20.43
21.28
22.12
22.94
-21.72
-18.88
-16.29
-13.88
-11.65
-9.55
-7.57
-5.7
-3.93
-2.23
-0.61
0.93
2.42
3.85
5.23
6.57
7.86
9.11
10.33
11.5
12.65
13.76
14.85
15.91
16.94
17.95
18.94
19.9
20.85
21.77
22.68
23.57
24.44
25.29
26.13
26.96
27.77
28.56
10.5
10.75
11
11.25
11.5
11.75
12
12.25
12.5
12.75
13
13.25
13.5
13.75
14
14.25
14.5
14.75
15
15.25
15.5
15.75
16
16.25
16.5
16.75
17
17.25
17.5
17.75
18
18.25
18.5
18.75
19
19.25
19.5
19.75
23.74
24.54
25.32
26.09
26.85
27.6
28.34
29.06
29.78
30.49
31.18
31.87
32.55
33.22
33.89
34.54
35.19
35.83
36.46
37.08
37.7
38.31
38.92
39.52
40.11
40.69
41.27
41.85
42.41
42.98
43.53
44.09
44.63
45.17
45.71
46.24
46.77
47.29
29.35
30.12
30.87
31.62
32.35
33.08
33.79
34.5
35.19
35.87
36.55
37.21
37.87
38.51
39.16
39.79
40.41
41.03
41.64
42.24
42.84
43.42
44.01
44.58
45.15
45.71
46.27
46.82
47.37
47.91
48.44
48.97
49.5
50.02
50.53
51.04
51.55
52.05
20
20.25
20.5
20.75
21
21.25
21.5
21.75
22
22.25
22.5
22.75
23
23.25
23.5
23.75
24
24.25
24.5
24.75
25
25.25
25.5
25.75
26
26.25
26.5
26.75
27
27.25
27.5
27.75
28
28.25
28.5
28.75
29
29.25
47.81
48.32
48.83
49.34
49.84
50.34
50.83
51.32
51.8
52.28
52.76
53.24
53.71
54.17
54.64
55.1
55.55
56.01
56.46
56.9
57.35
57.79
58.23
58.66
59.09
59.52
59.95
60.37
60.79
61.21
61.63
62.04
62.45
62.86
63.27
63.67
64.07
64.47
52.55
53.04
53.53
54.01
54.49
54.96
55.43
55.9
56.36
56.82
57.28
57.73
58.18
58.62
59.07
59.5
59.94
60.37
60.8
61.22
61.65
62.07
62.48
62.9
63.31
63.71
64.12
64.52
64.92
65.31
65.71
66.1
66.49
66.87
67.26
67.64
68.02
68.39
25
13.3 - Condenser coil
We recommend, that finned coils are inspected regularly to
check the degree of fouling. This depends on the environment
where the unit is installed, and will be worse in urban and
industrial installations and near trees that shed their leaves.
For coil cleaning proceed as follows:
•
Remove fibres and dust collected on the condenser face
with a soft brush (or vacuum cleaner).
•
Clean the coil with the appropriate cleaning agents.
13.4 - Replacement of motor and pump impeller subassembly on the hydronic module.
13.4.1 - Complete sub-assembly replacement
procedure for motor, impeller and cross-brace (called
" complete assembly " ) for hydronic pumps used for
30RA 040 to 240 units.
The replacement of a " complete sub-assembly " on a
hydronic pump permits quick on-site intervention if
mechanical, electrical or leak problems in the mechanical
seals occur.
We recommend TOTALINE products for coil cleaning:
Part No. P902 DT 05EE: traditional cleaning method
Part No. P902 CL 05EE: cleaning and degreasing.
The sub-assembly includes: the motor, the impeller assembly
and the cross-brace.
These products have a neutral pH value, do not contain phosphates, are not harmful to the human body, and can be disposed
of through the public drainage system.
Before beginning with the pump removal, disconnect the unit
power supply with the disconnect switch, close the shutoff
valves in the water entering and leaving lines and drain the
hydronic circuit, using the plug at the low point of the leaving
water piping.
Depending on the degree of fouling both products can be used
diluted or undiluted.
For normal maintenance routines we recommend using 1 kg
of the concentrated product, diluted to 10%, to treat a coil
surface of 2 m2. This process can either be carried out with
a TOTALINE applicator gun (part No. TE01 WA 4000EE)
or using a high-pressure spray gun in the low-pressure position.
With pressurised cleaning methods care should be taken not to
damage the coil fins. The spraying of the coil must be done:
- in the direction of the fins
- in the opposite direction of the air flow direction
- with a large diffuser (25-30°)
- at a distance of 300 mm.
After replacing the complete sub-assembly recharge the circuit
with water and purge it with the pressure gauge port three-way
valve located in the plate heat exchanger water entering pipe.
13.4.1.1 - Pumps for 30RA 040 to 100 units
30RA 040 to 100
Pump type
Single pump
Dual pump
V-ph-Hz
Pump manufacturer reference*
Carrier pump reference
Carrier ref., complete sub-assy.
400-3-50
LRL 204 121.5
30RA 500 612 EE
**
400-3-50
JRL 204 121.5
30RA 500 652EE
**
** See spare parts list
The two cleaning products can be used for any of the following
coil finishes: Cu/Cu, Cu/Al, Cu/Al with Polual, Blygold and/or
Heresite protection.
It is not necessary to rinse the coil, as the products used are pH
neutral. To ensure that the coil is perfectly clean, we
recommend rinsing with a low water flow rate. The pH value
of the water used should be between 7 and 8.
WARNING
Never use pressurized water without a large diffusor.
Concentrated and/or rotating water jets are strictly forbidden.
Correct and frequent cleaning (approximately every three
months) will prevent 2/3 of the corrosion problems.
Removal and replacement of the complete subassembly
LRL pumps (see single pump diagram)
1 - Disconnect the motor (connectors).
2 - Unscrew the 8 CHC M6 screws (item A) to loosen the
bearing lantern (item B) from the pump body (item C).
3 - Remove the assembly: impeller (item D), bearing lantern
(item B), motor (item E).
4 - Keep the pump body O-ring (item F).
JRL pumps
Proceed in the same way to remove the other sub-assembly.
Re-assembly
1 - Reposition the O-ring (item F).
2 - Place the complete sub-assembly on the pump body.
3 - Tighten the 8 CHC M6 screws (item A) with a torque of
10 Nm (cross tightening).
4 - Reconnect the motor electrically.
26
13.4.1.2 - Pumps for 30RA 120 to 160 units
30RA 120 to 160
Pump type
V-ph-Hz
Pump manufacturer reference*
Carrier pump reference
Carrier ref., complete sub-assy.
Single pump
400-3-50
LRC 205 14 3
30RA 500 632 EE
**
Dual pump
400-3-50
JRC 205 14 3
30RA 500 672 EE
**
Single pump
400-3-50
LRC 208 15 5.5
30RA 504 262
**
Dual pump
400-3-50
JRC 208 15 5.5
30RA 504 272
**
13.4.2 - Replacement of the mechanical seals only,
after removal of the complete sub-assembly
It is recommended to replace the mechanical seals only in a
specialised workshop approved by the pump manufacturer.
The table below indicates the reference number of the seal kit
in accordance with the pump type.
30RA 200 to 240
Pump type
V-ph-Hz
Pump manufacturer reference*
Carrier pump reference
Carrier ref., complete sub-assy.
** See spare parts list
See single pump diagram (LRL 204 12 1.5)
Removal and replacement of the complete subassembly
LRC pumps
1 - Disconnect the motor (connectors).
2 - Unscrew the 8 CHC M6 screws (item A) to loosen the
cross-brace (item B) from the pump body (item C).
3 - Remove the assembly: impeller (item D), cross-brace (item
B), motor (item E).
4 - Keep the pump body O-ring (item F).
A description of the removal and replacement of the mechanical seals from the pump manufacturer is supplied with the
replacement kit.
Pump type
Pump reference*
Reference, mechanical seals*
Single pump
Dual pump
Single pump
Dual pump
Single pump
Dual pump
LRL 204 12 1.5
JRL 204 12 1.5
LRC 205 14 3
JRC 205 14 3
LRC 208 15 5.5
JRC 208 15 5.5
74400000001
74400000001
74626200001
74626200001
74626200001 - Quantity: 1
74626200001 - Quantity: 2
* Salmson reference No.
Single-pump cross section diagram LRL 204 12 1.5
Carrier reference No. 30 RH 500 612 EE
JRC pumps
Proceed in the same way to remove the other sub-assembly.
Re-assembly
1 - Reposition the O-ring (item F).
2 - Place the complete sub-assembly on the pump body.
3 - Tighten the 8 CHC M6 screws (item A) with a torque of
7 Nm (cross tightening).
4 - Reconnect the motor electrically.
27
14 - START-UP CKECKLIST FOR 30RA LIQUID CHILLERS (USE FOR JOB FILE)
Preliminary information
Job name: ................................................................................................................................................................................................
Location: .................................................................................................................................................................................................
Installing contractor: ...............................................................................................................................................................................
Distributor: .............................................................................................................................................................................................
Start-up preformed by: ............................................................... Date: ...............................................................................................
Equipment
Model 30RA: .................................................................................. S/N ..............................................................................................
Compressors
Circuit A
Circuit B
1. Model # ...................................................................................... 1. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
2. Model # ...................................................................................... 2. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
3. Model # ..................................................................................... 3. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
Air handling equipment
Manufacturer .........................................................................................................................................................................................
Model # ........................................................................................... S/N ..............................................................................................
Additional air handling units and accessories ........................................................................................................................................
................................................................................................................................................................................................................
Preliminary equipment check
Is there any shipping damage? ....................................................... If so, where? ................................................................................
................................................................................................................................................................................................................
Will this damage prevent unit start-up? ..................................................................................................................................................
Unit is level in its installation
Power supply agrees with the unit name plate
Electrical circuit wiring has been sized and installed properly
Unit ground wire has been connected
Electrical circuit protection has been sized and installed properly
All terminals are tight
All cables and thermistors have been inspected for crossed wires
All plug assemblies are tight
Check air handling systems
All air handlers are operating
All chilled water valves are open
All fluid piping is connected properly
All air has been vented from the system
Chilled water pump is operating with the correct rotation. CWP amperage: Rated: ......................... Actual............
28
Unit start-up
Chilled water pump starter has been properly interlocked with the chiller
Oil level is correct
Unit has been leak checked (including fittings)
Locate, repair, and report any refrigerant leaks
................................................................................................................................................................................................................
................................................................................................................................................................................................................
................................................................................................................................................................................................................
Check voltage imbalance: AB ..................
Average voltage = .....................................
Maximum deviation = ..............................
Voltage imbalance = .................................
AC ................. BC .................
(see installation instructions)
(see installation instructions)
(see installation instructions) .
Voltage imbalance is less than 2%
WARNING
Do not start chiller if voltage imbalance is greater than 2%. Contact local power company for assistance.
All incoming power voltage is within rated voltage range
Check evaporator water loop
Water loop volume = ................... (litres)
Calculated volume = ................... (litres)
2.50 litres/nominal kW capacity for air conditioning (30RA 050 to 240)
3.50 litres/nominal kW capacity for air conditioning (30RA 040)
Proper loop volume established
Proper loop corrosion inhibitor included .............. litres of ...........................
Proper loop freeze protection included (if required) ........................ litres of .............................
Water piping includes electric tape heater up to the evaporator
Return water piping is equipped with a screen filter with a mesh size of 1.2 mm
Check pressure drop across the evaporator
Entering evaporator = ............................... (kPa)
Leaving evaporator = ................................ (kPa)
Pressure drop (entering - leaving) = ......... (kPa)
WARNING
Plot the pressure drop on the evaporator flow/pressure drop curve to determine the flow rate in l/s at the nominal operating
conditions for the installation.
If necessary use the control valve to impose the flow rate on the nominal value.
Flow rate from the pressure drop curve, l/s = ................
Nominal flow rate, l/s = .......................
The flow rate in l/s is higher than the minimum unit flow rate
The flow rate in l/s corresponds to the specification of ......................... (l/s)
29
Carry out the QUICK TEST function (see 30RA/RY - RH/RYH Pro-Dialog Plus Control manual):
Check and log on to the user menu configuration
Load sequence selection ........................................................................................................................................................
Capacity ramp loading selection ...........................................................................................................................................
Start-up delay .........................................................................................................................................................................
Burner section ........................................................................................................................................................................
Pump control .........................................................................................................................................................................
Set-point reset mode ..............................................................................................................................................................
Night-time capacity setback ..................................................................................................................................................
Re-enter the set-points (see Controls section)
To start up the chiller
WARNING
Be sure that all service valves are open, and that the pump is on before attempting to start this machine. Once all checks have been
made, start the unit in the " LOCAL ON " position.
Unit starts and operates properly
Temperatures and pressures
WARNING
Once the machine has been operating for a while and the temperatures and pressures have stabilized, record the following
Evaporator entering water .....................................................................................................................................................
Evaporator leaving water .......................................................................................................................................................
Ambient temperature .............................................................................................................................................................
Circuit A suction pressure ......................................................................................................................................................
Circuit B suction pressure .....................................................................................................................................................
Circuit A discharge pressure ..................................................................................................................................................
Circuit B discharge pressure ..................................................................................................................................................
Circuit A suction temperature ................................................................................................................................................
Circuit B suction temperature ................................................................................................................................................
Circuit A discharge temperature ............................................................................................................................................
Circuit B discharge temperature ............................................................................................................................................
Circuit A liquid line temperature ...........................................................................................................................................
Circuit B liquid line temperature ...........................................................................................................................................
NOTES:
...............................................................................................................................................................................................
...............................................................................................................................................................................................
...............................................................................................................................................................................................
30
Order No.: 13011-76, 03.2001 - Supersedes order No.: 13011-76, 12.1999
Manufacturer reserves the right to change any product specificatiuons without notice.
Manufactured by: Carrier SA, Montluel, France
Printed in the Netherlands on totally chlorine-free paper.