30HZ_HZV_eng_iom.pdf

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30HZ/HZV 043-280

Water-Cooled/CondenserlessLiquid Chillers

Nominal cooling capacity 30HZ: 134-783 kWNominal cooling capacity 30HZV: 126-735 kW

50 Hz

Installation, operation and maintenance instructions


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The cover illustration is for illustrative purposes only and is not part of any offer for sale or contract.

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, WEIGHT DISTRIBUTION .............................................................................................. 8

3.1 - 30HZ/HZV 043-065...................................................................................................................................................................8

3.2 - 30HZ/HZV 091-225...................................................................................................................................................................8

3.3 - 30HZ/HZV 250-280...................................................................................................................................................................9

4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22) .........................................................................10

4.1 - Physical data (R407C)..............................................................................................................................................................10

4.2 - Electrical data (R407C) ............................................................................................................................................................10

4.3 - Physical data (R22) ..................................................................................................................................................................11

4.4 - Electrical data (R22) ................................................................................................................................................................12

4.5 - Power supply ............................................................................................................................................................................134.6 - Voltage phase imbalance (%)...................................................................................................................................................13

4.7 - Recommended wire sections .................................................................................................................................................... 14

5 - APPLICATION DATA ............................................................................................................................................................15

5.1 - Unit operating range.................................................................................................................................................................15

5.2 - Minimum chilled water flow.................................................................................................................................................... 15

5.3 - Maximum chilled water flow ................................................................................................................................................... 15

5.4 - Variable flow evaporator ..........................................................................................................................................................16

5.5 - System minimum water volume...............................................................................................................................................16

5.6 - Evaporator flow rate (l/s) .........................................................................................................................................................16

5.7 - Condenser water flow rates ......................................................................................................................................................17

5.8 - Condenser water flow restrictor ...............................................................................................................................................17

6 - WATER CONNECTIONS .......................................................................................................................................................18

6.1 - Operating precautions ..............................................................................................................................................................18

6.2 - Water connections ....................................................................................................................................................................19

6.3 - Flow control .............................................................................................................................................................................19

6.4 - Condenser connections.............................................................................................................................................................19

6.5 - Frost protection ........................................................................................................................................................................20

6.6 - Refrigerant line connections (30HZV)..................................................................................................................................... 20

6.7 - Operation of two units in master/slave mode...........................................................................................................................24


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CONTENTS (contd)

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

8 - MAIN OPTIONS AND ACCESSORIES................................................................................................................................26

8.1 - Units for low evaporator outlet temperature applications (options 5 and 6) ............................................................................26

8.2 - Electrical protection to IP 44 (option 20)................................................................................................................................. 26

8.3 - High- and low-pressure gauges (option 26) ............................................................................................................................. 26

8.4 - Compressor oil pressure safety device ..................................................................................................................................... 26

8.5 - Condenser with copper-nickel tubes (option 33) .....................................................................................................................26

8.6 - RS 485 communication interface (option 148) ........................................................................................................................ 26

8.7 - Additional capacity step 30HZ/HZV 043 to 065 (option 94) ..................................................................................................26

8.8 - Evaporator pump starter (options 84 and 84D) ........................................................................................................................ 26

8.9 - Condenser pump starter (option 84R) ...................................................................................................................................... 26

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

10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS...................................................................................31


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1 - INTRODUCTION

Prior to the initial start-up of the 30HZ/HZV 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 30HZ/HZV 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.

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.

1.1 - Installation 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,

especially that no components or pipes have shifted (e.g. follow-

ing 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.

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 desig-

nated lifting points marked on the unit.

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 globe valve in the water circuit and the

globe valve(s) in the refrigerant circuit(s).

Ensure that the valves are correctly installed, before

operating the unit.

In certain cases the globe stops are installed on ball valves.

These valves are factory-supplied lead-sealed in the open

position. This system permits isolating and removing theglobe stop for checking and replacing. The globe stops are

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.

The safety valves must be connected to discharge pipes. These

pipes must be installed in a way that ensures that people and

property are not exposed to refrigerant leaks. These fluids

may be diffused in the air, but far away from any building air

intake, or they must be discharged in a quantity that is

appropriate for a suitably absorbing environment.

Periodic check of the globe valves: See paragraph

Maintenance safety considerations.

Provide a drain in the discharge circuit, close to each valve,

to avoid an accumulation of condensate.

Ensure good ventilation, as 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

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.

1.3 - Maintenance safety considerations

Engineers working on the electric or refrigeration components

must be authorized, trained and fully qualified to do so (electri-

cians trained and qualified in accordance with IEC 60364

Classification BA4).

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.

Any manipulation (opening or closing) of a shut-off valve must

be carried out by a qualified and authorised engineer. These

procedures must be carried out with the unit shut-down.

NOTE: The unit must never be left shut down with the liquid

line valve closed, as liquid refrigerant can be trapped between

this valve and the expansion device. (This valve is situated on

the liquid line before the filter drier box.)

During any handling, maintenance and service operations

the engineers working on the unit must be equipped with

safety gloves, glasses, shoes and protective clothing.

Never work on a unit that is still energized.


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Ensure that you are using the correct refrigerant type before

recharging the unit (see unit name plate).

Charging any refrigerant other than the original charge type

will impair machine operation and can even lead to a

destruction of the compressors.

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 refri-

gerant circuit component until all refrigerant (liquid and

vapour) has been removed from chiller. Traces of vapour

should be displaced with dry air nitrogen. Refrigerant incontact with an open flame produces toxic gases.

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 andconsult 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.

During refrigerant removal and storage operations follow

applicable regulations. These regulations, permitting condition-

ing and recovery of halogenated hydrocarbons under opti-

mum quality conditions for the products and optimum safety

conditions for people, property and the environment are

described in standard NFE 29795.

Any refrigerant transfer and recovery operations must be

carried out using a transfer unit. A 3/8 SAE connector on

the manual liquid line valve is supplied with all units for

connection to the transfer station. The units must never be

modified to add refrigerant and oil charging, removal and

purging devices. All these devices are provided with the units.

Please refer to the certified dimensional drawings for the units.

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 notincinerate.

Never work on any of the electrical components, until the

general power supply to the unit has been cut using the

disconnect switch(es) in the control box(es).

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.

Protection of electronic boards : If the boards need to be

handled wear anti-static gloves to avoid exposing the electronic

components to a destructive voltage. Only unpack the boards

from their anti-static bag when they need to be installed.

Once a year check that the high-pressure safety switch is

correctly connected and that it cuts out at the correct value.

Operating checks: During the life-time of the system,

inspection and tests must be carried out in accordance with

national regulations.

The information on operating inspections given in annex C

of standard EN278-2 can be used if no similar criteria exist

in the national regulations.

Safety device checks (annex C6 EN378-2): The safety

devices must be checked on site once a year for safety devices

(high-pressure switches), and every five years for externaloverpressure devices (safety globe valves).

Check manual 30HZ/HZV Pro-Dialog Plus control for a

detailed explanation of the high-pressure switch test method.

At least once a year thoroughly inspect the protection devices

(valves). 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 or if the refrigerant becomes polluted (e.g. by a

short circuit in a motor) remove the complete charge using a

recovery unit and store the refrigerant in mobile containers.

Repair the leak detected and recharge the circuit with the totalR407C or R22 charge, as indicated on the unit name plate.

Only charge liquid refrigerant R407C or R22 at the liquid line

(see chapter Refrigerant charge).


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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.

The unit name plate must include the following

information:

- Version number

- Model number

- CE marking

- Serial number

- Year of manufacture and test date

- Refrigerant used and refrigerant class

- Refrigerant charge per circuit

- Containment fluid to be used

- PS: Min./max. allowable pressure (high and low

pressure side)

- TS: Min./max. allowable temperature (high and low

pressure side)- Globe valve cut-out pressure

- Pressure switch cut-out pressure

- Unit leak test pressure

- Voltage, frequency, number of phases

- Maximum current drawn

- Maximum power input

- Unit net weight

Confirm that all accessories ordered for on-site installation

have been delivered, and are complete and undamaged.

The unit must be checked periodically during its whole

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 - 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, theposition of the unit mounting holes, and the weight distribu-

tion points, refer to the certified dimensional drawing supplied

with the unit.

Typical applications of these units are in refrigeration

systems, and they do not require earthquake resistance.

Earthquake resistance has not been verified.

CAUTION: Only use slings at the designated lifting points

which are marked on the unit.

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.

ATTENTION: No part of the unit must use feet, racks or

supports during operation. Periodically monitor and repair

or if necessary replace any component or piping that shows

signs of damage.

The refrigerant 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, winch, etc.)to lift or move heavy components. 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 compo-

nent 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.


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2.2.3 - Check compressor mountings

Before any start-up of the unit proceed as follows:

For 30HZ/HZV 043-065 units

1. Remove the wooden block located under the compressor

foot.

2. Remove the screw and washer used for transportation.

3. Assemble screw (A), snubber (B) and plain washer (C).

For 30HZ/HZV 091-280 units

Remove the centre bolt (A) from each spring mounting, so that

the compressor support can float freely.

Before siting the unit check that:

the permitted loading at the site is adequate or that

appropriate strenghtening measures have been taken.

the unit is installed level on an even surface (maximum

tolerance is 5 mm in both axes).

there is adequate space above the unit to ensure access to

the components for maintenance.

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.

If 30HZ/HZV units are hoisted with rigging, it is advisable to

protect the control box against accidental shocks. Do not tilt a

unit more than 15.

WARNING: Never push or lever the chassis or the control

box of the unit.

Checks before system start-up

Before the start-up of the refrigeration system, the complete

installation, including the refrigeration system must be verified

against the installation drawings, dimensional drawings, system

piping and instrumentation diagrams and the wiring diagrams.

During the installation test national regulations must be

followed. If no national regulation exists, paragraph 9-5 of

standard EN 378-2 can be used as a guide.

External visual installation checks:

Compare the complete installation with the refrigeration

system and power circuit diagrams. Check that all components comply with the design

specifications.

Check that all safety documents and equipments that are

required by current European standards are present.

Verify that all safety and environmental protection devices

and arrangements are in place and comply with the current

European standard.

Verify that all document for pressure containers,

certificates, name plates, files, instruction manuals that are

required documents required by the current European

standards are present.

Verify the free passage of access and safety routes.

Check that ventilation in the special plant room is adequate. Check that refrigerant detectors are present.

Verify the instructions and directives to prevent the

deliberate removal of refrigerant gases that are harmful to

the environment.

Verify the installation of connections.

Verify the supports and fixing elements (materials, routing

and connection).

Verify the quality of welds and other joints.

Check the protection against mechanical damage.

Check the protection against heat.

Check the protection of moving parts.

Verify the accessibility for maintenance or repair and tocheck the piping.

Verify the status of the valves.

Verify the quality of the thermal insulation and of the

vapour barriers.


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3 - DIMENSIONS, CLEARANCES

3.1 - 30HZ/HZV 043-065

3.2 - 30HZ/HZV 091-225

A

B

2200

1

2

600

C

750

600

3

3

3

4

3

3

3

4

2

1

A

C

B

2550

800

800

800


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30HZ - units with condenser A B C

043 2452 1520 915052 2750 1505 915065 2750 1505 915091 2630 1915 950101 2940 1915 950111 2940 1915 950121 2940 1915 950141 3350 1915 950161 3350 1915 950195 4255 1950 950225 4255 1950 950250-280 4070 2150 1275

30HZV - units without condenser A B C

043 2452 1260 904

052 2750 1245 904065 2750 1245 904091 2630 1300 950101 2940 1300 950111 2940 1300 950121 2940 1300 950141 3350 1300 950161 3350 1300 950195 4255 1340 950225 4255 1340 950250-280 4070 1680 1275

Dimensions in mm

3.3 - 30HZ/HZV 250-280

Legend:

Evaporator

Condensers

Clearances required for operation and maintenance

Clearances recommended for heat exchanger tube removal

Power supply

Water inlet

Water outlet

3

3

3

4

2

1

B

850

C

1000

2750

800

A

1

2

3

4

FLOOR MOUNTING

For the positioning of the fixing points, weight distribution and centre of gravity coordinates, refer to the certified drawings.

NOTE:Non-contractual drawings. Certified dimensional drawings, available onrequest.


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4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22)

4.1 - Physical data (R407C)

30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280

Net nominal cooling capacity* kW30HZ 134 153 199 230 270 300 316 371 415 533 626 719 78330HZV 126 144 194 216 260 278 297 352 388 500 588 677 735

Operating weight** kg30HZ 1090 1183 1252 2039 2370 2460 2510 2730 2830 3505 3805 4470 490030HZV 880 968 1018 1672 1960 2000 2040 2260 2300 2975 3267 3780 4106

Refrigerant charge*** kg R-407CCircuit 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 62.5Circuit 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/sQuantity - Circuit A 1 1 1 2 2 2 2 2 2 3 3 4 4Quantity - Circuit B 1 1 1 1 2 2 2 2 2 2 3 3 4

Capacity control PRO-DIALOG Plus controlNo. of control steps 4 4 4 6 11 11 11 11 11 5 6 7 8Minimum step capacity % 40 33 33 22 20 18 16 19 16 20 16 14 12

Evaporator One, direct expansion, multi-tube shellNet water volume l 55 63 63 92 154 154 154 199 199 242 242 276 276No. of refrigerant circuits 2 2 2 2 2 2 2 2 2 2 2 2 2Water connectionsInlet/outlet 3 gas threaded PN16DN100 PN16DN125 PN16DN150

NFE 03005 NFE 29203 NFE 29203 NFE29203Drain 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 3/8Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Condenser Shell and multi-tubeQuantity 2 2 2 2 2 2 2 2 2 2 2 2 2Net water volume lCircuit A 10 10 12 25 18 25 25 25 30 37 37 51 51Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51Water connections in Gas threaded Flat flange, brazedInlet/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 3Inlet/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 3Drain 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 3/8Max. 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 = 12C/7C, condenser entering/leaving water temperature = 30C/35C- evaporator and condenser fouling factor = 0.000044 m2K/W- condensing temperature dew point 45C- 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.

4.2 - Electrical data (R407C)

30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280

Power wiringNominal power supply V-ph-Hz 400-3-50System voltage range V 360-440

Control circuit power supply The control circuit is supplied via a factory-installed transformer.

Nominal operating power input* kW30HZ 38.5 48.9 68 69 78 86 92 112 131 165 201 239 27030HZV 38.5 48.6 65 70 77 86 94 112 135 165 200 234 266

Nominal operating current* A30HZ 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** kW30HZ circuit A and B 45 55 77 82 90 100 109 132 155 194 232 - -30HZ circuit A - - - - - - - - - - - 155 15530HZ circuit B - - - - - - - - - - - 116 15530HZV circuit A and B 54 65 90 98 107 119 130 155 180 225 270 - -30HZV circuit A - - - - - - - - - - - 180 18030HZV circuit B - - - - - - - - - - - 135 180

Maximum operating current (Un-10%)*** A30HZ circuit A and B 87 105 150 158 174 192 211 255 299 374 449 - -30HZ circuit A - - - - - - - - - - - 299 29930HZ circuit B - - - - - - - - - - - 224 29930HZV circuit A and B 101 123 170 185 203 224 246 293 340 425 509 - -30HZV circuit A - - - - - - - - - - - 340 34030HZV circuit B - - - - - - - - - - - 255 340

* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12C/7C, condenser entering/leaving water temperature 30C/35C.

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) = 12C, saturated condensing temperature (dew point) = 52C(30HZ)/66C (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.


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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)*** A30HZ circuit A and B 78 95 135 142 157 173 190 230 269 336 404 - -30HZ circuit A - - - - - - - - - - - 269 26930HZ circuit B - - - - - - - - - - - 202 26930HZV circuit A and B 91 111 153 166 182 202 221 264 306 382 458 - -30HZV circuit A - - - - - - - - - - - 306 30630HZV circuit B - - - - - - - - - - - 229 306

Maximum unit starting current (Un) A30HZ circuit A and B 182 198 273 245 227 275 291 330 404 470 536 - -

30HZ circuit A - - - - - - - - - - - 404 40430HZ circuit B - - - - - - - - - - - 338 40430HZV circuit A and B 188 207 283 263 251 299 318 360 436 513 589 - -30HZV circuit A - - - - - - - - - - - 436 43630HZV 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 1.5030HZ 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 1.4330HZV Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.57 1.43

Holding current for three-phase short circuits kA30HZ circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -30HZ circuit A - - - - - - - - - - - 25 2530HZ circuit B - - - - - - - - - - - 25 2530HZV circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -30HZV circuit A - - - - - - - - - - - 25 2530HZV circuit B - - - - - - - - - - - 25 25

Customer unit standby power for evaporator andcondenser pump connections ACircuit A 6 8 10 10 10 10 10 12 15 24 32 25 32Circuit B - - - - - - - - - - - 20 20

* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12C/7C, condenser entering/leaving water temperature 30C/35C.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) = 12C, saturated condensing temperature (dew point) = 52C(30HZ)/66C (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.

4.3 - Physical data (R22)

30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280

Net nominal cooling capacity* kW30HZ 144 166 215 250 292 323 342 402 447 578 677 779 84730HZV 136 157 208 234 280 300 321 380 417 538 633 729 792

Operating weight** kg30HZ 1090 1183 1252 2039 2370 2460 2510 2730 2830 3505 3805 4470 490030HZV 880 968 1018 1672 1960 2000 2040 2260 2300 2975 3267 3780 4106

Refrigerant charge*** kg R22Circuit A 13.5 14 16.2 33.5 25.5 30 30 34 40 48 48 59 59Circuit 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/sQuantity - Circuit A 1 1 1 2 2 2 2 2 2 3 3 4 4Quantity - Circuit B 1 1 1 1 2 2 2 2 2 2 3 3 4

Capacity control PRO-DIALOG Plus controlNo. of control steps 4 4 4 6 11 11 11 11 11 5 6 7 8Minimum 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 276No. of refrigerant circuits 2 2 2 2 2 2 2 2 2 2 2 2 2Water connectionsInlet/outlet 3 gas threaded PN16DN100 PN16DN125 PN16DN150

NFE 03005 NFE 29203 NFE 29203 NFE29203Drain 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 3/8Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000

Condenser Shell and multi-tubeQuantity 2 2 2 2 2 2 2 2 2 2 2 2 2Net water volume lCircuit A 10 10 12 25 18 25 25 25 30 37 37 51 51Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51Water connections in Gas threaded Flat flange, brazedInlet/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 3Inlet/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 3Drain 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 3/8Max. 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 = 12C/7C, condenser entering/leaving water temperature = 30C/35C- evaporator and condenser fouling factor = 0.000044 m2K/W- condensing temperature 45C (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.


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4.4 - Electrical data (R22)

30HZ/HZV 043 052 065 091 101 111 121 141 161 195 225 250 280

Power wiringNominal power supply V-ph-Hz 400-3-50System voltage range V 360-440

Control circuit power supply The control circuit is supplied via a factory-installed transformer.

Nominal operating power input* kW30HZ 35.8 45.5 64 64 72 80 85 104 122 154 189 224 25330HZV 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 41830HZV 63.2 79.6 108 114 126 141 154 184 221 272 328 387 438

Maximum operating power input** kW30HZ circuit A and B 46 55 79 83 91 101 111 134 158 198 237 - -30HZ circuit A - - - - - - - - - - - 158 15830HZ circuit B - - - - - - - - - - - 119 15830HZV circuit A and B 54 65 90 98 107 119 130 155 180 225 270 - -30HZV circuit A - - - - - - - - - - - 180 18030HZV circuit B - - - - - - - - - - - 135 180

Maximum operating current (Un-10%)*** A30HZ circuit A and B 88 107 153 161 177 195 214 260 305 382 458 - -30HZ circuit A - - - - - - - - - - - 305 30530HZ circuit B - - - - - - - - - - - 229 30530HZV circuit A and B 101 123 170 185 203 224 246 293 340 425 509 - -30HZV circuit A - - - - - - - - - - - 340 34030HZV 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 27530HZ circuit B - - - - - - - - - - - 206 27530HZV circuit A and B 91 111 153 166 182 202 221 264 306 382 458 - -30HZV circuit A - - - - - - - - - - - 306 30630HZV circuit B - - - - - - - - - - - 229 306

Maximum unit starting current (Un) A30HZ circuit A and B 183 199 274 246 229 277 293 333 408 475 542 - -30HZ circuit A - - - - - - - - - - - 408 40830HZ circuit B - - - - - - - - - - - 341 40830HZV circuit A and B 188 207 283 263 251 299 318 360 436 513 589 - -30HZV circuit A - - - - - - - - - - - 436 43630HZV 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 1.4930HZ 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 1.4330HZV Ratio max. starting current/max. current, circ. B A - - - - - - - - - - - 1.57 1.43

Holding current for three-phase short circuits kA30HZ circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -30HZ circuit A - - - - - - - - - - - 25 2530HZ circuit B - - - - - - - - - - - 25 2530HZV circuit A and B 15 15 15 15 20 20 20 20 20 25 25 - -30HZV circuit A - - - - - - - - - - - 25 2530HZV circuit B - - - - - - - - - - - 25 25

Customer unit standby power for evaporator andcondenser pump connections ACircuit A 6 8 10 10 10 10 10 12 15 24 32 25 32Circuit B - - - - - - - - - - - 20 20

* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12C/7C, condenser entering/leaving water temperature 30C/35C.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) = 12C, saturated condensing temperature (dew point) = 53C(30HZ)/68C (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 largestcompressor). Current and power inputs not included in the values above.


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4.5 - Power supply

The power supply must conform to the specification on the

chiller nameplate. 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 at once and ensure that the chiller is

not switched on until corrective measures have been taken.

4.6 - 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

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.

Notes for electrical data: 30HZ/HZV 043 to 225 units have a single power connection point; 30HZ/HZV

250 to 280 units have two connection points. The control box includes the following standard features:

- Starter and motor protection devices for each compressor- Control devices

Field connections:All connections to the system and the electrical installations must be in fullaccordance with all applicable codes.

The Carrier 30HZ/HZV chillers are designed and built to ensure conformancewith local codes. The recommendations of European standard EN 60204-1(corresponds to IEC 60204-1) (machine safety - electrical machinecomponents - part 1: general regulations) are specifically taken into account,when designing the electrical equipment.

IMPORTANT: Conformance with EN 60204-1 is the best means of ensuring compliance with

the Machines Directive and 1.5.1. Generally the recommendations of IEC60364 are accepted as compliance with the requirements of the installationdirectives.

Annex B of EN 60204-1 describes the electrical characteristics used for theoperation of the machines.

1. The operating environment for the 30HZ/HZV chillers is specified below:

a. Environment* - Environment as classified in IEC 60364 3:- ambient temperature range: +5C to +40C, class AA4- humidity range (non-condensing)*:

50% relative humidity at 40C90% relative humidity at 20C

- altitude: 2000 m

- indoor installation*- presence of water: class AD2* (possibility of water droplets)- presence of hard solids, class AE2* (no significant dust present)- presence of corrosive and polluting substances, class AF1 (negligible)- vibration and shock, class AG2, AH2

b. Competence of personnel, class BA4* (trained personnel - IEC 60364)

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. Over-current 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 alocal earth, consult competent local organisations to complete the electricalinstallation.

NOTE: If particular aspects of an actual installation do not conform to theconditions described above, or if there are other conditions which should beconsidered, always contact your local Carrier representative.

* The protection level required to conform to this class is IP21B (according to

reference document IEC 60529). All 30HZ/HZV units are protected to IP23Cand fulfil this protection condition.

Motor


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14

4.7 - Recommended wire sections

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 instal-

ler 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.

The calculations are based on the maximum machine current

(see electrical data tables).

For the design the following standardised installation methods

are used, in accordance with IEC 60364, table 52C:

For 30HZ/HZV units installed inside the building:

No. 13: Horizontal perforated cable conduits and No. 14:

closed cable conduit.

The calculation is based on PVC or XLPE insulated cables

with copper or aluminium core. The maximum temperature is

40C. The given wire length limits the voltage drop to < 5%.

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 then terminal block or the main disconnect/

isolator switch.

4.7.1 - Field control wiring

Refer to the 30HZ/HZV Pro-Dialog Plus Controls IOM and the

certified wiring diagram supplied with the unit for the field

control wiring of the following features:

Evaporator pump interlock (mandatory)

Remote on/off switch

Remote heat/cool switch

Demand limit external switch 1

Remote dual set point

Alarm report by circuit

Evaporator pump control

Condenser pump control

Remote set point reset or outside air temperature sensor

reset (0-10 V)

4.7.2 - Selection table of minimum and maximum wire sections for connection by phase to 30HZ/HZV units

MIN. WIRE SECTION MAX. WIRE SECTION

30HZ/HZV Section (mm2) Wire type Max. length (400 V) Section (mm2) Wire type Max. length (400 V)

043 1x 25 XLPE Copper 130 1x 95 PVC Aluminium 250052 1x 35 XLPE Copper 142 1x 120 PVC Aluminium 260065 1x 50 XLPE Copper 162 1x 120 XLPE Aluminium 205091 1x 70 XLPE Copper 168 1x 150 XLPE Aluminium 210101 1x 70 XLPE Copper 168 1x 150 XLPE Aluminium 210111 1x 70 XLPE Copper 168 1x 185 XLPE Aluminium 220

121 1x 95 XLPE Copper 178 1x 240 XLPE Aluminium 225141 1x 120 XLPE Copper 185 2x 95 XLPE Aluminium 195161 1x 150 XLPE Copper 188 2x 120 XLPE Aluminium 205195 1x 240 XLPE Copper 192 2x 185 XLPE Aluminium 220225 2x 95 XLPE Copper 172 2x 240 XLPE Aluminium 225250 circuit A 1x 150 XLPE Copper 188 2x 120 PVC Copper 295

2x 150 XLPE Aluminium 210250 circuit B 1x 95 XLPE Copper 178 2x 70 PVC Copper 270

1x 240 XLPE Aluminium 225280 circuit A 1x 185 XLPE Copper 190 2x 95 XLPE Copper 215

2x 150 XLPE Aluminium 210280 circuit B 1x 150 XLPE Copper 188 2x 120 PVC Copper 295

2x 120 XLPE Aluminium 205


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15

5 - APPLICATION DATA

5.1 - Unit operating range

Evaporator Minimum Maximum

Entering water temperature at start-up C 6.8* 30Leaving water temperature during operation C 4** 10

Condenser Minimum Maximum

Entering water temperature C 15 Leaving water temperature C 20 45

Notes:* For application requiring operation at less than 6.8C, contact Carrier s.a. for

unit selection using the Carrier electronic catalog.** For operation between 4C and -15C, 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 +15C 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/HZVunits the minimum and maximum allowable temperatures are 20C and+50C. It is recommended that these temperatures are used for transport bycontainer.

5.1.1 - Operating range 30HZ

5.2 - Minimum chilled water flow

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

be recirculated, as shown in the diagram. The temperature of

the mixture leaving the evaporator must never be less than

2.8 K lower than the chilled water entering temperature.

For minimum chilled water flow rate

Legend1 Evaporator2 Recirculat ion

5.3 - Maximum chilled water flow

The maximum chilled water flow is limited by the maximum

permitted pressure drop in the evaporator. It is provided in the

table on the next page. If the flow exceeds the maximum value,

two solutions are possible:

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

highter temperature difference with a lower evaporator

flow rate.

For maximum chilled water flow rate

1

2

1

2

Legend1 Evaporator2 Bypass

Legend:A 30HZB 30HZ with option 150 (high condensing temperature)C 30HZ with option 5

D 30HZ with option 150 + 5E 30HZ with option 6

Notes:1. Evaporator and condenserT = 5 K

Leaving evaporator water temperature C

Leavingc

ondenserwatertemperatureC

45

40

35

30

25

20

39

44

42

36

A

B

C

D

E

-15 -10 -5 0 5 10-6


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16

5.4 - Variable flow evaporator

Variable evaporator flow can be used in standard chillers. The

chillers maintain a constant leaving water temperature under all

flow conditions. For this to happen, the minimum flow rate

must be higher than the minimum flow given in the table of

permissible flow rates and must not vary by more than 10% per

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.

5.5 - System minimum water volume

Whichever the system, the water loop minimum capacity is

given by the formula:

Capacity = Cap (kW) x N Liters

Application N

Normal air conditioning 3.25Process type cooling 6.5

Where Cap is the nominal system cooling capacity (kW) at the

nominal operating conditions of the installation.

This volume is necessary for stable operation and accurate

temperature control.

5.6 - Evaporator flow rate (l/s)

30HZ/HZV Min. water flow rate, l/s

Closed loop

043 4.1052-065 5.0091 6.0101-121 8.5141-161 9.9195-280 12.0

Bad

Bad

Good

Good

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

internally baffled in order to ensure proper mixing of the liquid

(water or brine). Refer to the examples below.

NOTE: The compressor must not restart more than 6 times in

an hour.

Evaporator pressure drop curves, standard units

Pressuredrop,kPa Legend

1 30HZ/HZV 0432 30HZ/HZV 052-0653 30HZ/HZV 0914 30HZ/HZV 101-1215 30HZ/HZV 141-1616 30HZ/HZV 195-225

7 30HZ/HZV 250-280

Water flow rate l/s

1

10

100

10-10 5030

3

1 2

64 5 7


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17

5.7 - Condenser water flow rates

30HZ/HZV Passes Minimum flow rate, l/s* Maximum flow rate, l/s**

Closed loop Open loop

043 2 1.20 3.60 14.8052 2 1.20 3.60 14.8065 2 1.40 4.20 17091 2 2.47 7.42 30101 2 2.60 7.64 31111 2 3.04 9.13 37121 2 3.54 10.62 43

141 2 3.54 10.62 43161 2 3.54 10.62 43195 2 4.00 12.00 48.00225 2 4.46 13.40 54250 2 5.04 15.14 61280 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

3

1 2

6

4

5 7

1

10

100

100 3020 5040

8

9

10

11

Legend:1 30HZ/HZV 043-052

2 30HZ/HZV 0653 30HZ/HZV 0914 30HZ/HZV 1015 30HZ/HZV 1116 30HZ/HZV 121-1417 30HZ/HZV 1618 30HZ/HZV 1959 30HZ/HZV 22510 30HZ/HZV 25011 30HZ/HZV 280

Pressuredrop,kPa

Water flow rate, l/s

Condenser pressure drop curves, standard units

5.8 - Condenser water flow restrictor

CAUTION: To ensure correct operation of the units, these

restrictors must be installed. The restrictor is supplied with

the machine, inside the control box.

30HZ/HZV Passes* OD, mm Location

043 2 31 Condenser 09RS 022 circuit B - water outlet091 2 47 Condenser 09RS 054 - water outlet111 2 47 Condenser 09RS 054 - water outlet195 2 47 Condenser 09RS 070 - water outlet250 2 56 Condenser 09RS 084 - water outlet

Legend:* No. of passes


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18

6 - WATER CONNECTIONS

For size and position of the heat exchanger 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 water supply must be analysed and appropriate water

treatment elements installed: (filters, additives, intermediate

heat exchangers, purges, vents, shut-off valves, etc) to prevent

corrosion, fouling and deterioration of the pump fittings. Consult

either a water treatment specialist or appropriate literature on

the subject.

6.1 - Operating precautions

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

circuit and install a safety valve as well as an 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 ofvibrations.

Insulate all pipework, after testing for leaks, both to

reduce thermal leaks and to prevent condensation.

Cover the insulation with a vapour barrier.

Where there are particles in the fluid that could foul the

heat exchanger, a screen filter should be installed ahead of

the pump. The mesh size of the filter must be 1.2 mm (see

Typical water circuit diagram on the right).

Before the system start-up verify that the water circuits are

connected to the appropriate heat exchangers (e.g. no

reversal between evaporator and condenser).

Do not introduce any significant static or dynamic

pressure into the heat exchange circuit (with regard to thedesign operating pressures).

Before any start-up verify that the heat exchange fluid is

compatible with the materials and the water circuit

coating.

In case additives or other fluids than those recommended

by Carrier s.a are used, ensure that the fluids are not

considered as a gas, and that they belong to class 2, as

defined in directive 97/23/EC.

Carrier s.a. recommendations on heat exchange fluids:

1. No NH4+ammonium ions in the water, they are very

detrimental for copper. This is one of the most important

factors for the operating life of copper piping. A content

of several tenths of mg/l will badly corrode the copper

over time.

2. Cl-Chloride ions are detrimental for copper with a risk of

perforations by corrosion by puncture. If possible keep

below 10 mg/l.

3. SO4

2-sulphate ions can cause perforating corrosion, if

their content is above 30 mg/l.

4. No fluoride ions (2.8 K. Values between 10 and 25

can be recommended. This will facilitate scale deposit that

can limit corrosion of copper. TH values that are too high

can cause piping blockage over time. A total alkalimetric

titre (TAC) below 100 is desirable.

8. Dissolved oxygen: Any sudden change in water oxygen-ation conditions must be avoided. It is as detrimental to

deoxygenate the water by mixing it with inert gas as it is

to over-oxygenate it by mixing it with pure oxygen. The

disturbance of the oxygenation conditions encourages

destabilisation of copper hydroxides and enlargement of

particles.

9. Specific resistance electric conductivity: the higher the

specific resistance, the slower the corrosion tendency.

Values above 3000 Ohm/cm are desirable. A neutral

environment favours maximum specific resistance values.

For electric conductivity values in the order of 200-6000

S/cm can be recommended.10. pH: Ideal case pH neutral at 20-25C

7 < pH < 8

- If the water circuit must be emptied for longer than

one month, the complete circuit must be placed under

nitrogen charge to avoid any risk of corrosion by

differential aeration.

- Charging and removing heat exchange fluids should

be done with devices that must be included on the

water circuit by the installer. Never use the unit heat

exchangers to add heat exchange fluid.


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19

Potentiometer adjustment

2

1

Legend1 Setting potentiometer sensitivity2 Chain of LEDs

- red LED lights: the unit is not adjusted- yellow LED lights: the output is switched- green LED lights: the unit is adjusted

6.4 - Condenser connections

The condenser is of the multi-tube shell and tube type with

removable water boxes to facilitate cleaning of the tubes.

6.4.1 - Before making water connections

Tighten the bolts in both heads to the lower torque shown,

following the method described. Tighten in the pairs and

sequence indicated according to the size of bolt (see below)

using a torque value at the low end of the range given.

Water box tightening sequence

7

4

6

2

8

3

5

1

Sequence 1: 1 2 3 4Sequence 2: 5 6 7 8

Bolt size M12 - 71-87 NmBolt size M16 - 171-210 NmBolt size M20 - 171-210 Nm

6.2 - Water connections

This diagram shows a typical water installation.

Typical water circuit diagram

Legend1 Control valve2 Air vent

3 Flow switch for the evaporator4 Flexible connection5 Heat exchanger6 Pressure tap7 Thermostat sleeve8 Drain9 Buffer tank10 Filter (mesh size: 1.2 mm = 20 mesh)11 Expansion tank12 Fill valve

6.3 - Flow control

6.3.1 - Evaporator flow switch and chilled water pump

interlock

IMPORTANT: On 30HZ/HZV units, the unit chilled water

flow switch must be energised, and the chilled water pump

interlock must be connected. Failure to follow this instruction

will void the Carrier guarantee.

The flow switch is supplied, installed on the evaporator

entering water pipe and factory-set to the minimum water flow

rate. If adjustment is necessary:

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 time).

2. Turn the potentiometer until one green LED is illuminated.

The further the green LED is from the yellow LED, thesafer the adjustment (standby capacity in case of flow or

temperature fluctuations).

3. After the adjustment attach the label supplied to the

potentiometer, in order to protect it against unauthorised

tampering.

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).

1 2

3

4 5

6

78

9

10

11

12


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20

6.6 - Refrigerant line connections (30HZV)

6.6.1 - Recommendations for the installation of liquid

chillers with remote condensers

To guarantee optimum and reliable performance of the 30HZV

units (split units for connection to condensers) it is necessary to

comply with the regulations described below, when these units

are connected to remote condensers.

1. Install a valve in the discharge piping (valves are factory-

installed in sizes 043-063, and supplied non-installed in

sizes 091-280).

2. Size the discharge and liquid line piping according to the

recommendations in the following paragraphs (if neces-

sary, install a double riser to ensure correct oil circulation

in the refrigerant circuit).

3. Depending on the layout and the routing of the discharge

piping it may be necessary to install additional silencers

(to reduce pulsations and noise emission) between the

liquid chiller and the condenser.

4. Select a condenser with an integrated subcooler to obtain

a minimum of 3 K subcooling at the inlet to the expansion

device.5. Keep the condensing pressure as stable as possible

(pressostat staging or fan control via Pro-Dialog Plus). A

speed controller may be required for the first fan stage for

operation at low ambient temperature and partial load.

6. If the system can have several operating modes (summer/

winter, dual set point etc.), it is necessary to install a tank

(or receiver) to absorb the variations in charge.

6.6.2 - General

Refrigerant pipe sizing must be carried out, taking account of

the following constraints:

Oil return to the compressor must be ensured for the majority of

applications. Oil return is ensured by entrainment. A minimum

refrigerant velocity is required to ensure entrainment. This

velocity depends on the pipe diameter, the refrigerant and oil

temperature (these are treated as being the same in most cases).

A reduction of the pipe diameter permits an increase of the

refrigerant velocity. The problem of a minimum entrainment

velocity does not exist for the pipes that carry liquid refrigerant

as the oil is fully miscible here.

The pressure drop at the compressor discharge (pipes linking

the compressor outlet with the condenser inlet) must be limited

to avoid system performance losses (the compressor powerinput inceases, and the cooling capacity decreases).

As a first estimate and for standard air conditioning applica-

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.

The pressure drop in the liquid line (linking the condenser

outlet to the expansion device) must not result in a change in

phase. The estimate of these pressure drops must include those

for the possible accessories, such as solenoid valves, filters,filter drier, etc.

6.4.2 - Pipe connections

After welding the pipes to the flanges previously removed from

the water boxes:

1. Reinstall the pipes and tighten lightly to a torque at the

low end of the range.

2. Fill the system with water.

3. Wait for 10 minutes and check for minor leaks

- at the water box joints

- at the flange joints

4. Drain the system.

5. Disconnect the pipework.

6. Tighten the head bolts to their final torque (middle of the

range) in the sequence illustrated.

7. Reconnect the water pipes, tightening the flange bolts to

the mid-range torque value.

8. Refill the system with water.

9. Pressurize the system.

6.5 - Frost protection

The 30HZ and 30HZV units are designed to be installed under

cover at outside temperatures between +5C and +40C.

Therefore they do not include anti-freeze protection, as standard.

If the water piping is in an area where the ambient temperature

can fall below 0C it is recommended to install a trace heater on

the piping and 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 be reached 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 climatic 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 add

ethylene glycol to 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 installermust 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).


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21

6.6.3 - Use of pipe sizing diagrams

On page 21 of this document two pipe sizing diagrams are

shown. They allow an estimate of the cooling capacity, corres-

ponding to 1.5 K pressure drop for different pipe diameters,

based on the pipe length.

The following procedure can be used for pipe sizing:

1. Measure the length (in metres) of the piping under

consideration.

2. Add 40 to 50% to take account of special characteristics.

3. Multiply this length by the appropriate correction factor

from Table 1 (this correction factor depends on the

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.

The diagrams in the appendix can obviously be used to calculate

the actual pressure drops for the piping under consideration:

7. Based on the pipe diameter and the cooling capacity find

the equivalent length, producing 1.5 K pressure drop in

Figs. Discharge piping and Liquid line piping.

8. Calculate the equivalent pipe length as described in steps

1, 2, 3 and 5.

9. Calculate the length ratio from steps 8 and 7 (equivalent

length from step 8 DIVIDED by the equivalent length

from step 7).

10. Multiply this ratio by 1.5 to find the equivalent pressure

drops in C.

6.6.4 - Discharge pipe sizing

The discharge piping must be sized to achieve reasonable

pressure drops: a variation of 1.5 K of the saturated tempera-

ture is normally accepted (approx. 60 kPa variation for a

condensing temperature of 50C).

For most applications the refrigerant gas velocity is sufficient

to entrain the liquid refrigerant/oil mixture. Nevertheless, Table

2 shows the minimum required cooling capacities for different

pipe diameters and different saturated discharge temperatures.

This table is based on 8 K superheat, a saturated suctiontemperature of 4C and 8 K subcooling. Table 3 shows the

correction factors to be applied to the values from Table 2, if

the operating conditions are different from those previously

stated.

6.6.5 - Liquid line sizing

The 30HZV compressors are supplied with an oil that is fully

miscible with refrigerant R407C in the liquid phase. Conse-

quently low refrigerant velocities in the liquid lines are not a

problem.

The admissible pressure drops in the liquid lines depend mainlyon the subcooling level of the liquid refrigerant at the con-

denser outlet. Pressure drops corresponding to 1.5C saturated

temperature must not be exceeded.

Special attention must be paid to the liquid line sizing when the

expansion device ist positioned higher than the condenser. It

may now be necessary to increase the pipe diameter to com-

pensate for the additional pressure of the liquid refrigerant

column. If the liquid refrigerant head ist very high, it may even

be necessary to increase the subcooling to prevent an phase

change in the liquid line. This can be done e.g. by a liquid-

vapour heat exchanger or an additional coil.

At 45C the volume mass of refrigerant R407C in the liquid

phase is approximately 1050 kg/m3. A pressure of 1 bar

corresponds to a liquid head of: 100 000/(1050 x 9.81) = 9.7 m.


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22

Table 1 - R-407C correction factors for copper tube

30HZV Saturated suction temperature, C

Cond. temp. -18 -12 -7 -1 4 10C S HG L S HG L S HG L S HG L S HG L S HG L

27 2.01 1.36 1.09 1.61 1.34 1.07 1.31 1.30 1.06 1.07 1.26 1.04 0.89 1.23 1.03 0.74 1.19 1.0132 2.11 1.27 1.08 1.69 1.23 1.06 1.37 1.19 1.04 1.12 1.16 1.03 0.93 1.12 1.01 0.77 1.09 1.0038 2.22 1.17 1.08 1.78 1.13 1.06 1.44 1.10 1.04 1.18 1.06 1.02 0.97 1.03 1.01 0.81 1.00 0.9943 2.34 1.09 1.08 1.88 1.06 1.06 1.52 1.02 1.04 1.24 0.99 1.02 1.03 0.96 1.00 0.85 0.93 0.9949 2.49 1.03 1.09 1.99 0.99 1.07 1.61 0.96 1.05 1.32 0.93 1.03 1.09 0.90 1.01 0.90 0.87 0.9954 2.66 0.97 1.12 2.13 0.94 1.10 1.72 0.90 1.07 1.40 0.87 1.05 1.16 0.85 1.03 0.96 0.82 1.0160 2.87 0.93 1.16 2.29 0.90 1.13 1.85 0.86 1.11 1.50 0.83 1.08 1.24 0.81 1.06 1.03 0.78 1.04

66 3.13 0.91 1.21 2.49 0.87 1.18 2.01 0.84 1.15 1.63 0.81 1.12 1.34 0.78 1.10 1.11 0.75 1.0871 3.46 0.89 1.29 2.74 0.85 1.26 2.21 0.82 1.22 1.79 0.78 1.19 1.47 0.76 1.16 1.21 0.73 1.13

LegendS SuctionHG Hot gasL Liquid

Table 2 - Minimum capacity for oil entrainment in the discharge piping (kW) for R407C copper tube

30HZV Outside pipe diameter

1/2 5/8 3/4 7/8 1-1/8 1-3/8 1-5/8 2-1/8 2-5/8 3-1/8 3-5/8 4-1/8Saturated condensing temperature, C

27 0.81 1.48 2.39 3.66 7.14 12.06 18.64 37.21 63.94 99.81 145.60 201.9832 0.84 1.51 2.46 3.76 7.28 12.34 19.06 38.09 65.42 102.13 148.94 206.6638 0.84 1.51 2.50 3.80 7.42 12.56 19.41 38.76 66.61 103.96 151.62 210.35

43 0.88 1.55 2.53 3.87 7.53 12.73 19.66 39.25 67.42 105.23 153.48 212.9249 0.88 1.55 2.53 3.87 7.56 12.80 19.77 39.50 67.84 105.90 154.43 214.2654 0.88 1.55 2.53 3.87 7.56 12.80 19.77 39.46 67.81 105.86 154.40 214.1960 0.84 1.55 2.53 3.87 7.49 12.70 19.62 39.18 67.32 105.05 153.24 212.6066 0.84 1.51 2.46 3.80 7.39 12.45 19.27 38.44 66.08 103.12 150.42 208.6671 0.81 1.48 2.43 3.69 7.17 12.17 18.78 37.49 64.43 100.55 146.69 203.49

Table 3 - R407C correction factorsfor oil entrainment in the discharge piping

Saturated suction temperature, C

-23 -18 -12 -7 -1 4 100.86 0.89 0.92 0.94 0.97 1.00 1.03

See chapter "Discharge pipe sizing"


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23

10

100

10 100 1000

30

20

40

50

2

3

4

5

3 4 5 20 30 40 50

200

200 300 400

1 2 3 4 5 6 7

Discharge piping

Liquid piping

Legend1 1/2"2 3/8"3 3/4"4 7/8"5 1 1/8"6 1 3/8"7 1 5/8"8 2 1/8"

Legend1 3/8"2 1/2"3 5/8"4 3/4"5 7/8"6 1 1/8"7 1 3/8"

Cooling capacity (kW)

Equivalentlength(m)

Cooling capacity (kW)

Equivalentle

ngth(m)

10 100 10003 4 5 20 30 40 50 200 300 400 500

1 2 3 4 5 6 7 8

10

100

30

20

40

50

2

3

4

5

200


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6.7 - 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 configura-

tion). 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, loadshedding etc.) are controlled by the unit configured as master

and must only be applied to the master unit.

Each unit controls its own water pump. If there is only one

common pump, in cases with variable flow, isolation valves

must be installed on each unit. They will be activated at the

opening and closing by the control of each unit (in this case the

valves are controlled using the dedicated water pump outputs).

See the 30HZ/HZV Pro-Dialog Plus Control IOM for a more

detailed explanation.

30HZ/HZV with configuration: leaving water control

Legend

1 Master unit2 Slave unit

Control boxes of the master and slave units

Water inlet

Water outlet

Water pumps for each unit (included as standard for units with hydronicmodule)Additional sensors for leaving water control, to be connected to channel 1 ofthe slave boards of each master and slave unitCCN communication busConnection of two additional sensors

7 - MAJOR SYSTEM COMPONENTS AND OPERATIONDATA FOR STANDARD UNITS

7.1 - Compressors

30HZ/HZV units use reciprocating, semi-hermetic compressors.

As standard, each compressor is equipped with:

a discharge valve

a suction valve

an oil crankcase heater with a safety device that shuts off

the compressor in case of a fault

a discharge line muffler

anti-vibration mounts

With options 5 and 6 (low leaving brine temperature) each

compressor is equipped with a thermostat controlling the

discharge gas temperature. This sensor is activated, if the

temperature exceeds the safety limit and shuts off the

compressor (cut-out: 146C - cut-in: 115C).

7.2 - Lubricant

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.

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.)

- Capella WF 32-150

- Clavus G32 (Shell Oil Co.)

CAUTION: R407C oils are absolutely not compatible with

R22 oils.

7.3 - Pressure vessels

7.3.1 - Condensers (30HZ units)

The condensers (one per circuit) are shell-and-tube condensers.

They have been tested and stamped in accordance with the

applicable pressure code for a maximum refrigerant-side

operating pressure of 3200 kPa and for a water-side operating

pressure of 1000 kPa.

The seamless copper tubes are finned on the refrigerant side,

and expanded onto the tube sheets.

For option 150A (heat pump), the condensers have a thermal

insulation of 19 mm thick polyurethane foam.The condenser shell can have a thermal insulation of 19 mm

polyurethane foam, and can be equipped with a water drain and

purge.

1 2


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7.3.2 - Evaporator

The evaporator is a shell-and-tube type with two refrigerant

circuits. It has been tested and stamped in accordance with

applicable pressure codes for a maximum operating pressure of

2100 kPa refrigerant-side and 1000 kPa water-side. The seam-

less copper tubes are finned on the refrigerant side and expanded

onto the tube sheets.

The heat exchanger shell has a thermal insulation of 19 mm

polyurethane foam, and is equipped with a water drain and purge.

The products that may be added for thermal insulation of the

containers during the water piping connection procedure must

be chemically neutral in relation to the materials and coatings

to which they are applied. This is also the case for the products

originally supplied by Carrier s.a.

NOTES: Monitoring during operation, re-qualification, re-

testing and re-testing dispensation:

- Follow the regulations on monitoring pressurised

equipment.

- It is normally required that the user or operator sets up

and maintains a monitoring and maintenance file.- Follow the control programmes of EN 378-2, annexes A,

B, C and D.

- If they exist follow local professional recommendations.

- Regularly inspect the condition of the coating (paint) to

detect blistering resulting from corrosion. To do this,

check a non-insulated section of the container or the

rust formation at the insulation joints.

- Regularly check for possible presence of impurities (e.g.

silicon grains) in the heat exchange fluids. These impuri-

ties maybe the cause of the wear or corrosion by puncture.

- Filter the heat exchange fluid check and carry out

internal inspections as described in EN 378-2, annex C.- In case of re-testing take possible maximum pressure

differences, as indicated in (2) above into consideration.

- The reports of periodical checks by the user or operator

must be included in the supervision and maintenance

file.

Repair

Any repair or modification, including the replacement of

moving parts:

- must follow local regulations and be made by qualified

operators and in accordance with qualified procedures,

including changing the heat exchanger tubes

- must be made in accordance with the instructions of theoriginal manufacturer. Repair and modification that

necessitate permanent assembly (soldering, welding,

expanding etc.) must be made using the correct

procedures and by qualified operators.

- An indication of any modification or repair must be

shown in the monitoring and maintenance file.

Recycling

The unit is wholly or partly recyclable. After use it contains

refrigerant vapours and oil residue. It is coated by paint.

Operating lifeThis unit is designed for:

- prolonged storage of 15 years under nitrogen charge

with a temperature difference of 20 K per day.

- 452000 cycles (start-ups) with a maximum difference of

6 K between two neighbouring points in the container,

based on 6 start-ups per hour over 15 years at a usage

rate of 90%.

Excess corrosion thickness

Gas side: 0 mm

Heat exchange fluid side: 1 mm for tubular plates in lightly

alloyed steels, 0 mm for stainless steel plates or plates with

copper-nickel or stainless steel protection.

7.4 - Electronic expansion device (EXV)

These are an option for sizes 30HZ/HZV 043-065.

The microprocessor controls the EXD through the EXV board

module. Inside this EXV is a linear actuator stepper motor.

The stepper motor moves in increments and is controlled

directly by the processor module. As the stepper motor rotates,

motion is transferred into linear movement by the lead screw.

Through the stepper motor and lead screws, 1500 discrete steps

of motion a

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