30HZ/HZV 043-280 Water-Cooled/Condenserless Liquid Chillers · 30HZ/HZV 043-280 Water-Cooled/Condenserless Liquid Chillers Nominal cooling capacity 30HZ: 134-783 kW ... pressure,

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

2

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

CONTENTS

1 - INTRODUCTION ....................................................................................................................................................................... 41.1 - Installation safety considerations .............................................................................................................................................. 41.2 - Equipment and components under pressure .............................................................................................................................. 41.3 - Maintenance safety considerations ............................................................................................................................................41.4 - Repair safety considerations ...................................................................................................................................................... 5

2 - PRELIMINARY CHECKS ........................................................................................................................................................62.1 - Check equipment received ......................................................................................................................................................... 62.2 - Moving and siting the unit ......................................................................................................................................................... 6

3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION .............................................................................................. 83.1 - 30HZ/HZV 043-065 ...................................................................................................................................................................83.2 - 30HZ/HZV 091-225 ...................................................................................................................................................................83.3 - 30HZ/HZV 250-280 ...................................................................................................................................................................9

4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22) ..........................................................................104.1 - Physical data (R407C) .............................................................................................................................................................104.2 - Electrical data (R407C) ...........................................................................................................................................................104.3 - Physical data (R22) ..................................................................................................................................................................114.4 - Electrical data (R22) ................................................................................................................................................................ 124.5 - Power supply ............................................................................................................................................................................ 134.6 - Voltage phase imbalance (%) ..................................................................................................................................................134.7 - Recommended wire sections ................................................................................................................................................... 14

5 - APPLICATION DATA .............................................................................................................................................................155.1 - Unit operating range ................................................................................................................................................................ 155.2 - Minimum chilled water flow ................................................................................................................................................... 155.3 - Maximum chilled water flow ................................................................................................................................................... 155.4 - Variable flow evaporator ......................................................................................................................................................... 165.5 - System minimum water volume .............................................................................................................................................. 165.6 - Evaporator flow rate (l/s) ......................................................................................................................................................... 165.7 - Condenser water flow rates ......................................................................................................................................................175.8 - Condenser water flow restrictor ...............................................................................................................................................17

6 - WATER CONNECTIONS .......................................................................................................................................................186.1 - Operating precautions ..............................................................................................................................................................186.2 - Water connections ....................................................................................................................................................................196.3 - Flow control .............................................................................................................................................................................196.4 - Condenser connections ............................................................................................................................................................196.5 - Frost protection ........................................................................................................................................................................206.6 - Refrigerant line connections (30HZV) ....................................................................................................................................206.7 - Operation of two units in master/slave mode ..........................................................................................................................24

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CONTENTS (cont’d)

7 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA FOR STANDARD UNITS ........................................... 247.1 - Compressors ............................................................................................................................................................................. 247.2 - Lubricant .................................................................................................................................................................................. 247.3 - Pressure vessels ........................................................................................................................................................................ 247.4 - Electronic expansion device (EXV) ........................................................................................................................................ 257.5 - Refrigerant ............................................................................................................................................................................... 257.6 - High-pressure safety switch ..................................................................................................................................................... 257.7 - Moisture indicator ....................................................................................................................................................................257.8 - Filter drier ................................................................................................................................................................................25

8 - MAIN OPTIONS AND ACCESSORIES ................................................................................................................................268.1 - Units for low evaporator outlet temperature applications (options 5 and 6) ..........................................................................268.2 - Electrical protection to IP 44 (option 20) ................................................................................................................................268.3 - High- and low-pressure gauges (option 26) ............................................................................................................................. 268.4 - Compressor oil pressure safety device .................................................................................................................................... 268.5 - Condenser with copper-nickel tubes (option 33) ....................................................................................................................268.6 - RS 485 communication interface (option 148) ....................................................................................................................... 268.7 - Additional capacity step 30HZ/HZV 043 to 065 (option 94) ................................................................................................. 268.8 - Evaporator pump starter (options 84 and 84D) ....................................................................................................................... 268.9 - Condenser pump starter (option 84R) ......................................................................................................................................26

9 - MAINTENANCE ...................................................................................................................................................................... 279.1 - Soldering and welding ............................................................................................................................................................. 279.2 - Maintenance of the refrigerant circuit ..................................................................................................................................... 279.3 - Electrical maintenance ............................................................................................................................................................. 289.4 - Evaporator maintenance .......................................................................................................................................................... 299.5 - 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 peopleinvolved in the on-site installation, start-up, operation, andmaintenance of this unit should be thoroughly familiar with theseinstructions and the specific project data for the installation site.

The 30HZ/HZV liquid chillers are designed to provide a veryhigh level of safety during installation, start-up, operation andmaintenance. They will provide safe and reliable service whenoperated within their application range.

This manual provides the necessary information to familiarizeyourself with the control system before performing start-upprocedures. The procedures in this manual are arranged in thesequence required for machine installation, start-up, operationand maintenance.

Be sure you understand and follow the procedures and safetyprecautions contained in the instructions supplied with themachine, as well as those listed in this guide.

1.1 - Installation safety considerations

After the unit has been received, when it is ready to beinstalled or reinstalled, and before it is started up, it must beinspected for damage. Check that the refrigerant circuit(s) is(are) intact, especially that no components or pipes have shifted(e.g. following a shock). If in doubt, carry out a leak tightnesscheck and verify with the manufacturer that the circuitintegrity has not been impaired. If damage is detected uponreceipt, immediately file a claim with the shipping company.

Do not remove the skid or the packaging until the unit is inits final position. These units can be moved with a fork lifttruck, as long as the forks are positioned in the right placeand 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. Useslings with the correct capacity, and always follow the liftinginstructions on the certified drawings supplied with the unit.

Safety is only guaranteed, if these instructions are carefullyfollowed. If this is not the case, there is a risk of materialdeterioration and injuries to personnel.

Never cover any safety devices.

This applies to the globe valve in the water circuit and theglobe valve(s) in the refrigerant circuit(s).

Ensure that the valves are correctly installed, beforeoperating the unit.

In certain cases the globe stops are installed on ball valves.These valves are factory-supplied lead-sealed in the openposition. This system permits isolating and removing theglobe stop for checking and replacing. The globe stops aredesigned and installed to ensure protection against fire risk.Removing the globe stops is only permitted if the fire risk isfully 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 thatpeople and property are not exposed to refrigerant leaks.These fluids may be diffused in the air, but far away from anybuilding air intake, or they must be discharged in a quantitythat 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 inan enclosed space can displace oxygen and causeasphyxiation or explosions.

Inhalation of high concentrations of vapour is harmful andmay cause heart irregularities, unconsciousness, or death.Vapour is heavier than air and reduces the amount of oxygenavailable for breathing. These products cause eye and skinirritation. Decomposition products are hazardous.

1.2 - Equipment and components under pressure

These products incorporate equipment or components underpressure, manufactured by Carrier or other manufacturers. Werecommend that you consult your appropriate national tradeassociation or the owner of the equipment or components underpressure (declaration, re-qualification, retesting, etc.). Thecharacteristics of this equipment/these components are givenon the nameplate or in the required documentation, suppliedwith the products.

1.3 - Maintenance safety considerations

Engineers working on the electric or refrigeration componentsmust be authorized, trained and fully qualified to do so(electri-cians trained and qualified in accordance with IEC60364 Classification BA4).

All refrigerant circuit repairs must be carried out by a trainedperson, fully qualified to work on these units. He must havebeen trained and be familiar with the equipment and theinstallation. All welding operations must be carried out byqualified specialists.

Any manipulation (opening or closing) of a shut-off valvemust 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 liquidline valve closed, as liquid refrigerant can be trappedbetween this valve and the expansion device. (This valve issituated on the liquid line before the filter drier box.)

During any handling, maintenance and service operationsthe engineers working on the unit must be equipped withsafety 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 beforerecharging the unit (see unit name plate).

Charging any refrigerant other than the original charge typewill impair machine operation and can even lead to adestruction of the compressors.

Do not use oxygen to purge lines or to pressurize a machinefor 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 testpressures by checking the instructions in this manual and thepressures given on the unit name plate.

Do not use air for leak testing. Use only refrigerant or drynitrogen.

Do not unweld or flamecut the refrigerant lines or any refri-gerant circuit component until all refrigerant (liquid andvapour) has been removed from chiller. Traces of vapourshould be displaced with dry air nitrogen. Refrigerant incontact with an open flame produces toxic gases.

The necessary protection equipment must be available, andappropriate fire extinguishers for the system and the refrigeranttype used must be within easy reach.

Do not siphon refrigerant.

Avoid spilling liquid refrigerant on skin or splashing it intothe eyes. Use safety goggles. Wash any spills from the skinwith 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 refrigerantcontainer. Dangerous overpressure can result. If it isnecessary to heat refrigerant, use only warm water.

During refrigerant removal and storage operations followapplicable regulations. These regulations, permitting condition-ing and recovery of halogenated hydrocarbons under opti-mum quality conditions for the products and optimum safetyconditions for people, property and the environment aredescribed in standard NFE 29795.

Any refrigerant transfer and recovery operations must becarried out using a transfer unit. A 3/8” SAE connector onthe manual liquid line valve is supplied with all units forconnection to the transfer station. The units must never bemodified to add refrigerant and oil charging, removal andpurging 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 attemptto refill them. It is dangerous and illegal. When cylinders areempty, evacuate the remaining gas pressure, and move thecylinders to a place designated for their recovery. Do notincinerate.

Never work on any of the electrical components, until thegeneral power supply to the unit has been cut using thedisconnect 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 ofthe machine.

If the work is interrupted, always ensure that all circuits arestill deenergized before resuming the work.

ATTENTION: Even if the unit has been switched off, thepower circuit remains energized, unless the unit or circuitdisconnect switch is open. Refer to the wiring diagram forfurther details. Attach appropriate safety labels.

Protection of electronic boards : If the boards need to behandled wear anti-static gloves to avoid exposing the electroniccomponents to a destructive voltage. Only unpack the boardsfrom their anti-static bag when they need to be installed.

Once a year check that the high-pressure safety switch iscorrectly 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 withnational regulations.

The information on operating inspections given in annex Cof standard EN278-2 can be used if no similar criteria existin the national regulations.

Safety device checks (annex C6 – EN378-2): The safetydevices 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 adetailed 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 incharge, in order to avoid material deterioration and injuries topeople. Faults and leaks must be repaired immediately. Theauthorized technician must have the responsibility to repair thefault immediately. Each time repairs have been carried out tothe unit, the operation of the safety devices must be re-checked.

If a leak occurs or if the refrigerant becomes polluted (e.g. by ashort circuit in a motor) remove the complete charge using arecovery 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 isdetected, or if shipment is incomplete, immediately file aclaim with the shipping company.

• Confirm that the unit received is the one ordered. Comparethe name plate data with the order.

• The unit name plate must include the followinginformation:- 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

High pressure Low pressureMin. Max. Min. Max.

PS (bar) -0.9 32 -0.9 21TS (°C) -20 74 -20 55Pressure switch cut-out pressure (bar) 21.8 -Valve cut-out pressure (bar) 30 21Test pressure, unit leak test (bar) 15

• Confirm that all accessories ordered for on-site installationhave been delivered, and are complete and undamaged.

The unit must be checked periodically during its wholeoperating life to ensure that no shocks (handling accessories,tools etc.) have damaged it. If necessary, the damaged partsmust be repaired or replaced. See also chapter “Maintenance”.

2.2 - Moving and siting the unit

2.2.1 - MovingSee chapter 1.1 "Installation safety considerations".

2.2.2 - Siting the unit

Always refer to the chapter "Dimensions and clearances" toconfirm that there is adequate space for all connections andservice 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 suppliedwith the unit.

Typical applications of these units are in refrigerationsystems, and they do not require earthquake resistance.Earthquake resistance has not been verified.

Do not attempt to remove refrigerant circuit components orfittings, while the machine is under pressure or while it isrunning. Be sure pressure is at 0 kPa before removingcomponents or opening a circuit.

Do not attempt to repair or recondition any safety deviceswhen corrosion or build-up of foreign material (rust, dirt,scale, etc.) is found within the valve body or mechanism. Ifnecessary, replace the device. Do not install safety valves inseries or backwards.

ATTENTION: No part of the unit must use feet, racks orsupports during operation. Periodically monitor and repairor if necessary replace any component or piping that showssigns of damage.

The refrigerant lines can break under the weight and releaserefrigerant, causing personal injury.

Do not climb on a machine. Use a platform, or staging towork 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 orlosing your balance.

Use only original replacement parts for any repair or compo-nent replacement. Consult the list of replacement parts thatcorresponds to the specification of the original equipment.

Do not drain water circuits containing industrial brines,without informing the technical service department at theinstallation site or a competent body first.

Close the entering and leaving water shutoff valves andpurge the unit hydronic circuit, before working on thecomponents installed on the circuit (screen filter, pump,water flow switch, etc.).

Periodically inspect all valves, fittings and pipes of therefrigerant and hydronic circuits to ensure that they do notshow any corrosion or any signs of leaks.

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• 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.

2.2.3 - Check compressor mountingsBefore any start-up of the unit proceed as follows:

For 30HZ/HZV 043-065 units

1. Remove the wooden block located under the compressorfoot.

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 thatthe compressor support can float freely.

CAUTION: Only use slings at the designated lifting pointswhich are marked on the unit.

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. Tiltingand jarring can damage the unit and impair unit operation.

If 30HZ/HZV units are hoisted with rigging, it is advisable toprotect the control box against accidental shocks. Do not tilt aunit more than 15°.

WARNING: Never push or lever the chassis or the controlbox of the unit.

Checks before system start-up

Before the start-up of the refrigeration system, the completeinstallation, including the refrigeration system must be verifiedagainst the installation drawings, dimensional drawings,system piping and instrumentation diagrams and the wiringdiagrams.

During the installation test national regulations must befollowed. If no national regulation exists, paragraph 9-5 ofstandard 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 withthe current European standard.

• Verify that all document for pressure containers,certificates, name plates, files, instruction manuals thatare required documents required by the current Europeanstandards 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 tothe 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.

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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

C75

0

600

3

3

3

4

3

3

3

4

2

1

A

CB

2550

800

800

800

9

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 3550 1915 950161 3550 1915 950195 4255 1950 950225 4255 1950 950250-280 4070 2150 1275

30HZV - units without condenser A B C

043 2452 1260 904052 2750 1245 904065 2750 1245 904091 2630 1300 950101 2940 1300 950111 2940 1300 950121 2940 1300 950141 3550 1300 950161 3550 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

B85

0C

1000

2750

800

A

1

2

3

4

FLOOR MOUNTINGFor 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 = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C- evaporator and condenser fouling factor = 0.000044 m2 K/W- condensing temperature dew point 45°C- fluid temperature = condensing temperature at dew point - refrigerant glide - 5 K subcooling.- Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)

** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.*** The 30HZV units have a nitrogen holding charge only.

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 44830HZV 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 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).

** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12°C, saturated condensing temperature (dew point) = 52°C(30HZ)/66°C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).

*** Maximum unit operating current at maximum unit power input.† Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest

compressor).‡ Current and power inputs not included in the values above.

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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





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 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

* Nominal Eurovent conditions:- evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C- evaporator and condenser fouling factor = 0.000044 m2 K/W- condensing temperature 45°C (30HZV)- fluid temperature = condensing temperature - 5 K subcooling (30HZV)- Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)

** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.*** The 30HZV units have a nitrogen holding charge only.

12

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* A30HZ 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)*** A30HZ – 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





13

4.5 - Power supply

The power supply must conform to the specification on thechiller nameplate. The supply voltage must be within the rangespecified in the electrical data table. For connections refer tothe wiring diagrams.

WARNING: Operation of the chiller with an improper supplyvoltage or excessive phase imbalance constitutes abuse whichwill invalidate the Carrier warranty. If the phase imbalanceexceeds 2% for voltage, or 10% for current, contact yourlocal electricity supply at once and ensure that the chiller isnot switched on until corrective measures have been taken.

4.6 - Voltage phase imbalance (%)

100 x max. deviation from average voltageAverage voltage

Example:On a 400 V - 3 ph - 50 Hz supply, the individual phase voltageswere 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 greatestpercentage 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: +5°C to +40°C, class AA4- humidity range (non-condensing)*:

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

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

Motor

14

4.7 - Recommended wire sections

Wire sizing is the responsibility of the installer, and dependson the characteristics and regulations applicable to eachinstallation site. The following is only to be used as aguideline, and does not make Carrier in any way liable. Afterwire sizing has been completed, using the certifieddimensional drawing, the instal-ler must ensure easyconnection and define any modifications necessary on site.

The connections provided as standard for the field-suppliedpower entry cables to the general disconnect/isolator switchare designed for the number and type of wires, listed in thetable below.

The calculations are based on the maximum machine current(see electrical data tables).

For the design the following standardised installation methodsare 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 cableswith copper or aluminium core. The maximum temperature is40°C. 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 checkthe correct order of the 3 phases before proceeding to theconnection on then terminal block or the main disconnect/isolator switch.

4.7.1 - Field control wiringRefer to the 30HZ/HZV Pro-Dialog Plus Controls IOM and thecertified wiring diagram supplied with the unit for the fieldcontrol 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 220121 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

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 6.8°C, contact Carrier s.a. for

unit selection using the Carrier electronic catalog.** For operation between 4°C and -15°C, the unit must be equipped with option 5

or 6, and the use of anti-freeze is required.† For an application, requiring operation up to +15°C leaving water temperature,

contact Carrier for the selection of the unit.‡ Depends on the maximum condenser flow rate.

Maximum outside temperature: For transport and storage of the 30HZ/HZVunits the minimum and maximum allowable temperatures are –20°C and+50°C. 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 thenext page. If the flow is less than this, the evaporator flow canbe recirculated, as shown in the diagram. The temperature ofthe mixture leaving the evaporator must never be less than2.8 K lower than the chilled water entering temperature.

For minimum chilled water flow rate

Legend1 Evaporator2 Recirculation

5.3 - Maximum chilled water flow

The maximum chilled water flow is limited by the maximumpermitted pressure drop in the evaporator. It is provided in thetable 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 evaporatorflow 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 5D 30HZ with option 150 + 5E 30HZ with option 6

Notes:1. Evaporator and condenser �T = 5 K

Leaving evaporator water temperature °C

Leav

ing

cond

ense

r w

ater

tem

pera

ture

°C

45

40

35

30

25

20

39

44

42

36

A

B

C

D

E

-15 -10 -5 0 5 10-6

16

5.4 - Variable flow evaporator

Variable evaporator flow can be used in standard chillers. Thechillers maintain a constant leaving water temperature underall flow conditions. For this to happen, the minimum flow ratemust be higher than the minimum flow given in the table ofpermissible flow rates and must not vary by more than 10% perminute.

If the flow rate changes more rapidly, the system should containa 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 isgiven 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 thenominal operating conditions of the installation.

This volume is necessary for stable operation and accuratetemperature 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 inorder to achieve the required volume. The tank must itself beinternally baffled in order to ensure proper mixing of theliquid (water or brine). Refer to the examples below.

NOTE: The compressor must not restart more than 6 times inan hour.

Evaporator pressure drop curves, standard units

Pre

ssur

e dr

op, k

Pa

Legend1 30HZ/HZV 0432 30HZ/HZV 052-0653 30HZ/HZV 0914 30HZ/HZV 101-1215 30HZ/HZV 141-1616 30HZ/HZV 195-2257 30HZ/HZV 250-280

Water flow rate l/s

1 2

34

5 6 7

1

10

100

1 10 100

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 43141 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

Legend:1 30HZ/HZV 043-0522 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

Pre

ssur

e dr

op, k

Pa

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, theserestrictors must be installed. The restrictor is supplied withthe 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

12

3

9

4 5 6

7 8 10

11

1

10

100

1 10 100

18

6 - WATER CONNECTIONS

For size and position of the heat exchanger water inlet andoutlet connections refer to the certified dimensional drawingssupplied with the unit.

The water pipes must not transmit any radial or axial force tothe heat exchangers nor any vibration.

The water supply must be analysed and appropriate watertreatment elements installed: (filters, additives, intermediateheat exchangers, purges, vents, shut-off valves, etc) to preventcorrosion, fouling and deterioration of the pump fittings. Consulteither a water treatment specialist or appropriate literature onthe subject.

6.1 - Operating precautions

The water circuit should be designed to have the least numberof elbows and horizontal pipe runs at different levels. Belowthe 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 expansiontank.

• Install thermometers in both the entering and leavingwater connections.

• Install drain connections at all low points to allow thewhole circuit to be drained.

• Install stop valves, close to the entering and leaving waterconnections.

• Use flexible connections to reduce the transmission ofvibrations.

• Insulate all pipework, after testing for leaks, both toreduce 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 aheadof 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 circuitsare connected to the appropriate heat exchangers (e.g. noreversal between evaporator and condenser).

• Do not introduce any significant static or dynamicpressure into the heat exchange circuit (with regard to thedesign operating pressures).

• Before any start-up verify that the heat exchange fluid iscompatible with the materials and the water circuitcoating.

In case additives or other fluids than those recommendedby Carrier s.a are used, ensure that the fluids are notconsidered as a gas, and that they belong to class 2, asdefined 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 importantfactors for the operating life of copper piping. A contentof several tenths of mg/l will badly corrode the copperover time.

2. Cl- Chloride ions are detrimental for copper with a risk ofperforations by corrosion by puncture. If possible keepbelow 10 mg/l.

3. SO42- sulphate ions can cause perforating corrosion, if

their content is above 30 mg/l.4. No fluoride ions (<0.1 mg/l).5. No Fe2+ and Fe3+ ions with non negligible levels of

dissolved oxygen must be present. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l.

6. Dissolved silicon: silicon is an acid element of water andcan also lead to corrosion risks. Content < 1mg/l.

7. Water hardness: TH >2.8 K. Values between 10 and 25can be recommended. This will facilitate scale depositthat can limit corrosion of copper. TH values that are toohigh can cause piping blockage over time. A totalalkalimetric titre (TAC) below 100 is desirable.

8. Dissolved oxygen: Any sudden change in water oxygen-ation conditions must be avoided. It is as detrimental todeoxygenate the water by mixing it with inert gas as it isto over-oxygenate it by mixing it with pure oxygen. Thedisturbance of the oxygenation conditions encouragesdestabilisation of copper hydroxides and enlargement ofparticles.

9. Specific resistance – electric conductivity: the higher thespecific resistance, the slower the corrosion tendency.Values above 3000 Ohm/cm are desirable. A neutralenvironment favours maximum specific resistancevalues. For electric conductivity values in the order of200-6000 S/cm can be recommended.

10. pH: Ideal case pH neutral at 20-25°C7 < pH < 8- If the water circuit must be emptied for longer than

one month, the complete circuit must be placedunder nitrogen charge to avoid any risk of corrosionby differential aeration.

- Charging and removing heat exchange fluids shouldbe done with devices that must be included on thewater circuit by the installer. Never use the unit heatexchangers to add heat exchange fluid.

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 withremovable water boxes to facilitate cleaning of the tubes.

6.4.1 - Before making water connectionsTighten the bolts in both heads to the lower torque shown,following the method described. Tighten in the pairs andsequence 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

62

8

3

51

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 vent3 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 pumpinterlock

IMPORTANT: On 30HZ/HZV units, the unit chilled waterflow switch must be energised, and the chilled water pumpinterlock must be connected. Failure to follow thisinstruction will void the Carrier guarantee.

The flow switch is supplied, installed on the evaporatorentering water pipe and factory-set to the minimum water flowrate. If adjustment is necessary:1. Switch on the unit. Set it to constant flow (preset value).

The yellow LED is illuminated, and the output isswitched for approximately 20 seconds (power-on delaytime).

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 ortemperature fluctuations).

3. After the adjustment attach the label supplied to thepotentiometer, in order to protect it against unauthorisedtampering.

Terminals 34 and 35 are provided for field installation of thechilled water pump interlock (auxiliary contact for pumpoperation to be wired on site).

1 2

3

4 5

6

78

9

1011

12

20

6.6 - Refrigerant line connections (30HZV)

6.6.1 - Recommendations for the installation of liquidchillers with remote condensersTo guarantee optimum and reliable performance of the 30HZVunits (split units for connection to condensers) it is necessaryto comply with the regulations described below, when theseunits 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 insizes 091-280).

2. Size the discharge and liquid line piping according to therecommendations in the following paragraphs (if neces-sary, install a double riser to ensure correct oil circulationin the refrigerant circuit).

3. Depending on the layout and the routing of the dischargepiping it may be necessary to install additional silencers(to reduce pulsations and noise emission) between theliquid chiller and the condenser.

4. Select a condenser with an integrated subcooler to obtaina minimum of 3 K subcooling at the inlet to the expansiondevice.

5. Keep the condensing pressure as stable as possible(pressostat staging or fan control via Pro-Dialog Plus). Aspeed controller may be required for the first fan stage foroperation 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 - GeneralRefrigerant pipe sizing must be carried out, taking account ofthe following constraints:

Oil return to the compressor must be ensured for the majority ofapplications. Oil return is ensured by entrainment. A minimumrefrigerant velocity is required to ensure entrainment. Thisvelocity depends on the pipe diameter, the refrigerant and oiltemperature (these are treated as being the same in mostcases). A reduction of the pipe diameter permits an increase ofthe refrigerant velocity. The problem of a minimumentrainment velocity does not exist for the pipes that carryliquid refrigerant as the oil is fully miscible here.

The pressure drop at the compressor discharge (pipes linkingthe compressor outlet with the condenser inlet) must be limitedto 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 sidedecreases the cooling capacity 2% and increases the compres-sor power input by 3%. Increasing the pipe diameter permitslimiting the pressure drops.

The pressure drop in the liquid line (linking the condenseroutlet to the expansion device) must not result in a change inphase. The estimate of these pressure drops must include thosefor the possible accessories, such as solenoid valves, filters,filter drier, etc.

6.4.2 - Pipe connectionsAfter welding the pipes to the flanges previously removedfrom 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 undercover at outside temperatures between +5°C and +40°C.Therefore they do not include anti-freeze protection, as standard.

If the water piping is in an area where the ambient temperaturecan fall below 0°C it is recommended to install a trace heater onthe piping and to add an antifreeze solution to protect the unitand the water piping to a temperature of 10 K below the lowesttemperature likely to be reached at the installation site. Useonly antifreeze solutions, approved for heat exchanger duty. Ifthe system is not protected by an antifreeze solution and willnot be used during the freezing weather conditions, draining ofthe cooler and outdoor piping is mandatory. Damage due tofreezing is not covered by the warranty.

IMPORTANT: Depending on the climatic conditions in yourarea you must:- Add ethylene glycol with an adequate concentration to

protect the installation up to a temperature of 10 Kbelow the lowest temperature likely to occur at theinstallation site.

- If the unit is not used for an extended period, it isrecommended to drain it, and as a safety precaution addethylene glycol to the heat exchanger, using the waterentering purge valve connection.At the start of the next season, refill the unit with waterand add an inhibitor.

- For the installation of auxiliary equipment, the installermust comply with basic regulations, especially forminimum and maximum flow rates, which must bebetween the values listed in the operating limit table(application data).

21

6.6.3 - Use of pipe sizing diagramsOn page 21 of this document two pipe sizing diagrams areshown. 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 thesaturated 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 thepiping under consideration (such as valves, filters,connections).The equivalent lengths are normally available from thecomponent supplier. Add these lengths to the lengthcaculated in step 3.

6. Repeat steps 4 and 5 is necessary.

The diagrams in the appendix can obviously be used to calculatethe 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 inFigs. “Discharge piping” and “Liquid line piping”.

8. Calculate the equivalent pipe length as described in steps1, 2, 3 and 5.

9. Calculate the length ratio from steps 8 and 7 (equivalentlength from step 8 DIVIDED by the equivalent lengthfrom step 7).

10. Multiply this ratio by 1.5 to find the equivalent pressuredrops in °C.

6.6.4 - Discharge pipe sizingThe discharge piping must be sized to achieve reasonablepressure drops: a variation of 1.5 K of the saturated tempera-ture is normally accepted (approx. 60 kPa variation for acondensing temperature of 50°C).

For most applications the refrigerant gas velocity is sufficientto entrain the liquid refrigerant/oil mixture. Nevertheless,Table 2 shows the minimum required cooling capacities fordifferent pipe diameters and different saturated dischargetemperatures.

This table is based on 8 K superheat, a saturated suctiontemperature of 4°C and 8 K subcooling. Table 3 shows thecorrection factors to be applied to the values from Table 2, ifthe operating conditions are different from those previouslystated.

6.6.5 - Liquid line sizingThe 30HZV compressors are supplied with an oil that is fullymiscible with refrigerant R407C in the liquid phase. Conse-quently low refrigerant velocities in the liquid lines are not aproblem.

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 1.5°C saturatedtemperature must not be exceeded.

Special attention must be paid to the liquid line sizing whenthe 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 refrigerantcolumn. If the liquid refrigerant head ist very high, it may evenbe necessary to increase the subcooling to prevent an phasechange in the liquid line. This can be done e.g. by a liquid-vapour heat exchanger or an additional coil.

At 45°C the volume mass of refrigerant R407C in the liquidphase is approximately 1050 kg/m3. A pressure of 1 barcorresponds to a liquid head of: 100 000/(1050 x 9.81) = 9.7 m.

22

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

30HZV Saturated suction temperature, °C

Cond. temp. -18 -12 -7 -1 4 10°C 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 1.0466 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” 4-1/8”Saturated 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 66.61 103.96 151.62 210.3543 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"

23

10

100

10 100 1000

30

20

4050

2

345

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)

Equ

ival

ent l

engt

h (m

)

Cooling capacity (kW)

Equ

ival

ent l

engt

h (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

4050

2

3

45

200

24

6.7 - Operation of two units in master/slave mode

The control of a master/slave assembly is in the entering waterand does not require any additional sensors (standard configura-tion). It can also be located in the leaving water. In this casetwo additional sensors must be added on the common piping.

All parameters, required for the master/slave function must beconfigured using the Service Configuration menu. All remotecontrols of the master/slave assembly (start/stop, set point,load shedding etc.) are controlled by the unit configured asmaster and must only be applied to the master unit.

Each unit controls its own water pump. If there is only onecommon pump, in cases with variable flow, isolation valvesmust be installed on each unit. They will be activated at theopening and closing by the control of each unit (in this casethe valves are controlled using the dedicated water pumpoutputs). See the 30HZ/HZV Pro-Dialog Plus Control IOM fora 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 unit

CCN communication bus

Connection of two additional sensors

7 - MAJOR SYSTEM COMPONENTS ANDOPERATION DATA 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) eachcompressor is equipped with a thermostat controlling thedischarge gas temperature. This sensor is activated, if thetemperature exceeds the safety limit and shuts off thecompressor (cut-out: 146°C - cut-in: 115°C).

7.2 - Lubricant

The compressors installed in these units have an oil charge (9l) to ensure their correct operation.

Check that the oil level is between 1/8 and 3/8 up the sightglass before start-up and after normal unit operation.

NOTE: Use only oils which have been approved for thecompressors. 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 withR22 oils.

7.3 - Pressure vessels

7.3.1 - Condensers (30HZ units)The condensers (one per circuit) are shell-and-tubecondensers. They have been tested and stamped in accordancewith the applicable pressure code for a maximum refrigerant-side operating pressure of 3200 kPa and for a water-sideoperating 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 thermalinsulation of 19 mm thick polyurethane foam.

The condenser shell can have a thermal insulation of 19 mmpolyurethane foam, and can be equipped with a water drainand purge.

1 2

25

7.3.2 - EvaporatorThe evaporator is a shell-and-tube type with two refrigerantcircuits. It has been tested and stamped in accordance withapplicable pressure codes for a maximum operating pressureof 2100 kPa refrigerant-side and 1000 kPa water-side. Theseam-less copper tubes are finned on the refrigerant side andexpanded onto the tube sheets.

The heat exchanger shell has a thermal insulation of 19 mmpolyurethane foam, and is equipped with a water drain andpurge.

The products that may be added for thermal insulation of thecontainers during the water piping connection procedure mustbe chemically neutral in relation to the materials and coatingsto which they are applied. This is also the case for the productsoriginally 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 therust 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 outinternal inspections as described in EN 378-2, annex C.

- In case of re-testing take possible maximum pressuredifferences, as indicated in (2) above into consideration.

- The reports of periodical checks by the user or operatormust be included in the supervision and maintenancefile.

RepairAny repair or modification, including the replacement ofmoving 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 thatnecessitate permanent assembly (soldering, welding,expanding etc.) must be made using the correctprocedures and by qualified operators.

- An indication of any modification or repair must beshown in the monitoring and maintenance file.

RecyclingThe unit is wholly or partly recyclable. After use it containsrefrigerant 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.

- 710000 cycles (start-ups) with a maximum difference of6 K between two neighbouring points in the container,based on 6 start-ups per hour over 15 years at a usagerate of 90%.

Excess corrosion thicknessGas side: 0 mmHeat exchange fluid side: 1 mm for tubular plates in lightlyalloyed steels, 0 mm for stainless steel plates or plates withcopper-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 boardmodule. Inside this EXV is a linear actuator stepper motor.

The stepper motor moves in increments and is controlleddirectly 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 discretesteps of motion are obtained. The large number of steps andlong stroke result in very accurate control of refrigerant flow.At initial start-up, the EXV position is at zero. After that, themicroprocessor keeps accurate track of the valve position inorder to use this information as input for the other controlfunctions. It does this by initializing the EXV’s at startup. Theprocessor sends out enough closing pulses to the valve to moveit from fully open to fully closed, then resets the positioncounter to zero. From this point on, until the initialization, theprocessor counts the total number of open and closed steps ithas sent to each valve.

7.5 - Refrigerant

30HZ/HZV standard units operate with refrigerant R407C.Optionally (option 7A) the units can use R22.

7.6 - High-pressure safety switch

30HZ/HZV units are equipped with a high-pressure safetyswitch, calibrated to 2700 kPa for 30HZ units and 2900 kPa for30HZV units.

This switch is located on the central block of each lead com-pressor.

7.7 - Moisture indicator

Located on the liquid line, permits control of the unit chargeand indicates moisture in the circuit. The presence of bubblesin the sight-glass indicates an insufficient charge or non-condensables in the system. The presence of moisture changesthe colour of the indicator paper in the sight-glass.

7.8 - Filter drier

The role of the filter drier is to keep the circuit clean andmoisture-free. The moisture indicator shows, when it isnecessary to change the elements. A difference in temperaturebetween the filter inlet and outlet shows that the elements aredirty.

26

8 - MAIN OPTIONS AND ACCESSORIES

Depending on the applications for which the units are selected,they can be equipped with options. This chapter describes themain components that require special information for correctstart-up and maintenance of these units, except where this iscontained in a separate document.

8.1 - Units for low evaporator outlet temperatureapplications (options 5 and 6)

Compressors (option 5 or 6)The capacity reductions are suppressed. The number ofcapacity stages is the same as the number of compressors.

Each compressor is equipped with a temperature sensorlocated in the discharge block which permits control of thedischarge gas temperature.

Expansion devices (option 5 or 6)The expansion devices are chosen in accordance with theoperating conditions supplied when the unit was ordered.

Evaporator (option 6)This is designed and made of special materials, and permitsoperation down to -15°C fluid-side. The evaporator shell hasdouble thermal insulation of polyurethane foam (2 x 19 mm).

Condensers (option 6)Because the thermal heat rejection is less important, thecondensers are down-graded by one size.

8.2 - Electrical protection to IP44 (option 20)

The control boxes and compressor terminal boxes are designedto provide protection in accordance with class IP44 CW.

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

The units are equipped with a high-pressure gauge and a low-pressure gauge on each circuit.

8.4 - Compressor oil pressure safety device

Each compressor is equipped with a pressure sensor located onthe oil pump outlet.

The normal oil pressure for 06E compressors is 82 kPa to 124kPa above the suction pressure.

8.5 - Condenser with CuNi tubes (option 33)

The condensers are manufactured with Copper-Nickel 90/10tubes and plated CuNi 90/10 tube sheets.

8.6 - RS 485 communication interface (option 148)

Each unit is equipped with an additional interface board whichpermits unit connection to a JBus network.

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

Compressor B1 of the 30HZ 043-065 units is equipped with acapacity reduction that increases the available capacity stepsto five steps.

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

Option 84: single evaporator pumpOption 84D: dual evaporator pumpThe unit control boxes are equipped with a disconnect-contactor assembly (2 for option 84D) that allows control ofthe evaporator pump.

8.9 - Condenser pump starter (option 84R)

The unit control boxes are equipped with a disconnect-contactor assembly that allows control of the condenser pump.

27

9 - MAINTENANCE

During the unit operating life the service checks and tests mustbe carried out in accordance with applicable nationalregulations.

If there are no similar criteria in local regulations, theinformation on checks during operation in annex C of standardEN 378-2 can be used.

External visual checks: annex D of standard EN 378-2. Thesecontrols must be carried out:- After an intervention that is likely to affect the resistance

or a change in use or change of high-pressure refrigerant,or after a shut down of more than two years. Componentsthat do not comply, must be changed. Test pressuresabove the respective component design pressure must notbe applied (annex B and D).

- After repair or significant modifications or significantsystem or component extension (annex B)

- After re-installation at another site (annexes A, B and D)- After repair following a refrigerant leak (annex D). The

frequency of refrigerant leak detection can vary fromonce per year for systems with less than 1% leak rate peryear to once a day for systems with a leak rate of 35% peryear or more. The frequency is in proportion with the leakrate.

NOTE: High leak rates are not acceptable. The necessarysteps must be taken to eliminate any leak detected.

NOTE 2: Fixed refrigerant detectors are not leak detectors,as they cannot locate the leak.

9.1 - Soldering and welding

Component, piping and connection soldering and weldingoperations must be carried out using the correct proceduresand by qualified operators. Pressurised containers must not besubjected to shocks, nor to large temperature variations duringmaintenance and repair operations.

Any technician attending the machine for any purpose must befully qualified to work on refrigerant and electrical circuits.

WARNING: Before doing any work on the machine ensurethat the power is switched off. If a refrigerant circuit isopened, it must be evacuated, recharged and tested for leaks.Before any operation on a refrigerant circuit, it is necessaryto remove the complete refrigerant charge from the unit witha refrigerant charge recovery group.

All refrigerant removal and draining operations must becarried out by a qualified technician and with the correctmaterial for the unit. Any inappropriate handling can lead touncontrolled fluid or pressure leaks.

If an oil draining or recovery operation becomes necessary,the fluid transfer must be made using mobile containers.

9.2 - Maintenance of the refrigerant circuit

• Keep the unit itself and the space around it clean and freeof obstructions. Remove all rubbish such as packingmaterials, as soon as the installation is completed.

• Regularly clean the exposed pipework to remove all dustand dirt. This makes detection of water leaks easier, andthey can be repaired before more serious faults develop.

• Confirm that all screwed and bolted connections andjoints are secure. Secure connections prevent leaks andvibration from developing.

• Check that all insulation joints are securely closed andthat all insulation is firmly in place. Check all heatexchangers and all pipework.

9.2.1 - Verification of the refrigerant charge

CAUTION: The 30HZ/HZV units are supplied with a preciserefrigerant charge (see Physical Data table).

To verify the correct system charge prodeed as follows:Ensure that no bubbles appear in the sight-glass, when operat-ing the unit at full load for a while. Under these conditions theapparent subcooling which is equal to the saturatedcondensing temperature (1 - on the saturated dew point curve)minus the liquid refrigerant temperature (3) ahead of theexpansion device must be between 12 and 14°C. Thiscorresponds to an actual subcooling temperature of between 5and 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 liquidrefrigerant temperature (3) ahead of the expansion device. Usethe pressure tap supplied on the liquid piping to chargerefrigerant and to find out the pressure of the liquid refrigerant.If the subcooling value is not correct, i.e. lower than thespecified values, a leak detection test must be carried out onthe unit, as it no longer contains its original charge.

WARNING: To ensure proper operation of 30HZ/HZV unitsthere must be at least 12 K of subcooling as the liquidrefrigerant enters the expansion valve.

The 30HZ/HZV units use refrigerant. For your information,we are reproducing here some extracts from the officialpublication dealing with the design, installation, operationand maintenance of air conditioning and refrigerationsystems and the training of people involved in these activities,agreed by the air conditioning and refrigeration industry.

28

9.2.3 - Recharging liquid refrigerant

CAUTION: 30HZ units are charged with liquid HFC-407Crefrigerant.

This non-azeotropic refrigerant blend consists of 23% R-32,25% of R-125 and 52% R-134a, and is characterised by thefact that at the time of the change in state the temperature ofthe liquid/vapour mixture is not constant, as with azeotropicrefrigerants. All checks must be pressure tests, and theappropriate pressure/temperature ratio table must be used todetermine the corresponding saturated temperatures(saturated bubble point curve or saturated dew point curve).

Leak detection is especially important for units charged withrefrigerant R-407C. Depending on whether the leak occurs inthe liquid or in the vapour phase, the proportion of thedifferent components in the remaining liquid is not the same.

NOTE: Regularly carry out leak checks and immediatelyrepair any leak found.

9.2.4 - UnderchargeIf there is not enough refrigerant in the system, this isindicated by gas bubbles in the moisture sight glass.

If the undercharge is significant, large bubbles appear in themoisture sight glass, and the suction pressure drops. Thecompressor suction superheat is also high. The machine mustbe recharged after the leak has been repaired.

Find the leak and completely drain the system with a refrigerantrecovery unit. Carry out the repair, leak test and then rechargethe system.

IMPORTANT: After the leak has been repaired, the circuitmust be tested, without exceeding the maximum low-sideoperating pressure shown on the unit name plate.

The refrigerant must always be recharged in the liquid phaseinto the liquid line.The refrigerant cylinder must always contain at least 10% ofits initial charge. For the refrigerant quantity per circuit, referto the data on the unit name plate.

9.2.5 - Characteristics of R407CSee the table on the following page.Saturated bubble point temperatures (bubble point curve)Saturated dew point temperatures (dew point curve)

9.3 - Electrical maintenance

When working on the unit comply with all safety precautionsdecribed in section 1.2.• 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 operatingtemperatures,

c. then regularly once a year.

Apparent and actual subcooling

3

45

1

6

2

L

L + V

V

Pre

ssur

e

Enthalpy

R407C

Legend1 Saturated condensing temperature at the dew point2 Saturated liquid temperature at the bubble point3 Liquid refrigerant temperature4 Saturation curve at the dew point5 Saturation curbe at the bubble point6 Isotherms7 Apparent subcooling (1 - 3)8 Real subcooling (2 - 3)L LiquidL + V Liquid + vapourV Vapour

9.2.2 - Refrigerant guidelines

Refrigeration installations must be inspected and maintainedregularly and rigorously by specialists. Their activities must beoverseen and checked by properly trained people. To minimisedischarge to the atmosphere, refrigerants and lubricating oilmust be transferred using methods which reduce leaks andlosses 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 connectionof quick-connect recovery valves without loss ofrefrigerant.

• If the residual pressure is too low to make the transferalone, a purpose-built refrigerant recovery unit must beused.

• Compressor lubricating oil contains refrigerant. Any oildrained from a system during maintenance musttherefore be handled and stored accordingly.

• Refrigerant under pressure must never be discharged tothe atmosphere.

29

Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew(relative) point temp. point temp. (relative) point temp. point temp. (relative) point temp. point temp.

1 -28.55 -21.72 10.5 23.74 29.35 20 47.81 52.551.25 -25.66 -18.88 10.75 24.54 30.12 20.25 48.32 53.041.5 -23.01 -16.29 11 25.32 30.87 20.5 48.83 53.531.75 -20.57 -13.88 11.25 26.09 31.62 20.75 49.34 54.012 -18.28 -11.65 11.5 26.85 32.35 21 49.84 54.492.25 -16.14 -9.55 11.75 27.6 33.08 21.25 50.34 54.962.5 -14.12 -7.57 12 28.34 33.79 21.5 50.83 55.432.75 -12.21 -5.7 12.25 29.06 34.5 21.75 51.32 55.93 -10.4 -3.93 12.5 29.78 35.19 22 51.8 56.363.25 -8.67 -2.23 12.75 30.49 35.87 22.25 52.28 56.823.5 -7.01 -0.61 13 31.18 36.55 22.5 52.76 57.283.75 -5.43 0.93 13.25 31.87 37.21 22.75 53.24 57.734 -3.9 2.42 13.5 32.55 37.87 23 53.71 58.184.25 -2.44 3.85 13.75 33.22 38.51 23.25 54.17 58.624.5 -1.02 5.23 14 33.89 39.16 23.5 54.64 59.074.75 0.34 6.57 14.25 34.54 39.79 23.75 55.1 59.55 1.66 7.86 14.5 35.19 40.41 24 55.55 59.945.25 2.94 9.11 14.75 35.83 41.03 24.25 56.01 60.375.5 4.19 10.33 15 36.46 41.64 24.5 56.46 60.85.75 5.4 11.5 15.25 37.08 42.24 24.75 56.9 61.226 6.57 12.65 15.5 37.7 42.84 25 57.35 61.656.25 7.71 13.76 15.75 38.31 43.42 25.25 57.79 62.076.5 8.83 14.85 16 38.92 44.01 25.5 58.23 62.486.75 9.92 15.91 16.25 39.52 44.58 25.75 58.66 62.97 10.98 16.94 16.5 40.11 45.15 26 59.09 63.317.25 12.02 17.95 16.75 40.69 45.71 26.25 59.52 63.717.5 13.03 18.94 17 41.27 46.27 26.5 59.95 64.127.75 14.02 19.9 17.25 41.85 46.82 26.75 60.37 64.528 14.99 20.85 17.5 42.41 47.37 27 60.79 64.928.25 15.94 21.77 17.75 42.98 47.91 27.25 61.21 65.318.5 16.88 22.68 18 43.53 48.44 27.5 61.63 65.718.75 17.79 23.57 18.25 44.09 48.97 27.75 62.04 66.19 18.69 24.44 18.5 44.63 49.5 28 62.45 66.499.25 19.57 25.29 18.75 45.17 50.02 28.25 62.86 66.879.5 20.43 26.13 19 45.71 50.53 28.5 63.27 67.269.75 21.28 26.96 19.25 46.24 51.04 28.75 63.67 67.6410 22.12 27.77 19.5 46.77 51.55 29 64.07 68.0210.25 22.94 28.56 19.75 47.29 52.05 29.25 64.47 68.39

9.4 - Evaporator maintenance

Check that:• the insulating foam is intact and securely in place.• the sensors are correctly operating, secured and

positioned.• the water-side connections are clean and show no sign of

leakage.

9.4.1 - Multitube evaporatorsTo access the evaporator tubes, use the following procedure:• Close the chilled water supply and return valves (if

installed), and disconnect the chilled water supply andreturn pipe connections.

• Drain the water from the cooler.• Remove all temperature sensors from the cooler.• Completely drain the refrigerant charge, using a refrigerant

recovery unit.• Fold back the insulation at the refrigerant line

connections.• Remove the header panels from the evaporator.

When the evaporator heads and manifolds are removed, theouter tube end plates will be visible.

Six or eight evaporator tubes are swaged into the end plate andcannot be removed. A dot punch mark in the end plate oppositeeach one identifies each of them. If any of them develop aleak, the tube must be plugged, as described below.

9.4.2 - Plugging evaporator tubesA leaking tube can be plugged pending replacement. The numberof tubes plugged will determine when they should be replaced.Check with Carrier the effect upon chiller performance ofplugging a number of tubes. Carrier will need to know thenumber of tubes to be plugged and their positions. The figurebelow shows the Elliott method of plugging tubes.

WARNING: Take care when inserting plugs not to damagethe plate material between the tubes. Avoid excessive force.Clean all components with Locquic N and then coat allsurfaces with several drops of Loctite 75 to ensure a goodseal without applying excessive force.

Elliott tube plug

Components Part number

Tube brass plug ---T-853--103500S-*Tube brass ring ---T-853--002570S-*

Brass plug (holes without tubes) ---T-853--1031—S-*Brass ring (holes without tubes) ---T-853--002631S-*

Loctite No. 75Locquic “N”

* Order directly from your Carrier distributor

Plug

Ring

Tube plate

30

7

4

6

28

3

5

1

9.4.3 - Replacing cooler tubesRetubing must be done only by a properly trained serviceengineer. Most standard practices can be applied, but forcooler tubes a 5% crush allowance is made for tube expansionand twisting (15.87 mm diameter tubes are used in thesecoolers).

The table below gives the specification of the materials used.

Example:

Tube sheet hole diameter 16.00 mmTube outside diameter 15.87 mmClearance 0.13 mmTube inside diameter before rolling 14.27 mmTube inside diameter after rolling 14.48 mm

NOTE: Tubes next to the gasket webs must be flush with thetube sheets at either end of the cooler.

9.4.4 - Preparation of gasketsWhen rebuilding the cooler, new gaskets must always be used.They must conform to the Carrier specification for compressedgaskets.• Clean the gasket and its place on the tube sheet.• Cover the two matching surfaces (gasket and tube sheet)

with adhesive, and stick them together.• Let the joint dry for 5 minutes.• Moisten the joint with a small amount of compressor oil.• Reinstall the evaporator head within 30 minutes.

9.4.5 - Tightening cooler head boltsCooler head bolts must be tightened in the specified sequenceand to the correct torque.

9.4.6 - Tightening sequence:The following tightening sequence is recommended:• Hand tighten the first four bolts as shown below in stage 1.• Hand tighten the next bolts as shown below in stage 2.• Starting at the 12 o'clock position, and working

clockwise, insert and hand tighten the remaining outerbolts.

• Insert and tighten the six screws in the center of the head.• Starting again at 12 o’clock and working clockwise

tighten the outer bolts to the correct torque.• Not less than one hour later insert and tighten the six

bolts in the centre of the head, using the torque valuesgiven.

• After the cooler has been refilled with clean refrigerant,use a soap and water solution or an electronic detector toconfirm that there are no leaks.

• Replace the evaporator insulation and temperature sensors.

Stage 1

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

Stage 2

9.5 - Corrosion control

All metallic parts of the unit (chassis, casing panels, controlboxes, heat exchangers etc.) are protected against corrosion bya coating of powder or liquid paint. To prevent the risk ofblistering corrosion that can appear when moisture penetratesunder the protective coatings, it is necessary to carry outperiodic checks of the coating (paint) condition.

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10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS (USE FOR JOB FILE)

Preliminary information

Job name: ................................................................................................................................................................................................Location: .................................................................................................................................................................................................Installing contractor: ..............................................................................................................................................................................Distributor: .............................................................................................................................................................................................Start-up preformed by: ...........................................................................................................................................................................

CompressorsModel: ............................................................................................ S/N ..............................................................................................

CompresseursCircuit A Circuit B1. Model # ...................................................................................... 1. Model # .................................................................................

S/N ............................................................................................. S/N ..............................................................................................Mtr # ........................................................................................... Mtr # ...........................................................................................

2. Model # ...................................................................................... 2. Model # .................................................................................S/N ............................................................................................. S/N ..............................................................................................Mtr # ........................................................................................... Mtr # ...........................................................................................



CoolerModel # ........................................................................................... Manufactured by .........................................................................S/N .................................................................................................. Date .............................................................................................

CondensersManufacturer ..........................................................................................................................................................................................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 nameplate 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 (CWP) is operating with the correct rotation. CWP amperage: Rated: .......... Actual............

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Unit start-up CWP starter has been properly interlocked with the chiller Oil heaters have been energized for at least 24 hours Oil level is correct All discharge, suction and liquid valves are open Unit has been leak checked (including fittings)

Locate, repair, and report any refrigerant leaks................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

Check voltage imbalance: AB .................. AC ................. BC ................Average voltage = ..................................... (see installation instructions)Maximum deviation = .............................. (see installation instructions)Voltage imbalance = ................................. (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 cooler water loopWater loop volume = ................................ (liters)Calculated volume = ................................ (liters)3.25 liters/nominal kW capacity for air conditioning6.5 liters/nominal kW capacity for process cooling

Proper loop volume established Proper loop corrosion inhibitor included .............. liters of ........................... Proper loop freeze protection included (if required) ....................... liters of ............................. Piping includes electric heater tape, if exposed to the outside Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm

Check pressure drop across the coolerEntering cooler = ...................................... (kPa)Leaving cooler = ....................................... (kPa)(Leaving - entering) = .............................. (kPa)

WARNING: Plot cooler pressure drop on performance data chart (in product data literature) to determine total liters persecond (l/s) and find unit's minimum flow rate.

Total l/s = ..................................................l/s / nominal kW = ....................................

Total l/s is greater than unit's minimum flow rate Total l/s meets job specified requirement of .......................................... (l/s)

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Perform TEST function (indicate positive result):

WARNING: Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the TESTfunction instructions in the Controls and Troubleshooting literature (follow the procedure in the Controls IOM).Be sure all service valves are open before beginning the compressor test section.

Examine and register the configuration at the installation site <2> <SRVC>

Evaporator fluid select ................................................................... External reset sensor ...................................................................Minimum load select ...................................................................... Evaporator pump interlock .........................................................Loading sequence select ................................................................. Evaporator pump control ...........................................................Lead/lag sequence select ................................................................Head pressure control .....................................................................Motormaster select* ....................................................................... *If installed

To start the chiller

WARNING: Be sure that all service valves are open, and all pumps are on before attempting to start this machine. Once allchecks have been made, move the switch to "LOCAL" or "REMOTE" from "OFF".

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 thefollowing:

Evaporator EWT ............................................................................. Ambient temperature ..................................................................Evaporator LWT ............................................................................. Condenser EWT ..........................................................................

Condenser LWT ..........................................................................

Circuit A suction pressure .............................................................. Circuit B suction pressure ..........................................................Circuit A discharge temperature .................................................... Circuit B suction temperature ....................................................Circuit A suction temperature ........................................................ Circuit B discharge pressure .......................................................Circuit A discharge pressure .......................................................... Circuit B discharge temperature .................................................Circuit A liquid line temperature ................................................... Circuit B liquid line temperature ...............................................

Compressor oil pressure A1* ......................................................... Compressor oil pressure B1* .....................................................A2* ......................................................... B2* .....................................................A3* ......................................................... B3* .....................................................A4* ......................................................... B4* .....................................................

* if installed

NOTES:...........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

Order No: 13412-76, 03.2003. Supersedes order No: 13412-76, 08.2002 Manufacturer: Carrier s.a., Montluel, France.Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on chlorine-free paper.

Documents

30HZ/HZV 043-280 Water-Cooled/Condenserless Liquid Chillers · 30HZ/HZV 043-280 Water-Cooled/Condenserless Liquid Chillers Nominal cooling capacity 30HZ: 134-783 kW ... pressure,