Carrier 30 GA Technical data

30GH/GZ 009-035
Air-Cooled Liquid Chillers
50 Hz
Installation, Operation and Maintenance Instructions
1
CONTENTS
Page
Start-up checklist .......................................................................................................................................................................... 3
Dimensions/clearances (standard unit) ....................................................................................................................................... 4
Dimensions/clearances (unit with optional Hydroflow kit) ...................................................................................................... 6
Physical/electrical data ................................................................................................................................................................. 8
Application data (standard unit) ............................................................................................................................................... 10
Minimum evaporator water flow rates ......................................................................................................................................... 10
Maximum evaporator chilled water flow rates ............................................................................................................................. 10
Water loop volume ....................................................................................................................................................................... 10
Application data (unit with optional Hydroflow kit) .............................................................................................................. 11
Water flow rates ........................................................................................................................................................................... 11
Available static pressure ............................................................................................................................................................... 11
Water loop volume ....................................................................................................................................................................... 12
Installation ................................................................................................................................................................................... 13
Safety considerations .................................................................................................................................................................... 13
Preliminary checks ....................................................................................................................................................................... 13
Moving and siting the unit ............................................................................................................................................................ 13
Water connections ...................................................................................................................................................................... 14
Optional Hydroflow kit ................................................................................................................................................................ 15
Power supply ............................................................................................................................................................................... 15
Electrical checks ........................................................................................................................................................................... 15
Start-up ........................................................................................................................................................................................ 15
Preliminary checks ....................................................................................................................................................................... 15
Actual start-up .............................................................................................................................................................................. 16
Electromechanical control ............................................................................................................................................................ 16
PRO-DIALOG control ................................................................................................................................................................. 16
Servicing refrigeration components .......................................................................................................................................... 17
General maintenance .................................................................................................................................................................... 17
Liquid refrigerant charging ........................................................................................................................................................... 17
Compressors ................................................................................................................................................................................. 18
Heat exchangers ............................................................................................................................................................................ 19
Condenser coil .............................................................................................................................................................................. 19
Fan motor replacement ................................................................................................................................................................. 20
Fan motor protection .................................................................................................................................................................... 20
Refrigerant circuit ......................................................................................................................................................................... 20
Pressure switch settings ................................................................................................................................................................ 20
Troubleshooting chart ................................................................................................................................................................ 21
The photo shown on the front cover is solely for information, and not contractually binding. The manufacturer reserves the right to make changes
without previous notification.
2
START-UP CHECK LIST
Start-up date:
Equipment sold by:
Contract No.:
Installed by:
Contract No.:
Site address:
Start-up date:
Equipment type and serial number: 30GH/GZ
Electrical data:
Supply voltage:
Ph.
Nominal voltage:
V
Current draw:
Ph. 1
V
Ph. 2
V
Ph. 3
V
A
Ph. 3
A
% network voltage:
Control circuit voltage
A
Ph. 2
V
Circuit breaker rating
Main circuit breaker rating:
A
A
Technical data:
Condenser:
Cooler:
Entering air temperature:
°C
Entering water temperarture:
°C
Leaving air temperature:
°C
Leaving water temperature:
°C
Pressure drop (air):
kPa
Discharge air pressure:
Pressure drop (water):
kPa
Pa
Fan speed:
r/s or rpm
Fan motor current:
Ph. 1
A
Ph. 2
A
Ph. 3
A
Ph. 1
A
Ph. 2
A
Ph. 3
A
Safety device setting:
High pressure switch:
cut-out
kPa:
cut-in
kPa
Low-pressure switch:
cut-out
kPa
cut-in
kPa
Safety thermostat:
cut-out
°C
cut-in
°C
Control thermostat:
cut-out first step
°C
cut-in first step
°C
cut-out second step
°C
cut-in second step
°C
Oil level:
Oil visible in sight glass:
Colour of moisture indicator:
Air bubbles visible in sight glass:
Accessories:
Commissioning engineer (name):
Customer agreement
Name:
Date:
Remarks:
NOTE: Please fill in this sheet during the installation
3
Dimensions and clearances (standard unit)
30GH/GZ
A
B
C
D
E
F
G
009-013
015-025
030-035
1160
1720
2060
1220
1160
1370
1060
1112
1231
1200
1200
1200
1000
1000
1000
1000
1000
1000
1000
1000
1200
Legend:
All dimensions are given in mm.
Required service clearance
30GH and 30GZ 009-013
Do not obstruct
Power supply
Water inlet
Water outlet
Note:
Certified drawings are available on request.
30GH and 30GZ 015-025
Do not obstruct
4
30GH and 30GZ 030-035
Do not obstruct
Floor mounting
•
•
For unit mounting holes, weight distribution and centre of gravity coordinates, refer to the dimensional
drawings.
These units are designed for outdoor installation.
CAUTION:
•
•
•
Ensure the air flow around the unit is not obstructed.
If several units are installed, next to each other, ensure that the space in between the units is the same as the
unit depth.
There must not be any roof or cover above the unit.
5
Dimensions and clearances (unit with optional Hydroflow kit)
CAUTION: ONLY PRO-DIALOG UNITS CAN BE EQUIPPED WITH THE OPTIONAL HYDROFLOW KIT.
30GH/GZ
A
B
C
D
E
F
G
009-013
015-025
030-035
1160
1720
2150
1310
1246
1370
1781
1833
2052
1200
1200
1200
1000
1000
1000
1000
1000
1000
1000
1000
1200
Legend:
Required service clearance
All dimensions are given in mm.
Power supply
Water inlet
Water outlet
30GH and 30GZ 009-013
Note:
Certified drawings are available on request.
30GH and 30GZ 015-025
6
30GH and 30GZ 030-035
Floor mounting
•
•
For unit mounting holes, weight distribution and centre of gravity coordinates, refer to the dimensional
drawings.
These units are designed for outdoor installation.
CAUTION:
•
•
•
Ensure the air flow around the unit is not obstructed.
If several units are installed, next to each other, ensure that the space in between the units is the same as the unit
depth.
There must not be any roof or cover above the unit.
7
Physical data
Size
009
013
015
020
025
030
035
31.6
32.0
40.1
41.0
52.0
53.0
64.0
65.0
74.0
75.0
93.0
94.0
Net nominal cooling capacity 30GH*
Net nominal cooling capacity 30GZ*
kW
kW
21.2
21.0
Operating weight
kg
265
283
400
460
510
682
725
Refrigerant charge (R-22 - 30GH)
Refrigerant charge (R-407C - 30GZ)
kg
kg
6.5
7.5
8.0
9.0
9.2
10.5
11.9
13.5
13.3
15.0
15.7
15.7
16.5
18.6
%
1 ... hermetic, 48.3 r/s
1 ... semi-hermetic, 4 or 6 cylinders, 24.2 r/s
PRO-DIALOG or electromechanical
1
1
2
2
2
100
100
66
50
66
2
66
2
66
Compressor
Control type
Capacity control steps
Minimum capacity step
Evaporator
Water volume
No. of refrigerant circuits
Water conncetions
Inlet/outlet
Max. water side operating pressure
kPa
Direct-expansion, plate heat exchanger
1.9
2.8
3.8
1
1
1
Gas thread
1-1/2
1-1/2
1-1/2
1000
1000
1000
Condenser
Fans
Quantity
Total air flow
Fan speed**
l/s
r/s
Copper tube, aluminium fins
Propeller
1
1
2640
2640
15.8/12.5
15.8/12.5
Low-noise shrouded axial Flying Bird fan
1
1
1
4700
4700
4700
12.5
12.5
12.5
2
9400
12.5
2
9400
12.5
OPTIONAL HYDROFLOW KIT
Nominal water flow rate
Available pressure
Unit operating weight
Buffer tank capacity
l/s
kPa
kg
l
1
70
297
100
1.5
36
616
100
3.0
72
854
150
2.5
62
915
150
3.1
45
966
150
3.6
60
1369
300
4.5
59
1413
300
l
l
8
112
18
113
18
174
18
175
18
176
24
337
24
338
in
in
1-1/2
1-1/4
1-1/2
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
2-1/2
1-1/2
2-1/2
Expansion tank capacity
Water volume
Water connections
Inlet
Outlet
l
in
4.7
1
5.6
1
6.6
1
7.5
1
1-1/2
1000
1-1/2
1000
1-1/2
1000
1-1/2
1000
* Net cooling capacity = gross cooling capacity minus the water pump heat against the internal evaporator pressure drop.
Evaporator entering/leaving water temperature 12°C and 7°C. Condenser entering air temperature 35°C.
** The first figure is for the standard fan, the second figure is for the optional low speed fan.
Electrical data
Size
009
013
015
020
025
030
035
Power supply
Nominal power supply
Voltage range
V-ph-Hz
V
400-3-50
360-440
Auxiliary circuit
Auxiliary circuit power input (heaters)
V-ph-Hz
W
230-1-50
70
70
110
250
250
250
250
Fan power input
Fan power supply
kW
V-ph-Hz
0.80
400-3-50
0.80
1.15
1.15
1.15
2.30
2.30
Nominal unit power input*
Maximum unit power input**
Maximum unit starting current
Nominal unit current drawn*
Maximum unit current drawn**
kW
kW
A
A
A
8.4
10.0
83.2
13.2
24.7
13.7
16.8
136.7
22.5
38.7
13.6
16.4
87.0
21.1
34.0
18.2
22.0
107.0
29.0
38.9
24.2
29.0
134.0
39.3
51.0
26.9
32.3
158.0
42.1
60.0
37.8
46.2
213.0
60.7
83.0
UNIT WITH OPTIONAL HYDRAULIC KIT
Nominal unit power input*
kW
Maximum unit power input**
kW
Maximum unit starting current
A
Nominal unit current drawn*
A
Maximum unit current drawn**
A
Heater power input
W
8.9
10.6
84.5
14.4
26.0
120
14.2
17.4
138.0
23.7
40.0
120
14.3
17.2
88.7
27.7
35.7
150
18.9
22.8
108.7
30.6
40.6
150
24.9
29.8
135.7
40.9
52.7
150
28.3
33.8
161.0
45.0
62.9
220
39.2
47.7
216.0
63.6
85.9
220
* Evaporator entering/leaving water temperature 12°C and 7°C. Condenser entering air temperature 35°C.
** Evaporator entering/leaving water temperature 18°C and 13°C. Condenser entering air temperature 45°C. Currents are given at nominal voltage.
8
NOTES:
•
30GH/GZ 009-035 units have a single power connection
point.
•
A separate power source (230 V, 1 ph, 50 Hz) that does
not exceed the main switch capacity is required to power
the compressor crankcase heater circuit. This source must
be supplied from a transformer. It must not be supplied
from a phase + neutral supply (for ground + neutral
systems).
•
The control box includes the following standard features:
Starter and motor protection devices for each
compressor and the fan(s)
Control devices
•
Field connections:
All connections to the system and the electrical
installations must be in full accordance with all
applicable codes.
•
The Carrier 30GH/GZ 009-035 chillers are designed and
built to ensure conformance with local codes. The
recommendations of European standard EN 60 204-1
(machine safety - electrical machine components - part 1:
general regulations) are specifically taken into account,
when designing the electrical equipment.
•
Conformance with EN 60 204 is the best means of
ensuring compliance with the Machines Directive and
§1.5.1. Generally the recommendations of IEC 364 are
accepted as compliance with the requirements of the
installation directives.
•
Annex B of EN 60204-1 describes the electrical
characteristics used for the operation of the machines.
1.
•
•
The operating environment for the 30GH/GZ 009-035
chillers is specified below:
Environment* - Environment as classified in IEC 60 721:
- outdoor installation*
- ambient temperature range: -18°C to +46°C, class 4K4H*
- altitude: ≤ 2000 m*
- presence of hard solids, class 4S2 (no significant dust
present)
- presence of corrosive and polluting substances, class
4C2 (negligible)
- vibration and shock, class 4M2
Competence of personnel, class BA4* (trained personnel IEC 364)
* The protection level required to conform to this class is
IP43BW (according to reference document IEC 529). All
30GH/GZ 009-035 units are protected to IP44CW and
fulfill this protection condition.
2.
3.
4.
5.
Power supply frequency variation: ± 2 Hz.
The neutral (N) line must not be connected directly to the
unit (if necessary use a transformer).
Overcurrent protection of the power supply conductors is
not provided with the unit.
The factory-installed circuit breaker is of type “a” (EN 60
204-1 § 5.3.2).
NOTE: If particular aspects of an actual installation do not
conform to the conditions described above, or if there are other
conditions which should be considered, always contact your
local Carrier representative.
9
APPLICATION DATA (STANDARD UNIT)
NOTE: The compressor must not restart more than 10 times in
an hour.
Minimum evaporator water flow rates
Min. flow rate, l/s
009
013
015
020
025
030
035
0.3
0.5
0.7
0.8
1.0
1.2
1.3
STANDARD 30GH
30GH WITH LOW TEMPERATURE OPTION
50
45
OUTDOOR AIR TEMPERATURE, °C
30GH/GZ
30GH Operating range
If the flow rate is lower, follow the recommendations below:
a. It is possible to install several chillers of lower capacity in
series, each one supplying a part of the ∆T.
b. The water from the evaporator can be recirculated, in
order to increase the flow rate. The temperature of the
mixed water entering the evaporator must be at least 2.8 K
higher than the leaving water temperature.
Maximum evaporator chilled water flow rate
40
40
30
33
20
12
10
30GH 009-025
0
30GH 030-035
01
-10
-5
*
*
WATER
0
5
10
15
EVAPORATOR LEAVING WATER TEMPERATURE, °C
* Application down to -18°C with head pressure control option
Note: Evaporator ∆t = 5 K
30GZ Operating range
30GZ with glycol option
CONDENSER ENTERING AIR TEMPERATURE, °C
2.2
3.2
4.0
5.3
6.5
7.3
9.2
The minimum temperature difference is 2.8 K which
corresponds to a water flow rate of 0,9 l/s per kW.
Water loop volume
13
GLYCOL
Max. flow rate, l/s
009
013
015
020
025
030
035
30GH 009
30GH 013
30GH 025
43
36
This is limited by the maximum permitted evaporator pressure
drop.
30GH/GZ
45
42
50
45
43
40
42
40
39
39
30GZ009-025
30
20
10
30GZ009-013
12
0
GLYCOL
-10
-5
0
WATER
5
10
15
EVAPORATOR LEAVING WATER TEMPERATURE, °C
* Application down to -18°C with head pressure control option
Note: Evaporator ∆t = 5 K
Whatever the size of the system, the water loop minimum
volume is given by the following formula:
Evaporator pressure drop curve
100
90
80
70
60
Volume = CAP (kW) x N* = litres
where CAP is the nominal system capacity (kW) at the nominal
operating conditions of the installation.
50
40
30
It is often necessary to add a storage tank to the circuit in order to
achieve the required volume. The tank must itself be internally
baffled in order to ensure proper mixing of the liquid (water or
brine). Refer to the examples below.
05
5
4
/G
Z
30 013
GH
/G
Z
30
GH 015
/G
30
Z0
GH
20
30
/
GH GZ 0
/G
25
Z
30
03
GH
0
/G
Z0
35
10
9
8
7
6
GH
This volume is necessary for stable operation and accurate
temperature control.
20
GH
/G
Z0
3.25
6.5
10.8
30
Air conditioning
Industrial process cooling
Low temperature operation
30
N*
Pressure drop, kPa
Application
3
2
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
Bad
Good
0.2
0.1
0.1
0.2
0.3
0.4 0.5
1
Water flow rate, l/s
Bad
10
Good
2
3
4
5
6 7 8 9 10
APPLICATION DATA (UNIT WITH OPTIONAL HYDRONIC KIT)
Water flow rate
30GH/30GZ
HYDROFLOW module option
Maximum flow rate*
Minimum flow rate
l/s
l/s
009
013
015
020
025
030
035
1.6
0.3
1.7
0.5
3.0
0.7
3.3
0.8
3.3
1.0
4.6
1.2
5.7
1.3
* Maximum water flow rate for an available static system pressure of zero.
Available static pressure
Available static pressure for a single pump
kPa
m WG
200
20
180
18
160
16
140
14
120
12
100
10
80
8
60
6
40
4
20
2
0
0
1
1 30GH/GZ 009-013
2 30GH/GZ 015-025
3
2
3 30GH/GZ 030-035
2
3
4
6
5
7
8 9 10
20
15
30
40
50
60 70 80
m3/h.
I/s.
0,5
1,5
1
2,5
3,5
10
7
5
15
20
Available static pressure for a dual pump
kPa
1 30GH/GZ 009-013
2 30GH/GZ 015-025
3 30GH/GZ 030-035
m WG
200
20
180
18
160
16
140
14
120
12
100
10
80
8
60
6
40
4
20
2
0
0
1
3
2
2
3
4
5
6
4
6
8
10
12
7
8 9 10
15
20
30
40
14 16 18 20
30
40
60
80
50
60 70 80
Qm3/h.
Qm3/h.
two pumps in paralle
100 120 140 160
I/s.
0,5
kPa
m WG
150
15
140
14
130
13
120
12
110
11
100
10
90
9
80
8
70
7
60
6
50
5
40
4
30
3
20
2
10
1
0
0
1
1,5
2,5
3,5
5
7
10
15
20
Available static pressure for HYDROFLOW units
(30GH/GZ 009-013)
01
3
00
9
1
2
3
4
5
6
7
0,28
0,55
0,83
1,11
1,39
1,67
1,94
m3/h.
I/s.
11
Available static pressure for HYDROFLOW units (30GH/GZ 015-025)
kPa
m WG
150
15
140
14
130
13
120
12
110
11
100
10
90
9
8
70
7
60
6
50
5
3
20
2
10
1
0
0
020
4
30
5
02
40
5
01
80
5
10
15
1,39
2,78
4,17
20 m3/h.
I/s.
5,56
Available static pressure for HYDROFLOW units (30GH/GZ 030, 035)
kPa
m WG
150
15
140
14
130
13
120
12
110
11
100
10
90
9
7
60
6
50
5
3
20
2
10
1
0
0
`
5
4
30
0
40
03
8
70
03
80
5
10
15
20
1,39
2,78
4,17
5,56
25 m3/h.
I/s.
•
•
•
12
The water circulating pumps in the HYDROFLOW
module are sized to cover the widest application range.
For this reason it is essential to install a water flow
controller in the hydraulic circuit to maintain the water
flow at the desired flow rate. With the pressure loss
generated by the water flow controller in the water circuit,
the controller must be able to impose the system pressure/
flow curve on the pump pressure/flow curve, to obtain the
desired operating point.
The pressure gauge installed on the pump, together with
the isolating valves upstream and downstream, allows the
pressures upstream and downstream of the pump to be
read.
Using the total pressure difference read, the water flow
rate for the installation is taken from the pressure/flow
curve for the pump alone. This flow rate is adjusted with
the flow controller and reading the flow rate from the
corresponding curves.
6,95
If the water circuit has a pressure drop that is higher than the
pressure available from the HYDROFLOW unit, the water
flow rate will be reduced, and the difference between the
HYDROFLOW module water entering and leaving
temperatures will increase.
To reduce the pressure drop in the hydraulic circuit:
•
minimize the individual pressure drops in number and size
(elbows, bends, accessories).
•
use correctly sized piping.
•
avoid extensions and branches in the water circuit as much
as possible
Water loop volume
The unit includes an integrated buffer tank. A supplementary
buffer tank should be installed, if the built-in buffer tank does
not supply sufficient capacity (see chapter Water loop volume
under Application Data for the standard unit on page 11.
INSTALLATION
SAFETY CONSIDERATIONS
Installation, start-up and servicing this equipment can be
hazardous due to system pressures, electrical components and
equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start-up and service this equipment.
Untrained personnel can perform basic functions, such as
cleaning coils. All other operations should be performed by
trained service personnel.
CAUTION: Before lifting the unit, check that all casing panels
are securely fixed in place. Lift and set down the unit with
great care. Tilting and jarring can damage the unit and impair
unit operation.
The units can be hoisted with rigging or lifted by forklift. Coils
should always be protected against crushing while a unit is
being moved. Use struts or spreader bars to spread the slings
above the unit. Do not tilt a unit more than 15°.
WARNING: Never push or lever on any of the enclosure panels
of the unit. Only the base of the unit frame is designed to
withstand such stresses.
When working on the equipment, observe precautions in the
literature, and on tags, stickers, and labels attached to the
equipment.
•
•
•
Follow all safety codes.
Wear safety glasses and work gloves.
Use care in handling, rigging and setting down bulky
equipment.
WARNING: Before doing any work ensure that the power
supply (400 V and 230 V) is disconnected, and switches and
isolators are opened and tagged.
During operation some parts of the unit reach or exceed
temperatures of 70°C (e.g. compressor discharge side,
discharge line). Only trained and qualified engineers, aware of
these hot surfaces, are allowed to perform maintenance
operations.
Preliminary checks
Check equipment received
•
Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately file a
claim with the shipping company.
•
Confirm that the unit received is the one ordered.
Compare the nameplate data with the order.
•
Confirm that all accessories ordered for on-site installation
have been delivered, and are complete and undamaged.
Moving and siting the unit
Location for installation
•
•
•
•
•
•
The permitted loading at the site must be adequate or
appropriate strenghtening measures must be taken.
The surface must be horizontal, flat and intact.
There must be adequate space around the unit to make
power and water connections and for service and air flow.
There must be adequate support points and they must be
in the right places.
The location must not be subject to flooding.
Where heavy snowfall is likely and long periods of subzero temperatures are normal, provision has been made to
prevent snow accumulating by raising the unit above the
height of drifts normally experienced. Baffles may be
necessary to deflect strong winds and to prevent snow
from blowing directly into the unit. They must not restrict
air flow into the unit.
13
Water connections
Water-loop connections
Make the water-side heat exchanger connections, using
appropriate hardware capable of ensuring water-tightness of the
threaded unions.
Refer to the certified dimensional drawings for the sizes and
positions of all water inlet and outlet connections. The water
pipes must not transmit any radial or axial force to the heat
exchangers or any vibration to the pipework or building.
Allowable load (Nm) for brazed plate heat exchangers
The water supply must be analysed and appropriate filtering,
treatment, control devices, isolation and bleed valves and
circuits built in, as necessary. Consult either a water treatment
specialist or appropriate literature on the subject.
Operating precautions
The water circuit should be designed to have the least number
of elbows and horizontal pipe runs at different levels. Below
the basic checks to be done (see also the illustration of a typical
hydraulic circuit below).
•
•
•
•
•
•
•
•
•
•
•
Note the water inlets and outlets of the heat exchangers.
Install manual or automatic air purge valves at all high
points in the water circuit.
Use an expansion chamber or an expansion/relief valve to
maintain pressure in the system.
Install water thermometers in both the entering and
leaving water connections close to the evaporator.
Install drain valves at all low points to allow the whole
circuit to be drained.
Install stop valves, close to the evaporator, in the entering
and leaving water lines.
Use flexible connections to reduce the transmission of
vibration to the pipework.
Insulate all pipework, after testing for leaks, both to
reduce thermal leaks and to prevent condensation.
Cover the insulation with a vapour barrier.
A flow switch should be installed on a straight, horizontal
stretch of piping, with a minimum length of five times the
line diameter both before and after it.
Where there are particles in the fluid that could block the
heat exchanger, strainers should be used. Particles up to
1 mm in diameter will not cause any probblems. These
correspond to a mesh size of 16-20 (depending on the
diameter of the wire used).
Bending
Twisting
Assembly conditions 1**
Assembly conditions 2*
160
350
100
200
* Assembly load in cold conditions
** Loads due to piping forces during normal operation
The illustration below shows a typical hydraulic circuit.
IMPORTANT: In winter frost can cause cooler damage. Use
appropriate methods of protection, according to the climatic
conditions:
•
Add ethylene glycol.
•
Increase the insulation thickness.
•
Do not de-energize the cooler and the hydraulic circuit
heaters.
•
For a prolonged shutdown period, drain the water from
the cooler and replace it with ethylene glycol. At the
beginning of the next cooling season, refill the cooler and
add the recommended inhibitor.
Auxiliary equipment should be installed according to
basic refrigeration and piping practices, especially with
respect to minimum and maximum cooler water flow
rates, which must be between the values given in the
tables in the 'Application data' section.
NOTE: We strongly recommend the installation of the
strainers.
Typical hydraulic circuit diagram
AIR VENT
CONTROL VALVE
FLOW SWITCH
FLEXIBLE CONNECTION
HEAT
EXCHANGER
BUFFER TANK
FILL
VALVE
EXPANSION TANK
14
Pressure tap
FILTER
DRAIN
Thermostat
sleeve
Hydraulic diagram
Power supply
The power supply must conform to the specification on the
chiller nameplate. The supply voltage must be within the range
specified in the electrical data table.
For connections refer to the wiring diagrams.
WARNING: Operation of the chiller with an improper supply
voltage or with excessive phase imbalance constitutes abuse
which will invalidate the Carrier warranty. If the phase
imbalance exceeds 2% for voltage, contact your local
electricity supply company at once and ensure that the chiller
is not switched on until corrective measures have been taken.
Voltage phase imbalance (%) :
= 100 x max.deviation from average voltage deviation
Average voltage
Electrical checks
1
2
3
4
5
6
7
8
9
10
11
12/13
14
Evaporator
Water flow switch
Buffer tank
Manual drain valve
Manual air vent valve
Expansion tank
Pressure gauge
Safety valve
Isolating valve
Filter
Pump
Isolating valves (pressure check upstream/downstream of the pump)
Pressure gauge
WARNING: Never switch off the power supply to the crankcase
heaters unless the chiller is out of service for a seasonal
shutdown or lengthy repair. The heaters must be re-energised
for at least 24 hours before the chiller is restarted.
1.
2.
3.
4.
5.
IMPORTANT: The flow controller prevents any unit start-up if
the flow rate is not sufficient.
Its changeover point is controlled and calibrated at the factory.
Hydraulic connections
Please refer to the previous chapter.
Install purge valves and drain valves for the unit and the
system (a drain valve is provided in the lower part of the buffer
tank with a quarter turn globe valve).
Purge valves must be installed at all high points of the system,
with a drain valve at the lowest point.
The standard filter can be backed up by a supplementary filter
in the external circuit, if the mesh or filter is inadequate.
IMPORTANT: The defrost function, using an electric trace
heater, has continued power supply to the heater, if the pump is
switched off. This allows keeping the HYDROFLOW module
frost-free down to an outdoor air temperature of -12°C.
Outside drains and pipes for the HYDROFLOW module are
recommended, if the unit is not used at temperatures below
0°C. It is recommended to protect the chilled water pipes that
are exposed to low ambient temperatures by a strip heater and
by wrapping them with closed-cell insulation material of 19 mm
thickness.
Switch the unit off.
Open the control circuit disconnect switch.
Check the transformer connections.
Ensure that the control circuit corresponds to the wiring
diagram for the unit.
Check that all electrical connections are secure at the
terminals, contactors, bus bars and compressor terminal
blocks.
Start-up
Preliminary checks
•
Never be tempted to start the chiller without reading fully,
and understanding, the operating instructions and without
having carried out the following pre-start checks :
•
Confirm that all crankcase heaters are working by feeling
all compressor crankcases. Every compressor has a
cartridge heater (see the wiring diagram). The heater
remains energised even when the chiller is shut down to
stop the lubricating oil from absorbing refrigerant.
•
Check the operation of all accessories - chilled water
circulating pumps, air handlers and other equipment
connected to the evaporator. Follow the individual
manufacturer's instructions for this equipment.
•
It is recommended to connect the auxiliary contact of the
water pump contactor to ensure maximum unit safety (see
wiring diagram delivered with the unit).
•
Fill the chilled water circuit with clean water, and an
inhibitor formulated specifically for this purpose, or fill it
with another non-corrosive fluid to be chilled.
•
Purge air at all high points in the system. If water temperatures below 4°C (30GH) or 5°C (30GZ) are likely, add the
appropriate volume of ethylene glycol to prevent freezing.
•
Confirm that the suction and discharge line stop valves are
fully opened.
•
Open the refrigerant line valves. Check again that the
water circuit valves are open.
15
•
•
•
•
•
Check that oil is visible in each compressor sight glass to
between 1/8 and 3/8 of the total glass depth (check for all
compressors).
Confirm that there are no refrigerant leaks.
Confirm that the installation is correct and check the
secure positioning of all control sensors.
Confirm that discharge muffler securing bands and
discharge line connections are tight.
Check that all electrical connections are secure.
Design set point adjustment (three-step thermostat)
TEMPERATURE
DROP
TEMPERATURE
RISE
F
0
RY3
RB3
RY3
RB3
F
0
0
F
RY2
RB2
RY1
RB1
F
0
0
F
A
RY2
RB2
RY1
RB1
B
0
F
SET POINT
Checks before start-up at the optional hydronic kit
IMPORTANT:
•
The safety valve installed in the Hydroflow module is
activated at 370 kPa, during charging. Please ensure that
this pressure is not exceeded.
•
The nitrogen pressure of the expansion tank is controlled
to 100 kPa above the static pressure of the installation.
•
Using the pump pressure gauge and the curves for the
available static pressure of the pump, verify the water
flow for the installation.
Actual start-up
IMPORTANT:
•
Commissioning and start-up of the chiller must be
supervised by a qualified refrigeration engineer.
•
Start-up and operating tests must be carried out with a
thermal load applied and water circulating in the
evaporator.
•
All set point adjustments and control tests must be carried
out before the unit is started up.
•
Please refer to the controls manual for the unit.
Electromechanical control
Multi-step thermostat
This consists of a series of load switches actuated by the
pressure developed inside a temperature sensing bulb, installed
in the cooler inlet.
Legend:
A
B
R, Y, B O
F
-
Differential between stages
Differential on one contact
Thermostat contact reference
Open contact
Closed contact
Set point adjustment
When the unit is ready for operation, insert a small screwdriver
in the adjusting slot to turn the dial (the dial may also be turned
by hand).
Rotate the screwdriver, until the design set point for the
installation appears directly under the pointer. Insert a
thermometer in the return water connection and allow the unit
to run through a complete cycle.
When switch No. 1 opens, the last capacity step appears
directly under the pointer. Read the temperature. If it is not the
same as the dial reading, it can be compensated by shifting the
control point slightly.
NOTE: Do not force the dial past the stop. This could cause
loss of the control point and damage the instrument.
Set point adjustment
POINTER
ADJUSTING SLOT
Before replacing the bulb, half fill the well with a heat
conducting sealing compound. Replace the sensor in the well
recess. The thermostat is factory-set to control from the return
water temperature through a cooling range of 5.6 K.
The sequence switches are factory-calibrated and sealed
and should not need any field calibration. One step on sizes
009-013, two steps on sizes 015-020 and three steps on sizes
025, 030 and 035 are available.
WARNING: Alteration of factory settings other than the design
set point, without the manufacturer's authorization, may void
the warranty.
If a different return water range or leaving water control is
specified, or if brine is to be used, the controller must be
changed. Consult your local Carrier representative for the
proper control.
16
STOP
SET POINTS
CALIBRATED DIAL
Units with PRO-DIALOG control
Please refer to the installation, operation and maintenance
instructions for the PRO-DIALOG control (order No. 13163-76).
SERVICING REFRIGERATION COMPONENTS
Servicing must be done by a qualified refrigeration engineer.
WARNING: Before doing any work on the machine ensure that
the power is switched and locked off and that all isolators are
tagged. If a refrigerant circuit is opened, it must be evacuated,
and recharged, after ensuring that the refrigerant is clean and
free from impurities, the filter-drier has been changed and the
unit has been tested for leaks. Before any operation on a refrigerant circuit, it is necessary to remove the complete charge of
refrigerant from the unit with a refrigerant charge recovery group.
General maintenance
•
•
•
•
•
•
Keep the unit itself and the space around it clean and free
of obstructions. Remove all rubbish such as packing
materials, as soon as the installation is completed.
Regularly clean the exposed pipework to remove all dust
and dirt. This makes detection of water leaks easier, and
they can be repaired before more serious faults develop.
Confirm that all screwed and bolted connections and
joints are secure. Secure connections prevent leaks and
vibration from developing.
Check that all insulation joints are securely closed and that
all insulation is firmly in place. Check all heat exchangers
and all pipework.
Confirm regularly that any phase imbalance in the threephase power supply is within acceptable limits.
Lubricate the hinges, locks and latches on the electrical
control box doors sparingly.
WARNING: To ensure proper operation of 30GH and 30GZ
units there must be at least 5 K liquid subcooling at the inlet to
the expansion valve.
The 30GH and 30GZ units use halocarbon refrigerant. For
your information, we are reproducing here some extracts from
the official publication dealing with the design, installation, operation and maintenance of air conditioning and refrigeration
systems and the training of people involved in these activities,
agreed by the air conditioning and refrigeration industry.
Refrigerant guidelines
Refrigeration installations must be inspected and maintained
regularly and rigorously by specialists. Their activities must be
overseen and checked by properly trained people. To minimise
discharge to the atmosphere, refrigerants and lubricating oil
must be transferred using methods which reduce leaks and
losses to a minimum.
•
•
•
•
•
Leaks must be repaired immediately
A valve on the condenser liquid refrigerant outlet line
enables the refrigerant charge to be transferred to the
receiver provided specifically for this purpose.
If the residual pressure is too low to make the transfer
alone, a purpose-built refrigerant recovery unit must be
used.
Compressor lubricating oil contains refrigerant. Any oil
drained from a system during maintenance must therefore
be handled and stored accordingly.
Refrigerant under pressure must never be discharged to
the atmosphere.
Liquid refrigerant charging
Recharging liquid refrigerant
Checking the charge
CAUTION: 30GZ 009-035 units are charged with liquid
HFC-407C refrigerant.
WARNING: When adjusting the refrigerant charge always
ensure that water is circulating in the evaporator in order to
prevent any possibility of freezing up. Damage caused by
freezing is not covered by the product warranty.
30GH and 30GZ units are shipped with a full normal charge of
refrigerant. Refer to the Physical Data table. If it is nevertheless
necessary to add more refrigerant, run the unit at full capacity
for some time and then add refrigerant until there are no
bubbles in the sight glass. This will generally mean adding
more refrigerant than would be needed to prevent bubbles from
being seen in the sight glass.
Positive pressure shows that refrigerant is present. If there is no
refrigerant vapour pressure, the whole circuit must be checked
for leaks. When all leaks have been repaired, the entire circuit
must be pumped out and evacuated before being recharged
with clean refrigerant.
Refer to the Standard Service Techniques, Chapter 1, which
describes leak testing methods and pumping down and
evacuation procedures.
Liquid refrigerant charging is recommended as the method to
be used when adding a supplementary refrigerant charge. Charge
through the 1/4" flare connection on the liquid line stop valve.
Never add liquid refrigerant through the low pressure side of
the circuit.
This non-azeotropic refrigerant blend consists of 23% R-32,
25% of R-125 and 52% R-134a, and is characterised by the fact
that at the time of the change in state the temperature of the
liquid/vapour mixture is not constant, as with azeotropic
refrigerants. All checks must be pressure tests, and the
appropriate pressure/temperature ratio table must be used for
the interpretation of the values.
Leak detection is especially important for units charged with
refrigerant R-407C. Depending on whether the leak occurs in
the liquid or in the vapour phase, the proportion of the different
components in the remaining liquid is not the same.
NOTE: Regularly carry out leak checks and immediately repair
any leak found.
Undercharge
If there is not enough refrigerant in the system, this is indicated
by gas bubbles in the moisture sight glass. There are two
possiblities:
•
Small undercharge (bubbles in the sight glass, no
significant change in suction pressure).
After detection and repair the unit can be recharged.
The replenishment of the charge must always be done
in the liquid phase at the liquid line. The refrigerant
cylinder must contain a minimum of 10% of its initial
charge.
17
•
Significant undercharge (large bubbles in the sight glass,
drop in suction pressure).
Small units (charge below 20 kg per circuit).
After detection and repair completely drain the
refrigerant charge, using a refrigerant recovery unit,
then recharge completely, following the precautions
given above.
Large units (charge above 20 kg per circuit).
After detection and repair completely recharge the unit
as described above, operate it for a few minutes and
then let a specialist carry out a chromatographic
analysis to verify the composition of the blend
(range: R-32: 22-24%, R-125: 23-27%, R-134a: 50-54%).
Compressors
Checking the oil charge
Check the oil level and add or remove oil as necessary so that
the level is 1/8 to 3/8 up each sight glass with the compressors
running normally.
WARNING: Use only oils which have been approved for use in
refrigeration compressors. Never use oil which has been
exposed to air.
Discharge gas thermostat
(30GH/GZ 015/035) - electromechanical version or units
with low-temperature option
A sensor in each compressor discharge line opens to shut down
the compressor if the discharge gas temperature exceeds the
preset level.
Cut out 146°C
Cut in 113°C
Crankcase heater
The compressor is fitted with an electric resistance crankcase
heater which prevents the absorption of refrigerant by the
compressor lubricating oil when the compressor is shut down.
Each heater is held in place by a screw clip which must be
secure. Prolonged exposure of the heater to air will result in its
destruction. The heater is energized when the compressor is
switched off.
WARNING: Never open or disconnect any switch which will
cut the supply to the heaters, unless the unit is to be shut down
for lengthy service or repair or for a seasonal shut down. In all
cases the heater must be energised for at least 24 hours before
a compressor is restarted.
Recommended oil:
Compressor protection circuit board (STARTERGUARD)
- 30GH/GZ 015-035
39GH units (semi-hermetic compressors):
Mineral oil, Carrier specification No. PP 33-02
Suniso 3 GS (Sun Oil Co)
Clavus G 32 (Shell Oil Co)
Gargoyle Artic 155 (Mobil Oil) - Carrier reference 470 EE
as original charge, in 5 liter containers
The purpose of this card is to monitor the compressor operating environment, in particular:
•
the crankcase heaters
•
the contactors
•
the part winding start timer
•
the control wiring between these components
30GZ units (semi-hermetic compressors):
Poyester oil without additives (POE), Carrier
specification No. PP 47-26
Mobil EAL Artic 68 - Carrier reference P 903 EAL
6805EE, in 4 liter containers.
The status of the controlled components is displayed via three
different-coloured LEDs:
•
Green LED: correct operation
•
Orange LED: signals that the magnetic loop of the card
has detected the presence of a current, either in the
compressor crankcase heater or in the compressor motor.
WARNING: All fixing devices and fittings which may have
been removed during servicing must always be replaced upon
completion of the work and before restarting the unit.
•
Tightening torques to be applied
Description
Diameter, mm
Torque, Nm
Discharge valve
Cylinder head
Suction and liquid line flange
Suction valve
M16
M12
M12
M16
135-140
75-87
75-87
135-140
Compressor motor protection
Circuit breaker
Calibrated, thermo-magnetic, manually-reset circuit breaker
protects the compressors against locked rotors and overloads. It
also offers protection against excessive current draw up to the
trip capacity given in the wiring diagram.
WARNING: Never bypass a circuit breaker or increase its
setting. If a circuit breaker trips, find out why it has done so
and correct the problem before resetting the breaker.
18
If the green and orange LEDs are illuminated together,
this indicates that there is no fault.
Red LED - fault related to:
the heater, if the orange LED is not lit
the contactor or the power line of the compressor
motor, if the orange LED is lit
If a fault is detected, the compressor is shut down.
Power supply and resetting:
The STARTERGUARD card uses 24 V AC ± 10%, 50 Hz or
60 Hz. When a fault occurs, the 24 V supply must be
interrupted and then restored, in order to reset the card. The
green LED lights up.
Heat exchangers
3.
Brazed plate heat exchanger (evaporator)
Start with cleaning the joints to be soldered. Clean the
inside of the connection on the plate heat exchanger and
the outside of the pipe. Degrease the connections properly
with some kind of solvent (e.g. Trichlorethylene).
Centre the pipe in the connection.
Initial cooling is achieved by keeping nitrogen flowing
through the heat exchanger and by the wet cloth. The final
cooling could be done with water.
Protection devices - freeze-up prevention thermostat
The evaporator is protected against freeze-up. The protection is
provided by a sensor installed in the unit in the PRO-DIALOG
version and by a thermostat in the electromechanical version.
4.
5.
Evaporator maintenance
Check that:
•
the insulating foam is intact and securely in place.
•
the cooler heaters are operating, secure and correctly
positioned.
•
the water-side connections are clean and show no sign of
leakage.
Recommendation:
The minimum silver content of the compound is 45%.
Cleaning
In some applications, heat exchanger fouling can be very high,
for example when using extremely hard water. The heat exchanger can be cleaned by circulating a cleaning solution. Use a tank
with a weak acid solution, 5% phosphoric acid or, if the heat
exchanger is frequently cleaned, 5% oxalic acid. Pump the cleaning solution through the heat exchanger. For optimum cleaning,
the cleaning solution flow rate should be 1.5 times that of the
normal circulation rate, and the direction of flow should be
opposite to that of normal circulation. Afterwards rinse with
large amounts of fresh water, in order to remove all the acid,
before starting up the system again. Clean at regular intervals.
Cleaning in place
Condenser coil
We recommend, that finned coils are inspected regularly to
check the degree of fouling. This depends on the environment
where the unit is installed, and will be worse in urban and
industrial installations and near trees that shed their leaves.
For coil cleaning proceed as follows:
•
Remove fibres and dust collected on the condenser face
with a soft brush (or vacuum cleaner).
•
Clean the coil with the appropriate cleaning agents.
We recommend TOTALINE products for coil cleaning:
Part No. P902 DT 05EE: traditional cleaning method
Part No. P902 CL 05EE: cleaning and degreasing.
These products have a neutral pH value, do not contain
phosphates, are not harmful to the human body, and can be
disposed of through the public drainage system.
Depending on the degree of fouling both products can be used
diluted or undiluted.
HEAT
EXCHANGER
WEAK ACID
SOLUTION
Soldering instructions
All brazed plate heat exchangers are vacuum brazed with
copper. This means that the plate heat exchanger temperatures
must never exceed 800°C under normal soldering conditions
(no vacuum), because the copper solder would change its state
and the result would be internal or external leakage at the
connections.
The soldering process
1. We recommend to protect and cool the heat exchanger by
using a wet cloth around the connection to reduce the heat
transferred to the heat exchanger during soldering.
2. Oxidation within the connection pipes is not allowed in
refrigeration installations. It is recommended to avoid this
by circulating nitrogen through the pipe/plate heat
exchanger during the soldering procedure. (The nitrogen
flow could be between 0.1 and 0.3 l/s, depending on the
size of the pipe).
For normal maintenance routines we recommend using 1 kg of
the concentrated product, diluted to 10%, to treat a coil surface
of 2 m2. This process can either be carried out with a
TOTALINE applicator gun (part No. TE01 WA 4000EE) or
using a high-pressure spray gun in the low-pressure position.
With pressurised cleaning methods care should be taken not to
damage the coil fins. The spraying of the coil must be done:
- in the direction of the fins
- in the opposite direction of the air flow direction
- with a large diffuser (25-30°)
- at a distance of 300 mm.
The two cleaning products can be used for any of the following
coil finishes: Cu/Cu, Cu/Al, Cu/Al with Polual, Blygold and/or
Heresite protection.
It is not necessary to rinse the coil, as the products used are pH
neutral. To ensure that the coil is perfectly clean, we recommend
rinsing with a low water flow rate. The pH value of the water
used should be between 7 and 8.
WARNING: Never use pressurized water without a large
diffusor. Concentrated and/or rotating water jets are strictly
forbidden.
Correct and frequent cleaning (approximately every three
months) will prevent 2/3 of the corrosion problems.
19
Fan motor replacement
a)
30GH/GZ 009-013 units
Fan motors can be removed through the top of the unit.
Carefully follow the safety considerations and do not damage
the propeller. Label the wires when they are removed.
30GH/GZ 009-013 unit fan
80 mm + 0 mm
Filter-drier
The filter-drier keeps the circuit clean and free of moisture. The
sight glass indicates when it is necessary to change the cartridge
in the filter-drier. A temperature difference between the inlet
and the outlet of the filter-drier indicates fouling of the drier.
NOTE: The unit must run for at least 12 hours before it can
give an accurate indication, because only with the unit running
is the indicator in continuous contact with the refrigerant.
2
MAXIMUM
CLEARANCE
Liquid line service valve
This valve provides, in each circuit, a liquid refrigerant charging
port and, in conjunction with the compressor discharge line
valves, enables liquid refrigerant to be pumped to the highpressure side of the system.
Pressure switch setting
b)
30GH/GZ 015-035 units
This presents no special problems. The work is done from
above the unit.
•
Remove the grille with its support air duct assembly.
•
Remove the fan shaft protection cap.
•
Pull the fan from the shaft using a FACOM U35 or similar
hub puller
•
Unscrew the fan motor fixing bolts. Remove only the
lower bolts to prevent the motor from falling.
•
Withdraw the fan motor.
Installation is in reverse order. Take care not to damage the
plastic components when installing the fan and position the fan
to maintain a clearance of 170 + 0/+2 mm between the upper
edge of the fan and the upper edge of the volute. Tighten the
fan motor fixing bolts to a torque value of 9 Nm.
High pressure switch
The high pressure switch has fixed non-adjustable settings.
To check: Switch off the unit. Disconnect the fan power, until
the compressor shuts down. This should be at the cut-out
pressure indicated. When the pressure drops to the cut-in
setting, reset the switch.
Low pressure switch (electromechanical version)
This protects against loss of charge.
To check: Slowly close the suction shut-off valve and allow
the compressor to pump down. Do not allow the compressor to
pump down below 3 kPa. The compressor should shut down
when the suction pressure drops to the cut-out pressure, and
restart when it builds up to the cut-in pressure indicated.
CAUTION: On unit sizes 30GH/GZ 015-035 the fan rotation is
counter-clockwise viewed from above.
High pressure switch
30GH/GZ 009-013
30GH/GZ 015-035
30GH/GZ015-035 unit fan
0
170 + mm
2
MAXIMUM
CLEARANCE
Low pressure switch
30GH/GZ 009-035
(electromechanical control)
Cut-out
Cut-in
2500 kPa
2900 kPa
2150 kPa
2200 kPa
50 kPa
150 kPa
Optional hydronic kit
Pump
Fan motor protection
Verify the water flow rate, using the pump performance curves.
A decrease in the flow rate may be a sign of fouling of the filter
installed upstream of the pump or the hydraulic circuit itself.
Clean as necessary.
All fan motors are protected by one thermo-magnetic circuit
breaker (30GH/GZ 009-025) or by two thermo-magnetic circuit
breakers (30GH/GZ 030-035).
During the periodic maintenance check that the current draw is
within the operating range, in order to avoid bearing wear. Also
check the wear of the mechanical fittings.
Refrigerant circuit
Expansion tank
Ensure that the Hydroflow module pressure gauge does not
show a pressure drop. The nitrogen pressure can be adjusted
with the valve on the side opposite to the hydraulic connection.
Thermostatic expansion valve (TXV)
The function of the thermostatic expansion is to control the
flow of liquid refrigerant. The valve is controlled by a heat
sensitive sensor bulb in the suction line. It is factory-set to
maintain a superheat of 4 K. Never change the setting, unless
absolutely necessary.
20
TROUBLESHOOTING CHART
Below we list a series of possible faults, along with the probable causes and suggested solutions. In the event of a unit
malfunction, it is advisable to disconnect the power supply and ascertain the cause.
SYMPTOMS
CAUSE
REMEDY
Unit does not start
Lack of power supply
Connect power supply
Main switch open
Close switch
Low line voltage
Check voltage and remedy the deficiency
A protection device has tripped
Reset
Contactor stuck open
Replace contactor
Seized compressor or short circuit
Check windings (grounded or short circuit), replace
compressor
Loose electrical connections
Check connections
Flow switch open
Check the circulating pump, check the controller
Defective compressor contactor
Replace contactor
Defective compressor
Check valves, replace compressor
Refrigerant losses
Check and add the necessary charge
Low pressure switch defective
Check the capillary tube, if necessary replace the
pressure switch
Refrigerant losses
Add the necessary refrigerant charge
Low water flow in the evaporator
Check water pump
Blocked expansion valve
Clean or replace
Blocked filter drier
Replace filter
Defective high pressure switch
Replace pressure switch
Defective fan(s)
Check the fan(s) and the contactor(s)
Low water flow in the condenser
Clean the condenser
Noisy compressor
Check valve plate, change if necessary
Badly fitting panels
Install correctly
Piping vibrations
Support piping, check supports and tightness
Leak in the system
Repair leak
Compressor loses oil
Defective inlet or outlet connections
Check and tighten if necessary
Water losses
Expansion valve admitting excess refrigerant
Adjust expansion valve
Frosted or sweating suction line
Shortage of refrigerant due to leak
Repair leak and recharge
Hot liquid line
Restricted filter-drier
Remove restriction or replace filter-drier
Frosted liquid line
Burned out coil
Replace coil
Compressor will not unload
Leaky bypass piston
Clean or replace
Miswired solenoid
Wire correctly
Weak bypass piston spring
Replace
Damaged bypass piston
Replace
Miswired solenoid
Wire correctly
Plugged bypass port strainer (high side)
Clean
Unit operates continually or starts and
stops frequently
Compressor continually cuts out at low
pressure or via the DGT (electromechanical version or low-temperature
option)
Compressor continually cuts out at high
pressure
Noises in the system
Compressor will not load
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TROUBLESHOOTING CHART - HYDRAULIC KIT OPTION
SYMPTOMS
CAUSE
REMEDY
Pump will not start
Isolator switch open
Flow controller open
Circuit breaker open
Close isolator switch
Check controller
Trace and correct fault, reset circuit breaker
Contactor stuck open
Pump connections loose
Replace contactor
Check and tighten pump electrical terminals
Control components poorly connected
Low supply voltage
Thermal sensor tripped
Pump seized
Check and tighten all connections
Check voltage and correct
Manually reset thermal sensor
Replace pump bearings
Pump stops
Flow controller open
Check water pressure drops and filter and
evaporator for fouling
Pump runs continuously
Control contacts welded
Replace control component at fault
Noises in system
Vibrating pipes
Noisy pump
Fix, check all hangers etc.
Check purge valves on pump
Check and change pump bearings
Leaky pump seals
Leak in water circuit
Expansion membrane ruptured
Replace
Check purge valves
Replace expansion tank
Pressure loss
22
23
Order No. 13030-76, September 1997. Supersedes order No.: 13030-76, June 1996
Manufacturer reserves the right to change any product specifications without notice.
24
Manufactured by Carrier SA, Montluel, France
Printed on Totally Chlorine-Free Paper.
Printed in the Netherlands