Carrier AQUASNAP 30RH Unit installation

R QUALIT
TE
Y
SURANC
E
AS
•
YD'S REGI
S
LO
AQUASNAP
30RA / 30RH
IS O
900 1
L
ol
ntr
co
PR
DI
O-
AL
OG
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
30RA/30RH
For the use of the control system, refer to the Pro-Dialog Plus control manual.
Contents
Physical data .................................................................................................................................
Electrical data ................................................................................................................................
Dimensions and location of hydraulic connections .......................................................................
Clearance and electric cables .......................................................................................................
General information and hydronic module ...................................................................................
Water connections .........................................................................................................................
Electrical connections ....................................................................................................................
Refrigerant charge .........................................................................................................................
Electronic control ...........................................................................................................................
Start-up ..........................................................................................................................................
Compressor replacement ..............................................................................................................
Pump replacement ........................................................................................................................
Unit protection devices ..................................................................................................................
Operating limits and operating range ............................................................................................
Maintenance ..................................................................................................................................
Final recommendations .................................................................................................................
Troubleshooting .............................................................................................................................
Page
2/3
2/3
4
4
5
6/8
9
9/10
10
11
11
11
11/12
12
13
13
14
Start-up check list
ENGLISH
Air-cooled liquid chillers and reversible air-to-water heat pumps
with integrated hydronic module
Start up date _____________________
Equipment sold by: ___________________________________________ Contract No: ____________________________
Installed by: _________________________________________________ Contract No: ____________________________
Site address _______________________________________________________________________________________
Equipment type and serial No:
30RA ___________________________________________________________
30RH ___________________________________________________________
ELECTRICAL DATA:
Supply voltage
Ph 1: ____________ V
Ph 2: ____________ V
Ph 3: _____________ V
Nominal voltage: ____________________________________ V
% network voltage _______________________
Current draw
Ph 1: ____________ A
Ph 2: ____________ A
Ph 3: _____________ A
Control circuit voltage: ________________________________ V
Control circuit fuse _____________________ A
Main circuit breaker rating _____________________________________________________________________________
PHYSICAL DATA:
Coil:
Entering air temp.: _______________________ °C
Leaving air temp.: _______________________ °C
Plate heat exchanger:
Entering water temp.: __________________ °C
Leaving water temp.: __________________ °C
Pressure drop (water): _________________ kPa
SAFETY DEVICE SETTING:
High pressure switch: cut-out: _____________ kPa
cut-in: _____________________ kPa
Oil level ___________________________________________________________________________________________
OPTIONS:
Commissioning engineer (name) _______________________________________________________________________
Customer agreement
Name: ________________________________
Date: ______________________________
Note: Complete this start-up list at the time of installation
GB - 1
30RA
Physical data and electrical data - Model RA
Table I: Physical data - Model RA
30RA
Net cooling capacity*
kW
017
021
026
033
17.70
21.60
25.80
31.70
Operating weight
without hydronic module
kg
200
220
250
285
with hydronic module
kg
220
240
280
315
Refrigerant charge R-407C
kg
4.80
5.13
6.41
7.70
Compressor
One scroll compressor
Evaporator
One plate heat exchanger
Net water volume
Water connections (MPT gas)
l
inches
1.50
1
1.88
1
2.16
1-1/4
2.82
1-1/4
Maximum water pressure
(unit without hydronic module)
kPa
1000
1000
1000
1000
Hydronic module
Pump
Available pressure**
Pump, mesh filter, expansion tank, flow switch, pressure gauges, automatic air purge valve and drain plug,
flow control valve and safety valve.
One single-speed pump
kPa
138
126
150
138
Water inlet connection (MPT gas)
Water outlet connection (MPT gas)
inches
inches
1-1/4
1
1-1/4
1
1-1/4
1-1/4
1-1/4
1-1/4
Closed expansion tank water volume
l
8
8
8
8
Inlet/outlet diameter (MPT gas)
Condenser
inches
1/2
1/2
One, copper tubes and aluminium fins
1/2
1/2
Tube diameter
No. of rows
inches
3/8
2
3/8
3
3/8
2
3/8
3
52
1.81
60
1.81
60
1.81
Water fill system (option)
Tubes/row
Fin spacing
mm
52
1.81
Fan
Diameter
mm
Two,axial type with two speeds
500
500
610
610
No. of blades
Air flow (high speed)
l/s
5
2450
5
2222
5
3278
5
3000
Fan speed (high speed)
r/s
12.83
12.91
11.05
10.96
026
033
9.56
12.39
* The ratings indicated refer to an evaporator entering/leaving temperature of 12/7 °C,and air entering the condenser at 35 °C.
** At nominal water flow rate.
Table II: Electrical data - Model RA
30RA
017
021
Power supply
V-ph-Hz
400-3-50 / 400-3-50+N
Voltage range
V
360-440
Nominal power input*
kW
6.43
Effective power input**
kW
6.54
8.72
9.75
12.60
Nominal current drawn*
A
10.75
15.50
18.80
24.55
Effective current drawn**
A
10.95
15.75
19.10
24.95
Maximum power drawn***
kW
7.87
10.8
12.23
14.95
Maximum current drawn**
A
13.50
20.00
22.50
28.00
Starting current
A
87
132
134
139
Pump power input
kW
0.65
0.68
0.89
0.93
8.57
Based on an outdoor entering air temperature of 35 °C db,an evaporator entering water temperature of 12 °C and an evaporator leaving water temperature of 7 °C,unit without hydronic
module
** The power and current values indicated refer to Eurovent Standard conditions.
*** The power and current values indicated refer to an evaporator leaving water temperature of 10 °C and condenser entering air temperature of 46 °C.
*
GB - 2
30RH
Physical data and electrical data - Model RH
ENGLISH
Table I: Physical data - Model RH
30RH
017
021
026
033
Net cooling capacity*
kW
16.70
21.60
24.60
29.00
Net heating capacity**
kW
18.80
24.80
27.80
34.00
without hydronic module
with hydronic module
kg
kg
235
255
265
285
285
315
315
345
Refrigerant charge R-407C
kg
7.15
7.84
9.30
11.00
Operating weight
Compressor
One scroll compressor
Control system
Pro Dialog-Plus
Refrigerant-water heat exchanger
One plate heat exchanger
Net water volume
Water connections (MPT gas)
l
inches
1.50
1
1.88
1
2.16
1-1/4
2.82
1-1/4
Maximum water pressure
(unit without hydronic module)
kPa
1000
1000
1000
1000
Hydronic module
Pump
Pump, mesh filter, expansion tank, flow switch, pressure gauges, automatic air purge valve and drain plug,
flow control valve and safety valve.
One single-speed pump
Available pressure***
Water inlet connection (MPT gas)
kPa
inches
142
1-1/4
125
1-1/4
155
1-1/4
149
1-1/4
Water outlet connection (MPT gas)
Drain tap coupling (MPT gas)
inches
inches
1
1/2
1
1/2
1-1/4
1/2
1-1/4
1/2
Closed expansion tank water volume
l
8
8
8
8
Inlet/outlet diameter (MPT gas)
Refrigerant-air heat exchanger
inches
1/2
1/2
One, copper tubes and aluminium fins
1/2
1/2
Tube diameter
No. of rows
inches
3/8
3
3/8
2
3/8
3
3/8
4
60
1.81
60
1.81
60
1.81
Water fill system (option)
Tubes/row
Fin spacing
mm
52
1.81
Fan
Diameter
mm
Two, axial type with two speeds
500
610
610
610
No. of blades
Air flow (high speed)
l/s
5
2222
5
3611
5
3111
5
3333
Fan speed (high speed)
r/s
12.83
10.83
11.67
11.83
*
*The ratings indicated refer to an evaporator entering/leaving temperature of 12/7 °C,and air entering the condenser at 35 °C.
** The ratings indicated refer to a condenser entering/leaving temperature of 40/45 °C,and air entering the condenser at 7 °C d.b.and 6 °C w.b.
*** At nominal water flow rate during cooling.
Table II: Electrical data - Model RH
30RH
017
021
026
033
9.13
11.83
Power supply
V-ph-Hz
400-3-50 / 400-3-50+N
Voltage range
V
360-440
Nominal power input*
kW
6.21
Effective power input**
kW
6.30
8.10
9.30
12.00
Nominal current drawn*
A
10.75
14.80
18.70
23.65
Effective current drawn**
A
10.90
15.05
19.05
24.00
Maximum power drawn***
kW
7.87
10.8
12.23
14.95
Maximum current drawn***
A
13.50
20.00
22.50
28.00
Starting current
A
87
132
134
139
Pump power input
kW
0.65
0.68
0.89
0.93
7.95
Based on an outdoor entering air temperature of 35 °C db, an evaporator entering water temperature of 12 °C and an evaporator leaving water temperature of 7 °C, unit without hydronic
module
** The power and current values indicated refer to Eurovent Standard conditions.
*** The power and current values indicated refer to an evaporator leaving water temperature of 10 °C and a condenser entering air temperature of 46 ° C.
*
GB - 3
30RA/30RH
Dimensions and location of hydraulic connections (mm)
Mod. 30RA 017 - 021
Mod. 30RH 017
Mod. 30RA 026 - 033
Mod. 30RH 021 - 026 - 033
1503
1328
3 1
3 1
1003
859
796
940
1453.5
2
175 105
1657.5
2
180 125
130
130
40
40
1243
578
478
130
635
1068
635
578
478
130
12x20
12x20
1. Water inlet
2. Water outlet
3. 3/4” gas safety valve outlet
20
200
70
Main switch
Grommet: 1 Pg 29 and 2 Pg 16 for power
supply and control cables entry
GB - 4
400
0
0
30RA/30RH
General information and hydronic module
Unit installation
Read this instruction manual thoroughly before starting the
installation.
This unit complies with low-voltage (EEC/73/23) and electromagnetic compatibility (EEC/89/336) directives.
• The installation must be carried out by a qualified installer.
• Follow all current national safety code requirements.
In particular ensure that a properly sized and connected ground
wire is in place.
• Check that voltage and frequency of the mains power supply are
those required; the available power must be adequate to operate
any other possible appliances connected to the same line.
Also ensure that national safety code requirements have been
followed for the mains supply circuit.
• After installation thoroughly test the system operation and
explain all system functions to the owner.
• Leave this manual with the owner for consultation during future
periodic maintenance.
• Be sure the unit and its components are checked periodically to
look for loosen, damaged or broken components.
In case of persisting defects, the unit may cause personal injury
or property damage.
IMPORTANT:
During the unit installation make first the hydronic
connections and then electrical connections. If unit is
uninstalled first disconnect electrical cables, then the
hydronic connections.
WARNING:
Disconnect the mains power supply switch before servicing
the system or handling any internal parts of the unit.
All mains supply circuits must be disconnected.
• The manufacturer declines any liability for damage resulting from
modifications or errors in the electrical or hydronic connections.
• Failure to observe the installation instructions or use of the unit
under conditions other than those indicated in Tables “Operating
limits”, will immediately void the unit warranty.
• Failure to observe electric safety codes may cause a fire hazard
in case of short circuits.
• Inspect equipment for damage due to improper transportation or
handling: file an immediate claim with the shipping company.
Do not install or use damaged units.
• During unit operation, some of the refrigerant circuit elements
could reach a temperature in excess of 70oC so only trained and
qualified personnel should access areas protected by access
panels.
• In case of any malfunctioning turn the unit off, disconnect the
mains power supply and contact a qualified service engineer.
• All of the manufacturing and packaging materials used for
your new appliance are compatible with the environment
and can be recycled.
• Dispose of the packaging material in accordance with local
requirements.
• This equipment contains refrigerant R407-C that must be
disposed of in a proper manner. When disposing of the unit after
its operational life, remove it carefully. The unit must then be
delivered to an appropriate disposal center or to the original
equipment dealer.
• Carefully recover refrigerant within this unit before final disposal
or when servicing. Never vent refrigerant to atmosphere.
This is necessary to prevent ice from accumulating on the frame
and to permit correct operation also in the event of heavy
snowfalls.
The unit must be levelled on both axes (the tolerance is less than
2 mm per metre).
• In some cases it may be necessary to fit deflectors against
strong winds and to stop snow from hitting the coil directly.
These deflectors must be installed so that the normal air
circulation is not obstructed.
Siting the unit
Check that:
- The location is able to support unit operating weight (Table I).
- There is sufficient space for servicing and air flow around the
unit (see “Clearances”figure).
- The selected site is without dust or foreign material which could
obstruct the coil.
- When installing the unit on the ground, the selected site is not
subject to flooding.
- The installation is in accordance with local rules and standards
governing the installation of air conditioning equipment.
- Vibration absorbers have been provided throughout the
installation to prevent noise from being transmitted.
Transport
1. Use spreader bars to lift the unit to avoid damage to the
panels. Avoid violent movements.
2. Never roll or swing the unit more than 15°.
IMPORTANT:
Ensure that all unit panels are fixed in place before moving
the unit. Raise and set down the unit carefully.
IMPORTANT:
Always ensure that the unit is levelled correctly.
Hydronic module
The hydronic module is factory-installed.
This eliminates the need to install the necessary components
on-site, making the unit more compact and easy to install.
Automatic purge
Pressure gauge for
hydraulic circuit
static pressure
Flow switch
Safety valve
Arrangement for
possible installation
of automatic fill kit
option
Expansion vessel
Mesh filter*
Flow control valve*
Hydronic module
drain valve
Pump drain plug
Pump
*
Choosing the installation site
• This unit should not be installed in an explosive atmosphere.
• The unit can operate in normal radioelectric atmospheres in
residential, commercial and light industrial installations.
For other applications, please consult Carrier.
• In the case of heat pump operation with an outdoor temperature
of less than 0 °C the unit must be installed at least 300 mm
above ground level.
ENGLISH
Factory-supplied,
fit during
installation
GB - 5
30RA/30RH
Water connections
Typical water circuit diagram for units without hydronic module
Legend for units without
hydronic module:
30RA - RH unit
without hydronic
module
Fan coil units
Water circulating
pump
Expansion vessel
Pressure gauges
Manual shut-off
valves
Mesh filter
Pressure couplings
Thermometers
Flow switch
Automatic purge valve
Hydraulic circuit drain
valve
Charge valve
Flexible coupling
Safety valve
Plate-type heat
exchanger drain valve
Typical water circuit diagram for units with hydronic module
Legend for units with
hydronic module:
30RA - RH unit with
hydronic module
Fan coil units
Pressure gauges
Manual shut-off
valves
Pressure couplings
Thermometers
Plate-type heat
exchanger drain valve
NOTE:
If the automatic
fill kit option is used on the unit,
fitting an extra charging
valve is unnecessary.
Charge valve
Flexible coupling
Shut-off valve with
incorporated stop
Pressure reducer
Hydraulic circuit drain
valve
Mesh filter *
Flow control valve *
*
Factory-supplied, fit
during installation
Power supply
Automatic fill kit option
GB - 6
30RA/30RH
Water connections
ENGLISH
Freezing temperature of water- ethylene glycol mixture °C
Ethylene glycol curve
ATTENTION:
The pump leakproof
components are not suitable
for use with propylene
glycol.
Weight concentration of ethylene glycol in water %
CAUTION:
Using water with glycol may
make it necessary to change the
configuration of the control
system.
Make the plate heat exchanger hydraulic connections with the
necessary components, using material which will guarantee that
the screwed joints are leakproof.
The typical hydraulic circuit diagram shows a typical water circuit
installation in an air conditioning system.
For an application with a water circuit, the following
recommendations must be taken into account:
1. The pump must be fitted immediately before of the heat
exchanger and after the connection to the system return (unit
without hydronic module).
2. It is advisable to install shut-off valves to allow isolation of the
most important circuit components, as well as the heat
exchanger itself.
These valves (ball, globe or butterfly valves) should produce a
minimum loss of charge when they are open.
3. Provide unit and system drains and vents at the lowest system
point.
4. Install purges in the higher sections of the installation.
5. Pressure ports and pressure gauges should be installed
upstream and downstream of the water pump (unit without
hydronic module).
6. Thermometers should be installed in the unit water inlet and
outlet.
7. All piping must be adequately insulated and supported.
Installation of the following components is obligatory:
1. A flow switch should be installed in a straight horizontal stretch
with a length of at least five times the line diameter on either
side.
The flow switch must be positioned in the exchanger inlet pipe.
It must be electrically connected in accordance with the wiring
diagram (only unit without hydronic module).
If this is not possible, the installation should incorporate a
protection device which is activated when there is no water
circulating in the heat exchanger.
2. The presence of particles in the water can lead to obstructions
in the heat exchanger.
It is therefore necessary to protect the heat exchanger inlet with
an extractable mesh filter.
The filter mesh gauge must be at least 10 mesh/cm2.
The standard supply of the unit with hydronic module includes a
mesh filter to be fitted during installation.
3. After assembling the system, or repairing the circuit, the whole
system must be thoroughly cleaned with special attention paid
to the state of the filters.
4. Pump flow rate control is made through a flow control valve
supplied with the unit with hydronic module, which must be
installed on the delivery pipe during installation.
5. In case of water refrigeration at temperatures lower than 5°C, or
if the unit is installed in areas where temperatures drop below
0°C, water must be mixed with a proper quantity of ethylene
glycol (see the curve above).
Use the curve to determine the correct ethylene glycol
concentration for the temperature.
Frost protection
The plate heat exchanger and the water connections of the
hydronic module pump may be damaged in spite of the anti-freeze
protection system these units are fitted with.
Frost protection of the plate heat exchanger and of the circuit
inside the hydronic module is always guaranteed down to -10°C
by the electric heaters that are automatically activated if needed.
The power supply to the electric heaters of the plate heat
exchanger and to the internal circuit of the hydronic module must
never be interrupted.
IMPORTANT:
Both the appliance main switch (Q1) and the auxiliary
protection switch for the electric heaters (QF101) must
always be in the closed position (the positions of Q1 and
QF101 are indicated in the wiring diagram).
GB - 7
30RA/30RH
Water connections
Pressure drop , kPa
Water pressure drop of the unit without hydronic module
A.
B.
C.
D.
30RA-RH 017
30RA-RH 021
30RA-RH 026
30RA-RH 033
Water flow rate, l/s
Available static pressure, kPa
Outlet available static pressure of the unit with hydronic module
A.
B.
C.
D.
Water flow rate, l/s
GB - 8
30RA-RH 017
30RA-RH 021
30RA-RH 026
30RA-RH 033
30RA/30RH
Electrical connections and refrigerant charge
Electrical connections
Liquid refrigerant charge
WARNING:
To prevent electrical shock or equipment damage, make sure
disconnects are open before electrical connections are made.
If this action is not taken, personal injury may occur.
Checking the charge
Power supply cable size and external connection must be made by
the installer according to the unit installation characteristics and the
applicable standards. The power supply and earthing multicore
cable of the unit must be connected to the main disconnecting
switch by passing it through the grommet on the front pedestal
after removing the lateral access panel. The maximum section
allowable for flexible copper cable is 25 mm2.
Before connection, check that phase sequence L1 – L2 – L3 is
correct.
Take special care when making the earth connection.
The maximum permitted voltage and current imbalance is 10% of
the values indicated in Table II.
Contact your local power company for correction of an incorrect line
voltage.
Before selecting the power supply line fuses - which must be of the
type "gG" - check the voltage and the size indicated on the unit
name plate is.
WARNING:
Operation of the unit on improper line voltage constitutes
abuse and is not covered by the Carrier warranty.
IMPORTANT:
To ensure the correct unit power supply (cable entry,
conductor cross section, protection devices etc.), consult the
electrical data table, the wiring diagram supplied with the unit
and the applicable standards concerning the installation of air
conditioning equipment.
Never operate a unit if the voltage imbalance exceeds 2%.
The following formula must be used to determine the percentage of
voltage imbalance.
Voltage imbalance (%) =
Largest deviation from average voltage x 100
———————————————————————————Average voltage
Example:
Nominal supply: 400-3-50
AB =
BC =
AC =
404 V
399 V
394 V
Motor
Determine maximum deviation from average voltage
404 - 400 = 4
400 - 399 = 1
400 - 394 = 6
Largest deviation is 6 volts. Percentage voltage imbalance is
therefore:
6
400
WARNING:
When adjusting the refrigerant charge always ensure that
water is circulating in the heat exchanger to prevent any
possibility of freezing up. Damage caused by freezing is not
covered by the product warranty.
30RA-RH units are shipped with a full operating charge of
refrigerant. Refer to Table I.
If it is nevertheless necessary to add more refrigerant, run the unit
for some time in cooling mode and then slowly add liquid refrigerant
into the suction side until there are no bubbles in the sight glass.
WARNING:
To ensure proper operation of 30RA-RH units there must be at
least 5 K of subcooling as the liquid refrigerant enters the
expansion valve.
30RA-RH units use a HFC-407C refrigerant charge. 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.
• Service valves fitted to the flow and return lines permit charge
transfer to a suitably arranged external container.
• It is indispensable to use a dedicated transfer station.
• 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.
Recharging liquid refrigerant
Average voltage = 404 + 399 + 394 = 399 ≈ 400 V
3
AB =
BC =
AC =
ENGLISH
x 100 = 1,5 %
CAUTION:
The installer must install protection devices, as required by
the applicable legislation.
CAUTION:
30RA-RH units are charged with liquid HFC-407C refrigerant.
This non-azeotropic refrigerant blend consists of 23% R-32, 25% of
R-125 and 52% R-134a, and is characterised by the fact that at the
time of the change in state the temperature of the liquid/vapour
mixture is not constant, as with azeotropic refrigerants.
All checks must be pressure tests, and the appropriate pressure/
temperature ratio table must be used 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
fluid is not the same.
NOTE:
Regularly carry out leak checks and immediately repair any
leak found.
GB - 9
30RA/30RH
Refrigerant charge and electronic control
Undercharge
If there is not enough refrigerant in the system, this is indicated by
gas bubbles in the moisture sight glass.
There are two possibilities:
• 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
cooling mode, slowly introducing liquid refrigerant at the suction
side, until there are no bubbles in the sight glass.
• Significant undercharge (large bubbles in the sight glass,
significant drop in suction pressure).
- Completely drain the refrigerant charge, using a refrigerant
recovery unit. After detection and repair check the charge with
the unit off, drain the system and recharge the full amount of
liquid refrigerant (see Table I) on the suction and discharge side.
- The refrigerant container used must contain a minimum of 10%
of its initial charge.
WARNING:
If brazing is to be done, the refrigerant circuit must be filled with
nitrogen.
Combustion of refrigerant produces toxic phosgene gas.
IMPORTANT:
-
Never use the compressor as a vacuum pump.
Always add refrigerant via the suction line.
Refrigerant must be added very slowly.
The complete refrigerant charge must never be filled into the
suction line.
- Do not overcharge the system with refrigerant.
Electronic control
Operation and control of all units is carried out via the electronic
control.
The instructions supplied with the control include comprehensive
descriptions.
PRO-Dialog Plus electronic control
PRO-DIALOG Plus is an advanced numeric control system that
combines complex intelligence with great operating simplicity.
PRO-DIALOG Plus constantly monitors all machine parameters
and safety devices, and precisely manages the operation of
compressor and fans for optimum energy efficiency.
It also controls the operation of the water pump.
A powerful control system
The PID control algorithm with permanent compensation for the
difference between entering and leaving water temperature and
anticipation of load variations regulates compressor operation for
intelligent leaving water temperature control.
To optimise power absorption, the PRO-DIALOG PLUS
automatically re-calibrates the set point of the entering water
temperature based on the outside air temperature to one of the two
pre-set values (occupied building and of an unoccupied building for
example).
PRO-DIALOG Plus control is auto-adaptive for full compressor
protection. The system permanently optimises compressor run
times according to the application characteristics (water loop
inertia), preventing excessive cycling. In most comfort air
conditioning applications this feature makes a buffer tank
unnecessary.
Clear and easy-to-use control system
The operator interface is clear and user-friendly: LEDs and two
numeric displays ensure immediate verification of all unit operating
data.
10 menus offer direct access to all machine controls, including a
history of possible faults, for rapid and complete chiller fault
diagnosis.
Extended communications capabilities
PRO-DIALOG Plus allows remote control and monitoring of the
unit through a wired connection: start/stop, cooling/heating mode
selection (only 30RH unit), power demand limit or dual set-point
and customer safety lock.
The system permits remote signalling of any general anomaly for
each refrigerant circuit.
Three independent time schedules permit definition of: chiller
start/stop, operation at the second set-point (e.g. unoccupied
mode), and operation at low fan speed (e.g. during the night).
This option also permits cascade operation of two units and
remote control via communication bus (RS 485 serial port).
GB - 10
30RA/30RH
Start-up, compressor and pump replacement, unit protection devices
ENGLISH
Start-up
Unit start-up is done by the electronic control described above, and
must always be carried out under the supervision of a qualified air
conditioning engineer.
Necessary checks/precautions before start-up
- Ensure that all electrical connections are properly tightened.
- Ensure that the unit is level and well-supported.
- Check that the hydraulic circuit has sufficient water flow and that
the pipe connections correspond to the installation diagram.
- Ensure that there are no water losses. Check the correct
operation of the valves installed.
- All panels should be fitted and firmly secured with the
corresponding screws.
- Make sure that there is sufficient space for servicing and
maintenance purposes.
- Ensure that there are no refrigerant leaks.
- Confirm that the electrical power source agrees with the unit
nameplate rating, wiring diagram and other documentation for the
unit.
- Ensure that the power supply corresponds to the applicable
standards.
- Make sure that compressors float freely on the mounting springs.
Compressor replacement
As the compressors are hermetic, when an internal fault occurs,
the compressor must be replaced.
This must be done as detailed below:
- Disconnect the unit from the electrical supply.
- Remove the access panels.
- Remove the gas from the refrigerant circuit using recovery
equipment to avoid harming the atmosphere.
- Electrically disconnect the compressor.
- Unbraze or unscrew the suction and discharge lines, taking care
not to damage the rest of the components.
- Remove the compressor fastenings.
- Replace the compressor, ensuring that it contains sufficient oil.
-
Braze or screw in the lines.
Connect the compressor according to the wiring diagram.
Evacuate the compressor.
Introduce the quantity of refrigerant indicated on the nameplate
through the service couplings located on the high and low
pressure side.
Pipe union
Screw
Pipe union
Description of unit protection devices
The unit includes the following protection devices:
- Internal compressor protection.
- Fan motor internal thermal protection.
- Main switch.
- Anti-short-cycle protection.
- Thermomagnetic main switch.
NOTE:
This operation must be carried out by a qualified person.
- Thermomagnetic control switch.
- Fans and electric heaters thermomagnetic switch.
Pump replacement
If the water pump needs to be replaced, proceed as follows:
- Disconnect the unit from the power supply.
- Remove the access panel.
- Electrically disconnect the pump.
- Empty all water from the hydronic module.
- Loosen the pipe unions a and c.
- Remove the four pump fixing screws b.
- Replace the pump.
- Fit the pump fixing screws b.
- Tighten the pipe unions a and c.
- Electrically connect the pump
- Connect the unit to the power supply
- Make sure the pump rotates in the right direction using the hole in
the back panel.
- Reinstall the lateral access panel.
- Defrost thermostat.
- Fault detector for the temperature and pressure sensors.
- High pressurestat: this protects the unit against excessive
condensing pressure.
The high pressurestat has factory-fixed non-adjustable settings.
The appliance stops due to the intervention of the high pressure
alarm threshold, before the high pressurestat intervenes.
This function is performed by the electronic control device via a
pressure transducer.
- Low pressurestat: This function is performed by the electronic
control device via a pressure transducer.
Only on appliances with hydronic module
- Pump motor external thermal protection.
GB - 11
30RA/30RH
Unit protection devices, operating limits and operating range
High pressurestat
Cut-out
Reset
30 bar
Manual
WARNING:
Alteration of factory settings other than the design set-point, without
manufacturer's authorisation, may void the warranty.
In case of use other than the manufacturer configuration, Carrier
Service must be asked for permission to change the Pro-Dialog Plus
system configuration.
30RA - Operating limits
These units have been designed to operate within the following limits:
Evaporator
Minimum°C Maximum°C
Water entering temp. (at start-up)
Water leaving temp. (in operation)
Water entering temp. (at shut-down)
Condenser
7,8 *
5**
-
30
13
55
Air entering temperature
-10
46
NOTE:
For industrial process cooling applications, where high
stability of water temperature levels must be achieved, the
values above must be increased.
We recommend consulting the factory for these particular
applications.
Operating range - 30RA units
Outdoor air temperature °C
Table III: Pressure switch settings
50
46
42
38
34
30
26
22
18
14
10
6
2
-2
-6
-10
-14
-1 0
30RH - Operating limits
1
2
3
4
5
6
7
8
9 10 11 12 13 14
Leaving water temperature °C
Cooling cycle
Plate heat exchanger
Water entering temp. (at start-up)
Water leaving temp. (in operation)
Water entering temp. (at shut-down)
Coil
Air entering temperature
Minimum°C
7.8*
5**
-
Maximum°C
30
13
55
-10
46
Minimum°C
10
25
Minimum°C
-10
Maximum°C
45
50
55
Maximum°C
20
Operating range - 30RH units
Plate heat exchanger
Water entering temp. (at start-up)
Water leaving temp. (in operation)
Water entering temp. (at shut-down)
Coil
Air entering temperature
Contact Carrier if an entering water temperature lower than 7.8 °C is
necessary.
In case of operation with a leaving temperature of less than 5 °C, it is
necessary to add ethylene glycol to the water in circulation.
*
**
Outdoor air temperature °C
Heating cycle
50
46
42
38
34
30
26
22
18
14
10
6
2
-2
-6
-10
-14
-1 0
1
Minimum and maximum water flow rates in
the plate heat exchangers
2
3
4
5
6
7
8
9 10 11 12 13 14
Leaving water temperature °C
017
021
026
033
*
**
Minimum flow
rate, l/s
Maximum flow
rate, l/s*
Maximum flow
rate, l/s**
0,45
0,57
0,67
0,87
1,4
1,6
2,1
2,3
1,3
1,6
1,9
2,4
Maximum water flow rate with an available static pressure of 50 kPa (units
with hydronicmodule)
Maximum water flow rate at a plate heat exchanger pressure drop of
100 kPa (units without hydronic module)
Water circuit water content
Whatever the size of the system, the minimum content of the water
circuit is given by the following formula:
Volume = CAP(kW) x N = Litres
where CAP is the nominal system capacity (kW) at nominal
operating conditions of the installation.
Application
Air conditioning
Industrial process cooling
N
3.5
See note
This volume is necessary for stable operation and accurate
temperature control.
It is often necessary to add a buffer water tank to the circuit in order
to achieve the required volume.
GB - 12
Outdoor air temperature °C
30 RA RH
25
20
15
10
5
0
-5
-10
-15
20
25
30
35
40
45
50
55
Leaving water temperature °C
Notes:
1. The temperature rise of the water through the plate heat exchanger = 5K.
2. Both the plate exchanger and the circuit inside the hydronic module
are protected against frost down to a temperature of -10°C.
Operating range with anti-freeze solution and with special
configuration of the Pro-Dialog control system.
30RA/30RH
General maintenance, maintenance and final recommendations E N G L I S H
General maintenance
ATTENTION:
Before starting any servicing or maintenance operation on the unit,
make sure that the power supply has been disconnected.
A current discharge could cause personal injury.
In order to obtain maximum performance from the unit special
attention should be paid to the following points.
- Electrical connections:
The supply voltage should be within the limits indicated in Table II.
Ensure that no faulty contacts exist in the terminal blocks,
contactor boards, etc.
Make sure that all the electrical connections are properly
tightened, and that all the electrical components (contactors,
relays, etc) are firmly secured to the corresponding rails.
Pay special attention to the condition of the connecting cables
between the control elements and the electrical box, and to that of
the unit power supply cable.
They should not be twisted and there should be no slits or notches
in the insulation.
Check that the starting and running consumptions are within the
limits specified in Table II.
- Water connections:
Make sure there are no water leaks from the system.
Should the unit be shutdown for long periods, open the drain valve
installed on the hydronic module and partially drain the pump and
the water pipes as well as the drain valve on the plate-type
exchanger, which must be installed on the hydraulic circuit.
This operation is essential if temperatures are expected to drop
below freezing.
If the unit is not drained, the main switch should remain connected
so that the defrost thermostat can operate.
Carefully clean the system water filter.
- Plate heat exchanger cleaning:
In some applications, for example when very hard water is used,
there is an increased tendency for fouling.
In these cases the installation of a descaling filter is
recommended.
The heat exchanger can always be cleaned by circulating a
cleaning fluid.
A weak acid solution should be used (5% phosphoric acid or, if
frequently cleaned 5% oxalic acid), and the cleaning fluid should be
pumped through the exchanger.
The tank installation can be permanent or, alternatively, the
connections can be prepared and, at any given time, a portable
cleaning device can be connected.
To achieve optimum cleaning the acid solution should be circulated
at a minimum of 1.5 times the normal operational flow speed, and
preferably in reverse direction.
The installation should then be flushed with large amounts of water
to totally remove the acid before the system is started up.
Tank installation
Heat exchanger
Weak acid
solution tank
Cleaning should be done at regular intervals and should never be
left until the unit has become blocked.
The time intervals between cleaning depend on the quality of the
water used, but as a general rule it is advisable to clean it at least
once a year.
- Refrigerant circuit:
Ensure that there is no leakage of refrigerant or oil from the
compressor.
Check that the high and low side operating pressures are normal.
Check the cleanliness of the refrigerant-water heat exchangers by
checking the pressure drop across them.
- Controls:
Check the operation of all the electrical components, the high
pressurestat and of the high and low pressure transducers and
the water, air and defrost temperature detector.
Maintenance
Servicing recommendations
- Maintenance of the unit must be carried out by skilled personnel
only.
Nevertheless, the easiest operations, such as cleaning of the
battery and the unit external parts can be carried out by nonskilled personnel.
- For any operation on the unit follow thoroughly the instructions
shown in the manual and on the unit labels as well as the Safety
Standards.
Always wear the protective gloves and safety glasses. Pay
attention to burns when brazing.
- Use only Carrier Original Spare Parts when repair is required.
Always make sure the spare parts are installed correctly. Always
install the spare parts in the original position.
- Before replacing any of the elements in the cooling circuit, ensure
that the entire refrigerant charge is removed from both the high
and low pressure sides of the unit.
- The control elements of the cooling system are highly sensitive.
If they need to be replaced, care should be taken not to overheat
them with blowlamps whilst soldering.
A damp cloth should be wrapped around the component to be
soldered, and the flame directed away from the component body.
- Silver alloy soldering rods should always be used.
- If the total unit gas charge has to be replaced, the quantity should
be as given on the nameplate and the unit should be properly
evacuated beforehand.
- During unit operation all panels should be in place, including the
electrical box access panel.
- If it is necessary to cut the lines of the refrigerant circuit, tube
cutters should always be used and never tools which produce
burrs. All refrigerant circuit tubing should be of copper, specially
made for refrigeration purposes.
Final recommendations
The unit you have purchased has undergone strict quality control
procedures before leaving the factory.
All components, including the control systems and electrical
equipment, etc., are certified by our Quality Control Department,
and tested under the harshest possible operating conditions in our
laboratories. However, after leaving the factory, it is possible that
one or more of these elements may be damaged due to causes
beyond our control. In such an event, the user should not work
on any of the internal components, or subject the unit to
operating conditions which are not specified in this manual,
since serious damage may result and the guarantee would be
invalidated. Repair and maintenance work should always be left to
the installer.
All recommendations concerning unit installation are intended as a
guideline. The installer should carry out the installation according to
the design conditions and should comply with all applicable
regulations for air conditioning and refrigeration installations.
NOTE:
The manufacturer does not accept responsibility for any
malfunctions resulting from misuse of the equipment.
GB - 13
30RA/30RH
Troubleshooting
A list of possible faults, as well as the probable cause and
suggested solutions is shown as follows. In the event of a unit
malfunction it is recommended to disconnect the power supply and
ascertain the cause.
Symptoms
Cause
REMEDY
Unit does not start:
- No power supply;
CONNECT POWER SUPPLY.
- Main switch open;
CLOSE SWITCH.
- Low line voltage;
CHECK VOLTAGE AND REMEDY THE DEFICIENCY.
- A protection has tripped;
RESET.
- Contactor stuck open;
CHECK AND IF NECESSARY REPLACE CONTACTOR.
- Seized compressor;
CHECK AND IF NECESSARY REPLACE COMPRESSOR.
- Loose electrical connections;
CHECK CONNECTIONS.
Unit runs continuously or starts and stops frequently:
- Defective compressor contactor;
- CHECK AND IF NECESSARY REPLACE CONTACTOR.
- Defective compressor;
CHECK AND IF NECESSARY REPLACE COMPRESSOR.
- Refrigerant losses;
CHECK AND ADD THE NECESSARY QUANTITY.
- Total water flow too low
CHECK FOR PRESSURE DROP IN THE HYDRAULIC CIRCUIT.
- Static pressure in the hydraulic circuit too low;
CHECK IT ON THE PRESSURE GAUGE AND RESTORE IT IF NECESSARY.
Unit continuously cuts out at low pressure:
- Refrigerant losses;
CHECK AND ADD THE NECESSARY QUANTITY.
- Low water flow in the exchanger;
CHECK WATER PUMP.
- Unit start-up delay;
WAIT UNTIL THE SYSTEM HAS STABILISED.
Unit continuously cuts out at high pressure:
- Defective high pressurestat;
CHECK AND IF NECESSARY REPLACE PRESSURESTAT.
- Blocked expansion valve;
CHECK AND REPLACE IF NECESSARY.
- Blocked filter drier;
CHECK AND IF NECESSARY REPLACE FILTER.
- The outdoor fan/s does/do not work;
CHECK THE CONDITION OF THE FAN MOTOR/S AND ITS/THEIR ELECTRICAL
CONNECTIONS.
- Obstructed or dirty battery;
REMOVE THE OBSTRUCTION OR CLEAN THE BATTERY.
Abnormal system noise:
- Piping vibration;
SUPPORT PIPING.
- Noisy compressor;
CHECK AND CHANGE IF NECESSARY.
- Hissing expansion valve;
CHECK AND ADD REFRIGERANT IF NECESSARY.
GB - 14
- Badly fitting panels;
INSTALL CORRECTLY.
Compressor loses oil:
- Leaking refrigeration circuit;
REPAIR LEAK.
Water loss:
- Defective entering or leaving connections;
CHECK AND TIGHTEN IF NECESSARY.
The unit does not defrost
(only for 30RH units):
- Four-way reversing valve faulty;
CHECK AND REPLACE THE VALVE IF NECESSARY.
- Defrost sensor broken;
CHECK AND REPLACE THE SENSOR IF NECESSARY.
L010126H27 - 0405
Via R. Sanzio, 9 - 20058 Villasanta (MI) Italy - Tel. 039/3636.1
The manufacturer reserves the right to change any product specifications without notice.
Order No. 13024-74 April 2005. Supersedes Order No. 13024-74, June 2004.
Printed in Italy