Carrier PRO-DIALOG Plus 30GK Series Operating instructions

30GH 040-245
30GZ 040-245
Air-cooled liquid chillers
50 Hz
Carrier is participating in
the Eurovent Certification
Programme. Products are
as listed in the Eurovent
Directory of Certified
Products.
Installation, operation and maintenance instructions
1
CONTENTS
Page
Start-up checklist .......................................................................................................................................................................... 3
Dimensions/clearances ................................................................................................................................................................. 4
Technical/electrical data .............................................................................................................................................................. 6
Application data ............................................................................................................................................................................ 7
Maximum cooler water flow rates .................................................................................................................................................. 7
Water loop volume ......................................................................................................................................................................... 7
Installation ..................................................................................................................................................................................... 7
Safety considerations ...................................................................................................................................................................... 7
Preliminary checks ......................................................................................................................................................................... 8
Moving and siting the unit .............................................................................................................................................................. 8
Check compressor mountings ......................................................................................................................................................... 8
Water connections ........................................................................................................................................................................ 9
Power supply ............................................................................................................................................................................... 10
Electrical checks ........................................................................................................................................................................... 10
Start-up ........................................................................................................................................................................................ 10
Preliminary checks ....................................................................................................................................................................... 10
Actual start-up .............................................................................................................................................................................. 10
Servicing refrigeration components .......................................................................................................................................... 11
General maintenance .................................................................................................................................................................... 11
Liquid refrigerant charging ........................................................................................................................................................... 11
Compressors ................................................................................................................................................................................. 12
Compressor protection circuit board (STARTERGUARD) ......................................................................................................... 12
Heat exchangers ............................................................................................................................................................................ 13
Condenser coil .............................................................................................................................................................................. 14
Fan motor replacement ................................................................................................................................................................. 15
Fan motor protection .................................................................................................................................................................... 15
Refrigerant circuit ......................................................................................................................................................................... 15
Troubleshooting chart ................................................................................................................................................................ 16
The photo on the front cover is only for illustration purposes and not contractually binding (photo shows unit with optional
compressor sound enclosure).
The manufacturer reserves the right to make modifications at any time without prior notice.
2
START-UP CHECK LIST
Start-up date:
Equipment sold by:
Contract No.:
Installed by:
Contract No.:
Site address:
Equipment type and serial numbers: 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 calibration
A
Main circuit breaker rating:
A
Physical data:
Condenser:
Cooler:
Entering air temperature:
°C
Entering water temperature:
°C
Leaving air temperature:
°C
Leaving water temperature:
°C
Pressure drop (air):
kPa
Discharge air pressure:
Pressure drop (water):
Pa
Fan speed:
r/s or rpm
Fan motor input:
Ph. 1
V
Ph. 2
V
Ph. 3
V
Ph. 1
V
Ph. 2
V
Ph. 3
V
Ph. 1
V
Ph. 2
V
Ph. 3
V
Ph. 1
V
Ph. 2
V
Ph. 3
V
Safety device setting:
High pressure switch:
kPa
°C
cut-out
kPa
cut-in
kPa
Low-pressure protection: cut-out
kPa
cut-in
kPa
Defrost protection:
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):
Name
Date
Remarks:
NOTE: Please fill in this sheet during the installation
3
Legend:
Dimensions/clearances (mm)
30GH/GZ
A
B
C
D
E
F
G
040-045
2450
1870
1912
2500
1200
500
1200
050-060
2900
2156
2060
2500
1200
500
1200
085-100
3404
2328
2471
1600
1800
1600
1800
120-145
4322
2328
2471
1600
1800
1600
1800
150-170
6229
2328
2471
1600
1800
1600
1800
190-220
7147
2328
2471
1600
1800
1600
1800
245
8983
2328
2471
1600
1800
1600
1800
Space required for clearance
Power supply
Water inlet
Water outlet
NOTE :
Dimensional drawings are available on request.
30GH/GZ 040-060
30GH/GZ 085-145
Do not obstruct
C
C
Do not obstruct
A
F
E
F
E
A
B
B
D
4
G
G
D
30GH/GZ 150-245
Do not obstruct
Do not obstruct
C
For 30GH/GZ 170-245
only
ATTENTION:
30GH/GZ 170- 245
have two power
connection points.
A
G
B
E
F
D
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.
At least two sides of the units must be free from obstructions, to ensure proper air flow.
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
Physical data
30GH/GZ
040
045
050
060
085
095
100
120
130
145
150
160
170
190
220
245
Net nominal cooling capacity*
30GH (R-22)
30GZ (R-407C)
kW 107
kW 102
124
118
156
150
190
181
255
244
300
287
344
329
396
379
442
417
457
437
498
476
516
499
562
538
631
603
729
697
808
773
Operating weight
kg 1380
1445
1710
1780
3012
3067
3439
3884
4330
4452
5010
5172
5592
6442
6742
7992
Refrigerant charge R-22
Circuit A
Circuit B
kg 15
kg 15
15
15
17.2
17.2
19.5
19.5
33.2
19
34.2
23.7
29.4
29.4
37
37
48.4
32.3
46.5
35.1
53.1
38.9
59.8
47.4
59.8
49.3
60
57
60
60
67.4
67.4
Refrigerant charge R-407C
Circuit A
Circuit B
kg 16.5
kg 16.5
16.5
16.5
19
19
21.5
21.5
24
15
34
24
28
28
36
36
47
32
46
35
53
38.5
59
46
59
48
59
56
59
59
66
66
Compressors
Circuit A
Circuit B
Semihermetic, 4 or 6 cylinders 24.2 r/s (1450 rpm)
1
1
1
1
2
2
2
1
1
1
1
1
1
2
2
2
3
2
3
2
3
2
3
2
3
3
4
3
4
4
4
4
Control type
No. of capacity stages
Minimum capacity
PRO-DIALOG control
4
4
4
4
25
33
33
33
4
25
5
17
5
17
5
20
5
20
6
14
7
12
8
10
8
12.5
154
199
242
199
242
242
242
242
242
%
Evaporator
Net water volume
l
Water connections
Inlet/outlet
Drain (NPT)
in
Max. water side operating pressure kPa
Condenser
Fans
Quanitity
Total air flow
Speed
6
20
6
22
4
22
Direct-expansion, multi-tube shell, two circuits
55
55
63
63
92
92
154
Flat flanges PN 16, in accordance with NFE 29 203
DN80 DN80 DN80 DN80 DN100 DN100 DN125
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1000 1000 1000 1000 1000 1000 1000
Copper tubes and aluminium fins
DN125 DN150 DN150 DN150 DN150 DN150 DN150 DN150 DN150
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1/2
1000 1000 1000 1000 1000 1000 1000 1000 1000
Shrouded axial FLYING-BIRD fan
2
2
4
4
6
6
6
8
8
8
10
10
10
12
12
16
l/s 9944 9944 19890 19890 29830 29830 29830 39780 39780 39780 49720 49720 49720 59670 59670 79560
r/s 12.5 12.5 12.5 12.5 12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
12.5
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C and 7°C. Condenser entering air temperature 35°C.
Net cooling capacity = gross cooling capacity minus the water pump heat against the internal evaporator pressure drop.
Electrical data
30GH/GZ
040
045
050
060
085
095
100
V-ph-Hz 230-1-50
W
570 570
570
570
980
980
1160 1160 1460 1460 1460 1460 1640 1820 2000 2000
kW
kW
70
64
95
87
117
110
142
134
162
152
189
174
209
192
209
202
237
228
237
225
257
241
304
282
349
328
379
358
Max. unit power input with separate supply (possibible on 30G 170-245)
30GH circuit A
kW
30GH circuit B
kW
30GZ circuit A
kW
30GZ circuit B
kW
-
-
-
-
-
-
-
-
-
-
142
115
141
100
175
129
165
117
175
175
164
164
190
190
179
179
Fan power supply
Fan power input
V-ph-Hz 400-3-50
kW
2.3 2.3
4.6
4.6
7
7
7
9
9
9
12
12
12
14
14
19
Max. starting current (comp. + fans)
30GH/GZ standard unit
30GH/GZ with part-winding start
30GH/GZ with separate power supply circuit A**
30GH/GZ with separate power supply circuit B**
A
A
A
A
144
std
-
186
std
-
219
std
-
296
std
-
476
338
-
518
380
-
553
415
-
601
463
-
636
498
-
636
498
-
684
546
-
684
546
-
719
581
517
469
802
664
574
497
879
741
574
574
934
796
601
601
Max. unit current drawn (comp. + fans)*
30GH
30GZ
30GH with separate power supply circuit A**
30GH with separate power supply circuit B**
30GZ with separate power supply circuit A**
30GZ with separate power supply circuit B**
A
A
A
A
A
A
78
72
-
102
97
-
120
113
-
166
153
-
204
194
-
250
236
-
280
268
-
333
306
-
364
338
-
364
356
-
416
401
-
416
396
-
447
424
250
197
248
176
530
496
304
229
290
206
608
577
304
304
289
289
666
630
333
333
315
315
Power wiring
Nominal power supply
Voltage range
V-ph-Hz 400-3-50
V
360-440
Auxiliary circuit (heaters)
Power input
Max. unit power input (comp. + fans)**
30GH
30GZ
45
41
59
55
120
130
145
150
160
170
190
220
245
* Compressor and fan, at maximum unit operating values
** Unit sizes 30GZ 170-245 have a separate power supply per circuit. All currents are given at nominal voltage
Electrical data notes (cont.)
•
30GZ units have a single power connection point (except 30GZ 170-245 which have two connection
points).
•
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 local codes.
•
The Carrier 30GZ chillers are designed and built to ensure conformance with these 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.
NOTES:
•
Generally the recommendations of IEC 364 are accepted as compliance with the requirements of the
installation directives. Conformance with EN 60 204 is the best means of ensuring compliance with
the Machines Directive § 1.5.1.
6
•
1.
•
•
2.
3.
4.
5.
Annex B of EN 60204-1 describes the electrical characteristics used for the operation of the
machines.
The operating environment for the 30GZ chillers is specified below:
Environment* - Environment as classified in EN 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)
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 optional 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.
* The required protection level for this class is IP43BW (according to reference document IEC 529). All
30GZ units are protected to IP44CW and fulfill this protection condition.
APPLICATION DATA
INSTALLATION
Minimum cooler water flow rates
30GH/GZ
Min flow rate, l/s
040-045
050-060
085-095
100-120
130
145
150
160-245
3.6
4.0
6.0
8.5
9.8
12.1
9.8
12.1
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.
Maximum chilled water flow rate
The maximum chilled water flow is limited by the maximum
permitted pressure drop in the evaporator. It must have a
minimum temperature difference at the evaporator of 2.8 K,
corresponding to a flow rate of 0,9 l/s per kW.
When working on the equipment, observe precautions in the
literature, and on tags, stickers, and labels attached to the
equipment.
•
•
•
Water loop volume
Whatever the size of the system, the water loop minimum
volume is given by the following formula:
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.
Volume = CAP (kW) x N* = litres
where CAP is the nominal system capacity (kW) at the nominal
operating conditions of the installation.
Application
N
Air conditioning
Industrial process cooling
Low temperature operation
3.25
6.5
6.5
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.
This volume is necessary for stable operation and accurate
temperature control.
It is often necessary to add a buffer water reservoir to the
circuit in order to achieve the required volume. The reservoir
must itself be internally baffled in order to ensure proper
mixing of the liquid (water or brine). Refer to the examples
below.
NOTE: The compressor must not restart more than 6 times in
an hour.
Bad
Good
Bad
Good
7
Preliminary checks
Check compressor mountings
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.
Before the first start-up of the unit proceed as follows:
Moving and siting the unit
Moving
Do not remove skids, pallets or protective packaging until the
unit is in its final position. Move the chiller using tubes or
rollers, or lift it, using slings of the correct capacity.
All compressors are mounted on anti-vibration mountings. For
the 30GH/GZ 040-060 units, please do not loosen the bolts or
fixing screws.
For 30GH/GZ 085-245 units
The compressors are mounted on anti-vibration mountings. For
shipping purposes these are packed solid with wedges, angle
pieces and retaining bolts. These must be removed, when the
installation is completed to allow the vibration absorbing
mountings to do their job (see figure below).
Cross section of anti-vibration mounting
(30GH/GZ 085-100)
CAUTION: Only use slings at the designated lifting points
which are marked on the unit.
Siting
Before siting the unit check that :
•
•
•
•
•
•
the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
the surface is horizontal, flat and intact.
there is adequate space around the unit to make power and
water connections for service and air flow.
there are adequate support points and that they are in the
right places.
the location is not subject to flooding.
where heavy snowfall is likely and long periods of subzero temperatures are normal, provision has been made to
prevent snow accumulating by raising the unit above the
height of drifts normally experienced.
Baffles may be necessary to deflect strong winds and to
prevent snow from blowing directly into the unit. They
must not restrict air flow into the unit.
CAUTION: Before lifting the unit, check that all casing panels
are securely fixed in place. Lift and set down the unit with
great care. Tilting and jarring can damage the unit and impair
unit operation.
The 30GH/GZ units can be hoisted with rigging. Coils should
always be protected against crushing while a unit is being
moved. Use struts or spreader bars to spread the slings above
the unit. Do not tilt a unit more than 15°.
WARNING: Never push or lever on any of the enclosure panels
of the unit. Only the base of the unit frame is designed to
withstand such stresses.
8
Anti-vibration mountings
Wedge and angle-piece
Water connections
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.
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.
Water-loop connections
Make the water-side heat exchanger connections, using
appropriate hardware capable of ensuring water-tightness of
threaded unions.
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 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.
Typical hydraulic circuit diagram
Air vent
Control valve
Flow switch
Heat exchanger
Flexible connection
Buffer tank
Fill valve
Filter
Expansion tank
Drain
Pressure tap
Thermostat sleeve
9
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.
ATTENTION: Units 30GH/GZ 040-160 have only one power
connection point.
Units 30GH/GZ 170-245 have two power connection points.
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 5°C for R-407C and 4°C for R-22 are likely, add the
appropriate volume of ethylene glycol to prevent freezing.
Confirm that the suction and discharge line stop valves are
fully opened.
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
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.
a.
b.
c.
d.
e.
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 firmly in place, and
check the secure positioning of all control sensors.
Confirm that all crankcase heaters are working by feeling all
compressor crankcases. Every compressor has a 180 W
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).
10
Open the refrigerant line valves. Check again that the water
circuit valves are open.
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 discharge muffler securing bands and discharge
line connections are tight.
Check that all electrical connections are secure.
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.
1.
2.
3.
Ensure that the crankcase heaters have been energized for
24 hours before starting up the unit for the first time.
Start up the unit.
Check that all safety devices are satisfied, paticularly the
high pressure switches.
For this purpose:
Stop the condenser fans.
Operate the machine until the high pressure switch
trips and verify that the pressure does not exceed the
cut-out value of 2900 kPa.
Using the control point as a reference, verify the
correct operation of the unit.
SERVICING REFRIGERATION COMPONENTS
Any technician attending the machine for any purpose must be
a fully 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 three-phase
power supply is within acceptable limits.
Lubricate the hinges, locks and latches on the electrical control
box doors sparingly.
Liquid refrigerant charging
Checking the charge
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/GZ units are shipped with a full normal charge of
refrigerant. Refer to the Physical Data table. Ensure that there
are bubbles visible in the sight glass are not due to an excessive
pressure drop in the liquid line piping. If it is 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. Ensure that the humidity is maintained at the
correct level.
WARNING: To ensure proper operation of 30GH/GZ units
there must be at least 7 K (30GH) or 12 K (30GZ) of
subcooling as the liquid refrigerant enters the expansion valve.
The units 30GH/GZ 040-245 use refrigerant. For your
information, we are reproducing here some extracts from the
official publication dealing with the design, installation,
operation and maintenance of air conditioning and refrigeration systems and the training of people involved in these
activities, agreed by the air conditioning and refrigeration
industry.
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.
Recharging liquid refrigerant
CAUTION: 30GZ 040-245 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 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.
11
•
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 compressor
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 DGT
(only for 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
Each compressor is fitted with an electric resistance crankcase
heater which prevents any 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. Regularly check that the heater operates correctly
when the unit is shut down.
WARNING: Never open or disconnect any switch or circuit
breaker 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.
Compressor protection circuit board (STARTERGUARD)
CAUTION: R-22 oils are NOT compatible with R-407C.
Recommended oil:
R-22 compressors:
Mineral oil, Carrier specification No. PP 33-2
Suniso 3 GS (Sun Oil Co)
Capella WF 32-150
Clavus G 32 (Shell Oil Co)
Gargoyle Artic (Mobil Oil) - original charge
R-407C compressors:
-
Oil, Carrier specification No. PP 47-26
Mobiloil EAL 68 - Carrier reference 470EE as original
charge, in 5 liter containers
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.
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
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.
•
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
Tightening torques to be applied
If a fault is detected, the compressor is shut down.
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
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.
Circuit breaker
Calibrated, thermo-magnetic, manually reset circuit breaker to
protect the motor against locked rotors and excessive current
draw. It also protects against overcurrents up to the trip
capacity indicated on the wiring diagram.
Heat exchangers
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.
Freeze-up prevention thermostat
The evaporator is protected against freeze-up. The protection is
provided by two sensors installed in the unit.
12
Evaporator
Protection devices
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.
Replacing cooler tubes
Retubing must be done only by a properly trained service
engineer. Most standard practices can be applied, but for cooler
tubes a 5% crush allowance is made for tube expansion and
twisting (15.87 mm diameter tubes are used in these coolers).
The table below gives the specification of the materials used.
Example:
Multitube evaporators
The evaporator can be removed using the following procedure:
•
Close the chilled water supply and return valves (if
installed), and disconnect the chilled water supply and
return pipe connections.
•
Drain the water from the cooler.
•
Remove all temperature sensors from the cooler.
•
Fold back the insulation at the refrigerant line
connections.
When the evaporator heads and manifolds are removed, the
outer tube end plates will be visible.
Four evaporator tubes on 30GH/GZ 040-060 units and six
tubes on 30GH/GZ 085-245 units are swaged into the end plate
and cannot be removed. A dot punch mark in the end plate
opposite each one identifies each of them. If any of them
develop a leak, the tube must be plugged, as described below.
Plugging evaporator tubes
A leaking tube can be plugged pending replacement. The
number of tubes plugged will determine when they should be
replaced. Check with Carrier the effect upon chiller performance
of plugging a number of tubes. Carrier will need to know the
number of tubes to be plugged and their positions. The figure
below shows the Elliott method of plugging tubes.
WARNING: Take care when inserting plugs not to damage the
plate material between the tubes. Avoid excessive force. Clean
all components with Locquic N and then coat all surfaces with
several drops of Loctite 75 to ensure a good seal without
applying excessive force.
Tube sheet hole diameter
Tube outside diameter
Clearance
Tube inside diameter before rolling
Tube inside diameter after rolling
16.00 mm
15.87 mm
0.13 mm
14.27 mm
14.48 mm
NOTE: Tubes next to the gasket webs must be flush with the
tube sheets at either end of the cooler.
Preparation of gaskets
When rebuilding the cooler, new gaskets must always be used.
They must conform to the Carrier specification for compressed
gaskets.
•
Clean the gasket and its place on the tube sheet.
•
Cover the two matching surfaces (gasket and tube sheet)
with adhesive, and stick them together.
•
Let the joint dry for 5 minutes.
•
Moisten the joint with a small amount of compressor oil.
•
Reinstall the evaporator head within 30 minutes.
Tightening cooler head bolts
Cooler head bolts must be tightened in the specified sequence
and to the correct torque.
Use this tightening sequence:
•
Hand tighten the first four bolts as shown below in stage 1.
•
Hand tighten the next bolts as shown below in stage 2.
•
Starting at the 12 o'clock position, and working clockwise,
insert and hand tighten the remaining outer bolts.
•
Insert and tighten the six screws in the center of the head.
Elliott tube plug
Bolt size M12 - 71-87 Nm
Bolt size M16 - 171-210 Nm
Bolt size M20 - 171-210 Nm
Tube plate
Stage 1
Stage 2
7
1
5
Plug
4
3
Ring
6
2
8
Components
Part number
Tube brass plug
Tube brass ring
---T-853--103500S-*
---T-853--002570S-*
Brass plug (holes without tubes)
Brass ring (holes without tubes)
---T-853--1031—S-*
---T-853--002631S-*
Loctite
Locquic
No. 75*
“N”*
•
•
•
* Order directly from your Carrier distributor
•
Starting again at 12 o’clock and working clockwise tighten
the outer bolts to the correct torque.
Not less than one hour later insert and tighten the six bolts
in the centre of the head, using the torque values given.
After the cooler has been refilled with clean refrigerant,
use a soap and water solution or an electronic detector to
confirm that there are no leaks.
Replace the evaporator insulation and temperature sensors.
13
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.
Installation is in the reverse order. Take care not to damage the
plastic components when installing the fan and position the fan
to maintain a clearance of 117 + 0/-2 mm between the upper
edge of the fan and the upper edge of the volute.
CAUTION: On unit sizes 30GH/GZ 040-245 the fan rotation is
counter clockwise, viewed from above.
30GH/GZ 040-245 fan
117 +0/-2
We recommend TOTALINE products for coil cleaning:
Part No. P902 DT 05EE: traditional cleaning method
Part No. P902 CL 05EE: cleaning and degreasing.
Maximum
clearance
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.
Fan motor protection
All units are equipped with a fan protection circuit breaker.
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.
Refrigerant circuit
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.
Fan motor replacement
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.
14
Thermal expansion valve (TXV)
The function of the thermal expansion valve is to control the
flow of liquid refrigerant. The valve is controlled by a sensor
bulb in the compressor suction line. It is factory set to maintain
refrigerant superheat of 4 K.
This setting should not be changed unless absolutely necessary.
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.
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 high
pressure side of the system.
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
Defective compressor contactor
Replace contactor
Defective compressor
Check valves, replace compressor
Refrigerant losses
Check and add the necessary charge
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
Piping vibrations
Support piping, check supports and
tightness
Noisy compressor
Check valve plate, change if necessary
Badly fitting panels
Install correctly
Compressor loses oil
Leak in the system
Repair leak
Water losses
Defective inlet or outlet connections
Check and tighten if necessary
Unit operates continually or
starts and stops frequently
Compressor continually cuts out
at low pressure or via the DGT
Compressor continually cuts out
at high pressure
Noises in the system
15
Order No. 13187-76, September 1997. Supersedes order No.: 13187-76, July 1996
Manufacturer reserves the right to change any product specifications without notice.
16
Printed on Totally Chlorine-Free Paper.
Printed in the Netherlands
Manufactured by: Carrier SA, Montluel, France