Specifications | Carrier 30MPA Refrigerator User Manual

AQUASNAP®
30MPA,MPW015-045
Liquid Chillers
with Scroll Compressors
and COMFORTLINK™ Controls
Installation Instructions
CONTENTS
Page
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1,2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 1 — Inspect Shipment . . . . . . . . . . . . . . . . . . . . 2
Step 2 — Position the Unit . . . . . . . . . . . . . . . . . . . . . 2
Step 3 — Place the Unit. . . . . . . . . . . . . . . . . . . . . . . . 7
Step 4 — Check Compressor Mounting . . . . . . . . 7
Step 5 — Make Piping Connections. . . . . . . . . . . . 7
• 30MPA SYSTEM CONDENSER
• 30MPW CONDENSER DESCRIPTION
• 30MPW CONDENSER
• EVAPORATOR DESCRIPTION
• EVAPORATOR PIPING
• AIR SEPARATION
Step 6 — Fill the Chilled Water Loop. . . . . . . . . . .13
• WATER SYSTEM CLEANING
• FILLING THE SYSTEM
Step 7 — Make Electrical Connections. . . . . . . . .14
• FLOW SWITCH
• CONTROL BOX, POWER SECTION
• CONTROL BOX, CONTROLS SECTION
• CONTROL BOX, FIELD CONTROL WIRING
SECTION
• UNBALANCED 3-PHASE SUPPLY VOLTAGE
.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation. There
may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work
is completed.
a30-5029
GENERAL
Fig. 1 — 30MPA Unit
These installation instructions cover the 30MPA, MPW units
with ComfortLink controls. The 30MPA units are condenserless
units and the 30MPW units are all fluid cooled.
SAFETY CONSIDERATIONS
Installing, starting up, and servicing this equipment (Fig. 1
and 2) can be hazardous due to system pressures, electrical
components, and equipment location (roofs, elevated structures, etc.). Model number structure is shown in Fig. 3.
Only trained, qualified installers and service technicians
should install, start up, and service this equipment.
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 bulky
equipment.
a30-5030
Fig. 2 — 30MPW Unit
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300054-01
Printed in U.S.A.
Form 30MP-1SI
Pg 1
910
1-10
Replaces: New
30MP A 030 6 0 -
0
0 0
0
5
Packaging Options
5 – Bag
B – Export Crate
30MP – Aquasnap® Liquid Chiller with ComfortLink™ Controls
Condenser Option
A – Chiller without Condenser (Air-Cooled)
W – Chiller with Condenser (Water-Cooled)
Controls/Interface Options
0 – Scrolling Marquee Display (Std)
5 – Scrolling Marquee Display, EMM
Unit Size – Nominal Tons (kW)
015 – 15 (54)
040 – 40 (138)
020 – 20 (71)
045 – 45 (161)
030 – 30 (108)
Disconnect Options
0 – Standard (Terminal Block)
1 – Non-Fused Disconnect Switch
Voltage Options
1 – 575-3-60
2 – 380-3-60
5 – 208/230-3-60
6 – 460-3-60
Capacity Control Options
0 – Standard
1 – Hot Gas Bypass
Comfort Cooling/Medium Temp Brine Options
0 – Comfort Cooling Duty (32-60 F) (Std)
7 – Medium Temperature Brine (15-32 F)
Sound/Mounting Options
0 – None
1 – Sound Enclosure Panels
3 – Height Adjustment Kit
4 – Height Adjustment Kit, Sound Enclosure Panels
9 – Mobility Kit (Wheels)
B – Mobility Kit (Wheels), Sound Enclosure Panels
D – Height Adjustment Kit, Mobility Kit (Wheels)
F – Height Adjustment Kit, Mobility Kit (Wheels), Sound Enclosure Panels
Design Revision Level
- – Initial Release
a30-5038
LEGEND
EMM — Energy Management Module
LON — Local Operating Network
UPC — Unitary Protocol Controller
Fig. 3 — 30MP Model Number Nomenclature
Additional weight of factory-installed sound enclosure option is 75 lb (34 kg).
INSTALLATION
Location — Do not store units in an area exposed to weather because of sensitive control mechanisms and electronic
devices. Locate unit indoors. See Fig. 4 and 5 for unit dimensional details.
When considering location, consult National Electrical
Code (NEC) and local code requirements. Allow sufficient
space for wiring, piping, and service. Install unit in an area
where it will not be exposed to ambient temperatures below
50 F (10 C).
Allow 36 in. (914 mm) in front of the unit for control box
access door. Additional clearance may be required per local
codes. Prior to installation determine which direction compressor will be removed, and leave 3 to 4 ft (914 to 1219 mm)
clearance for removal.
On all units leave 3 ft (0.9 m) of clearance behind the unit to
make water/brine connections to the evaporator, accessing the
TXV (thermostatic expansion valve), fluid thermistors, and
proof of flow switch.
On all units, leave 2 ft (610 mm) on one side for making refrigeration connections (30MPA) or fluid connections
(30MPW) to condenser. See Fig. 4 and 5.
The floor must be strong enough to support the unit operating weight (see Tables 1A and 1B and Fig. 4-6). If necessary,
add a supporting structure (steel beams or reinforced concrete
slabs) to the floor to transfer weight to nearest beams.
CAUTION
Be sure interconnecting piping and electrical conduits
are suspended freely, and are not in contact with any
adjacent walls. Be sure unit capillaries are not rubbing
against anything. Damage to unit or walls may result.
Step 1 — Inspect Shipment — Inspect unit for damage or missing parts. If damaged, or if shipment is incomplete,
file a claim immediately with the shipping company.
CAUTION
Unit is top heavy. Unit may tip if handled without care.
Damage to unit or injury may result.
Step 2 — Position the Unit — The unit may be
moved by means of rollers under the rails or a forklift truck.
If accessory mobility kit is to be used, install this accessory
after bringing unit into building and before moving the unit to
its final location per installation instructions provided with the
accessory. The factory-installed mobility kit option consists of
4 swivel-type wheels that are field-mounted to the legs of the
unit. See Fig. 7.
NOTE: The wheels are equipped with a thumb-screw brake.
2
934 (424 kg)
30MPA045
3
D
25.90
(658 mm)
26.00
(660 mm)
17.50
(445 mm)
17.40
(442 mm)
5.99
(152 mm)
5.87
(149 mm)
LIQ. LINE
SOLENOID
VALVE
33.49
(851 mm)
33.50
(851 mm)
D
5.54
(141 mm)
OPPOSITE CONTROL PANEL END
OUT
COOLER
IN
26.00
(660 mm)
17.00
(432 mm)
30.69
(780 mm)
31.39
(797 mm)
25.20
(640 mm)
C
17.60
(447 mm)
B
31.49
(800 mm)
A
17.80
25.10
(452 mm) (638 mm)
17.72
(450 mm)
17.95
(456 mm)
18.50
(470 mm)
F
P,T
ACCESS
PORTS
1/4" FPT
ACCESS
3
2
1/4" SAE
FLARE RELIEF
CONNECTION
OUT
STD UNIT 55.00
[1397 ]
52.30
[1328 ]
MOUNTING HOLES 9/16"
OPTIONAL SOUND ENCLOSURE 57.00 [1448]
-
FORK POCKETS
COOLER
B
Fig. 4 — Dimensions — 30MPA015-045 Units
1.75
[44 ]
IN
OPTIONAL SOUND ENCLOSURE 48.42 [1230]
COMPRESSOR
(SEE TABLE FOR QTY)
NO.OF
COMPRESSORS
WATER CONNECTIONS
(IN/OUT)
2" VICTAULIC (015-020)
2 1/2" VICTAULIC (030-045)
11.00
(279 mm)
11.12
(282 mm)
6.44
(164 mm)
E
NOTES:
1. Operating weight includes weight of water and refrigerant.
2. Denotes center of gravity.
3. Dimensions are shown in inches. Dimensions in [ ] are in
millimeters.
4. Allow 36-in. (914 mm) clearance on control panel end, opposite
control panel end and above the unit. All clearances must be in
accordance with local codes.
5.
Denotes accessory or factory-installed option.
C
E
913 (414 kg)
30MPA040
F
722 (327 kg)
30MPA030
OPTIONAL
SOUND
ENCLOSURE
65.05
[1652]
626 (284 kg)
635 (288 kg)
30MPA015
30MPA020
OPERATING
WEIGHT (lb)
UNIT
3.85
[98 ]
MOBILITY KIT
(WHEEL) OPTIONAL
LIQ. LINE
ISOLATION VALVE
REMOTE CONDENSER
CONNECTION
ENSURE CLEARANCE
PER LOCAL CODES
CONTROL PANEL
END OF UNIT
CONTROL BOX
ACCESS DOOR
CLEARANCE
36"(914)
NON-FUSED
DISCONNECT
(OPTIONAL)
OPTIONAL SOUND
ENCLOSURE
040,045 TON
ONLY
POWER
ENTRY
FIELD CONNECTION
(4) 7/8" K.O
4.03
[102 ]
-
A
CONTROL PANEL END
STD UNIT 32.00
[813 ]
29.13
[740 ]
MOUNTING HOLES 9/16"
COOLER
OPTIONAL SOUND ENCLOSURE 32.12 [816]
4.00 [102]
ISOLATOR-OPTIONAL
62.50
[1588 ]
SCROLLING
MARQUEE DISPLAY
4.46
[113]
a30-5032
910
4
Fig. 5 — Dimensions — 30MPW015-045 Units
NOTES:
1. Operating weight includes weight of water and refrigerant.
2. Denotes center of gravity.
3. Dimensions are shown in inches. Dimensions in [ ] are in
millimeters.
4. Allow 36-in. (914 mm) clearance on control panel end, opposite
control panel end and above the unit. All clearances must be in
accordance with local codes.
5.
Denotes accessory or factory-installed option.
a30-5033
Table 1A — 30MPA Air-Cooled and 30MPW Liquid-Cooled Units — English
UNIT 30MPA,MPW
NOMINAL TONS
OPERATING WT (lb)
MPA
MPW
REFRIGERANT (lb)
MPA
MPW
COMPRESSOR
Quantity
Speed (rpm)
Compressor Nominal Tons
Oil Charge (pt)
Capacity Control — Standard
No. of Steps
Minimum Step Capacity (%)
Capacity Control — Optional Hot Gas Bypass
No. of Steps
Minimum Step Capacity (%)
EVAPORATOR
Weight (lb, empty)
Net Fluid Volume (gal.)
Maximum Refrigerant Pressure (psig)
Maximum Fluid-Side Pressure (psig)
Water Connections (in.)
Inlet and Outlet (Victualic)
Drain (NPT)
CONDENSER (30MPW Only)
Weight (lb, empty)
Net Fluid Volume (gal.)
Maximum Refrigerant Pressure (psig)
Maximum Fluid-Side Pressure (psig)
Water Connections (in.)
Inlet and Outlet (Victualic)
CHASSIS DIMENSIONS (in.)
Length
Width
Height
MINIMUM SYSTEM FLUID VOLUME (gal. per Ton)
Normal Air Conditioning
Standard
Optional Hot Gas Bypass
Low Outdoor Ambient Cooling Operation (30MPA Units)
Standard
Optional Hot Gas Bypass
CAPACITY STEPS
Step 1
Step 2
Step 3
Step 4
MINIMUM FLOW RATES (gpm)
Evaporator
Condenser
MAXIMUM FLOW RATES (gpm)
Evaporator
Condenser
015
15
020
20
030
30
040
40
045
45
626
680
635
704
913
1099
934
1190
—
11.6
—
15.2
—
29.4
—
34.4
2
3500
7.5
10.6
2
3500
10
13.8
722
862
R-410A
—
23.1
Scroll, Hermetic
2
3500
15
13.8
3
3500
13
20.6
3
3500
15
20.6
2
50
2
50
2
50
3
33
3
33
3
18
3
25
3
34
4
21
4
22
27.5
0.8
650
300
40.3
1.2
650
300
91.8
2.4
650
300
122.3
3.2
650
300
128.3
3.4
650
300
2
2 1 /2
1/
2
2 1 /2
1/
2
2 1 /2
1/
2
2
1/
1/
2
2
34.9
1.2
650
300
43.6
1.6
650
300
104.6
2.9
650
300
136.7
4.1
650
300
188.3
5.9
650
300
2
2
2 1 /2
2 1 /2
2 1 /2
55
32
63
55
32
63
55
32
63
55
32
63
55
32
63
6
4
6
4
6
4
4
3
4
3
10
7
10
7
10
7
8
6
8
6
100%
50%
18%*
—
100%
50%
25%*
—
100%
50%
34%*
—
100%
67%
33%
21%*
100%
67%
33%
22%*
22
22
28
28
43
43
55
55
64
64
74
74
97
97
148
148
188
188
220
220
* With optional hot gas bypass.
NOTES:
1. Operating weight includes refrigerant operating charge and
weight of fluid in the heat exchangers.
2. 30MPW units are shipped with full operating charge.
5
Table 1B — 30MPA Air-Cooled and 30MPW Liquid-Cooled Units — SI
UNIT 30MPA,MPW
NOMINAL KW
OPERATING WT (kg)
MPA
MPW
REFRIGERANT (kg)
MPA
MPW
COMPRESSOR
Quantity
Speed (r/s)
Compressor Nominal kW
Oil Charge (L)
Capacity Control — Standard
No. of Steps
Minimum Step Capacity (%)
Capacity Control — Optional Hot Gas Bypass
No. of Steps
Minimum Step Capacity (%)
EVAPORATOR
Weight (kg, empty)
Net Fluid Volume (L)
Maximum Refrigerant Pressure (kPa)
Maximum Fluid-Side Pressure (kPa)
Water Connections (in.)
Inlet and Outlet (Victualic)
Drain (NPT)
CONDENSER (30MPW)
Weight (kg, empty)
Net Fluid Volume (L)
Maximum Refrigerant Pressure (kPa)
Maximum Fluid-Side Pressure (kPa)
Water Connections (in.)
Inlet and Outlet (Victualic)
CHASSIS DIMENSIONS (mm)
Length
Width
Height
MINIMUM SYSTEM FLUID VOLUME (L per kW)
Normal Air Conditioning
Standard
Optional Hot Gas Bypass
Low Outdoor Ambient Cooling Operation (30MPA Units)
Standard
Optional Hot Gas Bypass
CAPACITY STEPS
Step 1
Step 2
Step 3
Step 4
MINIMUM FLOW RATES (L/s)
Evaporator
Condenser
MAXIMUM FLOW RATES (L/s)
Evaporator
Condenser
015
54
020
71
030
108
040
138
045
161
284
308
288
319
414
499
424
540
—
5.2
—
6.9
—
13.3
—
15.6
2
58
26
5.0
2
58
35
6.5
327
391
R-410A
—
10.5
Scroll, Hermetic
2
58
53
6.5
3
58
45
9.8
3
58
53
9.8
2
50
2
50
2
50
3
33
3
33
3
18
3
25
3
34
4
21
4
22
12.5
2.9
4482
2068
18.3
4.6
4482
2068
41.6
8.9
4482
2068
55.5
12.0
4482
2068
58.2
13.0
4482
2068
2
2 1 /2
1/
2
2 1 /2
1/
2
2 1 /2
1/
2
2
1/
1/
2
2
15.8
4.5
4482
2068
19.8
5.9
4482
2068
47.4
11.1
4482
2068
62.0
15.4
4482
2068
85.4
22.4
4482
2068
1 1 /2
1 1 /2
2
2
2
1397
813
1600
1397
813
1600
1397
813
1600
1397
813
1600
1397
813
1600
23
15
23
15
23
15
15
11
15
11
38
25
38
25
38
25
30
23
30
23
100%
50%
18%*
—
100%
50%
25%*
—
100%
50%
34%*
—
100%
67%
33%
21%*
100%
67%
33%
22%*
1.4
1.4
1.8
1.8
2.7
2.7
3.5
3.5
4.0
4.0
4.7
4.7
6.1
6.1
9.3
9.3
11.9
11.9
13.9
13.9
* With optional hot gas bypass.
NOTES:
1. Operating weight includes refrigerant operating charge and
weight of fluid in the heat exchangers.
2. 30MPW units are shipped with full operating charge.
6
30MPA units varies only in field piping required for the remote
condenser.
When the unit is in its final position, remove the packaging
and remove the mobility kit wheels (if equipped). Remove
3/ -in. wheel nuts to remove wheels from unit legs. Level the
8
unit (using a level), and bolt the unit to the floor or pad.
If unit is to be mounted on unit external vibration
isolators, follow the mounting instructions included with
the accessory vibration isolator.
If unit has accessory leveling kit installed, follow the instructions provided with the accessory to make sure unit is level and in the correct position.
C
B
Step 4 — Check Compressor Mounting — As
shipped, units with two compressors are held down with 6 bolts
through rubber grommets. All units with three compresors are
held down with 8 bolts per pair through grommets. After unit is
installed, verify mounting bolt torque 7 to10 ft-lb (9 to 14 Nm).
a30-5040
D
A
CONTROL
PANEL
SIDE
Step 5 — Make Piping Connections — See
Fig. 8 and 9 for typical piping applications.
30MPA SYSTEM CONDENSER — For detailed condenser
piping installation instructions for 30MPA systems, refer to
separate instructions packaged with the remote condenser
units.
Condenser refrigerant piping for 30MPA units should be
sized to minimize the amount of refrigerant required.
The 30MPA units that use air-cooled evaporative condensers must have adequate means for head pressure control when
operating below 60 F (15.6 C).
Carrier recommends that a field-supplied pressure relief device be installed in each discharge line of 30MPA units. Most
local codes require the discharge line relief valve to be vented
directly to the outdoors. The vent must not be smaller than the
discharge line relief valve outlet.
30MPW CONDENSER DESCRIPTION — All 30MPW
units use a brazed-plate heat-exchanger-type condenser. These
heat exchangers are made of embossed plates of acid-resistant
stainless steel. Every other plate is reversed so that the ridges
of the herringbone pattern intersect one another on adjacent
plates, forming a lattice of contact points. These plates are
vacuum-brazed together to form a compact and pressureresistant heat exchanger.
After brazing, the impressions in the plates form 2 separate
systems of channels where the refrigerant and water flows are
counterflow. The number of plates varies depending on unit
tonnage. The condensers provide approximately 10º to 12º F
(6º to 8º C) liquid subcooling at the standard Air Conditioning,
Heating and Refrigeration Institute (AHRI) rating condition.
30MPW CONDENSER — When facing the unit control box,
the condenser is the uninsulated heat exchanger located on the
left-hand side. The water connections are on the right-hand
side of the heat exchanger with the LIQUID-IN connection at
the bottom, and the LIQUID-OUT connection at the top.
A strainer with a minimum of 40 mesh must be installed
within 10 ft (3 m) of the condenser water inlet to prevent debris
from clogging or damaging the heat exchanger. The strainer is
required for operation and is available as an accessory.
To install the victaulic coupling (see Fig. 10):
1. Lubricate the gasket lips and stretch the gasket over
the end of the heat exchanger coupling. Avoid twisting
the gasket when installing.
2. Bring the pipe and heat exchanger coupling ends together
into alignment. Slide the gasket so that it is centered over
the ends. Apply a light film of lubricant to the gasket, or
to the outside diameter of the pipe. Avoid twisting the
gasket during installation.
WEIGHT DISTRIBUTION AT EACH MOUNTING
HOLE — Lb (kg)
UNIT 30MP
A015
A020
A030
A040
A045
W015
W020
W030
W040
W045
A
MOUNTING HOLE
B
C
156 (71)
159 (72)
181 (82)
228 (104)
234 (106)
170 (77)
176 (80)
216 (98)
275 (125)
298 (135)
D
Fig. 6 — Mounting Hole Weight Distribution
a30-5041
Fig. 7 — Mobility Kit
Step 3 — Place the Unit
NOTE: These units are not suitable for unprotected outdoor
use.
Carrier recommends that these units be located in the basement or on the ground floor. However, if it is necessary to locate the unit on an upper floor, be sure the structure has been
designed to support the unit weight. If necessary, add structural
support to floor. Also, be sure the surface for installation is
level. Refer to Fig. 4 and 5 for space requirements and weight
distribution.
Only electrical power connections, water connections for
condenser, fluid connections for evaporator, and strainer installation are required for 30MPW installation. Installation of
7
a30-4997
8
Fig. 8 — Typical Piping with Liquid-Cooled 30MPW Chiller
NOTES:
1. Chiller must be installed level to maintain proper compressor oil return.
2. Wiring and piping shown are general points-of-connection guides only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system and are not in accordance
with recognized standards. Units should be installed using certified drawings.
3. All wiring must comply with applicable local and national codes.
4. All piping must follow standard piping techniques. Refer to Carrier System Design Manual or appropriate ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers) handbook
for details.
5. See Tables 1A and 1B for minimum system fluid volume. This system may require the addition of a
holding tank to ensure adequate volume.
6. A strainer with a minimum of 40 mesh must be installed within 10 ft (3 m) of the evaporator fluid inlet to
prevent debris from clogging or damaging the heat exchanger. This strainer is required and is available
as an accessory.
7. Piping, wiring, switches, vents, strainers, drains, and vibration isolation are all field-supplied.
a30-4998
09DP
AIR-COOLED
CONDENSER
NOTES:
1. Chiller must be installed level to maintain proper compressor oil
return.
2. Wiring and piping shown are general points-of-connection guides
only and are not intended for a specific installation. Wiring and piping shown are for a quick overview of system and are not in accordance with recognized standards. Units should be installed using
certified drawings.
3. All wiring must comply with applicable local and national codes.
4. All piping must follow standard piping techniques. Refer to Carrier
System Design Manual part 3, Carrier E20-II software Refrigerant
Piping program, or appropriate ASHRAE (American Society of
Heating, Refrigerating, and Air Conditioning Engineers) handbook
for details on proper piping sizes and design.
5. See Tables 1A and 1B for minimum system fluid volume. This system may require the addition of a holding tank to ensure adequate
volume.
6. Hot gas lines should rise above refrigerant level in condenser circuit. Double riser may be required; check unit minimum capacity.
7. Trap should be installed on hot gas lines to prevent condenser oil
and refrigerant vapor migration from accumulating in compressor
during off cycle.
8. Pitch all horizontal lines downward in the direction of refrigerant
flow.
9. Provide support to liquid and gas lines near the connections to the
condenser coil.
10. For pressure relief requirements, see latest revision of ASHRAE
Standard 15, Safety Code for Mechanical Refrigeration.
11. A strainer with a minimum of 40 mesh must be installed within 10 ft
(3 m) of the evaporator fluid inlet to prevent debris from clogging or
damaging the heat exchanger. This strainer is required and is available as an accessory.
12. Piping, wiring, switches, vents, strainers, drains, and vibration isolation are all field-supplied.
Fig. 9 — Typical Piping with 30MPA Unit and 09DP Remote Air-Cooled Condenser
9
A strainer with a minimum of 40 mesh must be installed
within 10 ft of the evaporator fluid inlet to prevent debris from
clogging or damaging the heat exchanger. This strainer is required and is available as an accessory.
See Carrier System Design Manual, Part 3, Piping Design,
for chilled fluid piping details.
The evaporator fluid inlet and outlet connections are victualic. The fluid enters at the top connection and leaves at the
bottom connection. Procedures for making the connections are
the same as for the 30MPW condensers. See 30MPW Condenser section on page 7 for more details.
Run the pump for 10 minutes, then clean the strainer before
starting the unit.
An evaporator flow switch is standard on all units. This is a
thermal dispersion type switch that is installed in the evaporator fluid outlet. The switch is set to open when the evaporator
fluid flow drops below the minimum set point.
For variable primary flow applications, it may be necessary
to adjust the flow switch set point to avoid nuisance trips. Contact Carrier service engineering for the mthod needed to adjust
the switch.
See Table 1 for minimum flow rates and loop volume.
The thermistors used to sense entering and leaving fluid
temperature are factory-installed in the evaporator entering and
leaving fluid nozzles.
AIR SEPARATION — For proper system operation, it is
essential that water loops be installed with proper means to
manage air in the system. Free air in the system can cause
noise, reduce terminal output, stop flow, or even cause pump
failure due to pump cavitation. For closed systems, equipment
should be provided to eliminate all air from the system.
The amount of air that water can hold in solution depends
on the pressure and temperature of the water/air mixture. Air is
less soluble at higher temperatures and at lower pressures.
Therefore, separation can best be done at the point of highest
water temperature and lowest pressure. Typically, this point
would be on the suction side of the pump as the water is returning from the system or terminals. Generally speaking, this is
the best place to install an air separator, if possible.
1. Install automatic air vents at all high points in the system.
(If the 30MP unit is located at the high point of the
system, a vent can be installed on the piping entering the
heat exchanger on the ¼-in. NPT female port.)
2. Install an air separator in the water loop, at the place
where the water is at higher temperatures and lower
pressures — usually in the chilled water return piping.
On a primary-secondary system, the highest temperature
water is normally in the secondary loop, close to the
decoupler. Preference should be given to that point on the
system (see Fig. 13). In-line or centrifugal air separators
are readily available in the field.
It may not be possible to install air separators at the place of
lowest pressure and highest temperature. In such cases, preference should be given to the points of highest temperature. It is
important that pipe be sized correctly so that free air can be
moved to the point of separation. Generally, a water velocity of
at least 2 feet per second will keep free air entrained and
prevent it from forming air pockets.
Automatic vents should be installed at all physically elevated points in the system so that air can be eliminated during
system operation. Provision should also be made for manual
venting during the water loop fill. It is important that the
automatic vents be located in accessible locations for
maintenance purposes, and that they be located where they can
be prevented from freezing.
a30-1245
Fig. 10 — Install the Victualic Coupling
3. Install the inside coupling half over the gasket and then
install the outer half. Connect with nuts and bolts. Tighten
the nuts equally on both sides. Ensure there is no gap between the two halves of the coupling.
4. Alternately tighten the nuts with a wrench to draw the
coupling halves together uniformly. The joint is now
complete.
30MPW UNITS — In order to minimize the water pressure
drop in the system, use as few bends as possible in the field
water piping, and run the lines as short as possible. Size the
water lines according to the available pump pressure (not necessarily the connection size), especially on cooling tower applications. See Carrier System Design Manual, Part 3, Piping Design.
See Fig. 11 for condenser pressure drops.
Set water regulating valve, if installed, to maintain design
head pressure. Do not adjust to compensate for high head pressures caused by fouled condensers, excess refrigerant, or the
presence of noncondensables. Due to changes in water temperature, it may be necessary to adjust the valve seasonally. After
adjusting for design head pressure, shut unit down. The water
regulating valve should shut off the flow of water in a few minutes. If it does not, raise head pressure setting. Make sure that
the capillary tube from each water regulating valve is connected to the proper condenser access fitting.
Provide a means for draining the system in the winter (if not
used) and for maintenance.
Water leaving the condenser is under pressure and should
not be connected directly into sewer lines. Check local codes.
EVAPORATOR DESCRIPTION — All 30MP units use a
brazed-plate heat-exchanger type evaporator. The heat exchanger is constructed essentially the same as the brazed-plate
condenser used on 30MPW units. See 30MPW Condenser Description section on page 7 for more details. Similar to the condenser, the evaporator can only be chemically cleaned. See Fig.
12 for evaporator pressure drops.
EVAPORATOR PIPING — Plan evaporator fluid piping for
minimum number of changes in elevation, and for the fewest
number of bends possible. Install manual or automatic vent
valve at high points in the line. Maintain system pressure by
using a pressure tank or a combination of relief and reducing
valves.
10
ENGLISH
4
3
2
1
40
5
35
Water Pressure Drop ()
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
GPM
a30-5036
SI
11
120
2
3
5
4
Water Pressuree Drop (kPa)
100
80
60
40
20
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Liters/second
1
2
3
4
5
LEGEND
— 30MP015
— 30MP020
— 30MP030
— 30MP040
— 30MP045
a30-5037
Fig. 11 — Condenser Water Pressure Drop
11
15
ENGLISH
3
2
1
40
4
5
170
180
35
Water Pressure Drop ()
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100
a30-5034
110
120
130
140
150
160
190
200
GPM
SI
3
2
11
120
4
5
Water Pressuree Drop (kPa)
100
80
60
40
20
0
0
1
2
3
4
5
LEGEND
— 30MP015
— 30MP020
— 30MP030
— 30MP040
— 30MP045
1
2
3
4
5
6
7
8
9
10
Liters/second
a30-5035
Fig. 12 — Evaporator Water Pressure Drop
12
11
12
13
a30-3226
Zone 3
Expansion
Tank(s)
Zone 2
Decoupler
Zone 1
Chiller 2
Chiller 1
Distribution Pump
Air Separator
with Vent
NOTE: Expansion tanks must be disconnected for chillers placed parallel in the primary water loop.
Fig. 13 — Typical Air Separator and Expansion Tank Location on Primary-Secondary Systems
d. Remove temporary bypass when cleaning is
complete.
Step 6 — Fill the Chilled Water Loop
WATER SYSTEM CLEANING — Proper water system
cleaning is of vital importance. Excessive particulates in the
water system can cause excessive pump seal wear, reduce or
stop flow, and cause damage of other components. Water
quality should be maintained within the limits indicated in
Table 2. Failure to maintain proper water quality may result in
heat exchanger failure.
Table 2 — Water Quality Characteristics
and Limitations
WATER CHARACTERISTIC
Alkalinity (HCO3-)
CAUTION
Failure to properly clean all piping and components of the
chilled water system before unit start-up may result in
plugging of the heat exchanger, which can lead to poor performance, nuisance alarms and damage from freezing.
Freezing damage caused by an improperly cleaned system
represents abuse and may impair or otherwise negatively
affect the Carrier product warranty.
1. Install a temporary bypass around the chiller to avoid circulating dirty water and particulates into the pump package and chiller during the flush. Use a temporary circulating pump during the cleaning process. Also, be sure that
there is capability to fully drain the system after cleaning.
(See Fig 14.)
2. Be sure to use a cleaning agent that is compatible with all
system materials. Be especially careful if the system
contains any galvanized or aluminum components. Both
detergent-dispersant and alkaline-dispersant cleaning
agents are available.
3. It is a good idea to fill the system through a water meter.
This provides a reference point for the future for loop
volume readings, but it also establishes the correct
quantity of cleaner needed in order to get the required
concentration.
4. Use a feeder/transfer pump to mix the solution and fill the
system. Circulate the cleaning system for the length of
time recommended by the cleaning agent manufacturer.
a. After cleaning, drain the cleaning fluid and flush the
system with fresh water.
b. A slight amount of cleaning residue in the system can
help keep the desired, slightly alkaline, water pH of 8
to 9. Avoid a pH greater than 10, since this will
adversely affect pump seal components.
c. A side stream filter is recommended (see Fig. 15)
during the cleaning process. Filter side flow rate
should be enough to filter the entire water volume
every 3 to 4 hours. Change filters as often as necessary during the cleaning process.
QUALITY LIMITATION
70 – 300 ppm
Sulfate (SO42-)
Less than 70 ppm
HCO3-/SO42Electrical Conductivity
pH
Ammonium (NH3)
Chorides (Cl-)
Free chlorine (Cl2)
Greater than 1.0
10 – 500S/cm
7.5 – 9.0
Less than 2 ppm
Less than 300 ppm
Less than 1 ppm
Hydrogen Sulfide (H2S)*
Less than 0.05 ppm
Free (aggressive) Carbon
Dioxide (CO2)†
Less than 5 ppm
Total Hardness (dH)
Nitrate (NO3)
4.0 – 8.5
Less than 100 ppm
Iron (Fe)
Aluminum (Al)
Manganese (Mn)
Less than 0.2 ppm
Less than 0.2 ppm
Less than 0.1 ppm
*Sulfides in the water quickly oxidize when exposed to air, requiring that
no agitation occur as the sample is taken. Unless tested immediately
at the site, the sample will require stabilization with a few drops of one
Molar zinc acetate solution, allowing accurate sulfide determination up
to 24 hours after sampling. A low pH and high alkalinity cause system
problems, even when both values are within the ranges shown. The
term pH refers to the acidity, basicity, or neutrality of the water supply.
Below 7.0, the water is considered to be acidic. Above 7.0, water is
considered to be basic. Neutral water contains a pH of 7.0.
†Dissolved carbon dioxide can either be calculated from the pH and
total alkalinity values, shown below, or measured on the site using a
test kit. Dissolved Carbon Dioxide, PPM = TA x 2[(6.3-pH)/0.3] where TA
= Total Alkalinity, PPM as CaCO3.
FILLING THE SYSTEM — The initial fill of the chilled
water system must accomplish three purposes:
1. The entire piping system must be filled with water.
2. The pressure at the top of the system must be high enough
to vent air from the system (usually 4 psig is adequate for
most vents).
3. The pressure at all points in the system must be high
enough to prevent flashing in the piping or cavitation in
the pump.
The pressure created by an operating pump affects system
pressure at all points except one — the connection of the
compression tank to the system. This is the only location in the
system where pump operation will not give erroneous pressure
indications during the fill. Therefore, the best location to install
the fill connection is close to the expansion tank. An air vent
should be installed close by to help eliminate air that enters
during the fill procedure.
13
Step 7 — Make Electrical Connections — All
field wiring must comply with local code requirements.
Electrical data for the complete unit and for the compressors is
shown in Table 3. See Fig. 16 for field wiring connections. A
field-supplied branch circuit disconnect switch that can be
locked in either OPEN or OFF position must be installed.
Control circuit power is 24 v on all units. Factory-installed
control transformer (TRAN 1) uses line voltage for all units.
All control transformers are factory-installed and wired. For
208/230-3-60 units operating at 208-3-60 line voltage, TRAN1
primary connections must be moved to terminals H3 and H4.
Inside the control box are terminals for field power and ground
(earth) wiring. A ground wire must be installed with each field
power supply. Compressors are wired for across-the-line start.
Refer to Table 3 for electrical data.
FLOW SWITCH — A condenser flow switch is available as
an accessory for all 30MPW units, and can be field-installed.
The Carrier flow switch accessory (part no. 30MP-900---004)
is available for this purpose. Flow switch wiring terminals are
located in the field wiring compartment of the control box. The
flow switch should be wired between terminals LVT-16 and
LVT-17 for all units.
CONTROL BOX, POWER SECTION — The electrical
power supply is brought in through the top left-hand side of the
control box. Pressure-lug connections on the terminal blocks
are suitable for only for copper conductors.
The control box power section contains the following
components:
• power terminal block
• optional disconnect switch
• compressor circuit breaker(s)
• compressor contactor(s)
• current sensor boards
• control transformer
• ground lug
• neutral terminal (380-3-60 units only)
• crankcase heater relay (30MPA units only)
• fuses
CONTROL BOX, CONTROLS SECTION — The control
box controls section contains the following components:
• main base board (MBB)
• scrolling marquee display
• optional energy management module
• control-circuit breakers for 24-v circuits
• control-circuit ON-OFF switch
• unit Enable/Off/Remote contact switch
• unit Alarm/Alert indicator light
CONTROL BOX, FIELD CONTROL WIRING SECTION — Inside this section is the low-voltage, field-wiring
terminal strip (LVT). All low-voltage field-wiring connections
are made to this terminal block. There are three 7/8-in. (22 mm)
knockouts provided for field wiring in this section. Connections for condenser flow switch, chilled fluid pump interlock,
condenser pump interlock, remote alarm output, condenser
output, and dual chiller thermistor accessory are made at these
locations. See Fig. 16 for specific location of connections.
The unit has the capability to control field-supplied devices.
They are: alarm signal, condenser pump or condenser fan output, and chilled water pump output. The unit provide 24-v
power with a minimum 5 va rating per output allowed.
UNBALANCED 3-PHASE SUPPLY VOLTAGE — Never
operate a compressor where a phase imbalance in the supply
voltage is greater than 2%. Use the following formula to determine the percent voltage imbalance:
% Voltage Imbalance =
SYSTEM
DILUTED
CLEANING
AGENT
POT FEEDER AND
TRANSFER PUMP
x
TEMPORARY
PUMP
30MP UNIT
x
a30-5047
TO DRAIN
TEMPORARY
BYPASS
Fig. 14 — Typical Set Up for Cleaning Process
SYSTEM
SIDE
STREAM
FILTER
DILUTED
CLEANING
AGENT
POT FEEDER AND
TRANSFER PUMP
x
TEMPORARY
PUMP
30MP UNIT
x
a30-5048
TO DRAIN
TEMPORARY
BYPASS
Fig. 15 — Cleaning Using a Side Stream Filter
Ensure the following when filling the system:
1. Remove temporary bypass piping and cleaning/flushing
equipment.
2. Check to make sure all drain plugs are installed.
3. Open the blow-down valve to flush the strainer.
Normally, a closed system needs to be filled only once. The
actual filling process is generally a fairly simple procedure. All
air should be purged or vented from the system. Thorough
venting at the high points and circulation at room temperature
for several hours is recommended.
NOTE: Local codes concerning backflow devices and other
protection of the city water system should be consulted and
followed to prevent contamination of the public water
supply. This is especially important when antifreeze is used
in the system.
Set Water Flow Rate — Once the system is cleaned, pressurized, and filled, the flow rate through the chiller needs to be
established.
NOTE: Carrier recommends a differential pressure gage when
measuring pressures across the pumps or balancing valves.
This provides for greater accuracy and reduces error build-up
that often occurs when subtracting pressures made by different
gages.
On primary/secondary systems, it is advisable to set the
30MP balancing valve to maintain design flow plus 10%
through the chiller.
A rough estimate of water flow can also be obtained from
measuring the pressure drop across the 30MP heat exchanger.
Figures 11 and 12 show the relationship between gpm and heat
exchanger pressure drop. It should be noted that these curves
are for “clean” heat exchangers; they do not apply to heat exchangers with fouling. Adjust the external balancing valve until
the correct pressure drop is obtained for the required gpm.
100 x
14
max voltage deviation from average voltage
average voltage
(AC) 239 – 238 = 1 v
Maximum deviation is 4 v.
Determine percent voltage imbalance:
4
% Voltage Imbalance = 100 x
239
= 1.7%
This amount of phase imbalance is satisfactory as it is below
the maximum allowable 2%.
EXAMPLE: Supply voltage is 240-3-60.
AB = 243 v
BC = 236 v
AC = 238 v
243 + 236 + 238
3
= 239 v
Determine maximum deviation from average voltage:
(AB) 243 – 239 = 4 v
(BC) 239 – 236 = 3 v
Average Voltage =
IMPORTANT: If the supply voltage phase imbalance
is more than 2%, contact your local utility company
immediately.
Table 3 — Electrical Data — 30MPA,MPW Units
UNIT SIZE
30MPA,MPW
015
020
030
040
045
ICF
kcmil
LRA
MCA
MOCP
NEC
Rec
Fuse
VOLTS
NAMEPLATE
(3 ph, 60 Hz)
208/230
380
460
575
208/230
380
460
575
208/230
380
460
575
208/230
380
460
575
208/230
380
460
575
VOLTAGE*
Min
Max
187
342
414
518
187
342
414
518
187
342
414
518
187
342
414
518
187
342
414
518
253
418
508
632
253
418
508
632
253
418
508
632
253
418
508
632
253
418
508
632
COMPRESSOR
LRA
Quantity
(ea.)
195
123
2
95
80
239
145
2
125
80
340
196
2
179
132
300
139
3
150
109
340
196
3
179
132
LEGEND
Maximum instantaneous current flow during starting.
Thousand circular mils
Locked rotor amps.
Minimum circuit amps (for wire sizing). Complies with
NEC, Section 430-24.
— Maximum Overcurrent Protection
— National Electrical Code (U.S.A.)
— Recommended dual element fuse amps (150% of compressor RLA). Size up to the next standard fuse size.
—
—
—
—
3.
4.
*Supply Range — Units are suitable for use on electrical systems
where voltage supplied to the unit terminals is not below or above
the listed range limits.
5.
6.
NOTES:
1. All units have one field power terminal block.
2. Maximum incoming wire size is as follows:
For units with terminal block:
350 kcmil for unit sizes 030-045; 208/230-3-60 voltages.
2/0 for all other unit sizes; all voltages.
For units with optional non-fused disconnect:
350 kcmil for unit sizes:
030-045; 208/230-3-60 voltages.
045; 380-3-60 voltage.
15
UNIT
MCA
66.4
37.6
33.1
27.5
80.6
53.4
40.3
32.2
125.6
76.5
60.5
53.3
166.7
87.4
75.1
64.7
181.4
110.5
87.4
77.0
ICF
MOCP
224.5
139.7
109.7
92.2
274.8
168.7
142.9
94.3
395.8
230.0
205.9
155.7
402.6
192.8
196.2
148.8
451.6
264.0
232.8
179.4
90
50
45
35
110
70
50
45
175
110
80
70
200
110
90
80
225
125
110
100
Rec
Fuse
80
45
40
35
90
60
45
40
150
90
70
60
200
100
90
70
200
125
100
90
3/0 for unit sizes:
015,020; 208/230-3-60 voltages.
020-040; 380-3-60 voltage.
030-045; 460-3-60 and 575-3-60 voltages.
2 AWG for unit sizes:
015; 380-3-60 voltage.
015-020; 460-3-60 and 575-3-60 voltages.
Additional control circuit power is not required.
Any field modification of factory wiring must be in compliance
with all applicable codes. Field-installed power wires must be
rated 75 C minimum.
Use copper conductors only.
Control circuit power supply is 24-v single phase. Control
power is supplied by the factory-installed control transformer.
ALMR
AWG
CFR
CNFS
CNP
CNPI
CWP
CWPI
CWV
EMM
LVT
NEC
OAT
SPT
—
—
—
—
—
—
—
—
—
—
—
—
—
—
LEGEND
Alarm Relay (24 V) 5 VA Max
American Wire Gage
Condenser Fan Relay
Condenser Flow Switch
Condenser Pump
Condenser Pump Interlock
Chilled Water Pump
Chilled Water Pump Interlock
Condenser Water Valve
Energy Management Module
Low Voltage Terminal Strip
National Electrical Code
Outside Air Temperature
Space Temperature
Fig. 16 — Typical Low Voltage Control Wiring
NOTES:
1. Factory wiring is in accordance with UL 1995 standards. Field modifications or additions must be in
compliance with all applicable codes.
2. All units or modules have single point primary power connection. Main power must be supplied
from a field or factory supplied disconnect.
3. Wiring for main field supply must be rated 75 C. Use copper conductors only.
a. Incoming wire size range for terminal block with MCA up to 120 amps is 14 AWG (American
Wire Gage) to 2/0.
b. Incoming wire size range for terminal block with MCA from 120.1 amps to 310 amps is 6 AWG
to 350 kcmil.
c. Incoming wire size range for non-fused disconnect with MCA up to 50 amps is 10 AWG to
2 AWG.
d. Incoming wire size range for non-fused disconnect with MCA from 50.1 amps to 90 amps is 6
AWG to 3/0.
e. Incoming wire size range for non-fused disconnect with MCA from 90.1 amps to 250 amps is 4
AWG to 350 kcmil.
4. Refer to certified dimensional drawings for exact locations of the main power and control power
entrance locations.
5. Terminal 24 of the LVT is for controlof chilled water pump (CWP) starter. Terminal 20 of the LVT is
for control of condenser pump (CNP) starter or condenser fan relay (CFR). The maximum load
allowed for the relays is 5 VA sealed. 10 VA inrush at 24 VAC. Field power supply is required.
6. Terminal 25 of LVT is for an alarm relay. The maximum load allowed for alarm relay is 5 VA sealed,
10 VA inrush at 24 VAC. Field power supply is not required.
7. Make approprate connections to LVT as shown for energy management board options. The contacts for demand limit and ice done options must be rated for dry circuit application capable of handling 24 VAC load up to 50 mA. Installation of optional energy management board required.
8. Remove jumper between terminals 16 and 17 when field chilled water pump interlock (CWPI) is
installed.
9. Terminals 18 and 19 of LVT are for floating point control of condenser water valve (CWV). Teminal
18 commands valve closed. Terminal 19 commands valve open. The maximum load allowed for
condenser water valve is 5.5 VA at 24 VAC. Field power supply is not required.
10. All discrete inputs are 24 VAC.
a30-5039
Copyright 2010 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300054-01
Printed in U.S.A.
Form 30MP-1SI
Pg 16
910
1-10
Replaces: New
Download PDF

advertising