Installation, operation and maintenance instructions

61WG/30WG/30WGA 020-090
Water-Cooled/Condenserless
Liquid Chillers/Water-Sourced
Heat Pumps with or without
Integrated Hydronic Module
Nominal cooling capacity 25-95 kW
Nominal heating capacity 29-117 kW
Unit with optional
hydronic module
Standard unit
Installation, operation and maintenance instructions
CONTENTS
1 - INTRODUCTION...................................................................................................................................................................... 6
1.1 - Installation safety considerations............................................................................................................................................ 6
1.2 - Equipment and components under pressure......................................................................................................................... 7
1.3 - Maintenance safety considerations......................................................................................................................................... 7
1.4 - Repair safety considerations.................................................................................................................................................... 8
2 - PRELIMINARY CHECKS....................................................................................................................................................... 9
2.1 - Check equipment received....................................................................................................................................................... 9
2.2 - Moving and placing the unit.................................................................................................................................................... 9
3 - DIMENSIONS, CLEARANCES............................................................................................................................................ 11
3.1 - 61WG/30WG 020-045 - standard unit................................................................................................................................... 11
3.2 - 61WG/30WG 020-045 - unit with top connections (option 274)....................................................................................... 11
3.3 - 61WG/30WG 020-045 - unit with evaporator hydronic module (option 116)................................................................. 12
3.4 - 61WG/30WG 020-045 - unit with condenser hydronic module (option 270)................................................................... 12
3.5 - 61WG/30WG 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270)................................. 12
3.6 - 61WG/30WG 020-045 - unit with hydronic module and top connections........................................................................ 13
(options 116 + 274 or 270 + 274 or 116 + 270 + 274)................................................................................................................... 13
3.7 - 61WG/30WG 020-045 - stackable unit (option 273)........................................................................................................... 13
3.8 - 61WG/30WG 050-090 - standard unit................................................................................................................................... 14
3.9 - 61WG/30WG 050-090 - unit with top connections (option 274)....................................................................................... 14
3.10 - 61WG/30WG 050-090 - unit with evaporator hydronic module (option 116)............................................................... 15
3.11 - 61WG/30WG 050-090 - unit with condenser hydronic module (option 270)................................................................. 15
3.12 - 61WG/30WG 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270)............................... 15
3.13 - 61WG/30WG 050-090 - unit with hydronic module and top connections...................................................................... 16
(options 116 + 274 or 270 + 274 - 116 or 270 + 274).................................................................................................................... 16
3.14 - 61WG/30WG 050-090 - stackable unit (option 273)......................................................................................................... 16
3.15 - 30WGA 020-045 - standard unit.......................................................................................................................................... 17
3.16 - 30WGA 020-045 - unit with evaporator hydronic module (option 116)........................................................................ 17
3.17 - 30WGA 020-045 - stackable unit (option 273).................................................................................................................. 18
3.18 - 30WGA 050-090 - standard unit.......................................................................................................................................... 18
3.19 - 30WGA 050-090 - unit with evaporator hydronic module (option 116)........................................................................ 19
3.20 - 30WGA 050-090 - stackable unit (option 273).................................................................................................................. 19
4 - PHYSICAL AND ELECTRICAL DATA 61WG/30WG.................................................................................................... 20
4.1 - Physical data 61WG................................................................................................................................................................ 20
4.2 - Physical data 30WG................................................................................................................................................................ 20
4.3 - Physical data 30WGA............................................................................................................................................................. 21
4.4 - Physical data 61WG/30WG/30WGA units with hydronic module .................................................................................. 21
4.5 - Electrical data 61WG/30WG/30WGA ................................................................................................................................ 22
4.6 - Short-circuit stability current (TN system*) - standard unit (with main disconnect switch)......................................... 22
4.7 - Electrical data, optional hydronic module........................................................................................................................... 23
4.8 - Compressor usage and electrical data table......................................................................................................................... 24
5 - APPLICATION DATA............................................................................................................................................................ 25
5.1 - Operating limits 61WG........................................................................................................................................................... 25
5.2 - Operating range 61WG.......................................................................................................................................................... 25
5.3 - Operating limits 30WG........................................................................................................................................................... 25
5.4 - Operating range 30WG.......................................................................................................................................................... 25
5.5 - Operating limits 30WGA....................................................................................................................................................... 26
5.6 - Operating range 30WGA....................................................................................................................................................... 26
5.7 - Minimum chilled water flow.................................................................................................................................................. 26
5.8 - Maximum chilled water flow.................................................................................................................................................. 26
5.9 - Variable flow............................................................................................................................................................................ 26
5.10 - Water flow rates..................................................................................................................................................................... 26
5.11 - Minimum water volume....................................................................................................................................................... 27
5.12 - Maximum water loop volume (evaporator and condenser side)..................................................................................... 27
5.13 - Expansion tank...................................................................................................................................................................... 27
5.14 - Protection against cavitation (option 116)......................................................................................................................... 28
5.15 - Plate heat exchanger pressure drop (includes internal piping)....................................................................................... 28
3
6 - ELECTRICAL CONNECTION............................................................................................................................................. 29
6.1 - Electrical connections, control box 61WG/30WG/ 30WGA.............................................................................................. 29
6.2 - Power supply............................................................................................................................................................................ 29
6.3 - Voltage phase imbalance (%)................................................................................................................................................ 29
6.4 - Recommended wire sections................................................................................................................................................. 29
6.5 - 24 V user power reserve......................................................................................................................................................... 31
7 - 30WGA UNIT CONNECTIONS ........................................................................................................................................... 31
7.1 - Recommendations for the installation of liquid chillers with remote condenser............................................................ 31
7.2 - Piping installation and connection........................................................................................................................................ 31
8 - PIPE SIZING WITH REFRIGERANT FOR 30WGA UNITS........................................................................................ 32
8.1 - General considerations and pipe size limits......................................................................................................................... 32
8.2 - Pipe sizing................................................................................................................................................................................. 32
8.3 - Discharge pipe sizing.............................................................................................................................................................. 32
8.4 - Liquid line sizing..................................................................................................................................................................... 33
9 - WATER CONNECTIONS....................................................................................................................................................... 33
9.1 - Operating precautions............................................................................................................................................................ 33
9.2 - Water connections................................................................................................................................................................... 34
9.3 - Frost protection....................................................................................................................................................................... 35
9.4 - Flow switch (units without hydronic module)..................................................................................................................... 35
10 - NOMINAL WATER FLOW CONTROL WITH FIXED-SPEED PUMP.................................................................... 35
10.1 - General................................................................................................................................................................................... 35
10.2 - Water flow control procedure ............................................................................................................................................. 35
11 - NOMINAL WATER FLOW CONTROL WITH VARIABLE-SPEED PUMP........................................................... 36
11.1 - Pump flow/pressure curve.................................................................................................................................................... 36
11.2 - Available external static pressure (variable-speed high-pressure pumps, units with hydronic module...................... 37
11.3 - Available external static pressure (fixed-speed low-pressure pumps, units with hydronic module)......................................38
11.4 - Pump curve (units with hydronic modules)....................................................................................................................... 39
12 - OPERATION OF 61WG UNITS WITH SPECIFIC HEATING CONTROL (OPTION 153).................................. 39
12.1 - Operating principle............................................................................................................................................................... 39
12.2 - Auxiliary electronic board (AUX1) - analogue
and digital inputs and outputs .................................................. 39
13 - OPERATION OF 61WG UNITS WITH THE HEATING SYSTEM MANAGER (HSM)...........................................40
14 - 30WG UNIT OPERATION WITH A DRYCOOLER (OPTION 154).......................................................................... 41
14.1 - Operating principle............................................................................................................................................................... 41
14.2 - Auxiliary electronic board (AUX1) - analogue and digital inputs and outputs - to control the drycooler.................... 41
14.3 - Configuration of the number of fan stages and the automatic changeover of the fan stages...................................... 41
14.4 - Fan stage assignment............................................................................................................................................................. 41
14.5 - 30WG units without evaporator and condenser pump, three-way valve configuration for low outside temperature
application........................................................................................................................................................................................ 42
14.6 - Drycooler installation on 30WG units................................................................................................................................ 42
15 - 30WGA UNIT OPERATION WITH A REMOTE AIR-COOLED CONDENSER (OPTION 154)....................... 42
15.1 - Operating principle............................................................................................................................................................... 42
15.2 - Lead fan.................................................................................................................................................................................. 42
15.3 - Auxiliary electronic board (AUX1) - analogue and digital inputs and outputs - to control the remote air-cooled
condenser.......................................................................................................................................................................................... 42
15.4 - Configuration of the number of fan stages and fan type based on the air-cooled condenser model used in the
installation........................................................................................................................................................................................ 42
16 - START-UP................................................................................................................................................................................ 43
16.1 - Preliminary checks................................................................................................................................................................ 43
16.2 - Actual start-up....................................................................................................................................................................... 43
16.3 - Refrgerant charge adjustment............................................................................................................................................. 43
16.4 - Oil charge adjustment........................................................................................................................................................... 44
16.5 - Operation of two units in master/slave mode (option 58)................................................................................................ 44
16.6 - Parallel or serial connection of two 61WG/30WG/ 30WGA units.................................................................................. 44
4
17 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA................................................................................... 44
17.1 - Compressors.......................................................................................................................................................................... 44
17.2 - Lubricant................................................................................................................................................................................ 45
17.3 - Evaporators and water-cooled condensers........................................................................................................................ 45
17.4 - Electronic expansion valve (EXV)..................................................................................................................................... 45
17.5 - Refrigerant............................................................................................................................................................................. 45
17.6 - High-pressure switch and high-pressure sensor................................................................................................................ 46
17.7 - High and low-pressure side safety valves........................................................................................................................... 46
17.8 - Moisture indicator................................................................................................................................................................. 46
17.9 - Filter drier in the refrigerant circuit.................................................................................................................................... 46
17.10 - Fixed-speed pump............................................................................................................................................................... 47
17.11 - Variable-speed pump.......................................................................................................................................................... 47
17.12 - Evaporator and condenser pump suction filter............................................................................................................... 47
17.13 - Connection sleeves.............................................................................................................................................................. 47
17.14 - Option 272: High-temperature water production with glycol solution........................................................................... 47
17.15 - Outside air temperature sensor......................................................................................................................................... 47
18 - OPTIONS AND ACCESSORIES......................................................................................................................................... 48
19 - MAINTENANCE.................................................................................................................................................................... 49
19.1 - Soldering and welding.......................................................................................................................................................... 49
19.2 - General system maintenance............................................................................................................................................... 49
19.3 - Refrigerant undercharge...................................................................................................................................................... 49
19.4 - Refrigerant guidelines ......................................................................................................................................................... 49
19.5 - Leak detection....................................................................................................................................................................... 50
19.6 - Evacuation ............................................................................................................................................................................ 50
19.7 - Recharging liquid refrigerant.............................................................................................................................................. 50
19.8 - Characteristics of R-410A.................................................................................................................................................... 50
19.9 - Electrical maintenance......................................................................................................................................................... 51
19.10 - Tightening torques for the main electrical connections.................................................................................................. 51
19.11 - Tightening torques for the main bolts and screws........................................................................................................... 51
19.12 - Compressors........................................................................................................................................................................ 51
19.13 - Evaporator and condenser maintenance.......................................................................................................................... 51
19.14 - Corrosion check................................................................................................................................................................... 51
20 - AQUASNAP MAINTENANCE PROGRAM................................................................................................................... 52
20.1 - Maintenance schedule.......................................................................................................................................................... 52
20.2 - Description of the maintenance operations....................................................................................................................... 52
21 - START-UP CKECKLIST FOR 61WG/30WG/30WGA UNITS (USE FOR JOB FILE)............................................ 53
The illustrations in this document are for illustrative purposes only and not part of any offer for sale or contract.
5
1 - INTRODUCTION
Prior to the initial start-up of the 61WG/30WG/30WGA
units, the people involved in the on-site installation, start-up,
operation and maintenance of this unit should be thoroughly
familiar with these instructions and the specific project
data for the installation site.
The 61WG/30WG/30WGA units are designed to provide a
very high level of safety during installation, start-up,
opera-tion and maintenance. They will provide safe and
reliable service when operated within their application
range.
This manual provides the necessary information to familiarize yourself with the control system before performing
start-up procedures. The procedures in this manual are
arranged in the sequence required for machine installation,
start-up, operation and maintenance.
Be sure you understand and follow the procedures and
safety precautions contained in the instructions supplied
with the machine, as well as those listed in this guide.
To find out, if these products comply with European
directives (machine safety, low voltage, electromagnetic
compatibility, equipment under pressure etc.) check the
declarations of conformity for these products.
1.1 - Installation safety considerations
After the unit has been received, when it is ready to be
installed or reinstalled, and before it is started up, it must be
inspected for damage. Check that the refrigerant circuit(s)
is (are) intact, especially that no components or pipes have
shifted (e.g. following a shock). If in doubt, carry out a leak
tightness check and verify with the manufacturer that the
circuit integrity has not been impaired. If damage is detected
upon receipt, immediately file a claim with the shipping
company.
Do not remove the skid or the packaging until the unit is
in its final position. These units can be moved with a fork
lift truck, as long as the forks are positioned in the right
place and direction on the unit.
The units can also be lifted with slings, using only the
designated lifting points marked on the unit.
30WGA are supplied without safety valve on the highpressure refrigerant circuit and are equipped with automatically reset pressure switches in accordance with EN378.
For unit installation and connection to the remote condenser
it is necessary to:
• Check the applicable air conditioning regulations
and safety standards (e.g. PED and EN378 for the
European Union)
• Determine which accessories (safety valves, fuses
etc.) are required so that these circuits comply with
the applicable regulations and standards.
If shut-off valves are used on the circuit, ensure that these
valves do not shut off the safety valve for the different
containers that they protect.
The protection devices include the fuse plugs and safety
valves (if used) in the refrigerant or heat transfer medium
circuits. Check if the original protection plugs are still
present at the valve outlets. These plugs are generally made
of plastic and should not be used. If they are still present,
please remove them. Install devices at the valve outlets or
drain piping that prevent the penetration of foreign bodies
(dust, building debris, etc.) and atmospheric agents (water
can form rust or ice). These devices, as well as the drain
piping, must not impair operation and not lead to a pressure
drop that is higher than 10% of the control pressure.
Classification and control
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European
Union the protection devices for these machines are
classified as follows:
Refrigerant side
High-pressure switch
External relief valve***
Rupture disk
Fuse plug
Heat transfer fluid side
External relief valve****
Safety
Damage limitation accessory**
accessory* in case of an external fire
x
x
x
x
x
x
* Classified for protection in normal service situations.
** Classified for protection in abnormal service situations.
*** The instantaneous over-pressure limited to 10% of the operating pressure
does not apply to this abnormal service situation. The control pressure can be
higher than the service pressure. In this case either the design temperature or
the high-pressure switch ensures that the service pressure is not exceeded in
normal service situations.
**** The classification of these safety valves must be made by the personnel that
completes the whole hydronic installation.
These units are not designed to be lifted from above. Use
slings with the correct capacity, and always follow the
lifting instructions on the certified drawings supplied with
the unit.
Do not remove these valves and fuses, even if the fire risk
is under control for a particular installation. There is no
guarantee that the accessories are re-installed if the installation is changed or for transport with a gas charge.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
All factory-installed safety valves are lead-sealed to
prevent any calibration change. If the safety valves are
installed on a reversing valve (change-over), this is
equipped with a safety valve on each of the two outlets.
Only one of the two safety valves is in operation, the other
one is isolated. Never leave the reversing valve in the
intermediate position, i.e. with both ways open (locate
the control element in the stop position).
DO NOT COVER ANY PROTECTION DEVICES.
6
If a safety stop is removed for checking or replacement
please ensure that there is always an active safety stop on
each of the reversing valves installed in the unit.
The external safety valves must always be connected to
drain pipes for units installed in a closed room. Refer to
the installation regulations, for example those of European
standard EN 378 and EN 13136.
These pipes must be installed in a way that ensures that
people and property are not exposed to refrigerant leaks.
As the fluids can be diffused in the air, ensure that the
outlet is far away from any building air intake, or that
they are discharged in a quantity that is appropriate for a
suitably absorbing environment.
Periodic check of the safety valves: See paragraph 1.3
- “Maintenance safety considerations”.
Provide a drain in the drain pipe, close to each safety valve,
to avoid an accumulation of condensate or rain water.
Any manipulation (opening or closing) of a shut-off
valve must be carried out by a qualified and authorised
engineer. These procedures must be carried out with the
unit shut down.
Any intervention on the refrigerant circuit, including
changing of drier blocks, is only permitted after the
complete removal of the refrigerant charge. For these
units transfer of the refrigerant charge from the high or
low-pressure side is not possible, nor permitted.
During any handling, maintenance and service operations
the engineers working on the unit must be equipped with
safety gloves, glasses, shoes and protective clothing.
Never work on a unit that is still energised.
Never work on any of the electrical components, until the
general power supply to the unit has been cut using the
disconnect switch in the control box.
All precautions concerning handling of refrigerant must
be observed in accordance with local regulations.
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead
of the machine.
Ensure good ventilation, as accumulation of refrigerant in
an enclosed space can displace oxygen and cause asphyxiation or explosions.
If the work is interrupted, always ensure that all circuits
are still deenergized before resuming the work.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and
skin irritation. Decomposition products are hazardous.
1.2 - Equipment and components under pressure
These products incorporate equipment or components under
pressure, manufactured by Carrier or other manufacturers.
We recommend that you consult your appropriate national
trade association or the owner of the equipment or components under pressure (declaration, re-qualification, retesting,
etc.). The characteristics of this equipment/these components
are given on the nameplate or in the required documentation, supplied with the products.
Do not introduce significant static or dynamic pressure with
regard to the operating pressures used during operation or
for tests in the refrigerant circuit or in the heat exchange
circuits.
1.3 - Maintenance safety considerations
Engineers working on the electric or refrigeration components must be authorised, trained and fully qualified to do so
(e.g. electricians trained and qualified in accordance with
IEC 60364 classification BA4).
All refrigerant circuit repairs must be carried out by a trained
person, fully qualified to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualified specialists.
ATTENTION: Even if the compressor motors have been
switched off, the power circuit remains energized, unless
the unit or circuit disconnect switch is open. Refer to the
wiring diagram for further details.
Attach appropriate safety labels.
If any intervention is required on the air-cooled condenser
in 30WGA units please refer to the safety instructions
supplied by the condenser manufacturer.
It is recommended to install an indicating device to show
if part of the refrigerant has leaked from the valve. The
presence of oil at the outlet orifice is a useful indicator that
refrigerant has leaked. Keep this orifice clean to ensure that
any leaks are obvious. The calibration of a valve that has
leaked is generally lower than its original calibration. The
new calibration may affect the operating range. To avoid
nuisance tripping or leaks, replace or re-calibrate the valve.
Operating checks:
IMPORTANT INFORMATION REGARDING THE
REFRIGERANT USED:
• This product contains fluorinated greenhouse gas
covered by the Kyoto protocol.
Refrigerant type: R-410A
Global Warming Potential (GWP): 1975
ATTENTION:
• Attach the label supplied that shows the refrigerant
used to the side used for topping up and/or recovery.
• On the label clearly indicate the topped up refrigerant
quantity in indelible ink.
7
•
•
•
•
•
•
Prevent the release of fluorinated gas from the unit.
Ensure that fluorinated gas is never released to the
atmosphere during installation, maintenance or
disposal. If a leak of fluorinated gas is detected, stop
the leak and repair it as quickly as possible.
Only a qualified service technician is allowed to access
this product and to correct the fault.
Any handling of fluorinated gas contained in this
product (e.g. moving the product or topping up the
gas) must comply with EC regulation no. 842/2006
about certain fluorinated greenhouse gases and any
other applicable local legislation.
Contact your local dealer if you have any questions.
Periodic inspections for refrigerant leaks may be
required depending on European or local legislation.
Please contact your local dealer for more information.
During the life-time of the system, inspection and
tests must be carried out in accordance with national
regulations.
The information on operating inspections given in annex
C of standard EN378 can be used if no similar criteria
exist in the national regulations.
Protection device checks:
• If no national regulations exist, check the protection
devices on site in accordance with standard EN378:
once a year for the high-pressure switches, every five
years for external safety valves.
• The detailed description of the high-pressure switch
test method is given in the service manual for the unit.
At least once a year thoroughly inspect the protection
devices (valves, pressure switches). If the machine operates
in a corrosive environment, inspect the protection devices
more frequently.
Regularly carry out leak tests and immediately repair any
leaks.
1.4 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries
to people. Faults and leaks must be repaired immediately.
The authorized technician must have the responsibility to
repair the fault immediately. After each repair of the unit,
check the operation of the protection devices and create a
report of the parameter operation at 100%.
Comply with the regulations and recommendations in unit
and HVAC installation safety standards, such as: EN 378,
ISO 5149, etc.
If a leak occurs or if the refrigerant becomes polluted (e.g.
by a short circuit in a motor or BPHE frost) remove the
complete charge using a recovery unit and store the
refrigerant in mobile containers.
Repair the leak detected and recharge the circuit with the
total R-410A charge, as indicated on the unit name plate.
Do not top up the refrigerant charge. Only charge liquid
refrigerant R-410A at the liquid line.
8
Ensure that you are using the correct refrigerant type before
recharging the unit.
Charging any refrigerant other than the original charge
type (R-410A) will impair machine operation and can
even destroy the compressors. The compressors operating
with this refrigerant type are lubricated with a synthetic
polyol-ester oil.
Before any intervention on the refrigerant circuit the
complete refrigerant charge needs to be recovered.
For 30WGA units with remote condenser the installer
must be clearly note the total refrigerant charge used in the
system (in kg) on the label attached to the 30WGA.
RISK OF EXPLOSION: Never use air or a gas containing
oxygen during leak tests to purge lines or to pressurise a
machine. Pressurised air mixtures or gases containing
oxygen can be the cause of an explosion. Oxygen reacts
violently with oil and grease.
Only use dry nitrogen for leak tests, possibly with an
appropriate tracer gas.
If the recommendations above are not observed, this can
have serious or even fatal consequences and damage the
installation.
Never exceed the specified maximum operating pressures.
Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and
the pressures given on the unit name plate.
Do not unweld or flamecut the refrigerant lines or any
refrigerant circuit component until all refrigerant (liquid
and vapour) as well as the oil have been removed from
unit. Traces of vapour should be displaced with dry
nitrogen. Refrigerant in contact with an open flame
produces toxic gases.
The necessary protection equipment must be available,
and appropriate fire extinguishers for the system and the
refrigerant type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it
into the eyes. Use safety goggles and safety gloves. Wash
any spills from the skin with soap and water. If liquid
refrigerant enters the eyes, immediately and abundantly
flush the eyes with water and consult a doctor.
Never apply an open flame or live steam to a refrigerant
container. Dangerous overpressure can result. If it is
necessary to heat refrigerant, use only warm water.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting conditioning and recovery of halogenated hydrocarbons under
optimum quality conditions for the products and optimum
safety conditions for people, property and the environment
are described in standard NF E29-795.
Any refrigerant transfer and recovery operations must be
carried out using a transfer unit. 3/8” SAE connectors on
the liquid, suction and discharge lines are available for all
units for connection to the transfer station. The units must
never be modified to add refrigerant and oil charging,
removal and purging devices. All these devices are provided
with the units. Please refer to the certified dimensional
drawings for the units.
Do not re-use disposable (non-returnable) cylinders or
attempt to refill them. It is dangerous and illegal. When
cylinders are empty, evacuate the remaining gas pressure,
and move the cylinders to a place designated for their
recovery. Do not incinerate.
Do not attempt to remove refrigerant circuit components
or fittings, while the machine is under pressure or while it
is running. Be sure pressure is at 0 kPa and that the unit
has been shut down and de-energised before removing
components or opening a circuit. If the refrigerant circuit
is open to carry out a repair, all circuit openings must be
plugged, if the repair takes longer than 30 minutes. This
prevents humidity from contaminating the circuit, especially
the oil. If the work is expected to take longer, charge the
circuit with nitrogen.
Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism.
If necessary, replace the device. Do not install safety valves
in series or backwards.
ATTENTION: No part of the unit must be used as a walkway, rack or support. The refrigerant lines can break under
the weight and release refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.)
to lift or move heavy components. For lighter components,
use lifting equipment when there is a risk of slipping or
losing your balance.
Use only original replacement parts for any repair or component replacement. Consult the list of replacement parts that
corresponds to the specification of the original equipment.
Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body first.
Close the entering and leaving water shutoff valves and
purge the unit water circuit, before working on the components installed on the circuit (screen filter, pump, water
flow switch, etc.).
Periodically inspect all valves, fittings and pipes of the
refrigerant and hydronic circuits to ensure that they do
not show any corrosion or any signs of leaks.
2 - PRELIMINARY CHECKS
2.1 - 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.
Compare the name plate data with the order. The name
plate is attached in two places to the unit:
- on one of the unit sides on the outside
- on the control box door on the inside.
The unit name plate must include the following
information:
- Version number
- Model number
- CE marking
- Serial number
- Year of manufacture and test date
- Refrigerant used and refrigerant class
- Refrigerant charge per circuit
- Containment fluid to be used
- PS: Min./max. allowable pressure (high and low
pressure side)
- TS: Min./max. allowable temperature (high and
low pressure side)
- Pressure switch cut-out pressure
- Unit leak test pressure
- Voltage, frequency, number of phases
- Maximum current drawn
- Maximum power input
- Unit net weight
Confirm that the options ordered for on-site installation
have been supplied, are complete and undamaged.
Do not keep the 61WG/30WG/30WGA units outside
where they are exposed to the weather, as the sensitive
control mechanism and the electronic modules may be
damaged.
The unit must be checked periodically during its whole
operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, repair or replace
the damaged parts (see chapter 15 “Maintenance”).
The machine must be installed in a place that is not
accessible to the public or protected against access by
non-authorised persons.
2.2 - Moving and placing the unit
2.2.1 - Moving
See chapter 1.1 - “Installation safety considerations”.
2.2.2 - Placing the unit
Always refer to the chapter “Dimensions and clearances”
to confirm that there is adequate space for all connections
and service operations. For the centre of gravity coordinates,
the position of the unit mounting holes, and the weight
distribution points, refer to the certified dimensional
drawing supplied with the unit.
It is recommended to wear ear defenders, when working
near the unit and the unit is in operation.
9
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been verified.
In case of extra-high units the machine environment must
permit easy access for maintenance operations.
CAUTION: Only use slings at the designated lifting
points which are marked on the unit.
Before siting the unit check that:
• the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
• the unit support points are located at the four lower
corners.
• the positioning at these four points must be horizontal
(level tolerance 1.5 mm/m in both axes)
• if the support structure is sensitive to vibration and/or
noise transmission it it advisable to insert anti-vibration
mounts (elastomeric mounts or springs) between the unit
and the structure. Selection of these devices is based
on the system characteristics and the comfort level
required and should be made by technical specialists.
• there is adequate space above the unit for air flow and
to ensure access to the components.
• the number of support points is adequate and that
they are in the right places.
• the location is not subject to flooding.
• No material or object that can be affected by condensate
(even a small amount) must be left under the machine
or in the water flow direction.
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.
ATTENTION: Stacked units must not be moved.
If 61WG/30WG/30WGA units are hoisted with rigging,
it is necessary to protect the unit frame (side and rear
panels and front doors) against accidental crushing. Use
struts or lifting beams to spread the slings above the unit.
Do not tilt a unit more than 15°, or 5° for units with the
stacking option (option 273). Always follow the instructions
on the handling notice attached to the unit.
If a unit includes a hydronic module (options 116 or 270),
the hydronic module and pump piping must be installed in
a way that does not submit it to any strain. The hydronic
module pipes must be fitted so that the pump does not
support the weight of the pipes.
Never push or lever on any of the enclosure panels (panels,
uprights, front access doors) of the unit. Only the base of
the unit frame is designed to withstand such stresses.
10
Checks before system start-up
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be
verified against the installation drawings, dimensional
drawings, system piping and instrumentation diagrams and
the wiring diagrams.
For these checks national regulations must be followed. If
the national regulation does not specify any details, refer
to standard EN 378 as follows:
External visual installation checks:
• Compare the complete installation with the refrigeration system and power circuit diagrams.
• Check that all components comply with the design
specifications.
• Check that all protection documents and equipment
provided by the manufacturer (dimensional drawings,
P&ID, declarations etc.) to comply with the regulations
are present.
• Verify that the environmental safety and protection and
devices and arrangements provided by the manufacturer
to comply with the regulations are in place.
• Verify that all documents for pressure containers, certificates, name plates, files, instruction manuals provided
by the manufacturer to comply with the regulations
are present.
• Verify the free passage of access and safety routes.
• Check that ventilation in the plant room is adequate.
• Check that refrigerant detectors are present.
• Verify the instructions and directives to prevent the
deliberate removal of refrigerant gases that are harmful
to the environment.
• Verify the installation of connections.
• Verify the supports and fixing elements (materials,
routing and connection).
• Verify the quality of welds and other joints.
• Check the protection against mechanical damage.
• Check the protection of moving parts.
• Verify the accessibility for maintenance or repair and
to check the piping.
• Verify the status of the valves.
• Verify the quality of the thermal insulation and of the
vapour barriers.
• Ensure that the position of the condensate drain piping
allows draining and that the connections are correct
for the water used.
• Avoid common routing of the customer power wiring
and other machine wiring, especially for longer runs
(> 200 mm).
3 - DIMENSIONS, CLEARANCES
3.1 - 61WG/30WG 020-045 - standard unit
160
237
5
2
Only for option 70F
470
470
901
1
3
153
153
2
625
161
237
600
1044
1
1058
900
700
700
4
3
700
4
4
4
3.2 - 61WG/30WG 020-045 - unit with top connections (option 274)
938
901
700
4
600
1044
Legend:
All dimensions are in mm.
900
86
700
Evaporator
Condenser
1
4
4
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
4
143
700
105
2
104
105
700
4
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings
available on request, when designing an installation.
11
3.3 - 61WG/30WG 020-045 - unit with evaporator hydronic module (option 116)
Only for option 70F
379
5
161 237
2
3
153
153
470
704
868
1463
1
2
625
1
600
1044
1058
900
700
700
4
3
700
4
4
4
3.4 - 61WG/30WG 020-045 - unit with condenser hydronic module (option 270)
142
2
398
2
1
Legend:
All dimensions are in mm.
Condenser
161
470
623
Evaporator
153
398
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
1
3.5 - 61WG/30WG 020-045 - unit with evaporator/condenser hydronic modules (options 116 + 270)
142 237
2
1
161
398
12
153
1
623
1021
2
NOTE: Non-contractual drawings. Refer to the certified
dimensional drawings available on request, when
designing an installation.
3.6 - 61WG/30WG 020-045 - unit with hydronic module and top connections
(options 116 + 274 or 270 + 274 or 116 + 270 + 274)
1500
1463
700
4
1044
167
900
86
1
1
4
700
4
4
143 237
221
700
4
2
167 86
700
2
3.7 - 61WG/30WG 020-045 - stackable unit (option 273)
1841
1014
1014
NOTE: The water and electrical connections are identical to those of the standard unit.
600
1058
900
700
Legend:
All dimensions are in mm.
700
Evaporator
Condenser
4
4
4
700
4
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings
available on request, when designing an installation.
13
3.8 - 61WG/30WG 050-090 - standard unit
252
Only for option 70F
310
201
253
2
310
901
905
451
204
456
450
2
3
5
1
880
1474
1
1489
900
700
700
4
3
4
4
700
4
938
4
901
700
3.9 - 61WG/30WG 050-090 - unit with top connections (option 274)
1474
880
900
80
700
700
4
4
Legend:
All dimensions are in mm.
1
4
4
4
4
Condenser
700
253
2
142 168 142
Evaporator
4
4
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings
available on request, when designing an installation.
14
3.10 - 61WG/30WG 050-090 - unit with evaporator hydronic module (option 116)
Only for option 70F
558
704
252
204
1021
657
3
1463
5
1
2
2
905
253 307
880
1474
1
1488
900
700
700
Legend:
All dimensions are in mm.
4
Evaporator
3
4
Condenser
4
700
4
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
3.11 - 61WG/30WG 050-090 - unit with condenser hydronic module (option 270)
277
2
2
252
204
657
1021
1
1
559
3.12 - 61WG/30WG 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270)
277 282
2
1
252
204
1021
657
2
559
1
NOTE: Non-contractual drawings. Refer to the
certified dimensional drawings available on
request, when designing an installation.
15
3.13 - 61WG/30WG 050-090 - unit with hydronic module and top connections
(options 116 + 274 or 270 + 274 - 116 or 270 + 274)
1500
1463
700
4
1474
172
80
1
700
4
1
4
700
278
4
282
900
4
172
80 700
2
2
3.14 - 61WG/30WG 050-090 - stackable unit (option 273)
1014
1014
1841
NOTE: The water and electrical connections are identical to those of the standard unit.
880
1489
700
900
700
Legend:
All dimensions are in mm.
Evaporator
4
Condenser
4
4
700
16
4
Safety valve
Clearances required for maintenance (see note)
Control box
Water inlet
Water outlet
Power wiring connection
NOTE: Non-contractual drawings. Refer to the certified dimensional drawings
available on request, when designing an installation.
3.15 - 30WGA 020-045 - standard unit
For option 70F only
625
153
146
470
901
397
50
144
203
600
1044
1058
900
700
Legend:
All dimensions are in mm.
700
Evaporator
Condenser
Safety valve
Control box
700
6
7
Clearances required for maintenance (see note)
Refrigerant inlet
Refrigerant outlet
Water inlet
Water outlet
Power wiring connection
3.16 - 30WGA 020-045 - unit with evaporator hydronic module (option 116)
For option 70F only
379
5
1058
900
700
4
700
6
600
1044
1
3
4
700
7
51
203
3
153
146
704
868
1463
1
144
625
4
4
NOTE: Non-contractual drawings. Refer to the
certified dimensional drawings available on
request, when designing an installation.
17
3.17 - 30WGA 020-045 - stackable unit (option 273)
1840
1014
1014
NOTE: The water and electrical connections are identical to those of the standard unit.
1058
600
900
700
Legend:
All dimensions are in mm.
700
Evaporator
4
Condenser
Safety valve
Control box
4
700
4
4
238
321
Power wiring connection
905
3
6
204
192
451
450
461
7
Water outlet
For option 70F only
5
1
Refrigerant outlet
901
315
Refrigerant inlet
Water inlet
3.18 - 30WGA 050-090 - standard unit
247
6
7
Clearances required for maintenance (see note)
1474
880
1488
1
700
700
900
4
3
4
700
4
18
4
NOTE: Non-contractual drawings. Refer to the
certified dimensional drawings available on
request, when designing an installation.
3.19 - 30WGA 050-090 - unit with evaporator hydronic module (option 116)
For option 70F only
558
905
5
7
1021
1463HT
1
192
204
653
6
3
704
247
238
321
880
1474
1
1488HT
700
700
900
Legend:
All dimensions are in mm.
Evaporator
4
4
Condenser
4
700
3
4
Safety valve
Control box
6
7
Refrigerant inlet
Refrigerant outlet
Water inlet
3.20 - 30WGA 050-090 - stackable unit (option 273)
Clearances required for maintenance (see note)
Water outlet
Power wiring connection
880
1488
700
900
700
4
4
4
700
1841
1014
1014
NOTE: The water and electrical connections are identical to those of the standard unit.
4
NOTE: Non-contractual drawings. Refer to the
certified dimensional drawings available on
request, when designing an installation.
19
4 - PHYSICAL AND ELECTRICAL DATA 61WG/30WG
4.1 - Physical data 61WG
61WG
020
025
030
035
040
045
Operating weight*
kg
191
200
200
207
212
220
Sound levels**
dB(A)
67.0
68.5
69.0
69.3
70.0
70.1
Sound power level 10-12 W, standard unit
Hermetic scroll 48.3 r/s
Compressors
Quantity
1
1
1
1
1
1
Number of capacity steps
1
1
1
1
1
1
Minimum capacity
%
100
100
100
100
100
100
Refrigerant*
R-410A
Charge, standard unit
kg
3.5
3.5
3.6
3.7
4.0
4.6
Charge, unit with option 272
kg
2.7
2.9
2.9
3.0
3.2
3.9
Oil
160SZ
Charge per compressor
l
3
3.3
3.3
3.3
3.3
3.6
Control
Pro-Dialog+
Evaporator
Direct-expansion plate heat exchanger
Water volume
l
3.3
3.6
3.6
4.2
4.6
5.0
Water connections
Victaulic
Inlet/outlet
in
1.5
1.5
1.5
1.5
1.5
1.5
Max. water-side operating pressure without kPa
1000
1000
1000
1000
1000
1000
hydronic module
Condenser
Plate heat exchanger
Net water volume
l
3.3
3.6
3.6
4.2
4.6
5.0
Water connections
Victaulic
Inlet/outlet
in
1.5
1.5
1.5
1.5
1.5
1.5
Max. water-side operating pressure without kPa
1000
1000
1000
1000
1000
1000
hydronic module
* Weight shown is a guideline only. To find out the unit refrigerant charge, please refer to the unit nameplate
** In accordance with ISO 9614-1, measured in a free field. The sound levels only apply to units without options.
050
386
060
392
070
403
080
413
090
441
71.5
72.0
72.0
73.0
73.4
2
2
50
2
2
50
2
2
50
2
2
50
2
2
50
7.6
7.2
7.8
7.3
7.9
7.4
8.7
7.6
11.5
10.5
3.3
3.3
3.3
3.3
3.6
8.4
9.2
9.6
10.4
12.5
2
1000
2
1000
2
1000
2
1000
2
1000
8.4
9.2
9.6
10.4
12.5
2
1000
2
1000
2
1000
2
1000
2
1000
050
386
060
392
070
403
080
413
090
441
71.5
72.0
72.0
73.0
73.4
2
2
50
2
2
50
2
2
50
2
2
50
2
2
50
7.6
7.8
7.9
8.7
11.5
3.3
3.3
3.3
3.3
3.6
8.4
9.2
9.6
10.4
12.5
2
1000
2
1000
2
1000
2
1000
2
1000
8.4
9.2
9.6
10.4
12.5
2
1000
2
1000
2
1000
2
1000
2
1000
4.2 - Physical data 30WG
30WG
020
025
030
035
040
045
Operating weight*
kg
191
200
200
207
212
220
Sound levels**
dB(A)
67.0
68.5
69.0
69.3
70.0
70.1
Sound power level 10-12 W
Hermetic scroll 48.3 r/s
Compressors
Quantity
1
1
1
1
1
1
Number of capacity steps
1
1
1
1
1
1
Minimum capacity
%
100
100
100
100
100
100
Refrigerant*
R-410A
Charge
kg
3.5
3.5
3.6
3.7
4.0
4.6
Oil
160SZ
Charge per compressor
l
3
3.3
3.3
3.3
3.3
3.6
Control
Pro-Dialog+
Evaporator
Direct-expansion plate heat exchanger
Water volume
l
3.3
3.6
3.6
4.2
4.6
5.0
Water connections
Victaulic
Inlet/outlet
in
1.5
1.5
1.5
1.5
1.5
1.5
Max. water-side operating pressure without kPa
1000
1000
1000
1000
1000
1000
hydronic module
Condenser
Plate heat exchanger
Net water volume
l
3.3
3.6
3.6
4.2
4.6
5.0
Water connections
Victaulic
Inlet/outlet
in
1.5
1.5
1.5
1.5
1.5
1.5
Max. water-side operating pressure without kPa
1000
1000
1000
1000
1000
1000
hydronic module
* Weight shown is a guideline only. To find out the unit refrigerant charge, please refer to the unit nameplate
** In accordance with ISO 9614-1, measured in a free field. The sound levels only apply to units without options.
20
4.3 - Physical data 30WGA
30WGA
020
025
030
035
040
045
Operating weight*
kg
164
171
171
177
180
185
Sound levels**
dB(A)
67.0
68.5
69.0
69.3
70.0
70.1
Sound power level 10-12 W
Hermetic scroll 48.3 r/s
Compressors
Quantity
1
1
1
1
1
1
Number of capacity steps
1
1
1
1
1
1
Minimum capacity
%
100
100
100
100
100
100
Refrigerant
R-410A
Oil
160SZ
Charge per compressor
l
3
3.3
3.3
3.3
3.3
3.6
Control
Pro-Dialog+
Evaporator
Direct-expansion plate heat exchanger
Water volume
l
3.3
3.6
3.6
4.2
4.6
5.0
Water connections
Victaulic
Inlet/outlet
in
1.5
1.5
1.5
1.5
1.5
1.5
Max. water-side operating pressure without kPa
1000
1000
1000
1000
1000
1000
hydronic module
Refrigerant connections
Discharge line diameter
in
7/8
7/8
7/8
7/8
7/8
7/8
Liquid line diameter
in
5/8
5/8
5/8
5/8
5/8
5/8
* Weight shown is a guideline only. To find out the unit refrigerant charge, please refer to the unit nameplate
** In accordance with ISO 9614-1, measured in a free field. The sound levels only apply to units without options.
050
321
060
324
070
332
080
339
090
354
71.5
72.0
72.0
73.0
73.4
2
2
50
2
2
50
2
2
50
2
2
50
2
2
50
3.3
3.3
3.3
3.3
3.6
8.4
9.2
9.6
10.4
12.5
2
1000
2
1000
2
1000
2
1000
2
1000
1-1/8
7/8
1-1/8
7/8
1-1/8
7/8
1-1/8
7/8
1-1/8
7/8
4.4 - Physical data 61WG/30WG/30WGA units with hydronic module
61WG/30WG/30WGA
020
025
030
035
040
045
050
060
070
080
090
Operating weight 30WG/61WG (option 116J + 270J)*
kg
305
313
313
321
327
334
513
521
533
544
574
Weight 30WGA (option 116J)*
kg
250
258
258
263
266
271
431
435
442
449
465
Height**
mm
1463
1463
1463
1463
1463
1463
1463
1463
1463
1463
1463
Hydronic module
Maximum operating pressure
kPa
300
300
300
300
300
300
300
300
300
300
300
Water filter (max. removed particle diameter)
mm
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
Expansion tank capacity***
l
8
8
8
8
8
8
12
12
12
12
12
Water connections
in
1.5
1.5
1.5
1.5
1.5
1.5
2
2
2
2
2
* Weight shown is a guideline only. .
** The length and width dimensions are the same as for the standard unit.
*** When delivered, the standard pre-inflation of the tanks is not necessary the optimal value for the system. To permit changing the water volume, change the inflation
pressure to a pressure that is close to the static head of the system. Fill the system with water (purging the air) to a pressure value that is 10 to 20 kPa higher than the
pressure in the tank.
21
4.5 - Electrical data 61WG/30WG/30WGA
61WG without hydronic module
Power circuit
Nominal voltage
Voltage range
Control circuit supply
Maximum start-up current draw (Un)*
Standard unit
Unit with electronic starter option
Unit power factor at maximum capacity**
Maximum operating power input**
Nominal unit operating current draw***
Maximum operating current draw (Un)****
Maximum operating current draw (Un-10%)†
Customer-side unit power reserve
Short-circuit stability and protection
020
025
030
035
040
045
V-ph-Hz
V
400-3-50
360-440
24 V, via internal transformer
A
A
98
142
142
147
158
197
53.9
78.1
78.1
80.9
86.9
108.4
0.83
0.82
0.84
0.83
0.82
0.84
9.7
11.4
12.8
14.7
16.6
18.7
12.9
15.8
16.8
19.2
20.7
24.6
16.1
19.6
21.1
24.4
26.7
30.9
17.8
21.6
23.2
26.9
29.4
34.0
Customer reserve at the 24 V control power circuit
See table below "Short-circuit stability current"
kW
A
A
A
050
060
070
080
090
161
98
0.82
22.8
31.6
39.2
43.2
163
99
0.82
25.6
33.6
42.2
46.4
172
105
0.83
29.4
38.4
48.8
53.8
185
114
0.82
33.2
41.4
53.4
58.8
226
139
0.84
37.4
49.2
61.8
68.0
* Maximum instantaneous start-up current at operating limit values (maximum operating current of the smallest compressor(s) + locked rotor current or limited start-up current of the largest compressor).
** Maximum power input at the unit operating limits. *** Values obtained at standardised Eurovent conditions: evaporator entering/leaving water temperature 10 °C/7 °C, condenser entering/leaving water temperature 30 °C/35 °C.
**** Maximum unit operating current at maximum unit power input and 400 V.
† Maximum unit operating current at maximum unit power input and 360 V.
30WG without hydronic module
Power circuit
Nominal voltage
Voltage range
Control circuit supply
Maximum start-up current draw (Un)*
Standard unit
Unit with electronic starter option
Unit power factor at maximum capacity**
Maximum operating power input**
Nominal unit operating current draw***
Maximum operating current draw (Un)****
Maximum operating current draw (Un-10%)†
Customer-side unit power reserve
Short-circuit stability and protection
020
025
030
035
040
045
V-ph-Hz
V
400-3-50
360-440
24 V, via internal transformer
A
A
98
142
142
147
158
197
53.9
78.1
78.1
80.9
86.9
108.4
0.83
0.82
0.84
0.83
0.82
0.84
9.7
11.4
12.8
14.7
16.6
18.7
12.9
18.8
16.8
19.2
20.7
24.6
15.6
18.7
19.8
23.2
25.4
29.0
17.2
20.6
21.8
25.6
28.0
31.9
Customer reserve at the 24 V control power circuit
See table below "Short-circuit stability current"
kW
A
A
A
050
060
070
080
090
161
96.8
0.82
22.8
31.6
37.5
41.2
163
97.9
0.82
24.6
33.6
39.6
43.6
172
104.1
0.83
29.4
38.4
46.4
51.2
185
112.3
0.82
33.2
41.4
50.8
56.0
227
137.4
0.84
37.4
49.2
58.0
63.8
* Maximum instantaneous start-up current at operating limit values (maximum operating current of the smallest compressor(s) + locked rotor current or limited start-up current of the largest compressor).
** Maximum power input at the unit operating limits.
*** Values obtained at standardised Eurovent conditions: evaporator entering/leaving water temperature 12 °C/7 °C, condenser entering/leaving water temperature 30 °C/ 35 °C.
**** Maximum unit operating current at maximum unit power input and 400 V.
† Maximum unit operating current at maximum unit power input and 360 V.
30WGA without hydronic module
Power circuit
Nominal voltage
Voltage range
Control circuit supply
Maximum start-up current draw (Un)*
Standard unit
Unit with electronic starter option
Unit power factor at maximum capacity**
Maximum operating power input**
Nominal unit operating current draw***
Maximum operating current draw (Un)****
Maximum operating current draw (Un-10%)†
Customer-side unit power reserve
Short-circuit stability and protection
020
025
030
035
040
045
V-ph-Hz
V
400-3-50
360-440
24 V, via internal transformer
A
A
98
142
142
147
158
197
53.9
78.1
78.1
80.9
86.9
108.4
0.83
0.82
0.84
0.83
0.82
0.84
9.7
11.4
12.8
14.7
16.6
18.7
11.4
13.8
14.7
16.5
18.1
21.2
14.7
17.7
19.3
21.7
24.1
27.5
16.2
19.5
21.3
23.9
26.5
30.3
Customer reserve at the 24 V control power circuit
See table below "Short-circuit stability current"
kW
A
A
A
050
060
070
080
090
161
96.8
0.82
22.8
27.6
35.4
39.0
163
97.9
0.82
25.6
29.4
38.7
42.6
172
104.1
0.83
29.4
33.0
43.5
47.8
185
112.3
0.82
33.2
36.2
48.1
53.0
228
137.4
0.84
37.4
42.4
55.0
60.6
* Maximum instantaneous start-up current at operating limit values (maximum operating current of the smallest compressor(s) + locked rotor current or limited start-up current of the largest compressor).
** Maximum power input at the unit operating limits.
*** Values obtained at the following conditions: evaporator entering/leaving water temperature 12 °C/7 °C, condenser entering/leaving water temperature 45 °C.
**** Maximum unit operating current at maximum unit power input and 400 V.
† Maximum unit operating current at maximum unit power input and 360 V.
4.6 - Short-circuit stability current (TN system*) - standard unit (with main disconnect switch)
61WG/30WG/30WGA
020
025
030
035
040
045
050
060
070
080
090
Value with non-specified upstream protection
Short-term current at 1 s - Icw - kA rms
3
3
3
3
3
3
3
3
3
3
3
Admissible peak current - Ipk - kA pk
6
6
6
6
6
6
6
6
6
6
6
Maximum value with upstream protection (by circuit breaker)
Conditional short-circuit current Icc - kA rms
40
40
40
40
40
40
40
40
40
40
40
Schneider circuit breaker - Compact series
NSX 100N
Reference number**
LV429795
* Earthing system type
** If another current limitation protection system is used, its time-current and thermal constraint (I²t) trip characteristics must be at least equivalent to those of the
recommended Schneider circuit breaker. Contact your nearest Carrier office.
The short-circuit stability current values above are in accordance with the TN system.
22
4.7 - Electrical data, optional hydronic module
The pumps that are factory-installed in these units have
motors with efficiency class IE2. The additional electrical
data required* is as follows:
Motors of fixed-speed hydronic module pumps, 61WG/30WG/30WGA (options 116F and 270F)
No.** Description***
1
1
1
2
3
4
5
6
7-1
7-2
8
9-1
9-2
10
11
12
Nominal efficiency at full load and nominal voltage
Nominal efficiency at 75% rated load and nominal voltage
Nominal efficiency at 50% rated load and nominal voltage
Efficiency level
Year of manufacture
Manufacturer's name and trademark, commercial registration
number and place of manufacturer
Product's model number
Number of motor poles
Rated shaft power output at full load and nominal voltage (400 V)
Maximum power input (400 V)****
Rated input frequency
Rated voltage
Maximum current drawn (400 V)†
Rated speed
Product disassembly, recycling or disposal at end of life
Operating conditions for which the motor is specifically designed
I - Altitudes above sea level
II - Ambient air temperature
IV - Maximum air temperature
%
%
%
kW
kW
Hz
V
A
r/s
rpm
m
°C
V - Potentially explosive atmospheres
61WG/30WG/30WGA - options 116F and 270F (low-pressure pumps)
20
25
30
35
40
45
50
60
70
80
79.5
79.5
79.5
79.5
79.5
79.5
79.5
79.5
79.5
79.5
78.2
78.2
78.2
78.2
78.2
78.2
78.2
78.2
78.2
78.2
74.5
74.5
74.5
74.5
74.5
74.5
74.5
74.5
74.5
74.5
IE2
This information varies depending on the manufacturer and model at the time of
incorporation. Please refer to the motor name plates.
90
82.3
81.8
79.7
2
2
2
2
2
2
2
2
2
2
2
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
1.25
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.5
50
3 x 400
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.3
2.3
2.3
3.1
2838 2838 2838 2838 2838 2838 2838 2838 2838 2838 2892
47
47
47
47
47
47
47
47
47
47
48
Disassembly using standard tools. Disposal and recycling using an appropriate company.
< 1000††
< 40
Please refer to the operating conditions given in this manual or in the specific conditions
in the Carrier selection programs.
Non-ATEX environment
Motors of variable-speed hydronic module pumps, 61WG/30WG/30WGA (options 116J and 270J)
No.** Description***
1
1
1
2
3
4
5
6
7-1
7-2
8
9-1
9-2
10
11
12
Nominal efficiency at full load and nominal voltage
Nominal efficiency at 75% rated load and nominal voltage
Nominal efficiency at 50% rated load and nominal voltage
Efficiency level
Year of manufacture
Manufacturer's name and trademark, commercial registration
number and place of manufacturer
Product's model number
Number of motor poles
Rated shaft power output at full load and nominal voltage (400 V)
Maximum power input (400 V)****
Rated input frequency
Rated voltage
Maximum current drawn (400 V)†
Rated speed
Product disassembly, recycling or disposal at end of life
Operating conditions for which the motor is specifically designed
I - Altitudes above sea level
II - Ambient air temperature
IV - Maximum air temperature
V - Potentially explosive atmospheres
%
%
%
kW
kW
Hz
V
A
r/s
rpm
m
°C
61WG/30WG/30WGA - options 116J and 270J (high-pressure pumps)
20
25
30
35
40
45
50
60
70
80
82.3
82.3
82.3
82.3
82.3
82.3
81.9
81.9
81.9
81.9
81.8
81.8
81.8
81.8
81.8
81.8
81.8
81.8
81.8
81.8
79.7
79.7
79.7
79.7
79.7
79.7
79.1
79.1
79.1
79.1
IE2
This information varies depending on the manufacturer and model at the time of
incorporation. Please refer to the motor name plates.
90
81.9
81.8
79.1
2
2
2
2
2
2
2
2
2
2
2
1.25
1.25
1.25
1.25
1.25
1.25
1.70
1.70
1.70
1.70
1.70
1.50
1.50
1.50
1.50
1.50
1.50
2.30
2.30
2.30
2.30
2.30
50
3 x 400
3.1
3.1
3.1
3.1
3.1
3.1
4.3
4.3
4.3
4.3
4.3
48
48
48
48
48
48
48
48
48
48
48
2892 2892 2892 2892 2892 2892 2863 2863 2863 2863 2863
Disassembly using standard tools. Disposal and recycling using an appropriate company.
< 1000††
< 40
Please refer to the operating conditions given in this manual or in the specific conditions
in the Carrier selection programs.
Non-ATEX environment
* Required by regulation 640/2009 with regard to the application of directive 2005/32/EC on the eco-design requirements for electric motors
** Item number imposed by regulation 640/2009, annex I2b.
*** Description given by regulation 640/2009, annex I2b.
**** To obtain the maximum power input for a unit with hydronic module add the maximum unit power input from the electrical data table to the pump power input.
† To obtain the maximum unit operating current draw for a unit with hydronic module add the maximum unit current draw from the electrical data table to the pump current
draw.
†† Above 1000 m, a degradation of 3% for each 500 m should be taken into consideration.
23
4.8 - Compressor usage and electrical data table
Compressor Reference
SH090
SH105
SH120
SH140
SH161
SH184
00PSG001482000
00PSG001482100
00PSG001482200
00PSG001482300
00PSG001482400
00PSG001482500
Compressor Reference
WSH090
WSH105
WSH120
WSH140
WSH161
WSH184
00PSG001549100
00PSG001549200
00PSG001549300
00PSG001549400
00PSG001549500
00PSG001549600
Compressor Reference
I Nom
I Max
(Un)
I Max
LRA*
(Un - 10%)
10.5
13.2
13.8
15.6
16.2
20.2
16.1
19.6
21.1
24.4
26.7
30.9
17.8
21.6
23.2
26.9
29.4
34.0
98
142
142
147
158
197
I Nom
I Max
(Un)
I Max
LRA*
(Un - 10%)
10.6
12.9
13.3
15.2
16.5
19.7
15.6
18.7
19.8
23.2
25.4
29
17.2
20.6
21.8
25.6
28.0
31.9
98
142
142
147
158
197
I Nom
I Max
(Un)
I Max
LRA*
(Un - 10%)
LRA**
53.9
78.1
78.1
80.9
86.9
108.4
LRA**
53.9
78.1
78.1
80.9
86.9
108.4
LRA**
61WG
020
025
1
1
30WG
020
025
1
1
30WGA
020
025
1
1
030
1
030
1
035
040
045
050
2
1
035
1
040
1
2
070
2
1
045
050
2
1
060
060
2
070
2
1
030
035
040
045
WSH090
00PSG001549100 11.4
14.7
16.2
98
53.9
WSH105
00PSG001549200 13.8
17.7
19.5
142
78.1
WSH120
00PSG001549300 14.7
19.3
21.3
142
78.1
1
WSH140
00PSG001549400 16.5
21.7
23.8
147
80.9
1
WSH161
00PSG001549500 18.1
24.1
26.5
158
86.9
1
WSH184
00PSG001549600 21.2
27.5
30.3
197
108.4
1
Legend
I Nom Nominal current draw (A) at standard Eurovent conditions see definition of conditions under nominal unit current draw)
I Max Maximum operating current, A
LRA* Locked rotor current at nominal voltage, A
LRA** Locked rotor current with electronic starter at nominal voltage, A
050
2
060
2
070
2
080
2
080
2
080
2
090
2
090
2
090
2
Electrical data notes and operating conditions:
•
•
•
•
61WG/30WG/30WGA units have a single power connection point, located
immediately upstream of the main disconnect switch.
The control box includes the following standard features:
- a main disconnect switch,
- the starter and motor protection devices for each compressor and the pumps
- the 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 61WG/30WG/30WGA units are designed and built to ensure
conformance with these codes. The recommendations of European standard
EN 60204-1 (machine safety ‑ electrical machine components ‑ part 1: general
regulations - corresponds to IEC 60204-1) are specifically taken into account,
when designing the electrical unit equipment.
NOTES:
•
•
1.
24
Generally the recommendations of IEC 60364 are accepted as compliance with
the requirements of the installation directives. Conformance with EN 60204-1
is the best means of ensuring compliance with the Machines Directive § 1.5.1.
Annex B of EN 60204-1 describes the electrical characteristics used for the
operation of the machines.
The operating conditions for the units are specified below:
Environment* ‑ Environment as classified in EN 60721 (equivalent to
CEI60721):
- Indoor installation
- ambient temperature range: +5 °C for the temperature minimum to +40 °C,
class 4K4H
- humidity range (non-condensing)*:
- 50% relative humidity at 40 °C
- 90% relative humidity at 20 °C
- altitude: ≤ 2000 m (see note for table 4.7 - Electrical data, hydronic module)
- indoor installation*
2.
3.
4.
5.
6.
7.
- presence of water: class AD2 (possibility of water droplets)
- presence of hard solids, class 4S2 (no significant dust present)
- presence of corrosive and polluting substances, class 4C2 (negligible)
- vibration and shock, class AG2, AH2
- competence of personnel, class BA4* (trained personnel ‑ IEC 60364)
Power supply frequency variation: ± 2 Hz.
The neutral (N) conductor must not be connected directly to the unit (if
necessary use a transformer).
Over-current protection of the power supply conductors is not provided with
the unit.
The factory-installed disconnect switch(es)/circuit breaker(s) is (are) of a type
suitable for power interruption in accordance with EN 60947.
The units are designed for simplified connection on TN(s) networks (IEC 60364).
For IT networks provide a local earth and consult competent local organisations
to complete the electrical installation. Units delivered with speed drive
(option116F/116J and 270F/270J) are not compatible with IT network.
Derived currents: If protection by monitoring of derived currents is necessary to
ensure the safety of the installation, the control of the cut-out value must take the
presence of leak currents into consideration that result from the use of frequency
converters in the unit. A value of at least 150 mA is recommended to control
differential protection devices.
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 protection level of the control boxes required to conform to this class is IPX1B
(according to reference document IEC 60529). All 61WG/30WG/30WGA units
fulfil this protection condition.
Units equipped with front casing panel meet class IP23. If the casing panel has
been removed, access to energised components is protected to level IPXXB.
5 - APPLICATION DATA
5.1 - Operating limits 61WG
5.3 - Operating limits 30WG
61WG
Minimum
Maximum
Evaporator
Entering water temperature at start-up
°C
7.5*
27
Leaving water temperature during operation
°C
5**
20
Entering/leaving water temperature difference
K
2.5
7
Condenser
Entering water temperature at start-up
°C
15***
60****
Leaving water temperature during operation
°C
20
65
Entering/leaving water temperature difference
K
2.5
18
* For entering water temperatures below 7.5 °C at start-up, contact Carrier.
** If the leaving water temperature is below 5 °C, a frost protection solution
must be used. Please refer to option 272 for evaporator leaving water lowtemperature applications (< 5 °C).
*** For applications with a condenser entering temperature below 15 °C the use of
a three-way valve is recommended. This three-way valve can be controlled by
the 0-10 V analogue output of the Pro-Dialog+ control.
**** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
30WG
Minimum
Maximum
Evaporator
Entering water temperature at start-up
°C
7.5*
27
Leaving water temperature during operation
°C
5**
20
Entering/leaving water temperature difference
K
2.5
7
Condenser
Entering water temperature at start-up
°C
15***
55****
Leaving water temperature during operation
°C
20
60
Entering/leaving water temperature difference
K
2.5
18
* For entering water temperatures below 7.5 °C at start-up, contact Carrier.
** If the leaving water temperature is below 5 °C, a frost protection solution must
be used. Please refer to option 6 for evaporator leaving water low-temperature
applications (< 5 °C).
*** For applications with a condenser entering temperature below 15 °C the use of
a three-way valve is recommended. This three-way valve can be controlled by
the 0-10 V analogue output of the Pro-Dialog+ control.
**** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
61WG + option 272 (geothermal application)
Minimum
Maximum
Evaporator
Entering water temperature at start-up
°C
-2.5*
25
Leaving water temperature during operation
°C
-5*
20
Entering/leaving water temperature difference
K
2.5
5
Condenser
Entering water temperature at start-up
°C
15**
60***
Leaving water temperature during operation
°C
20
65
Entering/leaving water temperature difference
K
2.5
18
* A frost protection solution must be used.
** For applications with a condenser entering temperature below 15 °C the use of
a three-way valve is recommended. This three-way valve can be controlled by
the 0-10 V analogue output of the Pro-Dialog+ control.
*** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
30WG + option 6
Minimum
Maximum
Evaporator
Entering water temperature at start-up
°C
-9.5*
27
Leaving water temperature during operation
°C
-12*
20
Entering/leaving water temperature difference
K
2.5
3
Condenser
Entering water temperature at start-up
°C
15**
55***
Leaving water temperature during operation
°C
20
60
Entering/leaving water temperature difference
K
2.5
18
Note: Do not exceed the maximum operating temperature.
* A frost protection solution must be used.
** For applications with a condenser entering temperature below 15 °C the use of
a three-way valve is recommended. This three-way valve can be controlled by
the 0-10 V analogue output of the Pro-Dialog+ control.
*** For a water flow rate that corresponds to a maximum water-side temperature
difference of 5 K.
65
60
55
50
45
40
35
30
25
20
15
Option 272
-8
-6
-4
-2
0
2
Standard
4
6
8
10
12
14
Evaporator leaving water temperature, °C
61WG standard unit
61WG unit with option 272 (brine to water)
16
18
20
30WG + drycooler
Minimum
Maximum
Evaporator
Entering water temperature at start-up
°C
7.5*
27
Leaving water temperature during operation
°C
5**
20
Entering/leaving water temperature difference
K
2.5
7
Condenser without hydronic kit
Entering air temperature at start-up + during
°C
10-15***
40-45****
operation
Condenser with option 270J (kit with variable-speed pump)
Entering air temperature at start-up+ during
°C
-10†
40-45****
operation
* For entering water temperatures below 7.5 °C at start-up, contact Carrier.
** If the leaving water temperature is below 5 °C, a frost protection solution must
be used. Please refer to option 6 for evaporator leaving water low-temperature
applications (< 5 °C).
*** The minimum entering air temperature is based on the drycooler selection.
**** The maximum entering air temperature is based on the drycooler selection.
† For applications with a low condenser entering air temperature the use of a
three-way valve is recommended. This thre-way valve can be controlled by the
0-10 V analogue output of the Pro-Dialog+ control.
5.4 - Operating range 30WG
Condenser leaving water temperature, °C
Condenser leaving water temperature, °C
5.2 - Operating range 61WG
65
60
55
50
45
40
Option 6
Standard
35
30
25
20
15
-14 -12 -10 -8 -6 -4 -2
0
2
4
6
8 10 12 14 16 18 20
Evaporator leaving water temperature, °C
30WG standard unit
30WG unit with option 6 (brine)
25
5.5 - Operating limits 30WGA
5.10 - Water flow rates
30WG
Minimum Maximum
Evaporator
Entering water temperature at start-up
°C 7.5*
27
Leaving water temperature during operation
°C 5**
20
Entering/leaving water temperature difference
K
2,5
7
Air entering temperature (at start-up and during operation)***
Air entering temperature (fixed-speed fan)
°C 0***
35 to 48‡
Air entering temperature (variable-speed fan)
°C -10 to -20† 35 to 48‡
* For entering water temperatures below 7.5 °C at start-up, contact Carrier.
** 30WGA unit can operate down to 0 °C if the configuration of the fluid type used
is modified. If the leaving water temperature is below 5 °C, a frost protection
solution must be used.
*** The minimum temperature range is based on the condenser selected. If
the condenser only has a few fan stages, the use of variable-speed fans is
recommended from 10 °C.
† The minimum temperature range is based on the condenser selected.
‡ The maximum temperature range is based on the condenser selected.
5.10.1 - Standard 61WG
*
5.6 - Operating range 30WGA
Condensing temperatre, °C
60
55
50
Medium
temperature
application
40
35
Standard
30
25
20
-2
0
2
4
6
8
10
12
14
16
Evaporator leaving water temperature, °C
Maximum***
Low
High
pressure pressure
3.1
3.6
3.3
3.8
3.3
3.8
3.6
4.2
3.8
4.4
4.0
4.6
5.4
7.8
6.1
8.0
6.2
8.1
6.3
8.3
7.8
8.7
Maximum****
3.8
4.1
4.1
4.7
5.0
5.4
9.2
9.9
10.3
10.9
12.5
Units with hydronic module
Flow rate for a maximum permitted temperature difference at the minimum
leaving water temperature
** Units without hydronic module
Flow rate for a maximum permitted temperature difference at the minimum
leaving water temperature
*** Units with hydronic module
Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
**** Units without hydronic module
Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger.
65
45
61WG Evaporator water flow rate, l/s
Minimum*
Minimum**
Low
High
pressure pressure
020
1.0
0.9
0.5
025
1.0
1.0
0.5
030
1.0
1.0
0.5
035
1.1
1.1
0.6
040
1.2
1.1
0.6
045
1.2
1.1
0.8
050
1.6
1.4
0.8
060
1.5
1.6
1.0
070
1.6
1.5
1.1
080
1.6
1.5
1.3
090
2.0
1.6
1.5
18
20
30WGA standard unit
30WGA unit for medium temperature application (% glycol < 25%)
5.7 - Minimum chilled water flow
If the system water flow rate is lower than the minimum
water flow rate, recirculation of the evaporator flow may
occur. The temperature of the mixture leaving the evaporator
must never be less than 2.5 K lower than the chilled water
entering temperature.
5.8 - Maximum chilled water flow
The maximum chilled water flow is limited by the maximum
permitted pressure drop in the evaporator. It is provided in
the tables in chapter 5.7. If the flow exceeds the maximum
value, two solutions are possible:
• Modify the flow rate with a control valve.
• Bypass the evaporator to obtain a highter temperature
difference with a lower evaporator flow rate.
5.9 - Variable flow
A pump with variable flow can be used in these units. The
units maintain a constant leaving water temperature under
all flow conditions. For this to happen, the minimum flow
rate must be higher than the minimum flow given in the
table of permissible flow rates and must not vary by more
than 10% per minute.
If the flow rate changes more rapidly, the system should
contain a minimum of 6.5 litres of water per kW instead of
the values below.
26
61WG Condenser water flow rate, l/s
Minimum*
Maximum**
Low pressure
020
0.3
3.1
025
0.3
3.3
030
0.3
3.3
035
0.4
3.5
040
0.4
3.7
045
0.4
3.9
050
0.4
4.8
060
0.5
5.5
070
0.5
5.6
080
0.6
5.8
090
0.6
7.2
High pressure
3.5
3.8
3.8
4.1
4.3
4.5
6.8
7.0
7.2
7.4
7.9
Maximum***
3.8
4.1
4.1
4.7
5.0
5.4
7.0
7.5
7.8
8.2
9.3
*
**
Units with or without hydronic module
Minimum flow rate for a water temperature difference of 18 KNote: Operation permitted up to a value of 20 K.
Units with hydronic module
Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
*** Units without hydronic module
Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger
5.10.2 - 61WG with option 272
61WG
Minimum evaporator glycol solution flow rate - option 272*, l/s
Minimum**
Minimum***
Low pressure
High pressure
020
0.5
0.5
0.5
025
0.5
0.5
0.5
030
0.5
0.5
0.5
035
0.6
0.6
0.6
040
0.6
0.6
0.6
045
0.8
0.8
0.8
050
2.0
1.9
0.8
060
1.9
1.9
1.0
070
1.9
1.9
1.1
080
1.9
2.0
1.3
090
2.2
2.0
1.5
* Option 272: Condenser side high-temperature water production, evaporator
side with glycol solution,
** Units with hydronic module
Minimum flow rate for a maximum permitted temperature difference at the
minimum leaving water temperature
*** Units without hydronic module
Minimum flow rate for a maximum permitted temperature difference at the
minimum leaving water temperature
5.10.3 - Standard 30WG/30WGA
5.11 - Minimum water volume
30WG
Evaporator water flow rate, l/s
30WGA Minimum*
Minimum** Maximum***
Maximum****
Low
High
Low
High
pressure pressure
pressure pressure
020
1.0
0.9
0.5
3.1
3.6
3.8
025
1.0
1.0
0.5
3.3
3.8
4.1
030
1.0
1.0
0.5
3.3
3.8
4.1
035
1.1
1.1
0.6
3.6
4.2
4.7
040
1.1
1.1
0.6
3.8
4.4
5
045
1.2
1.1
0.8
4.0
4.6
5.4
050
1.6
1.4
0.8
5.4
7.8
9.2
060
1.5
1.6
1.0
6.1
8.0
9.9
070
1.6
1.5
1.1
6.2
8.1
10.3
080
1.6
1.5
1.3
6.3
8.3
10.9
090
2.0
1.6
1.5
7.8
8.7
12.5
* Units with hydronic module
Flow rate for a maximum permitted temperature difference at the minimum
leaving water temperature
** Units without hydronic module
Flow rate for a maximum permitted temperature difference at the minimum
leaving water temperature
*** Units with hydronic module
Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
**** Units without hydronic module
Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger.
Whichever the system, the water loop minimum capacity is
given by the formula: Capacity = Cap (kW) x N Liters
30WG Condenser water flow rate, l/s
Minimum*
Maximum**
Maximum***
Low pressure
Low pressure
High pressure
020
0.3
3.1
3.5
3.8
025
0.3
3.3
3.8
4.1
030
0.3
3.3
3.8
4.1
035
0.4
3.5
4.1
4.7
040
0.4
3.7
4.3
5.0
045
0.4
3.9
4.5
5.4
050
0.4
4.8
6.8
7.0
060
0.5
5.5
7.0
7.5
070
0.5
5.6
7.2
7.8
080
0.6
5.8
7.4
8.2
090
0.6
7.2
7.9
9.3
* Units with or without hydronic module
Minimum flow rate for a water temperature difference of 18 K
Note: Operation permitted up to a value of 20 K.
** Units with hydronic module
Maximum flow rate for an available pressure of 20 kPa (unit with low-pressure
hydronic module) or 50 kPa (unit with high-pressure hydronic module)
*** Units without hydronic module
Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger
5.10.4 - 30WG with option 6
30WG
Minimum evaporator glycol solution flow rate - option 6*, l/s
Minimum**
Minimum***
Low pressure
High pressure
020
1.4
1.3
0.5
025
1.5
1.3
0.5
030
1.5
1.3
0.5
035
1.6
1.5
0.6
040
1.7
1.5
0.6
045
1.8
1.5
0.8
050
2.5
2.2
0.8
060
2.2
2.3
1.0
070
2.2
2.4
1.1
080
2.3
2.4
1.3
090
2.5
2.5
1.5
* Option 6: Glycol solution production, very low temperature
** Units with hydronic module
Minimum flow rate for a maximum permitted temperature difference at the
minimum leaving water temperature
*** Units without hydronic module
Minimum flow rate for a maximum permitted temperature difference at the
minimum leaving water temperature
Cap is the nominal system cooling capacity (kW) at the
nominal system operating conditions. This volume is necessary for stable operation and accurate temperature control.
Application
61WG/30WG/30WGA
N
2.5
ATTENTION: Minimum water volume required between
the unit and possible customer-supplied valves to the
outside of the unit.
Industrial process applications
Certain industrial processes may require high leaving water
stability. In these cases the values above must be increased.
It may be necessary to add a buffer water tank to the circuit
in order to achieve the required volume. The tank must
itself be internally baffled in order to ensure proper mixing
of the liquid (water or brine). Refer to the examples below.
Bad
Good
Bad
Good
5.12 - Maximum water loop volume (evaporator and
condenser side)
Units with hydronic module incorporate an expansion
tank sized for the maximum water loop volume. The table
below gives the maximum water loop volume (in litres) for
pure water or ethylene glycol with various concentrations.
61WG/30WG/30WGA
Static pressure
Pure water
10% ethylene glycol
20% ethylene glycol
35% ethylene glycol
kPa
bar
l
l
l
l
020-045
100
200
1
2
220
450
165
110
100
70
85
55
300
3
75
53
35
30
060-090
100
200
1
2
340
225
255
170
150
100
130
85
300
3
115
85
50
45
5.13 - Expansion tank
The expansion tank is supplied with a pressure of 1 bar
relative (±20%). The maximum operating pressure for the
tank is 3 bar.
27
5.14 - Protection against cavitation (option 116)
To ensure the durability of the pumps in the integrated
hydronic modules, the control algorithm of the 61WG/30WG/
30WGA units incorporates anti-cavitation protection.
It is therefore necessary to ensure a minimum pump entering
pressure of 60 kPa (0.6 bar) during operation and at shutdown. A pressure below 60 kPa will prohibit unit start-up
or cause an alarm with the unit shutting down.
In order to obtain sufficient pressure, it is recommended:
• to pressurise the hydronic circuit between 100 kPa
and 300 kPa (1 and 3 bar) maximum on the suction
side of the pump,
• to clean the hydronic circuit before charging water,
• to regularly clean the screen filter.
5.15 - Plate heat exchanger pressure drop (includes internal piping)
Evaporator - standard unit without hydronic module
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0
1
2
3
4
5
61WG/30WG/30WGA 050-090
Pressure drop, kPa
Pressure drop, kPa
61WG/30WG/30WGA 020-045
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
-10
Water flow rate, l/s
0
61WG/30WG/30WGA 020 61WG/30WG/30WGA 025 to 61WG/30WG/30WGA 030
61WG/30WG/30WGA 035
61WG/30WG/30WGA 040
61WG/30WG/30WGA 045
1
6
7
8
9
10
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16
Water flow rate, l/s
61WG/30WG/30WGA 050
61WG/30WG/30WGA 060
61WG/30WG/30WGA 070
61WG/30WG/30WGA 080
61WG/30WG/30WGA 090
Condenser - standard unit without hydronic module
Pressure drop, kPa
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0
Water flow rate, l/s
1
2
3
4
5
28
61WG/30WG 020
61WG/30WG 025 to 61WG/30WG 030
61WG/30WG 035
61WG/30WG 040
61WG/30WG 045
Pressure drop, kPa
61WG/30WG 050-090
61WG/30WG 020-045
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
0
6
7
8
9
10
1
2
3
4
61WG/30WG 050
61WG/30WG 060
61WG/30WG 070
61WG/30WG 080
61WG/30WG 090
5
6
7
8
Water flow rate, l/s
9
10
11
12
13
6 - ELECTRICAL CONNECTION
6.2 - Power supply
6.1 - Electrical connections, control box 61WG/30WG/
30WGA
The power supply must conform to the specification on the
unit nameplate. The supply voltage must be within the
range specified in the electrical data table. For connections
refer to the wiring diagrams.
1
In 30WGA units the power supply must not be disconnected
after the unit has been commissioned, except for quick
maintenance interventions (one day). For longer maintenance
tasks or if the unit is put into storage (for example during
the winter, when the unit is not used for cooling), the unit
power supply must be ensured to guarantee supply to the
compressor heaters on the crankcase.
WARNING: Operation of the unit with an incorrect
supply voltage or excessive phase imbalance constitutes
abuse which will invalidate the Carrier warranty. If the
phase imbalance exceeds 2% for voltage, or 10% for
current, contact your local electricity supply at once and
ensure that the unit is not switched on until corrective
measures have been taken.
6.3 - Voltage phase imbalance (%)
1
100 x max. deviation from average voltage
Average voltage
18
26
79
18
PE
Example:
On a 400 V - 3 ph - 50 Hz supply, the individual phase
voltages were measured to be:
AB = 406 V ; BC = 399; AC = 394 V
S
Legend
1 Main disconnect switch
PE Earth connection
S Power supply cable section (see table “Recommended wire sections”).
NOTES:
The 61WG/30WG/30WGA 020-090 units have only one
power connection point located at the main disconnect
switch.
Before connecting electric power cables, it is imperative
to check the correct order of the 3 phases (L1 - L2 - L3).
Non-certified drawings.
Refer to the certified dimensional drawings.
Before connecting the unit check that the phase order in the
customer control box is the same as shown in the customer
wiring diagrams.
Average voltage= (406 + 399 + 394)/3 = 1199/3
= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average:
(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
Motor
The maximum deviation from the average is 6 V. The
greatest percentage deviation is: 100 x 6/400 = 1.5 %
This is less than the permissible 2% and is therefore
acceptable.
6.4 - Recommended wire sections
Wire sizing is the responsibility of the installer, and depends
on the characteristics and regulations applicable to each
installation site. The following is only to be used as a guideline, and does not make Carrier in any way liable. After wire
sizing has been completed, using the certified dimensional
drawing, the installer must ensure easy connection and
define any modifications necessary on site.
The connections provided as standard for the field-supplied
power entry cables to the general disconnect/isolator switch
are designed for the number and type of wires, listed in the
table on the next page.
29
The calculations are based on the maximum machine current
(see electrical data tables). For the design the following
standardised installation methods are used, in accordance
with IEC 60364, table 52C:
• For units installed inside the building:
No.13: perforated horizontal cable conduit, and No.
41: closed conduit.
The calculation is based on PVC or XLPE insulated cables
with copper or aluminium core. A maximum ambient
temperature of 40 °C has been taken into account. The
given wire length limits the voltage drop to < 5%.
IMPORTANT: Before connection of the main power cables
(L1 - L2 - L3) on the terminal block, it is imperative to
check the correct order of the 3 phases before proceeding
to the connection on then terminal block or the main
disconnect/isolator switch.
6.4.2 - On-site control wiring
6.4.1 - Field control wiring
IMPORTANT: Field connection of interface circuits may
lead to safety risks: any control box modification must
maintain equipment conformity with local regulations.
Precautions must be taken to prevent accidental electrical
contact between circuits supplied by different sources:
• The routing selection and/or conductor insulation
characteristics must ensure dual electric insulation.
• In case of accidental disconnection, conductor fixing
between different conductors and/or in the control
box prevents any contact between the conductor ends
and an active energised part.
Refer to the 61WG/30WG/30WGA Pro-Dialog+ Controls
IOM and the certified wiring diagram supplied with the
unit for the field control wiring of the following features:
• Remote on/off switch
• Remote heat/cool switch
• Demand limit external switch 1
• Remote dual set point
• Alarm report
• Pump control - unit without hydronic module.
• Relief boiler or electric heater
• Valve control - see description of options 153 and 154 in
the 61WG/30WG/30WGA Pro-Dialog+ controls manual
Selection of minimum and maximum wire sections for connection to 61WG units
61WG
020
025
030
035
040
045
050
060
070
080
090
Max.
connectable
section*
Section
Calculation favourable case: Suspended aerial lines
(standardised routing No. 17)
PVC insulated cable
Section**
Max. length for
Cable type
voltage drop <5%
mm² (per phase) mm² (per phase) m
1 x 35
1 x 2.5
60
PVC Cu
1 x 35
1 x 2.5
60
PVC Cu
1 x 35
1x4
80
PVC Cu
1 x 35
1x4
80
PVC Cu
1 x 35
1x6
100
PVC Cu
1 x 35
1x6
100
PVC Cu
1 x 35
1 x 10
120
PVC Cu
1 x 35
1 x 10
120
PVC Cu
1 x 35
1 x 16
140
PVC Cu
1 x 35
1 x 16
140
PVC Cu
1 x 35
1 x 25
170
PVC Cu
Calculation unfavourable case: Conductors in conduits or multiconductor cables in closed conduit (standardised routing No. 41)
PVC insulated cable, if possible
Section**
Max. length for voltage
Cable type***
drop <5%
mm² (per phase)
m
1x4
100
PVC Cu
1x4
100
PVC Cu
1x6
120
PVC Cu
1x6
120
PVC Cu
1 x 10
150
PVC Cu
1 x 10
150
PVC Cu
1 x 16
180
PVC Cu
1 x 16
180
PVC Cu
1 x 25
205
PVC Cu
1 x 25
205
PVC Cu
1 x 35
225
PVC Cu
Selection of minimum and maximum wire sections for connection to 30WG/30WGA units
30WG
Max.
30WGA connectable
section*
Section
Calculation favourable case: Suspended aerial lines
Calculation unfavourable case: Conductors in conduits or multi(standardised routing No. 17)
conductor cables in closed conduit (standardised routing No. 41)
PVC insulated cable
PVC insulated cable, if possible
Section**
Max. length for
Cable type
Section**
Max. length for voltage drop Cable typee***
voltage drop <5%
<5%
mm² (per phase) mm² (per phase) m
mm² (par phase)
m
1 x 35
1 x 2,5
60
PVC Cu
1x4
100
PVC Cu
020
1 x 35
1 x 2,5
60
PVC Cu
1x4
100
PVC Cu
025
1 x 35
1x4
80
PVC Cu
1x6
120
PVC Cu
030
1 x 35
1x4
80
PVC Cu
1x6
120
PVC Cu
035
1 x 35
1x4
80
PVC Cu
1x6
120
PVC Cu
040
1 x 35
1x6
100
PVC Cu
1 x 10
150
PVC Cu
045
1 x 35
1 x 10
120
PVC Cu
1 x 16
180
PVC Cu
050
1 x 35
1 x 10
120
PVC Cu
1 x 16
180
PVC Cu
060
1 x 35
1 x 16
140
PVC Cu
1 x 16
180
PVC Cu
070
1 x 35
1 x 16
140
PVC Cu
1 x 25
205
PVC Cu
080
1 x 35
1 x 16
140
PVC Cu
1 x 25
225
PVC Cu
090
* Connection capacities actually available for each machine, defined according to the connection terminal size, the control box access opening size and the available
space inside the control box.
** Selection simultation result considering the hypothesis indicated.
*** If the maximum calculated section is for an XLPE cable type, this means that a selection based on a PVC cable type can exceed the connection capacity actually
available. Special attention must be given to the selection.
Note: The currents considered are given for a machine equipped with a hydronic kit operating at maximum current.
30
6.5 - 24 V user power reserve
After all possible options have been connected, the transformer ensures the availability of a usable 24 VA or 1 A
power reserve for the control circuit on site.
7 - 30WGA UNIT CONNECTIONS
7.1 - Recommendations for the installation of liquid
chillers with remote condenser
The 30WGA units (split units for connection to air-cooled
condensers) have been specially designed to optimise the
operation of split system installations, using air-cooled
condensers as the chiller heat rejection system.
The refrigerant circuit installation of an operational system
is limited to the connection of the air-cooled condenser
inlet and outlet to the 30WGA unit.
The components such as the check valve (in the discharge
line), moisture sight glass and solenoid valves are installed
and wired in the factory.
The filter-drier is supplied with the unit and must be
installed upstream of the solenoid valve on the liquid line.
•
A fan speed controller may is recommended for the
first fan stage for operation at low ambient temperature
at part load and for condensers with few fans.
ATTENTION: The air-cooled condenser must always be
used with a subcooler. Normally 8 K subcooling at the
condenser outlet is recommended.
7.2 - Piping installation and connection
On all units release the holding charge pressure before
opening the circuit.
Use the various valves and/or remove the safety cap from
the conical Schrader valve supplied. Push in the valve tip
to release the complete system holding charge (nitrogen).
Preparation before unsoldering the liquid and discharge
line plugs:
• Remove all components that may be damaged during
the unsoldering procedure
• Pipe soldering: remove the cores from the conical
Schrader valves near the area, remove the pipe collars,
remove the cladding panels and the metal crossbars.
All these components must be replaced before commissioning
the system.
The Pro-Dialog+ control system of the 30WGA units
incorporates the logic to permit control of the different fan
versions (fixed or variable-speed).
To guarantee optimum and reliable performance of the
units it is necessary to comply with the regulations described
below, when these units are connected to remote condensers:
• Size the discharge and liquid line piping according to
the recommendations in the following paragraphs (if
necessary, install a double riser to ensure correct oil
circulation in the refrigerant circuit).
• Select a condenser with an integrated subcooler to
obtain a minimum of 3 K subcooling at the inlet to the
expansion device.
• Install the filter drier supplied with the unit as close as
possible to the liquid line filter drier.
• Install the outside air temperature sensor supplied
near the air-cooled condenser.
For units with remote condenser control (option 154),
the sensor is supplied. The outside air temperature
information is required for correct operation of the
complete system.
Control of the remote air-cooled condenser using option 154
• Connect the fan stages electrically to the control board,
using auxiliary electronic board AUX 1. To assign the
fan stages refer to chapters 14 and 15 with the description
of the analogue and digital inputs and outputs.
• Make the communication bus connection (twisted and
shielded cable type for communication bus RS485)
between the specific electronic AUX 1 board, that
must be integrated in the condenser control box and
using the NRCP master board of the 30WG unit.
• The Pro-Dialog+ control is used to configure the number
of fan stages and the fan type based on the air-cooled
condenser model used in the installation.
Components be removed before soldering
•
•
•
•
Unsolder the plugs and prepare the pipes for connection.
Connect the liquid line to the system, install the filter
drier upstream of the unit.
Make the high-pressure connections (discharge line)
between the unit and the condenser.
During these operations circulate and inert gas such
as nitrogen in the pipes to prevent the formation of
copper oxyde.
IMPORTANT: The condenser circuit piping must be in
accordance with good practices relating to the static support
and the thermal expansion of copper pipes.
To ensure system vibration control, the collar positions on
the piping in the unit must not be changed. At the outlet
of the refrigerant section there are pipe flange collars. It is
imperative to tighten these collars to prevent vibrations
and possible breaks.
31
The piping between the 30WGA and the condenser must be
correctly supported in line with its size and the operating
weight. Piping support is required to ensure that vibration
levels at the piping are lower than the values at the
compressor. If resonance occurs, reduce the width between
the collar until the vibration levels are acceptable.
8 - PIPE SIZING WITH REFRIGERANT FOR 30WGA
UNITS
8.1 - General considerations and pipe size limits
Pipe size limits
30WGA
Linear length (discharge - liquid line)
Height difference
Maximum
30 m
12 m
The pipes must be as short as possible and have the least
possible changes (bends etc.) to minimise pressure drops. If
there is a risk of poor piping use, adequate measures must be
taken (design, positioning, protection) to prevent incorrect
use.
The following constraints must be taken into account whe
the refrigerant pipes are sized:
• Oil return to the compressor is ensured by entrainment.
A minimum refrigerant velocity is required to ensure
entrainment. This velocity depends on the pipe diameter,
the refrigerant and oil temperature (these are treated
as being the same in most cases). A reduction of the
pipe diameter permits an increase of the refrigerant
velocity. The problem of a minimum entrainment
velocity does not exist for the pipes that carry liquid
refrigerant as the oil is fully miscible here.
• The pressure drop at the compressor discharge (pipes
linking the compressor outlet to the condenser inlet)
must be limited to avoid system performance losses
(increased compressor power input and decreased
cooling capacity). Increasing the pipe diameter permits
limiting the pressure drops.
30WGA
Equivalent length
0-10 m
10-20 m
20-30 m
30-40 m
40- 50 m
50-60 m
60-70 m
70 m or more
*
32
025
3/4
7/8
7/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
3/4
7/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
The pressure drop in the liquid line (linking the condenser outlet to the expansion device) must not result in a
change of phase. The estimate of these pressure drops
must include those generated by possible accessories
such as solenoid valves and filter driers.
• In applications with low outside temperature and with
long pipes use of a check valve at the condenser outlet
is recommended to overcome the poor supply of the
expansion device during the start-up phase. Select a
valve that is not pressure-tight to avoid significant
pressure rises of the liquid refrigerant that may be
trapped between the solenoid valve (tight) and the
check valve.
8.2 - Pipe sizing
The following procedure can be used for pipe sizing:
1. Measure the length (in metres) of the piping under
consideration.
2. Add 50% to take account of special characteristics.
3. Read the pipe size from tables 1 and 2 below.
4. Calculate the equivalent lengths for parts included in
the piping under consideration (such as valves, filters,
connections). The equivalent lengths are normally
available from the component supplier. Add these
lengths to the length calculated above.
5. Repeat steps 3 and 4 if necessary.
6. See tables “Discharge line piping” and “Liquid line
piping” below.
8.3 - Discharge pipe sizing
The discharge piping must be sized to achieve reasonable
pressure drops: a variation of 1.5 K of the saturated temperature is normally accepted (approx. 90 kPa variation for a
condensing temperature of 45 °C).
Table 1 - Discharge line piping*
030
035
040
045
050
060
070
080
090
7/8
7/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
7/8
1-1/8
1-1/8
1-1/8
1-1/8
1-1/8
1-3/8
1-3/8
7/8
1-1/8
1-1/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
7/8
1-1/8
1-1/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-1/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-1/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-1/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-3/8
1-1/8
1-3/8
1-3/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
Recommended diameters to ensure oil return in the application range.
30WGA
Equivalent length
0-10 m
10-20 m
20-30 m
30-40 m
40- 50 m
50-60 m
60 m or more
*
in
in
in
in
in
in
in
in
020
•
in
in
in
in
in
in
in
Table 2 - Liquid line piping*
020
025
030
035
040
045
050
060
070
080
090
1/2
1/2
1/2
1/2
5/8
5/8
5/8
1/2
1/2
1/2
5/8
5/8
5/8
5/8
1/2
1/2
1/2
5/8
5/8
5/8
5/8
1/2
1/2
5/8
5/8
5/8
5/8
5/8
1/2
5/8
5/8
5/8
5/8
5/8
3/4
1/2
5/8
5/8
5/8
5/8
3/4
3/4
1/2
5/8
5/8
3/4
3/4
3/4
3/4
5/8
5/8
5/8
3/4
3/4
3/4
3/4
5/8
5/8
3/4
3/4
3/4
3/4
7/8
5/8
3/4
3/4
3/4
3/4
7/8
7/8
5/8
3/4
3/4
3/4
7/8
7/8
7/8
Recommended diameters to limit the impact of the 1.5 K pressure loss.
For most applications the refrigerant gas velocity is sufficient to entrain the liquid refrigerant/oil mixture. Nevertheless, table 3 shows the minimum required cooling capacities
for different pipe diameters and different saturated discharge
temperatures.
Table 3 - Minimum capacity (kW) to ensure oil return
for different pipe diameters
30WGA
Saturated
condensing
temperature, °C
30
35
40
45
50
55
60
Outside pipe diameter, in
3/4
7/8
1-1/8
1-3/8
1-5/8
2-1/8
2-5/8
3.8
3.8
3.9
3.9
4.0
4.0
4.1
31.0
31.5
31.9
32.3
32.7
33.1
33.5
48.9
49.5
50.2
50.9
51.5
52.2
52.8
86.5
87.7
88.9
90.1
91.2
92.4
93.6
5.6
5.7
5.8
5.9
5.9
6.0
6.1
11.5
11.7
11.8
12.0
12.1
12.3
12.4
19.7
19.9
20.2
20.5
20.8
21.0
21.3
Correction factor, oil entrainment in the discharge lines
Saturated evaporating temperature, °C
-7
-1
4
Correction factor
0.94 0.97 1
10
1.03
16
1.06
Table 1 "Discharge line piping" shows the different pipe
diameters based on the unit size and the equivalent circuit
length. These recommended diameters allow oil return
within the application range.
IMPORTANT: Siphon traps must be inserted in the vertical
riser pipes:
• at the bottom of the piping
• every 3 m of vertical length
• at the top of the piping (counter-siphon).
Examples
Bottom of piping
Table 4 - Equivalent length (m) for filter drier, solenoid
valves, moisture sight-glass (standard supply)
30WGA
1/2” diameter
5/8'' diameter
3/4'' diameter
7/8'' diameter
020
4.2
12.3
-
025
4.2
12.3
-
030
4.2
12.3
-
035
4.2
12.3
-
040
4.2
12.3
29.9
-
045
4.2
12.3
29.9
-
050
2.2
5.4
12.4
-
060
5.4
12.4
-
070
5.4
12.4
25.1
080
5.4
12.4
25.1
090
5.4
12.4
25.1
The admissible pressure drops in the liquid lines depend
mainly on the subcooling level of the liquid refrigerant at
the condenser outlet. Pressure drops corresponding to 1.5 °C
saturated temperature must not be exceeded.
If the liquid refrigerant head is very high, it may be necessary
to increase the subcooling to prevent a phase change in the
liquid line. A liquid-vapour heat exchanger or an additional
coil can be used for this purpose.
It is advisable to include a slight slope (10 to 20 mm/m) in the
refrigerant flow direction in the horizontal piping between
the remote condenser and the 30WGA unit.
9 - WATER CONNECTIONS
For size and position of the heat exchanger water inlet and
outlet connections refer to the certified dimensional drawings
supplied with the unit. The water pipes must not transmit any
radial or axial force to the heat exchangers nor any vibration.
The water supply must be analysed and appropriate filtering,
treatment, control devices, isolation and bleed valves and
circuits built in, to prevent corrosion, fouling and deterioration of the pump fittings. Consult either a water treatment
specialist or appropriate literature on the subject.
9.1 - Operating precautions
Riser pipe
Counter-siphon
The siphon must be correctly sized to avoid trapping too
much of the liquid oil/refrigérant mixture.
It is advisable to include a slight slope (10 to 20 mm/m) in
the refrigerant flow direction in the horizontal piping between
the 30WGA unit and the condenser.
8.4 - Liquid line sizing
The 30WGA compressors are supplied with an oil that is
fully miscible with refrigerant R-410A in the liquid phase.
Consequently low refrigerant velocities in the liquid lines
are not a problem.
Table 2 “Liquid line piping” shows the different pipe diameters based on the unit size and the equivalent circuit length.
To determine the equivalent liquid line length the filter
drier and the solenoid valve pressure drops must be taken
into consideration. Table 4 below shows the equivalent
length for each unit based on the diameter used.
Design the water circuit with the least number of elbows
and horizontal pipe runs at different levels. The main points
to be checked for the connection are:
• Comply with the water inlet and outlet connections
shown on the unit.
• Install manual or automatic air purge valves at all high
points in the circuit(s).
• Use a pressure reducer to maintain pressure in the
circuit(s) and install a safety valve as well as an expansion tank. Units with hydronic module include the
safety valve and expansion tank.
• Install drain connections at all low points to allow the
whole circuit to be drained.
• Install stop valves, close to the entering and leaving
water connections.
• Use flexible connections to reduce vibration transmission.
• If the insulation provided is not sufficient, insulate the
cold-water piping, after testing for leaks, both to reduce
heat loss and to prevent condensation.
• Cover the insulation with a vapour barrier.
• If the external water piping to the unit is in an area where
the ambient temperature can fall below 0 °C, insulate
the piping and install an electric heater on the piping.
NOTE: For units without hydronic module a screen filter
must be installed as close as possible to the heat exchanger
and in a position that is easily accessible for removal and
cleaning. Units with a hydronic module include this filter.
33
The mesh size of the filter must be 1.2 mm. If this filter is
not installed, the plate heat exchanger can quickly become
contaminated at the first start-up, as it takes on the filter
function, and correct unit operation is affected (reduced
water flow due to increased pressure drop).
•
•
Before the system start-up verify that the water circuits are
connected to the appropriate heat exchangers (e.g. no reversal
between evaporator and condenser).
•
Do not introduce any significant static or dynamic pressure
into the heat exchange circuit (with regard to the design
operating pressures).
Dissolved silicon: silicon is an acid element of water
and can also lead to corrosion risks. Content < 1mg/l.
Water hardness: > 0.5 mmol/l. Values between 1 and
2.5 can be recommended. This will facilitate scale
deposit that can limit corrosion of copper. Values that
are too high can cause piping blockage over time. A
total alkalimetric titre (TAC) below 100 is desirable.
Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to
deoxygenate the water by mixing it with inert gas as it
is to over-oxygenate it by mixing it with pure oxygen.
The disturbance of the oxygenation conditions
encourages destabilisation of copper hydroxides and
enlargement of particles.
Electric conductivity 10-600µS/cm
pH: Ideal case pH neutral at 20-25 °C - 7 < pH < 8
Before any start-up verify that the heat exchange fluid is
compatible with the materials and the water circuit coating.
•
•
If additives or other fluids than those recommended by Carrier
are used, ensure that the fluids are not considered as a gas, and
that they belong to class 2, as defined in directive 97/23/EC.
If the water circuit must be emptied for longer than one
month, the complete circuit must be placed under nitrogen
charge to avoid any risk of corrosion by differential aeration.
Carrier recommendations on heat exchange fluids:
• No NH4+ ammonium ions in the water, they are very
detrimental for copper. This is one of the most important
factors for the operating life of copper piping. A content
of several tenths of mg/l will badly corrode the copper
over time (the plate heat exchangers used for these
units have brazed copper joints).
• Cl- Chloride ions are detrimental for copper with a risk
of perforations by corrosion by puncture. If possible
keep below 10 mg/l.
• SO42- sulphate ions can cause perforating corrosion, if
their content is above 30 mg/l.
• No fluoride ions (<0.1 mg/l).
• No Fe2+ and Fe3+ ions with non negligible levels of
dissolved oxygen must be present. Dissolved iron < 5
mg/l with dissolved oxygen < 5 mg/l.
ATTENTION: Filling, completing and draining the water
circuit charge must be done by qualified personnel, using the
air purges and materials that are suitable for the products.
Charging and removing heat exchange fluids should be
done with devices that must be included on the water
circuit by the installer. Never use the unit heat exchangers
to add heat exchange fluid.
9.2 - Water connections
The diagram below illustrates a typical hydronic installation.
When the hydronic circuit is charged, use the air vents to
evacuate any residual air pockets.
Typical water piping diagram, 61WG/30WG/30WGA units with hydronic modules
2
1
PT
Unit water inlet
3
6
4
5
TT
7
15
9
Components of unit and hydronic module
Condenser water loop (61WG/30WG)
Unit water outlet
2
1
PT
Unit water inlet
6
3
TT
PT
10
8
4
6
5
13
TT
9
7
Evaporator water loop (61WG/30WG/30WGA)
Unit water outlet
12
34
TT
PT
10
8
14
16
1 Victaulic screen filter
2 Expansion tank
3 Safety valve
4 Water pump
5 Air vent
6 Water drain valve
7/8 Entering/leaving pressure sensor
9/10Entering/leaving temperature probe
12 Flow switch 61WG option 272 (sizes 020-045
only)
13Compressor
14Evaporator
15 Condenser
16 Expansion device
NOTE: Units without hydronic
module include a flow switch.
6
9.3 - Frost protection
The units are designed to be installed under cover at outside
temperatures between +5 °C and +40 °C. Therefore they do
not include anti-freeze protection, as standard.
10 - NOMINAL WATER FLOW CONTROL WITH FIXEDSPEED PUMP
10.1 - General
If the water piping is in an area where the ambient temperature can fall below 0 °C it is recommended to install a trace
heater on the piping and to add an antifreeze solution to
protect the unit and the water piping to a temperature of
10 K below the lowest temperature likely to be reached at
the installation site.
The water circulation pumps of the 61WG/30WG units
have been sized to allow the hydronic modules to cover all
possible configurations based on the specific installation
conditions, i.e. for various temperature differences between
the entering and the leaving water (∆T) at full load, which
can vary between 2.5 and 7 K for evaporators and 3 and 18
K for condensers.
Use only antifreeze solutions, approved for heat exchanger
duty. If the system is not protected by an antifreeze solution
and will not be used during the freezing weather conditions,
draining of the cooler and outdoor piping is mandatory.
Damage due to freezing is not covered by the warranty.
This required difference between the entering and leaving
water temperature determines the nominal system flow rate.
It is above all absolutely necessary to know the nominal
system flow rate to allow its control via a manual valve.
IMPORTANT: Depending on the climatic conditions in
your area you must:
• Add ethylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 K
below the lowest temperature likely to occur at the
installation site.
• If the unit is not used for an extended period, it is
recommended to drain it, and as a safety precaution
add ethylene glycol to the heat exchanger, using the
heat exchanger water entering purge valve connection.
• At the start of the next season, refill the unit with water
and add an inhibitor.
• For the installation of auxiliary equipment, the installer
must comply with basic regulations, especially for
minimum and maximum flow rates, which must be
between the values listed in the operating limit table
(chapter 5 - “Application data”).
• To avoid corrosion by differential aeration, the
complete heat exchange circuit must be charged with
nitrogen, if it is drained for longer than one month. If
the heat exchange fluid does not comply with Carrier
recommendations, the circuit must immediately be
filled with nitrogen.
Manual control valves for the unit are not supplied and must
be installed upstream and downstream of the evaporator
and condenser water loops to ensure correct flow control.
With the pressure loss generated by the control valve in
the hydronic system, the valve is able to impose the system
pressure/flow curve on the pump pressure/flow curve, to
obtain the desired operating point (see example).
The pressure drop reading in the plate heat exchanger is
used to control and adjust the nominal system flow rate.
The pressure drop is measured with the pressure sensors
connected to the heat exchanger water inlet and outlet.
Use this specification for the unit selection to know the
system operating conditions and to deduce the nominal air
flow as well as the plate heat exchanger pressure drop at the
specified conditions. If this information is not available at
the system start-up, contact the technical service department
responsible for the installation to get it.
These characteristics can be obtained from the technical
literature using the unit performance tables or the Electronic
Catalogue selection program for all conditions.
9.4 - Flow switch (units without hydronic module)
10.2 - Water flow control procedure
IMPORTANT: On 61WG/30WG/30WGA units, the unit
water flow switch must be energised, and the chilled water
pump interlock must be connected. Failure to follow this
instruction will void the Carrier guarantee.
As the total system pressure drop is not known exactly at
the start-up, the water flow rate must be adjusted with the
control valve to obtain the specific flow rate for this
application.
The flow switch is supplied, installed on the evaporator
leaving water pipe and preset at the factory to cut out
when there is insufficient water flow.
Proceed as follows:
Open the valve fully.
Terminals 34 and 35 are provided for field installation of
the chilled water pump interlock (auxiliary contact for
pump operation to be wired on site).
Start-up the pump using the forced start command (refer to
the controls manual) and let the pump run for two consecutive hours to clean the hydronic circuit of the system
(presence of solid contaminants).
Read the hydronic module pressure drop by taking the
difference of the readings at the machine connected to the
hydronic module inlet and outlet. Compare this value after
two hours of operation.
35
Entering water pressure reading
Example: Unit with a given nominal flow rate of 4.8 l/s
200
4
175
O
3
F
F
Leaving water pressure reading
Pressure drop, kPa
150
1
125
100
75
2
50
F
25
O
F
0
2
Legend
OOpen
F
Closed
Water inlet
Water outlet
Pressure gauge
If the pressure drop has increased, this indicates that the
screen filter must be removed and cleaned, as the hydronic
circuit contains solid particles. In this case close the shutoff
valves at the water inlet and outlet and remove the screen
filter after emptying the hydronic section of the unit.
Renew, if necessary, to ensure that the filter is not contaminated.
When the circuit is cleaned, read the pressures at the unit
(entering water pressure - leaving water pressure), expressed
in kPa to find out the plate heat exchanger pressure drop.
Compare the value obtained with the theoretical selection
value. If the pressure drop measured is higher than the value
specified this means that the flow rate in the plate heat
exchanger (and thus in the system) is too high. The pump
supplies an excessive flow rate based on the global pressure drop of the application. In this case close the control
valve one turn and read the new pressure difference.
Proceed by successively closing the control valve until you
obtain the specific pressure drop that corresponds to the
nominal flow rate at the required unit operating point.
• If the system has an excessive pressure drop in relation
to the available static pressure provided by the pump,
the resulting water flow rate will de reduced and the
difference between entering and leaving water temperature of the hydronic module will be increased.
To reduce the hydronic system pressure drops, it is necessary:
• to reduce the individual pressure drops as much as
possible (bends, level changes, accessories, etc.)
• to use a correctly sized piping diameter.
• to avoid hydronic system extensions, wherever possible.
36
4
6
Water flow rate, l/s
8
10
Legend
1 Unit pump curve
2 Plate heat exchanger pressure drop (to be measured with the pressure gauge
installed at the water inlet and outlet)
3 Installation pressure drop with control valve wide open
4 Installation pressure drop after valve control to obtain the specified flow rate
11 - NOMINAL WATER FLOW CONTROL WITH
VARIABLE-SPEED PUMP
11.1 - Pump flow/pressure curve
61WG/30WG/30WGA units with variable-speed hydronic
module include a water pump that automatically adjusts
the flow to maintain a constant pressure or constant
temperature difference.
No control is required at start-up, but the control mode must
be selected at the unit interface (refer to the 61WG/30WG/
30WGA Pro-Dialog+ Control manual).
11.2 - Available external static pressure (variable-speed high-pressure pumps, units with hydronic module
Data applicable for:
- Fresh water 20 °C
- In case of use of the glycol, the maximum water flow is reduced
- The curves represented below are in normal conditions: leaving water on the back side of the unit (without option 274).
Evaporator
9
160
150
160140
150130
140120
130
110
120
100
110
90
100
80
90
80 70
70 60
60 50
50
61WG/30WG/30WGA 050-090
210
190
210
Pressure head, kPa
Pressure head, kPa
61WG/30WG/30WGA 020-045
170
190
150
170
130
150
110
130
90
110
90
70
70
50
0.0
0.0
0.5
0.5
1.0
1.0
1.5
1.5
2.0
2.0
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
4.5
50 0
5.0
0
5.0
1
2
1
3
2
3
5
4
6
5
6
7
7
8
8
9
9
Water flow rate, l/s
Water flow rate, l/s
1
2
3
4
5
4
61WG/30WG/30WGA 020 61WG/30WG/30WGA 025 to 030
61WG/30WG/30WGA 035
61WG/30WG/30WGA 040
61WG/30WG/30WGA 045
6
7
8
9
10
61WG/30WG/30WGA 050
61WG/30WG/30WGA 060
61WG/30WG/30WGA 070
61WG/30WG/30WGA 080
61WG/30WG/30WGA 090
Condenser
61WG/30WG 050-090
8
210
210
160160
150150
140140
130130
120120
110110
100
100
90
90
80
80
70
70
60
50 60
50
0.0
190
190
Pressure head, kPa
Pressure head, kPa
61WG/30WG 020-045
170
150
130
110
110
90
90
70
70
0.0
0.5
0.5
1.0
1.0
1.5
1.5
2.0
2.0
2.5
2.5
3.0
3.0
3.5
3.5
4.0
4.0
4.5
4.5
50
50
0
0
1
1
2
2
Water flow rate, l/s
1
2
3
4
5
61WG/30WG 020
61WG/30WG 025 to 030
61WG/30WG 035
61WG/30WG 040
61WG/30WG 045
3
3
4
4
5
5
6
6
7
7
8
8
Water flow rate, l/s
6
7
8
9
10
61WG/30WG 050
61WG/30WG 060
61WG/30WG 070
61WG/30WG 080
61WG/30WG 090
37
11.3 - Available external static pressure (fixed-speed low-pressure pumps, units with hydronic module)
Data applicable for:
- Fresh water 20 °C
- In case of use of the glycol, the maximum water flow is reduced
- The curves represented below are in normal conditions: leaving water on the back side of the unit (without option 274).
Evaporator
61WG/30WG/30WGA 020-045
61WG/30WG/30WGA 050-090
140
130
120
Pressure head, kPa
Pressure head, kPa
110
100
90
80
70
60
50
40
30
0
0.5
1
1.5
2
2.5
3
3.5
4
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
0
4.5
1
2
3
Water flow rate, l/s
1
2
3
4
5
4
5
6
7
8
9
Water flow rate, l/s
61WG/30WG/30WGA 020 61WG/30WG/30WGA 025 to 030
61WG/30WG/30WGA 035
61WG/30WG/30WGA 040
61WG/30WG/30WGA 045
6
7
8
9
10
61WG/30WG/30WGA 050
61WG/30WG/30WGA 060
61WG/30WG/30WGA 070
61WG/30WG/30WGA 080
61WG/30WG/30WGA 090
Condenser
61WG/30WG 050-090
61WG/30WG 020-045
140
130
120
100
Pressure head, kPa
Pressure head, kPa
110
90
80
70
60
50
40
30
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
0
1
Water flow rate, l/s
1
2
3
4
5
38
61WG/30WG 020
61WG/30WG 025 to 030
61WG/30WG 035
61WG/30WG 040
61WG/30WG 045
2
3
4
Water flow rate, l/s
6
7
8
9
10
61WG/30WG 050
61WG/30WG 060
61WG/30WG 070
61WG/30WG 080
61WG/30WG 090
5
6
7
8
9
11.4 - Pump curve (units with hydronic modules)
Data applicable for:
- Fresh water 20 °C
- In case of use of the glycol, the maximum water flow is
reduced
- The curves represented below are in normal conditions:
leaving water on the back side of the unit (without option
274).
11.4.1 - Low pressure pumps 61WG/30WG/30WGA
(options 116F - 270F)
160
2
61WG units are specially designed to optimise the operation
of heating installations that require hot-water production
for a traditional heating system and domestic hot-water
production.
1
100
80
60
NOTE: The installer is responsible for ensuring that the
installation complies with the applicable legislation in
terms of electrical and thermal safety.
0
0
1
2
3
4
5
6
7
8
9
10
Water flow rate, l/s
1 61WG/30WG/30WGA 020-080
2 61WG/30WG/30WGA 090
12.2 - Auxiliary electronic board (AUX1) - analogue
and digital inputs and outputs
SIO
J9
STATUS
T
P
V
J8
CH14
-- G +
3 2 1
SIO
J1
24VAC
12 11
11.4.2 - High pressure pumps 61WG/30WG/30WGA
(options 116J - 270J)
J2
200
4
Pressure head, kPa
180
CH -- CH -- CH -- CH -1
2
3
4
160
J3
CH -- CH -- CH -- CH -5
6
7
8
J4
CH
9
J5
--
CH
10
J6
--
CH13
CH -11
V
J7
T
P
220
-- G +
3 2 1
20
R S V
CH14
40
R S V
CH13
Pressure head, kPa
120
12.1 - Operating principle
The Pro-Dialog+ control system of the 61WG units includes
algorithms that permit constant automatic optimisation of:
• control of a directional on/off three-way valve based
on the heating or domestic hot water requirements
• control of the electric heating stages allowing relief of
the heating loop
• hot-water setpoint reset (heating application) based
on the air temperature
• priority control between heating application and
domestic hot-water application.
180
140
12 - OPERATION OF 61WG UNITS WITH SPECIFIC
HEATING CONTROL (OPTION 153)
CH -12
3
140
•
120
100
•
80
60
•
40
20
•
0
0
1
2
3
4
5
6
7
Water flow rate, l/s
3 61WG/30WG/30WGA 020-045
4 61WG/30WG/30WGA 050-090
8
9
10
11
12
•
•
Connector J2: Digital outputs CH 1 to 4 for fan stages
1 to 4.
Connector J3: Digital output CH 6 to control a
directional on/off three-way valve
Connector J6: Analogue input CH 11 for outside air
temperature sensors
Connector J6: Analogue input CH 12 for information
on domestic hot water demand
Connector J7: Analogue input CH 13 for information
on domestic hot water demand
Connector J8: Analogue input CH 14 for information
on summer operation only (domestic hot water only)
To apply the different configurations required, refer to the
instructions in the Pro-Dialog+ Control IOM.
39
13 - OPERATION OF 61WG UNITS WITH THE HEATING
SYSTEM MANAGER (HSM)
HSM control box
HSM accessory: 00PPG000488000- or 00PPG000488100or 00PPG000488200The Heating System Manager (HSM) accessory allows
improved integration of the 61WG heat pump to maximise
energy efficiency performance.
With three system levels for nine typical configurations,
most heating only applications are covered - from the
simplest to the most complex, such as interfacing with a
district heating system.
Each of these accessory configurations is described in
detail in the user manual for these accessories. They offer:
• choice of additional control options (on/off volt-free
contact or 0-10 V signal for increased performance)
• domestic hot water production temperature control
and distribution.
The control box can supply all auxiliary devices such as the
circulating pumps or the mixing or switching valves.
The heat pump is controlled by a CCN bus and the control
box includes an NRCP2-BASE board, a Pro-Dialog interface
as well as all required sensors.
HSM control box dimensions
603
180
120
52
Installation safety notes
• The hydronic installation must be carried out by qualified personnel in
accordance with applicable laws and following standard accepted practices.
• The hydronic installation must be regularly serviced.
• An incorrect hydronic installation that does not comply with the safety,
electrical and thermal standards, as well as lacking/poor maintenance can lead
to excessive pressures and cause piping breaks.
25
536
33
170
559
382
442
17
416
17
1,5
20,5
1
400
10
Legend:
All dimensions are in mm.
1 Clearance required to open the door and for customer connection
40
14 - 30WG UNIT OPERATION WITH A DRYCOOLER
(OPTION 154)
14.1 - Operating principle
30WG units have been specially designed to optimise the
operation of systems, using drycoolers as heat rejection
system.
With a variable-speed condenser water pump integrated
into the 30WG, the complexity of traditional systems, using
a three-way valve has been reduced.
The installation of an operational system is limited on the
condensing water loop side to connecting the drycooler
entering and leaving water piping to the 30WG unit.
The Pro-Dialog+ control of the 30WG includes algorithms
to permit constant automatic optimisation of:
• drycooler fan stage operation
• water flow rate variation in the loop between the
condenser and the drycooler.
Parallel control of the fan stages (up to 8 stages maximum)
and of the variable water flow rate of the loop permit
year-round system operation down to ‑10 °C outside
temperature without any additional control.
14.2 - Auxiliary electronic board (AUX1) - analogue and
digital inputs and outputs - to control the drycooler
CH -- CH -- CH -- CH -1
2
3
4
•
•
•
•
•
J3
CH -- CH -- CH -- CH -5
6
7
8
J4
CH
9
J5
--
CH
10
J6
--
CH13
CH -11
V
J7
-- G +
3 2 1
R S V
CH14
T
P
R S V
CH13
V
J8
T
P
-- G +
3 2 1
SIO
J1
24VAC
12 11
CH14
J2
The electronic board (AUX1) integrated in the control box
of the drycooler has analogue inputs for outside air temperature and drycooler leaving water temperature sensors, as
well as eight digital outputs permitting control of up to
eight fan stages.
14.3 - Configuration of the number of fan stages and
the automatic changeover of the fan stages
Please refer to the instructions in the 61WG/30WG/30WGA
Pro-Dialog+ IOM for the configuration of the number of
fan stages to be controlled. It is enough to enter the number
of fan stages of the drycooler in the Pro-Dialog+ service
menu. The number of digital outputs controlling the fans are
activated by the control.
Pro-Dialog+ controls the automatic switching of all fan
stages, based on operating time and number of start-ups of
the different stages. This function prevents fan motors from
only running a little or not at all and the shafts seizing up,
especially during periods with a low cooling demand, when
the outside temperature is low. Switching is often specified
by the drycooler manufacturers to ensure a long operating
life of fan motors that are only used a little or not at all in
these particular operating conditions.
14.4 - Fan stage assignment
SIO
J9
STATUS
Pro-Dialog+ optimises system operation to obtain the best
efficiency with variation of the water flow rate and the
number of fans required for any thermal load and outside
temperature conditions.
CH -12
Connector J2: Digital outputs CH 1 to 4 for fan stages
1 to 4.
Connector J3: Digital outputs CH 5 to 8 for fan stages
5 to 8.
Connectors J4 and J5: Analogue outputs 0-10 V dc not
used on the drycoolers (only used for fan speed variation
of the air-cooled condensers).
Connector J6: Analogue inputs CH 11 and 12 for drycooler leaving water and outside temperature sensors.
Connector J9: Communication bus with NRCP master
board of the 30WG unit.
The electronic board specifically integrated in the control
box of the drycooler and a communication bus connected
to the microprocessor board of the 30WG is used for the
overall system control.
The option supplied with the cooling unit must be installed
in the drycooler control box. Connect the unit to board
AUX1 in the drycooler, using a communication bus cable.
The minimum configuration of the number of fan stages is
2 for correct operation.
Depending on the drycooler capacity the number of fans
can be between 2 and 8. They can be controlled by one fan
or by linked pairs, if necessary.
A drycooler with 4 or 6 fans installed in series for example
along the length of the unit will result in a configuration of
4 or 6 fan stages.
Reciprocally a drycooler with 8 or 12 fans arranged in pairs
along the length of the unit will also result in a configuration
of 4 or 6 fan stages.
Configuration with 4 and 6 stages (min. 2 - max. 8)
A
1
2
3
4
5
6
Fans linked in pairs 4 and 6-stage configuration (min. 2 - max. 8)
1
2
3
4
5
6
1
2
3
4
5
6
A
Legend
A Entering and leaving water manifold side
1 to 6 fans
41
T
P
J2
CH -- CH -- CH -- CH -1
2
3
4
J3
CH -- CH -- CH -- CH -5
6
7
8
J4
CH
9
J5
--
CH
10
J6
--
CH13
CH -11
V
R S V
CH14
V
R S V
CH13
T
P
J8
In this case Pro-Dialog+ should be configured for threeway valve system control from an analogue 0-10 volt output
on the Carrier NRCP type master board. An adequate
condensing temperature will be maintained with constant
condenser flow rate. This configuration permits year-round
system operation down to -20 °C outside temperature.
-- G +
3 2 1
SIO
J1
CH14
-- G +
3 2 1
SIO
J9
STATUS
24VAC
12 11
30WG units can be supplied from the factory without evaporator and condenser pump. If year-round low-temperature
operation is planned, the unit will be installed with a threeway valve that is not supplied with the unit.
15.3 - Auxiliary electronic board (AUX1) - analogue and
digital inputs and outputs - to control the remote aircooled condenser
J7
14.5 - 30WG units without evaporator and condenser
pump, three-way valve configuration for low outside
temperature application
CH -12
Control and changeover of the fan stages, described in chapter
“Configuration of the number of fan stages and automatic
changeover of the fan stages” is identical in this case.
•
14.6 - Drycooler installation on 30WG units
•
For the drycooler installation follow professional guidelines.
• Water pipe sizing
• Maximum piping and shut-off valve pressure drops
based on the available pressure of the 30WG pumps
• Maximum drycooler elevation in relation to the unit
(safety valve at 3 bar on the 30WG water circuit).
• Fan stage control (see “Fan stage control”).
• Good positioning of the outside air temperature and
drycooler leaving water temperature sensors.
•
15 - 30WGA UNIT OPERATION WITH A REMOTE AIRCOOLED CONDENSER (OPTION 154)
The option supplied with the cooling unit must be installed
in the condenser control box. Connect the unit to board
AUX1 in the condenser, using a twisted and shielded type
RS485 communication bus cable.
15.1 - Operating principle
30WGA units have been specially designed to optimise the
operation of split installations, using air-cooled condensers
as the chiller heat rejection system. The installation of an
operational system is limited to the connection of the aircooled condenser inlet and outlet piping to the 30WGA unit.
The Pro-Dialog+ control system of the 30WGA includes a
logic to permit control the different fixed and variable-speed
fan variants.
15.2 - Lead fan
The physical position of the air-cooled condenser with fixed
or variable-speed fans depends on the position of the
leaving liquid refrigerant manifold. In all cases there is
always a so-called lead fan. This is the fixed or variablespeed fan that is physically the closest to the leaving liquid
refrigerant manifold.
This ensures optimum subcooling on the condenser outlet
side, especially at part load. This is the first fan to start in
each circuit and the last fan to stop. A fan configuration
with fixed-speed fans permits year-round system operation
down to 0 °C outside temperature.
A fan configuration with a variable-speed lead fan permits
year-round operation down to -10 °C outside temperature.
42
•
•
Connector J2: Digital outputs CH 1 to 4 for fan stages
1 to 4.
Connector J3: Digital outputs CH 5 to 8 for fan stages
5 to 8.
Connectors J4 and J5: Analogue outputs 0-10 V dc for
fan speed variation of the air-cooled condensers.
Connector J6: Analogue input CH 12 for outside
temperature sensors.
Connector J9: Communication bus with NRCP master
board of the 30WGA unit.
The electronic board specifically integrated in the control
box of the condenser and a communication bus connected
to the microprocessor board of the 30WGA is used for the
overall system control.
Pro-Dialog+ continuously optimises system operation to
obtain the best system efficiency by controlling the number of
fans required for any thermal load and outside temperature
conditions.
The outside air temperature sensor is required for correct
system operation (EXV, fans, condensing temperature,
setpoint). The position of the temperature sensor must be
chosen with great care and must be representative of the
outside temperature (limit any other source that could
have a negative influence on the control: gusts of wind,
other heat sources such as sun radiation and hot air recycling).
15.4 - Configuration of the number of fan stages and
fan type based on the air-cooled condenser model
used in the installation
Please refer to the instructions in the Pro-Dialog+ IOM
for the 61WG/30WG/30WGA units to carry out the
parameter setting of the air-cooled condenser used in the
installation:
• Use of speed variation on the lead fan(s)
• Number of fixed-speed fans
Based on the parameter setting used, the arrangement
of the digital and corresponding analogue outputs
controlling the fans will be activated by the control.
Pro-Dialog+ controls the automatic switching of all fan
stages, based on operating time and number of start-ups of
the different stages. This function prevents fan motors from
only running a little or not at all and the shafts seizing up,
especially during periods with a low cooling demand, when
the outside temperature is low. Switching is often specified
by the condenser manufacturers to ensure a long operating
life of the fan motors that are only used a little or not at all
in these particular operating conditions.
16 - START-UP
16.1 - Preliminary checks
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Never be tempted to start the unit without reading
fully, and understanding, the operating instructions and
without having carried out the following pre-start checks:
Check the chilled water circulation pump operation
with the Quick Test function.
Check the air handling units and all other equipment
connected to the evaporator. Refer to the manufacturer’s
instructions.
Check the condensing loop water circulation pump
operation with the Quick Test function (61WG/30WG).
For units without hydronic module, the water pump
overheat protection devices must be connected in series
with the pump contactor power supply (61WG/30WG/
30WGA).
Ensure that there are no refrigerant leaks.
Confirm that all pipe securing bands are tight.
Confirm the the electrical connections are secure.
Avoid a long common power wiring connection run
inside the unit close to the control or signal wiring.
Observe the clearances on each unit side to facilitate
maintenance.
The unit pipings are not 100% insulated whatever the
options. The insulation only protects against running
condensation.
To ensure that no condensate can run under the unit, a
condensate pan must be added under the unit that
collects 100% of the condensate.
If work is required in a control box or on the compressor
wiring, the phase order must be verified with a quick
test (refer to the 61WG/30WG/30WGA Pro-Dialog+
Control manual. The compressors cannot support
prolonged operation (>30 seconds) with reversed phases.
Ensure that the last refrigerant charge made by the
service team corresponds with the charge given on the
name plate - otherwise the operating ranges and the
unit efficiency will be impaired. The required tolerance
for the charge is ±2%.
Do not interchange material with another Carrier
unit. The elements used for this unit are specific to this
unit. Use the specific Carrier component list when
ordering any parts.
Before start-up ensure that the unit is level (1.5 mm/m).
Check the operation of the fans in the air-cooled
condensers.
ATTENTION: Use of units in an open loop is forbidden.
16.2 - Actual start-up
IMPORTANT
• Commissioning and start-up of the unit 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 and condenser.
• All set-point adjustments and control tests must be
carried out before the unit is started up.
Ensure that all safety devices are operational, especially
that the high pressure switches are switched on and that
the alarms are acknowledged.
For 30WGA units operating with a remote air-cooled
condenser the compressor oil level must be monitored
during the system start-up phase. This is to ensure that the
oil charge of the original compressors is sufficient for the
system size and the piping configuration. Once the oil
level has stabilised, it must not be lower than 1/4 of the oil
sight glass level for the compressors that operate.
16.3 - Refrgerant charge adjustment
IMPORTANT: It is imperative to empty the nitrogen
holding charge from the system and evacuate the system
before beginning to charge refrigerant into the unit. Never
charge refrigerant into the low-pressure side of the unit.
While charging refrigerant ensure that all fans of the
outdoor unit are operating.
With all fans operating add refrigerant until the subcooling
(upstream of the expansion device) is between 4 and 8 K.
To achieve this:
Measure the refrigerant pressure at the level of the service
valve in the liquid line of the 30WGA unit, measure the
liquid line temperature as close as possible to the service
valve.
Add charge until the refrigerant passing through the sight
glass is ‘clear’: the refrigerant is now only liquid. Then
complete the charge until the actual subcooling required is
between 4 et 8 K, based on the liquid line pressure drops
(filter drier, solenoid valve, special components and possible
liquid head).
The actual subcooling is equal to the saturated temperature
at the bubble point, minus the liquid line temperature
measured. If the actual subcooling value is higher than 8 K,
(unit outlet) an excess charge is possible. This excess charge
translates to an excessive condensing pressure and increases
the compressor power input.
If adding charge does not result in a clear sight glass and
the condensing pressure rises above the acceptable values,
ensure that the filter drier is not blocked and that one of
the solenoid valves is not partially closed.
43
16.4 - Oil charge adjustment
Leaving water control
If a suction riser is used, the oil charge must be adjusted.
Add the equivalent volume to half of the lower part of each
siphon trap (see figure below), when the unit is empty.
1
Oil volume for a siphon trap
Legend
2
Slave unit
1
16.5 - Operation of two units in master/slave mode
(option 58)
The control of a master/slave assembly is in the entering
water piping (system return). All parameters, required for
the master/slave function must be configured using the
Service Configuration menu.
2
Master unit
Additional CCN board (one per unit, with connection via communication bus)
Control boxes of the master and slave units
Water inlet (for customers with both units)
Water pumps for each unit (included as standard for units with hydronic module)
Water outlet (for customers with both units)
Additional sensors for leaving water control, to be connected to channel 1 of
the slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors
All remote controls of the master/slave assembly (start/stop,
set point, load shedding etc.) are controlled by the unit
configured as master and must only be applied to the
master unit.
17 - MAJOR SYSTEM COMPONENTS AND OPERATION
DATA
IMPORTANT: To permit master/slave operation both
units must be equipped with option 58.
61WG/30WG/30WGA units use hermetic scroll compressors.
The only refrigerant permitted for these compressors is
R-410A.
Depending on the installation and control type, each unit can
control its own water pump.
16.6 - Parallel or serial connection of two 61WG/30WG/
30WGA units
Entering water control for a hydronic kit
17.1 - Compressors
30WGA split units operating with an air-cooled condenser,
are supplied with the refrigerant circuit and consequently
the compressor under nitrogen pressure of 100 kPa (1 bar).
The compressors are not certified for mobile applications
or use in explosive environments.
For more information contact the Carrier service team for
maintenance instructions.
1
See legend in the next column.
2
IMPORTANT: All compressor and system pressure tests
must be carried out by qualified personnel, taking the
greatest care with potential dangers resulting from the
pressures used, and respecting the maximum operating
pressure limit on the high and low-pressure side, shown
on the unit and compressor name plates.
• Maximum operating pressure, low-pressure side
(61WG/30WG/30WGA): 2820 kPa (28.2 bar)
• Maximum operating pressure, high-pressure side
(61WG/30WG): 4870 kPa (48.7 bar).
• Maximum operating pressure, high-pressure side
(30WGA): 4170 kPa (41,7 bars)
These setpoint must be observed for 30WGA split units
using an air-cooled condenser, when the installer checks
the complete system leak tightness.
44
Any modification or alteration such as soldering on the
compressor shell may invalidate the right to use the
equipment.
Units using these compressors are installed in areas where
the temperature must be between 5 °C minimum and 40 °C
maximum. The temperature around the compressors must
not exceed 50 °C during unit shutdown cycles.
Shock absorbers are installed under the compressor feet.
17.2 - Lubricant
The compressors have the following factory lubricant charge:
polyolester oil (reference: POE 160SZ). Contact Carrier to
order the oil. This lubricant must not be mixed with other
lubricant types.
Before start-up and after normal unit operation check that
the oil level is visible.
If an additional oil quantity is required to compensate the
initial low level in the compressors, top up the charge, using
only the permitted lubricant shown on the compressor name
plate: polyolester oil (ref: POE 160SZ).
NOTE: Only use oil approved for these compressors. Do
not re-use oil that has been exposed to the air.
ATTENTION: R22 oils are not compatible with R410A
oils and vice-versa.
17.3 - Evaporators and water-cooled condensers
The evaporators and condensers are single-circuit plate heat
exchangers. They are tested and stamped for a maximum
operating pressure of 4870 kPa, 2820 kPa on the refrigerant
side and 1000 kPa on the water side.
For 61WG/30WG units the heat exchanger sizing for the
whole range ensures a saturated evaporating temperature
of 4.5 °C and a condensing temperature of around 38 °C
with actual subcooling of around 4 K at the condenser
leaving side, based on nominal Eurovent conditions.
The evaporators and condensers are single-circuit for all
units. The water connections between the heat exchangers
and the piping of the hydronic modules have quick-connect
Victaulic couplings to facilitate pump disassembly, if
required.
A drain with a 1/4 turn valve is included in the leaving
water of all heat exchangers.
The evaporators have 19 mm thick polyurethane foam
thermal insulation. For option 86 (condenser insulation), the
condensers also have 19 mm thick polyurethane foam
thermal insulation.
The products that may be added for thermal insulation of the
containers during the water piping connection procedure
must be chemically neutral in relation to the materials and
coatings to which they are applied. This is also the case for
the products originally supplied by Carrier.
NOTES: Monitoring during operation, re-qualification,
re-testing and re-testing dispensation:
• Follow the regulations on monitoring pressurised
equipment.
• It is normally required that the user or operator sets
up and maintains a monitoring and maintenance file.
• If there are no regulations or to complement them
follow the control programmes of EN 378.
• If they exist follow local professional recommendations.
• Regularly inspect the condition of the coating (paint)
to detect blistering resulting from corrosion. To do
this, check a non-insulated section of the container
or the rust formation at the insulation joints.
• Regularly check for possible presence of impurities
(e.g. silicon grains) in the heat exchange fluids. These
impurities maybe the cause of the wear or corrosion
by puncture.
• Filter the heat exchange fluid check and carry out
internal inspections as described in EN 378, annex C.
• In case of re-testing take the possible maximum
pressure difference of 25 bar into consideration.
• The reports of periodical checks by the user or operator
must be included in the supervision and maintenance
file.
Repair
Any repair or modification of the plate heat exchangers is
forbidden.
Only the replacement of the complete heat exchanger by
an original heat exchanger supplied by the manufacturer is
permitted. The replacement must be carried out by a
qualified technician.
• The heat exchanger replacement must be shown on
the monitoring and maintenance file.
Recycling
The plate heat exchanger is 100% recyclable. After use it
contains refrigerant vapours and oil residue.
Operating life
This unit is designed for:
• prolonged storage of 15 years under nitrogen charge
with a temperature difference of 20 K per day.
• 900000 cycles (start-ups) with a maximum difference of
6 K between two neighbouring points in the container,
based on 12 start-ups per hour over 15 years at a usage
rate of 57%.
17.4 - Electronic expansion valve (EXV)
The EXV is equipped with a stepper motor (2625 + 160 /- 0
steps) that is controlled via the EXV board.
17.5 - Refrigerant
61WG/30WG/30WGA units operate exclusively with
R-410A.
45
17.6 - High-pressure switch and high-pressure sensor
17.7 - High and low-pressure side safety valves
61WG/30WG units are equipped with an automatically
reset safety pressure switch on the liquid line. Refer to the
controls manual for the alarm acknowledgements.
The units are equipped with safety valves in accordance
with the European directive 97/23/CE. These safety valves
are calibrated and sized in accordance with the original
high and low-pressure side equipment.
It is strictly forbidden to modify the unit refrigerant circuit.
The pressure switch is specific to the 61WG/30WG units
- do not interchange it with other units. The pressure switch
tap does not include a Schrader valve.
Only 61WG/30WG units include high and low-pressure
side safety valves. 30WGA units are only equipped with a
low-pressure side safety valve. The installer must determine
which accessories (safety valves, fuses etc.) are required to
ensure that the completed high-pressure circuit complies
with the applicable regulations and standards.
17.8 - Moisture indicator
Located in the liquid line, permits control of the unit charge,
as well as the presence of moisture in the circuit. Bubbles in
the sight glass indicate an insufficient charge or the presence
of non-condensibles. Regarding 30WGA units, if the
indicator paper in the sight glass is yellow during the
delivery, it is not a non-conformity. It is necessary to verify
if the indicator paper in the sight glass is yellow after the
vaccum.
High-pressure switch
High-pressure sensor
The high-pressure sensor is however equipped with a
Schrader valve. It is specific to these units and must not be
replaced with one from other Carrier units.
30WGA units are equipped with an automatically reset
safety pressure switch on the discharge line. The pressure
switch is specific for the 30WGA unit. Do not exchange it
with other units including the 61WG/30WG units.
High-pressure sensor
High-pressure switch
17.9 - Filter drier in the refrigerant circuit
The filter keeps the circuit clean and moisture-free. The
moisture indicator shows when it is necessary to change
the filter cartridges. A temperature difference between the
filter drier inlet and outlet indicates a contamination of the
cartridges.
30WGA are equipped as standard with a filter drier that
needs to be soldered to the liquid line. It must be soldered
as close as possible to the 30WGA unit, upstream of the
solenoid valve and as soon as possible after the circuit has
been exposed to the atmosphere while connecting the
air-cooled condenser.
Filter drier position
46
17.10 - Fixed-speed pump
This pump is factory-installed as standard to guarantee the
nominal flow in the water loop. It is a fixed-speed pump
with available system pressure. See the pump flow/pressure
curves in chapters 10 and 11.
The nominal system flow rate must be adjusted with a
manual control valve supplied by the customer (see chapters
10 and 11 on the control of the nominal water flow rate).
The maximum permitted concentration of the glycol
additives (ethylene glycol or propylene glycol) is 35%.
All pumps are protected by a suction filter. This is easily
removable to recover solid particles. It protects the pump
and the plate heat exchanger against solid particles with a
size exceeding 1,2 mm. Before the unit start-up it is
important to turn the evaporator and condenser pump to
decontaminate the water loops of any solid pollution.
A specific pump start-up function in the Quick Test menu
is available for this task.
17.13 - Connection sleeves
The maximum pump suction pressure is limited to 300 kPa
(3 bar) due to the valve installed on the entering water
piping.
The use of any other glycol type additives must be approved
by Carrier.
ATTENTION: Use of hydronic kit in an open loop is
forbidden.
17.11 - Variable-speed pump
This pump is factory-installed. It is a variable-speed pump
with available system pressure. See the pump flow/pressure
curve.
The system flow rate is automatically adjusted via the
frequency converter built into the pump, based on the heat
rejection load on the drycooler.
The maximum permitted concentration of the glycol
additives is 35%.
The maximum pump suction pressure is limited to 300 kPa
(3 bar) due to the valve installed on the entering water piping.
The use of any other glycol type additives must be approved
by Carrier.
ATTENTION: Use of hydronic kit in an open loop is
forbidden.
17.12 - Evaporator and condenser pump suction filter
Position of the water connection sleeves in the unit
17.14 - Option 272: High-temperature water production
with glycol solution
ATTENTION: The temperature sensor positioned in the
discharge for option 272 is specific to this unit and must
not be interchanged with another temperature sensor. For
replacement please contact the Carrier service team.
17.15 - Outside air temperature sensor
30WGA units require information about the outside air
temperature. This is needed for correct system operation
(EXV, fans, condensing temperature, setpoint).
In units without control of the remote condenser (standard),
the sensor (25 m) is supplied with the control box of the
30WGA and must be installed near the air-cooled condenser.
In units with control of the remote condenser (option 154),
the sensor is supplied with the option and must be installed
near the air-cooled condenser.
Filter positions in the unit
The position of the temperature sensor must be chosen with
great care and must be representative of the outside temperature (limit any other source that could have a negative
influence on the control: gusts of wind, other heat sources
such as sun radiation and hot air recycling).
47
18 - OPTIONS AND ACCESSORIES
Options
Very low temperature glycol solution
No.
6
Description
Low temperature glycol solution production down to
-12 °C with ethylene glycol
Electronic compressor starter
Soft starter
25
Twinning
58
External disconnect handle
70F
Condenser insulation
86
Low-pressure single-pump hydronic module,
evaporator side
116F See hydronic module chapter
Unit equipped with an additional field-installed
leaving water temperature sensor, allowing master/
slave operation of two units connected in parallel.
The handle of the electrical disconnect switch is on
the outside of the unit
Thermal condenser insulation
High-pressure single-pump hydronic module, 116J See hydronic module chapter
variable-speed, evaporator side
JBus gateway
148B Two-directional communications board, complies
with JBus protocol
BacNet gateway
148C Two-directional communications board, complies
with BacNet protocol
LON gateway
148D Two-directional communications board, complies
with LON protocol
Built-in DHW and space heating control
153
Specific cooling control
154
Low sound level
257
Evaporator screw connection sleeves
264
Evaporator inlet/outlet screw connection sleeves
Condenser screw connection sleeves
265
Condenser inlet/outlet screw connection sleeves
Welded evaporator connection sleeves
266
Welded evaporator inlet/outlet connection sleeves
Welded condenser connection sleeves
267
Welded condenser inlet/outlet connection sleeves
Low-pressure single-pump hydronic module,
condenser side
High-pressure hydronic module with single
variabe-speed pump, condenser side
High-temperature water production, condenser
side, with glycol solution on the evaporator side
Unit stackable for operation
270F See hydronic module chapter
273
Condenser side water production up to 65 °C, with
glycol solution on the evaporator side to -5 °C
Unit stackable for operation
Customer water connection at the top of the
unit
Remote user interface
274
Customer water connection at the top of the unit
275
User interface for remote installation
Filter drier with replaceable solid core
277
Filter the fine particles and eliminates humidity
270J See hydronic module chapter
272
Accessories
00PPG000488000- Heating System Manager type A:
It controls one heat emitter type with an auxiliary
electric heater or boiler.
00PPG000488100- Heating System Manager type B:
It controls two heat emitter types (or independent
zones) and domestic hot water production with an
auxiliary electric heater or boiler.
00PPG000488200- Heating System Manager type C:
It controls two heat emitter types (or independent
zones) and domestic hot water production with a
district heating network as auxiliary source.
48
Control board factory-installed on the unit, control
using weather compensation, control of additional
electric heater (4 stages) or boiler, needle valve for
domestic hot-water production with programmable
time schedule.
Control box to be installed on the Carrier drycooler
or remote condenser for communication with the
unit via a bus.
Compressor sound enclosure and sound insulation
of main noise sources
Advantages
Covers specific applications such as ice
storage and industrial processe
Reduced compressor start-up current
Use
30WG 020-090
Permits the use of an energy-efficient
plug-and-play system
30WG 020-090
30WGA 020-090
30WG 020-090
61WG 020-090
30WGA 020-090
Optimised operation of two units connected 30WG 020-090
in parallel with operating time equalisation 61WG 020-090
30WGA 020-090
Quick access to the unit disconnect switch 30WG 020-090
61WG 020-090
30WGA 020-090
Optimisation for heating applications
30WG 020-090
61WG 020-090
Easy and fast installation
30WG 020-090
61WG 020-090
30WGA 020-090
Easy and fast installation, reduced power
30WG 020-090
consumption of the water circulation pump. 61WG 020-090
30WGA 020-090
Easy connection by communication bus to 30WG 020-090
a building management system
61WG 020-090
30WGA 020-090
Easy connection by communication bus to 30WG 020-090
61WG 020-090
a building management system
30WGA 020-090
Easy connection by communication bus to 30WG 020-090
61WG 020-090
a building management system
30WGA 020-090
Permits easy control of a basic heating
61WG 020-090
system
Reduced sound emissions
30WG 020-090
61WG 020-090
30WGA 020-090
Allows unit connection to a screw
30WG 020-090
connector
61WG 020-090
30WGA 020-090
Allows unit connection to a screw
30WG 020-090
connector
61WG 020-090
Allows welding of customer connections to 30WG 020-090
the unit
61WG 020-090
30WGA 020-090
Allows welding of customer connections to 30WG 020-090
the unit
61WG 020-090
Easy and fast installation
30WG 020-090
61WG 020-090
Easy and fast installation, reduced power
30WG 020-090
consumption of the water circulation pump. 61WG 020-090
Geothermal application and domestic
61WG 020-090
hot-water production
Reduced footprint size
30WG 020-090
61WG 020-090
30WGA 020-090
Reduced footprint size
30WG 020-090
61WG 020-090
Remote control of the unit and its operating 30WG 020-090
parameters
61WG 020-090
30WGA 020-090
Maintains the refrigerated circuit without
30WGA 020-090
humidity
Advantages
Additional control box not supplied with the unit, to
be installed remotely
Use
Heating system control facilitated
61WG 020-090
Additional control box not supplied with the unit, to
be installed remotely
Heating system control facilitated
61WG 020-090
Additional control box not supplied with the unit, to
be installed remotely
Heating system control facilitated
61WG 020-090
19 - MAINTENANCE
19.2 - General system maintenance
During the unit operating life the service checks and tests
must be carried out in accordance with applicable national
regulations.
•
•
If there are no similar criteria in local regulations, the
information on checks during operation in annex C of
standard EN 378 can be used.
•
External visual checks: annex A and B of standard EN378.
•
Corrosion checks: annex D of standard EN 378. These
controls must be carried out:
• After an intervention that is likely to affect the
resis-tance or a change in use or change of highpressure refrigerant, or after a shut down of more than
two years. Components that do not comply, must be
changed. Test pressures above the respective
component design pressure must not be applied
(annex B and D).
• After repair or significant modifications or significant
system or component extension (annex B).
• After re-installation at another site (annexes A, B and D).
• After repair following a refrigerant leak (annex D).
The frequency of refrigerant leak detection can vary
from once per year for systems with less than 1% leak
rate per year to once a day for systems with a leak
rate of 35% per year or more. The frequency is in
proportion with the leak rate.
NOTE: High leak rates are not acceptable. The necessary
steps must be taken to eliminate any leak detected.
NOTE 2: Fixed refrigerant detectors are not leak detectors,
as they cannot locate the leak.
19.1 - Soldering and welding
Component, piping and connection soldering and welding
operations must be carried out using the correct procedures
and by qualified operators. Pressurised containers must not
be subjected to shocks, nor to large temperature variations
during maintenance and repair operations.
Any technician attending the machine for any purpose must
be fully qualified to work on refrigerant and electrical
circuits.
WARNING: Before doing any work on the machine ensure
that the power is switched off. If a refrigerant circuit is
opened, it must be evacuated, recharged and tested for
leaks. Before any operation on a refrigerant circuit, it is
necessary to remove the complete refrigerant charge from
the unit with a refrigerant charge recovery unit.
All removal and refrigerant draining operations must be
carried out by a qualified technician and with the correct
material for the unit. Any inappropriate handling can
lead to uncontrolled fluid or pressure leaks.
If an oil draining or recovery operation becomes necessary,
the fluid transfer must be made using mobile containers.
•
•
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 foam insulation joints on the heat
exchanger piping are in good condition.
Regularly check that the vibration levels remain
acceptable and close to those at the start of using the unit.
19.3 - Refrigerant undercharge
If there is not enough refrigerant in the system, this is
indicated by gas bubbles in the moisture sight glass.
If the undercharge is significant, large bubbles appear in
the moisture sight glass, and the suction pressure drops.
The compressor suction superheat is also high. The machine
must be recharged after the leak has been repaired.
Find the leak and completely drain the system with a
refrigerant recovery unit. Carry out the repair, leak test
and then recharge the system.
IMPORTANT: After the leak has been repaired, the circuit
must be tested, without exceeding the maximum low-side
operating pressure shown on the unit name plate.
The refrigerant must always be recharged in the liquid phase
into the liquid line. The refrigerant cylinder must always
contain at least 10% of its initial charge. For the refrigerant
quantity per circuit, refer to the data on the unit name plate.
During applications with option 272 (brine to water) and
with positive evaporation, bubbles will appear in the
sight-glass. This is normal, when the charge is optimised
for improved efficiency in brine applications.
19.4 - 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.
• 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.
49
Before opening a refrigerant circuit, purge the circuit and
consult the pressure gauges.
Change the refrigerant after an equipment failure, following
a procedure such as the one described in NF E29-795 or
carry out a refrigerant analysis in a specialist laboratory.
If the refrigerant circuit remains open for longer than a day
after an intervention (such as a component replacement),
the openings must be plugged and the circuit must be
charged with nitrogen (inertia principle). The objective is
to prevent penetration of atmospheric humidity and the
resulting corrosion on the internal walls and on unprotected steel surfaces.
19.5 - Leak detection
Never use oxygen or dry air, as this would cause a risk of
fire or explosion.
• Carry out a leak detection test on the whole system
using the following methods: pressure test using
dehydrated nitrogen or a mixture of nitrogen and
refrigerant used for the system, helium leak test.
• Connect the compressor to the system by opening the
valves.
• The duration of the test must be sufficient to guarantee the absence of very small leaks in the circuit.
• Use specific tools, designed for leak detection.
• The low-pressure side test pressure must not exceed
pressure Ps indicated on the compressor and unit
name plates.
• If there is a leak, repair it and carry out the leak detection test again.
19.6 - Evacuation
To evacuate the system, observe the following recommendations:
Connect the vacuum pump to the high (HP) and lowpressure (LP) side for evacuation of the complete circuit.
All units are equipped with valves with 3/8” SAE connections on the suction, discharge and liquid lines, permitting
the connection of large-diameter flexible pipes limiting the
pressure drops for the evacuation.
1. The vacuum level achieved must be 0.67 mbar (500 µm
Hg).
2. Wait 30 minutes.
3. If the pressure increases rapidly, the system ist not
leak-tight. Localise and repair the leaks. Restart the
evacuation procedure and repeat steps 1, 2 etc.
4. If the pressure increeases slowly, this indicates that
moisture is present inside the system. Break the vacuum
with nitrogen and restart the evacuation procedure
(steps 1, 2 etc.).
5. Repeat the evacuation procedure (steps 1, 2); a vacuum
level of 0.67 mbar (500 µm Hg) must be achieved and
maintained for four hours.
50
This vacuum level must be measured at one of the system
connections and not at the vacuum pump pressure
gauge.
ATTENTION: Do not use a megohmmeter and do not
place any stress on the compressor motor when the system
has been evacuated. There is a risk of internal short circuits
between the motor windings.
Do not use additives for leak detection. Do not use CFCs/
HCFCs as tracer fluids for leak detection.
19.7 - Recharging liquid refrigerant
CAUTION: The units are charged with liquid R-410A
refrigerant.
With high-pressure R-410A refrigerant the unit operating
pressure is above 4000 kPa (40 bar), the pressure at 35 °C
air temperature is 50% higher than for R-22. Special
equipment must be used when working on the refrigerant
circuit (pressure gauge, charge transfer, etc.).
All checks must be pressure tests, and the appropriate
pressure/temperature ratio table must be used to determine
the corresponding saturated temperatures (saturated
bubble point curve or saturated dew point curve).
Leak detection is especially important for units charged
with refrigerant R-410A. 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.
19.8 - Characteristics of R-410A
Saturated temperatures (°C) based on the relative pressure (in kPa)
Satur.
Relative Satur.
Relative Satur.
Relative Satur.
Relative
temp.
pressure temp.
pressure temp.
pressure temp.
pressure
-20
297
4
807
28
1687
52
3088
-19
312
5
835
29
1734
53
3161
-18
328
6
864
30
1781
54
3234
-17
345
7
894
31
1830
55
3310
-16
361
8
924
32
1880
56
3386
-15
379
9
956
33
1930
57
3464
-14
397
10
987
34
1981
58
3543
-13
415
11
1020
35
2034
59
3624
-12
434
12
1053
36
2087
60
3706
-11
453
13
1087
37
2142
61
3789
-10
473
14
1121
38
2197
62
3874
-9
493
15
1156
39
2253
63
3961
-8
514
16
1192
40
2311
64
4049
-7
535
17
1229
41
2369
65
4138
2429
66
4229
-6
557
18
1267
42
-5
579
19
1305
43
2490
67
4322
-4
602
20
1344
44
2551
68
4416
-3
626
21
1384
45
2614
69
4512
-2
650
22
1425
46
2678
70
4610
-1
674
23
1467
47
2744
0
700
24
1509
48
2810
1
726
26
1596
49
2878
2
752
25
1552
50
2947
3
779
27
1641
51
3017
19.9 - Electrical maintenance
19.12 - Compressors
When working on the unit comply with all safety precautions described in section 1.3.
The compressors do not require any specific maintenance.
Nevertheless the preventive system maintenance operations
prevent specific compressor problems. The following periodic
preventive maintenance checks are strongly recommended:
• Check the operating conditions (evaporating temperature, condensing temperature, discharge temperature,
heat exchanger temperature difference, superheat,
subcooling). These operating parameters must always
be within the compressor operating range.
• Check that the safety devices are all operational and
correctly controlled.
• Check oil level and quality. If there is a colour change in
the sight glass, check the oil quality. This may include an
acidity test, moisture control, a spectrometric analysis etc.
• Check the leak tightness of the refrigerant circuit.
• Check the compressor motor power input, as well as
the voltage imbalance between phases.
• Check the tightening of all electrical connections.
• Ensure that the compressor is clean and runs correctly;
verify that there is no rust on the compressor shell and
no corrosion or oxydation at the electrical connections
and the piping.
It is strongly recommended to change the unit fuses every
15000 operating hours or every three years.
It is recommended to verify that all electrical connections
are tight:
• after the unit has been received at the moment of
installation and before the first start-up
• one month after the first start-up,when the electrical
components have reached their nominal operating
temperatures
• then regularly once a year.
19.10 - Tightening torques for the main electrical
connections
Component
Designation in
the unit
PE
Screw (PE) customer connection M8
Screw on switch inlet zones
Switch - MG 28904
QS_
Tunnel terminal screw, compressor contactor
Contactor LC1D12B7
KM*
Contactor LC1D18B7
KM*
Contactor LC1D25B7
KM*
Tunnel terminal screw, compressor circuit breaker
Circuit breaker 25507
QM*
Circuit breaker 25508
QM*
Circuit breaker 25509
QM*
Tunnel terminal screw, control power transformer
Transformer - ABL6TS16B
TC
Compressor earth terminal in the power wiring control box
M6
Gnd
Compressor earth connection
M8
Gnd
Tunnel terminal screw, pump disconnect switch
Disconnect switch GV2ME08
QM_
Disconnect switch GV2ME10
QM_
Tunnel terminal screw, pump contactor
Contactor LC1K0610B7
KM
Contactor LC1K09004B7
KM
Contactor LC1K0910B7
KM
Contactor LC1K0901B7
KM
Variable-frequency switch ATV21
GS
Value (N·m)
14.5
8
1.7
1.7
2.5
3.6
3.6
3.6
0.6
5.5
2.83
1.7
1.7
0.8 to 1.3
0.8 to 1.3
0.8 to 1.3
0.8 to 1.3
1.3
19.11 - Tightening torques for the main bolts and screws
Screw type
M8 nut
M10 nut
Oil nut
Taptite screw M6
H M6 screw
Used for
BPHE* fixing
Compressor mounting
Oil equalisation line
Panel fixing
Stauff clamps
* BPHE = Brazed plate heat exchanger
Torque (N·m)
15
30
100
7
10
ATTENTION: The compressor and piping surface temperatures can in certain cases exceed 100 °C and cause
burns. Particular caution is required during maintenance
opera-tions. At the same time, when the compressor is in
operation, the surface temperatures can also be very cold
(down to -15 °C for units with a low leaving water
temperature), and can cause frost burns.
19.13 - Evaporator and condenser maintenance
There is no particular maintenance necessary on the plate
heat exchanger. Check:
• that the insulating foam has not become detached or
damaged during work on the units
• that the entering and leaving water temperature
sensors are well connected
• the cleanliness on the water heat exchanger side (no
signs of leaks).
• that the periodic inspections required by local regulations have been carried out.
19.14 - Corrosion check
All metallic parts of the unit (chassis, casing panels, control
boxes, heat exchangers etc.) are protected against corrosion
by a coating of powder or liquid paint. To prevent the risk
of blistering corrosion that can appear when moisture
penetrates under the protective coatings, it is necessary to
carry out periodic checks of the coating (paint) condition.
51
20 - AQUASNAP MAINTENANCE PROGRAM
All maintenance operations must be carried out by
technicians who have been trained on Carrier products,
observing all Carrier quality and safety standards.
20.1 - Maintenance schedule
Electrical checks
• Check the tightening of the electric connections,
contactors, disconnect switch and transformer.
• Check the phase direction upstream of the unit and in
the customer’s electrical data table.
• Check the status of the contactors and fuses.
• Carry out a quick test (refer to the 61WG/30WG/
30WGA Pro-Dialog+ Controls manual).
Regular maintenance is indispensable to optimise equipment operating life and reliability. Maintenance operations Mechanical checks
must be carried out in accordance with the schedules below: • Verify the correct operation of the evaporator and
condenser pumps with the Quick Test function.
• Verify the correct operation of cooling fans, speed
ServiceFrequency
converter and condensing pumps.
AWeekly
BMonthly
Water circuit checks
CAnnually
• Check the leak-tightness of the circuit.
D
Special cases
If the equipment does not operate normally during main- Service C
tenance operations, refer to the chapter on diagnostics and Carry out the operations listed under Service B.
breakdowns of the 61WG/30WG/30WGA Pro-Dialog+
Refrigerant circuit
Controls manual).
• Check the leak-tightness of the circuit and ensure that
there is no piping damage.
IMPORTANT: Before each equipment maintenance
• Carry out an oil contamination test. If acid, water or
operation please ensure that:
metallic particles are present, replace the oil in the circuit.
• the unit is in the OFF position
• it is impossible for the unit to restart automatically • Verify the tightening of the thermostatic mechanism
of the expansion device.
during maintenance.
• Full-load operating test. In addition to the checks carried
out under Service B, validate the value between leaving
20.2 - Description of the maintenance operations
water and the saturated evaporating temperature.
The equipment is supplied with polyolester oil (POE). Use • Check the operation of the high-pressure switch(es).
Replace them if there is a fault.
only Carrier-approved oil. On request Carrier can carry
• Check the fouling of the filter drier (by checking the
out an oil analysis of your installation.
temperature difference in the copper piping). Replace
it if necessary.
Service A
Full-load operating test
Electrical checks
Verify the following values:
• Check the status and insulation of the electrical cables.
• compressor high-pressure side discharge pressure
• Check the phase/earth insulation of the compressors
• compressor low-pressure side suction pressure
and pumps.
• charge visible in the sight glass
• temperature difference between the heat exchanger • Check the compressor and pump winding status.
water entering and leaving temperature.
Mechanical checks
• Check that no water has penetrated into the control box.
Verify the alarm status
• Clean the filter of the air inlet grille and if necessary
replace the filter.
Service B
Carrier out the operations listed under Service A.
Water circuit checks
• Clean the water filter.
Refrigerant circuit
• Full-load operating test. In addition to the operations • Purge the circuit with air.
described under Service A, check the following values:• Verify the correct operation of the water flow switch.
• Check the status of the thermal piping insulation.
- compressor discharge pressure
• Check the water flow by checking the heat exchanger
- compressor oil level
pressure difference (using a pressure gauge).
- actual liquid subcooling
• Check the concentration of the anti-freeze protection
- overheating at the expansion device
solution (ethylene glycol or polyethylene glycol).
• Verify the charge status by checking the colour
indicator of the sight glass. If the colour has turned to • Check the heat transfer fluid status or the water quality.
yellow, change the charge and replace the filter drier • Check the steel pipe corrosion.
cartridges after carrying out a leak test of the circuit.
52
21 - START-UP CKECKLIST FOR 61WG/30WG/30WGA UNITS (USE FOR JOB FILE)
Preliminary information
Job name:................................................................................................................................................................................................
Location:.................................................................................................................................................................................................
Installing contractor:..............................................................................................................................................................................
Distributor:.............................................................................................................................................................................................
Start-up preformed by:..........................................................................................................................................................................
Equipment
Model:............................................................................................. Serial No......................................................................................
Compressors
1. Model No. .................................................................................. 2. Model No................................................................................
Serial No..................................................................................... Serial No.................................................................................
Motor No.................................................................................... Motor No................................................................................ Evaporator
Model No........................................................................................ Manufactured by .......................................................................
Serial No.......................................................................................... Date.............................................................................................
Condensers
Model No........................................................................................ Manufactured by .......................................................................
Serial No.......................................................................................... Date.............................................................................................
Additional air handling units and accessories....................................................................................................................................
.................................................................................................................................................................................................................
Preliminary equipment check
Is there any shipping damage?..................................................... If so, where?................................................................................
.................................................................................................................................................................................................................
Will this damage prevent unit start-up?..............................................................................................................................................
Unit is level in its installation
Power supply agrees with the unit nameplate
Electrical circuit wiring has been sized and installed properly
Unit ground wire has been connected
Electrical circuit protection has been sized and installed properly
All terminals are tight
All cables and thermistors have been inspected for crossed wires
All plug assemblies are tight
Check air handling systems
All air handlers are operating
All chilled water valves are open
All fluid piping is connected properly
All air has been vented from the system
Chilled water pump (CWP) is operating with the correct rotation. CWP amperage: Rated:.............. Actual............
Unit start-up
CWP starter has been properly interlocked with the unit
Oil level is correct
All discharge and liquid valves are open
Unit has been leak checked (including fittings)
Locate, repair, and report any refrigerant leaks
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
Check voltage imbalance: AB.................AC.................. BC..................
Average voltage = .................................... (see installation instructions)
Maximum deviation = ............................. (see installation instructions)
Voltage imbalance = ................................ (see installation instructions)
Voltage imbalance is less than 2.
53
WARNING: Do not start unit if voltage imbalance is greater than 2%. Contact local power company for assistance.
All incoming power voltage is within rated voltage range
Check cooler water loop
Water loop volume = ............................... (litres)
Calculated volume = ................................(litres)
Proper loop volume established
Proper loop corrosion inhibitor included..........litres of............................ Proper loop freeze protection included (if required).................. litres of............................... Piping includes electric heater tape, if exposed to the outside
Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm (unit without pump)
Check pressure drop across the evaporator
Entering evaporator = .............................(kPa)
Leaving evaporator = ..............................(kPa)
(Leaving - entering) = .............................(kPa)
WARNING: Calculate the cooler pressure drop in performance data table (in the product data literature) to determine
total litres per second (l/s) and find unit’s minimum flow rate.
Total l/s = ..................................................
l/s / nominal kW = ....................................
Total l/s is greater than unit’s minimum flow rate
Total l/s meets job specified requirement of....................................... (l/s)
Perform TEST function (indicate positive result):
WARNING: Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the
TEST function instructions in the Controls and Troubleshooting literature (follow the procedure in the Controls IOM).
Be sure that all service valves are open, before beginning the compressor test section.
To start the unit
WARNING: Be sure that all service valves are open, and all pumps are on before attempting to start this machine.
Once all checks have been made, move the switch to “LOCAL” or “REMOTE” from “OFF”.
Unit starts and operates properly
Temperatures and pressures
WARNING: Once the machine has been operating for a while and the temperatures and pressures have stabilized,
record the following:
Evaporator EWT........................................................................... Ambient temperature................................................................
Evaporator LWT............................................................................ Condenser EWT........................................................................
Condenser LWT.........................................................................
Suction pressure, circuit A............................................................ Discharge pressure, cicuit A......................................................... Suction temperature, circuit A..................................................... Discharge temperature, circuit A................................................. Liquid line temperature, circuit A............................................... Suction pressure, circuit B*.......................................................
Discharge pressure, cicuit B*....................................................
Suction temperature, circuit B*................................................
Discharge temperature, circuit B*............................................
Liquid line temperature, circuit B*..........................................
Compressor oil pressure A1**..................................................... Compressor oil pressure B1**..................................................
Compressor oil pressure A2**..................................................... Compressor oil pressure B2**..................................................
*
**
if available and installed
if installed
NOTES:
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
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Order No: 16122-76, 02.2014 - Supersedes order No: 16122-76, 10.2013.
Manufacturer reserves the right to change any product specifications without notice.
Manufacturer: Carrier SCS, Montluel, France.
Printed in the European Union.
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