30GX 082-358 30HXC 080-375 Screw Compressor Water-Cooled Liquid Chillers and Air-Cooled Liquid Chillers Nominal cooling capacity 30HXC: 286-1300 kW Nominal cooling capacity 30GX: 282-1203 kW 50 Hz GLOBAL CHILLER Carrier is participating in the Eurovent Certification Programme. Products are as listed in the Eurovent Directory of Certified Products.
LIST OF CONTENTS 1 - INTRODUCTION ....................................................................................................................................................................... 4 1.1 - Installation safety considerations ............................................................................................................................................... 4 1.2 - Equipment and components under pressure ...........................................................................
8 - WATER CONNECTIONS ....................................................................................................................................................... 29 8.1 - Operating precautions .............................................................................................................................................................. 29 8.2 - Water connections .........................................................................................................................
1 - INTRODUCTION Prior to the initial start-up of the 30HXC/GX 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 30HXC/GX liquid chillers are designed to provide a very high level of safety during installation, start-up, operation and maintenance. They will provide safe and reliable service when operated within their application range.
NOTE: The unit must never be left shut down with the liquid line valve closed, as liquid refrigerant can be trapped between this valve and the expansion device. (This valve is situated on the liquid line before the filter drier box.) During any handling, maintenance and service operations the engineers working on the unit must be equipped with safety gloves, glasses, shoes and protective clothing.
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 before removing components or opening a circuit. 2 - PRELIMINARY CHECKS 2.
Before siting the unit check that: • the permitted loading at the site is adequate or that appropriate strenghtening measures have been taken. • the unit is installed level on an even surface (maximum tolerance is 5 mm in both axes). • 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.
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION 600 3.1 - 30HXC 080-190 C 3 1 30HXC-080 30HXC-090 30HXC-100 30HXC-110 2 D A E 500 3 4 B 4 700 3 F Legend: All dimensions are in mm. 1 Evaporator 2 Condenser 3 Clearances required for operation and maintenance 4 Clearances required for heat exchanger tube removal. Clearances D and E can be either on the left or on the right hand side.
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (cont’d) 500 3.2 - 30HXC 200-375 3 C 1 2 E 500 A D 3 4 700 B 4 3 F Legend: All dimensions are in mm. 1 Evaporator 2 Condenser 3 Clearances required for operation and maintenance 4 Clearances required for heat exchanger tube removal. Clearances D and E can be either on the left or on the right hand side.
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (cont’d) 3.3 - 30GX 082-182 Standard units 1351 2297 C1 30GX-082 30GX-092 30GX-102 30GX-112 30GX-122 30GX-132 30GX-152 30GX-162 30GX-182 A 500 1830 500 2254 4 1 1 2 1830 2 4 B Units with low and very low noise levels 500 1830 230 500 4 2254 3 1 1 2 1830 230 2 Legend: All dimensions are in mm.
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION (cont’d) 3.4 - 30GX 207-358 Standard units C1 1351 2297 C2 A 500 1830 500 1 2254 4 1 2 1830 2 4 B Units with low and very low noise levels 500 1830 500 230 4 2254 3 1 1 2 1830 230 2 4 B Legend: All dimensions are in mm.
3.5 - Multiple chiller installation NOTE: If the walls are higher than 2 m, contact the factory. Surface solide A 1830 1830 A 2000 2000 B B B B 1525 2000 B B 1525 Legend A Wall B Units Notes: Unit must have clearances for air flow as follows: Top: do not restrict in any way In case of multiple chillers (up to four units), the respective clearance between them should be increased from 1830 to 2000 mm for the side space requirement.
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HXC UNITS 4.
4.3 - Electrical data, 30HXC compressors Reference Size I nom. MHA LRA LRA (Y) LRA (S) 1 cp LRA (S) 2 cp 06NW2146S7N 06NW2174S7N 06NW2209S7N 06NW2250S7N 06NW2300S5N 06NW2300S5E 39 46 56 66 80 80+ 50 60 71 86 105 114 79 97 117 142 172 189 344 423 506 605 715 856 109 134 160 191 226 270 NA NA 260 330 370 385 NA NA 350 400 420 480 Legend: 06NW N E INOM MHA LRA LRA (Y) LRA (S) 1 cp. LRA (S) 2 cp.
The 30HXC 080-375 units for high condensing temperatures are directly derived from the standard models. Their application range is the same as that of the standard units, but permits operation at condenser leaving water temperatures up to 63°C. The PRO-DIALOG control offers all the advantages of the standard units, plus control of the condenser leaving water temperature.
Operating range 35% ethylene glycol Operating range 30% propylene glycol Condenser entering water temperature, °C Condenser entering water temperature, °C Evaporator leaving water temperature, °C Evaporator leaving water temperature, °C Notes 1. Evaporator ∆T = 4 K max. - condenser ∆T = 5 K 2. Operating range applicable for full and reduced load 3. At full load with a condenser entering water temperature below 20°C, a three-way valve must be used to maintain the correct condensing temperature.
4.5.4 - Evaporator pressure drop curve, units for very low temperature The evaporator is equipped with heat insulation of 38 mm thick polyurethane foam.
5 - PHYSICAL AND ELECTRICAL DATA FOR UNITS 30GX 5.
5.3 - Electrical data, 30GX and 30HXC compressors, option 150 + 150A Reference Size I nom. MHA LRA LRA (Y) LRA (S) 1 cp. LRA (S) 2 cp. 06NA2146S7N 06NA2174S7N 06NA2209S7N 06NA2250S7N 06NA2300S5N 06NA2300S5E 39 46 56 66 80 80+ 72 87 103 124 149 174 99 124 148 177 207 258 605 715 856 960 1226 1265 191 226 270 303 387 400 NA NA 330 435 490 510 NA NA 480 575 610 660 Legend: 06NA N E INOM MHA LRA LRA (Y) LRA (S) 1 cp. LRA (S) 2 cp.
6 - APPLICATION DATA 6.1.2 - Operating range 30GX ˚C 6.1 - Unit operating range Minimum Maximum 6.
6.3 - 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 table on the next page. If the flow exceeds the maximum value, two solutions are possible: a - Select a non-standard evaporator with one water pass less which will allow a higher maximum water flow rate. b - Bypass the evaporator as shown in the diagram to obtain a highter temperature difference with a lower evaporator flow rate.
6.8 - Evaporator pressure drop curve 200 2 7 6 3 9 5 1 11 Pressure drop, kPa 100 50 40 30 Legend 1 30HXC 080-090 / 30GX 082 2 30HXC 100 / 30GX 092-102 3 30HXC 110 / 30GX 112-122-132 4 30HXC 120-130 5 30HXC 140-155 / 30GX 152-162 6 30HXC 175-190 / 30GX 182 7 30HXC 200 / 30GX 207-227 8 30HXC 230 / 30GX 247 9 30HXC 260-285 / 30GX 267 10 30HXC 310 / 30GX 298 11 30HXC 345-375 / 30GX 328-358 20 10 8 8 10 4 1 2 3 4 10 20 30 40 100 Water flow rate, l/s 6.
7 - ELECTRICAL CONNECTION 7.1.3 - 30HXC 310-375 Control box 7.1 - Electrical connections 30HXC units 7.1.1 - 30HXC 080-190 Control box 30HXC A B C D E ØH Standard 080-190 (315/400A) 56 25 4 863 314 10.5 Legend 1 Main disconnect switch PE Earth connection S Power supply cable section (see table "Recommended wire sections"). Option 150/150A 080-140 (315/400A) 155-190 (630A) 56 68 25 32 4 6 863 880 314 307.5 10.5 12.5 30HXC A B C D E F 56 25 4 1492.
7 - ELECTRICAL CONNECTION 7.2.3 - 30GX 207-267 Control box 7.2 - Electrical connections 30GX units 7.2.1 - 30GX 082-132 Control box 1758 1872 X Y 30GX X Y 082-102 112-132 764 862 680 924 7.2.2 - 30GX 152-182 Control box Legend 1 Main disconnect switch PE Earth connection S Power supply cable section (see table "Recommended wire sections").
7.2.4 - 30GX 298-358 Control box 7.3 - Power supply The power supply must conform to the specification on the chiller nameplate. The supply voltage must be within the range specified in the electrical data table. For connections refer to the wiring diagrams. WARNING: Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutes abuse which will invalidate the Carrier warranty.
Electrical data notes for 30HXC units: • • • • • • • 1. a. - 30HXC 080-190 units have a single power connection point; 30HXC 200-375 units have two connection points. The control box includes the following standard features: Starter and motor protection devices for each compressor Control devices Field connections: All connections to the system and the electrical installations must be in full accordance with all applicable codes.
7.5 - 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.
7.5.3 - Selection table of minimum and maximum wire sections for connection to 30HXC units with high condensing temperatures (option 150 + 150A) 400 V-3 ph-50 Hz 30HXC Minimum wire section (mm2) Wire type L (m) 080 Opt. 150 090 Opt. 150 100 Opt. 150 110 Opt. 150 120 Opt. 150 130 Opt. 150 140 Opt. 150 155 Opt. 150 175 Opt. 150 190 Opt. 150 200 Opt.
8 - WATER CONNECTIONS ATTENTION: Before carrying out any water connections install the water box purge plugs (one plug per water box in the lower section - supplied in the control box). 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.
Potentiometer adjustment 8.2 - Water connections This diagram shows a typical water installation. Typical water circuit diagram 2 1 2 5 4 3 9 12 10 11 8 6 7 Legend 1 Control valve 2 Air vent 3 Flow switch for the evaporator 4 Flexible connection 5 Heat exchanger 6 Pressure tap 7 Thermostat sleeve 8 Drain 9 Buffer tank 10 Filter (mesh size: 1.2 mm = 20 mesh) 11 Expansion tank 12 Fill valve 8.3 - Flow control 8.3.
NOTE: Before this operation we recommend draining the circuit and disconnecting the pipes to be sure that the bolts are correctly and uniformly tightened. 8.5 - Frost protection 8.5.1 - Standard machine If the chiller or the water piping is in an area where the ambient temperature can fall below 0°C it is recommended 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.
9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA 9.1 - Geared twin screw compressor • • • • 30HXC and 30GX units use 06N geared twin screw compressors 06NA are used on 30GX (air-cooled condensing application) 06NW are used on 30HXC (water-cooled condensing application) Nominal capacities range from 39 to 80 tons. Economized or non economized models are used depending on the 30HXC and 30GX unit size. 9.1.1 - Oil filter The 06N screw compressor has an oil filter integral in the compressor housing.
NOTES: Monitoring during operation, re-qualification, retesting 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. Follow the control programmes of EN 378-2, annexes A, B, C and D. If they exist follow local professional recommendations. Regularly inspect the condition of the coating (paint) to detect blistering resulting from corrosion.
9.6 - Motor cooling valves 9.7 - Sensors Compressor motor winding temperatures are controlled to the optimum setpoint. The control accomplishes this by cycling the motor cooling solenoid valve to allow liquid refrigerant to flow across the motor windings as needed. On units equipped with economizers, a single valve per circuit controls the refrigerant flow required for the economizer effect and for motor cooling. This is a valve with progressive control.
10 - MAIN OPTIONS AND ACCESSORIES Depending on the applications for which the units are selected, they can be equipped with options. This chapter describes the main components that require special information for correct start-up and maintenance of these units, except where this is contained in a separate document. When the unit stops, the closure of the solenoid valves prevents migration of the refrigerant contained in the evaporator to the condenser, if this is the cold point of the circuit.
10.7 - Electric protection level of the 30HXC control boxes to IP44C (option 20) 11 - MAINTENANCE 11.1 - Maintenance instructions The control boxes are leak-tight and equipped with a ventilation system to ensure cooling of the electrical components. The control box fan is controlled by a thermostat (setpoint 55°C, differential 20°C). A safety thermostat switches the unit off, if the control box temperature exceeds 60°C. These elements can be shown on the unit and on the wiring diagram. 10.
11.4 - Indication of low charge on a 30HXC system 11.4.2 - Indication of low charge on 30GX systems NOTE : To check for low refrigerant charge on a 30HXC, several factors must be considered. A flashing liquid-line sightglass is not necessarily an indication of inadequate charge. There are many system conditions where a flashing sightglass occurs under normal operation. The 30HXC metering device is designed to work properly under these conditions. 1. 1. 2. 3. 4. 5. 6.
11.6.4 - Economizer pressure (circuits A & B) This input is used to monitor the oil pressure differential supplied to the compressor. 11.7 - Oil charging - low oil recharging 11.9 - Filter change-out schedule The filter should be checked after the first 1000 hours of operation, and every subsequent 4000 hours. The filter should be replaced at any time when the pressure differential across the filter exceeds 2.1 bar. 11.7.1 - Addition of oil charge to 30HXC/GX systems 1. 2. 3.
The switch that has been selected for detecting reverse rotation is Carrier part number HK01CB001. It is available as part of the "Compressor installation package" (part No. 06NA 660 013). This switch opens the contacts when the pressure falls below 50 mm of vacuum. The switch is a manual reset type that can be reset after the pressure has once again risen above 70 kPa. It is critical that the switch be a manual reset type to preclude the compressor from short cycling in the reverse direction. 11.11.
12 - START-UP CKECKLIST FOR 30HXC/GX LIQUID CHILLERS (USE FOR JOB FILE) Preliminary information Job name: ................................................................................................................................................................................................ Location: .................................................................................................................................................................................................
Check condenser system (30HXC) All condenser water valves are open All condenser piping is connected properly All air has been vented from the system Condenser water pump (CWP) is operating with the correct rotation. Condenser water pump amperage: Rated:……..
Check pressure drop across the condenser (30HXC only) Entering condenser = ................................ (kPa) Leaving condenser =................................. (kPa) (Leaving - entering) = ............................... (kPa) WARNING: Plot condenser pressure drop on performance data chart (in product data literature) to determine total liters per second (l/s) and find unit's minimum flow rate. Total l/s = .................................................. l/s / nominal kW = .........................
Order No: 13050-76 (phase 3), 02.2006 - Supersedes order No: 13050-76, 07.2003 Manufacturer reserves the right to change any product specifications without notice. Manufacturer: Carrier SCS, Montluel, France. Printed in the Netherlands on chlorine-free paper.
