INSTALLATION, OPERATION AND M A I N T E N A N C E I N S T R U C T I O N S

Transcription

1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Unit with low-noise option Air-Cooled Liquid Chillers 30RBM RBP Nominal cooling capacity kw 50 Hz Original instructions

2 CONTENTS - INTRODUCTION Specific aspects for 30RBP units Installation safety considerations Equipment and components under pressure Maintenance safety considerations Repair safety considerations PRELIMINARY CHECKS Check equipment received Moving and placing the unit Checks before system start-up Actual start-up DIMENSIONS, CLEARANCES RBM/30RBP (with and without hydronic module) RBM/30RBP (with and without hydronic module) RBM/30RBP (with and without hydronic module) Multiple chiller installation PHYSICAL AND ELECTRICAL DATA OF 30RBM AND 30RBP UNITS Physical data 30RBM Physical data 30RBP Electrical data 30RBM Electrical data 30RBP Short circuit stability current Electrical data of the hydronic module Compressor usage and electrical data ELECTRICAL CONNECTION Power supply Voltage phase imbalance (%) Power connection/disconnect switch Recommended wire sections Power cable entry Field control wiring Electric power reserve for the user APPLICATION DATA Unit operating range Minimum chilled water flow (units without hydronic module) Maximum chilled water flow (units without hydronic module) Evaporator with variable flow (units without hydronic module) Minimum system water volume Maximum system water volume Evaporator flow rate Pressure drop curves for the evaporator and standard entering/leaving water piping WATER CONNECTIONS Operating precautions and recommendations Hydronic connections Water flow detection Frost protection Protection against cavitation (with option 6) Operation of two units in Master/Slave mode (option 58)

3 8 - NOMINAL SYSTEM WATER FLOW CONTROL Units without hydronic module Units with hydronic module and fixed speed pump Units with hydronic module and variable speed pump - Pressure differential control Units with hydronic module and variable speed pump - Temperature differential control Units with hydronic module and variable speed pump - Controlling a fixed flow of the system Pump pressure/flow rate curves Available static system pressure MAIN COMPONENTS OF THE SYSTEM AND OPERATING RANGE Compressors Lubricant Condensers Fans Electronic expansion valve (EXV) Moisture indicator Filter drier Evaporator Refrigerant High-pressure safety switch Variable frequency drive (VFD) Power factor correction capacitors (option 23) Fan arrangement Fan stages (only 30RBM units) Variable speed fan (only 30RBP units) OPTIONS Touch Pilot Control (option 58) Hydronic module without variable speed (options 6R, 6S, 6T, 6U) Hydronic module with variable speed (options 6V, 6W) Units with fans with available pressure for indoor installation (Option 2-High Static Fan) Partial heat reclaim using desuperheaters (option 49) Other options STANDARD MAINTENANCE Level maintenance Level 2 maintenance Level 3 (or higher) maintenance Tightening torques for the main electrical connections Tightening torques for the main bolts and screws Condenser coil Evaporator maintenance Variable frequency drive maintenance Check of power factor correction capacitors Characteristics of R-40A START-UP CHECKLIST FOR 30RBM/30RBP LIQUID CHILLERS (USE FOR JOB FILE)...54 This manual applies to the following units: - 30RBM: Standard unit - 30RBP: Unit with variable speed fans For the operation of the control please refer to 30RBM/30RBP control manual. The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract. 3

4 - INTRODUCTION Prior to the initial start-up of the 30RBM/30RBP units, the people involved should be thoroughly familiar with these instructions and with the technical characteristics of the installation site. 30RBM/30RBP chillers are designed to provide a very high safety and reliability level making installation, start-up, operation and maintenance easier and more secure. They will provide safe and reliable service if used within their application range. They are designed for an operating life of 5 years by assuming a 75% utilisation factor; that is approximately 00,000 operating hours. 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, such as: protective clothing such as gloves, safety glasses, safety shoes and appropriate tools, and suitable qualifications (electrical, air conditioning, local legislation). 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.. - Specific aspects for 30RBP units The 30RBP units differ from the 30RBM units by introducing variable speed drives on all of the fans and optimising the overall energy efficiency of the unit depending on the condition of use (air temperature, circuit capacity). They thus improve the seasonal efficiency (ESEER). All fans in the same refrigerant circuit are controlled by a single variable speed drive. Therefore, they operate together at the same rotational speed. The rotational speed at full load or partial load of each circuit is controlled by an algorithm that continuously optimises the condensing temperature to obtain the best energy efficiency of unit (EER) whatever the operating conditions..2 - Installation safety considerations After the unit has been received, and before it is started up, it must be inspected for damage. Check that the refrigerant circuits are intact, especially that no components or pipes have shifted or been damaged (e.g. following a shock). If in doubt, carry out a leak tightness check. 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 (labels on the chassis and a label with all unit handling instructions are attached to the unit). 4 Use slings with the correct capacity, and always follow the lifting instructions on the certified drawings supplied for the unit. Safety is only guaranteed, if these instructions are carefully followed. If this is not the case, there is a risk of failure and injury to personnel. DO NOT COVER ANY PROTECTION DEVICES. This applies to fuse plugs and relief 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 0% 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 when fitted to these machines are classified as follows: Safety accessory* Refrigerant side High-pressure switch x External relief valve*** x Rupture disk x Fuse plug x Heat transfer fluid side External relief valve Damage limitation accessory** in case of an external fire * Classified for protection in normal service situations. ** Classified for protection in abnormal service situations. *** The instantaneous over-pressure limited to 0% 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. Do not remove valves / fusible plugs, 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. When the unit is subjected to fire, safety devices prevent rupture due to over-pressure by releasing the refrigerant. The fluid may then be decomposed into toxic residues when subjected to the flame: Stay away from the unit. Set up warnings and recommendations for personnel in charge to stop the fire. Fire extinguishers appropriate to the system and the refrigerant type must be easily accessible. All factory-installed relief valves are lead-sealed to prevent any calibration change. The external relief valves must always be vented to outside if the units are installed in a closed space. Refer to the installation regulations, for example those of European standard EN 378 and EN 336.

5 These pipes must be installed in a way that ensures that people and property are not exposed to vented refrigerant. As the fluids can be diffused in the air, ensure that refrigerant is discharged away from building air intakes, relief valves must be checked periodically. See paragraph Maintenance safety considerations. If the relief valves are installed on a change-over valve, this is equipped with a relief valve on each of the two outlets. Only one of the two relief valves is in operation, the other one is isolated. Never leave the change-over valve in the intermediate position, i.e. with both ways open (Bring the actuator in abutment, front or back according to the outlet to isolate). If a relief valve is removed for checking or replacement please ensure that there is always an active relief valve on each of the change-over valves installed in the unit. Provide a drain in vent line, close to each relief valve, to avoid an accumulation of condensate or rain water. All precautions concerning handling of refrigerant must be observed in accordance with local regulations..3 - Equipment and components under pressure These products incorporate equipment or components under pressure, manufactured by Carrier or other manufacturers. Ensure that you are familiar with the appropriate national regulations / guidance for the ownership, use and maintenance of such systems. The characteristics of this equipment/these components are given on the nameplate or in the required documentation, supplied with the products. These units comply with the European Pressure Equipment Directive. The units are intended to be stored and operate in an environment where the ambient temperature must not be less than the lowest allowable temperature indicated on the nameplate. 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. NOTES: Monitoring during operation, re-qualification, re-testing, exemption from retesting: Follow local regulations on the monitoring of pressurecontaining equipment. The user or the operator is usually requested to create and maintain a monitoring and maintenance register. In absence of regulation or in addition to the regulations, follow the guidance in EN 378. Follow the local professional recommendations, whenever they exist. Regularly monitor the surface of the components to detect cavernous corrosion. To do this check an uninsulated part of the pressure vessel or at a joint in the insulation. Regularly check for possible presence of impurities (e.g. silicon grains) in the heat exchange fluids. These impurities can cause wear and/or pitting corrosion. Filter the heat exchange fluid. The reports of the periodical checks by the user or the operator must be included in the monitoring and maintenance register. Repair: Any repair or modification of a pressure vessel is prohibited. Only the replacement of the vessel by an original part from the manufacturer is allowed. In this case, the replacement must be carried out by a qualified operator. The replacement of the vessel must be entered in the monitoring and maintenance register. Recycling: The pressure equipment can be recycled in whole or in part. After use they may contain refrigerant vapours and oil residue. Some parts are painted..4 - Maintenance safety considerations Carrier recommends the following drafting for a logbook (the table below should not be considered as reference and does not involve Carrier responsibility): Intervention Date Nature () Name of the commissioning engineer Applicable national regulations () Maintenance, repairs, regular verifications (EN 378), leakage, etc. Verification Organism Engineers working on the electrical or refrigeration components must be authorised, trained and fully qualified to do so. All refrigerant circuit work must be carried out by a trained person, fully qualified to work on these units. He/she must have been trained and be familiar with the equipment and the installation. All welding operations must be carried out by qualified specialists. 30RBM/30RBP units use high-pressure R-40A refrigerant (the unit operating pressure is above 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 gauges, charge transfer equipment, etc.). Do not clean the unit with hot water or steam. This may cause a pressure increase of the refrigerant. Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorised engineer, observing applicable standards (e.g. during draining operations). The unit must be switched off during maintenance. 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 and lead to the risk of a pressure increase. This valve is situated on the liquid line before the filter drier. 5

6 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. If any maintenance operations are carried out on the unit, lock the power supply circuit in the open position ahead of the machine. If the work is interrupted, always ensure that all circuits are still de-energised before resuming the work. ATTENTION: Even if the unit has been switched off, the power circuit remains energised, unless the unit or circuit disconnect switch is open. Refer to the wiring diagram for further details. Attach appropriate safety labels. When working in a fan area, specifically if the grilles have to be removed, isolate the power supply to the fans to prevent their operation. CAUTION: The option Power factor correction (23) and the variable frequency drives (VFD) fitted to the 30RBP units and the units with options 6V, 6W or 28 have capacitor banks whose discharge time is five (5) minutes after disconnecting the power supply. After disconnecting the power supply of the control box, wait for 5 minutes before accessing the control box or variable frequency drives. Before any intervention, verify that there is no voltage present at any accessible conducting parts of the power circuit. It is recommended to install an indicating device to show if part of the refrigerant has leaked from the relief 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. ATTENTION: In case of utilisation of service valves, do not forget to replace the protection cap in order to avoid leakages. OPERATING CHECKS: IMPORTANT INFORMATION REGARDING THE REFRIGERANT USED: This product contains fluorinated greenhouse gas covered by the Kyoto protocol. Refrigerant type: R-40A Global Warming Potential (GWP): 2088 CAUTION:. Any intervention on the refrigerant circuit of this product should be performed in accordance with the applicable legislation. In the EU, the regulation is called F-Gas, N 57/ Ensure that the refrigerant is never released to the atmosphere during installation, maintenance or equipment disposal. 3. The deliberate gas release into the atmosphere is not allowed. 4. If a refrigerant leak is detected, ensure that it is stopped and repaired as quickly as possible. 5. Only a qualified and certified personnel can perform installation operations, maintenance, refrigerant circuit leak test as well as the equipment disposal and the refrigerant recovering. 6. The gas recovery for recycling, regeneration or destruction is at customer charge. 7. Periodic leak tests have to be carried out by the customer or by third parties. The EU regulation set the periodicity here after: System WITHOUT leakage detection System WITH leakage detection Refrigerant charge/circuit (CO 2 equivalent) Refrigerant charge/ circuit (kg) R34a (GWP 430) R407C (GWP 774) R40A (GWP 2088) HFO s : R23ze No check No check < 5 tons Charge < 3.5 kg Charge < 2.8 kg Charge < 2.4 kg No requirement 2 months 6 months 3 months 24 months 2 months 6 months 5 charge < 50 tons 3.5 charge < 34.9 kg 2.8 charge < 28.2 kg 2.4 charge < 23.9 kg 50 charge < 500 tons 34.9 charge < kg 28.2 charge < 28.9 kg 23.9 charge < kg * From 0/0/207, units must be equipped with a leakage detection system. Charge > 500 tons* Charge > kg Charge > 28.9 kg Charge > kg 8. A logbook must be established for equipments subject to periodic leak tests. It should contain the quantity and the type of fluid present within the installation (added and recovered), the quantity of recycled fluid, regenerated or destroyed, the date and output of the leak test, the designation of the operator and its belonging company, etc. 9. Contact your local dealer or installer if you have any questions. Information on operating inspections given in EN 378 standard can be used when similar criteria do not exist in the national regulation. 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 relief valves. 6

7 The company or organisation that conducts a pressure switch test must establish and implement detailed procedures for: Safety measures Measuring equipment calibration Validating operation of protective devices Test protocols Recommissioning of the equipment. Consult Carrier Service for this type of test. Carrier mentions here only the principle of a test without removing the pressure switch: Verify and record the set-points of pressure switches and relief devices (valves and possible rupture discs) Be ready to switch-off the main disconnect switch of the power supply if the pressure switch does not trigger (avoid over-pressure or excess gas in case of valves on the high-pressure side with the recovery condensers) Connect a pressure gauge protected against pulsations (filled with oil with maximum pointer if mechanical), preferably calibrated (the values displayed on the user interface may be inaccurate in an instant reading because of the scanning delay applied in the control) Complete an HP Test as provided by the software (Refer to the Control IOM for details). CAUTION: If the test leads to replacing the pressure switch, it is necessary to recover the refrigerant charge, these pressure switches are not installed on automatic valves (Schrader type). At least once a year, visually inspect the protection devices (valves, pressure switches). If the machine operates in a corrosive environment, inspect the protection devices more frequently. Check regularly for leaks and repair immediately. Ensure regularly that the vibration levels remain acceptable and close to those at the initial unit start-up. After an equipment failure, carry out a refrigerant analysis at a specialist laboratory. If required, change the refrigerant following a procedure such as that described in NF E If the refrigerant circuit remains open after an intervention (such as a component replacement, etc.): Seal the openings if the duration is less than a day If more than day, charge the circuit with oxygen free nitrogen (inertia principle). The objective is to prevent penetration of atmospheric humidity and the resulting corrosion..5 - Repair safety considerations All installed parts must be maintained by the personnel in charge, in order to avoid deterioration and injury. Faults and leaks must be repaired immediately. The authorised technician must have the responsibility to repair the fault immediately. After each repair of the unit, check the operation of all protective devices and record their correct operation in the maintenance log. Comply with the regulations and recommendations in unit and HVAC installation safety standards, such as: EN 378, ISO 549, etc. If a leak occurs or if the refrigerant becomes contaminated (e.g by a motor burnout or evaporator freeze-up) remove the complete charge using a recovery unit and store the refrigerant in mobile containers. The compressors cannot transfer the whole refrigerant charge and can be damaged if used to pump-down. The refrigerant charge should not be transferred to the high-pressure side. Repair the leak, detect and recharge the circuit with the total R-40A charge, as indicated on the unit name plate. Do not top up the refrigerant charge. Only charge liquid refrigerant R-40A at the liquid line. Always ensure you are using the correct refrigerant type before recharging the unit. Charging any refrigerant other than the original type (R-40A) will impair machine operation and can even lead to a destruction of the compressors. The compressors operating with this refrigerant type are lubricated with a synthetic polyolester oil. Before any intervention on the refrigerant circuit, the complete refrigerant charge must be recovered. 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 chiller. 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. 7

8 The accidental releases of the refrigerant, due to small leaks or significant discharges following the rupture of a pipe or an unexpected release from a safety valve, can cause frostbites and burns to personnel exposed. Do not ignore such injuries. Installers, owners and especially service engineers for these units must: Seek medical attention before treating such injuries. Have access to a first-aid kit, especially for treating eye injuries. We recommend to apply standard EN Annex 3. Never apply an open flame or live steam to a refrigerant container. Dangerous overpressure can result. 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 E 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. It is dangerous and illegal to re-use disposable (nonreturnable) cylinders or attempt to refill them. When cylinders are empty, evacuate the remaining gas pressure, and move them to a designated place for 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 kpag and that the unit has been shut-down and de-energised before removing components or opening a circuit. When the refrigerant circuit is opened to repair, see the recommendations in chapter Maintenance safety considerations. 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 relief valves in series or backwards. ATTENTION: No part of the unit must be used as a walkway, rack or support. Periodically check and repair or if necessary replace any component or piping that shows signs of damage. Do not step on refrigerant lines. The 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 the heat exchange fluid circuit without informing the site technical / service department or other competent body first. Close the entering and leaving water shutoff valves and drain the unit hydronic 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. It is recommended to wear ear defenders, when working near the unit and the unit is in operation. 2 - PRELIMINARY CHECKS 2. - Check equipment received Check that the unit has not been damaged during transport and that no parts are missing. If the unit has been damaged or the shipment is incomplete, send a claim to 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: Model number - size CE marking Serial number Year of manufacture and pressure and leak tightness test date Fluid being transported Refrigerant used Refrigerant charge per circuit 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 all accessories ordered for on-site installation have been delivered, are complete and undamaged. The unit must be checked periodically, if necessary removing the insulation (thermal, acoustic), during its whole operating life to ensure that no shocks (handling accessories, tools, etc.) have damaged it. If necessary, the damaged parts must be repaired or replaced. See also chapter Maintenance. 8

9 2.2 - Moving and placing the unit Moving See chapter Installation safety considerations Placing the unit The machine must be installed in a place that is not accessible to the public and/or protected against access by nonauthorised persons. In case of extra-high units the machine environment must permit easy access for maintenance operations. 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. Typical applications of these units are in refrigeration systems, and they do not require earthquake resistance. Earthquake resistance has not been verified. CAUTION: Only use slings at the designated lifting points which are marked on the unit. Before placing the unit check that: The permitted loading at the site is adequate or that appropriate strengthening measures have been taken. The unit is installed level on an even surface (maximum tolerance is 5 mm in both axes). If the support structure is sensitive to vibration and/or noise transmission it is 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 (see dimensional drawings). The number of support points is adequate and that they are in the right places. The location is not subject to flooding. For outdoor installations, where heavy snowfall is likely and long periods of sub-zero temperatures are normal, provision has to be made to prevent snow accumulating by raising the unit above the height of drifts normally experienced. Baffles may be necessary to deflect strong winds. They must not restrict air flow into the unit. CAUTION: Before lifting the unit, check that all casing panels are securely fixed in place. Lift and set down the unit with great care. Tilting and jarring can damage the unit and impair unit operation. If 30RBM/30RBP units are hoisted with rigging, it is advisable to protect coils against crushing while a unit is being moved. Use struts or a lifting beam to spread the slings above the unit. Do not tilt a unit more than 5. WARNING: Never push or lever on any of the enclosure panels of the unit. Only the base of the unit frame is designed to withstand such stresses. No force or effort must be applied to pressurised parts, especially via pipes connected to the evaporator. If a unit includes a hydronic module (options 6R, S, T, U, V, W), 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 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. Heat exchange fluid temperatures above the maximum recommended can lead to an increase in the refrigerant pressure and can cause a loss of refrigerant due to the relief valve discharge. During the installation test 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: Ensure that the machine is charged with refrigerant, Verify on the unit nameplate that the fluid transported is R40A and is not nitrogen. 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, Pipe and instrument diagram (PID), declarations, etc.) to comply with the regulations are present. Verify that the environmental safety and protection 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. Verify the instructions and directives to prevent the deliberate removal of refrigerant gases. 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 against heat. 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. Check the condition of 400 V cable insulation. 9

10 2.4 - Actual start-up Never be tempted to start the chiller without reading fully, and understanding, the operating instructions and without having carried out the following pre-start checks: Check the chilled water circulation pumps, the air handling equipment and any other device connected to the evaporator. Refer to the manufacturer instructions. Refer to the electrical diagram delivered with the unit. Ensure that there is no refrigerant leak. Check the tightening of fixing clamps of all pipes. Check the power supply at the main connection point and the order of phases. Check the compressors crankcase heaters have been energised for 6 hours before starting the unit. WARNING: Commissioning and start-up of the chiller must be supervised by a qualified refrigeration engineer. Start-up and operating tests must be carried out with a thermal load applied and water circulating in the evaporator. All set-point adjustments and control tests must be carried out before the unit is started up. Refer to the Service guide. Proceed with the unit commissioning. Ensure that all safety devices are operational, especially that the high pressure switches are functioning and that any alarms have been acknowledged and corrected. NOTE: If the Carrier instructions (power and water connections and installation) are not observed, the Carrier warranty becomes invalid. 0

11 3 - DIMENSIONS, CLEARANCES RBM/30RBP (with and without hydronic module) WITHOUT HYDRONIC MODULE 30RBP only Power connection Legend: All dimensions are in mm. 2 Clearances required for maintenance and air flow 2 Clearances recommended for heat exchanger removal Water inlet Water outlet Air outlet, do not obstruct Control box NOTE: Non-contractual drawings. WITH HYDRONIC MODULE 2 When designing an installation, refer to the certified dimensional drawings, available on request. For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings. Option 6V/6W

12 3.2-30RBM/30RBP (with and without hydronic module) WITHOUT HYDRONIC MODULE 30RBP only Sizes Power connection Legend: 2 All dimensions are in mm. Clearances required for maintenance and air flow 2 Clearances recommended for heat exchanger removal Water inlet Water outlet Air outlet, do not obstruct Control box NOTE: Non-contractual drawings. WITH HYDRONIC MODULE Option 6V/6W When designing an installation, refer to the certified dimensional drawings, available on request. For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings

13 3.3-30RBM/30RBP (with and without hydronic module) WITHOUT HYDRONIC MODULE 30RBP only Size 520 Power connection Legend: 2 All dimensions are in mm. Clearances required for maintenance and air flow 2 Clearances recommended for heat exchanger removal Water inlet Water outlet Air outlet, do not obstruct Control box WITH HYDRONIC MODULE Option 6V/6W 2 NOTE: Non-contractual drawings. When designing an installation, refer to the certified dimensional drawings, available on request. For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings. 3

14 3.4 - Multiple chiller installation It is recommended to install multiple chillers in a single row, arranged as shown in the example below, to avoid recycling of warm air from one unit to another. If required, the units can be installed as following: 500 mm mini 500 mm mini A B Wall Units All dimensions in mm NOTES: If the height of walls exceeds 2 meters, consult your Carrier representative. The space required for removing the coils should be added if required. Do not merge the lateral spaces required for each unit in case of multiple chiller installation. 4

15 4 - PHYSICAL AND ELECTRICAL DATA OF 30RBM AND 30RBP UNITS 4. - Physical data 30RBM RBM Sound levels Standard unit Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Standard unit + option 5* Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Standard unit + option 5LS* Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Dimensions - Standard unit Length mm Width mm Height mm Operating weight** Standard unit kg Standard unit + option 5* kg Standard unit + option 5 + option 6S* kg Compressors Hermetic Scroll 48.3 r/s Circuit A Circuit B No. of control stages Refrigerant** R40A Circuit A kg teqco Circuit B kg teqco Capacity Control Pro-Dialog+ Control Minimum capacity % Condensers All-aluminium microchannel heat exchanger (MCHE) Fans - Standard unit Axial Flying Bird 4 fans with rotating shroud Quantity Maximum total air flow l/s Maximum rotational speed tr/s Evaporator Dual-circuit plate heat exchanger Water volume l Max water-side operating pressure without hydronic module kpa Hydronic module (option) Pump, Victaulic screen filter, safety valve, water and air drain valve, pressure sensors, expansion tank (option) Pump Centrifugal pump, monocell, 48.3 r/s, low or high pressure (as required), single or dual (as required) Expansion tank volume l Max water-side operating pressure with hydronic module kpa Water connections with/without Victaulic type hydronic module Diameters inch Outside tube diameter mm Chassis paint colour Color code RAL 7035 * Options: 5 = low sound level, 5LS = very low sound level, 6S = High-pressure dual-pump hydronic module. ** Weights are guidelines only. Refer to the unit nameplate. *** In db ref=0-2 W, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 487 (with an associated uncertainty of +/-3dB(A)). Measured in accordance with ISO 964- and certified by Eurovent. **** In db ref 20 µpa, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 487 (with an associated uncertainty of +/-3dB(A)). For information, calculated from the sound power level Lw(A). 5

16 4.2 - Physical data 30RBP RBP Sound levels Standard unit Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Standard unit + option 5* Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Standard unit + option 5LS* Sound power level*** db(a) Sound pressure level at 0 m**** db(a) Dimensions - Standard unit Length mm Width mm Height mm Operating weight** Standard unit kg Standard unit + option 5* kg Standard unit + option 5 + option 6S* kg Compressors Hermetic Scroll 48.3 r/s Circuit A Circuit B No. of controle stages Refrigerant** R40A Circuit A kg teqco Circuit B kg teqco Capacity Control Pro-Dialog+ Control Minimum capacity % Condensers All-aluminium microchannel heat exchanger (MCHE) Fans - Standard unit Axial Flying Bird 4 fans with rotating shroud Quantity Maximum total air flow l/s Maximum rotational speed tr/s Evaporator Dual-circuit plate heat exchanger Water volume l Max water-side operating pressure without hydronic module kpa Hydronic module (option) Pump, Victaulic strainer, safety valve, water and air drain valve, pressure sensors, expansion tank (option) Pump Centrifugal pump, monocell, 48.3 r/s, low or high pressure (as required), single or dual (as required) Expansion tank volume l Max water-side operating pressure with hydronic module kpa Water connections with/without Victaulic type hydronic module Diameters inch Outside tube diameter mm Chassis paint colour Color code RAL 7035 * Options: 5 = low sound level, 5LS = very low sound level, 6S = High-pressure dual-pump hydronic module. ** Weights are guidelines only. Refer to the unit nameplate. *** In db ref=0-2 W, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 487 (with an associated uncertainty of +/-3dB(A)). Measured in accordance with ISO 964- and certified by Eurovent. **** In db ref 20 µpa, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 487 (with an associated uncertainty of +/-3dB(A)). For information, calculated from the sound power level Lw(A). 6

17 4.3 - Electrical data 30RBM RBM Power circuit Nominal power supply V-ph-Hz Voltage range V Control circuit supply 24 V via internal transformer Nominal unit current draw* Circuit A&B A Maximum unit power input** Circuit A&B kw Cosine Phi unit at maximum power** 0,88 0,87 0,87 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 Maximum unit current draw (Un-0%)*** Circuit A&B A Maximum unit current draw (Un)**** Circuit A&B - Standard Unit A Circuit A&B - Unit with option 23 A Maximum start-up current, standard unit (Un) Circuit A&B A Max. start-up current, unit with soft starter (Un) Circuit A&B A * Conditions equivalent to the standardised Eurovent conditions (evaporator water entering-leaving temperature = 2 C/7 C, outside air temperature = 35 C). ** Power input, compressors and fans, at the unit operating limits (saturated suction temperature 5 C, saturated condensing temperature 68.3 C) and nominal voltage of 400 V (data given on the unit nameplate). *** Maximum unit operating current at maximum unit power input and at 360 V. **** Maximum unit operating current at maximum unit power input and at 400 V (values given on the unit nameplate). Maximum instantaneous start-up current at operating limits (maximum operating current of the smallest compressor(s) + fan current + locked rotor current of the largest compressor). Fan motor electrical data: at Eurovent equivalent conditions and motor ambient air temperature of 50 C at 400 V: 3.8 A, start-up current 20 A, power input.75 kw Electrical data 30RBP RBP Power circuit Nominal power supply V-ph-Hz Voltage range V Control circuit supply 24 V via internal transformer Nominal unit current draw* Circuit A&B A Maximum unit power input** Circuit A&B kw Cosine Phi unit at maximum power** 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88 Maximum unit current draw (Un-0%)*** Circuit A&B A Maximum unit current draw (Un)**** Circuit A&B - Standard Unit A Circuit A&B - Unit with option 23 A Maximum start-up current, standard unit (Un) Circuit A&B A Max. start-up current, unit with soft starter (Un) Circuit A&B A * Conditions equivalent to the standardised Eurovent conditions (evaporator water input-output temperature = 2 C/7 C, outside air temperature = 35 C) ** Power input, compressors and fans, at the unit operating limits (saturated suction temperature 5 C, saturated condensing temperature 68.3 C) and nominal voltage of 400 V (data given on the unit nameplate). *** Maximum unit operating current at maximum unit power input and at 360 V. **** Maximum unit operating current at maximum unit power input and at 400 V (values given on the unit nameplate). Maximum instantaneous start-up current at operating limits (maximum operating current of the smallest compressor(s) + fan current + locked rotor current of the largest compressor). Fan motor electrical data reported upstream the variable speed drive at Eurovent equivalent conditions and motor ambient air temperature of 50 C at 400 V: Current 3.8 A; Start-up current 20 A; Power input:.75 kw Short circuit stability current Short circuit stability current (TN system * ) 30RBM/30RBP Short time (s) assigned current Icw / Peak current Ipk Circuits A&B ka/ka 8/30 8/30 8/30 8/30 8/30 8/30 8/30 5/65 5/65 5/65 5/65 20/80 With fuses upstream maximun fuse values assigned (gl/gg) Circuits A&B A With fuses upstream assigned conditional short-circuit current Icc/Icf Circuits A&B ka * Type of system earthing IT system: The short circuit current stability values given above for the TN system are not valid for IT, modifications are required. 7

18 4.6 - Electrical data of the hydronic module The pumps that are factory-installed in these units have motors with efficiency class IE3. The additional electrical data required * is as follows: For the low-pressure single pump motors of units 30RBM/30RBP (option 6T) No.** Description*** Units 30RBM/30RBP 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 - IE3 3 Year of manufacture - This information varies depending on the manufacturer and model at the time of incorporation. Please refer to the motor name plates. 4 Manufacturer s name and trademark, commercial registration - Same as above number and place of manufacturer 5 Product s model number - Same as above 6 Number of motor poles Rated shaft power output at full load and nominal voltage kw (400 V) 7-2 Maximum power input (400 V) kw Rated input frequency Hz Rated voltage V 3 X Maximum current drawn (400 V) A Rated speed tr/s - tr/ min Product disassembly, recycling or disposal at end of life - Disassembly using standard tools. Disposal and recycling using an appropriate company. 2 Operating conditions for which the motor is specifically designed I - Altitudes above sea level m < 000**** II - Ambient air temperature C < 40 IV - Maximum air temperature C Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs. V - Potentially explosive atmospheres - 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. **** Above 000 m, a degradation of 3% for each 500 m should be taken into consideration. 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. For the low-pressure dual-pump motors of units 30RBM/30RBP (option 6U) No.** Description*** Units 30RBM/30RBP 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 - IE3 3 Year of manufacture - This information varies depending on the manufacturer and model at the time of incorporation. Please refer to the motor name plates. 4 Manufacturer s name and trademark, commercial registration - Same as above number and place of manufacturer 5 Product s model number - Same as above 6 Number of motor poles Rated shaft power output at full load and nominal voltage kw (400 V) 7-2 Maximum power input (400 V) kw Rated input frequency Hz Rated voltage V 3 X Maximum current drawn (400 V) A Rated speed tr/s - tr/ min Product disassembly, recycling or disposal at end of life - Disassembly using standard tools. Disposal and recycling using an appropriate company. 2 Operating conditions for which the motor is specifically designed I - Altitudes above sea level m < 000**** II - Ambient air temperature C < 40 IV - Maximum air temperature C Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs. V - Potentially explosive atmospheres - 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. **** Above 000 m, a degradation of 3% for each 500 m should be taken into consideration. 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. 8

19 For the high-pressure single and dual-pump motors of units 30RBM/30RBP (options 6R, 6S, 6V, 6W) No.** Description*** Units 30RBM/30RBP 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 2 Efficiency level - IE3 3 Year of manufacture - This information varies depending on the manufacturer and model at the time of incorporation. Please refer to the motor name plates. 4 Manufacturer s name and trademark, - Same as above commercial registration number and place of manufacturer 5 Product s model number - Same as above 6 Number of motor poles Rated shaft power output at full load and kw nominal voltage (400 V) 7-2 Maximum power input (400 V) kw Rated input frequency Hz Rated voltage V 3 X Maximum current drawn (400 V) A Rated speed tr/s - tr/min Product disassembly, recycling or disposal at end of life - Disassembly using standard tools. Disposal and recycling using an appropriate company. 2 Operating conditions for which the motor is specifically designed I - Altitudes above sea level m < 000**** II - Ambient air temperature C < 40 IV - Maximum air temperature C Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs. V - Potentially explosive atmospheres - 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. **** Above 000 m, a degradation of 3% for each 500 m should be taken into consideration. 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 Compressor usage and electrical data Cp I Nom I Max Un I Max Un-0 % LRA Un Cosinus Phi Max Circuit PSG009600A A B PSG A A B Cp Compressor I Nom Nominal current draw at Eurovent equivalent conditions (see definition of conditions under nominal unit current draw), A I Max Maximum operating current A LRA Locked rotor current, A Cos phi Max, 400 V 9

20 5 - ELECTRICAL CONNECTION Please refer to the certified dimensional drawings, supplied with the unit 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 and certified dimensional drawings. WARNING: Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutes abuse which will invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 0% for current, contact your local electricity supply at once and ensure that the chiller is not switched on until corrective measures have been taken. After the unit has been installed, the power supply must only be disconnected for quick maintenance operations (one day maximum). For longer maintenance operations or when the unit is taken out of service (for example, during winter when the unit does not need to generate cooling) the power supply of the unit must be maintained permanently Voltage phase imbalance (%) 00 x max. deviation from average voltage Average voltage Example: On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages were to be measured: AB = 406 V; BC = 399 V; AC = 394 V Average voltage = ( )/3 = 99/3 = say 400 V Calculate the maximum deviation from the 400 V average: (AB) = = 6 (BC) = = (CA) = = 6 Motor The maximum deviation from the average is 6 V. The greatest percentage deviation is: 00 x 6/400 =.5 % This is less than the permissible 2% and therefore acceptable Power connection/disconnect switch The power connection of the unit is carried out at a single point in upstream of the machine s disconnect switch. Electrical data notes for 30RBM/30RBP units: 30RBM/30RBP units have a single power connection point located immediately upstream of the main switch. Control box includes: Main disconnect switch, Start-up and motor protection devices for each compressor, fans and pumps, Control devices. Field connections: All connections to the system and the electrical installations must be in accordance with all applicable codes. The Carrier 30RBM/30RBP units are designed and built to ensure conformance with these codes. The recommendations of European standard EN (corresponds to IEC ) (machine safety - electrical machine components - part : General regulations) are specifically taken into account, when designing the electrical equipment. Notes Generally the recommendations of IEC are accepted as compliance with the requirements of the installation regulation. Conformance with EN is the best means of ensuring compliance (.5.) with the Machinery Directive. Appendix B of standard EN specifies the electrical features used for the operation of the machines. Operating conditions of 30RBM/30RBP units are described below:. Physical environment* The classification of environment is specified in standard EN 60364: Outdoor installation*, Ambient temperature range: Minimum temperature -20 C up to +48 C**, Altitude: AC Lower than or equal to 2000 m (for hydronic module, see paragraph 4.7 in the IOM) Presence of hard solid: Class AE3 (no significant dust present)*, Presence of corrosive and polluting substances, class AF (negligible), Competence of persons: BA4 (Persons wise). 2. Compatibility for low-frequency conducted disturbances according to class 2 levels per IEC standard: Power supply frequency variation : +-2Hz Phase imbalance : 2% Total Voltage Harmonic Distortion (THDV) : 8% 3. The neutral (N) line must not be connected directly to the unit (if necessary use a transformer). 4. Overcurrent protection of the power supply conductors is not provided with the unit. 5. The factory installed disconnect switch(es)/circuit breaker(s) is (are) of a type suitable for power interruption in accordance with EN (corresponds to IEC ). 6 The units are designed for connection to TN networks (IEC 60364). In IT networks the use of noise filters integrated into the variable frequency drive(s) make machine use unsuitable. In addition, the short-circuit holding current characteristics have been modified. Provide a local earth, consult competent local organisations to complete the electrical installation. 30RBM/30RBP machines are designed to use for domestic / residential and industrial environments: Machines that are not equipped with variable frequency drive(s) are in accordance with the standards codes.** : General standards - Standard emission for residential, commercial and light industry : General standards - Immunity for industrial environments. Machines that are equipped with variable frequency drive(s) (RBP, options: 28, 6V, 6W) are in accordance with standard EN electric power variable speed drives - part 3: EMC requirements and specific test methods for the following classifications:- - Use in the first and second environments***. - Category C2 applicable in the first environment, on stationary devices designed to be installed and commissioned by a professional. Warning: In a residential environment, this product may cause radio interference in which case additional mitigation measures could be required. Leakage currents: If protection by monitoring the leakage currents is necessary to ensure the safety of the installation, the presence of additional leakage currents introduced by the use of variable frequency drive(s) in the unit must be considered. In particular these protection devices shall be of reinforced immunity types and have a threshold not lower than 50 ma. Capacitors that are integrated as part of the option 23 can generate electrical disturbances in the installation the unit is connected to. Presence of these capacitors must be considered during the electrical study prior to the start-up. Note: If particular aspects of an actual installation do not conform to the conditions described above, or if there are other conditions which should be considered, always contact your local Carrier representative. * The required protection level for this class is IP43BW (according to reference document IEC 60529). All 30RBM/30RBP units are IP44CW and fulfil this protection condition. ** The maximun ambiant temperature allowed for mahines equipped with option 23 is +40 C *** - Example of installations of the first environment: Commercial and residential buildings. - Example of installations of the second environment: Industrial zones, technical premises powered from a dedicated transformer. 20

21 5.4 - 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 verify the appropriate means of 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 below. The calculations of favourable and unfavourable cases are performed by using the maximum current possible of each unit fitted with a hydronic kit (see the tables of electrical data of the unit and the hydronic module). The study includes the installation cases standardised according to IEC 60364: cables with PVC (70 C) or XLPE insulation (90 C) with copper core; installation practice in accordance with the table 52C of the standard. The maximum ambient temperature is 45 C. The maximum length mentioned is calculated to limit the voltage drop to 5 % Power cable entry The power cables can enter the 30RBM/30RBP control box from below. A removable aluminium plate below the control box allows introduction of the cables. It is important to check that the power cable bend radius is compatible with the connection space available in the control box. Refer to the certified dimensional drawing for the unit. Connection extension box This accessory permits stripping the power cables before they enter the control box, and must be used when the cable bend radius is not compatible with the connection space available in the control box. The accessory connection extension box ensures mechanical protection of the stripped cable, before it enters the control box. It is recommended to use this accessory in the following cases: Unit placed on the ground and the use of steel wired armored (SWA) cables. Unit placed on the ground and use of power cables with a section > 250 mm 2. WARNING: Before connection of the main power cables (L - L2 - L3) on the terminal block, it is necessary to check the correct order of the 3 phases before proceeding to the connection on the main disconnect/shut-off switch. Table of minimum and maximum wire sections (per phase) for connection to 30RBM/30RBP units Max connectable section* 30RBM/30RBP Standard lug Narrow lug Recommended max width lug Calculation of favourable case: - Suspended aerial line (standardised routing no. 7) - Cable with XLPE insulation Section** Max length for a voltage drop < 5% Calculation of unfavourable case: - Conductors in conduits or multi-conductor cables in closed conduit (standardised routing No. 4) - PVC insulated cable, if possible Cable type*** Section** Max length for a voltage drop < 5% Cable type*** mm² mm² mm mm² m - mm² m - (per phase) (per phase) (per phase) (per phase) 60 2x70 2x95 2 x XLPE Cuivre 2 x PVC Cuivre 80 2x70 2x95 2 x XLPE Cuivre 2 x PVC Cuivre 200 2x70 2x95 2 x XLPE Cuivre 2 x PVC Cuivre 220 2x70 2x95 2 x XLPE Cuivre 2 x PVC Cuivre 260 2x70 2x x XLPE Cuivre 2 x XLPE Cuivre 300 2x70 2x x XLPE Cuivre 2 x XLPE Cuivre 330 2x70 2x x XLPE Cuivre 2 x XLPE Cuivre 360 2x95 2x x XLPE Cuivre 2 x XLPE Cuivre 400 2x95 2x x XLPE Cuivre 2 x XLPE Cuivre 430 2x95 2x x XLPE Cuivre 2 x XLPE Cuivre 470 2x240 2x x XLPE Cuivre 2 x XLPE Cuivre 520 2x240 2x x XLPE Cuivre 2 x XLPE Cuivre Notes : * 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. The protection against direct contact at the electrical connection point is compatible with the addition of terminals extension. 2

22 5.6 - 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 Electric power reserve for the user Control circuit power reserve: After all possible options have been connected, the TC transformer ensures the availability of A on 24 V, 50 Hz. In option 284, this TC transformer has a circuit of 230 V, 50 Hz that allows powering only the battery chargers for laptops, maximum of 0.8 A at 230 V. WARNING: Connect only equipments of class I and II on this power socket. See the 30RBM/30RBP control manuals and the certified electric wiring diagram provided with the unit for the field control wiring of the following devices: Customer interlock (safety chain) Remote on/off switch Remote heat/cool switch Demand limit external switch Remote dual set point Alarm, alert and signals Evaporator pump control Setpoint reset via outside air temperature reset (0-0 V) Various interlocks on the Energy Management Module (EMM) board (accessory or option) 22

23 6 - APPLICATION DATA Operating range 30RBP units 6. - Unit operating range 30RBM units Evaporator Minimum Maximum Entering water temperature at start-up C 8* 40 Leaving water temperature during operation C 5** 20*** Condenser Minimum Maximum Outdoor ambiant operating temperature Standard units C 0****/0 48 Units with options 28B-28C (winter operation) C Units with option 28 (winter operation) C Units with option 6 (high ambiance operation) C 0/0 52 Available static pressure Standard units (outdoor installation) Pa RBP units Evaporator Minimum Maximum Entering water temperature at start-up C 8* 40 Leaving water temperature during operation C 5** 20*** Condenser Minimum Maximum Outdoor ambiant operating temperature Standard units C Available static pressure Standard units (outdoor installation) Pa 0 0 Notes * For application requiring operation at less than 8 C, contact Carrier for unit selection using the Carrier electronic catalog. ** Use of antifreeze protection is required if the leaving water temperature is below 5 C *** For applications requiring operation up to 20 C leaving water temperature, contact Carrier for the selection of the unit using Carrier electronic catalog. **** For operation from 0 C to -0 C the units must be equipped with option 28B-28C Winter operation. For operation from 0 C to -20 C the units must be equipped with option 28 Winter operation. For both options the unit must either be equipped with the evaporator frost protection option (for units without hydronic module option) or the evaporator and hydronic module frost protection option (for units with hydronic module option) or the water loop must be protected against frost by the installer, using an anti-freeze solution. The maximun ambiant temperature allowed for mahines equipped with option 23 is +40 C. Maximum ambient temperature: in case of 30RBM/30RBP units storage and transport, minimum and maximum ambient temperatures to respect are -20 C and +52 C. These temperature limits shall be considered in case of container shipment Operating range 30RBM units Part load with Option 6 Option 23 Part load Entering air temperature ( C) Option 23 Part load Leaving evaporator water temperature ( C) Notes. Evaporator T = 5 K 2. The evaporator is protected against frost down to -20 C (with frost protection option 4 or option 42A if hydronic module or loop protected by an anti freeze solution for the outdoor temperature < 0 C) 3. These ranges are given for illustrative purpose only. Verify the operating range with the Carrier electronic catalog Legend Standard unit 30RBM or 30RBP operating at full load. Operating range, 30RBM unit is equipped with options 28, 28B, 28C Winter operation. Options 28B, 28C (with two-speed lead fan for each circuit) allows operation down to -0 C outside temperature. Extension of the operating range, 30RBM unit equipped with option 28. Option 28 (with variable-speed lead fan for each circuit) allows operation below to -20 C outside temperature. In addition to the options 28, 28B, or 28C for 30RBM units or for operation at an air temperature below 0 C for 30RBP units, the machines must either be equipped with the evaporator frost protection option (for units without hydronic module option) or the evaporator and hydronic module frost protection option (for units with hydronic module option) or the water loop must be protected by the installer by adding a frost protection solution. ATTENTION: 30RBP units, option 28 and options 6V and 6W. If the outside temperature is below -0 C and the unit has been switched off for more than 4 hours, it is necessary to wait two hours after the unit has been switched on again to allow the frequency converter to warm up Minimum chilled water flow (units without hydronic module) Entering air temperature, C Options 28B-28C for size 60 Options 28B -28C Option 28 The minimum chilled water flow is shown in the table on the next page. If the system flow is less than this, the evaporator flow can be recirculated, as shown in the diagram. For minimum chilled water flow rate Leaving evaporator water temperature, C Legend Evaporator 2 Recirculation 23

24 6.3 - Maximum chilled water flow (units without hydronic module) The maximum chilled water flow is shown in the table on the next page. If the system flow exceeds the maximum value, it can be bypassed as shown in the diagram. For maximum chilled water flow rate CAUTION: Ensure that the system active volume (between the unit and possible customer-supplied valves) is greater than the minimum recommended Maximum system water volume Units supplied with a hydronic module may include an expansion vessel. The table below gives the maximum loop volume for pure water or ethylene glycol with various system concentrations, as well as the static pressures. If the maximum volume is insufficient, compared to the minimum system water loop volume, an additional expansion tank must be added to the system. Legend: Evaporator 2 Bypass Evaporator with variable flow (units without hydronic module) Variable evaporator flow can be used in standard chillers. The flow rate must be higher than the minimum flow given in the table of permissible flow rates and must not vary by more than 0% 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 2.5 l/kw Minimum system water volume Whichever the system, the water loop minimum capacity is given by the formula: Capacity = Cap (kw) x N Litres Application N Normal air conditioning 2.5 Process type cooling 6.5 Where Cap is the nominal system cooling capacity (kw) at the nominal operating conditions of the installation. This volume is necessary for stable operation. It can 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. Connection to a buffer tank Maximum water loop Volume, l 30RBM/30RBP Static Pressure(bar) 2 2,5 2 2,5 Pure water % ethylene glycol % ethylene glycol % ethylene glycol % ethylene glycol Evaporator flow rate Data applicable for pure water. 30RBM/30RBP units without hydronic module 30RBM/30RBP Minimum flow rate (l/s)* Maximum flow rate (l/s) ** * Minimum flow rate for the conditions of maximum permitted water temperature difference (0 K) at the minimum leaving water temperature (5 C) ** Maximum flow rate for a pressure drop of 00 kpa in the plate heat exchanger. 30RBM/30RBP units with low-pressure hydronic module 30RBM/30RBP Minimum flow rate (l/s)* Maximum flow rate (l/s) Single Dual Single Dual * Minimum water flow setting done in factory according to pump type Bad Bad Good Good 30RBM/30RBP units with high-pressure hydronic module 30RBM/30RBP Minimum flow rate (l/s)* Maximum flow rate (l/s) Single Dual Single Dual * Minimum water flow setting done in factory according to pump type 24

25 6.8 - Pressure drop curves for the evaporator and standard entering/leaving water piping Data applicable for pure water 20 C 30RBM/30RBP units Pressure drop, kpa 30RBM/30RBP RBM/30RBP RBM/30RBP RBM/30RBP RBM/30RBP Water flow rate, l/s 30RBM/30RBP units Pressure drop, kpa Water flow rate, l/s 6 30RBM/30RBP RBM/30RBP RBM/30RBP RBM/30RBP

26 7 - WATER CONNECTIONS For dimensions and position of the 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. Before any start-up verify that the heat exchange fluid is compatible with the water circuit materials. Where additives or other fluids than those recommended by Carrier are used, ensure that these are not considered as a gas, and that they are class 2, as defined in directive 97/23/EC. Carrier recommendations on heat exchange fluids: No NH 4+ 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. If required, use sacrificial anodes. Cl - Chloride ions are also detrimental for copper with a risk of perforating corrosion. Keep at a level below 25 mg/l. SO 4 2- sulphate ions can cause perforating corrosion, if their content is above 30 mg/l. No fluoride ions (<0. mg/l). No Fe 2+ and Fe 3+ ions with non-negligible levels of dissolved oxygen must be present. Dissolved iron < 5 mg/l with dissolved oxygen < 5 mg/l. Dissolved silicon: Silicon is an acid element of water and can also lead to corrosion risks. Content < mg/l. Water hardness: >0.5 mmol/l. Values between.0 and 2.5 mmol/l are 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 00 mg/l is desirable. Dissolved oxygen: Avoid any sudden change in water oxygenation conditions. 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 oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles. Electric conductivity µs/cm ph: Ideal case ph neutral at C (7 < ph < 9). CAUTION: Filling, supplementing, or emptying the water from the circuit must be carried out by a qualified personnel with the appropriate tools and equipment. Filling the chilled circuit should be carried out by the installer using appropriate equipment and procedures Operating precautions and recommendations Before the system start-up verify that the water circuits are connected to the appropriate heat exchangers. The water circuit should be designed to have the least number of elbows and horizontal pipe runs at different levels. Below the main points to be checked for the connection: Observe the water inlet and outlet connections shown on the unit. Install manual or automatic air purge valves at all high points in the circuit. Protect the chilled circuit against over-pressure with pressure reducers, an expansion tank and relief valve. Units supplied with a hydronic module include a chilled circuit relief valve. Units supplied with option 293 include an expansion tank. Install thermometers in both the entering and leaving water connections. 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 the transmission of vibrations. Insulate the pipework, after testing for leaks, to prevent heat transmission and condensation. Cover the insulation with a vapour barrier. If the water piping outside the unit passes through an area where the ambient temperature is likely to fall below 0 C, it must be protected against frost (glycol solution or trace heating). The use of different metals on hydraulic piping could generate eletrolytic pairs and consequently corrosion. Verify then, the need to install sacrificial anodes. NOTE: A screen filter must be installed for units supplied without a hydronic module. This must be installed in the water inlet connection to the unit, upstream of the pressure gauge and close to the unit evaporator. The mesh size of the filter must be.2 mm. If the filter is missing, the plate heat exchanger or the shell-and-tube evaporator can quickly become fouled during the first start-up, as it will perform the filter function, and correct unit operation will be affected (reduced water flow rate due to the increased pressure drop). Units with hydronic module include this type of filter. Do not introduce any excessive static or dynamic pressure into the heat exchange circuit (with regard to the design operating pressures). Thermal insulation of chiller / piping must be chemically neutral to the surfaces on which they are applied. All original materials supplied by Carrier comply with this requirement. 26

27 7.2 - Hydronic connections The hydronic module options are compatible only with closed heat exchange fluid loops. The use of hydronic modules on open loop system is prohibited. The pressure at the suction of the pump must be above 60 kpa (0.6 bar) to avoid the cavitation phenomena. Typical diagram of the hydronic circuit with the hydronic module 2 option P 4 T option 23 5 P T Typical diagram of the hydronic circuit without the hydronic module T 9 2 option 6 22 T Legend: Components of the unit and hydronic module Screen filter (mesh opening.2 mm = 20 mesh) 2 Expansion tank (option) 3 Safety valve 4 Water pump (single of dual pump) 5 Air purge 6 Water drain valve 7 Pressure sensor Note: Provides information of pressure at the suction of the pump 8 Temperature probe Note: Provides information of temperature at the heat exchanger outlet 9 Temperature probe Note: Provides information of temperature at the heat exchanger inlet 0 Pressure sensor Note: Provides information of pressure at unit outlet Plate heat exchanger 2 Evaporator heater for frost protection (option) 3 Flow switch for the evaporator (provided) Installation components 4 Air purge 5 Flexible connection 6 Shut-off valve 7 Screen filter (mandatory in the case of an unit without hydronic module) 8 Pressure gauge 9 Water flow control valve Note: Not required if hydronic module with variable speed pump 20 Charge valve 2 Bypass valve for frost protection (if shut-down valves are closed (item 6) during winter) 22 Flexible connection 23 Thermowell 24 Buffer tank (if required) Hydronic module (unit with hydronic module option) / Components delivered with chiller (unit without hydronic module option) Notes: - The unit must be protected against frost. - The hydronic module of the unit and the evaporator are protected (option 42 A installed in the factory) against frost with electric heaters (item 2 + ) (unit with hydronic module option). - The evaporator and the water outlet pipes are protected (option 4 installed in the factory) against frost with electric heaters (item 2 + ) (unit without hydronic module option). - The pressure sensors are assembled on connections without Schraeder. Depressurize and empty the network before intervention. 27

28 Water connections with hydronic module - Sizes 60 to 520 Example: Single pump Example: Dual pump Connection for expansion tank (option 293) Connection for expansion tank (option 293) See legend in the previous page. Water connections without hydronic module - Sizes 60 to 520 See legend in the previous page. 28

29 7.3 - Water flow detection Standard unit All units are equipped with a factory-set flow switch. It cannot be adjusted on site. The chilled water pump must be interlocked to the unit if the unit does not have the hydronic module option. The 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) Unit with hydronic module (options 6) The water flow detection functionality is handled by the option (via pressure sensors) Frost protection CAUTION: Damage caused by frost is not covered by the warranty. The plate heat exchanger, the pipes and the hydronic module pumps can be damaged by frost. The components of the unit (heat exchanger, pipes, hydronic module) will be protected by following the recommendations below. Protection of the remainder of the system is the responsibility of the installer Standard unit If the chiller or the water pipes are in an area where the ambient temperature can drop below 0 C, it is recommended to apply one of the three following strategies to protect the unit and the water pipes up to a temperature 0 K below the lowest ambient likely to occur locally;. Add an anti-freeze solution (45 % maximum) 2. Drain the chilled circuit when ambient temperatures fall below 0 C 3. Solution with heaters: Order (factory-installed) the option 4 (electric heaters on the evaporator and evaporator water outlet pipes) in order to protect the heat exchanger down to -20 C. If option 266 (evaporator connection sleeves) is also ordered, it is necessary to install a heater on each extension in order to protect the water pipes down to -20 C outdoor temperature. The anti-freeze solution and heaters can be combined Unit with hydronic module The recommendations from the previous chapter (points and 2) are applicable to the machines with hydronic module and protect them against frost. For the solution with heaters, order (factory-installed) the option 42A (electric heaters on the evaporator and different components of the hydronic module including the expansion tank) to ensure protection of the entire unit down to -20 C. The anti-freeze solution and heaters can be combined. Frost protection of units with hydronic modules require that water be circulated in the hydraulic circuit. The unit mounted pump will start, automatically, periodically. Combination of options for the periods when the machine is in standby mode. Ambiant unit temperature range 30RBM/30RBP without option 6 with option 6 > 0 C to 48 C C to 0 C Option 4 Option 42A* or or Anti-freeze solution appropriate (for example glycol) Anti-freeze solution appropriate (for example glycol)* * Allow the circulation of pumps. If there is a valve, install a bypass (see diagram for winter position). If the system is isolated by a valve, it is imperative to install a bypass as indicated below: Unit Winter position Open Closed Closed Water system 29

30 IMPORTANT REMINDERS: Following the atmospheric conditions of your region, you need to: Add only the anti-freeze solutions approved by Carrier for protecting the unit down to a temperature of 0 K below the lowest temperature likely to occur locally. For extended shutdowns in conditions of low ambient, drain the water system and add anti-freeze solution to the chiller evaporator (use the drain valve located at the evaporator water inlet). To prevent corrosion due to differential aeration, if the system is to be empty for more than month, the entire water loop should be protected with a blanket of dry, inert gas. (Maximum pressure 0.5 barg). In case of prolonged non-usage, the hydronic circuits must be protected by circulating a passivating solution. (Consult a specialist). At the commencement of the next cooling season, fill the system with water treated with appropriate corrosion inhibitors. For installation of auxiliary equipment, the installer must comply with the basic rules, especially by complying with the minimum and maximum flows which must be between the values mentioned in the operating limits tables (application data). If frost protection is dependent on the unit electric trace heaters, never switch off the main power supply. The main disconnect switch, auxiliary heater circuit and the control circuit must be energized. If trace heating is not used, or during a prolonged power failure, the entire chilled water system must be drained to protect the unit. The heat exchanger temperature sensor are part of its frost protection: If piping trace heaters are used, ensure the external heaters do not affect the measurement of these sensors Protection against cavitation (with option 6) To ensure the durability of pumps fitted with hydronic modules, the control algorithm 30RBM/30RBP units includes protection against cavitation. A pressure below 60 kpa will prevent the unit from starting, or will cause a shutdown. A pressure below 00 kpa (but above 60 kpa) will trigger an alert on the user interface. To obtain an adequate pressure, it is recommended: To pressurise the hydronic circuit between 00 kpa ( bar) and 400 kpa (4 bar) maximum at the pump inlet To clean the hydronic circuit during water filling or during its modification To regularly clean the screen filter Operation of two units in Master/Slave mode (option 58) The customer must connect both units with a communication bus in 0.75 mm² twisted, shielded cable (contact Carrier Service for the installation). All parameters required for Master/Slave operation must be configured by the Service configuration menu. All remote controls of the Master/slave assembly (start/stop, unloading, etc.) are managed by the unit configured as Master and must be applied only to the Master unit Units delivered with the hydronic kit The operation in Master/Slave is possible only when the units are installed in parallel: Control of both Master and Slave on inlet temperature is possible without any additional sensors (see example ). Control of Master and Slave on leaving temperature is possible by adding two additional sensors in the common supply pipe work (see example 2). Each unit controls its own water pump Units delivered without the hydronic kit In the case of units installed in parallel and if there is only one common pump installed by the installer, isolating valves must be installed on each unit. These should be controlled (opened and closed) using the water pump control outputs from the relevant unit. Consult the control manual 30RBM/30RBP for the connection addresses. The control of a variable speed pump must be, in this case, carried out by the unit via the 0-0 V dedicated output of the Master unit (control on Delta T only). An installation in series is only possible with a fixed speed pump (example 3): The operation of the pump will be controlled by the Master unit. The control of the Master/Slave assembly is done on the water outlet without additional sensor. The installation must be carried out only according to the diagram given in the example 3. WARNING: Both units must have the option 58 to allow the Master/Slave operation. 30

31 Example : Operation in parallel - control on water inlet for a hydronic kit 8 - NOMINAL SYSTEM WATER FLOW CONTROL Refer to the chapter Water connections for all references points mentioned in this chapter. 2 The water circulation pumps of 30RBM/30RBP units have been designed to allow the hydronic modules to operate at each possible conditions, i.e. with chilled water temperature differences at full load from 3 to 0 K. This temperature difference required between the water inlet and outlet determines the nominal flow of the system. Use the specification provided while selecting the unit to determine the operating conditions of the system. In particular, collect the data to be used for the control of the system flow rate: Example 2: Operation in parallel - control on water outlet for a hydronic kit 2 T T Example 3: Operation in series - control on water outlet for units assembly Units without hydronic module. The nominal unit pressure drop. This is measured with pressure gauges that must be (field) installed at the inlet and outlet of the unit. Units with fixed speed pumps. Nominal flow rate. The pressure of the fluid is measured by sensors at the inlet of the pump and outlet of the unit. The controls then calculate the flow rate associated with this pressure difference and display the result on the user interface. (refer to unit control manual). Units with variable speed pumps The constant pressure differential control based on readings at the hydronic module inlet and outlet. Units with variable speed pumps The control on temperature difference measured at the heat exchanger inlet and outlet. If this information is not available at the start-up of the system, contact the technical service department responsible for the installation to obtain them. These data can be obtained either from the technical document with unit performance tables for a Delta T of 5 K at the evaporator, or with the help of the Electronic Catalog selection program for all conditions of Delta T different from 5 K in the range of 3 to 0 K. 2 Légende Master Unit 2 Slave unit Control boxes of Master and Slave units Water inlet Water outlet Water pumps for each unit (normally included in the units with hydronic module) T Additional sensor for the control of the water outlet to be connected on channel of slave boards of each Master and Slave units Communication bus CCN Connection of two additional sensor Non-return valve 3

32 8. - Units without hydronic module General information The nominal flow of the unit will be set using a manual valve that should be installed on the outlet of the unit (item 9 on the schematic hydronic circuit). Changing the pressure drop of the valve allows adjustment of the system flow rate to achieve the design flow rate. As the total system pressure drop is not known exactly at the start-up, it is necessary to adjust the water flow with the control valve to obtain the specific flow of the system Procedure for cleaning the hydronic circuit Open the valve completely (item 9). Start-up the system pump. Read the pressure drop of the plate heat exchanger as the difference between the unit inlet and outlet pressures (item 8). Let the pump run for 2 hours consecutively to clean up the hydronic circuit of the system (presence of contaminating solids). Perform another reading. Compare this value to the initial value. A decrease in the pressure drop value indicates that the filters in the system need to be removed and cleaned. In this case, close the Shut-off valves on the water inlet and outlet (item 6) and remove the filters (item 7) after draining the hydronic part of the unit (item 6). Remove the air from the circuit (item 5). Repeat until the filter remains clean Procedure for controlling the water flow Once the circuit is cleaned, read the pressures on the pressure gauges (water inlet and outlet pressure) determine the pressure drop within the unit (plate heat exchanger + internal pipe work) Compare the value obtained with the design value predicted by the selection software. If the pressure drop reading is above the specified value, this indicates that the flow at the terminals of the unit (and hence in the system) is too high. In this case, close the control valve and read the new difference in pressure. Repeat as necessary until the pressure drop corresponding to the design flow rate is achieved Units with hydronic module and fixed speed pump General information See chapter 8.. Units without hydronic module Procedure for cleaning the hydronic circuit Open all valves completely (item 9). Start-up the system pump. Read the pressure drop of the hydronic module as the difference between the unit inlet and outlet pressures (item 8). Let the pump run for 2 hours consecutively to clean up the hydronic circuit of the system (presence of contaminating solids). Perform another reading. Compare this value to the initial value. A reducing value of the flow indicates that the filters on the system need to be removed and cleaned. In this case, close the Shut-off valves on the water inlet and outlet (item 6) and remove the filters (items 7 and ) after draining the hydronic part of the unit (item 6). Remove the air from the circuit (items 5 and 4). Repeat until the filter remains clean Procedure for controlling water flow Once the circuit is cleaned, read the flow value on the user interface and compare it with design value for the system. If the value of the flow is greater than the specified value, this indicates that the overall pressure drop in the system is too low against the available static pressure generated by the pump. In this case, close the control valve and read the flow value. Repeat as necessary until the pressure drop corresponding to the design flow rate is achieved. NOTE: If the network has an excessive pressure drop in relation to the available static pressure delivered by the unit pump, the nominal water flow cannot be obtained (lower resulting flow) and the difference in temperature between the water inlet and outlet of the evaporator will be increased. NOTE: If the network has an excessive pressure drop in relation to the available static pressure delivered by the system pump, the nominal water flow cannot be obtained (lower resulting flow) and the difference in temperature between the water inlet and outlet of the evaporator will be increased. To reduce the hydraulic system pressure drop: Reduce the pressure drops of individual components (bends, level changes, valves etc.) as much as possible Use the correct pipe diameter Do not extend the piping system. 32

33 To reduce the hydraulic system pressure drop: Reduce the pressure drops of individual components (bends, level changes, valves etc.) as much as possible Use the correct pipe diameter Do not extend the piping system. Example: Unit with specific nominal flow 0.6 l/s Perform another reading of the flow and compare this value with the initial value. A reducing value of the flow indicates that the filters on the system need to be removed and cleaned. In this case, close the shut-off valves on the water inlet and outlet (item 6) and remove the filters (items 7 and ) after draining the hydronic part of the unit (item 6). Remove the air from the circuit (items 5 and 4). Repeat if required the filter remains clean Procedure for controlling the pressure differential setpoint Pressure drop, kpa Water flow rate, l/s Legend Unit pump curve 2 Pressure drop in the hydronic kit (to be measured on the pressure gauge installed on the water inlet and outlet) 3 Pressure drop in the system with wide open control valve 4 Pressure drop in the system after controlling the valve to obtain the nominal flow specified Units with hydronic module and variable speed pump - Pressure differential control The system flow is not controlled to a fixed value. The flow rate will be adjusted, by varying the pump speed, to maintain a system pressure differential value defined by the user. This modulation is limited only by the maximum and minimum flow rates for the unit and by the maximum and minimum allowable pump speeds. See with Carrier Service to implement the procedures described below Procedure for cleaning the hydronic circuit Once the circuit is cleaned, place the hydronic circuit in the configuration for which the unit selection was performed generally (all valves open and all cooling coils active). Read the value of the flow on the user interface and compare it with the theoretical value of the range: If the value of the flow is greater than the specified value, reduce the pressure differential setpoint on the user interface to reduce the value of the flow. If the value of the flow is lower to the specified value, increase the pressure differential setpoint on the user interface to increase the value of the flow. Repeat until the design pressure drop / flow rate is achieved. Stop the forced operation of the pump and proceed to the configuration of the unit for the required control mode. Modify the control parameters: Set water flow control to pressure differential Set the value of the required differential pressure By default, the unit is configured at the minimum speed (frequency: 30 Hz). NOTES: If during controlling, the low or high frequency limits are reached before reaching the specified flow, keep the pressure differential value to its lower or higher limit to enter in the control parameters. If the user knows in advance the pressure differential value at the unit outlet to be maintained, this value can be entered directly as data to be declared. You should not, however, avoid the sequence of cleaning the hydronic circuit. Before proceeding, it is advisable to remove any possible contamination from the hydronic circuit. Start-up the system pump by using the forced start command. Control the frequency to the maximum value to generate a higher flow. If there is a Maximum flow exceeded alarm, reduce the frequency until an acceptable value is reached. Read the value of the flow on the user interface. Let the pump run for 2 hours consecutively to clean up the hydronic circuit of the system (presence of contaminating solids). 33

34 8.4 - Units with hydronic module and variable speed pump - Temperature differential control The system flow is not controlled to a fixed value. The flow rate will be adjusted, by varying the pump speed, to maintain a heat exchanger temperature differential value defined by the user. This modulation is limited only by the maximum and minimum flow rates for the unit and by the maximum and minimum allowable pump speeds. See with Carrier Service to implement the procedures described below Procedure for cleaning the hydronic circuit Refer to the procedure for cleaning the hydronic circuit from chapter Procedure for controlling the Delta T setpoint Once the circuit is cleaned, stop the forced start of the pump and proceed to the configuration of the unit for the required control mode. Modify the control parameters: Set water flow control to temperature differential Set the value of the required differential temperature. By default, the unit is configured at the minimum speed (frequency: 30 Hz) Units with hydronic module and variable speed pump - Controlling a fixed flow of the system The flow will be set to a nominal value. This value will remain constant and will not be dependent on variations of system load. See with Carrier Service to implement the procedures described below Procedure for cleaning the hydronic circuit Refer to the procedure for cleaning the hydronic circuit from chapter Procedure for controlling the flow Once the circuit is cleaned, stop the forced start of the pump and proceed to the configuration of the unit for the required control mode. Modify the control parameters: Set water flow control to fixed speed Set the value of the required pump VFD frequency. The pump VFD frequency should be adjusted manually until the required flow is achieved. By default, the unit is configured at the minimum speed (frequency: 30 Hz). 34

35 8.6 - Pump pressure/flow rate curves Units with hydronic module (fixed speed pump or variable speed pump at 50 Hz). Data applicable for: Fresh water 20 C. Refer to the chapter Evaporator flow rate for the values of maximum water flow. In case of use of ethylene-glycol, the maximum flow rate is reduced RBM/30RBP high-pressure pumps Single pumps Head pressure, kpa RBM-30RBP 60 to RBM-30RBP 260 to RBM-30RBP 330 to RBM-30RBP 430 to 520 Water flow rate, l/s Dual pumps Head pressure, kpa RBM-30RBP 60 to RBM-30RBP 260 to RBM-30RBP 330 to RBM-30RBP 430 to RBM-30RBP 520 Water flow rate, l/s 35

36 RBM/30RBP low-pressure pumps Single pumps Head pressure, kpa Water flow rate, l/s 30RBM-30RBP 60 to RBM-30RBP RBM-30RBP 300 to RBM-30RBP RBM-30RBP 400 to 470 Dual pumps Head pressure, kpa Water flow rate, l/s 30RBM-30RBP 60 to RBM-30RBP 200 to RBM-30RBP RBM-30RBP 300 to RBM-30RBP RBM-30RBP RBM-30RBP 430 to

37 8.7 - Available static system pressure Units with hydronic module (fixed speed pump or variable speed pump at 50 Hz). Data applicable for: Fresh water 20 C. Refer to the chapter Evaporator flow rate for the values of maximum water flow. In case of use of ethylene-glycol, the maximum flow rate is reduced RBM/30RBP high-pressure pumps Single pumps Sizes Sizes Available static pressure, kpa Water flow rate, l/s 30RBM-30RBP 60 to RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP 520 Dual pumps Available static pressure, kpa Sizes Sizes Water flow rate, l/s 30RBM-30RBP 60 to RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP

38 RBM/30RBP low-pressure pumps Single pumps Sizes Sizes Available static pressure, kpa Water flow rate, l/s RBM-30RBP 60 to RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP 470 Dual pumps Sizes Sizes Available static pressure, kpa Water flow rate, l/s 0 30RBM-30RBP 60 to RBM-30RBP 200 to RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP RBM-30RBP

39 9 - MAIN COMPONENTS OF THE SYSTEM AND OPERATING RANGE 9. - Compressors 30RBM/30RBP units use hermetic scroll compressors. Each compressor is equipped with a crankcase oil heater, as standard. There is no heater fault detection. Each compressor sub-assembly has: Anti-vibration mountings between the unit chassis and the chassis of the compressor sub-function Suction interconnecting pipe with internal compensation (for 3 and 4 compressor modules) to ensure oil equalization between all compressors A safety pressure switch at the discharge line of each circuit Pressure and temperature sensors at the common suction line and a pressure sensor at the common discharge line Lubricant The compressors installed on the units have an oil charge of 6.9 l, ensuring good lubrication under all operating conditions. The oil level check can be done: At commissioning: The oil level must be greater than or equal to half of the sight glass. Within a few minutes of the shutdown of a compressor sub-assembly: oil must be visible in the sight glass. If this is not the case, there might be a leak or an oil trap in the circuit. If there is an oil leak, find and repair it, then refill with oil. See the Service Guide for the oil removal and refill procedures. ATTENTION: Too much oil in the circuit can cause a unit defect. NOTE: Use only oils which have been approved for the compressors. Never use oils which have been exposed to air. CAUTION: R-22 oils are absolutely not compatible with R-40A oils and vice versa Condensers The 30RBM/30RBP coils are micro-channel condensers made entirely of aluminium Fans The fans are axial Flying Bird fans equipped with rotating shroud and made of composite recyclable material. Each motor is fixed with transverse supports. The motors are threephase, with permanently lubricated bearings and insulation class F. For detailed information, refer to the table below. According to the Regulation No. 327/20 implementing Directive 2009/25/EC with regard to ecodesign requirements for fans driven by motors with an electric input power between 25 W and 500 kw. Product 30RBM/30RBP Option Standard or option Option 2 Option 5LS Option 28B* Option 28C** 30RBP (VFD duty) Overall efficiency % Measurement category A A A A A A Efficiency category static static static static static static Target efficiency level N(205) 40 N(205) 40 N(205) 40 N(205) 40 N(205) 40 N(205) 40 ERP205 Efficiency level at optimum efficiency point Variable speed drive NO YES NO NO NO YES Year of manufacture See label on the unit See label on the unit See label on the unit See label on the unit See label on the unit See label on the unit Fan manufacturer Simonin Simonin Simonin Simonin Simonin Simonin Motor manufacturer Leroy Somer Leroy Somer Leroy Somer AOS/ Regal Beloit AOS/ Regal Beloit Leroy Somer Fan PN 00PSG A 00PSG A 00PSG A 00PSG A 00PSG A 00PSG A Motor PN 00PPG A 00PPG A 00PPG A 00PPG A 00PPG PPG A Nominal power of the motor kw Flow rate m 3 /s Pressure at optimum energy Pa efficiency Nominal speed rpm Specific ratio Relevant information to facilitate the disassembly, recycling or removal of the product at the end of life Relevant information to minimise impact on the environment See the Maintenance manual See the Maintenance manual * Only for the two-speed fans [ per circuit / the others are Standard] ** Only for the two-speed fans [ per circuit / the others are Option 5LS] See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual See the Maintenance manual 39

40 According to the Regulation No. 640/2009 and amendment 4/204 implementing Directive 2005/32/EC with regard to ecodesign requirements for electric motors. Product 30RBM/30RBP Option Standard or option 28 Option 2 Option 5LS Option 28B* Option 28C** 30RBP (VFD duty) Motor type Asynchronous Asynchronous Asynchronous Dual-speed Dual-speed Asynchronous asynchronous asynchronous Number of poles Nominal input frequency Hz Nominal voltage V Number of phases Motor included in the application NO NO NO NO NO NO domain of the regulation 640/2009 and amendment 4/204 Sales leaflet for exemption Article.2.c).(ii) Article.2.c).(ii) Article 2. Article 2. Article 2. Article.2.c).(ii) Ambient air temperature for which the motor is specifically designed C * Only for the two-speed fans [ per circuit / the others are Standard] ** Only for the two-speed fans [ per circuit / the others are Option 5LS] Electronic expansion valve (EXV) The EXV has a stepper motor (2785 to 3690 steps according to the model), and a sight glass that permits verification of the mechanism movement and the presence of the liquid gasket Moisture indicator Located on the EXV, permits monitoring of the unit charge and indicates moisture in the circuit. The presence of bubbles in the sight-glass indicates an insufficient charge or noncondensables in the system. The presence of moisture changes the colour of the indicator paper in the sight-glass Filter drier The role of the filter drier is to keep the circuit clean and moisture-free. The moisture indicator shows, when it is necessary to change the element. A difference in temperature between the filter inlet and outlet shows that the element is dirty Evaporator The evaporator is a brazed plate heat exchanger (BPHE) with two refrigerant circuits. It has been tested and stamped for a maximum operating pressure of 4520 kpa on refrigerant side and of 3200 kpa on the water side. The water connections of the heat exchanger are Victaulic connections. The evaporator is thermally insulated with 9 mm of nitrile foam rubber (elastomer). As an option it can be protected against frost (option 4: evaporator frost protection). Thermal insulation of chiller / piping must be chemically neutral to the surfaces on which they are applied. This is the case for materials supplied by Carrier Refrigerant 30RBM/30RBP units operate with refrigerant R-40A High-pressure safety switch 30RBM/30RBP units are equipped with high-pressure safety switches with automatic reset. These pressure switches are located at the discharge of each circuit Variable frequency drive (VFD) The 30RBP units are fitted with variable frequency drives to control the fan speed. For the 30RBP range, fmin = 5 Hz and fmax = 50 Hz. All fans on the same refrigerant circuit are controlled by a single variable frequency drive. Fan speed is changed by generating a controlled waveform in which frequency and voltage are varied (Pulse Width Modulation). Fan sequencing and frequency set-point is effected through RS485 communication via LEN Protocol from the Carrier Controller Power factor correction capacitors (option 23) The power factor correction is active for any operating condition of the machine. A minimun power factor performance of 0.95 is garantee when unit operates at a condition that involves a power input that exceeds the Eurovent standard condition. A capacitor bank is controled by a regulator which read the current draw by the unit and ajust the power factor with a set up at 0,95. Capacitors are dry type : no risk of leakage or fire. The capacitors are selected for each unit as per below table: Unit size RBM/P Capacitors Capacity (kvar) Capacity Capacitor (kvar) Ir(A) Capacity Capacitor 2 (kvar) Ir(A) Capacity Capacitor 3 (kvar) Ir(A) Caution: Operation of the unit without capacitors results in current raising

41 9.2 - Fan arrangement 30RBM/30RBP 60 30RBM/30RBP RBM/30RBP Elec 22 Elec 2 22 Elec CKT A CKT B CKT A CKT B CKT A CKT B 30RBM/30RBP RBM/30RBP Elec 2 3 Elec CKT A CKT B CKT A CKT B 30RBM/30RBP Elec CKT A CKT B Fan stages (only 30RBM units) Standard unit 30RBM/30RBP Circuit Stage Stage 2 Stage 3 Stage 4 Variable Frequency drive on 30RBP Variable Frequency drive on Option 28 Two-speed fan on Options 28B and 28C 60 A EV EV EV EV B EV2 EV2+EV22 EV2+EV22 EV2 EV A EV EV2 EV+ EV2 EV EV B EV2 EV2+ EV22 EV2+ EV22 EV2 EV A EV EV2 EV + EV2 EV EV B EV3 EV3+EV2 EV3+EV2+EV32 EV3+EV2+EV32 EV3 EV A EV EV2 EV + EV2 + EV22 EV + EV2 + EV22 EV EV B EV3 EV3+ EV32 EV3+ EV32 + EV2 EV3+ EV32 + EV2 EV3 EV A EV2 EV2 EV2+EV+EV22 EV2+EV+EV22 EV2 EV2 B EV3 EV3+EV4 EV3+EV4+EV32 EV3+EV4+EV32+EV42 EV3+EV4+EV32+EV42 EV3 EV3 520 A EV EV2 EV + EV2 + EV2 EV + EV2 + EV2 + EV22 EV + EV2 + EV2 + EV22 EV EV B EV3 EV3 + EV4 EV3 + EV4 + EV32 EV3 + EV4 + EV32 + EV42 EV3 + EV4 + EV32 + EV42 EV3 EV Variable speed fan (only 30RBP units) The 30RBP units differ from the 30RBM units by introducing variable speed drives on the fans to optimise the efficiency of the unit depending on the condition of use (air temperature, circuit capacity) and hence improve the seasonal efficiency (ESEER). All fans in the same refrigerant circuit are controlled by a single variable speed drive. Therefore, they operate together at the same rotational speed. The rotational speed at full load or partial load of each circuit is controlled by an algorithm that continuously optimises the condensing temperature to obtain the best energy efficiency (EER) whatever the operating conditions. Fan motor electrical protection The motors of a same circuit are electrically protected by the variable frequency drive in case of short-circuit, locked rotor or general overload. Each variable frequency drive follows a variable current characteristic, based on the frequency from 5 to 50 Hz and the number of fans controlled. In case of fan failure (e.g.: fan disconnected) the variable frequency drive will detect this problem and send an alert to the user interface. Refer to the 30RBM/30RBP control manual for the list of alarms. 4

42 0 - OPTIONS 0. - Touch Pilot Control (option 58) Hydronic module with variable speed (options 6V, 6W) The composition of the hydronic kit is similar to the previous chapter ( 0.2). In this case, the pump is controlled by a variable frequency drive that allows adjustment of the system flow in response to the chosen control mode (constant pressure or temperature differential, fixed flow) and the system operating conditions. CAUTION: The use of the hydronic kit on open systems is prohibited. Do not operate 2 units in master slave (option 58) with variable speed hydronic modules Units with fans with available pressure for indoor installation (Option 2-High Static Fan) The interface of the option 58 Touch Pilot Control has the following features: It has a 5-inch color screen. Clear and concise information is presented in the local language (8 available) The screen menus can be adapted for different users (final client, maintenance personnel, Carrier engineer). Unit use and configuration are secure. Password protection prevents non-authorized access to advanced settings. No password is required to access normal operating data and settings Hydronic module without variable speed (options 6R, 6S, 6T, 6U) The hydronic module is composed of the main hydronic components of the system: screen filter, safety valve and water pump installed in the factory. This pump provides the fixed, nominal flow rate for the system. Several types of water pump are proposed to suit all applications: single or dual low-pressure pump, single or dual high-pressure pump. The nominal flow of the system should be adjusted using a manual control valve provided by the client. The safety valve placed on the water inlet pipes at the pump inlet limits the pressure to 400 kpa (4 bar). A screen filter that can be easily removed is placed at the pump inlet and protects the pump and the plate heat exchanger against solid particles that are greater than.2 mm. Additional options can be ordered if necessary: Option 42A: Protection of the hydronic kit down to -20 C outdoor temperature. Option 293: Expansion tank for hydraulic system. CAUTION: The use of the hydronic kit on open system is prohibited. This option applies to 30RBP units installed inside the building in a plant room. For this type of installation, the hot air leaving the air condensers is discharged by the fans to the outside of the building, using a duct system that causes a pressure drop in the air path. Therefore, more powerful fan motors than those used for the standard units are installed in this option. For each installation, the duct pressure drops differ, depending on the duct length, the duct section and the direction changes. 30RBP units with option 2 are designed to operate with air discharge ducts with maximum pressure drop of 200 Pa (units are equipped with variable-speed fans with a maximum speed of 9 r/s, instead of 5.8 r/s for standard units). Use of variable speed up to 9 r/s can overcome the duct pressure drop while maintaining an optimized air flow per circuit. All fans in the same circuit, operating at the same time, have the same speed. The fan power input for fans with a speed of 9 r/s is increased compared to that of standard fans with a speed of 5.8 r/s (the multiplier coefficient is the same as the cube of the speed ratio, i.e. x.72). The full-load or part-load speed is controlled by a patented algorithm that permanently optimizes the condensing temperature to ensure the best unit energy efficiency (EER) whatever the operating conditions and pressure drop of the system ductwork. If necessary for a specific installation, the maximum fan speed of 30RBP unit can be fixed between 3.3 and 9 r/s, using the Service Configuration menu. Consult the 30RBM/RBP Control manual for this modification. The performances (capacity, efficiency) depend on the speed of the fans, then on the duct pressure drop: between 0 and 00 Pa, the unit performances are only slightly affected between 00 and 200 Pa, the unit performances may vary considerably, depending on the operating conditions (outdoor air temperature and water conditions) The noise level into the ductwork and radiated around the unit is also related to the pressure drop. 42

43 Please refer to the Carrier Electronic catalog to evaluate the impact of the estimated duct system on the 30RBP unit operating conditions Installation All fans in the same refrigerant circuit are controlled by a single speed inverter and therefore all run at the same speed. Each refrigerant circuit (A and B) must have a separate ducting system to prevent any air recycling between the air heat exchangers of the different refrigerant circuits Nominal and maximum air flows per circuit (A and B) for 30RBP sizes 30RBP Circuit A Circuit B Nominal/maximum air fow (l/s) Nominal/maximum air fow (l/s) / / / / / / / / / / / / Each fan of the 30RBP unit with option 2 is equipped with a factory-installed connection interface, allowing the connection to the ductwork. Please refer to the unit dimensional drawings for the exact dimensions of the connection interface. Please refer to the section 9.2 Fan arrangement to affect each fan to its own circuit Factory-installed duct connection interface on each fan V-shaped air heat exchangers View from above Side view Detail of the duct connection interface frame Size of the duct connection frame 860x860x00mm 43

44 Principle of the installation of the ducts Solution each fan has its own duct Solution 2 2 fans can used the same duct a Fan motor access hatches (provide a 700 x 700 mm hatch) for each single or dual duct Partial heat reclaim using desuperheaters (option 49) This option permits the production of free hot water using heat reclaim by desuperheating the compressor discharge gases. The option is avaiable for the whole 30RBM/30RBP range. A plate heat exchanger is installed in series with the air condenser coils on the compressor discharge line of each circuit. The control configuration for the desuperheater option is factory assembled (see chapter Control configuration) P hysical data, 30RBM/30RBP units with partial heat reclaim using desuperheaters (option 49) 30RBM/30RBP Desuperheater in circuits A/B Water volume circuits A/B Max. water-side operating pressure Refrigerant Circuit A Circuit B Water connections Connection Outside diameter 30RBM Operating weight* Standard unit + desuperheater option Unit with option 5 + desuperheater option Unit with option 5 and option 6S + desuperheater option 30RBP Operating weight* Standard unit + desuperheater option Unit with option 5 + desuperheater option Unit with option 5 and option 6S + desuperheater option l kpa Plate heat exchanger 2/3.75 2/3.75 2/ , kg teqco2 9, / / / / / / / / / ,4 27,9 2,9 26,9 4,3 30,0 3,6 28,4 5,0 3,3 7,3 36, 22,8 47,6 2,4 44,7 26,3 54,9 23,7 49,6 27,3 57,0 3,5 kg teqco2 28, Victaulic in 2" mm ,3 30,0 3,3 27,7 4,5 30,2 3,6 28,4 22,8 47,6 2, 44, 20,9 43,7 22,4 46,8 27,4 57, 27,3 57, 27,5 57,4 2" " " " " " " " " " " 60.3 kg kg kg kg kg kg * Weigths are guidelines only. Refer to the unit nemaplate

45 RBM/RBP (equipped with desuperheater option 49) 2297 HT 2 Victaulic HT Control power connection UNIT WITH HYDRONIC MODULE Legend: 2 All dimensions are in mm Clearances required for maintenance and air flow Clearances recommended for heat exchanger removal 2253 HT Water inlet Water outlet Control box 500 NOTE: Non-contractual drawings When designing an installation, refer to the certified dimensional drawings, available on request. UNIT WITHOUT HYDRONIC MODULE For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings HT

46 RBM/30RBP (equipped with desuperheater option 49) 2297 HT 2 Victaulic HT UNIT WITH HYDRONIC MODULE Legend: 2 All dimensions are in mm. Clearances required for maintenance and air flow 2 Clearances recommended for heat exchanger removal 2253 HT Water inlet Water outlet Control box NOTE: Non-contractual drawings. 500 UNIT WITHOUT HYDRONIC MODULE When designing an installation, refer to the certified dimensional drawings, available on request. For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings HT

47 RBM/30RBP (equipped with desuperheater option 49) 2297 HT 2 Victaulic HT UNIT WITH HYDRONIC MODULE Legend: 2 All dimensions are in mm. Clearances required for maintenance and air flow 2253 HT 2 Clearances recommended for heat exchanger removal Water inlet Water outlet Control box NOTE: Non-contractual drawings. UNIT WITHOUT HYDRONIC MODULE When designing an installation, refer to the certified dimensional drawings, available on request HT 2200 For the positioning of the fixing points, weight distribution points and centre of gravity coordinates please refer to the dimensional drawings

48 Installation and operation of the heat reclaim with desuperheater option During the unit installation the heat reclaim plate heat exchangers must be insulated and frost protected, if required. The 30RBM/30RBP units with the desuperheater option (No. 49) are supplied with one heat exchanger per refrigerant circuit. Please refer to the typical installation diagram below for the main components and functions of the 30RBM/30RBP units with the desuperheater option. Typical installation diagram of units with the desuperheater option % 4 4 & $ # y ^ t w w 2 9 t e t r 28 q ) W q q u o R p Q E 30RBM/30RBP unit with desuperheater option without hydfronic module Border between 30RBM/30RBP unit and the system Typical installation Legend 30RBM/30RBP unit components Evaporator 2 Compressor 3 Desuperheater (plate heat exchanger) 4 Air condenser (coils) 5 Expansion valve (EXV) 6 Damage limitation accessory in case of a fire (safety valve) 7 Electric heater to protect the desuperheater against frost (not supplied) 8 Desuperheater insulation (not supplied) 9 Unit control box 0 NA Desuperheater water inlet 2 Desuperheater water outlet 3 Evaporator water inlet 4 Evaporator water outlet 5 Unit with desuperheater option without hydronic module 6 System heat load 7 Border between the 30RBM/30RBP unit and the typical installation Installation components (installation example) 20 Pump (hydronic circuit of the desuperheater loop) 2 Shut-off valve 22 Desuperheater water flow balancing and control valve 23 Damage limitation accessory in case of a fire (safety valve) 24 Expansion tank 25 Charge or drain valve 26 Air purge 27 Heat exchange coil or plate heat exchanger 28 Pressure gauge 29 Flow switch 30 Pump (sanitary hot water circuit) 3 Three-way valve + controller 32 Filter to protect the pump and the desuperheaters 33 District water supply 34 Sanitary hot water outlet 48

49 Installation The water supply of each desuperheater is arranged in parallel. The water connections on the desuperheater water inlets and outlets must not cause any mechanical local constraint at the heat exchangers. If necessary, install flexible connection sleeves. Install water flow control and balancing valves at the heat exchanger outlet. Water flow control and balancing can be done by reading the pressure drop in the heat exchangers. This must be identical on all of them with the total water flow rate given by the "Electronic catalogue" selection program. Refer to the pressure drop curves below to control the balancing valves before starting up the installation. The water flow control of each desuperheater can de refined when the unit operates at full load by trying to obtain leaving water temperatures that are absolutely identical for each circuit. Desuperheater (plate heat exchanger pressure drop curves) 00 Operation of the pump (see typical diagram - item 20 of chapter 0.5.5) of the desuperheater water circuit can be linked to: - The start-up of the first compressor of the unit : terminal block 37/38 2- The heat water need : Output DO-0 terminal block n 49/492 of the EMM board (option 56) A dedicated flow switch (item 29) can also be installed to generate an alarm if there is a problem with the pump (customer control system). The volume of the desuperheater circuit water loop must be as low as possible so that the temperature can increase rapidly when the unit is started up. The minimum entering water temperature at the desuperheater is 25 C. This may require the use of a three-way valve (item 3), with a control-ler and the sensor controlling the minimum required entering water temperature. The desuperheater water loop must include a safety valve and an expansion tank. When selecting these, consider the water loop volume and the maximum temperature (20 C) when pump operation is stopped (item 20). Heat exchanger pressure drop, kpa Operating range Desuperheater Minimum Maximum Entering water temperature at start-up C 25* 75 Leaving water temperature during operation C Air condenser Minimum Maximum Outside operating temperature C 0** 46 * The entering water temperature at start-up must not be lower than 25 C. For installations with a lower temperature a three-way valve is necessary. ** The minimum outside temperature is 0 C; -20 C with the winter operation option Control configuration with the desuperheater option 0. 0 Heat exchanger water flow rate, l/s Circuit with compressor 2 Circuit with 2 compressors 3 Circuit with 3 compressors 4 Circuit with 4 compressors This configuration allows the user to enter a setpoint that is relative to the minimum condensing temperature (default = 30 C) to increase the heating capacity reclaimed at the desuperheaters, if required. The percentage of the reclaimed heating capacity compared with the total capacity rejected by the condenser increases in proportion to the saturated condensing temperature. For the setpoint control of the minimum saturated condensing temperature refer to the Pro-Dialog control manual. Other parameters directly affecting the effective capacity reclaimed at the desuperheater are principally: The unit load rates, that decide whether the unit operates at full load (00%) or part load (depending on the number of compressors per unit circuit). The water entering temperature in the desuperheater as well as the condenser entering air temperature. 49

50 0.6 - Other options Options No. Description Advantages Use Unit equipped for air discharge 30RBP ducting 50 2 Unit equipped with high static variable-speed fans (maximum 200 Pa), each fan equipped with a connection flange allowing the connection to the ducting system. Ducted fan discharge, optimised condensing (or evaporating on Heat pump version) temperature control, based on the operating conditions and system characteristics Low noise level 5 Aesthetic and sound absorbing compressor enclosure Noise level reduction by to 2 db(a) 30RBM/30RBP Very low noise level 5LS Aesthetic and sound absorbing compressor enclosure Noise level reduction by 6 to 7 db(a) 30RBM/30RBP associated with low-speed fans High ambient temperature 6 Unit equipped with electrical panel cooling fan Extended unit part-load operation up to 52 C ambient 30RBM temperature IP54 control box 20A Increased leak tightness of the unit Protects the inside of the electrical box from dusts, water 30RBM and sand. In general this option is recommended for installations in polluted environments Grilles and enclosure panels 23 Metal grilles on the 4 unit sides, plus side enclosure panels at Improves aesthetics, protection against intrusion to the 30RBM/30RBP each end of the coil unit interior, coil and piping protection against impacts. Enclosure panels 23A Side enclosure panels at each end of the coil Improves aesthetics, coil and piping protection against 30RBM/30RBP impacts. Soft Starter 25 Electronic starter on each compressor Reduced start-up current 30RBM/30RBP Winter operation down 28 Fan speed control of lead fan for each circuit using a variable Stable unit operation for outside air temperature from 0 30RBM to -20 C frequency drive C down to -20 C Winter operation down 28B Two-speed lead fan for each circuit Stable unit operation for outside air temperature from 0 30RBM to -0 C C down to -0 C Winter operation down 28C Two Low speed fans on lead fan on each circuit Reduces the noise level and enables stable unit 30RBM to -0 C low speed operation for outside air temperature down to -0 C Water exchanger frost 4 Electric heater on the water exchanger and the water piping Water exchanger module frost protection between 0 C 30RBM/30RBP protection and -20 C outside air temperature Water exchanger and hydraulic 42A Electric heater on the evaporator, hydronic module and Water exchanger and hydronic module frost protection 30RBM/30RBP mod. frost protection optional expansion tank between 0 C and -20 C outside air temperature Partial heat recovery 49 Unit equipped with one desuperheater on each refrigerant circuit Production of free high-temperature hot-water simultaneously with chilled water production (or hot water for Heat pump) 30RBM/30RBP Master/slave operation 58 Unit equipped with supplementary water outlet temperature sensor kit to be field-installed allowing master/slave operation of two units connected in parallel Optimised operation of two units connected in master/ slave operation with operating time equalisation 30RBM/30RBP Compressor suction and 92A Shut-off valves on the compressor suction and discharge Simplified maintenance. Possibility to store the refrigerant 30RBM/30RBP discharge valves piping charge in the cooler or condenser side during servicing Compressor discharge valves 93A Shut-off valves on the compressor discharge piping Simplified maintenance. Possibility to store the refrigerant 30RBM/30RBP charge in the condenser side during servicing HP single-pump hydronic module 6R Single high-pressure water pump, water filter, electronic water flow control, pressure transducers. For more details, refer to the dedicated chapter (expansion tank not included.option with built-in safety hydraulic components available.) Easy and fast installation (plug & play) 30RBM/30RBP HP dual-pump hydronic module 6S Dual high-pressure water pump, water filter, electronic water flow control, pressure transducers. For more details, refer to the dedicated chapter (expansion tank not included) Option with built-in safety hydraulic components available) Easy and fast installation (plug & play) 30RBM/30RBP LP single-pump hydronic module 6T Single low-pressure water pump, water filter, electronic water flow control, pressure transducers. For more details, refer to the dedicated chapter (expansion tank not included Option with built-in safety hydraulic components available) LP dual-pump hydronic module 6U Dual low-pressure water pump, water filter, electronic water flow control, pressure transducers. For more details, refer to the dedicated chapter (expansion tank not included Option with built-in safety hydraulic components available) HP variable-speed single-pump hydronic mod. HP variable-speed dual-pump hydronic mod. 6V 6W Single high-pressure water pump with variable speed drive (VSD), water filter, electronic water flow control, pressure transducers. Multiple possibilities of water flow control. For more details, refer to the dedicated chapter (expansion tank not included Option with built-in safety hydraulic components available) Dual high-pressure water pump with variable speed drive (VSD), water filter, electronic flow switch, pressure transducers. Multiple possibilities of water flow control. For more details, refer to the dedicated chapter (expansion tank not included Option with built-in safety hydraulic components available) Easy and fast installation (plug & play) 30RBM/30RBP Easy and fast installation (plug & play) 30RBM/30RBP Easy and fast installation (plug & play), significant pumping energy cost savings (more than two-thirds), tighter water flow control, improved system reliability Easy and fast installation (plug & play), significant pumping energy cost savings (more than two-thirds), tighter water flow control, improved system reliability 30RBM/30RBP RBM/30RBP J-Bus gateway 48B Two-directional communication board complying with JBus protocol Connects the unit by communication bus to a building management system 30RBM/30RBP Lon gateway 48D Two-directional communication board complying with Lon Talk Connects the unit by communication bus to a building 30RBM/30RBP protocol management system Bacnet over IP 49 Two-directional high-speed communication using BACnet protocol over Ethernet network (IP) Easy and high-speed connection by ethernet line to a building management system. Allows access to multiple unit parameters. 30RBM/30RBP Energy Management Module 56 Control board with additional inputs/outputs. See Energy Management Module option chapter. Extended remote control capabilities (Set-point reset, ice 30RBM/30RBP storage end, demand limits, boiler on/off command...) Touch Pilot control, 5" user 58 Touch Pilot control supplied with a 5 inch colour touch screen Control with advanced communication technology over 30RBM/30RBP interface user interface Ethernet (IP), user-friendly and intuitive user interface with 5" colour touch screen Compliance with Russian 99 EAC certification Conformance with Russian regulations 30RBM/30RBP regulations Power factor correction 23 Capacitors for automatic regulation of power factor (cos phi) Reduction of the apparent electrical power, compliance 30RBM/30RBP Enviro-Shield anti-corrosion protection Super Enviro-Shield anti-corrosion protection value to 0,95. with minimum power factor limit set by utilities 262 Coating by conversion process which modifies the surface of the Improved corrosion resistance, recommended for use in 30RBM/30RBP aluminium producing a coating that is integral to the coil. Complete moderately corrosive environments immersion in a bath to ensure 00% coverage. No heat transfer variation, tested 4000 hours salt spray per ASTM B Extremely durable and flexible epoxy polymer coating applied Improved corrosion resistance, recommended for use in 30RBM/30RBP on micro channel heat exchangers by electro coating process, extremely corrosive environments final UV protective topcoat. Minimal heat transfer variation, tested 6000 hours constant neutral salt spray per ASTM B7, superior impact resistance per ASTM D Victaulic piping connections with welded joints Easy installation 30RBM/30RBP Welded water exchanger connection kit 230V electrical plug V AC power supply source provided with plug socket and Permits connection of a laptop or an electrical device 30RBM/30RBP transformer (80 VA, 0.8 Amps) during unit commissioning or servicing Expansion tank bar expansion tank integrated in the hydraulic module Easy and fast installation (plug & play),& Protection of 30RBM/30RBP (require option 6) closed water systems from excessive pressure Screwed DSH water connection 303 DSH connections with screwed joints Easy installation.allows unit connection to a screw 30RBM/30RBP kit connector Welded DSH water connection kit 304 DSH inlet/outlet welded connection sleeves Easy installation 30RBM/30RBP

51 - STANDARD MAINTENANCE To ensure optimal efficiency and reliability of the units, we recommend establishing a maintenance contract with your local Carrier Service organisation. This contract will include regular inspections by Carrier Service specialists so that any malfunction is detected and corrected quickly, ensuring that no serious damage can occur. A Carrier Service maintenance contract is the best way to ensure the maximum operating life for your equipment and, through the expertise of Carrier technicians, provides the ideal way to manage your system cost effectively. Air conditioning equipment must be maintained by professional technicians, whilst routine checks can be carried out locally by specialised technicians. See the standard EN All refrigerant charging, removal and 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. 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 group. Simple preventive maintenance will allow you to get the best performance from your HVAC unit: Improved cooling performance Reduced power consumption Prevention of accidental component failure Prevention of major time consuming and costly work Protection of the environment There are five maintenance levels for HVAC units, as defined by the AFNOR X60-00 standard. NOTE: Any deviation or non-observation of these maintenance criteria will render the guarantee conditions for the HVAC unit nul and void, and the manufacturer, Carrier France, will no longer be responsible.. - Level maintenance These simple procedures can be carried out by the user: Check for traces of oil (indicates a refrigerant leak) Check for leaks in the hydraulic circuit (monthly) Clean the condenser coils (see chapter Condenser Coil ) Check for missing / damaged protective devices, and improperly closed doors / covers. Check and record alarms (see 30RBM/30RBP control manual) Verify the refrigerant charge in the liquid line sight glass Verify the chilled water temperature difference is correct Check for any signs of deterioration Check the anti-corrosion coatings.2 - Level 2 maintenance This level requires specific expertise in electrical, hydraulic and mechanical systems. The frequency of this maintenance level may be annual or monthly, depending on the verification type. The frequency of this maintenance level can be monthly or annually depending on the verification type. In these cases, the following maintenance operations are recommended: Carry out all level operations, then: Electrical checks (annual checks): At least once a year tighten the electrical connections of power supply circuits (see table with tightening torques). Check and tighten all control connections if required. Check the labelling of the system and instruments, reapply the missing labels if required. Remove the dust and clean the interior of the control boxes. Be careful not to blow dust or debris into components, use a brush / vacuum where possible. Clean the insulators and bus bar supports (dust combined with moisture reduces the insulation gaps / increases current leakage between phases and from phase to ground). Check the presence, condition and operation of electrical control devices. Replace the fuses every 3 years or every 5000 hours (aging). Check that no water has penetrated into the control box. On the main control box and for units equipped with a variable frequency drive regularly check the cleanliness of the filter media to maintain the correct air flow. Check the correct operation of the capacitor (power factor correction option 23) Mechanical checks: Check the tightness of the fan cowl, fan, compressor and control box fixing bolts. Hydronic checks: When working on the unit hydronic components be careful not to damage adjacent condenser coils. Verify the water connections. Check the condition of the expansion tank (presence of corrosion, or gas pressure loss) and replace it if required. Drain the water circuit (see chapter Water flow control procedure ). Clean the water filter (see chapter Water flow control procedure ). Replace the gland packing of the pump after hours of operation and the bearings after 7500 hours. Check the operation of the low water flow safety device. Check the condition of thermal insulation. Check the concentration of the anti-freeze protection solution (ethylene glycol or propylene glycol). Check the water flow using the heat exchanger pressure difference. Check the water / heat exchange fluid quality. Check for corrosion of the steel pipe work. 5

52 Refrigerant circuit checks: For MCHE coils, clean the condenser face by spraying the coil evenly, working from bottom to top, directing the water jet at right angles to the coil. Do not exceed a water pressure of 6200 kpa (62 bar) or an angle of 5 related to the coil. The nozzle must be at least 300 mm away from the coil surface. Check the unit operating parameters and compare them with the previous values. Check the operation of high-pressure switches. Replace as necessary. Check the fouling of the filter drier. Replace it if required. Keep and maintain a maintenance sheet, attached to each HVAC unit. For all these operations take adequate safety measures: use appropriate PPE (personal protective equipment), comply with all industry and local regulations, use common sense..3 - Level 3 (or higher) maintenance Maintenance at this level requires specific skills / qualifications / tools and expertise. Only the manufacturer, his representative or authorised agent are permitted to carry out this work. These maintenance operations include; Major component replacement (compressor, evaporator) Any intervention in the refrigerant circuit (refrigerant handling) Modification of factory-set parameters (change in application) Removal or dismantling Any intervention covered by warranty. To reduce waste, the refrigerant and the oil must be transferred in accordance with applicable regulations, using methods that limit refrigerant leaks and pressure drops and with materials that are suitable for the products. Any detected leaks must be repaired immediately. The compressor oil that is recovered during maintenance contains refrigerant and must be treated accordingly. Refrigerant under pressure must not be vented to the open air. If a refrigerant circuit is opened for a period of up to one day cap all openings. If the circuit is opened for more than one day, charge with oxygen free nitrogen..4 - Tightening torques for the main electrical connections Component Designation in the unit Value (N.m) Welded screw PE, customer connection (earth connection) - 40 Screw terminal, fuse holder FU, FU2, FU3, FU4 0 Screw terminal, fuse holder FU00 0,8-,2 Screw terminal, compressor contactor KM>KM2 3-4,5 Brass screw M6, compressor ground EC- 5 M6 screw, compressor connection EC- 5 Screw terminal, circuit breakers QM- 2 Screw terminal, pump contactor KM90 - KM90A 2,5 M8 screw customer connection (size ) QS00 5 à 22 M0 screw customer connection (size ) QS00 30 à 44 M2 screw customer connection (size ) QS00 50 à 75 Screw terminal, circuit breakers(taille ) QF00 3,2-3,7 Screw terminal, circuit breakers (taille ) QF Screw terminal, fuse holder 32A (opt23) Fu- 2,5 Screw terminal, fuse holder 00A (opt23) Fu- 3, Tightening torques for the main bolts and screws Screw type Use Value (N.m) Metal screw D=4,8 Condensing module, Casing, Supports 4.2 Taptite screw M0 Condensing module, chassis-structure, control 30 box fixing, plate heat exchanger and pump module. Taptite screw M6 Pipe supports, enclosure, variable frequency drive 7 supports Oil equalisation Oil equalisation line 45 screw Screw H M6 Pipe clip 0 Nut H M0 Compressor chassis, Compressor fixing Condenser coil We recommend that microchannel coils are inspected regularly to check the degree of fouling. This depends on the environment where the unit is installed, and will be worse in urban and industrial sites and near trees that shed their leaves. Recommendations for maintenance and cleaning of MCHE (microchannel) condenser coils: Regularly cleaning the coil surface is essential for correct unit operation. Eliminating contamination and removal of harmful residue will increase the operating life of the coils and the unit. The maintenance and cleaning procedures below are part of the regular maintenance to increase the operating life of coils. Specific recommendation in case of snow: For long term storage, regularly check that no snow has accumulated on the unit coils. Products qualified as suitable for cleaning untreated MCHE coils are available from the Carrier spare parts network. After cleaning, rinsing of the coil is mandatory (see Carrier standard RW025). The use of any other cleaning product is strictly prohibited. Remove all foreign objects or fragments/debris attached to the coil surface or wedged between the chassis and the supports. Use a low-pressure dry air jet to remove all traces of dust from the coil. 52

53 Use appropriate PPE including safety glasses / mask, waterproof clothes and safety gloves. It is recommended to wear clothing that covers the whole body. WARNING: Never use a pressure water spray without a large diffuser. Concentrated and/or rotating water jets are strictly forbidden. Never use a fluid with a temperature above 45 C to clean the air heat exchangers. Correct and frequent cleaning (approximately every three months) will prevent 2/3 of the corrosion problems. Protect the control box during cleaning operations..7 - Evaporator maintenance Check that: Insulation is intact and securely in place. The cooler heaters are operating, secure and correctly positioned. The water-side connections are clean and show no sign of leakage. The period inspections required by the local regulations have been carried out..8 - Variable frequency drive maintenance CAUTION: Before any work on the variable frequency drive ensure that the circuit is isolated and there is no voltage present. Note that it may take 5 minutes for the circuit capacitors to fully discharge after isolating the circuit. Only appropriately qualified personnel are authorised to work on the variable frequency drive. In case of any alarm or persistent problem related to the variable frequency drive, contact Carrier Service. The variable frequency drives fitted with 30RBM/30RBP units do not require an insulation test, even if being replaced; they are systematically verified before delivery. Moreover, the filtering components installed in the variable frequency drive can falsify the measurement and may even be damaged. If there is a need to test the insulation of the unit components (fan motors and pumps, cables, etc.), the variable frequency drive must be disconnected at the power circuit..9 - Characteristics of R-40A See the table below. Saturated temperatures based on the gauge pressure (in kpag) Saturated Temp. C Gauge pressure, kpag Saturated Temp. C Gauge pressure, kpag Saturated Temp. C Gauge pressure, kpag RBM/30RBP units use high-pressure R-40A refrigerant (the unit operating pressure is above 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.)..0 - Check of power factor correction capacitors The verification consists in measuring input current of each capacitor bank. Check shall be done using a true RMS meter reading: Check per phase current delivered by each capacitor and compare it to nominal values (in case of capacitance losses or unbalance, capacitors have to be replaced.) Ensure that the current throught the capacitor doesn t exceed.3xir. A higher value may indicate heavy presence of harmonics, that will impact the lifetime of the capacitor. Absence of current despite capacitor is energized is an indication that there is a defect. Confirmation shall be done by removing the capacitors and checking the underside Defect Good 53