Product Data. Features/Benefits. 30GTN Packaged Air-Cooled Reciprocating Chillers 50/60 Hz

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1 Product Data 30GTN Packaged Air-Cooled Reciprocating Chillers 50/60 Hz 60 Hz 15 to 35 Nominal Tons (53 to 13 Nominal ) 50 Hz 15 to 30 Nominal Tons (53 to 106 Nominal ) MODEL 30GTN ( Shown) Features/Benefits Simple and easy to use ComfortLink communicating controls Wide operating envelope from 8 to 5 C ( 0 to 15 F). Accurate temperature control with return fluid compensation. Value added features built-in; dual chiller control, reset from return. Precise multiple-step capacity. ComfortLink control Your link to a world of simple and easy to use air-cooled chillers that offer outstanding performance and value. The 30GTN liquid chillers employ more than the latest advanced microprocessor controls, they utilize an expandable platform that grows as your needs change. From stand-alone operation to remotely monitored and operated multi-chiller plants, ComfortLink controls can keep you plugged in. ComfortLink controls are fully communicating, and are cable ready for connection to a Carrier Comfort Network (CCN). Occupancy scheduling, temperature and pressure read-outs, and the ComfortLink scrolling marquee clear language display complement the standard features, linking you to a world of carefree comfort. The 30GTN chillers are built on the legendary performance of the Carrier model 30G Flotronic chiller and share many of the same time-proven features and technologies providing easy operation, quick installation, and start-ups that save you money! Superior temperature control equals potential for greater productivity Whether in the classroom, on the production floor, or in the office, ComfortLink controls can help you to adapt to changing weather and Copyright 1999 Carrier Corporation Form 30GTN-PD

2 business conditions. Accurate temperature control provided by the Carrier ComfortLink system helps to maintain higher levels of indoor air quality, thermal comfort, and productivity space. While many air-cooled chillers use only leaving fluid temperature control, the 30GTN chillers utilize leaving fluid temperature control with a standard entering fluid temperature compensation. This Carrier exclusive provides smart control and intelligent machine capacity staging. Unlike many chillers, Carrier model 30GTN chillers do not require constant fluid flow. The ability to operate with variable flow also allows building owners to realize even greater overall system energy savings of up to 85% in the chilled water pumping system, and not just at the chiller. Energy management made easy While 30GTN chillers have many standard features such as network communications capability and temperature reset based on return fluid temperature, they can also expand as needs change. Supply temperature reset based on outside air or space temperature is as easy as adding a thermistor. The Energy Management option can allow you to take advantage of changing utility rate structures with easy-to-use load shedding, demand limiting, and temperature reset capabilities. Reset triggered via 4 to 0 ma signal makes integrating from an existing building management system simple. The Energy Management option can be factory-supplied or can be added in the field at a later date as needs change. Full and part load efficiency advantage The 30GTN chillers with ComfortLink control offer outstanding efficiencies (EER [Energy Efficiency Ratio], COP [coefficient of performance], and IPLV [integrated part load value]) in both full (up to 9.9 EER) and part load operation (IPLVs up to 1.9). Increased part load efficiency is provided by dual independent refrigeration circuits, suction cut-off unloading, and return fluid temperature compensation. The fully integrated ComfortLink control system maintains efficient control over the compressors, unloaders, and condenser fans to optimize performance as conditions change. Building design flexibility Design and consulting engineers will appreciate the broad selection of sizes and wide operating range offered by the 30GTN chillers. With built-in dual chiller control, imaginative large tonnage systems can be easily engineered and controlled with smaller, easier to handle modules. Modular design allows engineers to consider side-by-side, offset, or angled placement to fit the awkward spaces that architects sometimes leave for mechanical systems. Or, in the case of planned expansion, additional cooling can be brought on-line and controlled from the same system. With the range of 4 (50 Hz) or 5 (60 Hz) popular sizes from 53 to 106 for 50 Hz (15 to 30 tons) or 15 to 35 tons for 60 Hz (53 to 13 ), there is a size for virtually every commercial building need. There is a complete line of factory-installed options and field-installed accessories that permits unit tailoring to a variety of job specifications and requirements. Copper fin/copper tube condenser coils are also available as standard production items. Model 30GTN is made to order for both new and retrofit applications. Operating reliability features Quality features include proven semihermetic 06D (60 Hz only) and 06E compressors. Fan motors are directdrive propeller type. Condenser coil is horizontal design which helps to prevent damage to fins during transit and handling. Year-round dependability is also assured by the control system which prevents rapid cycling of Table of contents compressor, high- and low-pressure switches, thermostatically controlled cooler heating cable, control relays, calibrated magnetic trip circuit breakers, and crankcase heater. Reliability is enhanced by the reduced refrigerant charge. The condenser is constructed of aluminum, or copper fins mechanically bonded to seamless copper tubes. The Carrier McMinnville, Tennessee (U.S.A.) plant is an ISO 900/BS 5750 part registered facility, as are many of Carrier s other component and assembly plants throughout the world. Easier installation and rigging The smaller and lighter packaging saves even more dollars for the building owner. The units are shipped jobready, and arrive at the jobsite factory assembled and tested, with a full R- operating charge. A 3 to 3% lower profile due to the compact, streamlined design helps eliminate many architectural problems. Horizontally positioned condenser eliminates need for lowambient wind baffles or hail guards. Vibration isolation is factory installed. Just a simple hookup to power and water lines (both are located on the same side of the unit) completes the installation procedure in a cost-saving minimum amount of time. The 60 Hz (08/30, 460, 575-v units are UL (Underwriters Laboratories U.S.A.) and CSA (Canadian Standards Association) approved, making electrical inspections more convenient. Page Features/Benefits Model Number Nomenclature Physical Data Factory-Installed Options Field-Installed Accessories Base Unit Dimensions Application Data Selection Procedure Performance Data Electrical Data Controls Typical Wiring Schematic Typical Piping and Wiring Guide Specifications

3 Features/Benefits (cont) 06E SEMI-HERMETIC COMPRESSOR LEAVING FLUID TEMPERATURE 44.1 F MODE Run Status Service Test Temperature Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Alarm Status ESCAPE ENTER AVAILABLE SCROLLING MARQUEE CLEAR LANGUAGE DISPLAY 3

4 Model number nomenclature LEGEND Al Aluminum Cu Copper 4

5 Physical data 60 Hz COMPRESSOR Weight, lb (kg) No....Type No. Cyl (ea)...speed, Rpm (r/s) Capacity Steps Minimum Capacity Step % UNIT 30GTN * Uses hot gas bypass at capacities less than 50%. Physical data 50 Hz * Uses hot gas bypass at capacities less than 50% (744) DG (9) (86) E (9) 50* Reciprocating, Semi-Hermetic 170 (984) E (9) (109) E (9) (1345) E (9) 3 33 REFRIGERANT CHARGE R- Total lb (kg) 5.0 (11.3) 31.0 (14.1) 43.0 (19.5) 47.0 (1.3) 57.0 (5.9) CONDENSER FANS, Type Fan Speed, Rpm (r/s) No. Blades...Diameter, in. (mm) No. Fans...Total Total Airflow, Cfm (L/s) CONDENSER COIL, Type Tubes, Copper, in. (mm) Rows...Fins/in. (Fin Spacing mm) Total Face Area, sq ft (m ) Max. Working Pressure Refrigerant, psig (kpa) Net Water Volume, gal. (L) Max. Design Working Pressure, psig (kpa) WATER CONNECTIONS, in. Inlet and Outlet Drain COMPRESSOR Weight, lb (kg) No....Type No. Cyl (ea)...speed, Rpm (r/s) Capacity Steps Minimum Capacity Step % ,600 (5000)...19 (1.34) 3.5 (.18) ,600 (5000) (1.49) 3.5 (.18) Propeller, Direct Driven 1140 (19) (76) ,700 (7400) Horizontal Plate Fin 3 / 8 (9.5) O.D (1.34) 39. (3.64) 450 (3103) ,700 (7400) (1.49) 39. (3.64) ,700 (11,00) (1.49) 58.4 (5.43) Shell-and-Tube, Direct Expansion 6.8 (5.7) 6.8 (5.7) 9.9 (37.5) 9.9 (37.5) 1.8 (48.4) Refrigerant Side 35 (160) Water Side 150 (1034) FPT 3 /4 MPT UNIT 30GTN 1741 (790) E (4.) 50* Reciprocating, Semi-Hermetic 1864 (846) E (4.) (995) E (4.) / FPT 3/ 4 MPT 33 (1058) E (4.) 3 33 REFRIGERANT CHARGE R- Total lb (kg) 6.0 (11.8) 35.0 (15.9) 40.0 (18.1) 49.0 (.) CONDENSER FANS, Type Fan Speed, Rpm (r/s) No. Blades...Diameter, in. (mm) No. Fans...Total Total Airflow, Cfm (L/s) CONDENSER COIL, Type Tubes, Copper, in. (mm) Rows...Fins/in. (Fin Spacing mm) Total Face Area, sq ft (m ) Max. Working Pressure Refrigerant, psig (kpa) Net Water Volume, gal. (L) Max. Design Working Pressure, psig (kpa) WATER CONNECTIONS, in. Inlet and Outlet Drain Propeller, Direct Driven 950 (15.8) (76) ,600 (5000) 10,600 (5000) 15,700 (7400) 15,700 (7400) Horizontal Plate Fin 3 / 8 (9.5) O.D (1.34) 3.5 (.18) (1.49) 3.5 (.18) 450 (3103)...19 (1.34) 39. (3.64) (1.49) 39. (3.64) Shell-and-Tube, Direct Expansion 6.8 (5.7) 6.8 (5.7) 9.9 (37.5) 9.9 (37.5) Refrigerant Side 35 (160) Water Side 150 (1034) FPT 3 /4 MPT 5

6 Factory-installed options Medium temperature brine option may be factory installed. The brine option permits unit operation from 15 to 37.9 F ( 9.4 to 3.3 C) leaving brine temperature. The refrigeration circuit components, such as the expansion device and low-pressure safety switch, are modified to permit the low refrigerant flow rates typical of brine duty operation. NOTE: When the medium temperature brine option is selected, it includes the Motormaster head pressure control device (all units except 575 v), which will be installed at the factory. Scrolling Marquee display gives clear language displays in English, Spanish, French, and Portuguese. Scrolls to allow access to chiller operating parameters (operating status, temperatures, and pressures). Scrolling Marquee option is generally recommended where time scheduling, temperature reset and EMM options are to be applied. SCROLLING MARQUEE DISPLAY Alternate condenser coil options are available from the factory and prolong the life of the condenser coil in applications noted in table below. Energy Management Module (EMM) is used for 4 to 0 ma leaving fluid temperature reset, cooling set point reset, 4 to 0 ma demand limit, and two-step demand limit. Temperature reset lets the unit reset the leaving fluid temperature to a higher temperature during low load conditions. Temperature reset can also be accomplished based on return fluid, outdoor air or space temperature. (The EMM option is not required when using enteringwater, outdoor-air, or space temperature for temperature reset. These types of reset are available with the main board. However, an accessory thermistor is required for outdoor air and/or space temperature reset.) Demand limiting allows the unit capacity to be limited during periods of peak energy usage. Demand limit requires an external 4 to 0 ma signal or a -step remote pair of dry contacts. Both the 4 to 0 ma and -step demand limit percentage values are adjustable. This is also available as a field-installed accessory. MODE Run Status Service Test Temperature Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Alarm Status ESCAPE ENTER COPPER-TUBE COILS WITH ENVIRO-SHIELD OPTIONS* CONDENSER COIL OPTION RECOMMENDATIONS ENVIRONMENT Standard Mild Coastal Severe Coastal Industrial Combined Industrial/Coastal AL Fins (Standard Coils) X CU Fins X AL Fins, E-coating X CU Fins, E-coating X X AL Fins, Pre-Coated X LEGEND AL Aluminum CU Copper * See page 16 for further details. 6

7 Field-installed accessories Motormaster head pressure control package allows unit operation to 0 F ( 9 C) ambient temperature by modulating condenser-fan motor speed in response to refrigerant condensing temperature. Chilled water flow switch prevents unit operation if chilled water flow stops. Compressor oil safety switch package provides protection against loss of oil pressure. One required for each compressor. Gage panel package provides a suction and a discharge pressure gage foreach refrigerant circuit. Energy Management Module (EMM) is used for 4 to 0 ma leaving fluid temperature reset, cooling set point reset, 4 to 0 ma demand limit, and two-step demand limit. Temperature reset lets the unit reset the leaving fluid temperature to a higher temperature during low load conditions. Temperature reset can also be accomplished based on return fluid, outdoor air, or space temperature. (The EMM option is not required when using entering-water, outdoor-air, or space temperature for temperature reset. These types of reset are available with the main board. However, an accessory thermistor is required for outdoor air and/or space temperature reset.) Demand limiting allows the unit capacity to be limited during periods of peak energy usage. Demand limit requires an external 4 to 0 ma signal or a -step remote pair of dry contacts. Both the 4 to 0 ma and -step demand limit percentage values are adjustable. This is also available as a factory-installed option. Hot gas bypass valve allows hot gas to pass directly into cooler circuit as an additional step of unloading, maintains constant suction pressure, and permits unit to operate at lower loads with less compressor cycling (standard on, 60 Hz and, 50 Hz). Control transformer provides control power where other source is not available. Part wind start reduces instantaneous current flow (ICF) and locked rotor amps on start-up. Contact your local Carrier representative for more information. Thermistor accessory is available for field installation (all sizes). Chillervisor System Manager III control can be used to regulate up to 8 30GTN chillers. Current ground fault sensor monitors all phases of the 3-phase power supply to the compressor. At the first sign of a short to ground, the sensor shuts down the compressor. 7

8 Base unit dimensions 30GTN, NOTES: 1. There must be a minimum 8 ft (440 mm) clear air space above unit.. Dimensions in [ ] are in millimeters. 3. The approximate operating weight of the unit is: UNIT 60 Hz 50 Hz 30GTN lb kg lb kg C C UNIT 30GTN A C [119] 4-0 [107] / COMPR MTG NEC VAV LEGEND Copper Coils Compressor Mounting National Electrical Code (U.S.A.) Variable-Air Volume 8

9 Base unit dimensions 30GTN, NOTES: 1. There must be a minimum 8 ft (440 mm) clear air space above unit.. Dimensions in [ ] are in millimeters. 3. The approximate operating weight of the unit is: UNIT 60 Hz 50 Hz 30GTN lb kg lb kg C C LEGEND C Copper Coils COMPR Compressor MTG Mounting NEC National Electrical Code (U.S.A.) VAV Variable-Air Volume 9

10 Base unit dimensions 30GTN (60 Hz only) NOTES: 1. There must be a minimum 8 ft (440 m) clear air space above unit.. Dimensions in [ ] are in millimeters. 3. The approximate operating weight of the unit is: 60 Hz Unit 30GTN lb kg C C COMPR MTG NEC LEGEND Copper Coils Compressor Mounting National Electrical Code (U.S.A.) 10

11 Application data Leveling unit Unit must be level within 1 / 8 in. per ft when installed to ensure proper oil return to the compressor. While most outdoor locations are suitable for 30GTN units, the roof is a common site that represents a problem if roof has been pitched to aid in water removal. To assure proper oil return, be sure that unit is level, particularly in its major lengthwise dimension, as compressor oil return piping runs in that direction. It should be determined prior to installation if any special treatment is required to assure a level installation. General electrical information 1. It is recommended that the , , and control circuit power be from a separate source, through a field-supplied fused disconnect rated at a maximum of 7 amps.. Power entry is at one end only. 3. Maximum field wire sizes allowed by lugs on terminal block are: 350 kcmil for models 30GTN, (08/ ). /0 for all other models. 4. Terminals for field power supply are suitable for copper, copper-clad aluminum, or aluminum conductors. Insulation must be rated 167 F (75 C) minimum. Cooler temperature 1. Maximum leaving chilled water temperature (LCWT) for standard 30GTN units is 60 F (16 C). Unit can start and pull down with up to 95 F (35 C) enteringwater temperature due to MOP (maximum operating pressure) feature of the expansion valve. For sustained operation, it is recommended that entering water temperature not exceed 85 F (9.4 C).. Minimum LCWT for standard 30GT units is 38 F (3.3 C). 3. Special order medium temperature brine units must be ordered for operation with leaving water temperatures in the range of 37.9 F (3.3 C) to 15 F ( 9 C). For ratings below 38 F (3.3 C) LCWT, contact your local Carrier representative. Medium temperature brine application Application of chiller for brine duty within the 37.9 to 15 F (3.3 to 9.4 C) range is possible by ordering the proper factory-installed brine option. For ratings below 38 F (3.3 C) LCWT, contact your local Carrier representative. Leaving-fluid temperature reset The Energy Management Module (EMM) is required for 4 to 0 ma reset of LCWT in constant fluid systems. Reset by return fluid, outdoor-air temperature, or space temperature does not require this option. Reset reduces compressor power usage at part load when design LCWT is not necessary. Humidity control should be considered since higher coil temperatures resulting from reset will reduce latent heat capacity. Three reset options are offered, based on the following: Return-fluid temperature Increase LCWT temperature set point as return (or entering) fluid temperature decreases (indicating load decrease). Option may be used in any application where return fluid provides accurate load indication. Limitation of return fluid reset is that LCWT may only be reset to value of design return fluid temperature. Outdoor-air temperature Increases LCWT as outdoor ambient temperature decreases (indicating load decrease). This reset should be applied only where outdoor ambient temperature is an accurate indication of load. An accessory thermistor is required. Space temperature Increases LCWT as space temperature decreases (indicating load decrease). This reset should be applied only where space temperature is an accurate indication of load. An accessory thermistor is required. Cooler flow range Ratings and performance data in this publication are for a cooling range of 10 F (5.6 C). 30GTN chillers may be operated at a 5 to 15 F (.8 to 8.3 C) temperature range provided flow limits are not exceeded. For minimum flow rates, see Minimum/Maximum Cooler Flow Rates and Minimum Loop Volume table on page 1. If outside this range, a change of controls is required. Variable cooler flow rates may be applied to standard 30GTN chillers. However, the unit will attempt to maintain a constant leaving chilled-water temperature. In such cases, minimum flow must be in excess of minimum flow given in Minimum Cooler and Condenser Water Flow Rates and Minimum Loop Volume table, and flow rate must change in steps of less than 10% per minute. Apply 6 gal. per ton (6.5 L per ) water loop volume minimum if flow rate changes more rapidly. NOTE: Always set variation (deadband) to cover the range for the worst possible case. Minimum cooler flow (maximum cooler temperature range) for standard units is shown in Minimum/Maximum Cooler Flow Rates and Minimum Loop Volume table on page 1. When gpm (L/s) required is lower (or range higher), follow recommendations below: 1. Multiple smaller chillers may be applied in series, each providing a portion of the design temperature range.. Cooler water may be recirculated to raise flow rate. However, mixed temperature entering cooler must be maintained at a minimum of 6 F (3.3 C) above the leaving chilled-water temperature. 3. Special cooler baffling is required to allow minimum flow rate to be reduced 1%. NOTE: Recirculation flow is shown below. RECIRCULATION 11

12 Application data (cont) Maximum cooler flow (> 5 gpm/ton or < 5 F range [> 0.09 L/s or <.7 C range]) results in practical maximum pressure drop through cooler. 1. Return water may bypass the cooler to keep pressure drop through cooler within acceptable limits. This permits a higher T with lower water flow through cooler and mixing after the cooler.. Special cooler baffling is available by special order to permit a cooler flow rate increase of 10%. NOTE: Bypass flow is shown below. BYPASS Minimum/Maximum Cooler Flow Rates and Minimum- Loop Volume table above.) For process jobs where accuracy is vital, there should be from 6 to 10 gallons per ton (6.5 to 10.8 liters per ). To achieve this volume, it is often necessary to install a tank in the loop. Tank should be baffled to ensure there is no stratification and that water (or brine) entering tank is thoroughly mixed with liquid in tank. Refer to ASHRAE (American Society of Heating, Refrigeration and Air Conditioning Engineers, U.S.A.) guides or similar publication for information on storage tank design. NOTE: Tank installation is shown below. TANK INSTALLATION UNIT 30GTN ARI N V MINIMUM/MAXIMUM S AND RECOMMENDED MINIMUM LOOP VOLUME MINIMUM MAXIMUM RECOMMENDED MINIMUM LOOP VOLUME Gpm L/s Gpm L/s G L LEGEND NOTES: 1. Operation below recommended minimum loop volumes will reduce accuracy of loop temperature control.. Minimum flow based on 1.5 fps (0.46 m/s) velocity in cooler without special cooler baffling. 3. Minimum Loop Volumes Gallons = V x ARI Cap. (tons) Liters = N x ARI Cap. () Water loop volume should range from 3 to 6 gallons per nominal ton of cooling (3.5 to 6.5 liters per ) for temperature stability and accuracy in normal air conditioning applications. (For example, a 30GTN would require 75 gallons (85 liters) in circulation in system loop see Air Conditioning and Refrigeration Institute (U.S.A.) Liters per Gallons per Ton Normal Air Conditioning Process Type Cooling Low Ambient Unit Operation APPLICATION V N 3 to 6 6 to 10 6 to to to to 10.8 Cooler fouling factor used to calculate tabulated ratings was ft hr F/Btu ( m K/W). As fouling factor is increased, both unit capacity and compressor power decrease. Standard ratings should be corrected using following multipliers: FOULING FACTOR CORRECTION FOULING FACTOR English (ft hr ºF/Btu) SI (m K/W) CAPACITY MULTIPLIER Condenser altitude correction factors must be applied to standard ratings of altitudes above 000 ft (610 m) using following multipliers. ALTITUDE CORRECTION FACTORS ALTITUDE English (ft) 0,000 4,000 6,000 8,000 10,000 SI (m) CAPACITY MULTIPLIER COMPRESSOR POWER MULTIPLIER COMPRESSOR POWER MULTIPLIER

13 Condenser airflow restrictions will affect the unit capacity condenser head pressure and compressor power input. Correction factors to be applied for external static restrictions up to 0. in. wg (50 Pa) are shown below. AIR CORRECTION FACTORS EXTERNAL STATIC COMPRESSOR CAPACITY English SI POWER MULTIPLIER (in. wg) (Pa) MULTIPLIER Draining the cooler and outdoor piping is recommended if system is not to be used during freezing weather conditions. In areas that experience subfreezing weather conditions, a suitable brine solution should be added to the system to protect cooler against loss of power. Use only antifreeze solutions approved for heat exchanger duty. Use of automotive antifreeze is not recommended because of fouling that can occur once their relatively short-lived inhibitor breaks down. Low ambient operation Standard 30GTN chillers start and operate at 35 F ( C) and above at loads above of the minimum chiller capacity step. 1. Cooler protection against low ambient freeze-up is required for unit operation in areas that experience temperatures below 3 F (0 ºC). Protection should be in the form of ethylene glycol or other suitable brine, and should protect down to 15 F (8 C) below minimum operating ambient temperature. Even though unit cooler is equipped with insulation and an electric heater that helps prevent freeze-up, it does not protect water piping external to unit. Use only antifreeze solutions approved for heat exchanger duty. Use of automotive type antifreezes is not recommended because of the fouling that can occur once their relatively short-lived inhibitor breaks down. Draining cooler and outdoor piping is recommended if system is not to be used during freezing weather conditions.. Motormaster head pressure control and its associated components must be added for operation below 35 F ( C) outdoor ambient. (Wind baffles and special winter start controls are not normally needed.) 3. Provide sufficient volume in the chilled-water loop: at least 6 gallons per ton of refrigeration (6.5 liters per ), provided there is a moderate system load. Operation at low outdoor ambient temperatures is not recommended if minimum load on chiller is below minimum step of unloading. Consult your local Carrier representative for complete details. Cooler protection in form of inhibited ethylene glycol (or other suitable brine) is recommended when operating inareas which experience temperatures below 35 F ( C) to protect cooler should there be a loss of cooler heater power. Even though unit cooler is protected with insulation and an electric heater that protects the cooler down to 10 F ( 1 C), it does not protect water piping external to unit. Use only antifreeze solution approved for heat exchanger duty. Use of automotive type antifreeze is not recommended because of the fouling that can occur once their relatively short-lived inhibitor breaks down. Draining cooler and outdoor piping is recommended if system is not to be used during freezing weather conditions. See section below for low-ambient operation. High-ambient temperature operation limit for standard chillers is up to 15 F (5 C) outdoor ambient temperature. Capacity correction (antifreeze) If unit or water lines connected to the unit are in an area where ambient temperature falls below 35 F ( C), it is strongly recommended that an appropriate antifreeze solution with suitable corrosion inhibitor be used in the chilled water circuit. Unit performance data must be corrected as shown in the following examples: Example English I Determine concentration of inhibited ethylene glycol (EG) solution required to protect system to 10 F (at zero flow). Given: Unit GTN Condenser Entering-Air Temperature F Leaving Chilled Water Temperature F Chilled Water Temperature Rise F Chilled Water Flow Gpm Cooler Pressure Drop ft water Capacity tons Power Input From curve on page 14, read 40% concentration at 10 F solution crystallization point. II Correct unit capacity. From curve on page 14, read 0.95 capacity correction at 40% concentration. Corrected capacity = 0.95 x Given Capacity = 0.95 x 7.1 = 5.8 tons III Correct chilled water flow. From curve on page 14, read 1.15 Gpm correction at 40% concentration. Chilled Water Flow (at corrected capacity) = Tons x 4 = 5.8 x 4 = 61.8 Gpm Rise º F 10 Chilled Water Flow (40% solution) = Water = 1.15 = 61.8 x 1.15 Flow = 71.1 Gpm IV Correct cooler pressure drop. From curve on page 14, read 1.33 cooler pressure drop correction at 40% concentration. From Cooler Pressure Drop curve on page 16, pressure drop for 71.1 Gpm of water is 10.0 ft water. Pressure drop for 40% solution = 1.33 x pressure drop for water = 1.33 x 10.0 = 13.3 ft water. 13

14 Application data (cont) V Correct compressor power input. On Power Correction curve below, read 0.97 correction factor at 40% concentration. Corrected Power Input = 0.97 x 30.6 = 9.7 Example SI I Determine concentration of inhibited ethylene glycol (EG) solution required to protect system to 3 C (at zero flow). Given: Unit GTN Condenser Entering-Air Temperature C Leaving Chilled Water Temperature C Chilled Water Temperature Rise C Chilled Water Flow L/s Cooler Pressure Drop kpa Capacity Power Input From curve on this page, read 40% concentration at 3 C solution crystallization point. II Correct unit capacity. From curve below, read 0.95 capacity correction at 40% concentration. Corrected capacity = 0.95 x Given Capacity = 0.95 x 96.5 = 91.7 III Correct chilled water flow. From curve below, read 1.15 Gpm correction at 40% concentration. INHIBITED ETHYLENE GLYCOL PERFORMANCE CORRECTION FACTORS AND SOLUTION CRYSTALLIZATION POINTS Chilled Water Flow (at corrected capacity) = Capacity () = 91.7 = 3.9 L/s 4. x Rise º C 4. x 5.6 Chilled Water Flow (40% solution) = Water x 1.15 = 3.9 x 1.15 Flow = 4.48 L/s IV Correct cooler pressure drop. From curve below, read 1.33 cooler pressure drop correction at 40% concentration. From Cooler Pressure Drop curve on page 16, pressure drop for 4.48 L/s of water is 30 kpa. Pressure drop for 40% solution = 1.33 x pressure drop for water = 1.33 x 34.5 = 45.9 kpa. V Correct compressor power input. On Power Correction curve below, read 0.97 correction factor at 40% concentration. Corrected Power Input = 0.97 x 30.9 = 30.0 Oversizing chillers Do not oversize chillers by more than 15% at design conditions as the system operating efficiency will be adversely affected (resulting in greater or excessive electrical demand). When future expansion of equipment is anticipated, install a single chiller to meet present load requirements and add a second chiller to meet the additional load demand. Installation of smaller chillers should also be considered where operation at minimum load is critical. The operation of a smaller chiller loaded to a greater percent of minimum is preferred to operating a single chiller at or near its minimum recommended value. Hot gas bypass should not be used to allow oversizing of chillers. Hot gas bypass should be given consideration where substantial operating time is anticipated below the minimum unloading step. Multiple chillers Where chiller capacities greater than 30 tons (106 ) are required, or where stand-by capability is desired, chillersmay be installed in parallel. Units should be of equal size to ensure balanced water flows. Where a large temperature drop (> 5 F [13.9 C]) is desired, chillers may be installed in series. Water temperature sensors need not be removed for multiple chiller operation. An additional temperature sensor (dual chiller leaving fluid temperature) must be installed and connected to the master chiller. An 8 ft (.4 m) separation is required between units for airflow, and a 4 ft (1. m ) distance is required from units to obstructions. See Multiple Unit Separation figure below. See dimensional drawings for service clearances. MULTIPLE UNIT SEPARATION 14

15 Electrical/utility interests Energy management Use of energy management practices can significantly reduce operating costs, especially during off-peak modes of operation. Demand limiting and temperature reset are techniques for accomplishing efficient energy management. See Demand Limiting (also called load shedding) section below and Leaving-Fluid Temperature Reset section on page 11 for further details. Demand limiting (also called load shedding) When a utility s demand for electricity exceeds a certain level, loads are shed to keep electricity demand below a prescribed maximum level. Typically, this happens on hot days when air conditioning is most needed. The Energy Management Module (EMM) can be added to accomplish this reduction. Demand may be limited on unit by resetting fluid temperature, or by unloading the chiller to a given predetermined percentage of the load. Demand limit may also be driven by an external 4 to 0 ma signal. These features require a signal from an intelligent central control. Do not cycle demand limiter for less than 10 minutes on and 5 minutes off. Duty cycling cycles electrical loads at regular intervals regardless of need. This reduces the electrical operating costs of building by fooling demand indicating devices. Duty cycling of compressors or fans is not recommended since motor winding and bearing life suffer from constant cycling. Remote on-off control Remote on-off control may be applied by hard-wired connection (see Controls and Troubleshooting literature) or by connection to a Carrier Comfort Network (CCN). Part-wind start This is not generally required on 30GTN chillers due to use of multiple compressors allowing smaller electrical load increments, but is available if required. Maximum instantaneous current flow (see ICF in Electrical Data table on page ) should be used in determining need. Strainers It is recommended that a strainer with a minimum of 0 mesh be installed in the cooler fluid inlet line, just ahead of and as close as possible to the cooler. Condenser coil protection (Enviro-Shield ) Pre-coated aluminum-fin coils have a durable epoxyphenolic coating applied to the fin prior to the fin stamping process to provide protection in mildly corrosive coastal environments. Pre-coated coils have an inert barrier between the aluminum fin and copper tube. This barrier electrically disconnects the dissimilar metals to minimize the potential for galvanic corrosion. This economical option provides substantial corrosion protection beyond the standard uncoated coil construction. Copper-fin coils provide increased corrosion resistance in moderate coastal environments where industrial air pollution is not present. All copper coils eliminate bi-metallic construction to eliminate the potential for galvanic corrosion. Application in industrial environments is not recommended due to potential attack from sulfur, sulfur oxide, nitrogen oxides, carbon and several other industrial airborne contaminants. In moderate seacoast environments, copper-fin coils have extended life compared to standard or pre-coated aluminum-fin coils. E-Coated aluminum-fin coils have an extremely flexible and durable epoxy coating uniformly applied to all surfaces. Unlike brittle phenolic dip and bake coatings. E-Coat provides superior protection with unmatched flexibility, edge coverage, metal adhesion, thermal performance, and most importantly, corrosion resistance. E-Coated coils provide this protection since all coil surfaces are completely encapsulated from environmental contamination. Specify E- Coated aluminum-fin coils for industrial environments with high levels of air pollution. This option also provides better protection compared to standard or pre-coated aluminumfin coils in industrial environments. E-Coated copper-fin coils have the same flexible and durable epoxy coating as E-Coated aluminum-fin coils. However, this option combines the natural salt and environmental resistance of all-copper construction with the highest level of corrosion protection. Specify E-Coated copper-fin coils in the harshest combination of coastal and industrial environments. 15

16 Selection procedure (with example) English (60 Hz) I II Determine job requirements. Given: Cooling Load Tons Leaving Chilled Water Temperature (LCWT) F Chilled Water Temperature Rise F Fouling Factor (Cooler) Condenser Entering-Air Temperature F NOTE: For other than 10 F temperature rise, data corrections must be made; also, on some units a change of controls is necessary. Refer to Application Data section on page 11 for correction procedure and information on controls. Determine capacity, unit size, power input, cooler flow, and pressure drop. Enter Cooling Capacities table on page 18 at 95 F condenser entering-air temperature and 44 F LCWT. Under Cap. heading, 6.8 tons is nearest to and greater than given load (6 tons). Read directly from table: Unit GTN Capacity tons Power Input Cooler Flow Gpm Cooler Pressure Drop (from graph at right) ft water Selection procedure (with example) SI (60 Hz) I II Determine job requirements. Given: Cooling Load Leaving Chilled Water Temperature (LCWT) C Chilled Water Temperature Rise C Fouling Factor (Cooler) Condenser Entering-Air Temperature C NOTE: For other than 5.6 C temperature rise, data corrections must be made; also, on some units a change of controls is necessary. Refer to Application Data section on page 11 for correction procedure and information on controls. Determine capacity, unit size, power input, cooler flow, and pressure drop. Enter Cooling Capacities table on page 19 at 35 C condenser entering-air temperature and 7 C LCWT. Under Cap. heading, 96.9 is nearest to and greater than given load (90 ). Read directly from table: Unit GTN Capacity Power Input Cooler Flow L/s Cooler Pressure Drop (from graph at right) kpa CORRECTION FACTOR, OTHER TEMPERATURE RISES ENGLISH Above 10 F, ADD correction to design LCWT, below 10 F, SUBTRACT TOTAL PRESSURE DROP (WITH NOZZLES) ENGLISH AND SI CORRECTION FACTOR, OTHER TEMPERATURE RISES SI Above 5.6 C, ADD correction to design LCWT, below 5.6 C, SUBTRACT 16

17 Performance data ARI* STANDARD RATINGS 60 Hz UNIT CAPACITY COMPRESSOR WATER FAN POWER 30GTN POWER PRESSURE DROP () Tons () ft water kpa EER COP IPLV ARI* STANDARD RATINGS 50 Hz UNIT CAPACITY COMPRESSOR WATER FAN POWER 30GTN POWER PRESSURE DROP () Tons () ft water kpa EER COP IPLV LEGEND COP Coefficient of Performance (Capacity [] Input Power []) EER Energy Efficiency Ratio (Capacity [Btuh] Input Power [W]) IPLV Integrated Part-Load Value * Air Conditioning and Refrigeration Institute (U.S.A.) NOTES: 1. Rated in accordance with ARI Standard 550/ at standard rating conditions.. Standard rating conditions are as follows: Cooler Conditions Leaving water temperature: 44 F (6.7 C) Entering water temperature: 54 F (1. C) Fouling Factor: ft x hr x F/Btu ( m x K/W) Condenser Conditions: Entering Air Temperature: 95 F (35 C) 3. IPLV is a single number part-load efficiency value calculated from the system full-load efficiency values and corrected for a typical building air-conditioning application. 4. All data in this table is rated in accordance with ARI Standard 550/590 as represented in the Packaged Chiller Selection Program (E-Cat) Version

18 18 COOLING CAPACITIES 60 Hz (ENGLISH) NOTE: Above ratings based on cooler water temperature drop of 10 F, fouling factor in cooler and Refrigerant. Ratings are in accordance with ARI Standard 550/ CONDENSER ENTERING AIR TEMPERATURE (F) LCWT (F) UNIT 30GTN (GPM) (GPM) (GPM) (GPM) (GPM) LEGEND ARI Air Conditioning and Refrigeration Institute (U.S.A.) Cap. Total Capacity (Tons) Compressor Kilowatts LCWT Leaving Chilled Water Temperature (F) Performance data (cont)

19 19 COOLING CAPACITIES 60 Hz (SI) NOTE: Above ratings based on cooler water temperature drop of 5.6 C, fouling factor in cooler and Refrigerant. Ratings are in accordance with ARI Standard 550/ CONDENSER ENTERING AIR TEMPERATURE (C) LCWT (C) UNIT 30GTN (L/s) (L/s) (L/s) (L/s) (L/s) LEGEND ARI Air Conditioning and Refrigeration Institute (U.S.A.) Cap. Total Capacity (Kilowatts) Compressor Kilowatts LCWT Leaving Chilled Water Temperature (C)

20 0 COOLING CAPACITIES 50 Hz (ENGLISH) NOTE: Above ratings based on cooler water temperature drop of 10 F, fouling factor in cooler and Refrigerant. Ratings are in accordance with ARI Standard 550/ CONDENSER ENTERING AIR TEMPERATURE (F) LCWT (F) UNIT 30GTN (GPM) (GPM) (GPM) (GPM) (GPM) LEGEND ARI Air Conditioning and Refrigeration Institute (U.S.A.) Cap. Total Capacity (Tons) Compressor Kilowatts LCWT Leaving Chilled Water Temperature (F) Performance data (cont)

21 1 COOLING CAPACITIES 50 Hz (SI) NOTE: Above ratings based on cooler water temperature drop of 5.6 C, fouling factor in cooler and Refrigerant. Ratings are in accordance with ARI Standard 550/ CONDENSER ENTERING AIR TEMPERATURE (C) LCWT (C) UNIT 30GTN (L/s) (L/s) (L/s) (L/s) (L/s) LEGEND ARI Air Conditioning and Refrigeration Institute (U.S.A.) Cap. Total Capacity (Kilowatts) Compressor Kilowatts LCWT Leaving Chilled Water Temperature (C)

22 Electrical data 0 UNIT 30GTN Voltage-Hz (3 Phase) 08/ / / / / UNIT COMPRESSOR FAN MOTORS CONTROL CIRCUIT Supplied* MCA MOCP (Fuse) ICF RLA LRA Quantity FLA Voltage-Hz Maximum Min Max (ea) (Single-Phase) Fuse Amps LEGEND FLA Full Load Amps ICF Maximum Instantaneous Current Flow during starting (the point in the starting sequence where the sum of the LRA for the starting compressor, plus the total RLA for all running compressors, plus the total FLA for all running fan motors is maximum) LRA Locked Rotor Amps MCA Minimum Circuit Amps (complies with NEC) MOCP Maximum Overcurrent Protection NEC National Electrical Code (U.S.A.) RLA Rated Load Amps * Units are suitable for use on electrical systems where voltage supplied to unit terminals is not below or above listed minimum and maximum limits. NOTE: Refer to Application Data section on page 11 for general electrical information. 08/30, 460, and 575-v, 60-Hz units only

23 Controls Microprocessor The ComfortLink microprocessor controls overall unit operation. Its central executive routine controls a number of processes simultaneously. These include internal timers, reading inputs, analog to digital conversions, fan control, display control, diagnostic control, output relay control, demand limit, capacity control, head pressure control, and temperature reset. Some processes are updated almost continuously, others every to 3 seconds, and some every 30 seconds. The microprocessor routine is started by switching the Emergency ON-OFF circuit breaker switch (switch ) to ON position. When the unit receives a call for cooling (either from the internal control or CCN network command), the unit stages up in capacity to maintain the cooler fluid set point. The first compressor starts 1 to 3 minutes after the call for cooling. The ComfortLink microprocessor controls the capacity of the chiller by unloading compressors at a rate to satisfy actual dynamic load conditions. The control maintains leaving-fluid temperature set point shown on quick set scrolling marquee display board through intelligent cycling of unloaders. Accuracy depends on loop volume, loop flow rate, load, outdoor-air temperature, number of stages, and particular stage being cycled off. No adjustment for cooling range or cooler flow rate is required, because the control automatically compensates for cooling range by measuring both return-fluid temperature and leaving-fluid temperature. This is referred to as leaving-fluid temperature control with return-fluid temperature compensation. The basic logic for determining when to add or remove a stage is a time band integration of deviation from set point plus rate of change of leaving-fluid temperature. When leaving-fluid temperature is close to set point and slowly moving closer, logic prevents addition of another stage. If leaving-fluid temperature is less than 34 F (1.1 C) for water, or 6 F (3.3 C) below the set point for brine units, the unit is shut off until the fluid temperature goes to 34 F (1.1 C) or to 6 F (3.3 C) above the set point to protect against freezing. If 1 F per minute (0.6 C per minute) pulldown control has been selected (factory setting), no additional steps of capacity are added as long as difference between leavingfluid temperature and set point is greater than 4 F (. C) and rate of change in leaving-fluid temperature is less than 1 F per minute (0.6 C per minute). If it has been less than 90 seconds since the last capacity change, compressors will continue to run unless a safety device trips. This prevents rapid cycling and also helps return oil during short on periods. The control also performs other special functions when turning on or off. When a circuit is to be turned off, liquid line solenoid valve (LLSV) is closed first, and compressor is run until conditions are met to terminate pumpout to remove refrigerant that was in the cooler. At start-up, if a circuit has not run in the last 15 minutes, circuit is run to remove any refrigerant that has migrated to the cooler. The oil pressure switch is bypassed for minutes during start-up and for 1 minute during normal operation. Thermistors Three thermistors are used for temperature-sensing inputs to microprocessor. Additional sensors may be used as remote temperature sensors for optional LCWT reset. Cooler leaving chilled fluid temperature (T1) Cooler entering fluid (return) temperature (T) Saturated condensing temperature (T3) Cooler saturation temperature The microprocessor uses these temperatures to control capacity and fan cycling. Control sequence Off cycle During unit off cycle, crankcase heater is energized. If ambient temperature is below 36 F ( C), cooler heaters (if equipped) are also energized. Start-up After control circuit switches on, prestart process takes place, then microprocessor checks itself and waits for temperature to stabilize. The controlled pulldown feature limits compressor loading on start-up to reduce demand on start-up and unnecessary compressor usage. The microprocessor limits supply-fluid temperature decrease (start-up only) to 1 F (0.6 C) per minute. Capacity control On first call for cooling, microprocessor starts initial compressor and fan stage on lead circuit. The LLSV remains closed, permitting a pumpout on start-up. After pumpout, the valves open and, if necessary, additional outdoor fans are energized. Crankcase heaters are deenergized when a compressor is started. As additional cooling is required, unloaders are deenergized. Speed at which capacity is added or reduced is controlled by 1) temperature deviation from set point and ) rate of temperature change of chilled fluid. The Main Base Board (MBB) responds to temperature of supply chilled water to cycle the compressor and to control compressor unloading and loading steps. Solenoid-operated cylinder bank unloaders, energized by the MBB, vary compressor capacity by unloading and loading cylinders to match cooling load requirements. Hot gas bypass valve, standard on 30GTN (50 Hz) and 30GTN (60 Hz), is energized by the MBB. Valve allows hot gas to pass directly into the cooler circuit on the final step of unloading. Hot gas bypass maintains constant suction pressure and permits unit to operate at lower loads with less compressor cycling. Valve starts to open when suction pressure drops to about 6 psig (47 kpa). If chilled water set point is lower or higher than 44 F (6.7 C), decrease or increase the valve setting for proper operation. 3

24 Controls (cont) When no further cooling is called for, LLSV closes and compressor and fans continue to run while pumping down the cooler. CAPACITY CONTROL STEPS UNIT CONTROL % OPERATING Hz 30GTN STEPS CAPACITY CYCLES , 50/60 60 *Uses hot gas bypass. * * Standard Quickset Display Standard control includes a single set point dial and an alarm light. Where time scheduling, temperature reset, and EMM options are to be applied with Quickset, ComfortWORKS software or CCN field service tool are required to configure those options. ALARM STATUS F C 0 SETPOINT 30GTN ComfortLink controls with Scrolling Marquee display module An optional four-digit alphanumeric display shows all of the ComfortLink control codes (with expandable clear language), plus set points, time of day, temperatures, pressures, and superheat. Additional information can be displayed all at once with the accessory Navigator display MODE Run Status Service Test Temperature Pressures Setpoints Inputs Outputs Configuration Time Clock Operating Modes Alarms Alarm Status ESCAPE ENTER Low-temperature override This feature prevents LCWT from overshooting the set point and possibly causing a nuisance trip-out by the freeze protection. High-temperature override This feature allows chiller to add capacity quickly during rapid load variations. Abnormal conditions All control safeties in chiller operate through compressor protection board or control relay and microprocessor. High-pressure switch directly shuts down compressor(s) through compressor protection board or control relay. For other safeties, microprocessor makes appropriate decision to shut down a compressor due to a safety trip or bad sensor reading and displays appropriate failure code on the display. Chiller holds in safety mode until reset. It then reverts to normal control when unit is reset. Oil pressure safety Factory installed on units with brine option. Field-installed accessory available for standard units. This safety switch cuts out if the oil-pressure differential is below minimum. Safety is bypassed for minutes on start-up and must be open for 1 minute during operation thereafter for unit to shut down. Loss-of-charge safety Safety cuts out if system pressure drops below minimum. High-pressure cutout Switch shuts down compressors if compressor discharge pressure increases to 46 psig (937 kpa). Ground current safety Safety opens on sensing a current-to-ground in compressor windings in excess of.5 amps (accessory for all sizes). Compressor anti-cycling This feature limits compressor cycling. Loss of flow protection Additional protection is provided by temperature differences between entering and leaving fluid temperature sensors if cooler temperature drops to 34 F (1.1 C). Proof of flow switches are required to be installed. Sensor failures Failures are detected by the microprocessor. 4

25 Accessory controls Demand can be further limited by controlling the chiller capacity through the demand limit control (the Energy Management Module is required for this function). This FIOP/ accessory interfaces with microprocessor to control unit so that chiller s demand does not exceed its setting. It is activated from an external switch. The standard ComfortLink control is programmed to accept various accessory temperature reset options (based on return-fluid temperature, outdoor-air temperature, or space temperature), that reset the LCWT. An accessory thermistor (T9 or T10) is required if outdoor-air temperature or space temperature reset is selected. The Energy Management Module (EMM) is only required for temperature reset that is initiated by a 4 to 0 ma signal. Demand limit If applied, limits the total power draw of unit to selected point by controlling number of operational compressors during periods of peak electrical demand. The Energy Management Module is required for either -stage or 4 to 0 ma demand limit. Temperature reset If applied, microprocessor compares either return fluid, space temperature, or outdoor-air temperature with the accessory board settings, and adjusts LCWT appropriately. The Energy Management Module can also be added for 4 to 0 ma reset. Thermostatic expansion valve The TXV controls refrigerant flow to the cooler for different operating conditions. An equalization line and temperature-controlled sensing bulb are used to maintain a fixed setting of superheated refrigerant leaving the cooler. Diagnostics For units with optional scrolling marquee display, the microprocessor may be put through a service test (see Controls, Start-Up, Operation, Service, and Troubleshooting literature) with the optional scrolling marquee display. Service test confirms microprocessor is functional, informs observer through display the condition of each sensor and switch in chiller, and allows observer to check for proper operation of fans and compressors. Default settings To facilitate quick start-ups, 30GTN chillers with ComfortLink controls are pre-configured with a default setting that assumes stand-alone operation supplying 44 F (6.7 C) chilled water. Configuration setting will be based on any options or accessories included with the unit at the time of manufacturing. Date and time are set to U.S.A. Central Time zone and will need reconfiguring based on location and local time zone. If operation based on occupancy scheduling is desired, this will also need to be set during installation. 5

26 Typical wiring schematic NOTES: 1. Factory wiring is in accordance with the National Electrical Code. Any field modifications or additions must be in compliance with all applicable codes.. Connect separate source of control power from field supplied fused disconnect to terminal 1 of TB4. Neutral side must be connected to terminal. This provides power for the unit control circuit, cooler heater, and compressor crankcase heater. 3. All field interlock contacts must have minimum rating of 360 VA pilot duty plus capacity required for field installed equipment. 4. For internal unit wiring, reference wiring book or unit wiring label diagram. 5. For GCS accessory, remove jumper wire between terminals 5 and 8 on terminal block TB. 6. For part wind start accessory, remove gray jumper wire between C-A1-C1 and C-A1A-C1. Time delay relay shown in suggested mounting position 7. Voltage requirements: MAIN POWER CONTROL POWER 08/ LEGEND C Compressor Contactor CB Circuit Breaker CCN Carrier Comfort Network CWFS Chilled Water Flow Switch CWP Chilled Water Pump CWPI Chilled Water Pump Interlock FC Fan Contactor FU Fuse GCS Ground Current Sensor LEN Local Equipment Network MBB Main Base Board NEC National Electrical Code TB Terminal Block TDR Time Delay Relay TRAN Transformer Field Power Wiring Field Control Power Wiring Field Control Wiring Factory Installed Wiring Field Installed Device 6

27 Typical piping and wiring NOTES: 1. Wiring and piping shown are general points-ofconnection guides only and are not intended for or to include all details for a specific installation.. All wiring must comply with applicable local and national codes. 3. All piping must follow standard piping techniques. Refer to Carrier System Design Manual for details. LEGEND FD Fused Disconnect NEC National Electrical Code (U.S.A.) ST Starter Airflow Through Condenser Airflow Through Air-Handling Unit Power Wiring Control Wiring Chilled Water Piping 7