30RYH 07-080 "B" Ductable Heat Pumps with Integrated Hydronic Module Nominal cooling capacity 7-76 kw Nominal heating capacity 8-78 kw 50 Hz AQUASNAP Carrier is participating in the Eurovent Certification Programme. Products are as listed in the Eurovent Directory of Certified Products. For the operation of the control please refer to the Pro-Dialog Control manual for the 30RA/RH - 30RY/RYH "B" series Installation, operation and maintenance instructions
CONTENTS - INTRODUCTION...4. - Installation safety considerations...4.2 - Equipment and components under pressure...4.3 - Maintenance safety considerations...5.4 - Repair safety considerations...5 2 - PRELIMINARY CHECKS...7 2. - Check equipment received...7 2.2 - Moving and siting the unit...7 3 - DIMENSIONS/CLEARANCES...9 4 - PHYSICAL DATA...0 5 - ELECTRICAL DATA...0 6 - APPLICATION DATA...2 6. - Unit operating range...2 6.2 - Heat exchanger water flow rates...2 6.3 - Minimum water flow rate...2 6.4 - Maximum evaporator water flow rate...2 6.5 - Water loop volume...2 6.6-30RYH unit operating range at full and part load in cooling mode...3 6.7-30RYH unit operating range at full and part load in heating mode...3 6.8 - Pressure drop in the plate heat exchangers...3 7 - ELECTRICAL CONNECTION...4 7. - Power supply...5 7.2 - Voltage phase imbalance (%)...5 8 - RECOMMENDED WIRE SECTIONS...5 8. - Field control wiring...5 9 - WATER CONNECTIONS...6 9. - Operating precautions and recommendations...6 9.2 - Hydronic connections...7 9.3 - Frost protection...7 9.4 - Installation of the accessory condensate recovery pan...7 0 - NOMINAL SYSTEM WATER FLOW CONTROL... 9 0. - Water flow control procedure...9 0.2 - Pump curve and water flow control as a function of the system pressure drops...20 0.3 - Pump pressure/flow rate curves... 2 0.4 - Available static system pressure...22 0.5 - Duct connection... 23 - START-UP...24. - Preliminary checks...24.2 - Actual start-up...24.3 - Operation of two units in master/slave mode...24.4 - Supplementary electric resistance heaters...25 The drawings in this document are for illustrative purposes only and is not part of any offer for sale or contract. 2
CONTENTS (continued) 2 - MAINTENANCE...27 2. - General maintenance of the refrigerant circuit... 27 2.2 - Refrigerant charge volume... 27 2.3 - Verification of the charge... 28 2.4 - Apparent and actual subcooling... 28 2.5 - Refrigerant guidelines... 29 2.6 - Recharging liquid refrigerant... 29 2.7 - Undercharge... 29 2.8 - Characteristics of R407C... 29 2.9 - Electrical maintenance... 29 2.0 - Condenser coil... 30 3 - AQUASNAP MAINTENANCE PROGRAM... 3 3. - Maintenance schedule... 3 3.2 - Description of the maintenance operations... 3 4 - START-UP CHECKLIST FOR 30RYH HEAT PUMPS... 33 3
- INTRODUCTION Prior to the initial start-up of the 30RYH units, the people involved in the on-site installation, start-up, operation, and maintenance of this unit should be thoroughly familiar with these instructions and the specific project data for the installation site. The 30RYH liquid chillers are designed to provide a very high level of safety during installation, start-up, operation and maintenance. They will provide safe and reliable service when operated within their application range. This manual provides the necessary information to familiarize yourself with the control system before performing start-up procedures. The procedures in this manual are arranged in the sequence required for machine installation, start-up, operation and maintenance. Be sure you understand and follow the procedures and safety precautions contained in the instructions supplied with the machine, as well as those listed in this guide. Earthquake resistance has not been verified for standard units.. - Installation safety considerations This machine must be installed in a location that is not accessible to the public and protected against access by non-authorised people. After the unit has been received, when it is ready to be installed or reinstalled, and before it is started up, it must be inspected for damage. Check that the refrigerant circuit(s) is (are) intact. Ensure especially that no components or pipes have shifted (e.g. following a shock). If in doubt, carry out a leak tightness check and verify with the manufacturer that the circuit integrity has not been impaired. If damage is detected upon receipt, immediately file a claim with the shipping company. Do not remove the skid or the packaging until the unit is in its final position. These units can be moved with a fork lift truck, as long as the forks are positioned in the right place and direction on the unit. The units can also be lifted with slings, using only the designated lifting points marked at the four corners at the unit base. These units are not designed to be lifted from above. Use slings with the correct capacity, and always follow the lifting instructions on the certified drawings supplied with the unit. Safety is only guaranteed, if these instructions are carefully followed. If this is not the case, there is a risk of material deterioration and injuries to personnel. Never cover any safety devices. This applies to the globe valve in the water circuit and the globe valve(s) in the refrigerant circuit(s). In certain cases the globe stops are installed on ball valves. These valves are factory-supplied lead-sealed in the open position. This system permits isolating and removing the globe stop for checking and replacing. The globe stops are designed and installed to ensure protection against fire risk. Removing the globe stops is only permitted if the fire risk is fully controlled and the responsibility of the user. All factory-installed globe valves are lead-sealed to prevent any calibration change. If the globe valves are installed on a reversing valve (change-over), this is equipped with a globe valve on each of the two outlets. Only one of the two glove valves is in operation, the other one is isolated. Never leave the reversing valve in the intermediate position, i.e. with both ways open (locate the control element in the stop position). If a globe stop is removed for checking or replacement please ensure that there is always an active globe stop on each of the reversing valves installed in the unit. Provide a drain in the discharge circuit, close to each valve, to avoid an accumulation of condensate or rain water. The safety valves must be connected to discharge pipes. These pipes must be installed in a way that ensures that people and property are not exposed to refrigerant leaks. These fluids may be diffused in the air, but far away from any building air intake, or they must be discharged in a quantity that is appropriate for a suitably absorbing environment. Periodic check of the globe valves: See paragraph Maintenance safety considerations. Accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation or explosions. Inhalation of high concentrations of vapour is harmful and may cause heart irregularities, unconsciousness, or death. Vapour is heavier than air and reduces the amount of oxygen available for breathing. These products cause eye and skin irritation. Decomposition products are hazardous..2 - Equipment and components under pressure These products incorporate equipment or components under pressure, manufactured by Carrier or other manufacturers. We recommend that you consult your appropriate national trade association or the owner of the equipment or components under pressure (declaration, re-qualification, retesting, etc.). The characteristics of this equipment/these components are given on the nameplate or in the required documentation, supplied with the products. Do not introduce high static and dynamic pressure compared with the existing operating pressures - either service or test pressures in the refrigerant circuit or in the heat transfer circuit, especially: - limiting the elevation of the condensers or evaporators - taking the circulating pumps into consideration. Ensure that the valve(s) (if used in the refrigerant circuit) are correctly installed, before operating the unit (the valves are not systematically installed on the units, but may be required by certain national safety codes, depending on the destination country). 4
.3 - Maintenance safety considerations Engineers working on the electric or refrigeration components must be authorized and fully qualified to do so (electricians trained and qualified in accordance with IEC 60364 Classification BA4). All refrigerant circuit repairs must be carried out by a trained person, fully qualified to work on these units. He must have been trained and be familiar with the equipment and the installation, and he must wear the necessary protective items (gloves, glasses, protective clothes, safety shoes). Soldering and welding: Component, piping and connection soldering and welding operations must be carried out using the correct procedures and by qualified operators. Pressurised containers must not be subjected to shocks, nor to large temperature variations during maintenance and repair operations. Never work on a unit that is still energized. Never work on any of the electrical components, until the general power supply to the unit has been cut using the disconnect switch in the control box. 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 deenergized before resuming the work. ATTENTION: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuit disconnect switch is open. Refer to the wiring diagram for further details. Attach appropriate safety labels. Operating checks: During the life-time of the system, inspection and tests must be carried out in accordance with national regulations. The information on operating inspections given in annex C of standard EN378-2 can be used if no similar criteria exist in the national regulations. Safety device checks (annex C6 EN378-2): The safety devices must be checked on site once a year for safety devices (high-pressure switches), and every five years for external overpressure devices (safety globe valves). Contact Carrier Service for a detailed explanation of the high-pressure switch test method. If the machine operates in a corrosive environment, inspect the protection devices more frequently. Regularly carry out leak tests and immediately repair any leaks..4 - Repair safety considerations All installation parts must be maintained by the personnel in charge, in order to avoid material deterioration and injuries to people. Faults and leaks must be repaired immediately. The authorized technician must have the responsibility to repair the fault immediately. Each time repairs have been carried out to the unit, the operation of the safety devices must be re-checked. If a leak occurs or if the refrigerant becomes polluted (e.g. by a short circuit in a motor) remove the complete charge using a recovery unit and store the refrigerant in mobile containers (careful in case the refrigerant decomposes due to high temperature increases, as the decomposition products are dangerous). If a leak occurs, evacuate all refrigerant, repair the leak detected and recharge the circuit with the total R407C charge, as indicated on the unit name plate. Only charge liquid refrigerant R407C at the liquid line. Ensure that you are using the correct refrigerant type before recharging the unit. Charging any refrigerant other than the original charge type (R407C) will impair machine operation and can even lead to a destruction of the compressors. The compressors operating with this refrigerant type are charged with a synthetic polyolester oil. These units have a hermetic refrigerant circuit and the original charge need not be topped up. Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances. 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 use air for leak testing. Use only refrigerant or dry nitrogen. Do not unweld or flamecut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and vapour) has been removed from chiller. Traces of vapour should be displaced with dry air 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. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, immediately and abundantly flush the eyes with water and consult a doctor. Never apply an open flame or live steam to a refrigerant container. Dangerous overpressure can result. If it is necessary to heat refrigerant, use only warm water. 5
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 NFE 29795. Any refrigerant transfer and recovery operations must be carried out using a transfer unit. A 3/8 SAE connector on the manual liquid line valve is supplied with all units for connection to the transfer station. The units must never be modified to add refrigerant and oil charging, removal and purging devices. All these devices are provided with the units. Please refer to the certified dimensional drawings for the units. Do not drain water circuits containing industrial brines, without informing the technical service department at the installation site or a competent body first. Close the entering and leaving water shutoff valves and purge the unit 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. Do not re-use disposable (non-returnable) cylinders or attempt to refill them. It is dangerous and illegal. When cylinders are empty, evacuate the remaining gas pressure, and move the cylinders to a place designated for their recovery. Do no incinerate. Do not attempt to remove refrigerant circuit components or fittings, while the machine is under pressure or while it is running. Be sure pressure is at 0 kpa before removing components or opening a circuit. Any manipulation (opening or closing) of a shut-off valve must be carried out by a qualified and authorised engineer. These procedures must be carried out with the unit shut-down. NOTE: The unit must never be left shut down with the liquid line valve closed, as liquid refrigerant can be trapped between this valve and the expansion device. (This valve is situated on the liquid line before the filter drier box.) Do not attempt to repair or recondition any safety devices when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. If necessary, replace the device. Do not install safety valves in series or backwards. CAUTION Do not step on refrigerant lines. The lines can break under the weight and release refrigerant, causing personal injury. No part of the unit must use feet, racks or supports during operation. Periodically monitor and repair or if necessary replace any component or piping that shows signs of damage. Do not climb on a machine. Use a platform, or staging to work at higher levels. Use mechanical lifting equipment (crane, hoist, etc.) to lift or move heavy components such as compressors or plate heat exchangers. 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. 6
2 - PRELIMINARY CHECKS 2. - Check equipment received Inspect the unit for damage or missing parts. If damage is detected, or if shipment is incomplete, immediately file a claim with the shipping company. Confirm that the unit received is the one ordered. Compare the name plate data with the order. The unit name plate must include the following information: - Version number - Model number - CE marking - Serial number - Year of manufacture and test date - Refrigerant used and refrigerant class - Refrigerant charge per circuit - Containment fluid to be used - PS: Min./max. allowable pressure (high and low pressure side) - TS: Min./max. allowable temperature (high and low pressure side) - Globe valve cut-out pressure - Pressure switch cut-out pressure - Unit leak test pressure - Voltage, frequency, number of phases - Maximum current drawn - Maximum power input - Unit net weight High pressure Low pressure Min. Max. Min. Max. PS (bar) -0.9 32-0.9 25 TS ( C) -20 72-20 62 Pressure switch cut-out pressure (bar) 29 - Valve cut-out pressure (bar) 32 25 Test pressure, unit leak test (bar) 5 Confirm that all accessories ordered for on-site installation have been delivered, and are complete and undamaged. The unit must be checked periodically during its whole operating life to ensure that no shocks (handling accessories, tools etc.) have damaged it. If necessary, the damaged parts must be repaired or replaced. See also chapter Maintenance. 2.2 - Moving and siting the unit 2.2. - Moving See chapter "Installation safety considerations" 2.2.2 - Siting the unit Always refer to the chapter "Dimensions and clearances" to confirm that there is adequate space for all connections and service operations. For the centre of gravity coordinates, the position of the unit mounting holes, and the weight distribution points, refer to the certified dimensional drawing supplied with the unit. CAUTION: Only use slings at the designated lifting points which are marked on the unit. Before siting the unit check that: the permitted loading at the site is adequate or that appropriate strengthening measures have been taken; the surface is horizontal, flat and intact; a channel is provided all the way around the unit to collect the condensate water. In heat pump mode it may be necessary to remove up to 5 litres of water per hour. if the unit is not equipped with the accessory condensate recovery pan, reference is made to the installation conditions in chapter 0.4; there is adequate space above the unit for air flow; there are adequate support points and that they are in the right places; the location is not subject to flooding; units with the outdoor installation option should not be installed where there is a risk of snow build-up. In areas that are subject to long periods of sub-zero temperatures raise the unit to a higher level. Baffles may be necessary to deflect strong winds and to prevent snow from blowing directly into the unit. 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. The 30RYH units can be hoisted with rigging. Coils should always be protected against crushing while a unit is being moved. Use struts or spreader bars 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. 7
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. During the installation test national regulations must be followed. If no national regulation exists, paragraph 9-5 of standard EN 378-2 can be used as a guide. External visual installation checks: Compare the complete installation with the refrigeration system and power circuit diagrams. Check that all components comply with the design specifications. Check that all safety documents and equipments that are required by current European standards are present. Verify that all safety and environmental protection devices and arrangements are in place and comply with the current European standard. Verify that all document for pressure containers, certificates, name plates, files, instruction manuals that are required documents required by the current European standards are present. Verify the free passage of access and safety routes. Check that ventilation in the plant room is adequate. Check that refrigerant detectors are present. Verify the instructions and directives to prevent the deliberate removal of refrigerant gases that are harmful to the environment. Verify the installation of connections. Verify the supports and fixing elements (materials, routing and connection). Verify the quality of welds and other joints. Check the protection against mechanical damage. Check the protection 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 and of the vapour barriers. 8
3 - DIMENSIONS/CLEARANCES 30RYH 07-033 962 822.5 863 2058 28 068 2097 2058 372 35 670 670 30RYH 040-080 000 000 820 Legend: All dimensions are given in mm Power supply 820 Water inlet Water outlet 000 Required clearances for air flow NOTE: Air entering connection Air leaving connection Power cable entry A B C Non-certified drawings. Refer to the certified dimensional drawings supplied with the unit or available on request, when designing an installation. For the location of fixing points, weight distribution and coordinates of the centre of gravity refer to the certified dimensional drawings. Install a condensate collection channel around the unit, or install the accessory condensate recovery pan. The unit must be installed level in both axes (less than 2 mm tolerance per metre). 9
4 - PHYSICAL DATA 30RYH 07 02 026 033 040 050 060 070 080 Nominal cooling capacity* kw 7.8 22.4 24. 3.3 37.8 44.7 56.0 65.0 76.0 Nominal heating capacity** kw 8.3 22. 25.6 34.5 37.0 48.3 55.0 62.0 78.0 Operating weight kg with hydronic module, single pump 40 440 460 475 550 62 627 688 736 with hydronic module, dual pump - - - - 630 692 707 768 83 without hydronic module 385 45 435 450 526 588 603 664 70 Refrigerant charge R-407C kg 6.4 6.6 7.4 8.6 0.3.4 2.5 3.3 7.3 Compressors Hermetic scroll compressors, 48.3 r/s Quantity 2 2 2 2 No. of capacity steps 2 2 2 2 Minimum capacity % 00 00 00 00 00 46 42 50 50 Control type PRO-DIALOG Plus Air heat exchanger Grooved copper tubes, aluminium fins Fan Axial with available pressure Quantity Available static pressure Pa 00 00 00 00 50 50 50 50 50 Total air flow (high speed) l/s 940 940 940 2500 3890 3890 4720 5830 5830 Speed (high/low speed) r/s 24/2 24/2 24/2 24/2 24/2 24/2 24/2 24/2 24/2 Water heat exchanger Direct-expansion welded plate heat exchanger Water volume l.6 2.0 2.3 3.0 3.6 4.6 5.9 6.5 7.6 Max. water-side operating pressure kpa Option without hydronic module 000 000 000 000 000 000 000 000 000 Unit with hydronic module 250 250 250 250 300 300 300 300 300 Hydronic module Pump (centrifugal) Single multicell pump, 48.3 r/s Single composite monocell pump, 48.3 r/s Quantity Expansion tank volume l 8 8 8 8 2 2 2 2 2 Expansion tank pressure*** kpa 50 50 50 50 00 00 00 00 00 Water connections Threaded male gas connections Victaulic (with and without hydronic module) (sleeves for welding or screw connections supplied) Diameter in -/4 -/4 -/4 -/4 2 2 2 2 2 Outside tube diameter in -/4 -/4 -/4 -/4 2 2 2 2 2 mm 42.4 42.4 42.4 42.4 60.3 60.3 60.3 60.3 60.3 * Nominal conditions: water heat exchanger entering/leaving temperature 2 C/7 C, outdoor air temperature 35 C. ** Nominal conditions: air heat exchanger entering/leaving temperature 40 C/45 C, outdoor air dry bulb temperature 7 C. *** When delivered, the pre-inflation of the tank keeps the plated membrane in the upper part of the tank. To permit changing the water volume, change the inflation pressure to a pressure that is close to the static head of the system (see below), fill the system with water (purging the air) to a pressure value that is 0 to 20 kpa higher than the pressure in the tank. Static head, m/pressure, bar/pressure, kpa 5-0,5-50 / 0 - - 00 / 5 -,5-50 / 20-2 - 200 / 25-2,5-250 5 - ELECTRICAL DATA 30RYH (without hydronic module) 07 02 026 033 040 050 060 070 080 Power circuit Nominal power supply V-ph-Hz 400-3-50 Voltage range V 360-440 Control circuit supply The control circuit is supplied via the unit-mounted transformer Maximum unit power input* kw 9.8 2. 3.8 8.0 2.0 25.3 32.3 38.2 42.9 Nominal unit current draw** A 3. 6.2 8.6 23.3 28.8 35.6 45.7 52. 59.4 Maximum unit current draw at 360 V*** A 7.0 2.3 24.5 3.2 37.8 46.5 59.5 67.8 77.5 Maximum unit current draw at 400 V**** A 5.5 9.3 22.2 28.3 34.5 42.3 54.3 62. 70.7 Maximum start-up current Standard unit A 87.8 3.8 3.8 47.4 59.3 5.8 73.5 8.2 95.5 With electronic starter option A - - - - 97.3 96.7.9 8.2 27.9 Short-circuit stability and protection See table on the next page * Power input of the compressor(s) + fan at maximum unit operating conditions: entering/leaving water temperature = 5 C/0 C, maximum condensing temperature of 67.8 C and 400 V nominal voltage (values given on the unit name plate). ** Nominal unit current draw at the following conditions: evaporator entering/leaving water temperature 2 C/7 C, outdoor air temperature 35 C. The current values are given at 400 V nominal voltage *** Maximum unit operating current at maximum unit power input and 360 V nominal voltage. **** Maximum unit operating current at maximum unit power input and 400 V nominal voltage (values given on the unit name plate). Maximum instantaneous starting current at 400 V nominal voltage and with compressor in across-the-line-start (maximum operating current of the smallest compressor(s) + fan current + locked rotor current of the largest compressor). Maximum instantaneous starting current at 400 V nominal voltage and with compressor with electronic starter (maximum operating current of the smallest compressor(s) + fan current + reduced start-up current of the largest compressor). Hydronic module 07 02 026 033 040 050 060 070 080 Single pump Shaft power kw 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75. Power input* kw 0.75 0.75 0.75 0.75.....4 Maximum current draw at 400 V** A 2.0 2.0 2.0 2.0 2. 2. 2. 2. 3. Dual pump Shaft power kw - - - - 2.2 2.2 2.2 2.2 2.2 Power input* kw - - - - 2.7 2.7 2.7 2.7 2.7 Maximum current draw at 400 V** A - - - - 4.7 4.7 4.7 4.7 4.7 Note: The water pump power input values are given for guidance only. * To obtain the maximum power input for a unit with hydronic module add the maximum unit power input from the top table to the pump power input (*) from the table above. ** To obtain the maximum unit operating current draw for a unit with hydronic module add the maximum unit current draw from the top table to the pump current draw from the table above. 0
Compressor usage and electrical data COMPRESSOR 30RYH Reference code I Nom I Max LRA* Circuit 07 02 026 033 040 050 060 070 080 DQ 2 CA 00EE 4.0 9. 30 A A A DQ 2 CA 002EE 6.2 22. 30 A A A2 A DQ 2 CA 025EE 4.8 20.3 86 A A DQ 2 CA 03EE 2.9 28.3 45 A A A2 A+A2 DQ 2 CA 036EE 24.5 32.9 55 A A A+A2 Legend: I Nom Nominal current draw at Eurovent conditions (see definition of conditions under nominal unit current draw), A I Max Maximum operating current at 360 V, A LRA Locked rotor current, A * With option 25 (electronic starter) the LRA value is reduced by 40%; the maximum start-up time per compresor is <0.8 seconds. Short-circuit stability and protection 30RYH Short-term short-circuit stability (s) With fuse Other fuses Other protection type Without fuse rms value/peak rms value rms value I 2 t (A 2 s)/peak limit ka* ka ** ka*** ka**** 07-033 5/7.5 40A gl:00 50A gl:00 8700/9 63A gl:00 80A gl:50 040-080 5/7.5 80A gl:50 00A gl:30 9200/2 25A gl:25 60A gl:6 * This value corresponds to the switch/disconnect capacity, to the power distribution bus bar system capacity (if used) and to the protection circuit capacity in the standard unit. ** If the available short-circuit current is higher, the unit can be protected by the fuse shown for the specific level. The fuses (not supplied for Carrier units) are as recommended, to be installed upstream of the unit. A fused disconnect switch, equipped with fuses, can be installed in place of the standard unit switch. This should be done on site; please contact the local service department or a qualified electrician. Alternatively please order the special version from the factory by contacting your local Carrier dealer. List of recommended components with Siemens reference details: 30RYH Fused disconnect Contact protection Control handle NH Fuses New protection level with fused diconnect switch, rms value, ka** 07-033 45 A: 3KL72-3AA00 3KX7-32-AA00 Use from disconnect switch 40 A 00gL: 3NA3 87 (3 off) 00 040-080 80 A: 3KL74-3AA00 3KX7-32-AA00 of the standard unit 80 A 00gL: 3NA3 824 (3 off) 00 *** Shows the new protection values with higher-capacity fuses than those specified in the previous column. If such fuses are part of the electrical installation upstream of the unit, this is sufficient as anti-short circuit protection to the specified level, without additional protection. **** If a protection device, other than the recommended fuses above, is used for the installation to ensure that no additional protection is required, the protection device must have the specified thermal limit (I 2 t) and limit effect characteristics for the short-circuit current. If the protection device does not have the specified characteristics, one of the specified protection fuses from the previous columns must be installed. Electrical data notes for 30RYH units: 30RYH 07-080 units have a single power connection point. The control box includes the following standard features: - Starter and motor protection devices for each compressor, fan, optional pump - Control devices Field connections: All connections to the system and the electrical installations must be in full accordance with all applicable codes. The Carrier 30RYH 07-080 units are designed and built to ensure conformance with local codes. The recommendations of European standard EN 60204- (machine safety - electrical machine components - part : general regulations - corresponds to IEC 60204-) are specifically taken into account when designing the electrical equipment. IMPORTANT: Generally the recommendations of IEC 60364 are accepted as compliance with the requirements of the installation directives. Conformance with EN 60204- is the best means of ensuring compliance with the Machines Directive.5.. Annex B of EN 60204- describes the electrical characteristics used for the operation of the machines.. The operating environment for the 30RYH units is specified below: a. 30RYH 07-080 Indoor installation Environment* - Environment as classified in IEC 60364 3: - ambient temperature range: +5 C to +40 C, class AA4 - humidity range (non-condensing)*: 50% relative humidity at 40 C 90% relative humidity at 20 C - altitude: 2000 m - indoor installation* - presence of water, class AD2* (possibility of water droplets) - presence of hard solids, class AE2* (no significant dust present) - presence of corrosive and polluting substances, class AF (negligible) - vibration and shock, class AG2, AH2 Competence of personnel, class BA4* (trained personnel - IEC 60364) b. 30RYH 040-080 outdoor installation Environment** - Environment as classified in EN 6072 (corresponds to IEC 6072): - outdoor installation** - ambient temperature range: -0 C to +46 C, class 4K3** - altitude: 2000 m - presence of hard solids: class 4S2** (no significant dust present) - presence of corrosive and polluting substances, class 4C2 (negligible) - vibration and shock, class 4M2 Competence of personnel, class BA4** (trained personnel - IEC 60364) 2. Power supply frequency variation: ± 2 Hz. 3. The neutral (N) conductor 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 60947. 6. The units are designed for connection to TN networks (IEC 60364). For IT networks the earth connection must not be at the network earth. Provide a local earth, consult competent local organisations to complete the electrical installation. NOTE: If particular aspects of an actual installation do not conform to the conditions described above, or if there are other conditions which should be considered, always contact your local Carrier representative. * The protection level required to conform to this class is IP2B (according to reference document IEC 60529). All 30RYH 07-080 units are protected to IP23C and fulfil this protection condition. ** The required protection level for this class is IP43BW (according to reference document IEC 60529). All 30RYH 040-080 units are protected to IP45CW and fulfil this protection condition.
6 - APPLICATION DATA 6. - Unit operating range Water heat exchanger (evaporator) Minimum C Maximum C Water entering temprature (at start-up) 7.8 * 35 Water leaving temprature (in operation) 5 ** 0 Water entering temprature (at shut down) - 60 Air heat exchanger (condenser) Entering air temprature -0*** 46*** Heating mode Water heat exchanger (condenser) Minimum C Maximum C Water entering temp. (at start-up) 0 50 Water leaving temp. (in operation) 20 50 Water entering temp. (at shut-down) 3 60 Air heat exchanger (evaporator) Entering air temp. -0*** 40*** Do not exceed the maximum operating temperature. * For a system requiring operation below 7,8 C, contact Carrier SA. ** For a system requiring operation below 5 C, anti-freeze must be added to the unit. *** Maximum outside temperature: For transport and storage of the 30RYH units the minimum and maximum allowable temperatures are 20 C and +60 C. It is recommended that these temperatures are used for transport by container. 6.2 - Heat exchanger water flow rates 30RYH Evaporator water flow Min. flow rate Max. flow rate* Max. flow rate** Single pump Dual pump l/s l/s l/s l/s 07 0.58.7 0.7 02 0.70.8 0.9 026 0.8.9 0 2.2 033.0 2.0 0 3.0 040.20 3.5 4.4 3.7 050.9 4.0 5.2 4.6 060.46 4.4 6.0 5.8 070.66 4.6 6.4 6.4 080.92 5.5 6.8 7.3 * Maximum flow rate at an available pressure of 50 kpa (unit with hydronic module). ** Maximum flow rate at a pressure drop of 00 kpa in the plate heat exchanger (unit without hydronic module). 6.3 - Minimum water flow rate If the installation flow rate is below the minimum flow rate, recirculation of the evaporator water flow may take place, leading to the risk of excessive fouling. 6.4 - Maximum evaporator water flow rate This is limited by the permitted evaporator pressure drop. Also, a minimum evaporator T of 2.8 K must be guaranteed, which corresponds to a water flow rate of 0.9 l/s per kw. 6.5 - Water loop volume 6.5. - Minimum water loop volume The minimum water loop volume, in litres, is given by the following formula: Volume = CAP (kw) x N* = litres, where CAP is the nominal cooling capacity at nominal operating conditions. Application N* Air conditioning 30RYH 07-040 3.5 30RYH 050-240 2.5 Industrial process cooling 30RYH 07-080 (See note) NOTE: For industrial process cooling applications, where high stability of the water temperature levels must be achieved, the values above must be increased. This volume is required to obtain temperature stability and precision. To achieve this volume, it may be necessary to add a storage tank to the circuit. This tank should be equipped with baffles to allow mixing of the fluid (water or brine). Please refer to the examples below. Bad Bad Good Good 6.5.2 - Maximum water loop volume Units with hydronic module incorporate an expansion tank that limits the water loop volume. The table below gives the maximum loop volume for pure water or ethylene glycol with various concentrations. 30RYH 07-033 30RYH 040-080 (in litres) (in litres) Pure water 400 600 Ethylene glycol 0% 300 450 Ethylene glycol 20% 250 400 Ethylene glycol 35% 200 300 EG: Ethylene glycol 2
6.6-30RYH unit operating range at full and part load in cooling mode C 46 6.8 - Pressure drop in the plate heat exchangers 2000 000 Entering air temperature 45 44.5 44 0-0 Pressure drop, kpa 00 0 2 3 4 5 6 0 7 8 9 2 3 4 5 6 7 8 Water flow rate, l/s 0 2 3 4 5 6 7 8 9 0 C Evaporator water leaving temperature Notes Evaporator DT = 5 K 2 The evaporator and the hydronic circuit pump are frost protected down to -20 C. Operating range with required anti-freeze solution and special Pro-Dialog control configuration Legend 30RYH 07 2 30RYH 02 3 30RYH 026 4 30RYH 033 5 30RYH 040 6 30RYH 050 7 30RYH 060 8 30RYH 070 9 30RYH 080 6.7-30RYH unit operating range at full and part load in heating mode C 40 35 30 Entering air temperature 25 20 5 0 5 0-5 -0 20 25 30 35 40 45 50 C Evaporator leaving water temperature 3
7 - ELECTRICAL CONNECTION 30RYH 07-033 Control box X A A 67 33 33 PE S L L2 L3 Y 347 30RYH 040-080 Control box X B B 68 33 33 5.5 347 95 PE S L L2 L3 Y Legend Main disconnect switch PE Earth connection S Power supply cable section (see table "Recommended wire sections"). For copper cables use electrolytic copper (AMP type) cable stiffeners with 6 mm terminal for sizes 07 to 080. 30RYH X (mm) Y (mm) 07-033 80 76 040-080 90 762 NOTES: The 30RYH units have only one power connection point located at the main disconnect switch. Before connecting electric power cables, it is imperative to check the correct order of the 3 phases (L - L2 - L3). Non-certified drawings. Refer to the certified drawings supplied with the unit or available on request. 4
7. - Power supply The power supply must conform to the specification on the chiller name plate. The supply voltage must be within the range specified in the electrical data table. For connections refer to the wiring diagrams. WARNING: Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutes abuse which will invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 0% for current, contact your local electricity supply source at once and ensure that the chiller is not switched on until corrective measures have been taken. 7.2 - 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 measured to be: AB = 406 V ; BC = 399 ; AC = 394 V Average voltage = (406 + 399 + 394)/3 = 99/3 = 399.7 say 400 V Calculate the maximum deviation from the 400 V average: (AB) = 406-400 = 6 (BC) = 400-399 = (CA) = 400-394 = 6 8 - RECOMMENDED WIRE SECTIONS Wire sizing is the responsibility of the installer, and depends on the characteristics and regulations applicable to each installation site. The following is only to be used as a guideline, and does not make Carrier in any way liable. After wire sizing has been completed, using the certified dimensional drawing, the installer must ensure easy connection and define any modifications necessary on site. The connections provided as standard for the field-supplied power entry cables to the general disconnect/ isolator switch are designed for the number and type of wires, listed in the table below. The calculations are based on the maximum machine current (see electrical data tables) and the standard installation practises, in accordance with IEC 60364, table 52C. - For 30RYH units, installed outside, the following standard installation practises have been maintained: No.7: suspended aerial lines, and No. 6: buried conduit with a derating coefficient of 20. The calculation is based on PVC or XLPE insulated cables with copper core. A maximum ambient temperature of 46 C has been taken into consideration. The given wire length limits the voltage drop to < 5% (length L in metres - see table below). IMPORTANT: Before connection of the main power cables (L - L2 - L3) on the terminal block, it is imperative to check the correct order of the 3 phases before proceeding to the connection on the main disconnect/isolator switch. 8. - Field control wiring 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 is therefore acceptable. For the field control wiring of the following elements please refer to the 30RA/RH - RY/RYH B series Pro-Dialog Plus Control manual, and the certified wiring diagram supplied with the unit: - Unit start/stop - Heating/cooling selection - Set-point selection - Customer interlock - (example: auxiliary contact of the chilled water pump contactor) - General alarm reporting, circuit A and circuit B Units S Min. (mm 2 ) Cable type L (m) S Max. (mm 2 ) Cable type L (m) by phase by phase 30RYH 07 x 6 XLPE Cu 90 x 6 PVC Cu 245 30RYH 02 x 6 XLPE Cu 90 x 6 PVC Cu 245 30RYH 026 x 6 XLPE Cu 90 x 6 PVC Cu 245 30RYH 033 x 6 XLPE Cu 90 x 6 PVC Cu 245 30RYH 040 x 6 XLPE Cu 90 x 6 PVC Cu 245 30RYH 050 x 6 XLPE Cu 80 x 25 PVC Cu 300 30RYH 060 x 0 XLPE Cu 0 x 25 PVC Cu 300 30RYH 070 x 0 XLPE Cu 00 x 35 PVC Cu 30 30RYH 080 x 6 XLPE Cu 25 x 50 PVC Cu 350 S Power supply cable section (see the diagram in chapter: "Electrical connection") 5
9 - WATER CONNECTIONS For size and position of the unit 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, shutoff and bleed valves and circuits built in, to prevent corrosion (example: damage to the protection of the tube surface if the fluid is polluted), fouling and deterioration of the pump fittings. Before any start-up verify that the heat exchange fluid is compatible with the materials and the water circuit coating. In case additives or other fluids than those recommended by Carrier s.a are used, ensure that the fluids are not considered as a gas, and that they belong to class 2, as defined in directive 97/23/EC. Carrier s.a. 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. 2. Cl - Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture. If possible keep below 0 mg/l. 3. SO 4 2- sulphate ions can cause perforating corrosion, if their content is above 30 mg/l. 4. No fluoride ions (<0. mg/l). 5. 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. 6. Dissolved silicon: silicon is an acid element of water and can also lead to corrosion risks. Content < mg/l. 7. Water hardness: TH >2.8 K. Values between 0 and 25 can be recommended. This will facilitate scale deposit that can limit corrosion of copper. TH values that are too high can cause piping blockage over time. A total alkalimetric titre (TAC) below 00 is desirable. 8. Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to deoxygenate the water by mixing it with inert gas as it is to over-oxygenate it by mixing it with pure oxygen. The disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles. 9. Specific resistance electric conductivity: the higher the specific resistance, the slower the corrosion tendency. Values above 3000 Ohm/cm are desirable. A neutral environment favours maximum specific resistance values. For electric conductivity values in the order of 200-6000 S/cm can be recommended. 0. ph: Ideal case ph neutral at 20-25 C (7 < ph < 8). ATTENTION: Charging, adding or draining fluid from the water circuit must be done by qualified personnel, using air vents and materials suitable for the products. The water circuit charging devices are field-supplied. Charging and removing heat exchange fluids should be done with devices that must be included on the water circuit by the installer. Never use the unit heat exchangers to add heat exchange fluid. 9. - Operating precautions and recommendations 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: Comply with the water inlet and outlet connections shown on the unit. Install manual or automatic air purge valves at all high points in the circuit. Use an expansion device to maintain pressure in the system and install a safety valve as well as an expansion tank. Units with a hydronic module include the safety valve and the 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 all pipework, after testing for leaks, both to reduce thermal leaks and to prevent condensation. If the external unit water pipes are in an area, where the ambient temperature is likely to fall below 0 C, insulate the piping and add an electric heater. The internal unit piping is protected down to -20 C. NOTE: For units not equipped with a hydronic module a screen filter must be installed as close to the heat exchanger as possible, in a position that is easily accessible for removal and cleaning. Units with hydronic module are equipped with this type of filter. The mesh size of the filter must be.2 mm. The plate heat exchanger can foul up quickly at the initial unit start-up, as it complements the filter function, and the unit operation will be impaired (reduced water flow rate due to increased pressure drop). Before the system start-up verify that the water circuits are connected to the appropriate heat exchangers (e.g. no reversal between evaporator and condenser). Do not introduce any significant static or dynamic pressure into the heat exchange circuit (with regard to the design operating pressures). The products that may be added for thermal insulation of the containers during the water piping connection procedure must be chemically neutral in relation to the materials and coatings to which they are applied. This is also the case for the products originally supplied by Carrier s.a. 6
9.2 - Hydronic connections The diagram on the next page shows a typical hydronic installation. When charging the water circuit use air vents to evacuate any residual air pockets. 9.3 - Frost protection The plate heat exchangers, the piping and the hydronic module pump can be damaged by frost, despite the built-in anti-freeze protection of these units. The frost protection of plate heat exchanger and all hydronic module components is guaranteed down to -20 C (sizes 040-080 only) by automatically energized heaters and pump cycling. Never switch off the evaporator and hydronic circuit heaters or the pump, otherwise frost protection cannot be guaranteed. - To prevent corrosion by differential aeration, the complete drained heat transfer circuit must be charged with nitrogen for a period of one month. If the heat transfer fluid does not comply with the Carrier S.A. regulations, the nitrogen charge must be added immediately. 9.4 - Installation of the accessory condensate recovery pan Ref. No.: 30RY 900 022 EE -- 30RYH 07-033 30RY 900 032 EE -- 30RYH 040-080 In heat pump mode it may be necessary to remove up to 5 litres of water per hour. Carrier can supply an accessory condensate recovery pan to be positioned under the unit. This pan is connected to the condensate recovery systems via a threaded " diameter gas pipe. For this reason the main unit disconnect switch (QS0) as well as the auxiliary protection switch (QF0) for the heaters must always be left closed (for location of QS and QF 0 see wiring diagram). To ensure frost protection down to -20 C, water circulation in the water circuit must be maintained by periodically switching on the pump. If a shut-off valve is installed, a bypass must be included as shown below. Winter position F A O F B Legend A Unit B Water network C Closed O Open IMPORTANT: Depending on the atmospheric conditions in your area you must do the following when switching the unit off in winter: - Add ethylene glycol with an adequate concentration to protect the installation up to a temperature of 0 K below the lowest temperature likely to occur at the installation site. - If the unit is not used for an extended period, it is recommended to drain it, and as a safety precaution introduce ethylene glycol in the heat exchanger, using the water entering purge valve connection. At the start of the next season, refill the unit with water and add an inhibitor. - For the installation of auxiliary equipment, the installer must comply with basic regulations, especially for minimum and maximum flow rates, which must be between the values listed in the operating limit table (application data). Legend Condensate recovery pan 2 Connection 2 7