Professional Documents
Culture Documents
30GZ 040-245
Air-cooled liquid chillers
50 Hz
Carrier is participating in
the Eurovent Certification
Programme. Products are
as listed in the Eurovent
Directory of Certified
Products.
CONTENTS
Page
Start-up checklist .......................................................................................................................................................................... 3
Dimensions/clearances ................................................................................................................................................................. 4
Technical/electrical data .............................................................................................................................................................. 6
Application data ............................................................................................................................................................................ 7
Maximum cooler water flow rates .................................................................................................................................................. 7
Water loop volume ......................................................................................................................................................................... 7
Installation ..................................................................................................................................................................................... 7
Safety considerations ...................................................................................................................................................................... 7
Preliminary checks ......................................................................................................................................................................... 8
Moving and siting the unit .............................................................................................................................................................. 8
Check compressor mountings ......................................................................................................................................................... 8
Water connections ........................................................................................................................................................................ 9
Power supply ............................................................................................................................................................................... 10
Electrical checks ........................................................................................................................................................................... 10
Start-up ........................................................................................................................................................................................ 10
Preliminary checks ....................................................................................................................................................................... 10
Actual start-up .............................................................................................................................................................................. 10
Servicing refrigeration components .......................................................................................................................................... 11
General maintenance .................................................................................................................................................................... 11
Liquid refrigerant charging ........................................................................................................................................................... 11
Compressors ................................................................................................................................................................................. 12
Compressor protection circuit board (STARTERGUARD) ......................................................................................................... 12
Heat exchangers ............................................................................................................................................................................ 13
Condenser coil .............................................................................................................................................................................. 14
Fan motor replacement ................................................................................................................................................................. 15
Fan motor protection .................................................................................................................................................................... 15
Refrigerant circuit ......................................................................................................................................................................... 15
Troubleshooting chart ................................................................................................................................................................ 16
The photo on the front cover is only for illustration purposes and not contractually binding (photo shows unit with optional
compressor sound enclosure).
The manufacturer reserves the right to make modifications at any time without prior notice.
2
Contract No.:
Installed by:
Contract No.:
Site address:
Equipment type and serial numbers: 30GH/GZ
Electrical data:
Supply voltage:
Ph.
Nominal voltage:
Current draw:
Ph. 1
Ph. 2
Ph. 3
Ph. 3
% network voltage:
Ph. 2
Physical data:
Condenser:
Cooler:
kPa
Pa
Fan speed:
r/s or rpm
Ph. 1
Ph. 2
Ph. 3
Ph. 1
Ph. 2
Ph. 3
Ph. 1
Ph. 2
Ph. 3
Ph. 1
Ph. 2
Ph. 3
kPa
C
cut-out
kPa
cut-in
kPa
kPa
cut-in
kPa
Defrost protection:
cut-out
cut-in
Control thermostat:
Oil level:
Oil visible in sight glass:
Colour of moisture indicator:
Air bubbles visible in sight glass:
Accessories:
Commissioning engineer (name):
Name
Date
Remarks:
Legend:
Dimensions/clearances (mm)
30GH/GZ
040-045
2450
1870
1912
2500
1200
500
1200
050-060
2900
2156
2060
2500
1200
500
1200
085-100
3404
2328
2471
1600
1800
1600
1800
120-145
4322
2328
2471
1600
1800
1600
1800
150-170
6229
2328
2471
1600
1800
1600
1800
190-220
7147
2328
2471
1600
1800
1600
1800
245
8983
2328
2471
1600
1800
1600
1800
Power supply
Water inlet
Water outlet
NOTE :
Dimensional drawings are available on request.
30GH/GZ 040-060
30GH/GZ 085-145
Do not obstruct
Do not obstruct
F
E
30GH/GZ 150-245
Do not obstruct
Do not obstruct
ATTENTION:
30GH/GZ 170- 245
have two power
connection points.
Floor mounting
For unit mounting holes, weight distribution and centre of gravity coordinates, refer to the dimensional drawings.
These units are designed for outdoor installation.
CAUTION:
Physical data
30GH/GZ
040
045
050
060
085
095
100
120
130
145
150
160
170
190
220
245
kW 107
kW 102
124
118
156
150
190
181
255
244
300
287
344
329
396
379
442
417
457
437
498
476
516
499
562
538
631
603
729
697
808
773
Operating weight
kg 1380
1445
1710
1780
3012
3067
3439
3884
4330
4452
5010
5172
5592
6442
6742
7992
kg 15
kg 15
15
15
17.2
17.2
19.5
19.5
33.2
19
34.2
23.7
29.4
29.4
37
37
48.4
32.3
46.5
35.1
53.1
38.9
59.8
47.4
59.8
49.3
60
57
60
60
67.4
67.4
kg 16.5
kg 16.5
16.5
16.5
19
19
21.5
21.5
24
15
34
24
28
28
36
36
47
32
46
35
53
38.5
59
46
59
48
59
56
59
59
66
66
Compressors
Circuit A
Circuit B
2
2
3
2
3
2
3
2
3
2
3
3
4
3
4
4
4
4
Control type
No. of capacity stages
Minimum capacity
PRO-DIALOG control
4
4
4
4
25
33
33
33
4
25
5
17
5
17
5
20
5
20
6
14
7
12
8
10
8
12.5
154
199
242
199
242
242
242
242
242
Evaporator
Net water volume
l
Water connections
Inlet/outlet
Drain (NPT)
in
Max. water side operating pressure kPa
Condenser
Fans
Quanitity
Total air flow
Speed
6
20
6
22
4
22
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12C and 7C. Condenser entering air temperature 35C.
Net cooling capacity = gross cooling capacity minus the water pump heat against the internal evaporator pressure drop.
Electrical data
30GH/GZ
040
045
050
060
085
095
100
V-ph-Hz 230-1-50
W
570 570
570
570
980
980
1160 1160 1460 1460 1460 1460 1640 1820 2000 2000
kW
kW
70
64
95
87
117
110
142
134
162
152
189
174
209
192
209
202
237
228
237
225
257
241
304
282
349
328
379
358
Max. unit power input with separate supply (possibible on 30G 170-245)
30GH circuit A
kW
30GH circuit B
kW
30GZ circuit A
kW
30GZ circuit B
kW
-
142
115
141
100
175
129
165
117
175
175
164
164
190
190
179
179
V-ph-Hz 400-3-50
kW
2.3 2.3
4.6
4.6
12
12
12
14
14
19
A
A
A
A
144
std
-
186
std
-
219
std
-
296
std
-
476
338
-
518
380
-
553
415
-
601
463
-
636
498
-
636
498
-
684
546
-
684
546
-
719
581
517
469
802
664
574
497
879
741
574
574
934
796
601
601
A
A
A
A
A
A
78
72
-
102
97
-
120
113
-
166
153
-
204
194
-
250
236
-
280
268
-
333
306
-
364
338
-
364
356
-
416
401
-
416
396
-
447
424
250
197
248
176
530
496
304
229
290
206
608
577
304
304
289
289
666
630
333
333
315
315
Power wiring
Nominal power supply
Voltage range
V-ph-Hz 400-3-50
V
360-440
45
41
59
55
120
130
145
150
160
170
190
220
245
30GZ units have a single power connection point (except 30GZ 170-245 which have two connection
points).
A separate power source (230 V, 1 ph, 50 Hz) that does not exceed the main switch capacity is
required to power the compressor crankcase heater circuit. This source must be supplied from a
transformer. It must not be supplied from a phase + neutral supply (for ground + neutral systems).
Field connections:
All connections to the system and the electrical installations must be in full accordance with all
applicable local codes.
The Carrier 30GZ chillers are designed and built to ensure conformance with these codes. The
recommendations of European standard EN 60 204-1 (machine safety - electrical machine
components - part 1: general regulations) are specifically taken into account, when designing the
electrical equipment.
NOTES:
Generally the recommendations of IEC 364 are accepted as compliance with the requirements of the
installation directives. Conformance with EN 60 204 is the best means of ensuring compliance with
the Machines Directive 1.5.1.
1.
2.
3.
4.
5.
Annex B of EN 60204-1 describes the electrical characteristics used for the operation of the
machines.
The operating environment for the 30GZ chillers is specified below:
Environment* - Environment as classified in EN 60 721:
outdoor installation*
ambient temperature range: -18C to +46C, class 4K4H*
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 364)
Power supply frequency variation: 2 Hz.
The neutral (N) line must not be connected directly to the unit (if necessary use a transformer).
Overcurrent protection of the power supply conductors is not provided with the unit.
The optional factory-installed circuit breaker is of type a (EN 60 204-1 5.3.2).
NOTE: If particular aspects of an actual installation do not conform to the conditions described above, or
if there are other conditions which should be considered, always contact your local Carrier representative.
* The required protection level for this class is IP43BW (according to reference document IEC 529). All
30GZ units are protected to IP44CW and fulfill this protection condition.
APPLICATION DATA
INSTALLATION
040-045
050-060
085-095
100-120
130
145
150
160-245
3.6
4.0
6.0
8.5
9.8
12.1
9.8
12.1
SAFETY CONSIDERATIONS
Installation, start-up and servicing this equipment can be
hazardous due to system pressures, electrical components and
equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start-up and service this equipment.
Untrained personnel can perform basic functions, such as
cleaning coils. All other operations should be performed by
trained service personnel.
Air conditioning
Industrial process cooling
Low temperature operation
3.25
6.5
6.5
Bad
Good
Bad
Good
Preliminary checks
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 30GH/GZ 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 15.
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.
Anti-vibration mountings
Water connections
Refer to the certified dimensional drawings for the sizes and
positions of all water inlet and outlet connections. The water
pipes must not transmit any radial or axial force to the heat
exchangers or any vibration to the pipework or building.
The water supply must be analysed and appropriate filtering,
treatment, control devices, isolation and bleed valves and
circuits built in, as necessary. Consult either a water treatment
specialist or appropriate literature on the subject.
Operating precautions
The water circuit should be designed to have the least number
of elbows and horizontal pipe runs at different levels. Below
the basic checks to be done (see also the illustration of a typical
hydraulic circuit below).
Water-loop connections
Make the water-side heat exchanger connections, using
appropriate hardware capable of ensuring water-tightness of
threaded unions.
The illustration below shows a typical hydraulic circuit.
IMPORTANT: In winter frost can cause cooler damage. Use
appropriate methods of protection, according to the climatic
conditions:
Air vent
Control valve
Flow switch
Heat exchanger
Flexible connection
Buffer tank
Fill valve
Filter
Expansion tank
Drain
Pressure tap
Thermostat sleeve
Power supply
The power supply must conform to the specification on the
chiller nameplate. The supply voltage must be within the range
specified in the electrical data table.
ATTENTION: Units 30GH/GZ 040-160 have only one power
connection point.
Units 30GH/GZ 170-245 have two power connection points.
Fill the chilled water circuit with clean water, and an inhibitor
formulated specifically for this purpose, or fill it with another
non-corrosive fluid to be chilled.
Purge air at all high points in the system. If water temperatures
below 5C for R-407C and 4C for R-22 are likely, add the
appropriate volume of ethylene glycol to prevent freezing.
Confirm that the suction and discharge line stop valves are
fully opened.
Start-up
Preliminary checks
Never be tempted to start the chiller without reading fully, and
understanding, the operating instructions and without having
carried out the following pre-start checks:
Confirm that all crankcase heaters are firmly in place, and
check the secure positioning of all control sensors.
Confirm that all crankcase heaters are working by feeling all
compressor crankcases. Every compressor has a 180 W
cartridge heater (see the wiring diagram). The heater remains
energised even when the chiller is shut down to stop the
lubricating oil from absorbing refrigerant.
Check the operation of all accessories - chilled water
circulating pumps, air handlers and other equipment connected
to the evaporator. Follow the individual manufacturer's
instructions for this equipment.
It is recommended to connect the auxiliary contact of the water
pump contactor to ensure maximum unit safety (see wiring
diagram delivered with the unit).
10
Open the refrigerant line valves. Check again that the water
circuit valves are open.
Check that oil is visible in each compressor sight glass to
between 1/8 and 3/8 of the total glass depth (check for all
compressors).
Confirm that there are no refrigerant leaks.
Confirm that discharge muffler securing bands and discharge
line connections are tight.
Check that all electrical connections are secure.
Actual start-up
IMPORTANT:
11
Compressors
Checking the oil charge
Check the oil level and add or remove oil as necessary so that
the level is 1/8 to 3/8 up each sight glass with the compressor
running normally.
WARNING: Use only oils which have been approved for use in
refrigeration compressors. Never use oil which has been
exposed to air.
Cut in 113C
Crankcase heater
Each compressor is fitted with an electric resistance crankcase
heater which prevents any absorption of refrigerant by the
compressor lubricating oil when the compressor is shut down.
Each heater is held in place by a screw clip which must be
secure. Prolonged exposure of the heater to air will result in its
destruction. The heater is energized when the compressor is
switched off. Regularly check that the heater operates correctly
when the unit is shut down.
WARNING: Never open or disconnect any switch or circuit
breaker which will cut the supply to the heaters, unless the unit
is to be shut down for lengthy service or repair or for a
seasonal shut down. In all cases the heater must be energised
for at least 24 hours before a compressor is restarted.
Compressor protection circuit board (STARTERGUARD)
the contactors
Diameter, mm
Torque, Nm
Discharge valve
Cylinder head
Suction and liquid line flange
Suction valve
M16
M12
M12
M16
135-140
75-87
75-87
135-140
Circuit breaker
Calibrated, thermo-magnetic, manually reset circuit breaker to
protect the motor against locked rotors and excessive current
draw. It also protects against overcurrents up to the trip
capacity indicated on the wiring diagram.
Heat exchangers
12
Evaporator
Protection devices
Evaporator maintenance
Check that:
Multitube evaporators
The evaporator can be removed using the following procedure:
16.00 mm
15.87 mm
0.13 mm
14.27 mm
14.48 mm
NOTE: Tubes next to the gasket webs must be flush with the
tube sheets at either end of the cooler.
Preparation of gaskets
When rebuilding the cooler, new gaskets must always be used.
They must conform to the Carrier specification for compressed
gaskets.
Insert and tighten the six screws in the center of the head.
Tube plate
Stage 1
Stage 2
7
1
5
Plug
Ring
6
2
8
Components
Part number
---T-853--103500S-*
---T-853--002570S-*
---T-853--1031S-*
---T-853--002631S-*
Loctite
Locquic
No. 75*
N*
Condenser coil
We recommend, that finned coils are inspected regularly to
check the degree of fouling. This depends on the environment
where the unit is installed, and will be worse in urban and
industrial installations and near trees that shed their leaves.
For coil cleaning proceed as follows:
117 +0/-2
Maximum
clearance
Refrigerant circuit
The two cleaning products can be used for any of the following
coil finishes: Cu/Cu, Cu/Al, Cu/Al with Polual, Blygold and/or
Heresite protection.
It is not necessary to rinse the coil, as the products used are pH
neutral. To ensure that the coil is perfectly clean, we
recommend rinsing with a low water flow rate. The pH value
of the water used should be between 7 and 8.
WARNING: Never use pressurized water without a large
diffusor. Concentrated and/or rotating water jets are strictly
forbidden.
Correct and frequent cleaning (approximately every three
months) will prevent 2/3 of the corrosion problems.
Fan motor replacement
This presents no special problems. The work is done from
above the unit.
14
TROUBLESHOOTING CHART
Below we list a series of possible faults, along with the probable causes and suggested solutions. In the event of a unit
malfunction, it is advisable to disconnect the power supply and ascertain the cause.
SYMPTOMS
CAUSE
REMEDY
Close switch
Reset
Replace contactor
Check connections
Replace contactor
Defective compressor
Refrigerant losses
Refrigerant losses
Clean or replace
Replace filter
Defective fan(s)
Piping vibrations
Noisy compressor
Install correctly
Repair leak
Water losses
15
Order No. 13187-76, September 1997. Supersedes order No.: 13187-76, July 1996
Manufacturer reserves the right to change any product specifications without notice.
16