30GX 082-358 30HXC 080-375 Screw Compressor Water …

1 30GX 082-35830 HXC 080-375 Screw Compressor Water -CooledLiquid Chillers andAir- cooled liquid ChillersNominal cooling capacity 30 HXC: 290-1286 kWNominal cooling capacity 30GX: 282-1203 kW50 HzInstallation, operation and maintenance instructionsGLOBAL CHILLERC arrier is participating in the Eurovent Certification Programme. Products are as listed in the Eurovent Directory of Certified cover photograph is for illustrative purposes only and is not part of any offer for sale or contract. LIST OF CONTENTS1 - INTRODUCTION .. - Installation safety considerations .. - Equipment and components under pressure .. - Maintenance safety considerations .. - Repair safety considerations .. 52 - PRELIMINARY CHECKS .. - Check equipment received .. - Moving and siting the unit .. 63 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION .. - 30 HXC 080-190 .. - 30 HXC 200-375 .. - 30GX 082-182 .. - 30GX 207-358 .. - Multiple chiller installation.

2 124 - PHYSICAL AND ELECTRICAL DATA FOR 30 HXC UNITS .. - Physical data 30 HXC .. - Electrical data 30 HXC .. - Electrical data, 30 HXC compressors .. - Electrical data for 30 HXC units with high condensing temperatures (option 150/150A) .. 145 - PHYSICAL AND ELECTRICAL DATA FOR UNITS 30GX .. - Physical data 30GX .. - Electrical data 30GX .. - Electrical data, 30GX and 30 HXC compressors, option 150 + 150A .. 176 - APPLICATION DATA .. - Unit operating range .. - Minimum chilled Water flow .. - Maximum chilled Water flow .. - Variable flow evaporator .. - System minimum Water volume .. - Cooler flow rate (l/s) .. - Condenser flow rate (l/s) .. - Evaporator pressure drop curve .. - Condenser pressure drop curve .. 207 - ELECTRICAL CONNECTION .. - Electrical connections 30 HXC units .. - Electrical connections 30GX units .. - Power supply .. - Voltage phase imbalance (%) .. - Recommended wire sections.

3 2538 - Water CONNECTIONS .. - Operating precautions .. - Water connections .. - Flow control .. - Evaporator (and condenser for the 30 HXC) Water box bolt tightening .. - Frost protection .. - Operation of two units in master/slave mode .. 299 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA .. - Geared twin Screw Compressor .. - Pressure vessels .. - Electronic expansion device (EXV) .. - Economizer .. - Oil pumps .. - Motor cooling valves .. - Sensors .. 3210 - MAIN OPTIONS AND ACCESSORIES .. - Compressor suction valves (option 92) .. - Compressor and evaporator noise insulation (30GX - option 14A) .. - Low-noise 30GX units equipped with acoustic panels (option 15) .. - Evaporator frost protection (30GX - option 41A) .. - Year-round operation of 30GX units (option 28) .. - Soft Start for 3- and 4- Compressor 30 HXC and 30GX units (option 25) .. - Electric protection level of the 30 HXC control boxes to IP44C (option 20).

4 - Tropicalised control box for 30 HXC and 30GX units (option 22) .. - Brine units for low-temperature evaporator leaving applications (option 5) .. - Disassembled 30 HXC units (option 52) .. - Available fan pressure of 150 Pa for 30GX units (option 12) .. 3411 - MAINTENANCE .. - Maintenance instructions .. - Soldering and welding .. - Refrigerant charging - adding charge .. - Indication of low charge on a 30 HXC system .. - Electrical maintenance .. - Pressure transducers .. - Oil charging - low oil recharging .. - Integral oil filter change .. - Filter change-out schedule .. - Filter change-out procedure .. - Compressor replacement .. - Corrosion control .. - Condenser coil .. 3712 - START-UP CKECKLIST FOR 30 HXC/GX liquid CHILLERS (USE FOR JOB FILE) .. 3841 - INTRODUCTIONP rior to the initial start-up of the 30 HXC/GX units, the peopleinvolved in the on-site installation, start-up, operation, andmaintenance of this unit should be thoroughly familiar with theseinstructions and the specific project data for the installation 30 HXC/GX liquid chillers are designed to provide a veryhigh level of safety during installation, start-up, operation andmaintenance.

5 They will provide safe and reliable service whenoperated within their application manual provides the necessary information to familiarizeyourself with the control system before performing start-upprocedures. The procedures in this manual are arranged in thesequence required for machine installation, start-up, operationand sure you understand and follow the procedures and safetyprecautions contained in the instructions supplied with themachine, as well as those listed in this - Installation safety considerationsAfter the unit has been received, when it is ready to be installedor reinstalled, and before it is started up, it must be inspectedfor damage. Check that the refrigerant circuit(s) is (are) intact,especially that no components or pipes have shifted ( follow-ing a shock). If in doubt, carry out a leak tightness check andverify with the manufacturer that the circuit integrity has notbeen impaired. If damage is detected upon receipt, immediatelyfile a claim with the shipping not remove the skid or the packaging until the unit is in itsfinal position.

6 These units can be moved with a fork lift truck,as long as the forks are positioned in the right place anddirection on the units can also be lifted with slings, using only the desig-nated lifting points marked on the units are not designed to be lifted from above. Useslings with the correct capacity, and always follow the liftinginstructions on the certified drawings supplied with the is only guaranteed, if these instructions are carefullyfollowed. If this is not the case, there is a risk of materialdeterioration and injuries to cover any safety applies to the relief valve in the Water circuit and therelief valve(s) in the refrigerant circuit(s).Ensure that the valves are correctly installed, beforeoperating the certain cases the relief valves are installed on isolatingvalves. These valves are factory-supplied lead-sealed in theopen position. This system permits isolation and removal ofthe relief valves for checking and replacing.

7 The relief valvesare designed and installed to ensure protection againstoverpressure caused by factory-installed relief valves are lead-sealed to preventany calibration change. If the relief valves are installed on achange-over manifold, this is equipped with a relief valve oneach of the two outlets. Only one of the two relief valves is inoperation, the other one is isolated. Never leave the change-over valve in the intermediate position, with both waysopen (locate the control element in the stop position). If arelief valve is removed for checking or replacement pleaseensure that there is always an active relief valve on each ofthe change-over valves installed in the safety valves must be connected to discharge pipes. Thesepipes must be installed in a way that ensures that people andproperty are not exposed to refrigerant leaks. These fluidsmay be diffused in the air, but far away from any building airintake, or they must be discharged in a quantity that isappropriate for a suitably absorbing a drain in the discharge circuit, close to each reliefvalve, to avoid an accumulation of condensate or rain check of the relief valves: See paragraph Maintenance safety considerations.

8 Ensure good ventilation, as accumulation of refrigerant in anenclosed space can displace oxygen and cause asphyxiationor of high concentrations of vapour is harmful andmay cause heart irregularities, unconsciousness, or is heavier than air and reduces the amount of oxygenavailable for breathing. These products cause eye and skinirritation. Decomposition products are - Equipment and components under pressureThese products incorporate equipment or components underpressure, manufactured by Carrier or other manufacturers. Werecommend that you consult your appropriate national tradeassociation or the owner of the equipment or components underpressure (declaration, re-qualification, retesting, etc.). Thecharacteristics of this equipment/these components are givenon the nameplate or in the required documentation, suppliedwith the - Maintenance safety considerationsEngineers working on the electric or refrigeration componentsmust be authorized, trained and fully qualified to do refrigerant circuit repairs must be carried out by a trainedperson, fully qualified to work on these units.

9 He must havebeen trained and be familiar with the equipment and theinstallation. All welding operations must be carried out byqualified manipulation (opening or closing) of a shut-off valvemust be carried out by a qualified and authorised procedures must be carried out with the unit : The unit must never be left shut down with the liquidline valve closed, as liquid refrigerant can be trapped betweenthis valve and the expansion device. (This valve is situated onthe liquid line before the filter drier box.)During any handling, maintenance and service operationsthe engineers working on the unit must be equipped withsafety gloves, glasses, shoes and protective work on a unit that is still work on any of the electrical components, until thegeneral power supply to the unit has been cut using thedisconnect switch(es) in the control box(es).If any maintenance operations are carried out on the unit,lock the power supply circuit in the open position ahead ofthe the work is interrupted, always ensure that all circuits arestill deenergized before resuming the : Even if the Compressor motors have beenswitched off, the power circuit remains energized, unless theunit or circuit disconnect switch is open.

10 Refer to the wiringdiagram for further details. Attach appropriate safety manual 30GX/30 HXC Pro-Dialog Plus control for adetailed explanation of the high-pressure switch test checks: During the life-time of the system,inspection and tests must be carried out in accordance withnational information on operating inspections given in annex Cof standard EN278-2 can be used if no similar criteria existin the national device checks (annex C6 EN378-2): The safetydevices must be checked on site once a year for safety devices(high-pressure switches), and every five years for externaloverpressure devices (pressure relief valves).If the machine operates in a corrosive environment, inspectthe protection devices more carry out leak tests and immediately repair any - Repair safety considerationsAll installation parts must be maintained by the personnel incharge, in order to avoid material deterioration and injuries topeople.