Carrier Pro-Dialog Plus 30HZ Manual
30HZ/HZV 043-280
Water-Cooled/Condenserless
Liquid Chillers
Nominal cooling capacity 30HZ: 134-783 kW
Nominal cooling capacity 30HZV: 126-735 kW
50 Hz
Installation, operation and maintenance instructions
2
CONTENTS
1 - INTRODUCTION ..................................................................................................................................................................... 4
1.1 - Installation safety considerations ........................................................................................................................................... 4
1.2 - Equipment and components under pressure ........................................................................................................................4
1.3 - Maintenance safety considerations ........................................................................................................................................4
1.4 - Repair safety considerations................................................................................................................................................... 5
2 - PRELIMINARY CHECKS ...................................................................................................................................................... 6
2.1 - Check equipment received...................................................................................................................................................... 6
2.2 - Moving and siting the unit....................................................................................................................................................... 7
3 - DIMENSIONS, CLEARANCES.............................................................................................................................................8
3.1 - 30HZ/HZV 043-065 ................................................................................................................................................................. 8
3.2 - 30HZ/HZV 091-225 ................................................................................................................................................................. 8
3.3 - 30HZ/HZV 250-280 ................................................................................................................................................................. 9
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV ............................................................................................ 10
4.1 - Physical data ........................................................................................................................................................................... 10
4.2 - Electrical data.........................................................................................................................................................................11
4.3 - Power supply........................................................................................................................................................................... 12
4.4 - Voltage phase imbalance (%) ............................................................................................................................................... 12
4.5 - Recommended wire sections ................................................................................................................................................ 12
5 - APPLICATION DATA...........................................................................................................................................................13
5.1 - Unit operating range.............................................................................................................................................................. 13
5.2 - Minimum chilled water flow ................................................................................................................................................. 13
5.3 - Maximum chilled water flow................................................................................................................................................. 13
5.4 - Variable flow evaporator ....................................................................................................................................................... 14
5.5 - System minimum water volume ........................................................................................................................................... 14
5.6 - Evaporator flow rate..............................................................................................................................................................14
5.7 - Condenser water flow rates................................................................................................................................................... 15
5.8 - Condenser water flow restrictor ...........................................................................................................................................15
6 - WATER CONNECTIONS...................................................................................................................................................... 16
6.1 - Operating precautions ...........................................................................................................................................................16
6.2 - Water connections .................................................................................................................................................................. 17
6.3 - Flow control ............................................................................................................................................................................ 17
6.4 - Condenser connections.......................................................................................................................................................... 17
6.5 - Frost protection ...................................................................................................................................................................... 18
6.6 - Refrigerant line connections (30HZV) ............................................................................................................................... 18
6.7 - Operation of two units in master/slave mode ..................................................................................................................... 22
7 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA FOR STANDARD UNITS..................................22
7.1 - Compressors............................................................................................................................................................................ 22
7.2 - Lubricant ................................................................................................................................................................................. 22
7.3 - Pressure vessels....................................................................................................................................................................... 22
7.4 - Electronic expansion device (EXV) ....................................................................................................................................23
7.5 - Refrigerant..............................................................................................................................................................................23
7.6 - High-pressure safety switch .................................................................................................................................................. 23
7.7 - Moisture indicator.................................................................................................................................................................. 23
7.8 - Filter drier ............................................................................................................................................................................... 23
3
The cover illustration is for illustrative purposes only and is not part of any offer for sale or contract.
8 - MAIN OPTIONS AND ACCESSORIES............................................................................................................................. 24
8.1 - Units for low evaporator outlet temperature applications (options 5 and 6) ................................................................. 24
8.2 - Electrical protection to IP44 (option 20).............................................................................................................................24
8.3 - High- and low-pressure gauges (option 26) ........................................................................................................................ 24
8.4 - Compressor oil pressure safety device ................................................................................................................................ 24
8.5 - Condenser with CuNi tubes (option 33).............................................................................................................................. 24
8.6 - RS 485 communication interface (option 148) ...................................................................................................................24
8.7 - Additional capacity step 30HZ/HZV 043 to 065 (option 94)............................................................................................24
8.8 - Evaporator pump starter (options 84 and 84D) ................................................................................................................. 24
8.9 - Condenser pump starter (option 84R) ................................................................................................................................ 24
9 - MAINTENANCE..................................................................................................................................................................... 25
9.1 - Soldering and welding............................................................................................................................................................25
9.2 - Maintenance of the refrigerant circuit................................................................................................................................. 25
9.3 - Electrical maintenance .......................................................................................................................................................... 26
9.4 - Evaporator maintenance.......................................................................................................................................................27
9.5 - Corrosion control ...................................................................................................................................................................28
10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS (USE FOR JOB FILE)..................................... 29
4
Prior to the initial start-up of the 30HZ/HZV 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 30HZ/HZV liquid chillers are designed to provide a
very high level of safety during installation, start-up, opera-
tion and maintenance. They will provide safe and reliable
service when operated within their application range.
This manual provides the necessary information to fami-
liarize 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.
To find out, if these products comply with European
directives (machine safety, low voltage, electromagnetic
compatibility, equipment under pressure etc.) check the
declarations of conformity for these products.
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, 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 on the unit.
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).
Ensure that the valves are correctly installed, before
operating the unit.
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.
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 “Mainte-
nance safety considerations”.
Provide a drain in the discharge circuit, close to each valve,
to avoid an accumulation of condensate.
Ensure good ventilation, as accumulation of refrigerant in
an enclosed space can displace oxygen and cause asphyxia-
tion 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 oxy-
gen available for breathing. These products cause eye and
skin irritation. Decomposition products are hazardous.
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 compo-
nents under pressure (declaration, re-qualification, retesting,
etc.).The characteristics of this equipment/these components
are given on the nameplate or in the required documenta-
tion, supplied with the products.
Engineers working on the electric or refrigeration compo-
nents must be authorized, trained 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. All welding operations must be carried out by
qualified specialists.
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.
5
• At least once a year thoroughly inspect the protection
devices (valves). If the machine operates in a corrosive
environment, inspect the protection devices more
frequently.
• Regularly carry out leak tests and immediately
repair any leaks.
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.
Repair the leak detected and recharge the circuit with the
total R-407C charge, as indicated on the unit name plate.
Only charge liquid R-407C refrigerant at the liquid line
(see chapter “Refrigerant charge”).
Ensure that you are using the correct refrigerant type
before recharging the unit (see unit name plate).
Charging any refrigerant other than the original charge
type will impair machine operation and can even lead to
a destruction of the compressors.
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. Refrige-
rant 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.
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.)
During any handling, maintenance and service operations
the engineers working on the unit must be equipped with
safety gloves, glasses, shoes and protective clothing.
Never work on a unit that is still energized.
Never work on any of the electrical components, until the
general power supply to the unit has been cut using the
disconnect 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
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.
Protection of electronic boards: If the boards need to be
handled wear anti-static gloves to avoid exposing the elec-
tronic components to a destructive voltage. Only unpack
the boards from their anti-static bag when they need to be
installed.
Once a year check that the high-pressure safety switch is
correctly connected and that it cuts out at the correct value.
Operating checks:
IMPORTANT INFORMATION REGARDING THE
REFRIGERANT USED:
• This product contains fluorinated greenhouse gas
covered by the Kyoto protocol.
Refrigerant type: R-407C
Global Warming Potential (GWP): 1653
Periodic inspections for refrigerant leaks may be
required depending on European or local legislation.
Please contact your local dealer for more information.
• 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 EN 378-2 can be used if no
similar criteria exist in the national regulations.
Safety device checks (annex C6 – EN 378-2):
• 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
valves).
• Check manual “30HZ/HZV Pro-Dialog Plus control”
for a detailed explanation of the high-pressure switch
test method.
6
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.
• 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
PS (bar) -0.9 32 -0.9 21
TS (°C) -20 74 -20 55
Pressure switch cut-out pressure (bar) 21.8 -
Valve cut-out pressure (bar) 30 21
Test pressure, unit leak test (bar) 15
• 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”.
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.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting condi-
tioning 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 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 not incinerate.
Do not attempt to remove refrigerant circuit components
or fittings, while the machine is under pressure or while it
is running. Be sure pressure is at 0 kPa before removing
components or opening a circuit.
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.
ATTENTION: No part of the unit must be used as a walk-
way, rack or support. Periodically check and repair or if
necessary replace any component or piping that shows signs
of damage.
The refrigerant lines can break under the weight and release
refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.)
to lift or move heavy components. For lighter components,
use lifting equipment when there is a risk of slipping or
losing your balance.
Use only original replacement parts for any repair or com-
ponent replacement. Consult the list of replacement parts
that corresponds to the specification of the original equip-
ment.
Do not drain water circuits containing industrial brines,
without informing the technical service department at the
installation site or a competent body first.
7
• 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, cer-
tificates, 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 special 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.
2.2.3 - Check compressor mountings
Before any start-up of the unit proceed as follows:
1. Remove the wooden block located under the compres-
sor foot.
2. Remove the screw and washer used for transportation.
3. Assemble screw (A), snubber (B) and plain washer (C).
Remove the centre bolt (A) from each spring mounting, so
that the compressor support can float freely.
2.2.1 - Moving
See chapter 1.1 “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 dis-
tribution points, refer to the certified dimensional drawing
supplied with the unit.
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been verified.
CAUTION: Only use slings at the designated lifting points
which are marked on the unit.
Before siting the unit check that:
• the permitted loading at the site is adequate or that
appropriate strenghtening measures have been taken.
• the unit is installed level on an even surface (maximum
tolerance is 5 mm in both axes).
• there is adequate space above the unit to ensure access
to the components for maintenance.
• the number of support points is adequate and that
they are in the right places.
• the location is not subject to flooding.
CAUTION: Lift and set down the unit with great care.
Tilting and jarring can damage the unit and impair unit
operation.
If 30HZ/HZV units are hoisted with rigging, it is advis-
able to protect the control box against accidental shocks.
Do not tilt a unit more than 15°.
WARNING: Never push or lever the chassis or the control
box of the unit.
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 refrigera-
tion 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.
8
3
3
3
4
2
1
A
CB
2550
800
800 800
9
Evaporator
Condensers
Clearances required for operation and maintenance
Clearances recommended for heat exchanger tube removal
Power supply
Water inlet
Water outlet
043 2452 1520 915
2750 1505 915
2750 1505 915
2630 1915 950
101 2940 1915 950
111 2940 1915 950
121 2940 1915 950
141 3550 1915 950
3550 1915 950
4255 1950 950
4255 1950 950
4070 2150 1275
043 2452 1260 904
2750 1245 904
2750 1245 904
2630 1300 950
101 2940 1300 950
111 2940 1300 950
121 2940 1300 950
141 3550 1300 950
3550 1300 950
4255 1340 950
4255 1340 950
4070 1680 1275
Dimensions in mm
NOTE: Non-contractual drawings. Certified dimensional
drawings, available on request.
FLOOR MOUNTING
For the positioning of the fixing points, weight distribution and centre of gravity coordinates, refer to the certified
drawings.
1
2
3
4
10
kW
30HZ 134 153 199 230 270 300 316 371 415 533 626 719 783
30HZV 126 144 194 216 260 278 297 352 388 500 588 677 735
kg
30HZ 1090 1183 1252 2039 2370 2460 2510 2730 2830 3505 3805 4470 4900
30HZV 880 968 1018 1672 1960 2000 2040 2260 2300 2975 3267 3780 4106
kg R-407C
Circuit A 15.7 17.5 21.0 38.2 29.5 34.5 33.5 38.0 42.0 54.0 54.0 62.5 62.5
Circuit B 15.7 17.5 21.0 19.5 29.5 29.5 33.5 38.0 42.0 46.5 54.0 60.5 62.5
06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s
Quantity - Circuit A 1 1 1 2 2 2 2 2 2 3 3 4 4
Quantity - Circuit B 1 1 1 1 2 2 2 2 2 2 3 3 4
PRO-DIALOG Plus control
No. of control steps 4 4 4 6 11 11 11 11 11 5 6 7 8
Minimum step capacity % 40 33 33 22 20 18 16 19 16 20 16 14 12
One, direct expansion, multi-tube shell
Net water volume l 55 63 63 92 154 154 154 199 199 242 242 276 276
No. of refrigerant circuits 2 2 2 2 2 2 2 2 2 2 2 2 2
Water connections
Inlet/outlet 3” gas threaded PN16DN100 PN16DN125 PN16DN150
NFE 03005 NFE 29203 NFE 29203 NFE29203
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Shell and multi-tube
Quantity 2 2 2 2 2 2 2 2 2 2 2 2 2
Net water volume l
Circuit A 10 10 12 25 18 25 25 25 30 37 37 51 51
Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51
Water connections in Gas threaded Flat flange, brazed
Inlet/outlet, circuit A 1-1/2 1-1/2 2 2-1/2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3
Inlet/outlet, circuit B 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3
Drain and vent NPT in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* Nominal Eurovent conditions:
- evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C
- evaporator and condenser fouling factor = 0.000044 m2K/W
- condensing temperature dew point 45°C
- fluid temperature = condensing temperature at dew point - refrigerant glide - 5 K subcooling
- Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)
** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.
*** The 30HZV units have a nitrogen holding charge only.
11
Nominal power supply V-ph-Hz 400-3-50
System voltage range V 360-440
The control circuit is supplied via a factory-installed transformer.
30HZ kW 38.5 48.9 68 69 78 86 92 112 131 165 201 239 270
30HZV kW 38.5 48.6 65 70 77 86 94 112 135 165 200 234 266
30HZ A 63.8 81.1 112 114 129 142 152 185 217 273 333 396 448
30HZV A 63.8 80.6 108 116 127 142 156 185 224 273 332 388 441
30HZ - circuit A and B kW 45 55 77 82 90 100 109 132 155 194 232 - -
30HZ - circuit A kW - - - - - - - - - - - 155 155
30HZ - circuit B kW - - - - - - - - - - - 116 155
30HZV - circuit A and B kW 54 65 90 98 107 119 130 155 180 225 270 - -
30HZV - circuit A kW - - - - - - - - - - - 180 180
30HZV - circuit B kW - - - - - - - - - - - 135 180
30HZ - circuit A and B A 87 105 150 158 174 192 211 255 299 374 449 - -
30HZ - circuit A A - - - - - - - - - - - 299 299
30HZ - circuit B A - - - - - - - - - - - 224 299
30HZV - circuit A and B A 101 123 170 185 203 224 246 293 340 425 509 - -
30HZV - circuit A A - - - - - - - - - - - 340 340
30HZV - circuit B A - - - - - - - - - - - 255 340
30HZ - circuit A and B A 78 95 135 142 157 173 190 230 269 336 404 - -
30HZ - circuit A A - - - - - - - - - - - 269 269
30HZ - circuit B A - - - - - - - - - - - 202 269
30HZV - circuit A and B A 91 111 153 166 182 202 221 264 306 382 458 - -
30HZV - circuit A A - - - - - - - - - - - 306 306
30HZV - circuit B A - - - - - - - - - - - 229 306
30HZ - circuit A and B A 182 198 273 245 227 275 291 330 404 470 536 - -
30HZ - circuit A A - - - - - - - - - - - 404 404
30HZ - circuit B A - - - - - - - - - - - 338 404
30HZV - circuit A and B A 188 207 283 263 251 299 318 360 436 513 589 - -
30HZV - circuit A A - - - - - - - - - - - 436 436
30HZV - circuit B A - - - - - - - - - - - 360 436
A 2.33 2.09 2.03 1.72 1.45 1.59 1.53 1.44 1.50 1.40 1.33 1.50 1.50
A - - - - - - - - - - - 1.68 1.50
A 2.06 1.87 1.85 1.58 1.37 1.48 1.44 1.37 1.43 1.34 1.28 1.43 1.43
A - - - - - - - - - - - 1.57 1.43
30HZ - circuit A and B kA 15 15 15 15 20 20 20 20 20 25 25 - -
30HZ - circuit A kA - - - - - - - - - - - 25 25
30HZ - circuit B kA - - - - - - - - - - - 25 25
30HZV - circuit A and B kA 15 15 15 15 20 20 20 20 20 25 25 - -
30HZV - circuit A kA - - - - - - - - - - - 25 25
30HZV - circuit B kA - - - - - - - - - - - 25 25
Circuit A A 6 8 10 10 10 10 10 12 15 24 32 25 32
Circuit B A - - - - - - - - - - - 20 20
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.
Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).
** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12°C, saturated condensing temperature (dew point) = 52°C
(30HZ)/66°C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
† Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest
compressor).
‡ Current and power inputs not included in the values above.
• 30HZ/HZV 043 to 225 units have a single power connection point; 30HZ/HZV
250 to 280 units have two connection points.
• The control box includes the following standard features:
- Starter and motor protection devices for each compressor
- Control devices
•
All connections to the system and the electrical installations must be in full
accordance with all applicable codes.
• The Carrier 30HZ/HZV chillers are designed and built to ensure conformance
with local codes. The recommendations of European standard EN 60204-1
(corresponds to IEC 60204-1) (machine safety - electrical machine components
- part 1: general regulations) are specifically taken into account, when designing
the electrical equipment.
• Conformance with EN 60204-1 is the best means of ensuring compliance with the
Machines Directive and § 1.5.1. Generally the recommendations of IEC 60364
are accepted as compliance with the requirements of the installation directives.
• Annex B of EN 60204-1 describes the electrical characteristics used for the
operation of the machines.
1. The operating environment for the 30HZ/HZV chillers is specified below:
a. 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:≤2000m
- 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 AF1 (negligible)
- vibration and shock, class AG2, AH2
b. 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. Over-current 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 net-
works the earth connection must not be at the network earth. Provide a local earth,
consult competent local organisations to complete the electrical installation.
* The protection level required to conform to this class is IP21B (according to
reference document IEC 60529). All 30HZ/HZV units are protected to IP23C
and fulfil this protection condition.
12
The power supply must conform to the specification on the
chiller nameplate. The supply voltage must be within the
range specified in the electrical data table. For connections
refer to the wiring diagrams.
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 10% for
current, contact your local electricity supply at once and
ensure that the chiller is not switched on until corrective
measures have been taken.
100 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 V; AC = 394 V
Average voltage = (406 + 399 + 394)/3 = 1199/3
= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average:
(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
The maximum deviation from the average is 6 V. The
greatest percentage deviation is:
100 x 6/400 = 1.5%
This is less than the permissible 2% and is therefore
acceptable.
Motor
4.5.2 - Selection table of minimum and maximum wire sections for connection by phase to 30HZ/HZV units
2 2
043 1 x 25 XLPE Copper 130 1 x 95 PVC Aluminium 250
1 x 35 XLPE Copper 142 1 x 120 PVC Aluminium 260
1 x 50 XLPE Copper 162 1 x 120 XLPE Aluminium 205
1 x 70 XLPE Copper 168 1 x 150 XLPE Aluminium 210
101 1 x 70 XLPE Copper 168 1 x 150 XLPE Aluminium 210
111 1 x 70 XLPE Copper 168 1 x 185 XLPE Aluminium 220
121 1 x 95 XLPE Copper 178 1 x 240 XLPE Aluminium 225
141 1 x 120 XLPE Copper 185 2 x 95 XLPE Aluminium 195
1 x 150 XLPE Copper 188 2 x 120 XLPE Aluminium 205
1 x 240 XLPE Copper 192 2 x 185 XLPE Aluminium 220
2 x 95 XLPE Copper 172 2 x 240 XLPE Aluminium 225
1 x 150 XLPE Copper 188 2 x 120 PVC Copper 295
2 x 150 XLPE Aluminium 210
1 x 95 XLPE Copper 178 2 x 70 PVC Copper 270
1 x 240 XLPE Aluminium 225
1 x 185 XLPE Copper 190 2 x 95 XLPE Copper 215
2 x 150 XLPE Aluminium 210
1 x 150 XLPE Copper 188 2 x 120 PVC Copper 295
2 x 120 XLPE Aluminium 205
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 guide-
line, 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).
For the design the following standardised installation
methods are used, in accordance with IEC 60364, table 52C:
• For 30HZ/HZV units installed inside the building:
No. 13: Horizontal perforated cable conduits and No.
14: closed cable conduit.
The calculation is based on PVC or XLPE insulated cables
with copper or aluminium core.The maximum temperature
is 40°C.The given wire length limits the voltage drop to < 5%.
IMPORTANT: Before connection of the main power cables
(L1 - L2 - L3) on the terminal block, it is imperative to
check the correct order of the 3 phases before proceeding
to the connection on then terminal block or the main
disconnect/isolator switch.
4.5.1 - Field control wiring
Refer to the 30HZ/HZV Pro-Dialog Plus Controls IOM
and the certified wiring diagram supplied with the unit for
the field control wiring of the following features:
• Evaporator pump interlock (mandatory)
• Remote on/off switch
• Remote heat/cool switch
• Demand limit external switch 1
• Remote dual set point
• Alarm report by circuit
• Evaporator pump control
• Condenser pump control
• Remote set point reset or outside air temperature
sensor reset (0-10 V)
13
Entering water temperature at start-up °C 6.8* 30
Leaving water temperature during operation °C 4** 10†
Entering water temperature °C 15 ‡
Leaving water temperature °C 20 45
For application requiring operation at less than 6.8°C, contact Carrier for unit
selection using the Carrier electronic catalog.
** For operation between 4°C and -15°C, the unit must be equipped with option 5
or 6, and the use of anti-freeze is required.
† For an application, requiring operation up to +15°C leaving water temperature,
contact Carrier for the selection of the unit.
‡ Depends on the maximum condenser flow rate.
Maximum outside temperature: For transport and storage of the 30HZ/HZV
units the minimum and maximum allowable temperatures are –20°C and
+50°C. It is recommended that these temperatures are used for transport by
container.
5.1.1 - Operating range 30HZ
The minimum chilled water flow is shown in the table on the
next page. If the flow is less than this, the evaporator flow
can be recirculated, as shown in the diagram. The tempera-
ture of the mixture leaving the evaporator must never be
less than 2.8 K lower than the chilled water entering tempe-
rature.
1 Evaporator
2 Recirculation
The maximum chilled water flow is limited by the maximum
permitted pressure drop in the evaporator. It is provided in
the table on the next page. If the flow exceeds the maximum
value, two solutions are possible:
• Select a non-standard evaporator (-2 baffles) which
will allow a higher maximum water flow rate.
• Bypass the evaporator as shown in the diagram to
obtain a highter temperature difference with a lower
evaporator flow rate.
1 Evaporator
2 Bypass
A 30HZ
B 30HZ with option 150 (high condensing temperature)
C 30HZ with option 5
D 30HZ with option 150 + 5
E 30HZ with option 6
1. Evaporatorandcondenser∆T=5K
Leaving evaporator water temperature °C
Leaving condenser water temperature °C
45
40
35
30
25
20
39
44
42
36
A
B
C
D
E
-15 -10 -5 0 5 10-6
1
2
1
2
14
Variable evaporator flow can be used in standard chillers.
The chillers maintain a constant leaving water temperature
under all flow conditions. For this to happen, the minimum
flow rate must be higher than the minimum flow given in
the table of permissible flow rates and must not vary by
more than 10% per minute.
If the flow rate changes more rapidly, the system should
contain a minimum of 6.5 litres of water per kW instead of
3.25 l/kW.
Whichever the system, the water loop minimum capacity is
given by the formula:
Capacity = Cap (kW) x N litres
Normal air conditioning 3.25
Process type cooling 6.5
Where Cap is the nominal system cooling capacity (kW) at
the nominal operating conditions of the installation.
This volume is necessary for stable operation and accurate
temperature control.
043 4.1
5.0
6.0
101-121 8.5
9.9
12.0
Bad
Bad
Good
Good
It is often necessary to add a buffer water tank to the circuit
in order to achieve the required volume. The tank must
itself be internally baffled in order to ensure proper mixing
of the liquid (water or brine). Refer to the examples below.
NOTE: The compressor must not restart more than 6 times
in an hour.
Pressure drop, kPa
1 30HZ/HZV 043
2 30HZ/HZV 052-065
3 30HZ/HZV 091
4 30HZ/HZV 101-121
5 30HZ/HZV 141-161
6 30HZ/HZV 195-225
7 30HZ/HZV 250-280
Water flow rate l/s
15
043 2 1.20 3.60 14.80
2 1.20 3.60 14.80
2 1.40 4.20 17.00
2 2.47 7.42 30.00
101 2 2.60 7.64 31.00
111 2 3.04 9.13 37.00
121 2 3.54 10.62 43.00
141 2 3.54 10.62 43.00
2 3.54 10.62 43.00
2 4.00 12.00 48.00
2 4.46 13.40 54.00
2 5.04 15.14 61.00
280 2 5.62 16.88 68.00
* Based on a water velocity of 0.3 m/s in closed-loop and 0.9 m/s in open-loop
systems.
** Based on a water velocity of 3.6 m/s.
1 30HZ/HZV 043-052
2 30HZ/HZV 065
3 30HZ/HZV 091
4 30HZ/HZV 101
5 30HZ/HZV 111
6 30HZ/HZV 121-141
7 30HZ/HZV 161
8 30HZ/HZV 195
9 30HZ/HZV 225
10 30HZ/HZV 250
11 30HZ/HZV 280
Pressure drop, kPa
Water flow rate, l/s
CAUTION: To ensure correct operation of the units, these
restrictors must be installed. The restrictor is supplied with
the machine, inside the control box.
043 2 31 Condenser 09RS 022 circuit B - water outlet
2 47 Condenser 09RS 054 - water outlet
111 2 47 Condenser 09RS 054 - water outlet
2 47 Condenser 09RS 070 - water outlet
2 56 Condenser 09RS 084 - water outlet
* No. of passes
1
2
3
9
456
7810
11
1
10
100
1 10 100
16
For size and position of the heat exchanger 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 water
treatment elements installed: filters, additives, intermediate
heat exchangers, purges, vents, shut-off valves, etc., to prevent
corrosion, fouling and deterioration of the pump fittings.
Consult either a water treatment specialist or appropriate
literature on the subject.
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
circuit and install a safety valve as well as an expansion
tank.
• Install thermometers in both the entering and leaving
water connections.
• Install drain connections at all low points to allow the
whole circuit to be drained.
• Install stop valves, close to the entering and leaving
water connections.
• Use flexible connections to reduce the transmission of
vibrations.
• Insulate all pipework, after testing for leaks, both to
reduce thermal leaks and to prevent condensation.
• Cover the insulation with a vapour barrier.
• Where there are particles in the fluid that could foul
the heat exchanger, a screen filter should be installed
ahead of the pump. The mesh size of the filter must be
1.2 mm (see ‘Typical water circuit’ diagram on the right).
• 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).
• 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 recommend-
ed by Carrier 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 recommendations on heat exchange fluids:
• No NH4+ 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 con-
tent of several tenths of mg/l will badly corrode the
copper over time.
• Cl-Chloride ions are detrimental for copper with a risk
of perforations by corrosion by puncture. If possible
keep below 10 mg/l.
• SO4
2- sulphate ions can cause perforating corrosion, if
their content is above 30 mg/l.
• No fluoride ions (< 0.1 mg/l).
• No Fe2+ and Fe3+ ions with non negligible levels of dis-
solved oxygen must be present. Dissolved iron < 5 mg/l
with dissolved oxygen < 5 mg/l.
• Dissolved silicon: silicon is an acid element of water
and can also lead to corrosion risks. Content < 1mg/l.
• Water hardness: > 0.5 mmol/l. Values between 1 and
2.5 can be recommended. This will facilitate scale
deposit that can limit corrosion of copper.Values that
are too high can cause piping blockage over time. A
total alkalimetric titre (TAC) below 100 is desirable.
• Dissolved oxygen:Any sudden change in water oxygena-
tion 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.
• Specific resistance – electric conductivity: the higher
the specific resistance, the slower the corrosion tendency.
Values above 30 Ohm·m are desirable.A neutral
environment favours maximum specific resistance
values. For electric conductivity values in the order of
20-60 mS/m can be recommended.
• pH: Ideal case pH neutral at 20-25°C
7 < pH < 8
If the water circuit must be emptied for longer than one
month, the complete circuit must be placed under nitrogen
charge to avoid any risk of corrosion by differential aeration.
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.
17
1 Setting potentiometer sensitivity
2 Chain of LEDs
- red LED lights: the unit is not adjusted
- yellow LED lights: the output is switched
- green LED lights: the unit is adjusted
The condenser is of the multi-tube shell and tube type with
removable water boxes to facilitate cleaning of the tubes.
6.4.1 - Before making water connections
Tighten the bolts in both heads to the lower torque shown,
following the method described. Tighten in the pairs and
sequence indicated according to the size of bolt (see below)
using a torque value at the low end of the range given.
Sequence 1: 1 2 3 4
Sequence 2: 5 6 7 8
Bolt size M12 - 71-87 Nm
Bolt size M16 - 171-210 Nm
Bolt size M20 - 171-210 Nm
This diagram shows a typical water installation.
1 Control valve
2 Air vent
3 Flow switch for the evaporator
4 Flexible connection
5 Heat exchanger
6 Pressure tap
7 Thermostat sleeve
8 Drain
9 Buffer tank
10 Filter (mesh size: 1.2 mm = 20 mesh)
11 Expansion tank
12 Fill valve
6.3.1 - Evaporator flow switch and chilled water pump
interlock
IMPORTANT: On 30HZ/HZV units, the unit chilled
water flow switch must be energised, and the chilled water
pump interlock must be connected. Failure to follow this
instruction will void the Carrier guarantee.
The flow switch is supplied, installed on the evaporator
entering water pipe and factory-set to the minimum water
flow rate. If adjustment is necessary:
1. Switch on the unit. Set it to constant flow (preset value).
The yellow LED is illuminated, and the output is
switched for approximately 20 seconds (power-on
delay time).
2. Turn the potentiometer until one green LED is illumi-
nated. The further the green LED is from the yellow
LED, the safer the adjustment (standby capacity in
case of flow or temperature fluctuations).
3. After the adjustment attach the label supplied to the
potentiometer, in order to protect it against unautho-
rised tampering.
Terminals 34 and 35 are provided for field installation of the
chilled water pump interlock (auxiliary contact for pump
operation to be wired on site).
12
3
45
6
7
8
9
10
11
12
2
1
7
4
6
2
8
3
5
1
18
6.6.1 - Recommendations for the installation of liquid
chillers with remote condensers
To guarantee optimum and reliable performance of the
30HZV units (split units for connection to condensers) it is
necessary to comply with the regulations described below,
when these units are connected to remote condensers.
1. Install a valve in the discharge piping (valves are
factory-installed in sizes 043-063, and supplied non-
installed in sizes 091-280).
2. Size the discharge and liquid line piping according to
the recommendations in the following paragraphs (if
necessary, install a double riser to ensure correct oil
circulation in the refrigerant circuit).
3. Depending on the layout and the routing of the dis-
charge piping it may be necessary to install additional
silencers (to reduce pulsations and noise emission)
between the liquid chiller and the condenser.
4. Select a condenser with an integrated subcooler to
obtain a minimum of 3 K subcooling at the inlet to the
expansion device.
5. Keep the condensing pressure as stable as possible
(pressostat staging or fan control via Pro-Dialog Plus).
A speed controller may be required for the first fan
stage for operation at low ambient temperature and
partial load.
6. If the system can have several operating modes (sum-
mer/winter, dual set point etc.), it is necessary to install
a tank (or receiver) to absorb the variations in charge.
6.6.2 - General
Refrigerant pipe sizing must be carried out, taking account
of the following constraints:
Oil return to the compressor must be ensured for the majo-
rity of applications. Oil return is ensured by entrainment. A
minimum refrigerant velocity is required to ensure entrain-
ment. This velocity depends on the pipe diameter, the refri-
gerant and oil temperature (these are treated as being the
same in most cases). A reduction of the pipe diameter per-
mits an increase of the refrigerant velocity. The problem of
a minimum entrainment velocity does not exist for the pipes
that carry liquid refrigerant as the oil is fully miscible here.
The pressure drop at the compressor discharge (pipes
linking the compressor outlet with the condenser inlet)
must be limited to avoid system performance losses (the
compressor power input inceases, and the cooling capacity
decreases).
As a first estimate and for standard air conditioning appli-
cations, a one degree Celsius pressure drop on the discharge
side decreases the cooling capacity 2% and increases the
compressor power input by 3%. Increasing the pipe diameter
permits limiting the pressure drops.
The pressure drop in the liquid line (linking the condenser
outlet to the expansion device) must not result in a change
in phase. The estimate of these pressure drops must include
those for the possible accessories, such as solenoid valves,
filters, filter drier, etc.
6.4.2 - Pipe connections
After welding the pipes to the flanges previously removed
from the water boxes:
1. Reinstall the pipes and tighten lightly to a torque at
the low end of the range.
2. Fill the system with water.
3. Wait for 10 minutes and check for minor leaks
- at the water box joints
- at the flange joints
4. Drain the system.
5. Disconnect the pipework.
6. Tighten the head bolts to their final torque (middle of
the range) in the sequence illustrated.
7. Reconnect the water pipes, tightening the flange bolts
to the mid-range torque value.
8. Refill the system with water.
9. Pressurize the system.
The 30HZ and 30HZV units are designed to be installed
under cover at outside temperatures between +5°C and
+40°C.Therefore they do not include anti-freeze protection,
as standard.
If the water piping is in an area where the ambient tempera-
ture can fall below 0°C it is recommended to install a trace
heater on the piping and to add an antifreeze solution to
protect the unit and the water piping to a temperature of
10 K below the lowest temperature likely to be reached at
the installation site.
Use only antifreeze solutions, approved for heat exchanger
duty. If the system is not protected by an antifreeze solution
and will not be used during the freezing weather conditions,
draining of the cooler and outdoor piping is mandatory.
Damage due to freezing is not covered by the warranty.
IMPORTANT: Depending on the climatic conditions in
your area you must:
• Add ethylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 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
add ethylene glycol to 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 instal-
ler 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).
19
6.6.3 - Use of pipe sizing diagrams
On page 23 of this document two pipe sizing diagrams are
shown.They allow an estimate of the cooling capacity, corre-
sponding to 1.5 K pressure drop for different pipe diameters,
based on the pipe length.
The following procedure can be used for pipe sizing:
1. Measure the length (in metres) of the piping under
consideration.
2. Add 40 to 50% to take account of special characteristics.
3. Multiply this length by the appropriate correction
factor from Table 1 (this correction factor depends on
the saturated suction and discharge temperatures).
4. Read the pipe size from diagrams “Discharge piping”
and “Liquid line piping”.
5. Calculate the equivalent lengths for parts included in
the piping under consideration (such as valves, filters,
connections).
The equivalent lengths are normally available from the
component supplier.Add these lengths to the length
caculated in step 3.
6. Repeat steps 4 and 5 is necessary.
The diagrams in the appendix can obviously be used to
calculate the actual pressure drops for the piping under
consideration:
7. Based on the pipe diameter and the cooling capacity
find the equivalent length, producing 1.5 K pressure
drop in the figures “Discharge piping” and “Liquid
line piping”.
8. Calculate the equivalent pipe length as described in
steps 1, 2, 3 and 5.
9. Calculate the length ratio from steps 8 and 7 (equivalent
length from step 8 DIVIDED by the equivalent length
from step 7).
10. Multiply this ratio by 1.5 to find the equivalent pressure
drops in °C.
6.6.4 - Discharge pipe sizing
The discharge piping must be sized to achieve reasonable
pressure drops: a variation of 1.5 K of the saturated tempe-
rature is normally accepted (approx. 60 kPa variation for a
condensing temperature of 50°C).
For most applications the refrigerant gas velocity is sufficient
to entrain the liquid refrigerant/oil mixture. Nevertheless,
Table 2 shows the minimum required cooling capacities for
different pipe diameters and different saturated discharge
temperatures.
This table is based on 8 K superheat, a saturated suction
temperature of 4°C and 8 K subcooling.Table 3 shows the
correction factors to be applied to the values from Table 2, if
the operating conditions are different from those previously
stated.
6.6.5 - Liquid line sizing
The 30HZV compressors are supplied with an oil that is
fully miscible with refrigerant R-407C in the liquid phase.
Consequently low refrigerant velocities in the liquid lines
are not a problem.
The admissible pressure drops in the liquid lines depend
mainly on the subcooling level of the liquid refrigerant at
the condenser outlet. Pressure drops corresponding to 1.5°C
saturated temperature must not be exceeded.
Special attention must be paid to the liquid line sizing when
the expansion device ist positioned higher than the conden-
ser. It may now be necessary to increase the pipe diameter
to compensate for the additional pressure of the liquid refri-
gerant column. If the liquid refrigerant head is very high, it
may even be necessary to increase the subcooling to prevent
a phase change in the liquid line. This can be done e.g. by a
liquid-vapour heat exchanger or an additional coil.
At 45°C the volume mass of refrigerant R-407C in the liquid
phase is approximately 1050 kg/m3. A pressure of 1 bar
corresponds to a liquid head of: 100 000/(1050 x 9.81) = 9.7 m.
20
2.01 1.36 1.09 1.61 1.34 1.07 1.31 1.30 1.06 1.07 1.26 1.04 0.89 1.23 1.03 0.74 1.19 1.01
32 2.11 1.27 1.08 1.69 1.23 1.06 1.37 1.19 1.04 1.12 1.16 1.03 0.93 1.12 1.01 0.77 1.09 1.00
38 2.22 1.17 1.08 1.78 1.13 1.06 1.44 1.10 1.04 1.18 1.06 1.02 0.97 1.03 1.01 0.81 1.00 0.99
43 2.34 1.09 1.08 1.88 1.06 1.06 1.52 1.02 1.04 1.24 0.99 1.02 1.03 0.96 1.00 0.85 0.93 0.99
2.49 1.03 1.09 1.99 0.99 1.07 1.61 0.96 1.05 1.32 0.93 1.03 1.09 0.90 1.01 0.90 0.87 0.99
2.66 0.97 1.12 2.13 0.94 1.10 1.72 0.90 1.07 1.40 0.87 1.05 1.16 0.85 1.03 0.96 0.82 1.01
2.87 0.93 1.16 2.29 0.90 1.13 1.85 0.86 1.11 1.50 0.83 1.08 1.24 0.81 1.06 1.03 0.78 1.04
3.13 0.91 1.21 2.49 0.87 1.18 2.01 0.84 1.15 1.63 0.81 1.12 1.34 0.78 1.10 1.11 0.75 1.08
3.46 0.89 1.29 2.74 0.85 1.26 2.21 0.82 1.22 1.79 0.78 1.19 1.47 0.76 1.16 1.21 0.73 1.13
S Suction
HG Hot gas
L Liquid
0.81 1.48 2.39 3.66 7.14 12.06 18.64 37.21 63.94 99.81 145.60 201.98
32 0.84 1.51 2.46 3.76 7.28 12.34 19.06 38.09 65.42 102.13 148.94 206.66
38 0.84 1.51 2.50 3.80 7.42 12.56 19.41 38.76 66.61 103.96 151.62 210.35
43 0.88 1.55 2.53 3.87 7.53 12.73 19.66 39.25 67.42 105.23 153.48 212.92
0.88 1.55 2.53 3.87 7.56 12.80 19.77 39.50 67.84 105.90 154.43 214.26
0.88 1.55 2.53 3.87 7.56 12.80 19.77 39.46 67.81 105.86 154.40 214.19
0.84 1.55 2.53 3.87 7.49 12.70 19.62 39.18 67.32 105.05 153.24 212.60
0.84 1.51 2.46 3.80 7.39 12.45 19.27 38.44 66.08 103.12 150.42 208.66
0.81 1.48 2.43 3.69 7.17 12.17 18.78 37.49 64.43 100.55 146.69 203.49
-23 -18 -12 -7 -1 4 10
0.86 0.89 0.92 0.94 0.97 1.00 1.03
See chapter “Discharge pipe sizing”
This manual suits for next models
1
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