30RY 017-080 "B"

Ductable Liquid Chillers withIntegrated Hydronic Module

Nominal cooling capacity 18-79 kW

50 Hz

Installation, operation and maintenance instructions

AQUASNAP

For the operation of the control please refer to

the Pro-Dialog Control manual for the

30RA/RH - 30RY/RYH "B" series

Carrier is participating in the Eurovent Certification Programme. Products are as listed in the Eurovent Directory of Certified Products.

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The drawings in this document are for illustrative purposes only and is not part of any offer for sale or contract.

CONTENTS

1 - INTRODUCTION ....................................................................................................................................................................... 41.1 - Installation safety considerations ............................................................................................................................................... 41.2 - Equipment and components under pressure .............................................................................................................................. 41.3 - Maintenance safety considerations ............................................................................................................................................51.4 - Repair safety considerations ...................................................................................................................................................... 5

2 - PRELIMINARY CHECKS ........................................................................................................................................................72.1 - Check equipment received ......................................................................................................................................................... 72.2 - Moving and siting the unit ......................................................................................................................................................... 7

3 - DIMENSIONS/CLEARANCES .................................................................................................................................................9

4 - PHYSICAL DATA ....................................................................................................................................................................10

5 - ELECTRICAL DATA ..............................................................................................................................................................10

6 - APPLICATION DATA.............................................................................................................................................................126.1 - Unit operating range ................................................................................................................................................................ 126.2 - Evaporator water flow rates .....................................................................................................................................................126.3 - Minimum water flow rate ........................................................................................................................................................126.4 - Maximum evaporator water flow rate ......................................................................................................................................126.5 - Water loop volume ...................................................................................................................................................................126.6 - 30RY unit operating range at full and part load ...................................................................................................................... 126.7 - Pressure drop in the plate heat exchangers ..............................................................................................................................13

7 - ELECTRICAL CONNECTION .............................................................................................................................................. 147.1 - Power supply ............................................................................................................................................................................ 157.2 - Voltage phase imbalance (%) ................................................................................................................................................... 15

8 - RECOMMENDED WIRE SECTIONS ................................................................................................................................... 158.1 - Field control wiring ..................................................................................................................................................................15

9 - WATER CONNECTIONS .......................................................................................................................................................169.1 - Operating precautions and recommendations ..........................................................................................................................169.2 - Hydronic connections ..............................................................................................................................................................179.3 - Frost protection ........................................................................................................................................................................179.4 - Installation of the accessory condensate recovery pan ............................................................................................................17

10 - NOMINAL SYSTEM WATER FLOW CONTROL ........................................................................................................... 1910.1 - Water flow control procedure ................................................................................................................................................ 1910.2 - Pump curve and water flow control as a function of the system pressure drops ................................................................... 2010.3 - Pump pressure/flow rate curves ............................................................................................................................................. 2010.4 - Available static system pressure ............................................................................................................................................ 2110.5 - Duct connection ..................................................................................................................................................................... 21

11 - START-UP ............................................................................................................................................................................... 2311.1 - Preliminary checks ................................................................................................................................................................. 2311.2 - Actual start-up ........................................................................................................................................................................ 2311.3 - Operation of two units in master/slave mode ......................................................................................................................... 23

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CONTENTS (cont’d)

12 - MAINTENANCE .................................................................................................................................................................... 2412.1 - General maintenance of the refrigerant circuit ....................................................................................................................... 2412.2 - Verification of the refrigerant charge ..................................................................................................................................... 2412.3 - Apparent and actual subcooling ............................................................................................................................................. 2412.4 - Refrigerant guidelines ............................................................................................................................................................ 2512.5 - Recharging liquid refrigerant ................................................................................................................................................. 2512.6 - Undercharge ........................................................................................................................................................................... 2512.7 - Characteristics of R407C ....................................................................................................................................................... 2512.8 - Electrical maintenance ........................................................................................................................................................... 2512.9 - Condenser coil ........................................................................................................................................................................ 26

13 - AQUASNAP MAINTENANCE PROGRAM ....................................................................................................................... 2713.1 - Maintenance schedule ............................................................................................................................................................ 2713.2 - Description of the maintenance operations ............................................................................................................................ 27

14 - START-UP CHECKLIST FOR 30RY LIQUID CHILLERS ............................................................................................ 29

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1 - INTRODUCTION

Prior to the initial start-up of the 30RY units, the peopleinvolved in the on-site installation, start-up, operation, andmaintenance of this unit should be thoroughly familiar withthese instructions and the specific project data for theinstallation site.

The 30RY liquid chillers are designed to provide a very highlevel of safety during installation, start-up, operation andmaintenance. They will provide safe and reliable service whenoperated within their application range.

This 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 maintenance.

Be sure you understand and follow the procedures and safetyprecautions contained in the instructions supplied with themachine, as well as those listed in this guide.

Earthquake resistance has not been verified for standard units.

1.1 - Installation safety considerations

This machine must be installed in a location that is not accessibleto the public and protected against access by non-authorisedpeople.

After 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.Ensure especially that no components or pipes have shifted(e.g. following a shock). If in doubt, carry out a leak tightnesscheck and verify with the manufacturer that the circuit integrityhas 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 itsfinal position. These units can be moved with a fork lift truck,as long as the forks are positioned in the right place anddirection on the unit.

The units can also be lifted with slings, using only the desig-nated lifting points marked at the four corners at the unit base.

These 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 unit.

Safety is only guaranteed, if these instructions are carefullyfollowed. If this is not the case, there is a risk of materialdeterioration and injuries to personnel.

Never cover any safety devices.

This applies to the globe valve in the water circuit and theglobe valve(s) in the refrigerant circuit(s).

Ensure that the valves (if used in the refrigerant circuit) arecorrectly 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 openposition. This system permits isolating and removing theglobe stop for checking and replacing. The globe stops aredesigned and installed to ensure protection against fire risk.Removing the globe stops is only permitted if the fire risk isfully controlled and the responsibility of the user.

All factory-installed globe valves are lead-sealed to preventany calibration change. If the globe valves are installed on areversing valve (change-over), this is equipped with a globevalve on each of the two outlets. Only one of the two glovevalves is in operation, the other one is isolated. Never leavethe reversing valve in the intermediate position, i.e. with bothways open (locate the control element in the stop position). Ifa globe stop is removed for checking or replacement pleaseensure that there is always an active globe stop on each of thereversing valves installed in the unit.

Provide a drain in the discharge circuit, close to each valve,to avoid an accumulation of condensate or rain water.

The safety valves must be connected to discharge pipes. 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 environment.

Periodic check of the globe valves: See paragraph“Maintenance safety considerations”.

Accumulation of refrigerant in an enclosed space candisplace oxygen and cause asphyxiation or explosions.

Inhalation of high concentrations of vapour is harmful andmay cause heart irregularities, unconsciousness, or death.Vapour is heavier than air and reduces the amount of oxygenavailable for breathing. These products cause eye and skinirritation. Decomposition products are hazardous.

1.2 - Equipment and components under pressure

These 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 products.

Do not introduce high static and dynamic pressure comparedwith the existing operating pressures - either service or testpressures in the refrigerant circuit or in the heat transfer circuit,especially:- limiting the elevation of the condensers or evaporators- taking the circulating pumps into consideration.

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1.3 - Maintenance safety considerations

Engineers working on the electric or refrigeration componentsmust be authorized and fully qualified to do so (electricianstrained and qualified in accordance with IEC 60364 Classi-fication BA4).

All refrigerant circuit repairs must be carried out by a trainedperson, fully qualified to work on these units. He must havebeen trained and be familiar with the equipment and theinstallation, and he must wear the necessary protective items(gloves, glasses, protective clothes, safety shoes).

Soldering and welding: Component, piping and connectionsoldering and welding operations must be carried out using thecorrect procedures and by qualified operators. Pressurisedcontainers must not be subjected to shocks, nor to largetemperature variations during maintenance and repair operations.

Never work on a unit that is still energized.

Never work on any of the electrical components, until thegeneral power supply to the unit has been cut using thedisconnect switch in the control box.

If any maintenance operations are carried out on the unit,lock the power supply circuit in the open position ahead ofthe machine.

If the work is interrupted, always ensure that all circuits arestill deenergized before resuming the work.

ATTENTION: Even if the unit has been switched off, thepower circuit remains energized, unless the unit or circuitdisconnect switch is open. Refer to the wiring diagram forfurther details. Attach appropriate safety labels.

Operating checks: During the life-time of the system,inspection and tests must be carried out in accordance withnational regulations.

The information on operating inspections given in annex C ofstandard EN378-2 can be used if no similar criteria exist inthe national regulations.

Safety 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 (safety globe valves).

Contact Carrier Service for a detailed explanation of thehigh-pressure switch test method.

If the machine operates in a corrosive environment, inspectthe protection devices more frequently.

Regularly carry out leak tests and immediately repair any leaks.

1.4 - Repair safety considerations

All installation parts must be maintained by the personnel incharge, in order to avoid material deterioration and injuries topeople. Faults and leaks must be repaired immediately. Theauthorized technician must have the responsibility to repair thefault immediately. Each time repairs have been carried out tothe unit, the operation of the safety devices must be re-checked.

If a leak occurs or if the refrigerant becomes polluted (e.g. by ashort circuit in a motor) remove the complete charge using arecovery unit and store the refrigerant in mobile containers(careful in case the refrigerant decomposes due to high tempera-ture increases, as the decomposition products are dangerous).

If a leak occurs, evacuate all refrigerant, repair the leak detectedand recharge the circuit with the total R407C charge, as indi-cated on the unit name plate. Never top up the charge. Onlycharge liquid refrigerant R407C at the liquid line.

Ensure that you are using the correct refrigerant type beforerecharging the unit.Charging any refrigerant other than the original charge type(R407C) will impair machine operation and can even lead toa destruction of the compressors. The compressors operatingwith this refrigerant type are charged with a synthetic polyol-ester oil.

These units have a hermetic refrigerant circuit and theoriginal charge need not be topped up.

Do not use oxygen to purge lines or to pressurize a machinefor 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 pres-sures by checking the instructions in this manual and thepressures given on the unit name plate.

Do not use air for leak testing. Use only refrigerant or drynitrogen.

Do not unweld or flamecut the refrigerant lines or any refri-gerant circuit component until all refrigerant (liquid andvapour) has been removed from chiller. Traces of vapourshould be displaced with dry air nitrogen. Refrigerant incontact with an open flame produces toxic gases.

The necessary protection equipment must be available, andappropriate fire extinguishers for the system and therefrigerant type used must be within easy reach.

Do not siphon refrigerant.

Avoid spilling liquid refrigerant on skin or splashing it intothe eyes. Use safety goggles. Wash any spills from the skinwith soap and water. If liquid refrigerant enters the eyes,immediately and abundantly flush the eyes with water andconsult a doctor.

Never apply an open flame or live steam to a refrigerantcontainer. Dangerous overpressure can result. If it isnecessary to heat refrigerant, use only warm water.

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During refrigerant removal and storage operations followapplicable regulations. These regulations, permitting condition-ing and recovery of halogenated hydrocarbons under opti-mum quality conditions for the products and optimum safetyconditions for people, property and the environment aredescribed in standard NFE 29795.

Any refrigerant transfer and recovery operations must becarried out using a transfer unit. A 3/8” SAE connector onthe manual liquid line valve is supplied with all units forconnection to the transfer station. The units must never bemodified to add refrigerant and oil charging, removal andpurging 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 orattempt to refill them. It is dangerous and illegal. Whencylinders are empty, evacuate the remaining gas pressure,and move the cylinders to a place designated for theirrecovery. Do not incinerate.

Do not attempt to remove refrigerant circuit components orfittings, while the machine is under pressure or while it isrunning. Be sure pressure is at 0 kPa before removingcomponents or opening a circuit.

Any manipulation (opening or closing) of a shut-off valvemust be carried out by a qualified and authorised engineer.These procedures must be carried out with the unit shut-down.

NOTE: The unit must never be left shut down with the 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.)

Do not attempt to repair or recondition any safety deviceswhen corrosion or build-up of foreign material (rust, dirt,scale, etc.) is found within the valve body or mechanism. Ifnecessary, replace the device. Do not install safety valves inseries or backwards.

CAUTION: Do not step on refrigerant lines. The lines canbreak under the weight and release refrigerant, causingpersonal injury.

No part of the unit must use feet, racks or supports duringoperation. Periodically monitor and repair or if necessaryreplace any component or piping that shows signs of damage.

Do not climb on a machine. Use a platform, or staging towork at higher levels.

Use mechanical lifting equipment (crane, hoist, etc.) to lift ormove heavy components such as compressors or plate heatexchangers. For lighter components, use lifting equipmentwhen there is a risk of slipping or losing your balance.

Use only original replacement parts for any repair or compo-nent replacement. Consult the list of replacement parts thatcorresponds to the specification of the original equipment.

Do not drain water circuits containing industrial brines,without informing the technical service department at theinstallation site or a competent body first.

Close the entering and leaving water shutoff valves andpurge the unit hydronic circuit, before working on thecomponents installed on the circuit (screen filter, pump, waterflow switch, etc.).

Periodically inspect all valves, fittings and pipes of therefrigerant and hydronic circuits to ensure that they do notshow any corrosion or any signs of leaks.

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2 - PRELIMINARY CHECKS

2.1 - Check equipment received

• Inspect the unit for damage or missing parts. If damage isdetected, or if shipment is incomplete, immediately file aclaim 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 followinginformation:- Version number- Model number- CE marking- Serial number- Year of manufacture and test date- Refrigerant used and refrigerant class- Refrigerant charge per circuit- Containment fluid to be used- PS: Min./max. allowable pressure (high and low

pressure side)- TS: Min./max. allowable temperature (high and low

pressure side)- Globe valve cut-out pressure- Pressure switch cut-out pressure- Unit leak test pressure- Voltage, frequency, number of phases- Maximum current drawn- Maximum power input- Unit net weight

High pressure Low pressureMin. Max. Min. Max.

PS (bar) -0.9 32 -0.9 25TS (°C) -20 72 -20 62Pressure switch cut-out pressure (bar) 29 -Valve cut-out pressure (bar) - 25Test pressure, unit leak test (bar) 15

• Confirm that all accessories ordered for on-site installationhave been delivered, and are complete and undamaged.

• The unit must be checked periodically during its wholeoperating life to ensure that no shocks (handlingaccessories, tools etc.) have damaged it. If necessary, thedamaged parts must be repaired or replaced. See alsochapter “Maintenance”.

2.2 - Moving and siting the unit

2.2.1 - Moving

See chapter "Installation safety considerations"

2.2.2 - Siting the unit

Always refer to the chapter "Dimensions and clearances" toconfirm that there is adequate space for all connections andservice operations. For the centre of gravity coordinates, theposition of the unit mounting holes, and the weight distribu-tion points, refer to the certified dimensional drawing suppliedwith the unit.

CAUTION: Only use slings at the designated lifting pointswhich are marked on the unit.

Before siting the unit check that:• the permitted loading at the site is adequate or that

appropriate strengthening measures have been taken;• the surface is horizontal, flat and intact;• a channel is provided all the way around the unit to collect

the condensate water.• if the unit is not equipped with the accessory condensate

recovery pan, reference is made to the installation condi-tions in chapter 10.4;

• there is adequate space above the unit for air flow;• there are adequate support points and that they are in the

right places;• the location is not subject to flooding;• units with the outdoor installation option should not be

installed where there is a risk of snow build-up. In areasthat are subject to long periods of sub-zero temperaturesraise the unit to a higher level.

Baffles may be necessary to deflect strong winds and toprevent snow from blowing directly into the unit. Theymust not restrict air flow into the unit.

CAUTION: Before lifting the unit, check that all casingpanels are securely fixed in place. Lift and set down the unitwith great care. Tilting and jarring can damage the unit andimpair unit operation.

The 30RY units can be hoisted with rigging. Coils shouldalways be protected against crushing while a unit is beingmoved. Use struts or spreader bars to spread the slings abovethe unit. Do not tilt a unit more than 15°.

WARNING: Never push or lever on any of the enclosurepanels of the unit. Only the base of the unit frame is designedto withstand such stresses.

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Checks before system start-up

Before the start-up of the refrigeration system, the completeinstallation, including the refrigeration system must be verifiedagainst the installation drawings, dimensional drawings, systempiping and instrumentation diagrams and the wiring diagrams.

During the installation test national regulations must befollowed. If no national regulation exists, paragraph 9-5 ofstandard EN 378-2 can be used as a guide.

External visual installation checks:• Compare the complete installation with the refrigeration

system and power circuit diagrams.• Check that all components comply with the design

specifications.• Check that all safety documents and equipments that are

required by current European standards are present.• Verify that all safety and environmental protection devices

and arrangements are in place and comply with the currentEuropean standard.

• Verify that all document for pressure containers,certificates, name plates, files, instruction manuals that arerequired documents required by the current Europeanstandards are present.

• Verify the free passage of access and safety routes.• Check that ventilation in the plant room is adequate.• Check that refrigerant detectors are present.• Verify the instructions and directives to prevent the

deliberate removal of refrigerant gases that are harmful tothe 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.

9

1372

11281068

20972058

820

820

1

1000

1000

1

2058863

822.5962

1351

670

670

1

1000

30RY 040-080

30RY 017-033

3 - DIMENSIONS/CLEARANCES

NOTE:

A Non-certified drawings.Refer to the certified dimensional drawings supplied with the unit oravailable on request, when designing an installation.

For the location of fixing points, weight distribution and coordinates ofthe centre of gravity refer to the certified dimensional drawings.

B Install a condensate collection channel around the unit, or install theaccessory condensate recovery pan.

C The unit must be installed level in both axes (less than 2 mm toleranceper metre).

Legend:All dimensions are given in mm

Power supply

Water inlet

Water outlet

Required clearances for air flow

Air entering connection

Air leaving connection

Power cable entry

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4 - PHYSICAL DATA

30RY 017 021 026 033 040 050 060 070 080

Nominal cooling capacity* kW 18.6 23.1 25.8 31.7 39.4 50.0 58.0 67.0 79.0

Operating weight kgwith hydronic module, single pump 386 416 436 451 510 572 587 638 675with hydronic module, dual pump - - - - 590 652 667 718 752without hydronic module 361 391 411 426 486 548 563 614 649

Refrigerant charge R-407C kg 6.6 6.3 7.45 7.85 9.75 11.1 11.8 13.3 17.0

Compressors Hermetic scroll compressors, 48.3 r/sQuantity 1 1 1 1 1 2 2 2 2No. of capacity steps 1 1 1 1 1 2 2 2 2Minimum capacity % 100 100 100 100 100 46 42 50 50

Control type PRO-DIALOG Plus

Condenser Grooved copper tubes, aluminium fins

Fan Axial with available pressureQuantity 1 1 1 1 1 1 1 1 1Available static pressure Pa 100 100 100 100 150 150 150 150 150Total air flow (high speed) l/s 1940 1940 1940 2500 3890 3890 4720 5830 5830Speed (high/low speed) r/s 24/12 24/12 24/12 24/12 24/12 24/12 24/12 24/12 24/12

Evaporator Direct-expansion welded plate heat exchangerWater volume l 1.6 2.0 2.3 3.0 3.6 4.6 5.9 6.5 7.6Max. water-side operating pressure kPaOption without hydronic module 1000 1000 1000 1000 1000 1000 1000 1000 1000Unit with hydronic module 250 250 250 250 300 300 300 300 300

Hydronic modulePump (centrifugal) Single multicell pump, 48.3 r/s Single composite monocell pump, 48.3 r/sQuantity 1 1 1 1 1 1 1 1 1Expansion tank volume l 8 8 8 8 12 12 12 12 12Expansion tank pressure** kPa 50 50 50 50 100 100 100 100 100

Water connections Threaded male gas connections Victaulic(with and without hydronic module) (sleeves for welding or screw connections supplied)Diameter in 1-1/4 1-1/4 1-1/4 1-1/4 2 2 2 2 2Outside tube diameter in 1-1/4 1-1/4 1-1/4 1-1/4 2 2 2 2 2

mm 42.4 42.4 42.4 42.4 60.3 60.3 60.3 60.3 60.3

* Nominal conditions: evaporator entering/leaving temperature 12°C/7°C, outdoor air temperature 35°C.** When delivered, the pre-inflation of the tank keeps the plated membrane in the upper part of the tank. To permit changing the water volume, change the inflation

pressure to a pressure that is close to the static head of the system (see below), fill the system with water (purging the air) to a pressure value that is 10 to 20 kPahigher than the pressure in the tank.Static head, m/Pressure, bar/Pressure, kPa5 - 0,5 - 50 / 10 - 1 - 100 / 15 - 1,5 - 150 / 20 - 2 - 200 / 25 - 2,5 - 250

5 - ELECTRICAL DATA

30RY (without hydronic module) 017 021 026 033 040 050 060 070 080

Power circuitNominal power supply V-ph-Hz 400-3-50Voltage range V 360-440

Control circuit supply The control circuit is supplied via the unit-mounted transformer

Maximum unit power input* kW 9.8 12.1 13.8 18.0 21.0 25.3 32.3 38.2 42.9Nominal unit current draw** A 13.1 16.2 18.6 23.3 28.8 35.6 45.7 52.1 59.4Maximum unit current draw at 360 V*** A 17.0 21.3 24.5 31.2 37.8 46.5 59.5 67.8 77.5Maximum unit current draw at 400 V**** A 15.5 19.3 22.2 28.3 34.5 42.3 54.3 62.1 70.7Maximum start-up currentStandard unit† A 87.8 131.8 131.8 147.4 159.3 151.8 173.5 181.2 195.5With electronic starter option‡ A - - - - 97.3 99.8 115.5 123.2 133.5

Short-circuit stability and protection See table on the next page

* Power input of the compressor(s) + fan at maximum unit operating conditions: entering/leaving water temperature = 15°C/10°C, maximum condensing temperature of67.8°C and 400 V nominal voltage (values given on the unit name plate).

** Nominal unit current draw at the following conditions: evaporator entering/leaving water temperature 12°C/7°C, outdoor air temperature 35°C. The current values aregiven at 400 V nominal voltage

*** Maximum unit operating current at maximum unit power input and 360 V nominal voltage.**** Maximum unit operating current at maximum unit power input and 400 V nominal voltage (values given on the unit name plate).† Maximum instantaneous starting current at 400 V nominal voltage and with compressor in across-the-line-start (maximum operating current of the smallest

compressor(s) + fan current + locked rotor current of the largest compressor).‡ Maximum instantaneous starting current at 400 V nominal voltage and with compressor with electronic starter (maximum operating current of the smallest

compressor(s) + fan current + reduced start-up current of the largest compressor).

Hydronic module 017 021 026 033 040 050 060 070 080

Single pumpShaft power kW 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 1.1Power input* kW 0.75 0.75 0.75 0.75 1.1 1.1 1.1 1.1 1.4Maximum current draw at 400 V** A 2.0 2.0 2.0 2.0 2.1 2.1 2.1 2.1 3.1

Dual pumpShaft power kW - - - - 2.2 2.2 2.2 2.2 2.2Power input* kW - - - - 2.7 2.7 2.7 2.7 2.7Maximum current draw at 400 V** A - - - - 4.7 4.7 4.7 4.7 4.7

Note: The water pump power input values are given for guidance only.* To obtain the maximum power input for a unit with hydronic module add the maximum unit power input from the top table to the pump power input (*) from the table

above.** To obtain the maximum unit operating current draw for a unit with hydronic module add the maximum unit current draw from the top table to the pump current draw from

the table above.

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Compressor usage and electrical data

COMPRESSOR 30RY

Reference code I Nom I Max LRA* Circuit 017 021 026 033 040 050 060 070 080

DQ 12 CA 001EE 14.0 19.1 130 A A1 A1

DQ 12 CA 002EE 16.2 22.1 130 A A1 A2 A1

DQ 12 CA 025EE 14.8 20.3 86 A A1

DQ 12 CA 031EE 21.9 28.3 145 A A1 A2 A1+A2

DQ 12 CA 036EE 24.5 32.9 155 A A1 A1+A2

Legend:I Nom Nominal current draw at Eurovent conditions (see definition of conditions under nominal unit current draw), AI Max Maximum operating current at 360 V, ALRA Locked rotor current, A

* With option 25 (electronic starter) the LRA value is reduced by 40%; the maximum start-up time per compresor is

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6 - APPLICATION DATA

6.1 - Unit operating range

Evaporator Minimum °C Maximum °C

Water entering temp. (at start-up) 7.8 * 30Water leaving temp. (in operation) 5 ** 10Water entering temp. (at shut down) - 50

Condenser

Entering air temp. -10*** 46***

Do not exceed the maximum operating temperature.* For a system requiring operation below 7,8°C, contact Carrier SA.** For a system requiring operation below 5°C, anti-freeze must be added to the

unit.*** Maximum outside temperature: For transport and storage of the 30RY units

the minimum and maximum allowable temperatures are –20°C and +55°C. Itis recommended that these temperatures are used for transport by container.

6.2 - Evaporator water flow rates

30RY Evaporator water flow

Min. flow rate Max. flow rate* Max. flow rate**Single pump Dual pump

l/s l/s l/s l/s

017 0.58 1.7 0 1.7021 0.70 1.8 0 1.9026 0.81 1.9 0 2.2033 1.10 2.0 0 3.0040 1.20 3.5 4.4 3.7050 1.19 4.0 5.2 4.6060 1.46 4.4 6.0 5.8070 1.66 4.6 6.4 6.4080 1.92 5.5 6.8 7.3

* Maximum flow rate at an available pressure of 50 kPa (unit with hydronicmodule).

** Maximum flow rate at a pressure drop of 100 kPa in the plate heat exchanger(unit without hydronic module).

6.3 - Minimum water flow rate

If the installation flow rate is below the minimum flow rate,recirculation of the evaporator water flow may take place,leading to the risk of excessive fouling.

6.4 - Maximum evaporator water flow rate

This is limited by the permitted evaporator pressure drop.Also, a minimum evaporator ∆T of 2.8 K must be guaranteed,which corresponds to a water flow rate of 0.9 l/s per kW.

6.5 - Water loop volume

6.5.1 - Minimum water loop volumeThe minimum water loop volume, in litres, is given by thefollowing formula:Volume = CAP (kW) x N* = litres, where CAP is the nominalcooling capacity at nominal operating conditions.

Application N*

Air conditioning30RY 017-040 3.530RY 050-240 2.5

Industrial process cooling30RY 017-080 (See note)

NOTE: For industrial process cooling applications, wherehigh stability of the water temperature levels must beachieved, the values above must be increased.

0 6 7 8 9 10 ˚C

-10

0

44

45

46˚C

44.5

1 2 3 4 5

This volume is required to obtain temperature stability andprecision.

To achieve this volume, it may be necessary to add a storagetank to the circuit. This tank should be equipped with baffles toallow mixing of the fluid (water or brine). Please refer to theexamples below.

6.5.2 - Maximum water loop volumeUnits with hydronic module incorporate an expansion tank thatlimits the water loop volume. The table below gives themaximum loop volume for pure water or ethylene glycol withvarious concentrations.

30RY 017-033 30RY 040-080(in litres) (in litres)

Pure water 400 600Ethylene glycol 10% 300 450Ethylene glycol 20% 250 400Ethylene glycol 35% 200 300

EG: Ethylene glycol

6.6 - 30RY unit operating range at full and part load

Notes1 Evaporator �T = 5 K2 The evaporator and the hydronic circuit pump are frost protected down

to -20°C.

Operating range with required anti-freeze solution and special Pro-Dialogcontrol configuration

Ent

erin

g ai

r tem

pera

ture

Evaporator water leaving temperature

Bad Good

Bad Good

13

Legend1 30RY 0172 30RY 0213 30RY 0264 30RY 0335 30RY 0406 30RY 0507 30RY 0608 30RY 0709 30RY 080

1

10

100

1000

2000

1 10

12

3

4

5

6

7

8

9

6.7 - Pressure drop in the plate heat exchangers

Pre

ssur

e dr

op, k

Pa

Water flow rate, l/s

14

347

67 3333

L1 L3L2L1S

A A

Y

X

1

PE

347 PE

1

BB

Y

X

333368

5.5

95

L1 L2 L3S

30RY 040-080Control box

7 - ELECTRICAL CONNECTION

30RY 017-033Control box

Legend1 Main disconnect switchPE Earth connectionS Power supply cable section (see table "Recommended wire sections").

For copper cables use electrolytic copper (AMP type) cable stiffeners with6 mm terminal for sizes 017 to 080.

30RY X (mm) Y (mm)

017-033 1180 761040-080 190 762

NOTES: The 30RY units have only one power connectionpoint located at the main disconnect switch.

Before connecting electric power cables, it is imperative tocheck the correct order of the 3 phases (L1 - L2 - L3).

Non-certified drawings. Refer to the certified drawingssupplied with the unit or available on request.

15

7.1 - Power supply

The power supply must conform to the specification on thechiller name plate. The supply voltage must be within the rangespecified in the electrical data table.For connections refer to the wiring diagrams.

WARNING: Operation of the chiller with an improper supplyvoltage or excessive phase imbalance constitutes abuse whichwill invalidate the Carrier warranty. If the phase imbalanceexceeds 2% for voltage, or 10% for current, contact your localelectricity supply source at once and ensure that the chiller isnot switched on until corrective measures have been taken.

7.2 - Voltage phase imbalance (%)

100 x max. deviation from average voltage

Average voltage

Example:On a 400 V - 3 ph - 50 Hz supply, the individual phase voltageswere measured to be:

AB = 406 V ; BC = 399 ; 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 greatestpercentage deviation is:100 x 6/400 = 1.5 %

This is less than the permissible 2% and is therefore acceptable.

Motor

8 - RECOMMENDED WIRE SECTIONS

Wire sizing is the responsibility of the installer, and depends onthe characteristics and regulations applicable to each installationsite. The following is only to be used as a guideline, and doesnot make Carrier in any way liable. After wire sizing has beencompleted, using the certified dimensional drawing, the instal-ler must ensure easy connection and define any modificationsnecessary on site. The connections provided as standard for thefield-supplied power entry cables to the general disconnect/isolator switch are designed for the number and type of wires,listed in the table below.

The calculations are based on the maximum machine current(see electrical data tables) and the standard installation practises,in accordance with IEC 60364, table 52C.

- For 30RY units, installed outside, the following standardinstallation practises have been maintained:

No.17: suspended aerial lines, and No. 61: buriedconduit with a derating coefficient of 20.

The calculation is based on PVC or XLPE insulatedcables with copper core.

A maximum ambient temperature of 46°C has beentaken into consideration.

The given wire length limits the voltage drop to< 5% (length L in metres - see table below).

IMPORTANT: Before connection of the main power cables(L1 - L2 - L3) on the terminal block, it is imperative to checkthe correct order of the 3 phases before proceeding to theconnection on the main disconnect/isolator switch.

8.1 - Field control wiring

For the field control wiring of the following elements pleaserefer to the 30RA/RH - RY/RYH “B” series Pro-Dialog PlusControl manual, and the certified wiring diagram supplied withthe unit:- Unit start/stop- Heating/cooling selection- Set-point selection- Customer interlock - (example: auxiliary contact of the

chilled water pump contactor)- General alarm reporting, circuit A and circuit B

Units S Min. (mm2) Cable type L (m) S Max. (mm2) Cable type L (m)by phase by phase

30RY 017 1x 6 XLPE Cu 90 1x 16 PVC Cu 24530RY 021 1x 6 XLPE Cu 90 1x 16 PVC Cu 24530RY 026 1x 6 XLPE Cu 90 1x 16 PVC Cu 24530RY 033 1x 6 XLPE Cu 90 1x 16 PVC Cu 24530RY 040 1x 6 XLPE Cu 90 1x 16 PVC Cu 24530RY 050 1x 6 XLPE Cu 80 1x 25 PVC Cu 30030RY 060 1x 10 XLPE Cu 110 1x 25 PVC Cu 30030RY 070 1x 10 XLPE Cu 100 1x 35 PVC Cu 31030RY 080 1x 16 XLPE Cu 125 1x 50 PVC Cu 350

S Power supply cable section (see the diagram in chapter: "Electrical connection")

16

9 - WATER CONNECTIONS

For size and position of the unit water inlet and outlet connec-tions refer to the certified dimensional drawings supplied withthe unit. The water pipes must not transmit any radial or axialforce to the heat exchangers nor any vibration.

The water supply must be analysed and appropriate filtering,treatment, control devices, shutoff and bleed valves and circuitsbuilt in, to prevent corrosion (example: damage to the protectionof the tube surface if the fluid is polluted), fouling and deter-ioration of the pump fittings.

Before any start-up verify that the heat exchange fluid iscompatible with the materials and the water circuit coating.

In case additives or other fluids than those recommended byCarrier s.a are used, ensure that the fluids are not considered asa gas, and that they belong to class 2, as defined in directive97/23/EC.

Carrier s.a. recommendations on heat exchange fluids:1. No NH4+ ammonium ions in the water, they are very

detrimental for copper. This is one of the most importantfactors for the operating life of copper piping. A contentof several tenths of mg/l will badly corrode the copperover time.

2. Cl- Chloride ions are detrimental for copper with a risk ofperforations by corrosion by puncture. If possible keepbelow 10 mg/l.

3. SO42- sulphate ions can cause perforating corrosion, if

their content is above 30 mg/l.4. No fluoride ions (2.8 K. Values between 10 and 25can be recommended. This will facilitate scale deposit thatcan limit corrosion of copper. TH values that are too highcan cause piping blockage over time. A total alkalimetrictitre (TAC) below 100 is desirable.

8. Dissolved oxygen: Any sudden change in water oxygen-ation conditions must be avoided. It is as detrimental todeoxygenate the water by mixing it with inert gas as it isto over-oxygenate it by mixing it with pure oxygen. Thedisturbance of the oxygenation conditions encouragesdestabilisation of copper hydroxides and enlargement ofparticles.

9. Specific resistance – electric conductivity: the higher thespecific resistance, the slower the corrosion tendency.Values above 3000 Ohm/cm are desirable. A neutralenvironment favours maximum specific resistance values.For electric conductivity values in the order of 200-6000S/cm can be recommended.

10. pH: Ideal case pH neutral at 20-25°C (7 < pH < 8).

ATTENTION: Charging, adding or draining fluid from thewater circuit must be done by qualified personnel, using airvents and materials suitable for the products. The watercircuit charging devices are field-supplied.

Charging and removing heat exchange fluids should be donewith devices that must be included on the water circuit by theinstaller. Never use the unit heat exchangers to add heatexchange fluid.

9.1 - Operating precautions and recommendations

The water circuit should be designed to have the least numberof elbows and horizontal pipe runs at different levels. Belowthe main points to be checked for the connection:• Comply with the water inlet and outlet connections shown

on the unit.• Install manual or automatic air purge valves at all high

points in the circuit.• Use an expansion device to maintain pressure in the

system and install a safety valve as well as an expansiontank.Units with a hydronic module include the safety valve andthe expansion tank.

• Install thermometers in both the entering and leavingwater connections.

• Install drain connections at all low points to allow thewhole circuit to be drained.

• Install stop valves, close to the entering and leaving waterconnections.

• Use flexible connections to reduce the transmission ofvibrations.

• Insulate all pipework, after testing for leaks, both toreduce thermal leaks and to prevent condensation.

• If the external unit water pipes are in an area, where theambient temperature is likely to fall below 0°C, insulate thepiping and add an electric heater. The internal unit pipingis protected down to -20°C.

NOTE: For units not equipped with a hydronic module ascreen filter must be installed as close to the heat exchangeras possible, in a position that is easily accessible for removaland cleaning. Units with hydronic module are equipped withthis type of filter.

The mesh size of the filter must be 1.2 mm.

The plate heat exchanger can foul up quickly at the initialunit start-up, as it complements the filter function, and theunit operation will be impaired (reduced water flow rate dueto increased pressure drop).

Before the system start-up verify that the water circuits areconnected to the appropriate heat exchangers (e.g. noreversal between evaporator and condenser).

Do not introduce any significant static or dynamic pressureinto the heat exchange circuit (with regard to the designoperating pressures).

The products that may be added for thermal insulation of thecontainers during the water piping connection proceduremust be chemically neutral in relation to the materials andcoatings to which they are applied. This is also the case forthe products originally supplied by Carrier s.a.

17

9.2 - Hydronic connections

The diagram on the next page shows a typical hydronicinstallation.When charging the water circuit use air vents to evacuate anyresidual air pockets.

9.3 - Frost protection

The plate heat exchangers, the piping and the hydronic modulepump can be damaged by frost, despite the built-in anti-freezeprotection of these units.

The frost protection of plate heat exchanger and all hydronicmodule components is guaranteed down to -20°C (sizes 040-080 only) by automatically energized heaters and pump cycling.

Never switch off the evaporator and hydronic circuit heaters orthe pump, otherwise frost protection cannot be guaranteed.

For this reason the main unit disconnect switch (QS101) aswell as the auxiliary protection switch (QF101) for the heatersmust always be left closed (for location of QS and QF 101 seewiring diagram).

To ensure frost protection down to -20°C, water circulation inthe water circuit must be maintained by periodically switchingon the pump. If a shut-off valve is installed, a bypass must beincluded as shown below.

Winter position

LegendA UnitB Water networkC ClosedO Open

IMPORTANT:Depending on the atmospheric conditions in your area youmust do the following when switching the unit off in winter:- Add ethylene glycol with an adequate concentration to

protect the installation up to a temperature of 10 K belowthe lowest temperature likely to occur at the installationsite.

- If the unit is not used for an extended period, it isrecommended to drain it, and as a safety precautionintroduce ethylene glycol in the heat exchanger, usingthe water entering purge valve connection.At the start of the next season, refill the unit with waterand add an inhibitor.

- For the installation of auxiliary equipment, the installermust comply with basic regulations, especially forminimum and maximum flow rates, which must bebetween the values listed in the operating limit table(application data).

A BO

F

F

- To prevent corrosion by differential aeration, the com-plete drained heat transfer circuit must be charged withnitrogen for a period of one month. If the heat transferfluid does not comply with the Carrier S.A. regulations,the nitrogen charge must be added immediately.

9.4 - Installation of the accessory condensaterecovery pan

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��������������

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2

1

Legend1 Condensate recovery pan2 Connection

18

Installation components

12 Air vent13 Thermometer sleeve14 Flexible connection15 Check valve16 System water drain plug (on connection pipe supplied in the unit)17 Pressure gauge18 Freeze-up protection bypass valve (when valve No. 15 are closed during

winter)19 Charge valve

--- Hydronic module (unit with hydronic module)

Note:Units without hydronic module are equipped with a flow switch and an internalpiping heater.

Legend

Components of the unit and hydronic module

1 Victaulic screen filter2 Expansion tank3 Safety valve4 Available pressure pump5 Purge valve and pressure tap6 Pressure gauge to measure the plate heat exchanger pressure drop (to be

isolated with valve No. 5 if not used)7 System air vent8 Flow switch9 Flow control valve10 Plate heat exchanger11 Evaporator defrost heater

Typical hydronic circuit diagram

1

2

3

4

5

6

75

8

10

11

9

18

15

1714

1417

15

16

13

19

13

12

19

O

F F

O

F

F

O

O

F

LegendO OpenF Closed

Water inlet

Water outlet

Pressure gauge

NOTE: Applies to units 040 to 080

If the pressure drop has increased, this indicates that the screenfilter must be removed and cleaned, as the hydronic circuitcontains solid particles. In this case close the shutoff valves atthe water inlet and outlet and remove the screen filter afteremptying the hydronic section of the unit.

Renew, if necessary, to ensure that the filter is not contami-nated. Purge the air from the circuit (see 'Air vent' diagram).

Entering water pressure reading

Leaving water pressure reading

Air vent

10 - NOMINAL SYSTEM WATER FLOW CONTROL

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10.1 - Water flow control procedure

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20

10.3 - Pump pressure/flow rate curves

Single pump

Legend1 30RY 017-0332 30RY 040-0703 30RY 080

Pre

ssur

e su

pplie

d, k

Pa

Water flow rate, l/s

50

75

100

125

150

175

200

225

250

275

300

0 1 2 3 4 5 6 7 8

1

2

3

50

75

100

125

150

175

200

225

250

0 1 2 3 4 5 6 7 8

1

Dual pumpP

ress

ure

supp

lied,

kP

a

Water flow rate, l/s

Legend1 30RY 040-080

When the circuit is cleaned, read the pressures at thepressure gauge (entering water pressure - leaving waterpressure), expressed in bar and convert this value to kPa(multiply by 100) to find out the plate heat exchangerpressure drop.

Compare the value obtained with the theoretical selection value.If the pressure drop measured is higher than the value specifiedthis means that the flow rate in the plate heat exchanger (andthus in the system) is too high. The pump supplies an excessiveflow rate based on the global pressure drop of the application.In this case close the control valve one turn and read the newpressure difference.

Proceed by successively closing the control valve until youobtain the specific pressure drop that corresponds to the nominalflow rate at the required unit operating point.- If the system has an excessive pressure drop in relation to

the available static pressure provided by the pump, theresulting water flow rate will de reduced and thedifference between entering and leaving watertemperature of the hydronic module will be increased.

To reduce the pressure drops of the hydronic system, it isnecessary:- to reduce the individual pressure drops as much as

possible (bends, level changes, accessories, etc.)- to use a correctly sized piping diameter.- to avoid hydronic system extensions, wherever possible.

10.2 - Pump curve and water flow control as afunction of the system pressure drops

Example: 30RY 080 at Eurovent conditions of 3.8 l/s

Water flow rate, l/s

Legend

1 Pump curve, 30RY 0802 Plate heat exchanger pressure drop (to be measured with the pressure gauge

installed at the water inlet and outlet)3 Installation pressure drop with control valve wide open4 Installation pressure drop after valve control to obtain nominal flow rate

Pre

ssur

e dr

op, k

Pa

0

20

40

60

80

100

120

140

160

180

200

2 4 6 873 5

2

1

4

3

21

Air temperaturesensor position

Accessory filters

10.5 - Duct connection

The 30RY 017-080 can be installed inside a building andconnected to an air ductwork system:- air heat exchanger side, i.e. at the fresh air inlet side- fan discharge side, i.e. where the air treated by the heat

exchanger is discharged.Installation in a room is thus possible without disturbing theroom temperature.

10.5.1 - Air return without accessory filterThe units are supplied with a collar that permits connection ofa return air duct.

Provide a removable window on the return air duct to permitmaintenance of the air temperature sensor.

10.5.2 - Air return with accessory filterThe suction side connection collar must first be removed.

Installation of the accessory on the unit can be done as follows:

10.4 - Available static system pressure

Single pumpA

vaila

ble

stat

ic p

ress

ure,

kP

a

Water flow rate, l/s

Legend1 30RY 0172 30RY 0213 30RY 0264 30RY 0335 30RY 0406 30RY 0507 30RY 0608 30RY 0709 30RY 080

50

75

100

125

150

175

200

225

250

275

300

0 2 4 6

4

5 61 2

3

7 8 9

25

50

75

100

125

150

175

200

225

0 2 4 6 8

1 2 3 4 5

25

Dual pump

Ava

ilabl

e st

atic

pre

ssur

e, k

Pa

Water flow rate, l/s

Legend1 30RY 0402 30RY 0503 30RY 0604 30RY 0705 30RY 080

22

Fan data

30RY Minimum available Nominal available Maximum availablestatic pressure* static pressure static pressure

Pressure Flow Pressure Flow Pressure FlowPa l/s Pa l/s Pa l/s

017-026 0 2500 100 1940 150 1530033 0 2920 100 2500 200 1940040-050 0 4580 150 3890 230 3330060 0 5560 150 4720 230 4030070-080 0 6810 150 5830 230 5280

* Operation without duct system

Maximum air entering temperature, °C

30RY At minimum At nominal At maximumair flow air flow air flow

017-026 44 46 47.5033 44 46 47040-050 44.5 46 47060 44.5 46 47070-080 44.5 46 47

Performance correction factors

30RY Cooling capacity Power inputMin. flow Max. flow* Min. flow Max. flow*

017-026 0.98 1.01 1.03 0.97033 0.98 1.005 1.03 0.98040-050 0.985 1.005 1.02 0.98060 0.985 1.005 1.02 0.98070-080 0.985 1.005 1.01 0.98

* Operation without duct system

Correction factor for the published performances, given at nominal air flow

Accessory suction filter pressure drop

Unit size

Add

ition

al p

ress

ure

drop

, Pa

0

2

4

6

8

10

12

14

017/026 033 040/050 060 070/080

Accessory reference number:30RY-017-033: 30RY-900—002—EE—30RY-040-080: 30RY-900—012—EE—

Replacement filter reference number:—KH—12AE-005—EE—

30RY-017-033: quantity: 430RY-040-080: quantity: 6

The connection of the return air duct is now very easy, directlyon the air filter accessory.

Filter access for maintenance is ensured by removing the twoMetric screws on the unit side (rear view of the unit).

The cover panel, supplied with a handle, can now be removed.

The filters are attached to each other with a bracket that permitssliding them into the frames.

10.5.3 - Fan dischargeA square flange is supplied mounted on the unit. An availablestandard round flange can easily be installed at the fan discharge,if the installer prefers the use of a round connection duct.

The unit is supplied with a cover panel on the dischargeside. This panel has to be removed before connection to theduct system.

30RY-017-033: standard 560 mm diameter fan30RY-040-080: standard 710 mm diameter fan

It is advisable to make the connection to the duct system with aflexible collar. If this recommendation is not observed, a lot ofvibration and noise may be transmitted to the building structure.

The unit construction does not permit the support of a ductweighing more than 10 kg. Non-observance may lead todamage of the unit.

10.5.4 - Applicable regulations for units used with an airduct systemEnsure that the return or supply air openings cannot accidentallybe obstructed by panels (for example low return air or openingof doors).

Unit performances are given for an air-side pressure drop thatis indicated in the Physical Data table.

The three tables that follow contain fan characteristics, maxi-mum air entering temperatures and performance correctionfactors, depending on the air system used with the units.

23

Depending on the installation and control type, each unit cancontrol its own water pump. If there is only one common pumpfor the two units, the master unit can control this. In this caseshut-off valves must be installed on each unit. They will beactivated at the opening and closing by the control of each unit(and the valves will be controlled using the dedicated waterpump outputs).

30RY 017 to 080 (standard configuration: return watercontrol)

21

Legend

1 Master unit2 Slave unit

Additional CCN board (one per unit, with connection via communicationbus)

Control boxes of the master and slave units

Water inlet

Water outlet

Water pumps for each unit (included as standard for units with hydronic

module)Additional sensors for leaving water control, to be connected to channel 1of the slave boards of each master and slave unitCCN communication busConnection of two additional sensors

30RY 017 to 080 (with configuration: leaving watercontrol)

1 2

11 - START-UP

11.1 - Preliminary checks

- Never be tempted to start the chiller without reading fully,and understanding, the operating instructions and withouthaving carried out the following pre-start checks:

- Check the chilled water circulation pumps, air handlingunits and all other equipment connected to the eva-porator.

- Refer to the manufacturer's instructions.- For units without hydronic module, the water pump

overheat protection device must be connected in serieswith the pump contactor power supply. If the pump is notsupplied with the unit (unit without hydronic module),verify that the power input of the field-installed pumpdoes not exceed the rating of the standard pump contactor,supplied in the control box (max. 3 kW).

- Refer to the wiring diagram supplied with the unit.- Ensure that there are no refrigerant leaks.- Confirm that all pipe securing bands are tight.- Confirm the the electrical connections are secure.

11.2 - Actual start-up

IMPORTANT• Commissioning and start-up of the chiller must be

supervised by a qualified refrigeration engineer.• It is strictly forbidden to energise the units, if the fan has

not been connected to a duct system.

The outdoor installation option includes a protectiongrille that does not require this connection.

• Start-up and operating tests must be carried out with athermal load applied and water circulating in theevaporator.

• All set-point adjustments and control tests must becarried out before the unit is started up.

• Please refer to the Controls manual for these units.

The unit should be started up in Local ON mode.Ensure that all safety devices are satisfied, especially the highpressure switches.

11.3 - Operation of two units in master/slave mode

The control of a master/slave assembly is in the entering waterand does not require any additional sensors (standard confi-guration).

All parameters, required for the master/slave function must beconfigured using the Service Configuration menu. All remotecontrols of the master/slave assembly (start/stop, set point, loadshedding etc.) are controlled by the unit configured as masterand must only be applied to the master unit.

24

WARNING: To ensure proper operation of 30RY units theremust be at least 12 K of subcooling as the liquid refrigerantenters the expansion valve.

The 30RY units use refrigerant. For your information, we arereproducing here some extracts from the official publicationdealing with the design, installation, operation andmaintenance of air conditioning and refrigeration systemsand the training of people involved in these activities, agreedby the air conditioning and refrigeration industry.

12.3 - Apparent and actual subcooling

Pre

ssur

e

Enthalpy

3

45

1

6

2

L

L + V

V

12 - MAINTENANCE

Any technician attending the machine for any purpose must befully qualified to work on refrigerant and electrical circuits.

All refrigerant charging, removal and draining operationsmust be carried out by a qualified technician and with thecorrect material for the unit. Any inappropriate handling canlead to uncontrolled fluid or pressure leaks.

WARNING: Before doing any work on the machine ensurethat the power is switched off. If a refrigerant circuit is opened,it must be evacuated, recharged and tested for leaks. Beforeany operation on a refrigerant circuit, it is necessary toremove the complete refrigerant charge from the unit with arefrigerant charge recovery group.

12.1 - General maintenance of the refrigerant circuit

• Keep the unit itself and the space around it clean and freeof obstructions. Remove all rubbish such as packingmaterials, as soon as the installation is completed.

• Regularly clean the exposed pipework to remove all dustand dirt. This makes detection of water leaks easier, andthey can be repaired before more serious faults develop.

• Confirm that all screwed and bolted connections andjoints are secure. Secure connections prevent leaks andvibration from developing.

• Check that all insulation joints are securely closed andthat all insulation is firmly in place. Check all heatexchangers and all pipework.

If water jets are used inside the units (e.g. to clean the coils), thelower holes (for possible condensate removal) must be blocked.

12.2 - Verification of the refrigerant charge

CAUTION: The 30RY units are supplied with a preciserefrigerant charge (see Physical Data table).

To verify the correct system charge prodeed as follows:Ensure that no bubbles appear in the sight-glass, when operat-ing the unit at full load for a while, at a saturated condensingtemperature of between 55 and 57°C. If necessary cover asection of the coil surface to obtain this condensing tempera-ture. Under these conditions the apparent subcooling which isequal to the saturated condensing temperature (1 - on thesaturated dew point curve) minus the liquid refrigerant tem-perature (3) ahead of the expansion device must be between 12and 14°C. This corresponds to an actual subcooling temperatureof between 5 and 7 K at the condenser outlet, depending on theunit type. Actual subcooling is equal the saturated liquid tem-perature (2 - on the saturated bubble point curve) minus theliquid refrigerant temperature (3) ahead of the expansion device.Use the pressure tap supplied on the liquid piping to chargerefrigerant and to find out the pressure of the liquid refrigerant.If the subcooling value is not correct, i.e. lower than the speci-fied values, a leak detection test must be carried out on the unit,as it no longer contains its original charge.

In order to measure the liquid refrigerant pressure and tem-perature ahead of the expansion device, an access port must beopened on the expansion device which causes a slight airbypass on the condenser. Wait until unit operation has stabil-ized before carrying out pressure and temperature measurements.

Legend1 Saturated condensing temperature at the dew point2 Saturated liquid temperature at the bubble point3 Liquid refrigerant temperature4 Saturation curve at the dew point5 Saturation curbe at the bubble point6 Isotherms7 Apparent subcooling (1 - 3)8 Real subcooling (2 - 3)L LiquidL + V Liquid + vapourV Vapour

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12.6 - Undercharge

If there is not enough refrigerant in the system, this is indicatedby gas bubbles in the moisture sight glass.

If the undercharge is significant, large bubbles appear in themoisture sight glass, and the suction pressure drops. Thecompressor suction superheat is also high. The machine mustbe recharged after the leak has been repaired.

Find the leak and completely drain the system with a refrigerantrecovery unit. Carry out the repair, leak test and then rechargethe system.

IMPORTANT: After the leak has been repaired, the circuitmust be tested, without exceeding the maximum low-sideoperating pressure shown on the unit name plate.

The refrigerant must always be recharged in the liquid phaseinto the liquid line.The refrigerant cylinder must always contain at least 10% of itsinitial charge.For the refrigerant quantity per circuit, refer to the data on theunit name plate.

12.7 - Characteristics of R407C

See the table following.Saturated bubble point temperatures (bubble point curve)Saturated dew point temperatures (dew point curve)

12.8 - Electrical maintenance

When working on the unit comply with all safety precautionsdescribed in section “Maintenance safety considerations”.

- It is strongly recommended to change the fuses in theunits every 15000 operating hours or every 3 years.

- It is recommended to verify that all electrical connectionsare tight:a. after the unit has been received at the moment of

installation and before the first start-up,b. one month after the first start-up,when the electrical

components have reached their nominal operatingtemperatures,

c. then regularly once a year.

12.4 - Refrigerant guidelines

Refrigeration installations must be inspected and maintainedregularly and rigorously by specialists. Their activities must beoverseen and checked by properly trained people. To minimisedischarge to the atmosphere, refrigerants and lubricating oilmust be transferred using methods which reduce leaks andlosses to a minimum and with materials that are suitable for theproducts.• Leaks must be repaired immediately.• All units are equipped with two special connections on the

suction and liquid line, which permit the connection ofquick-connect recovery valves without loss of refrigerant.

• If the residual pressure is too low to make the transferalone, a purpose-built refrigerant recovery unit must beused.

• Compressor lubricating oil contains refrigerant. Any oildrained from a system during maintenance must thereforebe handled and stored accordingly.

• Refrigerant under pressure must never be discharged tothe atmosphere.

• If the refrigerant circuit is opened, plug all openings if theoperation takes up to one day, or charge the circuit withnitrogen for longer operations.

12.5 - Recharging liquid refrigerant

CAUTION: 30RY units are charged with liquid HFC-407Crefrigerant.

This non-azeotropic refrigerant blend consists of 23% R-32,25% of R-125 and 52% R-134a, and is characterised by thefact that at the time of the change in state the temperature ofthe liquid/vapour mixture is not constant, as with azeotropicrefrigerants. All checks must be pressure tests, and theappropriate pressure/temperature ratio table must be used todetermine the corresponding saturated temperatures(saturated bubble point curve or saturated dew point curve).

Leak detection is especially important for units charged withrefrigerant R-407C. Depending on whether the leak occurs inthe liquid or in the vapour phase, the proportion of thedifferent components in the remaining liquid is not the same.

NOTE: Regularly carry out leak checks and immediatelyrepair any leak found.

If there is a leak in the plate heat exchanger, this part mustbe replaced.

26

Characteristics of R407C

Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew Bar Saturated bubble Saturated dew(relative) point temp., °C point temp., °C (relative) point temp., °C point temp., °C (relative) point temp., °C point temp., °C

1 -28.55 -21.72 10.5 23.74 29.35 20 47.81 52.551.25 -25.66 -18.88 10.75 24.54 30.12 20.25 48.32 53.041.5 -23.01 -16.29 11 25.32 30.87 20.5 48.83 53.531.75 -20.57 -13.88 11.25 26.09 31.62 20.75 49.34 54.012 -18.28 -11.65 11.5 26.85 32.35 21 49.84 54.492.25 -16.14 -9.55 11.75 27.6 33.08 21.25 50.34 54.962.5 -14.12 -7.57 12 28.34 33.79 21.5 50.83 55.432.75 -12.21 -5.7 12.25 29.06 34.5 21.75 51.32 55.93 -10.4 -3.93 12.5 29.78 35.19 22 51.8 56.363.25 -8.67 -2.23 12.75 30.49 35.87 22.25 52.28 56.823.5 -7.01 -0.61 13 31.18 36.55 22.5 52.76 57.283.75 -5.43 0.93 13.25 31.87 37.21 22.75 53.24 57.734 -3.9 2.42 13.5 32.55 37.87 23 53.71 58.184.25 -2.44 3.85 13.75 33.22 38.51 23.25 54.17 58.624.5 -1.02 5.23 14 33.89 39.16 23.5 54.64 59.074.75 0.34 6.57 14.25 34.54 39.79 23.75 55.1 59.55 1.66 7.86 14.5 35.19 40.41 24 55.55 59.945.25 2.94 9.11 14.75 35.83 41.03 24.25 56.01 60.375.5 4.19 10.33 15 36.46 41.64 24.5 56.46 60.85.75 5.4 11.5 15.25 37.08 42.24 24.75 56.9 61.226 6.57 12.65 15.5 37.7 42.84 25 57.35 61.656.25 7.71 13.76 15.75 38.31 43.42 25.25 57.79 62.076.5 8.83 14.85 16 38.92 44.01 25.5 58.23 62.486.75 9.92 15.91 16.25 39.52 44.58 25.75 58.66 62.97 10.98 16.94 16.5 40.11 45.15 26 59.09 63.317.25 12.02 17.95 16.75 40.69 45.71 26.25 59.52 63.717.5 13.03 18.94 17 41.27 46.27 26.5 59.95 64.127.75 14.02 19.9 17.25 41.85 46.82 26.75 60.37 64.528 14.99 20.85 17.5 42.41 47.37 27 60.79 64.928.25 15.94 21.77 17.75 42.98 47.91 27.25 61.21 65.318.5 16.88 22.68 18 43.53 48.44 27.5 61.63 65.718.75 17.79 23.57 18.25 44.09 48.97 27.75 62.04 66.19 18.69 24.44 18.5 44.63 49.5 28 62.45 66.499.25 19.57 25.29 18.75 45.17 50.02 28.25 62.86 66.879.5 20.43 26.13 19 45.71 50.53 28.5 63.27 67.269.75 21.28 26.96 19.25 46.24 51.04 28.75 63.67 67.6410 22.12 27.77 19.5 46.77 51.55 29 64.07 68.0210.25 22.94 28.56 19.75 47.29 52.05 29.25 64.47 68.39

12.9 - Condenser coil

We recommend, that finned coils are inspected regularly tocheck the degree of fouling. This depends on the environmentwhere the unit is installed, and will be worse in urban andindustrial installations and near trees that shed their leaves.

For coil cleaning proceed as follows:• Remove fibres and dust collected on the condenser face

with a soft brush (or vacuum cleaner).• Clean the coil with the appropriate cleaning agents.

We recommend TOTALINE products for coil cleaning:Part No. P902 DT 05EE: traditional cleaning methodPart No. P902 CL 05EE: cleaning and degreasing.

These products have a neutral pH value, do not contain phos-phates, are not harmful to the human body, and can be disposedof through the public drainage system. Depending on thedegree of fouling both products can be used diluted or undiluted.

For normal maintenance routines we recommend using 1 kg ofthe concentrated product, diluted to 10%, to treat a coil surfaceof 2 m2. This process can either be carried out witha TOTALINEapplicator gun (part No. TE01 WA 4000EE) or using a high-pressure spray gun in the low-pressure position. With pressur-ised cleaning methods care should be taken not to damage thecoil fins. The spraying of the coil must be done:- in the direction of the fins- in the opposite direction of the air flow direction- with a large diffuser (25-30°)- at a distance of 300 mm.

The two cleaning products can be used for any of the followingcoil finishes: Cu/Cu, Cu/Al, Cu/Al with Polual, Blygold and/orHeresite protection.

It is not necessary to rinse the coil, as the products used are pHneutral. To ensure that the coil is perfectly clean, we recommendrinsing with a low water flow rate. The pH value of the waterused should be between 7 and 8.

WARNING: Never use pressurized water without a largediffusor. Concentrated and/or rotating water jets are strictlyforbidden.

Correct and frequent cleaning (approximately every threemonths) will prevent 2/3 of the corrosion problems.

Never use a fluid with a temperature above 45°C to clean theair heat exchangers.

27

13 - AQUASNAP MAINTENANCE PROGRAM

All maintenance operations must be carried out by technicianswho have been trained on Carrier products, observing allCarrier quality and safety standards.

Maintenance instructionsDuring the unit operating life the service checks and tests mustbe carried out in accordance with applicable national regulations.

If there are no similar criteria in local regulations, theinformation on checks during operation in annex C of standardEN 378-2 can be used.

External visual checks: annex A and B of standard EN 378-2

Corrosion checks: annex D of standard EN 378-2. Thesecontrols must be carried out:- After an intervention that is likely to affect the resistance

or a change in use or change of high-pressure refrigerant,or after a shut down of more than two years. Componentsthat do not comply, must be changed. Test pressuresabove the respective component design pressure must notbe applied (annex B and D).

- After repair or significant modifications or significantsystem or component extension (annex B)

- After re-installation at another site (annexes A, B and D)- After repair following a refrigerant leak (annex D). The

frequency of refrigerant leak detection can vary from onceper year for systems with less than 1% leak rate per yearto once a day for systems with a leak rate of 35% per yearor more. The frequency is in proportion with the leak rate.

NOTE: High leak rates are not acceptable. The necessarysteps must be taken to eliminate any leak detected.

NOTE 2: Fixed refrigerant detectors are not leak detectors,as they cannot locate the leak.

13.1 - Maintenance schedule

Regular maintenance is indispensable to optimise the operatinglife and reliability of the equipment. Maintenance operationsmust be carried out in accordance with the schedules below:

Service FrequencyA WeeklyB MonthlyC AnnuallyD Special cases

If the equipment does not operate normally during maintenanceoperations, please refer to the paragraph on diagnostics andbreakdowns of the '30RA/RH- 30RY/RYH “B” Pro-Dialog Plus'controls manual.

IMPORTANT: Before each equipment maintenanceoperation please ensure that:- the unit is in the OFF position- it is impossible for the unit to restart automatically

during maintenance.

13.2 - Description of the maintenance operations

The equipment is supplied with polyolester oil (POE). Onlyuse oil approved by Carrier. On request Carrier can carry outan oil analysis of your installation.

Service AFull-load operating testVerify the following values:- compressor high-pressure side discharge pressure- compressor low-pressure side suction pressure- charge visible in the sight glass- temperature difference between the heat exchanger water

entering and leaving temperature.

Verify the alarm status

Service BCarrier out the operations listed under Service A.Refrigerant circuit- Verify the air heat exchanger cleanliness status and clean

it at least once a year, or more often if the equipmentenvironment is especially demanding. To clean theequipment, follow the Carrier recommendations. Amongother things, this ensures that the unit performances canbe guaranteed.

- Full-load operating test. In addition to the operationsdescribed under Service A, check the following values:- compressor discharge pressure- compressor oil level- actual liquid subcooling- overheating at the expansion device- on heat pumps verify correct defrost of the air heat

exchanger.- Verify the charge status by checking the colour indicator

of the sight glass. If the colour has turned to yellow,change the charge and replace the filter drier aftercarrying out a leak test of the circuit.

Electrical checks- Check the tightening of the electric connections,

contactors, disconnect switch and transformer.- Check the status of the contactors, fuses and capacitators,

as required.- Carry out a quick test (refer to the manual for the

Aquasnap Pro-Dialog Plus control).

Mechanical checks- Verify that nothing impedes the rotation of the fan

impeller of the air heat exchanger.

Water circuit checks- Check th