Carrier 30RQM 160 Installation, Operation And Maintenance Instructions Download

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INSTALLATION, OPERATION AND
M A I N T E N A N C E I N S T R U C T I O N S

Reversible air-to-water heat pump

30RQM 160-520

30RQP 160-520

Unit with low-noise option

Nominal heating capacity 170 - 540 kW

Nominal cooling capacity 160 - 510 kW

Summary of Contents for 30RQM 160

Page 1: ...ION AND MAINTENANCE INSTRUCTIONS Reversible air to water heat pump 30RQM 160 520 30RQP 160 520 Unit with low noise option Nominal heating capacity 170 540 kW Nominal cooling capacity 160 510 kW Unit with low noise option ...

Page 2: ...rcuit current withstand capability 16 4 6 Electrical data notes for the hydraulic module 17 4 7 Compressor usage and electrical data 19 5 ELECTRICAL CONNECTION 20 5 1 Power supply 20 5 2 Voltage phase imbalance 20 5 3 Power connection disconnect switch 20 5 4 Recommended wire sections 21 5 5 Power cable access routing 22 5 6 Field control wiring 22 5 7 Electric power reserve for the user 22 6 APPL...

Page 3: ... 11 Variable frequency drive VFD 40 9 12 Power factor correction capacitors option 231 40 9 13 Medium and low temperature brine solution option Option 6B 41 9 14 Fan arrangement 42 9 15 Fan stages 30RQM units only 42 9 16 Variable speed ventilation 30RQP units only 42 9 17 Touch Pilot control 42 10 OPTIONS 43 10 1 Hydraulic module without variable speed options 116R 116S 116T 116U 43 10 2 Hydrauli...

Page 4: ...eat transfer fluid circuits Check whether the original protection plugs are still present at the valve outlets These plugs are generally made of plastic and must be removed before operation If they are still present please remove them Fit devices at the valve or drain piping outlets to prevent the penetration of foreign bodies dust building debris etc and atmospheric agents water can form rust or ...

Page 5: ... organisation Date Nature 1 1 Maintenance repairs regular verifications EN 378 leakage etc Engineers working on the electrical or refrigeration components must be authorised trained and fully qualified to do so All work on the refrigerant circuit must be carried out by a trained person fully qualified to work on these units He she must have been specifically trained on this equipment and system Al...

Page 6: ...ng equipment Values and tolerances for cut off and discharge devices Test stages Recommissioning of the equipment Please contact Carrier Service for this type of test The test principle set out here by Carrier does not involve removal of the pressure switch Verify and record the nominal values for activation of the pressure switches and external relief devices pressure relief valves or rupture dis...

Page 7: ... injuries We recommend that standard EN 378 3 Annex 3 is applied Never apply an open flame or live steam to a refrigerant container This can result in dangerous overpressure During refrigerant removal and storage operations follow applicable regulations These regulations permitting conditioning and recovery of halogenated hydrocarbons under optimum quality conditions for the products and optimum s...

Page 8: ...g and positioning 2 2 1 Handling See the section on Installation safety considerations In some cases uprights are added for transporting and handling the unit The uprights must be removed if necessary for access or connection Important follow the disassembly procedure indicated in the disassembly instructions Undo the bolt 3 Remove the upright 2 Remove the plate 1 Keep the uprights following start...

Page 9: ...ation and is not nitrogen Comparethecompletesystemwiththerefrigerationsystem and power circuit diagrams Check that all components comply with the design specifications Check that all protection equipment and documents provided by the manufacturer dimensional drawings Pipe andinstrumentdiagram PID declarations etc tocomply with the regulations are present Verifythattheenvironmentalprotectionandsafe...

Page 10: ...aintenance and air flow 2 Clearance recommended for coil removal Water inlet Water outlet Air outlet do not obstruct Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of ...

Page 11: ...rol box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of gravity coordinates WITH WATER BUFFER TANK MODULE Main hydraulic connection Electrical power connection ...

Page 12: ...ce and air flow 2 Clearance recommended for coil removal Water inlet Water outlet Air outlet do not obstruct Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of gravity ...

Page 13: ...rol box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of gravity coordinates WITH WATER BUFFER TANK MODULE Main hydraulic connection Electrical power connection ...

Page 14: ...d air flow 2 Clearance recommended for coil removal Water inlet Water outlet Air outlet do not obstruct Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of gravity coord...

Page 15: ...rol box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight distribution points and centre of gravity coordinates WITH WATER BUFFER TANK MODULE Main hydraulic connection Electrical power connection ...

Page 16: ...g of air from one unit to another If the floor space does not allow this arrangement contact your Carrier distributor to assess the various installation options 3 5 Distance to the wall To guarantee correct operation in most cases If h H S minimum 3 m If h H or S 3 m contact your Carrier distributor to assess the various installation options Anti vibration mounts ...

Page 17: ...r Grooved copper tubes and aluminum fins Fans Axial Flying Bird 4 with rotating shroud Quantity 3 4 4 4 5 5 6 6 7 8 8 8 Maximum total air flow l s 13542 18056 18056 18056 22569 22569 27083 27083 31597 36111 36111 36111 Maximum rotation speed rps 16 16 16 16 16 16 16 16 16 16 16 16 Water heat exchanger Dual circuit plate heat exchanger Water volume l 15 15 15 19 27 27 35 44 44 44 47 53 Max water si...

Page 18: ...5 20 20 17 14 13 13 13 Air heat exchanger Grooved copper tubes and aluminium fins Fans Axial Flying Bird 4 with rotating shroud Quantity 3 4 4 4 5 5 6 6 7 8 8 8 Maximum total air flow l s 13542 18056 18056 18056 22569 22569 27083 27083 31597 36111 36111 36111 Maximum rotation speed rps 16 16 16 16 16 16 16 16 16 16 16 16 Water heat exchanger Dual circuit plate heat exchanger Water volume l 15 15 1...

Page 19: ...ircuit A B A 97 107 130 144 147 162 186 195 227 260 288 316 Cosine Phi unit at maximum power 2 Circuit A B kW 81 88 108 118 120 134 153 161 188 215 237 259 Cosinus Phi unité à puissance maximale 2 0 88 0 88 0 88 0 88 0 88 0 88 0 88 0 88 0 88 0 88 0 88 0 88 Maximum unit current draw Un 10 3 Circuit A B A 142 154 189 208 211 237 268 284 331 378 416 454 Maximum unit current draw Un 4 Circuit A B Stan...

Page 20: ...able to the pump power input 6 To obtain the maximum unit operating current draw for a unit with hydraulic module add the maximum unit current draw from the electrical data table to the pump current draw For the low pressure dual pump motors for 30RQM 30RQP 160 520 units option 116U No 2 Description 3 Units 30RQM 30RQP 160 180 210 230 240 270 310 330 380 430 470 520 1 Nominal efficiency at full lo...

Page 21: ...aulic module add the maximum unit current draw from the electrical data table to the pump current draw For the high pressure single and dual pump motors for 30RQM 30RQP 160 520 units options 116S and 116W No 2 Description 3 Units 30RQM 30RQP 160 180 210 230 240 270 310 330 380 430 470 520 1 Nominal efficiency at full load and nominal voltage 87 5 87 5 89 6 89 6 89 6 89 7 89 7 89 7 90 8 90 8 90 8 9...

Page 22: ...0 00PSG001961100A 30 41 44 215 0 89 A 1 2 2 2 2 2 2 3 4 4 B 2 2 2 3 4 4 4 00PSG001748000A 37 50 54 260 0 89 A 1 4 B 2 2 3 4 4 I Nom Nominal current draw A at standardised Eurovent equivalent conditions see definition of conditions under nominal unit current draw I Max Maximum operating current A LRA Locked rotor current A Cos phi Max I Max 400 V 50 Hz ...

Page 23: ... AC1 Lower than or equal to 2000 m for hydraulic module see paragraph 4 7 in the IOM Presence of hard solid Class AE3 no significant dust present Presence of corrosive and polluting substances class AF1 negligible Competence of persons BA4 Persons wise 2 Compatibility for low frequency conducted disturbances according to class 2 levels per IEC61000 2 4 standard Power supply frequency variation 2Hz...

Page 24: ...conductor cables in closed conduits standardised routing no 41 Cable with PVC insulation 30RQM 30RQP Standard lug Narrow lug Recommended max lug width Section 2 Max length for a voltage drop 5 Cable type 3 Section 2 Max length for a voltage drop 5 Cable type 3 mm per phase mm per phase mm mm per phase m mm per phase m 160 2x70 2x95 21 1 x 50 200 XLPE Copper 2 x 50 388 PVC Copper 180 2x70 2x95 21 1...

Page 25: ...cations to the electrical box must ensure that the equipment remains compliant with local regulations In particular precautions must be taken to prevent accidental electrical contact between the circuits supplied by different sources The choice of routing and or insulation characteristics of the conductors ensures double electrical insulation The conductors should be fixed together inside the elec...

Page 26: ...eandtransport minimum and maximum ambient temperatures to respect are 20 C and 52 C These temperature limits shall be considered in case of container shipment 30RQM 30RQP 160 520 units Cooling mode 30 20 10 0 10 20 30 40 50 10 5 0 5 10 15 20 Option 15LS 30RQM option 28 ou 30RQP 30RQP 180 230 270 310 seulement Option 231 Inlet air temperature C Evaporator water outlet temperature C 30RQM 30RQP 160 ...

Page 27: ...arious concentrations and static pressures If the maximum volume is insufficient compared to the minimum system water loop volume an additional expansion tank vessel must be added to the system Maximum water loop volume litres 30RQM 30RQP 160 230 240 520 Static pressure bar 1 2 2 5 1 2 2 5 Pure water 2400 1600 1200 3960 2640 1980 10 EG 1800 1200 900 2940 1960 1470 20 EG 1320 880 660 2100 1400 1050...

Page 28: ...r at 20 C 30RQM 30RQP 160 310 units 10 100 1 10 100 Pressure drop kPa Flow rate l s 1 2 3 4 1 30RQM 30RQP 160 180 210 2 30RQM 30RQP 230 3 30RQM 30RQP 240 270 4 30RQM 30RQP 310 30RQM 30RQP 330 520 units 10 100 10 100 5 6 7 Pressure drop kPa Flow rate l s 5 30RQM 30RQP 330 380 430 6 30RQM 30RQP 470 7 30RQM 30RQP 520 ...

Page 29: ...alified personnel using tools and equipment suitable for the products The heat transfer fluid should be filled using devices fitted to the hydraulic circuit by the installer 7 1 Operating precautions and recommendations Before any system start up verify that the hydraulic circuits are connected to the appropriate heat exchangers The water circuit should be designed to have the least number of elbo...

Page 30: ...ote Provides temperature information for the water exchanger inlet see Control manual 10 Pressure sensor Note Provides pressure information for the water exchanger outlet see Control manual 11 Check valve if dual pump 12 Plate heat exchanger 13 Heater or heat trace cable for frost protection Option 14 Water type heat exchanger flow rate sensor 15 BufferTank Module Option System components 16 Pocke...

Page 31: ...r vase d expansion option 293 See legend on the previous page Example Single pump Example Dual pump Coupling for expansion vessel option 293 6 7 9 10 8 5 3 1 4 Raccord pour vase d expansion option 293 Coupling for expansion vessel option 293 Figure 3 Water connections with hydraulic module and with buffer tank module option A 15 5 23 6 ...

Page 32: ...c circuit The pump will periodically start automatically Combination of options for the periods when the machine is in standby mode Ambient unit temperature range 30RQM 30RQP 160 520 without option 116 with option 116 0 C to 48 C 20 C to 0 C Option 41 Option 42A 1 or or Appropriate anti freeze solution for example glycol Appropriate anti freeze solution for example glycol 1 1 Allow the pumps to ci...

Page 33: ...e mode is only possible when the units are installed in parallel The master slave assembly is controlled on the water inlet without any additional sensors system return see example 1 Control of Master and Slave on the water outlet is possible by adding two additional sensors in the common supply pipe work see example 2 Each unit controls its own water pump 7 6 2 Units delivered without the hydraul...

Page 34: ...ge 2 3 Stage 3 4 Stage 4 safety A Variation of the heat pump output with air temperature B Building thermal load C Point of equilibrium between the heat pump output and the building thermal load 7 7 Auxiliary electric heaters To compensate for the reduction in the heat pump s output at low ambient temperatures which changes significantly as shown in the graph below it is possible to install auxili...

Page 35: ...ircuit schematic diagram By causing the pressure in the water system to drop this flow control valve aligns the system pressure flow curve with that of the pump so that the nominal flow rate corresponding to the desired operating point is obtained As the exact total system pressure drop is not known at start up it is necessary to adjust the water flow with the control valve to obtain the system s ...

Page 36: ...vel changes options etc as much as possible Use the correct pipe diameter Do not extend the hydraulic systems Example Unit with specified nominal flow rate of 10 6 l s Water flow rate l s Pressure drop kPa Key 1 Unit pump curve 2 Pressure drop in the hydraulic kit to be measured on the pressure gauge installed on the water inlet and outlet 3 Pressure drop in the installation with wide open control...

Page 37: ...l value The flow rate will be adjusted by varying the pump speed to maintain a heat exchanger temperature differential value defined by the user This variation in flow rate is limited by the maximum and minimum permissible flow rate values for the unit and by the maximum and minimum pump supply frequency values Contact Carrier Service to discuss the implementation of the procedures set out below 8...

Page 38: ...f ethylene glycol the maximum flow rate is reduced 8 6 1 30RQM 30RQP high pressure pumps Single pumps Water flow rate l s Manometric head kPa 1 2 3 4 5 1 30RQM 30RQP 160 180 2 30RQM 30RQP 210 230 240 3 30RQM 30RQP 270 310 330 380 4 30RQM 30RQP 430 470 5 30RQM 30RQP 520 Dual pumps Water flow rate l s Manometric head kPa 1 3 2 4 5 1 30RQM 30RQP 160 180 2 30RQM 30RQP 210 230 240 3 30RQM 30RQP 270 310...

Page 39: ...P 160 180 2 30RQM 30RQP 210 230 3 30RQM 30RQP 240 270 310 4 30RQM 30RQP 330 380 430 5 30RQM 30RQP 470 520 Dual pumps Water flow rate l s Manometric head kPa 1 2 3 4 6 5 7 1 30RQM 30RQP 160 2 30RQM 30RQP 180 3 30RQM 30RQP 210 230 4 30RQM 30RQP 240 270 310 5 30RQM 30RQP 330 380 430 6 30RQM 30RQP 470 7 30RQM 30RQP 520 ...

Page 40: ... 180 2 30RQM 30RQP 210 3 30RQM 30RQP 230 4 30RQM 30RQP 240 Dual pumps Available static pressure kPa 1 30RQM 30RQP 160 180 2 30RQM 30RQP 210 3 30RQM 30RQP 230 4 30RQM 30RQP 240 Sizes 160 240 Sizes 270 520 5 30RQM 30RQP 270 310 6 30RQM 30RQP 330 380 7 30RQM 30RQP 430 470 8 30RQM 30RQP 520 5 30RQM 30RQP 270 6 30RQM 30RQP 310 7 30RQM 30RQP 330 8 30RQM 30RQP 380 430 9 30RQM 30RQP 470 10 30RQM 30RQP 520...

Page 41: ...30 Sizes 160 270 Sizes 310 520 Sizes 160 230 Sizes 240 520 5 30RQM 30RQP 310 6 30RQM 30RQP 330 380 430 7 30RQM 30RQP 470 8 30RQM 30RQP 520 5 30RQM 30RQP 240 270 6 30RQM 30RQP 310 7 30RQM 30RQP 330 380 430 8 30RQM 30RQP 470 9 30RQM 30RQP 520 Water flow rate l s Water flow rate l s Water flow rate l s Water flow rate l s Available static pressure kPa Available static pressure kPa Available static pr...

Page 42: ...xial Flying Bird fans equipped with a rotating shroud and made of composite recyclable material Each motor is fixed with transverse supports The motors are three phase with permanently lubricated bearings and class F insulation For detailed information refer to the table below According to the Regulation No 327 2011 implementing Directive 2009 125 EC with regard to eco design requirements for fans...

Page 43: ...ithin the fmin fmax frequency range for the standard 30RQP fmin 5 Hz and fmax 50 Hz All fans on the same refrigerating circuit are actuated and controlled by a single variable frequency drive Fan speed is changed by generating a controlled waveform in which frequency and voltage are varied Pulse Width Modulation Fan start up shut down and the working range frequency setpoint is controlled by the C...

Page 44: ...on values given by our supplier are as follows these values may change depending on the suppliers It is therefore recommended that a medium or low temperature installation be commissioned by the manufacturer 9 13 2 Required glycol concentration Ethylene and Propylene glycol freezing curve Glycol concentration Minimum frost protection temperature C Ethylene glycol Propylene glycol Minimum frost pro...

Page 45: ...r temperature circuit capacity and thereby improve the seasonal efficiency ESEER and SCOP All fans in the same refrigerant circuit are controlled by a single variable speed drive Therefore they operate together at the same rotational speed The rotational speed at full load or part load of each circuit is controlled by an algorithm that continuously optimises the condensing temperature in cooling m...

Page 46: ...gers is discharged by the fans to theoutsideofthebuilding usingaductsystemthatcausesapressure drop in the air path Thereforethisoptionfeaturesmorepowerfulfanmotorsthanthose fitted to standard units For each installation the duct pressure drops differ depending on the duct length the duct section and the direction changes 30RQP unitswithoption12aredesignedtooperatewithairdischargeducts with maximum...

Page 47: ... system to prevent any air recycling between the air heat exchangers of the different refrigerant circuits Each fan of the 30RQP unit with option 12 is equipped with a factory installed connection interface allowing the connection to the ductwork Please refer to the unit dimensional drawings for the exact dimensions of the connection interface Please refer to the section 9 12 Fan arrangements to a...

Page 48: ...nd the fan protection grilles must always remain in their position inside the ducts Use bellows or flexible sleeves for the duct connection At the outlet of each duct provide an access hatch with a minimum size of 700 x 700 mm to allow motor replacement and disassembly of the fan impeller Fan motor electrical protection In case of a locked rotor or an overload the motors of each circuit are electr...

Page 49: ...erant Circuit A kg 16 0 22 2 23 7 25 5 29 2 29 2 32 8 36 8 46 2 55 2 56 7 59 2 tCO2 e 33 4 46 4 49 5 53 2 61 0 61 0 68 5 76 8 96 5 115 3 118 4 123 6 Circuit B kg 23 7 23 7 23 7 25 5 37 1 38 5 49 7 55 2 55 2 55 2 56 7 59 2 tCO2 e 49 5 49 5 49 5 53 2 77 5 80 4 103 8 115 3 115 3 115 3 118 4 123 6 Water connections Connection Victaulic 2 2 2 2 2 2 2 2 2 2 2 2 Outside diameter 60 3 60 3 60 3 60 3 60 3 ...

Page 50: ...DULE Key All dimensions are in mm 1 Clearances required for maintenance and air flow 2 Clearance recommended for coil removal Water inlet Water outlet Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight ...

Page 51: ...ic Key All dimensions are in mm 1 Clearances required for maintenance and air flow 2 Clearance recommended for coil removal Water inlet Water outlet Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight di...

Page 52: ... 2200 Key All dimensions are in mm 1 Clearances required for maintenance and air flow 2 Clearance recommended for coil removal Water inlet Water outlet Control box NOTE Non contractual drawings When designing a system refer to the certified dimensional drawings provided with the unit or available on request Please refer to the certified dimensional drawingsforthepositioningofthefixingpoints weight...

Page 53: ...er option without hydraulic module 16 System heat load 17 Border between the 30RQM 30RQP unit and the typical installation Installation components installation example 20 Pump hydraulic circuit of the desuperheater loop 21 Shut off valve 22 Desuperheater water flow balancing and control valve 23 Damage limitation accessory in case of a fire 24 Expansion tank 25 Charge or drain valve 26 Air bleed 2...

Page 54: ... water temperature during operation C 30 80 Entering water temperature at shut down C 3 60 Air heat exchanger condenser Entering air temperature C 0 46 Available static pressure Pa 0 0 Heating mode Minimum Maximum Water heat exchanger condenser Entering water temperature at start up C 8 45 Leaving water temperature during operation C 20 50 Entering water temperature at shut down C 3 60 Desuperheat...

Page 55: ... hydronic module 116T Single low pressure water pump water filter electronic water flow control pressure transducers See hydraulic module option chapter Easy and fast installation plug play 30RQM 30RQP 160 520 LP dual pump hydronic module 116U Dual low pressure water pump water filter electronic water flow control pressure transducers See hydraulic module option chapter Easy and fast installation ...

Page 56: ... traces of oil indicates a refrigerant leak Check for leaks in the hydraulic circuit monthly Clean the air heat exchangers see chapter 11 6 Air coil Level 1 cleaning Check that the protective grilles are present and in good condition andthatthedoorsandcoversareproperlyclosed Check the unit s alarm report see 30RQM 30RQP control manual Verify the refrigerant charge in the liquid line sight glass Ve...

Page 57: ...ctrical connections Component Designation in the unit Value N m Welded screw PE customer connection earth connection 40 Screw terminal fuse holder FU1 FU2 FU3 FU4 10 Screw terminal fuse holder FU100 0 8 1 2 Screw terminal compressor contactor KM1 KM12 3 4 5 Brass screw M6 compressor ground EC 5 M6 screw compressor connection EC 5 Screw terminal circuit breakers QM QF 2 Screw terminal pump contacto...

Page 58: ...e table below Saturated temperatures based on the gauge pressure in kPa Saturated Temp Pressure gauge Saturated Temp Pressure gauge Saturated Temp Pressure gauge Saturated temp Pressure gauge 20 297 4 807 28 1687 52 3088 19 312 5 835 29 1734 53 3161 18 328 6 864 30 1781 54 3234 17 345 7 894 31 1830 55 3310 16 361 8 924 32 1880 56 3386 15 379 9 956 33 1930 57 3464 14 397 10 987 34 1981 58 3543 13 4...

Page 59: ...es Preliminary equipment check Is there any shipping damage If so where Will this damage prevent unit start up The unit is installed level The power supply corresponds to the unit nameplate The electrical circuit wiring has been sized and installed properly The unit ground wire has been connected The electrical circuit protection has been sized and installed properly All terminals are tight All ca...

Page 60: ...n inhibitor included litres of Correct loop frost protection included if required litres of Water pipes have been fitted an electric heater for trace heating up to the evaporator Return water piping is equipped with a screen filter with a mesh size of 1 2 mm Checking the pressure drop across the evaporator without hydraulic module or ESP with hydraulic module Evaporator inlet kPa Evaporator outlet...

Page 61: ... all checks are complete start up the unit The unit starts and operates correctly Temperatures and pressures WARNING Once the machine has been operating for a while and the temperatures and pressures have stabilised record the following Evaporator water inlet Evaporator water outlet Ambient temperature Circuit A suction pressure Circuit B suction pressure Circuit A discharge pressure Circuit B dis...

Page 62: ...tive number 10018 02 2017 supercedes no 10018 10 2016 Manufacturer Carrier SCS Montluel France The manufacturer reserves the right to change any product specifications without notice Printed in the European Union ...

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