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Carrier Pro-Dialog Plus 30HZ, Installation, Operation And Maintenance Instructions

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Carrier Pro-Dialog Plus 30HZ Installation, Operation And Maintenance Instructions Download Page 29

29

10 - sTaRT-UP ChECklIsT FOR 30hZ/hZV lIqUID ChIllERs (UsE FOR jOB FIlE)

Preliminary information

Job name: ...............................................................................................................................................................................................
Location: ................................................................................................................................................................................................
Installing contractor:.............................................................................................................................................................................
Distributor: ............................................................................................................................................................................................
Start-up preformed by: .........................................................................................................................................................................

equipment

Model No.  .....................................................................................  Serial No.  ...................................................................................

Compressors
Circuit a 

Circuit b

1.  Model No.  .................................................................................  1.  Model No. ..............................................................................
  Serial No.  ..................................................................................    Serial No. ...............................................................................
  Motor No.  .................................................................................    Motor No.  .............................................................................  
 
2.  Model No.  .................................................................................  2.  Model No. ..............................................................................
  Serial No.  ..................................................................................    Serial No.  ..............................................................................
  Motor No.  .................................................................................    Motor No.  .............................................................................

3.  Model No. ..................................................................................  3.  Model No. ..............................................................................
  Serial No.  ..................................................................................    Serial No.  ..............................................................................
  Motor No.  .................................................................................    Motor No.  .............................................................................  
 
4.  Model No. ..................................................................................  4.  Model No. ..............................................................................
  Serial No.  ..................................................................................    Serial No.  ..............................................................................
  Motor No.  .................................................................................    Motor No.  .............................................................................  
 

Cooler

Model No. ......................................................................................  Manufactured by  ......................................................................
Serial No.  .......................................................................................  Date ............................................................................................
 

Condensers

Manufacturer  ........................................................................................................................................................................................
Model No. ......................................................................................  Serial No.  ...................................................................................

Additional air handling units and accessories ...................................................................................................................................
.................................................................................................................................................................................................................

Preliminary equipment check

Is there any shipping damage ? ...................................................  If so, where ? ..............................................................................
.................................................................................................................................................................................................................
Will this damage prevent unit start-up ? ............................................................................................................................................

 Unit is level in its installation
 Power supply agrees with the unit nameplate
 Electrical circuit wiring has been sized and installed properly
 Unit ground wire has been connected
 Electrical circuit protection has been sized and installed properly
 All terminals are tight
 All cables and thermistors have been inspected for crossed wires
 All plug assemblies are tight

Check air handling systems

  All air handlers are operating
  All chilled water valves are open
  All fluid piping is connected properly
  All air has been vented from the system
  Chilled water pump (CWP) is operating with the correct rotation. CWP amperage: Rated: .............. Actual ................

Summary of Contents for Pro-Dialog Plus 30HZ

Page 1: ...30HZ HZV 043 280 Water Cooled Condenserless Liquid Chillers Nominal cooling capacity 30HZ 134 783 kW Nominal cooling capacity 30HZV 126 735 kW 50 Hz Installation operation and maintenance instructions ...

Page 2: ... 1 Unit operating range 13 5 2 Minimum chilled water flow 13 5 3 Maximum chilled water flow 13 5 4 Variable flow evaporator 14 5 5 System minimum water volume 14 5 6 Evaporator flow rate 14 5 7 Condenser water flow rates 15 5 8 Condenser water flow restrictor 15 6 WATER CONNECTIONS 16 6 1 Operating precautions 16 6 2 Water connections 17 6 3 Flow control 17 6 4 Condenser connections 17 6 5 Frost p...

Page 3: ...ssor oil pressure safety device 24 8 5 Condenser with CuNi tubes option 33 24 8 6 RS 485 communication interface option 148 24 8 7 Additional capacity step 30HZ HZV 043 to 065 option 94 24 8 8 Evaporator pump starter options 84 and 84D 24 8 9 Condenser pump starter option 84R 24 9 MAINTENANCE 25 9 1 Soldering and welding 25 9 2 Maintenance of the refrigerant circuit 25 9 3 Electrical maintenance 2...

Page 4: ...n the refrigerant circuit s Ensure that the valves are correctly installed before operating the unit In certain cases the globe stops are installed on ball valves These valves are factory supplied lead sealed in the open position This system permits isolating and removing the globe stop for checking and replacing The globe stops are designed and installed to ensure protection against fire risk Rem...

Page 5: ... with soap and water If liquid refrigerant enters the eyes immediately and abundantly flush the eyes with water and consult a doctor NOTE The unit must never be left shut down with the liquid line valve closed as liquid refrigerant can be trapped between this valve and the expansion device This valve is situated on the liquid line before the filter drier box During any handling maintenance and ser...

Page 6: ... and recovery of halogenated hydrocarbons under optimum quality conditions for the products and optimum safety conditions for people property and the environment are described in standard NFE 29795 Any refrigerant transfer and recovery operations must be carried out using a transfer unit A 3 8 SAE connector on the manual liquid line valve is supplied with all units for connection to the transfer s...

Page 7: ...r the centre of gravity coordinates the position of the unit mounting holes and the weight dis tribution points refer to the certified dimensional drawing supplied with the unit Typical applications of these units are in refrigeration systems and they do not require earthquake resistance Earthquake resistance has not been verified CAUTION Only use slings at the designated lifting points which are ...

Page 8: ... 3 dimensions clearances 3 1 30HZ HZV 043 065 3 2 30HZ HZV 091 225 3 3 3 4 2 1 A C B 2550 800 800 800 ...

Page 9: ... 1950 950 225 4255 1950 950 250 280 4070 2150 1275 30HZV units without condenser A B C 043 2452 1260 904 052 2750 1245 904 065 2750 1245 904 091 2630 1300 950 101 2940 1300 950 111 2940 1300 950 121 2940 1300 950 141 3550 1300 950 161 3550 1300 950 195 4255 1340 950 225 4255 1340 950 250 280 4070 1680 1275 Dimensions in mm NOTE Non contractual drawings Certified dimensional drawings available on r...

Page 10: ...29203 NFE 29203 NFE29203 Drain and vent NPT in 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 Max water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 Condenser Shell and multi tube Quantity 2 2 2 2 2 2 2 2 2 2 2 2 2 Net water volume l Circuit A 10 10 12 25 18 25 25 25 30 37 37 51 51 Circuit B 10 10 12 12 18 18 25 25 30 30 37 37 51 Water connectio...

Page 11: ...nt 52 C 30HZ 66 C 30HZV and a nominal voltage of 400 V data given on the unit name plate Maximum unit operating current at maximum unit power input Maximum instantaneous starting current maximum operating current of the smallest compressor s locked rotor current or reduced starting current of the largest compressor Current and power inputs not included in the values above Notes for electrical data...

Page 12: ...opper 188 2 x 120 PVC Copper 295 2 x 150 XLPE Aluminium 210 250 circuit B 1 x 95 XLPE Copper 178 2 x 70 PVC Copper 270 1 x 240 XLPE Aluminium 225 280 circuit A 1 x 185 XLPE Copper 190 2 x 95 XLPE Copper 215 2 x 150 XLPE Aluminium 210 280 circuit B 1 x 150 XLPE Copper 188 2 x 120 PVC Copper 295 2 x 120 XLPE Aluminium 205 4 5 Recommended wire sections Wire sizing is the responsibility of the install...

Page 13: ...er flow is shown in the table on the next page If the flow is less than this the evaporator flow can be recirculated as shown in the diagram The tempera ture of the mixture leaving the evaporator must never be less than 2 8 K lower than the chilled water entering tempe rature For minimum chilled water flow rate Legend 1 Evaporator 2 Recirculation 5 3 Maximum chilled water flow The maximum chilled ...

Page 14: ...ng 6 5 Where Cap is the nominal system cooling capacity kW at the nominal operating conditions of the installation This volume is necessary for stable operation and accurate temperature control 5 6 Evaporator flow rate 30HZ HZV Min water flow rate l s Closed loop 043 4 1 052 065 5 0 091 6 0 101 121 8 5 141 161 9 9 195 280 12 0 Bad Bad Good Good It is often necessary to add a buffer water tank to t...

Page 15: ...HZ HZV 043 052 2 30HZ HZV 065 3 30HZ HZV 091 4 30HZ HZV 101 5 30HZ HZV 111 6 30HZ HZV 121 141 7 30HZ HZV 161 8 30HZ HZV 195 9 30HZ HZV 225 10 30HZ HZV 250 11 30HZ HZV 280 Pressure drop kPa Water flow rate l s Condenser pressure drop curves standard units 5 8 Condenser water flow restrictor CAUTION To ensure correct operation of the units these restrictors must be installed The restrictor is suppli...

Page 16: ...rials and the water circuit coating In case additives or other fluids than those recommend ed by Carrier are used ensure that the fluids are not considered as a gas and that they belong to class 2 as defined in directive 97 23 EC Carrier recommendations on heat exchange fluids No NH4 ammonium ions in the water they are very detrimental for copper This is one of the most important factors for the o...

Page 17: ... Drain 9 Buffer tank 10 Filter mesh size 1 2 mm 20 mesh 11 Expansion tank 12 Fill valve 6 3 Flow control 6 3 1 Evaporator flow switch and chilled water pump interlock IMPORTANT On 30HZ HZV units the unit chilled water flow switch must be energised and the chilled water pump interlock must be connected Failure to follow this instruction will void the Carrier guarantee The flow switch is supplied in...

Page 18: ...op on the discharge side decreases the cooling capacity 2 and increases the compressor power input by 3 Increasing the pipe diameter permits limiting the pressure drops The pressure drop in the liquid line linking the condenser outlet to the expansion device must not result in a change in phase The estimate of these pressure drops must include those for the possible accessories such as solenoid va...

Page 19: ...ed to achieve reasonable pressure drops a variation of 1 5 K of the saturated tempe rature is normally accepted approx 60 kPa variation for a condensing temperature of 50 C For most applications the refrigerant gas velocity is sufficient to entrain the liquid refrigerant oil mixture Nevertheless Table 2 shows the minimum required cooling capacities for different pipe diameters and different satura...

Page 20: ... 79 0 78 1 19 1 47 0 76 1 16 1 21 0 73 1 13 Legend S Suction HG Hot gas L Liquid Table 2 Minimum capacity for oil entrainment in the discharge piping kW for R407C copper tube 30HZV Outside pipe diameter 1 2 5 8 3 4 7 8 1 1 8 1 3 8 1 5 8 2 1 8 2 5 8 3 1 8 3 5 8 4 1 8 Saturated condensing temperature C 27 0 81 1 48 2 39 3 66 7 14 12 06 18 64 37 21 63 94 99 81 145 60 201 98 32 0 84 1 51 2 46 3 76 7 2...

Page 21: ...iping Liquid piping Legend 1 1 2 2 3 8 3 3 4 4 7 8 5 1 1 8 6 1 3 8 7 1 5 8 8 2 1 8 Legend 1 3 8 2 1 2 3 5 8 4 3 4 5 7 8 6 1 1 8 7 1 3 8 Cooling capacity kW Equivalent length m Cooling capacity kW Equivalent length m ...

Page 22: ...OR STANDARD UNITS 7 1 Compressors 30HZ HZV units use reciprocating semi hermetic com pressors As standard each compressor is equipped with a discharge valve a suction valve an oil crankcase heater with a safety device that shuts off the compressor in case of a fault a discharge line muffler anti vibration mounts With options 5 and 6 low leaving brine temperature each compressor is equipped with a ...

Page 23: ...The unit is wholly or partly recyclable After use it contains refrigerant vapours and oil residue It is coated by paint Operating life This unit is designed for prolonged storage of 15 years under nitrogen charge with a temperature difference of 20 K per day 710000 cycles start ups with a maximum difference of 6 K between two neighbouring points in the container based on 6 start ups per hour over ...

Page 24: ... option 20 The control boxes and compressor terminal boxes are designed to provide protection in accordance with class IP44 CW 8 3 High and low pressure gauges option 26 The units are equipped with a high pressure gauge and a low pressure gauge on each circuit 8 4 Compressor oil pressure safety device Each compressor is equipped with a pressure sensor located on the oil pump outlet The normal oil ...

Page 25: ...ead to uncontrolled fluid or pressure leaks If an oil draining or recovery operation becomes necessary the fluid transfer must be made using mobile containers 9 2 Maintenance of the refrigerant circuit Keep the unit itself and the space around it clean and free of obstructions Remove all rubbish such as packing materials as soon as the installation is completed Regularly clean the exposed pipework...

Page 26: ...r the first start up when the elec trical components have reached their nominal operating temperatures c then regularly once a year Apparent and actual subcooling R 407C Pressure Enthalpy Legend 1 Saturated condensing temperature at the dew point 2 Saturated liquid temperature at the bubble point 3 Liquid refrigerant temperature 4 Saturation curve at the dew point 5 Saturation curbe at the bubble ...

Page 27: ... 86 66 87 9 5 20 43 26 13 19 45 71 50 53 28 5 63 27 67 26 9 75 21 28 26 96 19 25 46 24 51 04 28 75 63 67 67 64 10 22 12 27 77 19 5 46 77 51 55 29 64 07 68 02 10 25 22 94 28 56 19 75 47 29 52 05 29 25 64 47 68 39 9 4 Evaporator maintenance Check that the insulating foam is intact and securely in place the sensors are correctly operating secured and positioned the water side connections are clean an...

Page 28: ...s must be tightened in the specified sequence and to the correct torque 9 4 6 Tightening sequence The following tightening sequence is recommended Hand tighten the first four bolts as shown below in stage 1 Hand tighten the next bolts as shown below in stage 2 Starting at the 12 o clock position and working clock wise insert and hand tighten the remaining outer bolts Insert and tighten the six scr...

Page 29: ...al air handling units and accessories Preliminary equipment check Is there any shipping damage If so where Will this damage prevent unit start up Unit is level in its installation Power supply agrees with the unit nameplate Electrical circuit wiring has been sized and installed properly Unit ground wire has been connected Electrical circuit protection has been sized and installed properly All term...

Page 30: ...ltage range Check cooler water loop Water loop volume litres Calculated volume litres 3 25 litres nominal kW capacity for air conditioning 6 5 litres nominal kW capacity for process cooling Proper loop volume established Proper loop corrosion inhibitor included litres of Proper loop freeze protection included if required litres of Piping includes electric heater tape if exposed to the outside Inle...

Page 31: ...he chiller warning Be sure that all service valves are open and all pumps are on before attempting to start this machine Once all checks have been made move the switch to LOCAL or REMOTE from OFF Unit starts and operates properly Temperatures and pressures warning Once the machine has been operating for a while and the temperatures and pressures have stabilized record the following Evaporator EWT ...

Page 32: ... 13412 76 12 2008 Supersedes order No 13412 76 03 2003 Manufactured by Carrier SCS Montluel France Manufacturer reserves the right to change any product specifications without notice Printed in the Netherlands ...

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