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Installation, operation and maintenance instructions

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1. Component Designation in Value N m the unit Screw PE customer connection M8 PE 14 5 Screw on switch inlet zones Switch MG 28904 Qs_ 8 Tunnel terminal screw compressor contactor Contactor LC1D12B7 KM 1 7 Contactor LC1D18B7 KM 1 7 Contactor LC1D25B7 KM 25 Tunnel terminal screw compressor circuit breaker Circuit breaker 25507 QM 3 6 Circuit breaker 25508 QM 3 6 Circuit breaker 25509 QM 3 6 Tunnel terminal screw control power transformer Transformer ABL6TS16B TC 0 6 Compressor earth terminal in the power wiring control box M6 Gnd 5 5 Compressor earth connection M8 Gnd 2 83 Tunnel terminal screw pump disconnect switch Disconnect switch GV2ME08 QM_ 1 7 Disconnect switch GV2ME10 QM_ 1 7 Tunnel terminal screw pump contactor Contactor LC1K0610B7 KM 0 8 to 1 3 Contactor LC1K09004B7 KM 0 8 to 1 3 Contactor LC1K0910B7 KM 0 8 to 1 3 Contactor LC1K0901B7 KM 0 8 to 1 3 Variable frequency switch ATV21 GS 1 3 19 11 Tightening torques for the main bolts and screws Screw type Used for Torque N m M8 nut BPHE fixing 15 M10 nut Compressor mounting 30 Oil nut Oil equalisation line 100 Taptite screw M6 Panel fixing 7 H M6 screw Stauff clamps 10 BPHE Brazed plate heat exchanger 19 12 Compressors The compressors do not require any specific maintenance Nevertheless the preventive system maintenance operations prevent specific compressor problems
2. Pressure drop kPa 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 05 5 6 0 6 5 7 0 7 5 8 0 Water flow rate l s 61WG 30WG 020 61WG 30WG 025 to 61WG 30WG 030 61WG 30WG 035 61WG 30WG 040 61WG 30WG 045 akon 28 61WG 30WG 30WGA 050 090 Pressure drop kPa 012 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Water flow rate l s 61WG 30WG 30WGA 050 61WG 30WG 30WGA 060 61WG 30WG 30WGA 070 61WG 30WG 30WGA 080 61WG 30WG 30WGA 090 OOND Oo 61WG 30WG 050 090 Pressure drop kPa 180 170 160 150 140 130 120 110 100 80 70 60 50 30 20 10 CITICON 0 1 2 3 4 5 6 Water flow rate I s OOND 61WG 30WG 050 61WG 30WG 060 61WG 30WG 070 61WG 30WG 080 0 61WG 30WG 090 7 8 9 10 11 12 13 6 ELECTRICAL CONNECTION 6 1 Electrical connections control box 61WG 30WG 30WGA L 03 A E A mie 7 li He Hs ja l i tir TT u 3 2 Pern 1L UM DEENEN Legend 1 Main disconnect switch PE Earth connection S Power supply cable section see table Recommended wire sections NOTES The 6
3. Satur Relative Satur Relative Satur Relative Satur Relative temp pressure temp pressure temp pressure temp pressure 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 13 415 11 1020 35 2034 59 3624 12 434 12 1053 36 2087 60 3706 11 453 13 1087 37 2142 61 3789 10 473 14 1121 38 2197 62 3874 9 493 15 1156 39 2253 63 3961 8 514 16 1192 40 2311 64 4049 7 535 17 1229 41 2369 65 4138 6 557 18 1267 42 2429 66 4229 5 579 19 1305 43 2490 67 4322 4 602 20 1344 44 2551 68 4416 3 626 21 1384 45 2614 69 4512 2 650 22 1425 46 2678 70 4610 1 674 23 1467 47 2744 0 700 24 1509 48 2810 1 726 26 1596 49 2878 2 752 25 1552 50 2947 3 779 27 1641 51 3017 19 9 Electrical maintenance When working on the unit comply with all safety precau tions described in section 1 3 It is strongly recommended to change the unit fuses every 15000 operating hours or every three years It is recommended to verify that all electrical connections are tight e after the unit has been received at the moment of installation and before the first start up e one month after the first start up when the electrical components have reached their nominal operating temperatures e then regularly once a year 19 10 Tightening torques for the main electrical connections
4. e 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 of moving parts Verify the accessibility for maintenance or repair and to check the piping Verify the status of the valves e Verify the quality of the thermal insulation and of the vapour barriers e Ensure that the position of the condensate drain piping allows draining and that the connections are correct for the water used e Avoid common routing of the customer power wiring and other machine wiring especially for longer runs gt 200 mm 3 DIMENSIONS CLEARANCES 3 1 61WG 30WG 020 045 standard unit 60 Ca 600 3 2 61WG 30WG 020 045 unit with top connections option 274 700 L 1044 L 1058 900 700 s 4 F p 4 4 fh T R 4 DN L 1044 900 86 S 4 N 1 2 Q S N 4 3 8 700 D ite ig on a Tol oO E 143 600 Legend All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Water inlet Water outlet SELOG Power wiring connection NOTE N
5. locked rotor current or limited start up current of the largest compressor Maximum power input at the unit operating limits Values obtained at standardised Eurovent conditions evaporator entering leaving water temperature 10 C 7 C condenser entering leaving water temperature 30 C 35 C Maximum unit operating current at maximum unit power input and 400 V t Maximum unit operating current at maximum unit power input and 360 V 30WG without hydronic module 020 025 030 035 040 045 050 060 070 080 090 Power circuit Nominal voltage V ph Hz 400 3 50 Voltage range V 360 440 Control circuit supply 24V via internal transformer Maximum start up current draw Un Standard unit A 98 142 142 147 158 197 161 163 172 185 227 Unit with electronic starter option A 53 9 78 1 78 1 80 9 86 9 108 4 96 8 97 9 104 1 112 3 137 4 Unit power factor at maximum capacity 0 83 0 82 0 84 0 83 0 82 0 84 0 82 0 82 0 83 0 82 0 84 Maximum operating power input kW 9 7 11 4 12 8 14 7 16 6 18 7 22 8 24 6 29 4 33 2 37 4 Nominal unit operating current draw A 12 9 18 8 16 8 19 2 20 7 24 6 31 6 33 6 38 4 41 4 49 2 Maximum operating current draw Un A 15 6 18 7 19 8 23 2 25 4 29 0 37 5 39 6 46 4 50 8 58 0 Maximum operating current draw Un 10 t A 17 2 20 6 21 8 25 6 28 0 31 9 41 2 43 6 541 2 56 0 63 8 Customer side unit power reserve Customer reserve at the 24 V control power circuit Short circuit stability and pro
6. 5 3 Operating limits 30WG 61WG Minimum Maximum 30WG Minimum Maximum Evaporator Evaporator Entering water temperature at start up C 7 5 27 Entering water temperature at start up C TS 27 Leaving water temperature during operation C 5 20 Leaving water temperature during operation C om 20 Entering leaving water temperature difference K 2 5 7 Entering leaving water temperature difference K 2 5 7 Condenser Condenser Entering water temperature at start up Q di5 60 Entering water temperature at start up C 10 ggm Leaving water temperature during operation C 20 65 Leaving water temperature during operation C 20 60 Entering leaving water temperature difference K 2 5 18 Entering leaving water temperature difference K 2 5 18 For entering water temperatures below 7 5 C at start up contact Carrier Ifthe leaving water temperature is below 5 C a frost protection solution must be used Please refer to option 272 for evaporator leaving water low temperature applications lt 5 C For applications with a condenser entering temperature below 15 C the use of a three way valve is recommended This three way valve can be controlled by the 0 10 V analogue output of the Pro Dialog control For a water flow rate that corresponds to a maximum water side temperature difference of 5 K For entering water temperatures below 7 5 C at start up contact Carrier If the leaving water temperature is below
7. EPOE ER E EEE E coveees E EE S E A E E sents S ES 49 19 5 Leak detection asuisi esiaren e esas vines eas E E E EE R E E E ER E ER SE 50 19 6 VACUA LOM ermine sss apesedteneacasscetscesss e AEDE aE E EO E O EET E E E ER ARER SRA 50 19 7 Recharging liquid Temi seramtiicsc ssscicsesietssectstvasssvensdestsvestebecssescanebetodenss rrara E Erea SEEE SE SESEO SE EEA NEDAS E Eor EKO IEEE E Ea ES 50 19 8 Characteristics of RATOA seisis erion sii bkeassabensbistskanests sees caxesatbvenss esseessinepdcssszerends cdpvssasdvesscuasyesibuesbinssteudesteesbiesdstses o 50 19 9 Electrical maimtem ance siseses stick caved cxpsceaks cdsa vavbicstsvessbacssuscsas causa sossees SEDE EE steroids EEAS SEE EEEE NE I rA ES 51 19 10 Tightening torques for the main electrical CONNECTIONS eee ce ses ee cece eteeeceeseseteseesesesseeecsssesecesaeseeseeaesessanesesaaaes 51 19 11 Tightening torques for the main bolts and SCLEWS e cee cette ees eeseececseseeceeaeseceseesesesseseecsssesesessessesseassessaeeseeaaags 51 TOD AC OTO S O R E N E NE ATE EER 51 19 13 Evaporat r and Condenser maimtenance sisesccsssesscustsdesesdecsnsscesescadusess osdvessopepsdesseies ids asvecasdvettenesscsdbnesotosbssnassausabteedsesestso 51 19 14 Corrosion CHECK nosiri isee ieni E cate oth costs SETE EE EEE EEEE EE EEEE SE N E 51 20 AQUASNAP MAINTENANCE PROGRAM sessssessesessosoososoccosoocoscocoscocoecoccseeeoseseoseseoseseoseseoroseososeososeososeososeocoseososeoceseoe 52 20 1
8. Liquid line piping below we ad 8 3 Discharge pipe sizing The discharge piping must be sized to achieve reasonable pressure drops a variation of 1 5 K of the saturated tempe rature is normally accepted approx 90 kPa variation for a condensing temperature of 45 C Table 1 Discharge line piping 30WGA 020 025 030 035 040 045 050 060 070 080 090 Equivalent length 0 10 m in 3 4 3 4 7 8 7 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 10 20 m in 7 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 20 30 m in 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 30 40 m in 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 40 50 m in 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 50 60 m in 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 60 70 m in 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 70 m or more in 1 1 8 1 1 8 1 1 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 5 8 Recommended diameters to ensure oil return in the application range Table 2 Liquid line piping 30WGA 020 025 030 035 040 045 050 060 070 080 090 Equivalent length 0 10 m in 1 2 1 2 1 2 1 2 1 2 1 2 1 2 5 8 5 8 5 8 5 8 10 20 m in 1 2 1 2 1 2 1 2 5 8 5 8 5 8 5 8 5 8 3 4 3 4 20 30 m in 1 2 1 2 1 2 5 8 5 8 5 8 5 8 5 8 3 4 3 4 3 4 30 40 m in 1 2 5 8 5 8 5 8 5 8 5 8 3 4 3 4 3 4 3 4 3 4 40 50m in 5 8 5 8 5 8 5 8 5 8 5 8 3 4 3 4 3 4 3 4 7 8 50 60 m in 5 8
9. N I 4 4 F Ij IIi N 4 700 3 16 30WGA 020 045 unit with evaporator hydronic module option 116 For option 70F only SEEL 625 600 Legend All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection For option 70F only NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 17 3 17 30WGA 020 045 stackable unit option 273 NOTE The water and electrical connections are identical to those of the standard unit Legend All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection Fss0000000 For option 70F only NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 18 3 19 30WGA 050 090 unit with evaporator hydronic module option 116 PD KY Tiam eg EJ D my IN 1021
10. The following periodic preventive maintenance checks are strongly recommended e Check the operating conditions evaporating tempera ture condensing temperature discharge temperature heat exchanger temperature difference superheat subcooling These operating parameters must always be within the compressor operating range e Check that the safety devices are all operational and correctly controlled e Check oil level and quality If there is a colour change in the sight glass check the oil quality This may include an acidity test moisture control a spectrometric analysis etc Check the leak tightness of the refrigerant circuit Check the compressor motor power input as well as the voltage imbalance between phases Check the tightening of all electrical connections Ensure that the compressor is clean and runs correctly verify that there is no rust on the compressor shell and no corrosion or oxydation at the electrical connections and the piping ATTENTION The compressor and piping surface tempe ratures can in certain cases exceed 100 C and cause burns Particular caution is required during maintenance opera tions At the same time when the compressor is in operation the surface temperatures can also be very cold down to 15 C for units with a low leaving water temperature and can cause frost burns 19 13 Evaporator and condenser maintenance There is no particular maintenance necessary on the plate heat exchan
11. are required to ensure that the completed high pressure circuit complies with the applicable regulations and standards 17 8 Moisture indicator Located in the liquid line permits control of the unit charge as well as the presence of moisture in the circuit Bubbles in the sight glass indicate an insufficient charge or the presence of non condensibles Regarding 30WGA units if the indicator paper in the sight glass is yellow during the delivery it is not a non conformity It is necessary to verify if the indicator paper in the sight glass is yellow after the vaccum 17 9 Filter drier in the refrigerant circuit The filter keeps the circuit clean and moisture free The moisture indicator shows when it is necessary to change the filter cartridges A temperature difference between the filter drier inlet and outlet indicates a contamination of the cartridges 30WGA are equipped as standard with a filter drier that needs to be soldered to the liquid line It must be soldered as close as possible to the 30WGA unit upstream of the solenoid valve and as soon as possible after the circuit has been exposed to the atmosphere while connecting the air cooled condenser Filter drier position A kid ldi To g AN mer i LAM e 17 10 Fixed speed pump This pump is factory installed as standard to guarantee the nominal flow in the water loop It is a fixed speed pump with available system pressure See the pump fl
12. e T e Connector J2 Digital outputs CH 1 to 4 for fan stages 1 to4 e Connector J3 Digital outputs CH 5 to 8 for fan stages 5 to 8 e Connectors J4 and J5 Analogue outputs 0 10 V dc for fan speed variation of the air cooled condensers e Connector J6 Analogue input CH 12 for outside temperature sensors e Connector J9 Communication bus with NRCP master board of the 30WGA unit The electronic board specifically integrated in the control box of the condenser and a communication bus connected to the microprocessor board of the 30WGA is used for the overall system control The option supplied with the cooling unit must be installed in the condenser control box Connect the unit to board AUX1 in the condenser using a twisted and shielded type RS485 communication bus cable Pro Dialog continuously optimises system operation to obtain the best system efficiency by controlling the number of fans required for any thermal load and outside temperature conditions The outside air temperature sensor is required for correct system operation EXV fans condensing temperature setpoint The position of the temperature sensor must be chosen with great care and must be representative of the outside temperature limit any other source that could have a negative influence on the control gusts of wind other heat sources such as sun radiation and hot air recycling 15 4 Configuration of the number of fan stages and fan ty
13. including changing of drier blocks is only permitted after the complete removal of the refrigerant charge For these units transfer of the refrigerant charge from the high or low pressure side is not possible nor permitted During any handling maintenance and service operations the engineers working on the unit must be equipped with safety gloves glasses shoes and protective clothing Never work on a unit that is still energised Never work on any of the electrical components until the general power supply to the unit has been cut using the disconnect 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 of the machine If the work is interrupted always ensure that all circuits are still deenergized before resuming the work ATTENTION Even if the compressor motors have been switched off the power circuit remains energized unless the unit or circuit disconnect switch is open Refer to the wiring diagram for further details Attach appropriate safety labels If any intervention is required on the air cooled condenser in 30WGA units please refer to the safety instructions supplied by the condenser manufacturer It is recommended to install an indicating device to show if part of the refrigerant has leaked from the valve The presence of oil at the outlet orifice is a useful indicator that refrigerant has leaked Keep this orifice clea
14. non authorised persons 2 2 Moving and placing the unit 2 2 1 Moving See chapter 1 1 Installation safety considerations 2 2 2 Placing the unit Always refer to the chapter Dimensions and clearances to confirm that there is adequate space for all connections and service operations For the centre of gravity coordinates the position of the unit mounting holes and the weight distribution 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 In case of extra high units the machine environment must permit easy access for maintenance operations CAUTION Only use slings at the designated lifting points which are marked on the unit Before siting the unit check that e the permitted loading at the site is adequate or that appropriate strenghtening measures have been taken e the unit support points are located at the four lower corners e the positioning at these four points must be horizontal level tolerance 1 5 mm m in both axes e if the support structure is sensitive to vibration and or noise transmission it it advisable to insert anti vibration mounts elastomeric mounts or springs between the unit and the structure Selection of these devices is based on the system characteristics and the comfort level required and should be ma
15. s OA E Water flow rate Vs OO 000 1 61WG 30WG 30WGA 020 2 61WG 30WG 30WGA 025 to 030 6 61WG 30WG 30WGA 050 3 61WG 30WG 30WGA 035 7 61WG 30WG 30WGA 060 4 61WG 30WG 30WGA 040 8 61WG 30WG 30WGA 070 5 61WG 30WG 30WGA 045 9 61WG 30WG 30WGA 080 10 61WG 30WG 30WGA 090 Condenser 61WG 30WG 020 045 61WG 30WG 050 090 g amp x ke 3 g 2 2 2 3 oO Qa 00 05 10 15 20 25 30 35 40 45 0 1 2 3 4 5 6 7 Water flow rate I s 6 Water flow rate I s O O0 61WG 30WG 020 1 6 61WG 30WG 050 2 61WG 30WG 025 to 030 7 61WG 30WG 060 3 61WG 30WG 035 8 61WG 30WG 070 4 61WG 30WG 040 9 61WG 30WG 080 5 61WG 30WG 045 10 61WG 30WG 090 37 11 3 Available external static pressure fixed speed low pressure pumps units with hydronic module Data applicable for Fresh water 20 C In case of use of the glycol the maximum water flow is reduced The curves represented below are in normal conditions leaving water on the back side of the unit without option 274 Evaporator 61WG 30WG 30WGA 020 045 140 130 120 bp e o s H So wo o N o Pressure head kPa a v D w AON 0 5 1 1 5 2 2 5 3 3 5 4 4 5 Water flow rate I s 61WG 30WG 30WGA 020 61WG 30WG 30WGA 025 to 030 61WG 30WG 30WGA 035 61WG 30WG 30WGA 040 61WG 30WG 30WGA 045 Condenser 61WG 30WG 020 045 140
16. sion tank Units with hydronic module include the safety valve and expansion tank e Install drain connections at all low points to allow the whole circuit to be drained e Install stop valves close to the entering and leaving water connections e Use flexible connections to reduce vibration transmission e Ifthe insulation provided is not sufficient insulate the cold water piping after testing for leaks both to reduce heat loss and to prevent condensation e Cover the insulation with a vapour barrier e If the external water piping to the unit is in an area where the ambient temperature can fall below 0 C insulate the piping and install an electric heater on the piping NOTE For units without hydronic module a screen filter must be installed as close as possible to the heat exchanger and in a position that is easily accessible for removal and cleaning Units with a hydronic module include this filter 33 The mesh size of the filter must be 1 2 mm If this filter is not installed the plate heat exchanger can quickly become contaminated at the first start up as it takes on the filter function and correct unit operation is affected reduced water flow due to increased pressure drop Before the system start up verify that the water circuits are connected to the appropriate heat exchangers e g no reversal between evaporator and condenser Do not introduce any significant static or dynamic pressure into the heat exchange c
17. 0 8 0 8 0 8 1 25 7 2 Maximum power input 400 V kw 1 1 1 1 11 1 1 11 1 1 1 1 1 4 11 11 1 5 8 Rated input frequency Hz 50 9 1 Rated voltage V 3x400 9 2 Maximum current drawn 400 V t A 20 2 0 2 0 2 0 2 0 2 0 2 0 2 3 2 3 2 3 3 1 10 Rated speed s 2838 2838 2838 2838 2838 2838 2838 2838 2838 2838 2892 rpm 47 47 47 47 47 47 47 47 47 47 48 11 Product disassembly recycling or disposal at end of life Disassembly using standard tools Disposal and recycling using an appropriate company 12 Operating conditions for which the motor is specifically designed Altitudes above sea level m lt 1000tt Il_ Ambient air temperature C lt 40 IV Maximum air temperature Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs V_ Potentially explosive atmospheres Non ATEX environment Motors of variable speed hydronic module pumps 61WG 30WG 30WGA options 116J and 270J No Description 61WG 30WG 30WGA options 116J and 270J high pressure pumps 20 25 30 35 40 45 50 60 70 80 90 1 Nominal efficiency at full load and nominal voltage 823 823 823 823 823 823 819 819 819 819 819 1 Nominal efficiency at 75 rated load and nominal voltage 818 818 818 818 818 818 818 818 81 8 818 818 1 Nominal efficiency at 50 rated load and nominal voltage T97 797 797 797 79 7 79 7 79 1 79 1 79 1 79 1 79 1 2
18. 090 30WGA 020 090 JBus gateway 148B Two directional communications board complies Easy connection by communication bus to 30WG 020 090 with JBus protocol a building management system 61WG 020 090 30WGA 020 090 BacNet gateway 148C Two directional communications board complies Easy connection by communication bus to 30WG 020 090 with BacNet protocol a building management system 61WG 020 090 30WGA 020 090 LON gateway 148D Two directional communications board complies Easy connection by communication bus to 30WG 020 090 with LON protocol a building management system 61WG 020 090 30WGA 020 090 Built in DHW and space heating control 153 Control board factory installed on the unit control Permits easy control of a basic heating 61WG 020 090 using weather compensation control of additional system electric heater 4 stages or boiler needle valve for domestic hot water production with programmable time schedule Specific cooling control 154 Control box to be installed on the Carrier drycooler Permits the use of an energy efficient 30WG 020 090 or remote condenser for communication with the plug and play system 30WGA 020 090 unit via a bus Low sound level 257 Compressor sound enclosure and sound insulation Reduced sound emissions 30WG 020 090 of main noise sources 61WG 020 090 30WGA 020 090 Evaporator screw connection sleeves 264 Evaporator inlet outlet screw connection sleeves Allows unit connection to a screw 30WG 020 090 connector 61WG 020
19. 090 30WGA 020 090 Condenser screw connection sleeves 265 Condenser inlet outlet screw connection sleeves Allows unit connection to a screw 30WG 020 090 connector 61WG 020 090 Welded evaporator connection sleeves 266 Welded evaporator inlet outlet connection sleeves Allows welding of customer connections to 30WG 020 090 the unit 61WG 020 090 30WGA 020 090 Welded condenser connection sleeves 267 Welded condenser inlet outlet connection sleeves Allows welding of customer connections to 30WG 020 090 the unit 61WG 020 090 Low pressure single pump hydronic module 270F See hydronic module chapter Easy and fast installation 30WG 020 090 condenser side 61WG 020 090 High pressure hydronic module with single 270J See hydronic module chapter Easy and fast installation reduced power 30WG 020 090 variabe speed pump condenser side consumption of the water circulation pump 61WG 020 090 High temperature water production condenser 272 Condenser side water production up to 65 C with Geothermal application and domestic 61WG 020 090 side with glycol solution on the evaporator side glycol solution on the evaporator side to 5 C hot water production Unit stackable for operation 273 Unit stackable for operation Reduced footprint size 30WG 020 090 61WG 020 090 30WGA 020 090 Customer water connection at the top of the 274 Customer water connection at the top of the unit Reduced footprint size 30WG 020 090 unit 61WG 020 090 Remote user interface 275 User i
20. 130 120 110 100 90 80 70 60 Pressure head kPa 50 40 30 akwon 38 0 5 1 1 5 2 2 5 4 5 3 3 5 4 Water flow rate l s 61WG 30WG 020 61WG 30WG 025 to 030 61WG 30WG 035 61WG 30WG 040 61WG 30WG 045 61WG 30WG 30WGA 050 090 170 160 150 140 w 130 2 120 J 110 100 o 90 2 80 2 70 a 60 50 40 30 N 20 1 2 3 4 5 6 7 8 9 Water flow rate l s O 6 61WG 30WG 30WGA 050 7 61WG 30WG 30WGA 060 8 61WG 30WG 30WGA 070 9 61WG 30WG 30WGA 080 10 61WG 30WG 30WGA 090 61WG 30WG 050 090 170 160 150 140 130 120 a T 90 80 g 3 70 N g 60 a 50 40 30 20 0 1 2 3 4 Water flow rate I s 61WG 30WG 050 61WG 30WG 060 61WG 30WG 070 61WG 30WG 080 0 61WG 30WG 090 gt OOND 5 OOOO 11 4 Pump curve units with hydronic modules Data applicable for Fresh water 20 C Incase of use of the glycol the maximum water flow is reduced The curves represented below are in normal conditions leaving water on the back side of the unit without option 274 11 4 1 Low pressure pumps 61WG 30WG 30WGA options 116F 270F 180 160 140 120 100 80 60 Pressure head kPa 40
21. 20 Water flow rate I s 1 61WG 30WG 30WGA 020 080 2 61WG 30WG 30WGA 090 11 4 2 High pressure pumps 61WG 30WG 30WGA options 116J 270J 220 200 gt 180 10 140 3 TN 120 100 80 60 40 20 Pressure head kPa Water flow rate l s 3 61WG 30WG 30WGA 020 045 4 61WG 30WG 30WGA 050 090 12 OPERATION OF 61WG UNITS WITH SPECIFIC HEATING CONTROL OPTION 153 12 1 Operating principle 61WG units are specially designed to optimise the operation of heating installations that require hot water production for a traditional heating system and domestic hot water production The Pro Dialog control system of the 61WG units includes algorithms that permit constant automatic optimisation of e control of a directional on off three way valve based on the heating or domestic hot water requirements e control of the electric heating stages allowing relief of the heating loop e hot water setpoint reset heating application based on the air temperature e priority control between heating application and domestic hot water application NOTE The installer is responsible for ensuring that the installation complies with the applicable legislation in terms of electrical and thermal safety 12 2 Auxiliary electronic board AUX1 analogue and digital inputs and outputs STATUS SIO O L L so
22. 3 1 653 3 20 30WGA 050 090 stackable unit option 273 NOTE The water and electrical connections are identical to those of the standard unit For option 70F only A sg9000000 Legend All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 19 4 PHYSICAL AND ELECTRICAL DATA 61WG 30WG 4 1 Physical data 61WG 61WG 020 025 030 035 040 045 050 060 070 080 090 Operating weight kg 191 200 200 207 212 220 386 392 403 413 441 Sound levels Sound power level 10 W standard unit dB A 67 0 68 5 69 0 69 3 70 0 70 1 TAS 72 0 72 0 73 0 73 4 Compressors Hermetic scroll 48 3 r s Quantity 1 1 1 1 1 1 2 2 2 2 2 Number of capacity steps 1 1 1 1 1 1 2 2 2 2 2 Minimum capacity 100 100 100 100 100 100 50 50 50 50 50 Refrigerant R 410A Charge standard unit kg 3 5 3 5 3 6 3 7 4 0 4 6 7 6 7 8 7 9 8 7 11 5 Charge unit with option 272 kg 2 7 2 9 2 9 3 0 3 2 3 9 7 2 7 3 7 4 16 10 5 Oil 160SZ Charge per compressor l 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3 3 3 3 3 6 Control Pro Dialog Evaporator Direct expansion plate heat exchanger
23. 5 8 5 8 5 8 5 8 3 4 3 4 3 4 3 4 7 8 7 8 60 m or more in 5 8 5 8 5 8 5 8 3 4 3 4 3 4 3 4 7 8 7 8 7 8 Recommended diameters to limit the impact of the 1 5 K pressure loss 32 For most applications the refrigerant gas velocity is suffi cient to entrain the liquid refrigerant oil mixture Neverthe less table 3 shows the minimum required cooling capacities for different pipe diameters and different saturated discharge temperatures Table 3 Minimum capacity kW to ensure oil return for different pipe diameters 30WGA Outside pipe diameter in Saturated 3 4 7 8 1 1 8 1 3 8 1 5 8 2 1 8 2 5 8 condensing temperature C 30 3 8 5 6 11 5 19 7 31 0 48 9 86 5 35 3 8 5 7 11 7 19 9 31 5 49 5 87 7 40 3 9 5 8 11 8 20 2 31 9 50 2 88 9 45 3 9 5 9 12 0 20 5 32 3 50 9 90 1 50 4 0 5 9 12 1 20 8 32 7 51 5 91 2 55 4 0 6 0 12 3 21 0 33 1 52 2 92 4 60 4 1 6 1 12 4 21 3 33 5 52 8 93 6 Correction factor oil entrainment in the discharge lines Saturated evaporating temperature C 7 1 4 10 16 Correction factor 0 94 0 97 1 1 03 1 06 Table 1 Discharge line piping shows the different pipe diameters based on the unit size and the equivalent circuit length These recommended diameters allow oil return within the application range IMPORTANT Siphon traps must be inserted in the vertical riser pipes e atthe bottom of the piping e every 3 m of vertical length e atthe top of the piping counter s
24. 7 4 3 5 0 045 0 4 3 9 4 5 5 4 050 0 4 4 8 6 8 7 0 060 0 5 5 5 7 0 TD 070 0 5 5 6 7 2 7 8 080 0 6 5 8 7 4 8 2 090 0 6 7 2 79 9 3 Units with or without hydronic module Minimum flow rate for a water temperature difference of 18 K Note Operation permitted up to a value of 20 K Units with hydronic module Maximum flow rate for an available pressure of 20 kPa unit with low pressure hydronic module or 50 kPa unit with high pressure hydronic module Units without hydronic module Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger 5 10 4 30WG with option 6 30WG Minimum evaporator glycol solution flow rate option 6 I s Minimum Minimum Low pressure High pressure 020 1 4 1 3 0 5 025 1 5 1 3 0 5 030 1 5 1 3 0 5 035 1 6 15 0 6 040 17 1 5 0 6 045 1 8 1 5 0 8 050 2 5 2 2 0 8 060 2 2 2 3 1 0 070 2 2 2 4 Val 080 2 3 2 4 1 3 090 2 5 2 5 1 5 Option 6 Glycol solution production very low temperature Units with hydronic module Minimum flow rate for a maximum permitted temperature difference at the minimum leaving water temperature Units without hydronic module Minimum flow rate for a maximum permitted temperature difference at the minimum leaving water temperature 5 11 Minimum water volume Whichever the system the water loop minimum capacity is given by the formula Capacity Cap kW x N Liters Cap is the nominal system cooling capacity kW at th
25. A total alkalimetric titre TAC below 100 is desirable e Dissolved oxygen Any sudden change in water oxygena tion conditions must be avoided It is as detrimental to deoxygenate the water by mixing it with inert gas as it is to over oxygenate it by mixing it with pure oxygen The disturbance of the oxygenation conditions encourages destabilisation of copper hydroxides and enlargement of particles e Electric conductivity 10 600uS cm e pH Ideal case pH neutral at 20 25 C 7 lt pH lt 8 If the water circuit must be emptied for longer than one month the complete circuit must be placed under nitrogen charge to avoid any risk of corrosion by differential aeration ATTENTION Filling completing and draining the water circuit charge must be done by qualified personnel using the air purges and materials that are suitable for the products Charging and removing heat exchange fluids should be done with devices that must be included on the water circuit by the installer Never use the unit heat exchangers to add heat exchange fluid 9 2 Water connections The diagram below illustrates a typical hydronic installation When the hydronic circuit is charged use the air vents to evacuate any residual air pockets Typical water piping diagram 61WG 30WG 30WGA units with hydronic modules Unit water outlet lt Unit water inlet Evaporator water loop 61WG 30WG 30WGA Unit water outlet lt oe Components of u
26. C saturated temperature must not be exceeded If the liquid refrigerant head is very high it may be necessary to increase the subcooling to prevent a phase change in the liquid line A liquid vapour heat exchanger or an additional coil can be used for this purpose It is advisable to include a slight slope 10 to 20 mm m in the refrigerant flow direction in the horizontal piping between the remote condenser and the 30WGA unit 9 WATER CONNECTIONS For size and position of the heat exchanger water inlet and outlet connections refer to the certified dimensional drawings supplied with the unit The water pipes must not transmit any radial or axial force to the heat exchangers nor any vibration The water supply must be analysed and appropriate filtering treatment control devices isolation and bleed valves and circuits built in to prevent corrosion fouling and deteriora tion of the pump fittings Consult either a water treatment specialist or appropriate literature on the subject 9 1 Operating precautions Design the water circuit with the least number of elbows and horizontal pipe runs at different levels The main points to be checked for the connection are e Comply with the water inlet and outlet connections shown on the unit e Install manual or automatic air purge valves at all high points in the circuit s e Use a pressure reducer to maintain pressure in the circuit s and install a safety valve as well as an expan
27. Operation of two units in master slave mode option 58 The control of a master slave assembly is in the entering water piping system return All parameters required for the master slave function must be configured using the Service Configuration menu All remote controls of the master slave assembly start stop set point load shedding etc are controlled by the unit configured as master and must only be applied to the master unit IMPORTANT To permit master slave operation both units must be equipped with option 58 Depending on the installation and control type each unit can control its own water pump 16 6 Parallel or serial connection of two 61WG 30WG 30WGA units Entering water control for a hydronic kit See legend in the next column 44 Leaving water control acer ec cere recceecccccccrcecs TEASE TEER ocean Legend 1 Master unit 2 Slave unit Additional CCN board one per unit with connection via communication bus 2 Control boxes of the master and slave units c4 Water inlet for customers with both units AD Water outlet for customers with both units Water pumps for each unit included as standard for units with hydronic module e Additional sensors for leaving water control to be connected to channel 1 of the slave boards of each master and slave unit seee CCN communication bus see Con
28. Water volume l 3 3 3 6 3 6 4 2 4 6 5 0 8 4 9 2 9 6 10 4 12 5 Water connections Victaulic Inlet outlet in 1 5 1 5 15 1 5 15 1 5 2 2 2 2 2 Max water side operating pressure without kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 hydronic module Condenser Plate heat exchanger Net water volume 3 3 3 6 3 6 4 2 4 6 5 0 8 4 9 2 9 6 10 4 125 Water connections Victaulic Inlet outlet in 1 5 1 5 1 5 1 5 1 5 1 5 2 2 2 2 2 Max water side operating pressure without kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 hydronic module Weight shown is a guideline only To find out the unit refrigerant charge please refer to the unit nameplate In accordance with ISO 9614 1 measured in a free field The sound levels only apply to units without options 4 2 Physical data 30WG 30WG 020 025 030 035 040 045 050 060 070 080 090 Operating weight kg 191 200 200 207 212 220 386 392 403 413 441 Sound levels Sound power level 10 W dB A 67 0 68 5 69 0 69 3 70 0 70 1 71 5 72 0 72 0 73 0 73 4 Compressors Hermetic scroll 48 3 r s Quantity 1 1 1 1 1 1 2 2 2 2 2 Number of capacity steps 1 1 1 1 1 1 2 2 2 2 2 Minimum capacity 100 100 100 100 100 100 50 50 50 50 50 Refrigerant R 410A Charge kg 3 5 3 5 3 6 3 7 4 0 4 6 7 6 7 8 7 9 8 7 11 5 Oil 160SZ Charge per compressor l 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3 3 3 3 3 6 Control Pro Dialog Evaporator Direct expansion plate heat exchanger Water volume l 3 3 3 6 3 6 4 2 4 6 5 0 8 4 9 2 9 6 10 4 12 5 Wat
29. all units release the holding charge pressure before opening the circuit Use the various valves and or remove the safety cap from the conical Schrader valve supplied Push in the valve tip to release the complete system holding charge nitrogen Preparation before unsoldering the liquid and discharge line plugs e Remove all components that may be damaged during the unsoldering procedure e Pipe soldering remove the cores from the conical Schrader valves near the area remove the pipe collars remove the cladding panels and the metal crossbars All these components must be replaced before commissioning the system Components be removed before soldering e Unsolder the plugs and prepare the pipes for connection e Connect the liquid line to the system install the filter drier upstream of the unit e Make the high pressure connections discharge line between the unit and the condenser e During these operations circulate and inert gas such as nitrogen in the pipes to prevent the formation of copper oxyde IMPORTANT The condenser circuit piping must be in accordance with good practices relating to the static support and the thermal expansion of copper pipes To ensure system vibration control the collar positions on the piping in the unit must not be changed At the outlet of the refrigerant section there are pipe flange collars It is imperative to tighten these collars to prevent vibrations and possible br
30. and damage the installation Never exceed the specified maximum operating pressures Verify the allowable maximum high and low side test pressures by checking the instructions in this manual and the pressures given on the unit name plate Do not unweld or flamecut the refrigerant lines or any refrigerant circuit component until all refrigerant liquid and vapour as well as the oil have been removed from unit Traces of vapour should be displaced with dry nitrogen Refrigerant in contact with an open flame produces toxic gases The necessary protection equipment must be available and appropriate fire extinguishers for the system and the refrigerant type used must be within easy reach Do not siphon refrigerant Avoid spilling liquid refrigerant on skin or splashing it into the eyes Use safety goggles and safety gloves Wash any spills from the skin with soap and water If liquid refrigerant enters the eyes immediately and abundantly flush the eyes with water and consult a doctor Never apply an open flame or live steam to a refrigerant container Dangerous overpressure can result If it is necessary to heat refrigerant use only warm water During refrigerant removal and storage operations follow applicable regulations These regulations permitting condi tioning and recovery of halogenated hydrocarbons under optimum quality conditions for the products and optimum safety conditions for people property and the environment are d
31. average voltage Average voltage Example On a 400 V 3 ph 50 Hz supply the individual phase voltages were measured to be AB 406 V BC 399 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 u BC 400 399 1 as CA 400 394 6 The maximum deviation from the average is 6 V The greatest percentage deviation is 100 x 6 400 1 5 This is less than the permissible 2 and is therefore acceptable 6 4 Recommended wire sections Wire sizing is the responsibility of the installer and depends on the characteristics and regulations applicable to each installation site The following is only to be used as a guide line and does not make Carrier in any way liable After wire sizing has been completed using the certified dimensional drawing the installer must ensure easy connection and define any modifications necessary on site The connections provided as standard for the field supplied power entry cables to the general disconnect isolator switch are designed for the number and type of wires listed in the table on the next page 29 The calculations are based on the maximum machine current see electrical data tables For the design the following standardised installation methods are used in accordance with IEC 60364 table 52C e For units installed inside the building No 13 perforated hor
32. conductor cables in closed conduit standardised routing No 41 section PVC insulated cable PVC insulated cable if possible Section Section Max length for Cable type Section Max length for voltage drop Cable typee voltage drop lt 5 lt 5 mm per phase mm per phase m mm par phase m 020 1x35 1x2 5 60 PVC Cu 1x4 100 PVC Cu 025 1x35 1x2 5 60 PVC Cu 1x4 100 PVC Cu 030 1x35 1x4 80 PVC Cu 1x6 120 PVC Cu 035 1x35 1x4 80 PVC Cu 1x6 120 PVC Cu 040 1x35 1x4 80 PVC Cu 1x6 120 PVC Cu 045 1x35 1x6 100 PVC Cu 1x10 150 PVC Cu 050 1x35 1x10 120 PVC Cu 1x 16 180 PVC Cu 060 1x35 1x10 120 PVC Cu 1x 16 180 PVC Cu 070 1x35 1x 16 140 PVC Cu 1x 16 180 PVC Cu 080 1x35 1x 16 140 PVC Cu 1x25 205 PVC Cu 090 1x35 1x 16 140 PVC Cu 1x25 225 PVC Cu space inside the control box Selection simultation result considering the hypothesis indicated k kkk available Special attention must be given to the selection Connection capacities actually available for each machine defined according to the connection terminal size the control box access opening size and the available If the maximum calculated section is for an XLPE cable type this means that a selection based on a PVC cable type can exceed the connection capacity actually Note The currents considered are given for a machine equipped with a hydronic kit operating at maximum current 30 6 5 24 V user power reserve After all possible options have been connected the
33. hot air recycling 47 18 OPTIONS AND ACCESSORIES Options No Description Advantages Use Very low temperature glycol solution 6 Low temperature glycol solution production downto Covers specific applications such as ice 30WG 020 090 12 C with ethylene glycol storage and industrial processe Soft starter 25 Electronic compressor starter Reduced compressor start up current 30WG 020 090 61WG 020 090 30WGA 020 090 Twinning 58 Unit equipped with an additional field installed Optimised operation of two units connected 30WG 020 090 leaving water temperature sensor allowing master in parallel with operating time equalisation 61WG 020 090 slave operation of two units connected in parallel 30WGA 020 090 External disconnect handle 70F The handle of the electrical disconnect switch ison Quick access to the unit disconnect switch 30WG 020 090 the outside of the unit 61WG 020 090 30WGA 020 090 Condenser insulation 86 Thermal condenser insulation Optimisation for heating applications 30WG 020 090 61WG 020 090 Low pressure single pump hydronic module 116F See hydronic module chapter Easy and fast installation 30WG 020 090 evaporator side 61WG 020 090 30WGA 020 090 High pressure single pump hydronic module 116J See hydronic module chapter Easy and fast installation reduced power 30WG 020 090 variable speed evaporator side consumption of the water circulation pump 61WG 020
34. hydronic module Option 116 oe eee seseseeeeeeteseeeeeeeteneeeseeeeees 15 3 11 61WG 30WG 050 090 unit with condenser hydronic module Option 270 eseesseseteeeeeeeeeteeeeseseseneneeeseseeees 15 3 12 61WG 30WG 050 090 unit with evaporator condenser hydronic modules options 116 270 tees 15 3 13 61 WG 30WG 050 090 unit with hydronic module and top CONNECTIONS eee cece ee ce eeeteeeeaeeesseeee cesses teseeseeeeees 16 options 116 4 274 OF 270 274 5 116 OF 270 4 274 sscccsseusevessasedscsassansscsvssesuetinoveven cpasbbsesetsaataacgeuuaptaanvoqustcaashdevueudasevanvsesastvesentes 16 3 14 61LWG 30WG 050 090 stackable Unit Option 273 occ ceeeeeesesescsesetetescecsesesescscscaesesesescacaeseseseseaeaeaeseseneaeasaseeseaeaeseaeseeees 16 319 30WGA 020 0454 standard UIt easair raoe oA EAE EEE E EOE RE EENE SEE RATES EOE quvducvsaemsbsanstsnesestteNevents 17 3 16 30WGA 020 045 unit with evaporator hydronic module Option 116 s s ssessssesssersesissesrssrierrertrserrerrsrresrerrrrerrsnrerres 17 3 17 30WGA 020 045 stackable unit Option 273 ceeeeeessseseetesesescsesescscscscsescsescscacaesesesescacaesescscseacasacseseaeacasssaescaeaeaeaeeeeeas 18 318 30 WG AI050 090 Stam ath WIM ie soles ass Srnu aerer eee AO EN e EE Ene NEE T OE ERDE E SEERA cosy dvevssdenstiapedtursbasutetesvass 18 3 19 30WGA 050 090 unit with evaporator hydronic module Option 116 s sessesessseeseseeresrserirrrertsrserierrsrrsrrerrerrsrenrerre
35. locate the control element in the stop position If a safety stop is removed for checking or replacement please ensure that there is always an active safety stop on each of the reversing valves installed in the unit The external safety valves must always be connected to drain pipes for units installed in a closed room Refer to the installation regulations for example those of European standard EN 378 and EN 13136 These pipes must be installed in a way that ensures that people and property are not exposed to refrigerant leaks As the fluids can be diffused in the air ensure that the outlet is far away from any building air intake or that they are discharged in a quantity that is appropriate for a suitably absorbing environment Periodic check of the safety valves See paragraph 1 3 Maintenance safety considerations Provide a drain in the drain pipe close to each safety valve to avoid an accumulation of condensate or rain water All precautions concerning handling of refrigerant must be observed in accordance with local regulations Ensure good ventilation as accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxia tion or explosions Inhalation of high concentrations of vapour is harmful and may cause heart irregularities unconsciousness or death Vapour is heavier than air and reduces the amount of oxygen available for breathing These products cause eye and skin irritation Decom
36. possible presence of impurities e g silicon grains in the heat exchange fluids These impurities maybe the cause of the wear or corrosion by puncture e Filter the heat exchange fluid check and carry out internal inspections as described in EN 378 annex C e Incase of re testing take the possible maximum pressure difference of 25 bar into consideration e The reports of periodical checks by the user or operator must be included in the supervision and maintenance file Repair Any repair or modification of the plate heat exchangers is forbidden Only the replacement of the complete heat exchanger by an original heat exchanger supplied by the manufacturer is permitted The replacement must be carried out by a qualified technician e The heat exchanger replacement must be shown on the monitoring and maintenance file Recycling The plate heat exchanger is 100 recyclable After use it contains refrigerant vapours and oil residue Operating life This unit is designed for e prolonged storage of 15 years under nitrogen charge with a temperature difference of 20 K per day e 900000 cycles start ups with a maximum difference of 6 K between two neighbouring points in the container based on 12 start ups per hour over 15 years at a usage rate of 57 17 4 Electronic expansion valve EXV The EXV is equipped with a stepper motor 2625 160 0 steps that is controlled via the EXV board 17 5 Refrigerant 61WG 30W
37. replace the device Do not install safety valves in series or backwards ATTENTION No part of the unit must be used as a walk way rack or support The refrigerant lines can break under the weight and release refrigerant causing personal injury Do not climb on a machine Use a platform or staging to work at higher levels Use mechanical lifting equipment crane hoist winch etc to lift or move heavy components For lighter components use lifting equipment when there is a risk of slipping or losing your balance Use only original replacement parts for any repair or compo nent replacement Consult the list of replacement parts that corresponds to the specification of the original equipment Do not drain water circuits containing industrial brines without informing the technical service department at the installation site or a competent body first Close the entering and leaving water shutoff valves and purge the unit water circuit before working on the compo nents installed on the circuit screen filter pump water flow switch etc Periodically inspect all valves fittings and pipes of the refrigerant and hydronic circuits to ensure that they do not show any corrosion or any signs of leaks It is recommended to wear ear defenders when working near the unit and the unit is in operation 2 PRELIMINARY CHECKS 2 1 Check equipment received e Inspect the unit for damage or missing parts If damage is detected o
38. s 200 175 x 150 125 100 Pressure drop kPa 75 50 25 o EES A S 6 Water flow rate l s Legend 1 Unit pump curve 2 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 open 4 Installation pressure drop after valve control to obtain the specified flow rate 11 NOMINAL WATER FLOW CONTROL WITH VARIABLE SPEED PUMP 11 1 Pump flow pressure curve 61WG 30WG 30WGA units with variable speed hydronic module include a water pump that automatically adjusts the flow to maintain a constant pressure or constant temperature difference No control is required at start up but the control mode must be selected at the unit interface refer to the 61 WG 30WG 30WGA Pro Dialog Control manual 11 2 Available external static pressure variable speed high pressure pumps units with hydronic module Data applicable for Fresh water 20 C In case of use of the glycol the maximum water flow is reduced The curves represented below are in normal conditions leaving water on the back side of the unit without option 274 Evaporator 61WG 30WG 30WGA 020 045 61WG 30WG 30WGA 050 090 160 150 poe Tt Et l d g 140 g ae 130 2 120 2 e 110 a Fa a 100 2 2 90 80 70 60 50 0 0 05 10 15 20 25 30 35 40 45 50 0 1 2 3 4 5 6 water flowrate
39. trans former ensures the availability of a usable 24 VA or 1 A power reserve for the control circuit on site 7 30WGA UNIT CONNECTIONS 7 1 Recommendations for the installation of liquid chillers with remote condenser The 30WGA units split units for connection to air cooled condensers have been specially designed to optimise the operation of split system installations using air cooled condensers as the chiller heat rejection system The refrigerant circuit installation of an operational system is limited to the connection of the air cooled condenser inlet and outlet to the 30WGA unit The components such as the check valve in the discharge line moisture sight glass and solenoid valves are installed and wired in the factory The filter drier is supplied with the unit and must be installed upstream of the solenoid valve on the liquid line The Pro Dialog control system of the 30WGA units incorporates the logic to permit control of the different fan versions fixed or variable speed To guarantee optimum and reliable performance of the units it is necessary to comply with the regulations described below when these units are connected to remote condensers e Size the discharge and liquid line piping according to the recommendations in the following paragraphs if necessary install a double riser to ensure correct oil circulation in the refrigerant circuit e Select a condenser with an integrated subcooler to obtain
40. unit with high pressure hydronic module Units without hydronic module Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger 61WG Condenser water flow rate I s Minimum Maximum Maximum Low pressure High pressure 020 0 3 3 1 3 5 3 8 025 0 3 3 3 3 8 4 1 030 0 3 3 3 3 8 4 1 035 0 4 3 5 4 1 4 7 040 0 4 3 7 4 3 5 0 045 0 4 3 9 4 5 5 4 050 0 4 4 8 6 8 7 0 060 0 5 5 5 7 0 7 5 070 0 5 5 6 7 2 7 8 080 0 6 5 8 7 4 8 2 090 0 6 7 2 7 9 9 3 Units with or without hydronic module Minimum flow rate for a water temperature difference of 18 K Note Operation permitted up to a value of 20 K Units with hydronic module Maximum flow rate for an available pressure of 20 kPa unit with low pressure hydronic module or 50 kPa unit with high pressure hydronic module Units without hydronic module Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger 5 10 2 61WG with option 272 61WG Minimum evaporator glycol solution flow rate option 272 I s Minimum Minimum Low pressure High pressure 020 0 5 0 5 0 5 025 0 5 0 5 0 5 030 0 5 0 5 0 5 035 0 6 0 6 0 6 040 0 6 0 6 0 6 045 0 8 0 8 0 8 050 2 0 1 9 0 8 060 1 9 1 9 1 0 070 1 9 1 9 1 1 080 1 9 2 0 1 3 090 2 2 2 0 1s Option 272 Condenser side high temperature water production evaporator side with glycol solution Units with hydronic module Minimum flow rate for a maximum permitt
41. up contact Carrier If the leaving water temperature is below 5 C a frost protection solution must be used Please refer to option 6 for evaporator leaving water low temperature applications lt 5 C The minimum entering air temperature is based on the drycooler selection The maximum entering air temperature is based on the drycooler selection t For applications with a low condenser entering air temperature the use of a three way valve is recommended This thre way valve can be controlled by the 0 10 V analogue output of the Pro Dialog control 5 4 Operating range 30WG 65 4 60 55 4 wees 50 a 45 40 35 30 4 25 4 20 aaa ee 15 qi E E E E E E E 14 12 10 8 6 4 2 0 2 4 6 8 10 12 14 16 18 20 Evaporator leaving water temperature C 30WG standard unit 30WG unit with option 6 brine Option 6 Standard Condenser leaving water temperature C 25 5 5 Operating limits 30WGA 30WG Minimum Maximum Evaporator Entering water temperature at start up 1G SY 27 Leaving water temperature during operation 30 57 20 Entering leaving water temperature difference K 25 7 Air entering temperature at start up and during operation Air entering temperature fixed speed fan c oT 35 to 48 Air entering temperature variable speed fan C 10to 20t 35 to 48 For entering water temperatures below 7 5 C at start up contact Carrier 30W
42. 1 WG 30WG 30WGA 020 090 units have only one power connection point located at the main disconnect switch Before connecting electric power cables it is imperative to check the correct order of the 3 phases L1 L2 L3 Non certified drawings Refer to the certified dimensional drawings Before connecting the unit check that the phase order in the customer control box is the same as shown in the customer wiring diagrams 6 2 Power supply The power supply must conform to the specification on the unit nameplate The supply voltage must be within the range specified in the electrical data table For connections refer to the wiring diagrams In 30WGA units the power supply must not be disconnected after the unit has been commissioned except for quick maintenance interventions one day For longer maintenance tasks or if the unit is put into storage for example during the winter when the unit is not used for cooling the unit power supply must be ensured to guarantee supply to the compressor heaters on the crankcase WARNING Operation of the unit with an incorrect supply voltage or excessive phase imbalance constitutes abuse which will invalidate the Carrier warranty If the phase imbalance exceeds 2 for voltage or 10 for current contact your local electricity supply at once and ensure that the unit is not switched on until corrective measures have been taken 6 3 Voltage phase imbalance 100 x max deviation from
43. 16 2 19 5 21 3 23 9 26 5 30 3 39 0 42 6 47 8 53 0 60 6 Customer side unit power reserve Customer reserve at the 24 V control power circuit Short circuit stability and protection See table below Short circuit stability current Maximum instantaneous start up current at operating limit values maximum operating current of the smallest compressor s locked rotor current or limited start up current of the largest compressor Maximum power input at the unit operating limits Values obtained at the following conditions evaporator entering leaving water temperature 12 C 7 C condenser entering leaving water temperature 45 C Maximum unit operating current at maximum unit power input and 400 V t Maximum unit operating current at maximum unit power input and 360 V 4 6 Short circuit stability current TN system standard unit with main disconnect switch 61WG 30WG 30WGA 020 025 030 035 040 045 050 060 070 080 090 Value with non specified upstream protection Short term current at 1 s low kA rms 3 3 3 3 3 3 3 3 3 3 3 Admissible peak current Ipk kA pk 6 6 6 6 6 6 6 6 6 6 6 Maximum value with upstream protection by circuit breaker Conditional short circuit current Icc KA rms 40 40 40 40 40 40 40 40 40 40 40 Schneider circuit breaker Compact series NSX 100N Reference number LV429795 Earthing system type If another current limitation protection system is used its time current and thermal
44. 4 4 Condenser Safety valve Clearances required for maintenance see note Control box KD Water inlet D Water outlet 5 Power wiring connection 8 i NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 13 3 8 61WG 30WG 050 090 standard unit 700 L 1474 L 1489 900 700 l 4 Q O N 3 9 61WG 30WG 050 090 unit with top connections option 274 700 1474 14 Only for option WORE 905 lt 880 880 Legend All dimensions are in mm A g590000 Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Water inlet Water outlet Power wiring connection NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 3 10 61WG 30WG 050 090 unit with evaporator hydronic module option 116 Only for option 70F 905 880 1474 1488 900 700 Legend LIL All dimensions are in mm Evaporator 700 iliii S Condenser Ili 7 7 Safety valve I I Clearances required for maintenan
45. 5 C a frost protection solution must be used Please refer to option 6 for evaporator leaving water low temperature applications lt 5 C For applications with a condenser entering temperature below 15 C the use of a three way valve is recommended This three way valve can be controlled by the 0 10 V analogue output of the Pro Dialog control For a water flow rate that corresponds to a maximum water side temperature difference of 5 K 61WG option 272 geothermal application Minimum Maximum 30WG option 6 Minimum Maximum Evaporator Evaporator Entering water temperature at start up Gs 22 5 25 Entering water temperature at start up C 9 5 27 Leaving water temperature during operation O C 5 20 Leaving water temperature during operation C 12 20 Entering leaving water temperature difference K 2 5 5 Entering leaving water temperature difference K 25 3 Condenser Condenser Entering water temperature at start up Gs lt 15 6o Entering water temperature at start up GC 157 5 Leaving water temperature during operation C 720 65 Leaving water temperature during operation C 20 60 Entering leaving water temperature difference K 2 5 18 Entering leaving water temperature difference K 25 18 A frost protection solution must be used For applications with a condenser entering temperature below 15 C the use of a three way valve is recommended This three way valve can be controlled by the 0 10 V a
46. 5 2 2 2 2 2 Max water side operating pressure without kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 hydronic module Refrigerant connections Discharge line diameter in 7 8 7 8 7 8 7 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 1 8 Liquid line diameter in 5 8 5 8 5 8 5 8 5 8 5 8 7 8 7 8 7 8 7 8 7 8 Weight shown is a guideline only To find out the unit refrigerant charge please refer to the unit nameplate In accordance with ISO 9614 1 measured in a free field The sound levels only apply to units without options k 4 4 Physical data 61WG 30WG 30WGA units with hydronic module 61WG 30WG 30WGA 020 025 030 035 040 045 050 060 070 080 090 Operating weight 30WG 61WG option 116J 270J kg 305 313 313 321 327 334 513 521 533 544 574 Weight 30WGA option 116J kg 250 258 258 263 266 271 431 435 442 449 465 Height mm 1463 1463 1463 1463 1463 1463 1463 1463 1463 1463 1463 Hydronic module Maximum operating pressure kPa 300 300 300 300 300 300 300 300 300 300 300 Water filter max removed particle diameter mm 12 1 2 12 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 Expansion tank capacity I 8 8 8 8 8 8 12 12 12 12 12 Water connections in 1 5 15 1 5 1 5 1 5 1 5 2 2 2 2 2 Weight shown is a guideline only The length and width dimensions are the same as for the standard unit When delivered the standard pre inflation of the tanks is not necessary the optimal value for the system To permit changing the water vo
47. 5149 etc If a leak occurs or if the refrigerant becomes polluted e g by a short circuit in a motor or BPHE frost remove the complete charge using a recovery unit and store the refrigerant in mobile containers Repair the leak detected and recharge the circuit with the total R 410A charge as indicated on the unit name plate Do not top up the refrigerant charge Only charge liquid refrigerant R 410A at the liquid line 8 Ensure that you are using the correct refrigerant type before recharging the unit Charging any refrigerant other than the original charge type R 410A will impair machine operation and can even destroy the compressors The compressors operating with this refrigerant type are lubricated with a synthetic polyol ester oil Before any intervention on the refrigerant circuit the complete refrigerant charge needs to be recovered For 30WGA units with remote condenser the installer must be clearly note the total refrigerant charge used in the system in kg on the label attached to the 30WGA RISK OF EXPLOSION Never use air or a gas containing oxygen during leak tests to purge lines or to pressurise a machine Pressurised air mixtures or gases containing oxygen can be the cause of an explosion Oxygen reacts violently with oil and grease Only use dry nitrogen for leak tests possibly with an appropriate tracer gas If the recommendations above are not observed this can have serious or even fatal consequences
48. 549600 19 7 29 31 9 197 108 4 1 2 Compressor Reference INom IMax IMax LRA LRA 30WGA Un Un 10 020 025 030 035 040 045 050 060 070 080 090 WSH090 0OPSG001549100 11 4 14 7 16 2 98 53 9 1 WSH105 00PSG001549200_ 13 8 17 7 19 5 142 78 1 1 2 WSH120 00PSG001549300 14 7 19 3 21 3 142 78 1 1 2 WSH140 00PSG001549400_ 16 5 21 7 23 8 147 80 9 1 2 WSH161 00PSG001549500_ 18 1 24 1 26 5 158 86 9 1 2 WSH184 O0OPSG001549600 21 2 27 5 30 3 197 108 4 1 2 Legend I Nom Nominal current draw A at standard Eurovent conditions see definition of conditions under nominal unit current draw Max Maximum operating current A LRA Locked rotor current at nominal voltage A LRA Locked rotor current with electronic starter at nominal voltage A Electrical data notes and operating conditions NO 61WG 30WG 30WGA units have a single power connection point located immediately upstream of the main disconnect switch The control box includes the following standard features a main disconnect switch the starter and motor protection devices for each compressor and the pumps the control devices Field connections All connections to the system and the electrical installations must be in full accordance with all applicable local codes The Carrier 61WG 30WG 30WGA units are designed and built to ensure conformance with these codes The recommendations of European standard EN 60204 1 machine safety electrical machine components part 1 gener
49. 61WG 30WG 30WGA 020 090 Water Cooled Condenserless Liquid Chillers Water Sourced Heat Pumps with or without Integrated Hydronic Module Nominal cooling capacity 25 95 kW Nominal heating capacity 29 117 kW Heating AQUASNAP ae Unit with optional hydronic module Standard unit AQUASNAP Installation operation and maintenance instructions 1SO9001 1SO14001 Quality and Environment Management Systems Approval CONTENTS 1 INTRODUCTION ccccsscsssssssscssssessscssesecsscescsssssscvesssesscsssesecsseesosessscsesssesscsssesesosecsosossssesacosesscsssssesossssesesosssussessssssssssesssesons 6 1 1 Installation safety COnSiCleratiOms ycssc sccssises sands cdnescaveseancs aeea ai a EREE A A Ea A ERASE ENER A 6 1 2 Equipment and components under pressure ssion ee seniore seai ueri u oa eaa Nae ia tai aE aaee a r A 7 1 3 Maintenance safety CONSIGCLATONS issssscess sasesesscscavsdevess aR ina E E EE EE E aT a aa a A 7 14 Repar Satety considerations nenesinin Ean a A EAE A NEE AA EE AEE E 8 2 PRELIMINARY CHECKS seseeseosccsccsecsecscooccsecsecsccoccsecoeosccoccsecsecoccocesecosecoccoecseesecoccoecsecoscoscoecsecsecoccoecsecoscoccocesecsscoscosesecsseseeoeee 9 Dal Check egiipment receive dii testers de sus esses caus AE En irae AE E r a a EE SE A AE E ENA IEAS DEEE RATE Seats E in SES 9 22s Moving ANG Place CASUAL esireast NNi canaksuessdestasess ER Earr aeaea ushssaavonns acetadessnis iossho
50. Efficiency level IE2 3 Year of manufacture This information varies depending on the manufacturer and model at the time of 4 Manufacturer s name and trademark commercial registration incorporation Please refer to the motor name plates number and place of manufacturer 5 Product s model number 6 Number of motor poles 2 2 2 2 2 2 2 2 2 2 2 7 1 Rated shaft power output at full load and nominal voltage 400 V kW 1 25 1 25 1 25 1 25 1 25 1 25 1 70 1 70 1 70 1 70 1 70 7 2 Maximum power input 400 V kw 1 50 1 50 1 50 150 150 150 230 230 230 2 30 2 30 8 Rated input frequency Hz 50 9 1 Rated voltage V 3 x 400 9 2 Maximum current drawn 400 V t A 3 1 3 1 3 1 3 1 3 1 3 1 4 3 4 3 4 3 4 3 4 3 10 Rated speed r s 48 48 48 48 48 48 48 48 48 48 48 rpm 2892 2892 2892 2892 2892 2892 2863 2863 2863 2863 2863 11 Product disassembly recycling or disposal at end of life Disassembly using standard tools Disposal and recycling using an appropriate company 12 Operating conditions for which the motor is specifically designed Altitudes above sea level m lt 1000tt Il_ Ambient air temperature C lt 40 IV Maximum air temperature Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs V Potentially explosive atmospheres Non ATEX environment xk kkk Required by regulation 640 2009 with regard to the application of directive 2005 32 EC on the eco design requireme
51. G 30WGA units operate exclusively with R 410A 45 17 6 High pressure switch and high pressure sensor 61WG 30WG units are equipped with an automatically reset safety pressure switch on the liquid line Refer to the controls manual for the alarm acknowledgements It is strictly forbidden to modify the unit refrigerant circuit The pressure switch is specific to the 61 WG 30WG units do not interchange it with other units The pressure switch tap does not include a Schrader valve I 1 Ii High pressure switch High pressure sensor The high pressure sensor is however equipped with a Schrader valve It is specific to these units and must not be replaced with one from other Carrier units 30WGA units are equipped with an automatically reset safety pressure switch on the discharge line The pressure switch is specific for the 30WGA unit Do not exchange it with other units including the 61WG 30WG units High pressure sensor High pressure switch 46 17 7 High and low pressure side safety valves The units are equipped with safety valves in accordance with the European directive 97 23 CE These safety valves are calibrated and sized in accordance with the original high and low pressure side equipment Only 61WG 30WG units include high and low pressure side safety valves 30WGA units are only equipped with a low pressure side safety valve The installer must determine which accessories safety valves fuses etc
52. GA unit can operate down to 0 C if the configuration of the fluid type used is modified If the leaving water temperature is below 5 C a frost protection solution must be used The minimum temperature range is based on the condenser selected If the condenser only has a few fan stages the use of variable speed fans is recommended from 10 C t The minimum temperature range is based on the condenser selected The maximum temperature range is based on the condenser selected 5 6 Operating range 30WGA 65 60 5a sof 45 Medium temperature application Standard 40 4 35 4 30 4 25 20 q Condensing temperatre C 2 0 2 4 6 8 10 12 14 16 18 20 Evaporator leaving water temperature C 30WGA standard unit 30WGA unit for medium temperature application glycol lt 25 5 7 Minimum chilled water flow If the system water flow rate is lower than the minimum water flow rate recirculation of the evaporator flow may occur The temperature of the mixture leaving the evaporator must never be less than 2 5 K lower than the chilled water entering temperature 5 8 Maximum chilled water flow The maximum chilled water flow is limited by the maximum permitted pressure drop in the evaporator It is provided in the tables in chapter 5 7 If the flow exceeds the maximum value two solutions are possible e Modify the flow rate with a control valve e Bypass the evaporator t
53. J9 LZE OWAre e Connector J2 Digital outputs CH 1 to 4 for fan stages 1 to 4 e Connector J3 Digital output CH 6 to control a directional on off three way valve e Connector J6 Analogue input CH 11 for outside air temperature sensors e Connector J6 Analogue input CH 12 for information on domestic hot water demand e Connector J7 Analogue input CH 13 for information on domestic hot water demand e Connector J8 Analogue input CH 14 for information on summer operation only domestic hot water only To apply the different configurations required refer to the instructions in the Pro Dialog Control IOM 39 13 OPERATION OF 61WG UNITS WITH THE HEATING SYSTEM MANAGER HSM HSM accessory 00PPG000488000 or 0OPPG000488100 or 00PPG000488200 The Heating System Manager HSM accessory allows improved integration of the 61WG heat pump to maximise energy efficiency performance With three system levels for nine typical configurations most heating only applications are covered from the simplest to the most complex such as interfacing with a district heating system Each of these accessory configurations is described in detail in the user manual for these accessories They offer e choice of additional control options on off volt free contact or 0 10 V signal for increased performance e domestic hot water production tempe
54. Maintenance SCHE QUIS sss cise deste iazeis scstswensa no oaeo eS E OR EE AEE EE EE 52 20 2 Description of the maintenance operations srona icini raui iiae Kin ru N SE Ei AA EE Ai NAR N Ei 52 21 START UP CKECKLIST FOR 61WG 30WG 30WGA UNITS USE FOR JOB FILE esessssessoseososcososcocoseocoseocoseoe 53 The illustrations in this document are for illustrative purposes only and not part of any offer for sale or contract 1 INTRODUCTION Prior to the initial start up of the 61WG 30WG 30WGA units the people involved in the on site installation start up operation and maintenance of this unit should be thoroughly familiar with these instructions and the specific project data for the installation site The 61WG 30WG 30WGA units are designed to provide a very high level of safety during installation start up opera tion and maintenance They will provide safe and reliable service when operated within their application range This manual provides the necessary information to fami liarize yourself with the control system before performing start up procedures The procedures in this manual are arranged in the sequence required for machine installation start up operation and maintenance Be sure you understand and follow the procedures and safety precautions contained in the instructions supplied with the machine as well as those listed in this guide To find out if these products comply with European directives machine safety low
55. P csscsssssssscssssssssssscssecsssessvesesssesees 36 11 1 Pump HOW PLESSULS CULV E siiani ainra iee da ee a i S ENESA OEE E EROSA ATAS S oS eps gecsdevesesecass 36 11 2 Available external static pressure variable speed high pressure pumps units with hydronic module 37 11 3 Available external static pressure fixed speed low pressure pumps units with hydronic MOdUIe cesses tesseenees 38 11 4 Pump curve units with hydronic modul s ose eeeseseseseseseseseeescscssseseececscasacseececscasasseececscasaeseecececasavaneeesssatanseeseeesaes 39 12 OPERATION OF 61WG UNITS WITH SPECIFIC HEATING CONTROL OPTION 153 scscscscscsoseseseseseseees 39 AD Le Operating I BULO 0 l EEE N E E A E cede E E exSectesoaveteeescnusseses custe E edusassseiestvee cnet 39 12 2 Auxiliary electronic board AUX1 analogue and digital inputs and OUtpUtS oo eee eeceeeeteeeeeaees 39 13 OPERATION OF 61WG UNITS WITH THE HEATING SYSTEM MANAGER HSM cccssscsssssssssssssesessssssesesees 40 14 30WG UNIT OPERATION WITH A DRYCOOLER OPTION 154 cccssssssscsssssssscsssesesscsscssesessecssessssesssesesseesees 41 14 1 Operating Principle sssini tsei e re anes vfeasessn E ASE EA AEAEE RER ESE AE AA EEEE ERE 41 14 2 Auxiliary electronic board AUX1 analogue and digital inputs and outputs to control the drycooler 0 41 14 3 Configuration of the number of fan stages and the automatic changeover of the fan s
56. P 10 1 General The water circulation pumps of the 61WG 30WG units have been sized to allow the hydronic modules to cover all possible configurations based on the specific installation conditions i e for various temperature differences between the entering and the leaving water AT at full load which can vary between 2 5 and 7 K for evaporators and 3 and 18 K for condensers This required difference between the entering and leaving water temperature determines the nominal system flow rate It is above all absolutely necessary to know the nominal system flow rate to allow its control via a manual valve Manual control valves for the unit are not supplied and must be installed upstream and downstream of the evaporator and condenser water loops to ensure correct flow control With the pressure loss generated by the control valve in the hydronic system the valve is able to impose the system pressure flow curve on the pump pressure flow curve to obtain the desired operating point see example The pressure drop reading in the plate heat exchanger is used to control and adjust the nominal system flow rate The pressure drop is measured with the pressure sensors connected to the heat exchanger water inlet and outlet Use this specification for the unit selection to know the system operating conditions and to deduce the nominal air flow as well as the plate heat exchanger pressure drop at the specified conditions If this information i
57. a minimum of 3 K subcooling at the inlet to the expansion device e Install the filter drier supplied with the unit as close as possible to the liquid line filter drier e Install the outside air temperature sensor supplied near the air cooled condenser For units with remote condenser control option 154 the sensor is supplied The outside air temperature information is required for correct operation of the complete system Control of the remote air cooled condenser using option 154 e Connect the fan stages electrically to the control board using auxiliary electronic board AUX 1 To assign the fan stages refer to chapters 14 and 15 with the description of the analogue and digital inputs and outputs e Make the communication bus connection twisted and shielded cable type for communication bus RS485 between the specific electronic AUX 1 board that must be integrated in the condenser control box and using the NRCP master board of the 30WG unit e The Pro Dialog control is used to configure the number of fan stages and the fan type based on the air cooled condenser model used in the installation e A fan speed controller may is recommended for the first fan stage for operation at low ambient temperature at part load and for condensers with few fans ATTENTION The air cooled condenser must always be used with a subcooler Normally 8 K subcooling at the condenser outlet is recommended 7 2 Piping installation and connection On
58. air cooled condenser inlet and outlet piping to the 30WGA unit The Pro Dialog control system of the 30WGA includes a logic to permit control the different fixed and variable speed fan variants 15 2 Lead fan The physical position of the air cooled condenser with fixed or variable speed fans depends on the position of the leaving liquid refrigerant manifold In all cases there is always a so called lead fan This is the fixed or variable speed fan that is physically the closest to the leaving liquid refrigerant manifold This ensures optimum subcooling on the condenser outlet side especially at part load This is the first fan to start in each circuit and the last fan to stop A fan configuration with fixed speed fans permits year round system operation down to 0 C outside temperature A fan configuration with a variable speed lead fan permits year round operation down to 10 C outside temperature 42 15 3 Auxiliary electronic board AUX1 analogue and digital inputs and outputs to control the remote air cooled condenser STATUS SIO O spm vj m A E oa 23 m oj E ia 7 te CH14 E low OO r B io OOJ P loojv 3 gt y OO T o JOO P ia OOjv n gt on J4 J5 Jo emg J2 J3 Oe oc eee IHH CH CH CH CH CH CH CH CH te a te m Pee ee e EEE
59. al regulations corresponds to IEC 60204 1 are specifically taken into account when designing the electrical unit equipment TES Generally the recommendations of IEC 60364 are accepted as compliance with the requirements of the installation directives Conformance with EN 60204 1 is the best means of ensuring compliance with the Machines Directive 1 5 1 Annex B of EN 60204 1 describes the electrical characteristics used for the operation of the machines The operating conditions for the units are specified below Environment Environment as classified in EN 60721 equivalent to CEI60721 Indoor installation ambient temperature range 5 C for the temperature minimum to 40 C class 4K4H humidity range non condensing 50 relative humidity at 40 C 90 relative humidity at 20 C altitude lt 2000 m see note for table 4 7 Electrical data hydronic module indoor installation presence of water class AD2 possibility of water droplets presence of hard solids class 4S2 no significant dust present presence of corrosive and polluting substances class 4C2 negligible vibration and shock class AG2 AH2 competence of personnel class BA4 trained personnel IEC 60364 Power supply frequency variation 2 Hz The neutral N conductor must not be connected directly to the unit if necessary use a transformer 4 Over current protection of the power supply conductors is not pro
60. amination test If acid water or metallic particles are present replace the oil in the circuit Verify the tightening of the thermostatic mechanism of the expansion device Full load operating test In addition to the checks carried out under Service B validate the value between leaving water and the saturated evaporating temperature Check the operation of the high pressure switch es Replace them if there is a fault Check the fouling of the filter drier by checking the temperature difference in the copper piping Replace it if necessary Electrical checks Check the status and insulation of the electrical cables Check the phase earth insulation of the compressors and pumps Check the compressor and pump winding status Mechanical checks Verify the alarm status e Service B Carrier out the operations listed under Service A Check that no water has penetrated into the control box Clean the filter of the air inlet grille and if necessary replace the filter Water circuit checks Refrigerant circuit 7 e Full load operating test In addition to the operations e described under Service A check the following values e compressor discharge pressure compressor oil level actual liquid subcooling overheating at the expansion device e Verify the charge status by checking the colour indicator of the sight glass If the colour has turned to e yellow change the charge and replace the filter drier e cart
61. ance is less than 2 53 WARNING Do not start unit if voltage imbalance is greater than 2 Contact local power company for assistance All incoming power voltage is within rated voltage range Check cooler water loop Water loop volume sesserenissssss litres Calculated volume ou eee litres Proper loop volume established Proper loop corrosion inhibitor included litres Of cesononcmeme Proper loop freeze protection included if required MeS Ofrena acne Piping includes electric heater tape if exposed to the outside Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1 2 mm unit without pump Check pressure drop across the evaporator Entering evaporator sassssnnerasisis kPa Leaving evaporator sisirin kPa Leaving entering oe kPa WARNING Calculate the cooler pressure drop in performance data table in the product data literature to determine total litres per second l s and find unit s minimum flow rate MO Call WS seacecesstaticess R V s nominal KW Sasainn Total l s is greater than unit s minimum flow rate Total l s meets job specified requirement Of eee I s Perform TEST function indicate positive result WARNING Once power is supplied to the unit check the display for any alarms such as phase reversal Follow the TEST function instructions in the Controls and Troubleshooti
62. are equipped with automa tically reset pressure switches in accordance with EN378 For unit installation and connection to the remote condenser it is necessary to e Check the applicable air conditioning regulations and safety standards e g PED and EN378 for the European Union e Determine which accessories safety valves fuses etc are required so that these circuits comply with the applicable regulations and standards If shut off valves are used on the circuit ensure that these valves do not shut off the safety valve for the different containers that they protect The protection devices include the fuse plugs and safety valves if used in the refrigerant or heat transfer medium circuits Check if the original protection plugs are still present at the valve outlets These plugs are generally made of plastic and should not be used If they are still present please remove them Install devices at the valve outlets or drain piping that prevent the penetration of foreign bodies dust building debris etc and atmospheric agents water can form rust or ice These devices as well as the drain piping must not impair operation and not lead to a pressure drop that is higher than 10 of the control pressure Classification and control In accordance with the Pressure Equipment Directive and national usage monitoring regulations in the European Union the protection devices for these machines are classified as follows Saf
63. ce see note a Control box fA Water inlet Water outlet Power wiring connection Ag590000 3 11 61WG 30WG 050 090 unit with condenser hydronic module option 270 1021 3 12 61WG 30WG 050 090 unit with evaporator condenser hydronic modules options 116 270 277_ 282 NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 15 3 13 61WG 30WG 050 090 unit with hydronic module and top connections options 116 274 or 270 274 116 or 270 274 O N 4 4 8 8 T T 900 172 80 s 4 N 82 eS 3 14 61WG 30WG 050 090 stackable unit option 273 172 700 NOTE The water and electrical connections are identical to those of the standard unit 1014 700 59000 700 16 All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Water inlet Water outlet Power wiring connection NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 3 15 30WGA 020 045 standard unit li 1044 L 1058 900 s 4
64. constraint I t trip characteristics must be at least equivalent to those of the recommended Schneider circuit breaker Contact your nearest Carrier office The short circuit stability current values above are in accordance with the TN system 22 4 7 Electrical data optional hydronic module The pumps that are factory installed in these units have motors with efficiency class E2 The additional electrical data required is as follows Motors of fixed speed hydronic module pumps 61WG 30WG 30WGA options 116F and 270F No Description 61WG 30WG 30WGA options 116F and 270F low pressure pumps 20 25 30 35 40 45 50 60 70 80 90 1 Nominal efficiency at full load and nominal voltage 795 795 795 795 795 795 795 795 795 795 823 1 Nominal efficiency at 75 rated load and nominal voltage 78 2 78 2 782 782 78 2 78 2 78 2 782 782 782 81 8 1 Nominal efficiency at 50 rated load and nominal voltage 745 745 745 745 745 745 745 745 745 745 79 7 2 Efficiency level IE2 3 Year of manufacture This information varies depending on the manufacturer and model at the time of 4 Manufacturer s name and trademark commercial registration incorporation Please refer to the motor name plates number and place of manufacturer 5 Product s model number 6 Number of motor poles 2 2 2 2 2 2 2 2 2 2 2 7 1 Rated shaft power output at full load and nominal voltage 400V kW 0 8 0 8 0 8 0 8 0 8 0 8 0 8
65. csncdssvens Sates cncvecsnessisbevienssssesnsvoune sonstdudsssnavencdebastenstenavansadsipvcocudns aa aaa aiai 47 17 Le Variable SpSed PUND enecens anere AREA T EE OREN ERA RETAS EAE AEEA A EEN TREA E EA EE 47 17 12 Evaporator and condenser pump suction MIET eis ccaccsascssesccveuscnavacnesncnnsnenadbe dounexednedsshe aesedsshaieenedsvasinenedsensusesescescuneseeses 47 AT V3 COMMSCHOM SIEC VES Soene E E e says ectaeesetls EEA E E EE A E A E EEE 47 17 14 Option 272 High temperature water production with glycol solution e se esseseeesesseseeesesresesreseseesrssesrsrenrenenrenesrerese 47 17137 Outside air temperare SENSOM eranen aer aE eeen E Eoo a De rea E o SESER AEE EERE AREE AEAEE EE EERE EEE 47 18 OPTIONS AND ACCESSORIES ssesesseseesoseososcosoocosoocoscocoscocosescoseseeecseoseoeoeeeeoeoseoroseososeososeososeocoococoocoreecoseecoceecseeseseeseseoses 48 19 MAINTENANCE ccccsssssssscssssssssssssscesscsscssecssssceseccsesessesesnsesossesosssossesosssessasssnsessscesosssessesosssessasosssesesoesosossscosessssssasoseseseeees 49 19 1 Soldering and Welding assesses ss5ssscces cescs tenes es cesses vases seat vesegsesteess A E oess caduees otasowesta via sesaeasessoeaes 49 19 2 General System aMtOMANCE sscesscscsecacsess tieer vsdes seas a eae ei n Eder te covsees odassoeess E EE AETA RE S E SiS 49 19 3 Refrigerant underchar tesirini e EEE R E ER E E E AER vascess 49 194 Refrigerant guidelines rsss sitse csessvssseuseapssbes cas
66. de by technical specialists e there is adequate space above the unit for air flow and to ensure access to the components e the number of support points is adequate and that they are in the right places e the location is not subject to flooding e No material or object that can be affected by condensate even a small amount must be left under the machine or in the water flow direction CAUTION Before lifting the unit check that all casing panels are securely fixed in place Lift and set down the unit with great care Tilting and jarring can damage the unit and impair unit operation ATTENTION Stacked units must not be moved If 61WG 30WG 30WGA units are hoisted with rigging it is necessary to protect the unit frame side and rear panels and front doors against accidental crushing Use struts or lifting beams to spread the slings above the unit Do not tilt a unit more than 15 or 5 for units with the stacking option option 273 Always follow the instructions on the handling notice attached to the unit If a unit includes a hydronic module options 116 or 270 the hydronic module and pump piping must be installed in a way that does not submit it to any strain The hydronic module pipes must be fitted so that the pump does not support the weight of the pipes Never push or lever on any of the enclosure panels panels uprights front access doors of the unit Only the base of the unit frame is designed to withstand suc
67. ditions The evaporators and condensers are single circuit for all units The water connections between the heat exchangers and the piping of the hydronic modules have quick connect Victaulic couplings to facilitate pump disassembly if required A drain with a 1 4 turn valve is included in the leaving water of all heat exchangers The evaporators have 19 mm thick polyurethane foam thermal insulation For option 86 condenser insulation the condensers also have 19 mm thick polyurethane foam thermal insulation The products that may be added for thermal insulation of the containers during the water piping connection procedure must be chemically neutral in relation to the materials and coatings to which they are applied This is also the case for the products originally supplied by Carrier NOTES Monitoring during operation re qualification re testing and re testing dispensation e Follow the regulations on monitoring pressurised equipment e Itis normally required that the user or operator sets up and maintains a monitoring and maintenance file e If there are no regulations or to complement them follow the control programmes of EN 378 e f they exist follow local professional recommenda tions e Regularly inspect the condition of the coating paint to detect blistering resulting from corrosion To do this check a non insulated section of the container or the rust formation at the insulation joints e Regularly check for
68. e nominal system operating conditions This volume is neces sary for stable operation and accurate temperature control Application N 61WG 30WG 30WGA 2 5 ATTENTION Minimum water volume required between the unit and possible customer supplied valves to the outside of the unit Industrial process applications Certain industrial processes may require high leaving water stability In these cases the values above must be increased It may be necessary to add a buffer water tank to the circuit in order to achieve the required volume The tank must itself be internally baffled in order to ensure proper mixing of the liquid water or brine Refer to the examples below bv Bad gt Good panny Mwy oe ay A gt Bad Good 5 12 Maximum water loop volume evaporator and condenser side Units with hydronic module incorporate an expansion tank sized for the maximum water loop volume The table below gives the maximum water loop volume in litres for pure water or ethylene glycol with various concentrations 61WG 30WG 30WGA 020 045 060 090 Static pressure kPa 100 200 300 100 200 300 bar 1 2 3 1 2 3 Pure water I 220 450 75 340 225 115 10 ethylene glycol I 165 110 53 255 170 85 20 ethylene glycol I 100 70 35 150 100 50 35 ethylene glycol 85 55 30 130 85 45 5 13 Expansion tank The expansion tank is supplied with a pressure of 1 bar relative 20 The maximum operating pres
69. e ee eeeeeeeeeeeeeeeeeeeeees Compressor oil pressure Al arsts aes aeaa AE E t Compressor oil pressure Bit nseri aR Compressor oil pressure A2 annoi n Compressor oil pressure B2 oo ce eteeeeeceeeeeneeeeees if available and installed if installed EUVUROVENT CERTIFIED PERFORMANCE www eurovent certification com www eurovent certification com www certiflash com Order No 16122 76 02 2014 Supersedes order No 16122 76 10 2013 Manufacturer Carrier SCS Montluel France Manufacturer reserves the right to change any product specifications without notice Printed in the European Union
70. eaks 31 The piping between the 30WGA and the condenser must be correctly supported in line with its size and the operating weight Piping support is required to ensure that vibration levels at the piping are lower than the values at the compressor If resonance occurs reduce the width between the collar until the vibration levels are acceptable 8 PIPE SIZING WITH REFRIGERANT FOR 30WGA UNITS 8 1 General considerations and pipe size limits Pipe size limits 30WGA Maximum Linear length discharge liquid line 30m Height difference 12m The pipes must be as short as possible and have the least possible changes bends etc to minimise pressure drops If there is a risk of poor piping use adequate measures must be taken design positioning protection to prevent incorrect use The following constraints must be taken into account whe the refrigerant pipes are sized e Oil return to the compressor is ensured by entrainment A minimum refrigerant velocity is required to ensure entrainment This velocity depends on the pipe diameter the refrigerant and oil temperature these are treated as being the same in most cases A reduction of the pipe diameter permits an increase of the refrigerant velocity The problem of a minimum entrainment velocity does not exist for the pipes that carry liquid refrigerant as the oil is fully miscible here e The pressure drop at the compressor discharge pipes linking the com
71. ecseseescseseseececesesenseceecsenesececaeseseeeeseseneeceeceeaseeeecaeaeeesee 28 5 15 Plate heat exchanger pressure drop includes internal piping 0 0 eee seseseeesetesescseseseseseacseseseseseaeaesesesessaeseseseeees 28 6 ELECTRICAL CONNECTION csscsssssssssccssssssscesesssssscsesssesscsssesessscssesessscsesesesscsssssesesessossssscesesssessasosesesesessesosesceseseseses 29 6 1 Electrical connections control box 61 WG 30WG 30WGA Q cccsccssscessecesseesseesssessececsecessecsseceseecsssecssceseesaecesseessesessecees 29 1 2 PO WEL SUPPLY renoneer ei iiien iran ra nirs ieir iniri aN aSa aD SaaS aaa eK stews dusesedabbencneasbbdvonsisbstesedtessanates 29 6 3 Voltage phase imbalance o au sdsssiciv desevesieavpsesiad n E E E E E O ERE ENS 29 6A Recommended Wire Sections win scsesasdseiecensssstensestescdesedeves iar iei ari n a E eE E E E R EERE RR 29 6 3 24V user POWEL TESELVE virei oirein aie een aay ar aA RE TEE E E E R ENEE E R O 31 7 30WGA UNIT CONNECTIONS essseseeseoscosccsecsecscooccsecseoscooecsecsecocoocesecsecoccoccsecoecocoocesecsececcoccsecoecoccocesecsecoccoecsecsecocooeeseeseoseese 31 7 1 Recommendations for the installation of liquid chillers with remote condenser s sessssesessssesssserssreresrerenrerenrerenreees 31 T 2 Piping installation and CONNECHON snose REN E 31 8 PIPE SIZING WITH REFRIGERANT FOR 30WGA UNITS esssssssecccceccoccccseocesccceseoeeseoeeseososeososecsoseososeososeocoscososeosese
72. ed out in accordance with the schedules below Service Frequency A Weekly B Monthly C Annually D Special cases e Verify the correct operation of the evaporator and condenser pumps with the Quick Test function Verify the correct operation of cooling fans speed converter and condensing pumps Water circuit checks Check the leak tightness of the circuit If the equipment does not operate normally during main Service C tenance operations refer to the chapter on diagnostics and Carry out the operations listed under Service B breakdowns of the 61WG 30WG 30WGA Pro Dialog Controls manual e IMPORTANT Before each equipment maintenance operation please ensure that e the unit is in the OFF position e itis impossible for the unit to restart automatically during maintenance 20 2 Description of the maintenance operations The equipment is supplied with polyolester oil POE Use only Carrier approved oil On request Carrier can carry out an oil analysis of your installation Service A Full load operating test Verify the following values e compressor high pressure side discharge pressure e compressor low pressure side suction pressure e charge visible in the sight glass e temperature difference between the heat exchanger water entering and leaving temperature Refrigerant circuit Check the leak tightness of the circuit and ensure that there is no piping damage Carry out an oil cont
73. ed temperature difference at the minimum leaving water temperature Units without hydronic module Minimum flow rate for a maximum permitted temperature difference at the minimum leaving water temperature 5 10 3 Standard 30WG 30WGA 30WG Evaporator water flow rate l s 30WGA Minimum Minimum Maximum Maximum Low High Low High pressure pressure pressure pressure 020 1 0 0 9 0 5 3 1 3 6 3 8 025 1 0 1 0 0 5 3 3 3 8 4 1 030 1 0 1 0 0 5 3 3 3 8 4 1 035 11 11 0 6 3 6 4 2 4 7 040 11 1 1 0 6 3 8 4 4 5 045 1 2 1 1 0 8 4 0 4 6 5 4 050 1 6 1 4 0 8 5 4 78 9 2 060 1 5 1 6 1 0 6 1 8 0 9 9 070 1 6 1 5 1 1 6 2 8 1 10 3 080 1 6 1 5 1 3 6 3 8 3 10 9 090 2 0 1 6 1 5 7 8 8 7 12 5 Units with hydronic module Flow rate for a maximum permitted temperature difference at the minimum leaving water temperature Units without hydronic module Flow rate for a maximum permitted temperature difference at the minimum leaving water temperature Units with hydronic module Maximum flow rate for an available pressure of 20 kPa unit with low pressure hydronic module or 50 kPa unit with high pressure hydronic module Units without hydronic module Maximum flow rate for a pressure drop of 100 kPa in the plate heat exchanger 30WG Condenser water flow rate I s Minimum Maximum Maximum Low pressure Low pressure High pressure 020 0 3 3 1 3 5 3 8 025 0 3 3 3 3 8 4 1 030 0 3 3 3 3 8 4 1 035 0 4 3 5 4 1 4 7 040 0 4 3
74. er connections Victaulic Inlet outlet in 1 5 1 5 1 6 1 5 16 1 5 2 2 2 2 2 Max water side operating pressure without kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 hydronic module Condenser Plate heat exchanger Net water volume l 3 3 3 6 3 6 4 2 4 6 5 0 8 4 9 2 9 6 10 4 12 5 Water connections Victaulic Inlet outlet in 1 5 1 5 1 5 1 5 1 5 1 5 2 2 2 2 2 Max water side operating pressure without kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 hydronic module oo 20 Weight shown is a guideline only To find out the unit refrigerant charge please refer to the unit nameplate In accordance with ISO 9614 1 measured in a free field The sound levels only apply to units without options 4 3 Physical data 30WGA 30WGA 020 025 030 035 040 045 050 060 070 080 090 Operating weight kg 164 171 171 177 180 185 321 324 332 339 354 Sound levels Sound power level 10 W dB A 67 0 68 5 69 0 69 3 70 0 70 1 71 5 72 0 72 0 73 0 73 4 Compressors Hermetic scroll 48 3 r s Quantity 1 1 1 1 1 1 2 2 2 2 2 Number of capacity steps 1 1 1 1 1 1 2 2 2 2 2 Minimum capacity 100 100 100 100 100 100 50 50 50 50 50 Refrigerant R 410A Oil 160SZ Charge per compressor 3 3 3 3 3 3 3 3 3 3 6 3 3 3 3 3 3 3 3 3 6 Control Pro Dialog Evaporator Direct expansion plate heat exchanger Water volume 3 3 3 6 3 6 4 2 4 6 5 10 8 4 9 2 9 6 10 4 12 5 Water connections Victaulic Inlet outlet in 1 5 15 1 5 ALD 1 5 1
75. escribed in standard NF E29 795 Any refrigerant transfer and recovery operations must be carried out using a transfer unit 3 8 SAE connectors on the liquid suction and discharge lines are available for all units for connection to the transfer station The units must never be modified to add refrigerant and oil charging removal and purging devices All these devices are provided with the units Please refer to the certified dimensional drawings for the units Do not re use disposable non returnable cylinders or attempt to refill them It is dangerous and illegal When cylinders are empty evacuate the remaining gas pressure and move the cylinders to a place designated for their recovery Do not incinerate Do not attempt to remove refrigerant circuit components or fittings while the machine is under pressure or while it is running Be sure pressure is at 0 kPa and that the unit has been shut down and de energised before removing components or opening a circuit If the refrigerant circuit is open to carry out a repair all circuit openings must be plugged if the repair takes longer than 30 minutes This prevents humidity from contaminating the circuit especially the oil If the work is expected to take longer charge the circuit with nitrogen Do not attempt to repair or recondition any safety devices when corrosion or build up of foreign material rust dirt scale etc is found within the valve body or mechanism If necessary
76. esonssesssecesncnsesecssesesnsssesesesnsosssesesccusnsssscecssnsosesesscseusesssssscsensosssssesesecesosecsceensosesers 25 5 1 Operating limits OLWG iere a RE EE A ENEE A RAAE EEA dani dn evimiato AEE 25 5 2 Operating rante OLWG upei oioi iee A E E E a E a aA EESE 25 5 3 Operatime imits 30W seneti ee eriin iei R EA E EEEE AEE E EE E EETA 25 5 4 Operating range 30W Gone dcisieccscsesebiessstecsvenssticsvessssbcosens a a n a iaa aa ea 25 5 9 Operating limits 3J0WGA vacinei ianiai iiei AATE EE EEA ES E EEE E K EEEE EAEE Eas 26 5 0 Operating range 30W GA ricente n a a n a iaa e 26 5 7 Minimum Chilled water WOW ss sccscsesessessssescseststecsvessssbeviescctarsuodestscecdcevsssensubedsevsndeaecenasnshivnsdedot EES ET K EEEE Aa EE Eas 26 5 8 Maximum Chilled water HOW senienas n a ia a ai ea 26 D D Variable HOW isssiireisrcosieo iieii eie oe a EE EE AEAT tess EEE EEEE EEA ESS E EE Er K EEEE AEE AEE Ea 26 5 10 Water HOW Tate wixcsccsnsseces tenannn a a a a n a aa iai ea 26 5 11 Mami Ut water volim n esee ioi iiai e AEE EEEE A RES E RE E E EE Ea E Eaa 27 5 12 Maximum water loop volume evaporator and condenser Side csseseseseseseseeetescecsesesescscacacscsesescaeaescseseaeaeaeseseeees 27 5 13 EXp nsion TANK oiscscscusseavetecsseccsedeses costs Sedesenss binsweseaticocences sieve seuss snust sucveuasubusiavssduuevenadussesaedetosedeveausns doves aa a aaa E 27 5 14 Protection against cavitation Option 116 oo eceesseseeetssseseseseceec
77. ety Damage limitation accessory accessory in case of an external fire Refrigerant side High pressure switch x External relief valve x Rupture disk x Fuse plug x Heat transfer fluid side External relief valve x x Classified for protection in normal service situations Classified for protection in abnormal service situations The instantaneous over pressure limited to 10 of the operating pressure does not apply to this abnormal service situation The control pressure can be higher than the service pressure In this case either the design temperature or the high pressure switch ensures that the service pressure is not exceeded in normal service situations The classification of these safety valves must be made by the personnel that completes the whole hydronic installation k kkk Do not remove these valves and fuses even if the fire risk is under control for a particular installation There is no guarantee that the accessories are re installed if the instal lation is changed or for transport with a gas charge All factory installed safety valves are lead sealed to prevent any calibration change If the safety valves are installed on a reversing valve change over this is equipped with a safety valve on each of the two outlets Only one of the two safety valves is in operation the other one is isolated Never leave the reversing valve in the intermediate position i e with both ways open
78. ger Check e thatthe insulating foam has not become detached or damaged during work on the units e that the entering and leaving water temperature sensors are well connected e the cleanliness on the water heat exchanger side no signs of leaks e that the periodic inspections required by local regu lations have been carried out 19 14 Corrosion check All metallic parts of the unit chassis casing panels control boxes heat exchangers etc are protected against corrosion by a coating of powder or liquid paint To prevent the risk of blistering corrosion that can appear when moisture penetrates under the protective coatings it is necessary to carry out periodic checks of the coating paint condition 51 52 20 AQUASNAP MAINTENANCE PROGRAM All maintenance operations must be carried out by technicians who have been trained on Carrier products observing all Carrier quality and safety standards 20 1 Maintenance schedule Regular maintenance is indispensable to optimise equip Electrical checks Check the tightening of the electric connections contactors disconnect switch and transformer Check the phase direction upstream of the unit and in the customer s electrical data table Check the status of the contactors and fuses Carry out a quick test refer to the 61 WG 30WG 30WGA Pro Dialog Controls manual ment operating life and reliability Maintenance operations Mechanical checks must be carri
79. h stresses 10 Checks before system start up Before the start up of the refrigeration system the complete installation including the refrigeration system must be verified against the installation drawings dimensional drawings system piping and instrumentation diagrams and the wiring diagrams For these checks national regulations must be followed If the national regulation does not specify any details refer to standard EN 378 as follows External visual installation checks e Compare the complete installation with the refrigera tion system and power circuit diagrams e Check that all components comply with the design specifications e Check that all protection documents and equipment provided by the manufacturer dimensional drawings P amp ID declarations etc to comply with the regulations are present e Verify that the environmental safety and protection and devices and arrangements provided by the manufacturer to comply with the regulations are in place e Verify that all documents for pressure containers certifi cates name plates files instruction manuals provided by the manufacturer to comply with the regulations 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 to the environment
80. imise discharge to the atmosphere refrigerants and lubricating oil must be transferred using methods which reduce leaks and losses to a minimum e Leaks must be repaired immediately e Ifthe residual pressure is too low to make the transfer alone a purpose built refrigerant recovery unit must be used e Compressor lubricating oil contains refrigerant Any oil drained from a system during maintenance must therefore be handled and stored accordingly e Refrigerant under pressure must never be discharged to the atmosphere 49 Before opening a refrigerant circuit purge the circuit and consult the pressure gauges Change the refrigerant after an equipment failure following a procedure such as the one described in NF E29 795 or carry out a refrigerant analysis in a specialist laboratory If the refrigerant circuit remains open for longer than a day after an intervention such as a component replacement the openings must be plugged and the circuit must be charged with nitrogen inertia principle The objective is to prevent penetration of atmospheric humidity and the resulting corrosion on the internal walls and on unpro tected steel surfaces 19 5 Leak detection Never use oxygen or dry air as this would cause a risk of fire or explosion e Carry out a leak detection test on the whole system using the following methods pressure test using dehydrated nitrogen or a mixture of nitrogen and refrigerant used for the system hel
81. ion pump operation with the Quick Test function 61WG 30WG e For units without hydronic module the water pump overheat protection devices must be connected in series with the pump contactor power supply 61 WG 30WG 30WGA Ensure that there are no refrigerant leaks Confirm that all pipe securing bands are tight Confirm the the electrical connections are secure Avoid a long common power wiring connection run inside the unit close to the control or signal wiring e Observe the clearances on each unit side to facilitate maintenance e The unit pipings are not 100 insulated whatever the options The insulation only protects against running condensation e To ensure that no condensate can run under the unit a condensate pan must be added under the unit that collects 100 of the condensate e If work is required in a control box or on the compressor wiring the phase order must be verified with a quick test refer to the 61 WG 30WG 30WGA Pro Dialog Control manual The compressors cannot support prolonged operation gt 30 seconds with reversed phases e Ensure that the last refrigerant charge made by the service team corresponds with the charge given on the name plate otherwise the operating ranges and the unit efficiency will be impaired The required tolerance for the charge is 2 e Do not interchange material with another Carrier unit The elements used for this unit are specific to this unit Use the specific Carrier c
82. ions during maintenance and repair operations Any technician attending the machine for any purpose must be fully qualified to work on refrigerant and electrical circuits WARNING Before doing any work on the machine ensure that the power is switched off If a refrigerant circuit is opened it must be evacuated recharged and tested for leaks Before any operation on a refrigerant circuit it is necessary to remove the complete refrigerant charge from the unit with a refrigerant charge recovery unit All removal and refrigerant draining operations must be carried out by a qualified technician and with the correct material for the unit Any inappropriate handling can lead to uncontrolled fluid or pressure leaks If an oil draining or recovery operation becomes necessary the fluid transfer must be made using mobile containers 19 2 General system maintenance e 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 e Regularly clean the exposed pipework to remove all dust and dirt This makes detection of water leaks easier and they can be repaired before more serious faults develop e Confirm that all screwed and bolted connections and joints are secure e Secure connections prevent leaks and vibration from developing e Check that all foam insulation joints on the heat exchanger piping are in good condition e Regula
83. iphon Examples Bottom of piping Riser pipe Counter siphon The siphon must be correctly sized to avoid trapping too much of the liquid oil refrig rant mixture It is advisable to include a slight slope 10 to 20 mm m in the refrigerant flow direction in the horizontal piping between the 30WGA unit and the condenser 8 4 Liquid line sizing The 30WGA compressors are supplied with an oil that is fully miscible with refrigerant R 410A in the liquid phase Consequently low refrigerant velocities in the liquid lines are not a problem Table 2 Liquid line piping shows the different pipe diame ters based on the unit size and the equivalent circuit length To determine the equivalent liquid line length the filter drier and the solenoid valve pressure drops must be taken into consideration Table 4 below shows the equivalent length for each unit based on the diameter used Table 4 Equivalent length m for filter drier solenoid valves moisture sight glass standard supply 30WGA 020 025 030 035 040 045 050 060 070 080 090 1 2 diameter 4 2 42 42 42 42 42 22 5 8 diameter 12 3 12 3 12 3 12 3 12 3 123 54 54 54 54 54 3 4 diameter 29 9 29 9 12 4 12 4 12 4 12 4 12 4 7 8 diameter 25 1 25 1 25 1 The admissible pressure drops in the liquid lines depend mainly on the subcooling level of the liquid refrigerant at the condenser outlet Pressure drops corresponding to 1 5
84. ircuit with regard to the design operating pressures Before any start up verify that the heat exchange fluid is compatible with the materials and the water circuit coating If additives or other fluids than those recommended 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 e No NH ammonium ions in the water they are very detrimental for copper This is one of the most important factors for the operating life of copper piping A content of several tenths of mg l will badly corrode the copper over time the plate heat exchangers used for these units have brazed copper joints e Ct Chloride ions are detrimental for copper with a risk of perforations by corrosion by puncture If possible keep below 10 mg l e SO sulphate ions can cause perforating corrosion if their content is above 30 mg l e No fluoride ions lt 0 1 mg l e No Fe and Fe ions with non negligible levels of dissolved oxygen must be present Dissolved iron lt 5 mg l with dissolved oxygen lt 5 mg l Dissolved silicon silicon is an acid element of water and can also lead to corrosion risks Content lt 1mg l e Water hardness gt 0 5 mmol l Values between 1 and 2 5 can be recommended This will facilitate scale deposit that can limit corrosion of copper Values that are too high can cause piping blockage over time
85. ium leak test e Connect the compressor to the system by opening the valves e The duration of the test must be sufficient to guaran tee the absence of very small leaks in the circuit e Use specific tools designed for leak detection e The low pressure side test pressure must not exceed pressure Ps indicated on the compressor and unit name plates e If there is a leak repair it and carry out the leak detec tion test again 19 6 Evacuation To evacuate the system observe the following recommen dations Connect the vacuum pump to the high HP and low pressure LP side for evacuation of the complete circuit All units are equipped with valves with 3 8 SAE connec tions on the suction discharge and liquid lines permitting the connection of large diameter flexible pipes limiting the pressure drops for the evacuation 1 The vacuum level achieved must be 0 67 mbar 500 um Hg 2 Wait 30 minutes 3 Ifthe pressure increases rapidly the system ist not leak tight Localise and repair the leaks Restart the evacuation procedure and repeat steps 1 2 etc 4 Ifthe pressure increeases slowly this indicates that moisture is present inside the system Break the vacuum with nitrogen and restart the evacuation procedure steps 1 2 etc 5 Repeat the evacuation procedure steps 1 2 a vacuum level of 0 67 mbar 500 um Hg must be achieved and maintained for four hours This vacuum level must be measured at one of the s
86. izontal cable conduit and No 41 closed conduit The calculation is based on PVC or XLPE insulated cables with copper or aluminium core A maximum ambient temperature of 40 C has been taken into account The given wire length limits the voltage drop to lt 5 IMPORTANT Before connection of the main power cables L1 L2 L3 on the terminal block it is imperative to check the correct order of the 3 phases before proceeding to the connection on then terminal block or the main disconnect isolator switch 6 4 2 On site control wiring 6 4 1 Field control wiring IMPORTANT Field connection of interface circuits may lead to safety risks any control box modification must maintain equipment conformity with local regulations Precautions must be taken to prevent accidental electrical contact between circuits supplied by different sources e The routing selection and or conductor insulation characteristics must ensure dual electric insulation e Incase of accidental disconnection conductor fixing between different conductors and or in the control box prevents any contact between the conductor ends and an active energised part Refer to the 61WG 30WG 30WGA Pro Dialog Controls IOM and the certified wiring diagram supplied with the unit for the field control wiring of the following features Remote on off switch Remote heat cool switch Demand limit external switch 1 Remote dual set point Alarm report Pump control unit wi
87. led in areas where the temperature must be between 5 C minimum and 40 C maximum The temperature around the compressors must not exceed 50 C during unit shutdown cycles Shock absorbers are installed under the compressor feet 17 2 Lubricant The compressors have the following factory lubricant charge polyolester oil reference POE 160SZ Contact Carrier to order the oil This lubricant must not be mixed with other lubricant types Before start up and after normal unit operation check that the oil level is visible If an additional oil quantity is required to compensate the initial low level in the compressors top up the charge using only the permitted lubricant shown on the compressor name plate polyolester oil ref POE 160SZ NOTE Only use oil approved for these compressors Do not re use oil that has been exposed to the air ATTENTION R22 oils are not compatible with R410A oils and vice versa 17 3 Evaporators and water cooled condensers The evaporators and condensers are single circuit plate heat exchangers They are tested and stamped for a maximum operating pressure of 4870 kPa 2820 kPa on the refrigerant side and 1000 kPa on the water side For 61WG 30WG units the heat exchanger sizing for the whole range ensures a saturated evaporating temperature of 4 5 C and a condensing temperature of around 38 C with actual subcooling of around 4 K at the condenser leaving side based on nominal Eurovent con
88. ler entering and leaving water piping to the 30WG unit The Pro Dialog control of the 30WG includes algorithms to permit constant automatic optimisation of e drycooler fan stage operation e water flow rate variation in the loop between the condenser and the drycooler Parallel control of the fan stages up to 8 stages maximum and of the variable water flow rate of the loop permit year round system operation down to 10 C outside temperature without any additional control 14 2 Auxiliary electronic board AUX1 analogue and digital inputs and outputs to control the drycooler STATUS SIO O Q m Ta ol E es 5 m Zi jm fie Mola CH14 m lon OO T es OOJ P ogv s gt OO T og OOJ P 5 OO v 5 gt 09 J4 J5 deo Oe J2 J3 fs amp CO TIM CH GH GH GH GH GH G GH 22 i E E E 6 E 8 st Go SH 198 e Connector J2 Digital outputs CH 1 to 4 for fan stages 1 to 4 e Connector J3 Digital outputs CH 5 to 8 for fan stages 5 to 8 e Connectors J4 and J5 Analogue outputs 0 10 V dc not used on the drycoolers only used for fan speed variation of the air cooled condensers e Connector J6 Analogue inputs CH 11 and 12 for dry cooler leaving water and outside temperature sensors e Connector J9 Communication bus with NRCP master board of
89. lume change the inflation pressure to a pressure that is close to the static head of the system Fill the system with water purging the air to a pressure value that is 10 to 20 kPa higher than the pressure in the tank k eke 21 4 5 Electrical data 61WG 30WG 30WGA 61WG without hydronic module 020 025 030 035 040 045 050 060 070 080 090 Power circuit Nominal voltage V ph Hz 400 3 50 Voltage range V 360 440 Control circuit supply 24 V via internal transformer Maximum start up current draw Un Standard unit A 98 142 142 147 158 197 161 163 172 185 226 Unit with electronic starter option A 53 9 78 1 78 1 80 9 86 9 108 4 98 99 105 114 139 Unit power factor at maximum capacity 0 83 0 82 0 84 0 83 0 82 0 84 0 82 0 82 0 83 0 82 0 84 Maximum operating power input kW 9 7 11 4 12 8 14 7 16 6 18 7 22 8 25 6 29 4 33 2 37 4 Nominal unit operating current draw A 12 9 15 8 16 8 19 2 20 7 24 6 31 6 33 6 38 4 41 4 49 2 Maximum operating current draw Un A 16 1 19 6 21 1 24 4 26 7 30 9 39 2 42 2 48 8 53 4 61 8 Maximum operating current draw Un 10 t A 17 8 21 6 23 2 26 9 29 4 34 0 43 2 46 4 53 8 58 8 68 0 Customer side unit power reserve Customer reserve at the 24 V control power circuit Short circuit stability and protection See table below Short circuit stability current Maximum instantaneous start up current at operating limit values maximum operating current of the smallest compressor s
90. n to ensure that any leaks are obvious The calibration of a valve that has leaked is generally lower than its original calibration The new calibration may affect the operating range To avoid nuisance tripping or leaks replace or re calibrate the valve Operating checks IMPORTANT INFORMATION REGARDING THE REFRIGERANT USED e This product contains fluorinated greenhouse gas covered by the Kyoto protocol Refrigerant type R 410A Global Warming Potential GWP 1975 ATTENTION e Attach the label supplied that shows the refrigerant used to the side used for topping up and or recovery e On the label clearly indicate the topped up refrigerant quantity in indelible ink e Prevent the release of fluorinated gas from the unit Ensure that fluorinated gas is never released to the atmosphere during installation maintenance or disposal If a leak of fluorinated gas is detected stop the leak and repair it as quickly as possible e Only a qualified service technician is allowed to access this product and to correct the fault e Any handling of fluorinated gas contained in this product e g moving the product or topping up the gas must comply with EC regulation no 842 2006 about certain fluorinated greenhouse gases and any other applicable local legislation e Contact your local dealer if you have any questions e Periodic inspections for refrigerant leaks may be required depending on European or local legislation Please contact yo
91. nalogue output of the Pro Dialog control For a water flow rate that corresponds to a maximum water side temperature difference of 5 K 5 2 Operating range 61WG 9 g 654 prersateceeotasenesece 1 re 60 4 S 55 E 50 Option 272 5 45 4 Standard S 44 2 34 gt 1 g 30 25 i 2 5 204 fss o 8 10 12 14 16 18 20 8 6 4 2 0 2 4 6 Evaporator leaving water temperature C 61WG standard unit 61WG unit with option 272 brine to water Note Do not exceed the maximum operating temperature A frost protection solution must be used For applications with a condenser entering temperature below 15 C the use of a three way valve is recommended This three way valve can be controlled by the 0 10 V analogue output of the Pro Dialog control For a water flow rate that corresponds to a maximum water side temperature difference of 5 K 30WG drycooler Minimum Maximum Evaporator Entering water temperature at start up C 75 27 Leaving water temperature during operation C g 20 Entering leaving water temperature difference K 25 7 Condenser without hydronic kit Entering air temperature at start up during C 10 15 40 45 operation Condenser with option 270J kit with variable speed pump Entering air temperature at start up during C 10F 40 45 operation For entering water temperatures below 7 5 C at start
92. nd the shafts seizing up especially during periods with a low cooling demand when the outside temperature is low Switching is often specified by the drycooler manufacturers to ensure a long operating life of fan motors that are only used a little or not at all in these particular operating conditions 14 4 Fan stage assignment The minimum configuration of the number of fan stages is 2 for correct operation Depending on the drycooler capacity the number of fans can be between 2 and 8 They can be controlled by one fan or by linked pairs if necessary A drycooler with 4 or 6 fans installed in series for example along the length of the unit will result in a configuration of 4 or 6 fan stages Reciprocally a drycooler with 8 or 12 fans arranged in pairs along the length of the unit will also result in a configuration of 4 or 6 fan stages Configuration with 4 and 6 stages min 2 max 8 OOOOK a Fans linked in pairs 4 and 6 stage configuration min 2 max 8 oct 1 Paj a N 1 i L5 yh 6 n ney ti n gf ia a 1 Be es a ee A Pie OOOOK end A Entering and leaving water manifold side 1 to 6 fans 41 14 5 30WG units without evaporator and condenser pump three way valve configuration for low outside temperature application 30WG units can be supplied from the factory without evapo rator and condenser pump If year round low tempe
93. nection of two additional sensors 17 MAJOR SYSTEM COMPONENTS AND OPERATION DATA 17 1 Compressors 61WG 30WG 30WGA units use hermetic scroll compressors The only refrigerant permitted for these compressors is R 410A 30WGA split units operating with an air cooled condenser are supplied with the refrigerant circuit and consequently the compressor under nitrogen pressure of 100 kPa 1 bar The compressors are not certified for mobile applications or use in explosive environments For more information contact the Carrier service team for maintenance instructions IMPORTANT All compressor and system pressure tests must be carried out by qualified personnel taking the greatest care with potential dangers resulting from the pressures used and respecting the maximum operating pressure limit on the high and low pressure side shown on the unit and compressor name plates e Maximum operating pressure low pressure side 61WG 30WG 30WGA 2820 kPa 28 2 bar e Maximum operating pressure high pressure side 61WG 30WG 4870 kPa 48 7 bar e Maximum operating pressure high pressure side 30WGA 4170 kPa 41 7 bars These setpoint must be observed for 30WGA split units using an air cooled condenser when the installer checks the complete system leak tightness Any modification or alteration such as soldering on the compressor shell may invalidate the right to use the equipment Units using these compressors are instal
94. nformation on checks during operation in annex C of standard EN 378 can be used External visual checks annex A and B of standard EN378 Corrosion checks annex D of standard EN 378 These controls must be carried out e After an intervention that is likely to affect the resis tance or a change in use or change of high pressure refrigerant or after a shut down of more than two years Components that do not comply must be changed Test pressures above the respective component design pressure must not be applied annex B and D e After repair or significant modifications or significant system or component extension annex B e After re installation at another site annexes A B and D e After repair following a refrigerant leak annex D The frequency of refrigerant leak detection can vary from once per year for systems with less than 1 leak rate per year to once a day for systems with a leak rate of 35 per year or more The frequency is in proportion with the leak rate NOTE High leak rates are not acceptable The necessary steps must be taken to eliminate any leak detected NOTE 2 Fixed refrigerant detectors are not leak detectors as they cannot locate the leak 19 1 Soldering and welding Component piping and connection soldering and welding operations must be carried out using the correct procedures and by qualified operators Pressurised containers must not be subjected to shocks nor to large temperature variat
95. ng literature follow the procedure in the Controls IOM Be sure that all service valves are open before beginning the compressor test section To start the unit 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 EW T xssscvesesvcsssseatvsctosscesviesek Seeks A RENEA ATIA Ambient TEM PSTALUTE c c ssess sai sseds ensue sesss cnvwavecsavetecdbesensesasiees Evaporator LW sitcisise criticisms Seals iaetiees Condenser EW Torrine N Condenser DWT ise sesesss ccvetsex er aaneen EE A A E SUCTION press rte CITCUIE Assistir siesd eedi SeSi S ction pressure CIFCUIE Bt igsisiys eres isssrsss r eer eestis asserit Discharge pressure CICUIt A sescesiosiscsseiniann ia Discharge pressure CICUIt B oo eeeeeeceeeseneeseneeseeeeeeeeeeeeeens Suction temperature CirCUit A sssr ee ann ii Suction temperature Circuit B z ssssssissssisssssssssersi ssie Discharge temperature CITCUIt Ao eee eecteeecseeecneeeeeeeeeeeseseees Discharge temperature circuit B oe ee eeeeeeeeteceeeeeeeeeeees Liquid line temperature circuit Av cece eeeseeecseeeeneeeeneeseeeees Liquid line temperature circuit B o
96. nit and hydronic module Victaulic screen filter Expansion tank Safety valve Water pump Air vent Water drain valve 7 8 Entering leaving pressure sensor 9 10Entering leaving temperature probe 12 Flow switch 61WG option 272 sizes 020 045 only 13 Compressor 14 Evaporator 15 Condenser 16 Expansion device oahwon NOTE Units without hydronic module include a flow switch 008 34 9 3 Frost protection The units are designed to be installed under cover at outside temperatures between 5 C and 40 C Therefore they do not include anti freeze protection as standard If the water piping is in an area where the ambient tempera ture can fall below 0 C it is recommended to install a trace heater on the piping and to add an antifreeze solution to protect the unit and the water piping to a temperature of 10 K below the lowest temperature likely to be reached at the installation site Use only antifreeze solutions approved for heat exchanger duty If the system is not protected by an antifreeze solution and will not be used during the freezing weather conditions draining of the cooler and outdoor piping is mandatory Damage due to freezing is not covered by the warranty IMPORTANT Depending on the climatic conditions in your area you must e Add ethylene glycol with an adequate concentration to protect the installation up to a temperature of 10 K below the lowest temperature likely to occur at the installati
97. nst solid particles with a size exceeding 1 2 mm Before the unit start up it is important to turn the evaporator and condenser pump to decontaminate the water loops of any solid pollution A specific pump start up function in the Quick Test menu is available for this task 17 13 Connection sleeves Position of the water connection sleeves in the unit 17 14 Option 272 High temperature water production with glycol solution ATTENTION The temperature sensor positioned in the discharge for option 272 is specific to this unit and must not be interchanged with another temperature sensor For replacement please contact the Carrier service team 17 15 Outside air temperature sensor 30WGA units require information about the outside air temperature This is needed for correct system operation EXV fans condensing temperature setpoint In units without control of the remote condenser standard the sensor 25 m is supplied with the control box of the 30WGA and must be installed near the air cooled condenser In units with control of the remote condenser option 154 the sensor is supplied with the option and must be installed near the air cooled condenser The position of the temperature sensor must be chosen with great care and must be representative of the outside tempera ture limit any other source that could have a negative influence on the control gusts of wind other heat sources such as sun radiation and
98. nterface for remote installation Remote control of the unit and its operating 30WG 020 090 parameters 61WG 020 090 30WGA 020 090 Filter drier with replaceable solid core 277 Filter the fine particles and eliminates humidity Maintains the refrigerated circuit without 30WGA 020 090 humidity Accessories Advantages Use OOPPG000488000 Heating System Manager type A It controls one heat emitter type with an auxiliary electric heater or boiler Additional control box not supplied with the unit to be installed remotely Heating system control facilitated 61WG 020 090 O0OPPG000488100 Heating System Manager type B It controls two heat emitter types or independent zones and domestic hot water production with an auxiliary electric heater or boiler Additional control box not supplied with the unit to be installed remotely Heating system control facilitated 61WG 020 090 0OPPG000488200 Heating System Manager type C It controls two heat emitter types or independent zones and domestic hot water production with a district heating network as auxiliary source Additional control box not supplied with the unit to be installed remotely Heating system control facilitated 61WG 020 090 48 19 MAINTENANCE During the unit operating life the service checks and tests must be carried out in accordance with applicable national regulations If there are no similar criteria in local regulations the i
99. nts for electric motors Item number imposed by regulation 640 2009 annex 12b Description given by regulation 640 2009 annex 12b To obtain the maximum power input for a unit with hydronic module add the maximum unit power input from the electrical data table to the pump power input t To obtain the maximum unit operating current draw for a unit with hydronic module add the maximum unit current draw from the electrical data table to the pump current draw tt Above 1000 m a degradation of 3 for each 500 m should be taken into consideration 23 4 8 Compressor usage and electrical data table Compressor Reference INom IMax IMax LRA LRA 61WG Un Un 10 020 025 030 035 040 045 050 060 070 080 090 SH090 00PSG001482000 10 5 16 1 178 98 53 9 1 SH105 00PSG001482100 13 2 196 216 142 78 1 1 2 SH120 00PSG001482200 13 8 211 23 2 142 78 1 1 2 SH140 00PSG001482300 15 6 24 4 26 9 147 80 9 1 2 SH161 O0OPSG001482400 16 2 26 7 29 4 158 86 9 1 2 SH184 00PSG001482500 20 2 30 9 34 0 197 108 4 1 2 Compressor Reference INom IMax IMax LRA LRA 30WG Un Un 10 020 025 030 035 040 045 050 060 070 080 090 WSH090 00PSG001549100 10 6 15 6 17 2 98 53 9 1 WSH105 00PSG001549200 12 9 18 7 20 6 142 78 1 1 2 WSH120 00PSG001549300 13 3 19 8 218 142 78 1 1 2 WSH140 00PSG001549400_ 15 2 23 2 25 6 147 80 9 1 2 WSH161 00PSG001549500 16 5 25 4 28 0 158 86 9 1 2 WSH184 00PSG001
100. o obtain a highter temperature difference with a lower evaporator flow rate 5 9 Variable flow A pump with variable flow can be used in these units The units maintain a constant leaving water temperature under all flow conditions For this to happen the minimum flow rate must be higher than the minimum flow given in the table of permissible flow rates and must not vary by more than 10 per minute If the flow rate changes more rapidly the system should contain a minimum of 6 5 litres of water per kW instead of the values below 26 5 10 Water flow rates 5 10 1 Standard 61WG 61WG Evaporator water flow rate I s Minimum Minimum Maximum Maximum Low High Low High pressure pressure pressure pressure 020 1 0 0 9 0 5 3 1 3 6 3 8 025 1 0 1 0 0 5 3 3 3 8 4 1 030 1 0 1 0 0 5 3 3 3 8 4 1 035 1 1 1 1 0 6 3 6 4 2 4 7 040 1 2 11 0 6 3 8 4 4 5 0 045 1 2 1 1 0 8 4 0 4 6 5 4 050 1 6 1 4 0 8 5 4 7 8 9 2 060 1 5 1 6 1 0 6 1 8 0 9 9 070 1 6 1 5 11 6 2 8 1 10 3 080 1 6 1 5 1 3 6 3 8 3 10 9 090 2 0 1 6 15 7 8 8 7 12 5 Units with hydronic module Flow rate for a maximum permitted temperature difference at the minimum leaving water temperature Units without hydronic module Flow rate for a maximum permitted temperature difference at the minimum leaving water temperature Units with hydronic module Maximum flow rate for an available pressure of 20 kPa unit with low pressure hydronic module or 50 kPa
101. oe 32 8 1 Generalconsiderations and Pipe SIZE LMMITS soissiscscseissensis tsveansgsentesssdonsdissonsnsvoosenvsl cos vavepees uactsys nsbsevsoasvebdendbontosSestesseectedssoasve 32 B 2 c PUPS SIZING TN cance NA AEN ANN E exndslondse use of tn ON NAE A us vnede epee NA ON A 32 834 Discharge Pipe SIZE oea AR sas vases EEA E a E exis tases tabas Tasdea A te aap gay toes Ree ALE eee 32 84 Li Gun WMS SZ Ges ocsssscscsoes sassasncdeas terete As suasedhssescscesss cass SEDASA EAEE A E vessossdedsessgpcanee sess EEE E E EARE 33 9 WATER CONNECTION ccscssccsssssssscscsssessscssesessscesesssssscsesssesscsssesessseesesscssscsesssesssssseseseseesosessscesesssessasosssesesessesossscenessseses 33 9 1 Operating PLECAULIONS mosii i iinei earar ia iair anir Eara E S i ai at 33 9 2 Water Connectors anioien ai custedusueudsnnecsovensuhess a a a a eaaa aeeai 34 OS S BOSE POU GO er re E E R EE E E EA AEA EA E EEE EEEE ORS 35 9 4 Flow switch units without hydronic Module cee eeeeeseseseseseecsesesescscscscsescsesescaesesesescacaesesescaeacaescseseseaeaescseseaeeeaeassesees 35 10 NOMINAL WATER FLOW CONTROL WITH FIXED SPEED PUMP ccccscssssscscscscscssssscscecssssscesnccecscssseecnsesees 35 MOM Generalne a ETE N E IEOS 35 10 2 Water flow control procedite occ sicsiscssascosvscsecscatvncasuscandecinandncosvncsavacesvebavecsavecaausevavecsncnivacescanchsvacdevachanbessvecsexscvevecaeeseyeesty 35 11 NOMINAL WATER FLOW CONTROL WITH VARIABLE SPEED PUM
102. omponent list when ordering any parts e Before start up ensure that the unit is level 1 5 mm m e Check the operation of the fans in the air cooled condensers ATTENTION Use of units in an open loop is forbidden 16 2 Actual start up IMPORTANT e Commissioning and start up of the unit must be supervised by a qualified refrigeration engineer e Start up and operating tests must be carried out with a thermal load applied and water circulating in the evaporator and condenser e All set point adjustments and control tests must be carried out before the unit is started up Ensure that all safety devices are operational especially that the high pressure switches are switched on and that the alarms are acknowledged For 30WGA units operating with a remote air cooled condenser the compressor oil level must be monitored during the system start up phase This is to ensure that the oil charge of the original compressors is sufficient for the system size and the piping configuration Once the oil level has stabilised it must not be lower than 1 4 of the oil sight glass level for the compressors that operate 16 3 Refrgerant charge adjustment IMPORTANT It is imperative to empty the nitrogen holding charge from the system and evacuate the system before beginning to charge refrigerant into the unit Never charge refrigerant into the low pressure side of the unit While charging refrigerant ensure that all fans of the outdoor unit a
103. on contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 11 3 3 61WG 30WG 020 045 unit with evaporator hydronic module option 116 Only for option 70F 625 Legend All dimensions are in mm Evaporator Condenser Safety valve Clearances required for maintenance see note Control box Water inlet Water outlet Power wiring connection Agg0000 3 5 61WG 30WG 020 045 unit with evaporator condenser hydronic modules options 116 270 142 237 NOTE Non contractual drawings Refer to the certified dimensional drawings available on request when designing an installation 3 6 61WG 30WG 020 045 unit with hydronic module and top connections options 116 274 or 270 274 or 116 270 274 1463 1500 1044 167 s6 900 in a 700 7 143 237 221 700 167 86 _ 700 3 7 61WG 30WG 020 045 stackable unit option 273 NOTE The water and electrical connections are identical to those of the standard unit q 1 lo g k roe 3 r C i S 600 Legend 900 700 All dimensions are in mm O Evaporator Q lt
104. on site e Ifthe unit is not used for an extended period it is recommended to drain it and as a safety precaution add ethylene glycol to the heat exchanger using the heat exchanger water entering purge valve connection e At the start of the next season refill the unit with water and add an inhibitor e For the installation of auxiliary equipment the installer must comply with basic regulations especially for minimum and maximum flow rates which must be between the values listed in the operating limit table chapter 5 Application data e To avoid corrosion by differential aeration the complete heat exchange circuit must be charged with nitrogen if it is drained for longer than one month If the heat exchange fluid does not comply with Carrier recommendations the circuit must immediately be filled with nitrogen 9 4 Flow switch units without hydronic module IMPORTANT On 61WG 30WG 30WGA units the unit water flow switch must be energised and the chilled water pump interlock must be connected Failure to follow this instruction will void the Carrier guarantee The flow switch is supplied installed on the evaporator leaving water pipe and preset at the factory to cut out when there is insufficient water flow Terminals 34 and 35 are provided for field installation of the chilled water pump interlock auxiliary contact for pump operation to be wired on site 10 NOMINAL WATER FLOW CONTROL WITH FIXED SPEED PUM
105. ow pressure curves in chapters 10 and 11 The nominal system flow rate must be adjusted with a manual control valve supplied by the customer see chapters 10 and 11 on the control of the nominal water flow rate The maximum permitted concentration of the glycol additives ethylene glycol or propylene glycol is 35 The maximum pump suction pressure is limited to 300 kPa 3 bar due to the valve installed on the entering water piping The use of any other glycol type additives must be approved by Carrier ATTENTION Use of hydronic kit in an open loop is forbidden 17 11 Variable speed pump This pump is factory installed It is a variable speed pump with available system pressure See the pump flow pressure curve The system flow rate is automatically adjusted via the frequency converter built into the pump based on the heat rejection load on the drycooler The maximum permitted concentration of the glycol additives is 35 The maximum pump suction pressure is limited to 300 kPa 3 bar due to the valve installed on the entering water piping The use of any other glycol type additives must be approved by Carrier ATTENTION Use of hydronic kit in an open loop is forbidden 17 12 Evaporator and condenser pump suction filter Filter positions in the unit All pumps are protected by a suction filter This is easily removable to recover solid particles It protects the pump and the plate heat exchanger agai
106. pe based on the air cooled condenser model used in the installation Please refer to the instructions in the Pro Dialog IOM for the 61WG 30WG 30WGA units to carry out the parameter setting of the air cooled condenser used in the installation e Use of speed variation on the lead fan s e Number of fixed speed fans Based on the parameter setting used the arrangement of the digital and corresponding analogue outputs controlling the fans will be activated by the control Pro Dialog controls the automatic switching of all fan stages based on operating time and number of start ups of the different stages This function prevents fan motors from only running a little or not at all and the shafts seizing up especially during periods with a low cooling demand when the outside temperature is low Switching is often specified by the condenser manufacturers to ensure a long operating life of the fan motors that are only used a little or not at all in these particular operating conditions 16 START UP 16 1 Preliminary checks e Never be tempted to start the unit without reading fully and understanding the operating instructions and without having carried out the following pre start checks e Check the chilled water circulation pump operation with the Quick Test function e Check the air handling units and all other equipment connected to the evaporator Refer to the manufacturer s instructions e Check the condensing loop water circulat
107. position products are hazardous 1 2 Equipment and components under pressure These products incorporate equipment or components under pressure manufactured by Carrier or other manufacturers We recommend that you consult your appropriate national trade association or the owner of the equipment or compo nents under pressure declaration re qualification retesting etc The characteristics of this equipment these components are given on the nameplate or in the required documenta tion supplied with the products Do not introduce significant static or dynamic pressure with regard to the operating pressures used during operation or for tests in the refrigerant circuit or in the heat exchange circuits 1 3 Maintenance safety considerations Engineers working on the electric or refrigeration compo nents must be authorised trained and fully qualified to do so e g electricians trained and qualified in accordance with IEC 60364 classification BA4 All refrigerant circuit repairs must be carried out by a trained person fully qualified to work on these units He must have been trained and be familiar with the equipment and the installation All welding operations must be carried out by qualified specialists Any manipulation opening or closing of a shut off valve must be carried out by a qualified and authorised engineer These procedures must be carried out with the unit shut down Any intervention on the refrigerant circuit
108. pressor outlet to the condenser inlet must be limited to avoid system performance losses increased compressor power input and decreased cooling capacity Increasing the pipe diameter permits limiting the pressure drops e The pressure drop in the liquid line linking the conden ser outlet to the expansion device must not result in a change of phase The estimate of these pressure drops must include those generated by possible accessories such as solenoid valves and filter driers e In applications with low outside temperature and with long pipes use of a check valve at the condenser outlet is recommended to overcome the poor supply of the expansion device during the start up phase Select a valve that is not pressure tight to avoid significant pressure rises of the liquid refrigerant that may be trapped between the solenoid valve tight and the check valve 8 2 Pipe sizing The following procedure can be used for pipe sizing 1 Measure the length in metres of the piping under consideration 2 Add 50 to take account of special characteristics Read the pipe size from tables 1 and 2 below 4 Calculate the equivalent lengths for parts included in the piping under consideration such as valves filters connections The equivalent lengths are normally available from the component supplier Add these lengths to the length calculated above Repeat steps 3 and 4 if necessary 6 See tables Discharge line piping and
109. r if shipment is incomplete immediately file a claim with the shipping company e Compare the name plate data with the order The name plate is attached in two places to the unit on one of the unit sides on the outside onthe control box door on the inside e The unit name plate must include the following information Version number Model number CE marking Serial number Year of manufacture and test date Refrigerant used and refrigerant class Refrigerant charge per circuit Containment fluid to be used PS Min max allowable pressure high and low pressure side TS Min max allowable temperature high and low pressure side Pressure switch cut out pressure Unit leak test pressure Voltage frequency number of phases Maximum current drawn Maximum power input Unit net weight e Confirm that the options ordered for on site installation have been supplied are complete and undamaged e Donot keep the 61WG 30WG 30WGA units outside where they are exposed to the weather as the sensitive control mechanism and the electronic modules may be damaged The unit must be checked periodically during its whole operating life to ensure that no shocks handling accessories tools etc have damaged it If necessary repair or replace the damaged parts see chapter 15 Maintenance The machine must be installed in a place that is not accessible to the public or protected against access by
110. rature operation is planned the unit will be installed with a three way valve that is not supplied with the unit In this case Pro Dialog should be configured for three way valve system control from an analogue 0 10 volt output on the Carrier NRCP type master board An adequate condensing temperature will be maintained with constant condenser flow rate This configuration permits year round system operation down to 20 C outside temperature Control and changeover of the fan stages described in chapter Configuration of the number of fan stages and automatic changeover of the fan stages is identical in this case 14 6 Drycooler installation on 30WG units For the drycooler installation follow professional guidelines e Water pipe sizing e Maximum piping and shut off valve pressure drops based on the available pressure of the 30WG pumps e Maximum drycooler elevation in relation to the unit safety valve at 3 bar on the 30WG water circuit e Fan stage control see Fan stage control e Good positioning of the outside air temperature and drycooler leaving water temperature sensors 15 30WGA UNIT OPERATION WITH A REMOTE AIR COOLED CONDENSER OPTION 154 15 1 Operating principle 30WGA units have been specially designed to optimise the operation of split installations using air cooled condensers as the chiller heat rejection system The installation of an operational system is limited to the connection of the
111. rature control and distribution The control box can supply all auxiliary devices such as the circulating pumps or the mixing or switching valves The heat pump is controlled by a CCN bus and the control box includes an NRCP2 BASE board a Pro Dialog interface as well as all required sensors HSM control box HSM control box dimensions 559 20 5 400 416 40 Installation safety notes e The hydronic installation must be carried out by qualified personnel in accordance with applicable laws and following standard accepted practices e The hydronic installation must be regularly serviced e An incorrect hydronic installation that does not comply with the safety electrical and thermal standards as well as lacking poor maintenance can lead to excessive pressures and cause piping breaks 170 442 382 Legend All dimensions are in mm 1 Clearance required to open the door and for customer connection 14 30WG UNIT OPERATION WITH A DRYCOOLER OPTION 154 14 1 Operating principle 30WG units have been specially designed to optimise the operation of systems using drycoolers as heat rejection system With a variable speed condenser water pump integrated into the 30WG the complexity of traditional systems using a three way valve has been reduced The installation of an operational system is limited on the condensing water loop side to connecting the drycoo
112. re operating With all fans operating add refrigerant until the subcooling upstream of the expansion device is between 4 and 8 K To achieve this Measure the refrigerant pressure at the level of the service valve in the liquid line of the 30WGA unit measure the liquid line temperature as close as possible to the service valve Add charge until the refrigerant passing through the sight glass is clear the refrigerant is now only liquid Then complete the charge until the actual subcooling required is between 4 et 8 K based on the liquid line pressure drops filter drier solenoid valve special components and possible liquid head The actual subcooling is equal to the saturated temperature at the bubble point minus the liquid line temperature measured If the actual subcooling value is higher than 8 K unit outlet an excess charge is possible This excess charge translates to an excessive condensing pressure and increases the compressor power input If adding charge does not result in a clear sight glass and the condensing pressure rises above the acceptable values ensure that the filter drier is not blocked and that one of the solenoid valves is not partially closed 43 16 4 Oil charge adjustment If a suction riser is used the oil charge must be adjusted Add the equivalent volume to half of the lower part of each siphon trap see figure below when the unit is empty Oil volume for a siphon trap 16 5
113. reliminary equipment check Is there any shipping damage s sisscsississisisneisirirssaiisa Kso whore 2 cave sachets asec ccctevasecedstccisex ssohiesexi R Will this damage prevent Umit starl Up merrnin a ER ROEE O TRA AER _ 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 L All fluid piping is connected properly All air has been vented from the system L Chilled water pump CWP is operating with the correct rotation CWP amperage Rated Actual Unit start up CWP starter has been properly interlocked with the unit _ Oil level is correct L_ All discharge and liquid valves are open _ Unit has been leak checked including fittings Locate repair and report any refrigerant leaks Check voltage imbalance AB AC urasan BOosicsreisiens Average Voltage sacconi see installation instructions Maximum deviation ssunosionicieiisss see installation instructions Voltage imbalance oo eeeeeeereeeeeeees see installation instructions Voltage imbal
114. ridges after carrying out a leak test of the circuit Clean the water filter Purge the circuit with air Verify the correct operation of the water flow switch Check the status of the thermal piping insulation Check the water flow by checking the heat exchanger pressure difference using a pressure gauge Check the concentration of the anti freeze protection solution ethylene glycol or polyethylene glycol Check the heat transfer fluid status or the water quality Check the steel pipe corrosion 21 START UP CKECKLIST FOR 61WG 30WG 30WGA UNITS USE FOR JOB FILE Preliminary information NOD TAT oeenn deed calutdacesvacta tune a a devel uate duceiaessttestesdauunudsaselGwasedevel cuetstvanl E cesses E Eo EEEE E A EA EIE cn IAEE E to vasvivedessisvaeastacks IAA T T locke Equipment MOGs sasaruanana a a N s Serial NO snusa a A R ARS Compressors de Model N Onenean a a E RRE 2 Model NO siscssessesevestessceezs sreescosesvacte aOR ERE Serial IN Oss ssssisascsssceasssasedsvsesseaceavscssnseascsstecsosseavenssaceev G R Serial NOs ss ssssssesivecsisecsessesssinscak ei EA EER aS IMO OL NOs A E RE Motor NOsiesresre iesen T i Evaporator Model N Oropa aira EEEE TO Manutactired Dy secrsreranapion irna AARO Seral N Osuni tassoresscesssvensvesesevesscnecsslens doses Ra D EEA N A E E E E Condensers Model Co rerreeerpeerere E EEE A EA Manutactured DY sccuiisiedines aarti ri ERO STAIN oninure e E A O E a DS cee Fase hasta a e R OE E OR a P
115. rly check that the vibration levels remain acceptable and close to those at the start of using the unit 19 3 Refrigerant undercharge If there is not enough refrigerant in the system this is indicated by gas bubbles in the moisture sight glass If the undercharge is significant large bubbles appear in the moisture sight glass and the suction pressure drops The compressor suction superheat is also high The machine must be recharged after the leak has been repaired Find the leak and completely drain the system with a refrigerant recovery unit Carry out the repair leak test and then recharge the system IMPORTANT After the leak has been repaired the circuit must be tested without exceeding the maximum low side operating pressure shown on the unit name plate The refrigerant must always be recharged in the liquid phase into the liquid line The refrigerant cylinder must always contain at least 10 of its initial charge For the refrigerant quantity per circuit refer to the data on the unit name plate During applications with option 272 brine to water and with positive evaporation bubbles will appear in the sight glass This is normal when the charge is optimised for improved efficiency in brine applications 19 4 Refrigerant guidelines Refrigeration installations must be inspected and maintained regularly and rigorously by specialists Their activities must be overseen and checked by properly trained people To min
116. s 19 3 20 30WGA 050 090 stackable unit Option 273 ces eesessssesesesesescsesesescscsesesesesescacaesesesescasasscseseacacaescscscacasasseseseacateeseseeees 19 4 PHYSICAL AND ELECTRICAL DATA 61WG 30WG csscscssssccssesssscessesssvsessssesssescssesessscesesssesessesesesesossesessseeseseseees 20 41 Physical data OL WG csccsssesecccsstscceceswssesesssvsnenslicsnwenssnns benccctesnesenss E E EET ETE E E eves EERTE 20 4 2 Physical data 30WG vsccssncssecssssisccesassssesessosectascsnsvesssnus coenesetesteseess tense E EREEREER E EE EREEREER 20 4 3 Physical data 30W GA nrerin griiiai iriarte EAR EEEE EEEE E EE EEEE R E 21 4 4 Physical data 61WG 30WG 30WGA units with hydronic module ssssessesessesessesessesesresessrnsssrntentntrenterenterererteneeeenesees 21 4 5 Electrical data 6SLWGBOWGBOW GA osists soitesisionsesa ce cunie coves sdvnsassds otsndatsbsenanssvinisdudansesasibevareceldbonsesatehdaedbsuvabasasensestassaite 22 4 6 Short circuit stability current TN system standard unit with main disconnect switch 0 0 0 0 ceeeeseeeeereeeeeeeteeee 22 4 T Electrical data Optional hydronic module cscs ssssciescsus ss scstves sends enade uansunseosedesdesesevestanse saveonsdedevsssetsty bes avedsvadessssbboensisoveteitaiys 23 4 8 Compressor usage and electrical data table s cisccsussesssses sontsenssvensesanseoasshssnsosevsshussones conovshesdusesssy ses Saksi ERSS E Saa 24 5 APPLICATION DATA cccscscscsssssesosescscssees
117. s not available at the system start up contact the technical service department responsible for the installation to get it These characteristics can be obtained from the technical literature using the unit performance tables or the Electronic Catalogue selection program for all conditions 10 2 Water flow control procedure As the total system pressure drop is not known exactly at the start up the water flow rate must be adjusted with the control valve to obtain the specific flow rate for this application Proceed as follows Open the valve fully Start up the pump using the forced start command refer to the controls manual and let the pump run for two conse cutive hours to clean the hydronic circuit of the system presence of solid contaminants Read the hydronic module pressure drop by taking the difference of the readings at the machine connected to the hydronic module inlet and outlet Compare this value after two hours of operation 35 Entering water pressure reading amp 0 i is F Leaving water pressure reading Q al O F ok oy D oO Open F Closed Water inlet Water outlet Pressure gauge If the pressure drop has increased this indicates that the screen filter must be removed and cleaned as the hydronic circuit contains solid particles In this case close the shutoff valves at the water inlet and outlet and remove the screen filter after emptying the h
118. sure for the tank is 3 bar 27 5 14 Protection against cavitation option 116 To ensure the durability of the pumps in the integrated hydronic modules the control algorithm of the 61 WG 30WG 30WGA units incorporates anti cavitation protection It is therefore necessary to ensure a minimum pump entering pressure of 60 kPa 0 6 bar during operation and at shut down A pressure below 60 kPa will prohibit unit start up or cause an alarm with the unit shutting down In order to obtain sufficient pressure it is recommended to pressurise the hydronic circuit between 100 kPa and 300 kPa 1 and 3 bar maximum on the suction side of the pump to clean the hydronic circuit before charging water to regularly clean the screen filter 5 15 Plate heat exchanger pressure drop includes internal piping Evaporator standard unit without hydronic module 61WG 30WG 30WGA 020 045 150 140 130 120 110 Pressure drop kPa oO 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 Water flow rate l s 61WG 30WG 30WGA 020 61WG 30WG 30WGA 025 to 61WG 30WG 30WGA 030 61WG 30WG 30WGA 035 61WG 30WG 30WGA 040 61WG 30WG 30WGA 045 ARON Condenser standard unit without hydronic module 61WG 30WG 020 045 150 DOODGA 140 130 120 110 100 90 80 70 60 50 40 30 20 10 0
119. tages eee 41 144 Pn stage as nME ben e a S A RE E A O E 41 14 5 30WG units without evaporator and condenser pump three way valve configuration for low outside temperature o a P A E E T E E A N A A S A E E T T teases 42 14 6 Drycooler installation on 30W G UMits sicsiieccssscssiccasscesscessececsvcassossssnsvsbsssosasssdocsssveosdse o cavdnsbedsensonsssbussa ossad sassdbebsdestosocsneves 42 15 30WGA UNIT OPERATION WITH A REMOTE AIR COOLED CONDENSER OPTION 154 sccsssssssees 42 Ls Me Operating Principle sssr aaraa EEE A E EEE EEEE E E EE A cists 42 2S A AMM OEE E E E T E E E E AE AE E E AA 42 15 3 Auxiliary electronic board AUX1 analogue and digital inputs and outputs to control the remote air cooled COMICS S CD sranie eer E N chsh fuse e E A tee EE A E E EEE E E EE E EE ERE 42 15 4 Configuration of the number of fan stages and fan type based on the air cooled condenser model used in the TS CAN TO n E T E E E E E E EE 42 16 START UP eseeseseeccscecesccceseseeseseesesecseoecseoecsoorosoorosooresooresoorecoereecereseseeeeeeeeeseoseseosesrorcsroresroreseososeososeorooeosoocosescoseecosesesseseoseseseosee 43 E a CHECKS E T EE E I A A E E S T 43 16 2 Actual statt UP ierererieris eriiic ieii E TETEK R E REEE E Ee EEATT EE E 43 16 3 Refreerant chargsadjustMent sviseceseisesscesssccccarenssazceaseseenseesnswsiesabssovenssnensnedevesbsesteresnvse aa io A EREET EE E iS a iie 43 16 4 Oil Charee AGIUSIMEM En casvsssssnsevcnc
120. tection See table below Short circuit stability current Maximum instantaneous start up current at operating limit values maximum operating current of the smallest compressor s locked rotor current or limited start up current of the largest compressor Maximum power input at the unit operating limits Values obtained at standardised Eurovent conditions evaporator entering leaving water temperature 12 C 7 C condenser entering leaving water temperature 30 C 35 C Maximum unit operating current at maximum unit power input and 400 V t Maximum unit operating current at maximum unit power input and 360 V 30WGA without hydronic module 020 025 030 035 040 045 050 060 070 080 090 Power circuit Nominal voltage V ph Hz 400 3 50 Voltage range V 360 440 Control circuit supply 24V via internal transformer Maximum start up current draw Un Standard unit A 98 142 142 147 158 197 161 163 172 185 228 Unit with electronic starter option A 53 9 78 1 78 1 80 9 86 9 108 4 96 8 97 9 104 1 112 3 137 4 Unit power factor at maximum capacity 0 83 0 82 0 84 0 83 0 82 0 84 0 82 0 82 0 83 0 82 0 84 Maximum operating power input kW 9 7 11 4 12 8 14 7 16 6 18 7 22 8 25 6 29 4 33 2 37 4 Nominal unit operating current draw A 11 4 13 8 14 7 16 5 18 1 21 2 27 6 29 4 33 0 36 2 42 4 Maximum operating current draw Un A 14 7 17 7 19 3 21 7 24 1 275 35 4 38 7 43 5 48 1 55 0 Maximum operating current draw Un 10 t A
121. the 30WG unit The electronic board specifically integrated in the control box of the drycooler and a communication bus connected to the microprocessor board of the 30WG is used for the overall system control The option supplied with the cooling unit must be installed in the drycooler control box Connect the unit to board AUX1 in the drycooler using a communication bus cable Pro Dialog optimises system operation to obtain the best efficiency with variation of the water flow rate and the number of fans required for any thermal load and outside temperature conditions The electronic board AUX1 integrated in the control box of the drycooler has analogue inputs for outside air tempe rature and drycooler leaving water temperature sensors as well as eight digital outputs permitting control of up to eight fan stages 14 3 Configuration of the number of fan stages and the automatic changeover of the fan stages Please refer to the instructions in the 61WG 30WG 30WGA Pro Dialog IOM for the configuration of the number of fan stages to be controlled It is enough to enter the number of fan stages of the drycooler in the Pro Dialog service menu The number of digital outputs controlling the fans are activated by the control Pro Dialog controls the automatic switching of all fan stages based on operating time and number of start ups of the different stages This function prevents fan motors from only running a little or not at all a
122. thout hydronic module Relief boiler or electric heater Valve control see description of options 153 and 154 in the 61 WG 30WG 30WGA Pro Dialog controls manual Selection of minimum and maximum wire sections for connection to 61WG units 61WG Max Calculation favourable case Suspended aerial lines Calculation unfavourable case Conductors in conduits or multi connectable standardised routing No 17 conductor cables in closed conduit standardised routing No 41 section PVC insulated cable PVC insulated cable if possible Section Section Max length for Cable type Section Max length for voltage Cable type voltage drop lt 5 drop lt 5 mm per phase mm per phase m mm per phase m 020 1x35 1x25 60 PVC Cu 1x4 100 PVC Cu 025 1x35 1x25 60 PVC Cu 1x4 100 PVC Cu 030 1x35 1x4 80 PVC Cu 1x6 120 PVC Cu 035 1x35 1x4 80 PVC Cu 1x6 120 PVC Cu 040 1x35 1x6 100 PVC Cu 1x10 150 PVC Cu 045 1x35 1x6 100 PVC Cu 1x10 150 PVC Cu 050 1x35 1x10 120 PVC Cu 1x 16 180 PVC Cu 060 1x35 1x10 120 PVC Cu 1x 16 180 PVC Cu 070 1x35 1x16 140 PVC Cu 1x25 205 PVC Cu 080 1x35 1x16 140 PVC Cu 1x25 205 PVC Cu 090 1x35 1x25 170 PVC Cu 1x35 225 PVC Cu Selection of minimum and maximum wire sections for connection to 30WG 30WGA units 30WG_ Max Calculation favourable case Suspended aerial lines Calculation unfavourable case Conductors in conduits or multi 30WGA connectable standardised routing No 17
123. tsntsesvessievcscuennssassesusveescuesebuosessisbeaveusnrsnsnessveutsnsessedavteseses AES AEE E ET A 44 16 5 Operation of two units in master slave mode option 58 eeceeeeseseeeseseseseseseeeecseaeseecscscatseseeceescasaeatecscecatanseecseesee 44 16 6 Parallel or serial connection of two 61WG 30WG 30WGA UNltS ee eee eee ceeeesesessteee cesses teceeseeeseeesesseneseesaae 44 17 MAJOR SYSTEM COMPONENTS AND OPERATION DATA cccccssssssscesssssssesesssessecesesessscesesecsscesessssscsoseseseces 44 1 1 COMPT ESS OTS oaoa nrn an a O NAE NEAT O UOOA EEEE E TEE NEETER 44 L722 UDI CAM onesie ie n EEE AEREE EE E E A A ET EE E eieiei 45 17 3 Evaporators and water cooled Condensers iiisscscecssveies sonsedecsscnsvesesvoesieboessesessanssoscocutene n a ai a 45 174 Electromcexpansion yal ve EXV reier e REE E E EA E E ET A E E 45 17 5 Refiperant asneira E EER E E A E EEE E AE EE K E ETE 45 17 6 High pressure switch and high pressure sensor escresenronuniorneminninnienn pennen eaan 46 17 7 High and low pressure side Safety Valves i cicccscsavssvouss sonsedecsscnsvesesvoesiebsesnavassavssevcocutene n a sdseotecd sdueutenssaunievesbeses 46 17 8 gt Moisture Indicato senesp a n a a cenevasbadodp scocudine des vedas uesntetivens segastsdestucuvensstiatent ovens 46 17 9 Filter Grier in The refrigerant CILCUME sicscscesessadviendsssaswsvouss nonan a des sedi eesutetavens seseoteabsdecuvenssesnaeeesbessu 46 17 10 FIXGO SPCCO PUMP seis csscc
124. ur local dealer for more information e During the life time of the system inspection and tests must be carried out in accordance with national regulations The information on operating inspections given in annex C of standard EN378 can be used if no similar criteria exist in the national regulations Protection device checks e I f no national regulations exist check the protection devices on site in accordance with standard EN378 once a year for the high pressure switches every five years for external safety valves e The detailed description of the high pressure switch test method is given in the service manual for the unit At least once a year thoroughly inspect the protection devices valves pressure switches If the machine operates in a corrosive environment inspect the 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 in charge in order to avoid material deterioration and injuries to people Faults and leaks must be repaired immediately The authorized technician must have the responsibility to repair the fault immediately After each repair of the unit check the operation of the protection devices and create a report of the parameter operation at 100 Comply with the regulations and recommendations in unit and HVAC installation safety standards such as EN 378 ISO
125. vesesn Voss sMotstesgscvesacauswielsadvosessdeudsatvene 9 3 DIMENSIONS CLEARANCE G ccsssssssscsscssessssssssesesssessesesssscssesessscssesosssessasssssessesesscesessesessscasevssssessesesesesessesessseevesossees 11 3 1 61 WG 30WG 020 045 stanid ard Units s assicies sessscnitacnvesisl n a ea sa vevueubudeds E a Ee ari aE er iiis 11 3 2 61WG 30WG 020 045 unit with top connections Option 274 os eseseseseeteeeeescesseseseseseacsesesescseasaeseseseneaeseesseeees 11 3 3 61WG 30WG 020 045 unit with evaporator hydronic module option 116 wees seeeeeeeteseseseseseseneneseseseeees 12 3 4 61WG 30WG 020 045 unit with condenser hydronic module Option 270 eeesessssseseeeseseceeetsseeseseseseneeseseseeees 12 3 5 61WG 30WG 020 045 unit with evaporator condenser hydronic modules options 116 270 eeeeeseseeeeeeeeee 12 3 6 61 WG 30WG 020 045 unit with hydronic module and top connections oe eee eee ee te ceeeeteeeeaesesseeteseesseteseeseetees 13 options 116 274 0r 270 274 oF 116 270 4274 unner ren nE o E EE dastl tote E E A e R 13 3 7 61WG 30WG 020 045 stackable unit Option 273 Jessnes seriei en a E E E a E E as 13 3 8 61 W G 30 W G 0502090 Stand ate Unterhose eaea Er E EE eree ETES NE NAE E eoe SPEA eSEE KEA E NEEESE EERS 14 3 9 61WG 30WG 050 090 unit with top connections option 274 ss sssessesssressserseresrtssserietrrtsstetierrestsnterrerrsstentetrerrerrnrerret 14 3 10 61 WG 30WG 050 090 unit with evaporator
126. vided with the unit 5 The factory installed disconnect switch es circuit breaker s is are of a type suitable for power interruption in accordance with EN 60947 6 The units are designed for simplified connection on TN s networks IEC 60364 For IT networks provide a local earth and consult competent local organisations to complete the electrical installation Units delivered with speed drive option116F 116J and 270F 270J are not compatible with IT network 7 Derived currents If protection by monitoring of derived currents is necessary to ensure the safety of the installation the control of the cut out value must take the presence of leak currents into consideration that result from the use of frequency converters in the unit A value of at least 150 mA is recommended to control differential protection devices on NOTE If particular aspects of an actual installation do not conform to the conditions described above or if there are other conditions which should be considered always contact your local Carrier representative The protection level of the control boxes required to conform to this class is IPX1B according to reference document IEC 60529 All 61 WG 30WG 30WGA units fulfil this protection condition Units equipped with front casing panel meet class IP23 If the casing panel has been removed access to energised components is protected to level IPXXB 24 5 APPLICATION DATA 5 1 Operating limits 61WG
127. voltage electromagnetic compatibility equipment under pressure etc check the declarations of conformity for these products 1 1 Installation safety considerations After the unit has been received when it is ready to be installed or reinstalled and before it is started up it must be inspected for damage Check that the refrigerant circuit s is are intact especially that no components or pipes have shifted e g following a shock If in doubt carry out a leak tightness check and verify with the manufacturer that the circuit integrity has not been impaired If damage is detected upon receipt immediately file a claim with the shipping company Do not remove the skid or the packaging until the unit is in its final position These units can be moved with a fork lift truck as long as the forks are positioned in the right place and direction on the unit The units can also be lifted with slings using only the designated lifting points marked on the unit These units are not designed to be lifted from above Use slings with the correct capacity and always follow the lifting instructions on the certified drawings supplied with the unit Safety is only guaranteed if these instructions are carefully followed If this is not the case there is a risk of material deterioration and injuries to personnel DO NOT COVER ANY PROTECTION DEVICES 30WGA are supplied without safety valve on the high pressure refrigerant circuit and
128. ydronic section of the unit Renew if necessary to ensure that the filter is not conta minated When the circuit is cleaned read the pressures at the unit entering water pressure leaving water pressure expressed in kPa to find out the plate heat exchanger pressure drop Compare the value obtained with the theoretical selection value If the pressure drop measured is higher than the value specified this means that the flow rate in the plate heat exchanger and thus in the system is too high The pump supplies an excessive flow rate based on the global pres sure drop of the application In this case close the control valve one turn and read the new pressure difference Proceed by successively closing the control valve until you obtain the specific pressure drop that corresponds to the nominal flow rate at the required unit operating point e Ifthe system has an excessive pressure drop in relation to the available static pressure provided by the pump the resulting water flow rate will de reduced and the difference between entering and leaving water tempe rature of the hydronic module will be increased To reduce the hydronic system pressure drops it is necessary e to reduce the individual pressure drops as much as possible bends level changes accessories etc e to use a correctly sized piping diameter e to avoid hydronic system extensions wherever possible 36 Example Unit with a given nominal flow rate of 4 8 I
129. ystem connections and not at the vacuum pump pressure gauge 50 ATTENTION Do not use a megohmmeter and do not place any stress on the compressor motor when the system has been evacuated There is a risk of internal short circuits between the motor windings Do not use additives for leak detection Do not use CFCs HCFCs as tracer fluids for leak detection 19 7 Recharging liquid refrigerant CAUTION The units are charged with liquid R 410A refrigerant With high pressure R 410A refrigerant the unit operating pressure is above 4000 kPa 40 bar the pressure at 35 C air temperature is 50 higher than for R 22 Special equipment must be used when working on the refrigerant circuit pressure gauge charge transfer etc All checks must be pressure tests and the appropriate pressure temperature ratio table must be used to determine the corresponding saturated temperatures saturated bubble point curve or saturated dew point curve Leak detection is especially important for units charged with refrigerant R 410A Depending on whether the leak occurs in the liquid or in the vapour phase the proportion of the different components in the remaining liquid is not the same NOTE Regularly carry out leak checks and immediately repair any leak found 19 8 Characteristics of R 410A Saturated temperatures C based on the relative pressure in kPa

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