30GX 082-358

30HXC 080-375
Screw Compressor Water-
Cooled Liquid Chillers and
Air-Cooled Liquid Chillers
Nominal cooling capacity 30HXC: 286-1300 kW
Nominal cooling capacity 30GX: 282-1203 kW

50 Hz

GLOBAL CHILLER

Installation, operation and maintenance instructions

 Contents

1 - INTRODUCTION...................................................................................................................................................................... 4
1.1 - Installation safety considerations............................................................................................................................................ 4
1.2 - Equipment and components under pressure......................................................................................................................... 4
1.3 - Maintenance safety considerations......................................................................................................................................... 4
1.4 - Repair safety considerations.................................................................................................................................................... 5
2 - Preliminary checks....................................................................................................................................................... 6
2.1 - Check equipment received....................................................................................................................................................... 6
2.2 - Moving and siting the unit........................................................................................................................................................ 7
3 - dimensions, clearances, weight distribution.......................................................................................... 8
3.1 - 30HXC 080-190.......................................................................................................................................................................... 8
3.2 - 30HXC 200-375.......................................................................................................................................................................... 9
3.3 - 30GX 082-182.......................................................................................................................................................................... 10
3.4 - 30GX 207-358.......................................................................................................................................................................... 11
3.5 - Multiple chiller installation.................................................................................................................................................... 12
4 - Physical and electrical data for 30HXC units....................................................................................... 13
4.1 - Physical data 30HXC.............................................................................................................................................................. 13
4.2 - Electrical data 30HXC............................................................................................................................................................ 13
4.3 - Electrical data, 30HXC compressors.................................................................................................................................... 14
4.4 - Electrical data for 30HXC units with high condensing temperatures (option 150/150A)............................................. 14
4.5 - Unit characteristics for 30HXC units with very low temperature option (option 6)...................................................... 15
5 - Physical and electrical data for units 30GX......................................................................................... 18
5.1 - Physical data 30GX................................................................................................................................................................. 18
5.2 - Electrical data 30GX............................................................................................................................................................... 18
5.3 - Electrical data, 30GX and 30HXC compressors, option 150 + 150A................................................................................ 19
6 - Application data............................................................................................................................................................ 20
6.1 - Unit operating range............................................................................................................................................................... 20
6.2 - Minimum chilled water flow.................................................................................................................................................. 20
6.3 - Maximum chilled water flow.................................................................................................................................................. 21
6.4 - Variable flow evaporator........................................................................................................................................................ 21
6.5 - System minimum water volume............................................................................................................................................ 21
6.6 - Cooler flow rate....................................................................................................................................................................... 21
6.7 - Condenser flow rate................................................................................................................................................................ 21
6.8 - Evaporator pressure drop curve............................................................................................................................................ 22
6.9 - Condenser pressure drop curve............................................................................................................................................. 22
7 - ELECTRICAL CONNECTION............................................................................................................................................. 23
7.1 - Electrical connections 30HXC units..................................................................................................................................... 23
7.2 - Electrical connections 30GX units........................................................................................................................................ 24
7.3 - Power supply............................................................................................................................................................................ 25
7.4 - Voltage phase imbalance........................................................................................................................................................ 25
7.5 - Recommended wire sections................................................................................................................................................. 27

The cover illustrations are for illustrative purposes only and are not part of any offer for sale or contract.


8 - WATER CONNECTIONS....................................................................................................................................................... 29
8.1 - Operating precautions............................................................................................................................................................ 29
8.2 - Water connections................................................................................................................................................................... 30
8.3 - Flow control............................................................................................................................................................................. 30
8.4 - Evaporator (and condenser for the 30HXC) water box bolt tightening.......................................................................... 30
8.5 - Frost protection....................................................................................................................................................................... 31
8.6 - Operation of two units in master/slave mode...................................................................................................................... 31
9 - Major system components and operation data.................................................................................... 32
9.1 - Geared twin screw compressor.............................................................................................................................................. 32
9.2 - Pressure vessels....................................................................................................................................................................... 32
9.3 - Electronic expansion device (EXV)..................................................................................................................................... 33
9.4 - Economizer.............................................................................................................................................................................. 33
9.5 - Oil pumps................................................................................................................................................................................. 33
9.6 - Motor cooling valves............................................................................................................................................................... 34
9.7 - Sensors...................................................................................................................................................................................... 34
10 - MAIN OPTIONS AND ACCESSORIES............................................................................................................................ 35
10.1 - Compressor suction valves (option 92).............................................................................................................................. 35
10.2 - Compressor and evaporator noise insulation (30GX - option 14A)............................................................................... 35
10.3 - Low-noise 30GX units equipped with acoustic panels (option 15)................................................................................. 35
10.4 - Evaporator frost protection (30GX - option 41A)............................................................................................................ 35
10.5 - Year-round operation of 30GX units (option 28).............................................................................................................. 35
10.6 - Soft Start for 3- and 4-compressor 30HXC and 30GX units (option 25)....................................................................... 35
10.7 - Electric protection level of the 30HXC control boxes to IP44C (option 20)................................................................ 36
10.8 - Tropicalised control box for 30HXC and 30GX units (option 22).................................................................................. 36
10.9 - Brine units for low-temperature evaporator leaving applications (option 5)................................................................ 36
10.10 - Disassembled 30HXC units (option 52)........................................................................................................................... 36
10.11 - Available fan pressure of 150 Pa for 30GX units (option 12)........................................................................................ 36
11 - Maintenance.................................................................................................................................................................... 36
11.1 - Maintenance instructions..................................................................................................................................................... 36
11.2 - Soldering and welding.......................................................................................................................................................... 36
11.3 - Refrigerant charging - adding charge................................................................................................................................. 36
11.4 - Indication of low charge on a 30HXC system................................................................................................................... 37
11.5 - Electrical maintenance......................................................................................................................................................... 37
11.6 - Pressure transducers............................................................................................................................................................. 38
11.7 - Oil charging - low oil recharging......................................................................................................................................... 38
11.8 - Integral oil filter change....................................................................................................................................................... 38
11.9 - Filter change-out schedule................................................................................................................................................... 38
11.10 - Filter change-out procedure............................................................................................................................................... 38
11.11 - Compressor replacement................................................................................................................................................... 38
11.12 - Corrosion control................................................................................................................................................................ 39
11.13 - Condenser coil..................................................................................................................................................................... 39
12 - start-up ckecklist for 30HXC/GX Liquid chillers (use for job file)..................................... 40


1 - INTRODUCTION In certain cases the relief valves are installed on isolating
valves. These valves are factory-supplied lead-sealed in the
Prior to the initial start-up of the 30HXC/GX units, the open position. This system permits isolation and removal
people involved in the on-site installation, start-up, operation of the relief valves for checking and replacing. The relief
and maintenance of this unit should be thoroughly familiar valves are designed and installed to ensure protection
with these instructions and the specific project data for the against overpressure caused by fire.
installation site.
All factory-installed relief valves are lead-sealed to prevent
The 30HXC/GX liquid chillers are designed to provide a any calibration change. If the relief valves are installed on
very high level of safety during installation, start-up, opera- a change-over manifold, this is equipped with a relief valve
tion and maintenance. They will provide safe and reliable on each of the two outlets. Only one of the two relief valves
service when operated within their application range. is in operation, the other one is isolated. Never leave the
change-over valve in the intermediate position, i.e. with both
This manual provides the necessary information to fami- ways open (locate the control element in the stop position).
liarize yourself with the control system before performing If a relief valve is removed for checking or replacement
start-up procedures. The procedures in this manual are please ensure that there is always an active relief valve on
arranged in the sequence required for machine installation, each of the change-over valves installed in the unit.
start-up, operation and maintenance.
The safety valves must be connected to discharge pipes.
Be sure you understand and follow the procedures and These pipes must be installed in a way that ensures that
safety precautions contained in the instructions supplied people and property are not exposed to refrigerant leaks.
with the machine, as well as those listed in this guide. These fluids may be diffused in the air, but far away from
any building air intake, or they must be discharged in a
To find out, if these products comply with European quantity that is appropriate for a suitably absorbing
directives (machine safety, low voltage, electromagnetic environment.
compatibility, equipment under pressure etc.) check the
declarations of conformity for these products. Periodic check of the relief valves: See paragraph ‘Mainte-
nance safety considerations’.
1.1 - Installation safety considerations
Provide a drain in the discharge circuit, close to each
After the unit has been received, when it is ready to be relief valve, to avoid an accumulation of condensate or
installed or reinstalled, and before it is started up, it must be rain water.
inspected for damage. Check that the refrigerant circuit(s)
is (are) intact, especially that no components or pipes have Ensure good ventilation, as accumulation of refrigerant in
shifted (e.g. following a shock). If in doubt, carry out a leak an enclosed space can displace oxygen and cause asphyxia-
tightness check and verify with the manufacturer that the tion or explosions.
circuit integrity has not been impaired. If damage is detected
upon receipt, immediately file a claim with the shipping Inhalation of high concentrations of vapour is harmful and
company. may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxy-
Do not remove the skid or the packaging until the unit is gen available for breathing. These products cause eye and
in its final position. These units can be moved with a fork skin irritation. Decomposition products are hazardous.
lift truck, as long as the forks are positioned in the right
place and direction on the unit. 1.2 - Equipment and components under pressure

The units can also be lifted with slings, using only the These products incorporate equipment or components under
designated lifting points marked on the unit. pressure, manufactured by Carrier or other manufacturers.
We recommend that you consult your appropriate national
These units are not designed to be lifted from above. Use trade association or the owner of the equipment or compo-
slings with the correct capacity, and always follow the nents under pressure (declaration, re-qualification, retesting,
lifting instructions on the certified drawings supplied with etc.). The characteristics of this equipment/these components
the unit. are given on the nameplate or in the required documenta-
tion, supplied with the products.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material 1.3 - Maintenance safety considerations
deterioration and injuries to personnel.
Engineers working on the electric or refrigeration compo-
Never cover any safety devices. nents must be authorized, trained and fully qualified to do so.

This applies to the relief valve in the water circuit and the All refrigerant circuit repairs must be carried out by a trained
relief valve(s) in the refrigerant circuit(s). person, fully qualified to work on these units. He must have
been trained and be familiar with the equipment and the
Ensure that the valves are correctly installed, before installation. All welding operations must be carried out by
operating the unit. qualified specialists.


Any manipulation (opening or closing) of a shut-off If the machine operates in a corrosive environment, inspect
valve must be carried out by a qualified and authorised the protection devices more frequently.
engineer. These procedures must be carried out with the
unit shut-down. Regularly carry out leak tests and immediately repair
any leaks.
NOTE: The unit must never be left shut down with the
liquid line valve closed, as liquid refrigerant can be trapped 1.4 - Repair safety considerations
between this valve and the expansion device. (This valve
is situated on the liquid line before the filter drier box.) All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries
During any handling, maintenance and service operations to people. Faults and leaks must be repaired immediately.
the engineers working on the unit must be equipped with The authorized technician must have the responsibility to
safety gloves, glasses, shoes and protective clothing. repair the fault immediately. Each time repairs have been
carried out to the unit, the operation of the safety devices
Never work on a unit that is still energized. must be re-checked.

Never work on any of the electrical components, until the If a leak occurs or if the refrigerant becomes contaminated
general power supply to the unit has been cut using the (e.g. by a short circuit in a motor) remove the complete
disconnect switch(es) in the control box(es). charge using a recovery unit and store the refrigerant in
mobile containers.
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead Repair the leak detected and recharge the circuit with the
of the machine. total R-134a charge, as indicated on the unit name plate.
Certain parts of the circuit can be isolated. If leaks occur in
If the work is interrupted, always ensure that all circuits these sections it is possible to top up the refrigerant charge.
are still deenergized before resuming the work. Refer to chapter 11.2 ‘Refrigerant charging - adding charge’.
Only charge liquid refrigerant R-134a at the liquid line.
ATTENTION: Even if the compressor motors have been
switched off, the power circuit remains energized, unless Ensure that you are using the correct refrigerant type
the unit or circuit disconnect switch is open. Refer to the before recharging the unit.
wiring diagram for further details. Attach appropriate
safety labels. Charging any refrigerant other than the original charge
type (R-134a) will impair machine operation and can even
Operating checks: lead to a destruction of the compressors. The compressors
Important information regarding the operating with this refrigerant type are lubricated with a
refrigerant used: synthetic polyolester oil.
• This product contains fluorinated greenhouse gas
covered by the Kyoto protocol. Do not use oxygen to purge lines or to pressurize a machine
Refrigerant type: R-134a for any purpose. Oxygen gas reacts violently with oil,
Global Warming Potential (GWP): 1300 grease, and other common substances.

Periodic inspections for refrigerant leaks may be Never exceed the specified maximum operating pressures.
required depending on European or local legislation. Verify the allowable maximum high- and low-side test
Please contact your local dealer for more information. pressures by checking the instructions in this manual and
• During the life-time of the system, inspection and tests the pressures given on the unit name plate.
must be carried out in accordance with national
regulations. Do not use air for leak testing. Use only refrigerant or dry
nitrogen.
The information on operating inspections given in annex
C of standard EN278-2 can be used if no similar criteria Do not unweld or flamecut the refrigerant lines or any
exist in the national regulations. refrigerant circuit component until all refrigerant (liquid
and vapour) has been removed from chiller. Traces of
Safety device checks (annex C6 – EN 378-2): vapour should be displaced with dry air nitrogen. Refrige-
• The safety devices must be checked on site once a year rant in contact with an open flame produces toxic gases.
for safety devices (high-pressure switches), and every
five years for external overpressure devices (safety The necessary protection equipment must be available,
valves). and appropriate fire extinguishers for the system and the
• Check manual “30GX/30HXC Pro-Dialog Plus refrigerant type used must be within easy reach.
control” for a detailed explanation of the high-
pressure switch test method. Do not siphon refrigerant.


Avoid spilling liquid refrigerant on skin or splashing it Do not drain water circuits containing industrial brines,
into the eyes. Use safety goggles. Wash any spills from the without informing the technical service department at the
skin with soap and water. If liquid refrigerant enters the installation site or a competent body first.
eyes, immediately and abundantly flush the eyes with
water and consult a doctor. Close the entering and leaving water shutoff valves and
purge the unit water circuit, before working on the compo-
Never apply an open flame or live steam to a refrigerant nents installed on the circuit (screen filter, pump, water
container. Dangerous overpressure can result. If it is flow switch, etc.).
necessary to heat refrigerant, use only warm water.
Do not loosen the water box bolts until the water boxes
During refrigerant removal and storage operations follow have been completely drained.
applicable regulations. These regulations, permitting condi-
tioning and recovery of halogenated hydrocarbons under Periodically inspect all valves, fittings and pipes of the
optimum quality conditions for the products and optimum refrigerant and hydronic circuits to ensure that they do
safety conditions for people, property and the environment not show any corrosion or any signs of leaks.
are described in standard NFE 29795.
2 - Preliminary checks
Any refrigerant transfer and recovery operations must be
carried out using a transfer unit. A 3/8” SAE connector on 2.1 - Check equipment received
the manual liquid line valve is supplied with all units for
connection to the transfer station. The units must never be • Inspect the unit for damage or missing parts. If damage
modified to add refrigerant and oil charging, removal and is detected, or if shipment is incomplete, immediately
purging devices. All these devices are provided with the file a claim with the shipping company.
units. Please refer to the certified dimensional drawings for • Confirm that the unit received is the one ordered.
the units. Compare the name plate data with the order.
• The unit name plate must include the following
Do not re-use disposable (non-returnable) cylinders or information:
attempt to refill them. It is dangerous and illegal. When - Version number
cylinders are empty, evacuate the remaining gas pressure, - Model number
and move the cylinders to a place designated for their - CE marking
recovery. Do not incinerate. - Serial number
- Year of manufacture and test date
Do not attempt to remove refrigerant circuit components - Refrigerant used and refrigerant class
or fittings, while the machine is under pressure or while it - Refrigerant charge per circuit
is running. Be sure pressure is at 0 kPa before removing - Containment fluid to be used
components or opening a circuit. - PS: Min./max. allowable pressure (high and low
pressure side)
Do not attempt to repair or recondition any safety devices - TS: Min./max. allowable temperature (high and
when corrosion or build-up of foreign material (rust, dirt, low pressure side)
scale, etc.) is found within the valve body or mechanism. - Relief valve set pressure
If necessary, replace the device. Do not install safety valves - Pressure switch cut-out pressure
in series or backwards. - Unit leak test pressure
- Voltage, frequency, number of phases
ATTENTION: No part of the unit must be used as a walk- - Maximum current drawn
way, rack or support. Periodically check and repair or if - Maximum power input
necessary replace any component or piping that shows - Unit net weight
signs of damage. • Confirm that all accessories ordered for on-site
installation have been delivered, and are complete
The refrigerant lines can break under the weight and release and undamaged.
refrigerant, causing personal injury. • Do not keep the 30HXC units outside where they are
exposed to the weather, as the sensitive control
Do not climb on a machine. Use a platform, or staging to mechanism and the electronic modules may be damaged.
work at higher levels.
The unit must be checked periodically during its whole
Use mechanical lifting equipment (crane, hoist, winch, etc.) operating life to ensure that no shocks (handling accessories,
to lift or move heavy components. For lighter components, tools etc.) have damaged it. If necessary, the damaged parts
use lifting equipment when there is a risk of slipping or must be repaired or replaced. See also chapter “Mainte-
losing your balance. nance”.

Use only original replacement parts for any repair or com-

ponent replacement.

Consult the list of replacement parts that corresponds to

the specification of the original equipment.


2.2 - Moving and siting the unit Checks before system start-up
Before the start-up of the refrigeration system, the complete
2.2.1 - Moving installation, including the refrigeration system must be
verified against the installation drawings, dimensional
See chapter 1.1 “Installation safety considerations”. drawings, system piping and instrumentation diagrams and
the wiring diagrams.
2.2.2 - Siting the unit
During the installation test national regulations must be
Always refer to the chapter “Dimensions and clearances” followed. If no national regulation exists, paragraph 9-5 of
to confirm that there is adequate space for all connections standard EN 378-2 can be used as a guide.
and service operations. For the centre of gravity coordinates,
the position of the unit mounting holes, and the weight dis- External visual installation checks:
tribution points, refer to the certified dimensional drawing • Compare the complete installation with the refrigera-
supplied with the unit. tion system and power circuit diagrams.
• Check that all components comply with the design
Typical applications of these units are in refrigeration specifications.
systems, and they do not require earthquake resistance. • Check that all safety documents and equipments that
Earthquake resistance has not been verified. are required by current European standards are
present.
CAUTION: Only use slings at the designated lifting • Verify that all safety and environmental protection
points which are marked on the unit. devices and arrangements are in place and comply
with the current European standard.
Before siting the unit check that: • Verify that all relevant documents for pressure vessels
• the permitted loading at the site is adequate or that (certificates, name plates, files, instruction manuals etc.)
appropriate strenghtening measures have been taken. required by the current European standards are present.
• the unit is installed level on an even surface (maximum • Verify the free passage of access and safety routes.
tolerance is 5 mm in both axes). • Check that ventilation in the plant room is adequate.
• there is adequate space above the unit for air flow and • Check that refrigerant detectors are present.
to ensure access to the components. • Verify the instructions and directives to prevent the
• the number of support points is adequate and that deliberate removal of refrigerant gases that are harmful
they are in the right places. to the environment.
• the location is not subject to flooding. • Verify the installation of connections.
• for outdoor installations, where heavy snowfall is likely • Verify the supports and fixing elements (materials,
and long periods of sub-zero temperatures are normal, routing and connection).
provision has to be made to prevent snow accumulating • Verify the quality of welds and other joints.
by raising the unit above the height of drifts normally • Check the protection against mechanical damage.
experienced. Baffles may be necessary to deflect strong • Check the protection against heat.
winds. They must not restrict air flow into the unit. • Check the protection of moving parts.
• Verify the accessibility for maintenance or repair and
CAUTION: Before lifting the unit, check that all casing to check the piping.
panels are securely fixed in place. Lift and set down the • Verify the status of the valves.
unit with great care. Tilting and jarring can damage the • Verify the quality of the thermal insulation and of the
unit and impair unit operation. vapour barriers.

If 30GX units are hoisted with rigging, it is advisable to

protect coils against crushing while a unit is being moved.
Use struts or spreader bars to spread the slings above the
unit. Do not tilt a unit more than 15°.

WARNING: Never push or lever on any of the enclosure

panels of the unit. Only the base of the unit frame is
designed to withstand such stresses.


3 - dimensions, clearances, weight distribution

3.1 - 30HXC 080-190

600
1

C
30HXC-080
30HXC-090
30HXC-100
30HXC-110

D A E

500
4 4

3
700

Legend
All dimensions are in mm. 30HXC A B C D E F
1 080-090-100 2558 980 1800 2200 1000 385
Evaporator
110 2565 980 1850 2200 1000 385
2 Condenser 120-130-140-155 3275 980 1816 2990 1000 689
175-190 3275 980 1940 2990 1000 689
3 Clearances required for operation and maintenance

4 Clearances required for heat exchanger tube removal. Clearances D NOTE: Refer to the certified dimensional drawings
and E can be either on the left or on the right hand side.
supplied with the unit, when designing an installation.
Water inlet

Water outlet

Power supply


3.2 - 30HXC 200-375

500
1

C
2

D A E

500
4 4

B
3
700

Legend
All dimensions are in mm. 30HXC A B C D E F
1 200 3903 1015 1980 3600 1000 489
Evaporator
230-260-285 3924 1015 2060 3600 1000 489
2 Condenser 310-345-375 4533 1015 2112 4200 1000 503

3 Clearances required for operation and maintenance

NOTE: Refer to the certified dimensional drawings
4 Clearances required for heat exchanger tube removal. Clearances D
and E can be either on the left or on the right hand side. supplied with the unit, when designing an installation.
Water inlet

Water outlet

Power supply


3.3 - 30GX 082-182

Standard units

C1

2297

1351
30GX-082
30GX-092
30GX-152
30GX-102
30GX-162
30GX-112
30GX-182
30GX-122
30GX-132

A
500 500
1830

1
2254

2 2
1830

Units with low and very low noise levels

500 500

4
1830
230

1
2254

2 2
230
1830

Legend
All dimensions are in mm. 30GX A B C1
082-092-102 2967 1900 414
1 Clearances required for operation and maintenance
112-122-132 3425 1700 617
2 Clearances required for tube removal 152-162 4340 2400 1151
182 5994 1850 2226
3 Thickness of sound absorption kit
4 Clearances required for maintenance and air flow
NOTE: Refer to the certified dimensional drawings
supplied with the unit, when designing an installation.
Water inlet

Water outlet

Power supply

Air outlet - do not obstruct

10
3.4 - 30GX 207-358

Standard units

C1
C2

2297
1351
A
500
500
1830

2254
1 1

2 2
1830

Units with low and very low noise levels

500 500
1830

4
230

3
2254

1 1

2 2
230
1830

Legend
All dimensions are in mm. 30GX A B C1 C2
207-227 5994 2850 621 2662
1 Clearances required for operation and maintenance
247-267 6909 2850 621 2662
2 Clearances required for tube removal 298 7824 2050 1036 3578
328-358 8739 1150 1951 4493
3 Thickness of sound absorption kit
4 Clearances required for maintenance and air flow
NOTE: Refer to the certified dimensional drawings
supplied with the unit, when designing an installation.
Water inlet

Water outlet

Power supply

Air outlet - do not obstruct

11
3.5 - Multiple chiller installation

NOTE: If the walls are higher than 2 m, contact the factory.

A A

1830
1830

B B B

2000
2000

B B B
2000

1525
B
2000

1525

Legend
A Wall
B Units

Notes
Unit must have clearances for air flow as follows:
Top: do not restrict in any way

In case of multiple chillers (up to four units), the respective clearance between them
should be increased from 1830 to 2000 mm for the side space requirement.

If necessary, add the required clearances for evaporator tube removal.

12
4 - Physical and electrical data for 30HXC units

4.1 - Physical data 30HXC

30HXC 080 090 100 110 120 130 140 155 175 190 200 230 260 285 310 345 375
Cooling capacity* kW 286 312 348 374 412 449 509 541 598 651 699 812 897 985 1106 1204 1300
Operating weight kg 2274 2279 2302 2343 2615 2617 2702 2712 3083 3179 3873 4602 4656 4776 5477 5553 5721
Refrigerant charge** kg HFC-134a
Circuit A** 33 33 32 31 49 51 48 51 54 56 92 115 117 117 109 104 119
Circuit B** 34 34 30 35 52 47 48 50 50 59 54 63 75 75 106 102 137
Oil*** Polyolester oil CARRIER SPEC. PP 47-32
Circuit A/B l 17/17 17/17 17/17 17/17 17/17 17/17 17/17 17/17 17/17 17/17 30/17 30/17 30/17 30/17 34/34 34/34 34/34
Compressors† Semi-hermetic, twin-screw
Size - Circuit A† 39 46 46 56 56 66 80 80 80 80+ 66/56 80/56 80/80 80+/80+ 80/66 80/80 80+/80+
Size - Circuit B† 39 39 46 46 56 56 56 66 80 80+ 66 80 80 80+ 80/66 80/80 80+/80+
Capacity control PRO-DIALOG Plus control
No. of control steps 6 6 6 6 6 6 6 6 6 6 8 8 8 8 10 10 10
Minimum step capacity % 19 19 21 19 21 19 17 19 21 21 14 14 14 14 10 10 10
Evaporator Shell and tube with internally finned copper tubes
Net water volume l 50 50 58 69 65 65 75 75 88 88 126 155 170 170 191 208 208
Water connections Victaulic connections
Inlet/outlet in 4 4 4 5 5 5 5 5 5 5 6 6 6 6 8 8 8
Drain and vent (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Shell and tube with internally finned copper tubes
Net water volume l 48 48 48 48 78 78 90 90 108 108 141 190 190 190 255 255 255
Water connections Victaulic connections
Inlet/outlet in 5 5 5 5 5 5 5 5 6 6 6 8 8 8 8 8 8
Drain and vent (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C and 7°C. Condenser entering/leaving water temperature 30°C/35°C. Evaporator and condenser
fouling factor = 0.000044 m2 K/W.
** The weights shown are guidelines only. For the unit refrigerant charge please refer to the unit nameplate.
*** For options 150 and 150A the units are supplied with an additional charge of 3 litres per compressor.
† Nominal size per compressor. The compressor size is the same as its nominal cooling capacity in tons of refrigeration (1 ton = 3.517 kW).

4.2 - Electrical data 30HXC

30HXC 080 090 100 110 120 130 140 155 175 190 200 230 260 285 310 345 375
Power circuit
Nominal power supply (Un)* V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit supply The control circuit is supplied via the factory-installed transformer
Nominal power input* kW 53 62 67 76 80 89 102 112 121 129 140 164 192 195 221 250 263
Nominal current drawn* A 101 115 127 143 149 168 190 207 226 234 255 294 337 354 399 448 477
Max. power input** kW 87 97 108 119 131 144 161 175 192 212 223 257 288 318 350 384 424
Circuit A kW - - - - - - - - - - 144 161 192 212 175 192 212
Circuit B kW - - - - - - - - - - 79 96 96 106 175 192 212
Cosine phi, unit at full load 0.88 0.88 0.88 0.88 0.89 0.88 0.88 0.89 0.89 0.89 0.88 0.89 0.89 0.89 0.89 0.89 0.89
Max. current drawn (Un - 10%)*** A 158 176 195 215 235 259 289 314 344 379 401 461 517 568 628 688 758
Circuit A*** A - - - - - - - - - - 259 289 344 379 314 344 379
Circuit B*** A - - - - - - - - - - 142 172 172 189 314 344 379
Maximum current drawn (Un)*** A 143 160 177 195 213 236 263 285 312 344 365 419 468 516 570 624 688
Circuit A*** A - - - - - - - - - - 236 263 312 344 285 312 344
Circuit B*** A - - - - - - - - - - 129 156 156 172 285 312 344
Maximum starting current,
standard unit (Un)**** A 181 206 223 249 267 298 333 355 382 442 841 978 1027 1200 1129 1184 1373
Circuit A*** A - - - - - - - - - - 712 822 871 1028 844 871 1028
Circuit B*** A - - - - - - - - - - 605 715 715 856 844 871 1028
Max. starting current/max. current
draw ratio, unit 1.26 1.28 1.26 1.27 1.25 1.26 1.27 1.24 1.22 1.28 2.31 2.33 2.19 2.32 1.98 1.89 1.99
Max. starting current/max. current
draw ratio, circuit A - - - - - - - - - - 3.02 3.13 2.79 2.99 2.96 2.79 2.99
Max. starting current/max. current
draw ratio, circuit B - - - - - - - - - 4.70 4.58 4.58 4.97 2.96 2.79 2.99
Max. starting current - reduced
current start (Un) **** A std. std. std. std. std. std. std. std. std. std. 636 683 732 824 834 889 997
Circuit A A std. std. std. std. std. std. std. std. std. std. 507 527 576 652 549 576 652
Circuit B A std. std. std. std. std. std. std. std. std. std. 330 370 370 385 549 576 652
Max.starting current - red. current
start/max. current draw ratio, unit std. std. std. std. std. std. std. std. std. std. 1.74 1.63 1.56 1.60 1.46 1.42 1.45
Circuit A std. std. std. std. std. std. std. std. std. std. 2.15 2.00 1.84 1.89 1.93 1.84 1.98
Circuit B std. std. std. std. std. std. std. std. std. std. 2.56 2.37 2.37 2.24 1.93 1.84 1.89
Three-phase short circuit
holding current kA 25 25 25 25 25 25 25 25 25 25 N/A N/A N/A N/A N/A N/A N/A
Circuit A kA - - - - - - - - - - 25 25 25 25 25 25 25
Circuit B kA - - - - - - - - - - 15 15 15 15 25 25 25
Customer standby capacity,
unit or circuit B, for evaporator
water pump connections† kW 8 8 8 11 11 11 15 15 15 15 15 18 18 30 30 30 30
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C and 7°C. Condenser entering/leaving water temperature 30°C/35°C.
** Power input, compressor, at unit operating limits (evaporator water entering/leaving temperature = 15°C/10°C, condenser entering/leaving water temperature = 45°C/50°C) and a
nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
**** Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest compressor)
† Current and power inputs not included in the values above.
N/A Not applicable.

13
4.3 - Electrical data, 30HXC compressors

Reference Size I nom. MHA LRA LRA (Y) LRA (S) 1 cp LRA (S) 2 cp
06NW2146S7N 39 50 79 344 109 NA NA
06NW2174S7N 46 60 97 423 134 NA NA
06NW2209S7N 56 71 117 506 160 260 350
06NW2250S7N 66 86 142 605 191 330 400
06NW2300S5N 80 105 172 715 226 370 420
06NW2300S5E 80+ 114 189 856 270 385 480
Legend
06NW - Compressor for water-cooled units
N - Non-economized compressor
E - Economized compressor
I nom. - Average current draw of the compressor at Eurovent conditions (A)
MHA - Must hold amperes (maximum operating current) at 360 V (A)
LRA - Locked rotor current with across-the-line start (A)
LRA (Y) - Locked rotor current at reduced current (star/delta start-up mode) (A)
LRA (S) 1 cp. - Start-up with reduced current (A) with electronic starter (start-up duration 3 seconds max.) for one compressor per circuit
LRA (S) 2 cp. - Start-up with reduced current (A) with electronic starter (start-up duration 3 seconds max.) for two compressors per circuit

4.4 - Electrical data for 30HXC units with high condensing temperatures (option 150/150A)
30HXC 080 090 100 110 120 130 140 155 175 190 200 230 260 285 310 345 375
Power circuit
Nominal power supply (Un)* V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit supply The control circuit is supplied via the factory-installed transformer
Max. power input* kW 108 122 136 149 163 180 196 213 229 287 278 310 343 431 426 458 574
Circuit A kW - - - - - - - - - - 180 196 229 287 213 229 287
Circuit B kW - - - - - - - - - - 98 114 114 144 213 229 287
Max. current drawn (Un - 10%)** A 198 223 247 271 295 325 355 385 415 516 502 562 622 774 770 830 1032
Circuit A A - - - - - - - - - - 325 355 415 516 385 415 516
Circuit B A - - - - - - - - - - 177 207 207 258 385 415 516
Maximum current drawn (Un)** A 180 203 225 246 268 295 323 350 377 469 456 512 566 704 700 754 938
Circuit A A - - - - - - - - - - 295 323 377 469 350 377 469
Circuit B A - - - - - - - - - - 161 189 189 235 350 377 469
Maximum starting current,
standard unit (Un)*** A 281 316 338 382 404 437 521 548 576 635 1255 1549 1603 1734 1737 1792 1969
Circuit A*** A - - - - - - - - - - 1094 1360 1415 1500 1387 1415 1500
Circuit B*** A - - - - - - - - - - 960 1226 1226 1265 1387 1415 1500
Max. starting current/max. current
draw ratio, unit 1.56 1.56 1.51 1.55 1.51 1.48 1.62 1.57 1.53 1.35 2.75 3.03 2.83 2.46 2.48 2.38 2.10
Max. starting current/max. current
draw ratio, circuit A - - - - - - - - - - 3.71 4.22 3.75 3.19 3.97 3.75 3.19
Max. starting current/max. current
draw ratio, circuit B - - - - - - - - - 5.96 6.50 6.50 5.39 3.97 3.75 3.19
Max. starting current - reduced
current start (Un) *** A std. std. std. std. std. std. std. std. std. std. 870 933 987 1129 1121 1176 1364
Circuit A A std. std. std. std. std. std. std. std. std. std. 709 744 799 895 771 799 895
Circuit B A std. std. std. std. std. std. std. std. std. std. 435 490 490 510 771 799 895
Max.starting current - red. current
start/max. current draw ratio, unit std. std. std. std. std. std. std. std. std. std. 1.91 1.82 1.75 1.60 1.60 1.56 1.45
Circuit A std. std. std. std. std. std. std. std. std. std. 2.40 2.31 2.12 1.91 2.21 2.12 1.91
Circuit B std. std. std. std. std. std. std. std. std. std. 2.70 2.60 2.60 2.17 2.21 2.12 1.91
Three-phase short circuit holding current kA 25 25 25 25 25 25 25 25 25 25 N/A N/A N/A N/A N/A N/A
N/A
Circuit A kA - - - - - - - - -. - 25 25 25 25 25 25 25
Circuit B kA - - - - - - - - - - 15 15 15 15 25 25 25
Customer standby capacity, unit
or circuit B, for evaporator
water pump connections† kW 8 8 8 11 11 11 15 15 15 15 15 18 18 30 30 30 30
* Power input, compressor, at unit operating limits (evaporator water entering/leaving temperature = 15°C/10°C, condensing temperature = 68°C) and a nominal voltage of 400 V
(data given on the unit name plate).
** Maximum unit operating current at maximum unit power input.
*** Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest compressor)
† Current and power inputs not included in the values above
N/A Not applicable

14
The 30HXC 080-375 units for high condensing temperatures ATTENTION: If units have two different operating modes
are directly derived from the standard models. Their appli- - one with high condensing temperature and the other with
cation range is the same as that of the standard units, but low condensing temperature - and the transition is made
permits operation at condenser leaving water temperatures with the unit in operation, the temperature must not vary
up to 63°C. The PRO-DIALOG control offers all the advan- by more than 3 K per minute. In cases where this is not
tages of the standard units, plus control of the condenser possible, it is recommended to go through a unit start/stop
leaving water temperature. switch (remote start/stop available for standard units).

The main modifications are: 4.5 - Unit characteristics for 30HXC units with very
• Use of 30GX compressors (example: 06NA2300S5N low temperature option (option 6)
instead of 06NW 2300S5N).
• Modification of electrical components to operate with The 30HXC units with the very low temperature option
compressors for high condensing temperatures. are directly derived from the 30HXC models equipped
• Modification of heat exchangers to meet pressure code with the high condensing temperature option (option 150).
requirements (if necessary). Unit sizes available with the very low temperature option
are the following: 30HXC 090, 110, 130, 155, 175, 200, 230,
Option 150 260, 310, 345.
These units are designed for traditional applications for
water-cooled units, but for higher condender leaving water Their application range allows the production of glycol/
temperatures than 50°C. water solution down to -10°C with ethylene glycol at 35%
(by weight) or down to -7°C with propylene glycol at 30%
Like the standard units they are equipped with condenser (by weight). The precision of these amounts is critical for
entering and leaving water sensors. correct unit operation.

It is possible to control the machine at the condenser water In addition to the ones already listed for the high condensing
outlet, requiring a factory configuration change and the temperature option (see chapter 4.4) the main modifications
use of a heating/cooling inlet reversing device. are:
• the evaporator is equipped with reinforced thermal
Option 150A 38 mm insulation,
These units are designed for water-to-water heat pumps. • the electronic expansion valves are changed,
• the use of a wide-band oil differential sensor.
They are factory configured as heat pumps (heating/cooling
control as a function of the remote reversing device). The All technical data is the same as for the 30HXC units with
condenser incorporates thermal insulation that is identical option 150 except for the following chapters:
to that of the evaporator.
4.5.1 - Options and accessories
Technical information The options available for the 30HXC units equipped with
All information is identical to that of the standard 30HXC the very low temperature option are as follows: 20, 22, 60,
units, except for the following paragraphs. 61, 84, 84D, 84R, 92, 104A, 107, 107A, 152, 193, 194, 197, 199.

Selection 4.5.2 - Operating range, 30HXC units with very low

There are no nominal conditions for this unit type. The temperature option
selection is made using the current electronic catalogue. 30HXC evaporator with 35% ethylene glycol °C Minimum Maximum
Evaporator entering water temperature -7.2 21
Dimensions Evaporator leaving water temperature -10 15
30HXC evaporator with 30% polypropylene glycol
These are identical to those of the standard 30HXC units. Evaporator entering water temperature -4.2 21
The only difference is in the diameter of the incoming field Evaporator leaving water temperature -7 15
30HXC condenser
wiring connection, described in the chapter “Recommended Condenser entering water temperature 20 50
selection”. Refer to the dimensional drawings for these Condenser leaving water temperature 25 55
units, before proceeding with the wiring. Outdoor air temperature 6 40

Compressor For very low temperature applications the anti-freeze

See table in chapter 5.3. solution is critical for correct unit operation. The following
amounts (by weight) are required:
Options and accessories Evaporator leaving water, °C Ethylene glycol, % Propylene glycol, %
All options available for the standard 30HXC units are com- -6 25 27
-7 28 30
patible, except low-temperature option 5 for the evaporator -8 30 NA
available in the special unit. -9 33 NA
-10 35 NA

15
 Operating range 35% ethylene glycol Operating range 30% propylene glycol

50
48

Condenser entering water temperature, °C

Condenser entering water temperature, °C

44

20
15 C
13

-7 0 4 13 15
Evaporator leaving water temperature, °C Evaporator leaving water temperature, °C

Notes
1. Evaporator ∆T = 4 K max. - condenser ∆T = 5 K
2. Operating range applicable for full and reduced load
3. At full load with a condenser entering water temperature below 20°C, a three-way valve must be used to maintain the correct condensing temperature.

Legend
C Unit operating with a condensing pressure control with an analogue water control valve.
For transient operating modes (start-up and part load), the unit can operate down to a condenser water temperature of 13°C.
D Operation permitted, but performances is not optimized

4.5.3 - Evaporator water flow (l/s) for 35% ethylene glycol Evaporator water flow (l/s) for 30% propylene glycol
30HXC Min.* (closed loop) Max.** 30HXC Min.* (closed loop) Max.**
090 8.0 15.7 090 11.1 15.7
110 10.6 21.3 110 14.2 21.3
130 12.4 25.1 130 16.7 25.1
155 14.5 28.1 155 19.1 28.1
175 15.6 33.0 175 21.1 33.0
200 20.5 38.0 200 25.1 38.0
230 21.0 39.7 230 27.4 39.7
260 24.1 48.3 260 32.3 48.3
310 29.6 62.0 310 40.0 62.0
345 30.2 63.0 345 40.6 63.0
* Based on a Reynolds number of 4000
** Based on a water velocity of 3.6 m/s

16
4.5.4 - Evaporator pressure drop curve, units for very low temperature

The evaporator is equipped with heat insulation of 38 mm thick polyurethane foam.

Cooler pressure drop, 30HXC low-brine version

1000

5
34
10&
C3
HX
0
C 26
100 HX
0
C 23
HX

0
C 20
HX

5
10 C 17
Pressure drop, kPa

HX

5
C 15
30 HX
0 C1
11 HX
0 C
C 09 HX
1 HX

0,1

0,01
1 10 100

Pure water flow rate, l/s

17
5 - Physical and electrical data for units 30GX

5.1 - Physical data 30GX

30GX 082 092 102 112 122 132 152 162 182 207 227 247 267 298 328 358
Net nominal cooling capacity* kW 282 305 329 384 412 443 500 549 599 705 751 809 916 990 1116 1203
Net nominal cooling capacity*
Option 15LN* kW 277 299 322 377 404 434 490 518 588 677 744 801 907 980 1083 1191
Operating weight kg 3066 3097 3106 3350 3364 3378 3767 3783 4725 5520 5535 6121 6293 7339 7779 7950
Operating weight - option 15LN kg 3566 3597 3606 3922 3936 3950 4443 4459 5653 6462 6477 7191 7363 8521 9011 9268
Refrigerant charge** kg HFC-134a
Circuit A** 52 55 51 51 56 54 71 71 86 124 124 154 169 163 156 169
Circuit B** 53 48 51 50 54 52 66 72 90 81 81 88 104 148 157 167
Oil Polyolester oil CARRIER SPEC. PP 47-32
Circuit A l 20 20 20 20 20 20 20 20 20 40 40 40 40 40 40 40
Circuit B l 20 20 20 20 20 20 20 20 20 20 20 20 20 40 40 40
Compressors Semi-hermetic, twin-screw
Circ. A - nom. size per compressor** 46 46 56 56 66 66 80 80 80+ 66/56 80/66 80/80 80+/80+ 80/80 80/80 80+/80+
Circ. B. nom. size per compressor** 39 46 46 56 56 66 66 80 80+ 80 80 80 80+ 66/66 80/80 80+/80+
Capacity control PRO-DIALOG Plus control
No. of control steps 6 6 6 6 6 6 6 6 6 8 8 8 8 10 10 10
Minimum step capacity % 19 21 19 21 19 21 19 21 21 16 14 14 14 9 10 10
Evaporator Shell and tube with internally finned copper tubes
Net water volume l 50 58 58 69 69 73 65 65 88 126 126 155 170 191 208 208
Water connections Victaulic connections
Inlet/outlet in 4 4 4 5 5 5 5 5 5 6 6 6 6 8 8 8
Drain and vent (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condensers Copper tubes, aluminium fins
Condenser fans Axial FLYING BIRD 2 fan with a rotating shroud
Quantity 4 4 4 6 6 6 8 8 8 10 10 12 12 14 16 16
Fan speed r/s 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8 15.8
Total air flow l/s 21380 21380 21380 32070 32070 32070 42760 42760 42760 53450 53450 64140 64140 74830 85520 85520
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C and 7°C. Outdoor air temperature 35°C, evaporator fouling factor of 0.000044 m2 K/W.
Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3).
** The weights shown are guidelines only. For the unit refrigerant charge please refer to the unit nameplate.

5.2 - Electrical data 30GX

30GX 082 092 102 112 122 132 152 162 182 207 227 247 267 298 328 358
Power circuit
Nominal power supply V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit supply The control circuit is supplied via the factory-installed transformer
Nominal operating power input* kW 98 108 120 128 149 166 182 198 217 242 285 297 332 370 395 435
Nominal operating power input - option 15LN* kW 99 110 123 130 151 172 185 201 220 248 287 299 329 373 406 447
Nominal operating current drawn * A 170 188 206 220 256 290 313 340 373 413 478 498 547 621 675 744
Maximum power input** kW 132 145 159 177 194 211 232 248 306 318 351 372 459 459 496 612
Circuit A kW - - - - - - - - - 194 227 248 306 248 248 306
Circuit B kW - - - - - - - - - 124 124 124 153 211 248 306
Cosine phi, unit at full load 0.85 0.85 0.86 0.85 0.85 0.86 0.85 0.85 0.86 0.85 0.85 0.85 0.86 0.85 0.85 0.86
Maximum current drawn (Un - 10%)*** A 248 272 295 331 361 391 433 463 564 593 653 695 847 854 926 1129
Circuit A A - - - - - - - - - 361 421 463 564 463 463 564
Circuit B A - - - - - - - - - 232 232 232 283 391 463 564
Maximum current drawn (Un)*** A 225 247 268 301 328 355 394 421 513 539 594 632 770 776 842 1026
Circuit A A - - - - - - - - - 328 383 421 513 421 421 513
Circuit B A - - - - - - - - - 211 211 211 257 355 421 513
Maximum starting current,
standard unit**** (Un) A 338 360 404 437 470 497 592 620 679 1338 1631 1669 1800 1814 1880 2057
Circuit A**** A - - - - - - - - - 1127 1420 1459 1544 1459 1459 1544
Circuit B**** A - - - - - - - - - 1248 1248 1248 1287 1154 1459 1544
Max. starting current/max. current draw
ratio, unit 1.51 1.46 1.51 1.45 1.43 1.40 1.50 1.47 1.32 2.48 2.75 2.64 2.34 2.34 2.23 2.00
Max. starting current/max. current draw
ratio, circuit A - - - - - - - - - 3.43 3.71 3.46 3.01 3.46 3.46 3.01
Max. starting current/max. current draw
ratio, circuit B - - - - - - - - - 5.93 5.93 5.93 5.01 3.25 3.46 3.01
Max. starting current - reduced
current start**** (Un) A std. std. std. std. std. std. std. std. std. 953 1015 1053 1195 1198 1264 1452
Circuit A A std. std. std. std. std. std. std. std. std. 742 804 843 939 843 843 939
Circuit B A std. std. std. std. std. std. std. std. std. 512 512 512 532 769 843 939
Max.starting current - red. current
start/max. current draw ratio, unit std. std. std. std. std. std. std. std. std. 1.77 1.71 1.67 1.55 1.54 1.50 1.41
Circuit A std. std. std. std. std. std. std. std. std. 2.26 2.10 2.00 1.83 2.00 2.00 1.83
Circuit B std. std. std. std. std. std. std. std. std. 2.43 2.43 2.43 2.07 2.16 2.00 1.83
Three-phase short-circuit holding current kA 25 25 25 25 25 25 25 25 25 N/A N/A N/A N/A N/A N/A N/A
Circuit A kA - - - - - - - - -. 25 25 25 25 25 25 25
Circuit B kA - - - - - - - - - 25 25 25 25 25 25 25
Standby capacity, unit or circuit A†
for evaporator water pump connections kW 4 4 4 5.5 5.5 5.5 7.5 7.5 7.5 7.5 9 9 9 15 15 15
and for heat reclaim condenser pump kW 3 3 4 4 4 5.5 5.5 5.5 N/A 5.5 7.5 7.5 N/A 9 9 N/A
* Standard Eurovent conditions: Evaporator entering/leaving water temperature 12°C and 7°C. Outdoor air temperature 35°C.
** Power input, compressor and fan, at unit operating limits (evaporator water entering/leaving temperature = 15°C/10°C, outdoor air temperature = 46°C) and a nominal voltage of
400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
**** Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + fan current + locked rotor current or reduced starting current of the largest
compressor).
Fan electrical data = power input 2.4 kW and current draw 5.5 A per fan.
† Current and power inputs not included in the values above
N/A Not applicable

18
5.3 - Electrical data, 30GX and 30HXC compressors, option 150 + 150A

Reference Size I nom. MHA LRA LRA (Y) LRA (S) 1 cp. LRA (S) 2 cp.
06NA2146S7N 39 72 99 605 191 NA NA
06NA2174S7N 46 87 124 715 226 NA NA
06NA2209S7N 56 103 148 856 270 330 480
06NA2250S7N 66 124 177 960 303 435 575
06NA2300S5N 80 149 207 1226 387 490 610
06NA2300S5E 80+ 174 258 1265 400 510 660
Legend
06NA - Compressor for air-cooled units
N - Non-economized compressor
E - Economized compressor
I nom. - Average current draw of the compressor at Eurovent conditions (A)
MHA - Must hold amperes (maximum operating current) at 360 V (A)
LRA - Locked rotor current with across-the-line start (A)
LRA (Y) - Locked rotor current at reduced current (star/delta start-up mode) (A)
LRA (S) 1 cp. - Start-up with reduced current (A) with electronic starter (start-up duration 3 seconds max.) for one compressor per circuit
LRA (S) 2 cp. - Start-up with reduced current (A) with electronic starter (start-up duration 3 seconds max.) for two compressors per circuit

19
6 - Application data 6.1.2 - Operating range 30GX
°C
6.1 - Unit operating range

Evaporator 30HXC - 30GX Minimum Maximum 46

D 45 B
Evaporator entering water temperature °C 6.8* 21
Evaporator leaving water temperature °C 4** 15 43
42
Condenser (water-cooled) 30HXC Minimum Maximum

Ambient air temperature, °C

Condenser entering water temperature °C 20*** 45
Condenser leaving water temperature °C 25 50
A
Outside ambient operating temperature 30HXC °C 6 40
Condenser (air-cooled) 30GX Minimum Maximum
Outdoor ambient operating temperature °C 0† 46
Available static pressure kPa 0 0
Notes
* For application requiring operation at less than 6.8°C, contact Carrier for unit
selection using the Carrier electronic catalog. C
** For application requiring operation at less than 4°C, the units require the use of
antifreeze.
*** Water-cooled units (30HXC) operating at full load and below 20°C condenser -18
entering water temperature require the use of a head pressure control with
analogue water control valves (see paragraph on head pressure control).
Maximum ambient temperature: For transport and storage of the 30GX and
30HXC units the minimum and maximum allowable temperatures are -20°C °C
4 7 11 15
and +70°C. It is recommended that these temperatures are also applied for
transport by container. Evaporator leaving water temperature, °C
† For operation in ambient temperatures down to -18°C the unit must be equipped
with option 28.
Notes
1. Evaporator ∆T = 5 K
6.1.1 - Operating range 30HXC 2. If the ambient temperature can be below freezing, the evaporator must be
protected against frost.
3. Available static pressure zero.
58 4. For low evaporator leaving temperatures <+4°C and >-6°C order option 5

Legend
A Standard unit operating at full load.
Condenser water entering temperature, °C

50 B Standard unit operating at reduced load.

C With year-round operation option.
B
45 D Operating limit, units 30GX 267 and 358 at full load.

6.2 - Minimum chilled water flow

A

35 The minimum chilled water flow is shown in the table on the

next page. If the flow is less than this, the evaporator flow
30 can be recirculated, as shown in the diagram. The tempera-
ture of the mixture leaving the evaporator must never be
25
less than 2.8 K lower than the chilled water entering tempe-
20 rature.
15 C
13

4 5 10 13 15 °C

Evaporator leaving water temperature, °C

Notes
1. Evaporator and condenser ∆T = 5 K
2. For start-up at full load with a condenser water entering temperature below
20°C, a three-way valve must be used to maintain the correct condensing
temperature
3. Maximum condenser water leaving temperature 50°C (at full load)
4. For low evaporator leaving temperatures <+4°C and >-6°C order option 5

Legend
A Standard unit operating at full load.
B Standard unit operating at reduced load.
C Units operating with head pressure control with analogue water control
valve.
For transient operating modes (start-up and part load) the unit can operate Legend
down to a condenser water temperature of 13°C. 1 Evaporator
2 Recirculation
Additional operating range for high condensing temperature units and non-
reversible heat pumps.

20
6.3 - Maximum chilled water flow NOTE: The compressor must not restart more than 6 times
in an hour.
The maximum chilled water flow is limited by the maximum
permitted pressure drop in the evaporator. It is provided in
the table on the next page. If the flow exceeds the maximum
value, two solutions are possible:
• Select a non-standard evaporator with one water pass
less which will allow a higher maximum water flow rate. Bad Good
• Bypass the evaporator as shown in the diagram to
obtain a highter temperature difference with a lower
evaporator flow rate.

For maximum chilled water flow rate

Bad Good
1

6.6 - Cooler flow rate (l/s)

30HXC Min.* (closed loop) Max.**

080-090 5.2 20.8
100 6.5 25.9
110 7.4 29.6
120-130 8.3 33.4
140-155 9.4 37.8
175-190 11.5 45.9
200 14.1 56.3
230 16.3 65.2
260-285 18.3 73.4
310 20.9 83.7
Legend 345-375 23.0 91.9
1 Evaporator 30GX Min.* (closed loop) Max.**
2 Bypass 082 5.2 20.8
092-102 6.5 25.9
112-132 7.4 29.6
6.4 - Variable flow evaporator 152-162 9.4 37.8
182 11.5 45.9
207-227 14.1 56.3
Variable evaporator flow can be used in standard 30HXC 247 16.3 65.2
267 18.3 73.4
and 30GX chillers. The chillers maintain a constant leaving 298 20.9 83.7
water temperature under all flow conditions. For this to 328-358 23.0 91.9
happen, the minimum flow rate must be higher than the * Based on a water velocity of 0.9 m/s.
** Based on a water velocity of 3.6 m/s.
minimum flow given in the table of permissible flow rates
and must not vary by more than 10% per minute.
6.7 - Condenser flow rate (l/s)
If the flow rate changes more rapidly, the system should 30HXC Min.* Max.**
contain a minimum of 6.5 litres of water per kW instead of Closed loop Open loop
3.25 l/kW. 080-110 2.3 7.0 28.2
120-130 3.1 9.3 37.1
140-155 3.7 11.1 44.5
6.5 - System minimum water volume 175-190 4.3 13.0 51.9
200 4.9 14.8 59.2
230-285 6.7 20.1 80.4
Whichever the system, the water loop minimum capacity is 310-375 8.0 24.0 95.9
given by the formula: * Based on a water velocity of 0.3 m/s in a closed loop and 0.9 m/s in an open
loop.
** Based on a water velocity of 3.6 m/s.
Capacity = Cap (kW) x N litres
Application N
Normal air conditioning 3.25
Process type cooling 6.5

Where Cap is the nominal system cooling capacity (kW) at

the nominal operating conditions of the installation.

This volume is necessary for stable operation and accurate

temperature control.

It is often necessary to add a buffer water tank to the circuit

in order to achieve the required volume. The tank must
itself be internally baffled in order to ensure proper mixing
of the liquid (water or brine). Refer to the examples below.

21
 6.8 - Evaporator pressure drop curve

200
7 9
2 3 6
5
1
11
100

50
Pressure drop, kPa

40

30

Legend
1 30HXC 080-090/30GX 082
20 2 30HXC 100/30GX 092-102
3 30HXC 110/30GX 112-122-132
4 30HXC 120-130
5 30HXC 140-155/30GX 152-162
6 30HXC 175-190/30GX 182
7 30HXC 200/30GX 207-227
10 8 30HXC 230/30GX 247
8 10 9 30HXC 260-285/30GX 267
8 10 30HXC 310/30GX 298
4
11 30HXC 345-375/30GX 328-358

1 2 3 4 10 20 30 40 100
Water flow rate, l/s

6.9 - Condenser pressure drop curve

1000

400
300
200
2 3
4 5 6 7
100 1
Pressure drop, kPa

40
30
20

10

4
3
2

1
1 2 3 4 5 10 20 30 40 50 100
Water flow rate, l/s

Legend Note:
1 30HXC 080-090-100-110 The dotted part of the curves corresponds to the flow values only permitted for
2 30HXC 120-130 closed circuits.
3 30HXC 140-155
4 30HXC 175-190
5 30HXC 200
6 30HXC 230-260-285
7 30HXC 310-345-375

22
7 - ELECTRICAL CONNECTION 7.1.3 - 30HXC 310-375 control box

7.1 - Electrical connections 30HXC units

7.1.1 - 30HXC 080-190 control box

1
1

1 1

Legend
1 Main disconnect switch
30HXC A B C D E øH PE Earth connection
Standard S Power supply cable section (see table “Recommended wire sections”).
080-190 (315/400A) 56 25 4 863 314 10.5
Option 150/150A
080-140 (315/400A) 56 25 4 863 314 10.5 30HXC A B C D E F G øH
155-190 (630A) 68 32 6 880 307.5 12.5 Standard
Circuit A
310-375 (400A) 56 25 4 1492.6 314 1824 314 10.5
Circuit B
7.1.2 - 30HXC 200-285 control box 310-345 (400A) 56 25 4 1492.6 314 1824 314 10.5
375 (630A) 68 32 6 1510 307.5 1841 307.5 12.5
Option 150/150A
Circuit A
310 (400A) 56 25 4 1492.6 314 1824 314 10.5
345-375 (630A) 68 32 6 1510 307.5 1841 307.5 12.5
Circuit B
310-375 (630A) 68 32 6 1510 307.5 1841 307.5 12.5

NOTES:
The 30HXC 080-190 and 30GX 082-182 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).
1 1
Non-certified drawings.

Refer to the certified drawings supplied with the unit or

available on request.
30HXC A B C D E F G øH
Standard
Circuit A
200-285 (400A) 56 25 4 841 314 1183 314 10.5
Circuit B
200-285 (250A) 39 23.5 4 811.5 324 - - 8.5
Option 150/150A
Circuit A
200-230 (400A) 56 25 4 841 314 1183 314 10.5
260-285 (630A) 68 32 6 - - 1200 307.5 12.5
Circuit B
200-260 (250A) 39 23.5 4 811.5 324 - - 8.5
285 (400A) 56 25 4 841 314 1183 314 10.5

23
7.2 - Electrical connections 30GX units 7.2.3 - 30GX 207-267 control box

7.2.1 - 30GX 082-132 control box

1

1
1

1758
1872

X 1
Y

30GX X Y
082-102 764 680
112-132 862 924

1
7.2.2 - 30GX 152-182 control box

1 Legend
1 Main disconnect switch
PE Earth connection
S Power supply cable section (see table “Recommended wire sections”).
X Disconnect switch position referred to the unit side
Y Control box position referred to the unit base

1 NOTES:
The 30HXC 080-190 and 30GX 082-182 units have only
one power connection point located at the main disconnect
switch.
X
Y
Before connecting electric power cables, it is imperative
to check the correct order of the 3 phases (L1 - L2 - L3).

30GX X Y
Non-certified drawings.
152-162 682 798
182 912 1028
Refer to the certified drawings supplied with the unit or
available on request.

24
7.2.4 - 30GX 298-358 control box 7.3 - Power supply

The power supply must conform to the specification on the

1 chiller nameplate. The supply voltage must be within the
range specified in the electrical data table. For connections
refer to the wiring diagrams.

WARNING: Operation of the chiller with an improper

supply voltage or excessive phase imbalance constitutes
abuse which will invalidate the Carrier warranty. If the
phase imbalance exceeds 2% for voltage, or 10% for
1 current, contact your local electricity supply at once and
ensure that the chiller is not switched on until corrective
measures have been taken.
1758
1872
7.4 - Voltage phase imbalance (%)

100 x max. deviation from average voltage

Average voltage

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

AB = 406 V; BC = 399 V; AC = 394 V

Legend
1 Main disconnect switch Average voltage = (406 + 399 + 394)/3 = 1199/3
PE Earth connection
S Power supply cable section (see table “Recommended wire sections”). = 399.7 say 400 V

Calculate the maximum deviation from the 400 V average:

NOTES: (AB) = 406 - 400 = 6
The 30HXC 080-190 and 30GX 082-182 units have only (BC) = 400 - 399 = 1
one power connection point located at the main disconnect (CA) = 400 - 394 = 6
switch. Motor

Before connecting electric power cables, it is imperative

to check the correct order of the 3 phases (L1 - L2 - L3). The maximum deviation from the average is 6 V. The
greatest percentage deviation is:
Non-certified drawings.
100 x 6/400 = 1.5%
Refer to the certified drawings supplied with the unit or
available on request. This is less than the permissible 2% and is therefore
acceptable.

25
Electrical data notes for 30HXC units:
• 30HXC 080-190 units have a single power connection point; 30HXC 200-375 - humidity range (non-condensing)*:
units have two connection points. 50% relative humidity at 40°C
• The control box includes the following standard features: 90% relative humidity at 20°C
- Starter and motor protection devices for each compressor - altitude: ≤ 2000 m
- Control devices - indoor installation*
• Field connections: - presence of water: class AD2* (possibility of water droplets)
All connections to the system and the electrical installations must be in full - presence of hard solids, class AE2* (no significant dust present)
accordance with all applicable codes. - presence of corrosive and polluting substances, class AF1 (negligible)
• The Carrier 30HXC units are designed and built to ensure conformance with - vibration and shock, class AG2, AH2
local codes. The recommendations of European standard EN 60204-1 (corre- b. Competence of personnel, class BA4* (trained personnel - IEC 60364)
sponds to IEC 60204-1) (machine safety - electrical machine components - 2. Power supply frequency variation: ± 2 Hz.
part 1: general regulations) are specifically taken into account, when design- 3. The neutral (N) line must not be connected directly to the unit (if necessary use
ing the electrical equipment. a transformer).
• Electrical reserves: 4. Overcurrent protection of the power supply conductors is not provided with the
Circuit B has disconnect switches and branch sections, designed to supply the unit.
evaporator and condenser pump power input. 5. The factory‑installed disconnect switch(es)/circuit breaker(s) is (are) of a type
suitable for power interruption in accordance with EN 60947 (corresponds to
IMPORTANT: IEC 60947) .
• Generally the recommendations of IEC 60364 are accepted as compliance 6. The units are designed for connection to TN networks (IEC 60364). For IT
with the requirements of the installation directives. Conformance with EN networks the earth connection must not be at the network earth. Provide a
60204-1 is the best means of ensuring compliance with the Machines Directive local earth, consult competent local organisations to complete the electrical
and § 1.5.1. installation.
• Annex B of EN 60204‑1 describes the electrical characteristics used for the
operation of the machines. NOTE: If particular aspects of an actual installation do not conform to
the conditions described above, or if there are other conditions which
1. The operating environment for the 30HXC units is specified below: should be considered, always contact your local Carrier representative.
a. Environment* ‑ Environment as classified in IEC 60364 § 3:
- ambient temperature range: +5°C to +40°C, class AA4 * The protection level required to conform to this class is IP21B (according to
reference document IEC 60529). All 30HXC units are protected to IP23C and
fulfil this protection condition.

Electrical data notes for 30GX units:

• 30GX 082-182 units have a single power connection point; 30GX 207-358 - outdoor installation*
units have two connection points. - ambient temperature range: ‑18°C to +46°C, class 4K3*
• The control box includes the following standard features: - altitude: ≤ 2000 m
- Starter and motor protection devices for each compressor and the fan(s) - presence of hard solids, class 4S2* (no significant dust present)
- Control devices - presence of corrosive and polluting substances, class 4C2 (negligible)
• Field connections: - vibration and shock, class 4M2
All connections to the system and the electrical installations must be in full b. Competence of personnel, class BA4* (trained personnel ‑ IEC 60364)
accordance with all applicable local codes. 2. Power supply frequency variation: ± 2 Hz.
• The Carrier 30GX units are designed and built to ensure conformance with 3. The neutral (N) line must not be connected directly to the unit (if necessary use
these codes. The recommendations of European standard EN 60 204-1 a transformer).
(corresponds to IEC 60204-1) (machine safety - electrical machine compo- 4. Overcurrent protection of the power supply conductors is not provided with the
nents - part 1: general regulations) are specifically taken into account, when unit.
designing the electrical equipment. 5. The factory‑installed disconnect switch(es)/circuit breaker(s) is (are) of a type
• Electrical reserves: suitable for power interruption in accordance with EN 60947 (corresponds to
Circuit A has disconnect switches and branch sections, designed to supply the IEC 60947) .
evaporator pump power input. 6. The units are designed for connection to TN networks (IEC 60364). For IT
networks the earth connection must not be at the network earth. Provide a
IMPORTANT: local earth, consult competent local organisations to complete the electrical
• Generally the recommendations of IEC 60364 are accepted as compliance installation.
with the requirements of the installation directives. Conformance with EN 60 204
is the best means of ensuring compliance with the Machines Directive § 1.5.1. NOTE: If particular aspects of an actual installation do not conform to
• Annex B of EN 60204-1 describes the electrical characteristics used for the the conditions described above, or if there are other conditions which
operation of the machines. should be considered, always contact your local Carrier representative.

1. The operating environment for the 30GX units is specified below: * The required protection level for this class is IP43BW (according to reference
a. Environment* ‑ Environment as classified in EN 60 721 (corresponds to document IEC 60529). All 30GX units are protected to IP44CW and fulfil this
IEC 60721): protection condition.

26
7.5 - Recommended wire sections The calculation is based on PVC or XLPE insulated cables
with copper or aluminium core. The maximum temperature
Wire sizing is the responsibility of the installer, and depends is 40°C for 30HXC units and 46°C for 30GX units.
on the characteristics and regulations applicable to each
installation site. The following is only to be used as a guide- The given wire length limits the voltage drop to < 5%.
line, and does not make Carrier in any way liable. After wire
sizing has been completed, using the certified dimensional IMPORTANT: Before connection of the main power
drawing, the installer must ensure easy connection and cables (L1 - L2 - L3) on the terminal block, it is
define any modifications necessary on site. imperative to check the correct order of the 3 phases
before proceeding to the connection on then terminal
The connections provided as standard for the field-supplied block or the main disconnect/isolator switch.
power entry cables to the general disconnect/isolator switch
are designed for the number and type of wires, listed in the 7.5.1 - Field control wiring
table below. Refer to the 30GX/HXC Pro-Dialog Plus Controls IOM
and the certified wiring diagram supplied with the unit for
The calculations are based on the maximum machine current the field control wirting of the following features:
(see electrical data tables). • Evaporator pump interlock (mandatory)
• Remote on/off switch
For the design the following standardised installation • Condenser flow switch (field-supplied, 30HXC only)
methods are used, in accordance with IEC 60364, table 52C: • Remote heat/cool switch
• For 30HXC units installed inside the building: No.13: • Demand limit external switch 1
perforated horizontal cable conduit, and No. 41: closed • Remote dual set point
conduit. • Alarm report by circuit
• For 30GX units installed outside the building: No.17: • Evaporator pump control
suspended aerial lines, and No. 61: buried conduit with • Condenser pump control (30HXC only)
a derating coefficient of 20. • Remote set point reset or outside air temperature
sensor reset (0-10 V)

7.5.2 - Selection table of minimum and maximum wire sections for connection to 30HXC units

400 V-3 ph-50 Hz

30HXC Minimum wire Maximum wire
section (mm2)* Wire type L (m) section (mm2)* Wire type L (m)
080 1 x 50 XLPE Cu 160 1 x 120 XLPE Al 205
090 1 x 50 XLPE Cu 160 1 x 120 XLPE Al 205
100 1 x 70 XLPE Cu 170 1 x 150 XLPE Al 210
110 1 x 70 XLPE Cu 170 1 x 185 XLPE Al 220
120 1 x 95 XLPE Cu 180 1 x 185 XLPE Al 220
130 1 x 95 XLPE Cu 180 1 x 240 XLPE Al 225
140 1 x 120 XLPE Cu 185 2 x 95 XLPE Al 195
155 1 x 120 XLPE Cu 185 2 x 120 XLPE Al 205
175 1 x 150 XLPE Cu 190 2 x 120 XLPE Al 205
190 1 x 185 XLPE Cu 190 2 x 150 XLPE Al 210
200 Circuit A 1 x 95 XLPE Cu 180 1 x 185 XLPE Al 220
1 x 120 XLPE Cu 225
230 Circuit A 1 x 95 XLPE Cu 180 1 x 240 XLPE Al 225
1 x 150 XLPE Cu 230
260 Circuit A 1 x 120 XLPE Cu 185 2 x 150 XLPE Al 265
1 x 240 XLPE Cu 235
285 Circuit A 1 x 150 XLPE Cu 190 2 x 185 XLPE Al 270
2 x 120 XLPE Cu 280
310 Circuit A 1 x 120 XLPE Cu 185 2 x 120 XLPE Al 255
2 x 95 XLPE Cu 270
345 Circuit A 1 x 120 XLPE Cu 185 2 x 150 XLPE Al 265
2 x 95 XLPE Cu 270
375 Circuit A 1 x 150 XLPE Cu 190 2 x 185 XLPE Al 270
2 x 120 XLPE Cu 280
200 Circuit B 1 x 50 XLPE Cu 160 1 x 120 XLPE Al 205
1 x 70 XLPE Cu 205
230 Circuit B 1 x 70 XLPE Cu 170 1 x 150 XLPE Al 210
1 x 95 XLPE Cu 215
260 Circuit B 1 x 95 XLPE Cu 180 1 x 150 XLPE Al 210
1 x 95 XLPE Cu 215
285 Circuit B 1 x 95 XLPE Cu 180 1 x 185 XLPE Al 220
1 x 120 XLPE Cu 225
310 Circuit B 1 x 185 XLPE Cu 190 2 x 185 XLPE Al 270
1 x 240 XLPE Cu 235
345 Circuit B 1 x 185 XLPE Cu 190 2 x 185 XLPE Al 270
2 x 120 XLPE Cu 280
375 Circuit B 1 x 240 XLPE Cu 190 2 x 240 XLPE Al 280
2 x 150 XLPE Cu 290
* Power supply wire section (see diagrams/legend S in chapter ‘Electrical connection’). The disconnect switches are indicated by a 1.

27
7.5.3 - Selection table of minimum and maximum wire sections for connection to 30HXC units with high condensing
temperatures (option 150 + 150A)

400 V-3 ph-50 Hz

30HXC Minimum wire Maximum wire
section (mm2)* Wire type L (m) section (mm2)* Wire type L (m)
080 Opt. 150 1 x 70 XLPE Cu 170 1 x 150 XLPE Al 210
090 Opt. 150 1 x 70 XLPE Cu 170 1 x 185 XLPE Al 220
100 Opt. 150 1 x 95 XLPE Cu 180 1 x 240 XLPE Al 225
110 Opt. 150 1 x 95 XLPE Cu 180 1 x 240 XLPE Al 225
120 Opt. 150 1 x 120 XLPE Cu 185 2 x 95 XLPE Al 195
130 Opt. 150 1 x 120 XLPE Cu 185 2 x 120 XLPE Al 205
140 Opt. 150 1 x 150 XLPE Cu 190 2 x 120 XLPE Al 205
155 Opt. 150 1 x 185 XLPE Cu 190 2 x 150 XLPE Al 210
175 Opt. 150 1 x 185 XLPE Cu 190 2 x 150 XLPE Al 210
190 Opt. 150 2 x 95 XLPE Cu 170 2 x 240 XLPE Al 225
200 Opt. 150 Circuit A 1 x 120 XLPE Cu 185 2 x 150 XLPE Al 265
1 x 185 XLPE Cu 235
230 Opt. 150 Circuit A 1 x 150 XLPE Cu 190 2 x 150 XLPE Al 265
1 x 240 XLPE Cu 235
260 Opt. 150 Circuit A 1 x 185 XLPE Cu 190 2 x 240 XLPE Al 280
2 x 150 XLPE Cu 290
285 Opt. 150 Circuit A 1 x 240 XLPE Cu 190 2 x 240 XLPE Cu 295
310 Opt. 150 Circuit A 1 x 150 XLPE Cu 190 2 x 185 XLPE Al 270
2 x 120 XLPE Cu 280
345 Opt. 150 Circuit A 1 x 185 XLPE Cu 190 2 x 240 XLPE Al 280
2 x 150 XLPE Cu 290
375 Opt. 150 Circuit A 1 x 240 XLPE Cu 190 2 x 240 XLPE Cu 295
200 Opt. 150 Circuit B 1 x 70 XLPE Cu 170 1 x 150 XLPE Al 210
1 x 95 XLPE Cu 215
230 Opt. 150 Circuit B 1 x 70 XLPE Cu 170 1 x 185 XLPE Al 220
1 x 120 XLPE Cu 225
260 Opt. 150 Circuit B 1 x 70 XLPE Cu 170 1 x 185 XLPE Al 220
1 x 120 XLPE Cu 225
285 Opt. 150 Circuit B 1 x 120 XLPE Cu 185 2 x 150 XLPE Al 265
1 x 185 XLPE Cu 235
310 Opt. 150 Circuit B 1 x 185 XLPE Cu 190 2 x 240 XLPE Al 280
2 x 150 XLPE Cu 290
345 Opt. 150 Circuit B 1 x 240 XLPE Cu 190 2 x 240 XLPE Al 280
2 x 150 XLPE Cu 290
375 Opt. 150 Circuit B 2 x 95 XLPE Cu 170 2 x 240 XLPE Cu 295
* Power supply wire section (see diagrams/legend S in chapter ‘Electrical connection’). The disconnect switches are indicated by a 1.

7.5.4 - Selection table of minimum and maximum wire sections for connection to 30GX units

400 V-3 ph-50 Hz

30GX Minimum wire Maximum wire
section (mm2)* Wire type L (m) section (mm2)* Wire type L (m)
082 1 x 95 XLPE Cu 190 2 x 240 PVC Al 450
092 1 x 120 XLPE Cu 195 2 x 240 PVC Al 450
102 1 x 120 XLPE Cu 195 2 x 185 PVC Cu 470
112 1 x 150 XLPE Cu 200 2 x 240 PVC Cu 480
122 1 x 185 XLPE Cu 205 2 x 240 PVC Cu 480
132 1 x 185 XLPE Cu 205 3 x 240 XLPE Cu 355
152 1 x 240 XLPE Cu 205 3 x 240 PVC Cu 600
162 1 x 240 XLPE Cu 205 3 x 185 XLPE Cu 430
182 2 x 120 XLPE Cu 200 3 x 240 XLPE Cu 440
207 (Circuit A) 1 x 185 XLPE Cu 205 3 x 240 PVC Cu 685
227 (Circuit A) 1 x 240 XLPE Cu 205 3 x 185 XLPE Cu 490
247 (Circuit A) 1 x 240 XLPE Cu 205 3 x 240 XLPE Cu 505
267 (Circuit A) 2 x 120 XLPE Cu 200 3 x 240 XLPE Cu 505
298 (Circuit A) 2 x 95 XLPE Cu 190 3 x 240 XLPE Cu 505
328 (Circuit A) 2 x 95 XLPE Cu 190 3 x 240 XLPE Cu 505
358 (Circuit A) 2 x 120 XLPE Cu 200 3 x 240 XLPE Cu 505
207/227/247 (Circuit B) 1 x 95 XLPE Cu 190 2 x 240 PVC Al 560
2 x 95 XLPE Cu 380
267 (Circuit B) 1 x 120 XLPE Cu 195 2 x 240 XLPE Al 410
2 x 150 XLPE Cu 415
298 (Circuit B) 1 x 185 XLPE Cu 205 3 x 240 PVC Cu 685
328 (Circuit B) 1 x 240 XLPE Cu 205 3 x 185 XLPE Cu 490
358 (Circuit B) 2 x 120 XLPE Cu 200 3 x 240 XLPE Cu 505
* Power supply wire section (see diagrams/legend S in chapter ‘Electrical connection’). The disconnect switches are indicated by a 1.

28
8 - WATER CONNECTIONS Carrier recommendations on heat exchange fluids:
1. No NH4+ ammonium ions in the water, they are very
ATTENTION: Before carrying out any water connections detrimental for copper. This is one of the most important
install the water box purge plugs (one plug per water box factors for the operating life of copper piping. A con-
in the lower section - supplied in the control box). tent of several tenths of mg/l will badly corrode the
copper over time.
For size and position of the heat exchanger water inlet and 2. Cl- Chloride ions are detrimental for copper with a risk
outlet connections refer to the certified dimensional drawings of perforations by corrosion by puncture. If possible
supplied with the unit. keep below 10 mg/l.
3. SO42- sulphate ions can cause perforating corrosion, if
The water pipes must not transmit any radial or axial force their content is above 30 mg/l.
to the heat exchangers nor any vibration. 4. No fluoride ions (<0.1 mg/l).
5. No Fe2+ and Fe3+ ions with non negligible levels of dis-
The water supply must be analysed and appropriate filtering, solved oxygen must be present. Dissolved iron < 5 mg/l
treatment, control devices, isolation and bleed valves and with dissolved oxygen < 5 mg/l.
circuits built in, to prevent corrosion, fouling and deteriora- 6. Dissolved silicon: silicon is an acid element of water
tion of the pump fittings. Consult either a water treatment and can also lead to corrosion risks. Content < 1 mg/l.
specialist or appropriate literature on the subject. 7. Water hardness: > 0.5 mmol/l. Values between 1 and
2.5 can be recommended. This will facilitate scale
8.1 - Operating precautions deposit that can limit corrosion of copper. Values that
are too high can cause piping blockage over time. A
The water circuit should be designed to have the least total alkalimetric titre (TAC) below 100 is desirable.
number of elbows and horizontal pipe runs at different levels. 8. Dissolved oxygen: Any sudden change in water oxygena-
Below the main points to be checked for the connection: tion conditions must be avoided. It is as detrimental to
• Comply with the water inlet and outlet connections deoxygenate the water by mixing it with inert gas as it
shown on the unit. is to over-oxygenate it by mixing it with pure oxygen.
• Install manual or automatic air purge valves at all high The disturbance of the oxygenation conditions
points in the circuit(s). encourages destabilisation of copper hydroxides and
• Use an expansion device to maintain pressure in the enlargement of particles.
circuit(s) and install a safety valve as well as an expan- 9. Specific resistance – electric conductivity: the higher the
sion tank. specific resistance, the slower the corrosion tendency.
• Install thermometers in both the entering and leaving Values above 30 Ohm·m are desirable. A neutral
water connections. environment favours maximum specific resistance
• Install drain connections at all low points to allow the values. For electric conductivity values in the order of
whole circuit to be drained. 20-60 mS/m can be recommended.
• Install stop valves, close to the entering and leaving 10. pH: Ideal case pH neutral at 20-25°C
water connections. 7 < pH < 8
• Use flexible connections to reduce the transmission of
vibrations. If the water circuit must be emptied for longer than one
• Insulate all pipework, after testing for leaks, both to month, the complete circuit must be placed under nitrogen
reduce heat gains and to prevent condensation. charge to avoid any risk of corrosion by differential aeration.
• Cover the insulation with a vapour barrier.
• Where there are particles in the fluid that could foul Charging and removing heat exchange fluids should be done
the heat exchanger, a screen filter should be installed with devices that must be included on the water circuit by
ahead of the pump. The mesh size of the filter must be the installer. Never use the unit heat exchangers to add
1.2 mm (see ‘Typical water circuit’ diagram). heat exchange fluid.

Before the system start-up verify that the water circuits are
connected to the appropriate heat exchangers (e.g. no rever-
sal between evaporator and condenser).

Do not introduce any significant static or dynamic pressure

into the heat exchange circuit (with regard to the design
operating pressures).

Before any start-up verify that the heat exchange fluid is

compatible with the materials and the water circuit coating.

In case additives or other fluids than those 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.

29
8.2 - Water connections Potentiometer adjustment

This diagram shows a typical water installation.

Typical water circuit diagram

1 2
2

4 5

9
12
10
11
6
8
7

Legend
1 Control valve
2 Air vent
3 Flow switch for the evaporator 1
4 Flexible connection
5 Heat exchanger
6 Pressure tap
7 Thermostat sleeve Legend
8 Drain 1 Setting potentiometer sensitivity
9 Buffer tank 2 Chain of LEDs
10 Filter (mesh size: 1.2 mm = 20 mesh) - red LED lights: the unit is not adjusted
11 Expansion tank - yellow LED lights: the output is switched
12 Fill valve - green LED lights: the unit is adjusted

8.3 - Flow control 8.3.2 - Condenser water flow switch (30HXC)

The use of a condenser water flow switch is recommended.
8.3.1 - Evaporator flow switch and chilled water pump The flow switch is not supplied, and must be installed on
interlock site and connected in accordance with the wiring diagrams.

IMPORTANT: On 30GX and 30HXC units, the unit water 8.4 - Evaporator (and condenser for the 30HXC)
flow switch must be energised, and the chilled water pump water box bolt tightening
interlock must be connected. Failure to follow this instruc-
tion will void the Carrier guarantee. The evaporator (and condenser) are of the shell and tube
type with removable water boxes to facilitate cleaning. Re-
The flow switch is supplied, installed on the evaporator tightening or tightening must be done in accordance with
entering water pipe and preset at the factory to cut out when the illustration below.
there is insufficient water flow. If adjustment is necessary:
1. Switch on the unit. Set it to constant flow (preset value). Water box tightening sequence

The yellow LED is illuminated, and the output is

switched for approximately 20 seconds (power-on
delay time).
2. Turn the potentiometer until one green LED is illu-
minated.

The further the green LED is from the yellow LED,

the safer the adjustment (standby capacity in case of
flow or temperature fluctuations).
3. After the adjustment attach the label supplied to the
potentiometer, in order to protect it against unautho-
rised tampering.
Legend
Terminals 34 and 35 are provided for field installation of 1 Sequence 1: 1 2 3 4
the chilled water pump interlock (auxiliary contact for Sequence 2: 5 6 7 8
Sequence 3: 9 10 11 12
pump operation to be wired on site).
2 Tightening torque
Bolt size M16 - 171 - 210 Nm

NOTE: Before this operation we recommend draining the

circuit and disconnecting the pipes to be sure that the bolts
are correctly and uniformly tightened.

30
8.5 - Frost protection 8.6 - Operation of two units in master/slave mode

8.5.1 - Standard machine The control of a master/slave assembly is in the entering

If the chiller or the water piping is in an area where the water and does not require any additional sensors (standard
ambient temperature can fall below 0°C it is recommended configuration). It can also be located in the leaving water.
to add an antifreeze solution to protect the unit and the water In this case two additional sensors must be added on the
piping to a temperature of 10 K below the lowest tempera- common piping.
ture likely to be reached at the installation site. Use only
antifreeze solutions, approved for heat exchanger duty. If All parameters, required for the master/slave function must
the system is not protected by an antifreeze solution and be configured using the Service Configuration menu. All
will not be used during the freezing weather conditions, remote controls of the master/slave assembly (start/stop, set
draining of the cooler and outdoor piping is mandatory. point, load shedding etc.) are controlled by the unit confi-
Damage due to freezing is not covered by the warranty. gured as master and must only be applied to the master unit.

IMPORTANT: Depending on the climatic conditions in Each unit controls its own water pump. If there is only one
your area you must: common pump, in cases with variable flow, isolation valves
• Add ethylene glycol with an adequate concentration to must be installed on each unit. They will be activated at the
protect the installation up to a temperature of 10 K opening and closing by the control of each heat pump (in
below the lowest temperature likely to occur at the this case the valves are controlled using the dedicated water
installation site. pump outputs). See the 30GX/HXC Pro-Dialog Plus Con-
• If the unit is not used for an extended period, it is trol IOM for a more detailed explanation.
recommended to drain it, and as a safety precaution
add ethylene glycol to the heat exchanger, using the 30HXC/GX with configuration: leaving water control
water entering purge valve connection (a purge connec-
tion is available somewhere on the heat exchanger
water box in case the machine is not perfectly level).

At the start of the next season, refill the unit with water
and add an inhibitor.
• For the installation of auxiliary equipment, the instal-
ler must comply with basic regulations, especially for
minimum and maximum flow rates, which must be 1 2
between the values listed in the operating limit table
(application data).

8.5.2 - Optional evaporator frost protection (30GX)

In cases where it is not possible to apply the recommenda-
tions in paragraph 8.5.1, the units can be equipped with
heaters to protect the evaporator against frost (option 41A).
See chapter 10.4 “Evaporator frost protection (30GX)”.
Legend
1 Master unit
2 Slave unit
Control boxes of the master and slave units

Water inlet
Water outlet
Water pumps for each unit (included as standard for units with hydronic
module)
Additional sensors for leaving water control, to be connected to channel 1
of the slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors

31
9 - Major system components and operation 9.2 - Pressure vessels
data
9.2.1 - Evaporator
9.1 - Geared twin screw compressor 30HXC and 30GX chillers use a flooded evaporator. The
water circulates in the tubes and the refrigerant is on the
• 30HXC and 30GX units use 06N geared twin screw outside in the shell. One vessel is used to serve both refrige-
compressors rant circuits. There is a center tube sheet which separates
• 06NA are used on 30GX (air-cooled condensing appli- the two refrigerant circuits. The tubes are 3/4” diameter
cation) copper with an enhanced surface inside and out. There is
• 06NW are used on 30HXC (water-cooled condensing just one water circuit, and depending on the size of the
application) chiller, there may be two or three water passes.
• Nominal capacities range from 137 to 281 kW (39 to
80 tons). Economized or non economized models are At the top of the cooler are the two suction pipes, one in
used depending on the 30HXC and 30GX unit size. each circuit. Each has a flange welded to it, and the compres-
sor mounts on the flange.
9.1.1 - Oil filter
The 06N screw compressor has an oil filter integral in the The evaporator shell has a thermal insulation of 19 mm
compressor housing. This filter is field replaceable. thick polyurethane foam and a water drain and purge. With
the very low temperature option this insulation is 38 mm
9.1.2. - Refrigerant thick.
The 06N screw compressor is specially designed to be used
in R-134 a system only. 9.2.2 - Condenser and oil separator (30HXC)
30HXC chiller use a vessel that is a combination condenser
9.1.3 - Lubricant and oil separator. It is mounted below the cooler. Discharge
The 06N screw compressor is approved for use with the gas leaves the compressor and flows through an external
following lubricant: Carrier material spec PP 47-32. muffler to the oil separator, which is the upper portion of
the vessel. It enters the top of the separator where oil is
9.1.4 - Oil supply solenoid valve removed, and then flows to the bottom portion of the vessel,
An oil supply solenoid valve is standard on the compressor where gas is condensed and subcooled. One vessel is used
to isolate the compressor from oil flow when the compressor to serve both refrigerant circuits. There is a center tube
is not operating. sheet which separates the two refrigerant circuits. The tubes
are 3/4” or 1” diameter copper with enhanced surface inside
The oil solenoid is field replaceable. and out. There is just one water circuit with two water passes.

9.1.5 - Suction and economizer screens The condenser shell can have a thermal insulation of 19 mm
To increase the reliability of the compressor, a screen has thick polyurethane foam and a water drain and purge.
been incorporated as a standard feature into suction and
economizer inlets of the compressor. 9.2.3 - Oil separator (30GX)
In the air-cooled units, the oil separator is a pressure vessel
9.1.6 - Unloading system that is mounted under the outside vertical condenser coils.
The 06N screw compressor has an unloading system that is Discharge gas enters at the top of the separator where much
standard on all compressors. This unloading system consists of the oil separates and drains to the bottom. The gas then
of two steps of unloading that decrease the compressor capa- flows through a wire mesh screen where the remaining oil
city by rerouting partially compressed gas back to suction. is separated and drains to the bottom.

The oil separator vessel shell has a thermal insulation of

19 mm thick polyurethane foam.

The oil separator is equipped with a trace heater regulated

by the control. This heater is equipped with an internal ther-
mostat that disconnects the power supply when the tempe-
rature reaches 85°C and automatically resets when the tem-
perature again falls to a normal value.

The products that may be added for thermal insulation of

the vessels 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.

32
NOTES: Monitoring during operation, re-qualification, 9.3 - Electronic expansion device (EXV)
re-testing and re-testing dispensation:
• Follow the regulations on monitoring pressurised The microprocessor controls the EXV through the EXV
equipment. control module. Inside this EXV is a linear actuator stepper
• It is normally required that the user or operator sets motor. High-pressure liquid refrigerant enters the valve
up and maintains a monitoring and maintenance file. through the bottom. A series of calibrated slots are located
• Follow the control programmes of EN 378-2, annexes inside the orifice assembly. As refrigerant passes through the
A, B, C and D. orifice, the pressure drops and the refrigerant changes to a
• If they exist follow local professional recommenda- 2-phase condition (liquid and vapour). To control refrige-
tions. rant flow for different operating conditions, the sleeve moves
• Regularly inspect the condition of the coating (paint) up and down over the orifice, thereby changing effective
to detect blistering resulting from corrosion. To do flow area of expansion device. The sleeve is moved by a
this, check a non-insulated section of the container linear stepper motor. The stepper motor moves in incre-
or the rust formation at the insulation joints. ments and is controlled directly by the processor module.
• Regularly check for possible presence of impurities As the stepper motor rotates, motion is transferred into
(e.g. silicon grains) in the heat exchange fluids. These linear movement by the lead screw. Through the stepper
impurities maybe the cause of the wear or corrosion motor and lead screws, 1500 discrete steps of motion are
by puncture. obtained. The large number of steps and long stroke result
• Filter the heat exchange fluid check and carry out in very accurate control of refrigerant flow.
internal inspections as described in EN 378-2, annex C.
• In case of re-testing take the maximum pressure diffe- At initial start-up, the EXV position is at zero. After that, the
rence into consideration. Never exceed the maximum microprocessor keeps accurate track of the valve position
or minimum operating pressures given on the unit in order to use this information as input for the other
nameplate. control functions. It does this by initializing the EXV’s at
• The reports of periodical checks by the user or operator startup. The processor sends out enough closing pulses to
must be included in the supervision and maintenance the valve to move it from fully open to fully closed, then
file. resets the position counter to zero. From this point on,
until the initialization, the processor counts the total
Repair number of open and closed steps it has sent to each valve.
Any repair or modification, including the replacement of
moving parts: 9.4 - Economizer
• must follow local regulations and be made by qualified
operators and in accordance with qualified procedures, Economizers are installed on 30HXC 190, 285 and 375 and
including changing the heat exchanger tubes, 30GX 182, 267 and 358.
• must be made in accordance with the instructions of
the original manufacturer. Repair and modification The economizer improves both the chiller capacity and effi-
that necessitate permanent assembly (soldering, welding, ciency as well as providing motor cooling. The economizers
expanding etc.) must be made using the correct proce- used are direct-expansion plate heat exchangers.
dures and by qualified operators,
The flow of the direct-expansion plate heat exchanger
An indication of any modification or repair must be shown circuit is adjusted by the motor cooling valves. The circuit
in the monitoring and maintenance file. permits sub-cooling of the liquid circuit.

Recycling 9.5 - Oil pumps

The unit is wholly or partly recyclable. After use it contains
refrigerant vapours and oil residue. It is coated by paint. The 30GX/HXC screw chillers use one externally mounted
pre-lubricating oil pump per circuit. This pump is operated
Operating life as part ot the start-up sequence.
This unit is designed for:
• prolonged storage of 15 years under nitrogen charge ATTENTION: The operating temperature of the coil may
with a temperature difference of 20 K per day, reach 80°C. In certain temporary conditions (especially
• 452000 cycles (start-ups) with a maximum difference during start-up at low outside temperature or low conden-
of 6 K between two neighbouring points in the vessel, ser loop temperature) the oil pump can be reactivated.
based on 6 start-ups per hour over 15 years at a usage
rate of 57%. On 30GX units, the pumps are mounted to the base rails on
the oil separator side of the unit. The pumps are mounted
Corrosion allowances to a bracket on the condensers of 30HXC units. When a
• Gas side: 0 mm circuit is required to start, the controls will energize the oil
• Heat exchange fluid side: 1 mm for tubular plates in pump first so that the compressor starts with correct lubri-
lightly alloyed steels, 0 mm for stainless steel plates or cation. If the pump has built up sufficient oil pressure, the
plates with copper-nickel or stainless steel protection. compressor will be allowed to start. Once the compressor
has started, the oil pump will be turned off. If the pump was
not able to build up enough oil pressure, the control will
generate an alarm.

33
9.6 - Motor cooling valves 9.7 - Sensors

Compressor motor winding temperatures are controlled to The units use thermistors to measure the temperature, and
the optimum setpoint. The control accomplishes this by pressure transducers to control and regulate system opera-
cycling the motor cooling solenoid valve to allow liquid tion (see 30GX/HXC - Pro-Dialog Plus Control IOM for a
refrigerant to flow across the motor windings as needed. On more detailed explanation).
units equipped with economizers, a single valve per circuit
controls the refrigerant flow required for the economizer
effect and for motor cooling. This is a valve with progressive
control. The adjustment of the opening is determined by
Pro-Dialog, based on the compressor motor temperature.

30GX fan arrangement

GX082/102 GX112/132 GX152/162

EV31 EV32 EV31 EV32 EV33 EV31 EV32 EV33 EV34

EV12 EV11 EV13 EV12 EV11 EV14 EV13 EV12 EV11

GX182 GX207/227

EV31 EV33 EV13 EV11 EV31 EV33 EV15 EV13 EV11

EV32 EV34 EV14 EV12 EV32 EV34 EV16 EV14 EV12

GX247/267 GX298

EV31 EV33 EV17 EV15 EV13 EV11 EV31 EV33 EV35 EV17 EV15 EV13 EV11

EV32 EV34 EV18 EV16 EV14 EV12 EV32 EV34 EV36 EV18 EV16 EV14 EV12

GX328/358

EV31 EV33 EV35 EV37 EV17 EV15 EV13 EV11

EV32 EV34 EV36 EV38 EV18 EV16 EV14 EV12

34
10 - MAIN OPTIONS AND ACCESSORIES When the unit stops, the closure of the solenoid valves pre-
vents migration of the refrigerant contained in the evapora-
Depending on the applications for which the units are tor to the condenser, if this is the cold point of the circuit.
selected, they can be equipped with options. This chapter The heaters are activated, when the outdoor temperature
describes the main components that require special infor- is low and permit maintaining a saturated pressure in the
mation for correct start-up and maintenance of these units, evaporator (see 30GX/HXC Pro-Dialog Plus Control IOM
except where this is contained in a separate document. for a more detailed explanation).

10.1 - Compressor suction valves (option 92) Heater capacities 30GX units
30GX Capacity in kW
These valves are designed to isolate the compressor from the 082-132 4.3
rest of the circuit. Discharge valves, oil valves and cooling 152-162 4.8
182 5.3
valves are installed in the standard unit. A label attached 207-227 5.8
to the evaporator near each valve shows the open or closed 247-358 6.9
position of the valve. It is important to remove the cap in
order to manoeuvre the valve shaft and to replace it after IMPORTANT: To ensure that the protection works the
this operation to ensure leak-tightness. heaters and the control must be energised. The correct
operation of the heaters must be verified at start-up and
10.2 - Compressor and evaporator noise insulation must form part of the annual operation checks of these
(30GX - option 14A) units.

The evaporator and the compressor body are wrapped in a Never switch off the heaters. The main disconnect switch
noise-absorbing cover, consisting of a leak-tight enclosure, (QS 101) and the auxiliary heater disconnect switch must
protecting a flexible acoustic material. It is fixed with self- always remain energised (see wiring diagram for location
adhesive tape to the components. During maintenance opera- of QS and QF 101).
tions certain parts must be removed, and later replaced.
Take care to avoid damage the leak-tight enclosure of the 10.5 - Year-round operation of 30GX units (option 28)
acoustic material and the electrical connections.
The modifications compared with the standard units consist
10.3 - Low-noise 30GX units equipped with acoustic of placing insulated trace heaters on:
panels (option 15) • the oil piping
• the oil filter box body
The modifications compared with the standard units are:
• Factory-installation of an acoustic board. These elements can be shown on the unit and on the wiring
• Factory-installation of side panels. diagram.
• Field-installation of a fixing system for the acoustic
panels. The heaters are activated, based on the outdoor tempera-
• Field-installation of removable acoustic panels. ture (see 30GX/HXC Pro-Dialog Plus Control IOM for a
more detailed explanation).
These units have a special dimensional drawing. The mount-
ing instructions are supplied with the panel fixing system. The heaters are equipped with an internal thermostat that
Following these instructions will: disconnects the power supply when the temperature reaches
• facilitate installation 85°C and automatically resets when the temperature again
• identify the position of each panel falls to a normal value.
• identify the panel(s) behind which the control box is
located 10.6 - Soft Start for 3- and 4-compressor 30HXC and
• permit connection of a service tool linked to CCN 30GX units (option 25)
without removing the panels.
These units are equipped with an electronic compressor
10.4 - Evaporator frost protection (30GX - option 41A) starter. This permits optimising the start-up current, and
reducing nuisance cut-outs due to current surges in the
The modifications compared with the standard units are: electrical system at start-up. The starter parameters are
• additional solenoid valves at the condenser entering factory-set.
piping
• additional liquid solenoid valves at the evaporator For more detailed information refer to the specific docu-
entering refrigerant piping ment supplied with this option.
• additional heaters on the shell and the evaporator
water heads (under the insulation). IMPORTANT: If any work is carried out on the electrical
components, normal safety measures must be observed.
These elements can be shown on the unit and on the wiring Factory settings must not be modified. If these instructions
diagram. are not followed, the Carrier guarantee will become invalid.

35
10.7 - Electric protection level of the 30HXC control 11 - Maintenance
boxes to IP44C (option 20)
11.1 - Maintenance instructions
The control boxes are leak-tight and equipped with a venti-
lation system to ensure cooling of the electrical components. During the unit operating life the service checks and tests
The control box fan is controlled by a thermostat (setpoint must be carried out in accordance with applicable national
55°C, differential 20°C). A safety thermostat switches the regulations.
unit off, if the control box temperature exceeds 60°C.
If there are no similar criteria in local regulations, the
These elements can be shown on the unit and on the wiring information on checks during operation in annex C of
diagram. standard EN 378-2 can be used.

10.8 - Tropicalised control box for 30HXC and 30GX External visual checks: annex D of standard EN 378-2. These
units (option 22) controls must be carried out:
• After an intervention that is likely to affect the resis-
The control boxes are leak-tight and equipped with heaters. tance or a change in use or change of high-pressure
The standard components are already treated for “all- refrigerant, or after a shut down of more than two years.
weather” operation. Heating the air will reduce the mois- Components that do not comply, must be changed.
ture level in the control box and prevent condensation. Test pressures above the respective component design
pressure must not be applied (annex B and D).
10.9 - Brine units for low-temperature evaporator • After repair or significant modifications or significant
leaving applications (option 5) system or component extension (annex B).
• After re-installation at another site (annexes A, B and D).
These units are verified for compatibility between unit and • After repair following a refrigerant leak (annex D).
specific application. The frequency of refrigerant leak detection can vary
from once per year for systems with less than 1% leak
They have control configuration parameters that are rate per year to once a day for systems with a leak
matched to the application (see 30GX/HXC Pro-Dialog rate of 35% per year or more. The frequency is in
Plus Control IOM for a more detailed explanation). proportion with the leak rate.

10.10 - Disassembled 30HXC units (option 51) NOTE: High leak rates are not acceptable. The necessary
steps must be taken to eliminate any leak detected.
These units are equipped with flange connections on the
refrigerant piping to permit disassembly of the units without NOTE 2: Fixed refrigerant detectors are not leak detectors,
unwelding. The dimensional drawing for this option gives as they cannot locate the leak.
the weight of the different parts. The units are fully factory-
assembled, charged with oil and refrigerant and run-tested 11.2 - Soldering and welding
at the end of the assembly line. The refrigerant charge is
then removed and replaced by a nitrogen holding charge. Component, piping and connection soldering and welding
operations must be carried out using the correct procedures
IMPORTANT: The oil charge remains in the unit and and by qualified operators. Pressurised containers must not
must not be exposed to moisture during disassembly and be subjected to shocks, nor to large temperature variations
reassembly. The refrigerant charge is not supplied and must during maintenance and repair operations.
be provided on site. Please refer to the unit nameplate.
11.3 - Refrigerant charging - adding charge
10.11 - Available fan pressure of 150 Pa for 30GX
units (option 12) Important: These units are designed for use with R-134a
only. DO NOT USE ANY OTHER refrigerant in these
The electrical section and the fan disconnect switches are units.
matched to the application. The relevant certified dimen-
sional drawing shows the new elements (unit weights and CAUTION: When adding or removing charge, circulate
dimensions, duct connection diameters and location). water through the condenser (HX) and cooler at all times
to prevent freezing. Freezing damage is considered abuse
IMPORTANT: The units (supplied for operation with and may void the Carrier warranty.
discharge ducts) are shipped without fan discharge protec-
tion grilles. For safety reasons, the unit must not be started All refrigerant removal and draining operations must be
until the ducts have been connected. 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.

CAUTION: DO NOT OVERCHARGE system. Over-

charging results in higher discharge pressure with higher
cooling fluid consumption, possible compressor damage
and higher power consumption.

36
11.4 - Indication of low charge on a 30HXC system 7. Verify adequate charge by continuing to run at full-
load with 6°C ± 1.5 K evaporator leaving fluid tempe-
NOTE : To check for low refrigerant charge on a 30HXC, rature. Check that the refrigerant is not flashing in the
several factors must be considered. A flashing liquid-line liquid-line sightglass. The EXD Percent Open should
sightglass is not necessarily an indication of inadequate be between 40 and 60%. The cooler level indicator
charge. There are many system conditions where a flashing should be in the range of 1.5 - 2.5.
sightglass occurs under normal operation. The 30HXC
metering device is designed to work properly under these 11.4.2 - Indication of low charge on 30GX systems
conditions. 1. Make sure that the circuit is running at a full-load con-
dition and that the condensing temperature is 50°C
1. Make sure that the circuit is running at a full-load ± 1.5 K. To check whether circuit A is fully-loaded,
condition. To check whether circuit A is fully loaded, follow the procedure in the 30GX/HXC Pro-Dialog
follow the procedure described in the Controls manual. Plus Controls IOM.
2. It may be necessary to use the Manual Control feature 2. It may be necessary to use the Manual Control feature
to force the circuit into a full-load condition. If this is to force the circuit into a full-load condition. If this is
the case, see the instructions for using the Manual the case, see the instructions for using the Manual
Control feature in the Controls manual. Control function (procedure in the 30GX/HXC Pro-
3. With the circuit running at full-load, verify that the Dialog Plus Controls IOM).
cooler leaving fluid temperature is in the range of 6°C 3. With the circuit running at full-load, verify that the
± 1.5 K. cooler leaving fluid temperature is in the range of 6°C
4. At this condition, observe the refrigerant in the liquid ± 1.5 K.
line sightglass. If there is a clear sightglass, and no signs 4. Measure the air temperature entering the condenser
of flashing, then the circuit is adequately charged. Skip coils. Measure the liquid temperature after the tee
the remaining steps. where the two coil liquid lines join. The liquid tempera-
5. If the refrigerant appears to be flashing, the circuit is ture should be 8.3 K above the air temperature ente-
probably low on charge. Verify this by checking the EXV ring the coils. If the difference is more than this and
position (see 30GX/HXC Pro-Dialog Plus Controls the sightglass is flashing, the circuit is uncharged. Pro-
IOM). ceed to step 5.
6. If the opening position of the EXD is greater than 5. Add 2.5 kg of liquid charge into the cooler using char-
60%, and if the liquid-line sightglass is flashing, then ging valve located in the top of the cooler.
the circuit is low on charge. Follow the procedure for 6. Allow the system to stabilize and then recheck the
adding charge. liquid temperature. Repeat step 5 as needed allowing
the system to stabilize between each charge addition.
11.4.1 - To add charge to the 30HXC systems Slowly add charge as the sightglass begins to clear to
1. Make sure that the unit is running at full-load, and that avoid over-charging.
the cooler leaving fluid temperature is in the range of
5.6 to 7.8°C. 11.4.3 - Space temperature, outdoor air temperature
2. At these operating conditions, check the liquid-line (optional)
sightglass. If there is a clear sightglass, then the unit These temperatures are used to measure the temperature
has sufficient charge. If the sightglass is flashing, then of the space or the outside air temperature respectively for
check the EXD Percent Open. If this is greater than reset control based on Outside Air or Space Temperature
60%, then begin adding charge. reset options.

NOTE: A flashing liquid-line sightglass at operating con- 11.5 - Electrical maintenance

ditions other than those mentioned above is not necessarily
an indication of low refrigerant charge. When working on the unit comply with all safety precautions
decribed in section “Maintenance safety considerations”.
3. Add 2.5 kg of liquid charge into the evaporator using • It is strongly recommended to change the fuses in the
the charging valve located on the top of the evaporator. units every 15000 operating hours or every 3 years.
4. Observe the EXD Percent Open value. The EXD • It is recommended to verify that all electrical connec-
should begin closing as charge is being added. Allow tions are tight:
the unit to stabilize. If the EXD Percent Open remains - after the unit has been received at the moment of
above 60%, and there are still bubbles in the sightglass, installation and before the first start-up,
add an additional 2.5 kg of liquid charge. - one month after the first start-up,when the elec-
5. Allow the unit to stabilize, and again check the EXD trical components have reached their nominal
Percent Open. Continue adding 2.5 kg of liquid refri- operating temperatures,
gerant charge at a time, and allow the unit to stabilize - then regularly once a year.
before checking the EXD position.
6. When the EXD Percent Open is in the range of 40-60%,
check the liquid line sightglass. Slowly add enough addi-
tional liquid charge to ensure a clear sightglass. This
should be done slowly to avoid overcharging the unit.

37
11.6 - Pressure transducers 11.8 - Integral oil filter change

11.6.1 - Discharge pressure (circuits A and B) An integral oil filter in the 06N screw compressor is speci-
This input is used to measure the high side pressure of each fied to provide a high level of filtration (3 µ) required for
circuit of the unit. long bearing life. As system cleanliness is critical to reliable
system operation, there is also a prefilter (7 µ) in the oil line
It is used to provide the pressure to replace the discharge at the oil separator outlet.
pressure gauge and to control the head pressure.
The replacement integral oil filter element part number is:
11.6.2 - Suction pressure (circuits A and B)
This input is used to measure the pressure of the low side Carrier part number (including filter and O-ring): 06NA
of the unit. It is used to provide the pressure to replace the 660016S.
suction pressure gauge.
11.9 - Filter change-out schedule
11.6.3 - Oil pressure (each compressor)
This input is used to measure the oil pressure of each unit The filter should be checked after the first 1000 hours of
compressor. It is located on the oil pressure port of each operation, and every subsequent 4000 hours. The filter should
compressor. be replaced at any time when the pressure differential
across the filter exceeds 2.1 bar.
11.6.4 - Economizer pressure (circuits A and B)
This input is used to monitor the oil pressure differential The pressure drop across the filter can be determined by
supplied to the compressor. measuring the pressure at the filter service port and the oil
pressure port. The difference in these two pressures will be
11.7 - Oil charging - low oil recharging the pressure drop across the filter, check valve, and solenoid
valve. The pressure drop across the check valve and solenoid
11.7.1 - Addition of oil charge to 30HXC/GX systems valve is approximately 0.4 bar, which should be subtracted
1. If the 30HXC/GX unit shuts-off repeatedly on Low oil from the two oil pressure measurements to give the oil
Level, this may be an indication of inadequate oil charge. filter pressure drop. The oil filter pressure drop should be
It could also mean simply that oil is in the process of checked after any occasion that the compressor is shut
being reclaimed from the low-side of the system. down on a low oil pressure safety.
2. Begin by running the unit at full-load for an hour and
a half. 11.10 - Filter change-out procedure
3. After running for 1-1/2 hours allow the unit to re-start and
run normally. If the Low Oil Level alarms persist, the unit The following steps outline the proper method of changing
has a low oil charge. Add oil to the oil separator, using the integral oil filter.
the oil charging valve at the bottom of the condenser 1. Shutdown and lockout the compressor.
(30HXC) or at the bottom of the oil separator (30GX). 2. Manually force the operation of the oil solenoid valve, in
order to press the internal valve shutter onto its seat.
CAUTION: Do NOT add oil at any other location as 3. Close the oil filter service valve. Bleed pressure from
improper unit operation may result. the filter cavity through the filter service port.
4. Remove the oil filter plug. Remove the old oil filter.
4. Make sure that the unit is not running when adding 5. Prior to installing the new oil filter, “grease” the o-ring
oil, as this will make the oil charging process easier. with oil. Install the filter and replace the plug.
Because the system is under pressure even when the
unit is not running, it will be necessary to use a suitable Before closing up the lube oil system, take the oppor-
pump (hand or electric pump) to add oil to the system. tunity to replace the prefilter, as well.
5. Using a suitable pump, add 2 litres of Polyolester oil 6. When complete, evacuate the filter cavity through the
to the system (CARRIER SPEC: PP47-32). Make sure filter service port. Open the filter service valve. Remove
that the oil level safety switch is NOT jumpered, and any compressor lockout devices, the compressor is
allow the unit to re-start and run normally. ready to return to operation.
6. If low oil level problems persist, add another 1 or 2
litres of oil. If it is necessary to add more than 4 litres of 11.11 - Compressor replacement
oil to the system, then contact your Carrier distributor
service department. 11.11.1 - Compressor rotation control
Correct compressor rotation is one of the most critical
CAUTION: When transferring the refrigerant charge to a application considerations. Reverse rotation, even for a
storage unit, oil may be carried along when the unit is not very short duration, damages the compressor.
operating. Reuse first of all the amount of refrigerant trans-
ferred. After draining the oil, only recharge the amount The reverse rotation protection scheme must be capable of
drained (an excess oil charge may impair correct unit determining the direction of rotation and stopping the
operation). compressor within 300 milliseconds. Reverse rotation is
most likely to occur whenever the wiring to the compressor
If an oil draining or recovery operation becomes necessary, terminals is disturbed.
the fluid transfer must be made using mobile containers.

38
To minimize the opportunity for reverse rotation, the We recommend TOTALINE products for coil cleaning:
following procedure must be applied. Rewire the power Part No. P902 DT 05EE: traditional cleaning method
cables to the compressor terminal pin as originally wired. Part No. P902 CL 05EE: cleaning and degreasing.

For replacement of the compressor, a low pressure switch These products have a neutral pH value, do not contain
is included with the compressor. This low pressure switch phosphates, are not harmful to the human body, and can be
should be temporarily installed as a hard safety on the high disposed of through the public drainage system.
pressure part of the compressor. The purpose of this switch
is to protect the compressor against any wiring errors at the Depending on the degree of fouling both products can be
compressor terminal pin. The electrical contact of the switch used diluted or undiluted.
would be wired in series with the high pressure switch. The
switch will remain in place until the compressor has been For normal maintenance routines we recommend using 1 kg
started and direction of rotation has been verified; at this of the concentrated product, diluted to 10%, to treat a coil
point, the switch will be removed. surface of 2 m2. This process can either be carried out using
a high-pressure spray gun in the low-pressure position. With
The switch that has been selected for detecting reverse pressurised cleaning methods care should be taken not to
rotation is Carrier part number HK01CB001. It is available damage the coil fins. The spraying of the coil must be done:
as part of the “Compressor installation package” (part No. • in the direction of the fins
06NA 660 013). This switch opens the contacts when the • in the opposite direction of the air flow direction
pressure falls below 6,8 kPa absolute. The switch is a manual • with a large diffuser (25-30°)
reset type that can be reset after the pressure has once again • at a minimum distance of 300 mm from the coil.
risen above 69 kPa relative. It is critical that the switch be
a manual reset type to preclude the compressor from short The two cleaning products can be used for any of the
cycling in the reverse direction. following coil finishes: Cu/Cu, Cu/Al, Cu/Al with Italcoat
or Polual protection.
11.11.2 - EXD troubleshooting procedure
Follow steps below to diagnose and correct EXD problems. It is not necessary to rinse the coil, as the products used
are pH neutral. To ensure that the coil is perfectly clean,
Check EXD motor operation first (see procedure in the we recommend rinsing with a low water flow rate. The pH
30GX/HXC Pro-Dialog Plus Controls IOM). You should value of the water used should be between 7 and 8.
be able to feel the actuator moving by placing your hand
on the EXD. You should feel a hard knocking come from WARNING:
the actuator when it reaches the top of its stroke (can be Never use pressurized water without a large diffuser. Con-
heard if surroundings are relatively quiet). The actuator centrated and/or rotating water jets are strictly forbidden.
should knock when it reaches the bottom of its stroke. If it
is believed that the valve is not working properly, contact Correct and frequent cleaning (approximately every three
your Carrier service department for further checks on: months) will prevent 2/3 of the corrosion problems.
• output signals on EXD module
• wire connections (continuity and tight connection at Protect the control box during cleaning operations.
all pin terminals)
• resistance of the EXD motor windings. Never use a fluid with a temperature above 45°C to clean
the air heat exchangers.
11.12 - Corrosion control

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.

11.13 - Condenser coil

We recommend, that finned coils are inspected regularly to

check the degree of fouling. This depends on the environ-
ment where the unit is installed, and will be worse in urban
and industrial installations and near trees that shed their
leaves.

For coil cleaning proceed as follows:

• Remove fibres and dust collected on the condenser
face with a soft brush (or vacuum cleaner).
• Clean the coil with the appropriate cleaning agents.

39
12 - start-up ckecklist for 30HXC/GX Liquid chillers (use for job file)

Preliminary information

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

Equipment
Model:............................................................................................. Serial number.............................................................................

Compressors
Circuit A Circuit B
1. Model number........................................................................... 1. Model number.......................................................................
Serial number............................................................................ Serial number.........................................................................
Motor number........................................................................... Motor number........................................................................

2. Model number........................................................................... 2. Model number.......................................................................
Serial number............................................................................ Serial number.........................................................................
Motor number........................................................................... Motor number........................................................................

Cooler
Model number................................................................................ Manufactured by . .....................................................................
Serial number................................................................................. Date.............................................................................................

Condenser (30HXC)
Model number................................................................................ Manufactured by . .....................................................................
Serial number................................................................................. Date.............................................................................................

Air handling equipment
Manufacturer ........................................................................................................................................................................................
Model number................................................................................ Serial number.............................................................................

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

.................................................................................................................................................................................................................

Preliminary equipment check

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

Unit is level in its installation

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

Check air handling systems

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

40
Check condenser system (30HXC)
All condenser water valves are open
All condenser piping is connected properly
All air has been vented from the system
Condenser water pump (CWP) is operating with the correct rotation.
Condenser water pump amperage: Rated: .…….. Actual: ………

Unit start-up
CWP starter has been properly interlocked with the chiller
Oil heaters have been energized for at least 24 hours (30GX)
Oil level is correct
All discharge and liquid valves are open
All suction valves are open, if equipped
All oil line valves and economizer discharge bubbler valves (30HXC only if equipped) are open
Unit has been leak checked (including fittings)
Locate, repair, and report any refrigerant leaks
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................
.................................................................................................................................................................................................................

Check voltage imbalance: AB................. AC.................. BC..................

Average voltage = . .................................. (see installation instructions)
Maximum deviation = ............................. (see installation instructions)
Voltage imbalance = ................................ (see installation instructions)

Voltage imbalance is less than 2%

warning: Do not start chiller 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 = . ............................. (litres)
Calculated volume = ............................... (litres)
3.25 litres/nominal kW capacity for air conditioning
6.5 litres/nominal kW capacity for process cooling

Proper loop volume established

Proper loop corrosion inhibitor included..........litres of............................
Proper loop freeze protection included (if required)................. litres of...............................
Piping includes electric heater tape, if exposed to the outside
Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm

Check pressure drop across the cooler

Entering cooler = . ................................... (kPa)
Leaving cooler = ...................................... (kPa)
(Leaving - entering) = ............................. (kPa)

warning: Plot cooler pressure drop on performance data chart (in product data literature) to determine total litres
per second (l/s) and find unit’s minimum flow rate.

Total l/s = ..................................................

l/s / nominal kW = . ..................................
Total l/s is greater than unit’s minimum flow rate
Total l/s meets job specified requirement of....................................... (l/s)

Check condenser water loop

Proper loop corrosion inhibitor included..........litres of............................
Inlet piping to condenser includes a 20 mesh strainer with a mesh size of 1.2 mm

41
Check pressure drop across the condenser (30HXC only)
Entering condenser = .............................. (kPa)
Leaving condenser = ............................... (kPa)
(Leaving - entering) = ............................. (kPa)

warning: Plot condenser pressure drop on performance data chart (in product data literature) to determine total
litres per second (l/s) and find unit’s minimum flow rate.

Total l/s = ..................................................

l/s / nominal kW = . .................................
Total l/s is greater than unit’s minimum flow rate
Total l/s meets job specified requirement of....................................... (l/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 Troubleshooting literature (follow the procedure in the Controls IOM).

External reset sensor.................................................................

Cooler pump interlock..............................................................
Cooler fluid select.......................................................................... Cooler pump control.................................................................
Minimum load select..................................................................... Condenser pump control*........................................................
Loading sequence select............................................................... Condenser flow switch*.............................................................
Lead/lag sequence select............................................................... Condenser water sensors*........................................................
Head pressure control...................................................................
Motormaster select*...................................................................... *If installed
Water valve type*..........................................................................

To start the chiller

warning: Be sure that all service valves are open, and all pumps are on before attempting to start this machine.
Once all checks have been made, move the switch to “LOCAL” or “REMOTE” from “OFF”.

Unit starts and operates properly

Temperatures and pressures

warning: Once the machine has been operating for a while and the temperatures and pressures have stabilized,
record the following:

Cooler EWT................................................................................... Ambient temperature (GX).....................................................

Cooler LWT.................................................................................... Condenser EWT........................................................................
Condenser LWT.........................................................................

Circuit A oil pressure.................................................................... Circuit B oil pressure.................................................................

Circuit A suction pressure............................................................ Circuit B suction pressure.........................................................
Circuit A discharge temperature................................................. Circuit B suction temperature..................................................
Circuit A suction temperature..................................................... Circuit B discharge pressure.....................................................
Circuit A discharge pressure........................................................ Circuit B discharge temperature..............................................
Circuit A liquid line temperature................................................ Circuit B liquid line temperature.............................................

Note FOR option 51:

The pouch supplied with the unit contains the label indicating the refrigerant used and describing the procedure
required under the Kyoto Protocol F-Gas Regulation:
• Attach this label to the machine.
• Follow and observe the procedure described.

42
 Carrier is participating in the Eurovent Certification
Programme. Products are as listed in the Eurovent
Directory of Certified Products.

This programme covers air-cooled chillers up to

600 kW and water-cooled chillers up to 1500 kW.

Order No: 13050-76 (phase 3), 07.2008. Supersedes order No: 13050-76, 02.2006 Manufacturer: Carrier SCS, Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands.