30GV/30GY 020-059

Air-Cooled Liquid Chillers

50 Hz

Installation, Operation and Maintenance Instructions

1
CONTENTS

Page

Start-up checklist .......................................................................................................................................................................... 3

Dimensions and clearances .......................................................................................................................................................... 4

Physical and electrical data ......................................................................................................................................................... 6

Application data ............................................................................................................................................................................ 7

Minimum and maximum cooler water flow rates .......................................................................................................................... 7
Minimum operating temperature .................................................................................................................................................... 7
Water loop volume ......................................................................................................................................................................... 7

Installation ..................................................................................................................................................................................... 7
Safety considerations .................................................................................................................................................................... 7
Preliminary checks ......................................................................................................................................................................... 8
Moving and lifting the unit ............................................................................................................................................................. 8
Positioning of 30GV, GY 044-059 units ........................................................................................................................................ 8
Duct connections ............................................................................................................................................................................ 8
Fan module ..................................................................................................................................................................................... 9
Fan speed adjustment tables ........................................................................................................................................................... 9
Fan laws .......................................................................................................................................................................................... 9

Water connections ...................................................................................................................................................................... 10

Power supply ............................................................................................................................................................................... 12

Electrical checks ........................................................................................................................................................................... 12

Start-up ........................................................................................................................................................................................ 12
Preliminary checks ....................................................................................................................................................................... 12
Actual start-up .............................................................................................................................................................................. 13
Electromechanical control ............................................................................................................................................................ 13
Set point adjustment ..................................................................................................................................................................... 13
Control pressostats ........................................................................................................................................................................ 13

Servicing refrigeration components .......................................................................................................................................... 14

General maintenance .................................................................................................................................................................... 14
Liquid refrigerant charging ........................................................................................................................................................... 14
Compressors ................................................................................................................................................................................. 15
Compressor motor protection ...................................................................................................................................................... 15
Heat exchangers ............................................................................................................................................................................ 15
Evaporator .................................................................................................................................................................................... 15
Condenser coil .............................................................................................................................................................................. 16
Fan motor replacement ................................................................................................................................................................. 17

Troubleshooting chart ................................................................................................................................................................ 18

START-UP CHECK LIST

Equipment sold by: Contract No.:

Installed by: Contract No.:

Site address:

Start-up date:

Equipment type and serial numbers:

Electrical data:

Supply voltage: Ph. V Ph. 2 V Ph. 3 V

Nominal voltage: V % network voltage:

Current draw: Ph. 1 A Ph. 2 A Ph. 3 A

Main circuit breaker rating: A

Physical data:

Condenser: Cooler:

Entering air temperature: °C Entering water temperarture: °C

Leaving air temperature: °C Leaving water temperature: °C

Pressure drop (air): kPa Pressure drop (water): kPa

Discharge air pressure: Pa Suction pressure: kPa

Fan speed: r/s or rpm

Fan motor input: Ph. 1 V Ph. 2 V Ph. 3 V

Ph. 1 V Ph. 2 V Ph. 3 V

Safety device setting:

High pressure switch: cut-out kPa: cut-in kPa

Low-pressure switch: cut-out kPa cut-in kPa

Safety thermostat: cut-out °C cut-in °C

Control thermostat: cut-out first step °C cut-in first step °C

cut-out second step °C cut-in second step °C

Oil level:

Oil visible in sight glass?:

Colour of moisture indicator:

Air bubbles visible in sight glass?:

Accessories:

-
-

Commissioning engineer (name):

Purchase order number:

NOTE: Please fill in this sheet during the installation

 Dimensions and clearances

30GV/30GY 020 2103 36 36

36
1868
915

800
A

600

950

B
800

A-B: Clearance only required on one side

30GV/30GY 025-035
3327 36 36
36
2028

983

A
800

1800
600

950
800

A-B: Clearance only required on one side

4
 Dimensions and clearances, mm

30GV/30GY 044-059
36 36

36

36
2028
3327 2000

1000

1800
950

1800
1000

Alternative 1
Alternative 2

Floor mounting

• For unit mounting holes, weight distribution and centre of gravity coordinates, refer to the dimensional
drawings supplied with the unit.
• These units are designed for indoor installation.

CAUTION:

• Ensure the air flow around the unit is not obstructed.

• At least one side of the units must be free from obstructions, to ensure proper air flow.

5
 Physical data

30GV/30GY 020 025 030 035 044*** 049*** 059***

Nominal cooling capacity 30GV* kW 51 66 73 97 132 146 193

Nominal cooling capacity 30GY* kW 50 69 97 101 138 153 202

Operating weight kg 850.0 1030.0 1100.0 1250.0 2111.5 2255.0 2562.5

Refrigerant charge**** kg 9.8 14.5 15.2 17.0 29.0 29.0 34.0

Compressor Semi-hermetic, 4 or 6 cylinders, 24.2 r/s

Quantity
Circuit A/B 1/- 1/- 1/- 1/- 1/1 1/1 1/1
No. of capacity steps 2 2** 2** 2** 3 3 3
Capacity control % 50/100 66/100 66/100 66/100 33/66/100 33/66/100 33/66/100

Evaporator Coaxial Shell-and-tube

Net water volume l 21.7 31.0 31.0 43.0 62.0 62.0 86.0
Water connections in BSPC, conical gas, ISO R7
Inlet 2-1/2 MPT 2 FPT 2 FPT 2 FPT 3 FPT 3 FPT 3FPT
Outlet 2-1/2 MPT 2 MPT 2 MPT 2 MPT 3 FPT 3 FPT 3FPT
Max. water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000

Condenser Copper tubes, al;uminium fins

Condenser fan Single centrifugal Double centrifugal Two, double centrifigal
Nominal air flow l/s 3500 5600 5600 6900 11200 11200 13800
Speed at 150 Pa ESP r/s 10.33 10.33 10.67 10.53 10.33 10.67 10.83
Nominal fan motor power kW 3.0 4.0 4.0 4.5 2 x 4.0 2 x 4.0 2 c 4.5
Motor speed r/s 24.2 24.2 24.2 24.2 24.2 24.2 24.2

* Based on 12°C/7°C entering/leaving chilled water temperature, 35°C condenser entering air temperature and nominal fan speed.
** 3 steps with capacity reduction accessory
*** Supplied as two separate units as follows, with all electrical, hydraulic and mechanical components necessary for installation: size 044 = 2 x size 025, size 049 = 2 x
size 030, size 059 = 2 x size 035
**** 30GY units use refrigerant R-22, 30GV units use R-407C. The refrigerant charge shown is guidelines only. Always refer to the nameplate.

Electrical data

30GV/30GY Standard unit Fan

150 Pa 300 Pa (optional)
XL PW
V-ph-Hz RLA ICF ICF kW FLA kW FLA

020 230-3-50 62 263 163 3.7 11.7 4.9 15.7

400-3-50 36 180 111 3.7 6.3 4.9 9.0

025 230-3-50 84 359 222 4.9 15.7 8.8 26.4

400-3-50 48 232 143 4.9 9.0 8.8 15.2

030 230-3-50 94 383 237 4.9 15.7 8.8 26.4

400-3-50 54 262 161 4.9 9.0 8.8 15.2

035 230-3-50 135 564 346 5.5 17.9 8.8 26.4

400-3-50 77 356 218 5.5 10.3 8.8 15.2

044 230-3-50 167 442 305 9.8 2 x 15.7 17.6 2 x 26.4

400-3-50 96 280 191 9.8 2 x 9.0 17.6 2 x 15.2

049 230-3-50 187 476 330 9.8 2 x 15.7 17.6 2 x 26.4

400-3-50 108 316 215 9.8 2 x 9.0 17.6 2 x 15.2

059 230-3-50 270 699 808 11.0 2 x 17.9 17.6 2 x 26.4

400-3-50 154 433 295 11.0 2 x 10.3 17.6 2 x 15.2

Legend:
FLA - Full load amperes
ICF - Maximum instantaneous current flow, A (compressors)
kW - Maximum fan motor power input
RLA - Rated load amperes (compressors)
PW - Part-winding astart (compressors)
XL - Across-the-line-start (compressors)

Note: To obtain the maximum unit current, add the compressor maximum currecnt (RLA) to the fan motor current (FLA).

6
APPLICATION DATA INSTALLATION

Minimum and maximum evaporator water flow rates SAFETY CONSIDERATIONS

30GY/GV Min flow rate, l/s Max. flow rate, l/s Installation, start-up and servicing this equipment can be
020 1.2 4.8 hazardous due to system pressures, electrical components and
025 1.6 8.0 equipment location (roofs, elevated structures, etc.).
030 1.6 8.0
035 2.4 9.4
044 3.2 16.0 Only trained, qualified installers and service mechanics should
049 3.2 16.0
059 4.8 18.4
install, start-up and service this equipment.

Minimum operating temperature Untrained personnel can perform basic functions, such as
cleaning coils. All other operations should be performed by
°C trained service personnel.
Single-speed motor 14
Two-speed motor 4 When working on the equipment, observe precautions in the
Dampers -20 literature, and on tags, stickers, and labels attached to the
equipment.
Maximum chilled water flow rate
• Follow all safety codes.
The maximum chilled water flow (>0,09 l/s per kW or <2.8 K • Wear safety glasses and work gloves.
temperature difference) is limited by the maximum permitted • Use care in handling, rigging and setting down bulky
pressure drop in the evaporator. equipment.

Water loop volume WARNING: Before doing any work ensure that the power
supply (400 V and 230 V) is disconnected, and switches and
Whatever the size of the system, the water loop minimum isolators are opened and tagged.
volume is given by the following formula:
During operation some parts of the unit reach or exceed
Volume = CAP (kW) x N* = litres temperatures of 70°C (e.g. compressor discharge side,
discharge line). Only trained and qualified engineers, aware of
where CAP is the nominal system capacity (kW) at the nominal these hot surfaces, are allowed to perform maintenance
operating conditions of the installation. operations.
Application N*
Preliminary checks
Air conditioning 3.25
Industrial process cooling 6.5
Low temperature operation 10.8
Check equipment received
• Inspect the unit for damage or missing parts. If damage is
detected, or if shipment is incomplete, immediately file a
This volume is necessary for stable operation and accurate claim with the shipping company.
temperature control. • Confirm that the unit received is the one ordered.
Compare the nameplate data with the order.
It is often necessary to add a buffer water reservoir to the • Confirm that all accessories ordered for on-site installation
circuit in order to achieve the required volume. The reservoir have been delivered, and are complete and undamaged.
must itself be internally baffled in order to ensure proper
mixing of the liquid (water or brine). Refer to the examples Moving and lifting the unit
below.
Moving
NOTE: The compressor must not restart more than 10 times in Do not remove skids, pallets or protective packaging until the
an hour. unit is in its final position. Move the chiller using tubes or
rollers, or lift it, using slings of the correct capacity. Before
moving the unit, ensure that all panels are correctly fixed.

Lifting
Refer to dimensional drawings 99 DI-035 GY 500 250E and
the lifting instructions label on the unit.
Bad Good

Bad Good

7
Preliminary checks 5 6-7

Before installing and connecting the unit check:

- The required clearances for correct unit operation and 4
6-7
maintenance.
- Size and location of the chilled water piping.
- Location and electrical characteristics of the available
power supply which must agree with the unit nameplate 4
rating.
- Location and correct installation of the ductwork. Unit A Unit B
- That there is not only sufficient space for routine service
and maintenance work, but also for operations such as: fan 3 1 6-7

shaft inspection, compressor removal etc. Refer to the

certified drawings for the units. Duct connections

Positioning The fan motor assembly is mounted on a self-supporting frame,

Once the unit has been installed in its final location, remove the and permits connection to a ductwork system without using
skids, level the unit with a spirit level and bolt it to the floor or additional flexible connections.
to a pad.
Suction side
CAUTION: These units must not be installed outside, except When designing ducts, the possible installation of accessory
under cover. filters and air dampers must be taken into consideration. For
30GV,GY 044-059 units it is preferable to leave the two
If it is necessary to locate the unit on an upper floor, be sure suction openings free. The units will also function correctly
that the structure is designed to support the weight. If required, with only one suction opening. In this case it is necessary to
strengthen the floor. Also ensure that the installation surface is increase the fan speed of the rear unit (in this case unit B) by
level. Check the dimensional drawing for unit dimensions and 8% in relation to the front unit (unit A with direct air intake, in
weight distribution. order to balance the air flows for the two modules.

Positioning of the 30GV/GY 044-059 units Discharge side

For units 30GV,GY 025-035 the selection curves are based on
Mechanical connection a connection separated by two ducts (four for 30GV, GY 044
to 059). If this is not the case, the additional pressure, which is
Step 1 due to the change in the dynamic pressure, must be taken into
account (see table below).
- First position unit B (the control box of this unit does not
include a disconnect switch). CAUTION: The following rules for centrifugal fans must
- Fasten beams 2 and 3 with screw 6 and washer 7 to unit B. always be adhered to, in order to ensure that the maximum
- Move unit A close so that it can be fastened to beams 2 power input of the motor is not exceeded:
and 3 from the inside of the unit. - The fan must not be rotated without the panels being fitted.
- The unit should not be operated without a discharge duct.

Use panels to ensure that the suction or discharge opening

cannot obstructed (e.g. bottom supply or opening of doors).
Unit B
Minimum outdoor operating temperature (°C)
2 2

Unit size 020 025-059

% load 100 50 100 66 33

Single-speed motor 10 12 10 12 14
Two-speed motor 0 2 0 2 4
Dampers -20 -20 -20 -20 -20

3 2 6-7 2 3
Fan module

Before the final start-up of the unit, check that the ductwork is
Step 2 correctly attached to the unit. After checking the correct
positioning of the pulley elements on the shaft and the belt
- Fasten panel 4 to the front of the assembly using screws 6 tension, the fan motor must be switched on, as follows:
and washers 7, and panel 5 to the rear of the assembly 1. Check the rated motor current on the nameplate.
using screws 6 and washers 7. 2. Check that all panels are fitted.
- Fasten the control box to front panel 4, which was 3. Start the fan motor using a contactor. Measure the current. If
previously fastened with screws 6 and washers 7. the value is higher than the value established in step 1, or
more than 15% below that value, it may be necessary to
adjust the fan speed as shown in the following tables:

8
 Fan speed adjustment tables

30GV and 30GY 020

Air flow 6 r/s 7 r/s 8 r/s 9 r/s 10 r/s 11 r/s 12 r/s 13 r/s 14 r/s

l/s ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW

1900 61 0.6 97 0.9 137 1.1 180 1.4 226 1.7 277 1.9 330 2.2 388 2.4 445 2.7
2100 52 0.7 89 1.0 130 1.3 174 1.6 222 1.8 274 2.1 329 2.4 387 2.7 446 3.0
2300 40 0.8 79 1.1 121 1.4 167 1.7 216 2.0 269 2.3 325 2.6 385 3.0 445 3.3
2500 27 0.8 67 1.2 110 1.5 157 1.8 208 2.2 262 2.5 320 2.9 381 3.2 442 3.5
2700 12 0.9 53 1.3 98 1.6 146 2.0 198 2.4 253 2.7 312 3.1 375 3.5 437 3.8
2900 0 37 1.4 83 1.8 133 2.1 186 2.5 243 2.9 303 3.3 367 3.7 431 4.1
3100 20 1.4 67 1.9 118 2.3 173 2.7 231 3.1 293 3.6 358 4.0 425 4.4
3300 1 50 2.0 102 2.4 158 2.9 217 3.3 280 3.8 347 4.2 413 4.7
3500 30 2.1 84 2.6 141 3.1 201 3.5 266 4.0 334 4.5 401 5.0
3700 8 2.2 63 2.7 122 3.2 184 3.7 250 4.2 319 4.8 388 5.3
3900 0 42 2.9 101 3.4 165 3.9 232 4.5 302 5.0 372 5.5
4100 18 3.0 79 3.6 144 4.1 212 4.7 284 5.3 355 5.8
4300 0 55 3.8 121 4.4 190 4.9 263 5.5 336 6.1
4500 29 3.9 96 4.6 167 5.2 241 5.8 316 6.4
4700 1 70 4.8 142 5.4 217 6.0 293 6.7
4900 41 5.0 115 5.6 192 6.3 269 7.0
5100 11 5.2 86 5.9 164 6.5 243 7.2
5300 0 55 6.1 135 6.8 215 7.5

30GV and 30GY 025-030-035

Air flow 6 r/s 7 r/s 8 r/s 9 r/s 10 r/s 11 r/s 12 r/s 13 r/s 14 r/s

l/s ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW ESP kW

3000 60 0.9 89 1.2 122 1.5 157 1.8 194 2.0 235 2.3 278 3.1 324 3.7 373 4.3
3500 52 1.1 83 1.4 117 1.7 153 2.1 193 2.4 235 2.7 279 3.6 327 4.3 377 5
4000 41 1.3 74 1.6 109 2 147 2.4 188 2.8 232 3.2 278 4.1 327 4.9 379 5.8
4500 28 1.4 62 1.8 99 2.2 138 2.7 181 3.1 226 3.6 274 4.7 324 5.5 378 6.5
5000 12 1.6 47 2 86 2.5 127 2.9 171 3.5 217 4 267 5.2 319 6.1 374 7.2
5500 0 30 2.2 70 2.7 113 3.2 158 3.8 206 4.5 257 5.7 311 6.8 367 7.9
6000 10 2.4 52 2.9 96 3.5 143 4.2 193 4.9 245 6.2 300 7.4 358 8.6
6500 0 31 3.2 77 3.8 125 4.6 176 5.3 230 6.7 287 8 347 9.4
7000 7 3.4 55 4.1 105 4.9 157 5.8 213 7.3 271 8.6 332 10.1
7500 0 30 4.4 81 5.3 136 6.2 193 7.8 253 9.2 315 10.8
8000 2 4.7 56 5.6 111 6.6 170 8.3 231 9.8 296 11.5
8500 27 6 85 7.1 145 8.8 208 10.4 273 12.2
9000 0 55 7.5 117 9.3 181 11 248 12.9
9500 23 7.9 86 9.9 152 11.7 221 13.7
10000 0 53 10.4 120 12.3 190 14.4
10500 17 10.9 86 12.9 158 15.1

ESP External static pressure, Pa

kW Fan motor power input, kW
r/s Revolutions per second

Note : As units 30GV and 30GY 044 to 059 are two GV and GY 025 to 035 units connected, the tables above apply to them as well.

Fan laws

The fan laws state that for a given system resistance and air density:

- The air flow rate varies as a direct function of the speed ratio: Qv2 = Qv1 x N2/N1
- The pressure varies as a function of the square value of the speed ratio: P2 = P1 x (N2/N1)2
- The output varies as a function of the cube value of the speed ratio: Pa2 = Pa1 x (N2/N1)3

9
Water connections Operating precautions
The water circuit should be designed to have the least number
Refer to the certified dimensional drawings for the sizes and of elbows and horizontal pipe runs at different levels. Below
positions of all water inlet and outlet connections. The water the basic checks to be done (see also the illustration of a typical
pipes must not transmit any radial or axial force to the heat hydraulic circuit below).
exchangers or any vibration to the pipework or building.
• Note the water inlets and outlets of the heat exchangers.
The water supply must be analysed and appropriate filtering, • Install manual or automatic air purge valves at all high
treatment, control devices, isolation and bleed valves and points in the water circuit.
circuits built in, as necessary. Consult either a water treatment • Use an expansion chamber or an expansion/relief valve to
specialist or appropriate literature on the subject. maintain pressure in the system.
• Install water thermometers in both the entering and
leaving water connections close to the evaporator.
• Install drain valves at all low points to allow the whole
circuit to be drained. Connect a stop valve in the drain line
before operating the chiller.
• Install stop valves, close to the evaporator, in the entering
and leaving water lines.
• Use flexible connections to reduce the transmission of
vibration to the pipework.
• Insulate all pipework, after testing for leaks, both to
reduce thermal leaks and to prevent condensation.
• Cover the insulation with a vapour barrier.

Typical hydraulic circuit diagram

Air vent
Control valve
Flow switch

Flexible connection Heat exchanger

Buffer tank

Fill valve
Filter Pressure tap
Thermostat sleeve
Drain
Expansion tank

10
Water connections (30GY/GV 044-059) IMPORTANT: The heat exchanger can be damaged by frost in
winter. Depending on the atmospheric conditions in your area
There are two alternatives: you can:
- Water entering at the left of the duplex unit and leaving on - Add ethylene glycol.
the right. - Increase the thickness of the insulation.
- Water entering at the right of the duplex unit and leaving - Never disconnect the evaporator heaters.
on the left. - If the unit is not used for a prolonged period, empty the
the heat exchanger and add ethylene glycol. At the
The water inlet must be on one evaporator, and the outlet on beginning of the following season, again fill the unit with
the other one, in order to correctly balance the flow rates in the water and an added inhibitor.
evaporators. When installing and connecting the components
ensure that there is no leak at any of the connections (see If auxiliary equipment is installed, the installer must
diagram below). follow basic installation principles and ensure that the
minimum and maximum flow rates are not exceeded; the
values must be between the values given in the Physical
Data table.

Water connections (30GV/GY 044-059)

First alternative Second alternative

Water inlet Water outlet

Water inlet
Water outlet

Evaporator 2 Evaporator 1 Evaporator 2 Evaporator 1

Refrigerant inlet and outlet Refrigerant inlet and outlet

11
Power supply Start-up

The power supply must conform to the specification on the Preliminary checks
chiller nameplate. The supply voltage must be within the range Never be tempted to start the chiller without reading fully, and
specified in the electrical data table. understanding, the operating instructions and without having
carried out the following pre-start checks :
For connections refer to the wiring diagram.
• Confirm that all crankcase heaters are working by feeling
Electrical connections (30GY/GV 044-059) all compressor crankcases. Every compressor has a 200 W
Carry out the electrical connections between the control boxes cartridge heater (see the wiring diagram). The heater
in accordance with the diagram below and with the wiring remains energised even when the chiller is shut down to
diagram supplied with the unit; ensure that the cables are stop the lubricating oil from absorbing refrigerant.
routed through the conduits. • Check the operation of all accessories - chilled water
circulating pumps, air handlers and other equipment
All cables are labeled A B C D and E F (option 70). connected to the evaporator. Follow the individual
manufacturer's instructions for this equipment.
Electrical connections • It is recommended to connect the auxiliary contact of the
water pump contactor to ensure maximum unit safety (see
Control box B Control box A wiring diagram delivered with the unit).
• Fill the chilled water circuit with clean water, and an
1
inhibitor formulated specifically for this purpose, or fill it
with another non-corrosive fluid to be chilled.
• Purge air at all high points in the system. If water
temperatures below 5°C are likely, add the appropriate
volume of ethylene glycol to prevent freezing.
• Confirm that the suction and discharge line stop valves are
fully opened.
D D A
• Open the refrigerant line valves. Check again that the
C C B
B
water circuit valves are open.
A • Check that oil is visible in each compressor sight glass to
between 1/8 and 3/8 of the total glass depth (check for all
compressors).
• Confirm that there are no refrigerant leaks.
WARNING: Operation of the chiller with an improper supply • Confirm that all crankcase heaters are firmly in place, and
voltage or with excessive phase imbalance constitutes abuse check the secure positioning of all control sensors.
which will invalidate the Carrier warranty. If the phase • Confirm that discharge muffler securing bands and
imbalance exceeds 2% for voltage, or 1% for current, contact discharge line connections are tight.
your local electricity supply company at once and ensure that • Check that all electrical connections are secure.
the chiller is not switched on until corrective measures have • Turn the fan shafts by hand to ensure that they rotate
been taken. freely. Check the stability of the fan wheels on the shafts.
Check the tightness of the fan shaft bearing mounts. All
Voltage phase imbalance (%) : fan bearings are lubricated with lithium grease for a rated
minimum life of 40,000 hours.
= 100 x max.deviation from average voltage deviation • Check the alignment of the motor and fan pulleys.
Average voltage • Belt tension: too little will allow the belts to slip on the
pulley, too much will put the bearing under stress.
Electrical checks • At the start-up observe the fan and verify that its rotation
is correct, as indicated by the arrow on the scroll. To
WARNING: Never switch off the power supply to the crankcase reverse the rotation, interchange any two of the three
heaters unless the chiller is out of service for a seasonal phases in the junction box of the motor.
shutdown or lengthy repair. The heaters must be re-energised
for at least 24 hours before the chiller is restarted.

a. Switch the unit off.

b. Open the control circuit disconnect switch.
c. Check the transformer connections.
d. Ensure that the control circuit corresponds to the wiring
diagram for the unit.
e. Check that all electrical connections are secure at the
terminals, contactors, bus bars and compressor terminal
blocks.

12
Actual start-up Design set point adjustment (three-step thermostat)

IMPORTANT: Temperature Temperature

• Commissioning and start-up of the chiller must be drop rise
supervised by a qualified refrigeration engineer. F RY3
• Start-up and operating tests must be carried out with a 0 RB3
thermal load applied and water circulating in the F RY2
evaporator. RY3 0 0 RB2
RB3 F A
• All set point adjustments and control tests must be carried F RY1
out before the unit is started up. RY2 0 0 RB1
RB2 F
• Please refer to the controls manual for the unit. B
RY1 0
RB1 F
a. Start up the unit. Set point

b. Check that all safety devices are satisfied, paticularly the

high pressure switches. Legend:
A - Differential between stages
B - Differential on one contact
For this purpose: R, Y, B - Thermostat contact reference
- Stop the condenser fans. O - Open contact
- Operate the machine until the high pressure switch F - Closed contact

trips and verify that the pressure does not exceed the Set point adjustment
cut-out value of 2900 kPa.
- Using the control point as a reference, verify the When the unit is ready for operation, insert a small screwdriver
correct operation of the unit. in the adjusting slot to turn the dial (the dial may also be turned
by hand). Rotate the screwdriver, until the design set point for
Electromechanical control the installation appears directly under the pointer. Insert a
thermometer in the return water connection and allow the unit
Multi-step thermostat to run through a complete cycle. When switch No. 1 opens, the
This consists of a series of load switches actuated by the last capacity step appears directly under the pointer. Read the
pressure developed inside a temperature sensing bulb, installed temperature. If it is not the same as the dial reading, it can be
in the cooler inlet. compensated by shifting the control point slightly.

Before replacing the bulb, half fill the well with a heat NOTE: Do not force the dial past the stop. This could cause
conducting sealing compound. Replace the sensor in the well loss of the control point and damage the instrument.
recess. The thermostat is factory-set to control from the return
water temperature through a cooling range of 5.6 K. Set point adjustment

The sequence switches are factory-calibrated and sealed Pointer

and should not need any field calibration. Two steps on Adjusting slot
30GV and 30GY 020 to 035 and three steps on 30GV and
30GY 044 to 059 are available.
Stop
WARNING: Alteration of factory settings other than the design
set point, without the manufacturer's authorization, may void
the warranty.
Set points
If a different return water range or leaving water control is
specified, or if brine is to be used, the controller must be
changed. Consult your local Carrier representative for the Calibrated dial
proper control.

Control pressostats

Low pressure switch

Switches the unit off, if the evaporating temperature is too low:
Cut-out: 200 kPa
Cut-in: 350 kPa

Condensing pressure switch (2-speed option)

Energizes and de-energizes the second fan speed as a function
of the condensing pressure:
Cut-out: 1700 kPa
Cut-in: 1090 kPa

13
SERVICING REFRIGERATION COMPONENTS Refrigerant guidelines
Refrigeration installations must be inspected and maintained
Any technician attending the machine for any purpose must be regularly and rigorously by specialists. Their activities must be
a fully qualified refrigeration engineer. overseen and checked by properly trained people. To minimise
discharge to the atmosphere, refrigerants and lubricating oil
WARNING: Before doing any work on the machine ensure that must be transferred using methods which reduce leaks and
the power is switched and locked off and that all isolators are losses to a minimum.
tagged. If a refrigerant circuit is opened, it must be evacuated,
and recharged, after ensuring that the refrigerant is clean and • Leaks must be repaired immediately
free from impurities, the filter-drier has been changed and the • A valve on the condenser liquid refrigerant outlet line
unit has been tested for leaks. Before any operation on a enables the refrigerant charge to be transferred to the
refrigerant circuit, the complete unit refrigerant charge must receiver provided specifically for this purpose.
be removed with a refrigerant charge recovery group. • If the residual pressure is too low to make the transfer
alone, a purpose-built refrigerant recovery unit must be used.
General maintenance • Compressor lubricating oil contains refrigerant. Any oil
drained from a system during maintenance must therefore
Keep the unit itself and the space around it clean and free of be handled and stored accordingly.
obstructions. Remove all rubbish such as packing materials, as • Refrigerant under pressure must never be discharged to
soon as the installation is completed. the atmosphere.

Regularly clean the exposed pipework to remove all dust and Recharging liquid refrigerant (30GV units)
dirt. This makes detection of water leaks easier, and they can
be repaired before more serious faults develop. CAUTION: 30GV 020 to 059 units are charged with liquid
HFC-407c refrigerant.
Confirm that all screwed and bolted connections and joints are
secure. Secure connections prevent leaks and vibration from This non-azeotropic refrigerant blend consists of 23% R-32,
developing. 25% of R-125 and 52% R-134a, and is characterised by the fact
that at the time of the change in state the temperature of the
Check that all insulation joints are securely closed and that all liquid/vapour mixture is not constant, as with azeotropic
insulation is firmly in place. Check all heat exchangers and all refrigerants. All checks must be pressure tests, and the
pipework. appropriate pressure/temperature ratio table must be used for
the interpretation of the values.
Confirm regularly that any phase imbalance in the three-phase
power supply is within acceptable limits. Leak detection is especially important for units charged with
refrigerant R-407c. Depending on whether the leak occurs in
Lubricate the hinges, locks and latches on the electrical control the liquid or in the vapour phase, the proportion of the different
box doors sparingly. components in the remaining liquid is not the same.

Liquid refrigerant charging NOTE: Regularly carry out leak checks and immediately repair
any leak found.
Checking the charge
Undercharge (30GV units)
WARNING: When adjusting the refrigerant charge always
If there is not enough refrigerant in the system, gas bubbles
ensure that water is circulating in the evaporator in order to
appear in the moisture sight glass. There are two possiblities:
prevent any possibility of freezing up. Damage caused by
• Small undercharge (bubbles in the sight glass, no
freezing is not covered by the product warranty.
significant change in suction pressure).
- After detection and repair the unit can be recharged.
30GV and 30GY units are shipped with a full normal charge of
- The replenishment of the charge must be done in the
refrigerant. Refer to the Physical Data table. If it is nevertheless
liquid phase at the liquid line. The refrigerant cylinder
necessary to add more refrigerant, run the unit at full capacity
must contain a minimum of 10% of its initial charge.
for some time and then add refrigerant until there are no
• Significant undercharge (large bubbles in the sight glass,
bubbles in the sight glass. This will generally mean adding
drop in suction pressure).
more refrigerant than would be needed to prevent bubbles from
- Small units (charge below 20 kg per circuit).
being seen in the sight glass.
After detection and repair completely drain the
refrigerant charge, using a refrigerant recovery unit,
WARNING: To ensure proper operation of 30GV and 30GY
then recharge completely, following the precautions
units there must be at least 5 K of subcooling as the liquid
given above.
refrigerant enters the expansion valve.
- Large units (charge above 20 kg per circuit).
After detection and repair completely recharge the
30GV and 30GY units use a halogen refrigerant. For your
unit as described above, operate it for a few minutes
information, please find below an extract from the official
and then let a specialist carry out a chromatographic
publication dealing with the design, installation, operation and
analysis to verify the composition of the blend (range:
maintenance of air conditioning and refrigeration systems and
R-32: 22-24%, R-125: 23-27%, R-134a: 50-54%).
the training of people involved in these activities, as agreed by
the air conditioning and refrigeration industry.

14
Compressors WARNING: Never open or disconnect any switch or circuit
breaker which will cut the supply to the heaters, unless the unit
Checking the oil charge is to be shut down for lengthy service or repair or for a
Check the oil level and add or remove oil as necessary so that seasonal shut down. In all cases the heater must be energised
the level is 1/8 to 3/8 up each sight glass with the compressors for at least 24 hours before a compressor is restarted.
running normally.
Heat exchangers
WARNING: Use only oils which have been approved for use in
refrigeration compressors. Never use oil which has been Evaporator
exposed to air.
Protection devices
Recommended oil:
30GV Freeze-up prevention thermostat
- Polyolester Mobil Oil EAL 68 for semihermetic The evaporator is protected against loss of water and freeze-up.
compressors The protection is provided by a thermostat installed in the unit.

30GY Evaporator maintenance

- Mineral oil, Carrier specification No. PP 33-2
- Suniso 3 GS (Sun Oil Co.) Check that:
- Capella WF 32-150 • the insulating foam is intact and securely in place.
- Clavus G 32 (Shell Oil Co.) • the cooler heaters are operating, secure and correctly
- Gargoyle Artic (Mobil Oil) - original charge positioned.
• the water-side connections are clean and show no sign of
leakage.
WARNING: All fixing devices and fittings which may have
been removed during servicing must always be replaced upon Tube-in-tube evaporator (size 020) - cleaning
completion of the work and before restarting the unit. In some applications, heat exchanger fouling can be very high,
for example when using extremely hard water. The heat
Tightening torques to be applied exchanger can be cleaned by circulating a cleaning solution.
Use a tank with a weak acid solution, 5% phosphoric acid or, if
Description Diameter, mm Torque, Nm
the heat exchanger is frequently cleaned, 5% oxalic acid. Pump
Discharge valve M16 135-140 the cleaning solution through the heat exchanger. For optimum
Cylinder head M12 75-87 cleaning, the cleaning solution flow rate should be 1.5 times that
Suction and liquid line flange M12 75-87
Suction valve M16 135-140 of the normal circulation rate, and the direction of flow should
be opposite to that of normal circulation. Afterwards rinse with
Compressor motor protection large amounts of fresh water, in order to remove all the acid,
before starting up the system again. Clean at regular intervals.
Circuit breaker
Calibrated, thermo-magnetic, manually reset circuit breakers Cleaning in place
protect the compressors against locked rotors and excessive
current draw.

WARNING: Never bypass a circuit breaker or increase its

setting. If a circuit breaker trips, find out why it has done so
and correct the problem before resetting the breaker. Heat exchanger Weak acid
solution
Discharge gas thermostat (DGT)
A sensor in each compressor discharge line opens to shut down
the compressor if the discharge gas temperature exceeds the
preset level.

Cut out 146°C Cut in 113°C

Multitube evaporators (30GV and 30GY 025-059)
Crankcase heater The evaporator can be removed using the following procedure:
Each compressor is fitted with an electric resistance crankcase • Close the chilled water supply and return valves (if
heater which prevents any absorption of refrigerant by the installed), and disconnect the chilled water supply and
compressor lubricating oil when the compressor is shut down. return pipe connections.
Each heater is held in place by a screw clip which must be • Drain the water from the cooler.
secure. Prolonged exposure of the heater to air will result in its • Remove all temperature sensors from the cooler.
destruction. The heater is energized when the compressor is • Fold back the insulation at the refrigerant line
switched off. connections.
When the evaporator heads and manifolds are removed, the
outer tube end plates will be visible.

15
Four evaporator tubes are swaged into the end plate and cannot Preparation of gaskets
be removed. A dot punch mark in the end plate opposite each When rebuilding the cooler, new gaskets must always be used.
one identifies each of them. If any of them develop a leak, the They must conform to the Carrier specification for compressed
tube must be plugged, as described below. gaskets.
• Clean the gasket and its place on the tube sheet.
Plugging evaporator tubes • Cover the two matching surfaces (gasket and tube sheet)
A leaking tube can be plugged pending replacement. The
number of tubes plugged will determine when they should be Tightening cooler head bolts
replaced. Check with Carrier the effect upon chiller performance Cooler head bolts must be tightened in the specified sequence
of plugging a number of tubes. Carrier will need to know the and to the correct torque.
number of tubes to be plugged and their positions. The figure
below shows the Elliott method of plugging tubes. Use this tightening sequence:
• Hand tighten the four bolts as shown below in stage 1.
WARNING: Take care when inserting plugs not to damage the • Hand tighten the next four bolts as shown below in stage 2.
plate material between the tubes. Avoid excessive force. Clean • Starting at the 12 o'clock position, and working clockwise,
all components with Locquic N and then coat all surfaces with insert and hand tighten the remaining outer bolts.
several drops of Loctite 75 to ensure a good seal without • Insert and tighten the six screws in the centre of the head.
applying excessive force.
Bolt size M12 - 71-87 Nm
Elliott tube plug Bolt size M16 - 171-210 Nm
Bolt size M20 - 171-210 Nm
Stage 1

7 Stage 2
1

4 3

2
8

30GV and 30GY 020-059

Components Part number

• Starting again at 12 o'clock and working clockwise,
Tube brass plug ---T-853--103500S-* tighten the outer bolts to the correct torque.
Tube brass ring ---T-853--002570S-* • Not less than one hour later insert and tighten the six bolts
Brass plug (holes without tubes) ---T-853--1031—S-* in the centre of the head, using the torque values given.
Brass ring (holes without tubes) ---T-853--002631S-* • After the cooler has been refilled with clean refrigerant,
Loctite No. 75* use a soap and water solution or an electronic detector to
Locquic “N”* confirm that there are no leaks.
• Replace the evaporator insulation and temperature sensors.
*Order directly from your Carrier distributor

Replacing cooler tubes Condenser coil

Retubing must be done only by a properly trained service
engineer. Most standard practices can be applied, but for cooler We recommend, that finned coils are inspected regularly to
tubes a 5% crush allowance is made for tube expansion and check the degree of fouling. This depends on the environment
twisting (15.87 mm diameter tubes are used in these coolers). where the unit is installed, and will be worse in urban and
industrial installations and near trees that shed their leaves.
The table below gives the specification of the materials used.
Proceed as follows:
Example: • Remove fibres and dust collected on the condenser face
with a soft brush.
Tube sheet hole diameter 16.00 mm • Clean the coil with the appropriate cleaning agents.
Tube outside diameter 15.87 mm
Clearance 0.13 mm We recommend TOTALINE products for coil cleaning:
Tube inside diameter before rolling 14.27 mm Part No. P902 DT 05EE: traditional cleaning method
Tube inside diameter after rolling 14.48 mm Part No. P902 CL 05EE: cleaning and degreasing.

NOTE: Tubes next to the gasket webs must be flush with the These products have a neutral pH value, do not contain
tube sheets at either end of the cooler. phosphates, are not harmful to the human body, and can be
with adhesive, and stick them together. disposed of through the public drainage system.
• Let the joint dry for 5 minutes.
• Moisten the joint with a small amount of compressor oil. Depending on the degree of fouling both products can be used
• Reinstall the evaporator head within 30 minutes. diluted or undiluted.

16
For normal maintenance routines we recommend using 1 kg of 5. Using a straight-edge placed perdendicular to the motor
the concentrated product, diluted to 10%, to treat a coil surface pulleys, mark the tip of each rim with a felt pen or a spot
of 2 m2. This process can either be carried out with a of chalk. These marks will help count the number of turns.
TOTALINE applicator gun (part No. PE01 WA 4000EE) or 6. Now unscrew each pulley flange the number of turns
using a high-pressure spray gun. With pressurised cleaning required to obtain the required fan speed.
methods care should be taken not to damage the coil fins.
NOTE: Increasing the fan speed means increasing the
If at all possible the direction of cleaning should be the load on the fan motor. Do not exceed the maximum value
opposite of the air flow direction. indicated in the Physical Data table.

The two cleaning products can be used for any of the following 7. Set the movable flanges at the nearest pulley hub key-way
coil finishes: Cu/Cu, Cu/Al, Cu/Al with Polual, Blygold and/or and tighten the set screws.
Heresite protection. 8. Install the fan belts on the pulleys.
9. The correct tension is obtained when the belt can be
WARNING: Never use pressurized air or water, as this will flexed 15 mm with one finger half way between the two
damage the fins, and always clean them against the normal air pulleys and without excessive effort. Check the belt
flow direction. tension after three or four hours of operation.
10. After 24 to 48 hours of operation check the belt tension
Fan motor replacement once again. If the belt tension is to high or too low, this
will affect the operating lift of the belt.

Distance between centres L, mm

L
2
Deflection F, 15 mm

Load, kg

11. Pulley alignment should be checked before the belt

tension is adjusted. The straight-edge should be placed on
the side of the pulleys, and the belt must be parallel with
Proceed as follows: the edge. With movable flanges use a wooden block or
1. Remove the fan access panel on the control box side. similar to compensate the width difference. The block
2. Slide a sheet of cardboard over the coil to protect it. thickness should be half the pulley width difference.
3. Remove the damaged motor by sliding it from its support. 12. When the tension and alignment are correct, reinstall the
4. Fit the new motor by following the operation described bolts on the fan rotation axis. Refit the enclosure panels
above in reverse order. and connect the power supply. Start the unit and check to
5. Adjust the belt tension. ensure that the fan discharge volume is correct.
6. Replace all panels.

Fan adjustment and pulley alignment

In order to obtain the optimum fan performance, the following
instructions should be carried out during the unit installation: Straight-edge
once the system ducting is installed and the static pressure
requirement has been calculated, the necessary fan speed can
be established by referring to the corresponding chart in the
product data. On new units, the fan speed is factory-set to mid
range.

To modify the fan speed:

1. Disconnect the unit power supply. Wooden block

2. Remove the fan compartment enclosure panel on the

control box side.
3. Remove the fan belts. To do this, loosen the hexagonal fan
motor nut (ø 24 mm) and slide the motor on its support.
4. Move the fan motor forward and slip the belts over the
pulley rims. Loosen the movable pulley flange set screws
(on the fan motor pulley) and screw both movable flanges
completely toward the fixed centre flange.

17
TROUBLESHOOTING CHART

Below we list a series of possible faults, along with the probable causes and suggested solutions. In the event of a unit
malfunction, it is advisable to disconnect the power supply and ascertain the cause.

SYMPTOMS CAUSE REMEDY

Unit does not start Lack of power supply Connect power supply

Main switch open Close switch

Low line voltage Check voltage and remedy the deficiency

A protection device has tripped Reset

Contactor stuck open Replace contactor

Seized compressor or short circuit Check windings (grounded or short circuit),

replace compressor

Loose electrical connections Check connections

Unit operates continually or Defective compressor contactor Replace contactor

starts and stops frequently
Defective compressor Check valves, replace compressor

Refrigerant losses Check and add the necessary charge

Compressor continually cuts out Refrigerant losses Add the necessary refrigerant charge
at low pressure or via the DGT
Low water flow in the evaporator Check water pump

Blocked expansion valve Clean or replace

Blocked filter drier Replace filter

Compressor continually cuts out Defective high pressure switch Replace pressure switch
at high pressure
Defective fan(s) Check the fan(s) and the contactor(s)

Low water flow due to fouled condenser Clean the condenser

Noises in the system Piping vibrations Support piping, check supports and
tightness

Noisy compressor Check valve plate, change if necessary

Badly fitting panels Install correctly

Compressor loses oil Leak in the system Repair leak

Water losses Defective inlet or outlet connections Check and tighten if necessary

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 Order No. 13193-76, April 1996. Supersedes order No.: New Printed on Totally Chlorine-Free Paper
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands

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