Table of Contents
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I N S T A L L A T I O N ,
O P E R A T I O N
A N D
PRO-DIALOG
M A I N T E N A N C E
I N S T R U C T I O N S
Unit with optional hydronic module
Standard unit
Water-Cooled/Condenserless
Liquid Chillers/Water-Sourced Heat Pumps
with or without Integrated Hydronic Module
61WG/30WG/30GA 020-090
Nominal cooling capacity 25-95 kW
Nominal heating capacity 29-117 kW
Original document
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Table of Contents
Related Manuals for Carrier 61WG 020
Summary of Contents for Carrier 61WG 020
- Page 1 I N S T A L L A T I O N , O P E R A T I O N A N D PRO-DIALOG M A I N T E N A N C E I N S T R U C T I O N S Unit with optional hydronic module Standard unit Water-Cooled/Condenserless...
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Page 2: Table Of Contents
CONTENTS 1 - INTRODUCTION ..................................5 1.1 - Installation safety considerations ............................5 1.2 - Equipment and components under pressure ......................... 6 1.3 - Maintenance safety considerations ............................6 1.4 - Repair safety considerations ..............................7 1.5 - Measures, provisions, procedures against emergencies ......................9 2 - PRELIMINARY CHECKS .............................. - Page 3 6 - ELECTRICAL CONNECTION ............................29 6.1 - Electrical connections, control box 61WG/30WG/ 30WGA ..................... 29 6.2 - Power supply ................................... 29 6.3 - Voltage phase imbalance (%) ............................... 29 6.4 - Recommended wire sections ..............................29 6.5 - 24 V user power reserve ................................ 31 7 - 30WGA UNIT CONNECTIONS ............................
- Page 4 17 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA ................... 44 17 .1 - Compressors ................................... 44 17 .2 - Lubricant ....................................45 17 .3 - Evaporators and water-cooled condensers......................... 45 17 .4 - Electronic expansion valve (EXV) ............................. 45 17 .5 - Refrigerant ..................................... 45 17 .6 - High-pressure switch and high-pressure sensor .........................
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Page 5: Introduction
1 - INTRODUCTION 30WGA are supplied without safety valve on the high-pressure refrigerant circuit and are equipped with automa-tically reset pressure switches in accordance with EN378. Prior to the initial start-up of the 61WG/30WG/30WGA units, the people involved in the on-site installation, start-up, For unit installation and connection to the remote condenser operation and maintenance of this unit should be thoroughly it is necessary to:... -
Page 6: Equipment And Components Under Pressure
If the safety valves are installed on a reversing valve (change-over), this is equipped with a Carrier recommends the following drafting for a logbook safety valve on each of the two outlets. Only one of the two (the table below should not be considered as reference and safety valves is in operation, the other one is isolated. -
Page 7: Repair Safety Considerations
If any intervention is required on the air-cooled condenser Consult Carrier Service for this type of test. Carrier mentions in 30WGA units please refer to the safety instructions here only the principle of a test without removing the supplied by the condenser manufacturer. - Page 8 For 30WGA units with remote condenser the installer must Any refrigerant transfer and recovery operations must be be clearly note the total refrigerant charge used in the system carried out using a transfer unit. 3/8” SAE connectors on the (in kg) on the label attached to the 30WGA. liquid, suction and discharge lines are available for all units RISK OF EXPLOSION: Never use air or a gas containing for connection to the transfer station.
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Page 9: Measures, Provisions, Procedures Against Emergencies
1.5 - Measures, provisions, procedures against 2.2.1 - Moving emergencies See chapter 1.1 - “Installation safety considerations” . When the machine is subjected to heat or fire, a device 2.2.2 - Placing the unit prevents explosion by releasing the refrigerant (via the relief valve). - Page 10 a way that does not submit it to any strain. The hydronic to comply with the regulations are in place. module pipes must be fitted so that the pump does not support • Verify that all documents for pressure containers, certificates, the weight of the pipes.
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Page 11: Dimensions, Clearances
3 - DIMENSIONS, CLEARANCES 3.1 - 61WG/30WG 020-045 - standard unit Only for option 70F 1044 1058 3.2 - 61WG/30WG 020-045 - unit with top connections (option 274) 1044 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Water inlet Water outlet... -
Page 12: 61Wg/30Wg 020-045 - Unit With Evaporator Hydronic Module (Option 116)
3.3 - 61WG/30WG 020-045 - unit with evaporator hydronic module (option 116) Only for option 70F 161 237 1044 1058 3.4 - 61WG/30WG 020-045 - unit with condenser hydronic module (option 270) Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Water inlet Water outlet... -
Page 13: 61Wg/30Wg 020-045 - Unit With Hydronic Module And Top Connections (Options 116 + 274 Or 270 + 274 Or 116 + 270 + 274)
3.6 - 61WG/30WG 020-045 - unit with hydronic module and top connections (options 116 + 274 or 270 + 274 or 116 + 270 + 274) 1044 3.7 - 61WG/30WG 020-045 - stackable unit (option 273) NOTE: The water and electrical connections are identical to those of the standard unit. 1058 Legend: All dimensions are in mm. Evaporator Condenser Safety valve... -
Page 14: 61Wg/30Wg 050-090 - Standard Unit
3.8 - 61WG/30WG 050-090 - standard unit Only for option 70F 1474 1489 3.9 - 61WG/30WG 050-090 - unit with top connections (option 274) 1474 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Water inlet Water outlet Power wiring connection NOTE: Non-contractual drawings. Refer to the certified dimensional drawings available... -
Page 15: 61Wg/30Wg 050-090 - Unit With Evaporator Hydronic Module (Option 116)
3.10 - 61WG/30WG 050-090 - unit with evaporator hydronic module (option 116) Only for option 70F 1474 1488 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Water inlet Water outlet Power wiring connection 3.11 - 61WG/30WG 050-090 - unit with condenser hydronic module (option 270) 3.12 - 61WG/30WG 050-090 - unit with evaporator/condenser hydronic modules (options 116 + 270) 277 282 NOTE: Non-contractual drawings. Refer to the... -
Page 16: 61Wg/30Wg 050-090 - Unit With Hydronic Module And Top Connections (Options 116 + 274 Or 270 + 274 - 116 Or 270 + 274)
3.13 - 61WG/30WG 050-090 - unit with hydronic module and top connections (options 116 + 274 or 270 + 274 - 116 or 270 + 274) 1474 3.14 - 61WG/30WG 050-090 - stackable unit (option 273) NOTE: The water and electrical connections are identical to those of the standard unit. 1489 Legend: All dimensions are in mm. Evaporator Condenser Safety valve... -
Page 17: 30Wga 020-045 - Standard Unit
3.15 - 30WGA 020-045 - standard unit For option 70F only 1044 1058 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection 3.16 - 30WGA 020-045 - unit with evaporator hydronic module (option 116) For option 70F only 1044 1058... -
Page 18: 30Wga 020-045 - Stackable Unit (Option 273)
3.17 - 30WGA 020-045 - stackable unit (option 273) NOTE: The water and electrical connections are identical to those of the standard unit. 1058 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection 3.18 - 30WGA 050-090 - standard unit For option 70F only 1474 1488... -
Page 19: 30Wga 050-090 - Unit With Evaporator Hydronic Module (Option 116)
3.19 - 30WGA 050-090 - unit with evaporator hydronic module (option 116) For option 70F only 1474 1488 Legend: All dimensions are in mm. Evaporator Condenser Safety valve Clearances required for maintenance (see note) Control box Refrigerant inlet Refrigerant outlet Water inlet Water outlet Power wiring connection 3.20 - 30WGA 050-090 - stackable unit (option 273) NOTE: The water and electrical connections are identical to those of the standard unit. -
Page 20: Physical And Electrical Data 61Wg/30Wg
4 - PHYSICAL AND ELECTRICAL DATA 61WG/30WG 4.1 - Physical data 61WG 61WG Operating weight* Sound levels** Sound power level 10 W, standard unit dB(A) 67.0 68.5 69.0 69.3 70.0 70.1 71.5 72.0 72.0 73.0 73.4 Compressors Hermetic scroll 48.3 r/s Quantity Number of capacity steps Minimum capacity Refrigerant* R-410A... -
Page 21: Physical Data 30Wga
4.3 - Physical data 30WGA 30WGA Operating weight* Sound levels** Sound power level 10 dB(A) 67.0 68.5 69.0 69.3 70.0 70.1 71.5 72.0 72.0 73.0 73.4 Compressors Hermetic scroll 48.3 r/s Quantity Number of capacity steps Minimum capacity Refrigerant R-410A 160SZ Charge per compressor Control Pro-Dialog+ Evaporator Direct-expansion plate heat exchanger Water volume... -
Page 22: Electrical Data 61Wg/30Wg/30Wga
Maximum value with upstream protection (by circuit breaker) Conditional short-circuit current Icc - kA rms Schneider circuit breaker - Compact series NSX 100N Reference number** LV429795 Earthing system type ** If another current limitation protection system is used, its time-current and thermal constraint (I²t) trip characteristics must be at least equivalent to those of the recommended Schneider circuit breaker. Contact your nearest Carrier office. The short-circuit stability current values above are in accordance with the TN system. -
Page 23: Electrical Data, Optional Hydronic Module
< 1000†† II - Ambient air temperature °C < 40 IV - Maximum air temperature Please refer to the operating conditions given in this manual or in the specific conditions in the Carrier selection programs. V - Potentially explosive atmospheres Non-ATEX environment Motors of variable-speed hydronic module pumps, 61WG/30WG/30WGA (options 116V and 270V) No.** Description*** 61WG/30WG/30WGA - options 116V and 270V (high-pressure pumps) -
Page 24: Compressor Usage And Electrical Data Table
All connections to the system and the electrical installations must be in full use a transformer). accordance with all applicable local codes. 4. Over-current protection of the power supply conductors is not provided with the • The Carrier 61WG/30WG/30WGA units are designed and built to ensure unit. conformance with these codes. The recommendations of European standard 5. The factory-installed disconnect switch(es)/circuit breaker(s) is (are) of a type EN 60204-1 (machine safety - electrical machine components - part 1: general suitable for power interruption in accordance with EN 60947. -
Page 25: Application Data
°C 15*** 55**** Entering/leaving water temperature difference Leaving water temperature during operation °C Condenser Entering/leaving water temperature difference Entering water temperature at start-up °C 15*** 60**** For entering water temperatures below 7.5 °C at start-up, contact Carrier. Leaving water temperature during operation °C ** If the leaving water temperature is below 5 °C, a frost protection solution must Entering/leaving water temperature difference be used. Please refer to option 6 for evaporator leaving water low-temperature applications (< 5 °C). For entering water temperatures below 7.5 °C at start-up, contact Carrier. *** For applications with a condenser entering temperature below 15 °C the use of ** If the leaving water temperature is below 5 °C, a frost protection solution must a three-way valve is recommended. This three-way valve can be controlled by be used. Please refer to option 272 for evaporator leaving water low-temperature the 0-10 V analogue output of the Pro-Dialog+ control. -
Page 26: Operating Limits 30Wga
°C 0*** 35 to 48‡ Air entering temperature (variable-speed fan) °C -10 to -20† 35 to 48‡ For entering water temperatures below 7.5 °C at start-up, contact Carrier. ** 30WGA unit can operate down to 0 °C if the configuration of the fluid type used is modified. If the leaving water temperature is below 5 °C, a frost protection solution must be used. *** The minimum temperature range is based on the condenser selected. If the condenser only has a few fan stages, the use of variable-speed fans is recommended from 10 °C. -
Page 27: Minimum Water Volume
5.10.3 - Standard 30WG/30WGA 5.11 - Minimum water volume 30WG Evaporator water flow rate, l/s Whichever the system, the water loop minimum capacity is 30WGA Minimum* Minimum** Maximum*** Maximum**** given by the formula: Capacity = Cap (kW) x N Liters High High pressure... -
Page 28: Protection Against Cavitation (Option 116)
5.14 - Protection against cavitation (option 116) In order to obtain sufficient pressure, it is recommended: • to pressurise the hydronic circuit between 100 kPa and To ensure the durability of the pumps in the integrated 300 kPa (1 and 3 bar) maximum on the suction side of hydronic modules, the control algorithm of the 61WG/30WG/ the pump, •... -
Page 29: Electrical Connection
Non-certified drawings. installation site. The following is only to be used as a guide-line, and does not make Carrier in any way liable. After wire sizing Refer to the certified dimensional drawings. has been completed, using the certified dimensional drawing,... - Page 30 The calculations are based on the maximum machine current 6.4.1 - Field control wiring (see electrical data tables). For the design the following IMPORTANT: Field connection of interface circuits may standardised installation methods are used, in accordance with IEC 60364, table 52C: lead to safety risks: any control box modification must •...
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Page 31: 24 V User Power Reserve
6.5 - 24 V user power reserve • A fan speed controller may is recommended for the first fan stage for operation at low ambient temperature at After all possible options have been connected, the transformer part load and for condensers with few fans. ensures the availability of a usable 24 VA or 1 A power reserve for the control circuit on site. -
Page 32: Pipe Sizing With Refrigerant For 30Wga Units
The piping between the 30WGA and the condenser must be • The pressure drop in the liquid line (linking the condenser correctly supported in line with its size and the operating outlet to the expansion device) must not result in a weight. -
Page 33: Liquid Line Sizing
For most applications the refrigerant gas velocity is sufficient Table 4 - Equivalent length (m) for filter drier, solenoid to entrain the liquid refrigerant/oil mixture. Neverthe-less, valves, moisture sight-glass (standard supply) table 3 shows the minimum required cooling capacities for 30WGA 020 025 030 035 040 045 050 060 070 080 090 different pipe diameters and different saturated discharge... -
Page 34: Water Connections
If the water circuit must be emptied for longer than one If additives or other fluids than those recommended by Carrier month, the complete circuit must be placed under nitrogen are used, ensure that the fluids are not considered as a gas, and charge to avoid any risk of corrosion by differential aeration. -
Page 35: Frost Protection
If the heat exchange fluid does not comply with Carrier These characteristics can be obtained from the technical recommendations, the circuit must immediately be filled literature using the unit performance tables or the Electronic with nitrogen. -
Page 36: Nominal Water Flow Control With Variable-Speed Pump
Entering water pressure reading Proceed by successively closing the control valve until you obtain the specific pressure drop that corresponds to the nominal flow rate at the required unit operating point. • If the system has an excessive pressure drop in relation to the available static pressure provided by the pump, the resulting water flow rate will be reduced and the difference between entering and leaving water temperature... -
Page 37: Available External Static Pressure
11.2 - Available external static pressure (variable-speed high-pressure pumps, units with hydronic module Data applicable for: Fresh water (without antifreeze) 20 °C In case of use of the glycol, the maximum water flow is reduced The curves represented below are in normal conditions: leaving water on the back side of the unit (without option 274). -
Page 38: Available External Static Pressure (Fixed-Speed Low-Pressure Pumps, Units With Hydronic Module)
11.3 - Available external static pressure (fixed-speed low-pressure pumps, units with hydronic module) Data applicable for: Fresh water 20 °C In case of use of the glycol, the maximum water flow is reduced The curves represented below are in normal conditions: leaving water on the back side of the unit (without option 274). -
Page 39: Pump Curve (Units With Hydronic Modules)
11.4 - Pump curve (units with hydronic modules) 12 - OPERATION OF 61WG UNITS WITH SPECIFIC HEATING CONTROL (OPTION 153) Data applicable for: Fresh water 20 °C 12.1 - Operating principle In case of use of the glycol, the maximum water flow is reduced 61WG units are specially designed to optimise the operation The curves represented below are in normal conditions:... -
Page 40: Operation Of 61Wg Units With The Heating System Manager (Hsm)
13 - OPERATION OF 61WG UNITS WITH THE HEATING HSM control box SYSTEM MANAGER (HSM) HSM accessory: 00PPG000488000- or 00PPG000488100- or 00PPG000488200- The Heating System Manager (HSM) accessory allows improved integration of the 61WG heat pump to maximise energy efficiency performance. With three system levels for nine typical configurations, most heating only applications are covered - from the simplest to the most complex, such as interfacing with a district heating... -
Page 41: 30Wg Unit Operation With A Drycooler (Option 154)
14 - 30WG UNIT OPERATION WITH A DRYCOOLER Pro-Dialog+ optimises system operation to obtain the best (OPTION 154) efficiency with variation of the water flow rate and the number of fans required for any thermal load and outside temperature 14.1 - Operating principle conditions. -
Page 42: 30Wg Units Without Evaporator And Condenser Pump, Three-Way Valve Configuration For Low Outside Temperature Application
CH14 In this case Pro-Dialog+ should be configured for three-way valve system control from an analogue 0-10 volt output on the Carrier NRCP type master board. An adequate CH13 condensing temperature will be maintained with constant condenser flow rate. This configuration permits year-round system operation down to -20 °C outside temperature. -
Page 43: Start-Up
±2%. (unit outlet) an excess charge is possible. This excess charge • Do not interchange material with another Carrier unit. translates to an excessive condensing pressure and increases The elements used for this unit are specific to this unit. -
Page 44: Oil Charge Adjustment
The compressors are not certified for mobile applications or Entering water control for a hydronic kit use in explosive environments. For more information contact the Carrier service team for maintenance instructions. IMPORTANT: All compressor and system pressure tests must be carried out by qualified personnel, taking the greatest... -
Page 45: Lubricant
• Regularly check for possible presence of impurities (e.g. polyolester oil (reference: POE 160SZ). Contact Carrier to order the oil. This lubricant must not be mixed with other silicon grains) in the heat exchange fluids. These lubricant types. -
Page 46: High-Pressure Switch And High-Pressure Sensor
A temperature difference between the filter Schrader valve. It is specific to these units and must not be drier inlet and outlet indicates a contamination of the replaced with one from other Carrier units. cartridges. 30WGA units are equipped with an automatically reset safety 30WGA are equipped as standard with a filter drier that pressure switch on the discharge line. -
Page 47: Fixed-Speed Pump
ATTENTION: Use of hydronic kit in an open loop is forbidden. not be interchanged with another temperature sensor. For replacement please contact the Carrier service team. 17.12 - Evaporator and condenser pump suction filter 17.15 - Outside air temperature sensor 30WGA units require information about the outside air temperature. -
Page 48: Options And Accessories
Low temperature glycol solution production down to Covers specific applications such as ice 30WG 020-090 -12 °C with ethylene glycol storage and industrial processe Soft starter Electronic compressor starter Reduced compressor start-up current 30WG 020-090 61WG 020-090 30WGA 020-090 Twinning Unit equipped with an additional field-installed leaving Optimised operation of two units connected 30WG 020-090 water temperature sensor, allowing master/slave in parallel with operating time equalisation 61WG 020-090 operation of two units connected in parallel. -
Page 49: Maintenance
19 - MAINTENANCE 19.2 - General system maintenance During the unit operating life the service checks and tests • Keep the unit itself and the space around it clean and must be carried out in accordance with applicable national free of obstructions. Remove all rubbish such as packing regulations. -
Page 50: Leak Detection
Before opening a refrigerant circuit, purge the circuit and ATTENTION: Do not use a megohmmeter and do not place consult the pressure gauges. any stress on the compressor motor when the system has been evacuated. There is a risk of internal short circuits Change the refrigerant after an equipment failure, following between the motor windings. -
Page 51: Electrical Maintenance
19.9 - Electrical maintenance 19.12 - Compressors When working on the unit comply with all safety precau-tions The compressors do not require any specific maintenance. described in section 1.3. Nevertheless the preventive system maintenance operations prevent specific compressor problems. The following periodic It is strongly recommended to change the unit fuses every preventive maintenance checks are strongly recommended: 15000 operating hours or every three years. -
Page 52: Aquasnap Maintenance Program
• Check the operation of the high-pressure switch(es). The equipment is supplied with polyolester oil (POE). Use only Carrier-approved oil. On request Carrier can carry out Replace them if there is a fault. an oil analysis of your installation. •... -
Page 53: Start-Up Ckecklist For 61Wg/30Wg/30Wga Units (Use For Job File)
21 - START-UP CKECKLIST FOR 61WG/30WG/30WGA UNITS (USE FOR JOB FILE) Preliminary information Job name: ....................................... Location: ........................................ Installing contractor: ..................................... Distributor: ......................................Start-up preformed by: ..................................Equipment Model: .................... Serial No..................Compressors 1. Model No.................. 2. Model No................Serial No. - Page 54 WARNING: Do not start unit if voltage imbalance is greater than 2%. Contact local power company for assistance. All incoming power voltage is within rated voltage range Check cooler water loop Water loop volume = ......(litres) Calculated volume = ....... (litres) Proper loop volume established Proper loop corrosion inhibitor included ..litres of ......
- Page 56 Order No: 16122, 12.2016 - Supersedes order No: 16122, 10.2014. Manufacturer: Carrier SCS, Montluel, France. Manufacturer reserves the right to change any product specifications without notice. Printed in the European Union.
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