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Carrier 30RBM 160 Installation, Operation And Maintenance Instructions

Air-cooled liquid chillers
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INSTALLATION, OPERATION AND
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 low noise level option
Unit with low noise level option
Air-Cooled Liquid Chillers
30RBM 160-520
30RBP 160-520
Nominal cooling capacity 164 - 528 kW 50 Hz
Translation of the original document 23539, 10.2016

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  Summary of Contents for Carrier 30RBM 160

  • Page 1 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 low noise level option Unit with low noise level option Air-Cooled Liquid Chillers 30RBM 160-520 30RBP 160-520 Nominal cooling capacity 164 - 528 kW 50 Hz Translation of the original document 23539, 10.2016...
  • Page 2: Table Of Contents

    4.4 - Installing several units ................................14 4.5 - Distance to the wall ..................................14 5 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS ....................15 5.1 - Physical data 30RBM 160-520 ..............................15 5.2 - Physical data 30RBP 160-520 ..............................16 5.3 - Electrical data 30RBM 160-520 ..............................17 5.4 - Electrical data 30RBP 160-520 ..............................17...
  • Page 3 10 - SYSTEM START-UP .................................40 10.1 - Checks before system start-up ..............................40 10.2 - Commissioning ..................................40 10.3 - Essential points to check ................................41 11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS...........41 11.1 - Compressors....................................41 11.2 - Lubricant ....................................41 11.3 - Air-cooled exchanger ................................41 11.4 - Fans ......................................42 11.5 - Electronic expansion valve (EXV) ............................43...
  • Page 4: Introduction

    1 - INTRODUCTION Classification and control: The units are intended to cool water for building air In accordance with the Pressure Equipment Directive and conditioning or for industrial processes. national usage monitoring regulations in the European Union, the protective devices fitted to these units are classified as They are designed to provide a very high level of safety and follows: reliability, making installation, start-up, operation and...
  • Page 5: Refrigerant Safety Considerations

    1.2 - Refrigerant safety considerations Provide a drain in vent line, close to each relief valve, to avoid an accumulation of condensate or rain water. Use safety goggles and safety gloves. It is recommended to install an indicating device to check All precautions concerning handling of refrigerant must be whether some of the fluid has leaked from the relief valve.
  • Page 6 Do not clean the unit with hot water or steam. This could ► All interventions on this product's refrigerating circuit pressurise the refrigerant. must be performed in accordance with applicable legislation. Within the European Union, this legislation NOTE: notably includes regulation No. 517/2014, known as If a liquid line valve is present, never leave refrigerant in liquid F-Gas.
  • Page 7: Installation Safety Considerations

    1.3 - Installation safety considerations Repair: Any repair or modification, including replacement of removable After the unit has been received, and before it is started up, parts: it must be inspected for damage. Check that the refrigerant • Must comply with local regulations and must be performed circuits are intact, especially that no components or pipes have by qualified operators in accordance with qualified processes, shifted or been damaged (e.g.
  • Page 8: Repair Safety Considerations

    After disconnecting the power supply to the electrical box, No part of the unit must be used as a walkway, rack or support. wait for 5 minutes before accessing the electrical box or Periodically check and repair or, if necessary, replace any variable drives.
  • Page 9: Receipt Of Goods

    2 - RECEIPT OF GOODS 3 - HANDLING AND POSITIONING 2.1 - Check equipment received 3.1 - Handling Check that the unit and the accessories have not been damaged It is strongly recommended that a specialised company is during transport and that no parts are missing. If the unit and employed to unload the unit.
  • Page 10: Positioning

    3.2 - Positioning The unit must be installed in a place that is inaccessible to the public or protected against access by non-authorised persons. For extra-high units, the unit environment must permit easy access for maintenance operations. For the centre of gravity coordinates, the position of the unit mounting holes, and the weight distribution points, refer to the certified dimensional drawings.
  • Page 11: Dimensions, Clearances

    4 - DIMENSIONS, CLEARANCES 4.1 - 30RBM/RBP 160-260 WITHOUT HYDRONIC MODULE 30RBP only Power connection Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Air outlet, do not obstruct Control box NOTE: Non-contractual drawings.
  • Page 12: 30Rbm/Rbp 300-400

    4.2 - 30RBM/RBP 300-400 WITHOUT HYDRONIC MODULE 30RBP only Sizes 360-400 Power connection Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Air outlet, do not obstruct Control box NOTE: Non-contractual drawings.
  • Page 13: 30Rbm/Rbp 430-520

    4.3 - 30RBM/RBP 430-520 WITHOUT HYDRONIC MODULE 30RBP only Power connection Size 520 Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Air outlet, do not obstruct Control box NOTE: Non-contractual drawings.
  • Page 14: Installing Several Units

    4.4 - Installing several units It is recommended to install units in a single row, arranged as shown in the example below, to avoid recycling hot air between the units. 1500 mm 1500 mm min. min. 4.5 - Distance to the wall Plots Anti-vibration Antivibratiles...
  • Page 15: Physical And Electrical Data For The Units

    5 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS 5.1 - Physical data 30RBM 160-520 30RBM Sound levels Standard unit Sound power dB(A) Sound pressure at 10 m dB(A) Standard unit + option 15 Sound power dB(A) Sound pressure at 10 m...
  • Page 16: Physical Data 30Rbp 160-520

    5.2 - Physical data 30RBP 160-520 30RBP Sound levels Standard unit Sound power dB(A) Sound pressure at 10 m dB(A) Standard unit + option 15 Sound power dB(A) Sound pressure at 10 m dB(A) Standard unit + option 15LS Sound power dB(A) Sound pressure at 10 m dB(A)
  • Page 17: Electrical Data 30Rbm 160-520

    5.3 - Electrical data 30RBM 160-520 30RBM Power circuit V-ph-Hz 400 - 3 -50 Nominal voltage 360 - 440 Voltage range 24 V via internal transformer Control circuit supply Nominal unit current draw Circuit A&B Max. operating input power Circuit A&B...
  • Page 18: Electrical Data For The Hydronic Module

    IV - Maximum operating temperature °C 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 Required by regulation No. 640/2009 concerning the application of directive 2005/32/EC on the eco-design requirements for electric motors.
  • Page 19: Electrical Data Notes For The Compressors

    III - Maximum operating temperature °C "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 Required by regulation No. 640/2009 concerning the application of directive 2005/32/EC on the eco-design requirements for electric motors.
  • Page 20: Electrical Data Notes

    IEC61000-2-4 standard: be considered, always contact your local Carrier representative. Power supply frequency variation: +- 2Hz The required protection level for this class is IP43BW (according to reference Phase imbalance : 2% document IEC 60529).
  • Page 21: Electrical Connection

    6 - ELECTRICAL CONNECTION Calculate the maximum deviation from the 400 V average: Please refer to the certified dimensional drawings, supplied (AB) = 406 - 400 = 6 with the unit. (BC) = 400 - 399 = 1 (CA) = 400 - 394 = 6 Motor 6.1 - Power supply The maximum deviation from the average is 6 V.
  • Page 22: Power Cable Entry

    6.4 - Power cable entry See the control manual and the certified electric wiring diagram supplied with the unit for the field control wiring of The power cables for devices are routed into the electrical box the following devices: from underneath the unit, •...
  • Page 23: Application Data

    - 30 Standard units (outdoor installation) Water type exchanger leaving water temperature (°C) For applications requiring operation at less than 8°C, contact Carrier for unit selection using the Carrier electronic catalogue. NOTES Use of antifreeze is obligatory if the leaving water temperature is below 5°C.
  • Page 24: Minimum Heat-Transfer Fluid Flow Rate (Units Without Factory-Fitted Hydronic Module)

    7.2 - Minimum heat-transfer fluid flow rate (units 7.5 - System minimum water volume without factory-fitted hydronic module) Whichever the system, the water loop minimum volume is The minimum heat-transfer fluid flow rate is given in the given by the formula paragraph "Water exchanger min.
  • Page 25: Water Type Heat Exchanger Water Flow Rate

    7.7 - Water type heat exchanger water flow rate Data applicable for pure water. 30RBM/30RBP 160-520 units without hydronic module 30RBM/30RBP 160-520 units with high-pressure hydronic module 30RBM/30RBP Minimum flow rate (l/s) Maximum flow rate (l/s) 30RBM/30RBP Minimum flow rate (l/s) Maximum flow rate (l/s) Single...
  • Page 26: Pressure Drop Curves For The Water Type Heat Exchanger And Standard Water Inlet/Outlet Piping

    7.8 - Pressure drop curves for the water type heat exchanger and standard water inlet/outlet piping Data applicable for pure water at 20°C. 30RBM/30RBP 160-360 units 10.0 100.0 Water flow rate, l/s 30RBM/30RBP 160-20 30RBM/30RBP 260 30RBM/30RBP 300 30RBM/30RBP 330 30RBM/30RBP 360 30RBM/30RBP 400-520 units 10.0...
  • Page 27: Water Connections

    8 - WATER CONNECTIONS 8.1 - Operating precautions and recommendations When connecting units to the water distribution pipe work, Before the system start-up, make sure the hydronic circuits refer to the certified dimensional drawings supplied with the are connected to the appropriate heat exchangers. unit for the dimensions and position of the exchanger water The water circuit must have as few bends and horizontal inlet and outlet connections.
  • Page 28: Hydronic Connections

    8.2 - Hydronic connections The hydronic module options are only compatible with closed loops. The use of the hydronic module on open systems is prohibited. Schematic diagram of the hydronic circuit without hydronic module option Schematic diagram of the hydronic circuit with hydronic module option option Legend:...
  • Page 29 Water connections with hydronic module Example: Single pump Example: Single pump Raccord pour vase Raccord pour vase Raccord pour vase Raccord pour vase d’expansion (option 293) d’expansion (option 293) d’expansion (option 293) d’expansion (option 293) See legend on the previous page. Water connections without hydronic module See legend on the previous page.
  • Page 30: Cavitation Protection (With Hydronic Option)

    8.3 - Cavitation protection (with hydronic option) 8.5 - Frost protection To ensure the durability of pumps fitted on the integrated Damage caused by frost is not covered by the warranty. hydronic modules, the control algorithm of units in the range includes protection against cavitation.
  • Page 31 IMPORTANT: Depending on the atmospheric conditions in your region, you need to: • Add an appropriate antifreeze solution (maximum of 45%) to protect the system down to a temperature of 10 K below the lowest temperature likely to occur locally. •...
  • Page 32: Nominal System Water Flow Rate Control

    9 - NOMINAL SYSTEM WATER FLOW RATE CONTROL • Read the pressure drop of the plate heat exchanger using the pressure differential gauge to find the difference Refer to the schematic diagram in the "Water connections" between the unit inlet and outlet (item 21). paragraph for all item references in this chapter.
  • Page 33: Units With Hydronic Module And Fixed Speed Pump

    9.2 - Units with hydronic module and fixed speed Example: Unit with specific nominal flow 10.6 l/s pump General information See the paragraph on "Units without hydronic module" Hydronic circuit cleaning procedure • Open all control valves completely (item 22). •...
  • Page 34: Units With Hydronic Module And Variable Speed Pump - Pressure Differential Control

    9.3 - Units with hydronic module and variable speed Read the value of the flow on the user interface and compare pump – Pressure differential control it with the theoretical value of the range: • If the flow rate read is greater than the specified value, The system flow rate is not set at a nominal value.
  • Page 35: Units With Hydronic Module And Variable Speed Pump - Temperature Differential Control

    9.4 - Units with hydronic module and variable speed 9.5 - Units with hydronic module and variable speed pump – Temperature differential control pump – Setting a fixed flow rate for the system The system flow rate is not set at a nominal value. The flow will be set to a nominal value.
  • Page 36: Pump Pressure/Flow Rate Curves

    9.6 - Pump pressure/flow rate curves Units with hydraulic module (fixed speed pump or variable speed pump at 50 Hz). Data applicable for: • Pure water at 20°C. • Refer to the paragraph on "Water exchanger min. water volume and flow rate" for the maximum water flow rate values. •...
  • Page 37 Low pressure pumps Single pumps 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 Water flow rate, l/s 30RBM-30RBP 160 to 220 30RBM-30RBP 260 30RBM-30RBP 300 to 360 30RBM-30RBP 520 30RBM-30RBP 400 to 470 Dual pumps Water flow rate, l/s 30RBM-30RBP 160 to 180...
  • Page 38: Available Static System Pressure

    9.7 - Available static system pressure Units with hydronic module (fixed speed pump or variable speed pump at 50 Hz) Data applicable for: • Pure water at 20°C. • Refer to the "Water exchanger water flow" section for the maximum water flow values. •...
  • Page 39 Low pressure pumps Single pumps Sizes 400-520 Sizes 160-360 Water flow rate, l/s Water flow rate, l/s 30RBM-30RBP 160 to 220 30RBM-30RBP 260 30RBM-30RBP 520 30RBM-30RBP 300 30RBM-30RBP 400 30RBM-30RBP 360 30RBM-30RBP 430 30RBM-30RBP 330 30RBM-30RBP 470 Dual pumps Sizes 430-520 Sizes 160-400 Water flow rate, l/s Water flow rate, l/s...
  • Page 40: System Start-Up

    10 - SYSTEM START-UP 10.2 - Commissioning Always ensure you have read and fully understood the 10.1 - Checks before system start-up operating instructions for the units before starting up the unit, Before starting up the thermodynamic system, the complete and ensure the following precautions have been taken: system, including the thermodynamic system, must be verified •...
  • Page 41: Essential Points To Check

    10.3 - Essential points to check 11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS • Compressors Ensure that each compressor is rotating in the correct 11.1 - Compressors direction, checking that the discharge temperature rises quickly, the HP increases and the LP drops. If it is rotating in The units use hermetically sealed scroll compressors.
  • Page 42: Fans

    11.4 - Fans Each fan motor assembly is equipped with a high-performance impeller made from recyclable composite material. The motors are three-phase, with lifetime lubricated bearings and class F insulation (IP55 level). According to regulation No. 327/2011 implementing directive 2009/125/EC with regard to eco-design requirements for fans driven by motors with an electric input power between 125 W and 500 kW.
  • Page 43: Electronic Expansion Valve (Exv)

    11.5 - Electronic expansion valve (EXV) 11.9 - Refrigerant The EXV has a stepper motor and a sight glass which can be Units running with R410A. used to check the mechanism movement and the presence of 11.10 - High-pressure safety pressostat the liquid gasket.
  • Page 44: Fan Arrangement

    11.12 - Fan arrangement 30RBM/30RBP 30RBM/30RBP 30RBM/30RBP 300-330 180-200-220-260 CKT A CKT B CKT A CKT B CKT A CKT B 30RBM/30RBP 360-400 30RBM/30RBP 430-470 CKT A CKT B CKT A CKT B 30RBM/30RBP 520 CKT A CKT B 11.13 - Fan stages 30RBM standard Circuit Stage 1 Stage 2 Stage 3 Stage 4...
  • Page 45: Options

    220-520 free-cooling coil. See Dx Free-cooling option chapter Free Cooling Dx system 118B Patented Carrier free-cooling system with cooling micro-pump on one Energy savings for applications with reduced demand for cooling in 30RBM/30RBP on 1 circuit refrigerant circuit. Operation without glycol, no extra free-cooling coil.
  • Page 46 Options Description Advantages Super Enviro-Shield Extremely durable and flexible epoxy polymer coating applied to Improved corrosion resistance, recommended for use in extremely 30RBM/30RBP anti-corrosion protection micro-channel heat exchangers via an electro-coating process, with corrosive environments 160-520 a final UV protective topcoat. Minimal variation in heat transfer, tested to withstand more than 6000 hours of constant neutral salt spray as per ASTM B117, superior impact resistance as per ASTM D2794 Welded evaporator water...
  • Page 47: Description

    12.2 - Description Additional options can be ordered if necessary: • Protection of the hydronic module in outdoor temperatures 12.2.1 - Touch Pilot Control (option 158) of down to -20°C. • Expansion vessel. The interface of the "Touch Pilot Control" has the following characteristics: The use of the hydronic module on open systems is •...
  • Page 48 Dimensions, clearances 30RBM/RBP 160-520 2’’ Victaulic Power connection 2410 HT Unit With hydronic module Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Control box NOTE: Non-contractual drawings. When designing a system, refer to the certified dimensional drawings provided with the unit or available on request.
  • Page 49 30RBM/RBP 300-400 2’’ Victaulic 3604 HT Unit With hydronic module 1495 1500 Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Control box NOTE: Non-contractual drawings. When designing a system, refer to the certified dimensional drawings provided with the unit or available on request.
  • Page 50 30RBM/RBP 430-520 2’’ Victaulic 4797 HT Unit With hydronic module 2730 Legend: All dimensions are in mm. Clearances required for maintenance and air flow Clearance recommended for coil removal Water inlet Water outlet Control box NOTE: Non-contractual drawings. When designing a system, refer to the certified dimensional drawings provided with the unit or available on request.
  • Page 51 12.2.4.2 - Installation and operation of the heat recovery with desuperheater option Units with the desuperheater option are delivered with a plate heat exchanger for each refrigerating circuit. When installing the unit, the heat recovery plate heat exchangers must be insulated and protected against frost if required. Refer to the main diagram below for the main components or functions associated with a unit with desuperheater option in a standard system.
  • Page 52 This may require the use of a three-way valve (item 31), with 12.2.4.3 - Installation its controller and sensor controlling the minimum required The hydraulic supply for each desuperheater is delivered in entering water temperature. parallel. It is essential for the desuperheater water loop to comprise a The hydraulic connection on the desuperheater water inlet and valve and an expansion vessel which must be selected to take outlets must not generate any local mechanical stress on the...
  • Page 53 Example 1: operation in parallel - control on water inlet Units supplied with hydronic module for a hydronic kit Master/Slave operation is possible only when the units are installed in parallel: • The Master/Slave assembly is controlled on the water inlet without any additional sensors (standard configuration) (see example 1).
  • Page 54 Operating range • Low-temperature brine solution 30RBM 160-400 and 30RBP 160-400 30RBM 160-400 and 30RBP 160-400 Low-temperature Propylene Glycol Low-temperature Ethylene Glycol -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 -15 -14 -13 -12 -11 -10 -9 Brine solution mix type heat exchanger leaving water temperature (°C)
  • Page 55 Refrigerant charge for the low-temperature brine solution option 30RBM and RBP Circuit A standard unit + option 6B 8,40 10,90 10,90 12,60 12,55 14,15 14,90 20,30 20,60 17,5 22,8 22,8 26,3 26,2 29,5 31,1 42,4 43,0 Circuit BA standard unit + option 6B 12,25 12,60 12,05...
  • Page 56 12.2.7 - Units with variable operating pressure fans (Option 12) Similarly, in case of low outdoor temperatures when air-cooled exchangers freeze, the water from defrosting must be collected Ductable units are intended to be ducted on the fan discharge, so as to prevent any risk of flooding the rooms where the heat and can be installed inside a machine room.
  • Page 57 12.2.7 - Factory-installed duct connection interface on each fan V-shaped air heat exchangers View from above Side view Detail of the duct connection interface frame Size of the duct connection frame 860x860x100mm 12.2.7 - Duct installation principle Solution 1 Solution 2 each fan has its own duct 2 fans can used the same duct...
  • Page 58 Rules for a correct ductwork Fan motor electrical protection • each duct must serve a maximum of 2 fans – DO NOT In case of a locked rotor or an overload, the motors of each EXCEED this limit circuit are electrically protected by the circuit drive. •...
  • Page 59 12.2.8 - DX Free Cooling option (Options 118A and 118B) The DX Free Cooling option is used to produce chilled water when the ambient air temperature is lower than the temperature of the water to be cooled, without activating the compressors [the compressors can be used for a few seconds during a Free Cooling cycle to transfer the refrigerant charge to the Free Cooling circuit –...
  • Page 60 12.2.8.2 - Operation 12.2.8.3 - Operating limits Switching between Free Cooling and Cooling modes is Cooling mode controlled automatically (it is possible to disable switching in Evaporator (water) Minimum Maximum Entering water temperature at start-up °C Free Cooling by configuring - see the control manual). Leaving water temperature during operation °C The parameters (configurable) for switching are as follows:...
  • Page 61: Standard Maintenance

    13 - STANDARD MAINTENANCE 13.2 - Level 2 maintenance To ensure optimal efficiency and reliability of the equipment This level requires specific expertise in electrical, hydraulic and all its functions, we recommend taking out a maintenance and mechanical systems. it is possible that this expertise may contract with the local organisation set up by your manufacturer.
  • Page 62: Level 3 Maintenance

    13.4 - Tightening of the electrical connections Refrigerant circuit checks: • The unit is subject to F-gas tight regulatory checks. Component Designation in the Value Please refer to the table in the introduction. unit (N.m) • Check the unit operating parameters and compare them Welded screw PE, customer connection with the previous values, Screw terminal, fuse holder...
  • Page 63: Air-Cooled Exchanger

    13.6 - Air-cooled exchanger 13.7 - Water type heat exchanger We recommend that coils are inspected regularly to check the Check that: degree of fouling. This depends on the environment where the • The insulation has not been detached or torn during operations, unit is installed, in particular urban and industrial sites, and •...
  • Page 64: Refrigerant Properties

    13.10 - Refrigerant properties Properties of R410A Saturated temperatures based on the gauge pressure (in kPag) Saturated Temp. Pressure gauge Saturated Temp. Pressure gauge Saturated Temp. Pressure gauge Saturated Temp. Pressure gauge 1687 3088 1734 3161 1781 3234 1830 3310 1880 3386 1930...
  • Page 65: Final Shutdown

    14 - FINAL SHUTDOWN 14.1 - Shutting down Separate the units from their energy sources, allow them to cool then drain them completely. 14.2 - Recommendations for disassembly Use the original lifting equipment. Sort the components according to their material for recycling or disposal, in accordance with regulations in force. Check whether any part of the unit can be recycled for another purpose.
  • Page 66: Unit Start-Up Checklist For Installers Prior To Contacting The Manufacturer

    15 - UNIT START-UP CHECKLIST FOR INSTALLERS PRIOR TO CONTACTING THE MANUFACTURER Preliminary information Job name: ........................................Location: ........................................Installing contractor: ....................................Distributor: ....................................... Commissioning performed by: ..........Date: ....................Equipment Model 30RBM/30RBP: ..............Serial number ................Compressors Circuit A ..................Circuit B ..................
  • Page 67 Unit start-up Chilled water pump starter has been properly interlocked with the chiller Oil level is correct Unit has been leak checked (including couplings) Locate, repair, and report any refrigerant leaks ................................................................................................................................Check voltage imbalance: AB AC ..BC ....Average voltage = ............
  • Page 68 Carry out the QUICK TEST function (Consult Carrier Service): Check and log on to the user menu configuration Load sequence selection ..................................Capacity ramp loading selection ................................Start-up delay ......................................Pump control ......................................Setpoint reset mode ....................................Night mode capacity limit ..................................
  • Page 70 Order No: 13539, 10.2016 - Supersedes order No: 23539-76, 08.2016. Manufacturer: Carrier SCS, Montluel, France. The manufacturer reserves the right to make any changes, without notice. Printed in the European Union.