30HZ HZV Eng Iom PDF

30HZ/HZV 043-280
Water-Cooled/Condenserless
Liquid Chillers
Nominal cooling capacity 30HZ: 134-783 kW
Nominal cooling capacity 30HZV: 126-735 kW
50 Hz
Installation, operation and maintenance instructions
CONTENTS
1 - INTRODUCTION ....................................................................................................................................................................... 4
1.1 - Installation safety considerations ............................................................................................................................................... 4
1.2 - Equipment and components under pressure ............................................................................................................................... 4
1.3 - Maintenance safety considerations ............................................................................................................................................ 4
1.4 - Repair safety considerations ...................................................................................................................................................... 5
2 - PRELIMINARY CHECKS ........................................................................................................................................................ 6
2.1 - Check equipment received ......................................................................................................................................................... 6
2.2 - Moving and siting the unit ......................................................................................................................................................... 6
3 - DIMENSIONS, CLEARANCES, WEIGHT DISTRIBUTION .............................................................................................. 8
3.1 - 30HZ/HZV 043-065 ................................................................................................................................................................... 8
3.2 - 30HZ/HZV 091-225 ................................................................................................................................................................... 8
3.3 - 30HZ/HZV 250-280 ................................................................................................................................................................... 9
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22) ......................................................................... 10
4.1 - Physical data (R407C) .............................................................................................................................................................. 10
4.2 - Electrical data (R407C) ............................................................................................................................................................ 10
4.3 - Physical data (R22) .................................................................................................................................................................. 11
4.4 - Electrical data (R22) ................................................................................................................................................................ 12
4.5 - Power supply ............................................................................................................................................................................ 13
4.6 - Voltage phase imbalance (%) ................................................................................................................................................... 13
4.7 - Recommended wire sections .................................................................................................................................................... 14
5 - APPLICATION DATA ............................................................................................................................................................ 15
5.1 - Unit operating range ................................................................................................................................................................. 15
5.2 - Minimum chilled water flow .................................................................................................................................................... 15
5.3 - Maximum chilled water flow ................................................................................................................................................... 15
5.4 - Variable flow evaporator .......................................................................................................................................................... 16
5.5 - System minimum water volume ............................................................................................................................................... 16
5.6 - Evaporator flow rate (l/s) ......................................................................................................................................................... 16
5.7 - Condenser water flow rates ...................................................................................................................................................... 17
5.8 - Condenser water flow restrictor ............................................................................................................................................... 17
6 - WATER CONNECTIONS ....................................................................................................................................................... 18
6.1 - Operating precautions .............................................................................................................................................................. 18
6.2 - Water connections .................................................................................................................................................................... 19
6.3 - Flow control ............................................................................................................................................................................. 19
6.4 - Condenser connections ............................................................................................................................................................. 19
6.5 - Frost protection ........................................................................................................................................................................ 20
6.6 - Refrigerant line connections (30HZV) ..................................................................................................................................... 20
6.7 - Operation of two units in master/slave mode ........................................................................................................................... 24
The cover illustration is for illustrative purposes only and is not part of any offer for sale or contract.
2
CONTENTS (contd)
7 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA FOR STANDARD UNITS .......................................... 24
7.1 - Compressors ............................................................................................................................................................................. 24
7.2 - Lubricant .................................................................................................................................................................................. 24
7.3 - Pressure vessels ........................................................................................................................................................................ 24
7.4 - Electronic expansion device (EXV) ......................................................................................................................................... 25
7.5 - Refrigerant ................................................................................................................................................................................ 25
7.6 - High-pressure safety switch ..................................................................................................................................................... 25
7.7 - Moisture indicator .................................................................................................................................................................... 25
7.8 - Filter drier ................................................................................................................................................................................. 25
8 - MAIN OPTIONS AND ACCESSORIES ................................................................................................................................ 26
8.1 - Units for low evaporator outlet temperature applications (options 5 and 6) ............................................................................ 26
8.2 - Electrical protection to IP 44 (option 20) ................................................................................................................................. 26
8.3 - High- and low-pressure gauges (option 26) ............................................................................................................................. 26
8.4 - Compressor oil pressure safety device ..................................................................................................................................... 26
8.5 - Condenser with copper-nickel tubes (option 33) ..................................................................................................................... 26
8.6 - RS 485 communication interface (option 148) ........................................................................................................................ 26
8.7 - Additional capacity step 30HZ/HZV 043 to 065 (option 94) .................................................................................................. 26
8.8 - Evaporator pump starter (options 84 and 84D) ........................................................................................................................ 26
8.9 - Condenser pump starter (option 84R) ...................................................................................................................................... 26
9 - MAINTENANCE ...................................................................................................................................................................... 27
9.1 - Soldering and welding .............................................................................................................................................................. 27
9.2 - Maintenance of the refrigerant circuit ...................................................................................................................................... 27
9.3 - Electrical maintenance ............................................................................................................................................................. 28
9.4 - Evaporator maintenance ........................................................................................................................................................... 29
9.5 - Corrosion control ..................................................................................................................................................................... 30
10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS ................................................................................... 31
1 - INTRODUCTION
Prior to the initial start-up of the 30HZ/HZV units, the people
involved in the on-site installation, start-up, operation, and
maintenance of this unit should be thoroughly familiar with these
instructions and the specific project data for the installation site.
The 30HZ/HZV liquid chillers are designed to provide a very
high level of safety during installation, start-up, operation and
maintenance. They will provide safe and reliable service when
operated within their application range.
This manual provides the necessary information to familiarize
yourself with the control system before performing start-up
procedures. The procedures in this manual are arranged in the
sequence required for machine installation, start-up, operation
and maintenance.
Be sure you understand and follow the procedures and safety
precautions contained in the instructions supplied with the
machine, as well as those listed in this guide.
1.1 - Installation safety considerations
After the unit has been received, when it is ready to be installed
or reinstalled, and before it is started up, it must be inspected
for damage. Check that the refrigerant circuit(s) is (are) intact,
especially that no components or pipes have shifted (e.g. following a shock). If in doubt, carry out a leak tightness check and
verify with the manufacturer that the circuit integrity has not
been impaired. If damage is detected upon receipt, immediately
file a claim with the shipping company.
Do not remove the skid or the packaging until the unit is in its
final position. These units can be moved with a fork lift truck,
as long as the forks are positioned in the right place and
direction on the unit.
The units can also be lifted with slings, using only the designated lifting points marked on the unit.
These units are not designed to be lifted from above. Use
slings with the correct capacity, and always follow the lifting
instructions on the certified drawings supplied with the unit.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.
Never cover any safety devices.
This applies to the globe valve in the water circuit and the
globe valve(s) in the refrigerant circuit(s).
Ensure that the valves are correctly installed, before
operating the unit.
In certain cases the globe stops are installed on ball valves.
These valves are factory-supplied lead-sealed in the open
position. This system permits isolating and removing the
globe stop for checking and replacing. The globe stops are
designed and installed to ensure protection against fire risk.
Removing the globe stops is only permitted if the fire risk is
fully controlled and the responsibility of the user.
4
The safety valves must be connected to discharge pipes. These

pipes must be installed in a way that ensures that people and
property are not exposed to refrigerant leaks. These fluids
may be diffused in the air, but far away from any building air
intake, or they must be discharged in a quantity that is
appropriate for a suitably absorbing environment.
Periodic check of the globe valves: See paragraph
Maintenance safety considerations.
Provide a drain in the discharge circuit, close to each valve,
to avoid an accumulation of condensate.
Ensure good ventilation, as accumulation of refrigerant in an
enclosed space can displace oxygen and cause asphyxiation
or explosions.
Inhalation of high concentrations of vapour is harmful and
may cause heart irregularities, unconsciousness, or death.
Vapour is heavier than air and reduces the amount of oxygen
available for breathing. These products cause eye and skin
irritation. Decomposition products are hazardous.
1.2 - Equipment and components under pressure
These products incorporate equipment or components under
pressure, manufactured by Carrier or other manufacturers. We
recommend that you consult your appropriate national trade
association or the owner of the equipment or components under
pressure (declaration, re-qualification, retesting, etc.). The
characteristics of this equipment/these components are given
on the nameplate or in the required documentation, supplied
with the products.
1.3 - Maintenance safety considerations
Engineers working on the electric or refrigeration components
must be authorized, trained and fully qualified to do so (electricians trained and qualified in accordance with IEC 60364
Classification BA4).
All refrigerant circuit repairs must be carried out by a trained
person, fully qualified to work on these units. He must have
been trained and be familiar with the equipment and the
installation. All welding operations must be carried out by
qualified specialists.
Any manipulation (opening or closing) of a shut-off valve must
be carried out by a qualified and authorised engineer. These
procedures must be carried out with the unit shut-down.
NOTE: The unit must never be left shut down with the liquid
line valve closed, as liquid refrigerant can be trapped between
this valve and the expansion device. (This valve is situated on
the liquid line before the filter drier box.)
During any handling, maintenance and service operations
the engineers working on the unit must be equipped with
safety gloves, glasses, shoes and protective clothing.
Never work on a unit that is still energized.
Never work on any of the electrical components, until the

general power supply to the unit has been cut using the
disconnect switch(es) in the control box(es).
If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead of
the machine.
Ensure that you are using the correct refrigerant type before
recharging the unit (see unit name plate).
Charging any refrigerant other than the original charge type
will impair machine operation and can even lead to a
destruction of the compressors.
If the work is interrupted, always ensure that all circuits are

still deenergized before resuming the work.
Do not use oxygen to purge lines or to pressurize a machine

for any purpose. Oxygen gas reacts violently with oil, grease,
and other common substances.
ATTENTION: Even if the unit has been switched off, the

power circuit remains energized, unless the unit or circuit
disconnect switch is open. Refer to the wiring diagram for
further details. Attach appropriate safety labels.
Never exceed the specified maximum operating pressures.

Verify the allowable maximum high- and low-side test
pressures by checking the instructions in this manual and the
pressures given on the unit name plate.
Protection of electronic boards : If the boards need to be

handled wear anti-static gloves to avoid exposing the electronic
components to a destructive voltage. Only unpack the boards
from their anti-static bag when they need to be installed.
Do not use air for leak testing. Use only refrigerant or dry
nitrogen.
Once a year check that the high-pressure safety switch is

correctly connected and that it cuts out at the correct value.
Operating checks: During the life-time of the system,
inspection and tests must be carried out in accordance with
national regulations.
The information on operating inspections given in annex C
of standard EN278-2 can be used if no similar criteria exist
in the national regulations.
Safety device checks (annex C6 EN378-2): The safety
devices must be checked on site once a year for safety devices
(high-pressure switches), and every five years for external
overpressure devices (safety globe valves).
Check manual 30HZ/HZV Pro-Dialog Plus control for a
detailed explanation of the high-pressure switch test method.
At least once a year thoroughly inspect the protection devices
(valves). If the machine operates in a corrosive environment,
inspect the protection devices more frequently.
Regularly carry out leak tests and immediately repair any leaks.
1.4 - Repair safety considerations
All installation parts must be maintained by the personnel in
charge, in order to avoid material deterioration and injuries to
people. Faults and leaks must be repaired immediately. The
authorized technician must have the responsibility to repair the
fault immediately. Each time repairs have been carried out to
the unit, the operation of the safety devices must be re-checked.
If a leak occurs or if the refrigerant becomes polluted (e.g. by a
short circuit in a motor) remove the complete charge using a
recovery unit and store the refrigerant in mobile containers.
Repair the leak detected and recharge the circuit with the total
R407C or R22 charge, as indicated on the unit name plate.
Only charge liquid refrigerant R407C or R22 at the liquid line
(see chapter Refrigerant charge).
Do not unweld or flamecut the refrigerant lines or any refrigerant circuit component until all refrigerant (liquid and
vapour) has been removed from chiller. Traces of vapour
should be displaced with dry air nitrogen. Refrigerant in
contact with an open flame produces toxic gases.
The necessary protection equipment must be available, and
appropriate fire extinguishers for the system and the refrigerant
type used must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into
the eyes. Use safety goggles. Wash any spills from the skin
with soap and water. If liquid refrigerant enters the eyes,
immediately and abundantly flush the eyes with water and
consult a doctor.
Never apply an open flame or live steam to a refrigerant
container. Dangerous overpressure can result. If it is
necessary to heat refrigerant, use only warm water.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting conditioning and recovery of halogenated hydrocarbons under optimum quality conditions for the products and optimum safety
conditions for people, property and the environment are
described in standard NFE 29795.
Any refrigerant transfer and recovery operations must be
carried out using a transfer unit. A 3/8 SAE connector on
the manual liquid line valve is supplied with all units for
connection to the transfer station. The units must never be
modified to add refrigerant and oil charging, removal and
purging devices. All these devices are provided with the units.
Please refer to the certified dimensional drawings for the units.
Do not re-use disposable (non-returnable) cylinders or attempt
to refill them. It is dangerous and illegal. When cylinders are
empty, evacuate the remaining gas pressure, and move the
cylinders to a place designated for their recovery. Do not
incinerate.
Do not attempt to remove refrigerant circuit components or

fittings, while the machine is under pressure or while it is
running. Be sure pressure is at 0 kPa before removing
components or opening a circuit.
2 - PRELIMINARY CHECKS
2.1 - Check equipment received
Do not attempt to repair or recondition any safety devices

when corrosion or build-up of foreign material (rust, dirt,
scale, etc.) is found within the valve body or mechanism. If
necessary, replace the device. Do not install safety valves in
series or backwards.
ATTENTION: No part of the unit must use feet, racks or

supports during operation. Periodically monitor and repair
or if necessary replace any component or piping that shows
signs of damage.
The refrigerant lines can break under the weight and release
refrigerant, causing personal injury.
Do not climb on a machine. Use a platform, or staging to
work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.)
to lift or move heavy components. For lighter components,
use lifting equipment when there is a risk of slipping or losing
your balance.
Use only original replacement parts for any repair or component replacement. Consult the list of replacement parts that
corresponds to the specification of the original equipment.
Do not drain water circuits containing industrial brines,

without informing the technical service department at the
installation site or a competent body first.
Close the entering and leaving water shutoff valves and
purge the unit hydronic circuit, before working on the
components installed on the circuit (screen filter, pump, water
flow switch, etc.).
Periodically inspect all valves, fittings and pipes of the
refrigerant and hydronic circuits to ensure that they do not
show any corrosion or any signs of leaks.
Inspect the unit for damage or missing parts. If damage is

detected, or if shipment is incomplete, immediately file a
claim with the shipping company.
Confirm that the unit received is the one ordered. Compare
the name plate data with the order.
The unit name plate must include the following
information:
Version number
Model number
CE marking
Serial number
Year of manufacture and test date
Refrigerant used and refrigerant class
Refrigerant charge per circuit
Containment fluid to be used
PS: Min./max. allowable pressure (high and low
pressure side)
TS: Min./max. allowable temperature (high and low
pressure side)
Globe valve cut-out pressure
Pressure switch cut-out pressure
Unit leak test pressure
Voltage, frequency, number of phases
Maximum current drawn
Maximum power input
Unit net weight
Confirm that all accessories ordered for on-site installation
have been delivered, and are complete and undamaged.
The unit must be checked periodically during its whole

operating life to ensure that no shocks (handling accessories,
tools etc.) have damaged it. If necessary, the damaged parts
must be repaired or replaced. See also chapter Maintenance.
2.2 - Moving and siting the unit
2.2.1 - Moving
See chapter 1.1 "Installation safety considerations".
2.2.2 - Siting the unit
Always refer to the chapter "Dimensions and clearances" to
confirm that there is adequate space for all connections and
service operations. For the centre of gravity coordinates, the
position of the unit mounting holes, and the weight distribution points, refer to the certified dimensional drawing supplied
with the unit.
Typical applications of these units are in refrigeration
systems, and they do not require earthquake resistance.
Earthquake resistance has not been verified.
CAUTION: Only use slings at the designated lifting points
which are marked on the unit.
Before siting the unit check that:
the permitted loading at the site is adequate or that

appropriate strenghtening measures have been taken.
the unit is installed level on an even surface (maximum

tolerance is 5 mm in both axes).
there is adequate space above the unit to ensure access to

the components for maintenance.
the number of support points is adequate and that they are

in the right places.
the location is not subject to flooding.
2.2.3 - Check compressor mountings

Before any start-up of the unit proceed as follows:
For 30HZ/HZV 043-065 units
CAUTION: Lift and set down the unit with great care. Tilting
and jarring can damage the unit and impair unit operation.
If 30HZ/HZV units are hoisted with rigging, it is advisable to
protect the control box against accidental shocks. Do not tilt a
unit more than 15.
1.
WARNING: Never push or lever the chassis or the control
box of the unit.
2.
3.
Remove the wooden block located under the compressor

foot.
Remove the screw and washer used for transportation.
Assemble screw (A), snubber (B) and plain washer (C).
Checks before system start-up

For 30HZ/HZV 091-280 units
Before the start-up of the refrigeration system, the complete
installation, including the refrigeration system must be verified
against the installation drawings, dimensional drawings, system
piping and instrumentation diagrams and the wiring diagrams.
During the installation test national regulations must be
followed. If no national regulation exists, paragraph 9-5 of
standard EN 378-2 can be used as a guide.
External visual installation checks:
Compare the complete installation with the refrigeration

system and power circuit diagrams.
Check that all components comply with the design

specifications.
Check that all safety documents and equipments that are

required by current European standards are present.
Verify that all safety and environmental protection devices

and arrangements are in place and comply with the current
European standard.
Verify that all document for pressure containers,

certificates, name plates, files, instruction manuals that are
required documents required by the current European
standards are present.
Verify the free passage of access and safety routes.
Check that ventilation in the special plant room is adequate.
Check that refrigerant detectors are present.
Verify the instructions and directives to prevent the

deliberate removal of refrigerant gases that are harmful to
the environment.
Verify the installation of connections.
Verify the supports and fixing elements (materials, routing

and connection).
Verify the quality of welds and other joints.
Check the protection against mechanical damage.
Check the protection against heat.
Check the protection of moving parts.
Verify the accessibility for maintenance or repair and to

check the piping.
Verify the status of the valves.
Verify the quality of the thermal insulation and of the

vapour barriers.
Remove the centre bolt (A) from each spring mounting, so that
the compressor support can float freely.
3 - DIMENSIONS, CLEARANCES
3.1 - 30HZ/HZV 043-065
750
600
2200
600
3.2 - 30HZ/HZV 091-225

A
800
800
2550
3
800
3.3 - 30HZ/HZV 250-280
1
2
850
2750
1000
3
800
Legend:
30HZ - units with condenser
043
052
065
091
101
111
121
141
161
195
225
250-280
2452
2750
2750
2630
2940
2940
2940
3350
3350
4255
4255
4070
1520
1505
1505
1915
1915
1915
1915
1915
1915
1950
1950
2150
915
915
915
950
950
950
950
950
950
950
950
1275
30HZV - units without condenser A
043
052
065
091
101
111
121
141
161
195
225
250-280
1260
1245
1245
1300
1300
1300
1300
1300
1300
1340
1340
1680
904
904
904
950
950
950
950
950
950
950
950
1275
2452
2750
2750
2630
2940
2940
2940
3350
3350
4255
4255
4070
Evaporator
Condensers
Clearances required for operation and maintenance
Clearances recommended for heat exchanger tube removal
Power supply
Water inlet
Water outlet
Dimensions in mm
NOTE:
Non-contractual drawings. Certified dimensional drawings, available on
request.
FLOOR MOUNTING
For the positioning of the fixing points, weight distribution and centre of gravity coordinates, refer to the certified drawings.
4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22)

4.1 - Physical data (R407C)
30HZ/HZV
Net nominal cooling capacity*
30HZ
30HZV
kW
Operating weight**
30HZ
30HZV
kg
Refrigerant charge***
Circuit A
Circuit B
kg
043
052
065
091
101
111
121
141
161
195
225
250
280
134
126
153
144
199
194
230
216
270
260
300
278
316
297
371
352
415
388
533
500
626
588
719
677
783
735
1090
880
1183
968
1252
1018
2039
1672
2370
1960
2460
2000
2510
2040
2730
2260
2830
2300
3505
2975
3805
3267
4470
3780
4900
4106
R-407C
15.7
17.5
15.7
17.5
21.0
21.0
38.2
19.5
29.5
29.5
34.5
29.5
33.5
33.5
38.0
38.0
42.0
42.0
54.0
46.5
54.0
54.0
62.5
60.5
62.5
62.5
Compressors
Quantity - Circuit A
Quantity - Circuit B
06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s

1
1
1
2
2
1
1
1
1
2
2
2
2
2
2
2
2
2
3
2
3
3
4
3
4
4
Capacity control
No. of control steps
Minimum step capacity
PRO-DIALOG Plus control

4
4
4
6
40
33
33
22
11
20
11
18
11
16
11
19
11
16
5
20
6
16
7
14
8
12
One, direct expansion, multi-tube shell

55
63
63
92
2
2
2
2
154
2
154
2
154
2
199
2
199
2
242
2
242
2
276
2
276
2
3 gas threaded
NFE 03005
3/8
3/8
1000
1000
PN16DN100
NFE 29203
3/8
1000
PN16DN125
NFE 29203
3/8
3/8
1000
1000
3/8
1000
PN16DN150
NFE29203
3/8
3/8
1000
1000
3/8
1000
3/8
1000
3/8
1000
3/8
1000
Shell and multi-tube

2
2
2
10
10
10
10
Gas threaded
1-1/2
1-1/2
1-1/2
1-1/2
3/8
3/8
1000
1000
25
18
12
18
Flat flange, brazed
2-1/2
2
2
2
3/8
3/8
1000
1000
25
18
25
25
25
25
30
30
37
30
37
37
51
37
51
51
2-1/2
2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
3
2-1/2
3/8
1000
3
3
3/8
1000
Evaporator
Net water volume
No. of refrigerant circuits
Water connections
Inlet/outlet
%
l
Drain and vent NPT

in
Max. water-side operating pressure kPa
Condenser
Quantity
Net water volume
Circuit A
Circuit B
Water connections
Inlet/outlet, circuit A
Inlet/outlet, circuit B
Drain and vent NPT
Max. water-side operating pressure
3/8
1000
in
in
kPa
12
12
2
2
3/8
1000
Notes:
*
Nominal Eurovent conditions:
evaporator entering/leaving water temperature = 12C/7C, condenser entering/leaving water temperature = 30C/35C
evaporator and condenser fouling factor = 0.000044 m2 K/W
condensing temperature dew point 45C
fluid temperature = condensing temperature at dew point - refrigerant glide - 5 K subcooling.
Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)
** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.
*** The 30HZV units have a nitrogen holding charge only.
4.2 - Electrical data (R407C)

30HZ/HZV
Power wiring
Nominal power supply
System voltage range
043
065
091
101
111
121
141
161
195
225
250
280
V-ph-Hz 400-3-50
V
360-440
Control circuit power supply
The control circuit is supplied via a factory-installed transformer.
Nominal operating power input*

30HZ
30HZV
kW
Nominal operating current*

30HZ
30HZV
Maximum operating power input**

30HZ circuit A and B
30HZ circuit A
30HZ circuit B
30HZV circuit A and B
30HZV circuit A
30HZV circuit B
kW
Maximum operating current (Un-10%)***

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
052
38.5
38.5
48.9
48.6
68
65
69
70
78
77
86
86
92
94
112
112
131
135
165
165
201
200
239
234
270
266
63.8
63.8
81.1
80.6
112
108
114
116
129
127
142
142
152
156
185
185
217
224
273
273
333
332
396
388
448
441
45
54
-
55
65
-
77
90
-
82
98
-
90
107
-
100
119
-
109
130
-
132
155
-
155
180
-
194
225
-
232
270
-
155
116
180
135
155
155
180
180
87
101
-
105
123
-
150
170
-
158
185
-
174
203
-
192
224
-
211
246
-
255
293
-
299
340
-
374
425
-
449
509
-
299
224
340
255
299
299
340
340
Standard Eurovent conditions: Evaporator entering/leaving water temperature 12C/7C, condenser entering/leaving water temperature 30C/35C.
Nominal operating power input: unit power input (compressors, control) plus the capacity corresponding to the evaporator and condenser pressure drop (flow x drop/0.3).
** Power input, compressors, at unit operating limits (saturated evaporating temperature (dew point) = 12C, saturated condensing temperature (dew point) = 52C
(30HZ)/66C (30HZV), and a nominal voltage of 400 V (data given on the unit name plate).
*** Maximum unit operating current at maximum unit power input.
Maximum instantaneous starting current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced starting current of the largest
compressor).
Current and power inputs not included in the values above.
10
4.2 - Electrical data (R407C) - (continued)

30HZ/HZV
043
052
065
091
101
111
121
141
161
195
225
250
280
78
91
-
95
111
-
135
153
-
142
166
-
157
182
-
173
202
-
190
221
-
230
264
-
269
306
-
336
382
-
404
458
-
269
202
306
229
269
269
306
306
182
188
-
198
207
-
273
283
-
245
263
-
227
251
-
275
299
-
291
318
-
330
360
-
404
436
-
470
513
-
536
589
-
404
338
436
360
404
404
436
436
A
A
2.33
-
2.09
-
2.03
-
1.72
-
1.45
-
1.59
-
1.53
-
1.44
-
1.50
-
1.40
-
1.33
-
1.50
1.68
1.50
1.50
30HZV Ratio max. starting current/max. current, circ. A

30HZV Ratio max. starting current/max. current, circ. B
A
A
2.06
-
1.87
-
1.85
-
1.58
-
1.37
-
1.48
-
1.44
-
1.37
-
1.43
-
1.34
-
1.28
-
1.43
1.57
1.43
1.43
Holding current for three-phase short circuits

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
kA
15
15
-
15
15
-
15
15
-
15
15
-
20
20
-
20
20
-
20
20
-
20
20
-
20
20
-
25
25
-
25
25
-
25
25
25
25
25
25
25
25
6
-
8
-
10
-
10
-
10
-
10
-
10
-
12
-
15
-
24
-
32
-
25
20
32
20
Maximum operating current (Un)***

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
Maximum unit starting current (Un)

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
30HZ Ratio max. starting current/max. current, circ. A

30HZ Ratio max. starting current/max. current, circ. B
Customer unit standby power for evaporator and

condenser pump connections
Circuit A
Circuit B
compressor).
4.3 - Physical data (R22)

30HZ/HZV
Net nominal cooling capacity*
30HZ
30HZV
kW
Operating weight**
30HZ
30HZV
kg
Refrigerant charge***
Circuit A
Circuit B
kg
043
052
065
091
101
111
121
141
161
195
225
250
280
144
136
166
157
215
208
250
234
292
280
323
300
342
321
402
380
447
417
578
538
677
633
779
729
847
792
1090
880
1183
968
1252
1018
2039
1672
2370
1960
2460
2000
2510
2040
2730
2260
2830
2300
3505
2975
3805
3267
4470
3780
4900
4106
R22
13.5
13.5
14
14
16.2
15.3
33.5
17.5
25.5
25.5
30
25.5
30
30
34
34
40
40
48
43.5
48
50
59
47
59
56
Compressors
Quantity - Circuit A
Quantity - Circuit B
06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s

1
1
1
2
2
1
1
1
1
2
2
2
2
2
2
2
2
2
3
2
3
3
4
3
4
4
Capacity control
No. of control steps
Minimum step capacity
PRO-DIALOG Plus control

4
4
4
6
40
33
33
22
11
20
11
18
11
16
11
19
11
16
5
20
6
16
7
14
8
12
One, direct expansion, multi-tube shell

55
63
63
92
2
2
2
2
154
2
154
2
154
2
199
2
199
2
242
2
242
2
276
2
276
2
3 gas threaded
NFE 03005
3/8
3/8
1000
1000
PN16DN100
NFE 29203
3/8
1000
PN16DN125
NFE 29203
3/8
3/8
1000
1000
3/8
1000
PN16DN150
NFE29203
3/8
3/8
1000
1000
3/8
1000
3/8
1000
3/8
1000
3/8
1000
Shell and multi-tube

2
2
2
10
10
10
10
Gas threaded
1-1/2
1-1/2
1-1/2
1-1/2
3/8
3/8
1000
1000
25
18
12
18
Flat flange, brazed
2-1/2
2
2
2
3/8
3/8
1000
1000
25
18
25
25
25
25
30
30
37
30
37
37
51
37
51
51
2-1/2
2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
2-1/2
2-1/2
3/8
1000
3
2-1/2
3/8
1000
3
3
3/8
1000
Evaporator
Net water volume
No. of refrigerant circuits
Water connections
Inlet/outlet
%
l
Drain and vent NPT

in
Max. water-side operating pressure kPa
Condenser
Quantity
Net water volume
Circuit A
Circuit B
Water connections
Inlet/outlet, circuit A
Inlet/outlet, circuit B
Drain and vent NPT
Max. water-side operating pressure
3/8
1000
in
in
kPa
12
12
2
2
3/8
1000
Nominal Eurovent conditions:

evaporator entering/leaving water temperature = 12C/7C, condenser entering/leaving water temperature = 30C/35C
evaporator and condenser fouling factor = 0.000044 m2 K/W
condensing temperature 45C (30HZV)
fluid temperature = condensing temperature - 5 K subcooling (30HZV)
Net cooling capacity = gross cooling capacity minus the capacity corresponding to the evaporator pressure drop (flow x drop/0.3)
** The weights given are guidelines only. For the correct unit charge refer to the unit nameplate.
*** The 30HZV units have a nitrogen holding charge only.
11
4.4 - Electrical data (R22)

30HZ/HZV
Power wiring
Nominal power supply
System voltage range
043
052
065
091
101
111
121
141
161
195
225
250
280
V-ph-Hz 400-3-50
V
360-440
Control circuit power supply
The control circuit is supplied via a factory-installed transformer.
Nominal operating power input*

30HZ
30HZV
kW
Nominal operating current*

30HZ
30HZV
Maximum operating power input**

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
kW
Maximum operating current (Un-10%)***

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
Maximum operating current (Un)***

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
Maximum unit starting current (Un)

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
30HZ Ratio max. starting current/max. current, circ. A

30HZ Ratio max. starting current/max. current, circ. B
35.8
38.1
45.5
48
64
65
64
69
72
76
80
85
85
93
104
111
122
133
154
164
189
198
224
233
253
264
59.4
63.2
75.5
79.6
106
108
106
114
119
126
133
141
141
154
172
184
202
221
255
272
313
328
372
387
418
438
46
54
-
55
65
-
79
90
-
83
98
-
91
107
-
101
119
-
111
130
-
134
155
-
158
180
-
198
225
-
237
270
-
158
119
180
135
158
158
180
180
88
101
-
107
123
-
153
170
-
161
185
-
177
203
-
195
224
-
214
246
-
260
293
-
305
340
-
382
425
-
458
509
-
305
229
340
255
305
305
340
340
79
91
-
96
111
-
137
153
-
145
166
-
159
182
-
176
202
-
193
221
-
234
264
-
275
306
-
343
382
-
412
458
-
275
206
306
229
275
275
306
306
183
188
-
199
207
-
274
283
-
246
263
-
229
251
-
277
299
-
293
318
-
333
360
-
408
436
-
475
513
-
542
589
-
408
341
436
360
408
408
436
436
A
A
2.3
-
2.07
-
1.99
-
1.7
-
1.44
-
1.57
-
1.52
-
1.43
-
1.49
-
1.38
-
1.32
-
1.49
1.66
1.49
1.49
30HZV Ratio max. starting current/max. current, circ. A

30HZV Ratio max. starting current/max. current, circ. B
A
A
2.06
-
1.87
-
1.85
-
1.58
-
1.37
-
1.48
-
1.44
-
1.37
-
1.43
-
1.34
-
1.28
-
1.43
1.57
1.43
1.43
Holding current for three-phase short circuits

30HZ circuit A
30HZ circuit B
30HZV circuit A
30HZV circuit B
kA
15
15
-
15
15
-
15
15
-
15
15
-
20
20
-
20
20
-
20
20
-
20
20
-
20
20
-
25
25
-
25
25
-
25
25
25
25
25
25
25
25
6
-
8
-
10
-
10
-
10
-
10
-
10
-
12
-
15
-
24
-
32
-
25
20
32
20
Customer unit standby power for evaporator and

condenser pump connections
Circuit A
Circuit B
*
compressor).
12
4.5 - Power supply

The power supply must conform to the specification on the
chiller nameplate. The supply voltage must be within the range
specified in the electrical data table. For connections refer to
the wiring diagrams.
WARNING: Operation of the chiller with an improper supply
voltage or excessive phase imbalance constitutes abuse which
will invalidate the Carrier warranty. If the phase imbalance
exceeds 2% for voltage, or 10% for current, contact your
local electricity supply at once and ensure that the chiller is
not switched on until corrective measures have been taken.
4.6 - Voltage phase imbalance (%)

100 x max. deviation from average voltage
Average voltage
Example:
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages
were measured to be:
AB = 406 V ; BC = 399; AC = 394 V
Average voltage
= (406 + 399 + 394)/3 = 1199/3

= 399.7 say 400 V
Calculate the maximum deviation from the 400 V average:

(AB) = 406 - 400 = 6
(BC) = 400 - 399 = 1
(CA) = 400 - 394 = 6
Motor
The maximum deviation from the average is 6 V. The greatest

percentage deviation is:
100 x 6/400 = 1.5 %
This is less than the permissible 2% and is therefore acceptable.
Notes for electrical data:
30HZ/HZV 043 to 225 units have a single power connection point; 30HZ/HZV
250 to 280 units have two connection points.
The control box includes the following standard features:

Starter and motor protection devices for each compressor
Control devices
Field connections:
All connections to the system and the electrical installations must be in full
accordance with all applicable codes.
The Carrier 30HZ/HZV chillers are designed and built to ensure conformance
with local codes. The recommendations of European standard EN 60204-1
(corresponds to IEC 60204-1) (machine safety - electrical machine
components - part 1: general regulations) are specifically taken into account,
when designing the electrical equipment.
2.
3.
4.
5.
6.
indoor installation*
presence of water: class AD2* (possibility of water droplets)
presence of hard solids, class AE2* (no significant dust present)
presence of corrosive and polluting substances, class AF1 (negligible)
vibration and shock, class AG2, AH2
b. Competence of personnel, class BA4* (trained personnel - IEC 60364)
Power supply frequency variation: 2 Hz.
The neutral (N) conductor must not be connected directly to the unit (if
necessary use a transformer).
Over-current protection of the power supply conductors is not provided with
the unit.
The factory-installed disconnect switch(es)/circuit breaker(s) is (are) of a type
suitable for power interruption in accordance with EN 60947.
The units are designed for connection to TN networks (IEC 60364). For IT
networks the earth connection must not be at the network earth. Provide a
local earth, consult competent local organisations to complete the electrical
installation.
IMPORTANT:
Conformance with EN 60204-1 is the best means of ensuring compliance with

the Machines Directive and 1.5.1. Generally the recommendations of IEC
60364 are accepted as compliance with the requirements of the installation
directives.
Annex B of EN 60204-1 describes the electrical characteristics used for the

operation of the machines.
NOTE: If particular aspects of an actual installation do not conform to the

conditions described above, or if there are other conditions which should be
considered, always contact your local Carrier representative.
1.
The operating environment for the 30HZ/HZV chillers is specified below:

a. Environment* - Environment as classified in IEC 60364 3:
ambient temperature range: +5C to +40C, class AA4
humidity range (non-condensing)*:
50% relative humidity at 40C
90% relative humidity at 20C
altitude: 2000 m
The protection level required to conform to this class is IP21B (according to

reference document IEC 60529). All 30HZ/HZV units are protected to IP23C
and fulfil this protection condition.
13
4.7 - Recommended wire sections

Wire sizing is the responsibility of the installer, and depends on
the characteristics and regulations applicable to each installation
site. The following is only to be used as a guideline, and does
not make Carrier in any way liable. After wire sizing has been
completed, using the certified dimensional drawing, the installer must ensure easy connection and define any modifications
necessary on site.
The connections provided as standard for the field-supplied
power entry cables to the general disconnect/isolator switch
are designed for the number and type of wires, listed in the
table below.
4.7.1 - Field control wiring

Refer to the 30HZ/HZV Pro-Dialog Plus Controls IOM and the
certified wiring diagram supplied with the unit for the field
control wiring of the following features:
Evaporator pump interlock (mandatory)
Remote on/off switch
Remote heat/cool switch
Demand limit external switch 1
Remote dual set point
Alarm report by circuit
Evaporator pump control
Condenser pump control
Remote set point reset or outside air temperature sensor

reset (0-10 V)
The calculations are based on the maximum machine current

(see electrical data tables).
For the design the following standardised installation methods
are used, in accordance with IEC 60364, table 52C:
For 30HZ/HZV units installed inside the building:

No. 13: Horizontal perforated cable conduits and No. 14:
closed cable conduit.
The calculation is based on PVC or XLPE insulated cables
with copper or aluminium core. The maximum temperature is
40C. The given wire length limits the voltage drop to < 5%.
IMPORTANT: Before connection of the main power cables
(L1 - L2 - L3) on the terminal block, it is imperative to check
the correct order of the 3 phases before proceeding to the
connection on then terminal block or the main disconnect/
isolator switch.
4.7.2 - Selection table of minimum and maximum wire sections for connection by phase to 30HZ/HZV units
MIN. WIRE SECTION
MAX. WIRE SECTION
30HZ/HZV
Section (mm2)
Wire type
Max. length (400 V)
Section (mm2)
Wire type
Max. length (400 V)
043
052
065
091
101
111
121
141
161
195
225
250 circuit A
1x 25
1x 35
1x 50
1x 70
1x 70
1x 70
1x 95
1x 120
1x 150
1x 240
2x 95
1x 150
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
XLPE Copper
130
142
162
168
168
168
178
185
188
192
172
188
250 circuit B
1x 95
XLPE Copper
178
280 circuit A
1x 185
XLPE Copper
190
280 circuit B
1x 150
XLPE Copper
188
1x 95
1x 120
1x 120
1x 150
1x 150
1x 185
1x 240
2x 95
2x 120
2x 185
2x 240
2x 120
2x 150
2x 70
1x 240
2x 95
2x 150
2x 120
2x 120
PVC Aluminium
PVC Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
XLPE Aluminium
PVC Copper
XLPE Aluminium
PVC Copper
XLPE Aluminium
XLPE Copper
XLPE Aluminium
PVC Copper
XLPE Aluminium
250
260
205
210
210
220
225
195
205
220
225
295
210
270
225
215
210
295
205
14
5 - APPLICATION DATA
5.2 - Minimum chilled water flow
5.1 - Unit operating range
The minimum chilled water flow is shown in the table on the

next page. If the flow is less than this, the evaporator flow can
be recirculated, as shown in the diagram. The temperature of
the mixture leaving the evaporator must never be less than
2.8 K lower than the chilled water entering temperature.
Evaporator
Entering water temperature at start-up
Leaving water temperature during operation
C
C
Condenser
Entering water temperature
Leaving water temperature
C
C
Minimum
Maximum
6.8*
4**
30
10
Minimum
Maximum
15
20
45
For minimum chilled water flow rate
Notes:
*
For application requiring operation at less than 6.8C, contact Carrier s.a. for
unit selection using the Carrier electronic catalog.
** For operation between 4C and -15C, the unit must be equipped with option 5
or 6, and the use of anti-freeze is required.
For an application, requiring operation up to +15C leaving water temperature,
contact Carrier for the selection of the unit.
Depends on the maximum condenser flow rate.
Maximum outside temperature: For transport and storage of the 30HZ/HZV
units the minimum and maximum allowable temperatures are 20C and
+50C. It is recommended that these temperatures are used for transport by
container.
5.1.1 - Operating range 30HZ
Legend
1 Evaporator
2 Recirculation
Leaving condenser water temperature C
45
44
D
42
40
39
5.3 - Maximum chilled water flow

B
The maximum chilled water flow is limited by the maximum

permitted pressure drop in the evaporator. It is provided in the
table on the next page. If the flow exceeds the maximum value,
two solutions are possible:
a - Select a non-standard evaporator (-2 baffles) which will
allow a higher maximum water flow rate.
b - Bypass the evaporator as shown in the diagram to obtain a
highter temperature difference with a lower evaporator
flow rate.
36
35
30
25
For maximum chilled water flow rate
20
-15
-10 -6 -5
10
Leaving evaporator water temperature C
Legend:
A 30HZ
B 30HZ with option 150 (high condensing temperature)
C 30HZ with option 5
D 30HZ with option 150 + 5
E 30HZ with option 6
Notes:
1. Evaporator and condenser T = 5 K
Legend
1 Evaporator
2 Bypass
15
5.4 - Variable flow evaporator

Variable evaporator flow can be used in standard chillers. The
chillers maintain a constant leaving water temperature under all
flow conditions. For this to happen, the minimum flow rate
must be higher than the minimum flow given in the table of
permissible flow rates and must not vary by more than 10% per
minute.
It is often necessary to add a buffer water tank to the circuit in

order to achieve the required volume. The tank must itself be
internally baffled in order to ensure proper mixing of the liquid
(water or brine). Refer to the examples below.
NOTE: The compressor must not restart more than 6 times in
an hour.
If the flow rate changes more rapidly, the system should contain a
minimum of 6.5 liters of water per kW instead of 3.25 l/kW.
5.5 - System minimum water volume
Bad
Good
Bad
Good
Whichever the system, the water loop minimum capacity is

given by the formula:
Capacity = Cap (kW) x N Liters
Application
Normal air conditioning

Process type cooling
3.25
6.5
5.6 - Evaporator flow rate (l/s)

Where Cap is the nominal system cooling capacity (kW) at the
nominal operating conditions of the installation.
30HZ/HZV
Min. water flow rate, l/s

Closed loop
This volume is necessary for stable operation and accurate

temperature control.
043
052-065
091
101-121
141-161
195-280
4.1
5.0
6.0
8.5
9.9
12.0
Evaporator pressure drop curves, standard units

100
Pressure drop, kPa
Legend
1 30HZ/HZV 043
2 30HZ/HZV 052-065
3 30HZ/HZV 091
4 30HZ/HZV 101-121
5 30HZ/HZV 141-161
6 30HZ/HZV 195-225
7 30HZ/HZV 250-280
10
1
2
3
1
-10
10
30
Water flow rate l/s
16
50
5.7 - Condenser water flow rates

30HZ/HZV
s**
Passes
043
052
065
091
101
111
121
141
161
195
225
250
280
2
2
2
2
2
2
2
2
2
2
2
2
2
5.8 - Condenser water flow restrictor
Minimum flow rate, l/s*
CAUTION: To ensure correct operation of the units, these

restrictors must be installed. The restrictor is supplied with
the machine, inside the control box.
Maximum flow rate, l/
Closed loop Open loop

1.20
1.20
1.40
2.47
2.60
3.04
3.54
3.54
3.54
4.00
4.46
5.04
5.62
3.60
3.60
4.20
7.42
7.64
9.13
10.62
10.62
10.62
12.00
13.40
15.14
16.88
14.8
14.8
17
30
31
37
43
43
43
48.00
54
61
68
30HZ/HZV
Passes* OD, mm
Location
043
091
111
195
250
2
2
2
2
2
Condenser 09RS 022 circuit B - water outlet

Condenser 09RS 054 - water outlet
31
47
47
47
56
Legend:
*
No. of passes
Legend:
*
Based on a water velocity of 0.3 m/s in closed-loop and 0.9 m/s in open-loop
systems.
** Based on a water velocity of 3.6 m/s
Condenser pressure drop curves, standard units

100
5
Pressure drop, kPa
10
11
10
3
Legend:
1 30HZ/HZV 043-052
2 30HZ/HZV 065
3 30HZ/HZV 091
4 30HZ/HZV 101
5 30HZ/HZV 111
6 30HZ/HZV 121-141
7 30HZ/HZV 161
8 30HZ/HZV 195
9 30HZ/HZV 225
10 30HZ/HZV 250
11 30HZ/HZV 280
1
0
10
20
30
40
50
Water flow rate, l/s
17
6 - WATER CONNECTIONS
For size and position of the heat exchanger water inlet and
outlet connections refer to the certified dimensional drawings
supplied with the unit.
The water pipes must not transmit any radial or axial force to
the heat exchangers nor any vibration.
The water supply must be analysed and appropriate water
treatment elements installed: (filters, additives, intermediate
heat exchangers, purges, vents, shut-off valves, etc) to prevent
corrosion, fouling and deterioration of the pump fittings. Consult
either a water treatment specialist or appropriate literature on
the subject.
6.1 - Operating precautions
The water circuit should be designed to have the least number
of elbows and horizontal pipe runs at different levels. Below
the main points to be checked for the connection:
Comply with the water inlet and outlet connections shown

on the unit.
Install manual or automatic air purge valves at all high

points in the circuit.
Use an expansion device to maintain pressure in the

circuit and install a safety valve as well as an expansion
tank.
Install thermometers in both the entering and leaving

water connections.
Install drain connections at all low points to allow the

whole circuit to be drained.
Install stop valves, close to the entering and leaving water

connections.
Use flexible connections to reduce the transmission of

vibrations.
Insulate all pipework, after testing for leaks, both to

reduce thermal leaks and to prevent condensation.
Cover the insulation with a vapour barrier.
Where there are particles in the fluid that could foul the
heat exchanger, a screen filter should be installed ahead of
the pump. The mesh size of the filter must be 1.2 mm (see
Typical water circuit diagram on the right).
Before the system start-up verify that the water circuits are
connected to the appropriate heat exchangers (e.g. no
reversal between evaporator and condenser).
Do not introduce any significant static or dynamic

pressure into the heat exchange circuit (with regard to the
design operating pressures).
Before any start-up verify that the heat exchange fluid is

compatible with the materials and the water circuit
coating.
In case additives or other fluids than those recommended
by Carrier s.a are used, ensure that the fluids are not
considered as a gas, and that they belong to class 2, as
defined in directive 97/23/EC.
18
Carrier s.a. recommendations on heat exchange fluids:

1. No NH4+ ammonium ions in the water, they are very
detrimental for copper. This is one of the most important
factors for the operating life of copper piping. A content
of several tenths of mg/l will badly corrode the copper
over time.
2. Cl- Chloride ions are detrimental for copper with a risk of
perforations by corrosion by puncture. If possible keep
below 10 mg/l.
3. SO42- sulphate ions can cause perforating corrosion, if
their content is above 30 mg/l.
4. No fluoride ions (<0.1 mg/l).
5. No Fe2+ and Fe3+ ions with non negligible levels of
dissolved oxygen must be present. Dissolved iron < 5 mg/l
with dissolved oxygen < 5 mg/l.
6. Dissolved silicon: silicon is an acid element of water and
can also lead to corrosion risks. Content < 1mg/l.
7. Water hardness: TH >2.8 K. Values between 10 and 25
can be recommended. This will facilitate scale deposit that
can limit corrosion of copper. TH values that are too high
can cause piping blockage over time. A total alkalimetric
titre (TAC) below 100 is desirable.
8. Dissolved oxygen: Any sudden change in water oxygenation conditions must be avoided. It is as detrimental to
deoxygenate the water by mixing it with inert gas as it is
to over-oxygenate it by mixing it with pure oxygen. The
disturbance of the oxygenation conditions encourages
destabilisation of copper hydroxides and enlargement of
particles.
9. Specific resistance electric conductivity: the higher the
specific resistance, the slower the corrosion tendency.
Values above 3000 Ohm/cm are desirable. A neutral
environment favours maximum specific resistance values.
For electric conductivity values in the order of 200-6000
S/cm can be recommended.
10. pH: Ideal case pH neutral at 20-25C
7 < pH < 8
If the water circuit must be emptied for longer than
one month, the complete circuit must be placed under
nitrogen charge to avoid any risk of corrosion by
differential aeration.
Charging and removing heat exchange fluids should
be done with devices that must be included on the
water circuit by the installer. Never use the unit heat
exchangers to add heat exchange fluid.
6.2 - Water connections
Potentiometer adjustment
This diagram shows a typical water installation.

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

6.3 - Flow control
6.3.1 - Evaporator flow switch and chilled water pump
interlock
IMPORTANT: On 30HZ/HZV units, the unit chilled water
flow switch must be energised, and the chilled water pump
interlock must be connected. Failure to follow this instruction
will void the Carrier guarantee.
The flow switch is supplied, installed on the evaporator
entering water pipe and factory-set to the minimum water flow
rate. If adjustment is necessary:
1. Switch on the unit. Set it to constant flow (preset value).
The yellow LED is illuminated, and the output is switched
for approximately 20 seconds (power-on delay time).
2. Turn the potentiometer until one green LED is illuminated.
The further the green LED is from the yellow LED, the
safer the adjustment (standby capacity in case of flow or
temperature fluctuations).
3. After the adjustment attach the label supplied to the
potentiometer, in order to protect it against unauthorised
tampering.
Terminals 34 and 35 are provided for field installation of the
chilled water pump interlock (auxiliary contact for pump
operation to be wired on site).
The condenser is of the multi-tube shell and tube type with

removable water boxes to facilitate cleaning of the tubes.
6.4.1 - Before making water connections
Tighten the bolts in both heads to the lower torque shown,
following the method described. Tighten in the pairs and
sequence indicated according to the size of bolt (see below)
using a torque value at the low end of the range given.
Water box tightening sequence
1
5
4
8
6
2
Sequence 1: 1 2 3 4
Sequence 2: 5 6 7 8
Bolt size M12 - 71-87 Nm
19
6.4.2 - Pipe connections

After welding the pipes to the flanges previously removed from
the water boxes:
1. Reinstall the pipes and tighten lightly to a torque at the
low end of the range.
2. Fill the system with water.
3. Wait for 10 minutes and check for minor leaks
at the water box joints
at the flange joints
4. Drain the system.
5. Disconnect the pipework.
6. Tighten the head bolts to their final torque (middle of the
range) in the sequence illustrated.
7. Reconnect the water pipes, tightening the flange bolts to
the mid-range torque value.
8. Refill the system with water.
9. Pressurize the system.
6.6 - Refrigerant line connections (30HZV)

6.6.1 - Recommendations for the installation of liquid
chillers with remote condensers
To guarantee optimum and reliable performance of the 30HZV
units (split units for connection to condensers) it is necessary to
comply with the regulations described below, when these units
are connected to remote condensers.
1.
2.
3.
6.5 - Frost protection

The 30HZ and 30HZV units are designed to be installed under
cover at outside temperatures between +5C and +40C.
Therefore they do not include anti-freeze protection, as standard.
4.
5.
If the water piping is in an area where the ambient temperature
can fall below 0C it is recommended to install a trace heater on
the piping and to add an antifreeze solution to protect the unit
and the water piping to a temperature of 10 K below the lowest
temperature likely to be reached at the installation site. Use
only antifreeze solutions, approved for heat exchanger duty. If
the system is not protected by an antifreeze solution and will
not be used during the freezing weather conditions, draining of
the cooler and outdoor piping is mandatory. Damage due to
freezing is not covered by the warranty.
IMPORTANT: Depending on the climatic conditions in your
area you must:
Add ethylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 K below
the lowest temperature likely to occur at the installation
site.
If the unit is not used for an extended period, it is
recommended to drain it, and as a safety precaution add
ethylene glycol to the heat exchanger, using the water
entering purge valve connection.
At the start of the next season, refill the unit with water
and add an inhibitor.
For the installation of auxiliary equipment, the installer
must comply with basic regulations, especially for
minimum and maximum flow rates, which must be
between the values listed in the operating limit table
(application data).
6.
Install a valve in the discharge piping (valves are factoryinstalled in sizes 043-063, and supplied non-installed in
sizes 091-280).
Size the discharge and liquid line piping according to the
recommendations in the following paragraphs (if necessary, install a double riser to ensure correct oil circulation
in the refrigerant circuit).
Depending on the layout and the routing of the discharge
piping it may be necessary to install additional silencers
(to reduce pulsations and noise emission) between the
liquid chiller and the condenser.
Select a condenser with an integrated subcooler to obtain
a minimum of 3 K subcooling at the inlet to the expansion
device.
Keep the condensing pressure as stable as possible
(pressostat staging or fan control via Pro-Dialog Plus). A
speed controller may be required for the first fan stage for
operation at low ambient temperature and partial load.
If the system can have several operating modes (summer/
winter, dual set point etc.), it is necessary to install a tank
(or receiver) to absorb the variations in charge.
6.6.2 - General
Refrigerant pipe sizing must be carried out, taking account of
the following constraints:
Oil return to the compressor must be ensured for the majority of
applications. Oil return is ensured by entrainment. A minimum
refrigerant velocity is required to ensure entrainment. This
velocity depends on the pipe diameter, the refrigerant and oil
temperature (these are treated as being the same in most cases).
A reduction of the pipe diameter permits an increase of the
refrigerant velocity. The problem of a minimum entrainment
velocity does not exist for the pipes that carry liquid refrigerant
as the oil is fully miscible here.
The pressure drop at the compressor discharge (pipes linking
the compressor outlet with the condenser inlet) must be limited
to avoid system performance losses (the compressor power
input inceases, and the cooling capacity decreases).
As a first estimate and for standard air conditioning applications, a one degree Celsius pressure drop on the discharge side
decreases the cooling capacity 2% and increases the compressor power input by 3%. Increasing the pipe diameter permits
limiting the pressure drops.
The pressure drop in the liquid line (linking the condenser
outlet to the expansion device) must not result in a change in
phase. The estimate of these pressure drops must include those
for the possible accessories, such as solenoid valves, filters,
filter drier, etc.
20
6.6.3 - Use of pipe sizing diagrams

On page 21 of this document two pipe sizing diagrams are
shown. They allow an estimate of the cooling capacity, corresponding to 1.5 K pressure drop for different pipe diameters,
based on the pipe length.
The following procedure can be used for pipe sizing:
1. Measure the length (in metres) of the piping under
consideration.
2. Add 40 to 50% to take account of special characteristics.
3. Multiply this length by the appropriate correction factor
from Table 1 (this correction factor depends on the
saturated suction and discharge temperatures).
4. Read the pipe size from diagrams Discharge piping and
Liquid line piping.
5. Calculate the equivalent lengths for parts included in the
piping under consideration (such as valves, filters,
connections).
The equivalent lengths are normally available from the
component supplier. Add these lengths to the length
caculated in step 3.
6. Repeat steps 4 and 5 is necessary.
Special attention must be paid to the liquid line sizing when the
expansion device ist positioned higher than the condenser. It
may now be necessary to increase the pipe diameter to compensate for the additional pressure of the liquid refrigerant
column. If the liquid refrigerant head ist very high, it may even
be necessary to increase the subcooling to prevent an phase
change in the liquid line. This can be done e.g. by a liquidvapour heat exchanger or an additional coil.
At 45C the volume mass of refrigerant R407C in the liquid
phase is approximately 1050 kg/m3. A pressure of 1 bar
corresponds to a liquid head of: 100 000/(1050 x 9.81) = 9.7 m.
The diagrams in the appendix can obviously be used to calculate

the actual pressure drops for the piping under consideration:
7. Based on the pipe diameter and the cooling capacity find
the equivalent length, producing 1.5 K pressure drop in
Figs. Discharge piping and Liquid line piping.
8. Calculate the equivalent pipe length as described in steps
1, 2, 3 and 5.
9. Calculate the length ratio from steps 8 and 7 (equivalent
length from step 8 DIVIDED by the equivalent length
from step 7).
10. Multiply this ratio by 1.5 to find the equivalent pressure
drops in C.
6.6.4 - Discharge pipe sizing
The discharge piping must be sized to achieve reasonable
pressure drops: a variation of 1.5 K of the saturated temperature is normally accepted (approx. 60 kPa variation for a
condensing temperature of 50C).
For most applications the refrigerant gas velocity is sufficient
to entrain the liquid refrigerant/oil mixture. Nevertheless, Table
2 shows the minimum required cooling capacities for different
pipe diameters and different saturated discharge temperatures.
This table is based on 8 K superheat, a saturated suction
temperature of 4C and 8 K subcooling. Table 3 shows the
correction factors to be applied to the values from Table 2, if
the operating conditions are different from those previously
stated.
6.6.5 - Liquid line sizing
The 30HZV compressors are supplied with an oil that is fully
miscible with refrigerant R407C in the liquid phase. Consequently low refrigerant velocities in the liquid lines are not a
problem.
The admissible pressure drops in the liquid lines depend mainly
on the subcooling level of the liquid refrigerant at the condenser outlet. Pressure drops corresponding to 1.5C saturated
temperature must not be exceeded.
21
Table 1 - R-407C correction factors for copper tube

30HZV
Saturated suction temperature, C
Cond. temp.
C
-18
S
HG
-12
S
HG
-7
S
HG
-1
S
HG
4
S
HG
10
S
HG
27
32
38
43
49
54
60
66
71
2.01
2.11
2.22
2.34
2.49
2.66
2.87
3.13
3.46
1.36
1.27
1.17
1.09
1.03
0.97
0.93
0.91
0.89
1.09
1.08
1.08
1.08
1.09
1.12
1.16
1.21
1.29
1.61
1.69
1.78
1.88
1.99
2.13
2.29
2.49
2.74
1.34
1.23
1.13
1.06
0.99
0.94
0.90
0.87
0.85
1.07
1.06
1.06
1.06
1.07
1.10
1.13
1.18
1.26
1.31
1.37
1.44
1.52
1.61
1.72
1.85
2.01
2.21
1.30
1.19
1.10
1.02
0.96
0.90
0.86
0.84
0.82
1.06
1.04
1.04
1.04
1.05
1.07
1.11
1.15
1.22
1.07
1.12
1.18
1.24
1.32
1.40
1.50
1.63
1.79
1.26
1.16
1.06
0.99
0.93
0.87
0.83
0.81
0.78
1.04
1.03
1.02
1.02
1.03
1.05
1.08
1.12
1.19
0.89
0.93
0.97
1.03
1.09
1.16
1.24
1.34
1.47
1.23
1.12
1.03
0.96
0.90
0.85
0.81
0.78
0.76
1.03
1.01
1.01
1.00
1.01
1.03
1.06
1.10
1.16
0.74
0.77
0.81
0.85
0.90
0.96
1.03
1.11
1.21
1.19
1.09
1.00
0.93
0.87
0.82
0.78
0.75
0.73
1.01
1.00
0.99
0.99
0.99
1.01
1.04
1.08
1.13
Legend
S Suction
HG Hot gas
L Liquid
Table 2 - Minimum capacity for oil entrainment in the discharge piping (kW) for R407C copper tube
30HZV
Outside pipe diameter

1/2
5/8
3/4
7/8
1-1/8
1-3/8
1-5/8
2-1/8
2-5/8
3-1/8
3-5/8
4-1/8
0.81
0.84
0.84
0.88
0.88
0.88
0.84
0.84
0.81
1.48
1.51
1.51
1.55
1.55
1.55
1.55
1.51
1.48
2.39
2.46
2.50
2.53
2.53
2.53
2.53
2.46
2.43
3.66
3.76
3.80
3.87
3.87
3.87
3.87
3.80
3.69
7.14
7.28
7.42
7.53
7.56
7.56
7.49
7.39
7.17
12.06
12.34
12.56
12.73
12.80
12.80
12.70
12.45
12.17
18.64
19.06
19.41
19.66
19.77
19.77
19.62
19.27
18.78
37.21
38.09
38.76
39.25
39.50
39.46
39.18
38.44
37.49
63.94
65.42
66.61
67.42
67.84
67.81
67.32
66.08
64.43
99.81
102.13
103.96
105.23
105.90
105.86
105.05
103.12
100.55
145.60
148.94
151.62
153.48
154.43
154.40
153.24
150.42
146.69
201.98
206.66
210.35
212.92
214.26
214.19
212.60
208.66
203.49
Saturated condensing temperature, C

27
32
38
43
49
54
60
66
71
Table 3 - R407C correction factors

for oil entrainment in the discharge piping
Saturated suction temperature, C
-23
0.86
-18
0.89
-12
0.92
-7
0.94
See chapter "Discharge pipe sizing"
22
-1
0.97
4
1.00
10
1.03
Discharge piping
200
50
40
30
20
10
5
4
3
300
400 500
2
3
10
20
30
40
50
100
200
Legend
1 1/2"
2 3/8"
3 3/4"
4 7/8"
5 1 1/8"
6 1 3/8"
7 1 5/8"
8 2 1/8"
1000
Cooling capacity (kW)
Liquid piping
200
100
Equivalent length (m)
Equivalent length (m)
100
50
40
30
20
10
5
4
3
2
3
10
20
30 40 50
100
200
300 400
Legend
1 3/8"
2 1/2"
3 5/8"
4 3/4"
5 7/8"
6 1 1/8"
7 1 3/8"
1000
Cooling capacity (kW)
23
6.7 - Operation of two units in master/slave mode

The control of a master/slave assembly is in the entering water
and does not require any additional sensors (standard configuration). It can also be located in the leaving water. In this case
two additional sensors must be added on the common piping.
All parameters, required for the master/slave function must be
configured using the Service Configuration menu. All remote
controls of the master/slave assembly (start/stop, set point, load
shedding etc.) are controlled by the unit configured as master
and must only be applied to the master unit.
Each unit controls its own water pump. If there is only one
common pump, in cases with variable flow, isolation valves
must be installed on each unit. They will be activated at the
opening and closing by the control of each unit (in this case the
valves are controlled using the dedicated water pump outputs).
See the 30HZ/HZV Pro-Dialog Plus Control IOM for a more
detailed explanation.
7 - MAJOR SYSTEM COMPONENTS AND OPERATION

DATA FOR STANDARD UNITS
7.1 - Compressors
30HZ/HZV units use reciprocating, semi-hermetic compressors.
As standard, each compressor is equipped with:
a discharge valve
a suction valve
an oil crankcase heater with a safety device that shuts off

the compressor in case of a fault
a discharge line muffler
anti-vibration mounts
With options 5 and 6 (low leaving brine temperature) each
compressor is equipped with a thermostat controlling the
discharge gas temperature. This sensor is activated, if the
temperature exceeds the safety limit and shuts off the
compressor (cut-out: 146C - cut-in: 115C).
7.2 - Lubricant
30HZ/HZV with configuration: leaving water control

The compressors installed in these units have an oil charge (9 l)
to ensure their correct operation.
Check that the oil level is between 1/8 and 3/8 up the sight
glass before start-up and after normal unit operation.
NOTE: Use only oils which have been approved for the
compressors. Never use oils which have been exposed to air.
1
Recommended oils:
Legend
1
2
Master unit
Slave unit
Control boxes of the master and slave units
Water inlet
Water outlet
Water pumps for each unit (included as standard for units with hydronic
module)
Additional sensors for leaving water control, to be connected to channel 1 of
the slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors
R407C compressors:
- Carrier specification: PP 47 26
- Mobiloil EAL 68 (original charge)
R22 compressors:
- Mineral oil, Carrier specification: PP 33 26
- Gargoyle Artic (Mobil Oil, original charge)
- Suniso 3 GS (Sun Oil Co.)
- Capella WF 32-150
- Clavus G32 (Shell Oil Co.)
CAUTION: R407C oils are absolutely not compatible with

R22 oils.
7.3 - Pressure vessels
7.3.1 - Condensers (30HZ units)
The condensers (one per circuit) are shell-and-tube condensers.
They have been tested and stamped in accordance with the
applicable pressure code for a maximum refrigerant-side
operating pressure of 3200 kPa and for a water-side operating
pressure of 1000 kPa.
The seamless copper tubes are finned on the refrigerant side,
and expanded onto the tube sheets.
For option 150A (heat pump), the condensers have a thermal
insulation of 19 mm thick polyurethane foam.
The condenser shell can have a thermal insulation of 19 mm
polyurethane foam, and can be equipped with a water drain and
purge.
24
7.3.2 - Evaporator
The evaporator is a shell-and-tube type with two refrigerant
circuits. It has been tested and stamped in accordance with
applicable pressure codes for a maximum operating pressure of
2100 kPa refrigerant-side and 1000 kPa water-side. The seamless copper tubes are finned on the refrigerant side and expanded
onto the tube sheets.
The heat exchanger shell has a thermal insulation of 19 mm
polyurethane foam, and is equipped with a water drain and purge.
The products that may be added for thermal insulation of the
containers during the water piping connection procedure must
be chemically neutral in relation to the materials and coatings
to which they are applied. This is also the case for the products
originally supplied by Carrier s.a.
NOTES: Monitoring during operation, re-qualification, retesting and re-testing dispensation:
Follow the regulations on monitoring pressurised
equipment.
It is normally required that the user or operator sets up
and maintains a monitoring and maintenance file.
Follow the control programmes of EN 378-2, annexes A,
B, C and D.
If they exist follow local professional recommendations.
Regularly inspect the condition of the coating (paint) to
detect blistering resulting from corrosion. To do this,
check a non-insulated section of the container or the
rust formation at the insulation joints.
Regularly check for possible presence of impurities (e.g.
silicon grains) in the heat exchange fluids. These impurities maybe the cause of the wear or corrosion by puncture.
Filter the heat exchange fluid check and carry out
internal inspections as described in EN 378-2, annex C.
In case of re-testing take possible maximum pressure
differences, as indicated in (2) above into consideration.
The reports of periodical checks by the user or operator
must be included in the supervision and maintenance
file.
Repair
Any repair or modification, including the replacement of
moving parts:
must follow local regulations and be made by qualified
operators and in accordance with qualified procedures,
including changing the heat exchanger tubes
must be made in accordance with the instructions of the
original manufacturer. Repair and modification that
necessitate permanent assembly (soldering, welding,
expanding etc.) must be made using the correct
procedures and by qualified operators.
An indication of any modification or repair must be
shown in the monitoring and maintenance file.
452000 cycles (start-ups) with a maximum difference of

6 K between two neighbouring points in the container,
based on 6 start-ups per hour over 15 years at a usage
rate of 90%.
Excess corrosion thickness

Gas side: 0 mm
Heat exchange fluid side: 1 mm for tubular plates in lightly
alloyed steels, 0 mm for stainless steel plates or plates with
copper-nickel or stainless steel protection.
7.4 - Electronic expansion device (EXV)
These are an option for sizes 30HZ/HZV 043-065.
The microprocessor controls the EXD through the EXV board
module. Inside this EXV is a linear actuator stepper motor.
The stepper motor moves in increments and is controlled
directly by the processor module. As the stepper motor rotates,
motion is transferred into linear movement by the lead screw.
Through the stepper motor and lead screws, 1500 discrete steps
of motion are obtained. The large number of steps and long
stroke result in very accurate control of refrigerant flow. At
initial start-up, the EXV position is at zero. After that, the
microprocessor keeps accurate track of the valve position in
order to use this information as input for the other control
functions. It does this by initializing the EXVs at startup. The
processor sends out enough closing pulses to the valve to move
it from fully open to fully closed, then resets the position
counter to zero. From this point on, until the initialization, the
processor counts the total number of open and closed steps it
has sent to each valve.
7.5 - Refrigerant
30HZ/HZV standard units operate with refrigerant R407C.
Optionally (option 7A) the units can use R22.
7.6 - High-pressure safety switch
30HZ/HZV units are equipped with a high-pressure safety
switch, calibrated to 2700 kPa for 30HZ units and 2900 kPa for
30HZV units.
This switch is located on the central block of each lead compressor.
7.7 - Moisture indicator
Located on the liquid line, permits control of the unit charge
and indicates moisture in the circuit. The presence of bubbles
in the sight-glass indicates an insufficient charge or noncondensables in the system. The presence of moisture changes
the colour of the indicator paper in the sight-glass.
Recycling
The unit is wholly or partly recyclable. After use it contains
refrigerant vapours and oil residue. It is coated by paint.
7.8 - Filter drier
Operating life
This unit is designed for:
prolonged storage of 15 years under nitrogen charge
with a temperature difference of 20 K per day.
The role of the filter drier is to keep the circuit clean and
moisture-free. The moisture indicator shows, when it is
necessary to change the elements. A difference in temperature
between the filter inlet and outlet shows that the elements are
dirty.
25
8 - MAIN OPTIONS AND ACCESSORIES

Depending on the applications for which the units are selected,
they can be equipped with options. This chapter describes the
main components that require special information for correct
start-up and maintenance of these units, except where this is
contained in a separate document.
8.7 - Additional capacity step 30HZ/HZV 043 to 065

(option 94)
Compressor B1 of the 30HZ 043-065 units is equipped with a
capacity reduction that increases the available capacity steps to
five steps.
8.8 - Evaporator pump starter (options 84 and 84D)
8.1 - Units for low evaporator outlet temperature

applications (options 5 and 6)
Compressors (option 5 or 6)
The capacity reductions are suppressed. The number of
capacity stages is the same as the number of compressors.
Each compressor is equipped with a temperature sensor located
in the discharge block which permits control of the discharge
gas temperature.
Expansion devices (option 5 or 6)
The expansion devices are chosen in accordance with the
operating conditions supplied when the unit was ordered.
Evaporator (option 6)
This is designed and made of special materials, and permits
operation down to -15C fluid-side. The evaporator shell has
double thermal insulation of polyurethane foam (2 x 19 mm).
Condensers (option 6)
Because the thermal heat rejection is less important, the
condensers are down-graded by one size.
8.2 - Electrical protection to IP44 (option 20)
The control boxes and compressor terminal boxes are designed
to provide protection in accordance with class IP44 CW.
8.3 - High- and low-pressure gauges (option 26)
The units are equipped with a high-pressure gauge and a lowpressure gauge on each circuit.
8.4 - Compressor oil pressure safety device
Each compressor is equipped with a pressure sensor located on
the oil pump outlet.
The normal oil pressure for 06E compressors is 82 kPa to 124
kPa above the suction pressure.
8.5 - Condenser with CuNi tubes (option 33)
The condensers are manufactured with Copper-Nickel 90/10
tubes and plated CuNi 90/10 tube sheets.
8.6 - RS 485 communication interface (option 148)
Each unit is equipped with an additional interface board which
permits unit connection to a JBus network.
26
Option 84: single evaporator pump

Option 84D: dual evaporator pump
The unit control boxes are equipped with a disconnectcontactor assembly (2 for option 84D) that allows control of
the evaporator pump.
8.9 - Condenser pump starter (option 84R)
The unit control boxes are equipped with a disconnectcontactor assembly that allows control of the condenser pump.
9 - MAINTENANCE
9.2 - Maintenance of the refrigerant circuit
During the unit operating life the service checks and tests must
be carried out in accordance with applicable national
regulations.
If there are no similar criteria in local regulations, the

information on checks during operation in annex C of standard
EN 378-2 can be used.
External visual checks: annex D of standard EN 378-2. These
controls must be carried out:
After an intervention that is likely to affect the resistance
or a change in use or change of high-pressure refrigerant,
or after a shut down of more than two years. Components
that do not comply, must be changed. Test pressures
above the respective component design pressure must not
be applied (annex B and D).
After repair or significant modifications or significant
system or component extension (annex B)
After re-installation at another site (annexes A, B and D)
After repair following a refrigerant leak (annex D). The
frequency of refrigerant leak detection can vary from once
per year for systems with less than 1% leak rate per year
to once a day for systems with a leak rate of 35% per year
or more. The frequency is in proportion with the leak rate.
NOTE: High leak rates are not acceptable. The necessary
steps must be taken to eliminate any leak detected.
NOTE 2: Fixed refrigerant detectors are not leak detectors,
as they cannot locate the leak.
9.1 - Soldering and welding
Component, piping and connection soldering and welding
operations must be carried out using the correct procedures and
by qualified operators. Pressurised containers must not be
subjected to shocks, nor to large temperature variations during
maintenance and repair operations.
Any technician attending the machine for any purpose must be
fully qualified to work on refrigerant and electrical circuits.
WARNING: Before doing any work on the machine ensure
that the power is switched off. If a refrigerant circuit is
opened, it must be evacuated, recharged and tested for leaks.
Before any operation on a refrigerant circuit, it is necessary
to remove the complete refrigerant charge from the unit with
a refrigerant charge recovery group.
Keep the unit itself and the space around it clean and free
of obstructions. Remove all rubbish such as packing
materials, as soon as the installation is completed.
Regularly clean the exposed pipework to remove all dust
and dirt. This makes detection of water leaks easier, and
they can be repaired before more serious faults develop.
Confirm that all screwed and bolted connections and
joints are secure. Secure connections prevent leaks and
vibration from developing.
Check that all insulation joints are securely closed and that
all insulation is firmly in place. Check all heat exchangers
and all pipework.
9.2.1 - Verification of the refrigerant charge

CAUTION: The 30HZ/HZV units are supplied with a precise
refrigerant charge (see Physical Data table).
To verify the correct system charge prodeed as follows:
Ensure that no bubbles appear in the sight-glass, when operating the unit at full load for a while. Under these conditions the
apparent subcooling which is equal to the saturated condensing
temperature (1 - on the saturated dew point curve) minus the
liquid refrigerant temperature (3) ahead of the expansion device
must be between 12 and 14C. This corresponds to an actual
subcooling temperature of between 5 and 7 K at the condenser
outlet, depending on the unit type. Actual subcooling is equal
the saturated liquid temperature (2 - on the saturated bubble
point curve) minus the liquid refrigerant temperature (3) ahead
of the expansion device. Use the pressure tap supplied on the
liquid piping to charge refrigerant and to find out the pressure
of the liquid refrigerant. If the subcooling value is not correct,
i.e. lower than the specified values, a leak detection test must
be carried out on the unit, as it no longer contains its original
charge.
WARNING: To ensure proper operation of 30HZ/HZV units
there must be at least 12 K of subcooling as the liquid
refrigerant enters the expansion valve.
The 30HZ/HZV units use refrigerant. For your information,
we are reproducing here some extracts from the official
publication dealing with the design, installation, operation
and maintenance of air conditioning and refrigeration
systems and the training of people involved in these activities,
agreed by the air conditioning and refrigeration industry.
All refrigerant removal and draining operations must be

carried out by a qualified technician and with the correct
material for the unit. Any inappropriate handling can lead to
uncontrolled fluid or pressure leaks.
If an oil draining or recovery operation becomes necessary,
the fluid transfer must be made using mobile containers.
27
Apparent and actual subcooling

R407C
Pressure
Pression
9.2.3 - Recharging liquid refrigerant

CAUTION: 30HZ units are charged with liquid HFC-407C
refrigerant.
L+V
This non-azeotropic refrigerant blend consists of 23% R-32,

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 liquid/vapour mixture is not constant, as with azeotropic
refrigerants. All checks must be pressure tests, and the
appropriate pressure/temperature ratio table must be used to
determine the corresponding saturated temperatures
(saturated bubble point curve or saturated dew point curve).
Leak detection is especially important for units charged with
refrigerant R-407C. Depending on whether the leak occurs in
the liquid or in the vapour phase, the proportion of the
different components in the remaining liquid is not the same.
Enthalpy
Enthalpie
Legend
1
2
3
4
5
6
7
8
L
L+V
V
NOTE: Regularly carry out leak checks and immediately

repair any leak found.
Saturated condensing temperature at the dew point
Saturated liquid temperature at the bubble point
Liquid refrigerant temperature
Saturation curve at the dew point
Saturation curbe at the bubble point
Isotherms
Apparent subcooling (1 - 3)
Real subcooling (2 - 3)
Liquid
Liquid + vapour
Vapour
9.2.2 - Refrigerant guidelines

Refrigeration installations must be inspected and maintained
regularly and rigorously by specialists. Their activities must be
overseen and checked by properly trained people. To minimise
discharge to the atmosphere, refrigerants and lubricating oil
must be transferred using methods which reduce leaks and
losses to a minimum.
Leaks must be repaired immediately
All units are equipped with two special connections on the

suction and liquid line, which permit the connection of
quick-connect recovery valves without loss of refrigerant.
If the residual pressure is too low to make the transfer

alone, a purpose-built refrigerant recovery unit must be
used.
Compressor lubricating oil contains refrigerant. Any oil

drained from a system during maintenance must therefore
be handled and stored accordingly.
Refrigerant under pressure must never be discharged to

the atmosphere.
9.2.4 - Undercharge
If there is not enough refrigerant in the system, this is indicated
by gas bubbles in the moisture sight glass.
If the undercharge is significant, large bubbles appear in the
moisture sight glass, and the suction pressure drops. The
compressor suction superheat is also high. The machine must
be recharged after the leak has been repaired.
Find the leak and completely drain the system with a refrigerant
recovery unit. Carry out the repair, leak test and then recharge
the system.
IMPORTANT: After the leak has been repaired, the circuit
must be tested, without exceeding the maximum low-side
operating pressure shown on the unit name plate.
The refrigerant must always be recharged in the liquid phase
into the liquid line.
The refrigerant cylinder must always contain at least 10% of its
initial charge.
For the refrigerant quantity per circuit, refer to the data on the
unit name plate.
9.2.5 - Characteristics of R407C
See the table on the following page.
Saturated bubble point temperatures (bubble point curve)
Saturated dew point temperatures (dew point curve)
9.3 - Electrical maintenance
When working on the unit comply with all safety precautions
decribed in section 1.2.
It is strongly recommended to change the fuses in the

units every 15000 operating hours or every 3 years.
It is recommended to verify that all electrical

connections are tight:
a. after the unit has been received at the moment of
installation and before the first start-up,
b. one month after the first start-up,when the electrical
components have reached their nominal operating
temperatures,
c. then regularly once a year.
28
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
Bar
(relative)
Saturated bubble
point temp.
Saturated dew
point temp.
1
1.25
1.5
1.75
2
2.25
2.5
2.75
3
3.25
3.5
3.75
4
4.25
4.5
4.75
5
5.25
5.5
5.75
6
6.25
6.5
6.75
7
7.25
7.5
7.75
8
8.25
8.5
8.75
9
9.25
9.5
9.75
10
10.25
-28.55
-25.66
-23.01
-20.57
-18.28
-16.14
-14.12
-12.21
-10.4
-8.67
-7.01
-5.43
-3.9
-2.44
-1.02
0.34
1.66
2.94
4.19
5.4
6.57
7.71
8.83
9.92
10.98
12.02
13.03
14.02
14.99
15.94
16.88
17.79
18.69
19.57
20.43
21.28
22.12
22.94
-21.72
-18.88
-16.29
-13.88
-11.65
-9.55
-7.57
-5.7
-3.93
-2.23
-0.61
0.93
2.42
3.85
5.23
6.57
7.86
9.11
10.33
11.5
12.65
13.76
14.85
15.91
16.94
17.95
18.94
19.9
20.85
21.77
22.68
23.57
24.44
25.29
26.13
26.96
27.77
28.56
10.5
10.75
11
11.25
11.5
11.75
12
12.25
12.5
12.75
13
13.25
13.5
13.75
14
14.25
14.5
14.75
15
15.25
15.5
15.75
16
16.25
16.5
16.75
17
17.25
17.5
17.75
18
18.25
18.5
18.75
19
19.25
19.5
19.75
23.74
24.54
25.32
26.09
26.85
27.6
28.34
29.06
29.78
30.49
31.18
31.87
32.55
33.22
33.89
34.54
35.19
35.83
36.46
37.08
37.7
38.31
38.92
39.52
40.11
40.69
41.27
41.85
42.41
42.98
43.53
44.09
44.63
45.17
45.71
46.24
46.77
47.29
29.35
30.12
30.87
31.62
32.35
33.08
33.79
34.5
35.19
35.87
36.55
37.21
37.87
38.51
39.16
39.79
40.41
41.03
41.64
42.24
42.84
43.42
44.01
44.58
45.15
45.71
46.27
46.82
47.37
47.91
48.44
48.97
49.5
50.02
50.53
51.04
51.55
52.05
20
20.25
20.5
20.75
21
21.25
21.5
21.75
22
22.25
22.5
22.75
23
23.25
23.5
23.75
24
24.25
24.5
24.75
25
25.25
25.5
25.75
26
26.25
26.5
26.75
27
27.25
27.5
27.75
28
28.25
28.5
28.75
29
29.25
47.81
48.32
48.83
49.34
49.84
50.34
50.83
51.32
51.8
52.28
52.76
53.24
53.71
54.17
54.64
55.1
55.55
56.01
56.46
56.9
57.35
57.79
58.23
58.66
59.09
59.52
59.95
60.37
60.79
61.21
61.63
62.04
62.45
62.86
63.27
63.67
64.07
64.47
52.55
53.04
53.53
54.01
54.49
54.96
55.43
55.9
56.36
56.82
57.28
57.73
58.18
58.62
59.07
59.5
59.94
60.37
60.8
61.22
61.65
62.07
62.48
62.9
63.31
63.71
64.12
64.52
64.92
65.31
65.71
66.1
66.49
66.87
67.26
67.64
68.02
68.39
9.4 - Evaporator maintenance

Check that:
the insulating foam is intact and securely in place.
the sensors are correctly operating, secured and

positioned.
the water-side connections are clean and show no sign of

leakage.
9.4.1 - Multitube evaporators
To access the evaporator tubes, use the following procedure:
Close the chilled water supply and return valves (if

installed), and disconnect the chilled water supply and
return pipe connections.
Drain the water from the cooler.
Remove all temperature sensors from the cooler.
Completely drain the refrigerant charge, using a refrigerant

recovery unit.
Fold back the insulation at the refrigerant line

connections.
Remove the header panels from the evaporator.
9.4.2 - Plugging evaporator tubes

A leaking tube can be plugged pending replacement. The number
of tubes plugged will determine when they should be replaced.
Check with Carrier the effect upon chiller performance of
plugging a number of tubes. Carrier will need to know the
number of tubes to be plugged and their positions. The figure
below shows the Elliott method of plugging tubes.
WARNING: Take care when inserting plugs not to damage
the plate material between the tubes. Avoid excessive force.
Clean all components with Locquic N and then coat all
surfaces with several drops of Loctite 75 to ensure a good seal
without applying excessive force.
Elliott tube plug
Tube plate
Plug
When the evaporator heads and manifolds are removed, the

outer tube end plates will be visible.
Six or eight evaporator tubes are swaged into the end plate and
cannot be removed. A dot punch mark in the end plate opposite
each one identifies each of them. If any of them develop a leak,
the tube must be plugged, as described below.
Ring
Components
Part number
Tube brass plug

Tube brass ring
---T-853--103500S-*
---T-853--002570S-*
Brass plug (holes without tubes)

Brass ring (holes without tubes)
---T-853--1031S-*
---T-853--002631S-*
Loctite
Locquic
No. 75
N
Order directly from your Carrier distributor
29
9.4.3 - Replacing cooler tubes

Retubing must be done only by a properly trained service
engineer. Most standard practices can be applied, but for cooler
tubes a 5% crush allowance is made for tube expansion and
twisting (15.87 mm diameter tubes are used in these coolers).
The table below gives the specification of the materials used.
Example:
Tube sheet hole diameter
Tube outside diameter
Clearance
Tube inside diameter before rolling
Tube inside diameter after rolling
16.00 mm
15.87 mm
0.13 mm
14.27 mm
14.48 mm
NOTE: Tubes next to the gasket webs must be flush with the
tube sheets at either end of the cooler.
9.4.4 - Preparation of gaskets
When rebuilding the cooler, new gaskets must always be used.
They must conform to the Carrier specification for compressed
gaskets.
Clean the gasket and its place on the tube sheet.
Cover the two matching surfaces (gasket and tube sheet)

with adhesive, and stick them together.
Let the joint dry for 5 minutes.
Moisten the joint with a small amount of compressor oil.
Reinstall the evaporator head within 30 minutes.

9.4.5 - Tightening cooler head bolts
Cooler head bolts must be tightened in the specified sequence
and to the correct torque.
9.4.6 - Tightening sequence:
The following tightening sequence is recommended:
Hand tighten the first four bolts as shown below in stage 1.
Hand tighten the next bolts as shown below in stage 2.
Starting at the 12 o'clock position, and working clockwise,

insert and hand tighten the remaining outer bolts.
Insert and tighten the six screws in the center of the head.
Starting again at 12 oclock and working clockwise tighten

the outer bolts to the correct torque.
Not less than one hour later insert and tighten the six bolts
in the centre of the head, using the torque values given.
After the cooler has been refilled with clean refrigerant,

use a soap and water solution or an electronic detector to
confirm that there are no leaks.
Replace the evaporator insulation and temperature sensors.

Stage 1
Stage 2
7
1
5
4
6
2
8
30
9.5 - Corrosion control

All metallic parts of the unit (chassis, casing panels, control
boxes, heat exchangers etc.) are protected against corrosion by
a coating of powder or liquid paint. To prevent the risk of
blistering corrosion that can appear when moisture penetrates
under the protective coatings, it is necessary to carry out
periodic checks of the coating (paint) condition.
10 - START-UP CHECKLIST FOR 30HZ/HZV LIQUID CHILLERS (USE FOR JOB FILE)
Preliminary information
Job name: ................................................................................................................................................................................................
Location: .................................................................................................................................................................................................
Installing contractor: ...............................................................................................................................................................................
Distributor: ..............................................................................................................................................................................................
Start-up preformed by: ...........................................................................................................................................................................
Compressors
Model: ............................................................................................. S/N ..............................................................................................
Compresseurs
Circuit A
1. Model # ......................................................................................
S/N .............................................................................................
Mtr # ...........................................................................................
Circuit B
1. Model # .................................................................................
S/N ..............................................................................................
Mtr # ...........................................................................................
2. Model # ...................................................................................... 2. Model # .................................................................................

S/N ............................................................................................. S/N ..............................................................................................
Mtr # ........................................................................................... Mtr # ...........................................................................................
3. Model # ...................................................................................... 3. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
Mtr # ........................................................................................... Mtr # ...........................................................................................
4. Model # ...................................................................................... 4. Model # .................................................................................
S/N ............................................................................................. S/N ..............................................................................................
Mtr # ........................................................................................... Mtr # ...........................................................................................
Cooler
Model # ........................................................................................... Manufactured by .........................................................................
S/N .................................................................................................. Date .............................................................................................
Condensers
Manufacturer ..........................................................................................................................................................................................
Model # ........................................................................................... S/N ..............................................................................................
Additional air handling units and accessories ........................................................................................................................................
................................................................................................................................................................................................................
Preliminary equipment check
Is there any shipping damage ? ...................................................... If so, where ? ...............................................................................
................................................................................................................................................................................................................
Will this damage prevent unit start-up ? .................................................................................................................................................
Unit is level in its installation
Power supply agrees with the unit nameplate
Electrical circuit wiring has been sized and installed properly
Unit ground wire has been connected
Electrical circuit protection has been sized and installed properly
All terminals are tight
All cables and thermistors have been inspected for crossed wires
All plug assemblies are tight
Check air handling systems
All air handlers are operating
All chilled water valves are open
All fluid piping is connected properly
All air has been vented from the system
Chilled water pump (CWP) is operating with the correct rotation. CWP amperage: Rated: ........... Actual............
31
Unit start-up
CWP starter has been properly interlocked with the chiller
Oil heaters have been energized for at least 24 hours
Oil level is correct
All discharge, suction and liquid valves are open
Unit has been leak checked (including fittings)
Locate, repair, and report any refrigerant leaks
................................................................................................................................................................................................................
................................................................................................................................................................................................................
................................................................................................................................................................................................................
Check voltage imbalance: AB ..................
Average voltage = .....................................
Maximum deviation = ..............................
Voltage imbalance = .................................
AC ................. BC .................
(see installation instructions)
(see installation instructions)
(see installation instructions) .
Voltage imbalance is less than 2%

WARNING: Do not start chiller if voltage imbalance is greater than 2%. Contact local power company for assistance.
All incoming power voltage is within rated voltage range
Check cooler water loop
Water loop volume = ................................ (liters)
Calculated volume = ................................. (liters)
3.25 liters/nominal kW capacity for air conditioning
6.5 liters/nominal kW capacity for process cooling
Proper loop volume established
Proper loop corrosion inhibitor included .............. liters of ...........................
Proper loop freeze protection included (if required) ........................liters of .............................
Piping includes electric heater tape, if exposed to the outside
Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm
Check pressure drop across the cooler
Entering cooler = ...................................... (kPa)
Leaving cooler = ....................................... (kPa)
(Leaving - entering) = ............................... (kPa)
WARNING: Plot cooler pressure drop on performance data chart (in product data literature) to determine total liters per
second (l/s) and find unit's minimum flow rate.
Total l/s = ..................................................
l/s / nominal kW = ....................................
Total l/s is greater than unit's minimum flow rate
Total l/s meets job specified requirement of .......................................... (l/s)
32
Perform TEST function (indicate positive result):

WARNING: Once power is supplied to the unit, check the display for any alarms, such as phase reversal. Follow the TEST
function instructions in the Controls and Troubleshooting literature (follow the procedure in the Controls IOM).
Be sure all service valves are open before beginning the compressor test section.
Examine and register the configuration at the installation site <2> <SRVC>
Evaporator fluid select ....................................................................
Minimum load select ......................................................................
Loading sequence select .................................................................
Lead/lag sequence select ................................................................
Head pressure control .....................................................................
Motormaster select* .......................................................................
External reset sensor ...................................................................

Evaporator pump interlock .........................................................
Evaporator pump control ...........................................................
*If installed
To start the chiller

WARNING: Be sure that all service valves are open, and all pumps are on before attempting to start this machine. Once all
checks have been made, move the switch to "LOCAL" or "REMOTE" from "OFF".
Unit starts and operates properly
Temperatures and pressures
WARNING: Once the machine has been operating for a while and the temperatures and pressures have stabilized, record the
following:
Evaporator EWT ............................................................................. Ambient temperature ..................................................................
Evaporator LWT ............................................................................. Condenser EWT ..........................................................................
Condenser LWT ..........................................................................
Circuit A suction pressure ..............................................................
Circuit A discharge temperature .....................................................
Circuit A suction temperature .........................................................
Circuit A discharge pressure ...........................................................
Circuit A liquid line temperature ....................................................
Compressor oil pressure A1*
A2*
A3*
A4*
Circuit B suction pressure ...........................................................

Circuit B suction temperature .....................................................
Circuit B discharge pressure .......................................................
Circuit B discharge temperature .................................................
Circuit B liquid line temperature ................................................
......................................................... Compressor oil pressure B1* .....................................................

.........................................................
B2* .....................................................
.........................................................
B3* .....................................................
.........................................................
B4* .....................................................
* if installed
NOTES:
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
...............................................................................................................................................................................................................
33
Order No: 13412-76, 08.2002. Supersedes order No: 13412-76, 02.2002

Manufacturer: Carrier s.a., Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the Netherlands on chlorine-free paper.

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30HZ/HZV 043-280

Installation, operation and maintenance instructions

The safety valves must be connected to discharge pipes. These

Never work on any of the electrical components, until the

If the work is interrupted, always ensure that all circuits are

Do not use oxygen to purge lines or to pressurize a machine

ATTENTION: Even if the unit has been switched off, the

Never exceed the specified maximum operating pressures.

Protection of electronic boards : If the boards need to be

Once a year check that the high-pressure safety switch is

Do not attempt to remove refrigerant circuit components or

Do not attempt to repair or recondition any safety devices

ATTENTION: No part of the unit must use feet, racks or

Do not drain water circuits containing industrial brines,

Inspect the unit for damage or missing parts. If damage is

The unit must be checked periodically during its whole

Before siting the unit check that:

the permitted loading at the site is adequate or that

the unit is installed level on an even surface (maximum

there is adequate space above the unit to ensure access to

the number of support points is adequate and that they are

the location is not subject to flooding.

2.2.3 - Check compressor mountings

Remove the wooden block located under the compressor

Checks before system start-up

Compare the complete installation with the refrigeration

Check that all components comply with the design

Check that all safety documents and equipments that are

Verify that all safety and environmental protection devices

Verify that all document for pressure containers,

Verify the free passage of access and safety routes.

Check that ventilation in the special plant room is adequate.

Check that refrigerant detectors are present.

Verify the instructions and directives to prevent the

Verify the installation of connections.

Verify the supports and fixing elements (materials, routing

Verify the quality of welds and other joints.

Check the protection against mechanical damage.

Check the protection against heat.

Check the protection of moving parts.

Verify the accessibility for maintenance or repair and to

Verify the status of the valves.

Verify the quality of the thermal insulation and of the

3.2 - 30HZ/HZV 091-225

3.3 - 30HZ/HZV 250-280

30HZV - units without condenser A

Clearances required for operation and maintenance

Clearances recommended for heat exchanger tube removal

4 - PHYSICAL AND ELECTRICAL DATA FOR 30HZ/HZV (R407C/R22)

06E semi-hermetic, 4 or 6 cylinders, 24.2 r/s

PRO-DIALOG Plus control

One, direct expansion, multi-tube shell

Shell and multi-tube

Drain and vent NPT

4.2 - Electrical data (R407C)

Control circuit power supply

The control circuit is supplied via a factory-installed transformer.

Nominal operating power input*

Nominal operating current*

Maximum operating power input**

Maximum operating current (Un-10%)***

4.2 - Electrical data (R407C) - (continued)

30HZV Ratio max. starting current/max. current, circ. A