Air-Cooled Liquid Chillers Reversible Heat Pumps 30RB/30RQ 040R-160R
I N S TA L L AT I O N , O P E R AT I O N A N DMAINTENANCE INSTRUCTIONSAir-Cooled Liquid ChillersReversible heat pumps30RB/30RQ 040R-160RRated cooling capacity 40-160 kWR-32* The availability of sizes and options depends on the country. Please contact your local commercial dealer for more information.Translation of the original document
2
CONTENTS1 - INTRODUCTION AND SAFETY INSTRUCTIONS. 52 - RECEIPT OF GOODS. 52.1 - Checking the equipment received. 53 - HANDLING AND POSITIONING. 63.1 - Handling. 63.2 - Positioning. 64 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES. 74.1 - 30RB/30RQ 040R-080R, units with and without hydraulic module. 74.2 - 30RB/30RQ 090R-160R, units with and without hydraulic module. 84.3 - 30RB/30RQ 040R-080R, units with water buffer tank module. 94.4 - 30RB/30RQ 090R-160R, units with water buffer tank module. 104.5 - Free spaces and installing several units. 114.6 - Positioning of ATEX zones around the unit. 115 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS . 125.1 - Physical properties: 30RB/30RQ 40R-160R. 125.2 - Electrical data notes: 30RB/30RQ 040R-160R. 135.3 - Short circuit current withstand capability. 135.4 - Electrical data notes for the hydraulic module. 145.5 - Electrical data notes for the compressors. 165.6 - Distribution of compressors per circuit. 165.7 - Comments on electrical data notes. 176 - ELECTRICAL CONNECTION. 186.1 - Power supply. 186.2 - Voltage phase imbalance (%). 186.3 - Power connection/disconnect switch. 186.4 - Recommended cable sections. 186.5 - Power cable access routing. 206.6 - Field-installed control wiring. 206.7 - Electric and power reserve for the user. 207 - APPLICATION DATA. 217.1 - Operating range. 217.2 - Minimum heat transfer fluid flow rate (units without factory-fitted hydraulic module). 227.3 - Maximum heat transfer fluid flow rate (units without factory-fitted hydraulic module). 227.4 - Variable flow water type heat exchanger (units without factory-fitted hydraulic module) . 227.5 - Minimum system water volume. 227.6 - Maximum system water volume. 227.7 - Water type heat exchanger water flow rate. 237.8 - Pressure drop curves for the water exchanger and standard water inlet/outlet piping. 238 - WATER CONNECTIONS. 248.1 - Operating precautions and recommendations. 248.2 - Water connections. 258.3 - Units without hydraulic module. 278.4 - Units with hydraulic module and fixed-speed pump (for brine application only). 288.5 - Units with hydraulic module and variable-speed pump - pressure differential control. 288.6 - Units with hydraulic module and variable-speed pump - temperature difference control. 299 - NOMINAL SYSTEM WATER FLOW RATE CONTROL. 319.1 - Available static pressure for the installation. 3110 - SYSTEM START-UP . 3310.1 - Checks before system start-up. 3310.2 - Commissioning. 3310.3 - Essential points to check. 333
CONTENTS11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS. 3411.1 - Compressors. 3411.2 - Lubricant . 3411.3 - Air heat exchanger . 3411.4 - Fans. 3511.5 - Electronic expansion valve (EXV). 3611.6 - Moisture indicator. 3611.7 - Filter drier. 3611.8 - Water type heat exchanger. 3611.9 - Refrigerant. 3611.10 - High-pressure safety pressostat. 3611.11 - SmartVuTM control. 3612 - OPTIONS. 3712.1 - Tables of options. 3712.2 - Description. 3913 - STANDARD MAINTENANCE. 4513.1 - Level 1 maintenance. 4513.2 - Level 2 maintenance. 4513.3 - Level 3 maintenance. 4613.4 - Tightening of the electrical connections. 4713.5 - Tightening torques for the main fastenings. 4813.6 - Air heat exchanger. 4813.7 - Water type heat exchanger. 4813.8 - Frequency inverter. 4813.9 - Refrigerant volume. 4913.10 - Refrigerant properties. 4914 - FINAL SHUTDOWN. 5014.1 - Shutting down. 5014.2 - Recommendations for disassembly. 5014.3 - Fluids to be recovered for treatment. 5014.4 - Materials to be recovered for recycling. 5014.5 - Waste Electrical and Electronic Equipment (WEEE). 5015 - UNIT START-UP CHECKLIST FOR INSTALLERS PRIOR TO CONTACTING THE MANUFACTURER. 51This manual applies to the following units:- 30RB standard chiller- 30RQ standard chiller standard reversible heat pumpFor operation of the control, please refer to the 30RB/30RQ control manual.The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract.4
1 - INTRODUCTION AND SAFETY INSTRUCTIONSThe units are designed to cool water (for coolers) and cool or reheat water (for reversible heat pumps) for the air conditioning andheating of buildings and industrial processes.They are designed to provide a very high level of safety and reliability, making installation, start-up, operation and maintenance easierand safer.They will provide safe and reliable service if used within their application ranges.For all safety instructions, please refer to the safety manual. A paper version is delivered with the machine, the digital version is availablein the same place as the IOM, (contact your local distributor).In addition to this safety manual, the manufacturer states that the unit is designed for a maximum number of 120,000 start-ups.2 - RECEIPT OF GOODS2.1 - Checking the equipment receivedCheck that the unit and the accessories have not been damaged during transport and that no parts are missing. If the unit and theaccessories have been damaged or the shipment is incomplete, send a claim to the shipping company.Compare the name plate data with the order.The name plate is attached in two places to the unit:- On one side of the unit exterior,- On the inside of the electrical panel door.5
3 - HANDLING AND POSITIONING3.1 - Handling3.2 - PositioningCarrier strongly recommends employing a specialised companyto unload the machine.The machine must be installed outdoors in a place that is notaccessible to the public and is protected against access by nonauthorised persons.Do not remove the subbase or the packaging until the unit is in itsfinal position.These units can be safely moved by trained personnel with a forklift truck with the correct capacity for the dimensions and weightof the unit, as long as the forks are positioned in the location anddirection shown on the unit.The units can also be lifted with slings, using only the designatedlifting points marked on the unit (labels on the chassis and a labelwith all unit handling instructions, attached to the unit).Use slings with the correct capacity, and follow the liftinginstructions on the certified dimensional drawings supplied.IMPORTANT: Only attach slings to the designated liftingpoints which are marked on the unit.It is advisable to protect coils against crushing while a unit is beingmoved. Use struts or a lifting beam to spread the slings above theunit. Do not tilt the unit more than 15 .Safety when lifting can only be guaranteed if all these instructionsare followed. Otherwise, there is a risk of equipment damage orinjury to personnel.The machine must be installed outdoors. Installation indoors isforbidden.For extra-high units, the unit environment must permit easy accessfor maintenance operations.For the centre of gravity coordinates, the position of the unitmounting holes, and the weight distribution points, refer to thecertified dimensional drawings. Ensure the free space shown inthe dimensional drawings is respected to facilitate maintenanceand connection.The typical applications of these units are cooling and heating,which do not require earthquake resistance. Earthquake resistancehas not been verified.Before positioning the device, check that:- The permitted loading at the site is adequate or thatappropriate strengthening measures have been taken.- The unit is installed level on an even surface (maximumtolerance is 5 mm along both axes).- If the support structure is sensitive to vibration and/or noisetransmission it is advisable to insert anti-vibration mounts(elastomer mounts or metal springs) between the unit andthe structure. Selection of these devices is based on thesystem characteristics and the comfort level required andshould be made by technical specialists.- There is adequate space above and around the unit for airto circulate and for access to the components (seedimensional drawings).- the number of support points is adequate and that they arein the right places.- the location is not subject to flooding.- Avoid installing the unit where snow is likely to accumulate(in areas subject to long periods of sub-zero temperatures,the unit should be raised).- Baffles may be necessary to deflect strong winds. Thesemust not restrict the unit's air flow.IMPORTANT: Before lifting the unit, check that all enclosurepanels and grilles are securely fixed in place. Lift and setdown the unit with great care. Tilting and jarring can damagethe unit and impair unit operation.Never apply pressure or leverage to any of the unit's panelsor uprights; only the base of the unit frame is designed towithstand such stresses. No force or effort must be appliedto pressurised parts, especially via pipes connected to thewater type heat exchanger (with or without the hydraulicmodule if the unit is equipped with this). The hydraulic modulepipes must be fitted so that the pump does not support theweight of the pipes.All welding operations (connection to the hydraulic network) mustbe performed by qualified welders. The Victaulic connection orthe counter-flange must be removed before welding as a matterof course.6
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES4.1 - 30RB/30RQ 040R-080R, units with and without hydraulic moduleKey:All dimensions are given in mm.BCClearances required for maintenance and air flowClearance recommended for coil removalWater inletWater outletAir outlet, do not obstructNOTE: Non-contractual drawings.When designing a system, refer to the certified dimensionaldrawings provided with the unit or available on request.Refer to the certified dimensional drawings for the locationof fixing points, weight distribution and coordinates of thecentre of gravity, hydraulic and electrical connections.Control box7
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES4.2 - 30RB/30RQ 090R-160R, units with and without hydraulic moduleKey:All dimensions are given in mm.BCClearances required for maintenance and air flowClearance recommended for coil removalWater inletWater outletAir outlet, do not obstructControl box8NOTE: Non-contractual drawings.When designing a system, refer to the certified dimensionaldrawings provided with the unit or available on request.Refer to the certified dimensional drawings for the locationof fixing points, weight distribution and coordinates of thecentre of gravity, hydraulic and electrical connections.
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES4.3 - 30RB/30RQ 040R-080R, units with water buffer tank moduleKey:All dimensions are given in mm.BCClearances required for maintenance and air flowClearance recommended for coil removalWater inletWater outletAir outlet, do not obstructNOTE: Non-contractual drawings.When designing a system, refer to the certified dimensionaldrawings provided with the unit or available on request.Refer to the certified dimensional drawings for the locationof fixing points, weight distribution and coordinates of thecentre of gravity, hydraulic and electrical connections.Control box9
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES4.4 - 30RB/30RQ 090R-160R, units with water buffer tank moduleKey:All dimensions are given in mm.BCClearances required for maintenance and air flowClearance recommended for coil removalWater inletWater outletAir outlet, do not obstructControl box10NOTE: Non-contractual drawings.When designing a system, refer to the certified dimensionaldrawings provided with the unit or available on request.Refer to the certified dimensional drawings for the locationof fixing points, weight distribution and coordinates of thecentre of gravity, hydraulic and electrical connections.
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES4.5 - Free spaces and installing several unitsIn multiple-chiller installations (maximum of four units), the free space between the sides of the units should be increasedto between 1000 and 2000 mm.The height of the solid surface must not exceed 2 m.NOTE: If the walls are higher than 2 m, contact the factorySolid wallSolid wall4.6 - Positioning of ATEX zones around the unitElectrics box side60 cmDue to the nature of the refrigerant in these units (A2L fluid), ATEX zones have been identified and positioned around the units, asshown in the diagram opposite.The ATEX zones, as defined, must only be entered by suitably trained personnel equipped with the appropriate detectionmaterial and tools for working in an ATEX zone.ATEX zone 2 is involved.The machines are designed to be installed outdoors, in a free field-type, ventilated area.As the refrigerant used is heavier than air, it is essential that installations joined to the unit prevent the retention of refrigerant at thelowest point in the event of a leak.11
5 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS5.1 - Physical properties: 30RB/30RQ 40R-160R30RBSound levelsStandard unitSound power(1)Sound pressure at 10 m(2)Unit option 15LSSound power(1)Sound pressure at 10 m(2)Dimensions - standard unitStandard unitLengthWidthHeightUnit height (option 12)Unit height (option 307)Unit height (option 12 307)Operating weight(3)Standard unitUnit high pressure single pump optionUnit high pressure dual pump optionUnit high pressure single pump and buffer tank optionsUnit high pressure dual pump and buffer tank optionsCompressorsCircuit ACircuit BNumber of power stagesRefrigerant(3)Circuit ACircuit BOilCircuit ACircuit BCapacity controlMinimum capacityCondenserFansStandard unitQuantityMaximum total air flowMaximum rotation speedEvaporatorWater volumeMax. water-side operating pressure without hydraulicmoduleHydraulic module (option)PumpExpansion tank volumeMax. water-side operating pressure with hydraulic moduleHydraulic connections with/without hydraulic moduleConnectionsExternal diameterCasing paint colour040R 045R 050R 055R 060R 070R 080R 090R 100R 120R 140R 160RdB(A) 81,5 82,0 83,5 83,5 89,0 89,0 89,0 91,5 91,5 92,0 92,0 92,0dB(A) 50,0 50,5 52,0 52,0 57,5 57,5 57,5 60,0 60,0 60,5 60,5 60,5dB(A) 78,5 79,0 80,0 80,0 80,0 80,0 80,0 83,0 83,0 83,0 83,0 83,0dB(A) 47,0 47,5 48,5 48,5 48,5 48,5 48,5 51,5 51,5 51,5 51,5 13392222430 439 447 665 725 733450 460 467 684 745 758477 487 494 711 772 791802 812 819 1102 1163 1176829 838 846 1129 1190 1209Hermetic Scroll 48.3 01341193019722258205013301341193019722222233R32 / A2L / GWP 675 following AR43,72 3,92 4,43 4,90 4,70 4,87 4,84 7,75 8,40 9,00 0 6,00 6,60 6,60 6,60 7,20 7,20 7,20 10,80 10,80 um micro-channel coils (MCHE)Axial Flying Bird 6 with rotating shroud5,073,45,073,47,207,2025l1111111222223882 3802 4058 3900 5484 5452 5414 10568 10512 10974 10904 10827121212121818181818181818Direct expansion brazed-plate heat exchanger3,5544,44 4,44 5,18 6,07 6,96 7,4 8,44 9,92 12,69 14,31kPa1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000l/sr/sPump, Victaulic screen filter, relief valve, water and air drain valve, pressuresensors, expansion tank (option)Centrifugal pump, monocell, 48.3 r/s, low- or high-pressure (as required),single or dual (as required)l121212121212123535353535kPa400 400 400 400 400 400 400 400 400 400 400 400Victaulic typeinches222222222222mm 60,3 60,3 60,3 60,3 60,3 60,3 60,3 60,3 60,3 60,3 60,3 60,3Colour code RAL 7035(1) In dB ref 10-12 W, (A) weighting. Declared dual-number noise emission values in accordance with ISO 4871 with an associated uncertainty of /-3dB(A). Measured inaccordance with ISO 9614-1 and certified by Eurovent.(2) In dB ref 20 µPa, (A) weighting. Declared dual-number noise emission values in accordance with ISO 4871 with an associated uncertainty of /-3dB(A). For information,calculated from the sound power level Lw(A).(3) Values are guidelines only. Refer to the unit name plate.12
5 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS5.2 - Electrical data notes: 30RB/30RQ 040R-160R30RBPower circuit supplyNominal voltageVoltage rangeControl circuit supplyMaximum operating input power(1) or (2)Circuit A&BPower factor at maximum power(1) or (2)Standard unit power factorNominal unit current draw(4)Standard unitMaximum operating current draw (Un)(1) or (2)Standard unitMaximum current (Un-10%)(1) or (2)Standard unitMaximum start-up current (Un) (2) (3)Standard unit(1)(2)(3)(4)040R 045R 050R 055R 060R 070R 080R 090R 100R 120R 140R 160RV-ph-HzVkW400 - 3 -50360 - 44024 V via internal transformer1921242428313641485563710,81 0,82 0,82 0,82 0,84 0,84 0,85 0,82 0,84 0,85 0,84 177191238206223231251Values at the unit's permanent maximum operating condition (as shown on the unit's nameplate).Values at the unit's maximum operating condition (as shown on the unit's nameplate).Maximum operating current of the smallest compressor(s) fan current locked rotor current of the largest compressor.Standardised EUROVENT conditions, water-cooled heat exchanger water inlet/outlet 12 C/7 C, outdoor air temperature 35 C.5.3 - Short circuit current withstand capabilityShort-circuit withstand current (TN system(1))30RBRated short-circuit withstand currentsShort time (1s) assigned current - IcwRated peak current - IpkValue with upstream electrical protection (1)Conditional short circuit assigned current IccAssociated protection - type/supplierAssociated protection - rating/reference040R045R050R055R060R070RkA effkA pk3,36203,36203,36203,36203,36203,3620kA eff4040NS100H30RBRated short-circuit withstand currentsShort time (1s) assigned current - IcwRated peak current - IpkValue with upstream electrical protection (1)Conditional short circuit assigned current IccAssociated protection - type/supplierAssociated protection - rating/reference404040Circuit 80R090R100R120R140R160RkA effkA pk5,62155,62205,62205,62155,62205,6215kA eff4040NS100H404030Circuit 1) If another current limitation
Air-Cooled Liquid Chillers Reversible heat pumps 30RB/30RQ 040R-160R Rated cooling capacity 40-160 kW R-32. 2. CONTENTS . must not restrict the unit's air flow. IMPORTANT: Before lifting the unit, check that all enclosure panels and grilles are securely fixed in place. Lift and set
cause water-cooled chillers can take advantage of lower condensing temperatures than air-cooled chillers. Air-cooled chillers have a full load kW/ton of approxi-mately 1.25 while water-cooled chillers have a full load kW/ton of between 0.55 and 0.8 kW/ton. The kW draw of the cooling tower fans and con-denser water pump should be
Air Cooled Chiller Air Air 2 Air Air 6 AIR COOLED CHILLERS Air-cooled chillers are refrigeration machines that remove heat from cooling loads using chilled water and reject this heat into the atmosphere using refrigerant. THEY ALL HAVE fans, condenser coils, and compressors. Air-cooled chillers are used to provide cooling for human comfort and electronic equipment as well as industrial process .
Air-Cooled Reciprocating Liquid Chillers with ComfortLink Controls 50/60 Hz Nominal Capacities: 50 to 410 Tons 179 to 1445 kW Product Data Features/Benefits ComfortLink control Your link to a world of simple and easy to use air-cooled chillers that offer out-standing performance and value. The 30GTN,GTR liquid chillers employ more than the .
Air-Cooled Liquid Chillers The 30XAS Aquaforce liquid chillers are the premium solution for industrial and commercial applications where installers, consultants and building owners require optimal performances and maximum quality. The Aquaforce liquid chillers are designed to meet current and future requirements in terms of energy efficiency and
AIR-COOLED LIQUID CHILLERS Liquid chillers with partial heat recovery Liquid chillers with total heat recovery FOCS FOCS-D FOCS-R I dati contenuti possono essere variati senza obbligo di preavviso All specification and data are subject to change without notice CLIMAVENETA S.p.A. Via Sarson, 57/C Tel. ( 39) 0424 509 500 Fax ( 39) 0424 509 509
Maximum Series portable chillers can be used on a variety of process applications that require 20 F to 80 F chilled water. MAXIMUM SERIES † Air & Water-Cooled † 1/4 to 40 Tons † 20 F to 80 F † Using Non-Ozone Depleting Refrigerants 10 ton air-cooled model 10 ton water-cooled model 2 ton water-cooled model 1 ton air-cooled model
8 to 12 F for water-cooled chillers and 10 to 15 F for air-cooled chillers. ENSURE PROPER SUPERHEAT For air-cooled chillers, make sure fans work properly and coils are clean on the condenser side of the system. For water-cooled chillers, ensure that all flow rates and pressure drops on th
air-cooled screw liquid chillers e/v high efficiency and s/p standard efficiency air-cooled screw liquid chillers installation, operation, maintenance supersedes: 201.23-nm2 (610) form 201.23-nm2 (315) 035-21506-101 issue date: march 9, 2015. 2 johnson controls form 201.23-nm2
