Carrier 30GB060 User Manual
Advance
Product
Data
Packaged
Air-Cooled
Flotronic™
Liquid Chiller
Nominal 60-Ton Capacity
Features
• Unit nominal capacity serves virtually any large com
mercial or institutional air conditioning need or industrial
process cooling requirement.
• High-tech solid-state electronic control circuitry tested
to U.S. Government Space Agency standards.
• Microprocessor control maintains total control over
chiller functions, permitting intelligent control of the
refrigerant cycle.
• Diagnostic module with digital display included to
permit rapid troubleshooting just by pressing a button.
• Electronic expansion valves (EXV) operate down to
ISpsig (103 kPa) pressure differential. (Ordinary ther
mostatic expansion valve typically requires lOOpsig
[690 kPa] differential.) This reduces compressor motor
power requirements and improves the unit EER.
• Flotronic™ chiller provides up to 28% efficiency im
provement over standard 30GB chillers on an annual
basis.
• Additional operating cost savings with precise multiplestep compressor capacity control.
• Multiple compressors and dual refrigerant circuits help
to protect against the possibility of loss of total capacity.
• Semi-hermetic 06E compressors are serviceable in
the field.
30GB060
Designed for outdoor installation to minimize required
mechanical room space.
Air-cooled condenser design saves condenser water
and eliminates cooling tower.
Domestic units will operate to 115 F (46 C).
Protection against freeze-up — low water temperature
cutoff and electric heaters protect cooler.
Available as standard with aluminum fins and copper
tubes for normal applications, or with all-copper coils.
Field-installed accessories
• Demand limit control module (required for remote
ON/OFF control)
• Leaving chilled water temperature reset accessory board
• Sensor kit assembly for outdoor or space temperature
reset of chilled water temperature
• Ground current refrigeration circuit protection
• Discharge and suction pressure gage panel
• Oil pressure switch package includes oil pressure
switches (2) for unit
• Capacity control: accessory electric suction cutoff
unloader
• Motormaster® head pressure control (requires unit
modification for low-ambient operation)
Factory-Installed option (FlOP)
Thermal expansion valves — For those situations where
energy savings of the EXV are secondary and equipment
first costs are most important. With this option, the
electronic expansion valve and controls related to the
EXV function, head pressure control and its related
part-load energy savings, are deleted from unit and are
replaced by thermal expansion valves and liquid line
solenoid valves. Minimum operating ambient for FlOP
TXV-equipped units with standard head pressure control
is 32 F. Contact your Carrier representative for details
on operation at temperatures below 32 F. The FlOP model
continues to have microprocessor features and diagnostic
capability. Standard accessories are useable.
2-87
Form 30GB-1APD
Table of contents
Page
Features .............................................................................1
Field-Installed Accessories ...............................................1
Factory-Installed Option (FIOP)......................................1
Model Number Nomenclature ..........................................2
Physical Data....................................................................2
Application Data ............................................................2-6
Selection Procedure
Performance Data
..........................................................
...........................................................
7-9
Model number nomenclature
30GB 060 - 6
30GB-AIR-COOLED
OUTDOOR LIQUID CHILLER
UNIT SIZE (approximates chiller capacity in tons)
Page
Dimensions .................................................................... 10
Mounting Weights ......................................................... 10
Electrical Data ............................................................... 11
Controls ....................................................................... 11,12
Control Sequence
..........................................................
13
Typical Installation ........................................................ 14
6
Guide Specifications
....................................................
— 1 575-3-60
— 5 208/230-3-60
— 6 460-3-60
15,16
Physical data
MODEL 30GB 060
APPROX OPER WT - lb 4900
REFRIG CHG — lb
Circuit 1 65
Circuit 2 85
COMPRESSORS, Type...Rpm Reciprocating,
(No.) Circuit 1* (1) 6275
(No.) Circuit 2 (1) A299
Capacity Control Steps 4
Circuit 1 (%) 43
Circuit 2 (%) 57
Minimum Step Capacity (%)
CONDENSER FANS — Type Propeller, Direct Drive
Fan Speed — Rpm 1080
No. Biades...Diameter-in.
Circuit 1/Circuit 2 4...26/3 ..30
No. Fans...Total kW
Totai Airfiow — Cfm
CONDENSER COiLS — Type
Tubes (Copper), OD-in. '/2
Fins/in. Circuit 1/Circuit 2 14 2/15.0
No. Rows Circuit 1/Circuit 2 %
Face Area (sq ft) Circuit 1 57 5
Max. Working Pressure
Refrig psig
COOLER — No. ...Type
Modei 10HA400— 824
No. Refrigerant Circuits 2
Net Water Volume — Gal.
(includes nozzles)
Max. Working Press. — psig Refrigerant Side-235,
WATER CONNECTIONS MPT
Inlet and Outlet — in. 3
Drain — in. FPT
*6 prefix indicates one electric unioader.
"A” prefix indicates no unloader.
tCopper fins aiso avaiiabie
Circuit 2
Semi-Hermetic 1750
29
6. 1 92
46500
Plate Fins (Aluminumf)
57.5
450
One...Direct Expansion,
Shell & Tube
17 7
Water Side-150
%
Application data
Leveling unit
Unit must be level when installed to ensure proper oil
return to the compressors.
While most outdoor locations are suitable for 30GB
units, the roof is a common site that presents a problem
if roof has been pitched to aid in water removal. To
assure proper oil return, be sure that unit is level,
particularly in its major lengthwise dimension, as com
pressor oil return piping runs in that direction.
It should be determined prior to installation if any
special treatment is required to assure a level installation.
Cooler temperature
1. Maximum leaving chilled water temperature (LCWT)
for Model 30GB is 70 F (21 C). Unit can start and pull
down with up to 95 F (35 C) entering water tempera
ture due to MOP (maximum operating pressure)
feature of the expansion valve. For sustained opera
tion, it is recommended that entering water temperature
not exceed 85 F (29.4 C).
2. Minimum LCWT for standard Model 30GB is 40 F
(4.5 C). It is permissible to use a standard micro
processor-controlled Flotronic chiller with leaving
water temperatures in the range of 34 F (1°C) to 39.9 F
(4.4 C) only if a protective brine solution (20% antifreeze
solution, or greater) is used and microprocessor dip
switch is properly set. (See Controls and Trouble
shooting book for further information.) Special order
medium temperature brine units must be ordered for
operation with leaving water temperatures in the range
of 34 F (1°C) to 15 F (-9C). For ratings below 40 F
4.5 C) LCWT, contact your local Carrier representative.
Application data (cont)
MINIMUM COOLER WATER FLOW RATES
AND MINIMUM LOOP VOLUME
UNIT 30GB
060 67
NOTES.
1. Minimum flow based on 1 5 fps veiocity in cooier without special
cooler baffling
2. Minimum Loop Volumes:
Gallons = V X ARl Cap (tons)
APPLICATION
Normal Air Conditioning
Process Type Cooling
Low Ambient Unit Operation
MINIMUM
FLOW (1)
Gpm ft of water
PRESSURE
DROP
3.8
MINIMUM
VOLUME (2)
Gallons
180
Leaving water temperature reset
Accessory board* may be installed in 30GB chillers to
provide reset of LCWT in constant water flow systems.
Reset reduces compressor power usage at part load when
design LCWT is not necessary. Humidity control should
be considered since higher coil temperatures resulting
from reset will reduce latent heat capacity. Three reset
options are offered;
From return water temperature* — Increases LCWT
temperature set point as return (or entering) water tem
perature decreases (indicating load decrease). Option
may be used in any application where return water provides
accurate load indication. Limitation of return water reset is:
LCWT may only be reset to value of design return water
temperature. Return reset is the simplest of 3 reset acces
sories available, as return water sensor is already installed.
From outdoor temperature* — Increases LCWT as
outdoor ambient temperature decreases (indicating load
decrease). This reset should be applied only where outdoor
ambient is an accurate indication of load. An accessory
thermistor is required.
From space temperature* — Increases LCWT as space
temperature decreases (indicating load decrease). This
reset should be applied only where space temperature is
an accurate indication of load.
For details on applying a reset option, refer to 30GB
Controls and Troubleshooting Instructions.
*Obtain ordering part numbers from current price pages.
c. Special cooler baffling is required to allow minimum
flow rate to be reduced 12%.
CHILLER COOLER
RECIRCULATION
SUPPLY
RETURN
Maximum cooler flow (> 5 gpm/ton or < 5 F range
[>0.09 L/s . kW or <2.7 C range]) results in practical
maximum pressure drop through cooler.
a. Return water may bypass the cooler to keep pressure
drop through cooler within acceptable limits. This
permits a higher AT with lower water flow through
cooler and mixing after the cooler.
b. Special cooler baffling is available by special order,
to permit a cooler flow rate increase of 10%.
CHILLER COOLER
BYPASS
SUPPLY
RETURN
Cooler flow range
Ratings and performance data in this publication are
for a cooling range of 10°F or 6°C. Flotronic^" chillers with
microprocessor control may be operated at a different
temperature range provided flow limits are not exceeded.
For minimum flow rates, see Table. High flow rate is limited
by pressure drop that can be tolerated. If another range is
used, apply LCWT correction as given in selection example.
Minimum cooler flow (maximum cooler temperature
range) for standard units is shown in Table. When gpm
(L/s) required is lower (or range higher), follow recom
mendations below:
a. Multiple smaller chillers may be applied in series, each
providing a portion of the design temperature range.
b. Cooler water may be recirculated to raise flow rate.
However, mixed temperature entering cooler must
be maintained a minimum of at least 5°F (2.8°C) above
the leaving chilled water temperature.
Variable cooler flow rates may be applied to a standard
30GB chiller. Unit will, however, attempt to maintain a
constant leaving chilled water temperature. In such cases,
minimum flow must be in excess of minimum flow given in
Table and flow rate must change in steps of less than 10%
per minute. Apply 6 gallons per ton (6.5 liters per kW) water
loop volume minimum if flow rate changes more rapidly.
Water loop volume — In circulation must equal or
exceed 3 gallons (11.4 liters) per nominal ton of cooling
(3.25 liters per kW) for temperature stability and accuracy
in normal air conditioning applications. (For example, a
30GB060 would require 180 gallons in circulation in system
loop — see Table.) For process jobs where accuracy is
vital or for operation at ambient below 32 F (0°C) with low
unit loading conditions, there should be from 6 to 10 gallons
Application data (cont)
per ton (6.5 to 10.8 liters per kW). To achieve this volume,
it is often necessary to install a tank in the loop. Tank
should be baffled to insure that there is no stratification
and that water (or brine) entering tank is adequately mixed
with liquid in the tank.
GOOD
GOOD
Cooler fouling factor used to calculate tabulated ratings
was 0.0005 ft2. hr. °F/Btu (0.000088 m^. K/W). As fouling
factor is increased, both unit capacity and compressor
power decrease. Standard ratings should be corrected
using following multipliers:
FOULING FACTOR
ENGLISH
((F . hr. °F/Btu)
0.0005 0.000088 1.00
0.001 0.000176 0.97
0.002 0.000352 0.91
SI
(m*. K/W)
CAPACITY
MULTIPLIER
COMPRESSOR
POWER
MULTIPLIER
1 00
0.98
0.91
Cooler protection in form of ethylene glycol (or other
suitable brine) is recommended when operating in areas
which experience temperatures below 32 F (0°C) to
protect cooler should there be a loss of cooler heater
power. Even though unit cooler is protected with insula
tion and an electric heater that protects the cooler down
to 10 F (-12 C), it does not protect water piping external
to unit. Use only antifreeze solutions approved for heat
exchanger duty. Use of automotive antifreezes is not
recommended because of the fouling that can occur once
their relatively short-lived inhibitor breaks down.
Draining cooler and outdoor piping is recommended if
system is not to be used during freezing weather condi
tions. See section below for low-ambient operation.
Condenser
Altitude correction factors must be applied to standard
ratings at altitudes above 2000 ft (610m) using following
multipliers:
ALTITUDE
ENGLISH
(ft)
0
2000
4000 1220
6000
8000 2440
10000
SI
(m)
0 1 00
610 0 99
1830 0,97
3050 0.95
CAPACITY
MULTIPLIER
0 98
0.96
COMPRESSOR
POWER
MULTIPLIER
1.00
1.01
1.02
1.03
1.04
1.05
Condenser airflow restrictions will affect the unit
capacity, condenser head pressure and compressor
power input. Correction factors to be applied for external
static restrictions up to 0.2 in. wg (50 Pa) are shown below.
EXTERNAL
STATIC
RESISTANCE
ENGLISH
(in. wg)
0.0 0.0
0.1 25
0.2 50 0 968 1.03
SI
(Pa)
CAPACITY
MULTIPLIER
1 00 1.00
0 986
COMPRESSOR
POWER
MULTIPLIER
1 01
High-ambient temperature — Standard 30GB chillers
can operate to 115 F (46 C) ambient temperature.
Low-ambient operation
Flotronic^“ 30GB chillers with electronic expansion valves
(EXV) will start and operate at ambients down to 0°F
(-18 C) with following field provisions:
Wind baffles must be added for operation below 32 F (0°C).
A WARNING
Operation at low ambient is not recommended if
minimum load on chiller is below minimum step of
unloading.
Protection against freeze-up — It is recommended
that field-installed chilled water piping be protected at
lower ambient temperatures by wrapping with field-supplied
heating cable and covering with 2-in. (50-mm) thick closed
cell insulation.
Antifreeze solution must be added to water loop to
protect loop down to 15 F (8 C) below minimum operating
ambient temperature.
For operation of EXV-equipped chillers below 0°F
(-18 C) and for operation of TXV-equipped (factoryinstalled option) chillers below 32 F (0°C), down to -20 F
(-29 C), the Carrier Motormaster® condenser head pres
sure control and its associated components must be
added. Consult your local Carrier representative for
complete details.
Provide sufficient volume in the chilled water loop — At
least 6 gallons per ton of refrigerant (6.5 liters per kilowatt)
is recommended minimum, provided there is a moderate
system load.
Capacity Correction (Antifreeze)
Ethylene glycol (or other suitable brine) should be used in
installations where subfreezing temperatures are ex
pected. Unit performance data must be corrected for
the addition of ethylene glycol as shown in following
example. Correction factors may be derived from follow
ing curves.
Example: Where a 5 F outdoor temperature is anticipated,
determine concentration of ethylene glycol to protect
system to -10 F ambient temperature at zero flow.
Enter the solution crystallization point curve at -10 F,
read 40% concentration of ethylene glycol is required to
prevent crystals from forming in solution.
Consider the 30GB060 unit from the Selection Pro
cedure (Water) example (refer to correction curves at
40% solution).
Application data (cont)
Correct unit capacity — On glycol performance
capacity correction curve, read 0.95.
Corrected capacity = 0.95 x determined capacity
- 0.95 X 61.3
= 58.2 tons
Correct chilled water flow — On the gpm correction
factor curve, read 1.15.
Chilled water flow (at corrected capacity)
24 X corrected capacity
temperature rise
24 X 58.2 tons
14 F
99.8 U.S. gpm
= U.S. gpm
Chilled water flow (40% solution) = 1.15x99.8
= 114.7 U.S. gpm
Correct cooler pressure drop — On cooler pressure
drop correction curve, read 1.33.
On cooler pressure drop curve, for 114.7 gpm, read
PD = 10 ft water gage. The pressure drop for 40% solution =
1.33 X 10.0 = 13.3 ft water.
Correct compressor power input (kW) — On power
correction curve, read 0.97 correction factor at 40%
EG concentration.
Power input from Selection Procedure example
= 71.1 kW.
Corrected power input = 0.97 x 71.1 = 68.9 kW.
Oversizing chillers
Oversizing chillers by more than 15% at design conditions
must be avoided as the system operating efficiency would
be affected adversely (resulting in greater/excessive
electrical demand). When future expansion of equipment
is anticipated, it is strongly recommended that a single
chiller be installed to meet present load requirements
and a second chiller added to meet the additional load
demand.
It is also recommended that the installation of 2 smaller
chillers be considered where operation at minimum load
is critical. The operation of a smaller chiller loaded to a
greater percent of minimum is preferred to operating a
single chiller at or near its minimum recommended value.
Multiple chillers
Where chiller capacities greater than 200 tons (703 kW)
are required, or where stand-by capability is desired,
chillers may be installed in parallel. Units should be of
equal size to ensure balanced water flows. Where a large
temperature drop (>25F [13.9 C]) is desired, chillers
may be installed in series. Water temperature sensors
need not be moved for multiple chiller operation. A 10-ft
(3-m) separation is required between units for airflow,
and a 6-ft (1.8-m) distance is required from units to
obstructions. See figure. See Physical Data for service
clearances.
ETHYLENE GLYCOL PERFORMANCE
CORRECTION FACTORS AND SOLUTION
CRYSTALLIZATION POINTS
(F)
-40
-20
-10
0
+20
40
10 20 30 40
% CONCENTRATION (BY WEIGHT)
ETHYLENE GLYCOL
50
(C)
r-40
c -30
-20
-10
0
(3m) (I.Sm)
10 FT 6 FT
* MINIMUM
////// //
MULTIPLE UNIT SEPARATION
MINIMUM
Electrical/utility interests
Energy management — See 30GB Controls and Trouble
shooting manual and accessory installation instructions
for details.
Demand limiting (also called load shedding) — When
utilities demand for electricity exceeds a certain level,
loads are shed to keep electricity demand below a pre
scribed maximum level. Typically, this happens on hot
days when air conditioning is most needed.
Load shedding must be done intelligently. Demand
may be limited on Model 30GB by resetting water tem
perature, or by using a demand limit accessory that
unloads the chiller to a given predetermined percent of
the load. Both features require signal from an intelligent
central control. Do not cycle demand limiter for less than
10 minutes on and 5 minutes off.
Duty cycling cycles electrical loads at regular intervals
regardless of need. This reduces electrical operating
costs of a building by “fooling” demand indicating
devices. Duty cycling of compressors or fans is not
recommended since motor winding and bearing life
suffer from constant cycling.
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