Carrier Refrigerator 30MPA User Manual

AQUASNAP®  
30MPA,MPW015-045  
Liquid Chillers  
with Scroll Compressors  
and COMFORTLINK™ Controls  
Installation Instructions  
.
CONTENTS  
WARNING  
Page  
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Electrical shock can cause personal injury and death. Shut  
off all power to this equipment during installation. There  
may be more than one disconnect switch. Tag all discon-  
nect locations to alert others not to restore power until work  
is completed.  
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1,2  
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16  
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Step 1 — Inspect Shipment . . . . . . . . . . . . . . . . . . . . 2  
Step 2 — Position the Unit. . . . . . . . . . . . . . . . . . . . . 2  
Step 3 — Place the Unit. . . . . . . . . . . . . . . . . . . . . . . . 7  
Step 4 — Check Compressor Mounting. . . . . . . . 7  
Step 5 — Make Piping Connections. . . . . . . . . . . . 7  
• 30MPA SYSTEM CONDENSER  
• 30MPW CONDENSER DESCRIPTION  
• 30MPW CONDENSER  
• EVAPORATOR DESCRIPTION  
• EVAPORATOR PIPING  
• AIR SEPARATION  
Step 6 — Fill the Chilled Water Loop. . . . . . . . . . .13  
WATER SYSTEM CLEANING  
• FILLING THE SYSTEM  
Step 7 — Make Electrical Connections. . . . . . . . .14  
• FLOW SWITCH  
• CONTROL BOX, POWER SECTION  
• CONTROL BOX, CONTROLS SECTION  
• CONTROL BOX, FIELD CONTROL WIRING  
SECTION  
• UNBALANCED 3-PHASE SUPPLY VOLTAGE  
a30-5029  
GENERAL  
Fig. 1 — 30MPA Unit  
These installation instructions cover the 30MPA, MPW units  
with ComfortLink controls. The 30MPA units are condenserless  
units and the 30MPW units are all fluid cooled.  
SAFETY CONSIDERATIONS  
Installing, starting up, and servicing this equipment (Fig. 1  
and 2) can be hazardous due to system pressures, electrical  
components, and equipment location (roofs, elevated struc-  
tures, etc.). Model number structure is shown in Fig. 3.  
Only trained, qualified installers and service technicians  
should install, start up, and service this equipment.  
When working on the equipment, observe precautions in the  
literature and on tags, stickers, and labels attached to the  
equipment.  
Follow all safety codes.  
Wear safety glasses and work gloves.  
Use care in handling, rigging, and setting bulky  
equipment.  
a30-5030  
Fig. 2 — 30MPW Unit  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 04-53300054-01 Printed in U.S.A. Form 30MP-1SI Pg 1 910 1-10 Replaces: New  
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a30-5032  
3
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a30-5033  
910  
4
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Table 1A — 30MPA Air-Cooled and 30MPW Liquid-Cooled Units — English  
UNIT 30MPA,MPW  
NOMINAL TONS  
015  
15  
020  
20  
030  
30  
040  
40  
045  
45  
OPERATING WT (lb)  
MPA  
626  
680  
635  
704  
722  
862  
913  
1099  
934  
1190  
MPW  
REFRIGERANT (lb)  
R-410A  
23.1  
MPA  
11.6  
15.2  
29.4  
34.4  
MPW  
COMPRESSOR  
Scroll, Hermetic  
Quantity  
2
2
2
3
3
Speed (rpm)  
3500  
7.5  
3500  
10  
3500  
15  
13.8  
3500  
13  
3500  
15  
Compressor Nominal Tons  
Oil Charge (pt)  
10.6  
13.8  
20.6  
20.6  
Capacity Control — Standard  
No. of Steps  
2
50  
2
50  
2
50  
3
33  
3
33  
Minimum Step Capacity (%)  
Capacity Control — Optional Hot Gas Bypass  
No. of Steps  
3
18  
3
25  
3
34  
4
21  
4
22  
Minimum Step Capacity (%)  
EVAPORATOR  
Weight (lb, empty)  
27.5  
0.8  
650  
300  
40.3  
1.2  
650  
300  
91.8  
2.4  
650  
300  
122.3  
3.2  
650  
300  
128.3  
3.4  
650  
300  
Net Fluid Volume (gal.)  
Maximum Refrigerant Pressure (psig)  
Maximum Fluid-Side Pressure (psig)  
Water Connections (in.)  
Inlet and Outlet (Victualic)  
Drain (NPT)  
2
2
2
2
21/2  
2
2 1/2  
2
21/2  
1
1
1
1
1
/
/
/
/
/
2
CONDENSER (30MPW Only)  
Weight (lb, empty)  
34.9  
1.2  
650  
300  
43.6  
1.6  
650  
300  
104.6  
2.9  
650  
300  
136.7  
4.1  
650  
300  
188.3  
5.9  
650  
300  
Net Fluid Volume (gal.)  
Maximum Refrigerant Pressure (psig)  
Maximum Fluid-Side Pressure (psig)  
Water Connections (in.)  
Inlet and Outlet (Victualic)  
2
2
21/2  
2 1/2  
21/2  
CHASSIS DIMENSIONS (in.)  
Length  
Width  
55  
32  
63  
55  
32  
63  
55  
32  
63  
55  
32  
63  
55  
32  
63  
Height  
MINIMUM SYSTEM FLUID VOLUME (gal. per Ton)  
Normal Air Conditioning  
Standard  
6
4
6
4
6
4
4
3
4
3
Optional Hot Gas Bypass  
Low Outdoor Ambient Cooling Operation (30MPA Units)  
Standard  
10  
7
10  
7
10  
7
8
6
8
6
Optional Hot Gas Bypass  
CAPACITY STEPS  
Step 1  
100%  
50%  
18%*  
100%  
50%  
25%*  
100%  
50%  
34%*  
100%  
67%  
100%  
67%  
Step 2  
Step 3  
33%  
33%  
Step 4  
21%*  
22%*  
MINIMUM FLOW RATES (gpm)  
Evaporator  
22  
22  
28  
28  
43  
43  
55  
55  
64  
64  
Condenser  
MAXIMUM FLOW RATES (gpm)  
Evaporator  
74  
74  
97  
97  
148  
148  
188  
188  
220  
220  
Condenser  
* With optional hot gas bypass.  
NOTES:  
1. Operating weight includes refrigerant operating charge and  
weight of fluid in the heat exchangers.  
2. 30MPW units are shipped with full operating charge.  
5
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Table 1B — 30MPA Air-Cooled and 30MPW Liquid-Cooled Units — SI  
UNIT 30MPA,MPW  
NOMINAL KW  
015  
54  
020  
71  
030  
108  
040  
138  
045  
161  
OPERATING WT (kg)  
MPA  
284  
308  
288  
319  
327  
391  
414  
499  
424  
540  
MPW  
REFRIGERANT (kg)  
R-410A  
10.5  
MPA  
5.2  
6.9  
13.3  
15.6  
MPW  
COMPRESSOR  
Scroll, Hermetic  
Quantity  
2
2
2
3
3
Speed (r/s)  
58  
26  
5.0  
58  
35  
6.5  
58  
53  
6.5  
58  
45  
9.8  
58  
53  
9.8  
Compressor Nominal kW  
Oil Charge (L)  
Capacity Control — Standard  
No. of Steps  
2
50  
2
50  
2
50  
3
33  
3
33  
Minimum Step Capacity (%)  
Capacity Control — Optional Hot Gas Bypass  
No. of Steps  
3
18  
3
25  
3
34  
4
21  
4
22  
Minimum Step Capacity (%)  
EVAPORATOR  
Weight (kg, empty)  
12.5  
2.9  
4482  
2068  
18.3  
4.6  
4482  
2068  
41.6  
8.9  
4482  
2068  
55.5  
12.0  
4482  
2068  
58.2  
13.0  
4482  
2068  
Net Fluid Volume (L)  
Maximum Refrigerant Pressure (kPa)  
Maximum Fluid-Side Pressure (kPa)  
Water Connections (in.)  
Inlet and Outlet (Victualic)  
Drain (NPT)  
2
2
2
2
21/2  
2
2 1/2  
2
21/2  
1
1
1
1
1
/
/
/
/
/
2
CONDENSER (30MPW)  
Weight (kg, empty)  
15.8  
4.5  
4482  
2068  
19.8  
5.9  
4482  
2068  
47.4  
11.1  
4482  
2068  
62.0  
15.4  
4482  
2068  
85.4  
22.4  
4482  
2068  
Net Fluid Volume (L)  
Maximum Refrigerant Pressure (kPa)  
Maximum Fluid-Side Pressure (kPa)  
Water Connections (in.)  
Inlet and Outlet (Victualic)  
11/2  
11/2  
2
2
2
CHASSIS DIMENSIONS (mm)  
Length  
Width  
1397  
813  
1600  
1397  
813  
1600  
1397  
813  
1600  
1397  
813  
1600  
1397  
813  
1600  
Height  
MINIMUM SYSTEM FLUID VOLUME (L per kW)  
Normal Air Conditioning  
Standard  
23  
15  
23  
15  
23  
15  
15  
11  
15  
11  
Optional Hot Gas Bypass  
Low Outdoor Ambient Cooling Operation (30MPA Units)  
Standard  
38  
25  
38  
25  
38  
25  
30  
23  
30  
23  
Optional Hot Gas Bypass  
CAPACITY STEPS  
Step 1  
100%  
50%  
18%*  
100%  
50%  
25%*  
100%  
50%  
34%*  
100%  
67%  
100%  
67%  
Step 2  
Step 3  
33%  
33%  
Step 4  
21%*  
22%*  
MINIMUM FLOW RATES (L/s)  
Evaporator  
1.4  
1.4  
1.8  
1.8  
2.7  
2.7  
3.5  
3.5  
4.0  
4.0  
Condenser  
MAXIMUM FLOW RATES (L/s)  
Evaporator  
4.7  
4.7  
6.1  
6.1  
9.3  
9.3  
11.9  
11.9  
13.9  
13.9  
Condenser  
* With optional hot gas bypass.  
NOTES:  
1. Operating weight includes refrigerant operating charge and  
weight of fluid in the heat exchangers.  
2. 30MPW units are shipped with full operating charge.  
6
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30MPA units varies only in field piping required for the remote  
condenser.  
B
C
When the unit is in its final position, remove the packaging  
and remove the mobility kit wheels (if equipped). Remove  
3
/ -in. wheel nuts to remove wheels from unit legs. Level the  
8
unit (using a level), and bolt the unit to the floor or pad.  
If unit is to be mounted on unit external vibration  
isolators, follow the mounting instructions included with  
the accessory vibration isolator.  
If unit has accessory leveling kit installed, follow the in-  
structions provided with the accessory to make sure unit is lev-  
el and in the correct position.  
Step 4 — Check Compressor Mounting — As  
shipped, units with two compressors are held down with 6 bolts  
through rubber grommets. All units with three compresors are  
held down with 8 bolts per pair through grommets. After unit is  
installed, verify mounting bolt torque 7 to10 ft-lb (9 to 14 Nm).  
a30-5040  
D
A
CONTROL  
PANEL  
SIDE  
Step 5 — Make Piping Connections — See  
WEIGHT DISTRIBUTION AT EACH MOUNTING  
Fig. 8 and 9 for typical piping applications.  
HOLE — Lb (kg)  
30MPA SYSTEM CONDENSER — For detailed condenser  
piping installation instructions for 30MPA systems, refer to  
separate instructions packaged with the remote condenser  
units.  
Condenser refrigerant piping for 30MPA units should be  
sized to minimize the amount of refrigerant required.  
The 30MPA units that use air-cooled evaporative condens-  
ers must have adequate means for head pressure control when  
operating below 60 F (15.6 C).  
Carrier recommends that a field-supplied pressure relief de-  
vice be installed in each discharge line of 30MPA units. Most  
local codes require the discharge line relief valve to be vented  
directly to the outdoors. The vent must not be smaller than the  
discharge line relief valve outlet.  
30MPW CONDENSER DESCRIPTION — All 30MPW  
units use a brazed-plate heat-exchanger-type condenser. These  
heat exchangers are made of embossed plates of acid-resistant  
stainless steel. Every other plate is reversed so that the ridges  
of the herringbone pattern intersect one another on adjacent  
plates, forming a lattice of contact points. These plates are  
vacuum-brazed together to form a compact and pressure-  
resistant heat exchanger.  
MOUNTING HOLE  
UNIT 30MP  
A
B
C
D
A015  
A020  
A030  
A040  
A045  
W015  
W020  
W030  
W040  
W045  
156 (71)  
159 (72)  
181 (82)  
228 (104)  
234 (106)  
170 (77)  
176 (80)  
216 (98)  
275 (125)  
298 (135)  
Fig. 6 — Mounting Hole Weight Distribution  
a30-5041  
After brazing, the impressions in the plates form 2 separate  
systems of channels where the refrigerant and water flows are  
counterflow. The number of plates varies depending on unit  
tonnage. The condensers provide approximately 10º to 12º F  
(6º to 8º C) liquid subcooling at the standard Air Conditioning,  
Heating and Refrigeration Institute (AHRI) rating condition.  
30MPW CONDENSER — When facing the unit control box,  
the condenser is the uninsulated heat exchanger located on the  
left-hand side. The water connections are on the right-hand  
side of the heat exchanger with the LIQUID-IN connection at  
the bottom, and the LIQUID-OUT connection at the top.  
Fig. 7 — Mobility Kit  
A strainer with a minimum of 40 mesh must be installed  
within 10 ft (3 m) of the condenser water inlet to prevent debris  
from clogging or damaging the heat exchanger. The strainer is  
required for operation and is available as an accessory.  
Step 3 — Place the Unit  
NOTE: These units are not suitable for unprotected outdoor  
use.  
To install the victaulic coupling (see Fig. 10):  
Carrier recommends that these units be located in the base-  
ment or on the ground floor. However, if it is necessary to lo-  
cate the unit on an upper floor, be sure the structure has been  
designed to support the unit weight. If necessary, add structural  
support to floor. Also, be sure the surface for installation is  
level. Refer to Fig. 4 and 5 for space requirements and weight  
distribution.  
Only electrical power connections, water connections for  
condenser, fluid connections for evaporator, and strainer instal-  
lation are required for 30MPW installation. Installation of  
1. Lubricate the gasket lips and stretch the gasket over  
the end of the heat exchanger coupling. Avoid twisting  
the gasket when installing.  
2. Bring the pipe and heat exchanger coupling ends together  
into alignment. Slide the gasket so that it is centered over  
the ends. Apply a light film of lubricant to the gasket, or  
to the outside diameter of the pipe. Avoid twisting the  
gasket during installation.  
7
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a30-4997  
8
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NOTES:  
1. Chiller must be installed level to maintain proper compressor oil  
return.  
2. Wiring and piping shown are general points-of-connection guides  
only and are not intended for a specific installation. Wiring and pip-  
ing shown are for a quick overview of system and are not in accor-  
dance with recognized standards. Units should be installed using  
certified drawings.  
a30-4998  
3. All wiring must comply with applicable local and national codes.  
4. All piping must follow standard piping techniques. Refer to Carrier  
System Design Manual part 3, Carrier E20-II software Refrigerant  
Piping program, or appropriate ASHRAE (American Society of  
Heating, Refrigerating, and Air Conditioning Engineers) handbook  
for details on proper piping sizes and design.  
5. See Tables 1A and 1B for minimum system fluid volume. This sys-  
tem may require the addition of a holding tank to ensure adequate  
volume.  
09DP  
AIR-COOLED  
CONDENSER  
6. Hot gas lines should rise above refrigerant level in condenser cir-  
cuit. Double riser may be required; check unit minimum capacity.  
7. Trap should be installed on hot gas lines to prevent condenser oil  
and refrigerant vapor migration from accumulating in compressor  
during off cycle.  
8. Pitch all horizontal lines downward in the direction of refrigerant  
flow.  
9. Provide support to liquid and gas lines near the connections to the  
condenser coil.  
10. For pressure relief requirements, see latest revision of ASHRAE  
Standard 15, Safety Code for Mechanical Refrigeration.  
11. A strainer with a minimum of 40 mesh must be installed within 10 ft  
(3 m) of the evaporator fluid inlet to prevent debris from clogging or  
damaging the heat exchanger. This strainer is required and is avail-  
able as an accessory.  
12. Piping, wiring, switches, vents, strainers, drains, and vibration iso-  
lation are all field-supplied.  
Fig. 9 — Typical Piping with 30MPA Unit and 09DP Remote Air-Cooled Condenser  
9
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A strainer with a minimum of 40 mesh must be installed  
within 10 ft of the evaporator fluid inlet to prevent debris from  
clogging or damaging the heat exchanger. This strainer is re-  
quired and is available as an accessory.  
See Carrier System Design Manual, Part 3, Piping Design,  
for chilled fluid piping details.  
The evaporator fluid inlet and outlet connections are vict-  
ualic. The fluid enters at the top connection and leaves at the  
bottom connection. Procedures for making the connections are  
the same as for the 30MPW condensers. See 30MPW Con-  
denser section on page 7 for more details.  
Run the pump for 10 minutes, then clean the strainer before  
starting the unit.  
An evaporator flow switch is standard on all units. This is a  
thermal dispersion type switch that is installed in the evapora-  
tor fluid outlet. The switch is set to open when the evaporator  
fluid flow drops below the minimum set point.  
For variable primary flow applications, it may be necessary  
to adjust the flow switch set point to avoid nuisance trips. Con-  
tact Carrier service engineering for the mthod needed to adjust  
the switch.  
a30-1245  
See Table 1 for minimum flow rates and loop volume.  
The thermistors used to sense entering and leaving fluid  
temperature are factory-installed in the evaporator entering and  
leaving fluid nozzles.  
Fig. 10 — Install the Victualic Coupling  
AIR SEPARATION — For proper system operation, it is  
essential that water loops be installed with proper means to  
manage air in the system. Free air in the system can cause  
noise, reduce terminal output, stop flow, or even cause pump  
failure due to pump cavitation. For closed systems, equipment  
should be provided to eliminate all air from the system.  
The amount of air that water can hold in solution depends  
on the pressure and temperature of the water/air mixture. Air is  
less soluble at higher temperatures and at lower pressures.  
Therefore, separation can best be done at the point of highest  
water temperature and lowest pressure. Typically, this point  
would be on the suction side of the pump as the water is return-  
ing from the system or terminals. Generally speaking, this is  
the best place to install an air separator, if possible.  
1. Install automatic air vents at all high points in the system.  
(If the 30MP unit is located at the high point of the  
system, a vent can be installed on the piping entering the  
heat exchanger on the ¼-in. NPT female port.)  
2. Install an air separator in the water loop, at the place  
where the water is at higher temperatures and lower  
pressures — usually in the chilled water return piping.  
On a primary-secondary system, the highest temperature  
water is normally in the secondary loop, close to the  
decoupler. Preference should be given to that point on the  
system (see Fig. 13). In-line or centrifugal air separators  
are readily available in the field.  
It may not be possible to install air separators at the place of  
lowest pressure and highest temperature. In such cases, prefer-  
ence should be given to the points of highest temperature. It is  
important that pipe be sized correctly so that free air can be  
moved to the point of separation. Generally, a water velocity of  
at least 2 feet per second will keep free air entrained and  
prevent it from forming air pockets.  
Automatic vents should be installed at all physically elevat-  
ed points in the system so that air can be eliminated during  
system operation. Provision should also be made for manual  
venting during the water loop fill. It is important that the  
automatic vents be located in accessible locations for  
maintenance purposes, and that they be located where they can  
be prevented from freezing.  
3. Install the inside coupling half over the gasket and then  
install the outer half. Connect with nuts and bolts. Tighten  
the nuts equally on both sides. Ensure there is no gap be-  
tween the two halves of the coupling.  
4. Alternately tighten the nuts with a wrench to draw the  
coupling halves together uniformly. The joint is now  
complete.  
30MPW UNITS — In order to minimize the water pressure  
drop in the system, use as few bends as possible in the field  
water piping, and run the lines as short as possible. Size the  
water lines according to the available pump pressure (not neces-  
sarily the connection size), especially on cooling tower applica-  
tions. See Carrier System Design Manual, Part 3, Piping Design.  
See Fig. 11 for condenser pressure drops.  
Set water regulating valve, if installed, to maintain design  
head pressure. Do not adjust to compensate for high head pres-  
sures caused by fouled condensers, excess refrigerant, or the  
presence of noncondensables. Due to changes in water temper-  
ature, it may be necessary to adjust the valve seasonally. After  
adjusting for design head pressure, shut unit down. The water  
regulating valve should shut off the flow of water in a few min-  
utes. If it does not, raise head pressure setting. Make sure that  
the capillary tube from each water regulating valve is connect-  
ed to the proper condenser access fitting.  
Provide a means for draining the system in the winter (if not  
used) and for maintenance.  
Water leaving the condenser is under pressure and should  
not be connected directly into sewer lines. Check local codes.  
EVAPORATOR DESCRIPTION — All 30MP units use a  
brazed-plate heat-exchanger type evaporator. The heat ex-  
changer is constructed essentially the same as the brazed-plate  
condenser used on 30MPW units. See 30MPW Condenser De-  
scription section on page 7 for more details. Similar to the con-  
denser, the evaporator can only be chemically cleaned. See Fig.  
12 for evaporator pressure drops.  
EVAPORATOR PIPING — Plan evaporator fluid piping for  
minimum number of changes in elevation, and for the fewest  
number of bends possible. Install manual or automatic vent  
valve at high points in the line. Maintain system pressure by  
using a pressure tank or a combination of relief and reducing  
valves.  
10  
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ENGLISH  
4
3
1
2
5
40  
35  
30  
25  
20  
15  
10  
5
0
0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240  
GPM  
a30-5036  
SI  
1
5
2
3
4
120  
100  
80  
60  
40  
20  
0
0
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
Liters/second  
LEGEND  
1
2
3
4
5
30MP015  
30MP020  
30MP030  
30MP040  
30MP045  
a30-5037  
Fig. 11 — Condenser Water Pressure Drop  
11  
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ENGLISH  
3
4
1
2
5
40  
35  
30  
25  
20  
15  
10  
5
0
0
10  
20  
30  
40  
50  
60  
70  
80  
90  
100 110 120 130 140 150 160 170 180 190 200  
GPM  
a30-5034  
SI  
3
1  
2
5
4
120  
100  
80  
60  
40  
20  
0
0
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
Liters/second  
LEGEND  
1
2
3
4
5
30MP015  
30MP020  
30MP030  
30MP040  
30MP045  
a30-5035  
Fig. 12 — Evaporator Water Pressure Drop  
12  
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a30-3226  
Distribution Pump  
Decoupler  
Expansion  
Tank(s)  
Air Separator  
with Vent  
NOTE: Expansion tanks must be disconnected for chillers placed parallel in the primary water loop.  
Fig. 13 — Typical Air Separator and Expansion Tank Location on Primary-Secondary Systems  
d. Remove temporary bypass when cleaning is  
complete.  
Step 6 — Fill the Chilled Water Loop  
WATER SYSTEM CLEANING — Proper water system  
cleaning is of vital importance. Excessive particulates in the  
water system can cause excessive pump seal wear, reduce or  
stop flow, and cause damage of other components. Water  
quality should be maintained within the limits indicated in  
Table 2. Failure to maintain proper water quality may result in  
heat exchanger failure.  
Table 2 — Water Quality Characteristics  
and Limitations  
WATER CHARACTERISTIC  
-
QUALITY LIMITATION  
70 – 300 ppm  
Alkalinity (HCO  
2-  
)
3
Sulfate (SO  
)
Less than 70 ppm  
Greater than 1.0  
10 – 500S/cm  
7.5 – 9.0  
4
-
2-  
HCO /SO  
3
4
CAUTION  
Electrical Conductivity  
pH  
Failure to properly clean all piping and components of the  
chilled water system before unit start-up may result in  
plugging of the heat exchanger, which can lead to poor per-  
formance, nuisance alarms and damage from freezing.  
Freezing damage caused by an improperly cleaned system  
represents abuse and may impair or otherwise negatively  
affect the Carrier product warranty.  
Ammonium (NH )  
3
Less than 2 ppm  
Less than 300 ppm  
Less than 1 ppm  
-
Chorides (Cl )  
Free chlorine (Cl )  
2
Hydrogen Sulfide (H S)*  
2
Less than 0.05 ppm  
Less than 5 ppm  
Free (aggressive) Carbon  
Dioxide (CO )†  
2
Total Hardness (dH)  
4.0 – 8.5  
Nitrate (NO )  
3
Less than 100 ppm  
Less than 0.2 ppm  
Less than 0.2 ppm  
Less than 0.1 ppm  
1. Install a temporary bypass around the chiller to avoid cir-  
culating dirty water and particulates into the pump pack-  
age and chiller during the flush. Use a temporary circulat-  
ing pump during the cleaning process. Also, be sure that  
there is capability to fully drain the system after cleaning.  
(See Fig 14.)  
2. Be sure to use a cleaning agent that is compatible with all  
system materials. Be especially careful if the system  
contains any galvanized or aluminum components. Both  
detergent-dispersant and alkaline-dispersant cleaning  
agents are available.  
3. It is a good idea to fill the system through a water meter.  
This provides a reference point for the future for loop  
volume readings, but it also establishes the correct  
quantity of cleaner needed in order to get the required  
concentration.  
4. Use a feeder/transfer pump to mix the solution and fill the  
system. Circulate the cleaning system for the length of  
time recommended by the cleaning agent manufacturer.  
Iron (Fe)  
Aluminum (Al)  
Manganese (Mn)  
*Sulfides in the water quickly oxidize when exposed to air, requiring that  
no agitation occur as the sample is taken. Unless tested immediately  
at the site, the sample will require stabilization with a few drops of one  
Molar zinc acetate solution, allowing accurate sulfide determination up  
to 24 hours after sampling. A low pH and high alkalinity cause system  
problems, even when both values are within the ranges shown. The  
term pH refers to the acidity, basicity, or neutrality of the water supply.  
Below 7.0, the water is considered to be acidic. Above 7.0, water is  
considered to be basic. Neutral water contains a pH of 7.0.  
†Dissolved carbon dioxide can either be calculated from the pH and  
total alkalinity values, shown below, or measured on the site using a  
[(6.3-pH)/0.3]  
test kit. Dissolved Carbon Dioxide, PPM = TA x 2  
where TA  
= Total Alkalinity, PPM as CaCO .  
3
FILLING THE SYSTEM — The initial fill of the chilled  
water system must accomplish three purposes:  
1. The entire piping system must be filled with water.  
2. The pressure at the top of the system must be high enough  
to vent air from the system (usually 4 psig is adequate for  
most vents).  
3. The pressure at all points in the system must be high  
enough to prevent flashing in the piping or cavitation in  
the pump.  
The pressure created by an operating pump affects system  
pressure at all points except one — the connection of the  
compression tank to the system. This is the only location in the  
system where pump operation will not give erroneous pressure  
indications during the fill. Therefore, the best location to install  
the fill connection is close to the expansion tank. An air vent  
should be installed close by to help eliminate air that enters  
during the fill procedure.  
a. After cleaning, drain the cleaning fluid and flush the  
system with fresh water.  
b. A slight amount of cleaning residue in the system can  
help keep the desired, slightly alkaline, water pH of 8  
to 9. Avoid a pH greater than 10, since this will  
adversely affect pump seal components.  
c. A side stream filter is recommended (see Fig. 15)  
during the cleaning process. Filter side flow rate  
should be enough to filter the entire water volume  
every 3 to 4 hours. Change filters as often as neces-  
sary during the cleaning process.  
13  
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Step 7 — Make Electrical Connections — All  
field wiring must comply with local code requirements.  
Electrical data for the complete unit and for the compressors is  
shown in Table 3. See Fig. 16 for field wiring connections. A  
field-supplied branch circuit disconnect switch that can be  
locked in either OPEN or OFF position must be installed.  
SYSTEM  
POT FEEDER AND  
TRANSFER PUMP  
DILUTED  
CLEANING  
AGENT  
x
Control circuit power is 24 v on all units. Factory-installed  
control transformer (TRAN 1) uses line voltage for all units.  
All control transformers are factory-installed and wired. For  
208/230-3-60 units operating at 208-3-60 line voltage, TRAN1  
primary connections must be moved to terminals H3 and H4.  
Inside the control box are terminals for field power and ground  
(earth) wiring. A ground wire must be installed with each field  
power supply. Compressors are wired for across-the-line start.  
Refer to Table 3 for electrical data.  
TEMPORARY  
PUMP  
30MPUNIT  
x
a30-5047  
TEMPORARY  
BYPASS  
TO DRAIN  
Fig. 14 — Typical Set Up for Cleaning Process  
FLOW SWITCH — A condenser flow switch is available as  
an accessory for all 30MPW units, and can be field-installed.  
The Carrier flow switch accessory (part no. 30MP-900---004)  
is available for this purpose. Flow switch wiring terminals are  
located in the field wiring compartment of the control box. The  
flow switch should be wired between terminals LVT-16 and  
LVT-17 for all units.  
SYSTEM  
POT FEEDER AND  
TRANSFER PUMP  
DILUTED  
CLEANING  
AGENT  
SIDE  
STREAM  
FILTER  
CONTROL BOX, POWER SECTION — The electrical  
power supply is brought in through the top left-hand side of the  
control box. Pressure-lug connections on the terminal blocks  
are suitable for only for copper conductors.  
The control box power section contains the following  
components:  
x
x
TEMPORARY  
PUMP  
30MPUNIT  
a30-5048  
TEMPORARY  
BYPASS  
power terminal block  
TO DRAIN  
optional disconnect switch  
compressor circuit breaker(s)  
compressor contactor(s)  
current sensor boards  
Fig. 15 — Cleaning Using a Side Stream Filter  
Ensure the following when filling the system:  
1. Remove temporary bypass piping and cleaning/flushing  
equipment.  
2. Check to make sure all drain plugs are installed.  
3. Open the blow-down valve to flush the strainer.  
control transformer  
ground lug  
neutral terminal (380-3-60 units only)  
crankcase heater relay (30MPA units only)  
fuses  
Normally, a closed system needs to be filled only once. The  
actual filling process is generally a fairly simple procedure. All  
air should be purged or vented from the system. Thorough  
venting at the high points and circulation at room temperature  
for several hours is recommended.  
NOTE: Local codes concerning backflow devices and other  
protection of the city water system should be consulted and  
followed to prevent contamination of the public water  
supply. This is especially important when antifreeze is used  
in the system.  
CONTROL BOX, CONTROLS SECTION — The control  
box controls section contains the following components:  
main base board (MBB)  
scrolling marquee display  
optional energy management module  
control-circuit breakers for 24-v circuits  
control-circuit ON-OFF switch  
unit Enable/Off/Remote contact switch  
unit Alarm/Alert indicator light  
CONTROL BOX, FIELD CONTROL WIRING SEC-  
TION — Inside this section is the low-voltage, field-wiring  
Set Water Flow Rate — Once the system is cleaned, pressur-  
ized, and filled, the flow rate through the chiller needs to be  
established.  
terminal strip (LVT). All low-voltage field-wiring connections  
7
are made to this terminal block. There are three / -in. (22 mm)  
8
knockouts provided for field wiring in this section. Connec-  
tions for condenser flow switch, chilled fluid pump interlock,  
condenser pump interlock, remote alarm output, condenser  
output, and dual chiller thermistor accessory are made at these  
locations. See Fig. 16 for specific location of connections.  
NOTE: Carrier recommends a differential pressure gage when  
measuring pressures across the pumps or balancing valves.  
This provides for greater accuracy and reduces error build-up  
that often occurs when subtracting pressures made by different  
gages.  
On primary/secondary systems, it is advisable to set the  
30MP balancing valve to maintain design flow plus 10%  
through the chiller.  
A rough estimate of water flow can also be obtained from  
measuring the pressure drop across the 30MP heat exchanger.  
Figures 11 and 12 show the relationship between gpm and heat  
exchanger pressure drop. It should be noted that these curves  
are for “clean” heat exchangers; they do not apply to heat ex-  
changers with fouling. Adjust the external balancing valve until  
the correct pressure drop is obtained for the required gpm.  
The unit has the capability to control field-supplied devices.  
They are: alarm signal, condenser pump or condenser fan out-  
put, and chilled water pump output. The unit provide 24-v  
power with a minimum 5 va rating per output allowed.  
UNBALANCED 3-PHASE SUPPLY VOLTAGE — Never  
operate a compressor where a phase imbalance in the supply  
voltage is greater than 2%. Use the following formula to deter-  
mine the percent voltage imbalance:  
% Voltage Imbalance =  
max voltage deviation from average voltage  
100 x  
average voltage  
14  
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EXAMPLE: Supply voltage is 240-3-60.  
(AC) 239 – 238 = 1 v  
Maximum deviation is 4 v.  
Determine percent voltage imbalance:  
4
% Voltage Imbalance = 100 x  
239  
AB = 243 v  
BC = 236 v  
AC = 238 v  
= 1.7%  
This amount of phase imbalance is satisfactory as it is below  
the maximum allowable 2%.  
243 + 236 + 238  
Average Voltage  
=
3
IMPORTANT: If the supply voltage phase imbalance  
is more than 2%, contact your local utility company  
immediately.  
= 239 v  
Determine maximum deviation from average voltage:  
(AB) 243 – 239 = 4 v  
(BC) 239 – 236 = 3 v  
Table 3 — Electrical Data — 30MPA,MPW Units  
VOLTAGE*  
Min Max  
COMPRESSOR  
UNIT  
VOLTS  
UNIT SIZE  
NAMEPLATE  
(3 ph, 60 Hz)  
LRA  
(ea.)  
Rec  
30MPA,MPW  
Quantity  
MCA  
66.4  
37.6  
33.1  
27.5  
80.6  
53.4  
40.3  
32.2  
125.6  
76.5  
60.5  
53.3  
ICF  
MOCP  
Fuse  
208/230  
380  
460  
575  
208/230  
380  
460  
575  
208/230  
380  
460  
575  
208/230  
380  
460  
575  
187  
342  
414  
518  
253  
418  
508  
632  
195  
123  
95  
224.5  
139.7  
109.7  
92.2  
274.8  
168.7  
142.9  
94.3  
395.8  
230.0  
205.9  
155.7  
402.6  
192.8  
196.2  
148.8  
90  
50  
45  
35  
110  
70  
50  
45  
80  
45  
40  
35  
90  
60  
45  
40  
150  
90  
70  
60  
015  
020  
030  
040  
045  
2
80  
187  
342  
414  
518  
253  
418  
508  
632  
239  
145  
125  
80  
340  
196  
179  
132  
300  
139  
150  
109  
340  
196  
179  
132  
2
2
3
3
187  
342  
414  
518  
253  
418  
508  
632  
175  
110  
80  
70  
187  
342  
414  
518  
253  
418  
508  
632  
166.7  
87.4  
75.1  
64.7  
200  
110  
90  
200  
100  
90  
80  
70  
208/230  
380  
460  
575  
187  
342  
414  
518  
253  
418  
508  
632  
181.4  
110.5  
87.4  
451.6  
264.0  
232.8  
179.4  
225  
125  
110  
100  
200  
125  
100  
90  
77.0  
LEGEND  
3/0 for unit sizes:  
ICF  
Maximum instantaneous current flow during starting.  
Thousand circular mils  
015,020; 208/230-3-60 voltages.  
020-040; 380-3-60 voltage.  
kcmil  
LRA  
MCA  
Locked rotor amps.  
030-045; 460-3-60 and 575-3-60 voltages.  
2 AWG for unit sizes:  
Minimum circuit amps (for wire sizing). Complies with  
NEC, Section 430-24.  
015; 380-3-60 voltage.  
MOCP  
NEC  
Rec  
Maximum Overcurrent Protection  
National Electrical Code (U.S.A.)  
015-020; 460-3-60 and 575-3-60 voltages.  
3. Additional control circuit power is not required.  
Recommended dual element fuse amps (150% of com-  
pressor RLA). Size up to the next standard fuse size.  
4. Any field modification of factory wiring must be in compliance  
with all applicable codes. Field-installed power wires must be  
rated 75 C minimum.  
Fuse  
*Supply Range — Units are suitable for use on electrical systems  
where voltage supplied to the unit terminals is not below or above  
the listed range limits.  
5. Use copper conductors only.  
6. Control circuit power supply is 24-v single phase. Control  
power is supplied by the factory-installed control transformer.  
NOTES:  
1. All units have one field power terminal block.  
2. Maximum incoming wire size is as follows:  
For units with terminal block:  
350 kcmil for unit sizes 030-045; 208/230-3-60 voltages.  
2/0 for all other unit sizes; all voltages.  
For units with optional non-fused disconnect:  
350 kcmil for unit sizes:  
030-045; 208/230-3-60 voltages.  
045; 380-3-60 voltage.  
15  
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a30-5039  
Copyright 2010 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
Catalog No. 04-53300054-01  
Printed in U.S.A.  
Form 30MP-1SI  
Pg 16  
910  
1-10  
Replaces: New  
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