Factory Testing: 30RAP, 30RB, 30XA, & 30XV

As a part of its ISO approved quality procedures at Carrier’s Charlotte, NC, Commercial
manufacturing facility, every 30RAP, 30RB, 30XA, & 30XV Aqua Series air cooled chiller
package undergoes a complete battery of quality tests before it leaves the factory:

1. Mechanical strength testing:

Each condenser coil, evaporator and compressor is pressure tested as individual components
using a dry air/helium mixture prior to unit assembly.
Once assembled, the entire chiller is again pressurized with dry air/helium to 350 psig with
HFC134a chillers or 656 psig with HFC410a chillers to ensure the structural integrity of the
assembled refrigeration system including braze joints and seals.

2. Leak testing:

Each system is charged with a dry air/helium mixture, and all joints are leak checked.

3. Electrical testing:

Hypot testing is performed on the assembled chiller to ensure electrical insulation integrity.

4. Operational testing:

After the refrigerant charge is added, the chiller is put through a complete automated
“operational test” -- often called a run test “under load” which means water is pumped through
the chillers to provide the most realistic operation test possible.
The test facility allows operation of 60 Hz power with units ranging from 9 to 500 tons capacity.
Operational testing is automated to ensure consistent results.

Operational testing includes the checks for proper operation of the following:

• Microprocessor control operation is confirmed for: o Chilled water temperature control

o Chiller startup, shutdown
o Compressor loading and unloading
o Safety sequences
o Head pressure (fan cycling) control
o Response to inputs (set points, time schedule inputs)
• Thermistors: entering and leaving water, suction temperature: checked for calibration
• Pressure transducers: suction, discharge and oil pressure sensors: are checked for calibration
and proper operation
• Flow sensor: checked for operation
• Pressure switches: checked for calibration
• Fan contactors: check for staging sequence (fan VFDs when present)
• Compressor motor contactors: check compressor wye delta (XA only) start where applicable
• Compressor: check for correct rotation (screw and scroll), loading and unloading
• Fan operation: rotation direction is checked
• Electronic expansion valve: checked for proper response from microprocessor control and
operation over full range
• Economizer (30XA & 30XV): checked for proper response from microprocessor control and
operation over full range
• Evaporator pump and contactor (when applicable)
• Evaporator, crankcase, and pump heater: operational check

Criteria for pass/fails varies from a simple “yes/no” to some values that vary by chiller size and
voltage.
The operational test is very thorough. A report is included in each chiller control panel to confirm
testing has been completed (see sample below).