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Carrier AQUAFORCE 30XA080-500 Installation Instructions Manual

Air-cooled liquid chillers
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Step 1 - Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . 1
Step 2 - Place, Mount and Rig Unit. . . . . . . . . . . . . 2
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
• DUAL CHILLER CONTROL
• COOLER PUMP CONTROL
Step 4 - Fill the Chilled Water Loop . . . . . . . . . . . . 56
• SYSTEM PRESSURIZATION
• FILLING THE SYSTEM
• SET WATER FLOW RATE
• PUMP MODIFICATION/TRIMMING
• FREEZE PROTECTION
• PREPARATION FOR WINTER SHUTDOWN
• NON-CCN COMMUNICATION WIRING
• FIELD CONTROL OPTION WIRING
• DUAL CHILLER LEAVING WATER SENSOR
Step 6 - Install Accessories . . . . . . . . . . . . . . . . . . . . 77
• ENERGY MANAGEMENT MODULE
• MINIMUM LOAD ACCESSORY
• COMMUNICATION ACCESSORIES
• CONTROL TRANSFORMER
Step 7 - Leak Test Unit . . . . . . . . . . . . . . . . . . . . . . . . . 77
Step 8 - Refrigerant Charging . . . . . . . . . . . . . . . . . . 77
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300026-01

Installation Instructions

Page
Printed in U.S.A.
Air-Cooled Liquid Chillers

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be
hazardous due to system pressures, electrical components, and
equipment location. Only trained, qualified installers and service
mechanics 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.
WARNING
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.
IMPORTANT: This equipment generates, uses, and
can radiate radio frequency energy and if not installed
and used in accordance with these instructions may
cause radio interference. It has been tested and found
to comply with the limits of a Class A computing
device as defined by FCC (Federal Communications
Commission, U.S.A.) regulations, Subpart J of Part 15,
which are designed to provide reasonable protection
against such interference when operated in a commer-
cial environment.

INTRODUCTION

These instructions cover installation of 30XA080-500 air-
cooled liquid chillers with electronic controls and units with
factory-installed options (FIOPs). See Fig. 1.

INSTALLATION

If the unit is to be stored for a period of time be-

Storage -

fore installation or start-up, be sure to protect the machine
from construction dirt. Keep protective shipping covers in
place until the machine is ready for installation.

Step 1 - Inspect Shipment -

age upon arrival. If damage is found, immediately file a claim
with the shipping company, and contact your local Carrier
representative.
Form 30XA-10SI
Pg 1
AQUAFORCE
30XA080-500
Inspect unit for dam-
11-09
Replaces: 30XA-5SI
®

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Summary of Contents for Carrier AQUAFORCE 30XA080-500

  • Page 1: Table Of Contents

    Step 1 — Inspect Shipment — age upon arrival. If damage is found, immediately file a claim with the shipping company, and contact your local Carrier representative. Printed in U.S.A. Form 30XA-10SI...

  • Page 2: Step 2 - Place, Mount And Rig Unit

    Step 2 — Place, Mount, and Rig the Unit — When considering a location for the unit, be sure to consult NEC (National Electrical Code, U.S.A.) and/or local code requirements. Allow sufficient space for airflow, wiring, pip- ing, and service. See Fig. 2-14. NOTE: To facilitate refrigerant vent piping, all units have fus- ible plugs with in.
  • Page 3 30XA – AquaForce® Air-Cooled Chiller Design Series Unit Sizes 080 140 240 350 090 160 260 400 100 180 280 450 110 200 300 500 120 220 325 Voltage 1 – 575-3-60 2 – 380-3-60 4 – 230-3-60 6 – 460-3-60 7 –...
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  • Page 30 MOUNTING WEIGHT (lb) 30XA MCHX CONDENSER COILS UNIT SIZE 1947 1673 1670 1943 MOUNTING WEIGHT (lb) MCHX CONDENSER COILS 30XA UNIT SIZE 1201 2043 1226 2098 1239 2136 1006 1272 2174 1007 MOUNTING WEIGHT (lb) MCHX CONDENSER COILS 30XA UNIT SIZE 1897 1444 1181...
  • Page 31 30XA080 COOLER SIDE a30-4419 COMPRESSOR SIDE 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE 30XA140,160 COOLER SIDE a30-4421 COMPRESSOR SIDE 30XA180,200 COOLER SIDE a30-4422 COMPRESSOR SIDE Fig. 15A — Unit Mounting Weights (Units with MCHX Condenser Coils) (cont) 30XA220-300 COOLER SIDE a30-4423 COMPRESSOR SIDE 30XA325-350 COOLER SIDE...
  • Page 32 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE LEGEND MCHX — Microchannel Heat Exchanger Fig. 15A — Unit Mounting Weights (Units with MCHX Condenser Coils) (cont) SINGLE PUMP UNITS — ENGLISH MOUNTING WEIGHT (lb) MCHX CONDENSER COILS 1201 2754...
  • Page 33 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE LEGEND MCHX — Microchannel Heat Exchanger Fig. 15A — Unit Mounting Weights (Units with MCHX Condenser Coils) (cont) DUAL PUMP UNITS — ENGLISH MOUNTING WEIGHT (lb) MCHX CONDENSER COILS 1201 2962...
  • Page 34 MOUNTING WEIGHT (lb) — Al/Cu* 30XA UNIT SIZE 2059 1785 1778 2051 MOUNTING WEIGHT (lb) — Al/Cu* 30XA UNIT SIZE 1273 2188 1023 1299 2244 1054 1312 2284 1079 1346 2322 1082 MOUNTING WEIGHT (lb) — Al/Cu* 30XA UNIT SIZE 2007 1554 1254...
  • Page 35 30XA080 COOLER SIDE a30-4419 COMPRESSOR SIDE 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE 30XA140,160 COOLER SIDE a30-4421 COMPRESSOR SIDE 30XA180,200 COOLER SIDE a30-4422 COMPRESSOR SIDE Fig. 15B — Unit Mounting Weights (Units with Al/Cu Condenser Coils) (cont) 30XA220-300 COOLER SIDE a30-4423 COMPRESSOR SIDE 30XA325-350 COOLER SIDE...
  • Page 36 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE *Condenser Coil: Aluminum Fins/Copper Tubing. 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE Fig. 15B — Unit Mounting Weights (Units with Al/Cu Condenser Coils) (cont) SINGLE PUMP UNITS — ENGLISH MOUNTING WEIGHT (lb) —...
  • Page 37 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE *Condenser Coil: Aluminum Fins/Copper Tubing. 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE Fig. 15B — Unit Mounting Weights (Units with Al/Cu Condenser Coils) (cont) DUAL PUMP UNITS — ENGLISH MOUNTING WEIGHT (lb) —...
  • Page 38 MOUNTING WEIGHT (lb) — Cu/Cu* 30XA UNIT SIZE 2244 1970 1956 2228 MOUNTING WEIGHT (lb) — Cu/Cu* 30XA UNIT SIZE 1394 2429 1144 1420 2485 1174 1433 2525 1200 1467 2563 1202 MOUNTING WEIGHT (lb) — Cu/Cu* 30XA UNIT SIZE 2188 1735 1058...
  • Page 39 30XA080 COOLER SIDE 30-4419 COMPRESSOR SIDE 30XA090-120 COOLER SIDE 30-4420 COMPRESSOR SIDE 30XA140,160 COOLER SIDE 30-4421 COMPRESSOR SIDE 30XA180,200 COOLER SIDE 30-4422 COMPRESSOR SIDE Fig. 15C — Unit Mounting Weights (Units with Cu/Cu Condenser Coils) (cont) 30XA220-300 COOLER SIDE a30-4423 COMPRESSOR SIDE 30XA325-350 COOLER SIDE...
  • Page 40 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE *Condenser Coil: Copper Fins/Copper Tubing. 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE Fig. 15C — Unit Mounting Weights (Units with Cu/Cu Condenser Coils) (cont) SINGLE PUMP UNITS — ENGLISH MOUNTING WEIGHT (lb) —...

  • Page 41: Rigging Unit

    30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE 30XA UNIT SIZE *Condenser Coil: Copper Fins/Copper Tubing. 30XA090-120 COOLER SIDE a30-4420 COMPRESSOR SIDE Fig. 15C — Unit Mounting Weights (Units with Cu/Cu Condenser Coils) (cont) RIGGING UNIT (See Fig. 16-18) — The 30XA080-500 units are designed for overhead rigging and it is important that this method be used.
  • Page 42 Number of Passes Plus 1 Pass, Inlet and Outlet, Victaulic (in.) Number of Passes CONDENSER FANS Fan Speed (rpm) Standard/High Ambient** No. Blades...Diameter (in.) No. Fans (Ckt A/Ckt B/Ckt C) Total Airflow (cfm) 850 rpm Total Airflow (cfm) 1140 rpm CONDENSER COILS No.
  • Page 43 Number of Passes Plus 1 Pass, Inlet and Outlet, Victaulic (in.) Number of Passes CONDENSER FANS Fan Speed (r/s) Standard/High Ambient** No. Blades...Diameter (mm) No. Fans (Ckt A/Ckt B/Ckt C) Total Airflow (L/s) 14.2 r/s Total Airflow (L/s) 19.0 r/s CONDENSER COILS No.
  • Page 44 ALL PANELS MUST BE IN PLACE WHEN RIGGING. DO NOT ATTEMPT TO FORK THESE UNITS IF NO SKID IS SUPPLIED. NOTES: 1. 1.50 dia. (38.1mm) lifting holes provided for field supplied clevis. 2. Rig with a minimum of 25 ft (7620mm) length chains or cables. 3.
  • Page 45 ALL PANELS MUST BE IN PLACE WHEN RIGGING. DO NOT ATTEMPT TO FORK THESE UNITS IF NO SKID IS SUPPLIED. NOTES: 1. 1.50 dia. (38.1mm) lifting holes provided for field supplied clevis. 2. Rig with a minimum of 25 ft (7620mm) length chains or cables. 3.
  • Page 46 CAUTION - NOTICE TO RIGGERS: ALL PANELS MUST BE IN PLACE WHEN RIGGING. DO NOT ATTEMPT TO FORK THESE UNITS IF NO SKID IS SUPPLIED. NOTES: 1. 1.50 dia. (38.1mm) lifting holes provided for field supplied clevis. 2. Rig with a minimum of 25 ft (7620mm) length chains or cables. 3.
  • Page 47 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 or appropriate ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) handbook for details.
  • Page 48 a30-4413...
  • Page 49 CONTROL MASTER CHILLER CONTROL SLAVE CHILLER DUAL CHILLER LWT SENSORS & WELLS Fig. 21 — Parallel Dual Chiller Operation CONTROL SLAVE CHILLER CONTROL MASTER CHILLER a30-4418 Fig. 22 — Series Dual Chiller Operation PUMP & CHECK VALVE OR ISOLATION VALVE PUMP &...
  • Page 50 FLOW SWITCH Fig. 23 — Flow Switch INSIDE OUTSIDE LEGEND — Drain, -in. NPT D — Drain, -in. NPT — Expansion Tank Connection, -in. NPT FS — Flow Switch PP — Pipe Plug, -in. NPT PT — Pressure/Temperature Tap — Leaving Water Thermistor —...

  • Page 51: Units With A Hydronic Pump Package

    LEGEND — Drain, -in. NPT D — Drain, -in. NPT — Expansion Tank Connection, FS — Flow Switch PP — Pipe Plug, -in. NPT PT — Pressure/Temperature Tap — Leaving Water Thermistor — Entering Water Thermistor — Vent, -in. NPT *Field-supplied and installed.

  • Page 52: Units Without A Hydronic Pump Package

    The combination valve performs the following functions: • drip-tight shut-off valve • spring closure design with a non-slam check valve • flow-throttling valve When facing the cooler side of unit, the inlet (return) water connection is on the bottom. The outlet (supply) water connec- tion is on the top.

  • Page 53: Brine Units

    LEGEND — Drain, -in. NPT FS — Flow Switch PP — Pipe Plug, -in. NPT — Leaving Water Thermistor — Entering Water Thermistor — Vent, -in. NPT Fig. 28 — Typical Piping Diagram on 30XA Units without Hydronic Package IMPORTANT: Automatic vents should be located in accessible locations for maintenance purposes and protected from freezing.
  • Page 54 Contact your local Carrier representative for more information. † For applications requiring cooler entering water temperature operation at less than 45 F (7.2 C), contact your local Carrier representative for unit selection using the Carrier electronic catalog. MINIMUM 40 F (4.4 C)
  • Page 55 Low Ambient Temperature Head Pressure Control — If the unit is equipped with the low ambient temperature head pres- sure control option, field-fabricated and field-installed wind baffles are required if the wind velocity is anticipated to be greater than 5 mph (8 km/h). Two different baffles may be re- quired, facing the control box.

  • Page 56: Step 4 - Fill The Chilled Water Loop

    FILTER a30-4412 Fig. 32 — Cleaning Using a Side Stream Filter The Carrier ComfortLink™ controls provided have a built- in feature to remind building owners or operators to clean the strainer at a pre-set time interval. Properly installed, cleaned and maintained systems will rarely need the strainer cleaned after the initial fill.
  • Page 57 Trimming section. See below for the type of combination valve in 30XA units with the optional hydronic package. 30XA UNIT SIZE 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.
  • Page 58 30XA090,100 a30-4431 30XA110 a30-4432 30XA120 a30-4433 Fig. 33 — 30XA090-160 Single Pump Envelope Curves a30-4434 a30-4435 Selection 30XA140 30XA160 Pump Single 5HP Single 7.5HP Single 10HP Single 15HP...
  • Page 59 30XA090,100 a30-4436 30XA110 a30-4437 30XA120 a30-4438 Fig. 34 — 30XA090-160 Dual Pump Envelope Curves a30-4439 a30-4440 Selection 30XA140 30XA160 Pump Dual 5HP Dual 7.5HP Dual 10HP Dual 15HP...
  • Page 60 Head Pressure (m) ft of Fluid 6.19 in (45.7) 150 5.75 in (36.6) 120 5.50 in 5.25 in 5.00 in (27.4) 90 4.75 in 4.50 in (18.3) 60 (9.1) 30 (0.0) 0 a30-4441 0.00 LEGEND NPSHr — Net Positive Suction Head (Pressure) Required NOTE: Refer to Fig.
  • Page 61 –20 F (–29 C), except in the case of a power failure. The Carrier warranty does not cover damage due to freezing. All units are equipped with cooler heaters. Units are protect- ed from freezing down to 0°...

  • Page 62: Step 5 - Make Electrical Connections

    This is also required for the negative and signal ground pins of each system element. Wiring connections for CCN (Carrier Comfort Network) should be made at TB (terminal block) 3.
  • Page 63 GROUND AMPS SHLD SWITCH WATT WATT GROUND STEP LIMIT DEMAND OVERRIDE OCCUPANCY MLV-B DONE MLV-A MLV-C STEP LIMIT DEMAND (10K) TEMP SPACE LOCKOUT REMOTE GENERATOR LIMIT SIGNAL CAPACITY 4-20 GENERATOR SIGNAL RESET 4-20 SETPOINT...
  • Page 64 Table 5 — 30XA080-500 Electrical Data, Single Point (Standard Condenser Fan Motors) UNIT VOLTAGE NO HYDRONIC PACKAGE NUMBER UNIT Supplied V-Hz 30XA COND MOCP (3 Ph) Min Max FANS 230-60 207 315.5 200-60 187 347.6 460-60 414 157.7 575-60 518 121.2...
  • Page 65 Table 5 — 30XA080-500 Electrical Data, Single Point (Standard Condenser Fan Motors) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND (3 Ph) FANS 230-60 200-60 460-60 575-60 380-60 230-60 364.4 200-60 401.6 460-60 182.2 575-60 140.6 380-60 212.9 230-60 395.0...
  • Page 66 Table 6 — 30XA080-500 Electrical Data, Dual Point (Standard Condenser Fan Motors) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND MOCP (3 Ph) Min Max FANS 230-60 207 253 173.3/173.3 250/ 250 342.0/342.0 1028.0/1028.0 225/225 200-60 187 220 190.9/190.9 300/ 300 392.9/392.9 1181.9/1181.9 250/250 460-60 414 506 86.6/ 86.6 125/ 125 171.0/171.0...
  • Page 67 Table 6 — 30XA080-500 Electrical Data, Dual Point (Standard Condenser Fan Motors) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND MOCP (3 Ph) Min Max FANS 230-60 207 253 — 200-60 187 220 — 460-60 414 506 — 575-60 518 633 —...
  • Page 68 Table 6 — 30XA080-500 Electrical Data, Dual Point (Standard Condenser Fan Motors) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND (3 Ph) FANS 230-60 200-60 460-60 575-60 380-60 230-60 200-60 460-60 575-60 380-60 230-60 200-60 460-60 575-60 380-60 230-60...
  • Page 69 Table 7 — 30XA140-500 Electrical Data, Single Point (High Ambient Option) UNIT VOLTAGE NO HYDRONIC PACKAGE NUMBER UNIT Supplied V-Hz 30XA COND MOCP (3 Ph) Min Max FANS 230-60 207 562.0 200-60 187 618.8 460-60 414 281.0 575-60 518 216.3 380-60 342 328.3 230-60 207...
  • Page 70 Table 7 — 30XA140-500 Electrical Data, Single Point (High Ambient Option) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND (3 Ph) FANS 230-60 592.4 200-60 652.4 460-60 296.2 575-60 228.4 380-60 346.7 230-60 673.1 200-60 740.5 460-60 335.7 575-60 259.4 380-60 393.3...
  • Page 71 Table 8 — 30XA140-500 Electrical Data, Dual Point (High Ambient Option) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND MOCP (3 Ph) Min Max FANS 230-60 207 253 383.8/211.9 600/ 300 660.8/391.2 200-60 187 220 422.6/233.3 700/ 350 756.7/447.8 460-60 414 506 191.9/105.9 300/ 150 330.4/195.6 575-60 518 633 147.7/ 81.4 225/ 125 263.9/156.3...
  • Page 72 Table 8 — 30XA140-500 Electrical Data, Dual Point (High Ambient Option) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND (3 Ph) Min Max FANS 230-60 207 253 383.8/235.1 600/350 660.8/414.4 200-60 187 220 422.6/259.0 700/400 756.7/473.4 460-60 414 506 191.9/117.5 300/175 330.4/207.2 575-60 518 633 147.7/ 90.7 225/125 263.9/165.6...
  • Page 73 Table 8 — 30XA140-500 Electrical Data, Dual Point (High Ambient Option) (cont) UNIT VOLTAGE NUMBER UNIT Supplied V-Hz 30XA COND (3 Ph) FANS 230-60 200-60 460-60 575-60 380-60 230-60 200-60 460-60 575-60 380-60 230-60 200-60 460-60 575-60 380-60 230-60 200-60 460-60 575-60 380-60...
  • Page 74 VOLTAGE 30XA TYPE 3 PH 60 Hz SINGLE POINT DUAL POINT SINGLE POINT DUAL POINT SINGLE POINT DUAL POINT SINGLE POINT DUAL POINT SINGLE POINT DUAL POINT *COMBI box is located at the end of the unit. †PEB1 and PEB2 boxes are located on the side of the unit. If both boxes are used, the one on the left (viewing from the front of the boxes) is PEB1. Shaded area means that box is not used on this model.
  • Page 75 LEGEND LRA — Locked Rotor Amps WD — Wye Delta RLA — Rated Load Amps — Across-the-Line *Quantity of fan motors for incoming power supply Circuit 1/Circuit 2. LRA (All Units) LRA (All Units) High Ambient Standard Temp Cond. Fans Cond.
  • Page 76 See Fig. 39. For dual chiller control a CCN bus must be connected between the two modules. See the Carrier Comfort Network Communication Bus Wiring section for additional information. (+) (COM) (-) SHIELD SHIELD Fig.

  • Page 77: Step 6 - Install Accessories

    MINIMUM LOAD ACCESSORY — Contact your local Carrier representative for more details if a minimum load ac- cessory is required for a specific application. For installation details, refer to separate installation instructions supplied with the accessory package.

  • Page 78: Dehydration

    R-134a. The unit should not need to be charged at installation unless a leak was detected in Step 6 — Leak Test Unit section. If dehydration and recharging is necessary, use industry standard practices or refer to Carrier Standard Service Techniques Manual as required.
  • Page 80 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53300026-01 Printed in U.S.A. Form 30XA-10SI Pg 80 12-09A 11-09 Replaces: 30XA-5SI...

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