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Summary of Contents for Carrier AquaForce 30XBV-A0500
- Page 1 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E I N S T R U C T I O N S Liquid chiller with variable speed screw compressor and Greenspeed intelligence...
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Page 2: Table Of Contents
CONTENTS 1 - SYSTEM SAFETY CONSIDERATIONS ............................4 1.1 - Electrical safety considerations ..............................4 1.2 - Refrigerant safety considerations .............................. 4 1.3 - Pressure equipment safety considerations ..........................6 1.4 - Human interventions safety guidelines............................8 2 - INTRODUCTION ..................................11 2.1 - 30XBV-A family range ................................ - Page 3 CONTENTS 12 - OPTIONS ....................................50 12.1 - Option 15: Low Noise ................................51 12.2 - Option 16: High ambient temperature ........................... 51 12.3 - Option 58: Operation of two units as a Lead/Lag pair ......................53 12.4 - Option 70 - Main disconnect switch without fuse ........................54 12.5 - Option 70D: Main disconnect switch with short-circuit protection ..................
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Page 4: System Safety Considerations
1 - SYSTEM SAFETY CONSIDERATIONS 1.2 - Refrigerant safety considerations The units are designed to provide a very high level of safety and reliability. We recommend that standard EN 378-3 Annex 3 is applied. The procedures in this manual are arranged in the sequence The refrigerant used in the units in this range is R134a. - Page 5 1 - SYSTEM SAFETY CONSIDERATIONS 1.2.2 - Refrigerant & Oil charges transfer & storage OPERATING CHECKS: ■ Important: This product contains R134a which is an HFC During refrigerant transfer and storage operations follow applicable regulation. The standard NF E29-795 describes the regulations gas.
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Page 6: Pressure Equipment Safety Considerations
1 - SYSTEM SAFETY CONSIDERATIONS 1.3 - Pressure equipment safety considerations Corrosion build-up Below thickness values are applicable on evaporator shell-and 1.3.1 - Pressure Equipment regulations tube heat exchanger and on oil separator: Refrigerant side: 0 mm These products include pressure equipment or components manufactured by the unit manufacturer or by other manufacturers. - Page 7 ■ Recommissioning of the equipment. Do not install relief valves in series or backwards. The manufacturer recommends contacting Carrier Service for this type of test. An example of the test procedure without removing the pressure switch is given in section “SYSTEM MAINTENANCE”...
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Page 8: Risk Of Explosion
1 - SYSTEM SAFETY CONSIDERATIONS Qualifications requirements 1.3.3 - RISK OF EXPLOSION: Any person authorized to access the unit must be aware of the Oxygen reaction general and special safety precautions for the establishment and must also be qualified and trained in surveillance and maintenance. Never use air or gases containing oxygen during leak tests, Any person carrying out work concerning: to purge pipework or to pressurize a unit. - Page 9 1 - SYSTEM SAFETY CONSIDERATIONS Hot / Cold surfaces Maintenance Some pipes (discharge and liquid lines) as well as the compressors All installation parts must be maintained by the personnel in discharge side can reach temperatures higher than 65°C. Do not charge, in order to avoid material deterioration and injuries to touch those pipes without gloves.
- Page 10 1 - SYSTEM SAFETY CONSIDERATIONS Hydraulic circuit interventions Do not drain the heat transfer medium circuits without informing the installation technical department or other competent body first. Close the shut-off valves on the water inlet and outlet and drain the unit's hydraulic circuit before working on the components installed on the hydraulic circuit (screen filter, pump, water flow sensor, etc.). Do not loosen the water box bolts until the water boxes have been completely drained.
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Page 11: Introduction
2 - INTRODUCTION 2.1 - 30XBV-A family range 2.2 - Units Utilization 30XBV-A family consists of 12 units sizes. Application Range 10 units consist of one single piece (single units): The units are intended to cool water for building air conditioning ■... -
Page 12: Structural & Acoustical Description
3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.1 - Handling & Positioning 3.1.2 - Positioning 3.1.1 - Handling Regulations about frigorific units positionning Safety can only be guaranteed if the following instructions are Refer to ISO-5149 and EN-378. carefully followed. Failure to do so may result in damage to the The units are classified as "indirect heat exchange systems" (class ... -
Page 13: Structural & Acoustical System
■ If h < H (2.3 m), minimum S = 3 m. refrigerant type used must be accessible and visible close ■ If h > H or S < 3 m, contact your Carrier distributor to assess to the unit installation area. -
Page 14: Dimensions & Clearances Drawings
3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3 - Dimensions & Clearances Drawings 3.3.1 - Single Module Units 3.3.1.1 - 30XBV-A 0500/0600 5591 HT 2258 HT 2000 1500 3.3.1.2 - 30XBV-A 0700 2258 HT 6785 HT 1500 1500 NOTES: Legend Drawings are not contractually binding. All dimensions are given in mm, Before designing an installation, consult the certified Cooler water inlet and outlet... - Page 15 3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3.1.3 - 30XBV-A 0800/0900 2258 HT 7979 HT 1500 1500 3.3.1.4 - 30XBV-A 1000 9175 HT 2258 HT 2000 1500 NOTES: Legend Drawings are not contractually binding. All dimensions are given in mm, Before designing an installation, consult the certified Cooler water inlet and outlet dimensional drawings, available on request.
- Page 16 3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3.1.5 - 30XBV-A 1100 2258 HT 10369 HT 1500 1500 3.3.1.6 - 30XBV-A 1200 2258 HT 10363 HT 1500 1500 NOTES: Legend Drawings are not contractually binding. All dimensions are given in mm, Before designing an installation, consult the certified Cooler water inlet and outlet dimensional drawings, available on request.
- Page 17 3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3.1.7 - 30XBV-A 1300 2258 HT 11561 HT 1500 1500 3.3.1.8 - 30XBV-A 1450 12755 HT 2258 HT 1500 1500 NOTES: Legend Drawings are not contractually binding. All dimensions are given in mm, Before designing an installation, consult the certified Cooler water inlet and outlet dimensional drawings, available on request.
- Page 18 3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3.2 - Duplex Units - 30XBV-A 1600 3.3.2.1 - 30XBV-A 1600 – Module 1 7979 HT 2258 HT 1500 1500 3.3.2.2 - 30XBV-A 1600 – Module 2 7979 HT 2258 HT 1500 1500 NOTES: Legend Drawings are not contractually binding.
- Page 19 3 - STRUCTURAL & ACOUSTICAL DESCRIPTION 3.3.3 - Duplex Units - 30XBV-A 1800 3.3.3.1 - 30XBV-A 1800 – Module 1 7979 HT 2258 HT 1500 1500 3.3.3.2 - 30XBV-A 1800 – Module 2 7979 HT 2258 HT 1500 1500 NOTES: Legend Drawings are not contractually binding.
- Page 20 16437 HT 2258 HT VICTAULIC Ø 168.3 VICTAULIC Ø 168.3 7979 HT 7979 HT MODULE 1 MODULE 2 Pipe not supplied by carrier 1029 1023 7920 7920 Space required between Module 1 and Module 2 for coil service (1) For maintenance, if the distance is below 500 mm, the extraction of the final coils between modules is carried out by dismounting the roof of cover of the module ...
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Page 21: Electrical Description
■ The choice of routing and/or insulation characteristics of voltage or excessive phase imbalance constitutes misuse the conductors ensures double electrical insulation. which will invalidate the Carrier warranty. ■ The conductors should be fixed together inside the electrical box to prevent contact between the end of the 4.1.1 - Power cables access routing... - Page 22 After wire sizing has been completed, using the certified Cables with aluminum core require higher cables sections. Please dimensional drawing, the installer must verify the appropriate contact Carrier Service in case of such requirement. means of connection and define any modifications necessary on site. The maximum ambient temperature taken into consideration for this study is 46°C.
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Page 23: Electrical Components
Number of phases feedback for the variable frequency drives is transmitted by Nominal Input Frequency communication via the internal RS485 Bus using the LEN Protocol by the "Carrier controller". Maximum Input Power (400V) 1,96 Nominal Shaft Power Output For the compressors, the variable frequency drives provide the... - Page 24 4 - ELECTRICAL DESCRIPTION 4.3.2 - Units Electrical Data 30XBV-A Single Units 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Power circuit supply Nominal voltage V-ph-Hz 400-3-50 Voltage range 360-440 Input power Maximum operating input power Operating current draw Maximum Current (Un) Maximum Current (Un-10%) 1027...
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Page 25: Electrical Notes
Note: if aspects of an installation require different specifications from those § Technical premises powered from a § residential buildings listed below (or which are not listed), always contact your Carrier dedicated transformer. representative. (2) Category C3 is suitable for use in an industrial environment and is not designed... -
Page 26: Hydraulic Description
5 - HYDRAULIC DESCRIPTION 5.1 - Hydraulic Connections When connecting units to the water distribution pipe work, refer to the certified dimensional drawings supplied with the unit for the dimensions and position of the water inlet and outlet connections. For connection to the hydraulic network, the Victaulic connection or the counter-flange must be removed before all welding ® operations. 5.1.1 - Units Hydraulic Circuit Diagram 1 Module <... - Page 27 5 - HYDRAULIC DESCRIPTION 2 Modules < Legend Customer Hydraulic Circuit - Minimum Additional Components Unit Hydraulic Circuit - Components Flexible Connection Flow rate sensor Temperature sensor Expansion Vessel NOTE: Provides temperature measurement at the heat transfer medium Relief Valve heat exchanger(s) inlet (see Control Manual) Shut-off valve Water purge on water box...
- Page 28 5 - HYDRAULIC DESCRIPTION 5.1.2 - Piping Diameters & Connections Type Hydraulic Connections are all Victaulic clamping clips type. 30XBV-A Single Units 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Inlet Connection Diameter mm | in 127 | 5 127 | 5 152,4 | 6 152,4 | 6 152,4 | 6 152,4 | 6 152,4 | 6 152,4 | 6 152,4 | 6 152,4 | 6 Outlet Connection Diameter mm | in...
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Page 29: Hydraulic Components
(according to the size of the unit and the application). If adjustment is necessary, it must be performed by qualified personnel, approved by Carrier Service. IMPORTANT: The water flow switch for the machine must be operational. The Carrier warranty will be voided if this instruction is not adhered to. -
Page 30: Hydraulic System
■ Products used for the thermal insulation of components during hydraulic connection must have a chemically neutral effect on the surfaces to which they are applied. All original materials supplied by Carrier comply with this requirement. WARNING: ■ If additional equipment is added to the system, the installer must comply with the basic recommendations, especially the minimum and maximum flow rates. -
Page 31: Heat Transfer Medium
- Water boxes - Valves - Piping factory fitted inside each single unit and each module of a duplex unit. 5.4 - Heat Transfer Medium Carrier recommendations: 1. No NH ammonium ions in the water, as these cause 5.4.1 - Material Compatibility significant damage to copper. This is one of the most important factors governing the service life of copper ■... -
Page 32: Frost Protection
5 - HYDRAULIC DESCRIPTION Corrosion 5.4.3 - Fouling ■ To prevent any risk of corrosion by differential aeration, if the ■ If there are particles in the fluid which are liable to foul the hydraulic circuit is drained for a period of more than one month, exchanger, a screen filter must be installed upstream of the blanket the entire circuit with dry and inert gas (nitrogen for pump. The mesh size of this filter must be 1.2 mm. ... -
Page 33: Aeraulic Description
6 - AERAULIC DESCRIPTION 6.1 - Aeraulic Components 6.1.1 - Fan Fans are axial Flying Bird™ 6 VI impeller. They are trained with motors. Each fan is associated to one motor. Refer to section "Fans Motors" for more information about fan motors. According to the Regulation No. -
Page 34: Frigorific Description
Lubrizol Emkarate RL 220H (specification PP 47-13). Heat Transfer Medium Flooded Shell & Tube Heat Exchanger Heat Exchanger (FLHE) Contact Carrier ERCD to purchase oil top-up. Electronic Expansion Valve (EXV Eco) ; CAUTION: Too much oil in the circuit can cause the unit to Economizer Brazed Plates Heat Exchanger (BPHE Eco) malfunction. - Page 35 Depending on applications, silicone cover caps are required to be When one of the HPS sensors opens, the STO (Safe Torque Off) put on condenser coils block fittings. Please contact Carrier Service digital input opens, which instantly suppresses the control for more information. command for the thyristors which manage the supply for the compressor, independently of the on-off commands and 7.1.5 - Evaporation Components...
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Page 36: Frigorific System
54 | 119 59 | 130 62 | 137 84 | 185 83 | 183 86 | 190 86 | 190 113 | 249 Circuit B teqCO Oil Charge Oil for R134a. Contact Carrier ERCD for supplying. Circuit A L | gal 27 | 7,1... -
Page 37: Control Description
8 - CONTROL DESCRIPTION 8.1 - Control Components 8.1.1 - Pressure & Temperature Sensors The unit uses thermistors to measure temperature, and pressure transducers to monitor and control the operation of the system. Refer to the SmartVu™ control manual for more detailed explanations. 8.2 - System Controller Controller Features Human Machine Interface... -
Page 38: System Initial Start-Up
9 - SYSTEM INITIAL START-UP 9.1 - Checks before & after system initial start-up 9.1.4 - Refrigerant & Oil Checks All measures must be taken to ensure that the pressure and After the unit has been received, and before it is started up, it must temperature limits, specifically those listed on the unit nameplates, ... -
Page 39: Commissioning Operation Checks
9 - SYSTEM INITIAL START-UP 9.2 - Commissioning Operation Checks Always ensure you have read and fully understood the operating instructions for the units before starting up the unit, and ensure the following precautions have been taken: ■ Refer to these instructions. ■... -
Page 40: Unit Initial Start-Up Checklist
9 - SYSTEM INITIAL START-UP 9.3 - Unit initial start-up checklist Preliminary information Job name: ....................................... Location: ......................................... Installing contractor: ....................................Distributor: ......................................Equipment Model #: ........................................Compressors Module 1 Module 2 Model no..................Model no..................Serial number ................Serial number ................ - Page 41 9 - SYSTEM INITIAL START-UP Is there any shipping damage? ................................If so, where? ......................................Will this damage prevent unit start-up? ..............................□ The unit is installed level □ The power supply corresponds to the unit nameplate □ The electrical circuit wiring has been sized and installed correctly □...
- Page 42 WARNING: Operating the chiller with an incorrect supply voltage or excessive phase imbalance constitutes misuse which will invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 10% for current, contact your local electricity supplier immediately and ensure that the chiller is not switched on until corrective measures have been taken.
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Page 43: System Maintenance & Repair
■ Check for any general visible signs of deterioration. A Carrier Service maintenance contract is the best way to ensure ■ If the unit does not operate, check its alarm report (see the the maximum operating life for your equipment and, through the report in the SmartVu™... -
Page 44: Level 2 Maintenance
10 - SYSTEM MAINTENANCE & REPAIR 10.2 - Level 2 maintenance Refrigerant circuit: ■ Keep an up-to-date service booklet specific to the refrigeration See Note above. unit in question. This level requires specific expertise in electrical, hydraulic and ■ The unit is subject to F-gas tight regulatory checks. Please refer mechanical systems. it is possible that this expertise may be to the table in the introduction. -
Page 45: Tightening Torques
10 - SYSTEM MAINTENANCE & REPAIR 10.4 - Tightening Torques 10.4.1 - Tightening Torques for the Main Fastenings Screw type Value [N.m] Structural Fixing & Coverings Panels (Opt 23) Tapping screws D = 4,8mm Fan impeller protection housing Condenser modules fixing Tapping screws D = 6,3mm Fan impeller fixing Pipes supports M6 Taptite screw... -
Page 46: Hydraulic Maintenance & Repair
10 - SYSTEM MAINTENANCE & REPAIR 10.4.2 - Tightening Torques for the Main Electrical 10.5 - Hydraulic Maintenance & Repair Connections WARNING: Filling, topping up, or emptying of the water circuit must be carried out by qualified personnel using the air bleed Tightening Torques for the Main Electrical Connections of devices and tools and equipment suitable for the products. -
Page 47: Aeraulic Maintenance & Repair
Don't forget to remove protections after cleaning operations. During periodic inspections, check the condition of the ventilation grilles on the variable frequency drive door; ensure that they are not pierced, damaged or obstructed. For any other alarm or problem relating to the variable frequency drive, contact Carrier Service. -
Page 48: Frigorific Circuit Maintenance & Repair
The oil filter is specified to provide a high level of filtration (5 µ), top of the cabinet: Please contact Carrier Service. Similarly, necessary for ensuring the compressor has a long service life. precautions must be taken for handling, as the variable frequency drives are very heavy (between 65kg and 120kg, depending on The filter should be checked after the first 500 hours of operation, ... -
Page 49: System Final Shutdown
11 - SYSTEM FINAL SHUTDOWN The unit is fully or partially recyclable. After use, it may contain refrigerant vapors and oil residues. Some parts are painted. 11.1 - Shutting down Separate the units from their energy sources, allow them to cool then drain them completely. 11.2 - Recommendations for disassembly Use the original lifting equipment. -
Page 50: Options
12 - OPTIONS Option N° Description Advantage 30XBV-A Aesthetic and sound absorbing compressor Low noise level Noise level reduction 0500-1800 enclosure High ambient Electrical components sized for part load Extended unit part-load operation up to 55 °C 0500-1800 temperature operation up to 55°C air ambient ambient temperature Improves aesthetics, protection against intrusion Grilles and enclosure... -
Page 51: Option 15: Low Noise
12 - OPTIONS 12.1 - Option 15: Low Noise 12.1.1 - Structural & Acoustical Description 12.1.1.1 - Structural & Acoustical System Structural & Acoustical Data 30XBV-A Single Units + Option 15 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Weights 4930 |... -
Page 52: Electrical System
12 - OPTIONS 12.2.1.2 - Electrical System Units Electrical Data 30XBV-A Single Units + Option 16 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Power circuit supply Nominal voltage V-ph-Hz 400-3-50 Voltage range 360-440 Input power Maximum operating input power Operating current draw Maximum Current (Un) 1054... -
Page 53: Option 58: Operation Of Two Units As A Lead/Lag Pair
These ranges are given for indicative purpose. Check the operating range Additional sensors for the control of the leaving water temperature to be from Carrier electronic catalogue. connected on channel 1 of the Lag boards of both Lead and Lag unit... -
Page 54: Option 70 - Main Disconnect Switch Without Fuse
12 - OPTIONS 12.4 - Option 70 - Main disconnect switch without fuse 30XBV-A Single Units + Option 70 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Value with upstream electrical protection Rated conditional short circuit current Icc kA rms 30XBV-A Duplex Units + Option 70 1600_1... -
Page 55: Options Cumulation
13 - OPTIONS CUMULATION 13.1 - Options 335 + 16 : 400-3-60Hz power supply + High ambient temperature 13.1.1 - Structural & Acoustical Description 13.1.1.1 - Structural & Acoustical System Structural & Acoustical Data 30XBV-A Single Units + Options 335 + 16 0500 0600 0700... -
Page 56: Electrical Data
13 - OPTIONS CUMULATION 13.1.2.2 - Electrical Data 30XBV-A Single Units + Options 335 + 16 0500 0600 0700 0800 0900 1000 1100 1200 1300 1450 Power circuit supply Nominal voltage V-ph-Hz 400-3-60 Voltage range 360-440 Input power Maximum operating input power Operating current draw Maximum Current (Un) 1112... -
Page 57: Options 15 + 335 + 16 : Low Noise + 400-3-60Hz Power Supply + High Ambient Temperature
13 - OPTIONS CUMULATION 13.2 - Options 15 + 335 + 16 : Low Noise + 400-3-60Hz power supply + High ambient temperature 13.2.1 - Structural & Acoustical Description 13.2.1.1 - Structural & Acoustical System Structural & Acoustical Data 30XBV-A Single Units + Options 15 + 335 + 16 0500 0600 0700... -
Page 58: Appendices
14 - APPENDICES Appendices are provided in the document wallet with the instruction manual. 14.1 - Appendix 1: Declaration of conformity 14.2 - Appendix 2: Wiring diagram 14.3 - Appendix 3: Machine PID 14.4 - Appendix 4: Dimensional drawings... - Page 60 Please contact your sales representative for more information. Order No.: 10819, 05.2024. Supersedes order No.: New. Carrier, Route de Thil - BP49 01120 Montluel Cedex, France. Manufacturer reserves the right to change any product specifications without notice. Printed in the European Union.
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