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30XW-V/30XWHVVariable-Speed Water-Cooled

Liquid Chillers/Variable-Speed

Water-to-Water Heat Pumps

Nominal cooling capacity: 587-858 kWNominal heating capacity: 648-968 kW

50 Hz

Installation, operation and maintenance instructions

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CONTENTS

1 - INTRODUCTION .....................................................................................................................................................................41.1 - Installation safety considerations ...........................................................................................................................................41.2 - Equipment and components under pressure ........................................................................................................................51.3 - Maintenance safety considerations ........................................................................................................................................51.4 - Repair safety considerations ...................................................................................................................................................6

2 - PRELIMINARY CHECKS ......................................................................................................................................................72.1 - Check equipment received ......................................................................................................................................................7

2.2 - Moving and siting the unit .......................................................................................................................................................8

3 - DIMENSIONS, CLEARANCES .............................................................................................................................................9

4 - PHYSICAL AND ELECTRICAL DATA ............................................................................................................................104.1 - Physical data ...........................................................................................................................................................................104.2 - Electrical data .........................................................................................................................................................................104.3 - Short-circuit stability current for all units ........................................................................................................................... 114.4 - Compressor electrical data ....................................................................................................................................................114.5 - Compressor usage ..................................................................................................................................................................11

5 - ELECTRICAL CONNECTION ............................................................................................................................................125.1 - Power supply ...........................................................................................................................................................................125.2 - Voltage phase imbalance (%) ...............................................................................................................................................12

5.3 - Power connection/disconnect switch ....................................................................................................................................125.4 - Recommended wire sections ................................................................................................................................................125.5 - Power cable entry ...................................................................................................................................................................125.6 - Field control wiring ................................................................................................................................................................135.7 - 24 and 230 V power reserve for the user .............................................................................................................................13

6 - APPLICATION DATA ...........................................................................................................................................................136.1 - Operating limits ......................................................................................................................................................................136.2 - Minimum chilled water flow .................................................................................................................................................136.3 - Maximum chilled water flow .................................................................................................................................................146.4 - Condenser water flow rate ...................................................................................................................................................146.5 - Number of passes ..................................................................................................................................................................146.6 - Evaporator and condenser water flow rates .......................................................................................................................14

6.7 - Variable flow evaporator ....................................................................................................................................................... 146.8 - System minimum water volume ........................................................................................................................................... 146.9 - Pressure drop curves ..............................................................................................................................................................15

7 - WATER CONNECTIONS ......................................................................................................................................................167.1 - Operating precautions ...........................................................................................................................................................167.2 - Water connections ..................................................................................................................................................................177.3 - Flow control ............................................................................................................................................................................177.4 - Evaporator and condenser water box bolt tightening .......................................................................................................17

8 - HEAT PUMPS 30XWHV .......................................................................................................................................................178.1 - Physical data for heat pumps ................................................................................................................................................178.2 - Electrical data for heat pumps ..............................................................................................................................................178.3 - Dimensions and clearances for heat pumps ..........................................................................................................................17

8.4 - Operating range for heat pumps ..........................................................................................................................................178.5 - Operating modes for heat pumps .........................................................................................................................................17

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The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract.

This manual applies to the following two variable-speed 30XW unit types:

30XW-V Liquid chillers 30XWHV Heat pumps

For the operation of the control please refer to the Touch Pilot control manual.

9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA ..................................................................................... 189.1 - Compressors............................................................................................................................................................................189.2 - Oil filter ...................................................................................................................................................................................189.3 - Refrigerant ..............................................................................................................................................................................189.4 - Lubricant .................................................................................................................................................................................189.5 - Oil supply solenoid valve.......................................................................................................................................................189.6 - Pressure vessels.......................................................................................................................................................................18

9.7 - High-pressure safety switch ..................................................................................................................................................199.8 - Electronic expansion valve (EXV) ......................................................................................................................................199.9 - Moisture indicator ..................................................................................................................................................................199.10 - Filter drier ............................................................................................................................................................................. 199.11 - Sensors ...................................................................................................................................................................................199.12 - Frequency variator ...............................................................................................................................................................19

10 - OPTIONS ................................................................................................................................................................................20

11 - STANDARD MAINTENANCE ..........................................................................................................................................2111.1 - Level 1 maintenance ............................................................................................................................................................2111.2 - Level 2 maintenance ............................................................................................................................................................2111.3 - Level 3 (or higher) maintenance ........................................................................................................................................2111.4 - Tightening of the electrical connections ............................................................................................................................21

11.5 - Tightening torques for the main bolts and screws ............................................................................................................2211.6 - Evaporator and condenser maintenance ...........................................................................................................................2211.7 - Compressor maintenance ....................................................................................................................................................2211.8 - Frequency variator maintenance ........................................................................................................................................23

12 - START-UP CHECKLIST FOR 30XW-V/30XWHV UNITS (USE FOR JOB FILE) ................................................24

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1 INTRODUCTION

30XW-V/30XWHV units are designed to cool or heat waterfor the air conditioning and heating of buildings andindustrial procsses.

Prior to the initial start-up of the 30XW-V/30XWHV units,the people involved in the on-site installation, start-up,operation, and maintenance of this unit should be thoroughlyfamiliar with these instructions and the specific project

data for the installation site.

30XW-V/30XWHV units are designed for a very high level ofsafety during installation, start-up, operation and maintenance.

They will provide safe and long-lasting service when operatedwithin their application range.

This manual provides the necessary information to fami-liarize yourself with the control system before performingstart-up procedures. The procedures in this manual arearranged in the sequence required for machine installation,

start-up, operation and maintenance.

Always ensure that all required safety measures are followed,including those in this document, such as: wearing protec-tive clothing (gloves, ear defenders, safety glasses and shoes)using appropriate tools, employing qualified and skilledtechnicians (electricians, refrigeration engineers) andfollowing local regulations.

To find out, if these products comply with Europeandirectives (machine safety, low voltage, electromagneticcompatibility, equipment under pressure etc.) check the

declarations of conformity for these products.

1.1 - Inttion fet conidertion

Access to the unit must be reserved to authorised personnel,qualified and trained in monitoring and maintenance. Theaccess limitation device must be installed by the customer(e.g. cut-off, enclosure).

After the unit has been received and is ready to be installedor reinstalled and before it is started up, it must be inspectedfor damage. Check that the refrigerant circuit(s) is (are)intact, especially that no components or pipes have shifted

(e.g. following a shock). If in doubt, carry out a leak tightnesscheck and verify with the manufacturer that the circuitintegrity has not been impaired. If damage is detected uponreceipt, immediately file a claim with the shipping company.

Carrier strongly recommends employing a specialisedcompany to unload the machine.

It is compulsory to wear personal protection equipment.Do not remove the skid or the packaging until the unit isin its final position. These units can be moved with a fork

lift truck, as long as the forks are positioned in the rightplace and direction on the unit.

The units can also be lifted with slings, using only thedesignated lifting points marked on the unit.

Use slings or lifting beams with the correct capacity, andalways follow the lifting instructions on the certifieddrawings supplied with the unit. Do not tilt the unit morethan 15.

Safety is only guaranteed, if these instructions are carefullyfollowed. If this is not the case, there is a risk of materialdeterioration and injuries to personnel.

Never cover any protection devices.

This applies to the safety valves (if used) in the refrigerantor heat transfer medium circuits, the fuse plugs and thepressure switches.

Ensure that the valves are correctly installed, beforeoperating the unit.

If the relief valves are installed on a change-over manifold,this is equipped with a relief valve on each of the twooutlets. Only one of the two relief valves is in operation,the other one is isolated. Never leave the change-over

valve in the intermediate position, i.e. with both waysopen (locate the control element in the stop position). If arelief valve is removed for checking or replacement pleaseensure that there is always an active relief valve on eachof the change-over valves installed in the unit.

All factory-installed relief valves are lead-sealed to preventany calibration change.

The external safety valves and the fuses are designed andinstalled to ensure damage limitation in case of a fire.

In accordance with the regulations applied for the design,the European directive on equipment under pressure andin accordance with the national usage regulations: these safety valves and fuses are not safety accessories

but damage limitation accessories in case of a fire, the high pressure switches are the safety accessories.

The relief valve must only be removed if the fire risk isfully controlled and after checking that this is allowed bylocal regulations and authorities. This is the responsibilityof the operator.

The external safety valves must in principle be connected

to discharge pipes for units installed in a room. Refer tothe installation regulations, for example those of Europeanstandards EN 378 and EN 13136.

They include a sizing method and examples for configura-tion and calculation. Under certain conditions these stan-dards permit connection of several valves to the samedischarge pipe. Note: Like all other standards these ENstandards are available from national standards organi-sations.

These pipes must be installed in a way that ensures that

people and property are not exposed to refrigerant leaks.These fluids may be diffused in the air, but far away fromany building air intake, or they must be discharged in aquantity that is appropriate for a suitably absorbingenvironment.

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It is recommended to install an indicating device to showif part of the refrigerant has leaked from the valve. Thepresence of oil at the outlet orifice is a useful indicatorthat refrigerant has leaked. Keep this orifice clean toensure that any leaks are obvious.

The calibration of a valve that has leaked is generallylower than its original calibration. The new calibrationmay affect the operating range. To avoid a nuisancetripping or leaks, replace or re-calibrate the valve.

Periodic check of the relief valves: See paragraph 1.3Maintenance safety considerations.

Provide a drain in the discharge circuit, close to eachrelief valve, to avoid an accumulation of condensate orrain water.

All refrigerant handling precautions must comply withlocal regulations.

Ensure good ventilation, as accumulation of refrigerant

in an enclosed space can displace oxygen and causeasphyxiation or explosions.

Inhalation of high concentrations of vapour is harmfuland may cause heart irregularities, unconsciousness, ordeath. Vapour is heavier than air and reduces the amountof oxygen available for breathing. These products causeeye and skin irritation. Decomposition products arehazardous.

1.2 - Equipment nd component under preure

These products incorporate equipment or components underpressure, manufactured by Carrier or other manufacturers.We recommend that you consult your appropriate nationaltrade association or the owner of the equipment or compo-nents under pressure (declaration, re-qualification, retesting,etc.). The characteristics of this equipment/these componentsare given on the nameplate or in the required documenta-tion, supplied with the products.

See section 9.6 - Pressure vessels.

1.3 - Mintennce fet conidertion

Engineers working on the electric or refrigeration compo-nents must be authorized, trained and fully qualified to do so.

All refrigerant circuit repairs must be carried out by a trainedperson, fully qualified to work on these units. He must havebeen trained and be familiar with the equipment and theinstallation. All welding operations must be carried out byqualified specialists.

The insulation must be removed and heat generation mustbe limited by using a wet cloth.

Any manipulation (opening or closing) of a shut-off valvemust be carried out by a qualified and authorised engineer.These procedures must be carried out with the unit shut-down.

NOTE: The unit must never be left shut down with theliquid line valve closed, as liquid refrigerant can be trappedbetween this valve and the expansion device. (This valveis situated on the liquid line before the filter drier box.)

During any handling, maintenance and service operationsthe engineers working on the unit must be equipped withsafety gloves, glasses, shoes and protective clothing.

Never work on a unit that is still energized.

Never work on any of the electrical components, until thegeneral power supply to the unit has been cut using thedisconnect switch(es) in the control box(es).

If any maintenance operations are carried out on the unit,lock the power supply circuit in the open position aheadof the machine.

ATTENTION: The frequency variators used in the30XW-V/30XWHV units are equipped with capacitorbatteries with a discharge time of twenty (20) minutes

after disconnecting the power. If the discharge circuitinside the capacitor fails, it is not possible to define thedischarge time.

After disconnecting the power to the control box, waittwenty minutes before openeing the control box.

Before any intervention, verify that there is no voltagepresent at any accessible conducting parts of the powercircuit.

If the work is interrupted, always ensure that all circuits

are still deenergized before resuming the work.

ATTENTION: Even if the unit has been switched off, thepower circuit remains energized, unless the unit or circuitdisconnect switch is open. Refer to the wiring diagram forfurther details. Attach appropriate safety labels.

Operating checks:IMPORTANT INFORMATION REGARDING THEREFRIGERANT USED: This product contains fluorinated greenhouse gas

covered by the Kyoto protocol. Refrigerant type: R-134a

Global Warming Potential (GWP): 1300

Periodic inspections for refrigerant leaks may berequired depending on European or local legislation.Please contact your local dealer for more information.

During the life-time of the system, inspection and testsmust be carried out in accordance with nationalregulations.

Protection device checks: If no national regulations exist, check the protection

devices on site in accordance with standard EN378:

once a year for the high-pressure switches, every fiveyears for external safety valves.

The detailed description of the high-pressure switchtest method is given in the service manual for the unit.

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Charging any refrigerant other than the original chargetype (R-134a) will impair machine operation and can evenlead to a destruction of the compressors. The compressorsoperating with this refrigerant type are lubricated with asynthetic polyolester oil.

RISK OF EXPLOSION: Never use air or a gas containingoxygen during leak tests to purge lines or to pressurise amachine. Pressurised air mixtures or gases containingoxygen can be the cause of an explosion. Oxygen reactsviolently with oil and grease.

Never exceed the specified maximum operating pressures.Verify the allowable maximum high- and low-side testpressures by checking the instructions in this manual andthe pressures given on the unit name plate.

Only use dry nitrogen for leak tests, possibly with anappropriate tracer gas.

Do not unweld or flamecut the refrigerant lines or anyrefrigerant circuit component until all refrigerant (liquid

and vapour) has been removed from unit. Traces of vapourshould be displaced with dry air nitrogen. Refrigerant incontact with an open flame produces toxic gases.

The necessary protection equipment must be available,and appropriate fire extinguishers for the system and therefrigerant type used must be within easy reach.

Do not siphon refrigerant.

Avoid contact with liquid refrigerant on the skin orsplashing it into the eyes. Use safety goggles and gloves.

Wash any spills from the skin with soap and water. If liquidrefrigerant enters the eyes, immediately and abundantlyflush the eyes with water and consult a doctor.

Never apply an open flame or live steam to a refrigerantcontainer. Dangerous overpressure can result. If it isnecessary to heat refrigerant, use only warm water.

During refrigerant removal and storage operations followapplicable regulations. These regulations, permittingcondi-tioning and recovery of halogenated hydrocarbonsunder optimum quality conditions for the products andoptimum safety conditions for people, property and the

environment are described in standard NF E29-795.

Any refrigerant transfer and recovery operations must becarried out using a transfer unit. A 3/8 SAE connector onthe manual liquid line valve is supplied with all units forconnection to the transfer station. The units must never bemodified to add refrigerant and oil charging, removal andpurging devices. All these devices are provided with theunits. Please refer to the certified dimensional drawings forthe units.

Do not re-use disposable (non-returnable) cylinders or

attempt to refill them. It is dangerous and illegal. Whencylinders are empty, evacuate the remaining gas pressure,and move the cylinders to a place designated for theirrecovery. Do not incinerate.

At least once a year thoroughly inspect the protectiondevices (valves, pressure switches). If the machine operatesin a corrosive environment, inspect the protection devicesmore frequently.

Regularly carry out leak tests and immediately repairany leaks.

Ensure regularly that the vibration levels remain accep-table and close to those at the initial unit start-up.

Before opening a refrigerant circuit, purge and consult thepressure gauges.

Change the refrigerant when there are equipment failures,following a procedure as the one described in NF E29-795or carry out a refrigerant analysis in a specialist laboratory.

If the refrigerant circuit remains open for longer than a dayafter an intervention (such as a component replacement),the openings must be plugged and the circuit must becharged with nitrogen (inertia principle). The objective is

to prevent penetration of atmospheric humidity and theresulting corrosion on the internal walls and on non-protected steel surfaces.

1.4 - Repir fet conidertion

It is compulsory to wear personal protection equipment.

The insulation must be removed and warming up must belimited by using a wet cloth.

Before opening the unit always ensure that the circuit has

been purged.

If work on the evaporator is required, ensure that the pipingfrom the compressor is no longer pressurised (as the valveis not leaktight in the compressor direction.)

All installation parts must be maintained by the personnel incharge, in order to avoid material deterioration and injuriesto people. Faults and leaks must be repaired immediately.The authorized technician must have the responsibility torepair the fault immediately. Each time repairs have beencarried out to the unit, the operation of the protection devicesmust be re-checked.

Comply with the regulations and recommendations in unitand HVAC installation safety standards, such as: EN 378,ISO 5149, etc.

If a leak occurs or if the refrigerant becomes contaminated(e.g. by a short circuit in a motor) remove the completecharge using a recovery unit and store the refrigerant inmobile containers.

Repair the leak detected and recharge the circuit with thetotal R-134a charge, as indicated on the unit name plate.

Certain parts of the circuit can be isolated. Only chargeliquid refrigerant R-134a at the liquid line.

Ensure that you are using the correct refrigerant typebefore recharging the unit.

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2 PRElIMINaRy CHECks

2.1 - Chec equipment received

Inspect the unit for damage or missing parts. If damageis detected, or if shipment is incomplete, immediatelyfile a claim with the shipping company.

Confirm that the unit received is the one ordered. Thename plate is attached to the outside right-hand sideof the control box.

The unit name plate must include the followinginformation:

- Version number - Model number - CE marking - Serial number

- Year of manufacture and test date - Refrigerant used and refrigerant class - Refrigerant charge per circuit - Containment fluid to be used - PS: Min./max. allowable pressure (high and low

pressure side)

- TS: Min./max. allowable temperature (high andlow pressure side)

- Pressure switch cut-out pressures - Unit leak test pressure - Voltage, frequency, number of phases - Maximum current drawn - Maximum power input - Unit net weight Confirm that all accessories ordered for on-site

installation have been delivered, and are completeand undamaged.

The unit must be checked periodically during its wholeoperating life - if necessary by removing any thermal orsound insulation - to ensure that no shocks (handlingaccessories, tools etc.) have damaged it. If necessary, thedamaged parts must be repaired or replaced. See alsochapter 11 Standard maintenance.

The machine must be installed in a place that is notaccessible to the public or protected against access bynon-authorised persons.

Do not attempt to remove refrigerant circuit componentsor fittings, while the machine is under pressure or while itis running.

Be sure pressure is at 0 kPa and that the unit has beenshut down and de-energised before removing componentsor opening a circuit. If the refrigerant circuit is open tocarry out a repair, all circuit openings must be plugged, ifthe repair takes longer than 30 minutes. This preventshumidity from contaminating the circuit, especially the oil.If the work is expected to take longer, charge the circuitwith nitrogen.

Do not attempt to repair or recondition any safety deviceswhen corrosion or build-up of foreign material (rust, dirt,scale, etc.) is found within the valve body or mechanism.If necessary, replace the device. Do not install safety valvesin series or backwards.

ATTENTION: No part of the unit must be used as awalk-way, rack or support. Periodically check and repairor if necessary replace any component or piping that

shows signs of damage.

The refrigerant lines can break under the weight andrelease refrigerant, causing personal injury.

Do not climb on a machine. Use a platform, or staging towork at higher levels.

Use mechanical lifting equipment (crane, hoist, winch, etc.)to lift or move heavy components. For lighter components,use lifting equipment when there is a risk of slipping orlosing your balance.

Use only original replacement parts for any repair or compo-nent replacement. Consult the list of replacement partsthat corresponds to the specification of the original equip-ment.

Do not drain water circuits containing industrial brines,without informing the technical service department at theinstallation site or a competent body first.

Close the entering and leaving water shutoff valves andpurge the unit water circuit, before working on the compo-nents installed on the circuit (screen filter, pump, water

flow switch, etc.).

Do not loosen the water box bolts until the water boxeshave been completely drained.

Periodically inspect all valves, fittings and pipes of therefrigerant and hydronic circuits to ensure that they donot show any corrosion or any signs of leaks.

It is recommended to wear ear defenders, when workingnear the unit and the unit is in operation.

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Check that ventilation in the plant room is adequate. Check that refrigerant detectors are present. Verify the instructions and directives to prevent the

deliberate removal of refrigerant gases that are harmfulto the environment.

Verify the installation of connections. Verify the supports and fixing elements (materials,

routing and connection). Verify the quality of welds and other joints. Check the protection against mechanical damage. Check the protection against heat. Check the protection of moving parts. Verify the accessibility for maintenance or repair and

to check the piping. Verify the status of the valves. Verify the quality of the thermal insulation and of the

vapour barriers. Check the condition of the insulation of the 400 V

cables.

2.2 - Moving nd iting the unit

2.2.1 - Moving

See chapter 1.1 Installation safety considerations.

CAUTION: Only use slings at the designated liftingpoints which are marked on the unit.

2.2.2 - Siting the unit

Always refer to the chapter Dimensions and clearancesto confirm that there is adequate space for all connectionsand service operations. For the centre of gravity coordinates,the position of the unit mounting holes, and the weightdistribution points, refer to the certified dimensionaldrawing supplied with the unit.

Typical applications of these units are in refrigerationsystems, and they do not require earthquake resistance.Earthquake resistance has not been verified.

Before siting the unit check that: the permitted loading at the site is adequate or that

appropriate strenghtening measures have been taken. the unit is installed level on an even surface (maximum

tolerance is 5 mm in both axes). there is adequate space above the unit for air flow and

to ensure access to the components. the number of support points is adequate and that they

are in the right places. the location is not subject to flooding.

CAUTION: Lift and set down the unit with great care.Tilting and jarring can damage the unit and impair unitoperation.

2.2.3 - Checks before system start-up

Before the start-up of the refrigeration system, the completeinstallation, including the refrigeration system must be veri-fied against the installation drawings, dimensional drawings,system piping and instrumentation diagrams and the wiringdiagrams.

During the installation test national regulations must befollowed. If the national regulation does not specify anydetails, refer to standard EN 378-2 as follows:

External visual installation checks: Compare the complete installation with the refrigeration

system and power circuit diagrams. Check that all components comply with the design

specifications. Check that all protection documents and equipment

provided by the manufacturer (dimensional drawings,P&ID, declarations etc.) to comply with the regulationsare present.

Verify that the environmental safety and protection anddevices and arrangements provided by the manufacturerto comply with the regulations are in place.

Verify that all document for pressure containers, certi-

ficates, name plates, files, instruction manuals providedby the manufacturer to comply with the regulations arepresent.

Verify the free passage of access and safety routes.

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250

100

6FE

600

G 1000

A

00

7

00

7

B

C

900

D

2

1

1

1

D1

D2D3

1

D3D2D1

3 DIMENsIONs, ClEaRaNCEs

30XW-V/30XWHV 580-880

legend:All dimensions are given in mm.

Required clearances for maintenance

Recommended space for tube removal

Water inlet

Water outlet

Power supply connection

NOTES: Drawings are not contractually binding.

Before designing an installation, consultthe certified dimensional drawingssupplied with the unit or available onrequest.

For the positioning of the fixing points,weight distribution and centre of gravitycoordinates refer to the dimensional

drawings.

1

2

Dimenion in mm

a B C D E F G

30XW-V/30XWHV580 1743 968 1087 3059 168.3 168.3 2900

630 1743 968 1087 3059 168.3 168.3 2900

810 1950 1083 1237 3290 219.1 219.1 3100880 1950 1083 1237 3290 219.1 219.1 3100

Evaporator

Condenser

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4 PHysICal aND ElECTRICal DaTa

4.1 - Phic dt

30XW-V/30XWHV 580 630 810 880

Operting weight* kg 3152 3190 4157 4161

sound eve, tndrd unit

Sound power level** dB(A) 105 105 105 105

Sound pressure level at 1 m*** dB(A) 87 87 87 87

sound eve, unit with option 257Sound power level** dB(A) 102 102 102 102

Sound pressure level at 1 m*** dB(A) 84 84 84 84Compreor Semi-hermetic 06T screw compressor, 60 r/s

Circuit A - 1 1 1 1

Refrigernt chrge* R-134a

Circuit A kg 130 125 180 175

Oi chrge SW220 or RL220H

Circuit A l 32 32 36 36

Cpcit contro Touch Pilot, electronic expansion valve (EXV)Minimum capacity % 20 20 20 20

Evportor Multi-tube type oodedNet water volume l 106 106 154 154

Water connections Victaulic

Inlet/outlet**** in 6 6 8 8

Drain and purge (NPT) in 3/8 3/8 3/8 3/8

Maximum water-side operating pressure kPa 1000 1000 1000 1000

Condener Multi-tube typeNet water volume l 112 112 165 165

Water connections Victaulic

Inlet/outlet**** in 6 6 8 8

Drain and purge (NPT) in 3/8 3/8 3/8 3/8

Maximum water-side operating pressure kPa 1000 1000 1000 1000

* Weights are guidelines only. The refrigerant charge is given on the unit nameplate..** 10-12W in accordance with ISO 9614-1

*** In a free eld at full load (ref. 2 x 10-5Pa)**** For options 100C (single-pass evaporator) and 102C (single-pass condenser), please refer to chapter 7.2 - "Water connections"

4.2 - Eectric dt

30XW-V/30XWHV 580 630 810 880Power circuit

Nominal power supply V-ph-Hz 400-3-50Voltage range V 360-440

Contro circuit 24 V via the built-in transformer

strt-up current* A Negligible (lower than maximum current drawn)Power fctor -

At nominal capacity** 0.89 0.90 0.89 0.90

At maximum capacity*** 0.92 0.92 0.92 0.92

Coine phi > 0.98 > 0.98 > 0.98 > 0.98Total harmonic distortion**** % 40 40 40 40

Mximum power input kW 155 193 222 246

Eurovent current drw** A 175 200 240 265

Mximum current drw (Un) A 245 300 346 383

Mximum current drw (Un -10%)*** A 270 330 380 421Mximum power input with option 150B kW 141 173 199 221

Mximum current drw (Un) with option 150B A 222 272 314 348Diipted power*** W 3000 4200 4700 5300

* Instantaneous start-up current.

** Eurovent unit operating conditions: evaporator entering/leaving water temperature = 12C/7C, condenser entering/leaving water temperature = 30C/35C.*** Values obtained at operation with maximum unit power input.

**** The THDI may vary, based on the short-circuit current/max. current draw ratio of the system transformer. In most cases the THDI of the application will be between 35

and 48%. Values obtained at operation with maximum unit power input. Values given on the unit name plate.

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4.3 - short-circuit tbiit current for unit

Short-circuit stability current for all units using the TNsystem (earthing system type): 50 kA (conditional systemshort-circuit current Icc/Icf at the unit connection point asrms value).

All units are equipped with a main disconnect switch locatedin the control box immediately downstream of the unitpower connection point.

4.4 - Compreor eectric dt

Compreor I Nom (a)* I Mx (a)** MHa (a) lRDa (a) Coine phi nom.* Coine phi mx.**06TUX483 178 250 279 1537 0.88 0.9206TUX554 205 315 340 1537 0.89 0.92

06TVX680 245 362 390 2179 0.89 0.9206TVX753 260 400 430 2179 0.89 0.92

* Value at standard Eurovent conditions: evaporator entering/leaving water temperature = 12C/7C, condenser entering/leaving water temperature = 30C/35C.

** Value at maximum capacity and nominal voltage (400 V)

legendMHa - Maximum compressor operating current, limited by the unit (current given for maximum capacity at 360 V)lRDa - Locked rotor current for delta connection

4.5 - Compreor uge

30XW-V/30XWHV 580 630 810 880

06TUX483 A - - -06TUX554 - A - -

06TVX680 - - A -

06TVX753 - - - A

Note, eectric dt nd operting condition - 30XW-V/30XWHV unit

The control box includes the following standard features:

- One main disconnect switch per circuit - Anti-short cycle protection devices

- Control devices

Fied connection: All connections to the system and the electrical installations must be in full

accordance with all applicable codes.

The Carrier 30XW-V/30XWHV units are designed and built to ensure conformancewith local codes. The recommendations of European standard EN 60204-1

(corresponds to IEC 60204-1) (machine safety - electrical machine components- part 1: general regulations) are specically taken into account, when designing

the electrical equipment*.

Annex B of EN 60204 1 describes the electrical characteristics used for theoperation of the machines. The ones described below apply to 30XW-V/30XWHV

units and complement other information in this document:

1. Physical environment**: Environment as classied in EN 60721 (correspondsto IEC 60721):

- indoor installation

- ambient temperature range: minimum temperature +5C to +42C, class AA4 - altitude: lower than or equal to 2000 m

- presence of water: class AD2 (possibility of water droplets)

- presence of hard solids, class 4S2 (no signicant dust present) - presence of corrosive and polluting substances, class 4C2 (negligible)

2. Power supply frequency variation: 2 Hz.3. The neutral (N) line must not be connected directly to the unit (if necessary use

a transformer).

4. Overcurrent protection of the power supply conductors is not provided with the

unit.5. The factory installed disconnect switch(es)/circuit breaker(s) is (are) of a type

suitable for power interruption in accordance with EN 60947-3 (corresponds toIEC 60947-3).

6. The units are designed for connection to TN networks (IEC 60364). In IT networks

the use of noise lters integrated into the frequency variator(s) make machineuse unsuitable. In addition, the short-circuit holding current characteristics have

been modied. Provide a local earth, consult competent local organisations tocomplete the electrical installation.

7. Electromagnetic environment: classication of the electromagnetic environment

is described in standard EN 61800-3 (corresponds to IEC 61800-3): - Immunity to external interference dened by the second environment***

- Interference emission as dened in category C3

Due to the harmonic currents the integrated frequency variator in the 30XW-V/30XWHV units is a source of interference. An analysis may be required to verify

if these interferences exceed the compatibility limits of the other devices

connected to the same power supply network. The compatibility levels insidean electrical installation, that must be met at the in-plant coupling point (IPC) to

which other loads are connected are described in standard 61000-2-4.Two characteristics are required for this analysis:

- The short-circuit ratio (Rsce) of the installation calculated at the in-plant

coupling point (IPC).

- The total harmonic current distortion rate (THDI), calculated for the machine atmaximum capacity.

Note: The evaluation of the compatibility level of harmonic interference on thepublic low-voltage power distribution system can be done using technical

report IEC61000-3-4. In this document the THDI rate of the 30XW-V/30XWHV

units permits a stage 2 connection procedure for any Rsce value above 300:the connection is based on the system data and the material.

Derived currents: If protection by monitoring the leakage currents is necessary

to ensure the safety of the installation, the presence of derived currentsintroduced by the use of frequency variators in the unit must be considered. In

particular the choice the detection type and a control value not lower than 150 mAare recommended to control dierential protection devices.

NOTE: If prticur pect of n ctu inttion do not conform tothe condition decribed bove, or if there re other condition whichhoud be conidered, w contct our oc Crrier repreenttive.

* Generally the recommendations of IEC 60364 are accepted as compliance with

the requirements of the installation directives. Conformance with EN 60204-1is the best means of ensuring compliance with the Machinery Directive.

** The required protection level for this class is IP21B or IPX1B (according to

reference document IEC 60529). All 30XW-V/30XWHV have IP23 units full this

protection condition.*** Example of installations of the second environment: industrial zones, technical

locations supplied from a dedicated transformer. Category C3 is suitable for use in an industrial environment and is not designed

for use in a public low-voltage system that supplies residential locations. As an

option, conformity with category C2 permits this type of installation.

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Motor

A B C

5.3 - Power connection/diconnect witch

All units have one connection point per unit.

5.4 - Recommended wire ection

Wire sizing is the responsibility of the installer, and dependson the characteristics and regulations applicable to eachinstallation site. The following is only to be used as a guide-line, and does not make in any way liable. After wire sizinghas been completed, using the certified dimensional drawing,the installer must ensure easy connection and define anymodifications necessary on site. The connections providedas standard for the field-supplied power entry cables to thegeneral disconnect/isolator switch are designed for thenumber and type of wires, listed in the second column ofthe table below.

The calculations for favourable and unfavourable cases arebased on the maximum current for each unit (see electricaldata tables). For the design the standardised installationmethods in accordance with IEC 60364 are used: multicon-

ductor PVC (70C) or XLPE (90C) insulated cables withcopper core; arrangement to comply with table 52c of theabove standard. The maximum temperature is 42C. The givenmaximum length is calculated to limit the voltage drop to 5%.

5.5 - Power cbe entr

The power cables can enter the control box from abovethe unit. A removable aluminium plate on the upper partof the control box face allows introduction of the cables.Refer to the certified dimensional drawing for the unit.

Minimum nd mximum connectbe wire ection

Mx. connectbewire ection*

Ccution fvourbe ce:Perforted horizont conduit (tndrdied routing No. 13)XlPE inuted cbe

Ccution unfvourbe ce:Coed conduit (tndrdied routing No. 41)PVC inuted cbe, if poibe

30XW-V/30XWHV section, mm(per phase)

section**, mm(per phase)

Mx. ength, m Cbe tpe section**, mm(per phase)

Mx. ength, m Cbe tpe***

580 2 x 240 1 x 120 237 XLPE 1 x 240 420 PVC630 2 x 240 1 x 150 235 XLPE 2 x 185 480 PVC

810 2 x 240 1 x 185 245 XLPE 2 x 240 505 PVC880 2 x 240 1 x 240 275 XLPE 2 x 240 450 PVC

* Connection capacities actually available for each machine, dened according to the connection terminal size, the control box access opening size and the available

space inside the control box.** Selection simultation result considering the hypothesis indicated.

*** If the maximum calculated section is for an XLPE cable type, this means that a selection based on a PVC cable type can exceed the connection capacity actuallyavailable. Special attention must be given to the selection.

Note:The currents considered are given for a machine equipped with a hydronic kit operating at maximum current.

5 ElECTRICal CONNECTION

Please refer to the certified dimensional drawings, suppliedwith the unit.

5.1 - Power upp

The power supply must conform to the specification on theunit nameplate. The supply voltage must be within the rangespecified in the electrical data table. For connection details

refer to the wiring diagrams.

WARNING: Operation of the unit with an improper supplyvoltage or excessive phase imbalance constitutes abusewhich will invalidate the Carrier warranty. If the phaseimbalance exceeds 2% for voltage, or 10% for current,contact your local electricity supplier at once and ensurethat the unit is not switched on until corrective measureshave been taken.

5.2 - Votge phe imbnce (%)

100 x max. deviation from average voltageAverage voltage

Example:

On a 400 V - 3 ph - 50 Hz supply, the individual phasevoltages were measured to be:AB = 406 V; BC = 399 V; AC = 394 V

Average voltage = (406 + 399 + 394)/3 = 1199/3 = 399.7 say 400 V

Calculate the maximum deviation from the 400 V average:

(AB) = 406 - 400 = 6(BC) = 400 - 399 = 1(CA) = 400 - 394 = 6

The maximum deviation from the average is 6 V. Thegreatest percentage deviation is: 100 x 6/400 = 1.5 %

This is less than the permissible 2% and is thereforeacceptable.

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6.2 - Minimum chied wter ow

The minimum chilled water flow is shown in the table inchapter 6.6.

If the system flow is less than the minimum unit flow rate,the evaporator flow can be recirculated, as shown in thediagram.

For minimum chied wter ow rte

legend1 Evaporator2 Recirculation

Evaporator leaving water temperature, C

Condenserleavingwatertemperature,C

2

1

6 aPPlICaTION DaTa

6.1 - Operting imit

30XW-V/30XWHy Minimum Mximum

EvportorEntering temperature at start-up - 35.0C

Leaving temperature during operation 3.3C 20.0C

Entering/leaving temperature d ierence at fu ll load 2.8 K 11.1 K

CondenerEntering temperature at start-up 13.0C* -

Leaving temperature during operation 19.0C* 50.0CEntering/leaving temperature d ierence at fu ll load 2.8 K 11.1 K

* For lower condenser temperatures a water ow control valve must be used atthe condenser (two or three-way valve). Please refer to option 152 to ensure

the correct condensing temperature.

Note: Ambient temperatures: During storage and transport of the 30XW-V/30XWHVunits (including by container) the minimum and maximum permissible temperaturesare -20C and 72C (and 65C for option 200).

5.6 - Fied contro wiring

IMPORTANT: Field connection of interface circuits maylead to safety risks: any control box modification mustmaintain equipment conformity with local regulations.Precautions must be taken to prevent accidental electricalcontact between circuits supplied by different sources: The routing selection and/or conductor insulation

characteristics must ensure dual electric insulation. Conductor fixing between different conductors and/or

inside the control box must prevent accidental discon-nection and uncontrolled conductor displacement,where ends could touch an active energised part.

Refer to the Touch Pilot control manual and the certifiedwiring diagram supplied with the unit for the field controlwiring of the following features.

Available as standard: Customer interlock Remote on/off switch Demand limit external switch

Remote dual set point Alarm and operation report Evaporator pump control Condenser pump control Heating/cooling change-over

Available as an option: Water valve control Various interlocks and reports on the Energy

Management Module (EMM) board Refrigerant leak detection

CCN bus connection The permanent connection to the system CCN bus ismade at the terminal provided for this purpose insidethe control box.

The connection of the CCN service tool is possible at asocket under the control box, accessible from outside.

5.7 - 24 nd 230 V power reerve for the uer

Control circuit reserve:After all required options have been connected, the TCtransformer includes a power reserve of 1 A at 24 V a.c.that can be used for the field control wiring.

A second TCA transformer supplies the 230 V, 50 Hz circuitto charge a battery for a portable computer at 0.63 Amaximum at 230 V. The connection is via an EEC 7/16 typesocket (2 poles without earth) located on the inside frontof the control box and accessible from outside.

Only devices with class II double insulation can be connectedat this socket.

From approx. 50% to full load

Part load limit approx. 50% Minimum load limit approx. 20%

For more precise details please refer to the unit selection program.

15

20

25

30

35

40

45

50

55

0 5 10 15 20

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6.7 - Vribe ow evportor

Variable evaporator flow can be used. The controlled flowrate must be higher than the minimum flow given in thetable of permissible flow rates and must not vary by morethan 10% per minute.

If the flow rate changes more rapidly, the system shouldcontain a minimum of 6.5 litres of water per kW instead of3.25 l/kW.

6.8 - stem minimum wter voume

Whichever the system, the water loop minimum volume isgiven by the formula: Volume = Cap (kW) x N litres

appiction NNormal air conditioning 3.25

Process type cooling 6.5

Where Cap is the nominal system cooling capacity (kW) atthe nominal operating conditions of the installation.

This volume is necessary for stable operation.

It is often necessary to add a buffer water tank to the circuitin order to achieve the required volume. The tank mustitself be internally baffled in order to ensure proper mixingof the liquid (water or brine). Refer to the examples below.

Connection to buer tn

Bad

Bad

Good

Good

6.3 - Mximum chied wter ow

The maximum chilled water flow is limited by the permittedpressure drop in the evaporator. It is provided in the tablein chapter 6.6. Select the option with one water pass less that will

allow a higher maximum water flow rate (see option100C in the table in chapter 6.5).

Bypass the evaporator as shown in the diagram toobtain a lower evaporator flow rate.

For mximum chied wter ow rte

legend1 Evaporator2 Bypass

6.4 - Condener wter ow rte

The minimum and maximum condenser water flow ratesare shown in the table in chapter 6.6.

If the system flow is higher than the maximum unit flow

rate, select the option with one pass less that will allow ahigher maximum water flow rate. Please refer to option102C in the table in chapter 6.5.

2

1

6.5 - Number of pe

30XW-V/30XWHV 580 630 810 880

EvportorStandard 2 2 2 2

Option 100C 1 1 1 1

CondenerStandard 2 2 2 2

Option 102C 1 1 1 1

6.6 - Evportor nd condener wter ow rte

30XW-V/30XWHV 580 630 810 880

Evportor wter ow rte, /Minimum 10 10 13 13

Maximum 54 54 76 76

Condener wter ow rte, /

Minimum 6 6 8 8Maximum 52 52 74 74

Note- Minimum evaporator ow rate based on a water velocity of 0,5 m/s.

- Minimum condenser ow rate based on a water velocity of 0,3 m/s.- Maximum ow rate based on a pressure drop of 120 kPa (units with two evaporator passes and two condenser passes).

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15

10

20

30

40

50

60

70

80

90

100

110

0 10 20 30 40 50 60 70 80 90 100

580 - 630 810 - 880120

3

6

9

12

15

18

21

24

27

30

33

36

0 10 20 30 40 50 60 70 80 90 100

580 - 630 810 - 880

Pressuredrop

,kPa

Water ow rate, l/s

Pressuredrop,kPa

Water ow rate, l/s

Pressuredrop,kPa

Pressuredrop,kPa

6.9 - Preure drop curve

Water ow rate, l/sWater ow rate, l/s

Unit with two evportor pe (tndrd) Unit with one evportor p (option 100C)

Unit with two condener pe (tndrd) Unit with one condener p (option 102C)

10

20

30

40

50

60

70

80

90

100

110

120

0 10 20 30 40 50 60 70 80 90 100

580 - 630 810 - 880

3

6

9

12

15

18

21

24

27

30

33

0 10 20 30 40 50 60 70 80 90 100

580 - 630 810 - 880

36

Sizes Sizes Sizes Sizes

Sizes SizesSizes Sizes

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7 WaTER CONNECTIONs

ATTENTION: Before carrying out any water connectionsinstall the water box purge plugs (one plug per water boxin the lower section - supplied in the control box).

For size and position of the heat exchanger water inlet andoutlet connections refer to the certified dimensional drawingssupplied with the unit.

The water pipes must not transmit any radial or axial forceto the heat exchangers nor any vibration.

The water supply must be analysed and appropriate filtering,treatment, control devices, isolation and bleed valves andcircuits built in, to prevent corrosion, fouling and deteriora-tion of the pump fittings. Consult either a water treatmentspecialist or appropriate literature on the subject.

7.1 - Operting precution

The water circuit should be designed to have the least num-

ber of elbows and horizontal pipe runs at different levels.Below the main points to be checked for the connection: Comply with the water inlet and outlet connections

shown on the unit. Install manual or automatic air purge valves at all

high points in the circuit(s). Use a pressure reducer to maintain pressure in the

circuit(s) and install a safety valve as well as an expan-sion tank.

Install thermometers in both the entering and leavingwater connections.

Install drain connections at all low points to allow the

whole circuit to be drained. Install stop valves, close to the entering and leavingwater connections.

Use flexible connections to reduce the transmission ofvibrations.

Insulate all pipework, after testing for leaks, both toreduce heat gains and to prevent condensation.

Cover the insulation with a vapour barrier. Where there are particles in the fluid that could foul

the heat exchanger, a screen filter should be installedahead of the pump. The mesh size of the filter must be1.2 mm.

Before the system start-up verify that the water circuits

are connected to the appropriate heat exchangers (e.g.no reversal between evaporator and condenser).

Do not introduce any significant static or dynamic pres-sure into the heat exchange circuit (with regard to thedesign operating pressures).

Before any start-up verify that the heat exchange fluidis compatible with the materials and the water circuitcoating.

In case additives or other fluids than those recommend-ed by Carrier are used, ensure that the fluids are notconsidered as a gas, and that they belong to class 2, as

defined in directive 97/23/EC.

Carrier recommendations on heat exchange fluids:

No NH4+ammonium ions in the water, they are verydetrimental for copper. This is one of the most impor-tant factors for the operating life of copper piping. Acontent of several tenths of mg/l will badly corrode thecopper over time.

Cl-Chloride ions are detrimental for copper with a riskof perforations by corrosion by puncture. If possiblekeep below 10 mg/l.

SO42-sulphate ions can cause perforating corrosion, if

their content is above 30 mg/l. No fluoride ions ( 0.5 mmol/l. Values between 1 and2.5 can be recommended. This will facilitate scale depositthat can limit corrosion of copper. Values that are toohigh can cause piping blockage over time. A totalalkalimetric titre (TAC) below 100 mg/l is desirable.

Dissolved oxygen: Any sudden change in water oxy-genation conditions must be avoided. It is as detrimen-tal to deoxygenate the water by mixing it with inertgas as it is to over-oxygenate it by mixing it with pureoxygen. The disturbance of the oxygenation conditionsencourages destabilisation of copper hydroxides andenlargement of particles.

Specific resistance electric conductivity: the higher thespecific resistance, the slower the corrosion tendency.Values above 30 Ohmm are desirable. A neutralenvironment favours maximum specific resistancevalues. For electric conductivity values in the order of

20-60 mS/m can be recommended. pH: Ideal case pH neutral at 20-25C 7 < pH < 8

If the water circuit must be emptied for longer than onemonth, the complete circuit must be placed under nitrogencharge to avoid any risk of corrosion by differential aeration.

ATTENTION: Filling, completing and draining the watercircuit charge must be done by qualified personnel, using theair purges and materials that are suitable for the products.

Charging and removing heat exchange fluids should be

done with devices that must be included on the watercircuit by the installer. Never use the unit heat exchangersto add heat exchange fluid.

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7.3 - Fow contro

Evaporator flow switch and chilled water pump interlock

IMPORTANT: On 30XW-V/30XWHV units, the unitwater flow switch must be energised, and the chilled waterpump interlock must be connected. Failure to follow thisinstruction will void the Carrier guarantee.

The water flow switch is installed on the evaporator waterinlet and adjusted by the control, based on unit size andapplication. If adjustment is necessary, it must be carriedout by qualified personnel trained by Carrier Service.

Terminals are provided for field installation of the chilled

water pump interlock (auxiliary contact for pump operationto be wired on site).

7.4 - Evportor nd condener wter box bottightening

The evaporator (and condenser) are of the shell and tubetype with removable water boxes to facilitate cleaning.Re-tightening or tightening must be done in accordancewith the illustration in the example below.

Wter box tightening equence

legend1 Sequence 1: 1 2 3 4 Sequence 2: 5 6 7 8

Sequence 3: 9 10 11 12 Sequence 4: 13 14 15 16

2 Tightening torque

Bolt size M16 - 171 - 210 Nm

NOTE: Before this operation we recommend draining thecircuit and disconnecting the pipes to be sure that the boltsare correctly and uniformly tightened.

7.2 - Wter connection

The water connections are Victaulic type connections. The inlet and outlet connection diameters are identical.

Inlet/outlet diameters

Evportor 30XW-V/30XWHV 580 630 810 880

Unit without option 100CConnection in 6 6 8 8

Outside diameter mm 168.3 168.3 219.1 219.1

Unit with option 100CConnection in 6 6 8 8

Outside diameter mm 168.3 168.3 219.1 219.1

Condener 30XW-V/30XWHV 580 630 810 880

Unit without option 102CConnection in 6 6 8 8

Outside diameter mm 168.3 168.3 219.1 219.1

Unit with option 102CConnection in 8 8 8 8

Outside diameter mm 219.1 219.1 219.1 219.1

8 HEaT PUMPs 30XWHV

8.1 - Phic dt for het pump

The physical data for 30XWHV for heat pumps are thesame as for the 30XW-V units. Please refer to chapter 4.1.

8.2 - Eectric dt for het pump

The electrical data for 30XWHV for heat pumps are thesame as for the 30XW-V units. Please refer to chapter 4.2.

8.3 - Dimenion nd cernce for het pump

The dimensions and clearances are the same as for the

30XW-V units. Please refer to chapter 3.

8.4 - Operting rnge for het pump

The operating limits are the same as for the 30XW-V units.Please refer to chapter 6.1.

8.5 - Operting mode for het pump

8.5.1 - Cooling mode

This operating mode is the same as that for 30XW-V units.The unit controls on the cooling setpoint.

8.5.2 - Heating mode

Unlike in the cooling mode, the unit uses the heatingsetpoint in this configuration. The evaporator leaving watercontrol (lowest setpoint taken into consideration) is stillmaintained to prevent operation at very low temperatures.

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9.6.2 - Repair

Any repair or modification, including the replacement ofmoving parts: must follow local regulations and be made by qualified

operators and in accordance with qualified procedures,including changing the heat exchanger tubes.

must be made in accordance with the instructions of theoriginal manufacturer. Repair and modification thatnecessitate permanent assembly (soldering, welding,expanding etc.) must be made using the correct proce-dures and by qualified operators.

An indication of any modification or repair must beshown in the monitoring and maintenance file.

9.6.3 - Recycling

The unit is wholly or partly recyclable. After use it containsrefrigerant vapours and oil residue. It is coated by paint.

9.6.4 - Operating life

The evaporator and oil separator are designed for: prolonged storage of 15 years under nitrogen charge

with a temperature difference of 20 K per day.

452000 cycles (start-ups) with a maximum differenceof 6 K between two neighbouring points in the vessel,based on 6 start-ups per hour over 15 years at a usagerate of 57%.

9.6.5 - Corrosion allowances:

Gas side: 0 mmHeat exchange fluid side: 1 mm for tubular plates in lightlyalloyed steels, 0 mm for stainless steel plates or plates withcopper-nickel or stainless steel protection.

9.6.6 - Evaporator

30XW-V/30XWHV units use a flooded multi-tube evaporator.The water circulates in the tubes and the refrigerant is onthe outside in the shell. The tubes are 3/4 diameter copperwith an enhanced surface inside and out. There is just onewater circuit with two water passes (one pass with option100C, please refer to chapter 6.5).The evaporator shell has a polyurethane foam thermalinsulation and a water drain and purge.

It has been tested and stamped in accordance with theapplicable pressure codes. The maximum standard relativeoperating pressure is 2100 kPa for the refrigerant-side and

1000 kPa for the water-side. These pressures can be differentdepending on the code applied. The water connection ofthe heat exchanger is a Victaulic connection.

The products that may be added for thermal insulation ofthe containers during the water piping connection proceduremust be chemically neutral in relation to the materials andcoatings to which they are applied. This is also the case forthe products originally supplied by Carrier.

9 MajOR sysTEM COMPONENTs aND OPERaTIONDaTa

9.1 - Compreor

30XW-V/30XWHV units use 06T geared twin-screwcompressors equipped with a variable capacity slidevalve and controlled by a speed variator.

Compressor capacity control is ensured by successiveuse of speed variation (using a frequency variator) and

swept volume variation at the screws (ensured by theslide valve).

The combination of these two control modes permitsfine control of the unit capacity between 20% and 100%.

The 06T compressor models used are: 06TUX483, 06TUX554, 06TVX680, 06TVX753

9.2 - Oi ter

The 06T screw compressor has an independent oil filter.

9.3 - Refrigernt

30XW-V/30XWHV units only use refrigerant R-134a.

9.4 - lubricnt

The 06T screw compressor is approved for use with lubricants: Castrol Icematic SW220 (Carrier specification PP47-32) Lubrizol Emkarate RL220H (Carrier specification

PP47-13)

9.5 - Oi upp oenoid vve

An oil supply solenoid valve is installed on the oil returnline as standard to isolate the compressor from oil flowwhen the compressor is not operating. The oil solenoidvalve is field replaceable.

9.6 - Preure vee

9.6.1 - General

Monitoring during operation, re-qualification, re-testingand re-testing dispensation: Follow the regulations on monitoring pressurised

equipment. It is normally required that the user or operator sets

up and maintains a monitoring and maintenance file. If no regulations exist or to complement regulations,

follow the control programmes of EN 378. If they exist follow local professional recommendations. Regularly inspect the condition of the coating (paint)

to detect blistering resulting from corrosion. To do this,check a non-insulated section of the container or therust formation at the insulation joints.

Regularly check for possible presence of impurities(e.g. silicon grains) in the heat exchange fluids. Thesemaybe the cause of the wear or corrosion by puncture.

Filter the heat exchange fluid check and carry out

internal inspections as described in EN 378-2, annexe C. In case of re-testing please refer to the maximumoperating pressure given on the unit nameplate.

The reports of periodical checks by the user or operatormust be included in the supervision and maintenance file.

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9.6.7 - Condenser and oil separator

30XW-V/30XWHV units use a heat exchanger that is acombination condenser and oil separator. It is mountedbelow the evaporator. Discharge gas leaves the compressorand flows through an external muffler to the oil separator,which is the upper portion of the heat exchanger. It entersthe top of the separator where oil is removed, and then flowsto the bottom portion of the vessel, where gas is condensedand subcooled. The tubes are 3/4 or 1 diameter internallyand externally finned copper tubes.

There is just one water circuit with two water passes (onepass with option 102C, please refer to chapter 6.5). For theheat pumps the condenser shell can have a polyurethanefoam thermal insulation (option 86) and a water drain andpurge.

It has been tested and stamped in accordance with applicablepressure codes. The maximum standard relative operatingpressure is 2100 kPa for the refrigerant-side and 1000 kPafor the water-side. These pressures can be different dependingon the code applied. The water connection of the heat

exchanger is a Victaulic connection.

9.7 - High-preure fet witch

30XW-V/30XWHV units are equipped with high-pressuresafety switches.

In accordance with the applicable code the high-pressureswitches with manual reset, called PZH (former DBK), arebacked up by high-pressure switches that require resettingwith a tool. The high-pressure switches that require resettingwith a tool are called PZHH (former SDBK). If a PZHH

cuts out, the corresponding PZH in the same compressor isfaulty and must be replaced. The PZHH must be reset witha blunt tool with a diameter of less than 6 mm. Insert thistool into the opening on the pressure switch and push thereset button in this location.

These pressure switches are located at the discharge of eachcompressor. The pressure switch tap does not include aSchrader valve.

9.8 - Eectronic expnion vve (EXV)

The EXV is equipped with a stepper motor (2785 to 3690

steps, depending on the model) that is controlled via theEXV board.

The EXV is also equipped with a sightglass that permitsverification of the mechanism movement and the presenceof the liquid gasket.

9.9 - Moiture indictor

Located on the EXV, permits control of the unit charge andindicates moisture in the circuit. The presence of bubbles inthe sight-glass can indicate an insufficient charge or

non-con-densables in the system. The presence of moisturechanges the colour of the indicator paper in the sight-glass.

9.10 - Fiter drier

The role of the filter drier is to keep the circuit clean andmoisture-free. The moisture indicator shows, when it isnecessary to change the element. A difference in tempera-ture between the filter inlet and outlet shows that theelement is dirty.

9.11 - senor

The units use thermistors to measure the temperature, andpressure transducers to control and regulate system opera-tion (see Touch Pilot control manual for a more detailedexplanation).

9.12 - Frequenc vritor

9.12.1 - General

30XW-V/30XWHV units are equipped with a frequencyvariator that permits compressor capacity adjustment byvarying the motor speed in the 30-60 Hz frequency range.

The compressor drive uses power supply waveform genera-tion with variable frequency and voltage, generated bypulse width modulation (PWM).

Compressor start-up and stopping and the frequency settingfor the operating range is only by RS485 communicationin the LEN protocol via the Carrier controller.

One of the other frequency variator functions is to ensurethe unit safety stop function using wired pressure switchesat the digital drive inputs.

9.12.2 - Main sub-assemblies

Fuses

The fuses ensure fast frequency variator protection if amajor internal fault occurs.

RFI filter

The RFI filter ensures filtering of EMC interference inaccordance with standard IEC 61800-3. The standardfiltration level of 30XW-V/30XWHV units is class C3 mostlyused for operation in industrial environments. For moresevere environments (residential), class C2 is available asan option.

Rectifier bridges and capacitors

These components permit converting a.c. voltage (at theinput) to d.c. voltage. The module also controls capacitorload limitation during start-up. The direct voltage is thenthe basis for waveform generation at the outputs.

Self-balancing DC link smoothing choke (5%)

Choke with the main function of current smoothing (andthereby reducing the peak height and lengthening the diodeconduction time). This results in a large reduction of theharmonic distortion rate (current) to a value between 35 and

40% for operation at maximum power input. This function isoffered as standard for 30XW-V/30XWHV units.

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10 OPTIONs

Option No. Decription advntgeCondenser insulation 86 Thermal condenser insulation Allows conguration with special installation criteria (hot

parts insulated).

Service valve set 92 Valve set consisting of liquid line valve (evaporator inlet) and compressor

suction line valve to isolate the various refrigerant circuit components.

Simplied service and maintenance

Evaporator with one pass 100C Evaporator with one pass on the water-side. Evaporator inlet and

outlet on opposite sides.

Quick and easy installation. Reduced evaporator pressure

losses.

Condenser with one pass 102C Condenser with one pass on the water-side. Condenser inlet and

outlet on opposite sides.

Quick and easy installation. Reduced condenser pressure

losses.

21 bar evaporator 104 Reinforced evaporator for extension of the maximum water-sideservice pressure to 21 bar

Covers applications with a high water column (high buildings)

21 bar condenser 104A Reinforced condenser for extension of the maximum water-side

service pressure to 21 bar

Covers applications with a high water column (high buildings)

Reversed evaporator water

connections

107 Evaporator with reversed water inlet/outlet Simplication of the water piping

Reversed condenser waterconnections

107A Condenser with reversed water inlet/outlet Simplication of the water piping

JBus gateway 148B Two-directional communications board, complies with JBus protocol Easy connection by communication bus to a buildingmanagement system

BacNet gateway 148C Two-directional communications board, complies with BacNetprotocol

Easy connection by communication bus to a buildingmanagement system

LON gateway 148D Two-directional communications board, complies with LON protocol Easy connection by communication bus to a buildingmanagement system

Condensing temperature

limitation

150B Limitation of the maximum condenser leaving water temperature to

45C. Modication on the unit name plate to reect the reducedpower input and current values.

Avoids oversizing of the protection elements and the power

cables.

Control for low condensingtemperature systems

152 Output signal (0-10 V) to control the condenser water inlet valve. Used for applications with cold water at condenser inlet (wellwater). In this case the valve controls the water entering

temp. to maintain an acceptable condensing pressure.

Energy Management Module

EMM

156 Remote control module. Additional contacts for an extension of the

unit control functions.

Easy connection by wired connection to a building

management system

Leak detection 159 0-10 V signal to repor t any refrigerant leakage in the unit directly on

the controller (the leak detector itself must be supplied by the

customer)

Immediate customer notication of refrigerant losses to the

atmosphere, allowing timely correction

Code compliance for Switzer-

land in addition to PED code

197 Additional tests on the water heat exchangers. Additional supply of

PED documents, supplementary certicates and test certicates.

Conformance with Swiss regulations

Code compliance for Australia 200 Heat exchanger approved in accordance with the Australian code. Conformance with Australian regulations

Low noise level (-3 dB(A)compared to standard unit)

257 Evaporator sound insulation 3 dB(A) quieter than a unit without this option

Welded evaporator waterconnection kit

266 Victaulic piping connections with welded joints. Easy installation

Welded condenser waterconnection kit

267 Victaulic piping connections with welded joints. Easy installation

Flanged evaporator water

connection kit

268 Victaulic piping connections with anged joints. Easy installation

Flanged condenser water

connection kit

269 Victaulic piping connections with anged joints. Easy installation

Thermal compressor

insulation

271 Thermal compressor insulation Prevents condensation forming on the compressor (due to

the ambient air)

EMC classication according

to IEC 61800-3 - class C2

282 Frequency variator with RFI lter class C2. Reduces the risk of electromagnetic interference, if the unit

is installed in a residential environment

IGBT bridge at speed variator output

From the internal d.c. voltage and using pulse width modu-lation (PWM), the frequency variator generates forms atvariable voltage and frequency. This module also takesshort-circuit protection and overload at the compressoroutlet into consideration. The safety stop function of thepressure switches acts on this module and stops the outputin accordance with standard EN ISO 13849-1, complyingwith the requirements of the pressure equipment directive(PED).

Auxiliary and communication control boards

Board and component assembly that ensures auxiliaryfunctions: internal supplies, frequency variator fan control,communication in LEN protocol with the Carrier controller.

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Clean the water filter (see chapter 7 Water connec-tions).

Check the unit operating parameters and comparethem with previous values.

Keep and maintain a maintenance sheet, attached toeach HVAC unit.

All these operations require strict observation of adequatesafety measures: individual protection garments, compliancewith all industry regulations, compliance with applicablelocal regulations and using common sense.

11.3 - leve 3 (or higher) mintennce

See note below.The maintenance at this level requires specific skills/approval/tools and know-how and only the manufacturer,his representative or authorised agent are permitted tocarry out these operations. These maintenance operationsconcern for example: A major component replacement (compressor, evapo-

rator)

Any intervention on the refrigerant circuit (handlingrefrigerant)

Changing of parameters set at the factory (applicationchange)

Removal or dismantling of the HVAC unit Any intervention due to a missed established mainte-

nance operation Any intervention covered by the warranty.

NOTE: Any deviation or non-observation of these mainte-nance criteria will render the guarantee conditions for theHVAC unit nul and void, and the manufacturer, Carrier

France, will no longer be held responsible.

11.4 - Tightening of the eectric connection

11.4.1 - Tightening torques for the main electrical connections

screw tpe Deigntionin the unit

Torquevue, Nm

Cutomer connection

Screw-nut M12 at phase decks L1/L2/L3 50

Nut on earth terminal PE 81

Downtrem power connection in the contro box

Screw M10 at downstream main disconnect deck (QS10)* L1/L2/L3 50

Earth terminal M10 50

Power connection in the vritor Gs-

M10 nut on the phase pin 19M10 nut on the earth pin 19

Compreor phe connection termin

M12 1/2/3/4/5/6 on EC- 23

M16 1/2/3/4/5/6 on EC- 30

Compreor erth connection Gnd on EC- 25

Contro diconnect connection

Upstream and downstream screws at terminals QF 2

ATTENTION: The tightening of the connections at thecompressor terminals requires special precautions. Pleaserefer to the chapter below.

11 sTaNDaRD MaINTENaNCE

Air conditioning equipment must be maintained by profes-sional technicians, whilst routine checks can be carried outlocally by specialised technicians.

Simple preventive maintenance will allow you to get thebest performance from your HVAC unit: improved cooling performance reduced power consumption prevention of accidental component failure prevention of major time-consuming and costly inter-

ventions protection of the environment

There are five maintenance levels for HVAC units, as definedby the AFNOR X60-010 standard.

11.1 - leve 1 mintennce

See note below.Simple procedure can be carried out by the user:

Visual inspection for oil traces (sign of a refrigerantleak)

Air heat exchanger (condenser) cleaning - see chapterCondenser coil - level 1

Check for removed protection devices, and badlyclosed doors/covers

Check the unit alarm report when the unit does notwork (see report in the Touch Pilot control manual).

General visual inspection for any signs of deterioration.11.2 - leve 2 mintennce

See note opposite.This level requires specific know-how in the electrical,hydronic and mechanical fields. It is possible that theseskills are avail-able locally: existence of a maintenanceservice, industrial site, specialised subcontractor.

In these cases, the following maintenance operations arerecommended.

Carry out all level 1 operations, then: At least once a year tighten the power circuit electrical

connections (see tightening torques table).

Check and re-tighten all control/command connections,if required (see tightening torques table).

Check the differential switches for correct operationevery 6 months.

Remove the dust and clean the interior of the controlboxes, if required. Check the filter condition (if used).

Check the presence and the condition of the electricalprotection devices.

Replace the fuses every 3 years or every 15000 hours(age-hardening).

Replace the control box cooling fans (if used) everyfive years.

Check the water connections. Purge the water circuit (see chapter 7 Water connec-

tions).

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11.6 - Evportor nd condener mintennce

Check that: the insulating foam is intact and securely in place, the sensors and flow switch are correctly operating

and correctly positioned in their support, the water-side connections are clean and show no sign

of leakage.

11.7 - Compreor mintennce

11.7.1 - Oil filter change schedule

As system cleanliness is critical to reliable system operation,there is a filter in the oil line at the oil separator outlet. Theoil filter is specified to provide a high level of filtration (5 m)required for long compressor life.

The filter should be checked after the first 500 hours ofoperation, and every subsequent 2000 hours. The filter shouldbe replaced at any time when the pressure differentialacross the filter exceeds 2 bar.

The pressure drop across the filter can be determined bymeasuring the pressure at the discharge port (at the oilseparator) and the oil pressure port (at the compressor).The difference in these two pressures will be the pressuredrop across the filter, check valve, and solenoid valve. Thepressure drop across the check valve and solenoid valve isapproximately 0.4 bar, which should be subtracted from thetwo oil pressure measurements to give the oil filter pressuredrop.

11.7.2 - Compressor rotation control

Correct compressor rotation is one of the most critical appli-

cation considerations. Reverse rotation, even for a veryshort duration, damages the compressor and can evendestroy it.

The reverse rotation protection scheme must be capable ofdetermining the direction of rotation and stopping thecompressor within one second. Reverse rotation is mostlikely to occur whenever the wiring at the compressorterminals has been modified.

To minimise the opportunity for reverse rotation, the follow-ing procedure must be applied. Rewire the power cables tothe compressor terminals and/or the downstream variator

connection decks as originally wired.

For replacement of the compressor, a low pressure switchis included with the compressor. This low pressure switchshould be temporarily installed as a hard safety on the highpressure part of the compressor. The purpose of this switchis to protect the compressor against any wiring errors atthe compressor terminal pin. The electrical contact of theswitch would be wired in series with the high pressure switch.The switch will remain in place until the compressor hasbeen started and direction of rotation has been verified; atthis point, the switch will be removed.

13.4.2 - Connection precautions for the compressor powerterminals

These precautions must be applied during an interventionthat requires the removal of the power conductors connectedto the compressor supply terminals.

The tightening nut of terminal (6) supporting the isolator(7) must never be loosened, as ist ensures terminal tightnessand compressor leak tightness.

The tightening of phase lug (4) must apply the torquebetween counter nut (5) and tightening nut (3): during thisoperation a counter-torque must be applied at counter nut(5). Counter-nut (5) must not be in contact with the tighteningnut of terminal (6).

1. Torque application to tighten the lug

2. Avoid contact between the two nuts

3. Lug tightening nut4. Flat lug

5. Counter-nut

6. Terminal tightening nut7. Isolator

11.5 - Tightening torque for the min bot nd crew

screw tpe Ued for Torquevue, Nm

M20 nut Chassis 190

M20 nut Heat exchanger side-side connection 2