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Carrier AquaForce 30XW-V, Installation, Operation And Maintenance Instructions

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Carrier AquaForce 30XW-V Installation, Operation And Maintenance Instructions Download Page 1

INSTALLATION,  OPERATION AND 

M A I N T E N A N C E   I N S T R U C T I O N S

Original document

SmartVu™

Variable-Speed Water-Cooled Liquid Chillers/

Variable-Speed Water-to-Water Heat Pumps

30XW-V/30XWHV

Nominal cooling capacity: 587-1741 kW

Nominal heating capacity: 648-1932 kW

50 Hz

Summary of Contents for AquaForce 30XW-V

Page 1: ... N A N C E I N S T R U C T I O N S Original document SmartVu Variable Speed Water Cooled Liquid Chillers Variable Speed Water to Water Heat Pumps 30XW V 30XWHV Nominal cooling capacity 587 1741 kW Nominal heating capacity 648 1932 kW 50 Hz ...

Page 2: ...2 ...

Page 3: ...ts 17 6 2 Condenser side installation recommendation 17 6 3 Minimum chilled water flow 17 6 4 Maximum chilled water flow 17 6 5 Condenser water flow rate 17 6 6 Number of passes 18 6 7 Evaporator and condenser water flow rates 18 6 8 Minimum temperature difference 18 6 9 Variable flow evaporator 19 6 10 System minimum water volume 19 6 11 Pressure drop curves 19 7 WATER CONNECTIONS 20 7 1 Operatin...

Page 4: ...maintenance 28 11 3 Level 3 or higher maintenance 28 11 4 Tightening of the electrical connections 28 11 5 Tightening torques for the main bolts and screws 29 11 6 Evaporator and condenser maintenance 29 11 7 Compressor maintenance 29 11 8 Frequency variator maintenance 30 11 9 Service valve option 92 30 11 10 High pressure safety loop periodic test 30 12 FINAL SHUTDOWN 31 12 1 Shutting down 31 12...

Page 5: ...ansfer medium circuits the fuse plugs and the pressure switches Ensure that the valves are correctly installed before operating the unit Classification and control In accordance with the Pressure Equipment Directive and national usage monitoring regulations in the European Union the protection devices for these machines are classified as follows Classification of safety devices Safety device 1 Dev...

Page 6: ...eer Applicable national regulations Verification Organism Date Nature 1 1 Maintenance repairs regular verifications EN 378 leakage etc Engineers working on the electric or refrigeration components must be authorized trained and fully qualified to do so All refrigerant circuit repairs must be carried out by a trained person fully qualified to work on these units He must have been trained and be fam...

Page 7: ...ment inspect the protection devices more frequently Regularly carry out leak tests and immediately repair any 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 the pressure gauges Change the refrigerant when there are equipment failures following a procedure as the one described...

Page 8: ...ing gas pressure and move the cylinders to a place designated for their recovery Do not incinerate ATTENTION Use only refrigerant R 134a in accordance with standard 700AHRI Air Conditioning Heating and Refrigeration Institute Use of any other refrigerant can expose users and technicians working on the unit to unexpected risks Do not attempt to remove refrigerant circuit components or fittings whil...

Page 9: ...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 unit operation 2 2 3 Checks be...

Page 10: ...ixing points weight distribution and centre of gravity coordinates refer to the dimensional drawings Dimensions in mm A B C D E F G 30XW V 30XWHV 580 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 3100 880 1950 1083 1237 3290 219 1 219 1 3100 Legend All dimensions are given in mm Required clearances for maintenance Recommended space ...

Page 11: ...TES Drawings are not contractually binding Before design ing an installation consult the certified dimensional drawings supplied with the unit or available on request For the positioning of the fixing points weight distribu tion and centre of gravity coordinates refer to the dimensional drawings 3 DIMENSIONS CLEARANCES Legend All dimensions are given in mm Required clearances for maintenance Recom...

Page 12: ...TM inverter driven compressor electronic expansion valve EXV Minimum capcity 20 20 20 20 10 10 10 10 10 Evaporator Multi pipe flooded type Water volume l 106 106 154 154 297 297 297 297 297 Water connections Victaulic in 6 6 8 8 8 8 8 8 8 Drain and vent connections NPT in 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 3 8 Max water side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 Condense...

Page 13: ... A 270 330 330 380 421 With option 81 A 540 660 710 760 842 Maximum power input with option 150B 4 Circuit A kW 141 173 199 221 141 173 199 199 221 Circuit B kW 141 173 173 199 221 With option 81 kW 282 346 372 398 442 Maximum current draw Un with option 150B 4 Circuit A A 222 272 314 348 222 272 314 314 348 Circuit B A 222 272 272 314 348 With option 81 A 444 544 586 628 696 Dissipated power 3 W ...

Page 14: ...he factory installed disconnect switch es circuit breaker s is are of a type suitable for power interruption in accordance with EN 60947 3 corresponds to IEC 60947 3 6 The units are designed for connection to TN networks IEC 60364 In IT networks the use of noise filters integrated into the frequency variator s make machine use unsuitable In addition the short circuit holding current characteristic...

Page 15: ...h unit see electrical data tables For the design the standardised installation methods in accordance with IEC 60364 are used multicon ductor PVC 70 C or XLPE 90 C insulated cables with copper core arrangement to comply with table 52c of the above standard The maximum temperature is 42 C The given maximum length is calculated to limit the voltage drop to 5 5 5 Power cable entry The power cables can...

Page 16: ...his does not control condenser pump operation for this function add option 156 and flow switch Heating cooling change over Available as an option Water valve control Various interlocks and reports on the Energy Manage ment Module board option 156 Refrigerant leak detection CCN bus connection The permanent connection to the system CCN bus is made at the terminal provided for this purpose inside the...

Page 17: ...ser water temperature before start up t Time required to reach a temperature of 19 C at the condenser outlet 1 The unit can start without the use of a two or three way valve but operation will be more reliable with the control valve 2 The use of a two or three way valve is strongly recommended 3 The use of a two or three way valve is compulsory 4 The use of a two or three way valve is compulsory a...

Page 18: ... rate based on a water velocity of 0 5 m s Minimum condenser flow rate based on a water velocity of 0 3 m s 6 8 Minimum temperature difference The maximum flow rates recommended by Carrier limit unit operation with a T entering leaving of 3 K in the sections shown below 30XW V 1570 15 20 25 30 35 40 45 50 0 5 10 15 20 30XW 1570 Evaporator leaving water temperature C Condenser leaving water tempera...

Page 19: ...necessary to add a buffer water tank to the circuit in order to achieve the required volume The tank must itself be internally baffled in order to ensure proper mixing of the liquid water or brine Refer to the examples below Connection to a buffer tank Bad Bad Good Good 6 11 Pressure drop curves Units with two evaporator passes standard Pressure drop kPa Water flow rate l s 10 20 30 40 50 60 70 80...

Page 20: ...mpatible with the materials and water circuit coating The use of different metals on hydraulic piping could generate eletrolytic pairs and consequently corrosion Verify then the need to install sacrificial anodes In case additives or other fluids than those recommend ed by Carrier are used ensure that the fluids are not considered as a gas and that they belong to class 2 as defined in directive 20...

Page 21: ...orator flow switch and chilled water pump interlock IMPORTANT On 30XW V 30XWHV units the unit water flow switch must be energised Failure to follow this instruction will void the Carrier guarantee The water flow switch is installed on the evaporator water inlet and adjusted by the control based on unit size and application If adjustment is necessary it must be carried out by qualified personnel tr...

Page 22: ...s its own water pump If there is only one common pump in cases with variable flow isolation valves must be installed on each unit They will be activated at the opening and closing by the control of each unit in this case the valves are controlled using the dedicated water pump outputs See the SmartVuTM Control IOM for a more detailed explanation 30XW V 30XWHV with configuration leaving water contr...

Page 23: ...re the same as for the 30XW V units Please refer to chapter 3 8 4 Operating range for heat pumps The operating limits are the same as for the 30XW V units Please refer to chapter 6 1 8 5 Operating modes for heat pumps 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 ...

Page 24: ... the monitoring and maintenance file 9 6 3 Recycling The unit is wholly or partly recyclable After use it contains refrigerant 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 difference of 6 K b...

Page 25: ...F GS_1 drive 400 Vac HPS High pressure switch SP1F A SP2F A GS_1 Power drive for compressor GSA1 GSB1 During normal operation the speed regulator supplies and controls the compressor once the control signal is received via the digital on off input normal on off and the communication bus setting the frequency When one of the HPS sensors opens the STO Safe Torque Off digital input opens which instan...

Page 26: ...side Condenser inlet and outlet on opposite sides Easy to install depending on site Reduced pressure drops 580 1710 21 bar evaporator 104 Reinforced evaporator for extension of the maximum water side service pressure to 21 bar standard 10 bar Covers applications with a high water column evaporator side typically high buildings 580 1710 21 bar condenser 104A Reinforced condenser for extension of th...

Page 27: ...ter connection kit 267 Victaulic piping connections with welded joints Easy installation 580 1710 Flanged evaporator water connection kit 268 Victaulic piping connections with flanged joints Easy installation 580 1710 Flanged condenser water connection kit 269 Victaulic piping connections with flanged joints Easy installation 580 1710 Thermal compressor insulation 271 The compressor is covered wit...

Page 28: ...ations require strict observation of adequate safety measures individual protection garments compliance with all industry regulations compliance with applicable local regulations and using common sense 11 3 Level 3 or higher maintenance 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 ...

Page 29: ...suring the pressure at the discharge port at the oil separator and the oil pressure port at the compressor The difference in these two pressures will be the pressure drop across the filter check valve and solenoid valve The pressure drop across the check valve and solenoid valve is approximately 0 4 bar which should be subtracted from the two oil pressure measurements to give the oil filter pressu...

Page 30: ...uit Complete safety loop test The purpose of this periodic test is to verify the proper functioning and setting of the high pressure safety loop of a refrigerant circuit In order to reach the triggering pressure of the loop the pressure and temperature thresholds activating the discharge of the compressor by the regulation system are raised This procedure must be repeated for each circuit of the u...

Page 31: ...he unit can be recycled for another purpose 12 3 Fluids to be recovered for treatment Refrigerant Heat transfer fluid depending on the installation water brine solution etc Compressor oil 12 4 Materials to be recovered for recycling Steel Copper Aluminium Plastics Polyurethane foam insulation 12 5 Waste Electrical and Electronic Equipment WEEE At the end of its life this equipment must be disassem...

Page 32: ...roperly Unit ground wire has been connected Electrical circuit protection has been sized and installed properly All terminals are tight All chilled water valves are open All chilled water piping is connected properly All air has been vented from the chilled water circuit The unit is switched off again after the pump test has been completed Chilled water pump CWP is operating with the correct rotat...

Page 33: ...itioning 6 5 litres nominal kW capacity for process cooling Proper loop volume established Proper loop corrosion inhibitor included litres of Proper loop freeze protection included if required litres of Piping includes electric heater tape if exposed to temperatures below 0 C Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1 2 mm Check pressure drop across the cooler Enterin...

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Page 36: ...t CarrierS C S Montluel France Le fabricant se réserve le droit de changer sans préavis les spécifications du produit Imprimé dans l Union européenne CARRIER participe au programme ECP dans la catégorie LCP HP Vérifier la validité actuelle du certificat www eurovent certification com ...

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