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Carrier AquaForce 30XW-V User Manual

Carrier AquaForce 30XW-V
36 pages
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INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
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

Table of Contents

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Carrier AquaForce 30XW-V Specifications

General IconGeneral
BrandCarrier
ModelAquaForce 30XW-V
CategoryHeat Pump
LanguageEnglish

Summary

1 - INTRODUCTION

1.1 Installation safety considerations

Safety precautions for unit installation, including handling, site preparation, and personal protective equipment.

Classification and control

Classification of safety devices for protection against overpressure and fire damage.

1.2 Equipment and components under pressure

Information on equipment and components designed to operate under pressure, including compliance and documentation.

1.3 Maintenance safety considerations

Safety precautions for maintenance, including PPE, qualified personnel, and logbook requirements.

1.4 Repair safety considerations

Safety guidelines for repairs, including PPE, purging procedures, and handling of refrigerants and components.

Risk of Explosion

Warning about using air or oxygen for leak tests, which can cause explosions with oil and grease.

2 - PRELIMINARY CHECKS

2.1 Check equipment received

Procedure for inspecting the unit upon receipt for damage, missing parts, and confirming order accuracy.

2.2 Moving and siting the unit

Guidelines and precautions for moving and positioning the unit at the installation site.

2.2.3 Checks before system start-up

Pre-start-up verification checklist for the refrigeration system, installation, and components against diagrams.

3 - DIMENSIONS, CLEARANCES

3.1 30XW-V/30XWHV 580-880

Physical dimensions and required clearances for 30XW-V/30XWHV units, models 580 through 880.

3.2 30XW-V/30XWHV 1150-1710

Physical dimensions and required clearances for 30XW-V/30XWHV units, models 1150 through 1710.

4 - PHYSICAL AND ELECTRICAL DATA

4.1 Physical data

Technical specifications including sound levels, dimensions, weight, compressors, oil, refrigerant, and capacity control.

4.2 Electrical data

Detailed electrical specifications including power supply, start-up current, power factor, harmonic distortion, and power input.

4.3 Short-circuit stability current for all units

Information on the short-circuit stability current and main disconnect switch for all units.

4.4 Compressor electrical data

Nominal voltage, frequency, and current ratings for different compressor models.

4.5 Compressor usage

Table showing compressor models and their compatibility with specific unit ranges.

5 - ELECTRICAL CONNECTION

5.1 Power supply

Guidelines for power supply requirements, voltage range, and phase imbalance.

5.2 Voltage phase imbalance (%)

Explanation and example for calculating and checking voltage phase imbalance for safe operation.

5.3 Power connection/disconnect switch

Details on the number of connection points for power connection/disconnect switches based on unit model and options.

5.4 Recommended wire sections

Guideline for selecting appropriate wire sections for electrical connections based on current and installation methods.

5.5 Power cable entry

Information on how power cables enter the control box, including location and access.

5.6 Field control wiring

Instructions for field control wiring, precautions, and available standard/optional features.

5.7 24 and 230 V power reserve for the user

Details on the available 24 V AC and 230 V AC power reserves for user control wiring.

6 - APPLICATION DATA

6.1 Operating limits

Specifies the minimum and maximum operating limits for the evaporator and condenser.

6.2 Condenser-side installation recommendation

Recommendations for condenser-side installation, especially for low condenser water temperatures.

6.3 Minimum chilled water flow

Details on minimum chilled water flow requirements and recirculation options.

6.4 Maximum chilled water flow

Information on maximum chilled water flow limits and bypass options.

6.5 Condenser water flow rate

Details on minimum and maximum condenser water flow rates and options for higher flow.

6.6 Number of passes

Table showing the number of passes for evaporator and condenser based on unit model and options.

6.7 Evaporator and condenser water flow rates

Table providing minimum and maximum water flow rates for evaporator and condenser.

6.8 Minimum temperature difference

Graphical representation of minimum temperature differences for condenser and evaporator operation.

6.9 Variable flow evaporator

Guidelines for using variable evaporator flow, including control and system volume requirements.

6.10 System minimum water volume

Formula and guidance for calculating the minimum water loop volume for stable operation.

6.11 Pressure drop curves

Graphs showing pressure drop curves for evaporator and condenser based on water flow rate.

7 - WATER CONNECTIONS

7.1 Operating precautions

Precautions for water circuit design and connection, including pipework, air purging, and fluid compatibility.

Carrier recommendations on heat exchange fluids

Recommendations for heat exchange fluids, detailing acceptable ion content and pH levels.

7.2 Water connections

Details on Victaulic type water connections, including inlet/outlet diameters for evaporator and condenser.

7.3 Flow control

Information on evaporator flow switch and chilled water pump interlock, and adjustment procedures.

7.4 Evaporator and condenser water box bolt tightening

Procedure and sequence for tightening water box bolts on the evaporator and condenser.

7.5 Operation of two units in master/slave mode

Configuration and operation of two units in master/slave mode, including control and pump management.

8 - HEAT PUMPS 30XWHV

8.1 Physical data for heat pumps

Physical data for 30XWHV heat pumps, referencing chapter 4.1 for details.

8.2 Electrical data for heat pumps

Electrical data for 30XWHV heat pumps, referencing chapter 4.2 for details.

8.3 Dimensions and clearances for heat pumps

Dimensions and clearances for 30XWHV heat pumps, referencing chapter 3 for details.

8.4 Operating range for heat pumps

Operating limits for 30XWHV heat pumps, referencing chapter 6.1 for details.

8.5 Operating modes for heat pumps

Description of cooling and heating operating modes for 30XWHV heat pumps.

9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA

9.1 Compressors

Details on 06T geared twin-screw compressors, their control modes, and models used.

9.2 Oil filter

Information on the independent oil filter for the 06T screw compressor.

9.3 Refrigerant

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

9.4 Lubricant

Approved lubricants for the 06T screw compressor, including Carrier specifications.

9.5 Oil supply solenoid valve

Description of the oil supply solenoid valve used to isolate the compressor from oil flow.

9.6 Pressure vessels

Information on pressure vessels, including general monitoring, repair, recycling, and operating life.

9.7 SRMCR high-pressure safety circuit

Description of the SRMCR high-pressure safety circuit, its operation, and testing requirements.

10 - OPTIONS

Light-brine solution, down to -3°C

Option for chilled brine solution production down to -3°C using ethylene glycol.

Master/slave operation

Option for two units in parallel for optimised operation and time equalisation.

Single power connection point

Option for unit power connection via a single main supply connection.

Evap. pump power/control circuit

Option for electrical power and control for one or two evaporator pumps.

Condenser pump electrical power/control circuit

Option for electrical power and control for one or two condenser pumps.

Condenser insulation

Thermal insulation for the condenser to reduce thermal dispersions and aid compliance.

Service valve set

Includes liquid line and suction line valves for simplified service and maintenance.

Evaporator with one pass

Option for evaporator with one pass on the water-side, reducing pressure drops.

Condenser with one pass

Option for condenser with one pass on the water-side, reducing pressure drops.

21 bar evaporator

Reinforced evaporator for higher water-side service pressure (21 bar).

21 bar condenser

Reinforced condenser for higher water-side service pressure (21 bar).

Reversed evaporator water connections

Evaporator with reversed water inlet/outlet for specific site requirements.

Reversed condenser water connections

Condenser with reversed water inlet/outlet for specific site requirements.

LON gateway

Two-directional communication board complying with Lon Talk protocol.

Bacnet over IP gateway

High-speed communication via BACnet protocol over Ethernet network.

Modbus over IP and RS485

Bi-directional communication using Modbus protocol over Ethernet network.

Condensing temperature limitation

Limits maximum condenser leaving water temperature to 45°C for downsizing components.

Control for low condensing temperature systems

Output signal to control condenser water inlet valve for low temperature systems.

Energy Management Module EMM

Control board with additional inputs/outputs for extended remote control.

Leak detection

0-10 V signal to report refrigerant leakage, requiring customer-supplied detector.

Dual relief valves on 3-way valve

Three-way valve upstream of dual relief valves for facilitated replacement and inspection.

Compliance with Swiss regulations

Additional tests and PED documents for compliance with Swiss regulations.

Compliance with Russian regulations

EAC certification for compliance with Russian regulations.

Compliance with Australian regulations

Unit approval to Australian code for compliance with Australian regulations.

Low noise level

Evaporator piping sound insulation providing 3 dB(A) quieter operation than standard.

Welded evaporator water connection kit

Victaulic piping connections with welded joints for easy installation.

Welded condenser water connection kit

Victaulic piping connections with welded joints for easy installation.

Flanged evaporator water connection kit

Victaulic piping connections with flanged joints for easy installation.

Flanged condenser water connection kit

Victaulic piping connections with flanged joints for easy installation.

Thermal compressor insulation

Compressor covered with thermal insulation to prevent condensation.

EMC classification C2, as per EN 61800-3

Additional RFI filters on the unit power line for reduced electromagnetic interferences.

Compliance with UAE regulation

Label with rated power, current, EER for compliance with UAE standard.

Compliance with Morocco regulation

Specific documents according to Morocco regulation.

11 - STANDARD MAINTENANCE

11.1 Level 1 maintenance

Simple preventive maintenance tasks for users, including visual checks and filter inspection.

11.2 Level 2 maintenance

Maintenance requiring specific skills, including connection tightening and component checks.

11.3 Level 3 (or higher) maintenance

Advanced maintenance requiring manufacturer expertise, like component replacement or refrigerant handling.

11.4 Tightening of the electrical connections

Torque specifications for tightening main electrical connections, including customer and variator connections.

11.5 Tightening torques for the main bolts and screws

Torque specifications for tightening various bolts and screws on the unit, including chassis and compressor fixings.

11.6 Evaporator and condenser maintenance

Checks for evaporator and condenser maintenance, including insulation, sensors, and water connections.

11.7 Compressor maintenance

Details on compressor maintenance, including oil filter changes and rotation control.

11.8 Frequency variator maintenance

Maintenance procedures for the frequency variator, including safety precautions and fan replacement.

11.9 Service valve (option 92)

Description of optional service valves for facilitating maintenance and repair operations.

11.10 High pressure safety loop periodic test

Procedure for periodic testing of the high pressure safety loop and verification of trigger values.

12 - FINAL SHUTDOWN

12.1 Shutting down

Procedure for shutting down the units, including separation from energy sources and cooling.

12.2 Recommendations for disassembly

Guidelines for disassembling the unit, sorting components for recycling, and checking for reusable parts.

12.3 Fluids to be recovered for treatment

List of fluids like refrigerant, heat-transfer fluid, and compressor oil to be recovered for treatment.

12.4 Materials to be recovered for recycling

List of materials such as steel, copper, aluminium, and plastics for recycling.

12.5 Waste Electrical and Electronic Equipment (WEEE)

Procedure for disassembling and processing WEEE, including removal of contaminated fluids.

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

Preliminary information

Section for recording preliminary job, location, contractor, distributor, unit model, and component details.

Preliminary equipment check

Checklist for verifying shipping damage, unit installation, wiring, connections, and water venting.

Unit start-up

Checklist for unit start-up, including oil level, valve status, leak checks, and voltage imbalance.

Check cooler water loop

Checklist for cooler water loop, including volume, corrosion inhibitor, freeze protection, and piping.

Check pressure drop across the cooler

Procedure for checking pressure drop across the cooler and comparing with performance data.

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