Chiller-pre Commission Checks

8/16/2019 Chiller-pre Commission Checks

http://slidepdf.com/reader/full/chiller-pre-commission-checks 1/32

30XW - 30XWH

Water-Cooled Liquid ChillersNominal cooling capacity: 476-1178 kWNominal heating capacity: 506-1276 kW

50 Hz

Installation, operation and maintenance instructions



2

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 ...................................................................................................................................................... 7

2.1 - Check equipment received ......................................................................................................................................................72.2 - Moving and siting the unit .......................................................................................................................................................7

3 - DIMENSIONS, CLEARANCES .............................................................................................................................................93.1 - 30XW 452-602 ...........................................................................................................................................................................93.2 - 30XW 1002-1162 .....................................................................................................................................................................10

4 - PHYSICAL AND ELECTRICAL DATA FOR 30XW UNITS ........................................................................................114.1 - Physical data ...........................................................................................................................................................................114.2 - Sound levels ............................................................................................................................................................................114.3 - Short-circuit stability current for all units ........................................................................................................................... 114.4 - Electrical data 30XW (including option 81) .......................................................................................................................124.5 - Compressor electrical data 30XW ........................................................................................................................................124.6 - Compressor usage per circuit (A, B).................................................................................................................................... 12

5 - ELECTRICAL CONNECTION ............................................................................................................................................135.1 - Power supply ...........................................................................................................................................................................135.2 - Voltage phase imbalance (%) ...............................................................................................................................................135.3 - Power connection/disconnect switch ....................................................................................................................................135.4 - Recommended wire sections ................................................................................................................................................145.5 - Power cable entry ...................................................................................................................................................................145.6 - Field control wiring ................................................................................................................................................................145.7 - 24 and 230 V power reserve for the user .............................................................................................................................14

6 - APPLICATION DATA ...........................................................................................................................................................156.1 - Operating limits for 30XW units ..........................................................................................................................................156.2 - Minimum chilled water ow .................................................................................................................................................156.3 - Maximum chilled water ow .................................................................................................................................................156.4 - Condenser water ow rate ...................................................................................................................................................156.5 - Standard and optional number of water passes .................................................................................................................. 166.6 - Evaporator and condenser water ow rates .......................................................................................................................166.7 - Variable ow evaporator ....................................................................................................................................................... 166.8 - System minimum water volume ........................................................................................................................................... 166.9 - Evaporator pressure drop curves .........................................................................................................................................176.10 - Condenser pressure drop curves ........................................................................................................................................ 17

7 - WATER CONNECTIONS ......................................................................................................................................................187.1 - Operating precautions ...........................................................................................................................................................187.2 - Water connections ..................................................................................................................................................................197.3 - Flow control ............................................................................................................................................................................197.4 - Evaporator and condenser water box bolt tightening .......................................................................................................197.5 - Operation of two units in master/slave mode ..................................................................................................................... 198 - HEAT MACHINE UNITS 30XWH- AND 30XWHP ........................................................................................................208.1 - Technical data of the Heat Machine units ...........................................................................................................................208.2 - Electrical data for Heat Machine units ................................................................................................................................208.3 - Dimensions and clearances ...................................................................................................................................................208.4 - Operating range ......................................................................................................................................................................208.5 - Operating modes ....................................................................................................................................................................20



3

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 four 30XW unit types:• 30XW-- Standard-efciency units• 30XW-P High-efciency unitsand• 30XWH- Heat Machine standard-efciency units

• 30XWHP Heat Machine high-efciency units

For the operation of the control please refer to the 30XA/30XW-Pro-Dialog control manual.

9 - OPTION FOR HIGH CONDENSING TEMPERATURES (OPTION 150) ................................................................219.1 - Physical data for 30XW units with option 150 .................................................................................................................... 219.2 - Electrical data for 30XW units with option 150 (including option 81) ............................................................................219.3 - Dimensions and clearances ...................................................................................................................................................229.4 - Operating limits for 30XW units with option 150 ..............................................................................................................22

10 - LOW TEMPERATURE (OPTION 5) AND VERY LOW TEMPERATURE (OPTION 6) GLYCOL

SOLUTION OPTIONS ...............................................................................................................................................................2310.1 - Physical data, 30XW units with options 5 and 6 ...............................................................................................................2310.2 - Electrical data, 30XW units with options 5 and 6 ............................................................................................................. 2310.3 - Dimensions, clearances ........................................................................................................................................................2310.4 - Operating range, 30XW units with options 5 and 6 .......................................................................................................... 2410.5 - Minimum recommended evaporator ow rate with options 5 and 6 .............................................................................2410.6 - Nominal evaporator pressure drop with options 5 and 6 ................................................................................................24

11 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA ................................................................................... 2511.1 - Direct-drive twin-screw compressor with variable capacity slide valve ........................................................................2511.2 - Pressure vessels.....................................................................................................................................................................2511.3 - High-pressure safety switch ................................................................................................................................................2611.4 - Electronic expansion valve (EXV) ....................................................................................................................................2611.5 - Moisture indicator ................................................................................................................................................................2611.6 - Filter drier .............................................................................................................................................................................2611.7 - Sensors ...................................................................................................................................................................................26

12 - OPTIONS AND ACCESSORIES ........................................................................................................................................27

13 - STANDARD MAINTENANCE ..........................................................................................................................................2813.1 - Level 1 maintenance ............................................................................................................................................................2813.2 - Level 2 maintenance ............................................................................................................................................................2813.3 - Level 3 (or higher) maintenance ........................................................................................................................................ 2813.4 - Tightening torques for the main electrical connections ...................................................................................................2813.5 - Tightening torques for the main bolts and screws ............................................................................................................ 2913.6 - Evaporator and condenser maintenance ...........................................................................................................................2913.7 - Compressor maintenance ....................................................................................................................................................29

14 - START-UP CHECKLIST FOR 30XW LIQUID CHILLERS (USE FOR JOB FILE) ..............................................30



4

1 INTRODUCTION

The 30XW Aquaforce units are designed to cool water forthe air conditioning of buildings and industrial procsses.

Prior to the initial start-up of the 30XW units, the peopleinvolved in the on-site installation, start-up, operation, andmaintenance of this unit should be thoroughly familiar withthese instructions and the specic project data for theinstallation site.

The 30XW liquid chillers are designed to provide a very highlevel of safety during installation, start-up, operation andmaintenance. They will provide safe and reliable servicewhen operated within 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, shoes) and safety glasses, using appro-priate tools, employing qualied and skilled technicians(electricians, refrigeration engineers) and following localregulations.

To nd out, if these products comply with Europeandirectives (machine safety, low voltage, electromagneticcompatibility, equipment under pressure etc.) check thedeclarations of conformity for these products.

1.1 - In t tion et con ider tion

Access to the unit must be reserved to authorised personnel,qualied 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, when it is ready to beinstalled or reinstalled, and before it is started up, it must beinspected for damage. Check that the refrigerant circuit(s)is (are) intact, especially that no components or pipes haveshifted (e.g. following a shock). If in doubt, carry out a leaktightness check and verify with the manufacturer that thecircuit integrity has not been impaired. If damage is detectedupon receipt, immediately le a claim with the shippingcompany.

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 nal position. These units can be moved with a forklift truck, as long as the forks are positioned in the right

place and direction on the unit.

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

These units are not designed to be lifted from above. Use slings with the correct capacity, and always follow thelifting instructions on the certied drawings supplied withthe unit.

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

Never cover any safety devices.

This applies to the relief valve in the water circuit and therelief valve(s) in the refrigerant circuit(s).

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-overvalve in the intermediate position, i.e. with both ways

open (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 relief valves are designed and installed to ensure protection against overpressure caused by re.

The relief valve must only be removed if the re risk is

fully controlled and after checking that this is allowed bylocal regulations and authorities. This is the responsibilityof the operator.

If the unit is installed in a room, the safety valves must beconnected to discharge pipes.

If no local or contractual rule (e.g. national regulation or standard, contract etc.) covers treatment of the discharge piping of these safety valves, apply European standards EN 378-2 and EN 13136. They include a sizing methodand examples for conguration and calculation. Undercertain conditions these standards permit connection of

several valves to the same discharge pipe. Note: Like allother standards these EN standards are available fromnational standards organisations.

These pipes must be installed in a way that ensures that people and property are not exposed to refrigerant leaks.These uids 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.

It is recommended to install an indicating device to show

if part of the refrigerant has leaked from the valve. The presence of oil at the outlet orice is a useful indicatorthat refrigerant has leaked. Keep this orice clean toensure that any leaks are obvious.



5

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 1.3“Maintenance safety considerations”.

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

Ensure good ventilation, as accumulation of refrigerantin 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 - E uipment nd component under pre ure

See section “11.2 - Pressure vessels”.

1.3 - M inten nce et con ider tion

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

All refrigerant circuit repairs must be carried out by a trainedperson, fully qualied to work on these units. He must have

been trained and be familiar with the equipment and theinstallation. All welding operations must be carried out byqualied specialists.

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

Any manipulation (opening or closing) of a shut-offvalve must be carried out by a qualied and authorisedengineer. These procedures must be carried out with theunit 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 lter drier box.)

During any handling, maintenance and service operationsthe engineers working on the unit must be equipped with

safety gloves, glasses, shoes and protective clothing.

Never work on a unit that is still energized.

Never work on any of the electrical components, until the general power supply to the unit has been cut using the

disconnect 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.

If the work is interrupted, always ensure that all circuitsare still deenergized before resuming the work.

ATTENTION: Even if the unit has been switched off, the power circuit remains energized, unless the unit or circuitdisconnect switch is open. Refer to the wiring diagram for

further details. Attach appropriate safety labels.

Operating checks: IMPORTANT INFORMATION REGARDING THE REFRIGERANT USED:• This product contains uorinated 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 tests

must be carried out in accordance with nationalregulations.

Safety device checks (annex C6 – EN 378-2):The safety devices must be checked on site once a year for

safety devices (see chapter 11.3 - High-pressure safety switch), and every ve years for external overpressuredevices (safety valves).

At least once a year thoroughly inspect the protectiondevices (valves). If the machine operates in a corrosiveenvironment, 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 such as the one described in NFE 29-795 or carry out a refrigerant analysis in a specialistlaboratory.

If the refrigerant circuit remains open for longer than aday after an intervention (such as a componentreplacement), the openings must be plugged and thecircuit must be charged with nitrogen (inertia principle).The objective is to prevent penetration of atmospherichumidity and the resulting corrosion on the internal wallsand on non-protected steel surfaces.



6

1.4 - Rep ir et con ider tion

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 hasbeen purged.

If work on the evaporator is required, ensure that the piping from the compressor is no longer pressurised (asthe valve is 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 safety 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 charge

liquid refrigerant R-134a at the liquid line. Ensure that you are using the correct refrigerant typebefore recharging the unit.

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 a

synthetic polyolester oil.

Do not use oxygen to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

Never exceed the specied maximum operating pressures.Verify the allowable maximum high- and low-side test

pressures by checking the instructions in this manual andthe pressures given on the unit name plate.

Do not use air for leak testing. Use only refrigerant or drynitrogen.

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

and vapour) has been removed from chiller. Traces ofvapour should be displaced with dry air nitrogen. Refrige-rant in contact with an open ame produces toxic gases.

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

Do not siphon refrigerant.

Avoid spilling liquid refrigerant on skin or splashing itinto the eyes. Use safety goggles. Wash any spills from the

skin with soap and water. If liquid refrigerant enters theeyes, immediately and abundantly ush the eyes withwater and consult a doctor.

Never apply an open ame 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, permitting condi-tioning and recovery of halogenated hydrocarbons underoptimum quality conditions for the products and optimumsafety conditions for people, property and the environmentare described in standard NFE 29795.

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 bemodied to add refrigerant and oil charging, removal andpurging devices. All these devices are provided with theunits. Please refer to the certied dimensional drawings forthe units.

Do not re-use disposable (non-returnable) cylinders orattempt to rell them. It is dangerous and illegal. When

cylinders are empty, evacuate the remaining gas pressure,and move the cylinders to a place designated for theirrecovery. Do not incinerate.

Do not attempt to remove refrigerant circuit componentsor ttings, while the machine is under pressure or while itis running. Be sure pressure is at 0 kPa before removingcomponents or opening a circuit.

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 a walk-way, rack or support. Periodically check and repair or ifnecessary 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.



7

Use only original replacement parts for any repair or component replacement. Consult the list of replacement partsthat corresponds to the specication 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 rst.

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

ow switch, etc.).

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

Periodically inspect all valves, ttings 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 working

near the unit and the unit is in operation.

2 PRElIMINaRy ChECks

2.1 - C ec e uipment received

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

• Conrm that the unit received is the one ordered.Compare the name plate data with the order.

• The unit name plate must include the following

information: - Version number - Model number - CE marking - Serial number

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

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

low pressure side) - Relief valve set pressure - Pressure switch cut-out pressures - Unit leak test pressure - Voltage, frequency, number of phases - Maximum current drawn - Maximum power input - Unit net weight• Conrm that all accessories ordered for on-site

installation have been delivered, and are completeand undamaged.

The unit must be checked periodically during its whole

operating life to ensure that no shocks (handling accessories,tools etc.) have damaged it. If necessary, the damaged partsmust be repaired or replaced. See also chapter 13 “Standardmaintenance”.

2.2 - Movin nd itin t e unit

2.2.1 - Moving

See chapter 1.1 “Installation safety considerations”.

2.2.2 - Siting the unit

Always refer to the chapter “Dimensions and clearances”to conrm 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 certied 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 veried.

If the unit is ordered with the vibration damper kit, pleaseobserve the safety and installation notices in the kitinstallation instructions.

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

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 ow 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 ooding.

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

If 30XW units are hoisted with rigging, use struts or aspreader bar to spread the slings above the unit. Do not tilta unit more than 15°.

Checks before system start-upBefore the start-up of the refrigeration system, the completeinstallation, including the refrigeration system must be veri-ed against the installation drawings, dimensional drawings,system piping and instrumentation diagrams and the wiringdiagrams.

During the installation test national regulations must befollowed. If no national regulation exists, paragraph 9-5 ofstandard EN 378-2 can be used as a guide.



8

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

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

specications.• Check that all safety documents and equipments that

are required by current European standards are present.• Verify that all safety and environmental protection

devices and arrangements are in place and complywith the current European standard.

• Verify that all relevant documents for pressure vessels(certicates, name plates, les, instruction manuals etc.)required by the current European standards are present.

• Verify the free passage of access and safety routes.• 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 xing 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.



9

C

3 DIMENsIONs, ClEaRaNCEs

3.1 - 30XW 452-602

le end:All dimensions are given in mm.

Required clearances for maintenance

Recommended space for evaporator tube removal

Water inlet

Water outlet

Power supply connection

Dimen ion in mma B C D E F G

st nd rd-e icienc unit 30XW--/30XWh-452 1693 810 936 2742 141 141 2600552 1693 810 936 2742 141 141 2600602 1693 810 936 2742 141 141 2600hi -e icienc unit 30XW-P/30XWhP512 1743 968 936 3059 168 168 2900562 1743 968 936 3059 168 168 2900

See detail 2

See detail 1 See detail 3Condenser

Evaporator

NOTE: Drawings are not contractuallybinding. Before designing an installation,consult the certied dimensional drawings

supplied with the unit or available onrequest.

For the positioning of the xing points, weightdistribution and centre of gravity coordinates

please refer to the dimensional drawings.

Detail 2Detail 1 Detail 3

1

2



10

3.2 - 30XW 1002-1162

Dimen ion in mma B C D E F G

st nd rd-e icienc unit 30XW--/30XWh-1002 1870 950 1036 4085 219 168 38001052 1870 950 1036 4085 219 168 38001152 1926 950 1036 4093 219 219 3800hi -e icienc unit 30XW-P/30XWhP1012 1997 1512 1039 4795 219 219 45001162 1997 1512 1039 4795 219 219 4500

See detail 2

See detail 1See detail 3

Detail 2Detail 1 Detail 3

Condenser

Evaporator

NOTE: Drawings are not contractuallybinding. Before designing an installation,consult the certied dimensional drawings

supplied with the unit or available onrequest.

For the positioning of the xing points, weightdistribution and centre of gravity coordinates

please refer to the dimensional drawings.

le end:All dimensions are given in mm.

Required clearances for maintenance

Recommended space for evaporator tube removal

Water inlet

Water outlet

Power supply connection

1

2



11

4 PhysICal aND ElECTRICal DaTa fOR 30XW UNITs

4.1 - P ic d t

st nd rd-e icienc unit 30XW-- hi -e icienc unit 30XW-Psize 452 552 602 1002 1052 1152 512 562 1012 1162Nomin coo in c p cit * kW 476 535 548 1016 1060 1155 509 582 1030 1178Oper tin wei t** kg 2810 2850 2890 5550 5590 6100 3180 3220 7160 7260Compre or 06T semi-hermetic screw compressors, 50 r/s 06T semi-hermetic screw compressors, 50 r/sCircuit A 1 1 1 1 1 1 1 1 1 1Circuit B - - - 1 1 1 - - 1 1Re ri er nt c r e** R-134a R-134aCircuit A kg 82 82 82 85 85 105 130 130 120 120Circuit B kg - - - 110 110 140 - - 130 130Oi c r e’’ SW220 SW220Circuit A kg 32 32 32 32 32 32 32 32 32 32Circuit B kg - - - 32 32 32 - - 32 32C p cit contro PRO-DIALOG, electronic expansion valves (EXV) PRO-DIALOG, electronic expansion valves (EXV)Minimum capacity % 15 15 15 10 10 10 15 15 10 10Ev por tor Flooded multi-pipe type with internally finned copper tubes As standard-efficiency unitsNet water content l 91 91 91 219 219 255 129 129 361 361Water connections Victaulic connections Victaulic connectionsInlet/outlet in 5 5 5 6 6 8 6 6 8 8Drain and air purge (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8Maximum operating pressure, water side kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000Conden er Multi-pipe type with internally finned copper tubes As standard-efficiency unitsNet water content l 104 104 104 237 237 275 142 142 395 395Water connections Victaulic connections Victaulic connectionsInlet/outlet in 5 5 5 8 8 8 6 6 8 8Drain and air purge (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

Maximum operating pressure, water side kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000* Standardised Eurovent conditions: evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C, evaporator

and condenser fouling factor = 0.18 x 10 -4 (m 2 K)/W. Not applicable for units with high condensing temperature. Please refer to the electronic selection catalogue.** Weights are guidelines only. The refrigerant charge is given on the unit nameplate.

4.2 - sound eve

st nd rd-e icienc unit 30XW--/30XWh- hi -e icienc unit 30XW-P/30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Sound power level* dB(A) 99 99 99 102 102 102 99 99 102 102Sound pressure level at 1 m** dB(A) 82 82 82 83 83 83 81 81 83 83

* 10 -12 W - in accordance with ISO 9614-1** In a free field

4.3 - s ort-circuit t bi it current or unit

Short-circuit stability current for all units using the TNsystem (earthing system type): 50 kA (assumed systemcurrent at the unit connection point as rms value).

Except for the units with option 70E, all units are equippedwith protection fuses located in the control box immediatelydownstream from the unit connection point.

For units equipped with option 70E a protection devicemust be installed in the unit supply line. Its time-currentcharacteristic must be at least equivalent to that of therecommended gL fuse up to the estimated short-circuitcurrent value for the system.

M ximum l u e ize or unit wit option 70E (a)30XW Circuit size 452-512 size 552 - 562 - 602 size 1012 size 1002 size 1052 - 1162 - 1152Units without option 150 A 355 355 355 355 355 B - - 355 355 355Units with option 150 A 355 500 355 500 500 B 355 500 355 355 500



12

4.5 - Compre or e ectric d t 30XW

Compre or I Nom (a)* I M x (a)** Mha (a) lRya (a) lRDa (an) Co ine p i (nom.)* Co ine p i (m x.)**

06TUW483 142 217 230 414 1290 0.84 0.8906TUW554 160 242 260 414 1290 0.85 0.9006TUa483 150 275 300 587 1828 0.83 0.8806TUa554 170 300 330 587 1828 0.84 0.89

* Average value for the range (unit at Eurovent conditions)** Value at maximum capacity and nominal voltage (400 V)

le endMha - Maximum compressor operating current, limited by the unit (current given for maximum capacity at 360 V)lRya - Locked rotor current for star connection (connection during compressor start-up)lRDa - Locked rotor current for delta connection

4.6 - Compre or u e per circuit (a, B)

30XW 452-512 552 - 562 - 602 1012 1002 1052 - 1162 - 1152

Unit wit out option 150

06TUW483 A - AB B -06TUW554 - A - A ABUnit wit option 15006TUa483 A - AB B -06TUa554 - A - A AB

4.4 - E ectric d t 30XW (inc udin option 81)

st nd rd-e icienc unit 30XW--/30XWh- hi -e icienc unit 30XW-P/30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Power circuitNominal power supply V-ph-Hz 400-3-50Voltage range V 360-440Contro circuit upp 24 V via the built-in transformerNomin t rt-up current*Circuit A**** A 414 414 414 414 414 414 414 414 414 414Circuit B**** A - - - 414 414 414 - - 414 414Option 81 A - - - 574 574 574 - - 556 574M ximum t rt-up current**

Circuit A**** A 414 414 414 414 414 414 414 414 414 414Circuit B**** A - - - 414 414 414 - - 414 414Option 81 A - - - 656 656 656 - - 631 656Co ine p i nomin *** 0.84 0.85 0.85 0.85 0.85 0.85 0.84 0.85 0.84 0.85Co ine p i m ximum**** 0.89 0.90 0.90 0.90 0.90 0.90 0.89 0.90 0.89 0.90M ximum power input†Circuit A kW 134 151 151 151 151 151 134 151 134 151Circuit B kW - - - 134 151 151 - - 134 151Option 81 kW - - - 284 301 301 - - 267 301Nomin current dr wn***Circuit A A 142 160 160 160 160 160 142 160 142 160Circuit B A - - - 142 160 160 - - 142 160Option 81 A - - - 302 320 320 - - 285 320M ximum current dr wn (Un)†Circuit A A 217 242 242 242 242 242 217 242 217 242Circuit B A - - - 217 242 242 - - 217 242Option 81 A - - - 459 484 484 - - 434 484M ximum current dr wn (Un - 10%)****Circuit A A 230 260 260 260 260 260 230 260 230 260Circuit B A - - - 230 260 260 - - 230 260Option 81 A - - - 490 520 520 - - 460 520

* Instantaneous start-up current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced start-up current of the largest compressor).Values obtained at standard Eurovent unit operating conditions: evaporator entering/leaving water temperature = 12°C/7°C. condenser entering/leaving watertemperature = 30°C/35°C.

** Instantaneous start-up current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced start-up current of the largest compressor).Values obtained at operation with maximum unit power input.

*** Values obtained at standard Eurovent unit operating conditions: evaporator entering/leaving water temperature = 12°C/7°C. condenser entering/leaving watertemperature = 30°C/35°C

**** Values obtained at operation with maximum unit power input.† Values obtained at operation with maximum unit power input. Values given on the unit name plate



13

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.

5.3 - Power connection/di connect witc

Units Connection points30XW 452-602 1 per unit30XW 1002-1162 1 for circuit A 1 for circuit B

5 ElECTRICal CONNECTION

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

5.1 - Power upp

The power supply must conform to the specication on thechiller nameplate. The supply voltage must be within therange specied in the electrical data table. For connectionsrefer to the wiring diagrams.

WARNING: Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutesabuse which will invalidate the Carrier warranty. If the

phase imbalance exceeds 2% for voltage, or 10% forcurrent, contact your local electricity supply at once andensure that the chiller is not switched on until correctivemeasures have been taken.

5.2 - Vo t e p e imb nce (%)

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

E ectric d t note 30XW

• As standard: 30XW 0452 to 0602 units have a single power connection point located

immediately upstream of the main disconnect switch. 30XW 1002 to 1162 units have two connection points located immediately

upstream of the main disconnect switches.• The control box includes the following standard features: - One main disconnect switch per circuit* - Starter and motor protection devices for each compressor - Anti-short cycle protection devices** - Control devices• Field connections:

All connections to the system and the electrical installations must be in fullaccordance with all applicable codes.

• The Carrier 30XW units are designed and built to ensure conformance withlocal codes. The recommendations of European standard EN 60204-1(corresponds to IEC 60204-1) (machine safety - electrical machinecomponents - part 1: general regulations) are specifically taken into account,when designing the electrical equipment.

• The absence of power supply disconnect switch(es) and short-cycle protectiondevices in options 82A and 70E is an important factor that has to be taken intoconsideration at the installation site.

Units equipped with one of these two options are supplied with a declaration ofincorporation, as required by the machinery directive.

Note :• Generally the recommendations of IEC 60364 are accepted as compliance

with the requirements of the installation directives. Conformance with EN60204-1 is the best means of ensuring compliance with the Machines Directiveand § 1.5.1.

• Annex B of EN 60204 1 describes the electrical characteristics used for theoperation of the machines.

1. The operating environment for the 30XW units is specified below:• Environment*** Environment as classified in EN 60721 (corresponds to IEC

60721): - indoor installation - ambient temperature range: minimum temperature +5°C to +42°C, 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 significant 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). For ITnetworks the earth connection must not be at the network earth. Provide alocal earth, consult competent local organisations to complete the electricalinstallation.

NOTE: I p rticu r pect o n ctu in t tion do not con orm tot e condition de cribed bove, or i t ere re ot er condition w ic

ou d be con idered, w cont ct our oc C rrier repre ent tive.

* Not provided for units equipped with options 70E and 82A** Not provided for units equipped with option 70E*** The required protection level for this class is IP21BW (according to reference

document IEC 60529). All 30XW units are protected to IP23C and fulfil this

protection condition.

Motor



14

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 certied dimensional drawing,the installer must ensure easy connection and dene anymodications necessary on site.

The connections provided as standard for the eld-suppliedpower entry cables to the general disconnect/isolator switchare designed for the number and type of wires, listed in thetable below.

The calculations are based on the maximum unit current(see electrical data tables).

For the design the following standardised installationmethods are used, in accordance with IEC 60364, table 52C:For 30XW units installed inside the building:• Minimum wire section No. 13: perforated horizontal

cable conduit• Maximum wire section No. 41: closed conduit

The calculation is based on PVC (70°C) or XLPE (90°C)insulated cables with copper core. The maximum tempera-ture for 30XW units is 46°C.

The given wire length limits the voltage drop to < 5%.

5.5 - Power c b e entr

The power cables can enter the 30XW control box from

above the unit.A removable aluminium plate on the upper part of thecontrol box face allows introduction of the cables.

Refer to the certied dimensional drawing for the unit.

se ection t b e o minimum nd m ximum wire ection or connection to 30XW unit M x. connect b e Minimum c cu ted ection M ximum c cu ted ection wire ection30XW - Circuit a/B section (mm²)* section (mm²)* M x. en t (m) C b e t pe section (mm²)* M x. en t (m) C b e t peUnit wit out option 150 or 81452 - 512 1 x 240 1 x 95 230 XLPE Cu 1 x 185 390 PVC Cu552 - 562 - 602 1 x 240 1 x 95 275 XLPE Cu 1 x 185 360 PVC Cu1012 2 x 240 1 x 95/1 x 95 200/200 XLPE Cu 2 x 120/2 x120 400/400 PVC Cu1002 2 x 240 1 x 120/1 x 95 220/200 XLPE Cu 2 x 120/2 x120 375/400 PVC Cu1052 - 1152 - 1162 2 x 240 1 x 120/1 x 120 220/220 XLPE Cu 2 x 120/2 x120 375/375 PVC CuUnit wit option 150452 - 512 1 x 240 1 x 120 210 XLPE Cu 1 x 185 290 XLPE Cu552 - 562 - 602 1 x 240 1 x 150 230 XLPE Cu 1 x 240 340 XLPE Cu1012 2 x 240 1 x 150/1 x 150 220/220 XLPE Cu 2 x 185/2 x185 410/410 PVC Cu1002 2 x 240 1 x 185/1 x 185 220/230 XLPE Cu 2 x 150/2 x150 310/340 XLPE Cu1052 - 1152 - 1162 2 x 240 1 x 185/1 x 185 220/220 XLPE Cu 2 x 150/2 x150 310/310 XLPE CuUnit wit option 811002 to 1162 4 x 240 2 x 185 220 XLPE Cu 4 x 150 310 XLPE Cu

* Power supply wire section (see diagram in chapter ‘Electrical connection’).

Note: The current values used are given for a unit without option 84 (water pump supply).

5.6 - fie d contro wirin

Refer to the 30XA/30XW Pro-Dialog Controls IOM andthe certied wiring diagram supplied with the unit for theeld control wiring of the following features:• Customer interlock• Remote on/off switch• Demand limit external switch• Remote dual set point• Alarm, alert and operation report• Evaporator pump control• Heat reclaim condenser pump control (option)• Hot water valve control (option)• Various interlocks on the Energy Management Module

(EMM) board (accessory or option)

CCN bus connection• The permanent connection to the system CCN bus is

made 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 re erve or t e u er

Control circuit reserve:After all required options have been connected, the TCtransformer includes a power reserve that can be used forthe eld control wiring:• Unit without option 084* 2 A (24 V a.c.) or 48 VA• Unit with option 084* 1.3 A (24 V a.c.) or 30 VA

* 084 or 084R or 084D

At this TC transformer the 230 V, 50 Hz circuit allows thesupply of a battery charger for a portable computer at 0.8 Amaximum at 230 V. The connection is via an EEC 7/16 typesocket (2 poles without earth) located under the controlbox and accessible from outside. Only devices with class IIdouble insulation can be connected at this socket.



15

6 aPPlICaTION DaTa

6.1 - Oper tin imit or 30XW unit

30XW--/30XW-P Minimum M ximumEv por torEntering temperature at start-up - 35.0°CLeaving temperature during operation 3.3°C* 20.0°CEntering/leaving temperature difference at full load 2.8 K 11.1 K

Conden erEntering temperature at start-up 13.0°C -Leaving temperature during operation 19.0°C** 50.0°C***

Entering/leaving temperature difference at full load 2.8 K 11.1 K* For low-temperature applications, where the leaving water temperature is

below 3.3°C, a frost protection solution must be used. Please refer to option 5and option 6.

** If the temperature leaving the condenser is below 19°C, a water flow controlvalve must be used at the condenser (two or three-way valve). Please refer tooption 152 to ensure the correct condensing temperature.

*** Please refer to option 150 for applications with a high condenser leavingtemperature (up to 63°C).

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

6.2 - Minimum c i ed w ter ow

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

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

for minimum c i ed w ter ow r te

le end1 Evaporator2 Recirculation

6.3 - M ximum c i ed w ter ow

The maximum chilled water ow 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 ow rate (see option100C in the table in chapter 6.5).

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

for m ximum c i ed w ter ow r te

le end1 Evaporator2 Bypass

Evaporator leaving water temperature, °C

C o n d e n s e r l e a v i n g w a t e r t e m p e r a t u r e

, ° C

1

2

1

2

6.4 - Conden er w ter ow r te

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

If the system ow is higher than the maximum unit owrate, select the option with one pass less that will allow ahigher maximum water ow rate. Please refer to option102C in the table in chapter 6.5.

15

20

25

30

35

40

45

50

55

0 5 1 0 15 20

From approx. 45% to full load

Part load limit approx. 35% Minimum load limit approx.15%



16

6.7 - V ri b e ow ev por tor

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

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

Bad

Bad

Good

Good

6.5 - st nd rd nd option number o w ter p e

st nd rd-e icienc unit 30XW-- hi -e icienc unit 30XW-Psize 452 552 602 1002 1052 1152 512 562 1012 1162Ev por torStandard 2 2 2 1 1 1 2 2 1 1Option 100C 1 1 1 N/A N/A N/A 1 1 N/A N/AOption 100A N/A N/A N/A 2 2 2 N/A N/A 2 2Conden erStandard 2 2 2 2 2 2 2 2 2 2Option 102C N/A N/A N/A 1 1 1 N/A N/A 1 1

N/A - option not available for the specified size

6.6 - Ev por tor nd conden er w ter ow r te

st nd rd-e icienc unit 30XW-- hi -e icienc unit 30XW-Psize 452 552 602 1002 1052 1152 512 562 1012 1162Ev por tor w ter ow r te, /Minimum 4 4 4 15 15 18 6 6 22 22Maximum 40 40 40 173 173 197 57 57 223 223Conden er w ter ow r te, /Minimum 4 4 4 8 8 9 6 6 12 12Maximum 42 42 42 87 87 101 48 48 119 119

Note- Minimum flow rate based on a water velocity of 0,3 m/s- Maximum flow rate based on a pressure drop of 120 kPa

6.8 - s tem minimum w ter vo ume

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

app ic tion NNormal air conditioning 3.25Process 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 bafed in order to ensure proper mixingof the liquid (water or brine). Refer to the examples below.

Connection to bu er t n



17

P r e s s u r e d r o p

, k P a

Water flow rate, l/s

6.10 - Conden er pre ure drop curve


, k P a

Water flow rate, l/s


, k P a


, k P a

1

10

100

0 25 50 75 100 125 150 175 200

512 562

1012 116221

21

1 2

1

10

100

0 25 50 75 100 125 150 175 200

512 562

1012 116221

1

10

100

0 25 50 75 100 125 150 175 200

452 552 602

1002 1052

1152

1

2

3

1

2

3

1

10

100

0 25 50 75 100 125 150 175 200

452 552 602

1002 1052

1152

1

2

3

1

2

3

6.9 - Ev por tor pre ure drop curve

Standard-efciency units 30XW--/30XWH- High-efciency units 30XW-P/30XWHP

Standard-efciency units 30XW--/30XWH- High-efciency units 30XW-P/30XWHP

Water flow rate, l/s Water flow rate, l/s



18

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 certied 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 ltering,treatment, control devices, isolation and bleed valves andcircuits built in, to prevent corrosion, fouling and deteriora-tion of the pump ttings. Consult either a water treatmentspecialist or appropriate literature on the subject.

7.1 - Oper tin prec ution

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 an expansion device 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 exible 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 uid that could foul

the heat exchanger, a screen lter should be installedahead of the pump. The mesh size of the lter must be1.2 mm (see ‘Typical water circuit’ diagram on the right).

• Before the system start-up verify that the water circuitsare connected to the appropriate heat exchangers (e.g.no reversal between evaporator and condenser).

• Do not introduce any signicant 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 uidis compatible with the materials and the water circuitcoating.

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

dened in directive 97/23/EC.

Carrier recommendations on heat exchange uids:• No NH 4+ ammonium ions in the water, they are very

detrimental 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.

• SO 42- sulphate ions can cause perforating corrosion, if

their content is above 30 mg/l.• No uoride ions (<0.1 mg/l).• No Fe 2+ and Fe 3+ ions with non negligible levels of dis-

solved oxygen must be present. Dissolved iron < 5 mg/lwith dissolved oxygen < 5 mg/l.

• Dissolved silicon: silicon is an acid element of waterand can also lead to corrosion risks. Content < 1 mg/l.

• Water hardness: > 0.5 mmol/l. Values between 1 and2.5 can be recommended. This will facilitate scaledeposit that can limit corrosion of copper. Values thatare too high can cause piping blockage over time. Atotal alkalimetric titre (TAC) below 100 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.

• Specic resistance – electric conductivity: the higher thespecic resistance, the slower the corrosion tendency.Values above 30 Ohm·m are desirable. A neutralenvironment favours maximum specic resistancevalues. For electric conductivity values in the order of

20-60 mS/m can be recommended.• pH: Ideal case pH neutral at 20-25°C 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.

Charging and removing heat exchange uids should be donewith devices that must be included on the water circuit bythe installer. Never use the unit heat exchangers to addheat exchange uid.



19

7.2 - W ter connection

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

Inlet/outlet diameters

st nd rd-e icienc unit 30XW-- /30XWh- hi -e icienc unit 30XW-P/30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Ev por torUnit wit out option 100C or 100aDiameter in 5 5 5 6 6 8 6 6 8 8Outside diameter mm 141 141 141 168 168 219 168 168 219 219

Option 100C Diameter in 6 6 6 N/A N/A N/A 6 6 N/A N/AOutside diameter mm 168 168 168 N/A N/A N/A 168 168 N/A N/AOption 100a Diameter in N/A N/A N/A 6 6 8 N/A N/A 8 8Outside diameter mm N/A N/A N/A 168 168 219 N/A N/A 219 219Conden erUnit wit out option 102CDiameter in 5 5 5 8 8 8 6 6 8 8Outside diameter mm 141 141 141 219 219 219 168 168 219 219Option 102C Diameter in N/A N/A N/A 8 8 8 N/A N/A 8 8Outside diameter mm N/A N/A N/A 219 219 219 N/A N/A 219 219

N/A - option not available for the specified size

NOTE: Before this operation we recommend draining the

circuit and disconnecting the pipes to be sure that the boltsare correctly and uniformly tightened.

7.5 - Oper tion o two unit in m ter/ ve mode

The control of a master/slave assembly is in the enteringwater and does not require any additional sensors (standardconguration). It can also be located in the leaving water.In this case two additional sensors must be added on thecommon piping.

All parameters, required for the master/slave function mustbe congured using the MST_SLV menu.

All remote controls of the master/slave assembly (start/stop, set point, load shedding etc.) are controlled by theunit con-gured as master and must only be applied to themaster unit.

Each unit controls its own water pump. If there is only onecommon pump, in cases with variable ow, isolation valvesmust be installed on each unit. They will be activated at theopening and closing by the control of each heat pump (inthis case the valves are controlled using the dedicated waterpump outputs). See the 30XA/30XW Pro-Dialog Control

IOM for a more detailed explanation.

7.3 - f ow contro

Evaporator ow switch and chilled water pump interlock

IMPORTANT: On 30XW units, the unit water ow switchmust be energised, and the chilled water pump interlockmust be connected. Failure to follow this instruction willvoid the Carrier guarantee.

The water ow 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 qualied personnel trained by Carrier Service.

Terminals 34 and 35 are provided for eld installation ofthe chilled water pump interlock (auxiliary contact for pumpoperation to be wired on site).

7.4 - Ev por tor nd conden er w ter box bo tti tenin

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 accordance withthe illustration in the example below.

W ter box ti tenin e uence

1

2

1

2

3

1514

9

137

4

10

6

16

5

8

11

12

le end1 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



20

30XW wit con i ur tion: e vin w ter controle end

1 Master unit2 Slave unit

Control boxes of the master and slave units

Water inlet

Water outlet

Water pumps for each unit (included as standard for units with hydronicmodule)

Additional sensors for leaving water control, to be connected to channel 1 ofthe slave boards of each master and slave unit

CCN communication bus

Connection of two additional sensors

1 2

8 hEaT MaChINE UNITs 30XWh aND 30XWhP

8.1 - Tec nic d t o t e he t M c ine unit

st nd rd-e icienc unit 30XWh- hi -e icienc unit 30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Nominal cooling capacity* kW 476 538 553 1023 1060 1168 508 573 1039 1175Power input* kW 85 96 99 181 196 199 87 97 173 191Heating capacity* kW 553 625 643 1187 1238 1349 587 661 1196 1348

Nominal cooling capacity** kW 423 483 519 910 940 1091 470 537 961 1087Power input** kW 110 124 130 233 253 261 114 127 227 252Heating capacity** kW 523 595 637 1122 1169 1328 574 653 1168 1316

* Values based on the following conditions: evaporator entering/leaving water temperature = 10°C/7°C, condenser entering/leaving water temperature = 30°C/35°C,evaporator and condenser fouling factor = 0.18 x 10 -4 (m 2 K)/W.

Not applicable for units with high condensing temperatures. Please refer to the selection in the electronic catalogue or to chapter 9.1.** Values based on the following conditions: evaporator entering/leaving water temperature = 10°C/7°C, condenser entering/leaving water temperature = 40°C/45°C, evaporator and condenser fouling factor = 0.18 x 10 -4 (m 2 K)/W Not applicable for units with high condensing temperatures. Please refer to the selection in the electronic catalogue or to chapter 9.1.

8.2 - E ectric d t or he t M c ine unit

The electrical data for the Heat Machine units 30XWH-/30XWHP are the same as for the 30XW--/30XW-P units.Please refer to chapter 4.4.

8.3 - Dimen ion nd c e r nce

The dimensions and clearances are the same as for the30XW--/30XW-P units. Please refer to chapter 3.

8.4 - Oper tin r n eThe operating limits are the same as for the 30XW--/30XW-Punits. Please refer to chapter 6.1.

8.5 - Oper tin mode

8.5.1 - Cooling modeThis operating mode is the same as that for 30XW units.The unit controls on the cooling setpoint.

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



21

9 OPTION fOR hIgh CONDENsINg TEMPERaTUREs OPTION 150

9.1 - P ic d t or 30XW unit wit option 150

st nd rd-e icienc unit 30XW--/30XWh- hi -e icienc unit 30XW-P/30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Nominal cooling capacity* kW 467 521 536 990 1027 1130 503 560 1019 1147Power input* kW 94.6 99.9 103.3 194.7 208.8 209.2 101.3 104.1 197.6 214.8Heating capacity** kW 497 560 597 1051 1088 1245 561 622 1112 1245Nominal cooling capacity*** kW 425 482 518 911 934 1089 474 537 970 1080Power input*** kW 109 117 124 227 242 252 120 125 236 256Heating capacity*** kW 525 588 631 1117 1155 1318 584 651 1185 1313

* Values based on: evaporator entering/leaving water temp. = 12°C/7°C, condenser entering/leaving water temp. = 30°C/35°C, evaporator and condenser fouling factor= 0.18 x 10 -4 (m 2 K)/W

** Values based on: condenser entering/leaving water temp. = 40°C/45°C, evaporator entering water temp. = 10°C, same flow rate as for cooling mode conditions*** Values based on: evaporator entering/leaving water temp. = 10°C/7°C, condenser entering/leaving water temp. = 40°C/45°C, evaporator and condenser fouling factor

= 0.18 x 10 -4 (m 2 K)/W

9.2 - E ectric d t or 30XW unit wit option 150 (inc udin option 81)

st nd rd-e icienc unit 30XW--/30XWh- hi -e icienc unit 30XW-P/30XWhPsize 452 552 602 1002 1052 1152 512 562 1012 1162Power circuitNominal power supply V-ph-Hz 400-3-50 ± 10%Contro circuit upp 24 V via the built-in transformerNomin t rt-up current*Circuit A**** A 587 587 587 587 587 587 587 587 587 587Circuit B**** A - - - 587 587 587 - - 587 587Option 81 A - - - 757 757 757 - - 737 757

M ximum t rt-up current**Circuit A**** A 587 587 587 587 587 587 587 587 587 587Circuit B**** A - - - 587 587 587 - - 587 587Option 81 A - - - 887 887 887 - - 862 887Co ine p i nomin *** 0.83 0.84 0.84 0.84 0.84 0.84 0.83 0.84 0.83 0.84Co ine p i m ximum**** 0.88 0.89 0.89 0.89 0.89 0.89 0.88 0.89 0.88 0.89M ximum power input†Circuit A kW 167 185 185 185 185 185 167 185 167 185Circuit B kW - - - 167 185 185 - - 167 185Option 81 kW - - - 352 370 370 - - 335 370Nomin current dr wn***Circuit A A 150 170 170 170 170 170 150 170 150 170Circuit B A - - - 150 170 170 - - 150 170Option 81 A - - - 320 340 340 - - 299 340M ximum current dr wn (Un)†Circuit A A 275 300 300 300 300 300 275 300 275 300Circuit B A - - - 275 300 300 - - 275 300Option 81 A - - - 575 600 600 - - 550 600

M ximum current dr wn (Un - 10%)****Circuit A A 300 330 330 330 330 330 300 330 300 330Circuit B A - - - 300 330 330 - - 300 330Option 81 A - - - 630 660 660 - - 600 660

* Instantaneous start-up current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced start-up current of the largest compressor).Values based on standard Eurovent unit operating conditions: evaporator entering/leaving water temp. = 12°C/7°C. condenser entering/leaving water temp. = 30°C/35°C.

** Instantaneous start-up current (maximum operating current of the smallest compressor(s) + locked rotor current or reduced start-up current of the largest compressor).Values obtained at operation with maximum unit power input.

*** Values based on standard Eurovent unit operating conditions: evaporator entering/leaving water temp. = 12°C/7°C. condenser entering/leaving water temp. = 30°C/35°C.**** Values obtained at operation with maximum unit power input.† Values obtained at operation with maximum unit power input. Values given on the unit name plate.



22

9.3 - Dimen ion nd c e r nce

The dimensions and clearances are the same as for the30XW units. Please refer to chapter 3.

9.4 - Oper tin imit or 30XW unit wit option 150

30XW--/30XWh-/30XW-P/30XWhP Minimum M ximumEv por torEntering temperature at start-up - 35.0°CLeaving temperature during operation 3.3°C* 15.0°CEntering/leaving temperature difference at full load 2.8 K 11.1 KConden erEntering temperature at start-up 13.0°C -Leaving temperature during operation 23.0°C** 63.0°CEntering/leaving temperature difference at full load 2.8 K 11.1 K

* For low-temperature applications, where the leaving water temperature isbelow 3.3°C, a frost protection solution must be used. Please refer to option 5and option 6.

** If the temperature leaving the condenser is below 23°C, a water flow controlvalve must be used at the condenser (two or three-way valve). Please refer tooption 152 to ensure the correct condensing temperature.


Evaporator leaving water temperature, °C


, ° C

,

From approx. 60% to full load Part load limit approx. 50%

Minimum load limit approx.30%

1 5

2 0

2 5

3 0

3 5

4 0

4 5

5 0

5 5

6 0

6 5

7 0

0 5 1 0 1 5 2 0



23

Units with the low temperature (option 5) or very lowtemperature (option 6) option allow glycol solutionproduction down to:

- 6°C with ethylene glycol and option 5 (minimumweight concentration of 25%)- 3°C with propylene glycol and option 5 (minimumweight concentration of 22%)- 12°C with ethylene glycol and option 6 (minimumweight concentration of 35%)- 8°C with propylene glycol and option 6 (minimumweight concentration of 30%)

•

•

•

•

These options are available for the following unit referencenumbers:30XW- P051230XW- P056230XW- P101230XW--1152

Options 100A (evaporator with one pass more) and 100C(evaporator with one pass less) are not compatible withoptions 5 and 6. For option 5 the evaporator must be con-gured with two passes and for option 6 with three passes.

10.1 - P ic d t , 30XW unit wit option 5 nd 6

Option 5 ( ow temper ture) Option 6 (ver ow temper ture)Re erence number P0512 P0562 P01012 -1152 P0512 P0562 P1012 -1152Nomin coo in c p cit * kW 297 326 626 685 220 243 451 492Power input kW 85 93 175 192 80 87 163 177EER kW/kW 3.49 3.51 3.58 3.57 2.75 2.79 2.77 2.78Heating capacity kW 377 414 796 872 295 325 609 664Coefficient of performance (COP) kW/kW 4.44 4.45 4.55 4.54 3.69 3.74 3.74 3.75Nomin coo in c p cit ** kW 325 357 691 755 250 274 512 557

Power input kW 87 95 179 197 81 88 166 181EER kW/kW 3.74 3.76 3.86 3.83 3.09 3.11 3.08 3.08Heating capacity kW 407 447 855 947 326 357 673 733Coefficient of performance (COP) kW/kW 4.68 4.71 4.83 4.81 4.02 4.06 4.05 4.05

Option 5* Values based on 25% ethylene glycol, evaporator entering/leaving water temperatures of -2°C/-6°C and condenser entering/leaving water temperatures of 30°C/35°C.** Values based on 22% propylene glycol, evaporator entering/leaving water temperatures of +1°C/-3°C and condenser entering/leaving water temperatures of 30°C/35°C.Note: Evaporator with 2 pass configuration with water inlet and outlet on the same side.

Option 6* Values based on 35% ethylene glycol, evaporator entering/leaving water temperatures of -8°C/-12°C and condenser entering/leaving water temperatures of 30°C/35°C.** Values based on 30% propylene glycol, evaporator entering/leaving water temperatures of -4°C/-8°C and condenser entering/leaving water temperatures of 30°C/35°C.Note: Evaporator with 3 pass configuration with water inlet and outlet on opposite sides.

10.2 - E ectric d t , 30XW unit wit option 5 nd 6

The electrical data of 30XW units with options 5 and 6 arethe same as for 30XW units with option 150. Please referto chapter 9.2.

10.3 - Dimen ion , c e r nce

The dimensions and clearances are the same as for 30XWunits. Please refer to chapter 3.

10 lOW TEMPERaTURE OPTION 5 aND VERy lOW TEMPERaTURE OPTION 6 glyCOl sOlUTION OPTIONs



24

10.4 - Oper tin r n e, 30XW unit wit option 5 nd 6

Minimum M ximumEv por torEntering water temperature at start-up - 35.0°CLeaving temperature during operation*

EG 5 Option 5 with ethylene glycol -6°C 15.0°CPG 5 Option 5 with propylene glycol -3°C 15.0°CEG 6 Option 6 with ethylene glycol -12°C 15.0°CPG 6 Option 6 with propylene glycol -8°C 15.0°C

Entering/leaving temperature difference at full load 2.8 K 11.1 K**Conden erEntering water temperature at start-up 13.0°C -

Leaving temperature during operation 19.0°C/23°C *** 55°C/63.0°C†Entering/leaving temperature difference at full load 2.8 K 11.1 K

* The operating range with evaporator leaving temperatures above 3°C ispermitted, but the performances are not optimised.

** Please refer to chapter 10.5 for the minimum recommended evaporator glycolflow rate.

*** At a condenser leaving temperature below 19°C or 23°C, depending on theconditions at the evaporator, a water flow control valve must be installed at thecondenser (two-way or three-way). Please refer to option 152 to ensure thecorrect condensing temperature.

† Depends on the conditions at the evaporator and the load conditions.


15

20

25

30

35

40

45

50

55

60

65

70

-15 -10 -5 0 5 10 15 20

Evaporator leaving glycol temperature, °C


, ° C

Operating range permitted, but performances are not optimised Full load with option 5/6 and ethylene or propylene glycol Part load limit approx. 80% Part load limit approx. 50%

Part load limit approx. 30%

10.5 - Minimum recommended ev por tor ow r te wit option 5 nd 6

Option 5 ( ow temper ture) Option 6 (ver ow temper ture)Re erence number P0512 P0562 P01012 -1152 P0512 P0562 P1012 -1152Minimum evaporator flow rate* l/s 14.9 16.3 31.3 34.3 13.6 15.1 27.9 30.5Minimum evaporator flow rate** l/s 15.5 17.0 32.9 36.0 14.2 15.6 29.2 31.7

* Recommended values with ethylene glycol at the evaporator. Minimum concentration of 25% with option 5 and of 35% with option 6.** Recommended values with propylene glycol at the evaporator. Minimum concentration of 22% with option 5 and of 30% with option 6.

10.6 - Nomin ev por tor pre ure drop wit option 5 nd 6

Option 5 ( ow temper ture) Option 6 (ver ow temper ture)Re erence number P0512 P0562 P01012 -1152 P0512 P0562 P1012 -1152

Nominal evaporator flow rate* l/s 19.0 20.9 40.1 43.9 14.9 16.5 30.6 33.3Nominal evaporator pressure drop* kPa 42 50 71 63 33 39 100 96Nominal evaporator flow rate** l/s 19.9 21.8 42.2 46.1 15.6 17.1 31.9 34.7Nominal evaporator pressure drop** kPa 50 59 77 67 50 62 121 114

Option 5* Values based on 25% ethylene glycol, evaporator entering/leaving water temperatures of -2°C/-6°C and condenser entering/leaving water temperatures of 30°C/35°C.** Values based on 22% propylene glycol, evaporator entering/leaving water temperatures of +1°C/-3°C and condenser entering/leaving water temperatures of 30°C/35°C.

Option 6* Values based on 35% ethylene glycol, evaporator entering/leaving water temperatures of -8°C/-12°C and condenser entering/leaving water temperatures of 30°C/35°C.** Values based on 30% propylene glycol, evaporator entering/leaving water temperatures of -4°C/-8°C and condenser entering/leaving water temperatures of 30°C/35°C.

EG 5

PG 5

EG 6

PG 6



25

• Filter the heat exchange uid check and carry outinternal inspections as described in EN 378-2, annex 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 le.

RepairAny repair or modication, including the replacement ofmoving parts:• must follow local regulations and be made by qualied

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

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

• An indication of any modication or repair must beshown in the monitoring and maintenance le.

Recycling

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

Operating lifeThe 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 between two neighbouring points in the vessel,based on 6 start-ups per hour over 15 years at a usagerate of 57%.

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

11.2.1 - Evaporator30XW chillers use a ooded multi-tube evaporator. Thewater circulates in the tubes and the refrigerant is on theoutside in the shell. One vessel is used to serve bothrefrigerant circuits. There is a centre tube sheet whichseparates the two refrigerant circuits. The tubes are 3/4”diameter copper with an enhanced surface inside and out.There is just one water circuit, and depending on the sizeof the chiller, there may be one, two or three water passes. The evaporator shell has a thermal insulation of 19 mmthick polyurethane foam and a water drain and purge.

It has been tested and stamped in accordance with applicablepressure codes for a maximum operating pressure of 2100kPa refrigerant-side and 1000 kPa water-side. The waterconnection of the heat exchanger is a Victaulic connection.

The products that may be added for thermal insulation of

the 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.

11 MajOR sysTEM COMPONENTs aND OPERaTIONDaTa

11.1 - Direct-drive twin- crew compre or witv ri b e c p cit ide v ve

• 30XW units use 06T geared twin-screw compressorsequipped with a variable capacity slide valve for con-tinuous control between 15% and 100% of full load.

• Nominal capacities range from 476 to 1178 kW. Thetwo compressor models used in the 30XW range(06TUW483 and 06TUW554) are economised or non-economised (depending on the size).

11.1.1 - Oil lterThe 06T screw compressor has an independent oil lter.

11.1.2 - RefrigerantThe 30XW is a liquid chiller operating only with refrigerantR-134a.

11.1.3 - Lubricant

The 06T screw compressor is approved for use with the fol-lowing lubricant: CARRIER MATERIAL SPEC PP 47-32.

11.1.4 - Oil supply solenoid valveAn oil supply solenoid valve is installed on the oil returnline as standard to isolate the compressor from oil owwhen the compressor is not operating. The oil solenoidvalve is eld replaceable.

11.1.5 - Suction and economizer ltersTo increase the reliability of the compressor, a lter hasbeen incorporated as a standard feature into suction and

economizer inlets of the compressor.11.1.6 - Capacity control systemThe 06T screw compressor has an unloading system that isstandard on all compressors. This unloading system consistsof slide valve that permits changing the length of the screwused for the refrigerant compression. This valve is controlledby the action of a piston controlled by two solenoid valveson the oil return line.

11.2 - Pre ure ve e

GeneralMonitoring during operation, re-qualication, 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 le.• Follow the control programmes of EN 378-2, annexes

A, B, C and D.• 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 the

rust formation at the insulation joints.• Regularly check for possible presence of impurities(e.g. silicon grains) in the heat exchange uids. Theseimpurities maybe the cause of the wear or corrosionby puncture.



26

11.2.2 - Condenser and oil separatorThe 30XW chiller uses a heat exchanger that is a combinationcondenser and oil separator. It is mounted below theevaporator. Discharge gas leaves the compressor and owsthrough an external mufer to the oil separator, which isthe upper portion of the heat exchanger. It enters the topof the separator where oil is removed, and then ows tothe bottom portion of the vessel, where gas is condensedand subcooled. One vessel is used to serve both refrigerantcircuits. There is a center tube sheet which separates thetwo refrigerant circuits. The tubes are 3/4” or 1” diameterinternally and externally nned copper tubes.

There is just one water circuit with two water passes (onepass as an option). For the Heat Machine units the conden-ser shell can have a thermal insulation of 19 mm thickpolyurethane foam and a water drain and purge.

It has been tested and stamped in accordance with applicablepressure codes for a maximum operating pressure of 2100kPa refrigerant-side and 1000 kPa water-side. The waterconnection of the heat exchanger is a Victaulic connection.

11.2.3 - Economiser function (depending on model)The economiser function includes a liquid line valve, a lterdrier, two electronic expansion valves (EXVs), a plate heatexchanger as well as protection devices (fuse or valve).

At the condenser outlet a part of the liquid is expanded viathe secondary EXV in one of the heat exchanger circuitsand then returns as a gas. This expansion permits increaseof the liquid sub-cooling of the rest of the ow that pene-trates the evaporator via the principal EXV. This permitsincreasing the cooling capacity of the system as well as its

efciency.11.3 - hi -pre ure et witc

30XW units are equipped with high-pressure safety switches.

In accordance with the applicable code the high-pressureswitches with manual reset, called PZH (former DBK),may be backed up by high-pressure switches that requireresetting with a tool. The high-pressure switches thatrequire resetting with a tool are called PZHH (formerSDBK). If a PZHH cuts out, the corresponding PZH inthe same compressor is faulty and must be replaced. ThePZHH must be reset with a blunt tool with a diameter ofless than 6 mm. Insert this tool into the opening on thepressure switch and push the reset button in this location.

These pressure switches are located at the discharge of eachcompressor.

11.4 - E ectronic exp n ion v ve (EXV)

The EXV is equipped with a stepper motor (2785 to 3690steps, depending on the model) that is controlled via theEXV board.

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

11.5 - Moi ture indic tor

Located on the EXV, permits control of the unit charge andindicates moisture in the circuit. The presence of bubbles inthe sight-glass indicates an insufcient charge or non-con-densables in the system. The presence of moisture changesthe colour of the indicator paper in the sight-glass.

11.6 - fi ter drier

The role of the lter 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 lter inlet and outlet shows that theelement is dirty.

11.7 - sen or

The units use thermistors to measure the temperature, andpressure transducers to control and regulate system opera-tion (see 30XA/30XW Pro-Dialog Control IOM for amore detailed explanation).



27

12 OPTIONs aND aCCEssORIEs

Option No. De cription adv nt e U eLow temperature glycol solution 5 Low temperature glycol solution production down to -6°C Covers specific applications such as ice storage

and industrial processes30XW-/30XWH,ref. P0512, P0562,P1012-1152

Very low temperature glycolsolution

6 Very low temperature glycol solution production down to-12°C

Covers specific applications such as ice storageand industrial processes

As above

No disconnect switch/no short-circuit protection

70E Unit without disconnect switch and without short-circuitprotection device

Permits an external electrical disconnect systemfor the unit.

30XW 452-60230XW 1002-1162

Single power connection point 81 Power connection of the unit via one main supplyconnection

Quick and easy installation 30XW 1002-1162

No disconnect switch/but withshort-circuit protection

82A Unit without disconnect switch, but with short-circuitprotection device

Permits an external electrical disconnect systemfor the unit. Short-circuit protection of the unitremains.

30XW 452-60230XW 1002-1162

Evaporator pump electricalpower/control circuit

84 Unit equipped with an electrical power/control circuit forsingle evaporator pumps

Quick and easy installation 30XW 452-60230XW 1002-1162

Dual evaporator pumpelectrical power/control circuit

84D Unit equipped with an electrical power/control circuit fordual evaporator pumps


Condenser pump electricalpower/control circuit

84R Unit equipped with an electrical power/control circuit forsingle condenser pumps


Service valve set 92 Valve set consisting of liquid line valve (evaporator inlet),economiser return line valve and compressor suction linevalve to isolate the various refrigerant circuit components.

Simplified service and maintenance 30XW 452-60230XW 1002-1162

Evaporator with one pass more 100A Evaporator with one pass more on the water-side.Evaporator inlet and outlet on the same side.

Quick and easy installation. Slight improvementof the unit capacities.

30XW 1002-1162

Evaporator with one pass less 100C Evaporator with one pass less on the water-side.Evaporator inlet and outlet on opposite sides.

Quick and easy installation. Reducedevaporator pressure losses.

30XW 452-602

Condenser with one pass less 102C Condenser with one pass less on the water-side.Condenser inlet and outlet on opposite sides.

Quick and easy installation. Reducedcondenser pressure losses.

30XW 1002-1162

21 bar evaporator 104 Reinforced evaporator for extension of the maximumwater-side service pressure to 21 bar

Covers applications with a high water column(high buildings)

30XW 452-60230XW 1002-1162

21 bar condenser 104A Reinforced condenser for extension of the maximumwater-side service pressure to 21 bar

Covers applications with a high water column(high buildings)

30XW 452-60230XW 1002-1162

Reversed evaporator waterconnections

107 Evaporator with reversed water inlet/outlet Simplification of the water piping 30XW 452-60230XW 1002-1162

Reversed condenser waterconnections

107A Condenser with reversed water inlet/outlet Simplification of the water piping 30XW 452-60230XW 1002-1162

JBus gateway 148B Two-directional communications board, complies withJBus protocol

Easy connection by communication bus to abuilding management system

30XW 452-60230XW 1002-1162

BacNet gateway 148C Two-directional communications board, complies withBacNet protocol

Easy connection by communication bus to abuilding management system

30XW 452-60230XW 1002-1162

LON gateway 148D Two-directional communications board, complies with

LON protocol

Easy connection by communication bus to a

building management system

30XW 452-602

30XW 1002-1162High condensing temperature 150 Increased condenser leaving water temperature up to

63°C. To ensure control of the condenser leaving watertemperature, this option must be fitted for 30XWH units(but not for 30XW units).

Allows applications with high condensingtemperature (for heat reclaim or dry coolerapplications)

30XW 452-60230XW 1002-1162

Condensing temperaturelimitation

150B Limitation of the maximum condenser leaving watertemperature to 45°C. Modification on the unit name plateto reflect the reduced power input and current values.

Avoids oversizing of the protection elementsand the power cables.

30XW 452-60230XW 1002-1162

Control for low condensingtemperature systems

152 Output signal (0-10 V) to control the condenser waterinlet valve.

Used for applications with cold water at thecondenser inlet (well water). In this case thevalve controls the water entering temperature tomaintain an acceptable condensing pressure.

30XW 452-60230XW 1002-1162

Energy Management ModuleEMM

156 Remote control module. Additional contacts for anextension of the unit control functions.

Easy connection by wired connection to abuilding management system

30XW 452-60230XW 1002-1162

Code compliance forSwitzerland

197 Additional tests on the water heat exchangers. Supply ofPED documents, dimensional drawings and test

certificates.

Conformance with Swiss regulations 30XW 452-60230XW 1002-1162

Code compliance for Australia 200 Heat exchanger approved in accordance with theAustralian code.

Conformance with Australian regulations 30XW 452-60230XW 1002-1162

acce orie De cription adv nt e U eCCN JBus gateway See option 148B See option 148B 30XW 452-602

30XW 1002-1162CCN BacNet gateway See option 148C See option 148C 30XW 452-602

30XW 1002-1162CCN LON Talk gateway See option 148D See option 148D 30XW 452-602

30XW 1002-1162Energy Management ModuleEMM

See option 156 Easy connection by wired connection to abuilding management system

30XW 452-60230XW 1002-1162

Lead-lag kit Supplementary water outlet temperature sensor kit, field-installed, allows master/slave operation of two chillersconnected in parallel.

Optimised operation of two chillers connected inparallel with operating time balancing.

30XW 452-60230XW 1002-1162

Water connection kit for weldedconnections

Victaulic piping connections with welded joints. Easy installation 30XW 452-60230XW 1002-1162

Water connection kit for flangedconnections

Victaulic piping connections with flanged joints. Easy installation 30XW 452-60230XW 1002-1162



28

• Clean the water lter (see chapter 7 “Waterconnections”).

• 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.

13.3 - leve 3 (or i er) m inten nce

See note below.The maintenance at this level requires specic 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 the

HVAC unit nul and void, and the manufacturer, Carrier

France, will no longer be held responsible.13.4 - Ti tenin tor ue or t e m in e ectricconnection

screw t pe De i n tion Tor ue in t e unit v ue (Nm)screw on bu b r, cu tomer connectionM12 L1/L2/L3 70so dered crew PE, cu tomer connection (M12) PE 70screw on u ed di connect in et zoneFused disconnect 1034061/M10, customer connection L1/L2/L3 30Fused disconnect 1034061/M12, Y/D outlet QS10- 70Fused disconnect 3KL7141 QS10- 70Fused disconnect 3KL7151 QS10- 70Tunne termin crew, compre or cont ctorContactor 3RT104- KM- 5Contactor 3RT105- KM- 11Contactor 3RT106- KM- 21Tunne termin crew, current tr n ormerSize 2 (3RB2966-) TI- 11Compre or e rt termin in t e power wirin contro boxM12 Gnd 70Compre or p e connection termin M12 1/2/3/4/5/6 25 on EC-Compre or e rt connection Gnd on EC- 25Tunne termin crew, w ter pump di connectDisconnect switch 3RV101- QM90- 2,5Disconnect switch 3RV102- QM90- 2,5Disconnect switch 3RV103- QM90- 4Tunne termin crew, w ter pump cont ctorContactor 3RT102- KM90- 2.5Contactor 3RT103- KM90- 4

13 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 ve maintenance levels for HVAC units, asdened by the AFNOR X60-010 standard.

13.1 - leve 1 m inten nce

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 chapter“Condenser 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 30XA/30XW Pro-Dialog Pluscontrol manual).

General visual inspection for any signs of deterioration.

13.2 - leve 2 m inten nceSee note below.This level requires specic know-how in the electrical,hydronic and mechanical elds. 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 operation

every 6 months.• Remove the dust and clean the interior of the control

boxes, if required.• Check the presence and the condition of the electrical

protection devices.• Replace the fuses every 3 years or every 15000 hours

(age-hardening).• Replace the control box cooling fans used with option

22 (with designation EF22_) every ve years.• Check the water connections.• Purge the water circuit (see chapter 7 “Water

connections”).



29

13.5 - Ti tenin tor ue or t e m in bo t nd crew

screw t pe U ed or Tor ue v ue (Nm)Taptite screw M10 Economizer module, control box fixing 30Taptite screw M6 Piping support 7Screw H M6 Piping clip 10Screw H M8 Filter drier cover 40Screw H M12 Economiser port flange 40Screw H M16 Heat exchanger water boxes, structure, fixing compressor 190Screw H M20 Suction flanges 190Nut 5/8 ORFS Oil line 65

Nut 3/8 ORFS Oil line 26Nut 7/8 ORFS Oil line 125Nut M16 Discharge line 190Nut M20 Chassis 190

13.6 - Ev por tor nd conden er m inten nce

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

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

of leakage.

13.7 - Compre or m inten nce

13.7.1 - Oil lter change scheduleAs system cleanliness is critical to reliable system operation,there is a lter in the oil line at the oil separator outlet. Theoil lter is specied to provide a high level of ltration (5 µm)required for long compressor life.

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

The pressure drop across the lter 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 lter, 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 lter pressuredrop.

13.7.2 - 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 the com-pressor within one second. Reverse rotation is most likelyto occur whenever the wiring at the compressor terminalshas been modied.

To minimize the opportunity for reverse rotation, the follow-ing procedure must be applied. Rewire the power cables tothe compressor terminal pin as originally wired. Apply acounter-torque at the lower nut at the supply cable terminalduring installation.

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 veried; atthis point, the switch will be removed.

The switch that has been selected for detecting reverserotation is Carrier part number HK01CB001. This switchopens the contacts when the pressure falls below 7 kPa. Theswitch is a manual reset type that can be reset after thepressure has once again risen above 70 kPa. It is criticalthat the switch be a manual reset type to preclude thecompressor from short cycling in the reverse direction.



30

14 sTaRT UP ChECklIsT fOR 30XW lIqUID ChIllERs UsE fOR jOB fIlE

Pre imin r in orm tion

Job name: ...............................................................................................................................................................................................Location: ................................................................................................................................................................................................Installing contractor:.............................................................................................................................................................................Distributor: ............................................................................................................................................................................................

Unit

Model: ............................................................................................

CompresseursCircuit A Circuit BModel number ............................................................................... Model number ...........................................................................Serial number ................................................................................ Serial number ............................................................................Motor number ............................................................................... Motor number ...........................................................................

EvaporatorModel number ...............................................................................Serial number ................................................................................

Condenser sectionModel number ...............................................................................Serial number ................................................................................

Additional optional units and accessories ..........................................................................................................................................................................................................................................................................................................................................................

Pre imin r e uipment c ec

Is there any shipping damage? .................................................... If so, where? ................................................................................................................................................................................................................................................................................................Will this damage prevent unit start-up? .............................................................................................................................................

Unit is level in its installation Power supply agrees with the unit nameplate Electrical circuit wiring has been sized and installed properly 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 Chilled water pump (CWP) is operating with the correct rotation. Check the phase sequence of the electrical connection.If the unit is equipped with a hydronic module, use the pump test function (refer to the 30XA/30XW Pro-Dialog controlmanual). After the pump test has been completed, switch the unit off again

Circulate chilled water in the water circuit for at least two hours, then remove, clean and replace the screen lter. Afterthe pump test has been completed, switch the unit off again.

Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm. The compressor ange has been removed.



31

Unit start-up Oil level is correct All discharge and liquid valves are open Locate, repair and mark all refrigerant leaks All suction valves are open, if used All oil line valves and economizer valves (if used) are open Checks have been carried out for any possible leaks. Unit has been leak checked (including ttings)

- on the whole unit - at all connections Locate, repair, and report any refrigerant leaks ...................................................................................................................... ...................................................................................................................................................................................................... ......................................................................................................................................................................................................

Check voltage imbalance: AB ............ AC ................. BC.................. Average voltage = .............................. V Maximum deviation = ....................... V Voltage imbalance = .......................... %

Voltage imbalance is less than 2%

WARNING: Operation of the chiller with an improper supply voltage or excessive phase imbalance constitutes abusewhich will invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 10% for current, contact

your local electricity supply at once and ensure that the chiller is not switched on until corrective measures have beentaken.

Check cooler water loop Water loop volume = .......................... litres Calculated volume = .......................... litres 3.25 litres/nominal kW capacity for air conditioning 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 Entering cooler = ................................ kPa Leaving cooler = ................................. kPa Leaving - entering = ........................... kPa

WARNING: Plot cooler pressure drop on performance data table (in product data literature) to determine total litres per second (l/s) and nd unit’s minimum ow rate.

Total = .................................................. l/s Nominal kW = .................................... l/s Total l/s is greater than unit’s minimum ow rate Total l/s meets job specied requirement of ......................................... l/s

WARNING: Once power is supplied to the unit, check for any alarms (refer to the 30XA/30XW Pro-Dialog control IOM for the alarm menu).

Note all alarms: .................................................................................... .............................................................................

.............................................................................................. .............................................................................................

NOTE:The pouch supplied with the unit contains the label indicating the refrigerant used and describing the procedurerequired under the Kyoto Protocol F-Gas Regulation:• Attach this label to the machine.• Follow and observe the procedure described.

Notes: .................................................................................... .............................................................................................

.............................................................................................. .............................................................................................



Carrier is participating in the Eurovent Certification Programme for liquidchilling packages. Products are as listed in the Eurovent Directory of

Certified Products or on the Internet site www.eurovent-certification.com.

This programme covers air-cooled chillers up to 600 kW and water-cooled chillers up to 1500 kW.

Chiller-pre Commission Checks

Documents

Transcript of Chiller-pre Commission Checks