Carrier 30XV user guide manual

Variable Speed Air-Cooled Liquid Chillers

with Greenspeed

Installation Instructions

AquaForce

30XV140-500

®

Intelligence

®

CONTENTS

Page

SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . .1,2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 1 — Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . 3

Step 2 — Place, Mount and Rig the Unit . . . . . . . . . 3

•PLACING UNIT

• MOUNTING UNIT

• EXPORT SHIPPING RAILS

• RIGGING UNIT

Step 3 — Make Refrigerant, Evaporator Fluid

and Drain Piping Connections . . . . . . . . . . . . . . . . 83

• GENERAL

• EVAPORATOR PUMP CONTROL

• PREPARATION FOR YEAR-ROUND OPERATION

Step 4 — Fill the Chilled Water Loop . . . . . . . . . . . . 90

• WATER SYSTEM CLEANING

• WATER TREATMENT

• SYSTEM PRESSURIZATION

• FILLING THE SYSTEM

• SET WATER FLOW RATE

• FREEZE PROTECTION

• PREPARATION FOR WINTER SHUTDOWN

Step 5 — Make Electrical Connections . . . . . . . . . . 92

• POWER SUPPLY

• FIELD POWER CONNECTIONS

•POWER WIRING

• FIELD CONTROL POWER CONNECTIONS

• CARRIER COMFORT NETWORK
COMMUNICATION BUS WIRING

• NON-CCN COMMUNICATION WIRING

• FIELD CONTROL OPTION WIRING

• DUAL CHILLER LEAVING WATER SENSOR

Step 6 — Install Accessories . . . . . . . . . . . . . . . . . . . 107

• ENERGY MANAGEMENT MODULE

• UNIT SECURITY/PROTECTION ACCESSORIES

• COMMUNICATION ACCESSORIES

• SERVICE OPTIONS

Step 7 — Leak Test Unit. . . . . . . . . . . . . . . . . . . . . . . . 107

• DEHYDRATION

• REFRIGERANT CHARGE

®

WARNING

Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser­vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.

WARNING

Electrical shock can cause personal injury and death. After
unit power is disconnected, wait at least 20 minutes for the
VFD (variable frequency drive) capacitors to discharge
before opening drive.

WARNING

DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented in accordance
with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigerating and Air-Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen­trations of vapor is harmful and may cause heart irregulari­ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail­able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can

be hazardous due to system pressures, electrical compo­nents, and equipment location (roof, elevated structures,
etc.). Only trained, qualified installers and service techni­cians should install, start up, and service this equipment.
When working on this equipment, observe precautions in
the literature, on tags, stickers, and labels attached to the
equipment, and any other safety precautions that apply. Fol­low all safety codes. Wear safety glasses and work gloves.
Use care in handling, rigging, and setting this equipment,
and in handling all electrical components.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53300195-01 Printed in U.S.A. Form 30XV-6SI Pg 1 8-17 Replaces: 30XV-1SI

WARNING

CAUTION

DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.

To remove a component, wear protective gloves and gog­gles and proceed as follows:

a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-

tem using both high-pressure and low pressure ports.

c. Traces of vapor should be displaced with nitrogen and

the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.

d. Cut component connection tubing with tubing cutter

and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.

e. Carefully unsweat remaining tubing stubs when nec-

essary. Oil can ignite when exposed to torch flame.

Failure to follow these procedures may result in personal
injury or death.

CAUTION

Standard Tier units (units with S in the 10th position of
the model number) without condenser fan VFDs (units
with “-”, “1”, “3”, or “5” in the 13th position of the
model number) must have the condenser fan(s) rotation
verified to ensure proper phasing. Correct rotation is
counter-clockwise (reference arrow on fan cap). Swap
any two incoming power leads to correct condenser fan
rotation before starting chiller. Operating the unit with­out testing the condenser fan(s) for proper phasing could
result in equipment damage.

CAUTION

DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations. DO NOT leave refrigerant system open to
air any longer than the actual time required to service the
equipment. Seal circuits being serviced and charge with
dry nitrogen to prevent oil contamination when timely
repairs cannot be completed. Failure to follow these proce­dures may result in damage to equipment.

This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.

Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dis­sipate body electrostatic charge before working inside con­trol center.

Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.

This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio com­munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Inter­national Standard in North America EN 61000-2/3 which
are designed to provide reasonable protection against such
interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to
cause interference, in which case the user, at his own
expense, will be required to take whatever measures may
be required to correct the interference.

Always store and transport replacement or defective boards
in anti-static shipping bag.

CAUTION

To prevent potential damage to heat exchanger tubes,
always run fluid through heat exchanger when adding or
removing refrigerant charge. Use appropriate antifreeze
solutions in evaporator fluid loop to prevent the freezing of
heat exchanger or interconnecting piping when the equip­ment is exposed to temperatures below 32 F (0° C). Proof
of flow switch is factory installed on all models. Do NOT
remove power from this chiller during winter shut down
periods without taking precaution to remove all water from
heat exchanger. Failure to properly protect the system from
freezing may constitute abuse and may void warranty.

IMPORTANT: If the compressor VFD enclosure is
removed for service, it must be reinstalled to protect
the drive from water intrusion. Failure to reinstall the
compressor VFD enclosure may constitute abuse and
may void warranty.

2

INTRODUCTION

These instructions cover installation of 30XV140-500 air-

cooled liquid chillers with Greenspeed
tronic controls, and units with factory-installed options
(FIOPs). See Fig. 1.

®

intelligence and elec-

INSTALLATION

Storage —

fore installation or start-up, be sure to protect the machine
from construction dirt. Keep protective shipping covers in
place until the machine is ready for installation.

If the unit is to be stored for a period of time be-

Step 1 — Inspect Shipment — Inspect unit for dam-

age upon arrival. If damage is found, immediately file a claim
with the shipping company, and contact your local Carrier
representative.

Step 2 — Place, Mount, and Rig the Unit —

When considering a location for the unit, be sure to consult
NEC (National Electrical Code, U.S.A.) and/or local code
requirements. Allow sufficient space for airflow, wiring, pip­ing, and service. See Fig. 2-20.

NOTE: To facilitate refrigerant vent piping, all units have fus­ible plugs with
flares and pressure reliefs with 3/4 in. NPT and 3/8 in. SAE flare
fittings (if required by local codes).

PLACING UNIT — Locate the unit so that the condenser
airflow is unrestricted both above and on the sides of the
unit. Airflow and service clearances are 6 ft (1.8 m) around
the unit. Acceptable clearance on the sides or ends without
control boxes or VFDs can be reduced to 3 ft (1 m) without
sacrificing performance as long as the remaining three sides

1

/4 in. SAE (Society of Automotive Engineers)

are unrestricted. Acceptable clearance on the side with a
control box or VFD can be reduced to 4 ft (1.3 m) due to
NEC regulations, without sacrificing performance as long
as the remaining three sides are unrestricted. Provide ample
room for servicing and removing the evaporator. See Fig. 2­20 for required clearances. Local codes for clearances take
precedence over the manufacturer’s recommendations when
local codes call for greater clearances.

If multiple units are installed at the same site, a minimum
separation of 10 ft (3 m) between the sides of the machines is
required to maintain proper airflow and minimize the chances
of condenser air recirculation.

MOUNTING UNIT — The unit may be mounted on a level
pad directly on the base rails, on a raised mounting rail
around the unit, or on vibration isolation springs. For all
units, ensure placement area is strong enough to support
unit operating weight. See Table 1. Mounting holes are pro­vided for securing the unit to the pad, mounting rail or vi­bration isolation springs. Bolt the unit securely to pad or
rails. If vibration isolators (field-supplied) are required for a
particular installation, refer to unit weight distribution in
Fig. 21 to aid in the proper selection of isolators. Once in­stalled, the unit must be level to within

1

/8-in. per ft (1 cm
per meter) along the long axis of the oil separator. This is re­quired for oil return to the compressor(s). For more details
about physical data, see Tables 2 and 3.

NOTE: For units that are point loaded, such as those using rub­ber and shear isolators, the base rail must be supported with a
24 x 4 in. (610 x 102 mm) plate at each mounting location, or
base rail deflection may result. Fasten the unit to the plates
using the mounting holes.

3

LEGEND

*BACnet is a registered trademark of ASHRAE (American Society of Heating,
Refrigerating, and Air-Conditioning Engineers).

CFSP — Coil Face Shipping Protection
EMM — Energy Management Module
GFI — Ground Fault Interrupter
LON — Local Operating Network
SCCR — Short Circuit Current Rating

Fig. 1 — AquaForce® Chiller with GreenSpeed® Intelligence Model Number Designation

30XV – AquaForce® Air-Cooled Chiller

Design Series

Nominal Capacity

140 225 325 500
160 250 350
180 275 400
200 300 450

Voltage
1 – 575-3-60
2 – 380-3-60

5 – 208/230-3-60

6 – 460-3-60

Product Tiers & Evaporator Configuration

S – Standard Tier / Flooded Evaporator

M – Mid Tier / Flooded Evaporator
H – High Tier / Flooded Evaporator

- – Flooded Evaporator, 2 pass, without Heater
0 – Flooded Evaporator, 2 pass, with Heater
1 – Flooded Evaporator with Heater, Minus One Pass

2 – Flooded Evaporator with Heater for Brine Application

Evaporator Options

-

Packaging Options
L – Coil Face Shipping Protection (CFSP)
0 – CFSP, Coil Trim Panels
1 – CFSP, Coil Trim Panels, Security Grilles
2 – CFSP, Coil Trim Panels, Security Grilles, Hail Guards (End)

3 – Full Hail Guard

9 – CFSP, Coil Trim Panels, Skid + Bag
B – CFSP, Coil Trim Panels, Security Grilles, Skid + Bag
C – CFSP, Coil Trim Panels, S

ecurity Grilles, Hail Guards (End), Skid + Bag

D – Full Hail Guard, Skid, Bag

Controls Options

- – 7-in. Touch Pilot™ Display
0 – 7-in. Touch Pilot Display, EMM, GFI
1 – 7-in. Touch Pilot Display, BACnet* (MS/TP) Translator
2 – 7-in. Touch Pilot Display, EMM, GFI, BACnet (MS/TP) Translator

3 – 7-in. Touch Pilot Display, LON Translator

4 – 7-in. Touch Pilot Display, EMM, GFI, LON Translator

Electrical Options

- – Single Point Power, No Control Transformer, Std SCCR
0 – Single Point Power with Dis

connect, No Control Transformer, Std SCCR

1 – Dual Point Power, No Control Transformer, Std SCCR
2 – Dual Point Power with Disconnect, No Control Transformer, Std SCCR

3 – Single Point Power, Control Transformer, Std SCCR

4 – Single Point Power with Disconnect, Control Transformer, Std SCCR
5 – Dual Point Power, Control Transformer, Std SCCR
6 – Dual Point Power with Disconnect, Control Transformer, Std SCCR
8 – Single Point Power with Disconnect, No Control Transformer, High SCCR
B – D

ual Point Power with Disconnect, No Control Transformer, High SCCR

D – Single Point Power with Disconnect, Control Transformer, High SCCR
G – Dual Point Power with Disconnect, Control Transformer, High SCCR

Valve & Insulation Options

- – No Suction Service Valve, Actuated Discharge Valves,

No Suction Line Insulation
0 – Suction Service Valve, Actuated Discharge Valves,
No Suction Line Insulation
1 – No Suction Service Valve, Manual Discharge Valves
(Middle East only), No Suction Line Insulation
2 – Suction Service Valve, Manual Discharge Va

lves
(Middle East only), No Suction Line Insulation
5 – No Suction Service Valve, Actuated Discharge Valves,
Suction Line Insulation
6 – Suction Service Valve, Actuated Discharge Valves,
Suction Line Insulation
7 – No Suction Service Valve, Manual Discharge Valves
(Middle East only), Suction Line Insulation
8 – Suction Service Valve, Ma

nual Discharge Valves

(Middle East only), Suction Line Insulation

XV

140

Condenser Options

- – Aluminum Fin/Copper Tube
0 – Copper Fin/Copper Tube
1 – Aluminum Pre-Coat Fin/Copper Tube
2 – Aluminum E-Coat Fin/Copper Tube

3 – Copper E-Coat Fin/Copper Tube

4 – Microchannel
5 – E-Coat Microchannel

Condenser Fans & Sound Options

6 3H

- – Fixed Speed Condenser Fans (Std Tier) / Variable Speed Fans (Mid and High-Tier),

Std Sound

0 – Variable Speed Condenser Fans (Std Tier only), Std Sound
1 – Fixed Speed Condenser Fans (Std Tier) / Variable Speed Fans (Mid and High-Tier),

Low Sound Kit

2 – Variable Speed Condenser Fans (Std Tier only), Low

Sound Kit

3 – Fixed Speed Condenser Fans (Std Tier) / Variable Speed Fans (Mid and High-Tier),
Std Sound, Sound Optimization

4 – Variable Speed Condenser Fans (Std Tier only), Std Sound, Sound Optimization
5 – Fixed Speed Condenser Fans (Std Tier) / Variable Speed Fans (Mid and High-Tier),

Low Sound Kit, Sou

nd Optimization

6 – Variable Speed Condenser Fans (Std Tier only), Low Sound Kit, Sound Optimization

4

Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller

5

Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller (cont)

6

Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller (cont)

7

Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller

8

Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller (cont)

9

10

Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller (cont)

11

Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller

12

Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller (cont)

13

Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller (cont)

14

Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller

15

Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller (cont)

16

Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller (cont)

17

Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller

18

Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller (cont)

19

Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller (cont)

20

Fig. 7 — 30XV 225 Mid Tier Air-Cooled Chiller

21

Fig. 7 — 30XV 225 Mid Tier Air-Cooled Chiller (cont)

22

Fig. 7 — 30XV 225 Mid Tier Air-Cooled Chiller (cont)

23

Fig. 8 — 30XV 225 High Tier Air-Cooled Chiller

24

Fig. 8 — 30XV 225 High Tier Air-Cooled Chiller (cont)

25

Fig. 8 — 30XV 225 High Tier Air-Cooled Chiller (cont)

26

Fig. 9 — 30XV 250,275 Std Tier Air-Cooled Chiller

27

Fig. 9 — 30XV 250,275 Std Tier Air-Cooled Chiller (cont)

28

Fig. 9 — 30XV 250,275 Std Tier Air-Cooled Chiller (cont)

29

Fig. 10 — 30XV 250,275 Mid Tier; 300 Std Tier Air-Cooled Chiller

30

Fig. 10 — 30XV 250,275 Mid Tier; 300 Std Tier Air-Cooled Chiller (cont)31Fig. 10 — 30XV 250,275 Mid Tier; 300 Std Tier Air-Cooled Chiller (cont)