I N S TA L L AT I O N , O P E R AT I O N A N D

TM
SmartVu MAINTENANCE INSTRUCTIONS

Water-Cooled and heat pump variable speed

Liquid Chillers
AquaForce® PUREtec greenspeed with
R1234ze(E) or optionally with R515B refrigerant

30XW-VZE / 30XWHVZE 451-1301

Nominal cooling capacity: 270 - 1688 kW - 50Hz

Original document
CONTENTS

1 - INTRODUCTION............................................................................................................................................................................. 4
1.1 - Installation safety considerations............................................................................................................................................... 4
1.2 - Equipment and components under pressure............................................................................................................................. 6
1.3 - Maintenance safety considerations............................................................................................................................................ 6
1.4 - Repair safety considerations...................................................................................................................................................... 7
2 - PRELIMINARY CHECKS................................................................................................................................................................ 9
2.1 - Check equipment received......................................................................................................................................................... 9
2.2 - Moving and sitting the unit......................................................................................................................................................... 9
3 - DIMENSIONS, CLEARANCES..................................................................................................................................................... 10
3.1 - 30XW-VZE/30XWHVZE 451-651............................................................................................................................................. 10
3.2 - 30XW-VZE/30XWHVZE 851-1301........................................................................................................................................... 11
4 - PHYSICAL AND ELECTRICAL DATA......................................................................................................................................... 12
4.1 - Physical data............................................................................................................................................................................ 12
4.2 - Electrical data........................................................................................................................................................................... 13
4.3 - Short-circuit stability current .................................................................................................................................................... 14
4.4 - Compressor electrical data...................................................................................................................................................... 14
4.5 - Compressor usage per circuit (A, B)........................................................................................................................................ 14
5 - ELECTRICAL CONNECTION...................................................................................................................................................... 16
5.1 - Power supply............................................................................................................................................................................ 16
5.2 - Voltage phase imbalance (%).................................................................................................................................................. 16
5.3 - Power connection..................................................................................................................................................................... 16
5.4 - Recommended wire sections................................................................................................................................................... 16
5.5 - Power cable entry.................................................................................................................................................................... 16
5.6 - Field control wiring................................................................................................................................................................... 16
5.7 - 24 and 230 V power reserve for the user................................................................................................................................. 16
6 - APPLICATION DATA.................................................................................................................................................................... 17
6.1 - 30XW-VZE /30XWHVZE Operating limits................................................................................................................................ 17
6.2 - Condenser-side installation recommendation.......................................................................................................................... 17
6.3 - Minimum chilled water flow...................................................................................................................................................... 17
6.4 - Maximum chilled water flow..................................................................................................................................................... 17
6.5 - Condenser water flow rate....................................................................................................................................................... 17
6.6 - Standard and optional number of water passes....................................................................................................................... 18
6.7 - Evaporator and condenser water flow rates............................................................................................................................. 18
6.8 - Variable flow evaporator........................................................................................................................................................... 18
6.9 - System minimum water volume............................................................................................................................................... 18
6.10 - Evaporator pressure drop curves........................................................................................................................................... 19
6.11 - Condenser pressure drop curves........................................................................................................................................... 19
7 - WATER CONNECTIONS.............................................................................................................................................................. 20
7.1 - Operating precautions.............................................................................................................................................................. 20
7.2 - Water connections.................................................................................................................................................................... 21
7.3 - Flow control.............................................................................................................................................................................. 21
7.4 - Evaporator and condenser water box bolt tightening............................................................................................................... 21
7.5 - Operation of two units in master/slave mode........................................................................................................................... 21
8 - HEAT PUMPS 30XWHVZE........................................................................................................................................................... 22
8.1 - Physical data for heat pumps................................................................................................................................................... 22
8.2 - Electrical data for heat pumps.................................................................................................................................................. 22
8.3 - Dimensions and clearances for heat pumps............................................................................................................................ 22
8.4 - Operating range for heat pumps.............................................................................................................................................. 22
8.5 - Operating modes for heat pumps............................................................................................................................................. 22

The illustrations on the front cover and inside this document are for illustrative purposes only and not part of any offer for sale or
contract.

2
CONTENTS

9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA .............................................................................................................. 23

9.1 - Compressor.............................................................................................................................................................................. 23
9.2 - Oil filter..................................................................................................................................................................................... 23
9.3 - Refrigerant............................................................................................................................................................................... 23
9.4 - Lubricant.................................................................................................................................................................................. 23
9.5 - Oil supply solenoid valve.......................................................................................................................................................... 23
9.6 - Pressure vessels...................................................................................................................................................................... 23
9.7 - High Pressure SRMCR safety loop.......................................................................................................................................... 24
10 - OPTIONS AND ACCESSORIES................................................................................................................................................ 25
11 - STANDARD MAINTENANCE..................................................................................................................................................... 27
11.1 - Level 1 maintenance.............................................................................................................................................................. 27
11.2 - Level 2 maintenance.............................................................................................................................................................. 27
11.3 - Level 3 (or higher) maintenance............................................................................................................................................. 27
11.4 - Tightening of the electrical connections.................................................................................................................................. 27
11.5 - Tightening torques for the main bolts and screws.................................................................................................................. 28
11.6 - Evaporator and condenser maintenance................................................................................................................................ 28
11.7 - Compressor maintenance...................................................................................................................................................... 28
11.8 - Frequency variator maintenance........................................................................................................................................... 29
11.9 - High pressure safety loop periodic test.................................................................................................................................. 29
12 - START-UP CHECKLIST FOR 30XW-VZE LIQUID CHILLERS (USE FOR JOB FILE) ............................................................ 30

This manual applies to the following unit types:

- 30XW-VZE High-efficiency units
- 30XWHVZE Heat Machine high-efficiency units
For the operation of the control please refer to the SmartVuTM control manual.
The cover photograph is for illustrative purposes only and is not part of any offer for sale or contract.

3
1 - INTRODUCTION

The 30XW-VZE / 30XWHVZE units are designed to cool or heat For further details on physical properties, flammability &
water (or brine) for the air conditioning of buildings and industrial toxicity characteristics, hazards Identification, installation
processes. safety requirements, etc, refer to standards such as:
Prior to the initial start-up of the 30XW-VZE / 30XWHVZE units, - ASHRAE 34, EN-378, ISO-817 and ISO-5149
the people involved in the on-site installation, start-up, operation, - Safety Data Sheet (SDS) supplied by the refrigerant
and maintenance of this unit should be thoroughly familiar with manufacturer
these instructions and the specific project data for the installation - European union’s REACH database (Registration, Evaluation,
site (Machine room, etc). Authorisation and Restriction of Chemicals)
They are designed for an operating life of 15 years by assuming
a 75% utilisation factor; that is approximately 100,000 operating
1.1 - Installation safety considerations
hours. The 30XW-VZE / 30XWHVZE liquid chillers are classified as
This manual provides the necessary information to familiarize “indirect heat exchange system” and are designated to be installed
yourself with the control system before performing start-up in a special machinery room (Class C as per ISO-5149 and EN-
procedures. The procedures in this manual are arranged in the 378) where only authorized personnel have access, who are
sequence required for machine installation, start-up, operation acquainted with general and special safety precautions of the
and maintenance. establishment and are qualified and trained in monitoring and
maintenance. The access limitation device must be installed by
Always ensure that all required safety measures are followed,
the customer (e.g. cut-off, enclosure).
including those in this document, such as: wearing protective
clothing (gloves, safety glasses and shoes) using appropriate The refrigerant R1234ze(E) falls into refrigerant safety group A2L
tools, employing qualified and skilled technicians (electricians, in accordance to ISO-5149 and A2 in accordance to EN-378. No
refrigeration engineers) fully trained in the use of flammable Charge limitations apply for the level of occupancy is ‘C’. Please
refrigerants and following local regulations (see annexe E in EN refer to these standards for further details. This level needs to be
378-4-Guidelines for repairs of equipment using flammable confirmed by the customer.
refrigerants). After the unit has been received, when it is ready to be installed
To find out, if these products comply with European directives or reinstalled, and before it is started up, it must be inspected for
(machine safety, low voltage, electromagnetic compatibility, damage. Check that the refrigerant circuit(s) is (are) intact,
equipment under pressure etc.) check the declarations of especially that no components or pipes have shifted (e.g. following
conformity for these products. a shock). If in doubt, carry out a leak tightness check and verify
with the manufacturer that the circuit integrity has not been
According to ISO-819, R1234ze(E) is classified in safety group
impaired. If damage is detected upon receipt, immediately file a
A2L: Lower flammability. One of the characteristic of this
claim with the shipping company.
refrigerant is the absence of flammable mixture with air under
21°C of ambiance and controlled humidity conditions. Carrier strongly recommends employing a specialised company
However when humidity or temperature goes up, this to unload the machine.
refrigerant can become flammable and can represent a It is compulsory to wear personal protection equipment.
potential danger if flammability risks are not properly
Do not remove the skid or the packaging until the unit is in its final
mitigated within the machine room installation.
position. These units can be moved with a fork lift truck, as long
Local building codes and safety standards shall be followed. as the forks are positioned in the right place and direction on the
In absence of local codes and standards, please refer to EN- unit.
378 (2012) (Safety requirements for substances classified A2)
The units can also be lifted with slings, using only the designated
or to ISO-5149 (2014) (for substances classified A2L) as a
lifting points marked on the unit.
guide. Customer shall obtain approval from the local building
authorities. Use slings or lifting beams with the correct capacity, and always
follow the lifting instructions on the certified drawings supplied with
the unit. Do not tilt the unit more than 15°.
Safety is only guaranteed, if these instructions are carefully
followed. If this is not the case, there is a risk of material
deterioration and injuries to personnel.

Greyed text does not apply to units equipped with option 330 (Low GWP A1 R-515B refrigerant)

4
1 - INTRODUCTION

Never cover any protection devices. In accordance with the regulations applied for the design, the
This applies to the relief valves in the refrigerant or heat transfer European directive on equipment under pressure and in
medium circuits, and the pressure switches. accordance with the national usage regulations:
- These relief valves (and rupture disk if used) are not safety
Ensure that the valves are correctly installed, before operating the
accessories but damage limitation accessories in case of a
unit.
fire,
DO NOT OBSTRUCT ANY PROTECTIVE DEVICES: - The high pressure switches are the safety accessories.
This applies to any fusible plugs, rupture disks and valves fitted The relief valve must only be removed if the fire risk is fully
on the refrigerant or heat transfer fluid circuits. Check whether the controlled and after checking that this is allowed by local
original protection plugs are still present at the valve outlets. These regulations and authorities. This is the responsibility of the
plugs are generally made of plastic and should not be used. If they operator.
are still present, please remove them. Fit devices at the valve or
When the unit is subjected to fire, safety devices prevent rupture
discharge piping outlets to prevent the penetration of foreign
due to over-pressure by releasing refrigerant. The fluid may then
bodies (dust, building debris, etc.) and atmospheric agents (water
be decomposed into toxic residues when subjected to the flame:
can form rust or ice). These devices, as well as the discharge
- Stay away from the unit
piping, must not impair operation or lead to a pressure drop that
- Set up warnings and recommendations for personnel in
is higher than 10% of the set pressure.
charge to stop the fire.
CLASSIFICATION AND CONTROL: - Fire extinguishers appropriate to the system and the
In accordance with the Pressure Equipment Directive and national refrigerant type must be easily accessible.
usage monitoring regulations in the European Union, the protective The external relief valves must be connected to discharge pipes
devices fitted to these machines are classified as follows: for units installed in a room. Refer to the installation regulations,
for example those of European standards EN-378.
Device for damage
Safety These standards include a sizing method and examples for
limitation in the event of an
device(1)
external fire(2) configuration and calculation. Under certain conditions they permit
Refrigerant Side connection of several valves to the same discharge pipe.
High pressure safety loop(3) X Carrier recommends using flexible hose to connect the relief valves
External relief valve(4) X to discharge pipe. Special care shall be taken so that coupling to
Rupture disk X discharge pipe is not creating mechanical stress on relief valve
connection.
Heat transfer fuid side
External relief valve (5) (5) These pipes must be installed in a way that ensures that people
and property are not exposed to refrigerant leaks. These fluids
(1) Classified for protection in normal service situations.
may be diffused in the air, but far away from any building air intake,
(2) Classified for protection in abnormal service situations. These accessories are
sized for fires with a thermal flow of 10kW/m². No combustible matter should be or they must be discharged in a quantity that is appropriate for a
placed within 6.5m of the unit. suitably absorbing environment (Note that the R1234ze(E) and
(3) High pressure safety loop = SRMCR as described in component section of this R515B refrigerants are heavier than air).
manual and in electrical diagram.
(4) The instantaneous overpressure limitation of 10% of the operating pressure It is recommended to install an indicating device to show if part of
does not apply to this abnormal service situation. the refrigerant has leaked from the valve. The presence of oil at
The control pressure can be higher than the service pressure. In this case, either the outlet orifice is a useful indicator that refrigerant has leaked.
the design temperature or the high pressure switch ensures that the service
pressure is not exceeded in normal service situations.
Keep this orifice clean to ensure that any leaks are obvious.
(5) The selection of these relief valves must be made by the personnel responsible The calibration of a valve that has leaked is generally lower than
for completing the hydraulic installation. its original calibration. The new calibration may affect the operating
All factory-installed relief valves are lead-sealed to prevent cany range. To avoid a nuisance tripping or leaks, replace or re-calibrate
calibration change. The external relief valves must always be the valve.
vented to outside if the units are installed in a closed space. Refer Periodic check of the relief valves: See paragraph “Maintenance
to the installation regulations, for example those of European safety considerations”.
standard EN 378 and EN 13136. These pipes must be installed
Provide a drain in the discharge circuit, close to each relief valve,
in a way that ensures that people and property are not exposed
to avoid an accumulation of condensate or rain water.
to vented refrigerant. As the fluids can be diffused in the air, ensure
that refrigerant is discharged away from building air intakes, relief Ensure good ventilation, as accumulation of refrigerant in an
valves must be checked periodically. The valves must be checked enclosed space can displace oxygen and cause asphyxiation or
periodically. explosions.
The safety device shall be tested at least once a year to verify Inhalation of high concentrations of vapour is harmful and may
good operation and cut out value. cause heart irregularities, unconsciousness, or death. Vapour is
heavier than air and reduces the amount of oxygen available for
An example of test procedure without removing the pressure
breathing. These products cause eye and skin irritation.
switch is given in Section 13.8 of this manual.
Decomposition products are hazardous.
If the relief valves are installed on a change-over manifold, this is
equipped with a relief valve on each of the two outlets. Only one
of the two relief valves is in operation, the other one is isolated.
Never leave the change-over valve in the intermediate position,
i.e. with both ways open (locate the control element in the stop
position). If a relief valve is removed for checking or replacement
please ensure that there is always an active relief valve on each
of the change-over valves installed in the unit.
All factory-installed relief valves are lead-sealed to prevent any
calibration change.
The external relief valves are designed and installed to ensure
damage limitation in case of a fire.

5
1 - INTRODUCTION

1.2 - Equipment and components under NOTE: The unit must never be left shut down with the liquid
pressure line valve closed, as liquid refrigerant can be trapped between
this valve and the expansion device (This valve is situated
The units are intended to be stored and operate in an environment on the liquid line before the filter drier). In case of presence
where the ambient temperature must not be less than the lowest of a shut-off valve on the suction line (between evaporator
allowable temperature indicated on the nameplate. See section and compressor -factory option n°92), never close at the same
“Pressure vessels”. time the shut-off valve situated on the discharge line (between
compressor and condenser). One exception can be made in
1.3 - Maintenance safety considerations case of compressor removal from the refrigerant circuit.
Refer to EN378 norm for safe use of refrigerant in machinery Equip the engineers that work on the unit as follows:
rooms, especially for appropriate ventilation when using R1234ze Operations
A2L fluid. Personal protection
equipment (PPE) (1) Maintenance, Welding or
Handling
Engineers working on the electric or refrigeration components service brazing(2)
must be authorized, trained and fully qualified to do so. Protective gloves,
Never clean the chiller with a fluid at a temperature higher eye protection, X X X
safety shoe,
than 45°C. An over temperature could generate an over protective clothing.
pressure and make the relief valve discharge the refrigerant. Ear protection. X X
All refrigerant circuit repairs must be carried out by a trained Filtering respirator. X
person fully qualified to work on these units who must have
been: (1) We recommend to follow the instructions in EN 378-3.
- Trained and be familiar with the equipment and the (2) Performed in the presence of A1 refrigerant according to EN 378-1.
installation (including the refrigerant used). Never work on a unit that is still energized.
- Informed of the risks of possible explosive atmospheres Never work on any of the electrical components, until the
and can prevent them.They also have to be informed of general power supply to the unit has been cut using the
the working procedure for preventing the risk of disconnect switch(es) in the control box(es).
flammable refrigerant leaking into the atmosphere as
much as possible If any maintenance operations are carried out on the unit,
lock the power supply circuit in the open position ahead of
All welding operations must be carried out by qualified the machine.
specialists
AT T E N T I O N : T h e f r e q u e n c y v a r i a t o r s u s e d i n t h e
Maintenance operation have to be done according to national 30XW-VZE/30XWHVZE units are equipped with capacitor
rules and regulations that apply to explosive atmospheres batteries with a discharge time of twenty (20) minutes after
(e.g. reference to EN 1127-1) disconnecting the power.After disconnecting the power to
When performing service on the refrigeration circuit, ventilate the control box, wait twenty minutes before opening the
the area prior to performing any work and check for presence control box.
of refrigerant. During service operation, continue to ventilate If the work is interrupted, always ensure that all circuits are still
the air using the machine room ventilation or temporary fans. deenergized before resuming the work.
Before opening a refrigerant circuit, purge and consult the ATTENTION: Even if the unit has been stopped, the power
pressure gauges. Reclaim the refrigerant using a proper circuit remains energized, unless the unit or circuit disconnect
refrigerant reclaim device and reclaim cylinders. The switch is open. Refer to the wiring diagram for further details.
refrigerant circuit should be pumped down and then purged Attach appropriate safety labels.
with nitrogen before servicing.
CAUTION: INTERNAL FAILURE HAZARD
During a brazing operation, the refrigerant circuit should be
purged with nitrogen. Also when servicing the refrigerant An internal failure in the frequency converter can result in
circuit, all ignition sources should be disabled. serious injury, when the frequency converter is not properly
closed.
The insulation must be removed and heat generation must be
limited by using a wet cloth. Ensure that all safety covers are in place and securely
fastened, before applying power.
Any manipulation (opening or closing) of a shut-off valve must be
carried out by a qualified and authorised engineer. These
procedures must be carried out with the unit shut-down.

Greyed text does not apply to units equipped with option 330 (Low GWP A1 R-515B refrigerant)

6
1 - INTRODUCTION

OPERATING CHECKS: - A logbook must be established for the systems that

IMPORTANT INFORMATION REGARDING THE REFRIGERANT require a tightness check. It should contain the quantity
USED: and the type of fluid present within the installation (added
and recovered), the quantity of recycled fluid/regenerated/
This product contains fluorinated greenhouse gas covered
destroyed, the date and output of the leak test, the
by the Kyoto protocol.
designation of the operator and its belonging company,
Standard unit: etc.
- Fluid type: R1234ze(E) - Contact your local dealer or installer if you have any
- Global Warming Potential (GWP): 7 (source IPCC questions.
Assessment Report 4)
PROTECTION DEVICE CHECKS:
Unit with option 330: - Periodic inspections of the safety devices and external
- Fluid type: R515B overpressure devices (external relief valves) must be
- Global Warming Potential (GWP): 293 (source IPCC carried out in accordance with national regulations.
Assessment Report 4)
The company or organisation that conducts a pressure switch test
These refrigerant are classified group 2 “non-dangerous” shall establish and implement a detailed procedure to fix:
according to the critera of Pressure Equipment Directive - Safety measures
(PED) both 97/23/CE and 2014/68/CE. - Measuring equipment calibration
CAUTION: - Validating operation of protective devices
- Any handling of refrigerant contained in this product - Test protocols
must comply with the F-Gas Directive N° 517/2014 and - Recommissioning of the equipment.
any other applicable local legislation. An example of test procedure without removing the pressure
- Ensure that the refrigerant is never released to the switch is given in Section 11.9 of this manual. Consult Carrier
atmosphere during installation, maintenance or
Service for this type of test.
equipment disposal.
- The deliberate gas release into the atmosphere is strictly CAUTION: If the test leads to replacing the pressure switch,
not allowed. it is necessary to recover the refrigerant charge, these
- If a refrigerant leak is detected, ensure that it is stopped pressure switches are not installed on automatic valves
and repaired as quickly as possible. (Schraeder type).
- Only a qualified and certified personnel can perform At least once a year thoroughly inspect the protection devices
installation operations, maintenance, refrigerant circuit (valves). If the machine operates in a corrosive environment, inspect
leak test as well as the equipment disposal and the the protection devices more frequently.
refrigerant recovering. Regularly carry out leak tests and immediately repair any leaks
- The gas recovery for recycling, regeneration or (follow local codes)
destruction is at customer charge.
Ensure regularly that the vibration levels remain acceptable and
- The customer has to carry out periodic leak tests
close to those at the initial unit start-up.
In the European Union, article 2 of regulation (EU) No. 517/2014
Change the refrigerant when there are equipment failures, following a
makes these mandatory and sets their frequency. The table below
procedure such as the one described in NF E29-795 or carry out a
shows this frequency, as originally published in the regulation.
refrigerant analysis in a specialist laboratory.
Check whether an inspection frequency is also set by other
regulations or standards applicable to your system (e.g. EN 378, If the refrigerant circuit remains open for longer than a day after
ISO5149, etc.). an intervention (such as a component replacement), the openings
must be plugged and the circuit must be charged with nitrogen
System WITHOUT 12 No check
months 6 months 3 months (inertia principle). The objective is to prevent penetration of
leakage detection
System WITH leakage 24 atmospheric humidity and the resulting corrosion on the internal
No check months 12 months 6 months walls and on non-protected steel surfaces.
detection
5≤ 50 ≤
Refrigerant charge/ Charge > 1.4 - Repair safety considerations
circuit (CO2 equivalent) < 5 tons charge < charge < 500 tons*
50 tons 500 tons
Equip the engineers that work on the unit with the protections
7,4 ≤ 74,1 ≤ described in section 1.3 above.
Charge < charge Charge >
R32 (GWP 675) < charge <
7,4 kg 740,7 kg
74,1 kg 740,7 kg It is compulsory to wear personal protection equipment and a
detector of explosive atmospheres.
3,5 ≤ 34,9 ≤
R134a (GWP Charge < charge Charge >
< charge < The insulation must be removed and warming up must be limited
charge/ Circuit (kg)

1430) 3,5 kg 349,7 kg

34,9 kg 349,7 kg by using a wet cloth.
Refrigerant

2,8 ≤ 28,2 ≤ Before opening the unit, always ensure that the circuit has been
R407C (GWP Charge < charge Charge >
< charge <
1774) 2,8 kg 281,9 kg purged.
28,2 kg 281,9 kg
2,4 ≤ 23,9 ≤ If work on the evaporator is required, ensure that the piping from
R410A (GWP Charge < charge Charge >
< charge < the compressor is no longer pressurised (as the valve is not
2088) 2,4 kg 239,5 kg
23,9 kg 239,5 kg leaktight in the compressor direction.)
17,1 ≤ 170,6 ≤
Charge < Charge >
17,1 kg charge
R515B (GWP 293) < charge < 1706,5 kg
170,6 kg 1706,5 kg
HFO's :
R1234ze(E)
No requirement

(*) From 01/01/2017, customer installations must be equipped with a leakage

detection system

7
1 - INTRODUCTION

All installation parts must be maintained by the personnel in carried out using a transfer unit. An SAE connector
charge, in order to avoid material deterioration and injuries to (respectively 1/2” for R1234ze(E) and 3/8” for R515B) on the
people. Faults and leaks must be repaired immediately. The manual liquid line valve is supplied with all units for
authorized technician must have the responsibility to repair the connection to the transfer station. The units must never be
fault immediately. Each time repairs have been carried out to the modified to add refrigerant or oil charging devices, removal
unit, the operation of the protection devices must be re-checked. or purging devices. All these features are provided with the
Comply with the regulations and recommendations in unit and HVAC units. Please refer to the certified dimensional drawings for
installation safety standards, such as: EN-378, ISO-5149, etc. the units.
If a leak occurs or if the refrigerant becomes contaminated (e.g. Never use the compressor as a vacuum pump. It would
by a short circuit in a motor) remove the complete charge using damage the compressor.
a recovery unit and store the refrigerant in mobile containers. Do not re-use disposable (non-returnable) cylinders or
Repair the leak detected and recharge the circuit with the total attempt to refill them. It is dangerous and illegal. Proper
quantity of the original refrigerant (either R1234ze(E) or R515B), refrigerant cylinders designated and marked for the original
as indicated on the unit name plate. Certain parts of the circuit refrigerant stated on the nameplate should be used. When
can be isolated. Only charge liquid refrigerant at the liquid line. cylinders are empty, evacuate the remaining gas pressure,
and move the cylinders to a place designated for their
Ensure that you are using the correct refrigerant type before
recovery. Do not incinerate.
recharging the unit.
ATTENTION: Only use refrigerant, in accordance with AHRI
Charging any refrigerant other than the original charge type stated
700-2014 (Air conditioning, Heating and Refrigeration
on the nameplate will impair machine operation and can even lead
Institute). The use of any other refrigerant may expose users
to a destruction of the compressors. The compressors operating
and operators to unexpected risks.
with this refrigerant type are lubricated with a specific synthetic
polyolester oil. Do not attempt to remove refrigerant circuit components or
fittings, while the machine is under pressure or while it is
Do not use oxygen to purge lines or to pressurize a machine
running. Be sure pressure is at 0 kPa and has been purged
for any purpose. Pressurised air mixtures or gases containing
with nitrogen before removing components or opening a
oxygen can be the cause of an explosion. Oxygen reacts
circuit.
violently with oil and grease. Nitrogen should be used to
purge the system. It should also be used during brazing. Do not attempt to repair or recondition any safety devices
when corrosion or build-up of foreign material (rust, dirt,
Never exceed the specified maximum operating pressures.
scale, etc.) is found within the valve body or mechanism. If
Verify the allowable maximum high- and low-side test
necessary, replace the device. Do not install relief valves in
pressures by checking the instructions in this manual and
series or backwards.
the pressures given on the unit name plate.
ATTENTION: No part of the unit must be used as a walk-way,
Do not use air for leak testing. Use only refrigerant or dry
rack or support. Periodically check and repair or if necessary
nitrogen.
replace any component or piping that shows signs of damage.
Do not unweld or flamecut the refrigerant lines or any
The refrigerant lines can break under the weight and release
refrigerant circuit component until all refrigerant (liquid and
refrigerant, causing personal injury.
vapour) has been removed from chiller and the system has
been purged with nitrogen. Traces of vapour should be Do not climb on a machine. Use a platform, or staging to work
displaced with dry air nitrogen. Refrigerant in contact with at higher levels.
an open flame produces toxic gases. Use mechanical lifting equipment (crane, hoist, winch, etc.)
The necessary protection equipment must be available, and to lift or move heavy components. For lighter components,
appropriate fire extinguishers for the system and the use lifting equipment when there is a risk of slipping or losing
refrigerant type used must be within easy reach. your balance.
Do not siphon refrigerant. Use only original replacement parts for any repair or
component replacement. Consult the list of replacement parts
Avoid contact with liquid refrigerant on the skin or splashing
that corresponds to the specification of the original
it into the eyes. Use safety goggles. Wash any spills from the
equipment.
skin with soap and water. If liquid refrigerant enters the eyes,
immediately and abundantly flush the eyes with water and Do not drain water circuits containing industrial brines,
consult a doctor. without informing the technical service department at the
installation site or a competent body first.
The accidental releases of the refrigerant, due to small leaks
or significant discharges following the rupture of a pipe or Close the entering and leaving water shutoff valves and purge
an unexpected release from a relief valve, can cause frostbites the unit water circuit, before working on the components
and burns to personnel exposed. Do not ignore such injuries. installed on the circuit (screen filter, pump, water flow switch,
Installers, owners and especially service engineers for these etc.).
units must: Do not loosen the water box bolts until the water boxes have
- Seek medical attention before treating such injuries. been completely drained.
- Have access to a first-aid kit, especially for treating eye Periodically inspect all valves, fittings and pipes of the
injuries. refrigerant and hydraulic circuits to ensure that they do not
We recommend to apply standard EN-378. show any corrosion or any signs of leaks.
Never apply an open flame or live steam to a refrigerant It is recommended to wear ear defenders, when working near
container. Dangerous overpressure can result. the unit and the unit is in operation.
During refrigerant removal and storage operations follow
applicable regulations. These regulations, permitting
conditioning and recovery of halogenated hydrocarbons
under optimum quality conditions for the products and
optimum safety conditions for people, property and the
environment are described in standard NF E29-795.
Any refrigerant transfer and recovery operations must be

8
2 - PRELIMINARY CHECKS

2.1 - Check equipment received 2.2.3 - Checks before system start-up

■ Inspect the unit for damage or missing parts. If damage is Before the start-up of the refrigeration system, the complete
detected, or if shipment is incomplete, immediately file a claim installation, including the refrigeration system must be verified
with the shipping company. against the installation drawings, dimensional drawings, system
■ Confirm that the unit received is the one ordered. Compare the piping and instrumentation diagrams and the wiring diagrams.
name plate data with the order. During the installation test national regulations must be followed.
■ The unit name plate must include the following information: If no national regulation exists, standards such EN-378 or ISO-
- Version number 5149 can be used as a guide.
- Model number External visual installation checks:
- CE marking ■ Ensure that the machine is charged with refrigerant. Verify on
- Serial number the unit nameplate that the ‘fluid being transported’ is not
- Year of manufacture and test date nitrogen.
- Fluid being transported
■ Compare the complete installation with the refrigeration system
- Refrigerant used and refrigerant class
and power circuit diagrams.
- Refrigerant charge per circuit
- Containment fluid to be used ■ Check that all protection documents and equipment provided
- PS: Min./max. allowable pressure (high and low pressure by the manufacturer (dimensional drawings, P&ID, declarations
side) etc.) to comply with the regulations are present.
- TS: Min./max. allowable temperature (high and low pressure ■ Verify that the environmental safety and protection and devices
side) and arrangements provided by the manufacturer to comply with
- Pressure switch cut-out pressures the regulations are in place.
- Unit leak test pressure ■ Verify that all document for pressure containers, certificates,
- Voltage, frequency, number of phases name plates, files, instruction manuals provided by the
- Maximum current drawn manufacturer to comply with the regulations are present.
- Maximum power input
- Unit net weight ■ Verify the free passage of access and safety routes.

■ Confirm that all accessories ordered for on-site installation have ■ Check that ventilation in the plant room is adequate.
been delivered, and are complete and undamaged. ■ Check that refrigerant detectors are present.
The unit must be checked periodically during its whole ■ Verify the instructions and directives to prevent the deliberate
operating life to ensure that no shocks (handling accessories, removal of refrigerant gases that are harmful to the environment.
tools etc.) have damaged it. If necessary, the damaged parts ■ Verify the installation of connections.
must be repaired or replaced. See also chapter “Standard
■ Verify the supports and fixing elements (materials, routing and
maintenance”.
connection).

2.2 - Moving and sitting the unit ■ Verify the quality of welds and other joints.
■ Check the protection against mechanical damage.
2.2.1 - Moving ■ Check the protection against heat.
■ Check the protection of moving parts.
See chapter “Installation safety considerations”.
■ Verify the accessibility for maintenance or repair and to check
CAUTION: Only use slings at the designated lifting points
the piping.
which are marked on the unit.
■ Verify the status of the valves.
2.2.2 - Sitting the unit ■ Verify the quality of the thermal insulation and of the vapour
barriers
Always refer to the chapter “Dimensions and clearances” to confirm
that there is adequate space for all connections and service ■ Check the condition of the insulation of the 400 V cables.
operations. For the centre of gravity coordinates, the position of
the unit mounting holes, and the weight distribution points, refer
to the certified dimensional drawing supplied with the unit.
Typical applications of these units are in refrigeration systems,
and they do not require earthquake resistance. Earthquake
resistance has not been verified.
Before siting the unit check that:
■ the permitted loading at the site is adequate or that appropriate
strenghtening measures have been taken.
■ the unit is installed level on an even surface (maximum
tolerance is 5 mm in both axes).
■ there is adequate space above the unit for air flow and to ensure
access to the components.
■ the number of support points is adequate and that they are in
the right places.
■ the location is not subject to flooding.
CAUTION: Lift and set down the unit with great care. Tilting
and jarring can damage the unit and impair unit operation.

9
3 - DIMENSIONS, CLEARANCES

3.1 - 30XW-VZE/30XWHVZE 451-651 refer to the dimensional drawings.

See detail J

600
A

450

900
B
See detail H See detail K C

Dimensions en mm
A B C D E F G H
30XW-VZE/30XWHVZE
851 1998 1514 1164 4730 1162 219,1 219,1 4500
1001 1998 1514 1164 4730 1162 219,1 219,1 4500
1101 2051 1514 1164 4730 1264 219,1 219,1 4500
1201 2051 1514 1164 4730 1264 219,1 219,1 4500
1301 2051 1514 1164 4730 1264 219,1 219,1 4500

Legend
D All dimensions are given in mm.
B Services clearances required
C Space required to remove cooler tubes
Inlet water
Outlet water
700

Electrical supply entry

B

C B

H 1000

B
700
G

250

Detail H Detail J Detail K

NOTES:
• Drawings are not contractually binding. Before
designing an installation, consult the certified
dimensional drawings supplied with the unit or
available on request.
• For the positioning of the fixing points, weight
distribution and centre of gravity coordinates please

10
3 - DIMENSIONS, CLEARANCES

3.2 - 30XW-VZE/30XWHVZE 851-1301

See detail A

E
B

600
A

B 450
See detail C 900
See detail B C

Dimensions en mm
A B C D E F G H
30XW-VZE/30XWHVZE
451 1743 968 1087 3059 1086 168,3 168,3 2800
501 1743 968 1087 3059 1086 168,3 168,3 2800
601 1948 1083 1137 3290 1237 219,1 219,1 3100
651 1948 1083 1137 3290 1237 219,1 219,1 3100

D Legend
All dimensions are given in mm.
B Services clearances required
C Space required to remove cooler tubes
Inlet water
See detail D
Outlet water
800

Electrical supply entry

H
B
1000

C B

B
700

983

VICTAULIC VICTAULIC
STYLE 75 STYLE 75
410 30
150
G

44

250

Detail A Detail B Detail C Detail D

NOTES:
• Drawings are not contractually binding. Before designing an installation, consult the certified dimensional drawings
supplied with the unit or available on request.
• For the positioning of the fixing points, weight distribution and centre of gravity coordinates please refer to the
dimensional drawings.

11
4 - PHYSICAL AND ELECTRICAL DATA

4.1 - Physical data

30XW-VZE/30XWHVZE 451 501 601 651 851 1001 1101 1201 1301

Sound levels - standard unit

Sound power level(1) dB(A) 103 103 103 103 104 104 104 104 104
Sound pressure level at 1 m(2) dB(A) 85 85 85 85 85 85 85 85 85
Sound levels - standard unit + option 257(3)
Sound power level(1) dB(A) 100 100 100 100 101 101 101 101 101
Sound pressure level at 1 m(2) dB(A) 82 82 82 82 82 82 82 82 82
Dimensions - standard unit
Length mm 3059 3059 3290 3290 4730 4730 4730 4730 4730
Width mm 1087 1087 1237 1237 1164 1164 1264 1264 1264
Height mm 1743 1743 1948 1948 1997 1997 2051 2051 2051
Operating weight(4) kg 3223 3261 4263 4267 7477 7553 7731 7932 7970
Compressors Semi-hermetic 06T screw compressors, 50 r/s
Circuit A - 1 1 1 1 1 1 1 1 1
Circuit B - - - - - 1 1 1 1 1
Refrigerant - standard unit R1234ze( E )
kg 130 130 180 175 120 120 115 115 110
Circuit A
teq CO2 0,1 0,1 0,2 0,2 0,1 0,1 0,1 0,1 0,1
kg - - - - 120 120 120 115 110
Circuit B
teq CO2 - - - - 0,1 0,1 0,1 0,1 0,1
Refrigerant - option 330 R515B
kg 132 132 183 178 122 122 117 117 112
Circuit A
teq CO2 38,7 38,7 53,6 52,2 35,7 35,7 34,3 34,3 32,8
kg - - - - 122 122 122 117 112
Circuit B
teq CO2 - - - - 35,7 35,7 35,7 34,3 32,8
Oil - standard unit
Circuit A l 20 20 25 25 20 20 25 25 25
Circuit B l - - - - 20 20 20 25 25
Capacity control SmartVuTM, inverter-driven compressor, electronic expansion valve (EXV)
Minimum capcity % 20 20 20 20 10 10 10 10 10
Evaporator Multi-pipe flooded type
Water volume l 106 106 154 154 297 297 297 297 297
Water connections (Victaulic) in 6 6 8 8 8 8 8 8 8
Drain and vent connections (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000
Condenser Multi-pipe flooded type
Water volume l 112 112 165 165 340 340 340 340 340
Water connections (Victaulic) in 6 6 8 8 8 8 8 8 8
Drain and vent connections (NPT) in 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Max. water-side operating pressure kPa 1000 1000 1000 1000 1000 1000 1000 1000 1000

(1) In dB ref=10-12 W, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 4871 (with an associated uncertainty of +/-3dB(A)). Measured in
accordance with ISO 9614-1 and certified by Eurovent.
(2) In dB ref 20µPa, (A) weighting. Declared dualnumber noise emission values in accordance with ISO 4871 (with an associated uncertainty of +/-3dB(A)). For information,
calculated from the sound power level Lw(A).
(3) Option 257 = Low noise level
(4) Weight shown is guideline only. Please refer to the unit nameplate

12
4 - PHYSICAL AND ELECTRICAL DATA

4.2 - Electrical data

30XW-VZE /30XWHVZE 451 501 601 651 851 1001 1101 1201 1101

Power circuit
Nominal power supply V-ph-Hz 400-3-50
Voltage range V 360-440
Control circuit 24 V via the built-in transformer
Start-up current(1) Negligible (lower than maximum current drawn)
Maximum power factor(2) A 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93 0,91-0,93
Cosine phi A > 0,98 > 0,98 > 0,98 > 0,98 > 0,98 > 0,98 > 0,98 > 0,98 > 0,98
Harmonic distortion rate(3) A 35-45 35-45 35-45 35-45 35-45 35-45 35-45 35-45 35-45
Maximum power input(4)
Circuit A A 135 157 189 208 135 157 189 189 208
Circuit B A - - - - 135 157 157 189 208
Eurovent current draw* A
Circuit A 129 148 180 197 129 149 180 180 197
Circuit B - - - - 129 149 149 180 197
Maximum current draw (Un)(4)
Circuit A % 210 245 295 325 210 245 295 295 325
Circuit B - - - - 210 245 245 295 325
Maximum current draw (Un -10%)(3) kW
Circuit A kW 220 260 313 345 220 260 313 313 345
Circuit B kW - - - - 220 260 260 313 345
Maximum power input with option 150B(4)
Circuit A A 114 134 161 177 114 134 161 161 177
Circuit B A - - - - 114 134 134 161 177
Maximum current draw (Un) with option A
150B(4)
Circuit A 180 213 257 283 180 213 257 257 283
Circuit B A - - - - 180 213 213 257 283
Dissipated power(3) A 3000 4200 4700 5300 6000 8400 8900 9400 10600

(1) Instantaneous start-up current.

(2) May vary, based on the short-circuit current/max. current draw ratio of the system transformer. Values obtained at operation with maximum unit power input.
(3) Values obtained at operation with maximum unit power input.
(4) Values obtained at operation with maximum unit power input. Values given on the unit name plate.
* Eurovent unit operating conditions: evaporator entering/leaving water temperature = 12°C/7°C, condenser entering/leaving water temperature = 30°C/35°C. Gross
performances, not in accordance with EN14511-3:2013. These performances do not take into account the correction for the proportional heating capacity and power
input generated by the water pump to overcome the internal pressure drop in the heat exchanger.

13
4 - PHYSICAL AND ELECTRICAL DATA

4.3 - Short-circuit stability current

451 501 601 651 851 1001 1101 1201 1301

Value with unspecified upstream protection

Short-term current at 1s-Icw-kA rms 5,0 6,0 6,0 6,0 5,0 6,0 6,0 6,0 6,0
Admissible peak current - Ipk-kA pk 7,1 8,5 8,5 8,5 7,1 8,5 8,5 8,5 8,5
Max. value with upstream protection (circuit breaker)
Conditional short-circuit current Icc-kA rms 50 50 50 50 50 50 50 50 50
NSX400- NSX630- NSX630- NSX630- NSX400- NSX630- NSX630- NSX630- NSX630-
Reference number(1) 630- 630-
(1) Earthing system type
(2) If another current limitation protection system is used, its time-current and thermal constraints (l²t) trip characteristics must be at least equivalent to those of the
recommended Schneider circuit breaker.
The short circuit stability current values above are suitable with TN system.

4.4 - Compressor electrical data

Compressor nominal voltage/frequency: 380V/60Hz

Cosine phi Cosine phi

Compressor I Nom (A)(1) I Max (A)(2) MHA (A) LRDA (A)
nom(1) max(2)
06TUX483 134 227 240 1537 0,88 0,90
06TUX554 154 265 280 1537 0,88 0,90
06TVX680 184 304 322 2179 0,88 0,90
06TVX753 195 336 356 2179 0,88 0,90

(1) Value at standard Eurovent conditions: evaporator entering/leaving water temperature 12°C/7°C, condenser entering/leaving water temperature 30°C/35°C.
(2) Value at maximum capacity and nominal voltage.
Legend
MHA - Maximum compressor operating current, limited by the unit (current given for maximum capacity at 342 V)
LRDA - Locked rotor current for delta connection

4.5 - Compressor usage per circuit (A, B)

30XW-VZE/30XWHVZE 451 501 601 651 851 1001 1101 1201 1301

06TUX483 A - - - AB - - - -
06TUX554 - A - - - AB B - -
06TVX680 - - A - - - A AB -
06TVX753 - - - A - - - - AB

14
4 - PHYSICAL AND ELECTRICAL DATA

Electrical data notes and operating conditions, 30XW-VZE / 30XWHVZE units 5. The unit is designed for connection to TN systems (IEC 60364). For IT systems
• The unit has one connection point per circuit. the earth connection must not be at the network earth. Provide a local earth,
• The main switch disconnector and the main short circuit protection are not included consult competent local organisations to complete the electrical installation.
in the electrical cabinet. 6. Electromagnetic environment: classification of the electromagnetic environment
• Field connections: All connections to the system and the electrical installations is described in standard EN 61800-3 (corresponds to IEC 61800-3):
must be in full accordance with all applicable codes. - Immunity to external interference defined by the second environment(3)
- Interference emission as defined in category C3*
• The unit is designed and built to ensure conformance with local codes. The
recommendations of European standard EN 60204-1 (corresponds to IEC 60204- • Due to the harmonic currents the integrated frequency variator in the unit is a
1) (machine safety - electrical machine components - part 1: general regulations) source of interference. An analysis may be required to verify if these interferences
are specifically taken into account, when designing the electrical equipment(1). exceed the compatibility limits of the other devices connected to the same power
supply network. The compatibility levels inside an electrical installation, that must
• The absence of the main disconnect switch is an exception that shall be considered
be met at the in-plant coupling point (IPC) to which other loads are connected are
at the building installation level.
described in standard 61000-2-4. Two characteristics are required for this analysis:
• Compliance of the installation to 1999/92/CE directive on minimum requirements - The short-circuit ratio (Rsce) of the installation calculated at the in-plant coupling
for improving the safety and health protection of workers potentially at risk from point (IPC).
explosive atmospheres: The electrical equipment is not designed for compliance - The total harmonic current distortion rate (THDI), calculated for the machine at
to 2014/34/EU directive for equipment and protective systems intended for use maximum capacity.
in potentially explosive atmospheres. The compliance of the building installation
• Derived currents: If protection by monitoring the leakage currents is necessary to
with article 3 Prevention of and protection against explosions shall be achieved
ensure the safety of the installation, the presence of derived currents introduced
by all necessary measures in the installation for prevention of the formation of
by the use of frequency variators in the unit must be considered. In particular the
explosive atmospheres
reinforced immunity protection types and a control value not lower than 150 mA
• Annex B of EN 60204 1 describes the electrical characteristics used for the are recommended to control differential protection devices.
operation of the machines. The ones described below apply to 30XW-VZE / NOTE: If particular aspects of an actual installation do not conform to the
30XWHVZE units and complement other information in this document: conditions described above, or if there are other conditions which should be
The operating environment for the units is specified below: considered, always contact your local Carrier representative.
1. Environment as classified in EN 60721 (corresponds to IEC 60721)(2): (1) Generally the recommendations of IEC 60364 are accepted as compliance with
- indoor installation the requirements of the installation directives. Conformance with EN 60204-1
- ambient temperature range: minimum temperature +5°C to +42°C, class AA4 is the best means of ensuring compliance with the Machinery Directive.
- altitude: lower than or equal to 2000 m (2) The required protection level for this class is IP21B or IPX1B (according to
- presence of water: class AD2 (possibility of water droplets) reference document IEC 60529). All 30XW-VZE/30XWHVZE have IP23 units
- presence of hard solids, class 4S2 (no significant dust present) fulfil this protection condition.
- presence of corrosive and polluting substances, class 4C2 (negligible) (3) Example of installations of the second environment: industrial zones, technical
2. Power supply frequency variation: ± 2 Hz. locations supplied from a dedicated transformer.
3. The neutral (N) line must not be connected directly to the unit (if necessary * Category C3 is suitable for use in an industrial environment and is not designed
use a transformer). for use in a public low-voltage system that supplies residential locations. As an
option, conformity with category C2 permits this type of installation.
4. Overcurrent protection of the power supply conductors is not provided with
the unit.

Greyed text does not apply to units equipped with option 330 (Low GWP A1 R-515B refrigerant)

15
5 - ELECTRICAL CONNECTION

Please refer to the certified dimensional drawings, supplied with 5.6 - Field control wiring
the unit.
IMPORTANT: Field connection of interface circuits may lead
to safety risks: any control box modification must maintain
5.1 - Power supply equipment conformity with local regulations. Precautions
The power supply must conform to the specification on the unit must be taken to prevent accidental electrical contact between
nameplate. The supply voltage must be within the range specified circuits supplied by different sources:
in the electrical data table. For connection details refer to the wiring - The routing selection and/or conductor insulation
diagrams. characteristics must ensure dual electric insulation.
- In case of accidental disconnection, conductor fixing
WARNING: Operation of the unit with an improper supply
between different conductors and/or in the control box
voltage or excessive phase imbalance constitutes abuse
prevents any contact between the conductor ends and
which will invalidate the Carrier warranty. If the phase
an active energised part.
imbalance exceeds 2% for voltage, or 10% for current, contact
your local electricity supplier at once and ensure that the unit Refer to the SmartVuTM Control manual and the certified wiring
is not switched on until corrective measures have been taken. diagram supplied with the unit for the field control wiring of the
following features:
5.2 - Voltage phase imbalance (%) - Customer interlock
- Remote on/off switch
100 x max. deviation from average voltage - Demand limit external switch
Average voltage - Remote dual set point
Example: - Alarm, alert and operation report
On a 400 V - 3 ph - 50 Hz supply, the individual phase voltages - Evaporator pump control
were measured to be: - Condenser pump control signal (This does not control
condenser pump operation (for this function add option 156
AB = 406 V; BC = 399 V; AC = 394 V and flow switch).
Average voltage = (406 + 399 + 394)/3 = 1199/3 = 399.7 say 400 V - Heating/cooling change-over
Calculate the maximum deviation from the 400 V average: - Refrigerant leak detection
- Water valve control (option)
The maximum deviation from the average is 6 V. The greatest
- Various interlocks and reports on the Energy Management
percentage deviation is: 100 x 6/400 = 1.5 %. This is less than
Module board (option)
the permissible 2% and is therefore acceptable.
CCN bus connection
(AB) = 406 - 400 =6
- The permanent connection to the system CCN bus is made
(BC) = 400 - 399 =1 at the terminal provided for this purpose inside the control
(A) = 400 - 394 = 6 box.
- The connection of the CCN service tool is possible at a
Motor
socket under the control box, accessible from outside.
5.3 - Power connection
5.7 - 24 and 230 V power reserve for the user
Units with one compressor have one connection point
Control circuit reserve:
Units with two compressors have two connection pointst
After all required options have been connected, the TC transformer
includes a power reserve of 1 A at 24 V a.c. that can be used for
5.4 - Recommended wire sections the field control wiring.
Wire sizing is the responsibility of the installer, and depends on A second TCA transformer supplies the 230 V, 50 Hz circuit to
the characteristics and regulations applicable to each installation charge a battery for a portable computer at 0.63 A maximum at
site. The following is only to be used as a guideline, and does not 230 V. The connection is via an EEC 7/16 type socket (2 poles
make in any way liable. After wire sizing has been completed, without earth) located on the inside front of the control box and
using the certified dimensional drawing, the installer must ensure accessible from outside.
easy connection and define any modifications necessary on site.
Only devices with class II double insulation can be connected at
The maximum connectable wire section is 2x240mm² per phase. this socket.

5.5 - Power cable entry

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

16
6 - APPLICATION DATA

6.1 - 30XW-VZE /30XWHVZE Operating limits 6.3 - Minimum chilled water flow
The minimum chilled water flow is shown in the table in chapter
30XW-V/30XWHV Minimum Maximum
7.7.
Evaporator
If the system flow is less than the minimum unit flow rate, the
Entering temperature at start-up - 35,0°C evaporator flow can be recirculated, as shown in the diagram.
Leaving temperature during operation 3,3°C(1) 20,0°C
For munimum chiller flow rate
Entering/leaving temperature difference at full 2,8 K 11,1 K
load
Condenser 1
Entering temperature at start-up 13,0°C(2) -
Leaving temperature during operation 19,0°C(2) 55,0°C
Entering/leaving temperature difference at full 2,8 K 11,1 K
load
2
(1) 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 8
(2) For lower condenser temperatures a water flow control valve must be used at
the condenser (two or three-way valve). Please refer to option 152 to ensure
the correct condensing temperature.

60
Condenser leaving water temperature, °C

55
Legend
50 1 Evaporator
2 Recirculation
45
6.4 - Maximum chilled water flow
40
The maximum chilled water flow is limited by the permitted
35 pressure drop in the evaporator. It is provided in the table in chapter
7.7.
30 - Select the option with one water pass less that will allow a
higher maximum water flow rate (see option 100C in the table
25
in chapter 6.6 “Number of passes”.
20
- Bypass the evaporator as shown in the diagram to obtain a
lower evaporator flow rate.
15 For maximum chiller flow rate
0 5 10 15 20

Evaporator leaving water temperature, °C

1
From approx. 60% to full load
Part load limit approx. 50%
Minimum load limit 20%

Note: Ambient temperatures: These units are dedicated for 2

indoor environment. The external temperature at chiller start
up should be at least 5°C. For such low ambient, option 152
is recommended. During storage and transport of the 30XW-
VZE/30XWHVZE units (including by container) the minimum
and maximum permissible temperatures are -20°C and 70°C.

6.2 - Condenser-side installation

recommendation Legend
1 Evaporator
To ensure unit start-up at low condenser water temperature 2 Bypass
conditions, a specific installation may be necessary. Please refer
to the table below: 6.5 - Condenser water flow rate
0<t< 20 < t < 40 < t < The minimum and maximum condenser water flow rates are shown
t > 60min
20min 40min 60min in the table in chapter 7.7 “Evaporator and condenser water flow
15°C < x rates”.
13 < x < 15°C 1 2 If the system flow is higher than the maximum unit flow rate, select
11 < x < 13°C the option with one pass less that will allow a higher maximum
3 4 water flow rate. Please refer to option 102C in the table in chapter
8 < x < 11°C
x < 8°C 7.6 “Number of passes”.

x Condenser water temperature before start-up

t Time required to reach a temperature of 19°C at the condenser outlet
1 “The unit can start without the use of a two- or three-way valve, but operation
will be more reliable with the control valve.”
2 “The use of a two- or three-way valve is strongly recommended.”
3 “The use of a two- or three-way valve is compulsory.”
4 The use of a two- or three-way valve is compulsory and the use of variable
speed pumps is strongly recommended.

17
6 - APPLICATION DATA

6.6 - Standard and optional number of water 6.9 - System minimum water volume
passes
Whichever the system, the water loop minimum volume is given
30XW- by the formula:
451 501 601 651 851 1001 1101 1201 1301
VZE/30XWHVZE Volume = Cap (kW) x N litres
Evaporator
Standard 2 2 2 2 2 2 2 2 2 Application N
Option 100C 1 1 1 1 1 1 1 1 1 Normal air conditioning 3,25
Condenser Process type cooling 6,5
Standard 2 2 2 2 2 2 2 2 2
Option 102C 1 1 1 1 1 1 1 1 1 Where Cap is the nominal system cooling capacity (kW) at the
nominal operating conditions of the installation.
This volume is necessary for stable operation. It is often necessary
6.7 - Evaporator and condenser water flow to add a buffer water tank to the circuit in order to achieve the
rates required volume. The tank must itself be internally baffled in order
to ensure proper mixing of the liquid (water or brine). Refer to the
These below values are given for standard units. For options 100C
examples below.
and 102C, please refer to the unit selection program.
30XW-
Conection to buffer tank
451 501 601 651 851 1001 1101 1201 1301
V/30XWHV
Evaporator water flow rate, l/s
Minimum 6 6 8 8 15 15 15 15 15
Maximum 54 54 76 76 170 170 170 170 170
Condenser water flow rate, l/s Bad Good
Minimum 6 6 8 8 15 15 15 15 15
Maximum 52 52 74 74 170 170 170 170 170

Notes
- Minimum evaporator flow rate based on a water velocity
Bad Good
of 0,3 m/s.
- Minimum condenser flow rate based on a water velocity
of 0,3 m/s.

6.8 - Variable flow evaporator

Variable evaporator flow can be used. The pump drive can be
managed by unit control (0/10V output on terminal 90+ / 90-). The
controlled flow rate must be higher than the minimum flow given
in the table of permissible flow rates and must not vary by more
than 10% per minute.
If the flow rate changes more rapidly, the system should contain
a minimum of 6.5 liters of water per kW instead of 3.25 l/kW.

18
6 - APPLICATION DATA

6.10 - Evaporator pressure drop curves 6.11 - Condenser pressure drop curves

Units with two evaporator passes (standard) Units with two condenser passes (standard)
1 2 3 1 2 3
120 120
110 110
100
Pressure drop, kPa

100
90
90

Pressure drop, kPa

80
80
70
60 70
50 60
40 50
30
40
20
30
10
0 10 20 30 40 50 60 70 80 90 20

Water flow rate, l/s 10

0 10 20 30 40 50 60 70 80 90 100 110 120
Legend
Water flow rate, l/s
1 451, 501
2 601, 651
3 851, 1001, 1101, 1201, 1301

Units with one evaporator pass (option 100C) Units with one condenser pass (option 102C)
1 2 3 1 2 3
36 36

33 33

30 30
Pressure drop, kPa

27
Pressure drop, kPa

27
24 24

21 21

18 18

15 15

12 12

9 9

6 6

3 3
0 10 20 30 40 50 60 70 80 90 100 110 120 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

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

Legend Legend
1 451, 501 1 451, 501
2 601, 651 2 601, 651
3 851, 1001, 1101, 1201, 1301 3 851, 1001, 1101, 1201, 1301

19
7 - WATER CONNECTIONS

ATTENTION: Before carrying out any water connections Carrier recommendations on heat exchange fluids:
install the water box purge plugs (one plug per water box in - No NH4+ ammonium ions in the water, they are very
the lower section supplied in the control box). detrimental for copper. This is one of the most important
For size and position of the heat exchanger water inlet and outlet factors for the operating life of copper piping. A content of
connections refer to the certified dimensional drawings supplied several tenths of mg/l will badly corrode the copper over time.
with the unit. - Cl- Chloride ions are detrimental for copper with a risk of
perforations by corrosion by puncture. If possible keep below
The water pipes must not transmit any radial or axial force to the
125 mg/l.
heat exchangers nor any vibration.
- SO42- sulphate ions can cause perforating corrosion, if their
The water supply must be analysed and appropriate filtering, content is above 30 mg/l.
treatment, control devices, isolation and bleed valves and circuits - No fluoride ions (<0.1 mg/l).
built in, to prevent corrosion, fouling and deterioration of the pump - No Fe2+ and Fe3+ ions with non negligible levels of dissolved
fittings. Consult either a water treatment specialist or appropriate oxygen must be present. Dissolved iron < 5 mg/l with
literature on the subject dissolved oxygen < 5 mg/l.
- Dissolved silica: silica is an acid element of water and can
7.1 - Operating precautions also lead to corrosion risks. Content < 1 mg/l.
- Water hardness: > 0.5 mmol/l. Values between 1 and 2.5 can
The water circuit should be designed to have the least number of
be recommended. This will facilitate scale deposit that can
elbows and horizontal pipe runs at different levels. Below the main
limit corrosion of copper. Values that are too high can cause
points to be checked for the connection:
piping blockage over time. A total alkalimetric titre (TAC) below
- Comply with the water inlet and outlet connections shown on
100 mg/l is desirable.
the unit.
- Dissolved oxygen: Any sudden change in water oxygenation
- Install manual or automatic air purge valves at all high points
conditions must be avoided. It is as detrimental to
in the circuit(s).
deoxygenate the water by mixing it with inert gas as it is to
- Use a pressure reducer to maintain pressure in the circuit(s)
over-oxygenate it by mixing it with pure oxygen. The
and install a relief valve as well as an expansion tank.
disturbance of the oxygenation conditions encourages
- Install thermometers in both the entering and leaving water
destabilisation of copper hydroxides and enlargement of
connections.
particles.
- Install drain connections at all low points to allow the whole
- Electric conductivity 10-600µS/cm.
circuit to be drained.
- pH: Ideal case pH neutral at 20-25°C 7 < pH < 8
- Install stop valves, close to the entering and leaving water
connections. When the water circuit must be emptied for longer than one month
- Use flexible connections to reduce the transmission of or immediately if the water does not comply with the above
vibrations. description, the circuit must be either totally dried or placed under
- Insulate all pipework, after testing for leaks, both to reduce 0.5 bar maximum nitrogen charge. This is done to avoid any
heat gains and to prevent condensation. damage of the exchanger copper tubes with corrosion by
- Cover the insulation with a vapour barrier differential aeration. In case of nitrogen charge, the circuit must
- If there are particles in the fluid that could foul the heat be equipped with relief valves to avoid overpressure due to
exchanger, a screen filter should be installed ahead of the refrigerant leakage.
pump. The mesh size of the filter must be 1.2 mm. CAUTION: Filling, completing and draining the water circuit
- Before the system start-up verify that the water circuits are charge must be done by qualified personnel, using the air
connected to the appropriate heat exchangers purges and materials that are suitable for the products.
(e.g. no reversal between evaporator and condenser). Charging and removing heat exchange fluids should be done
- Do not introduce any significant static or dynamic pressure with devices that must be included on the water circuit by the
into the heat exchange circuit (with regard to the design installer. Never use the unit heat exchangers to add heat
operating pressures). exchange fluid.
- Before any start-up verify that the heat exchange fluid is
compatible with the materials and the water circuit coating.
- The use of different metals on hydraulic piping could generate
eletrolytic pairs and consequently corrosion. It could be
needed to add sacrificial anodes.
- In case additives or other fluids than those recommended by
Carrier are used, ensure that the fluids are not considered
as a gas, and that they belong to class 2, as defined in
directive 97/23/EC.

20
7 - WATER CONNECTIONS

7.2 - Water connections

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

Evaporator 30XW-V/30XWHV 451 501 601 651 851 1001 1101 1201 1301

Units without option 100C

Connection in 6 6 8 8 8 8 8 8 8
Outside diameter mm 168,3 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1
Units with option 100C
Connection in 6 6 8 8 8 8 8 8 8
Outside diameter mm 168,3 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1
Condenser 30XW-V/30XWHV 451 501 601 651 851 1001 1101 1201 1301
Units without option 102C
Connection in 6 6 8 8 8 8 8 8 8
Outside diameter mm 168,3 168,3 219,1 219,1 219,1 219,1 219,1 219,1 219,1
Units with option 102C
Connection in 8 8 8 8 8 8 8 8 8
Outside diameter mm 219,1 219,1 219,1 219,1 219,1 219,1 219,1 219,1 219,1

7.3 - Flow control 7.5 - Operation of two units in master/slave

mode
Evaporator flow switch and chilled water pump interlock
IMPORTANT: The unit water flow switch must be energised, The control of a master/slave assembly is in the entering water
and the chilled water pump interlock must be connected. and does not require any additional sensors (standard
Failure to follow this instruction will void the Carrier configuration). It can also be located in the leaving water. In this
guarantee. case two additional sensors must be added on the common piping.
The water flow switch is installed on the evaporator water inlet All parameters, required for the master/slave function must be
and adjusted by the control. If adjustment is necessary, it must be configured using the MST_SLV menu.
carried out by qualified personnel trained by Carrier Service. All remote controls of the master/slave assembly (start/ stop, set
point, load shedding etc.) are controlled by the unit configured as
7.4 - Evaporator and condenser water box bolt master and must only be applied to the master unit.
tightening Each unit controls its own water pump. If there is only one common
pump, in cases with variable flow, isolation valves must be installed
The evaporator (and condenser) are of the shell and tube type
on each unit. They will be activated at the opening and closing by
with removable water boxes to facilitate cleaning. Re-tightening
the control of each unit (in this case the valves are controlled using
or tightening must be done in accordance with the illustration in
the dedicated water pump outputs). See the SmartVuTM Control
the example below.
IOM for a more detailed explanation.
NOTE: Before this operation we recommend draining the
circuit and disconnecting the pipes to be sure that the bolts Unit with configuration: leaving water control
are correctly and uniformly tightened

Water box tightening sequence

1 2

Legend
1 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 Legend
Bolt size M 16 - 171 - 210 Nm
Master unit Additional sensors for leaving
water control, to be connected
Slave unit to channel 1of the slave boards
of each master and slave unit
Control boxes of the master
and slave units
CCN communication bus
Water inlet
Connection of two additional
Water outlet sensors
Water pumps for each unit
(included as standard for units
with hydraulic module)

21
8 - HEAT PUMPS 30XWHVZE

8.1 - Physical data for heat pumps

The physical data for 30XWHVZE for heat pumps are the same as for the 30XW-VZE units. Please refer to chapter 5.1.

8.2 - Electrical data for heat pumps

The electrical data for 30XWHVZE for heat pumps are the same as for the 30XW-VZE units. Please refer to chapter 5.2.

8.3 - Dimensions and clearances for heat pumps

The dimensions and clearances are the same as for the 30XW-VZE units. Please refer to chapter 4.

8.4 - Operating range for heat pumps

The operating limits are the same as for the 30XW-VZE units. Please refer to chapter 7.1.

8.5 - Operating modes for heat pumps

8.5.1 - Cooling mode

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

8.5.2 - Heating mode

Unlike in the cooling mode, the unit uses the heating setpoint in this configuration. The evaporator leaving water control (lowest setpoint
taken into consideration) is still maintained to prevent operation at very low temperatures.

22
9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA

9.1 - Compressor Repair

- 30XW-VZE/30XWHVZE units use 06T geared twin-screw Any repair or modification, including the replacement of moving
compressors equipped with a variable capacity slide valve parts:
and controlled by a speed variator. - must follow local regulations and be made by qualified
- Compressor capacity control is ensured by successive use operators and in accordance with qualified procedures,
of speed variation (using a frequency variator) and swept including changing the heat exchanger tubes.
volume variation at the screws (using the slide valve). - must be made in accordance with the instructions of the
- The combination of these two control modes permits fine original manufacturer. Repair and modification that
control of the unit capacity between 20% and 100%. necessitate permanent assembly (soldering, welding,
- The 06T compressor models used are: 06TUX483, expanding etc.) must be made using the correct procedures
06TUX554, 06TVX680, 06TVX753 and by qualified operators.
- An indication of any modification or repair must be shown in
9.2 - Oil filter the monitoring and maintenance file.
The 06T screw compressor has an independent oil filter.
Recycling
9.3 - Refrigerant The unit is wholly or partly recyclable. After use it contains
refrigerant vapours and oil residue. It is coated by paint.
The unit is a liquid chiller operating with refrigerant R1234ze(E)
(standard) or R515B (option 330). Operating life
The evaporator and oil separator are designed for:
9.4 - Lubricant - prolonged storage of 15 years under nitrogen charge with a
temperature difference of 20K per day.
The 06T screw compressor is approved for use with the following
- 452000 cycles (start-ups) with a maximum difference of 6 K
lubricant: CARRIER MATERIAL SPEC PP 47-38.
between two neighbouring points in the vessel, based on 6
start-ups per hour over 15 years at a usage rate of 57%.
9.5 - Oil supply solenoid valve
An oil supply solenoid valve is installed on the oil return line as Corrosion allowances
standard to isolate the compressor from oil flow when the
Gas side: 0 mm
compressor is not operating. The oil solenoid valve is field
replaceable. Heat exchange fluid side: 1 mm for tubular plates in lightly alloyed
steels, 0 mm for stainless steel plates or plates with copper-nickel
9.6 - Pressure vessels or stainless steel protection.

General
Monitoring during operation, re-qualification, re-testing and re-
testing dispensation:
- Follow the regulations on monitoring pressurised equipment.
- It is normally required that the user or operator sets up and
maintains a monitoring and maintenance file.
- If no regulations exist or to complement regulations, follow
the control programs of EN 378.
- If they exist follow local professional recommendations.
- Regularly inspect the condition of the coating (paint) to detect
blistering resulting from corrosion. To do this, check a non-
insulated section of the container or the rust formation at the
insulation joints.
- Regularly check for possible presence of impurities (e.g. silica
grains) in the heat exchange fluids. These impurities maybe the
cause of the wear or corrosion by puncture.
- Filter the heat exchange fluid. Check and carry out internal
inspections as described in EN 378, annex C.
- In case of re-testing please refer to the maximum operating
pressure given on the unit nameplate.
- The reports of periodical checks by the user or operator must
be included in the supervision and maintenance file.
- Filter the coolant and carry out internal inspections as
described in EN 378.
- In case of re-testing please refer to the maximum operating
pressure given on the unit nameplate.
- The reports of periodical checks by the user or operator must
be included in the supervision and maintenance file.

23
9 - MAJOR SYSTEM COMPONENTS AND OPERATION DATA

Evaporator 9.7.2 - Description of operation and resetting

30XW-VZE/30XWHVZE chillers use a flooded multi-tube The image below is intended to illustrate the operating description:
evaporator. The water circulates in the tubes and the refrigerant refer to the detailed machine drawing for the precise wiring
is on the outside in the shell. One vessel is used to serve both diagram.
refrigerant circuits. There is a center tube sheet which separates
the two refrigerant circuits. The tubes are 3/4” diameter copper
with an enhanced surface inside and out. There is just one water HPS SP_F
Pressure increase
circuit with two water passes. Direction of operation
The evaporator shell has a polyurethane foam thermal insulation HPS SP_F
and a water drain and purge. Pressure increase 400Vac
Direction of operation
It has been tested and stamped in accordance with the applicable
pressure codes. The maximum standard relative operating
pressure is 2100 kPa for the refrigerant side and 1000 kPa for the
water-side. These pressures can be different depending on the Normal
start-stop
Com bus for
frequency
STO Input
PLd- SIL2

code applied. The water connection of the heat exchanger is a

setting

Victaulic connection.
The products that may be added for thermal insulation of the
containers during the water piping connection procedure must be
chemically neutral in relation to the materials and coatings to which GS_1 drive
they are applied. This is also the case for the products originally
supplied by Carrier.

Condenser and oil separator

Compressor
06T
The 30XW-VZE/30XWHVZE chiller uses a heat exchanger that
is a combination condenser and oil separator. It is mounted below
the evaporator. Discharge gas leaves the compressor and flows HPS : High pressure switch SP1F(A)/SP2F(A)
through an external muffler to the oil separator, which is the upper GS_1 : Power drive for compressor GSA1/GSB1
portion of the heat exchanger. It enters the top of the separator
where oil is removed, and then flows to the bottom portion of the During normal operation, the speed regulator supplies and controls
vessel, where gas is condensed and subcooled. One vessel is the compressor once the control signal is received via the digital
used to serve both refrigerant circuits. There is a center tube sheet on-off input (normal on-off) and the communication bus (setting
which separates the two refrigerant circuits. The tubes are 3/4” or the frequency).
1” diameter internally and externally finned copper tubes.
When one of the HPS sensors opens, the STO (Safe Torque Off)
There is just one water circuit with two water passes. For the Heat digital input opens, which instantly suppresses the control
Machine units the condenser shell can have a polyure-thane foam command for the thyristors which manage the supply for the
thermal insulation (option 86) and a water drain and purge. compressor, independently of the on-off commands and
It has been tested and stamped in accordance with applicable frequencies: the compressor is no longer supplied and stops
pressure codes. The maximum standard relative operating immediately.
pressure is 2100 kPa for the refrigerant side and 1000 kPa for the
water-side. These pressures can be different depending on the 9.7.3 - Verification in case of a safety device failure
code applied. The water connection of the heat exchanger is a
Victaulic connection. If the unit operating pressure appears to have been exceeded at
some point (for example, after the relief valves have been opened),
the unit must be stopped immediately.
9.7 - High Pressure SRMCR safety loop
The safety loop unit must pass all the periodic verifications before
any restart is possible.
9.7.1 - General description
If the test reveals malfunctions likely to have caused overpressure
The unit is equipped with a high pressure safety loop, known as within the machine, a complete check of all the pressure equipment
the SRMCR (Safety-Related Measurement Control and must be performed to check their mechanical integrity.
Regulation) loop, comprising
- 2 high pressure switches (HPS) that require resetting with a 9.7.4 - Restarting after high pressure is detected
tool at the outlet for each compressor called PZHH
- The speed regulator which supplies the compressor is After overpressure is detected, it is necessary to manually reset
equipped with the Safe Torque Off (STO) function. the switched HPS. A blunt tool with a diameter of less than 6 mm
must be used for this.
Refer to the wiring diagram and the nomenclature for the machine
(references).
This SRMCR device is designed in accordance with standard EN
61508 for SIL (safety integrity level): 2.
Demand mode: bottom and top.
The mission time is 20 years.
Periodic testing: the test must be performed at least once a year
during the normal periodic pressure test. Refer to the description
in section 11.9.

24
10 - OPTIONS AND ACCESSORIES

Use for
Options N° Description Advantages 30XW-VZE
range
Implementation of new algorithms of control to allow
Light-brine Matches with most application requirements for 451-1301 (see
chilled brine solution production down to -3°C when
solution, down to 8 ground-sourced heat pumps and fits with many dedicated
ethylene glycol is
-3°C industrial processes requirements paragraph)
used (0°C with propylene glycol)
Unit equipped with supplementary water outlet Optimised operation of two units connected in
Master/slave temperature sensor kit to be field-installed allowing parrallele operation with operating time
58 451-1301
operation master/slave operation of two units connected in equalisation
parallel
Minimizes thermal dispersions condenser side
Condenser (key option for heat pump or heat recovery
86 Thermal condenser insulation 451-1301
insulation applications) and allows compliancy with
special installation criteria (hot parts insulated)
Allow isolation of various refrigerant circuit
92 Liquid line valve (evaporator inlet) and compressor
Service valve set components for simplified service and 451-1301
suction line valve maintenance
Evaporator with Evaporator with one pass on the water side. Easy to install, depending on site. Reduced
100C Evaporator inlet and outlet on opposite sides. 451-1301
one pass less pressure drops
Condenser with Condenser with one pass on the water side. Easy to install, depending on site. Reduced
102C Condenser inlet and outlet on opposite sides. 451-1301
one pass less pressure drops
21 bar Reinforced evaporator for extension of the maximum Covers applications with a high water column
104 451-1301
evaporator water-side service pressure to 21 bar (standard 10 bar) evaporator side (typically high buildings)
21 bar condenser 104A Reinforced condenser for extension of the maximum Covers applications with a high water column 451-1301
water-side service pressure to 21 bar (standard 10 bar) condenser side (typically high buildings)
Reversed Easy installation on sites with specific
evaporator water 107 Evaporator with reversed water inlet/outlet 451-1301
requirements
connections
Reversed Easy installation on sites with specific
condenser water 107A Condenser with reversed water inlet/outlet 451-1301
requirements
connections
148D Two-directional communication board complying with Connects the unit by communication bus to a
Lon gateway 451-1301
Lon Talk protocol building management system
Easy and high-speed connection by ethernet
149 Two-directional high-speed communication using
Bacnet over IP line to a building management system. Allows 451-1301
BACnet protocol over Ethernet network (IP) access to multiple unit parameters
Easy and high-speed connection by ethernet
Modbus over IP 149B Bi-directional high-speed communication using line to a building management system. Allows 451-1301
and RS485 Modbus protocol over Ethernet network (IP) access to multiple unit parameters
Condensing Reduced maximum power input and current
150B Limitation of the maximum condenser leaving water
temperature absorption: power cables and protection 451-1301
temperature to 45°C
limitation elements can therefore be downsized
Simple installation: for applications with cold
water at condenser inlet (ex. ground-source,
Control for low groundwater-source, superficial water-source
cond. Output signal (0-10 V) to control the condenser water
152 inlet valve applications) the signal permits to control a 2 451-1301
temperature or 3-way valve to maintain condenser water
systems temperature (and so condensing pressure) at
acceptable values
Energy Control board with additional inputs/outputs. See Extended remote control capabilities (Set-point
Management 156 EMM reset, ice storage end, demand limits, boiler 451-1301
Energy Management Module option chapter
Module on/off command...)
Additional tests on the water heat exchangers: supply
Compliance with
Swiss regulations 197 (additional of PED documents) supplementary Conformance with Swiss regulations 451-1301
certificates and test certifications
Compliance with
Australian 200 Unit approved to Australian code Conformance with Australian regulations 451-1301
regulations
Low noise level 257 Evaporator sound insulation 3 dB(A) quiter than standard unit 451-1301
Welded
evaporator 266 Victaulic piping connections with welded joints Easy installation 451-1301
connection kit
Welded
condenser water 267 Victaulic piping connections with welded joints Easy installation 451-1301
connection kit

25
10 - OPTIONS AND ACCESSORIES

Use for
Options N° Description Advantages 30XW-VZE
range
Flanged
evaporator water 268 Victaulic piping connections with flanged joints Easy installation 451-1301
connection kit
Flanged
condenser water 269 Victaulic piping connections with flanged joints Easy installation 451-1301
connection kit
Thermal The compressor is covered with a thermal insulation Prevents air humidity to condensate on the
compressor 271 451-1301
layer compressor surface
insulation
Reduces electromagnetic interferences for
EMC compliance with emission level category C2 in
classification C2,282 Additional RFI filters on the unit power line order to allow the units to operate in the first 451-1301
as per EN environment (so called, residential
61800-3 environment)
software algorithms to allow quick restart and fast Full capacity recovery in less than 5 minutes
Fast Capacity QM295 New after power failure. Matches requirements of 451-1301
Recovery loading while preserving unit-reliability typical critical missions applications
3G router board NOTE 1: require option 149
NOTE 2: when more than one machine is installed on
Carrier Connect site, only one of them shall be equipped with option
link (BSS regions 298 298 while all of them must be equipped with option 149 Enabler for Carrier Connect service offer 451-1301
only) NOTE 3: if the Carrier® PlantCTRL™ is on site, option
298 shall be integrated in the Carrier® PlantCTRL™
while option 149 is still mandatory for each single unit.
Low GWP A1 Reduced CO2 footprint (GWP < 300) A1 safety
330 Unit delivered with R-515B refrigerant charge class 451-1301
R-515B (A1, GWP 299) Reduced installed cost in technical room
refrigerant

26
11 - STANDARD MAINTENANCE

Air conditioning equipment must be maintained by professional 11.3 - Level 3 (or higher) maintenance
technicians, whilst routine checks can be carried out locally by
The maintenance at this level requires specific skills/ approval/
specialised technicians. See the standard EN 378-4.
tools and know-how and only the manufacturer, his representative
Simple preventive maintenance will allow you to get the best or authorised agent are permitted to carry out these operations.
performance from your HVAC unit: These maintenance operations concern for example:
- improved cooling performance - A major component replacement (compressor, evaporator)
- reduced power consumption - Any intervention on the refrigerant circuit (handling
- prevention of accidental component failure refrigerant)
- prevention of major time consuming and costly interventions - Changing of parameters set at the factory (application change)
- protection of the environment - Removal or dismantling of the HVAC unit
There are five maintenance levels for HVAC units, as defined by - Any intervention due to a missed established maintenance
the AFNOR X60-010 standard. operation
- Any intervention covered by the warranty
11.1 - Level 1 maintenance NOTE: Any deviation or non-observation of these maintenance
criteria will render the guarantee conditions for the HVAC unit
See note below.
nul and void, and the manufacturer, Carrier France, will no
Simple procedure can be carried out by the user: longer be held responsible
- Visual inspection for oil traces (sign of a refrigerant leak)
- Check for removed protection devices, and badly closed
11.4 - Tightening of the electrical connections
doors/covers
- Check the unit alarm report when the unit does not work (see
report in the SmartVuTM control manual). 11.4.1 - Tightening torques for the main electrical
connections
General visual inspection for any signs of deterioration.
Designation Torque
Screw type
11.2 - Level 2 maintenance in the unit value, N·m
Customer connection
This level requires specific know-how in the electrical, hydraulic
Screw-nut M12 at phase decks L1/L2/L3 50
and mechanical fields. It is possible that these skills are available
locally: existence of a maintenance service, industrial site, Nut on earth terminal PE 81
specialised subcontractor. Downstream power connections in the control box
In these cases, the following maintenance operations are Screw M10 at downstream main L1/L2/L3 50
disconnect deck (QS10)*
recommended.
Earth terminal M10 50
Carry out all level 1 operations, then:
Power connections in the variator GS-
- At least once a year tighten the power circuit electrical
connections (see tightening torques table). M10 nut on the phase pin 19-40
- Check and re-tighten all control/command connections, if M10 nut on the earth pin 19-40
required (see tightening torques table). Compressor phase connection terminals
- Check the differential switches for correct operation every 6 1/2/3/4/5/6
M12 23
months. on EC-
- Remove the dust and clean the interior of the control boxes, M16 1/2/3/4/5/6 30
if required. Check the filter condition. on EC-
- Check the presence and the condition of the electrical Compressor earth connection Gnd on EC- 25
protection devices. Control disconnect connections
- Replace the fuses every 3 years or every 15000 hours (age- Upstream and downstream screws at
hardening). QF 2
terminals
- Check the water connections.
- Purge the water circuit (see chapter 7 “Water connections”) ATTENTION: The tightening of the connections at the
- Clean the water filter (see chapter 7 “Water connections”). compressor terminals requires special precautions. Please
- Check the unit operating parameters and compare them with refer to the chapter below.
previous values.
- Keep and maintain a maintenance sheet, attached to each
HVAC unit.
All these operations require strict observation of adequate safety
measures: individual protection garments, compliance with all
industry regulations, compliance with applicable local regulations
and using common sense.

27
11 - STANDARD MAINTENANCE

11.4.2 - C
 onnection precautions for the compressor 11.6 - Evaporator and condenser maintenance
power terminals
Check that:
These precautions must be applied during an intervention that - the insulating foam is intact and securely in place,
requires the removal of the power conductors connected to the - the sensors and flow switch are correctly operating and
compressor supply terminals. correctly positioned in their support,
The tightening nut of terminal (6) supporting the isolator (7) must - the water-side connections are clean and show no sign of
never be loosened, as ist ensures terminal tightness and leakage.
compressor leak tightness.
The tightening of phase lug (4) must apply the torque between 11.7 - Compressor maintenance
counter nut (5) and tightening nut (3): during this operation a
counter-torque must be applied at counter nut (5). Counter-nut (5) 11.7.1 - Oil filter change schedule
must not be in contact with the tightening nut of terminal (6).
As system cleanliness is critical to reliable system operation, there
is a filter in the oil line at the oil separator outlet. The oil filter is
specified to provide a high level of filtration (5 µm) required for
long compressor life.
The filter should be checked after the first 500 hours of operation,
and every subsequent 2000 hours. The filter should be replaced
at any time when the pressure differential across the filter exceeds
2 bar.
The pressure drop across the filter can be determined by
measuring the pressure at the discharge port (at the oil separator)
and the oil pressure port (at the compressor). The difference in
these two pressures will be the pressure drop across the filter,
check valve, and solenoid valve. The pressure drop across the
check valve and solenoid valve is approximately 0.4 bar, which
should be subtracted from the two oil pressure measurements to
Legend give the oil filter pressure drop.
1. Torque application to tighten the lug
2. Avoid contact between the two nuts
3. Lug tightening nut
4. Flat lug
5. Counter-nut
6. Terminal tightening nut
7. Isolator

11.5 - Tightening torques for the main bolts and

screws
Torque value,
Screw type Used for
N·m
M20 nut Chassis 190
Heat exchanger side-side
M20 nut 240
connection
M16 nut Compressor fixing 190
Heat exchanger water boxes,
H M16 screw 190
structure
H M16 screw Compressor suction flanges 190
Compressor suction flanges TU
H M20 screw 240
& TV
M16 nut Compressor discharge line TU 190
M20 nut Compressor discharge line TV 240
H M8 screw Drier cover 35
1/8 NPT connection Oil line 12
TE nut Compressor oil line 24,5
7/8 ORFS nut Oil line 130
5/8 ORFS nut Oil line 65
3/8 ORFS nut Oil line 26
H M6 screw Stauff collar 10
Taptite screw M6 Oil line collar 7
Plate fixing, control box, terminal
Metric screw M6 7
box
Taptite screw M10 Oil filter, control box fixing 30

ATTENTION: The tightening of the connections at the

compressor terminals requires special precautions. Please
refer to the chapter above.

28
11 - STANDARD MAINTENANCE

11.7.2 - Compressor rotation control 11.9 - High pressure safety loop periodic test
Correct compressor rotation is one of the most critical application The aim of this periodic test is to check the settings of the high
considerations. Reverse rotation, even for a very short duration, pressure safety loop on one of the unit’s refrigerant circuits and
damages the compressor and can even destroy it. check it is operating correctly. This procedure must be repeated
The reverse rotation protection scheme must be capable of for each circuit.
determining the direction of rotation and stopping the compressor
within one second. Reverse rotation is most likely to occur 11.9.1 - Complete safety loop test
whenever the wiring at the compressor terminals has been The purpose of this periodic test is to verify the proper functioning
modified. and setting of the high-pressure safety loop of a refrigerant circuit.
To minimise the opportunity for reverse rotation, the following In order to reach the triggering pressure of the loop, the pressure
procedure must be applied. Rewire the power cables to the and temperature thresholds activating the discharge of the
compressor terminal pin as originally wired. Apply a counter-torque compressor by the regulation system are raised.
at the lower nut at the supply cable terminal during installation.
This procedure must be repeated for each circuit of the unit.
For replacement of the compressor, a low pressure switch is
included with the compressor. This low pressure switch should be 1. Set up a calibrated pressure gauge on the high pressure part
temporarily installed as a hard safety on the high pressure part of of the circuit (compressor discharge)
the compressor. The purpose of this switch is to protect the 2. Reset all activated alarms
compressor against any wiring errors at the compressor terminal 3. Activate the HP test mode for the corresponding circuit via the
pin. The electrical contact of the switch would be wired in series control interface.
with the high pressure switch. The switch will remain in place until
Enable Quick Test Mode (Quick Test Menu> [ QCK_TEST ]
the compressor has been started and direction of rotation has
parameter active)
been verified; at this point, the switch will be removed.
Activate the high pressure test for the desired circuit (Menu Quick
The switch that has been selected for detecting reverse rotation
Test> parameter [HP_TEST] to 0 for circuit A or 1 for the B circuit.
is Carrier part number HK01CB001. This switch opens the contacts
The corresponding circuit starts to perform the HP test.
when the pressure falls below 7 kPa.
4. Getting Started Machine
The switch is a manual reset type that can be reset after the
pressure has once again risen above 70 kPa. It is critical that the 5. For water-cooled units, stop the circulation of the secondary
switch be a manual reset type to preclude the compressor from circuit to the condenser in order to stop the condensation and
short cycling in the reverse direction. cause the increase in pressure (this operation is managed by
the control on air-cooled machines)
11.8 - Frequency variator maintenance 6. Record the trigger value
ATTENTION: Before any intervention at the frequency variator, 7. Check that both HPS were triggered
ensure that the disconnect/isolator switch is open and that If both HPS have tripped, go to step 10
no voltage is present (reminder: the capacitor discharge time If only one of the HPS has tripped, go to step 8
is approximately 20 minutes).
8. Replace the triggered HPS with another system whose trigger
Only a well-qualified person is allowed to replace or modify value is adequate .
the components inside the frequency variator.
Alternatively, an emergency stop button can be installed.
During periodic inspections, check the ventilation grilles at the
9. Repeat steps 2 to 6
frequency variator door; ensure that they are not pierced, damaged
or obstructed. 10. Check if the trigger values are correct
Replace the fan, if a “replace fan” alert/warning is displayed in the The release values should be between -1 .5 /+0.5 bars of nominal
alarm list. values indicated on the unit.
For any other alarm or problem at the frequency variator, contact 11. Reset all alarms
the Carrier service department. 12. Reset all HPS
The frequency variators do not require a dielectric test, even if Note:
they are replaced parts: they are systematically checked before Access to the maintenance functions can be protected by a
delivery. Otherwise the filtering components installed in the password. Contact your dealer or the manufacturer’s service
frequency variator can falsify the measurement and may even be department for more information.
damaged.
For step 8, the electrical disconnection of the triggered HPS
If it is necessary to test the insulation of a component and its substitution must be performed in an environment
(e.g. compressor, cables) the frequency variator must be with live parts. All the procedures and authorization provided
disconnected at the power circuit. for this type of intervention must be respected.
The type of connector must be WAGO 231-302 or equivalent.

29
12 - START-UP CHECKLIST FOR 30XW-VZE LIQUID CHILLERS (USE FOR
JOB FILE)

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

Unit

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

Compressors

Circuit A Circuit B
Model number.................................................................................. Model number...............................................................................
Serial number................................................................................... Serial number...............................................................................
Motor number................................................................................... Motor number................................................................................

Evaporator

Model number..................................................................................
Serial number...................................................................................

Condenser Section

Model number..................................................................................
Serial number...................................................................................

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

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

Preliminary equipment check

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
The unit is switched off again, after the pump test has been completed
Chilled water pump (CWP) is operating with the correct rotation. Check the phase sequence of the electrical connection.
Circulate chilled water in the water circuit for at least two hours, then remove, clean and replace the screen filter.
The unit is switched off again, after the pump test has been completed.
Inlet piping to cooler includes a 20 mesh strainer with a mesh size of 1.2 mm.

30
12 - START-UP CHECKLIST FOR 30XW-VZE LIQUID CHILLERS (USE FOR
JOB FILE)
Unit start-up

Oil level is correct

All discharge and liquid line 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 fittings)
on the whole unit
at all connections
Locate, repair, and report any refrigerant leaks..............................................................................................................................
.......................................................................................................................................................................................................
.......................................................................................................................................................................................................
Check that control box is vented – Fan on electrical box must be on before compressor start-up and during operation.
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 abuse which will
invalidate the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 10% for current, contact your local electricity
supplier at once and ensure that the chiller is not switched on until corrective measures have been taken.

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 chart (in product data literature) to determine total litres per
second (l/s) and find unit’s minimum flow rate.

Total = .................................................... l/s

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

WARNING: Once power is supplied to the unit, check for any alarms (refer to the SmartVuTM Control IOM for the alarm menu).

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

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

31
 CARRIER participates in the ECP programme for LCP/HP
Check ongoing validity of certificate:
www.eurovent-certification.com

Order No.: 10134, 09.2020. Supersedes order No.: 10134, 02.2018. Manufactured by: Carrier SCS, Montluel, France.
Manufacturer reserves the right to change any product specifications without notice. Printed in the European Union.