Carrier 30KAV-ZE Series Manual

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Original document
Liquid chiller with variable speed screw
compressor and greenspeed™ smart technology
30KAV-ZE 350A - 1300A
30KAVPZE 350A - 800A
30KAVIZE 500 - 1250
Rated cooling capacity 30KAV-ZE-A : 372 - 1344 kW - 50 Hz
Rated cooling capacity 30KAVPZE-A : 380 - 836 kW - 50 Hz
Rated cooling capacity 30KAVIZE- : 532 - 1307 kW - 50 Hz

2

CONTENTS
1 - SAFETY CONSIDERATONS........................................................................................................................................................... 5
1.1 - Protection devices safety considerations .................................................................................................................................... 5
1.2 - Refrigerant safety considerations................................................................................................................................................ 7
1.3 - Installation safety considerations ................................................................................................................................................ 9
1.4 - Maintenance safety considerations........................................................................................................................................... 10
1.5 - Electrical safety considerations................................................................................................................................................. 10
1.6 - System interventions safety considerations ...............................................................................................................................11
2 - RECEIPT OF GOODS ................................................................................................................................................................... 12
2.1 - Checking the equipment received............................................................................................................................................. 12
2.2 - Handling .................................................................................................................................................................................... 12
2.3 - Positioning................................................................................................................................................................................. 13
2.4 - Proximity to walls....................................................................................................................................................................... 13
2.5 - Underneath a roof ..................................................................................................................................................................... 13
2.6 - Installation of multiple chillers.................................................................................................................................................... 13
2.7 - Positionning of potentially ammable zone around the unit ...................................................................................................... 14
3 - DIMENSIONS, CLEARANCES...................................................................................................................................................... 15
3.1 - 30KAV-ZE 350A & 400A; 30KAVIZE 500; without hydraulic module......................................................................................... 15
3.2 - 30KAV-ZE 350A & 400A, with hydraulic module ....................................................................................................................... 15
3.3 - 30KAV-ZE 450A & 500A, without hydraulic module .................................................................................................................. 16
3.4 - 30KAV-ZE 450A & 500A, with hydraulic module ....................................................................................................................... 16
3.5 - 30KAV-ZE 550A & 600A; 30KAV-ZE 350A, 400A, 450A, 500A - opt 119; 30KAVPZE 350A, 400A, 450A, 500A; 30KAVIZE 800;
without hydraulic module..................................................................................................................................................................... 17
3.6 - 30KAV-ZE 550A & 600A; 30KAV-ZE 350A, 400A, 450A, 500A - opt 119; 30KAVPZE 350A, 400A, 450A, 500A;
with hydraulic module.......................................................................................................................................................................... 17
3.7 - 30KAV-ZE 650A & 750A; 30KAV-ZE 550A - opt 119; 30KAVPZE 550A; without hydraulic module .......................................... 18
3.8 - 30KAV-ZE 550A - opt 119 & 30KAVPZE 550A; with hydraulic module ..................................................................................... 18
3.9 - 30KAV-ZE 800A; 30KAV-ZE 600A & 650A - opt 119; 30KAVPZE 600A & 650A; without hydraulic module.............................. 19
3.10 - 30KAV-ZE 600A - opt 119; 30KAVPZE 600A; with hydraulic module...................................................................................... 19
3.11 - 30KAV-ZE 750A & 800A - opt 119; 30KAVPZE 750A & 800A.................................................................................................. 20
3.12 - 30KAV-ZE 900A; 30KAVIZE 1100; 30KAVIZE 1250................................................................................................................ 20
3.13 - 30KAV-ZE 1000A..................................................................................................................................................................... 21
3.14 - 30KAV-ZE 1100A; 30KAV-ZE 900A - opt 119 .......................................................................................................................... 21
3.15 - 30KAV-ZE 1200A & 1300A; 30KAV-ZE 1000A & 1100A - opt 119........................................................................................... 22
4 - WATER CONNECTIONS ............................................................................................................................................................... 23
4.1 - Operating precautions............................................................................................................................................................... 23
4.2 - Victaulic type hydraulic connections.......................................................................................................................................... 24
4.3 - Evaporator water boxes screws tightening................................................................................................................................ 25
4.4 - Flow rate detection.................................................................................................................................................................... 25
4.5 - Frost protection ......................................................................................................................................................................... 25
4.6 - Adjusting the installation nominal water ow rate...................................................................................................................... 26
4.7 - Evaporator water ow recirculation ........................................................................................................................................... 27
4.8 - Water ow evaporator bypass................................................................................................................................................... 28
4.9 - Variable ow evaporator............................................................................................................................................................ 28
4.10 - Minimum system water volume............................................................................................................................................... 28
4.11 - Maximum system water volume (option 293). ......................................................................................................................... 29
4.12 - Minimum & Maximum chilled water ow rate .......................................................................................................................... 29
4.13 - Evaporator pressure drop curves............................................................................................................................................ 30
5 - ELECTRICAL CONNECTIONS..................................................................................................................................................... 31
5.1 - Power supply............................................................................................................................................................................. 31
5.2 - Voltage phase imbalance (%) ................................................................................................................................................... 31
5.3 - Power connection/disconnect switch......................................................................................................................................... 31
5.4 - Power cable access routing ...................................................................................................................................................... 31
5.5 - Recommended cable sections .................................................................................................................................................. 32
5.6 - Field-installed control wiring...................................................................................................................................................... 33
5.7 - Customer and service power reserves...................................................................................................................................... 33
5.8 - Fan motors ................................................................................................................................................................................ 33
5.9 - Speed regulator......................................................................................................................................................................... 35
5.10 - Cabinets for the electrical equipment...................................................................................................................................... 35
5.11 - Electrical data .......................................................................................................................................................................... 36
5.12 - Short circuit current withstand capability................................................................................................................................. 39
5.13 - Compressor usage per circuit (A, B) ....................................................................................................................................... 40
5.14 - Electrical data notes................................................................................................................................................................ 41
3

The images used on the cover page and within this document are solely for illustration and are not contractually binding. The manufacturer reserves the right to change the
design at any time without notice.
CONTENTS
6 - MAJOR SYSTEM COMPONENTS................................................................................................................................................ 42
6.1 - Compression function................................................................................................................................................................ 42
6.2 - Evaporator function ................................................................................................................................................................... 44
6.3 - Economizer function.................................................................................................................................................................. 44
6.4 - Sensors ..................................................................................................................................................................................... 44
6.5 - Condenser function ................................................................................................................................................................... 44
7 - APPLICATION DATA..................................................................................................................................................................... 45
7.1 - Unit operating range.................................................................................................................................................................. 45
8 - PHYSICAL DATA........................................................................................................................................................................... 46
8.1 - Physical data............................................................................................................................................................................. 46
9 - SYSTEM INITAL START-UP ......................................................................................................................................................... 50
9.1 - Checks before system start-up.................................................................................................................................................. 50
9.2 - Commissioning.......................................................................................................................................................................... 50
9.3 - Essential points to check........................................................................................................................................................... 51
9.4 - Unit start-up checklist for installers prior to contacting Carrier Service..................................................................................... 52
10 - SYSTEM STANDARD MAINTENANCE ..................................................................................................................................... 55
10.1 - Level 1 maintenance ............................................................................................................................................................... 55
10.2 - Level 2 maintenance ............................................................................................................................................................... 56
10.3 - Level 3 (or higher) maintenance.............................................................................................................................................. 57
10.4 - Tightening torques.................................................................................................................................................................. 57
10.5 - Condenser Coils maintenance ................................................................................................................................................ 58
10.6 - Flooded Evaporator maintenance ........................................................................................................................................... 59
10.7 - Screw Compressor maintenance ............................................................................................................................................ 59
10.8 - Variable frequency drive maintenance .................................................................................................................................... 60
10.9 - Precautions when tting the casing panel to the side of the control cabinet........................................................................... 60
11 - SYSTEM FINAL SHUTDOWN .................................................................................................................................................... 61
11.1 - Shutting down.......................................................................................................................................................................... 61
11.2 - Recommendations for disassembly......................................................................................................................................... 61
11.3 - Fluids to be recovered for treatment........................................................................................................................................ 61
11.4 - Materials to be recovered for recycling.................................................................................................................................... 61
11.5 - Waste Electrical and Electronic Equipment (WEEE)............................................................................................................... 61
12 - OPTIONS ..................................................................................................................................................................................... 62
12.1 - Hydraulic module (options 116A / 116W) ................................................................................................................................ 65
12.2 - Free cooling dry cooler (option 313)........................................................................................................................................ 75
12.3 - Brine (options 5 / 6 / 8)............................................................................................................................................................ 76
12.4 - Heat recovery (options 49 / 50 / 50+)...................................................................................................................................... 82
12.5 - Operation of two units as a master/slave pair (option 58)....................................................................................................... 88
12.6 - Service valves (option 92)....................................................................................................................................................... 88
12.7 - Ultra fast capacity recovery (option 295+)............................................................................................................................... 89
12.8 - Connected Services (option 298A).......................................................................................................................................... 90
12.9 - Low & very low noise (options 15 / 15LS) ............................................................................................................................... 92
12.10 - VFD High Ambient (option 16)............................................................................................................................................... 93
13 - APPENDICES (PROVIDED IN THE DOCUMENT WALLET WITH THE INSTRUCTION MANUAL)......................................... 95
13.1 - Appendix 1: Declaration of conformity..................................................................................................................................... 95
13.2 - Appendix 2: Wiring diagram .................................................................................................................................................... 95
13.3 - Appendix 3: Machine PID........................................................................................................................................................ 95
13.4 - Appendix 4: Dimensional drawings ......................................................................................................................................... 95
4

1 - SAFETY CONSIDERATONS
The units are intended to cool water for building air conditioning
or for industrial processes.
They are designed to provide a very high level of safety and
reliability, making installation, start-up, operation and maintenance
easier and safer.
They will provide safe and reliable service if used within their
application ranges.
They are designed for a theoretical operating life of 15 years based
on load proles dened within the applicable Ecodesign regulations
Beyond this period, the manufacturer recommends to proceed to
a fatigue prevention survey on the refrigerating circuit conducted
by an operator qualied for the control of pressure equipments. It
is recommended to repeat this check every 5 years. This control
does not replace the requirements of applicable national
regulations.
Prior to the initial start-up of the units, everyone involved in the
works should be thoroughly familiar with these instructions and
with the characteristics of the installation site, and ensure these
are respected.
The procedures in this manual are arranged in the sequence
required for installation, start-up, operation and maintenance of
the units. Ensure that you follow them and that you take the
required safety precautions, including those listed in this guide,
which include wearing personal protective equipment (gloves,
safety glasses, safety shoes), having the appropriate tools, and
employing qualied, skilled technicians (electricians, refrigeration
system specialists).
To nd out if these products comply with European directives
(machine safety, low voltage, electromagnetic compatibility,
pressure equipment, etc.) check the declarations of conformity for
these products.
1.1 - Protection devices safety considerations
Check that the protective devices are well installed before
operating the unit.
An internal fault with the compressor variable frequency drive can
cause serious injury if the variable frequency drive has not been
closed correctly: it is essential to ensure that all covers are in place
and correctly secured before switching on the power supply to the
unit.
Do not obstruct any protective devices:
This applies to any fusible plugs, rupture disks and valves
tted on the refrigerant or energy transfer uid circuits. Check
if the original protection plugs are still present at the valve
outlets. These plugs are generally made of plastic and should
not be used. If they are still present, please remove them.
Fit devices at the valve or discharge pipe outlets to prevent
the penetration of foreign bodies (dust, building debris, etc.)
and atmospheric agents (water can form rust or ice). These
devices, as well as the discharge piping, must not impair
operation and not lead to a pressure drop that is higher than
10% of the set pressure.
Classication and control:
In accordance with the Pressure Equipment Directive and
national usage monitoring regulations in the European Union,
the protective devices tted to these machines are classied
as follows:
Safety
device(1)
Device for limitation of
damage in the event of
an external re(2)
Refrigerant side
High pressure safety loop(3) X
External relief valve(4) X
Rupture disk X
Heat transfer uid side
External relief valve (5) (5)
(1) Classied for protection in normal service situations.
(2) Classied for protection in abnormal service situations. These devices are sized
for res with a thermal ow of 10kW/m². No combustible matter should be placed
within 6.5m of the unit.
(3) High Pressure safety loop = SRMCR as described in section 6.2 and on the
wiring diagram.
(4) The instantaneous overpressure limitation of 10% of the operating pressure
does not apply to this abnormal service situation.
The set pressure can be higher than the operating pressure. In this case, either
the design temperature or the high pressure switch ensures that the operating
pressure is not exceeded in normal service situations.
(5) The selection of these relief valves must be made by the personnel responsible
for completing the hydraulic installation.
In compliance with the European Pressure Equipment
Directive (PED) and national regulations relating to design:
■These valves are not safety devices but accessories which
limit damage in the event of a re,
■The safety device is the high pressure safety loop
described in section 6.2.
5

Do not remove valves/fusible plugs, even if the re risk is
under control for a particular installation. There is no
guarantee that the accessories have been re-installed if the
system is changed or for transport with a gas charge.
When the unit is subjected to re, a safety device prevents
rupture due to over-pressure by releasing the refrigerant.
The uid may then break down into toxic residues when in
contact with ames:
■Stay away from the unit;
■Ensure the personnel in charge of extinguishing the re
are duly warned and issued with recommendations;
■Fire extinguishers appropriate to the system and the
refrigerant type must be easily accessible.
NOTE : Pressure equipment for the hydraulic side (optional)
are delivered as separate items. Their integration in the
complete hydraulic installation remain under the user's
responsibility.
All factory-tted relief valves are lead-sealed to prevent any
calibration change.
The external relief valves must always be connected to drain
pipes for units installed in a closed room. Refer to the
installation regulations, for example those of European
standard EN 378 and EN 13136. These pipes must be installed
in a way that ensures that people and property are not
exposed to refrigerant leaks. As the uids can be di󰀨used in
the air, ensure that refrigerant is discharged away from
building air intakes or that it is discharged into a su󰀩cient
quantity of suitable absorbent material (note that R1234ze(E)
refrigerant is heavier than air). The valves must be checked
periodically.
If the relief valves are factory-tted on a changeover valve,
this is equipped with a relief valve on each of the two outlets.
Only one of the two relief valve is in operation, the other one
is isolated. Never leave the changeover valve in the
intermediate position, i.e. with both circuits open (move the
lever fully forwards or backwards depending on the output
to be isolated). If a valve is removed for checking or
replacement, make sure there is still a valve active on each
of the changeover valves installed on the unit.
Provide a drain in the drain pipe, close to each relief valve,
to avoid an accumulation of condensate or rain water.
It is recommended to install an indicating device to check
whether any refrigerant has leaked from the relief valve.
The presence of oil at the outlet orice is a useful indicator
that refrigerant has leaked. Keep this orice clean to ensure
that any leaks are obvious. The calibration of a valve that has
leaked is generally lower than its original calibration. The new
calibration may a󰀨ect the operating range. To avoid nuisance
tripping or leaks, replace or re-calibrate the valve.
CHECKING THE PROTECTIVE DEVICE:
■External overpressure devices (external relief valves) must
be replaced or checked to ensure that their settings and
operation are correct at least every five years or in
accordance with national regulations, at the earliest
opportunity.
■The high pressure (SRMCR) safety loop must be tested at
least once a year to check it is operating correctly; this
must include the compressor shut-down and its activation
and deactivation values.
The company or organisation that conducts a pressure switch
test must establish and implement detailed procedures for:
-Safety measures,
-Measuring equipment,
-Values and tolerances for cut-o󰀨 and discharge devices,
-Test stages,
-Recommissioning of the equipment.
The manufacturer recommends contacting Carrier Service
for this type of test. An example of the test procedure without
removing the pressure switch is given in section 10.8.4 of
this manual.
WARNING: If the test results in the replacement of the
pressure switch, it is necessary to recover the refrigerant
charge. These pressure switches are not installed on
Schraeder type automatic valves.
If the machine operates in a corrosive environment, inspect the
protection devices more frequently.
Do not attempt to repair or recondition a valve if there has been
any corrosion or build-up of foreign material (rust, dirt, scale, etc.)
on the valve body or mechanism. In this case, it must be replaced.
Do not install relief valves in series or backwards.
1 - SAFETY CONSIDERATONS
6

1.2 - Refrigerant safety considerations
Use safety goggles and safety gloves.
All precautions concerning handling of refrigerant must be
observed in accordance with local regulations.
If a leak occurs or if the refrigerant becomes contaminated
(e.g. by a short circuit in a motor), and before any intervention,
remove the complete charge using a recovery unit and store the
refrigerant in mobile containers. The compressors cannot transfer
the whole refrigerant charge and can be damaged if used to
pump-down. The refrigerant charge should not be transferred to
the high-pressure side.
Detect and repair the leak, check the type of refrigerant in the
machine and then recharge the machine/circuit with the total
charge, as indicated on the unit nameplate. Do not top up the
refrigerant charge. Only charge the liquid refrigerant given on the
nameplate at the liquid line.
Charging any refrigerant other than the original type will impair
machine operation and can even cause irreparable damage to
the compressors. The compressors operating with this refrigerant
type are lubricated with a synthetic polyolester oil, which are
completely incompatible with mineral oils.
Do not unweld the refrigerant pipework or any refrigerant
circuit component or cut these with a torch until all refrigerant
(liquid and vapor) as well as the oil have been removed from
the unit. Traces of vapor should be displaced with dry
nitrogen. Refrigerant in contact with an open ame produces
toxic gases.
Do not siphon refrigerant.
Any accidental release of refrigerant, whether this is caused by a
small leak or signicant discharges following the rupture of a pipe
or an unexpected release from a relief valve, may cause any
personnel exposed to experience heart palpitations, faintness,
frostbite and burns. Always take any such event seriously.
Installers, owners and especially service engineers for these units
must:
■Create a procedure to ensure medical attention is sought before
treating any symptoms;
■Provide rst aid equipment, ush the eyes and skin immediately
if splashed with refrigerant, and seek medical attention.
We recommend that standard EN 378-3 Annex 3 is applied.
Ensure there is su󰀩cient ventilation if the unit is installed in an
enclosed area. In gas form, refrigerant is heavier than air and,
if allowed to accumulate in a conned area, it can reduce the
quantity of oxygen in the air, causing respiratory issues.
The refrigerant used in the units in this range is R1234ze(E).
Special equipment must be used when working on the refrigerant
circuit (pressure gauge, charge transfer equipment, etc.).
Do not clean the unit with hot water or steam. This may cause
the refrigerant pressure to rise.
NOTE: If a liquid line valve is present, never leave refrigerant
in liquid form between this closed valve and the expansion
valve as the change in temperature may cause the liquid to
expand, rupturing this section of the circuit. This valve is
situated on the liquid line before the lter drier.
Never apply an open flame or pressurized steam to a
refrigerant container. Dangerous overpressure can result. If
it is necessary to heat the refrigerant, only use liquid hot
water.
The standard NF E29-795 describes the 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. If any damage
is caused to the equipment, the refrigerant must be changed in
accordance with this standard, or an analysis of the uid must be
performed by a specialist laboratory.
Any refrigerant transfer and recovery operations must be carried
out using a transfer unit.
Service valves are positioned on the liquid, suction and discharge
lines and are available on all units for connection to the transfer
unit.
The units must never be modied to add refrigerant and oil
charging, removal and purging devices. These units have the
required openings. Refer to the certified dimensional
drawings.
It is dangerous and illegal to re-use disposable (non-
returnable) cylinders or attempt to rell them. When the
cylinders are empty, evacuate the remaining gas pressure,
ll out the relevant paperwork and hand them over to an
approved recovery agency. Do not incinerate.
1 - SAFETY CONSIDERATONS
7

OPERATING CHECKS:
■Important : This product contains R1234ze(E) which is an
HFO gas.
■Type of uid: Refer to the nameplate.
■Global Warming Potential (GWP) following AR5 : 1.
WARNING:
1. Ensure that the refrigerant is never released to the
atmosphere during installation, maintenance or equipment
disposal.
2. Deliberate refrigerant release into the atmosphere is not
allowed.
3. If a refrigerant leak is detected, ensure that the leak is
repaired quickly.
4. Onlycertied,qualiedpersonnelarepermittedtoinstall,
service and perform leak tightness tests on the refrigerant,
decommission the equipment and recover the refrigerant.
5. The operator must ensure that any refrigerant recovered
is recycled, regenerated or destroyed.
6. The operator is bound by the obligation to perform leak
tightness tests, or have these performed, at regular
intervals. Regulations within the European Union have set
the following intervals:
System WITHOUT
leakage detection No test 12 months 6 months 3 months
System WITH
leakage detection No test 24 months 12 months 6 months
Refrigerant
charge per circuit
(equivalent CO2)
< 5 tons 5 ≤ charge
< 50 tons
50 ≤ charge
< 500 tons
Charge
> 500 tons*
Refrigerant
charge per
circuit (kg)
R-1234ze(E)
(GWP 1) No requirement
* From 01/01/2017, units must be equipped with a leak detection system.
7. For all equipment subject to regular leak tightness tests,
the operator must keep a log used to record the following:
thequantitiesandtypesofuidscontainedinthesystem
(added and recovered), the quantity of uid recycled,
regenerated or destroyed, the date and results of the leak
tightness tests, the details of the technician and of the
company performing the work, etc.
8. Contact your local dealer or installer if you have any
questions.
Information on operating inspections given in EN 378 standard
can be used when similar criteria do not exist in the national
regulation.
Check regularly for leaks and repair immediately.
1.2.1 - Flammable refrigerant safety considerations
IMPORTANT INFORMATION REGARDING THE REFRIGERANT
USED:
R1234ze(E) refrigerant is classed in group 2 "non hazardous"
according to the criteria of the European pressure equipment
directives (PED) 2014/68/EC. In line with the standard ISO-819,
R1234ze(E) refrigerant is classed in safety group A2L: low
ammability.
One of the characteristics of this refrigerant is that no
flammable mixture is created with air below a room
temperature of 21 °C and under controlled humidity
conditions.
Nevertheless, when the humidity or temperature increases,
this refrigerant may become flammable and present a
potential hazard if the ammability risks are not correctly
mitigated within the installation's machine room.
The local safety regulations and standards relating to the
buildings must be respected.
In the absence of local regulations and standards, refer to
the standard EN-378 (2012) (Safety requirements for
substances classed A2) or ISO-5149 (2014) (for substances
classed A2L).
The customer must obtain the approval of the local authorities
governing the building. Carrier may also provide guidelines
on the safe use of refrigerant R1234ze(E), to complement the
safety standards and regulations relating to the buildings
with a view to ensuring risks are reduced to acceptable levels.
For more details on the physical properties, the ammability
and toxicity characteristics, the identication of risks, the
safety requirements for the installation, etc., refer to standards
such as the following:
■ASHRAE 34, EN-378, ISO-817 and ISO-5149
■Safety Data Sheets (SDS) provided by the refrigerant
manufacturer
■The European Union REACH database (registration,
evaluation, authorisation and restriction of chemicals)
Only employ qualied technicians well-trained in the use and the
risks associated with ammable refrigerants and the respect of
local regulations (see standard EN 378-4 in appendix E - repair
guidelines for equipment using ammable refrigerants).
Use a gas detector during any intervention on the machine.
1 - SAFETY CONSIDERATONS
8

1.3 - Installation safety considerations
The units are classied as "indirect heat exchange systems" and
are designed to be installed in a special location (class C in
accordance with ISO-5149 and EN-378) which only authorised
personnel are permitted to access; this personnel must be aware
of the general and special safety precautions for the establishment,
and must also be qualified and trained in surveillance and
maintenance. The customer is responsible for installing the access
restriction device.
The chiller must be located at least 6 m from the nearest entrance
to the building and must be installed in a room where air is able
to circulate freely. No charge limitation applies to class "C"
occupancy level for R-1234ze(E). Refer to these standards for
further details. This level must be conrmed by the customer.
After the unit has been received, and before it is started up, it must
be inspected for damage. Check that the refrigerant circuits are
intact, especially that no components or pipes have shifted or been
damaged (e.g. following a shock). If in doubt, carry out a leak
tightness check.
An extinguisher must be accessible and visible close to the
machine installation area
Pressure equipment and components
These products include pressure equipment or components
manufactured by the unit manufacturer or by other manufacturers.
We recommend that you contact your professional body to nd
out which regulations a󰀨ect you as the operator or owner of
pressure equipment or components (declaration, re-qualication,
re-testing). The characteristics of this equipment/these components
are given on the nameplate or in the required documentation,
supplied with the products.
These units comply with the European Pressure Equipment
Directive.
The units are intended to be stored and operated in an environment
where the ambient temperature does not drop below the minimum
allowable temperature indicated on the nameplate.
Do not introduce signicant static or dynamic pressure with
regard to the operating pressures used during operation or
for tests in the refrigerant circuit or in the heat exchange
circuits.
NOTE: Monitoring during operation, re-qualification,
re-testing, exemption from retesting:
■Follow the regulations on monitoring pressure equipment.
■The user or operator is usually required to create and
maintain a monitoring and maintenance log.
■In the absence of any regulations, or in addition to the
regulations, follow the guidance in EN 378.
■Follow the local professional recommendations, whenever
they exist.
■Regularly inspect the condition of the coating (paint) on
the surface of the components to detect blistering resulting
from corrosion. To do this, check an uninsulated part of
the vessel, or for rust drips at a joint in the insulation.
■Regularly check for the presence of any impurities
(e.g. sand, grit) in the heat transfer uids. These impurities
can cause wear and/or pitting corrosion.
■Filter the heat-transfer fluid and carry out internal
inspections as described in EN 378-2 Appendix C.
■The reports of the periodical checks by the user or the
operator must be included in the monitoring and
maintenance log.
■In case of re-testing please refer to the maximum operating
pressure given on the unit nameplate.
Repair:
Any repair or modification, including replacement of
removable parts:
■Must comply with local regulations and must be performed
by qualified operators in accordance with qualified
processes, including changing a wiring harness conductor,
■Must be approved by the original manufacturer. Repairs
and modications which involve a permanent assembly
(welding, soldering, expansion of tubes, etc.) must be
performed by qualified operators following operating
procedures,
■All modifications and repairs must be listed in the
monitoring and maintenance register,
■Never attempt to repair or modify a plate heat exchanger.
Recycling:
■The unit is fully or partially recyclable. After use, it may
contain refrigerant vapors and oil residues. Some parts
are painted.
Corrosion build-up :
Below thickness values are applicable on evaporator shell-and-
tube heat exchanger and on oil separator :
Gazeous refrigerant side: 0 mm
Heat-transfer medium side:
■1 mm for tube sheets in lightly alloyed steels,
■0 mm for stainless steel plates or plates with copper-nickel or
stainless-steel protection.
Water-box : 1 mm
Parts painted : 0 mm
If any part of the piece (with 0mm of acceptable corrosion) shows
corrosion, change the piece.
1 - SAFETY CONSIDERATONS
9

1.4 - Maintenance safety considerations
It is compulsory to wear ear protection when working near
the unit and the unit is in operation.
The manufacturer recommends the following template for the
maintenance log (the table below is only given as a guide and
does not engage the manufacturer's liability).
Operation Name of the
commissioning
engineer
Applicable
national
regulations
Verication
organisation
Date Nature(1)
(1) Maintenance
Any technician carrying out work on the electrical or refrigerating
section must be authorised, with the relevant qualications and
certications, including for brazing operations and for operation
of the shut-o󰀨 valve. He/she must have been specically trained
on this equipment and system.
The manual valves must only be manipulated when the machine
is o󰀨. Do not forget to ret protective caps to prevent leaks.
Technicians working on the units must be equipped as follows:
Personal protective
equipment (PPE) (1)
Operations
Handling Maintenance,
service
Welding or
brazing (2)
Protective gloves, eye
protection, safety shoe,
protective clothing.
XXX
Ear protection. X X
Filtering respirator. X
(1) We recommend compliance with the instructions in the EN 378-3 standard.
(2) Performed in the presence of A1 refrigerant according to EN 378-1.
Regularly check that the vibration levels remain acceptable and
close to those at initial machine start-up.
Before opening a refrigerant circuit, drain and consult the pressure
indicators.
If the refrigerant circuit remains open after an intervention (such
as a component replacement, etc.):
■Seal the openings if the duration is less than a day
■Beyond this time, charge the circuit with a dry, inert gas
(nitrogen).
The objective is to prevent penetration of atmospheric humidity
and the resulting corrosion of the unprotected internal steel walls.
1.5 - Electrical safety considerations
ELECTRICAL RISK:
Never work on a unit that is still energized.
Never work on any of the electrical components until the general
power supplies to the unit have been isolated and locked out.
WARNING: Even if the unit is stopped, the power circuit
remains energized, unless the unit or circuit disconnect
switch is open. Refer to the wiring diagram for further details.
Follow the appropriate safety guidelines.
When working close to the condenser fans, particularly when
removing the grilles, ensure that the power supply to the fans is
switched o󰀨 to ensure they cannot run.
WARNING:Thevariablefrequencydrives(VFD)ttedtothe
units have circuit capacitors which take twenty (20) minutes
to discharge after the power supply is disconnected.
After disconnecting the power supply to the electrical box, wait for
twenty minutes before accessing the electrical box or VFD. This
value is a guide and may di󰀨er from one VFD to another: refer to
the information given on the VFD to nd out the precise value.
Before any intervention, verify that there is no voltage present at
any accessible conducting parts of the power circuit.
WARNING : When option 295+ for Ultra Fast Capacity recovery
is present, energy is stored inside the equipment and 24Vdc
voltage is present even if the main disconnect switch was
switchedo.Refertosectiondescribingoption295+inthis
document for more explanations.
WARNING: The compressors on 30KAVPZE units
feature motors with permanent magnets. Do not open
the compressor. Ensure that the terminal box is
securely fixed in place before filling the machine with
refrigerant, draining the refrigerant or rotating the motor shaft.
The compressor cannot be removed.
WARNING: Strong magnetic eld inside the compressor
casing. An electrical current may be generated on the
compressor terminals and on the circuits which are connected
whenlling/emptyingtherefrigerant.
1 - SAFETY CONSIDERATONS
10

1 - SAFETY CONSIDERATONS
1.6 - System interventions safety considerations
Equip the engineers that work on the unit with the protections
described in section 1.4 above.
To prevent any damage or accidents, trained personnel must
service the various parts of this machine and must resolve any
malfunctions or leaks immediately.
Comply with the regulations and recommendations given in the
safety standards for refrigerant systems and machines, such as:
EN 378, ISO 5149, etc.
Risk of explosion:
Never use air or gases containing oxygen during leak tests,
to purge pipework or to pressurise a unit. Pressurised air
mixtures or gases containing oxygen can cause an explosion.
Oxygen reacts violently with oil and grease.
Only use dry nitrogen for leak tests, with an appropriate tracer gas
if necessary.
Failure to observe the above recommendations can have
serious or even fatal consequences and damage installations.
Never exceed the specied maximum operating pressures.
Verify the maximum permissible high and low test pressures
by checking the instructions in this manual or the pressures
given on the unit nameplate.
The necessary protective equipment must be available, and
appropriate re extinguishers for the system and the refrigerant
type used must be within easy reach.
Do not attempt to remove refrigerant circuit components or
ttings, while the machine is under pressure or while it is
running. Make sure the circuit pressure is zero and that the
unit has been shut down and de-energised before removing
components or opening a circuit. When the refrigerant circuit
is opened to repair, see the recommendations in chapter
“Maintenance safety considerations”.
WARNING: No part of the unit must be used as a walkway,
rack or support. Periodically check and repair or, if necessary,
replace any component or piping that shows signs of damage.
The refrigerant lines can break under the weight and release
refrigerant, causing personal injury.
Use a platform, or staging to work at higher levels.
Use mechanical lifting equipment (crane, hoist, winch, etc.) to lift
or move heavy components.
For lighter components, use lifting equipment if there is any risk
of slipping or losing your balance.
Use only original replacement parts for any repair or component
replacement. Consult the list of replacement parts that corresponds
to the original equipment.
Do not drain the heat exchange uid circuit without informing
the site technical / service department or other competent
body rst.
Close the shut-o󰀨 valves on the water inlet and outlet and drain
the unit's hydraulic circuit before working on the components
installed on the circuit (screen lter, pump, water ow sensor, etc.).
Periodically inspect all valves, ttings and pipes on the refrigerant
and hydraulic circuits to ensure that they do not show any signs
of corrosion or leaks.
Do not loosen the water box bolts until the water boxes have
been completely drained.
11

2 - RECEIPT OF GOODS
2.1 - Checking the equipment received
Check that the unit and the accessories have not been damaged
during transport and that no parts are missing. If the unit and the
accessories have been damaged or the shipment is incomplete,
send a claim to the shipping company.
Compare the name plate data with the order.
The name plate is attached in two places to the unit:
■On the outside of one of the unit frames,
■On the electrical cabinet, inside.
The unit name plate must include the following information:
■Model number - size, address of manufacturer,
■CE marking,
■Serial number,
■Year of manufacture and pressure and leak tightness test date,
■Fluid used for transport,
■Refrigerant used,
■Refrigerant charge per circuit,
■PS: Min./max. allowable pressure (high and low pressure side),
■TS: Min./max. allowable temperature (high and low pressure
side),
■Pressure switch cut-out pressure,
■Unit leak test pressure,
■Voltage, frequency, number of phases,
■Maximum current,
■Maximum power input,
■Unit net weight.
2.2 - Handling
It is strongly recommended that a specialised company is
employed to unload the machine.
Do not remove the skid or the packaging until the unit is in its nal
position.
These units can be safely moved by trained personnel with a fork
lift truck with the correct capacity for the dimensions and weight
of the unit, as long as the forks are positioned in the location and
direction shown on the unit.
The units can also be lifted with slings, using only the designated
lifting points marked on the unit (labels on the chassis and label
with the unit handling instructions, attached to the unit).
Use slings with the correct capacity, and follow the lifting
instructions on the certied dimensional drawings supplied for the
unit.
WARNING: Only attach slings to the designated lifting points
which are marked on the unit.
It is advisable to protect coils against crushing while a unit is being
moved. Use struts or a lifting beam to spread the slings above the
unit. Do not tilt a unit more than 15°.
Safety can only be guaranteed if these instructions are carefully
followed. Failure to do so may result in damage to the equipment
and physical injury.
See the slinging plan for each machine in section 3 and in
appendix 4.
CAUTION: Before lifting the unit, check that all casing panels
andgrillesaresecurelyxedinplace.Liftandsetdownthe
unit with great care. Tilting and jarring can damage the unit.
WARNING: Never apply pressure or leverage to any of the
unit's panels or uprights ; only the base of the unit frame is
designedtowithstandsuchstresses.Noforceoreortmust
be applied to pressurized parts, especially via pipes
connected to the water-cooled heat exchanger.
12

2.3 - Positioning
The unit must be installed in a place that is not accessible to the
public, or is protected against access by unauthorised persons.
This machine is not intended to operate in an ATEX area.
The machine must be installed outdoors (open space). The volume
of air supplied to the condenser coils must not be restricted to
ensure the operation of the machine is not adversely a󰀨ected.
In case of extra-high units, the machine environment must permit
easy access for maintenance operations.
For the centre of gravity coordinates, the position of the unit
mounting holes, and the weight distribution points, refer to the
certied dimensional drawings. Ensure the free space shown in
the dimensional drawings is respected to facilitate maintenance
and connection.
The typical applications of these units are cooling and heating,
which do not require earthquake resistance. Earthquake resistance
has not been veried.
Before retting the unit, check that:
■The chosen location can support the weight of the unit,
or that appropriate reinforcement measures have been taken,
■The unit is installed level on an even surface (maximum
tolerance is 5 mm along both axes),
■If the support structure is sensitive to vibration and/or noise
transmission it is advisable to insert anti-vibration mounts
(elastomer mounts or metal springs) between the unit and the
structure. Selection of these devices is based on the system
characteristics and the comfort level required and should be
made by technical specialists,
■There is adequate space above and around the unit for
air to circulate and for access to the components
(see dimensional drawings),
■The number of support points is adequate and that they are in
the right places,
■If the optional anti-vibration mounts are present, their number
and position must comply with the indications given on the
certied dimensional drawing.,
■ The location is not subject to ooding,
■For outdoor applications, avoid installing the unit in a location
where snow is likely to accumulate (in areas subject to long
periods of sub-zero temperatures, the unit should be raised),
■ Ba󰀪es may be necessary to deect strong winds. However,
they must not restrict air ow into the unit,
All welding operations (connection to the hydraulic network) must
be performed by qualied welders. The Victaulic®connection or
the counter-ange must be removed before welding as a matter
of course.
IMPORTANT : Follow the disassembly procedure indicated
in the disassembly instructions
2.4 - Proximity to walls
To guarantee correct operation in most cases:
■If h < H (2.3 m), minimum S = 3 m
■If h > H or S < 3 m, contact your Carrier distributor to assess
the various installation options.
Wall
Anti-vibration
mounts
HS
h
2.5 - Underneath a roof
The upper part of the machine (on top of the fans) must not be
covered.
If the oor space requires the machine to be partially covered,
contact your Carrier distributor to assess the various installation
options.
2.6 - Installation of multiple chillers
It is recommended that multiple chillers are installed in a single
row, arranged as shown in the example below, to avoid warm air
being recycled from one unit to another.
1.5 m
min.
1.5 m
min.
If the oor space does not allow this arrangement, contact your
Carrier distributor to assess the various installation options.
2 - RECEIPT OF GOODS
13

2 - RECEIPT OF GOODS
2.7 - Positionning of potentially ammable zone
around the unit
The full unit, including all options & accessories that are delivered
by the manufacturer, has been qualied for the use with A2L
refrigerant.
For that purpose, the manufacturer complies with EN 378-2 §6.2.14
and dened a potentially ammable zone using EN 60079-10-1
in order to identify where ignition sources must not be present.
Then the manufacturer designed the machine in order that, if the
unit is used the way it was designed for, there is no internal ignition
source in the internal potentially ammable zone.
Thus, the only residual risk is to have an ignition source introduced
in the potentially ammable zone by the user. For that purpose,
the manufacturer decided to represent the external potentially
ammable zone (see below schemes in section 3) where the user
must not introduce ignition source.
This indication is only here to help our customer to identify the
limits of the ammability risk.
But there is no risk of explosion linked to the used of A2L refrigerant
due to the machine itself.
Note (the following information is provided by the manufacturer
exclusively for informational purposes. The application of the
following directives relies exclusively upon the user):
According to directives 2009/104/EC and 1999/92/EC, these zones
might be qualied by the user as ATEX Zone based on the user’s
own risk analysis for which the user remains solely responsible.
According to the denition of Annex I of directive 1999/92/EC, this
zone might be classied Zone 2 as it might be a place in which
an explosive atmosphere consisting of a mixture of air with
ammable substances in the form of gas is not likely to occur in
normal operation but, if it does occur, will persist for a short period
only.
In case an additional equipment is necessary (motorized valve,
pump, etc.…), it must be:
■ Installed out of dened potentially ammable zone
■ Qualied as a non-ignition source for the uid used
14

3 - DIMENSIONS, CLEARANCES
3.1 - 30KAV-ZE 350A & 400A; 30KAVIZE 500; without hydraulic module
2261 HT
4387 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
3.2 - 30KAV-ZE 350A & 400A, with hydraulic module
2261 HT
5733 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
15

3.3 - 30KAV-ZE 450A & 500A, without hydraulic module
2261 HT
5578 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
3.4 - 30KAV-ZE 450A & 500A, with hydraulic module
2261 HT
5733 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
3 - DIMENSIONS, CLEARANCES
16

3.5 - 30KAV-ZE 550A & 600A; 30KAV-ZE 350A, 400A, 450A, 500A - opt 119; 30KAVPZE 350A, 400A,
450A, 500A; 30KAVIZE 800; without hydraulic module
2262 HT
6772 HT
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
C
C
C
1500
B
C
3.6 - 30KAV-ZE 550A & 600A; 30KAV-ZE 350A, 400A, 450A, 500A - opt 119; 30KAVPZE 350A, 400A,
450A, 500A; with hydraulic module
2262 HT
6926 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
3 - DIMENSIONS, CLEARANCES
17

3.7 - 30KAV-ZE 650A & 750A; 30KAV-ZE 550A - opt 119; 30KAVPZE 550A; without hydraulic module
2262 HT
7962 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
3.8 - 30KAV-ZE 550A - opt 119 & 30KAVPZE 550A; with hydraulic module
1500
1500
1500
1500
2324 HT
8116 HT 2261 HT
B
B
B
B
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
3 - DIMENSIONS, CLEARANCES
18

3.9 - 30KAV-ZE 800A; 30KAV-ZE 600A & 650A - opt 119; 30KAVPZE 600A & 650A; without hydraulic
module
2262 HT
9155 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
3.10 - 30KAV-ZE 600A - opt 119; 30KAVPZE 600A; with hydraulic module
2262 HT9310 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
3 - DIMENSIONS, CLEARANCES
19

3.11 - 30KAV-ZE 750A & 800A - opt 119; 30KAVPZE 750A & 800A
2262 HT
10346 HT
1500
1500
1500
1500
2324 HT
500
500
500
500
B
B
B
B
C
C
C
C
3.12 - 30KAV-ZE 900A; 30KAVIZE 1100; 30KAVIZE 1250
2261 HT
9157 HT
1500
1500
1500
1500
2325 HT
500
500
500
500
B
B
B
B
C
C
C
C
Key NOTE:
Non-contractual drawings.
Refer to the unit name plate to nd out the machine weight.
Refer to the certied dimensional drawings (appendix 4),
provided with the unit or available on request, when
designing an installation.
Please refer to the certified dimensional drawings
(appendix 4) for the positioning of the xing points, weight
distribution points and centre of gravity coordinates.
If the installation comprises several units or if these are
located close to walls, refer to sections 2.4 - Proximity to
walls and 2.6 - Installation of multiple chillers, to determine
the space required.
All dimensions are given in mm
B
Clearances required for maintenance (see Note)
C
Potentially ammable zone around the machine
Water inlet for standard units
Water outlet for standard units
Air outlet, do not obstruct
Power supply connection
Sling points
3 - DIMENSIONS, CLEARANCES
20