Carrier 30XV140-500 User manual

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300198-01 Printed in U.S.A. Form 30XV-7SI Pg 1 1-19 Replaces: 30XV-6SI
Installation Instructions
CONTENTS
Page
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 1 — Inspect Shipment . . . . . . . . . . . . . . . . . . . . . . 3
Step 2 — Place, Mount and Rig the Unit . . . . . . . . . 3
•PLACINGUNIT
• MOUNTING UNIT
• EXPORT SHIPPING RAILS
• RIGGING UNIT
Step 3 — Make Refrigerant, Evaporator Fluid
and Drain Piping Connections . . . . . . . . . . . . . . . . 90
• SPLIT UNIT ASSEMBLY
• GENERAL
• EVAPORATOR PUMP CONTROL
• PREPARATION FOR YEAR-ROUND OPERATION
Step 4 — Fill the Chilled Water Loop . . . . . . . . . . . 100
• WATER SYSTEM CLEANING
• WATER TREATMENT
• SYSTEM PRESSURIZATION
• FILLING THE SYSTEM
• SET WATER FLOW RATE
• FREEZE PROTECTION
• PREPARATION FOR WINTER SHUTDOWN
Step 5 — Make Electrical Connections . . . . . . . . . 102
• POWER SUPPLY
• FIELD POWER CONNECTIONS
•POWERWIRING
• FIELD CONTROL POWER CONNECTIONS
• CARRIER COMFORT NETWORK®
COMMUNICATION BUS WIRING
• BACNET IP OR ETHERNET COMMUNICATION
• NON-CCN COMMUNICATION WIRING
• FIELD CONTROL OPTION WIRING
• DUAL CHILLER LEAVING WATER SENSOR
Step 6 — Install Accessories . . . . . . . . . . . . . . . . . . . 127
• ENERGY MANAGEMENT MODULE
• UNIT SECURITY/PROTECTION ACCESSORIES
• COMMUNICATION ACCESSORIES
• SERVICE OPTIONS
Step 7 — Leak Test Unit. . . . . . . . . . . . . . . . . . . . . . . . 127
• DEHYDRATION
• REFRIGERANT CHARGE
SAFETY CONSIDERATIONS
Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install,
repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions
of cleaning coils and filters and replacing filters. All other
operations should be performed by trained service personnel.
When working on air-conditioning equipment, observe precau-
tions in the literature, tags and labels attached to the unit,
and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire extin-
guisher available for all brazing operations.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
WARNING
Electrical shock can cause personal injury and death. After
unit power is disconnected, wait at least 20 minutes for the
VFD (variable frequency drive) capacitors to discharge
before opening drive.
WARNING
DO NOT VENT refrigerant relief valves within a building.
Outlet from relief valves must be vented in accordance
with the latest edition of ANSI/ASHRAE (American
National Standards Institute/American Society of Heating,
Refrigerating and Air-Conditioning Engineers) 15 (Safety
Code for Mechanical Refrigeration). The accumulation of
refrigerant in an enclosed space can displace oxygen and
cause asphyxiation. Provide adequate ventilation in
enclosed or low overhead areas. Inhalation of high concen-
trations of vapor is harmful and may cause heart irregulari-
ties, unconsciousness or death. Misuse can be fatal. Vapor
is heavier than air and reduces the amount of oxygen avail-
able for breathing. Product causes eye and skin irritation.
Decomposition products are hazardous.
AquaForce®
30XV140-500
Variable Speed Air-Cooled Liquid Chillers
with Greenspeed®Intelligence

2
WARNING
DO NOT USE TORCH to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and gog-
gles and proceed as follows:
a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from sys-
tem using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen and
the work area should be well ventilated. Refrigerant in
contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter
and remove component from unit. Use a pan to catch
any oil that may come out of the lines and as a gage
for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when nec-
essary. Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal
injury or death.
CAUTION
Standard Tier units (units with S in the 10th position of
the model number) without condenser fan VFDs (units
with “-”, “1”, “3”, or “5” in the 13th position of the
model number) must have the condenser fan(s) rotation
verified to ensure proper phasing. Correct rotation is
counter-clockwise (reference arrow on fan cap). Swap
any two incoming power leads to correct condenser fan
rotation before starting chiller. Operating the unit with-
out testing the condenser fan(s) for proper phasing could
result in equipment damage.
CAUTION
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations. DO NOT leave refrigerant system open to
air any longer than the actual time required to service the
equipment. Seal circuits being serviced and charge with
dry nitrogen to prevent oil contamination when timely
repairs cannot be completed. Failure to follow these proce-
dures may result in damage to equipment.
CAUTION
This unit uses a microprocessor control system. Do not
short or jumper between terminations on circuit boards or
modules; control or board failure may result.
Be aware of electrostatic discharge (static electricity) when
handling or making contact with circuit boards or module
connections. Always touch a chassis (grounded) part to dis-
sipate body electrostatic charge before working inside con-
trol center.
Use extreme care when handling tools near boards and
when connecting or disconnecting terminal plugs. Circuit
boards can easily be damaged. Always hold boards by the
edges and avoid touching components and connections.
This equipment uses, and can radiate, radio frequency
energy. If not installed and used in accordance with the
instruction manual, it may cause interference to radio com-
munications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Inter-
national Standard in North America EN 61000-2/3 which
are designed to provide reasonable protection against such
interference when operated in a commercial environment.
Operation of this equipment in a residential area is likely to
cause interference, in which case the user, at his own
expense, will be required to take whatever measures may
be required to correct the interference.
Always store and transport replacement or defective boards
in anti-static shipping bag.
CAUTION
To prevent potential damage to heat exchanger tubes,
always run fluid through heat exchanger when adding or
removing refrigerant charge. Use appropriate antifreeze
solutions in evaporator fluid loop to prevent the freezing of
heat exchanger or interconnecting piping when the equip-
ment is exposed to temperatures below 32°F (0°C). Proof
of flow switch is factory installed on all models. Do NOT
remove power from this chiller during winter shut down
periods without taking precaution to remove all water from
heat exchanger. Failure to properly protect the system from
freezing may constitute abuse and may void warranty.
IMPORTANT: (Unit sizes 30XV140-325) If the com-
pressor VFD enclosure is removed for service, it must
be reinstalled to protect the drive from water intrusion.
Failure to reinstall the compressor VFD enclosure may
constitute abuse and may void warranty.

3
INTRODUCTION
These instructions cover installation of 30XV140-500 air-
cooled liquid chillers with Greenspeed®intelligence and elec-
tronic controls, and units with factory-installed options
(FIOPs). See Fig. 1.
INSTALLATION
Storage — If the unit is to be stored for a period of time be-
fore installation or start-up, be sure to protect the machine
from construction dirt. Keep protective shipping covers in
place until the machine is ready for installation. Follow these
storage guidelines:
• Store the unit in a clean and dry location.
• Avoid contamination.
• Maintain storage temperature of –13 to 149°F (–25 to
65°C).
• Before applying power, perform complete physical
inspection. Check for carbon deposits inside drive,
burned or damaged components, and blown fuses.
• The unit can be stored for 3 years maximum without
power. If the unit is stored for long periods of time with-
out use, special procedures must be performed to ensure
the safe and efficient operation of the VFD capacitor
banks. If the unit has been stored for more than 3 years
without power applied to the drives, contact Carrier Ser-
vice to obtain information and instructions for reforming
the capacitor banks.
• Perform a static test before applying power.
• Ensure a proper operating environment before applying
power: clean and dry; 5 to 100% humidity, non-condens-
ing; maximum temperature 126°F (52°C). If the tem-
perature is below 14°F (–10°C), the drive must be started
with 50% load for 10 minutes.
• When removing from storage, apply power for 3 to 4
hours to exercise capacitors.
Step 1 — Inspect Shipment — Inspect unit for dam-
age upon arrival. If damage is found, immediately file a claim
with the shipping company, and contact your local Carrier
representative.
Step 2 — Place, Mount, and Rig the Unit —
When considering a location for the unit, be sure to consult
NEC (National Electrical Code, U.S.A.) and/or local code
requirements. Allow sufficient space for airflow, wiring, pip-
ing, and service. See Fig. 2-22.
NOTE: To facilitate refrigerant vent piping, all units have fus-
ible plugs with 1/4in. SAE (Society of Automotive Engineers)
flares and pressure reliefs with 3/4in. NPT and 3/8in. SAE flare
fittings (if required by local codes).
PLACING UNIT — Locate the unit so that the condenser
airflow is unrestricted both above and on the sides of the
unit. Airflow and service clearances are 6 ft (1.8 m) around
the unit. Acceptable clearance on the sides or ends without
control boxes or VFDs can be reduced to 3 ft (1 m) without
sacrificing performance as long as the remaining three sides
are unrestricted. Acceptable clearance on the side with a
control box or VFD can be reduced to 4 ft (1.3 m) due to
NEC regulations, without sacrificing performance as long
as the remaining three sides are unrestricted. Provide ample
room for servicing and removing the evaporator. See Fig. 2-
20 for required clearances. Local codes for clearances take
precedence over the manufacturer’s recommendations when
local codes call for greater clearances.
If multiple units are installed at the same site, a minimum sepa-
ration of 10 ft (3 m) between the sides of the machines is
required to maintain proper airflow and minimize the chances
of condenser air recirculation.
MOUNTING UNIT — The unit may be mounted on a level
pad directly on the base rails, on a raised mounting rail
around the unit, or on vibration isolation springs. For all
units, ensure placement area is strong enough to support
unit operating weight. See Table 1. Mounting holes are pro-
vided for securing the unit to the pad, mounting rail or vi-
bration isolation springs. Bolt the unit securely to pad or
rails. If vibration isolators (field-supplied) are required for a
particular installation, refer to unit weight distribution in
Fig. 23 to aid in the proper selection of isolators. Once in-
stalled, the unit must be level to within 1/8-in. per ft (1 cm
per meter) along the long axis of the unit. This is required
for oil return to the compressor(s). For more details about
physical data, see Tables 2 and 3.
NOTE: For units that are point loaded, such as those using rub-
ber and shear isolators, the base rail must be supported with a
24 x 4 in. (610 x 102 mm) plate at each mounting location, or
base rail deflection may result. Fasten the unit to the plates
using the mounting holes.

4
LEGEND
*40A, 45A, and 50A are split units that are shipped in two pieces (40A and 40B,
45A and 45B, 50A and 50B). When they arrive at the jobsite, they are combined to
form the equivalent of 400, 450, or 500 size units.
†BACnet is a registered trademark of ASHRAE (American Society of Heating, Re-
frigerating, and Air-Conditioning Engineers).
CFSP — Coil Face Shipping Protection
EMM — Energy Management Module
GFI — Ground Fault Interrupter
LON — Local Operating Network
SCCR — Short Circuit Current Rating
Fig. 1 — AquaForce®Chiller with GreenSpeed®Intelligence Model Number Designation
30XV – AquaForce®Air-Cooled Chiller
Design Series
Nominal Capacity
Voltage
1– 575-3-60
2– 380-3-60
5– 208/230-3-60
6– 460-3-60
9– 400-3-50
G– 400-3-60
H– 380-3-50
J– 415-3-50
K– 440-3-50
Product Tiers& Evaporator Configuration
S– Standard Tier / Flooded Evaporator
M– Mid Tier / Flooded Evaporator
H– High Tier / Flooded Evaporator
- – Flooded Evaporator, 2 pass, without Heater
0– Flooded Evaporator, 2 pass, with Heater
1– Flooded Evaporator with Heater, one pass
2– Flooded Evaporator with Heater for Brine Application, 2 pass
B– Flooded Evaporator, 3pass, with Heater
C– Flooded Evaporator, with Heater for Brine Application, 3pass
R– Remote Evaporator, 2 pass (requiresprocessing viaETO)
Evaporator Options
-
PackagingOptions
L– Coil Face Shipping Protection (CFSP)
0– CFSP, Coil Trim Panels
1– CFSP, Coil Trim Panels, Security Grilles
2– CFSP, Coil Trim Panels, Security Grilles, Hail Guards(End)
3– Full Hail Guard
9– CFSP, Coil Trim Panels, Skid + Bag
B– CFSP, Coil Trim Panels, Security Grilles, Skid + Bag
C– CFSP, Coil Trim Panels, Security Grilles, Hail Guards(End), Skid + Bag
D– Full Hail Guard, Skid, Bag
ControlsOptions
-– 7-in. Touch Pilot™ Display
0– 7-in. Touch Pilot Display, EMM, GFI
1– 7-in. Touch Pilot Display, BACnet†(MS/TP) Translator
2– 7-in. Touch Pilot Display, EMM, GFI, BACnet (MS/TP) Translator
3– 7-in. Touch Pilot Display, LON Translator
4– 7-in. Touch Pilot Display, EMM, GFI, LON Translator
Electrical Options
-– Single Point Power, No Control Transformer, Std SCCR
0– Single Point Power with Disconnect, No Control Transformer, Std SCCR
1– Dual Point Power, No Control Transformer, Std SCCR
2– Dual Point Power with Disconnect, No Control Transformer, Std SCCR
3– Single Point Power, Control Transformer, Std SCCR
4– Single Point Power with Disconnect, Control Transformer, Std SCCR
5– Dual Point Power, Control Transformer, Std SCCR
6– Dual Point Power with Disconnect, Control Transformer, Std SCCR
8 – Single Point Power with Disconnect, No Control Transformer, High SCCR
B– Dual Point Power with Disconnect, No Control Transformer, High SCCR
D– Single Point Power with Disconnect, Control Transformer, High SCCR
G– Dual Point Power with Disconnect, Control Transformer, High SCCR
Valve & Insulation Options
- – No Suction Service Valve, Actuated Discharge Valves,
No Suction Line Insulation
0 – Suction Service Valve, Actuated Discharge Valves,
No Suction Line Insulation
1 – No Suction Service Valve, Manual Discharge Valves
(Middle East only), No Suction Line Insulation
2 – Suction Service Valve, Manual Discharge Valves
(Middle East only), No Suction Line Insulation
5 – No Suction Service Valve, Actuated Discharge Valves,
Suction Line Insulation
6 – Suction Service Valve, Actuated Discharge Valves,
Suction Line Insulation
7 – No Suction Service Valve, Manual Discharge Valves
(Middle East only), Suction Line Insulation
8 – Suction Service Valve, Manual Discharge Valves
(Middle East only), Suction Line Insulation
XV 140
Condenser Options
-– Aluminum Fin/Copper Tube
0– Copper Fin/Copper Tube
1– Aluminum Pre-Coat Fin/Copper Tube
2– Aluminum E-Coat Fin/Copper Tube
3– Copper E-Coat Fin/Copper Tube
4– Microchannel
5– E-Coat Microchannel
Condenser Fans& Sound Options
63H
-– Fixed Speed Condenser Fans(Std Tier) / Variable Speed Fans(Mid and High-Tier),
Std Sound
0– Variable Speed Condenser Fans(Std Tier only), Std Sound
1– Fixed Speed Condenser Fans(Std Tier) / Variable Speed Fans(Mid and High-Tier),
Low Sound Kit
2– Variable Speed Condenser Fans(Std Tier only), Low Sound Kit
3– Fixed Speed Condenser Fans(Std Tier) / Variable Speed Fans(Mid and High-Tier),
Std Sound, Sound Optimization
4– Variable Speed Condenser Fans(Std Tier only), Std Sound, Sound Optimization
5– Fixed Speed Condenser Fans(Std Tier) / Variable Speed Fans(Mid and High-Tier),
Low Sound Kit, Sound Optimization
6– Variable Speed Condenser Fans(Std Tier only), Low Sound Kit, Sound Optimization
7 – Variable Speed High Static Fans, Std Sound
8– Variable Speed High Static Fans, Low Sound Kit
140
160
180
200
225
250
275
300
325
350
400
40A/B*
450
45A/B*
500
50A/B*

5
Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller

6
Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller (cont)

7
Fig. 2 — 30XV 140,160,180 Std Tier; 140 Mid Tier Air-Cooled Chiller (cont)

8
Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller

9
Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller (cont)

10
Fig. 3 — 30XV 140 High Tier; 160,180 Mid Tier; 200 Std Tier Air-Cooled Chiller (cont)

11
Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller

12
Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller (cont)

13
Fig. 4 — 30XV 160,180 High Tier; 200 Mid Tier Air-Cooled Chiller (cont)

14
Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller

15
Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller (cont)

16
Fig. 5 — 30XV 200 High Tier Air-Cooled Chiller (cont)

17
Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller

18
Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller (cont)

19
Fig. 6 — 30XV 225 Std Tier Air-Cooled Chiller (cont)

20
Fig. 7 — 30XV 225 Mid Tier Air-Cooled Chiller