Carrier AQUASnap 30RB Manual

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Translation of the original document
* The availability of sizes and options depends on the country. Please contact your local commercial dealer for more information.
Air-Cooled Liquid Chillers
Reversible heat pumps
30RB/30RQ 040R-160R
Rated cooling capacity 40-160 kW
R-32

2

CONTENTS
1 - INTRODUCTION AND SAFETY INSTRUCTIONS....................................................................................................................5
2 - RECEIPT OF GOODS..................................................................................................................................................................5
2.1 - Checking the equipment received.............................................................................................................................................5
3 - HANDLING AND POSITIONING ................................................................................................................................................6
3.1 - Handling ....................................................................................................................................................................................6
3.2 - Positioning.................................................................................................................................................................................6
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES............................................................................. 7
4.1 - 30RB/30RQ 040R-080R, units with and without hydraulic module...........................................................................................7
4.2 - 30RB/30RQ 090R-160R, units with and without hydraulic module...........................................................................................8
4.3 - 30RB/30RQ 040R-080R, units with water bu󰀨er tank module .................................................................................................. 9
4.4 - 30RB/30RQ 090R-160R, units with water bu󰀨er tank module ................................................................................................ 10
4.5 - Free spaces and installing several units ................................................................................................................................. 11
4.6 - Positioning of ATEX zones around the unit ............................................................................................................................. 11
5 - PHYSICAL AND ELECTRICAL DATA FOR THE UNITS ......................................................................................................12
5.1 - Physical properties: 30RB/30RQ 40R-160R ...........................................................................................................................12
5.2 - Electrical data notes: 30RB/30RQ 040R-160R .......................................................................................................................13
5.3 - Short-circuit withstand current.................................................................................................................................................13
5.4 - Electrical data notes for the hydraulic module.........................................................................................................................14
5.5 - Electrical data notes for the compressors ...............................................................................................................................16
5.6 - Distribution of compressors per circuit ....................................................................................................................................16
5.7 - Comments on electrical data...................................................................................................................................................17
6 - ELECTRICAL CONNECTION...................................................................................................................................................18
6.1 - Power supply...........................................................................................................................................................................18
6.2 - Voltage phase imbalance (%)..................................................................................................................................................18
6.3 - Power connection/disconnect switch.......................................................................................................................................18
6.4 - Recommended cable sections ................................................................................................................................................18
6.5 - Power cable access routing ....................................................................................................................................................20
6.6 - Field control wiring ..................................................................................................................................................................20
6.7 - Electrical power reserve for the user....................................................................................................................................... 20
7 - APPLICATION DATA ................................................................................................................................................................. 21
7.1 - Operating range ......................................................................................................................................................................21
7.2 - Minimum heat transfer uid ow rate (units without factory-tted hydraulic module)..............................................................22
7.3 - Maximum heat transfer uid ow rate (units without factory-tted hydraulic module).............................................................22
7.4 - Variable ow water heat exchanger (units without factory-tted hydraulic module) ............................................................... 22
7.5 - System minimum water volume .............................................................................................................................................. 22
7.6 - System maximum water volume ............................................................................................................................................. 22
7.7 - Water type heat exchanger water ow rate.............................................................................................................................23
7.8 - Pressure drop curves for the water type heat exchanger and standard water inlet/outlet piping.............................................. 23
8 - WATER CONNECTIONS...........................................................................................................................................................24
8.1 - Operating precautions and recommendations ........................................................................................................................24
8.2 - Hydraulic connections .............................................................................................................................................................25
8.3 - Units without hydraulic module................................................................................................................................................27
8.4 - Units with hydraulic module and xed-speed pump (for application with brine only) .............................................................. 28
8.5 - Units with hydraulic module and variable-speed pump - pressure di󰀨erential control ............................................................ 28
8.6 - Units with hydraulic module and variable-speed pump - temperature di󰀨erential control ....................................................... 29
9 - NOMINAL SYSTEM WATER FLOW RATE CONTROL .......................................................................................................... 31
9.1 - Available static pressure for the system..................................................................................................................................31
10 - SYSTEM START-UP ...............................................................................................................................................................33
10.1 - Checks before system start-up................................................................................................................................................33
10.2 - Commissioning...................................................................................................................................................................... 33
10.3 - Essential points to check....................................................................................................................................................... 33
3

The cover photograph is for illustrative purposes only and is not part of any o󰀨er for sale or contract.
This manual applies to the following units:
- 30RB standard chiller
- 30RQ standard chiller standard reversible heat pump
For operation of the control, please refer to the 30RB/30RQ control manual.
CONTENTS
11 - MAIN COMPONENTS OF THE UNIT AND OPERATING CHARACTERISTICS ...............................................................34
11.1 - Compressors ..........................................................................................................................................................................34
11.2 - Lubricant ...............................................................................................................................................................................34
11.3 - Air-cooled exchanger .............................................................................................................................................................. 34
11.4 - Fans.......................................................................................................................................................................................35
11.5 - Electronic expansion valve (EXV) .........................................................................................................................................36
11.6 - Moisture indicator ....................................................................................................................................................................36
11.7 - Dehumidier lter...................................................................................................................................................................36
11.8 - Water type heat exchanger.....................................................................................................................................................36
11.9 - Refrigerant............................................................................................................................................................................... 36
11.10 - High pressure safety switch.................................................................................................................................................36
11.11 - SmartViewTM ...................................................................................................................................................................................................................................... control
36
12 - OPTIONS ..................................................................................................................................................................................37
12.1 - Tables of options ....................................................................................................................................................................37
12.2 - Description ..............................................................................................................................................................................39
13 - STANDARD MAINTENANCE .................................................................................................................................................45
13.1 - Level 1 maintenance ..............................................................................................................................................................45
13.2 - Level 2 maintenance .............................................................................................................................................................45
13.3 - Level 3 maintenance ...............................................................................................................................................................46
13.4 - Tightening the electrical connections .................................................................................................................................... 47
13.5 - Tightening torques for the main fastenings ............................................................................................................................ 48
13.6 - Air-cooled exchanger...............................................................................................................................................................48
13.7 - Water type heat exchanger .................................................................................................................................................... 48
13.8 - Frequency inverter .................................................................................................................................................................48
13.9 - Refrigerant volume.................................................................................................................................................................49
13.10 - Refrigerant properties...........................................................................................................................................................49
14 - FINAL SHUTDOWN.................................................................................................................................................................50
14.1 - Shutting down.........................................................................................................................................................................50
14.2 - Recommendations for disassembly .......................................................................................................................................50
14.3 - Fluids to be recovered for treatment ......................................................................................................................................50
14.4 - Materials to be recovered for recycling ..................................................................................................................................50
14.5 - Waste electrical and electronic equipment (WEEE)............................................................................................................... 50
15 - UNIT START-UP CHECKLIST FOR INSTALLERS PRIOR TO CONTACTING THE MANUFACTURER........................ 51
4

1 - INTRODUCTION AND SAFETY INSTRUCTIONS
The units are designed to cool water (for coolers) and cool or reheat water (for reversible heat pumps) for the air conditioning and
heating of buildings and 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.
For all safety instructions, please refer to the safety manual. A paper version is delivered with the machine, the digital version is available
in the same place as the IOM, (contact your local distributor).
In addition to this safety manual, the manufacturer states that the unit is designed for a maximum number of 120,000 start-ups.
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 one side of the unit exterior,
- On the inside of the electrical panel door.
5

3 - HANDLING AND POSITIONING
3.1 - Handling
Carrier strongly recommends employing a specialised company
to unload the machine.
Do not remove the subbase 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 a label
with all 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.
IMPORTANT: 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 the unit more than 15°.
Safety when lifting can only be guaranteed if all these instructions
are followed. Otherwise, there is a risk of equipment damage or
injury to personnel.
3.2 - Positioning
The machine must be installed outdoors in a place that is not
accessible to the public and is protected against access by non-
authorised persons.
The machine must be installed outdoors. Installation indoors is
forbidden.
For extra-high units, the unit 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 positioning the device, check that:
- The permitted loading at the site is adequate or that
appropriate strengthening 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.
- the location is not subject to ooding.
- Avoid installing the unit 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. These
must not restrict the unit's air ow.
IMPORTANT: Before lifting the unit, check that all enclosure
panels and grilles are securely xed in place. Lift and set
down the unit with great care. Tilting and jarring can damage
the unit and impair unit operation.
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 pressurised parts, especially via pipes connected to the
water type heat exchanger (with or without the hydraulic
module if the unit is equipped with this). The hydraulic module
pipes must be tted so that the pump does not support the
weight of the pipes.
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.
6

4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES
4.1 - 30RB/30RQ 040R-080R, units with and without hydraulic module
Key:
All dimensions are given in mm.
NOTE: Non-contractual drawings.
When designing a system, refer to the certied dimensional
drawings provided with the unit or available on request.
Refer to the certied dimensional drawings for the location
of xing points, weight distribution and coordinates of the
centre of gravity, hydraulic and electrical connections.
B
Clearances required for maintenance and air ow
C
Clearance recommended for coil removal
Water inlet
Water outlet
Air outlet, do not obstruct
Control box
7

4.2 - 30RB/30RQ 090R-160R, units with and without hydraulic module
Key:
All dimensions are given in mm.
NOTE: Non-contractual drawings.
When designing a system, refer to the certied dimensional
drawings provided with the unit or available on request.
Refer to the certied dimensional drawings for the location
of xing points, weight distribution and coordinates of the
centre of gravity, hydraulic and electrical connections.
B
Clearances required for maintenance and air ow
C
Clearance recommended for coil removal
Water inlet
Water outlet
Air outlet, do not obstruct
Control box
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES
8

4.3 - 30RB/30RQ 040R-080R, units with water bu󰀨er tank module
Key:
All dimensions are given in mm.
NOTE: Non-contractual drawings.
When designing a system, refer to the certied dimensional
drawings provided with the unit or available on request.
Refer to the certied dimensional drawings for the location
of xing points, weight distribution and coordinates of the
centre of gravity, hydraulic and electrical connections.
B
Clearances required for maintenance and air ow
C
Clearance recommended for coil removal
Water inlet
Water outlet
Air outlet, do not obstruct
Control box
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES
9

4.4 - 30RB/30RQ 090R-160R, units with water bu󰀨er tank module
Key:
All dimensions are given in mm.
NOTE: Non-contractual drawings.
When designing a system, refer to the certied dimensional
drawings provided with the unit or available on request.
Refer to the certied dimensional drawings for the location
of xing points, weight distribution and coordinates of the
centre of gravity, hydraulic and electrical connections.
B
Clearances required for maintenance and air ow
C
Clearance recommended for coil removal
Water inlet
Water outlet
Air outlet, do not obstruct
Control box
4 - DIMENSIONS, CLEARANCES, MINIMUM INSTALLATION DISTANCES
10