Carrier 30WI Manual

INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
Original document
HEAT PUMPS AND LIQUID COOLERS WITH
WATER COOLED CONDENSER
30WI

2

CONTENTS
1 - INTRODUCTION............................................................................................................................................................................4
2 - TRANSPORTING THE UNIT.........................................................................................................................................................4
3 - RECEIPT OF GOODS ...................................................................................................................................................................4
3.1 - Checking the equipmentl...........................................................................................................................................................4
3.2 - Identifying the equipment ..........................................................................................................................................................4
4 - SAFETY INSTRUCTIONS .............................................................................................................................................................5
5 - MACHINE COMPLIANCE .............................................................................................................................................................5
6 - UNIT LOCATION ...........................................................................................................................................................................6
7 - HANDLING AND POSITIONING ...................................................................................................................................................6
8 - INSTALLING THE UNIT ................................................................................................................................................................7
8.1 - Dimensions and oor mounting of the frames...........................................................................................................................7
8.2 - Anti-vibration mounts (not supplied by CARRIER)....................................................................................................................7
9 - OPERATING LIMITS .....................................................................................................................................................................8
9.1 - Operating range ........................................................................................................................................................................8
9.2 - Limits.........................................................................................................................................................................................8
9.3 - Evaporator limits........................................................................................................................................................................8
9.4 - Minimum/maximum water ow rates.........................................................................................................................................8
10 - LOCATION OF THE MAIN COMPONENTS................................................................................................................................9
11 - MAIN COMPONENTS OF THE REFRIGERATING CIRCUIT .....................................................................................................9
12 - HYDRAULIC CONNECTIONS...................................................................................................................................................10
13 - GLYCOL/WATER-MIX ANTIFREEZE PROTECTION ............................................................................................................... 11
14 - ELECTRICAL CONNECTIONS.................................................................................................................................................12
14.1 - Power connection..................................................................................................................................................................12
14.2 - Customer connection for remote control functions................................................................................................................12
15 - CONTROL AND SAFETY DEVICES.........................................................................................................................................14
15.1 - Electronic control and display module...................................................................................................................................14
15.2 - Main functions .......................................................................................................................................................................14
15.3 - Safety device management...................................................................................................................................................14
15.4 - Phase controller option..........................................................................................................................................................15
15.5 - Location of the safety sensors and devices ..........................................................................................................................16
15.6 - Adjusting the control and safety devices ...............................................................................................................................17
16 - COMMISSIONING .....................................................................................................................................................................17
16.1 - Commissioning......................................................................................................................................................................17
16.2 - Essential points that must be checked.................................................................................................................................. 18
17 - TECHNICAL AND ELECTRICAL SPECIFICATIONS ...............................................................................................................19
18 - SERVICING AND MAINTENANCE ...........................................................................................................................................21
18.1 - AQUASNAP 30WI operating readings ..................................................................................................................................21
18.2 - Unit maintenance and servicing ............................................................................................................................................21
19 - ECODESIGN..............................................................................................................................................................................23
20 - ARRÊT DÉFINITIF.....................................................................................................................................................................23
21 - TROUBLESHOOTING OPERATING PROBLEMS ...................................................................................................................24
22 - SCHEMATIC INSTALLATION DIAGRAM .................................................................................................................................25
22.1 - Cooling installation with drycooler.........................................................................................................................................25
22.2 - Cooling mode (Heating and cooling).....................................................................................................................................25
22.3 - Heating mode (Heating and cooling).....................................................................................................................................26
3

1 - INTRODUCTION
AQUASNAP 30WI series water chiller units are designed to meet the air conditioning and heating requirements of residential and
ofce buildings as well as the requirements of industrial processes. AQUASNAP 30WI series units are liquid chillers with water-cooled
condensers which guarantee safe and reliable operation in the operating range for which they have been designed.
All the units are factory tested and checked. They are supplied with a full refrigerant charge.
These units meet standard EN 60-204 and standard EN378-2 as well as the following European directives:
-Machinery 2006/42 EC
-EMC 2014/30/EU
-LVD 2014/35/EU
-RoHS 2011/65/EC:
-PED 2014/68/EU, see table below
AQUASNAP 30WI 700V to 1000V 1100V to 1200V 1400V to 1800V 2100V to 2400V
Categories II III II III
Pressure and temperature:
Test pressure (TP): because of the harmful effects it has on the unit, this test is carried out on a model representative of all 3 x PS
assemblies in compliance with § 5.3.2.2 a and 6.3.3 iii of standard 378-2.
Shipment temperature:
Min. -30°C - Max. +50°C.
Storage temperature:
Min. -30°C - Max. +50°C.
Operating temperature:
Refer to section 9, “Operating limits”, in these instructions.
Technicians who install, start up, operate and service the unit must possess the necessary training and certications, understand the
instructions given in this manual and be familiar with the specic technical characteristics of the installation site.
If they are to work on the unit’s refrigeration circuit, such training and certication must meet the requirements of Regulation (EC)
842/2006.
2 - TRANSPORTING THE UNIT
During shipment, the unit must be securely strapped in place to prevent it moving and to protect it from damage.
If the unit is shipped in a container, the container must be easy to load and unload.
Do not lift the unit using these accessories.
3 - RECEIPT OF GOODS
3.1 - Checking the equipmentl
Check the unit for any damage or missing components upon delivery.
Note any damaged or missing parts on the delivery slip.
IMPORTANT:
You must notify the carrier of any damage and/or missing parts by registered letter within three days of the delivery date.
Furthermore, ensure the unit is not stored in an outdoor location exposed to the elements.
3.2 - Identifying the equipment
Name plate:
Each unit has a manufacturer’s name plate (A) bearing the unit’s identication number (serial number)
and description.
AQUASNAP 30WI A
4

3 - RECEIPT OF GOODS
Make sure this information matches that on the order.
Markings (name plate, punch marks, labels) must remain visible. They must not be altered, removed or modied.
Key:
-Désignation/Description : Unit type.
-An(Year) : Year of manufacture.
-N° série/Serial Nbr : Production number. (to be quoted in all
correspondence)
-Refrigerant : Type of refrigerant.
-Refrigerant kg / TeqCO2: Refrigerant content in kg and in tonnes
of CO2equivalent.
-BP/LP Mini / PSM/MOP : For the low pressure circuit:
-BP/LP. Mini = Minimum operating pressure in bar.
-PSM/MOP = Maximum standard pressure in bar (SP according
to PED 2014/68/EU).
-HP Maxi PSM/MOP : For the high pressure circuit:
-HP. Maxi = Maximum operating pressure in bar.
-PSM/MOP = Maximum standard pressure in bar (SP according to PED 2014/68/EU).
-kW Absorbee/Input kW : Power input in kW.
-Tension/Voltage : Power supply.
-Intensite/Current A : Nominal current in A.
-Pression/Pressure Test : See “Pressure and temperature” section on the previous page.
-Service/Working kg : Operating weight of the unit, in kg.
-Temperatures Min/Max : See “Pressure and temperature” section on the previous page.
-IP : Machine electrical protection rating.
-No CE : Notied Body number.
Please include the identication number in all correspondence.
4 - SAFETY INSTRUCTIONS
To avoid any risk of accident during installation, start-up and adjustments, the following equipment specics must be taken into account:
-Pressurised refrigerating circuits
-Presence of refrigerant
-Presence of electrical voltage
Only experienced and qualied persons may work on such equipment.
The recommendations and instructions in this manual and on each drawing provided with the unit must be followed.
In the case of units with pressure equipment or components, we recommend that you contact your professional organisation for
information on the regulations that apply to operators or owners of pressure equipment or components. The specications of this
pressure equipment or these pressure components are given on the name plates or in the regulatory documentation provided with the
product.
A re protection device is tted as standard on all units.
IMPORTANT: Make sure the main disconnect switch in the unit’s electrical panel is in the OFF position before working on the unit.
5 - MACHINE COMPLIANCE
Refer to the document entitled “Declaration of conformity” supplied with your equipment.
Designation/Description
CARRIER SCS
Rte de Thil
01122 Montluel - France
Tél.: [phone] Made in France
Ref. produit/Item Nbr
An(Year) N. Serie/Serial Nbr No Produit
Refrigerant kW Absorbee/Imput kW Service/Working kg
Temperature Min/MaxTension/VoltageRefrigerant kg / TeqCO2
BP/LP Mini PSM/MOP Intensite/Current AIP
No CEPression/Pressure TestHP Maxi PSM/MOP
Contient des gaz fluorés à effet de serre / Contains fluorinated greenhouse gases
02438040/0001
3025277.423727 30WI 1200V
R410A 46.6 1088
CF NOTICE3 50HZ 400V13.5 + 14.0 / 28.2+29.2
2.5 BAR / 29.5 BAR
42 BAR / 42 BAR
140
PT=3XPS CF NOTICE
21
0060
5

6 - UNIT LOCATION
These units are typically used for refrigeration and are not required to withstand earthquakes. Earthquake resistance has therefore
not been checked.
Before setting up the unit in its intended location, the installer must check the following points:
-These units are designed to be installed and stored inside a machine room that is sheltered from frost and the elements. Failure
to do so will incur the loss of the manufacturer’s warranty.
-The surface area of the ground or structure must be strong enough to bear the unit’s weight.
-The unit must be perfectly level.
-There must be sufcient free space around and above the unit to allow servicing and maintenance (see dimensional drawing
provided with unit).
-The room housing the unit must comply with the requirements of regulation EN 378-3 and other specications applicable at the
installation site.
-The selected location must be above ood level.
-Sound level:
• Our units are designed to operate quietly.
• In the installation design, you must take into account the interior environment for radiated noise and the building type for airborne
and solid-borne noise transmission.
• To ensure vibrations transmitted by solid materials are reduced as much as possible, it is strongly recommended to t anti-
vibration mounts between the unit support and frame (see the section on anti-vibration mounts), as well as exible couplings
on the hydraulic piping.
• Have an analysis carried out by an acoustics engineer.
IMPORTANT: The ambient temperature must not exceed 50°C during the unit’s off cycles.
7 - HANDLING AND POSITIONING
To raise the unit, attach the slings to the designated handling holes.
The data relating to the centre of gravity and the position of the anchorage points are given on the dimensional drawing.
Detailed view of the anchorage point for handling
AQUASNAP 30WI
Holes for handling
Ø 35.2 mm
The unit can be handled with a forklift truck (check the maximum permissible load of the forklift).
In this case, it is important that the necessary precautions be taken to avoid the unit sliding on the forks of the forklift. You must observe
the instructions given on the label afxed to the unit. Failure to observe these instructions may result in the unit tipping over and causing
physical injury.
CAUTION:
-Attach the slings only to the anchorage points intended for this purpose and which are designated on the unit.
-Use slings with a suitable lifting capacity and follow the lifting instructions on the drawings provided with the unit.
-Caution: the centre of gravity is not necessarily at the middle of the unit and the forces applied to the slings are not always identical.
-Raise and set down the unit carefully. Take care not to tilt it by more than 15°, as this could adversely affect its operation.
-To avoid damaging the casing, use textile slings with shackles.
-Use a frame with an adjustable centre of gravity to keep the slings away from the top of the unit.
-Always protect the unit casing (panels, posts, front access door) from damage during handling. Only the base frame is designed
to withstand handling.
-Safety when lifting can only be guaranteed if all these instructions are followed.
Otherwise, there is a risk of damage to the equipment and personal injury.
This diagram is provided as a guide; always
refer to the pictograms on the unit
B
A
C
6

7 - HANDLING AND POSITIONING
AQUASNAP 30WI 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V
A996
B1400
C2580 2930 2860
For the empty weight, please refer to section 8.1
8 - INSTALLING THE UNIT
8.1 - Dimensions and oor mounting of the frames
The frame may be afxed to the ground. (Mounts with studs not supplied by CARRIER). The hardness is to be dened according to
the unit’s weight and centre of gravity.
EE
B
A
DFF
C
Ø 20.5 mm
1 m
0.5 m 0.5 m
1 m
Free space to be maintained to allow sufcient room for
maintenance of the unit.
It is important that the units are installed with the necessary
clearances.
AQUASNAP 30WI 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V
A2099 2499 3350
B984 984 984
C1271 1671 2366
D916 916 916
E414 414 492
F34 34 34
Weight (empty) Kg 1044 1156 1189 1312 1363 1425 1613 1708 2284 2376 2418
Weight (in operation) Kg 1088 1205 1246 1378 1436 1510 1713 1818 2472 2588 2637
8.2 - Anti-vibration mounts (not supplied by CARRIER)
Anti-vibration mounts must be installed beneath the unit for applications that generate extremely low vibrations. (See position (E) of
the mounting holes in the oor of the frame on the previous diagram).
7

9 - OPERATING LIMITS
9.1 - Operating range
The graph below represents the area of application (under full load) of the units.
AQUASNAP 30WI
Condenser outlet water temperature
Glycol compulsory
Evaporator outlet water temperature
9.2 - Limits
AQUASNAP 30WI
Condenser
ΔT min. °C / ΔT max. °C
Yes – 5 / 10
The customer should take all means necessary to achieve a minimum
water inlet temperature of 25°C on the condenser side.
Evaporator
ΔT min.°C / ΔT max. °C Variable according to water outlet temperature. See evaporator limit curves
9.3 - Evaporator limits
The curves below show the minimum and maximum allowable
temperature differences for chilled water or glycol/water solution
based on the water outlet temperature, for operation under full load.
Example:
For a water outlet temperature of +5°C
• The minimum TΔ is 2.6°C, which gives a water temperature
of 7.6/5°C
• The maximum TΔ is 6°C, which gives a water temperature
of 11/5°C
If the temperature difference calculated is outside the two curves,
contact us.
1
-8 -6 -4 -2 0 24681
01
2
6
5
2
3
4
7
8
9
Brazed-plate
evaporator
Water outlet temperature (°C)
Acceptable water inlet/outlet
TΔ (°C)
Δ T maximum
Δ T minimum
ΔT calculation for performance tables
glycol/water mix
9.4 - Minimum/maximum water ow rates
The ow rates in the exchangers must be maintained between the values given below.
AQUASNAP 30WI 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V
Evaporator min. m
3
/h 22 26 29 33 35 38 44 51 61 68 74
max. m
3
/h 70 81 92 105 113 124 137 151 150 150 150
Condenser min. m
3
/h 19 22 25 28 31 33 38 43 52 59 66
max. m
3
/h 64 74 84 95 103 112 129 143 150 150 153
8

10 - LOCATION OF THE MAIN COMPONENTS
Compressor
N° 4
Electrical cabinet
Electrical cabinet
Condenser
Evaporator
Compressor
N° 1
Compressor N° 2
Compressor N° 3
Evaporator
Electrical cabinet
Electrical cabinet
Condenser
Evaporator
Compressor
N° 3
Compressor
N° 2
Compressor N° 1
Evaporator
Compressor N° 6
Compressor
N° 4
Compressor
N° 5
AQUASNAP 30WI 700V to 1600V AQUASNAP 30WI 1800V to 2400V
11 - MAIN COMPONENTS OF THE REFRIGERATING CIRCUIT
Compressor
AQUASNAP 30WI units use hermetically sealed SCROLL
compressors.
Oil
The compressor is lubricated with a polyester oil, (POE) type
160SZ for the AQUASNAP 30WI 700 V to 1200 V chillers. This
oil will be the 3MAF (32 cSt) type for the AQUASNAP 30WI 1400
V to 2400 V chillers.
If necessary, top up the compressors with ICI Emkarate RL 32 CF
oil or Mobil EAL Arctic 22 CC oil if no 3MAF is available for R410A
models.
Refrigerant
AQUASNAP 30WI 700 V to 2400 V chillers operate using R410A.
The Global Warming Potential (GWP) is 2088 GWP for R410A,
in compliance with standard EN378-1.
Exchangers
With the AQUASNAP 30WI, the evaporators and condensers are
double-circuit brazed-plate heat exchangers.
The evaporators are thermally insulated with 10 mm thick
polyurethane foam. As an option, 19 mm insulation is available
(standard equipment for operation with low-temperature glycol/
water mix below 0°C).
The heat-transfer medium must be ltered and internal inspections
must be carried out.
Repairs or modications of any kind to the plate heat exchangers
are prohibited. Only the replacement of the heat exchanger by a
qualied technician using original equipment is authorized. If the
heat exchanger is replaced, this must be noted in the maintenance
booklet.
Electronic expansion valve
AQUASNAP 30WI units are equipped with electronic expansion
valves. The electrical equipment is installed in the electrical
cabinet.
All the expansion valve operating parameters are preset, including
evaporator superheating. Only qualied, experienced personnel
can carry out conguration.
A 24V backup battery is built into the driver. It allows the expansion
valve to be closed in the event of a power failure. It has a service
life of 8 years. After this time, the battery must be replaced.
Important : the valve must not be moved when there is no
refrigerant ow rate. When the system is stopped or evacuated,
the start-up potential-free (dry) contact must remain open.
Dehumidier
Every unit is tted as standard with a dehumidier lter (with a
replaceable cartridge) to keep the refrigerating circuit clean and
free of moisture. The dryer lter consists of aluminium oxide and
a molecular sieve that neutralises any acids in the refrigeration
circuit.
Liquid sight glass
Located on the liquid line just after the lter dryer, the liquid sight
glass is used to monitor the charge in the unit and to check for
moisture in the circuit. Bubbles in the sight glass mean that the
refrigerant load is insufcient or that non-condensable gases are in
the refrigeration circuit. If the sight glass indicator paper changes
colour, there is moisture in the circuit.
Warning: Some of the sight glasses may turn yellow when the
machine is powered off, as their sensitivity is affected by the uid
temperature.
The sight glasses should return to green after the unit has been
operating for a few hours.
If the sight glasses remain yellow, there is excessive moisture in the
circuit. A specialist intervention is required.
9

12 - HYDRAULIC CONNECTIONS
B
CD
E
AQUASNAP 30WI 700V 800V 900V 1000V 1100V 1200V 1400V 1600V 1800V 2100V 2400V
Chilled water inlet/outlet BCDiameter DN 100 PN 16 -
VICTAULIC DN 125 PN 16 - VICTAULIC DN 150 PN 16
VICTAULIC
Cooling water inlet/outlet
DEDiameter DN 100 PN 16 -
VICTAULIC DN 125 PN 16 - VICTAULIC DN 150 PN 16
VICTAULIC
Hydraulic connections must be made in accordance with the
diagram delivered with the unit. This diagram shows the positions
and dimensions of the water inlets and outlets on the exchangers.
Follow the requirements below when making these connections:
-Ensure the inlet and outlet pipes are connected in the
direction shown on the unit.
-In order to meet the operating conditions (ow rates, pressure
loss), a sizing calculation must be performed. The diameter
of the pipes may therefore be different to that specied on
the exchanger.
-The pipes and tubes should not transmit any axial or radial
forces to the exchangers or any vibrations.
-The water must be analysed and, if necessary, treated (we
recommend contacting a qualied water treatment specialist).
The analysis will reveal whether the water is suitable for use with
the various materials it will come into contact with and prevent the
formation of electrolytic couples:
• 99.9% copper tubes brazed with copper and silver
• Threaded bronze couplings or at steel anges, depending
on the unit model
• Plate heat exchangers and AISI 316 - 1.4401 stainless steel
connections brazed with copper and silver
-The water circuit must have as few bends and horizontal
sections at different levels as possible.
-Install shut-off valves near the water inlets and outlets in order
to isolate the exchangers.
-Install manual or automatic air bleed valves at the high points
of the circuit(s).
-The manual or automatic air bleed valves tted on the
machine are not intended to be used to bleed the rest of the
hydraulic circuit.
-A static pressure of 1 bar must be maintained at all times
(machine and pump off or on) on the pump intake.
-Install drain connections at all circuit low point(s).
-Install the accessories that are essential for any hydraulic
circuit (balancing valves, expansion vessel, safety valve,
thermometer pockets, etc.).
-Insulate the pipes and tubes (after performing leak tests) in
order to reduce heat losses and prevent damage from frost.
-Install heating elements on all pipes that could be exposed
to frost.
-The installer must provide the necessary systems for lling
and draining the energy transfer uid.
-To keep the pressure in the coolant circuit below the intended
operating pressure, avoid introducing static or dynamic
pressure into the circuit.
IMPORTANT:
-To prevent any risk of fouling or damage to the plate heat
exchangers (evaporator and condenser), it is essential to t
a strainer to the water inlets as close as possible to the
exchangers and in a place which is easily accessible for
disassembly and cleaning. The maximum mesh size of this
lter should be 800 μm.
-Flexible couplings must be used on the hydraulic pipework
(evaporator and condenser).
The system pipework must be secured to the wall of the building
and must not place any additional load on the unit.
-Using untreated or incorrectly treated water may cause
corrosion or erosion or the formation of scale, algae or sludge
deposits. CARRIER shall not be held liable for damage
resulting from the use of untreated or incorrectly treated water,
or of saline or brackish water.
When the unit is used as a heat pump, the maximum water
return temperature of the installation will be 55°C. Never
series-connect the condenser with a high-temperature water
network (boiler). Doing so will result in damage.
NOTE: The maximum operating pressure on the water side should
be 10 bar (evaporator and condenser). The water ow sensor is
supplied tted to the unit. Stopping the pumps will automatically
cause the unit to stop to avoid any risk of freezing. The pump
or pumps must be slaved to the refrigeration unit (auxiliary
operation switch of the pump to be wired).If the hydraulic circuit
is drained for a period of more than one month, ll the entire
circuit with nitrogen to prevent any risk of corrosion.
IMPORTANT :
If antifreeze is not added to the circuit and the unit is not operated
during periods of freezing weather, drain the evaporator and the
outside pipes.
10