Carrier 61AF-B SmartVu High Temperature Heat Pumps User Guide
- June 3, 2024
- Carrier
Table of Contents
61AF-B SmartVu High Temperature Heat Pumps
SmartVuTM
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
unit with protection grille option
High-temperature heat pumps
61AF-B
Nominal heating capacity 26-102 kW 50 Hz
Original document
CONTENTS
1 – INTRODUCTION………………………………………………………………………………………………………………………………………………………. 4
1.1 – Check equipment
received…………………………………………………………………………………………………………………………………….. 4 1.2 –
Installation safety considerations
……………………………………………………………………………………………………………………………. 4 1.3 – Equipment and
components under pressure ……………………………………………………………………………………………………………. 5 1.4 –
Maintenance safety considerations
…………………………………………………………………………………………………………………………. 5 1.5 – Repair safety
considerations ………………………………………………………………………………………………………………………………….. 7 2 –
PRELIMINARY CHECKS…………………………………………………………………………………………………………………………………………… 8 2.1
– Check equipment received……………………………………………………………………………………………………………………………………..
8 2.2 – Moving and siting the
unit………………………………………………………………………………………………………………………………………. 8 2.3 – Checks before
system start-up……………………………………………………………………………………………………………………………….. 8 2.4 –
Lifting labels ………………………………………………………………………………………………………………………………………………………… 9 3
– DIMENSIONS, CLEARANCES…………………………………………………………………………………………………………………………………. 10
3.1 – 61AF 030-035, units with and without hydraulic module
…………………………………………………………………………………………… 10 3.2 – 61AF 045-055, units with and
without hydraulic module …………………………………………………………………………………………… 11 3.3 – 61AF
075-105, units with and without hydraulic module
…………………………………………………………………………………………… 12 3.4 – 61AF 035 option 11, units with
and without hydraulic module……………………………………………………………………………………. 13 3.5 – 61AF
045-055 option 11, units with and without hydraulic module
…………………………………………………………………………….. 14 3.6 – 61AF 075-105 option 11, units with
and without hydraulic module …………………………………………………………………………….. 15 3.7 –
Multiple-unit installation
……………………………………………………………………………………………………………………………………….. 15 4 – PHYSICAL DATA
…………………………………………………………………………………………………………………………………………………… 16 5 – ELECTRICAL
DATA ……………………………………………………………………………………………………………………………………………….. 17 5.1 –
Compressor usage and electrical data for standard units
…………………………………………………………………………………………. 17 5.2 – Short-circuit stability current
(TN system(1)) – standard unit (with main disconnect without fuse)
……………………………………. 17 6 – APPLICATION DATA
………………………………………………………………………………………………………………………………………………. 19 6.1 – Unit
operating range……………………………………………………………………………………………………………………………………………. 19 6.2 –
Plate heat exchanger water flow
…………………………………………………………………………………………………………………………… 19 6.3 – Minimum water flow
rate ……………………………………………………………………………………………………………………………………… 19 6.4 – Maximum
plate heat exchanger water flow rate……………………………………………………………………………………………………….
19 6.5 – Water loop volume
……………………………………………………………………………………………………………………………………………… 20 6.6 – Plate heat
exchanger pressure drop curves……………………………………………………………………………………………………………. 20 7
– ELECTRICAL CONNECTION ………………………………………………………………………………………………………………………………….. 21
7.1 – Power supply……………………………………………………………………………………………………………………………………………………… 21
7.2 – Voltage phase imbalance
(%)……………………………………………………………………………………………………………………………….. 21 7.3 – Recommended
wire sections ……………………………………………………………………………………………………………………………….. 21 7.4 –
Field control wiring ……………………………………………………………………………………………………………………………………………… 21
7.5 – Power supply……………………………………………………………………………………………………………………………………………………… 21
7.6 – 24 V user power reserve
……………………………………………………………………………………………………………………………………… 21 8 – WATER CONNECTIONS
…………………………………………………………………………………………………………………………………………. 23 8.1 – Operating
precautions and recommendations ………………………………………………………………………………………………………… 23
8.2 – Hydraulic connections
…………………………………………………………………………………………………………………………………………. 23 8.3 – Frost
protection ………………………………………………………………………………………………………………………………………………….. 24 8.4 –
Protection against cavitation (option 116)
………………………………………………………………………………………………………………. 24 9 – NOMINAL SYSTEM WATER FLOW
CONTROL…………………………………………………………………………………………………………. 27 9.1 –
General……………………………………………………………………………………………………………………………………………………………… 27 9.2 –
Water flow control procedure (fixed
speed)…………………………………………………………………………………………………………….. 27 9.3 – Water flow control
procedure (variable speed)………………………………………………………………………………………………………… 28 9.4 –
Available system pressure for units with hydraulic module
……………………………………………………………………………………….. 28 10 – START-
UP……………………………………………………………………………………………………………………………………………………………. 29 10.1 –
Preliminary checks ……………………………………………………………………………………………………………………………………………. 29
10.2 – Actual start-up
………………………………………………………………………………………………………………………………………………….. 29 10.3 – Operation
of two units in master/slave mode ………………………………………………………………………………………………………… 29
10.4 – Supplementary electric resistance heaters
…………………………………………………………………………………………………………… 30
2
CONTENTS
11 – MAJOR SYSTEM COMPONENTS …………………………………………………………………………………………………………………………..
31 11.1 – Compressors
……………………………………………………………………………………………………………………………………………………. 31 11.2 –
Lubricant………………………………………………………………………………………………………………………………………………………….. 31 11.3
– Air evaporators …………………………………………………………………………………………………………………………………………………. 31
11.4 – Fans………………………………………………………………………………………………………………………………………………………………… 31
11.5 – Electronic expansion valve (EXV) of the main circuit
……………………………………………………………………………………………… 31 11.6 – Electronic expansion valve
(EXV) of the economised circuit……………………………………………………………………………………. 31 11.7 –
Four-way valve …………………………………………………………………………………………………………………………………………………. 31
11.8 – Moisture indicator
……………………………………………………………………………………………………………………………………………… 31 11.9 – Filter drier
………………………………………………………………………………………………………………………………………………………… 31 11.10 –
Condenser ……………………………………………………………………………………………………………………………………………………… 32 11.11 –
Economiser …………………………………………………………………………………………………………………………………………………….. 32 11.12
– Refrigerant……………………………………………………………………………………………………………………………………………………… 32
11.13 – High-pressure safety switch
……………………………………………………………………………………………………………………………… 32 12 – OPTIONS ET
ACCESSOIRES ……………………………………………………………………………………………………………………………….. 33 13 – UNITS
WITH FANS WITH AVAILABLE PRESSURE FOR INDOOR INSTALLATION (OPTION 11)
………………………………… 34 13.1 – Fan discharge connection
…………………………………………………………………………………………………………………………………. 34 13.2 – Applicable rules
for units incorporated into an air duct system …………………………………………………………………………………
34 13.3 – Electrical data for 61AF units with option 11
…………………………………………………………………………………………………………. 34 14 – HEATING SYSTEM MANAGER
(HSM)……………………………………………………………………………………………………………………. 35 14.1 – Accessory
00PPG000488000- Heating System Managere type A…………………………………………………………………………….
36 14.2 – Accessory 00PPG000488100- Heating System Manager type B
…………………………………………………………………………….. 36 14.3 – Accessory 00PPG000488200- Heating
System Manager type C …………………………………………………………………………….. 37 15 – STANDARD
MAINTENANCE…………………………………………………………………………………………………………………………………. 38 15.1 – Level
1 maintenance …………………………………………………………………………………………………………………………………………. 38 15.2 –
Level 2 maintenance …………………………………………………………………………………………………………………………………………. 38
15.3 – Level 3 (or higher)
maintenance………………………………………………………………………………………………………………………….. 38 15.4 –
Tightening torques for the main electrical screw connections
………………………………………………………………………………….. 39 15.5 – Tightening torques for the main
bolts and screws ………………………………………………………………………………………………….. 39 15.6 – Evaporator
coil …………………………………………………………………………………………………………………………………………………. 39 15.7 –
Condenser maintenance ……………………………………………………………………………………………………………………………………. 39
15.8 – Characteristics of R-407C
………………………………………………………………………………………………………………………………….. 40 16 – START-UP CHECKLIST
FOR 61AF HEAT PUMPS (USE FOR JOB FILE)………………………………………………………………….. 41
The cover photograph is for illustrative purposes only and is not part of any
offer for sale or contract.
3
1 – INTRODUCTION
Prior to the initial start-up of the 61AF units, the people involved should be
thoroughly familiar with these instructions and the specific project data for
the installation site.
The 61AF heat pumps are designed to provide a very high level of safety and
reliability making installation, start-up, operation and maintenance easier
and more secure. They will provide safe and reliable service when operated
within their application range.
They are designed for a theorical operating life of 15 years based on loads
profile defined 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
qualified for the control of pressure equipment. It is recommended to repeat
this check every 5 years. This control does not replace the requirements of
applicable national regulations.
The procedures in this manual are arranged in the sequence required for
machine installation, start-up, operation and maintenance.
Be sure you understand and follow the procedures and safety precautions
contained in the instructions supplied with the machine, as well as those
listed in this guide, such as: protective clothing such as gloves, safety
glasses, safety shoes and appropriate tools, and suitable qualifications
(electrical, air conditioning, local legislation).
To find out, if these products comply with European directives (machine
safety, low voltage, electromagnetic compatibility, equipment under pressure,
etc.) check the declarations of conformity for these products.
1.1 – Check equipment received
Inspect the unit for damage or missing parts. If damage is detected, or if
shipment is incomplete, immediately file a claim with the shipping company.
Confirm that the unit received is the one ordered. Compare the name plate data
with the order.
The name plate is attached to the unit in two locations: – on the outside on
one of the unit sides – on the control box door on the inside
This shows the following information: – Model number – size – CE marking –
Serial number – Year of manufacture and pressure and leak tightness test date
– 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 drawn –
Maximum power input – Unit net weight
Confirm that all accessories ordered for on-site installation have been
supplied, are complete and undamaged.
The unit must be checked periodically, if necessary removing the insulation
(thermal, acoustic), during its whole operating life to ensure that no shocks
(handling accessories, tools, etc.) have damaged it. If necessary, the damaged
parts must be repaired or replaced. See also chapter “Maintenance”.
1.2 – Installation safety considerations
After the unit has been received, when it is ready to be installed or
reinstalled, 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. If damage is detected upon receipt,
immediately file a claim with the shipping company.
This machine must be installed in a location that is not accessible to the
public and protected against access by non-authorised people.
Do not remove the skid or the packaging until the unit is in its final
position. These units can be moved with a fork lift truck, as long as the
forks are positioned in the right place and direction 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 are attached to the unit tank – refer to chapter 2.4).
Use slings with the correct capacity, and always follow the lifting
instructions on the certified drawings supplied for the unit.
Safety is only guaranteed, if these instructions are carefully followed. If
this is not the case, there is a risk of material deterioration and injuries
to personnel.
These units are not designed to be lifted from above.
DO NOT COVER ANY PROTECTION DEVICES.
This applies to fuse plugs and relief valve (if used) in the refrigerant or
heat transfer medium 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. Install
devices at the valve outlets or drain piping that 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 drain piping, must not impair
operation and not lead to a pressure drop that is higher than 10% of the
control pressure.
Ensure that the valves are correctly installed, before operating the unit.
Classification and control
In accordance with the Pressure Equipment Directive and national usage
monitoring regulations in the European Union the protection devices for these
machines are classified as follows:
Refrigerant side High-pressure switch External relief valve(3) Rupture disk Fuse plug Heat transfer fluid side External relief valve
Safety accessory(1)
Over pressure protection
in case of an external fire(2)
x x x x
(4)
(4)
(1) Classified for protection in normal service situations. (2) Classified for
protection in abnormal service situations. These accessories are
sized for fires with a thermal flow of 10kW/m². No combustible matter should
be placed within 6.5m of the unit (3) The instantaneous over-pressure
limitation to 10% of the operating pressure does not apply to this abnormal
service situation. The control pressure can be higher than the service
pressure. In this case, either the design temperature or the high-pressure
switch ensures that the service pressure is not exceeded in normal service
situations. (4) The classification of these relief valve must be made by the
personnel that completes the whole hydraulic installation.
4
1 – INTRODUCTION
Do not remove these valves and fuses, even if the fire risk is under control
for a particular installation. There is no guarantee that the accessories are
re-installed if the installation is changed or for transport with a gas
charge. When the unit is subjected to fire, safety devices prevent rupture due
to over-pressure by releasing the refrigerant. The fluid may then be
decomposed into toxic residues when subjected to the flame:
– Stay away from the unit. – Set up warnings and recommendations for personnel
in
charge to stop the fire. – Fire extinguishers appropriate to the system and
the
refrigerant type must be easily accessible.
All factory-installed relief valve are lead-sealed to prevent any calibration
change.
The external relief valve 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 fluids can be diffused in the
air, ensure that the outlet is far away from any building air intake, or that
they are discharged in a quantity that is appropriate for a suitably absorbing
environment. Relief valve must be checked periodically. See paragraph “Repair
safety considerations”.
If the relief valves are installed on a reversing valve (changeover), 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
reversing valve in the intermediate position, i.e. with both ways open (locate
the control element in the stop position). If a relief valve is removed for
checking or replacement please ensure that there is always an active relief
valve on each of the reversing valves installed in the unit.
Provide a drain in the drain pipe, close to each relief valve, to avoid an
accumulation of condensate or rain water.
All precautions concerning handling of refrigerant must be observed in
accordance with local regulations.
Accumulation of refrigerant in an enclosed space can displace oxygen and cause
asphyxiation or explosions.
Inhalation of high concentrations of vapour is harmful and may cause heart
irregularities, unconsciousness, or death. Vapour is heavier than air and
reduces the amount of oxygen available for breathing. These products cause eye
and skin irritation. Decomposition products can be hazardous.
1.3 – Equipment and components under pressure
These products incorporate equipment or components under pressure,
manufactured by Carrier or other manufacturers. We recommend that you consult
your appropriate national trade association or the owner of the equipment or
components under pressure (declaration, re-qualification, retesting, etc.).
The characteristics of this equipment/these components are given on the
nameplate or in the required documentation, supplied with the products.
The units are intended to be stored and operate in an environment where the
ambient temperature must not be less than the lowest allowable temperature
indicated on the nameplate.
Do not introduce significant 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.
1.4 – Maintenance safety considerations
Carrier recommends the following drafting for a logbook (the table below
should not be considered as reference and does not involve Carrier
responsibility): :
Intervention
Date
Nature(1)
Name of the commissioning
engineer
Applicable national
regulations
Verification Organism
(1) Maintenance, repairs, regular verifications (EN 378), leakage, etc.
Engineers working on the electric or refrigeration components must be
authorized, trained and fully qualified to do so (e.g. electricians trained
and qualified in accordance with IEC 60364 Classification BA4).
All refrigerant circuit work must be carried out by a trained person,fully
qualified to work on these units. He must have been trainedand be familiar
with the equipment and the installation. All welding operations must be
carried out by qualified specialists. 61AF units use refrigerant R-407C.
Special equipment must be used when working on the refrigerant circuit
(pressure gauge, charge transfer, etc.).
Any manipulation (opening or closing) of a shut-off valve must be carried out
by a qualified and authorised engineer, observing applicable standards (e.g.
during draining operations). The unit must be switched off while this is done.
Equip the engineers that work on the unit as follows:
Personal protection equipment (PPE)(1)
Protective gloves, eye protection, safety shoe, protective clothing..
Ear protection.
Filtering respirator
Handling
Operations
maintenance, service
Welding or brazing(2)
X
X
X
X
X
X
(1) We recommend to follow the instructions in EN 378-3. (2) Performed in the
presence of A1 refrigerant according to EN 378-1.
Never work on a unit that is still energized. Never work on any of the
electrical components, until the general power supply to the unit has been
cut.
If any maintenance operations are carried out on the unit, lock the power
supply circuit in the open position and secure the machine upstream with a
padlock.
If the work is interrupted, always ensure that all circuits are still
deenergized before resuming the work.
ATTENTION: Even if the unit has been switched off, the power circuit remains
energized, unless the unit or circuit disconnect switch is open, and remote
start-up is still possible.
Refer to the wiring diagram for further details. Attach appropriate safety
labels.
If any work is carried out in the fan area, specifically if the grilles or
casings have to be removed, cut the power supply to the fans to prevent their
operation. It is also rcommended to block the rotation of the blades during
the work.
It is recommended to install an indicating device to show if part of the
refrigerant has leaked from the valve. The presence of oil at the outlet
orifice is a useful indicator that refrigerant has leaked. Keep this orifice
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 affect the operating range. To avoid nuisance tripping or
leaks, replace or re-calibrate the valve.
5
1 – INTRODUCTION
Operating checks:
Important information regarding the refrigerant used:
This product contains fluorinated greenhouse gas covered by the Kyoto
protocol.
Fluid type: R407C
Global Warming Potential (GWP): 1774
CAUTION: :
1. Any intervention on the refrigerant circuit of this product should be
performed in accordance with the applicable legislation. In the EU, the
regulation is called F-Gas, N°517/2014.
2. Ensure that the refrigerant is never released to the atmosphere during
installation, maintenance or equipment disposal.
3. The deliberate gas release into the atmosphere is not allowed.
4. If a refrigerant leak is detected, ensure that it is stopped and repaired
as quickly as possible.
5. Only a qualified and certified personnel can perform installation
operations, maintenance, refrigerant circuit leak test as well as the
equipment disposal and the refrigerant recovering.
6. The gas recovery for recycling, regeneration or destruction is at customer
charge.
7. Periodic leak tests have to be carried out by the customer or by third
parties. The EU regulation set the periodicity here after:
System WITHOUT leakage detection
System WITH leakage detection
No Check 12 Months 6 Months 3 Months No Check 24 Months 12 Months 6 Months
Refrigerant charge/ circuit (CO2 equivalent)
< 5 Tons
5 charge < 50 Tons
50 Charge > charge < 500 500 Tons Tons(1)
R134A (GWP 1430)
R407C Refrigerant (GWP charge/ 1774) Circuit (kg) R410A
(GWP 2088)
HFO’s : R1234ze
Charge < 3,5 kg
Charge < 2,8 kg
Charge < 2,4 kg
3,5 charge < 34,9 kg
2,8 charge < 28,2 kg
2,4 charge < 23,9 kg
34,9 charge < 349,7 kg
28,2 charge < 281,9 kg
23,9 charge < 239,5 kg
Charge > 349,7 kg
Charge > 281,9 kg
charge > 239,5 kg
No requirement
(1) From 01/01/2017, units must be equipped with a leakage detection system
8. A logbook must be established for equipments subject to periodic leak
tests. It should contain the quantity and the type of fluid present within the
installation (added and recovered), the quantity of recycled fluid,
regenerated or destroyed, the date and output of the leak test, the
designation of the operator and its belonging company, etc.
9. Contact your local dealer or installer if you have any questions.
Protection device checks:
– If no national regulations exist, check the protection devices on site in
accordance with standard EN378: once a year for the high-pressure switches,
every five years for external relief valve.
The company or organisation that conducts a pressure switch test shall
establish and implement a detailed procedure to fix :
– Safety measures – Measuring equipment calibration – Validating operation of
protective devices – Test protocols – Recommissioning of the equipment..
Consult Carrier Service for this type of test. Carrier mentions here only the
principle of a test without removing the pressure switch:
– Verify and and record the set-points of pressure switches and relief devices
(valves and possible rupture discs)
– Be ready to switch-off the main disconnect switch of the power – supply if
the pressure switch does not trigger (avoid
overpressure or excess gas in case of valves on the highpressure side with the
recovery condensers) – Connect a pressure gauge protected against pulsations
(filled – with oil with maximum pointer if mechanical), preferably calibrated
(the values displayed on the user interface may be inaccurate in an instant
reading because of the scanning delay applied in the control) – Complete an HP
Test as provided by the software (refer to the Control IOM for details).
If the machine operates in a corrosive environment, inspect the protection
devices more frequently. Regularly carry out leak tests and immediately repair
any leaks.
Ensure regularly that the vibration levels remain acceptable and close to
those at the initial unit start-up. Before opening a refrigerant circuit,
transfer the refrigerant to bottles specifically provided for this purpose and
consult the pressure gauges.
Change the refrigerant after an equipment failure, following a procedure such
as the one described in NF E29-795 or carry out a refrigerant analysis in a
specialist laboratory.
If the refrigerant circuit remains open for longer than a day after an
intervention (such as a component replacement), the openings must be plugged
and the circuit must be charged with nitrogen (inertia principle). The
objective is to prevent penetration of atmospheric humidity and the corrosion
on the unprotected internal steel walls.
6
1 – INTRODUCTION
1.5 – Repair safety considerations
All installation parts must be maintained by the personnel in charge, in order
to avoid deterioration and injury. Faults and leaks must be repaired
immediately. The authorized technician must have the responsibility to repair
the fault immediately. After each repair of the unit, check the operation of
the protection devices and create a report of the parameter operation at 100%.
Comply with the regulations and recommendations in unit and HVAC installation
safety standards, such as: EN 378 and ISO 5149.
RISK OF EXPLOSION
Never use air or a gas containing oxygen during leak tests to purge lines or
to pressurise a machine. Pressurised air mixtures or gases containing oxygen
can be the cause of an explosion. Oxygen reacts violently with oil and grease.
Only use dry nitrogen for leak tests, possibly with an appropriate tracer gas.
If the recommendations above are not observed, this can have serious or even
fatal consequences and damage the installation.
Never exceed the specified maximum operating pressures. Verify the allowable
maximum high- and low-side test pressures by checking the instructions in this
manual and the pressures given on the unit name plate.
Do not unweld or flamecut the refrigerant lines or any refrigerant circuit
component until all refrigerant (liquid and vapour)as well as the oil have
been been transferred from the heat pump. Traces of vapour should be displaced
with dry air nitrogen. Refrigerant in contact with an open flame can produce
toxic gases. The necessary protection equipment must be available, and
appropriate fire extinguishers for the system and the refrigerant type used
must be within easy reach.
Do not siphon refrigerant.
Avoid spilling liquid refrigerant on skin or splashing it into the eyes. Use
safety goggles and safety gloves. Wash any spills from the skin with soap and
water. If liquid refrigerant enters the eyes, immediately and abundantly flush
the eyes with water and consult a doctor.
The accidental releases of the refrigerant, due to small leaks or significant
discharges following the rupture of a pipe or an unexpected release from a
relief valve, can cause frostbites and burns to personnel exposed. Do not
ignore such injuries. Installers, owners and especially service engineers for
these units must:
– Seek medical attention before treating such injuries. – Have access to a
first-aid kit, especially for treating eye
injuries.
We recommend to apply standard EN 378-3 Annex 3.
Never apply an open flame (blowlamp) or overheated steam (high-pressure
cleaner) to the refrigerant circuit. Dangerous overpressure can result
During refrigerant removal and storage operations follow applicable
regulations. These regulations, permitting conditioning and recovery of
halogenated hydrocarbons under optimum quality conditions for the products and
optimum safety conditions for people, property and the environment are
described in standard NF E29-795.
Refer to the certified dimensional drawings for the units.
It is dangerous and illegal to re-use disposable (nonreturnable) reclaim
cylinders or attempt to refill them. When reclaim cylinders are empty,
evacuate the remaining gas pressure, and move them to a designated place for
recovery. Do not incinerate.
Do not attempt to remove refrigerant circuit components or fittings, while the
machine is under pressure or while it is running. Be sure pressure is at 0 kPa
and that the unit has been shut-down and de-energised before removing
components or opening a circuit.
Do not attempt to repair or recondition any safety devices when corrosion or
build-up of foreign material (rust, dirt, scale, etc.) is found within the
valve body or mechanism. If necessary, replace the device. Do not install
relief valve in series or backwards.
ATTENTION: 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. Do not step on refrigerant lines. The lines can
break under the weight and release refrigerant, causing personal injury. Do
not climb on a machine. 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 when there is
a risk of slipping or losing your balance.
Use only original replacement parts for any repair or component replacement.
Consult the list of replacement parts for the specification of the original
equipment.
Do not drain water circuits containing industrial brines, without informing
the technical service department at the installation site or a competent body
first.
Close the entering and leaving water shut-off valves and purge the unit
hydraulic circuit, before working on the components
installed on the circuit (screen filter, pump, water flow switch, etc.).
Periodically inspect all valves, fittings and pipes of the refrigerant and
hydraulic circuits to ensure that they do not show any corrosion or any signs
of leaks.
It is recommended to wear ear defenders, when working near the unit and the
unit is in operation.
Always ensure you are using the correct refrigerant type before recharging the
unit.
Charging any refrigerant other than the original charge type (R-407C) will
impair machine operation and can even lead to a destruction of the
compressors. The compressors operate with R-407C and are charged with a
synthetic polyol-ester oil.
Before any intervention on the refrigerant circuit, the complete refrigerant
charge must be recovered.
7
2 – PRELIMINARY CHECKS
2.1 – Check equipment received
Check that the unit has not been damaged during transport and that no parts
are missing. If the unit has 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 of the unit sides on the outside – On the control
box door on the inside.
The unit name plate must include the following information: – Model number –
size – CE marking – Serial number – Year of manufacture and pressure and leak
tightness test date – Fluid being transported – 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 drawn – Maximum power input –
Unit net weight
Confirm that all accessories ordered for on-site installationhave been
delivered, are complete and undamaged.
– The unit must be checked periodically, if necessary removing the insulation
(thermal, acoustic), during its whole operating life to ensure that no shocks
(handling accessories, tools, etc.) have damaged it. If necessary, the damaged
parts must be repaired or replaced. See also chapter “Maintenance”.
2.2 – Moving and siting the unit
2.2.1 – Moving
See chapter 1.2 – “Installation safety considerations”.
2.2.2 – Siting the unit
The machine must be installed in a place that is not accessible to the public
or protected against access by non-authorised persons. In case of extra-high
units the machine environment must permit easy access for maintenance
operations.
Always refer to the chapter “Dimensions and clearances” to confirm that there
is adequate space for all connections and service operations. For the centre
of gravity coordinates, the position of the unit mounting holes, and the
weight distribution points, refer to the certified dimensional drawing
supplied with the unit.
Typical applications of these units do not require earthquake resistance.
Earthquake resistance has not been verified and the units are not explosion-
proof.
ATTENTION : Ne pas élinguer ailleurs que sur les points d’ancrage prévus et
signalés sur l’unité.
– Before siting the unit check that: – the permitted loading at the site is
adequate or that
appropriate strenghtening measures have been taken. – if the heat pump is
required to operate in temperatures below
0°C it must be raised at least 300 mm from the ground. This is necessary to
avoid ice build-up on the unit chassis and also to permit correct unit
operation in locations where the snow level may reach this height. – the unit
is installed level on an even surface (maximum tolerance is 5 mm in both
axes). – there is adequate space above the unit for air flow and to ensure
access to the components (see dimensional drawings).
– the number of support points is adequate and that they are in the right
places.
– the location is not subject to flooding. – Baffles may be necessary to
deflect strong winds. They must
not restrict air flow into the unit..
CAUTION: Before lifting the unit, check that all casing panels are securely
fixed in place. Lift and set down the unit with great care. Tilting and
jarring can damage the unit and impair unit operation.
If 61AF units are hoisted with rigging, 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°.
WARNING: Never push or lever on any of the enclosure panels of the unit. Only
the base of the unit frame is designed to withstand such stresses.
2.3 – Checks before system start-up
Before the start-up of the refrigeration system, the complete installation,
including the refrigeration system must be verified against the installation
drawings, dimensional drawings, system piping and instrumentation diagrams and
the wiring diagrams.
For these checks national regulations must be followed. If the national
regulation does not specify any details, refer to standard EN 378 as follows:
External visual installation checks: – Ensure that the machine is charged with
refrigerant, Verify on the unit nameplate that the `fluid transported’ is
R407C and is not nitrogen. – Compare the complete installation with the
refrigeration system and power circuit diagrams. – Check that all components
comply with the design specifications. – Check that all protection documents
and equipment provided by the manufacturer (dimensional drawings, P&ID,
declarations etc.) to comply with the regulations are present. – Verify that
the environmental safety and protection and devices and arrangements provided
by the manufacturer to comply with the regulations are in place. – Verify that
all documents for pressure containers, certificates, name plates, files,
instruction manuals provided by the manufacturer to comply with the
regulations are present. – Verify the free passage of access and safety
routes. – Verify the instructions and directives to prevent the deliberate
removal of refrigerant gases. – Verify the installation of connections. –
Verify the supports and fixing elements (materials, routing and connection). –
Verify the quality of welds and other joints. – Check the protection against
mechanical damage. – Check the protection against heat. – Check the protection
of moving parts. – Verify the accessibility for maintenance or repair and to
check the piping. – Verify the status of the valves. – Verify the quality of
the thermal insulation and of the vapour barriers. – Ensure that the
ventilation in the machine room is sufficient. – Check the refrigerant
detectors.
8
2 – PRELIMINARY CHECKS
2.4 – Lifting labels 61AF 030 to 035
61AF 045 to 055
X (mm) 536±15
Y (mm) 568±22
Z (mm) 557±18
X (mm) 841±31
Y (mm) 521±7
Z (mm) 563±33
61AF 075 to 105
NOTES: 1. Material: self-adhesive vinyl 9800 2. The symbols must be centred. 3. The symbols are black on a red background.
unit with protection grille option
X (mm) 798±25
Y (mm) 1121±2
Z (mm) 538±36
9
3 – DIMENSIONS, CLEARANCES
3.1 – 61AF 030-035, units with and without hydraulic module
1110
1327
1330
300 1000
1000 1
2 1
1000
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box
Water inlet Water outlet Air outlet, do not obstruct
Air outlet, do not obstruct
1000
2
NOTES: : A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings. B In multiple-unit installations
(maximum four units), the side clearance between the units should be increased
from 1000 to 2000 mm. C The height of the solid surface must not exceed 2 m.
10
3 – DIMENSIONS, CLEARANCES
3.2 – 61AF 045-055, units with and without hydraulic module
1114
2100
1330
300 1000
1000
1
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box Water inlet Water outlet Air outlet, do not obstruct Air outlet,
do not obstruct
1
2
2 1000
NOTES: : A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings. B In multiple-unit installations
(maximum four units), the side clearance between the units should be increased
from 1000 to 2000 mm. C The height of the solid surface must not exceed 2 m.
1000
11
3 – DIMENSIONS, CLEARANCES
3.3 – 61AF 075-105, units with and without hydraulic module
2100
2273
1330 1000
300
1000
2053 1
2
1
2261
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box
Water inlet Water outlet Air outlet, do not obstruct
Air outlet, do not obstruct
1000
1
1000
NOTES: :
A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings.
B In multiple-unit installations (maximum four units), the side clearance
between the units should be increased from 1000 to 2000 mm.
C The height of the solid surface must not exceed 2 m.
12
3 – DIMENSIONS, CLEARANCES
3.4 – 61AF 035 option 11, units with and without hydraulic module
1110
1327
1371
300 1000
1280 1
1000
2 1
1000
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box
Water inlet Water outlet Air outlet, do not obstruct
Air outlet, do not obstruct
1000
2
NOTES: : A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings. B In multiple-unit installations
(maximum four units), the side clearance between the units should be increased
from 1000 to 2000 mm. C The height of the solid surface must not exceed 2 m.
13
3 – DIMENSIONS, DÉGAGEMENTS
3.5 – 61AF 045-055 option 11, units with and without hydraulic module
1114
2100
1371
300 1000
1000
1
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box Water inlet Water outlet Air outlet, do not obstruct Air outlet,
do not obstruct
1000
1
2
2 1000
NOTES: : A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings. B In multiple-unit installations
(maximum four units), the side clearance between the units should be increased
from 1000 to 2000 mm. C The height of the solid surface must not exceed 2 m.
14
3 – DIMENSIONS, DÉGAGEMENTS
3.6 – 61AF 075-105 option 11, units with and without hydraulic module
2100
2273
1371
300
1000 1
1000
1
Legend : All dimensions are given in mm mm.
B Required clearances for air flow C Recommended clearances for maintenance
Control box Water inlet Water outlet Air outlet, do not obstruct Air outlet,
do not obstruct
3.7 – Multiple-unit installation Solid wall
1000
2
2 1000
NOTES: : A Non-certified drawings.
Refer to the certified dimensional drawings supplied with the unit or
available on request, when designing an installation. For the location of
fixing points, weight distribution and coordinates of the centre of gravity
refer to the certified dimensional drawings. B In multiple-unit installations
(maximum four units), the side clearance between the units should be increased
from 1000 to 2000 mm. C The height of the solid surface must not exceed 2 m.
Solid wall
NOTE: If the walls are higher than 2 m, contact the factory. 15
4 – PHYSICAL DATA
61AF
Operating weight(1) Standard unit without hydraulic module Standard unit +
optional hydraulic module Sound levels Sound power level(2) Sound pressure
level at 10 m(3) Dimensions Lenght Depth Height Compressors Quantity No. of
capacity steps Refrigerant
Charge
Oil Charge Capacity control Minimum capacity Condensers Water volume Max.
water-side operating pressure without hydraulic module Max. water-side
operating pressure with hydraulic module Fans Quantity Maximum total air flow
Max speed, standard unit Max speed, unit with option 11 Evaporator Hydraulic
module (option)
Variable speed pump
Water connections (with and without hydraulic module) Connections(4) Outside
tube diameter Chassis paint colour
030
035
045
055
075
105
kg
396
411
500
523
900
1020
kg
408
425
564
588
956
1076
dB(A)
78
83
82
84
84
85
dB(A)
46
51
51
53
52
53
mm
1110
mm
1327
mm
1330
1 1
kg teq CO2
8,8 15,6
1110 1114 1114 2273
1327 2100 2100 2100
1330 1330 1330 1330
Hermetic scroll compressor 48,3 r/s
1
1
1
2
1
1
1
2
R407C GWP = 1800 following AR4
9,7
10
13,2
22
17,2
17,7
23,4
39,0
2273 2100 1330
2 2
26,5 47,0
l
4,1
4,1
4,1
4,1
8,2
8,2
SmartVuTM
%
100
100
100
100
50
50
Direct-expansion welded plate heat exchanger
l
6,4
8,2
9,6
12,1
16,4
22,7
kPa
1000 1000 1000 1000 1000 1000
kPa
400
400
400
400
400
400
Axial Flying Bird 4 fans with rotating shroud
1
1
1
1
2
2
l/s
3748 3736 4035 4036 7479 8072
tr/s
12
12
12
12
12
12
tr/s
–
16
16
16
16
16
Grooved copper tubes, aluminium fins
Pump, Victaulic screen filter, relief valve, water + air purge valves cavitation pressure sensors
Victaulic
inch
11/4 11/2 11/2 11/2
2
2
mm
42,4
48,3
48,3
48,3
60,3
60,3
Colour code RAL 7035
(1) Weight shown is a guideline only. Please refer to the unit nameplate (2)
In dB ref=10-12 W, (A) weighting. Declared dualnumber noise emission values in
accordance with ISO 4871 (with an associated uncertainty of +/-2dB(A)).
Measured in
accordance with ISO 9614-1 and certified by Eurovent. (3) In dB ref 20 Pa, (A)
weighting. Declared dualnumber noise emission values in accordance with ISO
4871 (with an associated uncertainty of +/-2dB(A)). For information,
calculated from the sound power level Lw(A). (4) Unit 61AF 030 includes two
sleeves for a 1-1/4” Victaulic to 1-1/4” screw connection as standard.
16
5 – ELECTRICAL DATA
61AF – Standard unit (without hydraulic module)
Power circuit Nominal power supply Voltage range Control circuit supply
Maximum start-up current (Un)(1) Standard unit Unit with electronic starter
option Unit power factor at maximum capacity(2) Maximum unit power input(2)
Nominal unit current draw(3) Maximum unit current draw (Un)(4) Maximum unit
current draw (Un-10%)* Customer-side unit power reserve Short-circuit
stability and protection
030
035
045
055
075
105
V-ph-Hz V
400-3-50 360-440 24 V, via internal transformer
A
102
130
170
201
157
241
A
55
70
91
101
101
142
0,82
0,82
0,82
0,82
0,82
0,82
kW
12
15
19
23
30
46
A
16
20
23
28
40
55
A
20
26
32
38
53
76
A
22
29
35
42
57
83
Customer reserve at the 24 V control power circuit
See table on the next page
(1) Maximum instantaneous start-up current (maximum operating current of the
compressor + fan current + locked rotor current of the compressor). (2) Power
input, compressor and fan, at the unit operating limits (saturated suction
temperature 10 °C, saturated condensing temperature 65 °C) and nominal voltage
of
400V (data given on the unit nameplate). (3) Standardised Eurovent conditions:
evaporator entering/leaving water temperature 40 °C/45 °C, outside air
temperature db/wb = 7 °C/6 °C. (4) Maximum unit operating current at maximum
unit power input and 400 V (values given on the unit nameplate). * Maximum
unit operating current at maximum unit power input and 360 V.
5.1 – Compressor usage and electrical data for standard units
I Max
I Max
LRA(1)
LRA(2)
Cosine
Compressor I Nom
30
35
45
55
75
105
(Un) (Un-10 %)
A
A
phi max
ZH24KVE
13,6
18,3
20,3
99
51
0,85
1
–
–
–
–
–
ZH33KVE
17,3
24,2
26,9
127
66
0,85
–
1
–
–
2
–
ZH40KVE
20,4
30,0
33,2
167
87
0,89
–
–
1
–
–
–
ZH48KVE
24,9
36,0
40,0
198
97
0,89
–
–
–
1
–
2
Legend I Nom I Max (1)
(2
Nominal current draw at Eurovent conditions (see definition of conditions
under nominal unit current draw), A Maximum operating current at 360 V, A
Locked rotor current at nominal voltage, A
Locked rotor current at nominal voltage, electronic starter
5.2 – Short-circuit stability current (TN system(1)) – standard unit (with main disconnect without fuse)
61AF
030
035
045
055
075
105
Value without upstream protection Short-term current at 1 s – Icw – kA rms Admissible peak current – Ipk – kA pk Maximum value with upstream protection by circuit breaker Conditional short-circuit current Icc – kA rms Circuit breaker – Compact range Reference number(2) Value with upstream protection (fuses) Conditional short-circuit current Icc – kA rms Fuse (gL/gG)
0,6
0,6
1,26
1,26
1,26
2
4,5
4,5
6
6
6
10
7 40 5SY6340-7
7 40 5SY6340-7
7,7 50 5SY4350-7
7,7 63 5SY4363-8
6,1 80 5SP4380-7
10 100 5SP4391-7
50
50
50
50
14,5
22
40
40
63
63
80
125
(1) Earthing system type (2) If another current limitation protection system
is used, its time-current and thermal constraints (l²t) trip characteristics
must be at least equivalent to those of the
recommended circuit breaker. The short circuit stability current values above
are suitable with TN system.
17
5 – ELECTRICAL DATA
Electrical data and operating conditions notes:
· 61AF 030-105 units have a single power connection point located immediately
upstream of the main disconnect switch.
· The control box includes the following standard features: – a main
disconnect switch, – starter and motor protection devices for each compressor,
the fans and the pump, – the control devices.
Field connections : · All connections to the system and the electrical
installations must be in full
accordance with all applicable local codes. · The Carrier 61AF units are
designed and built to ensure conformance with these
codes. The recommendations of European standard EN 60204-1 (machine safety –
electrical machine components – part 1: general regulations – corresponds to
IEC 60204-1) are specifically taken into account, when designing the
electrical equipment.
NOTES:
· Generally the recommendations of IEC 60364 are accepted as compliance with
the requirements of the installation directives. Conformance with EN 60204-1
is the best means of ensuring compliance with the Machines Directive § 1.5.1.
· Annex B of EN 60204-1 describes the electrical characteristics used for the
operation of the machines.
· The operating environment for the 61AF units is specified below: 1.
Environment(1) – Environment as classified in EN 60721 (corresponds to IEC
60721): – outdoor installation(1) – ambient temperature range: -20°C to +40°C,
class 4K4H – altitude: 2000 m – presence of hard solids, class 4S2 (no
significant dust present) – presence of corrosive and polluting substances,
class 4C2 (negligible)
2. Power supply frequency variation: ± 2 Hz.
3. The neutral (N) conductor must not be connected directly tothe unit (if
necessary use a transformer).
4. 4. Overcurrent protection of the power supply conductors is notprovided
with the unit.
5. The factory-installed disconnect switch is of a type suitablefor power
interruption in accordance with EN 60947.
6. The units are designed for connection to TN networks (IEC60364). For IT
networks the earth connection must not be at the network earth. Provide a
local earth, consult competent local organisations to complete the electrical
installation. Units delivered with speed drive (options 116) are not
compatible with IT network.
Caution: If particular aspects of an actual installation do not conform to the
conditions described above, or if there are other conditions which should be
considered, always contact your local Carrier representative. (1) The required
protection level for this class is IP43BW (according to reference
document IEC 60529). All 61AF units are protected to IP44CW and fulfil this
protection condition.
18
6 – APPLICATION DATA
6.1 – Unit operating range
Condenser
Minimum Maximum
Entering water temperature at start-up
°C 8
57
Leaving water temperature during operation °C 30
65
Entering/leaving water temperature difference
K3
(2)
Evaporator
Minimum Maximum
Entering air temperature, standard unit(1) °C -20
40
Entering air temperature, unit with option °C -15
40
Note : Do not exceed the maximum operating temperature. (1) Outside
temperature: For transport and storage of the 61AF units the minimum
and maximum allowable temperatures are -20°C and +50°C. It is recommended that
these temperatures are used for transport by container. (2) Refer to the
minimum water flow rate for each machine (see chapter 6.2).
70
65
Leaving water temperature, °C
60
55
50
45
40
35
30
25
20 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 Entering temperature, °C
Full load
6.2 – Plate heat exchanger water flow
61AF
30 35 45 55 75 105
Maximum flow rate with hydraulic module, l/s(1)
2,4 2,8 3,8 4,6 5,9 6,1
Maximum flow rate without hydraulic
module, l/s(2)
2,4
3,1
3,8
4,6
6,4
8,5
(1) Maximum flow rate at an available pressure of 20 kPa minimum. (2) Maximum
flow rate at a water temperature difference of 3K in the plate heat
exchanger.
NOTE: For a domestic hot water application (leaving water temperature = 65°C),
the water temperature difference must be 8 K minimum for operation at 100%
capacity.
6.3 – Minimum water flow rate
Operation below the minimum flow rate of the machine can cause a risk of
freezing and excessive fouling of the condenser.
Minimum water flow rate,, l/s
0.75
0.70
C
0.65
0.60
0.55
0.50
B
0.45
0.40
0.35
25
35
45
55
65
Minimum water flow rate, l/s
1 61AF 030 2 61AF 035
1.30 1.25 1.20 1.15 1.10 1.05 1.00 0.95 0.90 0.85 0.80
25
Leaving water temperature, °C
35
45
55
C
B
65
Leaving water temperature, °C
Minimum water flow rate, l/s
1 61AF 045 2 61AF 055
2.40 2.20 2.00 1.80 1.60 1.40 1.20 1.00
25
1 61AF 075 2 61AF 105
35
45
55
Leaving water temperature, °C
C
B
65
6.4 – Maximum plate heat exchanger water flow rate
This is limited by the permitted plate heat exchanger pressure drop. Also, a
minimum condenser T of 3 K must be guaranteed, which corresponds to a water
flow rate of 0.09 l/s per kW.
19
6 – APPLICATION DATA
6.5 – Water loop volume
6.5.1 – Minimum water loop volume
The heat pump is used in a domestic hot water application and must heat an
intermediate loop that supplies domestic hot water via a heat exchanger. The
primary loop is charged with softened water. Regular checks must be carried
out on the water system to detect possible scale formation. The heat pump in
this type of application must never supply domestic hot water directly. The
minimum water loop volume, in litres, is given by the following formula:
Volume (l) = CAP (kW) x N, where CAP is the nominal heating capacity at
nominal operating conditions.
6.6 – Plate heat exchanger pressure drop curves
For pure water at 20°C
30
25
D C
20
B
15
10
Pressure drop, kPa
Heating or domestic hot water application
N
61AF 030-055
5,0 l
5
61AF 075-105
3,0 l
0
This volume is required to obtain temperature stability and
0
1
precision.
To achieve this volume, it may be necessary to add a storage tank
to the circuit. This tank should be equipped with baffles to allow mixing of
the fluid (water or brine). Please refer to the examples below.
1 61AF 030 2 61AF 035 3 61AF 045
50
2
3
Water flow rate, l/s
4
5
D
40
Bad
Good
C
30
B
20
Pressure drop, kPaa
Bad
Good
10
6.5.2 – Expansion tank volume
Units with hydraulic module do not incorporate an expansion tank.
0
This must be included in the water loop.
0
The table below gives the buffer tank volume that must be
2
4
6
8
10
Water flow rate, l/s
provided, based on the water loop volume, the fluid used and its concentration.
1 61AF 055 2 61AF 075 3 61AF 105
Expansion tank volume required
Pure water 10 % ethylene glycol 20 % ethylene glycol 30 % ethylene glycol 40 %
ethylene glycol
% of water loop volume(1) 3,0 3,0 3,5 3,8 4,2
(1) Calculation based on a charge temperature of 10°C.
20
7 – ELECTRICAL CONNECTION
Please refer to the certified dimensional drawings, supplied with the unit
(also available on the internet).
7.1 – Power supply
The power supply must conform to the specification on the unit nameplate. The
supply voltage must be within the range specified in the electrical data
table. For connections refer to the wiring diagrams and the certified
dimensional drawings. WARNING: Operation of the unit with an improper supply
voltage or excessive phase imbalance constitutes abuse which will invalidate
the Carrier warranty. If the phase imbalance exceeds 2% for voltage, or 10%
for current, contact your local electricity supply at once and ensure that the
heat pump is not switched on until corrective measures have been taken.
7.2 – Voltage phase imbalance (%)
100 x max. deviation from average voltage Average voltage
Example:
On a 400 V – 3 ph – 50 Hz supply, the individual phase voltages were measured
to be:
AB = 406 V; BC = 399 V; AC = 394 V
Average voltage = (406 + 399 + 394)/3 = 1199/3
= 399,7 say 400 V
Calculate the maximum deviation from the 400 V average:
(AB) = 406 – 400 = 6
(BC) = 400 – 399 = 1
(CA) = 400 – 394 = 6
Motor
The maximum deviation from the average is 6 V. The greatest percentage
deviation is: 100 x 6/400 = 1.5%
This is less than the permissible 2% and is therefore acceptable.
7.3 – Recommended wire sections
Wire sizing is the responsibility of the installer, and depends on the
characteristics and regulations applicable to each installation site. The
following is only to be used as a guideline, and does not make Carrier in any
way liable. After wire sizing has been completed, using the certified
dimensional drawing, the installer must ensure easy connection and define any
modifications necessary on site. The connections provided as standard for the
field-supplied power entry cables to the general disconnect/isolator switch
are designed for the number and type of wires, listed in the table below.
The calculations are based on the maximum machine current (see electrical data
tables). Standard installation practises for units installed outside have been
applied in accordance with IEC 60364, table 52C:
– No. 17: suspended aerial lines, – -No. 61: buried conduit with a derating
coefficient of 20.
The calculation is based on PVC or XLPE insulated cables with copper core. A
maximum ambient temperature of 40°C has been taken into consideration for 61AF
units. The given wire length limits the voltage drop to < 5%..
IMPORTANT: Before connection of the main power cables (L1 – L2 – L3) on the
terminal block, it is imperative to check the correct order of the 3 phases
before proceeding to the connection on the main disconnect/isolator switch.
7.3.1 – Power cable entry
The power cables can enter the 61AF control box from below or from the side of
the unit, at the bottom of the angle iron. Prepunched holes facilitate the
entry. Refer to the certified dimensional drawing for the unit. An opening
below the control box allows introduction of the cables.
7.4 – Field control wiring
Important: Field connection of interface circuits may lead to safety risks:
any control box modification must maintain equipment conformity with local
regulations. Precautions must be taken to prevent accidental electrical
contact between circuits supplied by different sources:
– The routing selection and/or conductor insulation characteristics must
ensure dual electric insulation.
– In case of accidental disconnection, conductor fixing between different
conductors and/or in the control box prevents any contact between the
conductor ends and an active energised part.
Refer to the 61AF SmartVuTM Control IOM and the certified wiring diagram
supplied with the unit for the field control wiring of the following features:
– Condenser pump interlock (mandatory) – Remote on/off switch – Demand limit
external switch – Remote dual setpoint switch – Alarm, alert and operation
report
7.5 – Power supply
After the unit has been commissioned, the power supply must only be
disconnected for quick maintenance operations (one day maximum). For longer
maintenance operations or when the unit is taken out of service and stored the
power supply must be maintained to ensure supply to the heaters (unit frost
protection).
7.6 – 24 V user power reserve
After all possible options have been connected, the transformer ensures the
availability of a usable 24 VA or 1 A power reserve for the control circuit on
site. This power reserve can not be used in case of additionnal electric
heaters control.
21
7 – ELECTRICAL CONNECTION
Table of minimum and maximum wire sections for connection to 61AF units
61AF
030 035 045 055 075 105
Disconnect switch
Max. connectable
section
Section (mm2)
1 x 10 1 x 10 1 x 16 1 x 16 1 x 16 1 x 35
Min. wire section
Section (mm2)
1 x 6 1 x 10 1 x 10 1 x 10 1 x 16 1 x 35
Max. length (m)
100 130 130 130 220 220
Connectable wire
Max. wire section
Wire type
XLPE Cu XLPE Cu XLPE Cu XLPE Cu XLPE Cu XLPE Cu
Section (mm2)
1 x 10 1 x 10 1 x 16 1 x 16 1 x 16 1 x 35
Max. length (m)
245 245 245 245 245 220
Note: Power supply cable section (see the diagram in the chapter “Electrical connection”).
Wire type
PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu PVC Cu
22
8 – WATER CONNECTIONS
For size and position of the unit water inlet and outlet connections refer to
the certified dimensional drawings supplied with the unit. The water pipes
must not transmit any radial or axial force to the heat exchangers nor any
vibration.
The water supply must be analysed and appropriate desilting, filtering,
treatment, control devices, shut-off and bleed valves built in, to prevent
corrosion (example: damage to the protection of the tube surface if the fluid
is polluted), fouling and deterioration of the water circuit.
Before any start-up verify that the heat exchange fluid is compatible with the
materials and the water circuit coating. The use of different metals on
hydraulic piping could generate eletrolytic pairs and consequently corrosion.
Verify then, the need to install sacrificial anodes.
In case additives or other fluids than those recommended by Carrier are used,
ensure that the fluids are not considered as a gas, and that they belong to
class 2, as defined in directive 2014/68/EU.
Carrier recommendations on heat exchange fluids: – No NH4+ ammonium ions in
the water, they are very detrimental for copper. This is one of the most
important factors for the operating life of copper piping. A content of
several tenths of mg/l will badly corrode the copper over time. – Cl- Chloride
ions are detrimental for copper with a risk of perforations by corrosion by
puncture. If possible keep below 125 mg/l. – SO4 2- sulphate ions can cause
perforating corrosion, if their content is above 30 mg/l. – No fluoride ions
(<0.1 mg/l). – No Fe2+ and Fe3+ ions with non negligible levels of dissolved
oxygen must be present. Dissolved iron < 5 mg/l with dissolved oxygen < 5
mg/l. – Dissolved silica: silica is an acid element of water and can also lead
to corrosion risks. Content < 1mg/l. – Water hardness: >0.5 mmol/l. Values
between 0.5 and 1.5 mmol/l are recommended. This will facilitate scale deposit
that can limit corrosion of copper. Values that are too high can cause piping
blockage over time. A total alkalimetric titre (TAC) below 100 is desirable in
primary domestic hot water loops and for heating applications. – Dissolved
oxygen: Any sudden change in water oxygenation conditions must be avoided. It
is as detrimental to deoxygenate the water by mixing it with inert gas as it
is to over-oxygenate it by mixing it with pure oxygen. The disturbance of the
oxygenation conditions encou-rages destabilisation of copper hydroxides and
enlarge-ment of particles. – Electric conductivity 10-600 S/cm – pH: Ideal
case pH neutral at 20-25°C (7.5<pH<9).
ATTENTION: Charging, adding or draining fluid from the water circuit must be
done by qualified personnel, using air vents and materials suitable for the
products. The water circuit charging devices are field-supplied.
Charging and removing heat exchange fluids should be done with devices that
must be included on the water circuit by the installer.
8.1 – Operating precautions and recommendations
The water circuit should be designed to have the least number of elbows and
horizontal pipe runs at different levels. Below the main points to be checked
for the connection:
– Comply with the water inlet and outlet connections shown on the unit.
– Install manual or automatic air purge valves at all high points in the
circuit.
– Use a pressure reducer to maintain pressure in the system and install a
relief valve and an expansion tank.
– Units with a hydraulic module include a relief valve. – Install thermometers
in both the entering and leaving water
connections. – Install drain connections at all low points to allow the whole
circuit to be drained. – Install stop valves, close to the entering and
leaving water
connections. – Use flexible connections to reduce vibration transmission. –
Insulate all pipework, after testing for leaks, to prevent heat
loss. – Wrap the insulations with a demisting screen. – If the external unit
water pipes are in an area where the
ambient temperature is likely to fall below 0°C, they must be protected
against frost (frost protection solution or electric heaters).
NOTE: For units not equipped with a hydraulic module a screen filter must be
installed. This must be installed on the water entering pipes upstream of the
pressure gauge at the unit inlet. It must be located in a position that is
easily accessible for removal and cleaning. The mesh size of the filter must
be 1.2 mm.
The plate heat exchanger can foul up quickly at the initial unit start-up, as
it complements the filter function, and the unit operation will be impaired
(reduced water flow rate due to increased pressure drop). Units with hydraulic
module are equipped with this type of filter.
Do not introduce any significant static or dynamic pressure into the heat
exchange circuit (with regard to the design operating pressures).
The products that may be added for thermal insulation of the containers during
the water piping connection procedure must be chemically neutral in relation
to the materials and coatings to which they are applied. This is also the case
for the products originally supplied by Carrier.
8.2 – Hydraulic connections
The diagram on the following page shows a typical hydraulic installation. When
charging the water circuit use air vents to evacuate any residual air pockets.
23
8 – WATER CONNECTIONS
8.3 – Frost protection
The plate heat exchangers, the piping and the hydraulic module pump can be
damaged by frost, despite the built-in anti-freeze protection of the units.
Frost protection of the plate heat exchanger and all hydraulic circuit
components is guaranteed:
– Down to -20°C by electric heaters (heat exchanger and internal piping) that
have an automatic supply (units without hydraulic module),
– Down to -10°C by an electric heater on the heat exchanger that has an
automatic supply and by pump cycling (standard for units with hydraulic
module),
– Down to -20°C by electric heaters (heat exchanger and internal piping) that
have an automatic supply and by pump cycling (units with hydraulic module and
“Reinforced frost protection” option).
Never switch off the plate heat exchanger and hydraulic circuit heaters or the
pump, otherwise frost protection cannot be guaranteed. The main unit
disconnect switch as well as the heater auxiliary protection switch must
always be left closed (for the location of these components see the wiring
diagram).
To ensure frost protection of the units with hydraulic module water
circulation in the water circuit must be maintained by periodically switching
on the pump. If a shut-off valve is installed, a bypass must be included as
shown below.
transfer fluid does not comply with the Carrier regulations, the nitrogen
charge must be added immediately.
8.4 – Protection against cavitation (option 116)
To ensure the durability of the pumps in the integreated hydraulic modules
(options 116), the control algorithm of the 61AF units incorporates anti-
cavitation protection.
It is therefore necessary to ensure a minimum pump entering pressure of 40 kPa
(0.4 bar) during operation and at shut-down. A pressure below 40 kPa will
prohibit unit start-up or cause an alarm with the unit shutting down. In order
to obtain sufficient pressure, it is recommended:
– to pressurise the hydraulic circuit between 1 and 4 bar (maximum),
– to clean the hydraulic circuit before charging water (see chapters 9.2 and
9.3),
– to regularly clean the screen filter,
ATTENTION: The use of integrated hydraulic kits in the open loop is not
permitted.
Winter position
Closed
Water network
Closed
Closed
Unit
It is recomended to use a primary glycol loop for low-temperature
applications, as shown below:
2
Water network
3
Unit
1
Legend
1 Primary glycol loop (minimum 10%)
2 Intermediate heat exchanger
3 Secondary loop
IMPORTANT: Depending on the climate conditions in your area do the following
when switching the unit off in winter:
– Add ethylene glycol or propylene glycol with an adequate concentration to
protect the installation up to a temperature of 10 K below the lowest
temperature likely propylene glycol is added, ensure that the unit pump is not
used to add pure glycol and to apportion the fluid amount (possible pump
damage). Always add a mixture that is measured in advance.
– If the unit is not used for an extended period, it should be drained, and as
a safety precaution ethylene glycol or propylene glycol introduced in the heat
exchanger, using the water entering purge valve connection.
– At the start of the next season, refill the unit with water and add an
inhibitor.
– For the installation of auxiliary equipment, the installer must comply with
basic regulations, especially for minimum and maximum flow rates, that must be
between the values listed in the operating limit table (application data).
– To prevent corrosion by differential aeration, the complete drained heat
transfer circuit must be charged with nitrogen for a period of one month. If
the heat
24
8 – WATER CONNECTIONS
Typical hydraulic circuit diagram
15 17
19
23
6
7
13
18
1
5
54
14 16 4
22
14 16
4 12
8
17 20 21
19
11
10
5
9
Legend Components of the unit and hydraulic module 1 Victaulic screen filter 2
Pressure sensor
Note: Gives pump suction pressure information (see installation manual) 3
Relief valve 4 Water drain valve
Note: A second valve is located on the heat exchanger leaving piping 5 Shut-
off valve 6 Available pressure pump 7 Temperature probe, BPHE inlet Note:
Gives heat exchanger entering temperature
information (see installation manual) 8 Pressure gauge
Note: Allows measuring of the pump suction pressure, the pump leaving pressure
and the heat exchanger leaving pressure 9 Temperature probe, BPHE outlet Note:
Gives heat exchanger leaving temperature information (see installation manual)
10 Automatic air vent 11 Flow switch 12 Plate heat exchanger frost protection
heater 13 Plate heat exchanger
Installation components 14 Temperature probe well 15 Air vent 16 Flexible
connection 17 Shut-off valve 18 Screen filter (obligatory for a unit without
hydraulic module) 19 Pressure gauge 20 Water flow control valve (optionnal
with hydraulic module option) 21 Charge valve 22 Frost protection bypass valve
(when shut-off valves [17] are closed during winter) — Hydraulic module (unit
with hydraulic module)
Notes: – Units without hydraulic module (standard units) are equipped with a
flow switch
and two temperature sensors (7 and 9). – For units equipped with hydraulic
module, the pressure sensor located upstream
of the pump to prevent cavitation is installed on a connection without
Schraeder valves. Depressurise and drain the system before any intervention.
25
8 – WATER CONNECTIONS
Hydraulic module – 61AF 61AF 030-035
61AF 045-105
Légende Composants du module hydraulique et de l’unité 1 Victaulic screen
filter 2 Pressure sensor
Note: Gives pump suction pressure information (see installation manual) 3
Relief valve 4 Water drain valve
Note: A second valve is located on the heat exchanger leaving piping 5 Shut-
off valve 6 Available pressure pump 7 Temperature probe, BPHE inlet Note:
Gives heat exchanger entering temperature
information (see installation manual) 8 Pressure gauge
Note: Allows measuring of the pump suction pressure, the pump leaving pressure
and the heat exchanger leaving pressure 9 Temperature probe, BPHE outlet
Note: Gives heat exchanger leaving temperature information (see installation
manual) 10 Automatic air vent 11 Flow switch
26
9 – NOMINAL SYSTEM WATER FLOW CONTROL
9.1 – General
The optional water circulation pumps of the 61AF units have been sized to
allow the hydraulic modules to cover all possible configurations based on the
specific installation conditions, i.e. for various temperature differences
between the entering and the leaving water (T) at full load, which can vary
between 3 and 10 K. This required difference between the entering and leaving
water temperature determines the nominal system flow rate.
The pump of the hydraulic module is a variable speed pump. Two different water
flow control can be selected:
– fixed speed control – variable speed control based on constant temperature
difference.
Default factory setting is fixed speed. Settings change need to be done by a
Carrier Service representant.
For both flow control and for energy saving, the speed of the pump will be
reduced to its minimum when unit capacity is 0%.
It is essential to know the nominal system flow rate to be able to control it,
using the variable pump speed or a manual valve that must be on the water
leaving piping of the system (item 20 in the typical hydraulic circuit
diagram).
The flow control with the pump speed or with the valve permits adjustment of
the pressure/system flow rate curve in accordance with the pump pressure/flow
rate curve to obtain the nominal flow rate at the required operating point
(see example for unit size 61AF 035). The pressure drop reading in the plate
heat exchanger is used as means of control and adjustment of the nominal
system flow rate. This reading can be taken with a differential pressure gauge
that must be installed at the heat exchanger inlet and outlet.
Use the specifications of the unit selection to know the system operating
conditions and to deduce the nominal flow rate and the plate heat exchanger
pressure drop at the specified conditions. If this information is not
available at the system start-up, contact the technical service department
responsible for the installation to get it.
These characteristics can be obtained with the Electronic Catalogue selection
program for all T conditions in the range of 3 to 10 K.
For domestic hot water applications (leaving water temperatures above 60°C)
the control cannot be made at a T below 8 K at the condenser.
9.2 – Water flow control procedure (fixed speed)
Hydraulic circuit cleaning procedure
– Open the valve fully (item 20) if present. – Start-up the system or unit
pump (by quick test), if the unit is
equipped with a hydraulic module with a pump. – Read the plate heat exchanger
pressure drop by taking the
difference of the readings of the pressure gauge connected to the unit inlet
and outlet (item 19). – Let the pump run for two consecutive hours to clean
the system hydraulic circuit (presence of solid contaminants). – Take another
reading. – Compare this value to the initial value. – If the pressure drop has
decreased, this indicates that the screen filter must be removed and cleaned,
as the hydraulic circuit contains solid particles. In this case close the
shut-off valves at the water inlet and outlet (item 17) and remove the screen
filter (item 18 or 1 for a unit with hydraulic module) after emptying the
hydraulic section of the unit (item 4). – Purge the air from the circuit
(items 10 and 15). – Renew, if necessary, to ensure that the filter is not
contaminated.
Water flow control procedure
– When the circuit is cleaned, read the pressures at the differential pressure
gauge (BPHE leaving water pressure -BPHE entering water pressure), to find out
the pressure drop for the plate heat exchanger and the internal piping.
– Compare the value obtained with the theoretical selection value.
– If the pressure drop measured is higher than the value specified this means
that the unit flow rate (and thus system flow rate) is too high. The pump
supplies an excessive flow rate based on the global pressure drop of the
application. In this case close the control valve or reduce the pump speed.
Read the new pressure difference.
– Proceed by successively closing the control valve or reducing the pump speed
until you obtain the specific pressure drop that corresponds to the nominal
flow rate at the required unit operating point.
– Verify the minimum speed pump setting(when unit capacity is 0%) is
compatible with the flow switch protection (no flow switch alarm for minimum
speed).
NOTE: If the system has an excessive pressure drop in relation to the
available static pressure provided by the system pump the nominal water flow
rate cannot be obtained (the resulting flow rate is lower) and the temperature
difference between the condenser entering and leaving water
will increase.
To reduce the pressure drops of the hydraulic system, it is
necessary: – to reduce the individual pressure drops as much as possible
(bends, level changes, accessories, etc.). – to use a correctly sized piping
diameter. – to avoid hydraulic system extensions, wherever possible.
Example: 61AF 035 at Eurovent conditions of 1.76 l/s
20
2
A
16
Pressure drop, kPa
12
B
8
4
4
1
5
3
0
0,5
1
1,5
2
2,5
3
3,5
4
Water flow rate, l/s
Legend 1 `BPHE pressure drop/flow rate” curve 2 With the valve open or with
the maximum pump speed, the pressure drop read
(18 kPa) gives point A on the curve. A Operating point reached with the valve
open / maximum pump speed. 3 The flow rate achieved is 3.4 l/s: this is too
high, and the valve must be closed or the pump speed decreased. 4 With valve
is partially closed or speed decreased, the pressure drop read (6 kPa) gives
point B on the curve. B Operating point reached with the valve partially
closed / pump speed reduced. 5 The flow rate achieved is 1.76 l/s: this is the
required flow rate and the settings are adequate
27
9 – NOMINAL SYSTEM WATER FLOW CONTROL
9.3 – Water flow control procedure (variable speed)
61AF units with variable speed hydraulic module include a water pump that
automatically adjusts the flow to maintain a constant temperature difference.
No control is required at start-up, but the control mode must be selected in
the unit control by a Carrier service representant.
9.4 – Available system pressure for units with hydraulic module
The available pressure curves for the 61AF units are given for the higher
variable speed of the pump (maximum available pressure). Data applicable for:
– Fresh water 20°C – In case of use of the glycol, the maximum water flow is
reduced
For pure water at 20°C
Available pressure, kPa
120 110 100
90 80 70 60 50 40 30 20
0,4
1 61AF 030 2 61AF 035
Available pressure, kPa
61AF
Maximum condenser water flow rate, l/s
30
2,4
35
2,8
45
3,8
55
4,6
75
5,9
105
6,1
(1) Maximum flow rate corresponding to an available pressure of 20 kPa minimum (units with hydraulic module).
C B
0,9
1,4
1,9
2,4
Water flow rate, l/s
B
C
1 61AF 045 2 61AF 055
Water flow rate, l/s
Available pressure, kPa
1 61AF 075 2 61AF 105
Water flow rate, l/s
C B
28
10 – START-UP
10.1 – Preliminary checks
Never be tempted to start the heat pump without reading fully,
andunderstanding, the operating instructions and without havingcarried out the
following pre-start checks:
– Check the water circulation pumps, air handling units and al other equipment
connected to the condenser.
– Refer to the manufacturer’s instructions. – Refer to the wiring diagram
supplied with the unit. – Ensure that there are no refrigerant leaks. –
Confirm that all pipe securing bands are tight. – Confirm the the electrical
connections are secure.
Standard configuration: return water control
10.2 – Actual start-up
IMPORTANT: – Commissioning and start-up of the chiller must be supervised by a
qualified refrigeration engineer. – Start-up and operating tests must be
carried out with a thermal load applied and water circulating in the
condenser. – All setpoint adjustments and control tests must be carried out
before the unit is started up. – Please refer to the 61AF SmartVuTM control
manual.
The unit should be started up in Local ON mode. Ensure that all safety devices
are satisfied, especially the high pressure switches.
Configuration: leaving water control
10.3 – Operation of two units in master/slave mode
The control of a master/slave assembly is in the entering water and does not
require any additional sensors (standard configuration). It can also be
located in the leaving water. In this case two additional sensors must be
added on the common piping.
All parameters, required for the master/slave function must be configured
using the Service Configuration menu. All remote controls of the master/slave
assembly (start/stop, setpoint, load shedding, etc.) are controlled by the
unit configured as master and must only be applied to the master unit.
Depending on the installation and control type, each unit can control its own
water pump. Please install check valves in the leaving water piping of each
unit, as shown in the following diagrams. If there is only one common pump for
the two units, the master unit can control this. In this case shut-off valves
must be installed on each unit. They will be activated at the opening and
closing by the control of each unit (and the valves will be controlled using
the dedicated water pump outputs).
Legend
B Master unit C Slave unit
Additional CCN board (one per unit, with connection via communication bus)
Water inlet. Water outlet
Water pumps for each unit (included for units with hydraulic module)
T
T Additional sensors for leaving water control, to be connected to channel 1 of the slave boards of each master and slave unit
CCN communication bus
Connection of two additional sensors
Check valve
29
10 – START-UP
10.4 – Supplementary electric resistance heaters
To permit staging of the capacity reduction of the heat pump at low ambient
temperatures, as shown in the diagram below, it is possible to install
supplementary electric heaters in the leaving water line. Their capacity can
compensate for the capacity drop of the heat pump.
These heaters can be controlled via an integrated electronic board.
Four outputs are available to control the heater contactors, permitting
gradual compensation of the heat pump capacity reduction.
These outputs are configurable to obtain a choice of two, three or four
stages. The last stage will only be activated after a shut-down
of the heat pump following a fault condition (safety device). This requires
only a 400 V-3 ph-50 Hz power supply source.
For the required configuration of the stages consult the 61AF SmartVuTM
control manual.
Example of additional electric heaters
120
Pump capacity, %
100
A
1
80
2
1
60
1
3
2
40
C
20
4
B
0
-25 -20 -15 -10
-5
0
5
Outdoor air temperature, °C
10
15
1
Operating range, in which the heat pump capacity is lower than the building
thermal loadt Operating range, in which the heat pump capacity is higher than
the building thermal load
Legend 1 Stage 1 2 Stage 2 3 Stage 3 4 Stage 4 A Heat pump capacity variation
as a function of the air temperature B Building thermal load C Balance point
between the capacity supplied by the heat pump and the thermal
load of the building
30
11 – MAJOR SYSTEM COMPONENTS
11.1 – Compressors
61AF units use hermetic scroll compressors with vapour injection. Each
compressor is equipped with a crankcase oil heater, as standard. Each
compressor function is equipped with:
Anti-vibration mountings between the unit chassis and the compressor(s).
A single pressure safety switch at the discharge.
11.2 – Lubricant
The compressors installed in these units have a specific oil charge,
indicated on the name plate of each compressor.
The oil level check must be done with the unit switched off, when then suction
and discharge pressures are equalised. The oil level must be visible and above
the middle of the sight-glass in the oil equalisation line. If this is not the
case, there may be an oil leak in the circuit. Search and repair the leak,
then recharge oil, so that it reaches a level between the middle and three
quarters of the sightglass (unit in vacuum).
ATTENTION: Too much oil in the circuit can cause a unit defect. Use only oils
which have been approved for the compressors. Never use oils which have been
exposed to air. R-22 oils are absolutely not compatible with R-407C oils and
vice versa.
11.3 – Air evaporators
The 61AF coils are air evaporators with internally grooved copper tubes with
aluminium fins..
11.4 – Fans
Axial Flying Bird fans equipped with a rotating shroud and made of composite
recyclable material. The motors are three-phase, with permanently lubricated
bearings and insulation class F. See table below.
According to the Regulation No. 327/2011 implementing Directive 2009/125/EC
with regard to ecodesign requirements for fans driven by motors with an
electric input power between 125 W and 500 kW.
Product/ Option
61AF standard
61AF Standard with option 11
Overall efficiency
%
36,6
38,0
Measurement category
A
A
Efficiency category
static
static
Energy efficiency target N(2015)
N(2015) 40
N(2015) 40
Efficiency level at optimum efficiency point
43,3
37,4
Variable speed drive
NO
NO
Year of manufacture
See label on the See label on the
unit
unit
Fan manufacturer
Simonin
Simonin
Motor manufacturer
A,O, Smith/Regal A,O, Smith/Regal
Beloit
Beloit
Fan PN
00PSG000000100A 00PSG000000100A
Motor PN
00PPG000464500A 00PPG000464600A
Nominal power of the motor
kW
0,88
2,09
Flow rate
m3/s
3,59
4,07
Pressure at optimum energy efficiency
Pa
90
195
Nominal speed
rpm
710
966
Specific ratio
1,002
1,002
Relevant information to facilitate the disassembly, recycling or removal of the product at the end of life
See service manual See service manual
Relevant information to minimise impact on the environment
See service manual See service manual
Above data for fans and motors, which are mandatory regarding eco-design regulation, are provided for a stand-alone component (not included in the chiller system)
11.5 – Electronic expansion valve (EXV) of the main circuit
The EXV is equipped with a stepper motor that is con-trolled via the EXV
board.
11.6 – Electronic expansion valve (EXV) of the economised circuit
The EXV is equipped with a stepper motor that is con-trolled via the EXV board
11.7 – Four-way valve
The four-way valve allows the reversal of the refrigerant cycle, required
during the unit defrost phases.
11.8 – Moisture indicator
Located on the liquid line, permits control of the unit charge and indicates
moisture in the circuit. The presence of bubbles in the sight-glass indicates
an insufficient charge or non-condensables in the system. The presence of
moisture changes the colour of the indicator paper in the sight-glass.
11.9 – Filter drier
One-piece, brazed filter drier, located in the liquid line. The filter drier
keeps the circuit clean and moisture-free. The moisture indicator shows when
the filter drier to be changed. A difference in temperature between the filter
inlet and outlet shows that the element is dirty.
According to the Regulation No. 640/2009 and amendment 4/2014 implementing
Directive 2009/125/EC with regard to ecodesign requirements for electric
motors.
Product/ Option
Motor type
Number of poles Nominal input frequency Nominal voltage Number of phases Motor
included in the application domain of the regulation 640/2009 and amendment
4/2014 Sales leaflet for exemption Ambient air temperature for which the motor
is specifically designed
61AF standard
61AF Standard with option
11
Asynchrone Asynchrone bi-vitesse bi-vitesse
8
6
Hz
50
50
V
400
400
3
3
Non
Non
Article 2,1
°C
68,5
Article 2,1 68,5
31
11 – MAJOR SYSTEM COMPONENTS
11.10 – Condenser
The condenser is a plate heat exchanger. The water connection of the heat
exchanger is a Victaulic connection. The condenser has a thermal insulation of
19 mm thick polyurethane foam. As standard the condenser is equipped with
frost protection.
11.11 – Economiser
The economiser is a plate-type economiser.
11.12 – Refrigerant
61AF units are charged with liquid R-407C refrigerant, a nonazeotropic
refrigerant blend consisting of 23% R-32, 25% R-125 and 52% R-134a and
characterised by the fact that when there is a change in state, the
temperature of the liquid/vapour mixture is not constant, as with azeotropic
refrigerants.
All checks must be pressure tests, and the appropriate pressure/ temperature
ratio table must be used to determine the corresponding saturated temperatures
(saturated bubble point curve or saturated dew point curve).
Leak detection is especially important for units charged with refrigerant
R-407C. Depending on whether the leak occurs in the liquid or in the vapour
phase, the proportion of the different components in the remaining liquid is
not the same.
NOTE: Regularly carry out leak checks and immediately repair any leak found.
If there is a leak in the plate heat exchanger, this part must be replaced.
The refrigerant must always be recharged in the liquid phase into the liquid
line.
The refrigerant cylinder must always contain at least 10% of its initial
charge.
For the refrigerant quantity per circuit, refer to the data on the unit name
plate.
11.13 – High-pressure safety switch
61AF units are equipped with automatically reset high-pressure safety
switches, calibrated to 3130 kPa relative pressure (soft alarm is manually
reset).
NOTES: Monitoring during operation:
– Follow the regulations on monitoring pressurised equipment.
– It is normally required that the user or operator sets up and maintains a
monitoring and maintenance file.
– Follow the control programmes of EN378, annex D. – If they exist follow
local professional recommendations. – Regularly inspect the condition of the
coating (paint) to
detect blistering resulting from corrosion. – Regularly check for possible
presence of impurities (e.g.
silica grains) in the heat exchange fluids. These impurities maybe the cause
of the wear or corrosion by puncture. – Filter the heat exchange fluid check
and carry out internal inspections as described in EN378, annex C. – The
reports of periodical checks by the user or operator must be included in the
supervision and maintenance file.
REPAIR
Any repair or modification, including the replacement of moving parts:
– must follow local regulations and be made by qualified operators and in
accordance with qualified procedures,
– must be made in accordance with the instructions of the original
manufacturer. Repair and modification that necessitate permanent assembly
(soldering, welding, expanding etc.) must be made using the correct procedures
and by qualified operators.
An indication of any modification or repair must be shown in the monitoring
and maintenance file.
32
12 – OPTIONS ET ACCESSOIRES
Options
N° Description
Advantages
Use
Corrosion protection, traditional coils Unit with ductable fans Low noise
level
Very low noise level Protection grilles Soft Starter Water Exchanger frost
protection
Master/slave operation
LP VSD single-pump
Modbus over IP and RS485
Lon gateway
Bacnet over IP Compliance with Russian regulations Condenser screw connection
sleeves kit Welded condenser water connection kit Set point adjustment by
4-20mA signal
3A
Fins made of pre-treated aluminium (polyurethane and epoxy)
11
Fans with 100 Pa maximum available pressure
15
Aesthetic and sound absorbing compressor enclosure
Aesthetic and sound absorbing 15LS compressor enclosure associated with
low-speed fans
23 Metallic protection grilles
25 Electronic starter on each compressor
Improved corrosion resistance, recommended for moderate marine and urban
environments Allows connection to discharge ducts in order to facilitate air
evacuation Noise level reduction by 1 to 2 dB(A)
Noise level reduction for sensible site
Coil protection against possible impact Reduced start-up current
42
Electric heater on the hydraulic module
hydraulic module frost protection at low outside temperatures down to -20°C
Unit equipped with supplementary water
outlet temperature sensor kit to be
Optimised operation of two units connected in
58 field-installed allowing master/slave
parrallele operation with operating time
operation of two units connected in
equalisation
parallel
Variable speed single pump, For more 116X details, refer to the dedicated
chapter
(expansion tank not included)
Easy and fast installation (plug & play),significant pumping energy cost savings (more than twothirds), tighter water flow control, improved sytem reliability
Bi-directional high-speed
Easy and high-speed connection by ethernet line
149B communication using Modbus protocol to a building management system. Allows access
over Ethernet network (IP)
to multiple unit parameters
148D
Bi-directional communication board complying with Lon Talk protocol
Connects the unit by communication bus to a building management system
Two-directional high-speed
Easy and high-speed connection by ethernet line
149 communication using BACnet protocol to a building management system. Allows access
over Ethernet network (IP)
to multiple unit parameters
61AF 030-105 61AF 035-105 61AF 030-105 61AF 035-105 61AF 030-105 61AF 030-105
61AF 030-105
with option 116X
61AF 030-105
61AF 030-105
61AF 030-105 61AF 030-105 61AF 030-105
199 EAC certification
Conformance with Russian regulations
61AF 030-105
265
Condenser inlet/outlet screw connection sleeves
Allows unit connection to a screw connector
267
Victaulic piping connections joints
with
welded
Easy
installation
311
Connections to allow a 4-20mA signal input
Easy energy managment, allow to adjust set point by a 4-20mA external signal
61AF 030-105 61AF 035-105 61AF 030-105
Accessories
Description
Advantages
00PPG000488000- Heating System Manager type A: controls one heat emitter type
with an auxiliary electric heater or boile
00PPG000488100- Heating System Manager type B: controls two heat emitter types
(or independent zones) and domestic hot water production with an auxiliary
electric heater or boiler
00PPG000488200- Heating System Manager type C: controls two heat emitter types
(or independent zones) and domestic hot water production with a district
heating system as auxiliary source
Additional control box not supplied with the unit, to be installed remotely
Additional control box not supplied with the unit, to be installed remotely
Additional control box not supplied with the unit, to be installed remotely
Heating system control facilitated Heating system control facilitated Heating system control facilitated
Use 61AF 030-105 61AF 030-105
61AF 030-105
33
13 – UNITS WITH FANS WITH AVAILABLE PRESSURE FOR INDOOR INSTALLATION (OPTION 11)
This option applies to 61AF units installed inside the building in a plant
room. For this type of installation the cold air leaving the air-cooled
evaporators is discharged by the fans to the outside of the building, using a
duct system.
The installation of a duct system at the air evaporator discharge line causes
a pressure drop due to the resistance caused by the air flow.
Therefore more powerful fan motors than those used for the standard units are
installed in the units with this option. For each installation of a unit
installed inside a plant room the duct pressure drops differ, depending on the
duct length, duct section and direction changes.
61AF units equipped with fans with available pressure are designed to operate
with air discharge ducts with maximum pressure drops of 100 Pa.
13.1 – Fan discharge connection
A square flange is supplied mounted on the unit. An available standard round
flange can easily be installed at the fan discharge, if the installer prefers
the use of a round connection duct. The unit is supplied with a grille on the
discharge side. This grille has to be removed before connection to the duct
system. It is advisable to make the connection to the duct system with a
flexible sleeve. If this recommendation is not observed, a lot of vibration
and noise may be transmitted to the building structure.
13.2 – Applicable rules for units incorporated into an air duct system
Ensure that the suction or discharge inlets are not accidentally obstructed by
the panel positioning (e.g. low return or open doors etc.).
13.3 – Electrical data for 61AF units with option 11
61AF – unit with option 11 (without hydraulic module)
035
045
055
075
105
Power circuit Nominal power supply Voltage range Control circuit supply Maximum start-up current (Un)(1) Standard unit Unit with electronic starter option Unit power factor at maximum capacity(2) Maximum unit power input(2) Nominal unit current draw(3) Maximum unit current draw (Un)(4) Maximum unit current draw (Un-10%)* Customer-side unit power reserve Short-circuit stability and protection
V-ph-Hz V
A A
kW A A A
400-3-50 360-440 24 V, via internal transformer
133,5
173,5
204,5
159,5
244
72,5
93,3
103,7
106,5
147,5
0,82
0,82
0,82
0,82
0,82
16
21
24
33
48
22
25
30
44
59
29
34
40
57
81
31
37
44
62
87
Customer reserve at the 24 V control power circuit
See table on page 18
(1) Maximum instantaneous start-up current (maximum operating current of the
compressor + fan current + locked rotor current of the compressor). (2) Power
input, compressor and fan, at the unit operating limits (saturated suction
temperature 10°C, saturated condensing temperature 65°C) and nominal voltage
of
400 V (data given on the unit nameplate). (3) Standardised Eurovent
conditions: condenser entering/leaving water temperature = 40°C/45°C, outside
air temperature db/wb = 7°C/6°C. (4) Maximum unit operating current at maximum
unit power input and 400 V (values given on the unit nameplate). * Maximum
unit operating current at maximum unit power input and 360 V.
34
14 – HEATING SYSTEM MANAGER (HSM)
The Heating System Manager (HSM) accessory allows improved integration of the
61AF heat pump to maximise energy efficiency performance.
With three system levels for nine typical configurations, most heating only
applications are covered – from the simplest to the most complex, such as
interfacing with a district heating system.
Each of these accessory configurations is described in detail in the IOM for
these accessories.They offer:
– Choice of control options (on/off volt-free contact or 0-10 V signal for
increased performance),
– Domestic hot water production temperature control and distribution.
The control box can supply all auxiliary devices such as the circulating pumps
or the mixing or switching valves.
The heat pump is controlled by a CCN bus and the control box includes an
NRCP2-BASE board, a SmartVuTM interface as well as all required sensors.
HSM control box
180 120
52
HSM control box dimensions
603
25
33
536
1,5
170
559
17
382
442
416
17
20,5 10
1
400
Installation safety notes · The hydraulic installation must be carried out by
qualified personnel in accordance
with applicable laws and following standard accepted practices. · The
hydraulic installation must be regularly serviced.An incorrect hydraulic
installation that does not comply withthe safety, electrical and thermal
standards, as well as lacking/poor maintenance can lead to excessive pressures
and cause piping breaks. Legend : All dimensions are in mm.
1
Clearance required to open the door and for customer connection
Heating system control: one heat emitter type with supplementary electric
heater or boiler:
Allows control of a non-reversible heating system that includes a 61AF heat pump
and a single heat emitter type or a single comfort zone. For optimised energy
efficiency the heat pump is controlled by a configurable weather compensation
system. The control box controls a supplementary electric heater or a stand-by
boiler. The control box supplies power to the circulating pumps.
35
14 – HEATING SYSTEM MANAGER (HSM)
14.1 – Accessory 00PPG000488000- Heating System Managere type A
Heating system control (as accessory 00PPG000488000) two heat emitter types or
independent zones and domestic hot water production
Allows control of a non-reversible heating system that includes a 61AF heat
pump and two different heat emitter types and/or two independent comfort
zones. For optimised energy efficiency the heat
pump is controlled by a configurable weather compensation system.
The control box controls a supplementary electric heater or a stand-by boiler.
The control box supplies power to the circulating pumps. Hot-water production
can be permanent or programmable with a second setpoint at the heat pump and
control of a switching valve.
Heating system example: one heat emitter type with supplementary electric heating or stand-by boiler
Heating system
GT3
P1
GT1 SV31
Back-up system
61AF + HSM
GT… P1… SV…
Hot water
Legend
GT1
Water temperature loop 1
P2
GT3
Outdoor air temperature
P1
Pump for water loop 1 (radiators)
P2
External water pump for the heat pump
SV31
Three-way mixing valve for the back-up heater
14.2 – Accessory 00PPG000488100- Heating System Manager type B
Heating system control (as accessory 00PPG000488000) two heat emitter types or
independent zones and domestic hot water production:
Allows control of a non-reversible heating system that includes a 61AF heat
pump and two different heat emitter types and/or two independent comfort
zones. For optimised energy efficiency the heat pump is controlled by a
configurable weather compensation system.
The control box controls a supplementary electric heater or a stand-by boiler. The control box supplies power to the circulating pumps. Hot-water production can be permanent or programmable with a second setpoint at the heat pump and control of a switching valve
Heating system example: two heat emitter types or independent zones and domestic hot water production
Heating system
P1
SV31
GT1
GT7:2
GT4 SV34
P4 Floor heating
GT5 SV35 GT7
P5
Domestic hot
water in
P7
GT3 Back-up system
P7-2 SV32
GT2
GT..
P..
SV..
61AF + HSM
P2 Hot water
Legend
Thermistors GT1 Water temperature loop 1 GT2 Domestic hot water tank
temperature GT3 Outdoor air temperature GT4 Water temperature loop 2 GT5
Domestic hot water temperature GT7 Additional domestic hot water tank t
emperature
Pumps P1 Pump for water loop 1 (radiators) P2 External water pump for the heat
pump P4 Pump for water loop 2 (floor heating) P5 Pump to pre-heat the domestic
hot water valve loop P7 Pump for domestic hot water circulation P7-2 Pump for
domestic hot water circulation in an aditional
tank
Valves SV31 Three-way mixing valve for the back-up heater SV32
Heating/domestic hot water change-over valve SV34 Three-way control valve for
water loop 2 SV35 Three-way mixing valve for domestic hot water
NOTES: : – This application example includes two zones and a supplementary boiler and domestic hot-water production. – The installation includes a switching valve (SV32) that allows switching from the heat pump capacity of the heating system to domestic hot-water production. – The primary heating circuit is the domestic hot-water production circuit. It includes a tank with an equivalent pressure drop to simplify system balancing.
36
14 – HEATING SYSTEM MANAGER (HSM)
14.3 – Accessory 00PPG000488200- Heating System Manager type C
Heating system control (as accessory 00PPG000488100-) with the possibility to
obtain additional heating and domestic hotwater production capacity from a
district heating system
Allows control of a non-reversible heating system that includes a 61AF heat
pump and two different heat emitter types and/or two independent comfort
zones. For optimised energy efficiency the heat pump is controlled by a
configurable weather compensation
system.
The control box controls the heating and/or domestic hot-water production
support from a district heating system. The control box supplies power to the
circulating pumps. Hot-water production can be permanent or programmable with
a second setpoint at the heat pump and control of a switching valve.
Heating system example: with the possibility to obtain additional heating and domestic hot-water productioncapacity from a district heating system
Heating system
P1 GT1 SV31 GT1:3
GT1:4 GT7:2
GT4 P4 SV34
Floor heating
GT3 SV21
SV27 SV32
61AF + HSM
GT5 SV35
GT7
P5
P7
Domestic hot water in
Legend
Thermistors GT1 Water temperature loop 1 GT1:3Heat exchanger leaving water
temperature, district heating GT1:4Heat exchanger entering water temperature,
district heating GT2 Domestic hot water tank temperature GT3 Outdoor air
temperature GT4 Water temperature loop 2 GT5 Domestic hot water temperature
GT7 Additional domestic hot water tank temperature GT7:2Back-up heat exchanger
temperature for domestic hot water Pompes P1 Pump for water loop 1 (radiators)
P2 External water pump for the heat pump P4 Pump for water loop 2 (floor
heating) P5 Pump to pre-heat the domestic hot water valve loop P7 Pump for
domestic hot water circulation Vannes SV21 Valve for district heating heat
exchanger for heating SV27 Valve for district heating heat exchanger for
domestic hot water SV31 Three-way mixing valve for the back-up heater SV32
Heating/domestic hot water change-over valve SV34 Three-way control valve for
water loop 2 SV35 Three-way mixing valve for domestic hot water
GT2
P2
GT.. P.. SV..
Hot water
37
15 – STANDARD MAINTENANCE
The heat pumps must be maintained by professional technicians, whilst routine
checks can be carried out locally by specialised technicians. See the standard
EN 378-4.
All refrigerant charging, removal and draining operations must be carried out
by a qualified technician and with the correct material for the unit. Any
inappropriate handling can lead to uncontrolled fluid or pressure leaks.
WARNING: Before doing any work on the machine ensure that the power is
switched off. If a refrigerant circuit is opened, it must be evacuated,
recharged and tested for leaks. Before any operation on a refrigerant circuit,
it is necessary to remove the complete refrigerant charge from the unit with a
refrigerant charge recovery group.
Simple preventive maintenance will allow you to get the best performance from
your heat pump unit:
– improved heating performance – reduced power consumption – prevention of
accidental component failure – prevention of major time-consuming and costly
interventions – protection of the environment
There are five maintenance levels for the heat pump units, as defined by the
AFNOR X60-010 standard.
15.1 – Level 1 maintenance
See note on the next page. Simple procedures, can be carried out by the user
on a weekly basis:
– Visual inspection for oil traces (sign of a refrigerant leak), – – Air heat
exchanger (evaporator) cleaning – see chapter
`Evaporator coil – level 1′, – Check for removed protection devices, and badly
closed doors/
covers, – Check the unit alarm report when the unit does not – work (see 61AF
SmartVuTM control manual), – General visual inspection for any signs of
deterioration, – Verify the charge in the sight-glass, – Check that the
temperature difference between the heat
exchanger inlet and outlet is correct.
15.2 – Level 2 maintenance
This level requires specific know-how in the electrical, hydraulic and
mechanical fields. It is possible that these skills are available locally:
existence of a maintenance service, industrial site, specialised
subcontractor.
The frequency of this maintenance level can be monthly or annually depending
on the verification type.
In these conditions, the following maintenance operations are recommended.
Carry out all level 1 operations, then:Electrical checks – At least once a
year tighten the power circuit electrical screw connections (see table with
tightening torques). – Check and retighten all control/command screw
connections, if required (see table with tightening torques). – Remove the
dust and clean the interior of the control boxes, if required. – Check the
status of the contactors and disconnect switches. – Check the presence and the
condition of the electrical protection devices. – Check the correct operation
of all heaters. – Replace the fuses every 3 years or every 15000 hours
(agehardening). – Check that no water has penetrated into the control box.
Water circuit checks
– Check the water connections. – Purge the water circuit (see chapter Water flow control procedure’). – Clean the water filter (see chapterWater flow control
procedure’). – Check the operation of the flow switch. – Check the status of
the thermal piping insulation. – Check the concentration of the anti-freeze
protection solution
(ethylene glycol or polyethylene glycol).
Refrigerant circuit
– Fully clean the air evaporators with a low-pressure jet and a bio-degradable
cleaner (counter-current cleaning – see chapter `Evaporator coil – level 2).
– Check the unit operating parameters and compare them with previous values.
– Carry out an oil contamination test. Replace the oil, if necessary.
– Check the operation of the high-pressure switches. Replace them if there is
a fault.
– Check the fouling of the filter drier. Replace it if necessary. – Keep and
maintain a maintenance sheet, attached to the
unit..
All these operations require strict observation of adequate safety measures:
individual protection garments, compliance with all industry regulations,
compliance with applicable local regulations and using common sense.
15.3 – Level 3 (or higher) maintenance
The maintenance at this level requires specific skills/approval/ tools and
know-how and only the manufacturer, his representative or authorised agent are
permitted to carry out these operations. These maintenance operations concern
for example:
– a major component replacement (compressor, condenser), – any intervention on
the refrigerant circuit (handling
refrigerant), – changing of parameters set at the factory (application
change), – removal or dismantling of the unit, – any intervention due to a
missed established maintenance
operation, – any intervention covered by the warranty.
To reduce waste, the refrigerant and the oil must be transferred in accordance
with applicable regulations, using methods that limit refrigerant leaks and
pressure drops and with materials that are suitable for the products.
Any detected leaks must be repaired immediately.
The compressor oil that is recovered during maintenance contains refrigerant
and must be treated accordingly. Refrigerant under pressure must not be purged
to the open air.
If a refrigerant circuit is opened, plug all openings, if the operation takes
up to one day, or for longer periods charge the circuit with nitrogen.
NOTE: Any deviation or non-observation of these maintenance criteria will
render the guarantee conditions for the unit nul and void, and the
manufacturer, Carrier SCS, will no longer be held responsible.
Mechanical checks
– Check the tightening of the fan tower, fan, compressor and control box
fixing bolts.
38
15 – STANDARD MAINTENANCE
15.4 – Tightening torques for the main electrical screw connections
Screw type
Designation in the unit
Torque (Nm)
Soldered screw (PE) customer connection
M8
PE
80
Screw on switch inlet zones
Switch 3LD2114-0TK51
QS_
2-2,5
Switch 3LD2214-0TK51
2-2,5
Switch 3LD2514-0TK51
2,5-3
Switch 3LD2714-0TK51
2,5-3
Tunnel terminal screw, compressor protection
Fuse 3NW6120-1
QM(1)
1,2
Tunnel terminal screw, compressor contactor
Contacteur 3RT1034-2AB00
KM(1)
3-4,5
Tunnel terminal screw, fan, heater, pump protection
Disconnect switch 3RV1011-1BA10
QM(1)
0,8-1,2
Tunnel terminal screw, heater relay
Relay 3RH1122-2AB00
KM(1)
0,8-1,2
Tunnel terminal screw, auxiliary contact
Auxiliary terminal block 3RH1911-2FA11
–
0,8-1,2
Auxiliary terminal block 3RH1921-2FA22
Tunnel terminal screw, control power transformer
Transformer 4AM3496-0FS30-0EN1
TC
0,8-1,2
Compressor earth terminal
M8
Gnd
12
(1) The spring-loaded terminal connections are designed to ensure permanent affixture on the conductor.
15.5 – Tightening torques for the main bolts and screws
Screw type
Used for
Compressor M8 nut M10 nut M16 nut Oil nut Taptite screw M6 Taptite screw M8 H M8 screw Metal screw H M6 screw Earth screw
Compressor support BPHE(1) fixing Compressor mounting Compressor fixing Oil
equalisation line
Fan support
Fan motor fixing
Fan scroll fixing Sheet metal plates Stauff clamps Compressor
(1) BPHE = Brazed plate heat exchanger
Torque (Nm) 30 15 30 30 75
7
13
18 4,2 10 2,8
15.6 – Evaporator coil
We recommend, that finned coils are inspected regularly to check the degree of
fouling. This depends on the environment where the unit is installed, and will
be worse in urban and industrial installations and near trees that shed their
leaves.
For coil cleaning, two maintenance levels are used, based on the AFNOR X60-010
standard:
Level 1
– If the evaporator coils are fouled, clean them gently in a vertical
direction, using a brush.
– Only work on air evaporators with the fans switched off. – For this type of
operation switch off the heat pump if service
considerations allow this. – Clean evaporators guarantee optimal operation of
your unit.
Cleaning is necessary when the evaporators begin to become fouled. The
frequency of cleaning depends on the season and location of the unit (venti-
lated, wooded, dusty area, etc.).
Level 2
The two cleaning products can be used for any Cu/Al coil with protection.
Clean the coil, using appropriate products.
We recommend TOTALINE products for coil cleaning:
Part No. P902 DT 05EE: traditional cleaning method
Part No. P902 CL 05EE: cleaning and degreasing.
These products have a neutral pH value, do not contain phosphates, are not
harmful to the human body, and can be disposed of through the public drainage
system.
Depending on the degree of fouling both products can be used diluted or
undiluted. For normal maintenance routines we recommend using 1 kg of the
concentrated product, diluted to 10%, to treat a coil surface of 2 m2. This
process can either be carried out using a high-pressure spray gun in the low-
pressure position.
With pressurised cleaning methods care should be taken not to damage the coil
fins. The spraying of the coil must be done:
– in the direction of the fins – in the opposite direction of the air flow
direction – with a large diffuser (25-30°) – at a minimum distance of 300 mm
from the coil.
It is not necessary to rinse the coil, as the products used are pH neutral. To
ensure that the coil is perfectly clean, we recommend rinsing with a low water
flow rate. The pH value of the water used should be between 7 and 8.
WARNING: Never use pressurised water without a large diffuser. Do not use
high-pressure cleaners for Cu/Al coils. Concentrated and/or rotating water
jets are strictly forbidden. Never use a fluid with a temperature above 45°C
to clean the air heat exchangers. Correct and frequent cleaning (approximately
every three months) will prevent 2/3 of the corrosion problems. Protect the
control box during cleaning operations.
15.7 – Condenser maintenance
Check that: – que la mousse isolante est intacte et bien en place. the
insulating foam is intact and securely in place. – the cooler heaters are
operating, secure and correctly positioned. – the water-side connections are
clean and show no sign of leakage.
39
15 – STANDARD MAINTENANCE
15.8 – Characteristics of R-407C
Relative pressure,
bar
1 1,25 1,5 1,75
2 2,25 2,5 2,75
3 3,25 3,5 3,75
4 4,25 4,5 4,75
5 5,25 5,5 5,75
6 6,25 6,5 6,75
7 7,25 7,5 7,75
8 8,25 8,5 8,75
9 9,25 9,5 9,75 10 10,25
Saturated bubble
point temp. , °C
-28,55 -25,66 -23,01 -20,57 -18,28 -16,14 -14,12 -12,21 -10,4 -8,67 -7,01 -5,43
-3,9 -2,44 -1,02 0,34 1,66 2,94 4,19 5,4 6,57 7,71 8,83 9,92 10,98 12,02 13,03 14,02 14,99 15,94 16,88 17,79 18,69 19,57 20,43 21,28 22,12 22,94
Saturated dew
point temp., °C
-21,72 -18,88 -16,29 -13,88 -11,65 -9,55 -7,57
-5,7 -3,93 -2,23 -0,61 0,93 2,42 3,85 5,23 6,57 7,86 9,11 10,33 11,5 12,65 13,76 14,85 15,91 16,94 17,95 18,94 19,9 20,85 21,77 22,68 23,57 24,44 25,29 26,13 26,96 27,77 28,56
Relative pressure,
bar
10,5 10,75
11 11,25 11,5 11,75
12 12,25 12,5 12,75
13 13,25 13,5 13,75
14 14,25 14,5 14,75
15 15,25 15,5 15,75
16 16,25 16,5 16,75
17 17,25 17,5 17,75
18 18,25 18,5 18,75
19 19,25 19,5 19,75
Saturated bubble
point temp. °C
Saturated dew point temp., °C
Relative pressure,
bar
23,74 24,54 25,32 26,09 26,85 27,6 28,34 29,06 29,78 30,49 31,18 31,87 32,55 33,22 33,89 34,54 35,19 35,83 36,46 37,08 37,7 38,31 38,92 39,52 40,11 40,69 41,27 41,85 42,41 42,98 43,53 44,09 44,63 45,17 45,71 46,24 46,77 47,29
29,35 30,12 30,87 31,62 32,35 33,08 33,79 34,5 35,19 35,87 36,55 37,21 37,87 38,51 39,16 39,79 40,41 41,03 41,64 42,24 42,84 43,42 44,01 44,58 45,15 45,71 46,27 46,82 47,37 47,91 48,44 48,97 49,5 50,02 50,53 51,04 51,55 52,05
20 20,25 20,5 20,75
21 21,25 21,5 21,75
22 22,25 22,5 22,75
23 23,25 23,5 23,75
24 24,25 24,5 24,75
25 25,25 25,5 25,75
26 26,25 26,5 26,75
27 27,25 27,5 27,75
28 28,25 28,5 28,75
29 29,25
Saturated Saturated dew
bubble
point temp.,
point temp. °C
°C
47,81 48,32 48,83 49,34 49,84 50,34 50,83 51,32 51,8 52,28 52,76 53,24 53,71 54,17 54,64 55,1 55,55 56,01 56,46 56,9 57,35 57,79 58,23 58,66 59,09 59,52 59,95 60,37 60,79 61,21 61,63 62,04 62,45 62,86 63,27 63,67 64,07 64,47
52,55 53,04 53,53 54,01 54,49 54,96 55,43 55,9 56,36 56,82 57,28 57,73 58,18 58,62 59,07 59,5 59,94 60,37 60,8 61,22 61,65 62,07 62,48 62,9 63,31 63,71 64,12 64,52 64,92 65,31 65,71 66,1 66,49 66,87 67,26 67,64 68,02 68,39
61AF units use R-407C refrigerant. Special equipment must be used when working on the refrigerant circuit (pressure gauge, charge transfer, etc.).
40
16 – START-UP CHECKLIST FOR 61AF HEAT PUMPS (USE FOR JOB FILE)
Preliminary information
Job name :………………………………………………………………………………………………………………………………………………………………………..
Location : ………………………………………………………………………………………………………………………………………………………………………….
Installing contractor :
…………………………………………………………………………………………………………………………………………………………. Distributor :
………………………………………………………………………………………………………………………………………………………………………. Start-up
preformed by :……………………………………………………….. Date: ………………………………………………………………………………..
Equipment Model 61AF : ……………………………………………………………………..
S/N …………………………………………………………………………………..
Compressors 1. Model No. …………………………………………………………………….
Serial No. ……………………………………………………………………..
.2. Model No ………………………………………………………………….. Serial No ……………………………………………………………………
Air handling equipment
Manufacturer …………………………………………………………………………………………………………………………………………………………………….
Model No ………………………………………………………………………….. Serial No
…………………………………………………………………………. Additional air handling units and
accessories…………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………………………………..
Preliminary equipment check
Is there any shipping damage ? ……………………………………………If so, where?
…………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………….. Will
this damage prevent unit start-up?
…………………………………………………………………………………………………………………………………
Unit is level in its installation Power supply agrees with the unit name plate
Electrical circuit wiring has been sized and installed properly Unit ground
wire has been connected Electrical circuit protection has been sized and
installed properly All terminals are tight All cables and thermistors have
been inspected for crossed wires All plug assemblies are tight
Check air handling systems
All air handlers are operating All water valves are open All fluid piping is
connected properly All air has been vented from the system Hot-water pump is
operating with the correct rotation. CWP amperage: Rated : ……………………………………………
Actual…………
Unit start-up Hot-water pump control has been properly interlocked with the
heat pump Oil level is correct Compressor crankcase heaters have been
energised for 12 hours Unit has been leak checked (including fittings) Locate,
repair, and report any refrigerant leaks
………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………….. Check
voltage imbalance : AB………………………………………………AC…………………………. BC…………………….. Average
voltage = ……………………………………………………………..(see installation instructions) Maximum
deviation = …………………………………………………………(see installation instructions) Voltage
imbalance = …………………………………………………………..(see installation instructions)
Voltage imbalance is less than 2% WARNING: Do not start the heat pump if
voltage imbalance is greater than 2%. Contact local power company for
assistance.
All incoming power voltage is within rated voltage range
41
16 – START-UP CHECKLIST FOR 61AF HEAT PUMPS (USE FOR JOB FILE)
Check condenser water loop
Water loop volume
= ………………. (litres)
Calculated volume
= ………………. (litres)
Proper loop volume established
Proper loop corrosion inhibitor included…………………………………………… litres of…………..
Proper loop freeze protection included (if required) …………………………… litres of…………..
Water piping includes electric tape heater up to the condenser
Return water piping is equipped with a screen filter with a mesh size of 1.2 mm
Check pressure drop across the unit condenser (without hydraulic module) or the external static pressure (with hydraulic module)
Entering condenser = ………………………………………………
(kPa)
Leaving condenser = ……………………………………………….
(kPa)
Pressure drop (entering – leaving) = …………………………..
(kPa)
WARNING (unit without hydraulic module): Plot the pre
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