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Carrier HFC-134a Product data
Product
Data
EVERGREEN®
23XRV
High-Efficiency Variable Speed Screw Chiller
with FOXFIRE™ Compression Technology
50/60 Hz
HFC-134a
300 to 550 Nominal Tons (1055 to 1934 Nominal kW)
®
Carrier’s Evergreen® 23XRV chiller is
the world’s first integrated variable
speed, water-cooled, screw chiller.
It incorporates significant breakthroughs in water-cooled chiller technology to provide excellent reliability
and achieve superior efficiencies at
true operating conditions without compromising the environment.
The 23XRV chiller provides:
• Variable speed, positive
displacement screw compressor.
• Air Conditioning, Heating, and
Refrigerant Institute (AHRI) certified
efficiencies to 0.33 kW/ton (AHRI
IPLV).
• Chlorine-free HFC-134a refrigerant.
• IEEE-519 compliance for harmonic
distortion.
• An ideal solution for constant and
variable flow pumping systems.
Features/Benefits
Quality design and construction make the Evergreen
23XRV chillers the best
choice for modern, efficient
chilled water plants.
Product reliability
23XRV
Copyright 2010 Carrier Corporation
The 23XRV chiller uses proven technology from Carrier’s existing line of
Evergreen chillers along with innovations that increase reliability. The
23XRV compressors are designed for
extremely high reliability. The advanced tri-rotor compressor features a
balanced rotor geometry and shorter
screw lengths, resulting in vastly reduced compressor bearing loads and a
minimum L10 compressor bearing life
in excess of 500,000 hours when operated at AHRI conditions.
Form 23XRV-3PD
Features/Benefits (cont)
Variable speed capacity control eliminates slide valves, their associated losses, and their potential failure modes.
Component count (both rotating and
total) has been minimized assuring
maximum reliability under a wide
range of operating conditions.
High efficiency
Per AHRI 550/590, chillers operate at
design conditions less than one percent
of the time. As a result, superior part
load efficiency is required for today’s
chilled water applications. The Evergreen® 23XRV screw chiller maximizes
chiller efficiency by optimizing compressor operation. Electric power consumption drops dramatically when the
motor speed slows. The 23XRV screw
chiller delivers industry-leading integrated part load values (IPLV) in an extremely broad range of applications
and climates.
Environmental leader
Carrier has long been committed to
the environment and its sustainability.
The Evergreen 23XRV screw chillers
provide our customers with a highefficiency, chlorine-free, long-term
solution unaffected by refrigerant
phase outs. Carrier’s decision to utilize
non-ozone depleting HFC-134a refrigerant provides our customers with a
safe and environmentally sound
product without compromising efficiency. In addition, HFC-134a was
given an A1 safety rating by ASHRAE
(American Society of Heating,
Refrigerating and Air Conditioning
Engineers), meaning that it is the safest
refrigerant available.
Quality design
Positive displacement compression — Positive displacement compression ensures stable operation
under all load conditions without the
possibility of compressor surge.
Superior oil management/cold
condenser water operation — All
Evergreen 23XRV chillers regulate oil
temperature, viscosity and pressure. A
patented process assures high quality
oil is delivered to the compressor bearings by a positive displacement pump.
Bearing lubrication is assured, allowing
continuous operation with cold
condenser water at all loads. Screw
chillers no longer need to rely on differential system pressure to effectively
lubricate the compressor. Should the
2
input power to the chiller be lost, the
system design assures proper lubrication of the bearings during coast down.
Small footprint — The Evergreen
23XRV chiller’s positive pressure
design reduces the chiller size by up
to 35% compared to negative-pressure
designs. Extremely high compression
efficiencies allow for compact,
high-efficiency chillers that require less
mechanical room floor space.
Constant or variable evaporator
flow — The 23XRV chiller combines
the advantages of positive displacement compression with variable speed
capacity control. This process provides
a chiller that reacts substantially better
than chillers equipped with inlet guide
vanes or slide valves. This allows for
easier transition when bringing additional chillers on line in multiple chiller
plants and eliminates any possibility of
surge, regardless of the changes in the
system.
Low harmonic distortion — The
Evergreen 23XRV chiller will generate
less than 5% total harmonic distortion
at the input to the VFD (variable
frequency drive) without the use of
any external filters or line reactors.
This assures the VFD alone cannot
exceed the IEEE-519 standard for
distortion at the point of common
coupling. Ultra-low harmonics can
eliminate the need for complicated
harmonic system studies.
Low starting current (inrush) —
The inrush current is limited to the
chiller full load amps (rated load
amperes). No other starting means can
equal this level of starting current. The
combination of low current and ultra
low harmonics can reduce backup
generator size requirements.
0.99 power factor — The Evergreen 23XRV chiller can operate at up
to 0.99 displacement power factor,
which helps building owners avoid
power factor penalties and decreases
electrical losses in cables and transformers. High power factor may also
reduce KVA requirements, saving electrical system costs on new projects or
freeing up electrical resources on existing systems operating near their maximum capacity.
Refrigerant-cooled VFD — Refrigerant cooling of the VFD minimizes
VFD size and ensures proper cooling
of the transistors for extended life.
Using R-134a refrigerant instead of
water also eliminates costly maintenance associated with the water cooling pump, heat exchanger and rubber
tubing used with water-cooled VFDs.
Hermetic motor — The Evergreen
23XRV chiller utilizes motors that are
hermetically sealed from the machine
room. Cooling is accomplished by
spraying liquid refrigerant on the
motor windings. This highly efficient
motor cooling method results in coolerrunning motors than could be realized
with air-cooled designs of the same
type.
In addition, Carrier’s hermetic design eliminates:
• Compressor shaft seals that require
maintenance and increase the likelihood of refrigerant leaks.
Table of contents
Page
Features/Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Model Number Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
Typical Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Control Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23
Guide Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-31
• Machine room cooling requirements
associated with air-cooled motors,
which dissipate heat to the mechanical room.
• High noise levels common with aircooled motors, which radiate noise
to the machine room and adjacent
areas.
• Shaft alignment problems that occur
with open-drive designs during startup and operation, when equipment
temperature variations cause thermal expansion.
Positive pressure design — Positive pressure designs eliminate the
need for costly low pressure containment devices, reducing the initial cost
of the system. The Evergreen® 23XRV
chiller’s positive pressure design ensures that air, moisture and other performance degrading contaminants are
not sucked inside the chiller. Purge
units and their associated maintenance are no longer necessary.
Optional refrigerant isolation
valves — The optional refrigerant
isolation valves allow the refrigerant
to be stored inside the chiller during
shipment from the factory, minimizing
start-up time. During servicing, the
“in-chiller” storage reduces refrigerant
loss and eliminates time-consuming
transfer procedures. As a self-contained
unit, the Evergreen 23XRV chiller does
not require additional remote storage
systems.
Optional pumpdown unit — Combined with the refrigerant isolation
valves listed above, the optional pumpdown unit eliminates complex connections to portable transfer systems,
thereby reducing service costs. The optional pumpdown compressor meets
Environmental Protection Agency’s
(EPA) vacuum level requirements that
mandate minimizing refrigerant emissions during service.
Modular construction — The cooler, condenser, and compressor assemblies are bolted together, making Evergreen 23XRV chillers ideally suited for
replacement jobs where ease of disassembly and reassembly at the jobsite
are essential.
Single point power — The 23XRV
chiller features internal control power
transformers to provide low voltage
power (115 v and 24 vdc) for machine
controls. Simply connecting the three
input power leads to the VFD provides
all unit power.
Marine container shipment — The
compact design allows for open-top
container shipment to export destinations, ensuring quality while reducing
shipping cost.
Heat exchanger combinations —
The Evergreen 23XRV chillers are
available with a complete line of heat
exchangers, ensuring the best combination of chiller components to meet
project specific tonnage and efficiency
requirements. One, 2 and 3-pass
arrangements are available to meet a
wide variety of flow conditions. Nozzlein-head and marine waterboxes are
available to meet 150 psig and
300 psig piping requirements.
Heat exchanger features
ASME certified construction — An
independent agency certifies the
design, manufacture, and testing of
all heat exchangers to American
Society of Mechanical Engineers
(ASME) standards, ensuring heat exchanger safety, reliability and long life.
The ASME U-stamp is applied to the
refrigerant side of the evaporator and
condenser and is applied to the water
side of heat exchangers when 300 psig
marine water boxes are provided.
High performance tubing — Carrier’s
Evergreen chillers utilize advances in heat
transfer technology, providing compact,
high-efficiency heat exchangers. Tubing
with advanced internally and externally
enhanced geometry improves chiller performance by reducing overall resistance
to heat transfer while reducing fouling.
Cooler tube expansion — Cooler
tube expansion at center support
sheets prevents unwanted tube movement and vibration, thereby reducing
the possibility of premature tube failure. Tube wall thickness is greater at
the expansion location, support sheets,
and end tube sheets in order to provide
maximum strength and long tube life.
Double-grooved end tube sheet
holes — This design provides a more
robust seal than single rolled joints, reducing the possibility of leaks between
the water and refrigerant sides of the
chiller.
Condenser baffle — The baffle deflects hot discharge gas before it contacts condenser tubes, reducing tube
vibration and wear while distributing
refrigerant more evenly over the
length of the vessel for improved
efficiency.
Closely spaced intermediate support sheets — Support sheets prevent tube sagging and vibration, thereby increasing heat exchanger life.
Refrigerant filter isolation valves
— These valves allow filter replacement without pumping down the chiller, reducing service time and expense.
FLASC (flash subcooler) — The
subcooler, located in the bottom of the
condenser, increases the refrigeration
effect by cooling the condensed liquid
refrigerant to a lower temperature,
thereby reducing compressor power
consumption.
AccuMeter™ system — The
AccuMeter system regulates refrigerant
flow according to load conditions,
providing a liquid seal at all operating
conditions, eliminating unintentional
hot gas bypass.
Microprocessor controls
features
Direct Digital Product Integrated
control (PIC III) — Carrier’s PIC III
provides unmatched flexibility and
functionality. Each unit integrates
directly with the Carrier Comfort
Network® (CCN) system, providing a
solution to controls applications.
International Chiller Visual Controller (ICVC) — The ICVC provides
an unparalleled ease of operation and
can be configured to display English or
metric values.
For convenience, a single display located on the chiller VFD panel displays
chiller and VFD data. The VGA 320 x
240 element LCD (liquid crystal display) features 4 menu specific softkeys. The default display offers an
all-in-one glance review of key chiller
operation data, simplifying the interaction between chiller and user.
The display includes 4 standard
languages:
• English
• Chinese
• Japanese
• Korean
Other languages are available.
Automatic capacity override —
This function unloads the compressor
whenever key safety limits are approached, increasing unit life. This
3
Features/Benefits (cont)
feature also allows the machine to
operate at reduced capacity, rather
than shut down, when key safety limits
are approached.
Chilled liquid reset — Reset can be
accomplished manually or automatically from the building management system. For a given capacity, reset allows
operation at slower compressor
speeds, saving energy when warmer
chilled liquid can be used.
Demand limiting — This feature limits the power draw of the chiller during
peak loading conditions. When incorporated into the Carrier Comfort
Network® building automation system,
a red line command holds chillers at
their present capacity and prevents any
other chillers from starting. If a load
shed signal is received, the compressors are unloaded to avoid demand
charges whenever possible.
Ramp loading — Ramp loading ensures smooth pulldown of liquid loop
temperature and prevents a rapid
increase in compressor power consumption during the pulldown period.
Automated controls test — The
test can be executed prior to start-up
to verify that the entire control system
is functioning properly.
365-day real time clock — This
feature allows the operator to program
a yearly schedule for each week, weekends, and holidays.
Occupancy schedules — Schedules
can be programmed into the controller
to ensure that the chiller operates
when cooling is required and remains
off when not needed by the tenants or
process.
Extensive service menu — Unauthorized access to the service menu
can be prevented through password
protection. Built-in diagnostic capabilities assist in troubleshooting and recommend proper corrective action for
preset alarms, resulting in greater
working time.
Alarm file — This file maintains the
last 25 time-and date-stamped alarm
messages in memory. This function reduces troubleshooting time and cost.
Alert file — This file maintains the
last 25 alert messages in memory. This
function provides prognostic information and corrective actions that can
avoid unit shutdown.
Configuration data backup —
Non-volatile memory provides
protection during power failures and
eliminates time consuming control
reconfiguration.
Model number nomenclature
S – Special
Not Used
23XRV – High Efficiency
Variable Speed Screw Chiller
Voltage Code
3 – 380-3-60
4 – 416-3-60
5 – 460-3-60
9 – 380/415-3-50
Cooler Size*
30-32
35-37
40-42
45-47
50-52
55-57
Drive
Code
AA
BA
BB
CC
Condenser Size*
30-32
35-37
40-42
45-47
50-52
55-57
Amps
In†
440
520
520
608
Amps
Out†
442
442
520
608
Motor Code
P
T
Q
U
R
V
S
Economizer Option
E – With Economizer
N – No Economizer
R – Compressor
*First number denotes frame size.
†Maximum limits only. Additional application
limits apply that may reduce these ampacities.
a23-1648
Quality Assurance
Certified to ISO 9001:2000
ASME
‘U’ Stamp
4
AHRI (Air Conditioning, Heating
and Refrigeration Institute)
Performance Certified
Physical data
23XRV COMPRESSOR AND MOTOR WEIGHTS
ENGLISH
MOTOR
SIZE
Total
Compressor
Weight
(lb)
Stator
Weight
(lb)
4866
441
P,Q,R,S,
T,U,V
SI
Rotor
Weight
(lb)
Motor
Terminal
Cover
(lb)
Compressor
Weight
(kg)
Stator
Weight
(kg)
Rotor
Weight
(kg)
Motor
Terminal
Cover
(kg)
229
46
2207
200
104
21
COMPONENT WEIGHTS
FRAME 3 HEAT
EXCHANGER
lb
kg
70
32
179
81
747
339
1650
749
700
318
542
246
COMPONENT
Isolation Valves
Suction Elbow
Discharge Elbow/Muffler
Control Center/VFD
Vaporizer and Oil Sump
Economizer
VFD
FRAME 4 HEAT
EXCHANGER
lb
kg
70
32
237
108
747
339
1650
749
700
318
542
246
FRAME 5 HEAT
EXCHANGER
lb
kg
115
52
232
105
747
339
1650
749
700
318
542
246
LEGEND
— Variable Frequency Drive
23XRV HEAT EXCHANGER WEIGHTS
ENGLISH
CODE
NUMBER
OF TUBES
Cooler Cond.
30
31
32
35
36
37
40
41
42
45
46
47
50
51
52
55
56
57
200
240
282
200
240
282
324
364
400
324
364
400
431
485
519
431
485
519
218
266
315
218
266
315
366
415
464
366
415
464
507
556
602
507
556
602
Dry Rigging
Weight
(lb)*
Cooler
Only
Cond.
Only
4148
4330
4522
4419
4627
4845
5008
5178
5326
5463
5659
5830
5827
6053
6196
6370
6631
6795
3617
3818
4023
4529
4758
4992
4962
5155
5347
5525
5747
5967
6013
6206
6387
6708
6930
7138
Machine Charge
METRIC (SI)
Dry Rigging
Weight
(kg)*
Machine Charge
Refrigerant
Liquid Weight
Refrigerant
Liquid Weight
Weight (lb)
(lb)
Weight (kg)
(kg)
Cooler Cond.
Only
Only
With
Without
With
Without
Economizer Economizer Cooler Cond.
Economizer Economizer Cooler Cond.
800
650
464
464
1877
1676
363
295
210
210
800
650
531
542
1959
1769
363
295
241
246
800
650
601
621
2046
1860
363
295
273
282
910
760
511
513
2000
2089
413
345
232
233
910
760
587
602
2094
2195
413
345
266
274
910
760
667
692
2193
2299
413
345
303
314
900
825
863
915
2675
2746
408
375
391
415
900
825
930
995
2758
2839
408
375
422
451
825
990
1074
2832
2932
408
375
449
487
900
1015
960
938
998
2882
3001
460
436
425
453
1015
960
1014
1088
2976
3108
460
436
460
494
1015
960
1083
1179
3061
3214
460
436
491
535
1250
1100
1101
1225
3182
3304
567
499
499
556
1250
1100
1192
1304
3294
3397
567
499
541
591
1250
1100
1248
1379
3364
3485
567
499
566
626
1430
1280
1201
1339
3429
3620
649
581
545
607
1430
1280
1304
1429
3556
3726
649
581
591
648
1430
1280
1369
1514
3636
3826
649
581
621
687
COND — Condenser
*Rigging weights are for standard tubes of standard wall thickness (EDE and
Spikefin 3, 0.025-in. [0.635 mm] wall).
NOTES:
1. Cooler includes the suction elbow and 1/2 the distribution piping weight.
2. Condenser includes float valve and sump, discharge elbow, and 1/2 the
distribution piping weight.
3. For special tubes, refer to the 23XRV Computer Selection Program.
4. All weights for standard 2-pass NIH (nozzle-in-head) design with victaulic grooves.
5
Physical data (cont)
ADDITIONAL WEIGHTS FOR 23XRV MARINE WATERBOXES*
150 psig (1034 kPa) MARINE WATERBOXES
FRAME
NUMBER
OF
PASSES
1 and 3
2
1 and 3
2
1 and 3
2
3
4
5
ENGLISH (lb)
Cooler
Condenser
Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt
730
700
N/A
N/A
365
350
365
350
1888
908
N/A
N/A
944
452
989
452
2445
1019
N/A
N/A
1223
510
1195
499
SI (kg)
Cooler
Condenser
Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt
331
318
N/A
N/A
166
159
166
159
856
412
N/A
N/A
428
205
449
205
1109
462
N/A
N/A
555
231
542
226
300 psig (2068 kPa) MARINE WATERBOXES
FRAME
3
4
5
NUMBER
OF
PASSES
1 and 3
2
1 and 3
2
1 and 3
2
ENGLISH (lb)
Cooler
Condenser
Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt
860
700
N/A
N/A
430
350
430
350
2162
908
N/A
N/A
1552
393
1641
393
2655
1019
N/A
N/A
1965
439
1909
418
SI (kg)
Cooler
Condenser
Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt
390
318
N/A
N/A
195
159
195
159
981
412
N/A
N/A
704
178
744
178
1204
462
N/A
N/A
891
199
866
190
*Add to cooler and condenser weights for total weights. Cooler and condenser weights may be found in the 23XRV Heat Exchanger
Weights table on page 5. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.
23XRV WATERBOX COVER WEIGHTS — ENGLISH (lb)
FRAMES 3, 4, AND 5
WATERBOX
DESCRIPTION
NIH,1 pass Cover 150 psig
NIH,2 pass Cover 150 psig
NIH,3 pass Cover 150 psig
NIH Plain End, 150 psig
MWB End Cover, 150 psig*
NIH,1 pass Cover 300 psig
NIH,2 pass Cover 300 psig
NIH,3 pass Cover 300 psig
NIH Plain End, 300 psig
MWB End Cover, 300 psig*
COOLER
Frame 4
Frame 3
Frame 5
Frame 3
CONDENSER
Frame 4
Frame 5
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
282
287
294
243
243/315
411
411
433
294
445/619
318
340
310
243
243/315
486
518
468
294
445/619
148
202
472
138
138/314
633
626
660
522
522/522
185
256
488
138
138/314
709
733
694
522
522/522
168
222
617
154
154/390
764
760
795
658
658/658
229
275
634
154
154/390
840
867
830
658
658/658
282
287
294
225
225/234
411
411
433
270
359/474
318
340
310
225
225/234
486
518
468
270
359/474
148
191
503
138
138/314
633
622
655
522
658/658
185
245
519
138
138/314
709
729
689
522
658/658
168
224
628
154
154/390
764
727
785
658
658/658
229
298
655
154
154/390
840
878
838
658
658/658
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
*Nozzle end weight/return end weight.
NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in
the heat exchanger weights shown on page 5.
23XRV WATERBOX COVER WEIGHTS — SI (kg)
FRAMES 3, 4, AND 5
WATERBOX
DESCRIPTION
NIH,1 pass Cover 1034 kPa
NIH,2 pass Cover 1034 kPa
NIH,3 pass Cover 1034 kPa
NIH Plain End, 1034 kPa
MWB End Cover, 2068 kPa*
NIH,1 pass Cover 2068 kPa
NIH,2 pass Cover 2068 kPa
NIH,3 pass Cover 2068 kPa
NIH Plain End, 2068 kPa
MWB End Cover, 2068 kPa*
LEGEND
NIH — Nozzle-in-Head
MWB — Marine Waterbox
6
Frame 3
COOLER
Frame 4
Frame 5
Frame 3
CONDENSER
Frame 4
Frame 5
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
Victaulic
Nozzles
Flanged
128
130
133
110
110/143
186
186
196
132
202/281
144
154
141
110
110/143
220
235
212
132
202/281
67
92
214
63
63/142
287
284
299
237
237/237
84
116
221
63
63/142
322
332
315
237
237/237
76
101
280
70
70/177
347
344
361
298
298/298
104
125
288
70
70/177
381
393
376
298
298/298
128
130
133
102
102/106
186
186
196
122
163/215
144
154
141
102
102/106
220
235
212
122
163/215
67
87
228
63
63/142
287
282
297
237
298/298
84
111
235
63
63/142
322
331
313
237
298/298
76
102
285
70
70/177
347
330
356
298
298/298
104
135
297
70
70/177
381
398
380
298
298/298
*Nozzle end weight/return end weight.
NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in
the heat exchanger weights shown on page 5.
Options and accessories
ITEM
.028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Copper Tubing — Cooler/Condenser
.028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Cupronickel Tubing — Condenser
.028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Copper Tubing — Cooler/Condenser
.028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Cupronickel Tubing — Condenser
Flanged Cooler and/or Condenser Waterbox Nozzles**
Hinged Waterboxes
Marine Waterboxes, 150 psig (1034 kPa)††
Marine Waterboxes, 300 psig (2068 kPa)††
Nozzle-in Head Waterbox, 300 psig (2068 kPa)
One, 2, or 3 Pass Cooler or Condenser Waterside Construction
Zinc Anodes
100K AIC (Amp Interrupt Capacity) High Interrupt Circuit Breaker with Shunt Trip
Analog Voltmeter and Ammeter with 3 Phase Selector Switch
BACnet*** Communications
LonWorks††† Carrier Translator
Sensor Package
Refrigerant Isolation Valves
Separate Storage Tank and Pumpout Unit
Shipped Factory Charged with Refrigerant
Stand-Alone Pumpout Unit
Unit-Mounted Pumpout Unit
Hot Gas Bypass
Soleplate Package
Spring Isolator Kit
Acoustical Sound Insulation Kit
Full Cold Surface Thermal Insulation (Except Waterbox Covers)
Customer Factory Performance Testing
Export Crating
Extended Warranty (North American Operations [NAO] only)
Service Contract
*Factory-installed.
†Field-installed.
**Standard waterbox nozzles are victaulic type. Flanged nozzles are
available as an option with either nozzle-in-head type waterboxes or
marine waterboxes.
OPTION* ACCESSORY†
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
††Optional marine waterboxes available for 23XRV heat exchanger
frames 3-5 only. Standard waterboxes for 23XRV are nozzle-in-head
type, 150 psig (1034 kPa).
***Sponsored by ASHRAE (American Society of Heating, Refrigerating,
and Air Conditioning Engineers).
†††Registered trademark of Echelon Corporation.
7
Dimensions
23XRV DIMENSIONS
TUBE REMOVAL
SPACE FOR
EITHER END
SIZES 30-32, 40-42
50-52
14’-3” (4343 mm)
SIZES 35-37, 45-47
55-57
14’-0” (4267 mm)
MOTOR SERVICE
CLEARANCE
1’-10” (559 mm)
FRAME R COMPRESSOR 3’-0” (915mm)
RECOMMENDED OVERHEAD SERVICE CLEARANCE
a23-1646
C
2’ MIN
(610 mm)
B
(WIDEST POINT)
A
4’ MIN
(1219 mm)
SERVICE AREA
4’-10” MIN
(1475 mm)
23XRV DIMENSIONS (NOZZLE-IN-HEAD WATERBOX)
HEAT EXCHANGER
SIZE
30 to 32
1 Pass
ft-in.
14- 31/4
35 to 37
15-113/4
A (Length, with Nozzle-in-Head Waterbox)
2-Pass*
3 Pass
mm
ft-in.
mm
ft-in.
mm
4350
13- 81/4
4172
14- 31/4
4350
4870
15- 43/4
31/
4693
15-113/4
4870
B (Width)
C (Height)
ft-in.
6- 4
mm
1930
ft-in.
7- 25/8
mm
2200
6- 4
1930
7- 25/8
2200
81/2
2045
7- 61/2
2299
40 to 42
14- 9
4496
14-
8
4347
14- 6
4420
6-
45 to 47
16- 51/2
5017
15-115/8
4867
16- 21/2
4940
6- 81/2
2045
7- 61/2
2299
50 to 52
14-10
4521
14- 41/2
4382
14- 61/2
4432
6-113/4
2127
7- 63/4
2305
55 to 57
16- 61/2
5042
16- 1
4902
16- 3
4953
6-113/4
2127
7- 63/4
2305
23XRV DIMENSIONS (MARINE WATERBOX)
HEAT EXCHANGER
SIZE
30 to 32
A (Length, Marine Waterbox)
2-Pass*
1 or 3 Pass†
ft-in.
mm
ft-in.
14- 9
4496
16- 43/4
mm
4997
ft-in.
6- 93/8
mm
2067
C (Height)
35 to 37
16- 51/2
5017
18- 11/4
5518
6- 93/8
2067
40 to 42
15- 23/4
4642
16- 31/4
5086
6- 93/4
2076
45 to 47
16-113/4
5163
18- 43/4
5607
6- 93/4
2076
50 to 52
15- 31/2
4661
16- 81/2
5093
7- 1
2159
55 to 57
17- 0
5182
18- 5
5613
7- 1
2159
*Assumes both cooler and condenser nozzles on same end of chiller.
†1 or 3 pass length applies if cooler is a 1 or 3 pass design.
NOTES:
1. Service access should be provided per American Society of Heating, Refrigerating, and Air Conditioning Engineers (ASHRAE) 15,
latest edition, National Fire Protection Association (NFPA) 70, and
local safety code.
2. Allow at least 3 ft (915 mm) overhead clearance for service rigging
for the compressor.
8
B (Width)
See unit
certified
drawings
3. Certified drawings available upon request.
4. Marine waterboxes may add 6 in. (152 mm), to the width of the
machine. See certified drawings for details.
5. ‘A’ length and ‘B’ width dimensions shown are for standard
150 psig (1034 kPa) design and victaulic connections. The
300 psig (2068 kPa) design and/or flanges will add length. See certified drawings.
6. Dished head waterbox covers not available for the 3-pass design.
Performance data
NOZZLE SIZE
NOZZLE SIZE (in.)
(Nominal Pipe Size)
FRAME
SIZE
3
4
5
1-Pass
10
10
10
Cooler
2-Pass
8
8
8
3-Pass
6
6
6
1-Pass
10
10
10
Condenser
2-Pass
8
8
10
3-Pass
6
6
8
23XRV HEAT EXCHANGER MIN/MAX FLOW RATES*
ENGLISH (GPM)
COOLER
Frame
Size
30
31
32
3
35
36
37
40
41
42
4
45
46
47
50
51
52
5
55
56
57
1 PASS
Min
Max
611
2,444
733
2,933
855
3,422
611
2,444
733
2,933
855
3,422
989
3,959
1112
4,448
1222
4,888
989
3,959
1112
4,448
1222
4,888
1316
5,267
1482
5,927
1586
6,343
1316
5,267
1482
5,927
1586
6,343
2 PASS
Min
Max
305
1222
367
1466
428
1710
305
1222
367
1466
428
1710
495
1979
556
2224
611
2444
495
1979
556
2224
611
2444
658
2634
741
2964
793
3171
658
2634
741
2964
793
3171
3 PASS
Min
Max
204
815
244
978
285
1141
204
815
244
978
285
1141
330
1320
371
1482
407
1775
330
1320
371
1482
407
1775
439
1756
494
1976
529
2114
439
1756
494
1976
529
2114
CONDENSER
Frame
Size
30
31
32
3
35
36
37
40
41
42
4
45
46
47
50
51
52
5
55
56
57
1 PASS
Min
Max
646
2,582
791
3,162
932
3,731
646
2,582
791
3,162
932
3,731
1096
4,383
1235
4,940
1371
5,485
1096
4,383
1235
4,940
1371
5,485
1507
6,029
1646
6,586
1783
7,131
1507
6,029
1646
6,586
1783
7,131
2 PASS
Min
Max
323 1291
395 1581
466 1865
323 1291
395 1581
466 1865
548 2192
618 2470
686 2743
548 2192
618 2470
686 2743
754 3015
823 3293
891 3565
754 3015
823 3293
891 3565
3 PASS
Min
Max
215
861
263 1054
311 1244
215
861
263 1051
311 1244
365 1461
412 1647
457 1828
365 1461
412 1647
457 1828
502 2010
549 2195
594 2377
502 2010
549 2195
594 2377
*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec);
maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.
SI (L/s)
COOLER
Frame
Size
30
31
32
3
35
36
37
40
41
42
4
45
46
47
50
51
52
5
55
56
57
1 PASS
Min
Max
38
154
46
185
54
215
38
154
46
185
54
215
62
249
70
281
77
307
62
249
70
281
77
307
83
332
93
374
100
400
83
332
93
374
100
400
2 PASS
Min
Max
19
77
23
92
27
108
19
77
23
92
27
108
31
125
35
140
38
154
31
125
35
140
38
154
42
166
47
187
50
200
42
166
47
187
50
200
3 PASS
Min
Max
13
51
15
62
18
72
13
51
15
62
18
72
21
83
23
93
26
112
21
93
23
93
26
112
28
111
31
125
33
133
28
111
31
125
33
133
CONDENSER
Frame
Size
30
31
32
3
35
36
37
40
41
42
4
45
46
47
50
51
52
5
55
56
57
1 PASS
Min
Max
41
163
50
199
59
235
41
163
50
199
59
235
69
277
78
312
86
346
69
277
78
312
86
346
95
380
104
416
112
450
95
380
104
416
112
450
2 PASS
Min
Max
20
81
25
100
29
118
20
81
25
100
29
118
35
138
39
156
43
173
35
138
39
156
43
173
48
190
52
208
56
225
48
190
52
208
56
225
3 PASS
Min
Max
14
54
17
67
20
79
14
54
17
67
20
79
23
92
26
104
29
115
23
92
26
104
29
115
32
127
35
138
37
150
32
127
35
138
37
150
*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec);
maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.
9
Electrical data
VFD FRAME SIZES
FRAME SIZE
AA
BA
BB
CC
MAX INPUT CURRENT*
440
520
520
608
MAX OUTPUT CURRENT*
442
442
520
608
*Maximum limits only. Additional application limits apply that will reduce these ampacities.
AUXILIARY RATINGS*
VOLTAGE
MAXIMUM
PROTECTIVE DEVICE
SIZE (AMPS)
WATTS
Controls, Oil Pump And Heater Circuit†
Oil Pump
Oil Sump Heater
115
115
115
15
1.48
4.35
—
130
500
Oil Vaporizer Heater Circuit†
Oil Vaporizer Heater
115
115
15
13
—
1500
ITEM
*Factory wired to VFD.
†Minimum circuit ampacity of 15 amps.
10
Controls
Microprocessor controls
Microprocessor controls provide the safety, interlock, capacity control, indications and accessibility necessary to
operate the chiller in a safe and efficient manner.
Control system
The microprocessor control on each Carrier chiller is
factory-mounted, factory-wired, and factory-tested to
ensure machine protection and efficient capacity control.
In addition, the program logic ensures proper starting,
stopping, and recycling of the chiller and provides a communication link to the Carrier Comfort Network® (CCN)
system.
Features
Control system
• Component test and diagnostic check
• Programmable recycle allows chiller to recycle at optimum loads for decreased operating costs
• Menu-driven keypad interface for status display, set
point control, and system configuration
• CCN system compatible
• Primary and secondary status messages
• Individual start/stop schedules for local and CCN operation modes
• Recall of up to 25 alarm messages and 25 alert messages with diagnostic help
• Two chiller lead/lag with third chiller standby is standard in the PIC III software
• Optional soft stop unloading decreases compressor
speed to unload the motor to the configured amperage
level prior to stopping
• Languages pre-programmed at factory for English, Chinese, Japanese, Korean
• ILT (International Language Translator) available for
conversion of extended ASCII characters
Safety cutouts
• Motor high temperature*†
• Refrigerant (condenser) high pressure*†
• Refrigerant (cooler) low temperature*†
• Lube oil low pressure*
• Compressor (refrigerant) high discharge temperature*
• Under voltage**
• Over voltage**
• Cooler and condenser liquid flow
• Motor overload†
• Motor acceleration time
• Intermittent power loss**
• Motor stall protection
• Low level ground fault
• Cooler and condenser freeze prevention*
• Low oil temperature
• Line voltage imbalance**
• Line current imbalance**
• Line frequency
• Motor current imbalance
• Motor rotation reversal
• Excessive motor amps
• Motor starts limit
• VFD speed out of range
• High VFD rectifier temperature*†
• High VFD inverter temperature*†
• DC bus voltage (Low/High)
Capacity control
• Leaving chilled liquid control
• Entering chilled liquid control
• Soft loading control by temperature or load ramping
• Hot gas bypass valve (optional)
• Power (demand) limiter
• Automatic chilled liquid reset (3 methods)
• Manual speed control
Interlocks
• Manual/automatic remote start
• Starting/stopping sequence
Pre-lube/post-lube
Pre-flow/post-flow
• Compressor run interlock
• Pre-start check of safeties and alerts
• Low chilled liquid (load) recycle
• Monitor/number compressor starts and run hours
• Manual reset of safeties
Indications
• Chiller operating status message
• Power-on
• Pre-start diagnostic check
• Compressor motor amps
• Alert (pre-alarm)††
• Alarm
• Contact for remote alarm
• Safety shutdown messages
• Elapsed time (hours of operation)
• Chiller input kW
• Demand kW
Drive control parameters
• Compressor 100% speed (Hz)
• Rated line voltage
• Rated line amps
• Rated line kW
• Motor rated Load kW
• Motor rated Load amps
• Motor nameplate amps
• Motor nameplate RPM
• Motor nameplate kW
• Inverter PWM frequency
*Can be configured by the user to provide alert indication
at user-defined limit.
†Override protection: Causes compressor to first unload
and then, if necessary, shut down.
**Will not require manual reset or cause an alarm if autorestart after power failure is enabled.
††By display code only.
11
Controls (cont)
CONTROL PANEL DISPLAY (Front View)
ICVC ENGLISH DISPLAY IN SI UNITS
CONTROL PANEL DISPLAY (Front View)
ICVC CHINESE DISPLAY IN METRIC UNITS
12
a23-1649
13
CCM —
BLACK
WHITE
RED
GROUND
LEGEND
Chiller Control Module
Factory Wiring
Field Wiring
DRAIN WIRE
BLACK
WHITE
RED
BLACK
WHITE
RED
DRAIN WIRE
NOTE: Field-supplied terminal strip must be located in control panel.
DRAIN WIRE
CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)
BLACK
WHITE
RED
DRAIN WIRE
Controls (cont)
Control sequence
CONTROL SEQUENCE
0
0
MACHINE SAFETIES,
EVAPORATOR PUMP
CONDENSER WATER
PUMP
WATER FLOWS
CHILLED WATER
TEMP, TOWER FAN
CONTROL
OIL PUMP
OIL PRESSURE
VERIFIED
VDF FAULT TEST
COMPRESSOR, PHASE
REVERSAL,
COMPRESSOR AND
SERVICE ONTIME
COMPRESSOR
RUNNING
RAMP VDF TO
TARGET SPEED
15-MINUTE
START-TO-START
TIMER
1-MINUTE
STOP-T O-START
TIMER (SOFTWARE
VERSION 13)
A B C
TIME
0
A
D
E F G
H I
J L O/A
K
— Phase reversal monitored
— START INITIATED: Pre-start checks are made; evaporator pump
started
B
— Condenser liquid pump started (5 seconds after A); tower fan control
enabled
C
— Liquid flows verified (30 sec to 5 minutes maximum after B)
D
— Chilled liquid temperature checked against control point; oil pump
on.
E
— Oil pressure verified (oil pressure verified 45-300 sec after D).
F
— VFD starts; phase reversal conditions monitored; compressor
ontime and service ontime start; 15-minute inhibit timer starts (VFD
fault tests for 15 sec after F)
G
— Verify average current >5% within 15 sec after VFD start, ramp to
VFD target speed.
H
— Compressor reaches target speed, chiller set to running status
I
— Shutdown initiated: Target VFD speed to 0% (or J occurs)
J
— Ramp down until percent line current < soft stop amps threshold
(0-60 sec after I)
K
— Oil pump relay off (1-20 sec after J)
L
— Evaporator pump deenergized (60 sec after K); condenser pump
and tower fan control may continue to operate if condenser pressure
is high; evaporator pump may continue if in RECYCLE mode
O/A — Restart permitted (both inhibit timers expired) (minimum of 15 minutes after F; minimum of 3 minutes after L)
14
To start — Local start-up (manual start-up) is initiated by
pressing the LOCAL or CCN menu softkey, which is indicated on the default international chiller visual control
(ICVC) screen. Time schedule 01 or 03, respectively, must
be in the Occupied mode and the internal 15-minute startto-start and the 1-minute stop-to-start inhibit timers must
have expired. All pre-start safeties are checked to verify
that all prestart alerts and safeties are within limits (if one is
not, an indication of the fault displays and the start will be
delayed or is aborted). The signal is sent to start the cooler
liquid pump. Five seconds later, the condenser liquid pump
is energized. If satisfied, it checks the chilled liquid temperature against the control point. If the temperature is less
than or equal to the chilled liquid control point, the condenser liquid pump is deenergized and the chiller goes into
a recycle mode.
If the chilled liquid temperature is high enough, the startup sequence continues. The oil pump is started and waits a
minimum of 45 sec to verify oil flow. Once oil flow is verified, the VFD is energized. The control will monitor for a
phase reversal condition. At this time, the following occurs:
• The “start-to-stop” timer is activated.
• The “compressor on-time” and “service on-time” timers
are activated.
• The “starts in 12-hour counter” advances by one.
• The “total compressor starts counter” advances by one.
Once started — If the VFD average current >5% within
15 seconds after VFD start, the machine enters run mode
and speed will be ramped up to meet VFD target speed.
Once the target speed is met the controls, enter the capacity control mode.
Shutdown sequence — The chiller shutdown is initiated
if any of the following occur:
• The Stop button is pressed for at least one second (the
alarm light blinks once to confirm the stop command).
• A recycle shutdown is initiated.
• The time schedule has gone into unoccupied mode.
• The chiller protective limit has been reached and the
chiller is in alarm.
• The start/stop status is overridden to stop from the
ICVC, CCN system, or building management system.
Once the controls shutdown sequence is initiated, the
compressor is stopped and the VFD target speed is set to 0.
If optional soft stop unloading is activated when the Stop
button is pressed or the remote contacts open, motor
speed decreases to a configured amperage level, and the
compressor is stopped. The display indicates “Shutdown in
Progress” while the motor speed decreases. Compressor
ontime and service ontime timers stop once the current in
all phases is <5%, indicating a VFD Stop Complete. The oil
pump and cooler liquid pump are then deenergized. The
condenser liquid pump shuts down when the refrigerant
temperature or entering condenser liquid temperature is below pre-established limits. The 3-minute start-to-stop timer
starts.
Restart — Restart is permitted after both inhibit timers
have expired. If shutdown was due to a safety shutdown,
the reset button must be depressed before restarting the
chiller.
Typical piping and wiring
23XRV CHILLER
1
1
7
6
1
1
MAIN COMPRESSOR
MOTOR POWER
8
TO CHILLED LIQUID PUMP
TO CONDENSER LIQUID PUMP
TO COOLING TOWER FAN
2
9
TO
COOLING
TOWER
9
3
3
FROM
COOLING
TOWER
TO
LOAD
FROM
LOAD
DRAIN
5
4
1
2
3
4
5
6
7
8
9
—
—
—
—
—
—
—
—
—
LEGEND
Disconnect
Unit-Mounted VFD/Control Center
Pressure Gages
Chilled Liquid Pump
Condenser Liquid Pump
Chilled Liquid Pump Starter
Condenser Liquid Pump Starter
Cooling Tower Fan Starter
Vents
Piping
Control Wiring
Power Wiring
NOTES:
1. Wiring and piping shown are for general point-of-connection only and are not
intended to show details for a specific installation. Certified field wiring and
dimensional diagrams are available on request.
2. All wiring must comply with applicable codes.
3. Refer to Carrier System Design Manual for details regarding piping techniques.
4. Wiring not shown for optional devices such as:
• remote start/stop
• remote alarms
• optional safety device
• 4 to 20 mA resets
• optional remote sensors
• kW output
• head pressure reference
5. Flow switches are NOT required.
15
Control wiring schematic
23XRV COMPONENT ARRANGEMENT
CCM
CCN
ICVC
GND
16
—
—
—
—
LEGEND
Chiller Control Module
Carrier Comfort Network®
International Chiller Visual Controller
Ground
Application data
23XRV MACHINE FOOTPRINT
A
D
C
CL
VESSELS
CL
ACCESSORY
SOLEPLATE
COND.
B
TYP.
0’-3”
[76.2mm]
F
CL
COOLER
a23-1650
E
X
X*
G
0’-01/2”
[13mm]
TYP.
Y*
Y
*See detail on page 18.
23XRV
HEAT EXCHANGER
SIZE
30-32
35-37
40-42
45-47
50-52
55-57
DIMENSIONS (ft-in.)
DIMENSIONS (mm)
A
B
C
D
E
F
G
A
B
C
D
E
F
G
12-103/4
14- 71/4
12-103/4
14- 71/4
12-103/4
14- 71/4
5-41/4
5-41/4
6-0
6-0
6-51/2
6-51/2
0
0
0-11/2
0-11/2
0- 1/2
0- 1/2
0-35/8
0-35/8
0-35/8
0-35/8
0-35/8
0-35/8
1-13/4
1-13/4
1-13/4
1-13/4
1-13/4
1-13/4
0-9
0-9
0-9
0-9
0-9
0-9
0-1/2
0-1/2
0-1/2
0-1/2
0-1/2
0-1/2
3931
4451
3931
4451
3931
4451
1937
1937
1829
1829
1969
1969
0
0
38
38
13
13
92
92
92
92
92
92
349
349
349
349
349
349
229
229
229
229
229
229
13
13
13
13
13
13
17
Application data (cont)
23XRV ISOLATION WITH ACCESSORY SOLEPLATE PACKAGE
STANDARD ISOLATION
TYPICAL ISOLATION
ELASTOMERIC PAD
VIEW Y-Y
ISOLATION WITH ISOLATION PACKAGE ONLY
(STANDARD)
NOTE: Isolation package includes 4 elastomeric pads.
a23-1647
ACCESSORY SOLEPLATE DETAIL
VIEW X-X
NOTES:
1. Dimensions in ( ) are in millimeters.
2. Accessory soleplate package includes 4 soleplates, 16 jacking screws and leveling
pads. Requires isolation package.
3. Jacking screws to be removed after grout has set.
4. Thickness of grout will vary, depending on the amount necessary to level chiller. Use
only pre-mixed non-shrinking grout, Ceilcote 748 or Chemrex Embeco 636 Plus
Grout, 0-11/2 (38.1) to 0-21/4 (57) thick.
5. Service clearance under the chiller is enhanced if leveling pads are not extended
along the entire length of the heat exchangers.
18
23XRV NOZZLE ARRANGEMENTS
NOZZLE-IN-HEAD WATERBOXES
DISCHARGE END
SUCTION END
FRAME 3
12
3
9
6
5
11
2
8
4
10
1
7
DISCHARGE END
SUCTION END
FRAMES 4 AND 5
NOZZLE ARRANGEMENT CODES FOR ALL 23XRV NOZZLE-IN-HEAD WATERBOXES
PASS
1
2
3
In
8
5
7
4
7
4
COOLER WATERBOXES
Arrangement
Out
Code*
5
A
8
B
9
C
6
D
6
E
9
F
PASS
1
2
3
In
11
2
10
1
10
1
CONDENSER WATERBOXES
Arrangement
Out
Code*
2
P
11
Q
12
R
3
S
3
T
12
U
*Refer to certified drawings.
19
Application data (cont)
23XRV NOZZLE ARRANGEMENTS (cont)
MARINE WATERBOXES
DISCHARGE END
SUCTION END
FRAME 3
NOZZLE ARRANGEMENT CODES
PASS
In
8
1
2
3
COOLER WATERBOXES
Arrangement
Out
Code
5
A
5
8
B
7
9
C
4
6
D
7
6
E
4
9
F
PASS
CONDENSER WATERBOXES
Arrangement
Out
Code
—
—
In
—
1
2
3
—
—
—
10
12
R
1
3
S
—
—
—
—
—
—
DISCHARGE END
SUCTION END
FRAMES 4, AND 5
NOZZLE ARRANGEMENT CODES
PASS
1
2
3
20
In
9
COOLER WATERBOXES
Arrangement
Out
Code
6
A
6
9
B
7
9
C
4
6
D
7
6
E
4
9
F
PASS
1
2
3
In
—
CONDENSER WATERBOXES
Arrangement
Out
Code
—
—
—
—
—
10
12
R
1
3
S
—
—
—
—
—
—
23XRV WATERBOX NOZZLE SIZES (Nozzle-In-Head and Marine Waterboxes
FRAME
SIZE
PRESSURE
psig (kPa)
3
150/300
(1034/2068)
4
150/300
(1034/2068)
5
150/300
(1034/2068)
NOMINAL PIPE SIZE (in.)
Cooler
Condenser
10
10
8
8
6
6
10
10
8
8
6
6
10
10
8
10
6
8
PASS
1
2
3
1
2
3
1
2
3
ACTUAL PIPE ID (in.)
Cooler
Condenser
10.020
10.020
7.981
7.981
6.065
6.065
10.020
10.020
7.981
7.981
6.065
6.065
10.020
10.020
7.981
10.020
6.065
7.981
RELIEF VALVE LOCATIONS
LOCATION
MUFFLER
COOLER
CONDENSER
OPTIONAL
STORAGE TANK
FRAME
SIZE
3-5
3-5
3-5
RELIEF VALVE
OUTLET SIZE
11/4-in. NPT FEMALE CONNECTOR
11/4-in. NPT FEMALE CONNECTOR
11/4-in. NPT FEMALE CONNECTOR
N/A
QUANTITY
1
1 or 2*
2
1-in. NPT FEMALE CONNECTOR
2
* Coolers without optional isolation require 2 relief valves.
NOTE: All valves relieve at 185 psig (1275 kPa).
RELIEF VALVE ARRANGEMENTS
WITH OPTIONAL ISOLATION OF DISCHARGE AND COOLER
WITH OPTIONAL ISOLATION
WITHOUT OPTIONAL ISOLATION
21
Application data (cont)
Vent and drain connections
Nozzle-in-head waterboxes have vent and drain connections on covers. Marine waterboxes have vent and drain
connections on waterbox shells.
Provide high points of the chiller piping system with vents
and the low points with drains. If shutoff valves are provided in the main liquid pipes near the unit, a minimal amount
of system liquid is lost when the heat exchangers are
drained. This reduces the time required for drainage and
saves on the cost of re-treating the system liquid.
It is recommended that pressure gages be provided at
points of entering and leaving liquid to measure pressure
drop through the heat exchanger. Gages may be installed
as shown in Pressure Gage Location table. Pressure gages
installed at the vent and drain connections do not include
nozzle pressure losses.
Use a reliable differential pressure gage to measure pressure differential when determining liquid flow. Regular gages of the required pressure range do not have the accuracy
to provide accurate measurement of flow conditions.
PRESSURE GAGE LOCATION
NUMBER
OF
PASSES
1 or 3
2
GAGE LOCATION
(Cooler or Condenser)
One gage in each waterbox
Two gages in waterbox with nozzles
ASME stamping
All 23XRV heat exchangers are constructed in accordance
with ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers) 15 Safety Code for
Mechanical Refrigeration (latest edition). This code, in
turn, requires conformance with ASME (American Society
of Mechanical Engineers) Code for Unfired Pressure Vessels wherever applicable.
Each heat exchanger and economizer (if equipped) is
ASME ‘U’ stamped on the refrigerant side of each vessel.
Relief valve discharge pipe sizing
See page 21 for number of relief valves.
Relief valve discharge piping size should be calculated
per the current version of the ASHRAE 15, latest edition,
code using the tabulated C factors for each vessel shown in
the table below.
23XRV RELIEF VALVE DISCHARGE PIPE SIZING
RELIEF
VESSEL
VALVE
FIELD
HEAT
FRAME REQUIRED
RATED
CONNECTION
EXCHANGER
SIZE
C FACTOR C FACTOR
SIZE (FPT)
(lb air/Min)
(lb air/Min)
30 to 32
43.4
70.8
1 1 /4 
35 to 37
49.5
70.8
1 1 /4 
40 to 42
50.4
70.8
1 1 /4 
COOLER
45 to 47
57.4
70.8
1 1 /4 
50 to 52
53.7
70.8
1 1 /4 
55 to 57
61.1
70.8
1 1 /4 
30 to 32
41.4
70.8
1 1 /4 
35 to 37
47.1
70.8
1 1 /4 
40 to 42
47.1
70.8
1 1 /4 
CONDENSER
45 to 47
53.7
70.8
1 1 /4 
50 to 52
51.2
70.8
1 1 /4 
55 to 57
58.3
70.8
1 1 /4 
Carrier further recommends that an oxygen sensor be
installed to protect personnel. Sensor should be able to
sense the depletion or displacement of oxygen in the machine room below 19.5% volume oxygen per ASHRAE
15, latest edition.
Design pressures
Design and test pressures for heat exchangers are listed
below.
DESIGN AND TEST PRESSURES (23XRV)
PRESSURES
Leak Test at Design Pressure*
Hydrostatic
Proof Test*
SHELL SIDE
(Refrigerant)
psig
kPa
185
1276
—
—
204
1407
STANDARD TUBE SIDE
(Liquid)
psig
kPa
150
1034
195
1344
—
—
OPTIONAL TUBE SIDE
(Liquid)
psig
kPa
300
2068
390
2689
—
—
*Nitrogen/Helium.
HEAT EXCHANGER MATERIAL SPECIFICATIONS
ITEM
Shell
Tube Sheet
Condenser/Cooler Waterbox Cover
Condenser/Cooler Waterbox Shell
Tubes
Discharge/Suction
Pipe
Flanges
LEGEND
ASME — American Society of Mechanical Engineers
HR
— Hot Rolled
22
MATERIAL
HR Steel
HR Steel
HR Steel
HR Steel
Finned Copper
Steel
Steel
SPECIFICATION
ASME SA516 GR 70
ASME SA516 GR 70
ASME SA516 GR 70, SA-36, or SA-285 GRC
ASME SA675 GR 60, SA-516 GR70, or SA-181 CL70,
SA-36, SA-675 GR70, SAE AME 7496
ASME SB359
ASME SA106 GRB
ASME SA105
Insulation
23XRV MINIMUM FIELD-INSTALLED INSULATION
REQUIREMENTS
COMPONENT
Cooler
Misc. Liquid Lines
Economizer
Compressor Motor
SIZE
30-32
35-37
40-42
45-47
50-52
55-57
All Sizes
All Sizes
All Sizes
INSULATION
ft2
m2
96
8.9
108
10.0
109
10.1
122
11.3
115
10.7
130
12.1
21
2.0
20
1.9
17
1.6
Factory insulation — Thermal insulation is factoryprovided to the following areas:
• Cooler (not including waterbox)
• Suction line
• Compressor and motor
• Oil cooling line and oil return system line (oil and refrigerant lines at or near evaporator pressure are insulated)
• VFD cooling line (oil and refrigerant lines at or near
evaporator pressure are insulated)
• Motor cooling line
• Vaporizer
• Liquid line and discharge line
• Float chamber
• Optional economizer (including vent line and economizer muffler)
Factory insulation is not available for the waterboxes.
Insulation applied at the factory is 1/2-in. (13 mm) thick
closed cell and 1/2-in. (13 mm) open cell PVC-Nitrile foam.
Some parts of the chiller are also treated with an outer
layer of 3/16-in. (5 mm) thick vinyl. The 1/2-in. (13 mm)
closed cell foam has a thermal conductivity K value of
0.28 (BTU in.)/(hr sqft °F) [0.0404 W/(m °C)] and
conforms with Underwriters Laboratories (UL) Standard
94, Classification 94 HF-1. Both the 1/2-in. foam and the
3/16-in. vinyl layer will pass flammability test method
MVSS 302.
Field insulation — As indicated in the Condensation vs
Relative Humidity table, the factory insulation provides
excellent protection against condensation under most operating conditions. If temperatures in the equipment area
exceed the maximum design conditions, extra insulation is
recommended.
If the machine is to be field insulated, obtain the approximate areas from the 23XRV Minimum Field-Installed Insulation Requirements table.
Insulation of waterbox is made only in the field and this
area is not included in 23XRV Minimum Field-Installed Insulation Requirements table. When insulating the covers,
allow for service access and removal of covers. To estimate
water-box cover areas, refer to certified drawings.
High humidity jobsite locations may require field supplied and installed insulation on the float chamber, suction
housing, and the lower half of the condenser.
CONDENSATION VS RELATIVE HUMIDITY*
AMOUNT OF
CONDENSATION
None
Slight
Extensive
ROOM DRY-BULB TEMPERATURE
80 F (27 C)
90 F (32 C)
100 F (38 C)
% Relative Humidity
80
76
70
87
84
77
94
91
84
*These approximate figures are based on 35 F (1.7 C) saturated suction
temperature. A 2° F (1.1° C) change in saturated suction temperature
changes the relative humidity values by 1% in the same direction.
23
Guide specifications
Variable Speed Screw Chiller
HVAC Guide Specifications
Size Range:
300 to 550 Tons (1055 to 1934 kW)
Nominal
Carrier Model Number: 23XRV
Part 1 — General
1.01 SYSTEM DESCRIPTION
A. Microprocessor-controlled liquid chiller shall use a
semi-hermetic screw compressor using refrigerant
HFC-134a only. Chiller refrigerant shall not have a
planned phase out date.
B. If a manufacturer proposes a liquid chiller using
HCFC-123 refrigerant, which has a planned phase
out date, then the manufacturer shall include in the
chiller price:
1. A vapor activated alarm system consisting of all
alarms, sensors, safeties, and ventilation equipment as required by ANSI/ASHRAE Standard
15 Safety Code for Mechanical Refrigeration
(latest edition) with the quotation. System shall
be capable of responding to HCFC-123 levels
of 10 ppm Allowable Exposure Limit (AEL).
2. A free-standing refrigerant storage tank and
pumpout unit shall be provided. The storage
vessels shall be designed per ASME Section VIII
Division 1 code with 300 psig (2068 kPa)
design pressure. Double relief valves per ANSI/
ASHRAE 15, latest edition, shall be provided.
The tank shall include a liquid level gage and
pressure gage. The pumpout unit shall use a
semi-hermetic reciprocating compressor with
water cooled condenser. Condenser water piping, 3-phase motor power, and 115-volt control
power shall be installed at the jobsite by the
installing contractor.
3. Zero emission purge unit capable of operating
even when the chiller is not operating.
4. Back-up relief valve to rupture disk.
5. Factory-installed chiller pressurizing system to
prevent leakage of noncondensables into the
chiller during shutdown periods.
6. Plant room ventilation.
7. Removal and disposal of refrigerant at the end
of the phase out period.
8. Chillers utilizing a purge unit shall include in the
machine price the costs to perform the following regular maintenance procedures:
a. Weekly: Check refrigerant charge.
b. Quarterly: Charge purge unit dehydrator at
least quarterly, more often if necessary.
Clean foul gas strainer. Perform chemical
analysis of oil.
c. Annually: Clean and inspect all valves. Drain
and flush purge shell. Clean orifices.
24
1.02 QUALITY ASSURANCE
A. Chiller performance shall be rated in accordance
with AHRI Standard 550/590, latest edition.
B. Equipment and installation shall be in compliance
with ANSI/ASHRAE 15 (latest edition).
C. Cooler and condenser refrigerant side shall include
ASME “U” stamp and nameplate certifying compliance with ASME Section VIII, Division 1 code for
unfired pressure vessels.
D. A manufacturer’s data report is required to verify
pressure vessel construction adherence to ASME
vessel construction requirements. Form U-1 as
required per ASME code rules is to be furnished
to the owner. The U-1 Form must be signed by a
qualified inspector, holding a National Board
Commission, certifying that construction conforms
to the latest ASME Code Section VIII, Div. 1 for
pressure vessels. The ASME symbol “U” must also
be stamped on the heat exchanger. Vessels specifically exempted from the scope of the code must
come with material, test, and construction methods
certification and detailed documents similar to
ASME U-1; further, these must be signed by an officer of the company.
E. Chiller shall be designed and constructed to meet
UL and UL of Canada requirements and have labels
appropriately affixed.
F. Unit shall be manufactured in a facility registered to
ISO 9001:2000 Manufacturing Quality Standard.
G. Each compressor assembly shall undergo a mechanical run-in test to verify vibration levels, oil pressures,
and temperatures are within acceptable limits. Each
compressor assembly shall be proof tested at a minimum 204 psig (1407 kPa) and leak tested at
185 psig (1276 kPa) with a tracer gas mixture.
H. Entire chiller assembly shall be proof tested at
204 psig (1407 kPa) and leak tested at 185 psig
(1276 kPa) with a tracer gas mixture on the refrigerant side. The leak test shall not allow any leaks
greater than 0.5 oz per year of refrigerant. The
water side of each heat exchanger shall be hydrostatically tested at 1.3 times rated working pressure.
I. Prior to shipment, the chiller automated controls
test shall be executed to check for proper wiring and
ensure correct controls operation.
J. Chillers shall have factory-mounted, factory-wired
and factory-tested unit-mounted variable frequency
drive (VFD). Proper VFD operation shall be confirmed prior to shipment.
1.03 DELIVERY, STORAGE AND HANDLING
A. Unit shall be stored and handled in accordance with
manufacturer’s instructions.
B. Unit shall be shipped with all refrigerant piping and
control wiring factory-installed.
C. Unit shall be shipped charged with oil and full
charge of refrigerant HFC-134a or a nitrogen holding charge as specified on the equipment schedule.
D. Unit shall be shipped with firmly attached labels that
indicate name of manufacturer, chiller model number, chiller serial number, and refrigerant used.
E. If the unit is to be exported, the manufacturer shall
provide sufficient protection against sea water corrosion, making the unit suitable for shipment in a
standard open top ocean shipping container.
F. Chiller and starter shall be stored indoors, protected
from construction dirt and moisture. Chiller shall be
inspected under shipping tarps, bags, or crates to be
sure water has not collected during transit. Protective shipping covers shall be kept in place until
machine is ready for installation. The inside of the
protective cover shall meet the following criteria:
1. Temperature is between 40 F (4.4 C) and
120 F (48.9 C)
2. Relative humidity is between 10% and 80%
non-condensing.
1.04 WARRANTY
Warranty shall include parts and labor for one year
after start-up or 18 months from shipment, whichever occurs first. A refrigerant warranty shall be
provided for a period of 5 years.
Part 2 — Products
2.01 EQUIPMENT
A. General:
Factory-assembled, single piece, liquid chiller shall
consist of compressor, motor, VFD, lubrication system, cooler, condenser, initial oil and refrigerant
operating charges, microprocessor control system,
and documentation required prior to start-up.
B. Compressor:
1. One variable speed, tri-rotor screw compressor
of the high performance type.
2. Compressor and motor shall be hermetically
sealed into a common assembly and arranged
for easy field servicing.
3. The compressor motor shall be accessible for
servicing without removing the compressor
base from the chiller. Connections to the compressor casing shall use O-rings and gaskets to
reduce the occurrence of refrigerant leakage.
Connections to the compressor shall be flanged
or bolted for easy disassembly.
4. Compressor bearings must have individual
design life of 500,000 hours or greater.
5. Compressor shall provide capacity modulation
from 100% to 15% capacity without the use of
hot gas bypass or mechanical unloaders.
6. Compressor shall be provided with a factoryinstalled positive pressure lubrication system to
deliver oil under pressure to bearings and rotors
at all operating conditions. Lubrication system
shall include:
a. Oil pump with factory-installed motor contactor with overload protection.
b. Oil pressure sensor with differential readout
at main control center.
c. Oil pressure regulator.
d. Oil filter with isolation valves to allow filter
change without removal of refrigerant
charge.
e. Oil sump heater [115 v, 50 or 60 Hz] controlled from unit microprocessor.
f. Oil reservoir temperature sensor with main
control center digital readout.
g. All wiring to oil pump, oil heater, and controls shall be pre-wired in the factory and
power shall be applied to check proper
operation prior to shipment.
7. Compressor shall be fully field serviceable.
Compressors that must be removed and
returned to the factory for service shall be
unacceptable.
8. Acoustical attenuation shall be provided as
required, to achieve a maximum (full load
or part load) sound level, measured per AHRI
Standard 575 (latest edition).
C. Motor:
1. Compressor motor shall be of the semihermetic, liquid refrigerant cooled, squirrel
cage, induction type suitable for voltage shown
on the equipment schedule.
2. If an open (air cooled) motor is provided, a
compressor shaft seal leakage containment
system shall be provided:
a. An oil reservoir shall collect oil and refrigerant that leaks past the seal.
b. A float device shall be provided to open
when the reservoir is full, directing the
refrigerant/oil mixture back into the compressor housing.
c. A refrigerant sensor shall be located next to
the open drive seal to detect leaks.
3. Motors shall be suitable for operation in a
refrigerant atmosphere and shall be cooled by
atomized refrigerant in contact with the motor
windings.
4. Motor stator shall be arranged for service or
removal with only minor compressor disassembly and without removing main refrigerant
piping connections.
5. Full load operation of the motor shall not
exceed nameplate rating.
6. One motor winding temperature sensor (and on
spare) shall be provided.
7. Should the mechanical contractor choose to
provide a chiller with an air-cooled motor
instead of the specified semi-hermetic motor,
the contractor shall install additional cooling
25
Guide specifications (cont)
equipment to dissipate the motor heat as per
the following formula:
Btuh = (FLkW motor) (0.05) (3413)
Btuh = (FLkW motor) (171)
and, alternately
Tons = Btuh/12,000
The additional piping, valves, air-handling
equipment, insulation, wiring, switchgear
changes, ductwork, and coordination with other
trades shall be the responsibility of the mechanical contractor. Shop drawings reflecting any
changes to the design shall be included in the
submittal, and incorporated into the final asbuilt drawings for the project.
8. Also, if an open motor is provided, a mechanical room thermostat shall be provided and set
at 104 F (40 C). If this temperature is
exceeded, the chillers shall shut down and an
alarm signal shall be generated to the central
Energy Management System (EMS) display
module, prompting the service personnel to
diagnose and repair the cause of the overtemperature condition. The mechanical contractor
shall be responsible for all changes to the
design, including coordination with temperature
control, electrical and other trades. In addition,
the electrical power consumption of any auxiliary ventilation and/or mechanical cooling
required to maintain the mechanical room conditions stated above shall be considered in the
determination of conformance to the scheduled
chiller energy efficiency requirement.
D. Unit-Mounted Variable Frequency Drive (VFD) with
Built-In Harmonic LiquiFlo™ II Filter:
The compressor shall be factory-mounted, factorywired and factory-tested prior to shipment by the
chiller manufacturer. All interconnecting wiring and
piping between the VFD and the chiller shall be
factory-installed. Customer electrical connection for
compressor motor power shall be limited to main
power leads to the VFD, and wiring liquid pumps
and tower fans to the chiller control circuit. The
VFD shall incorporate the following features:
1. Design:
a. The VFD shall be refrigerant cooled,
microprocessor based, pulse width modulated design. Water cooled designs are not
acceptable.
b. Input and output power devices shall be
Insulated Gate Bipolar Transistors (IGBTs).
c. Rectifier shall convert incoming fixed voltage/frequency to fixed DC voltage.
d. Transistorized inverter and control regulator
shall convert fixed DC voltage to a sinusoidal
PWM waveform.
e. Low voltage control sections and main
power sections shall be physically isolated.
26
2.
3.
4.
5.
6.
f. Integrated controls shall coordinate motor
speed to optimize chiller performance over a
wide variety of operating conditions.
Enclosure:
a. Pre-painted unit mounted, NEMA 1 cabinet
shall include hinged, lockable doors and
removable lifting lugs.
b. The VFD shall have a short circuit interrupt
and withstand rating of at least 65,000 amps.
c. Provisions to padlock main disconnect handle in the “Off” positions shall be provided.
Mechanical interlock to prevent opening
cabinet door with disconnect in the “On”
position or moving disconnect to the “On”
position while the door is open shall be
provided.
d. Provisions shall be made for top entry of
incoming line power cables.
Heat Sink:
a. The heat sink shall be refrigerant cooled.
Heat sink and mating flanges shall be suitable for ASME design working pressure of
185 psig (1276 kPa).
b. Refrigerant cooling shall be metered to
maintain heat sink temperature within
acceptable limits for ambient temperature.
VFD Rating:
a. Drive shall be suitable for operation at nameplate voltage ±10%.
b. Drive shall be suitable for continuous operation at 100% of nameplate amps and 150%
of nameplate amps for 5 seconds.
c. Drive shall comply with applicable ANSI,
NEMA, UL and NEC standards.
d. Drive shall be suitable for operation in ambient
temperatures between 40 and 122 F (4 and
50 C), 95% humidity (non-condensing) for
altitudes up to 6000 ft (1829 m) above sea
level. Specific drive performance at jobsite
ambient temperature and elevation shall be
provided by the manufacturer in the bid.
User Interface:
A single display shall provide interface for programming and display of VFD and chiller
parameters. Viewable parameters include:
a. Operating, configuration and fault messages
b. Frequency in hertz
c. Load and line side voltage and current (at the
VFD)
d. kW
e. IGBT temperature
VFD Performance:
a. The VFD Voltage Total Harmonic Distortion
(THD) and Harmonic Current Total Demand
Distortion (TDD) shall not exceed IEEE-519
requirements using the VFD circuit breaker
7.
8.
9.
10.
input terminals as the point of common coupling (PCC).
b. The VFD full load efficiency shall meet or
exceed 97% at 100% VFD rated ampacity.
c. Active rectifier shall regulate unity displacement power factor to 0.99 or higher.
d. Voltage boost capability to provide full motor
voltage at reduced line voltage conditions.
e. The VFD shall feature soft start, linear acceleration, and coast to stop capabilities.
f. Base motor frequency shall permit motor to
be utilized at nameplate voltage. Adjustable
frequency range shall permit capacity control down to 15%.
g. The VFD shall have 150% instantaneous
torque generation.
VFD Electrical Service (single point power):
a. The VFD shall have input circuit breaker
with minimum 65,000 amp interrupt
capacity.
b. The VFD shall have standard branch oil
pump circuit breaker to provide power for
chiller oil pump.
c. The VFD shall have standard 3 KVA control
power transformer with circuit breaker to
provide power for oil heater, VFD controls
and chiller controls.
d. The branch oil pump circuit breaker and
control power transformer shall be factorywired.
e. Input power shall be 380/460 vac, ±10%,
3 Phase, 50/60 Hz, ±2% Hz.
Discrete Outputs:
115-v discrete contact outputs shall be provided
for:
a. Circuit breaker shunt trip
b. Chilled water pump
c. Condenser water pump
d. Alarm status
Analog Output:
An analog (4 to 20 mA) output for head pressure reference shall be provided. This signal
shall be suitable to control a 2-way or 3-way
water regulating valve in the condenser piping.
Protection (the following shall be supplied):
a. Under-voltage
b. Over voltage
c. Phase loss
d. Phase reversal
e. Ground fault
f. Phase unbalance protection
g. Single cycle voltage loss protection
h. Programmable auto re-start after loss of
power
i. Motor overload protection (NEMA Class 10)
j. Motor over temperature protection
11. VFD Testing:
The VFD shall be factory-mounted, factorywired and factory-tested on the chiller prior to
shipment.
E. Evaporator and Condenser:
1. Evaporator and condenser shall be of shell and
tube type construction, each in separate shells.
Units shall be fabricated with high-performance
tubing, steel shell and tube sheets with fabricated steel waterboxes. Waterboxes shall be
nozzle-in-head type with stub out nozzles having
Victaulic grooves to allow for use of Victaulic
couplings.
2. Tubing shall be copper, high-efficiency type,
with integral internal and external enhancement unless otherwise noted. Tubes shall be
nominal 3/4-in. OD with nominal wall thickness
of 0.025 in. measured at the root of the fin
unless otherwise noted. Tubes shall be rolled
into tube sheets and shall be individually
replaceable. Tube sheet holes shall be double
grooved for joint structural integrity. Intermediate support sheet spacing shall not exceed
36 in. (914 mm).
3. Waterboxes and nozzle connections shall be
designed for 150 psig (1034 kPa) minimum
working pressure unless otherwise noted.
Nozzles should have grooves to allow use of
Victaulic couplings.
4. The tube sheets of the cooler and condenser
shall be bolted together to allow for field disassembly and reassembly.
5. The vessel shall display an ASME nameplate
that shows the pressure and temperature data
and the “U” stamp for ASME Section VIII,
Division 1. A re-seating pressure relief valve(s)
shall be installed on each heat exchanger. If a
non-reseating type is used, a backup reseating
type shall be installed in series.
6. Waterboxes shall have vents, drains, and covers
to permit tube cleaning within the space shown
on the drawings. A thermistor type temperature
sensor with quick connects shall be factoryinstalled in each water nozzle.
7. Cooler shall be designed to prevent liquid refrigerant from entering the compressor. Devices
that introduce pressure losses (such as mist
eliminators) shall not be acceptable because
they are subject to structural failures that can
result in extensive compressor damage.
8. Tubes shall be individually replaceable from
either end of the heat exchanger without affecting the strength and durability of the tube sheet
and without causing leakage in adjacent tubes.
9. The condenser shell shall include a FLASC
(Flash Subcooler) which cools the condensed
27
Guide specifications (cont)
liquid refrigerant to a reduced temperature,
thereby increasing the refrigeration cycle
efficiency.
F. Refrigerant Flow Control:
To improve part load efficiency, liquid refrigerant
shall be metered from the condenser to the cooler
using a float-type metering valve to maintain the
proper liquid level of refrigerant in the heat
exchangers under both full and part load operating
conditions. By maintaining a liquid seal at the float
valve, bypassed hot gas from the condenser to the
cooler is eliminated.
G. Controls, Safeties, and Diagnostics:
1. Controls:
a. The chiller shall be provided with a factoryinstalled and factory-wired microprocessor
control center. The control center shall include
a 16-line by 40-character liquid crystal display,
4 function keys, stop button, and alarm light.
Other languages are available using the international language translator software.
b. All chiller and motor control monitoring shall
be displayed at the chiller control panel.
c. The controls shall make use of non-volatile
memory.
d. The chiller control system shall have the ability
to interface and communicate directly to the
building control system.
e. The default standard display screen shall simultaneously indicate the following minimum
information:
1) Date and time of day
2) 24-character primary system status
message
3) 24-character secondary status message
4) Chiller operating hours
5) Entering chilled water temperature
6) Leaving chilled water temperature
7) Evaporator refrigerant temperature
8) Entering condenser water temperature
9) Leaving condenser water temperature
10) Condenser refrigerant temperature
11) Oil supply pressure
12) Oil sump temperature
13) Percent motor rated load amps (RLA)
f. In addition to the default screen, status
screens shall be accessible to view the status
of every point monitored by the control
center including:
1) Evaporator pressure
2) Condenser pressure
3) Compressor speed
4) Bearing oil supply temperature
5) Compressor discharge temperature
6) Motor winding temperature
7) Number of compressor starts
8) Control point settings
9) Discrete output status of various devices
28
g.
h.
i.
j.
k.
10) Variable frequency drive status
11) Optional spare input channels
12) Line current and voltage for each phase
13) Frequency, kW, kWhr, demand kW
Schedule Function:
The chiller controls shall be configurable for
manual or automatic start-up and shutdown.
In automatic operation mode, the controls
shall be capable of automatically starting and
stopping the chiller according to a stored
user programmable occupancy schedule.
The controls shall include built-in provisions
for accepting:
1) A minimum of two 365-day occupancy
schedules.
2) Minimum of 8 separate occupied/unoccupied periods per day
3) Daylight savings start/end
4) 18 user-defined holidays
5) Means of configuring an occupancy
timed override
6) Chiller start-up and shutdown via remote
contact closure
Service Function:
The controls shall provide a password
protected service function which allows
authorized individuals to view an alarm
history file which shall contain the last
25 alarm/alert messages with time and date
stamp. These messages shall be displayed in
text form, not codes.
Network Window Function:
Each chiller control panel shall be capable of
viewing multiple point values and statuses
from other like controls connected on a
common network, including controller maintenance data. The operator shall be able to
alter the remote controller’s set points or
time schedule and to force point values or
statuses for those points that are operator
forcible. The control panel shall also have
access to the alarm history file of all like controllers connected on the network.
Pump Control:
Upon request to start the compressor, the
control system shall start the chilled and
condenser water pumps and shall verify that
flows have been established.
Ramp Loading:
A user-configurable ramp loading rate, effective during the chilled water temperature
pulldown period, shall prevent a rapid
increase in compressor power consumption.
The controls shall allow configuration of the
ramp loading rate in either degrees per minute of chilled water temperature pulldown or
percent motor amps per minute. During the
ramp loading period, a message shall be
displayed informing the operator that the
chiller is operating in ramp loading mode.
l. Chilled Water Reset:
The control center shall allow reset of the
chilled water temperature set point based on
any one of the following criteria:
1) Chilled water reset based on an external
4 to 20 mA signal.
2) Chilled water reset based on a remote
temperature sensor (such as outdoor
air).
3) Chilled water reset based on water temperature rise across the evaporator.
m. Demand Limit:
The control center shall limit amp draw of
the compressor to the rated load amps or to
a lower value based on one of the following
criteria:
1) Demand limit based on a user input
ranging from 40% to 100% of compressor rated load amps
2) Demand limit based on external 4 to
20 mA signal.
n. Controlled Compressor Shutdown:
The controls shall be capable of being
configured to soft stop the compressor. The
display shall indicate “shutdown in progress.”
2. Safeties:
a. Unit shall automatically shut down when any
of the following conditions occur (each of
these protective limits shall require manual
reset and cause an alarm message to be displayed on the control panel screen, informing the operator of the shutdown cause):
1) Motor overcurrent
2) Over voltage*
3) Under voltage*
4) Single cycle dropout*
5) Low oil sump temperature
6) Low evaporator refrigerant temperature
7) High condenser pressure
8) High motor temperature
9) High compressor discharge temperature
10) Low oil pressure
11) Prolonged stall
12) Loss of cooler water flow
13) Loss of condenser water flow
14) Variable frequency drive fault
15) High variable frequency drive temperature
* Shall not require manual reset or cause an
alarm if auto-restart after power failure is
enabled.
b. The control system shall detect conditions
that approach protective limits and take selfcorrective action prior to an alarm occurring. The system shall automatically reduce
chiller capacity when any of the following
parameters are outside their normal operating range:
1) High condenser pressure
2) High motor temperature
3) Low evaporator refrigerant temperature
4) High motor amps
5) High VFD rectifier temperature
6) High VFD inverter temperature
c. During the capacity override period, a prealarm (alert) message shall be displayed
informing the operator which condition is
causing the capacity override. Once the condition is again within acceptable limits, the
override condition shall be terminated and
the chiller shall revert to normal chilled
water control. If during either condition the
protective limit is reached, the chiller shall
shut down and a message shall be displayed
informing the operator which condition
caused the shutdown and alarm.
d. Internal built in safeties shall protect the
chiller from loss of water flow. Differential
pressure switches shall not be allowed to be
the only form of freeze protection.
3. Diagnostics and Service:
a. A self diagnostic controls test shall be an
integral part of the control system to allow
quick identification of malfunctioning
components.
b. Once the controls test has been initiated, all
pressure and temperature sensors shall be
checked to ensure they are within normal
operating range. A pump test shall automatically energize the chilled water pump, condenser water pump, and oil pump. The
control system shall confirm that water flow
and oil pressure have been established and
require operator confirmation before proceeding to the next test.
c. In addition to the automated controls test,
the controls shall provide a manual test
which permits selection and testing of individual control components and inputs. A
thermistor test and transducer test shall display on the ICVC screen the actual reading
of each transducer and each thermistor
installed on the chiller. All out-of-range sensors shall be identified. Pressure transducers
shall be serviceable without the need for
refrigerant charge removal or isolation.
4. Multiple Chiller Control:
The chiller controls shall be supplied as standard with a two-chiller lead/lag and a third
chiller standby system. The control system shall
automatically start and stop a lag or second
chiller on a two-chiller system. If one of the two
chillers on line goes into a fault mode, the third
standby chiller shall be automatically started.
The two-chiller lead/lag system shall allow
29
Guide specifications (cont)
H.
I.
J.
K.
L.
30
manual rotation of the lead chiller and a staggered restart of the chillers after a power failure. The lead/lag system shall include load
balancing if configured to do so.
Electrical Requirements:
1. Electrical contractor shall supply and install
main electrical power line, disconnect switches,
circuit breakers, and electrical protection
devices per local code requirements and as indicated necessary by the chiller manufacturer.
2. Electrical contractor shall wire the chilled water
pump and flow, condenser water pump and
flow, and tower fan control circuit to the chiller
control circuit.
3. Electrical contractor shall supply and install
electrical wiring and devices required to interface the chiller controls with the building control
system if applicable.
4. Electrical power shall be supplied to the unit at
the voltage, phase, and frequency listed in the
equipment schedule.
Piping Requirements — Instrumentation and Safeties:
1. Mechanical contractor shall supply and install
pressure gages in readily accessible locations in
piping adjacent to the chiller such that they can
be easily read from a standing position on the
floor. Scale range shall be such that design values shall be indicated at approximately midscale.
2. Gages shall be installed in the entering and leaving water lines of the cooler and condenser.
Vibration Isolation:
Chiller manufacturer shall furnish neoprene isolator
pads for mounting equipment on a level concrete
surface.
Start-Up:
1. The chiller manufacturer shall provide a factorytrained representative, employed by the chiller
manufacturer, to perform the start-up procedures as outlined in the Start-Up, Operation
and Maintenance manual provided by the
chiller manufacturer.
2. Manufacturer shall supply the following
literature:
a. Start-up, operation and maintenance
instructions.
b. Installation instructions.
c. Field wiring diagrams.
d. One complete set of certified drawings.
Special Features:
1. Soleplate Package:
Unit manufacturer shall furnish a soleplate
package consisting of soleplates, jacking
screws, leveling pads, and neoprene pads.
2. Spring Isolators:
Spring isolators shall be field furnished and
selected for the desired degree of isolation.
3. Spare Sensors with Leads:
Unit manufacturer shall furnish additional temperature sensors and leads.
4. Sound Insulation Kit:
Unit manufacturer shall furnish a sound insulation kit that covers the compressor housing,
motor housing, compressor discharge pipe,
suction line, evaporator, and economizer (if
equipped).
5. Stand-Alone Pumpout Unit:
A free-standing pumpout unit shall be provided.
The pumpout unit shall use a semi-hermetic
reciprocating compressor with liquid-cooled
condenser. Condenser liquid piping and
3-phase motor power shall be installed at the
jobsite by the installing contractor.
6. Separate Storage Tank and Pumpout Unit:
A free-standing refrigerant storage tank and
pumpout unit shall be provided. The storage
vessels shall be designed per ASME Section VIII
Division 1 code with 150 psig (1034 kPa)
design pressure. Double relief valves per ANSI/
ASHRAE 15, latest edition, shall be provided.
The tank shall include a liquid level gage and
pressure gage. The pumpout shall use a
hermetic reciprocating compressor with watercooled condenser. Condenser water piping and
3-phase motor power shall be installed at the
jobsite by the installing contractor.
7. Building Control System Interface (LON):
The chiller control system shall have the ability
to interface and communicate directly to the
building control using a LON based system. The
LonWorks Carrier Translator shall output data
in standard LON profiles.
8. Refrigerant Charge:
The chiller shall ship from the factory fully
charged with R-134a refrigerant and oil.
9. Thermal Insulation:
Unit manufacturer shall insulate the cooler
shell, economizer, suction elbow, motor shell
and motor cooling lines. Insulation shall be 1 in.
(25.4 mm) thick with a thermal conductivity not
exceeding
0.28
(Btu · in.)
hr. Ft2 F
( 0.0404
W
mC
)
and shall conform to UL standard 94, classification 94 HF-1.
10. Automatic Hot Gas Bypass:
Hot gas bypass valve and piping shall be
factory-furnished to permit chiller operation for
extended periods of time.
11. Cooler and Condenser Tubes:
Contact a local Carrier Representative for other
tube offerings.
12. Cooler and Condenser Passes:
Unit manufacturer shall provide the cooler and/
or condenser with 1, 2 or 3 pass configuration
on the water side.
13. Nozzle-In-Head, 300 psig (2068 kPa):
Unit manufacturer shall furnish nozzle-in-head
style waterboxes on the cooler and/or condenser rated at 300 psig (2068 kPa).
14. Marine Waterboxes:
Unit manufacturer shall furnish marine style
waterboxes on cooler and/or condenser rated
at 150 psig (1034 kPA).
15. Marine Waterboxes:
Unit manufacturer shall furnish marine style
waterboxes on cooler and/or condenser rated
at 300 psig (2068 kPA).
16. Flanged Water Nozzles:
Unit manufacturer shall furnish standard
flanged piping connections on the cooler and/
or condenser.
17. Hinges:
Unit manufacturer shall furnish hinges on
waterboxes to facilitate tube cleaning.
18. Optional Compressor Discharge Isolation Valve
and Liquid Line Ball Valve:
These items shall be factory-installed to allow
isolation of the refrigerant charge in the condenser for servicing the compressor.
19. Pumpout Unit:
A refrigerant pumpout system shall be installed
on the chiller. The pumpout system shall
include a hermetic compressor and drive, internal piping, internal wiring, and motor. Fieldsupplied main power wiring and water piping
shall be required.
20. BACnet Communication Option:
Shall provide factory installed communication
capability with a BACnet MS/TP network.
Allows integration with i-Vu® Open control system or a BACnet building automation system.
31
Carrier Corporation • Syracuse, New York 13221
5-10
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Section 9
Pg 32
Catalog No. 04-52230002-01
Printed in U.S.A.
Form 23XRV-3PD
Replaces: 23XRV-2PD
Tab
9a
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