Carrier 23XRV High-Efficiency Variable Speed Screw Chiller Chiller Installation Instructions
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Publicitate
EVERGREEN®
23XRV High-Efficiency Variable Speed Screw Chiller with FOXFIRE™ Compression Technology and PIC III Controls
50/60 Hz
HFC-134a
Installation Instructions
SAFETY CONSIDERATIONS
Screw liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.
Be sure you understand and follow the procedures and safety precautions contained in the machine instructions, as well as those listed in this guide.
DANGER
Failure to follow these procedures will result in severe personal injury or death.
DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/
ASHRAE 15 (American National Standards Institute/
American Society of Heating, Refrigerating, and Air Conditioning Engineers). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.
PROVIDE adequate ventilation in accordance with ANSI/
ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Intentional misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.
DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.
DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.
NEVER EXCEED specified test pressures, VERIFY the allowable test pressure by checking the instruction literature and the design pressures on the equipment nameplate.
DO NOT VALVE OFF any safety device.
BE SURE that all pressure relief devices are properly installed and functioning before operating any machine.
RISK OF INJURY OR DEATH by electrocution. High (or medium) voltage is present on motor leads even though the motor is not running. Open the power supply disconnect before touching motor leads or terminals.
WARNING
Failure to follow these procedures may result in personal injury or death.
DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles and proceed as follows: a. Shut off electrical power to unit.
b. Recover refrigerant to relieve all pressure from system using both high-pressure and low pressure ports.
c. Traces of vapor should be displaced with nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.
d. Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gage for how much oil to add to the system.
e. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame.
DO NOT USE eyebolts or eyebolt holes to rig heat exchangers or the entire assembly.
DO NOT work on high (or medium) voltage equipment unless you are a qualified electrician.
DO NOT WORK ON electrical components, including control panels, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid-state components.
LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.
NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.
DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLE-
GAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT INCINERATE.
CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The introduction of the wrong refrigerant can cause machine damage or malfunction.
(Warnings continued on next page.)
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230006-01 Printed in U.S.A.
Form 23XRV-3SI Pg 1 8-12 Replaces: 23XRV-2SI
WARNING
Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE 15
(latest edition). Contact Carrier for further information on use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc., while machine is under pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief valve when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the valve.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.
CAUTION
Failure to follow these procedures may result in damage to equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components.
Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements
CAN ENGAGE THE STARTER, TOWER FAN, OR
PUMPS. Open the disconnect ahead of the starter, tower fan, and pumps. Shut off the machine or pump before servicing equipment.
USE only repaired or replacement parts that meet the code requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.
DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.
DO NOT re-use compressor oil or any oil that has been exposed to the atmosphere. Dispose of oil per local codes and regulations.
DO NOT leave refrigerant system open to air any longer than the actual time required to service the equipment. Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed.
2
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1,2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Job Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Step 1 —
Receive the Machine . . . . . . . . . . . . . . . . . . 3
Step 2 —
Rig the Machine . . . . . . . . . . . . . . . . . . . . . . . 8
Step 3 —
Separate Machine Components . . . . . . 17
• SEPARATE COOLER AND CONDENSER
• REMOVE THE CONTROLS/DRIVE ENCLOSURE
• REMOVE THE DISCHARGE PIPE ASSEMBLY
• SEPARATE THE COMPRESSOR FROM THE
• SEPARATE THE VAPORIZER FROM THE
Step 4 —
Install VFD. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Step 5 —
Install Machine Supports . . . . . . . . . . . . . 26
Step 6 —
Connect Piping . . . . . . . . . . . . . . . . . . . . . . . 28
• INSTALL WATER PIPING TO HEAT
• INSTALL VENT PIPING TO RELIEF VALVES
Step 7 —
Make Electrical Connections . . . . . . . . . 35
• GROUNDING THE CONTROLS/DRIVE
• INSTALLING INPUT POWER WIRING
• WIRING THE FIELD WIRING TERMINAL STRIPS
COMPLETING THE INSTALLATION . . . . . . . . . . . 49-56
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 49
Oil Pump and Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connect Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 49
Interface . . . . . . . . . . . . . 49
BACnet Communications Option Wiring. . . . . . . . . 50
Lead-Lag Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . 50
Install Field Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2
INTRODUCTION
General —
The 23XRV machine is factory assembled, wired, and leak tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. The rigging, installation, field wiring, field piping, and insulation of waterbox covers are the responsibility of the contractor and/or customer. Carrier has no installation responsibilities for the equipment.
Job Data —
Necessary information consists of:
• job contract or specifications
• machine location prints
• rigging information
• piping prints and details
• field wiring drawings
• starter manufacturer’s installation details
• Carrier certified print
INSTALLATION
Step 1 — Receive the Machine
INSPECT SHIPMENT
CAUTION
Do not open any valves or loosen any connections. The
23XRV machine may be shipped with a full refrigerant charge. Some machines may be shipped with a nitrogen holding charge as an option.
1. Inspect for shipping damage while machine is still on shipping conveyance. If machine appears to be damaged or has been torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufac-
turer is not responsible for any damage incurred in transit.
2. Check all items against shipping list. Immediately notify the nearest Carrier representative if any item is missing.
3. To prevent loss or damage, leave all parts in original packages until beginning installation. All openings are closed with covers or plugs to prevent dirt and debris from entering machine components during shipping. A full operating oil charge is placed in the oil sump before shipment.
IDENTIFY MACHINE (Fig. 1-4B) — Refer to machine nameplate in Fig. 1. The machine model number, serial number, and heat exchanger sizes are stamped on the Refrigeration
Machine nameplate located on the side of the VFD (variable frequency drive) enclosure. Check this information against shipping papers and jobdrive) enclosure. Check this information against shipping papers and job data.
23XRV – High Efficiency
Variable Speed Screw Chiller
Cooler Size*
30-32
35-37
40-42
45-47
50-52
55-57
Condenser Size*
30-32
35-37
40-42
45-47
50-52
55-57
Economizer Option
E – With Economizer
N – No Economizer
Compressor Code
Q†
R
a23-1547
Fig. 1 — Refrigeration Machine Nameplate
23XRV 40 42 N R V AA 5 0 S
S – Special
Compressor Option
0 – Full Load Optimized
1 – Part Load Optimized
Voltage Code
3 – 380-3-60
4 – 416-3-60
5 – 460-3-60
9 – 380/415-3-50
Drive Code**
AA – LF-2, 440 Amps In, 442 Amps Out
BA – LF-2, 520 Amps In, 442 Amps Out
R3 – Std Tier, 335 Amps In, 335 Amps Out
R4 – Std Tier, 445 Amps In, 445 Amps Out
Motor Code
P T
Q U
R V
S
* First number denotes frame size.
† Only type V motors are used with Q compressors.
**Maximum limits only. Additional application limits apply that may
reduce these ampacities.
a23-1654
Fig. 2 — Model Number Identification
3
Identifying Drive by Part Number — The LiquiFlo™ 2.0
(LF-2) AC drive can be identified by its part number (Fig. 5).
This number appears on the shipping label and on VFD nameplate.
Drive Input Component Location — Figure 6A identifies the control center components for the LF-2 VFD. Figure 6B identifies the control center components for the Std Tier VFD.
Identifying Power Module by ID Number — Each LiquiFlo 2.0
AC power module can be identified by its ID number. See Fig. 5.
This number appears on the shipping label and on the power module’s nameplate. Power ratings for LF-2 VFDs are provided in Table 1A. Power ratings for Std Tier VFDs are provided in
Table 1B.
INSTALLATION REQUIREMENTS — Certain installation requirements should be checked before continuing with the chiller’s electrical installation. Input power wire sizes, branch circuit protection, and control wiring are all areas that need to be evaluated.
Determining Wire Size Requirements — Wire size should be determined based on the size of the conduit openings, and applicable local, national, and international codes (e.g., NEC
[National Electric Code]/CEC [California Energy Commission] regulations). General recommendations are included in the Carrier field wiring drawing.
Conduit Entry Size — It is important to determine the size of the conduit openings in the enclosure power entry plate so that the wire planned for a specific entry point will fit through the opening. Do NOT punch holes or drill into the top surface of the control center enclosure for field wiring. Do not punch holes or drill into the top surface of the control center enclosure for field wiring. Knockouts are provided in the back of the control center for field control wiring connections.
Recommended Control and Signal Wire Sizes — The recommended minimum size wire to connect I/O signals to the control terminal blocks is 18 AWG (American Wire Gage).
Recommended terminal tightening torque is 7 to 9 in.-lb
(0.79 to 1.02 N-m).
Recommended Airflow Clearances — Be sure there is adequate clearance for air circulation around the enclosure.
A 6-in. (152.4 mm) minimum clearance is required wherever vents are located in the VFD enclosure.
Match Power Module Input and Supply Power Ratings — It is important to verify that building power will meet the input power requirements of the Machine Electrical Data nameplate input power rating. Be sure the input power to the chiller corresponds to the chiller’s nameplate voltage, current, and frequency. Refer to machine nameplate in Fig. 7. The machine electrical data nameplate is located on the right side of the control center.
PROVIDE MACHINE PROTECTION — Protect machine and VFD enclosure from construction dirt and moisture. Keep protective shipping covers in place until machine is ready for installation.
If machine is exposed to freezing temperatures after water circuits have been installed, open waterbox drains and remove all water from cooler and condenser. Leave drains open until system is filled.
It is important to properly plan before installing a 23XRV unit to ensure that the environment and operating conditions are satisfactory. The installation must comply with all requirements in the certified prints.
Chiller should be installed in an indoor environment where the ambient temperature is between 40 and 104 F (4 and 40 C) with relative humidity of 95% or less.
4
19
20
21
1
2
3
4
46
47
5
18
17
16
15
14
13
12
10
11
22
23
24
25
26
8
9
7
6
41
40
39
38 37
36
35 34
33
32
31
30
42
43
44
45
29
28
27
1 — Motor Terminal Cover Plate
2 — Variable Frequency Drive
3 — International Chiller Visual Controller (ICVC)
4 — Discharge Pipe Relief Valve
5 — Condenser
6 — Oil Reclaim Actuator
7 — Vaporizer Sight Glass
8 — Oil Filter Assembly (Hidden)
9 — Vaporizer
10 — Oil Charging/Drain Valve
11 — Oil Sump
12 — Condenser Refrigerant Pumpout Valve
13 — Condenser Float Chamber
14 — Cooler Inlet Isolation Valve
15 — ASME Nameplate, Economizer (Hidden)
16 — Filter Drier
17 — Oil Sump Heater
18 — Condenser Supply/Return End Waterbox
19 — Cooler Supply/Return End Waterbox
20 — Motor Cooling Supply Line
21 — VFD Disconnect a23-1658
22 — Discharge Pipe
23 — Compressor Discharge Check Valve Access Cover
24 — Condenser Relief Valves
25 — Refrigerant Charging Valve
26 — Cooler Relief Valve
27 — Tubesheet Mounting Brackets
28 — Typical Waterbox Drain Coupling
29 — ASME Nameplate, Condenser
30 — Oil Pump
31 — Oil Pump Inlet Strainer
32 — Strainer Housing Sight Glass
33 — Discharge Isolation Valve (Option or Accessory)
34 — Refrigeration Machine Nameplate
35 — Machine Electrical Data Nameplate
36 — Oil Sump Sight Glass
37 — Filter Drier Isolation Valve with Schrader Valve
38 — Economizer
39 — Motor Cooling Sight Glass
40 — Motor Cooling Isolation Valve
41 — Vaporizer Drain Sight Glass a23-1659
42 — VFD Cold Plate Refrigeration Inlet Connection
(Outlet Hidden)
43 — VFD Cold Plate Solenoid
44 — Compressor Nameplate
45 — Compressor Lubrication Block
46 — Economizer Muffler
47 — Vaporizer Condenser Gas Isolation Valve
48 — Hot Gas Bypass Isolation and Trim Valve
49 — VFD Cooling Refrigerant Strainer
50 — Cooler Refrigerant Pumpout Valve
51 — ASME Nameplate, Cooler
48
50
49 a23-1660
51
Fig. 3A — Typical 23XRV Components (Units with Q Compressor)
5
19
20
21
1
2 3
4
5
18
17
16
15
14
13
10
12
11
7
8
6
9
22
23
24
25
26
41
40
39
38
37
36
35 34
33
32
31
30
45
29
42
43
44
46
47
28
27
1 — Motor Terminal Cover Plate
2 — Variable Frequency Drive
3 — International Chiller Visual Controller (ICVC)
4 — Discharge Pipe Relief Valve
5 — Condenser
6 — Oil Reclaim Actuator
7 — Vaporizer Sight Glass
8 — Oil Filter Assembly (Hidden)
9 — Vaporizer
10 — Oil Charging/Drain Valve
11 — Oil Sump
12 — Condenser Refrigerant Pumpout Valve
13 — Condenser Float Chamber
14 — Cooler Inlet Isolation Valve
15 — ASME Nameplate, Economizer (Hidden)
16 — Filter Drier
17 — Oil Sump Heater
18 — Condenser Supply/Return End Waterbox
19 — Cooler Supply/Return End Waterbox
20 — Motor Cooling Supply Line
21 — VFD Disconnect a23-1548
22 — Discharge Pipe
23 — Compressor Discharge Check Valve Access Cover
24 — Condenser Relief Valves
25 — Refrigerant Charging Valve
26 — Cooler Relief Valve
27 — Tubesheet Mounting Brackets
28 — Typical Waterbox Drain Coupling
29 — ASME Nameplate, Condenser
30 — Oil Pump
31 — Oil Pump Inlet Strainer
32 — Strainer Housing Sight Glass
33 — Discharge Isolation Valve (Option or Accessory)
34 — Refrigeration Machine Nameplate
35 — Machine Electrical Data Nameplate
36 — Oil Sump Sight Glass
37 — Filter Drier Isolation Valve with Schrader Valve
38 — Economizer
39 — Motor Cooling Sight Glass
40 — Motor Cooling Isolation Valve
41 — Vaporizer Drain Sight Glass a23-1549
42 — VFD Cold Plate Refrigeration Inlet Connection
(Outlet Hidden)
43 — VFD Cold Plate Solenoid
44 — Compressor Nameplate
45 — Compressor Lubrication Block
46 — Economizer Muffler
47 — Vaporizer Condenser Gas Isolation Valve
48 — Hot Gas Bypass Isolation and Trim Valve
49 — VFD Cooling Refrigerant Strainer
50 — Cooler Refrigerant Pumpout Valve
51 — ASME Nameplate, Cooler
48
49
50 a23-1550
51
Fig. 3B — Typical 23XRV Components (Units with R Compressor)
6
1
2
3
4
5
6
1 — Condenser Pressure
2 — Evaporator Pressure
3 — Compressor Discharge Temperature
4 — Compressor Discharge Pressure
5 — Compressor Discharge High Pressure Switch
6 — Compressor Motor Winding Temperature (Hidden)
7 — Evaporator Refrigerant Liquid Temperature (Hidden)
8 — Condenser Liquid Temperature
9 — Condenser Liquid Flow (Optional)
9 a23-1661
7
8
20
19
10
18
11
12
13
14
15
10 — Inductor Temperature Switch (Inside VFD Enclosure)
11 — VFD Rectifier Temperature (Inside Power Module)
12 — VFD Cold Plate Temperature (Inside VFD Enclosure)
13 — VFD Inverter Temperature (Inside Power Module)
14 — Humidity Sensor (Inside VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
20 — Evaporator Liquid Flow (Optional)
16
17 a23-1662
Fig. 4A — Typical 23XRV Installation — Sensor Locations (Units with Q Compressor)
7
1
2
3
4
5
6
1 — Condenser Pressure
2 — Evaporator Pressure
3 — Compressor Discharge Temperature
4 — Compressor Discharge Pressure
5 — Compressor Discharge High Pressure Switch
6 — Compressor Motor Winding Temperature (Hidden)
7 — Evaporator Refrigerant Liquid Temperature (Hidden)
8 — Condenser Liquid Temperature
9 — Condenser Liquid Flow (Optional)
9
8
10 11
12 13
7
14 a23-1551
10 — Inductor Temperature Switch (Inside VFD Enclosure)
11 — VFD Rectifier Temperature (Inside Power Module)
12 — VFD Cold Plate Temperature (Inside VFD Enclosure)
13 — VFD Inverter Temperature (Inside Power Module)
14 — Humidity Sensor (Inside VFD Enclosure)
15 — Oil Pressure Leaving Filter (Hidden)
16 — Oil Sump Pressure (Hidden)
17 — Oil Sump Temperature (Hidden)
18 — Vaporizer Temperature
19 — Evaporator Liquid Temperature
20 — Evaporator Liquid Flow (Optional)
15
20
16 a23-1552
17
19
18
Fig. 4B — Typical 23XRV Installation — Sensor Locations (Units with R Compressor)
RIG MACHINE ASSEMBLY — See rigging instructions on label attached to machine. Also refer to rigging guide (Fig. 8), physical data in Fig. 9, and Tables 2-10B. Lift machine only
from the points indicated in rigging guide. Each lifting cable or chain must be capable of supporting the entire weight of the machine.
Fig. 5 — VFD Nameplate
Step 2 — Rig the Machine —
a23-1553
The 23XRV machine can be rigged as an entire assembly. Large interconnecting piping has flanged connections that allow the compressor, cooler, and condenser sections to be separated and rigged individually.
In addition, the VFD can be removed and rigged separately.
WARNING
Lifting machine from points other than those specified may result in serious damage to the unit and personal injury.
Rigging equipment and procedures must be adequate for machine weight. See Fig. 8 for machine weights.
NOTE: These weights are broken down into component sections for use when installing the unit in sections. For the complete machine weight, add all component sections and refrigerant charge together. See Tables 5-10B for machine component weights.
Contractors are not authorized to disassemble any part of the chiller without Carrier's supervision. Any request otherwise must be in writing from the Carrier Service Manager.
NOTE: Carrier suggests that a structural engineer be consulted if transmission of vibrations from mechanical equipment is of concern.
8
9 a23-1651
10
1 2
3
9
8
7
FRONT VIEW – DOORS REMOVED
6
5
LEGEND
1
— Input Circuit Breaker
2
— Power Module
3
— Control Relays (CR1 - CR6)
4
— Control Fuses
5
— Drive Status Indicator
6
— Ground Lug
7
— 120V Control Transformer
8
— 120V Vaporizer Heater Transformer
9
— 15 Amp Control Circuit Breaker
10
— Cooling Fan
Fig. 6B — Control Center Components (Std Tier VFD)
RIGHT SIDEWALL
INSIDE VIEW a23-1670
4 a23-1555
Fig. 7 — Machine Electrical Data Nameplate
10
Table 1A — Drive Assembly and Power Module Ratings (LF-2 VFD)
CARRIER PART NUMBER FRAME SIZE
ENCLOSURE
TYPE
23XRA2AA_ _ _ _ _ _ _ _ _ _ _
23XRA2BA_ _ _ _ _ _ _ _ _ _ _
23XRA2BB_ _ _ _ _ _ _ _ _ _ _
23XRA2CC_ _ _ _ _ _ _ _ _ _ _
Frame 2AA
Frame 2BA
Frame 2BB
Frame 2CC
NEMA 1
NEMA 1
NEMA 1
NEMA 1
*110% output current capability for one minute, 150% output current for 5 seconds.
INPUT
VOLTAGE (V)
RANGE
380 to 460
380 to 460
380 to 460
380 to 460
MAX INPUT
CURRENT
(AMPS)
440
520
520
608
MAX OUTPUT
CURRENT* at 4kHZ
(AMPS)
442
442
520
608
Table 1B — Drive Assembly and Power Module Ratings (Std Tier VFD)*
CARRIER PART NUMBER
23XVR0_ _ _00Y _ _ F0
(R = Rockwell)
23XVE0_ _ _00Y _ _ F0
(E = Eaton)
ENCLOSURE
TYPE
NEMA 1
(Digit Y of part number)
Y
3
4
5
7
9
INPUT VOLTAGE
Voltage/Hz
380v / 50 Hz
416v / 60 Hz
416v / 60 Hz
575v / 60 Hz
400v / 50 Hz
MAX INPUT
CURRENT
(AMPS)
230
335
445
485
550
605
MAX OUTPUT
CURRENT† at 2kHZ
(AMPS)
230
335
445
485
550
605
*All voltage and current combinations listed may not be available for sale. Please review Carrier Marketing literature for latest offering.
†110% output current capability for one minute, 150% output current for 5 seconds.
COMPRESSOR
TYPE*
HEAT EXHANGER
CODE
MAXIMUM WEIGHT
(lb)
VESSEL
LENGTH
Q
R
30-32
35-37
40-42
45-47
50-52
55-57
30-32
35-37
40-42
45-47
50-52
55-57
17,962
19,501
21,032
22,468
23,856
25,642
19,187
20,589
23,928
25,167
26,950
28,479
12 c
14 c
12 c
14 c
12 c
14 c
12 c
14 c
12 c
14 c
12 c
14 c
*The 11th character of the chiller model number indicates the compressor type.
DIM.
“A”
6 c-10s
7 c- 8s
6 c-10s
7 c- 8s
6 c-10s
7 c- 8s
6 c-10s
7 c- 8s
6 c-10s
7 c- 8s
6 c-10s
7 c- 8s
“B”
13 c- 5s
13 c-10s
13 c- 6s
13 c-11s
13 c-10s
14 c- 4s
13 c- 5s
13 c-10s
13 c- 6s
13 c-11s
13 c-10s
14 c- 4s
CHAIN LENGTH
“C”
13 c-0s
13 c-5s
12 c-8s
13 c-2s
12 c-7s
13 c-1s
13 c-0s
13 c-5s
12 c-8s
13 c-2s
12 c-7s
13 c-1s
“D”
12 c- 5s
12 c-10s
12 c- 3s
12 c- 8s
12 c- 9s
13 c- 1s
12 c- 5s
12 c-10s
12 c- 3s
12 c- 8s
12 c- 9s
13 c- 1s
DIM.
“E”
3 c-11s
3 c-11s
4 c- 1s
4 c- 1s
4 c- 0s
4 c- 0s
3 c-11s
3 c-11s
4 c- 1s
4 c- 1s
4 c- 0s
4 c- 0s
DIM.
“F”
3 c- 8s
3 c- 8s
3 c-11s
3 c-11s
4 c- 4s
4 c- 4s
3 c- 8s
3 c- 8s
3 c-11s
3 c-11s
4 c- 4s
4 c- 4s
CHAIN “B”
(SEE NOTE #2)
CHAIN “C”
(SEE NOTE #2) a23-1665
CHAIN “D”
(SEE NOTE #2)
CHAIN “B”
(SEE NOTE #2)
CHAIN “C”
(SEE NOTE #2) a23-1556
15´-0´´
MIN. HEIGHT
ABOVE FLOOR
CHAIN “D”
(SEE NOTE #2)
15´-0´´
MIN. HEIGHT
ABOVE FLOOR
“E”
“E”
“A”
“A”
“F”
“F”
UNITS WITH Q COMPRESSOR
UNITS WITH R COMPRESSOR
NOTES:
1. Each chain must be capable of supporting the entire weight of the machine. See chart for maximum weights.
2. Chain lengths shown are typical for 15 c lifting height. Some minor adjustments may be required.
Fig. 8 — Machine Rigging Guide (Cooler Size 30 Through 57)
11
TUBE REMOVAL
SPACE FOR
EITHER END
SIZES 30-32, 40-42,
50-52
12’-7½” (3848 mm)
SIZES 35-37, 45-47,
55-57
14’-4” (4369 mm)
MOTOR SERVICE
CLEARANCE
1’ - 10” (559 mm)
FRAME R COMPRESSOR 3’ - 0” (915mm)
RECOMMENDED OVERHEAD SERVICE CLEARANCE
C
0’-3”
4’-10”
0’-3”
0’-5”
2’ MIN
(610 mm)
A
B
(WIDEST POINT) a23-1557
SERVICE AREA 4’ - 10” MIN
(1219 mm)
Fig. 9 — 23XRV Dimensions (Unit with R Compressor shown)
HEAT EXCHANGER
SIZE
30 to 32
35 to 37
40 to 42
45 to 47
50 to 52
55 to 57
Table 2 — 23XRV Dimensions (Nozzle-In-Head Waterbox) ft-in.
14- 3 1 /
4
15-11 3 /
4
14- 9
16- 5
14-10
16- 6
1
1
/
/
A (Length, with Nozzle-in-Head Waterbox)
1 Pass 2-Pass* 3 Pass†
2
2
mm
4350
4870
4496
5017
4521
5042
ft-in.
13- 8 1 /
15- 4 3 /
14- 3 1 /
4
4
8
15-11 5 /
8
14- 4 1 /
2
16- 1
mm
4172
4693
4347
4867
4382
4902
ft-in.
14- 3 1 /
15-11 3 /
4
14- 6
16- 2 1
14- 6 1 /
16- 3
/
4
2
2
mm
4350
4870
4420
4940
4432
4953
B (Width) ft-in.
6- 4
6- 4
6- 8½
6- 8½
6-11 3 /
4
6-11 3 /
4
mm
1930
1930
2045
2045
2127
2127
*Assumes both cooler and condenser nozzles on same end of chiller.
†1 or 3 pass length applies if either (or both) cooler or condenser 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 frame R compressor.
3. Certified drawings available upon request.
4. Marine waterboxes may add 6 in. to the width of the machine. See certified drawings for details.
5. ‘A’ length dimensions shown are for standard 150 psig design and victaulic connections. The 300 psig design and/or flanges will add length. See certified drawings.
6. Dished head waterbox covers not available for 3 pass design.
Table 3 — 23XRV Dimensions (Marine Waterbox)
C (Height) ft-in.
7-2 5 /
8
7-2 5 /
8
7-6½
7-6½
7-6 3 /
4
7-6 3 /
4
mm
2200
2200
2299
2299
2305
2305
HEAT EXCHANGER
SIZE
30 to 32
35 to 37
40 to 42
45 to 47
50 to 52
55 to 57
A (Length, Marine Waterbox — not shown)
2-Pass* 1 or 3 Pass† ft-in.
mm ft-in.
mm
14- 9
16- 5
17- 0
1
15- 2 3 /
16-11 1 /
15- 3 1 /
/
2
4
4
2
4496
5017
4642
5163
4661
5182
16-4 3 /
4
18-1 1 /
4
16-8 1 /
4
18-4 3 /
4
16-8 1 /
2
18-5
4997
5518
5086
5607
5093
5613
ft-in.
6-9 3 /
8
6-9 3 /
8
6-9 3 /
4
6-9 3 /
4
7-1
7-1
MAXIMUM
B WIDTH mm
2067
2067
2076
2076
2159
2159
ft-in.
7-2 5 /
8
7-2 5 /
8
7-6 1 /
2
7-6 1 /
2
7-6 3 /
4
7-6 3 /
4
MAXIMUM
C HEIGHT mm
2200
2200
2299
2299
2305
2305
*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 frame R compressor.
3. Certified drawings available upon request.
4. Marine waterboxes may add 6 in. to the width of the machine. See certified drawings for details.
5. ‘A’ length and ‘B’ width dimensions shown are for standard 150 psig design and victaulic connections. The 300 psig design and/or flanges will add length. See certified drawings.
12
FRAME
SIZE
3
4
5
PRESSURE psig (kPa)
150/300
(1034/2068)
150/300
(1034/2068)
150/300
(1034/2068)
3
1
1
2
2
3
1
2
3
Table 4 — 23XRV Waterbox Nozzle Sizes
PASS
NOMINAL PIPE SIZE (in.)
Cooler
10
Condenser
10
10
8
8
6
8
6
10
8
6
10
8
6
6
10
10
8
COMPONENT
Table 6 — 23XRV Maximum Component Weights*
Isolation Valves
Suction Elbow
Discharge Elbow/
Muffler
Q Compressor
R Compressor
Q Compressor
R Compressor
Control Center/VFD (LF-2)
Control Center/VFD (Std Tier)
Vaporizer and Oil Sump
Economizer
LEGEND
VFD
— Variable Frequency Drive
*To determine compressor frame size, refer to Fig. 2.
159
179
597
747
FRAME 3 HEAT
EXCHANGER lb
70
kg
32
72
81
271
339
1650
1029
700
542
749
467
318
246
187
237
597
747
FRAME 4 HEAT
EXCHANGER lb
70
kg
32
85
108
271
339
1650
1029
700
542
749
467
318
246
ACTUAL PIPE ID (in.)
Cooler
10.020
Condenser
10.020
7.981
6.065
10.020
7.981
7.981
6.065
10.020
7.981
6.065
10.020
7.981
6.065
6.065
10.020
10.020
7.981
Table 5 — 23XRV Compressor and Motor Weights
ENGLISH
COMPRESSOR
TYPE
Q
R
MOTOR
SIZE
V
P,Q,R,S,T,
U,V
Total
Compressor
Weight
(lb)
4090
4866
Stator
Weight
(lb)
370
441
Rotor
Weight
(lb)
193
229
Motor
Terminal
Cover
(lb)
39
46
Total
Compressor
Weight
(kg)
1855
2207
Stator
Weight
(kg)
168
200
SI
Rotor
Weight
(kg)
88
104
Motor
Terminal
Cover
(kg)
18
21
FRAME 5 HEAT
EXCHANGER lb
115
kg
52
184
232
597
747
83
105
271
339
1650
1029
700
542
749
467
318
246
13
Table 7 — 23XRV Heat Exchanger Data
ENGLISH SI
Dry Rigging Weight
(lb)*
Machine Charge
Dry Rigging Weight
(kg)*
Machine Charge
CODE
36
37
40
41
30
31
32
35
50
51
52
55
42
45
46
47
Cooler
Only
4148
4330
4522
4419
4627
4845
5008
5178
5326
5463
5659
5830
5827
6053
6196
6370
Condenser
Only
3617
3818
4023
4529
4758
4992
4962
5155
5347
5525
5747
5967
6013
6206
6387
6708
Refrigerant
Weight (lb)
With
Economizer
Without
Economizer
800
800
800
910
910
910
900
900
900
1015
1015
1015
1250
1250
1250
1430
650
650
650
760
760
760
750
750
750
865
865
865
1100
1100
1100
1280
Liquid Weight
Cooler
464
531
601
511
587
667
863
930
990
938
1014
1083
1101
1192
1248
1201
(lb)
Condenser
464
542
621
513
602
692
915
995
1074
998
1088
1179
1225
1304
1379
1339
Cooler
Only
1877
1959
2046
2000
2094
2193
2675
2758
2832
2882
2976
3061
3182
3294
3364
3429
Condenser
Only
1676
1769
1860
2089
2195
2299
2746
2839
2932
3001
3108
3214
3304
3397
3485
3620
363
363
363
413
413
413
408
408
408
460
460
460
567
567
567
649
56
57
6631
6795
6930
7138
1430
1430
1280
1280
1304
1369
1429
1514
3556
3636
3726
3826
649
649
*Rigging weights are for standard tubes of standard wall thickness (Turbo-B3 and Spikefin 2, 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 stub-out, 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.
Refrigerant
Weight (kg)
With
Economizer
Without
Economizer
295
295
295
345
345
345
340
340
340
392
392
392
499
499
499
581
581
581
Weight (kg)
Cooler
210
241
273
232
266
303
391
422
449
425
460
491
499
541
566
545
591
621
Liquid
Condenser
210
246
282
233
273
314
415
451
487
453
494
535
556
591
626
607
648
687
Table 8 — 23XRV Additional Data for Cooler Marine Waterboxes*
HEAT EXCHANGER
FRAME, PASS
FRAME 3, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 3, 2 PASS, 150 psig (1034 kPa)
FRAME 4, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 4, 2 PASS, 150 psig (1034 kPa)
FRAME 5, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 5, 2 PASS, 150 psig (1034 kPa)
FRAME 3, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 3, 2 PASS, 300 psig (2068 kPa)
FRAME 4, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 4, 2 PASS, 300 psig (2068 kPa)
FRAME 5, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 5, 2 PASS, 300 psig (2068 kPa)
Rigging Weight
(lb) (see Note 2)
ENGLISH
Water Volume
(gal)
730
365
1888
944
2445
1223
860
430
2162
1552
2655
1965
84
42
109
54
122
61
84
42
109
47
122
53
*Add to heat exchanger data for total weights or volumes.
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame size.
2. For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volume).
Rigging Weight
(kg) (see Note 2)
331
166
856
428
1109
555
390
195
981
704
1204
891
SI
Table 9 — 23XRV Additional Data for Condenser Marine Waterboxes*
HEAT EXCHANGER
FRAME, PASS
FRAME 3, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 3, 2 PASS, 150 psig (1034 kPa)
FRAME 4, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 4, 2 PASS, 150 psig (1034 kPa)
FRAME 5, 1 AND 3 PASS, 150 psig (1034 kPa)
FRAME 5, 2 PASS, 150 psig (1034 kPa)
FRAME 3, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 3, 2 PASS, 300 psig (2068 kPa)
Rigging Weight
(lb) (see Note 2)
ENGLISH
N/A
365
N/A
989
N/A
1195
N/A
430
Water Volume
(gal)
N/A
42
N/A
54
N/A
60
N/A
42
FRAME 4, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 4, 2 PASS, 300 psig (2068 kPa)
FRAME 5, 1 AND 3 PASS, 300 psig (2068 kPa)
FRAME 5, 2 PASS, 300 psig (2068 kPa)
*Add to heat exchanger data for total weights or volumes.
N/A
1641
N/A
1909
N/A
47
N/A
50
NOTES:
1. Weight adder shown is the same for cooler and condenser of equal frame size.
2. For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volume).
Rigging Weight
(kg) (see Note 2)
N/A
166
N/A
449
N/A
542
N/A
195
N/A
744
N/A
866
SI
Water Volume
(L)
318
159
413
204
462
231
318
159
413
178
462
201
Water Volume
(L)
N/A
159
N/A
204
N/A
227
N/A
159
N/A
178
N/A
189
14
Table 10A — 23XRV Waterbox Cover Weights — English (lb)
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*
Frame 3
Victaulic
Nozzles
Flanged
COOLER CONDENSER
Frame 4
Victaulic
Nozzles
Flanged
Frame 5
Victaulic
Nozzles
Flanged
Frame 3
Victaulic
Nozzles
Flanged
Frame 4
Victaulic
Nozzles
Flanged
Frame 5
Victaulic
Nozzles
Flanged
282
287
294
243
318
340
310
243
148
202
472
138
185
256
488
138
168
222
617
154
229
276
634
154
282
287
294
225
318
340
310
225
148
191
503
138
185
245
519
138
168
224
628
154
229
298
655
154
243/315 243/315 138/314 138/314 154/390 154/390 225/234 225/234 138/314 138/314 154/390 154/390
411 486 633 709 764 840 411 486 633 709 764 840
411
433
291
518
468
291
626
660
522
733
694
522
760
795
658
867
830
658
411
433
270
578
468
270
622
655
522
729
689
522
727
785
658
878
838
658
445/619 445/619 522/522 522/522 658/658 658/658 359/474 359/474 522/522 522/522 658/658 658/658
Table 10B — 23XRV Waterbox Cover Weights — SI (kg)
COOLER CONDENSER
WATERBOX
DESCRIPTION
Frame 3
Victaulic
Nozzles
Flanged
Frame 4
Victaulic
Nozzles
Flanged
Frame 5
Victaulic
Nozzles
Flanged
Frame 3
Victaulic
Nozzles
Flanged
Frame 4
Victaulic
Nozzles
Flanged
Frame 5
Victaulic
Nozzles
Flanged
NIH 1 Pass Cover, 150 psig
NIH 2 Pass Cover, 150 psig
NIH 3 Pass Cover, 150 psig
128
130
133
144
154
141
67
92
214
NIH Plain End, 150 psig
110 110 63
MWB End Cover, 150 psig*
110/143 110/143 63/142
NIH 1 Pass Cover, 300 psig
186 220 287
84
116
221
63
63/142
322
76
101
280
70
70/177
347
104
125
288
70
70/177
381
128
130
133
144
154
141
67
87
228
102 102 63
102/106 102/106 63/142
186 220 287
84
111
235
63
63/142
322
76
102
285
70
70/177
346
104
135
297
70
70/177
381
NIH 2 Pass Cover, 300 psig
NIH 3 Pass Cover, 300 psig
NIH Plain End, 300 psig
186
196
132
235
212
132
284
299
237
332
315
237
344
361
298
393
376
298
186
196
122
235
212
122
282
297
237
331
313
237
330
356
298
398
380
298
MWB End Cover, 300 psig*
202/281 202/281 237/237 237/237 298/298 298/298 163/215 163/215 237/237 237/237 298/298 298/298
LEGEND
NIH —
Nozzle-in-Head
MWB —
Marine Waterbox
*Rows with two entries list nozzle end and return end weights.
NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown in Table 7.
RIG MACHINE COMPONENTS — Refer to Fig. 10-26 and
Carrier Certified Prints for machine component disassembly.
IMPORTANT: Only a qualified service technician should perform this operation.
WARNING
Do not attempt to disconnect flanges while the machine is under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.
CAUTION
Before rigging the compressor, disconnect all wires entering the power panel.
NOTE: Label each wire before removal when wiring must be disconnected (see Fig. 10 and 11). Clip all wire ties necessary when removing pressure and temperature sensors. Disconnect all pressure transducer wires at the sensor. Temperature sensors cannot be disconnected from their cables; remove temperature sensors from their thermowells and label as required.
15
CONDENSER
PRESSURE
CABLE
CABLE TRAY CONTAINING
VAPORIZER HTR CONDUIT
OIL HEATER CONDUIT
OIL PUMP CONDUIT
OIL SUMP TEMP. CABLE
OIL SUMP PRESS. CABLE
OIL PRESS. CABLE
OIL RECLAIM ACTUATOR CABLE
HGBP CONDUIT (OPTIONAL)
WATER SENSOR CABLES
FOR NOZZLE ARRANGEMENTS
A, B, C, E, F, P, Q, R, T AND U
(SAME FOR NOZZLE
ARRANGEMENTS D AND S ON
OTHER END OF MACHINE)
DISCHARGE END
CONTROL
PANEL
MOTOR TEMPERATURE
CABLE
SUCTION END a23-1558
DISCH. TEMP. CABLE
DISCH. PRESS. CABLE
DISCH. PRESS. SWITCH
COOLER
PRESSURE
CABLE
CABLE TRAY CONTAINING
ENT/LVG CHILLED LIQUID CABLES
ENT/LVG COND. LIQUID CABLES
COND, PRESS CABLE
COMP’R DISCH TEMP. CABLE
EVAP. PRESS. CABLE
EVAP. REFRIG. LIQUID TEMP. CABLE
MOTOR TEMP. CABLE
VFD COOLANT SOLENOID CABLE
OIL PRESS. CABLE
DISCH. PRESS. SWITCH CABLE
HGBP CONDUIT (OPTIONAL)
VFD COOLING
SOLENOID
CABLE
HGBP CONDUIT (OPTIONAL)
EVAP REFRIG. LIQUID
TEMP. CABLE
LEGEND
ENT/LVG — Entering/Leaving
HGBP
— Hot Gas Bypass
HTR
VFD
— Heater
— Variable Frequency Drive
Fig. 10 — Electrical Cable Routing — Top View (Unit with R Compressor Shown)
CABLE TRAY CONTAINING
OIL VAPORIZER CONDUIT
OIL HTR CONDUIT
OIL PUMP CONDUIT
OIL RECLAIM ACTUATOR CABLE
OIL SUMP PRESS. CABLE
OIL DISCH. PRESS. CABLE
OIL SUMP TEMP. CABLE
HGBP CONDUIT (OPTIONAL)
COMR’R DISCH. TEMP. CABLE
DISCH. PRESS. SWITCH
DISCH. PRESS. CABLE
COMP’R DISCHARGE
TEMP. CABLE
DISCH. PRESS. CABLE
DISCH. PRESS. SWITCH
CONDENSER
PRESSURE
CABLE
EVAPORATOR
PRESSURE
CABLE
DISCHARGE END
VFD COOLING
SOLENOID
MOTOR TEMP
CABLE
SUCTION END
LEGEND
OIL PUMP
CONDUIT
OIL RECLAIM
ACTUATOR
CABLE
ENT/LVG — Entering/Leaving
HGBP
— Hot Gas Bypass
HTR
VFD
— Heater
— Variable Frequency Drive
OIL
PRESSURE
LEAVING
FILTER
CABLE
OIL SUMP
PRESSURE
CABLE
OIL SUMP
TEMPERATURE
CABLE
CABLE TRAY CONTAINING
VAPORIZER HEATER CONDUIT
OIL HTR CONDUIT
OIL PUMP CONDUIT
OIL RECLAIM ACTUATOR CABLE
OIL SUMP PRESS. CABLE
OIL PRESS. CABLE
OIL SUMP TEMP. CABLE
HGBP CONDUIT (OPTIONAL)
OIL HEATER
CONDUIT
EVAPORATOR
REFRIG LIQUID
TEMPERATURE
SENSOR CABLE
Fig. 11 — Electrical Cable Routing — Back View (Unit with R Compressor Shown)
a23-1559
16
Step 3 — Separate Machine Components —
The design of the 23XRVchiller allows for disassembly at the job site so that the individual chiller components may be moved through existing doorways. Use the following procedures to separate the machine components.
Suggested locations to cut piping will minimize the width of the condenser/economizer assembly.
SEPARATE COOLER AND CONDENSER
IMPORTANT: If the cooler and condenser vessels must be separated, the heat exchangers should be kept level by placing a support plate under the tube sheets.
The support plate will also help to keep the vessels level and aligned when the vessels are bolted back together.
NOTE: For steps 1 through 13 refer to Fig. 12. The cooler has been removed from the picture to show the pipes and lines that must be cut.
Check that the holding charge has been removed from the chiller.
1. Place a support plate under each tube sheet to keep each vessel level.
2. Remove cooler relief valve and relief valve vent piping
(cooler not shown in Fig. 12, see Fig. 3A or 3B, item 26).
3. Cut the motor cooling refrigerant drain line (see Fig. 12, item 4).
4. Unbolt and rig the suction elbow off and disconnect the compressor suction line at the cooler and compressor. Remove bolts from the vaporizer vent line flange.
17
18
19
16
15
5. Cut the VFD cooling drain line (see Fig. 12, item 11).
6. Cut the oil reclaim line(s) (see Fig. 12, item 12) .
7. Cut the hot gas bypass line between the HGBP (hot gas bypass) solenoid valve and cooler feed line (see Fig. 12, item 10).
8. Unbolt the cooler liquid feed line (see Fig. 12, item 9), near the economizer or condenser float chamber at the flanged connection. Temporarily secure the in-line economizer orifice plate (economized chillers only) to the economizer flange.
9. Cut the vaporizer refrigerant return line as shown (see
Fig. 12, item 13).
10. Disconnect all sensors with cables that cross from the condenser side of the machine to the cooler side including: a. Evaporator refrigerant liquid temperature sensor.
See Fig. 13.
b. Entering and leaving chiller liquid temperature sensors. See Fig. 14.
c. Evaporator pressure sensor (not shown).
11. Disconnect the tubesheet mounting brackets from the vessel connectors on the tube cooler tubesheet.
12. Cover all openings.
13. Rig the cooler away from the condenser/compressor.
NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them.
1
2
3
5
14
5
6
4
5
13
12 a23-1560
1 — Suction Elbow (Unbolt)
2 — Vaporizer Vent Line (Unbolt)
3 — Motor Cooling Line (Unbolt)
4 — Motor Cooling Drain Line (Cut)
5 — Tubesheet Mounting Bracket
6 — Bearing Oil Drain Line
7 — Support Plate
8 — In-Line Economizer Orifice Plate
9 — Cooler Liquid Feed LIne (Unbolt)
10 — Hot Gas Bypass Line (Cut)
11
10
7
9
8
11 — VFD Cooling Drain Line
12 — Oil Reclaim Line (Cut)
13 — Vaporizer Hot Gas Return Line (Cut)
14 — Discharge Isolation Valve (Optional)
15 — Condenser Relief Valves
16 — Discharge Temperature Sensor
17 — Discharge Pipe Assembly Relief Valve (Unscrew)
18 — Discharge Pressure Sensor
19 — Discharge Pressure Switch
Fig. 12 — Cooler/Discharge Pipe Assembly Removal (Unit with R Compressor Shown)
17
OPTIONAL
HOT GAS
BYPASS LINE
EVAPORATOR
REFRIGERANT
LIQUID
TEMPERATURE
SENSOR
COOLER
REFRIGERANT
PUMPOUT
VALVE removal or installation. Evacuate the VFD coldplate through the Schrader valve (Fig. 15) on the VFD drain isolation valve.
2. Remove the shipping bracket between the VFD and the compressor if it is still in place. See Fig. 16.
NOTE: For seismic units, do not remove the shipping bracket.
a23-1635
Fig. 13 — Evaporator Refrigerant Liquid
Temperature Sensor on Bottom of Cooler
LEAVING CONDENSER
LIQUID TEMPERATURE
SENSOR
LEAVING CHILLED
LIQUID TEMPERATURE
SENSOR
VFD
REFRIGERANT
COOLING
ISOLATION
VALVE
VFD
REFRIGERANT
STRAINER
SCHRADER
VALVE
VFD DRAIN
ISOLATION
VALVE
FILTER DRIER
ISOLATION VALVE a23-1663
FILTER
DRIER
MOTOR
COOLING
SIGHT
GLASS
FILTER DRIER
ISOLATION VALVE
Fig. 15 — VFD Refrigerant Isolation Valves
SHIPPING BRACKET
(FOR SEISMIC UNITS,
DO NOT REMOVE)
ENTERING CONDENSER
LIQUID TEMPERATURE
SENSOR a23-1563
ENTERING CHILLED
LIQUID TEMPERATURE
SENSOR
Fig. 14 — Chiller End View
CAUTION
Do not rig the condenser before the control center and compressor are removed. The condenser/compressor assembly has a high center of gravity and may tip over when lifted at the tubesheet rigging points, which could result in equipment damage and/or serious personal injury.
REMOVE THE CONTROLS/DRIVE ENCLOSURE
FROM THE CONDENSER — Confirm that the power supply disconnect is open and all safety procedures are observed before removing the VFD. This procedure minimizes the number of sensors and cables that need to be disconnected.
WARNING
Do not attempt to remove the VFD without first closing the refrigerant isolation valves. Failure to do so during VFD removal will result in an uncontrolled refrigerant leak. A refrigerant leak can damage the unit as well as displace oxygen, causing asphyxiation.
1. Close the 2 filter drier isolation valves (Fig. 15) and the
2 VFD isolation valves. Isolate the refrigerant charge into the condenser to prevent a refrigerant leak if one of the motor terminals is accidentally damaged during VFD
18 a23-1664
Fig. 16 — VFD Shipping Bracket
(Unit with R Compressor Shown)
3. Remove any conduits that bring power to the VFD.
4. Remove the nuts that secure the terminal box transition piece to the motor housing.
5. Disconnect the motor leads from the motor terminals
(Fig. 17). Note the position of the motor terminal cable lugs so they can be reinstalled with sufficient clearance away from surrounding structure.
6. Remove the motor temperature sensor leads (Fig. 17), the motor ground lead, and the bolts that secure the VFD enclosure to the terminal box transition piece.
7. Disconnect the communication cables from the back of
ICVC (International Chiller Visual Controller) (Fig. 18).
8. Disconnect the high pressure switch leads from terminal strip TB1, terminals 15 and 16 (Fig. 19).
9. Unplug connectors CN1A, CN1B, CN2, and CN3
(Fig. 19).
10. Disconnect the control panel ground wire (Fig. 19) that is located next to connectors CN1A and CN1B.
11. Disconnect the VFD cooling lines (Fig. 20) and cover all openings.
12. Remove the 12 screws that secure the control panel to the
VFD enclosure. Tilt the control panel away from the back of the control center.
13. Position the control panel on top of the condenser and secure it in place to prevent damage.
MOTOR TERMINALS
MOTOR TERMINAL
BOX FRAME
CONNECTOR CN1A
CONTROL PANEL
GROUND WIRE
CONNECTOR CN1B
MOTOR
TEMPERATURE
SENSOR TERMINAL
BLOCK
MOTOR
TEMPERATURE
CABLE
Fig. 17 — Motor Terminals
a23-1566
CONNECTOR
CN2
CONNECTOR CN3
LOW VOLTAGE FIELD
WIRING TERMINAL STRIP a23-1570
Fig. 19 — Control Panel Connectors
OIL HEATER CONDUIT ASY
HIGH
PRESSURE
SWITCH
CABLE a23-1567
Fig. 18 — ICVC Communication Cables
19
OIL PUMP CONDUIT ASY
VAPORIZER HEATER CONDUIT ASY a23-1571
VFD COOLING LINE
O-RING FACE SEAL
COUPLINGS
OIL RECLAIM
ACTUATOR CABLE
VFD COOLING
SOLENOID CABLE
TEMPERATURE SENSOR
CABLES
PRESSURE SENSOR
CABLES
Fig. 20 — Control Panel Back
Lifting the Control Center — Care should be used to prevent damage due to dropping or jolting when moving the control center. A fork truck or similar means of lifting and transporting may be used. Sling in a manner that will equalize the load at the pickup points. Use a spreader bar if the angle of the sling is less than 45 degrees relative to horizontal. Do not jolt while lifting.
Use the following procedure to lift the control center.
1. Remove the rubber hole plugs in the top of the control center and fully thread in 4 eyebolts or swivel hoist rings
(see Fig. 21). Lifting hardware must have
3
/
4
in.-10 x 2 in.
long threads and must have a working load limit of at least 6000 lb (2722 kg). Typical eyebolts are Chicago
Hardware (size 28) or Grainger (P/N 5ZA63).
2. Attach a sling to the four lifting eyebolts. Make certain that the angle of the sling is not less than 45 degrees relative to horizontal.
3. Using an overhead or portable hoist (minimum 2 ton rated capacity), attach a free-fall chain to the sling secured to the drive. Take up any slack in the chain.
4. Rig the control center and remove the bolts that secure it to the VFD mounting brackets on the condenser (see
Fig. 21).
5. Confirm that welding procedures comply with local
Pressure Vessel Codes before removing a portion of the
VFD support bracket from the condenser. Custom brackets should be fabricated if part of the VFD supports must be cut off of the condenser to reduce the width of the condenser assembly. Clamp ¼-in. plates over both sides of the VFD bracket and drill two pairs of holes that straddle the line along which the VFD brackets will be cut. This will allow the VFD brackets to be reinstalled and welded in their original position.
NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them. (See Fig. 22.)
3/4 IN. - 10 x 2 IN. LIFTING EYEBOLT WITH
SHOULDER OR SWIVEL HOIST RING
6000 LB (2722 KG) WORKING LOAD LIMIT
TYPICAL — CHICAGO HARDWARE P/N 28
GRAINGER P/N 5ZA63
LIFTING
EYEBOLT
45° MIN
REMOVE THE DISCHARGE PIPE ASSEMBLY FROM
THE CONDENSER
NOTE: For steps 1 through 6 refer to Fig. 12.
The condenser relief valve and relief valve vent piping should be removed if they will interfere with discharge pipe assembly rigging.
1. Remove the discharge pipe assembly relief valve and relief valve vent piping.
2. Disconnect the compressor discharge temperature sensor
(see Fig. 12, item 16).
3. Disconnect the compressor discharge pressure sensor (see
Fig. 12, item 18) and remove the high discharge pressure switch (see Fig. 12, item 19).
4. Unbolt and rig the discharge pipe assembly off and remove the bolts from the compressor discharge and condenser inlet flange. Note the position and orientation of the discharge isolation valve on the condenser inlet flange.
5. Remove the discharge pipe assembly (see Fig. 12, item 17).
6. Cover all openings.
NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk of damaging them.
SEPARATE THE COMPRESSOR FROM THE
CONDENSER
CAUTION
Do not rig the condenser before the control center and compressor are removed. The condenser/compressor assembly has a high center of gravity and may tip over when lifted at the tubesheet rigging points, which could result in equipment damage and/or serious personal injury.
The VFD blocks access to the compressor mounting bolts.
It must be removed before the compressor can be separated from the condenser. Remove the VFD from the condenser using the Remove the Controls/Drive Enclosure from the Condenser section on page 18. Refer to Table 11.
a23-1561
Fig. 21 — Control Center Lifting Points
20
TO TERMINAL
J4-10 UPPER
HUMIDITY
SENSOR a23-1568
Fig. 22 — Control Panel Inputs
21 a23-1569
Table 11 — Compressor Fastener Identification
COMPRESSOR FASTENERS SIZE
Discharge Pipe Assembly to Compressor
Discharge Flange
1 in.-8 Grade 5 Hex Head
Suction Elbow to
Compressor Inlet
Compressor Mount to Condenser
Economizer Line
Q Compressor 3 /
4
in.-10 Grade 5 Hex Head
R Compressor 7 /
8
in.-9 Grade 5 Hex Head
Motor Cooling, Motor Drain, Oil Drain
3
/
4
in.-10 Studs (A-449)
5 /
8
in.-11 Grade 8 Hex Head
M12x1.75 Grade 10.9 Socket
Head
Compressor Lifting Points (2)
Stator Housing Lifting Point
Discharge Housing Lifting Point
M30x3.5 Threaded Holes
M30x3.5 Threaded Hole
M30x3.5 Threaded Hole
1. Disconnect the oil supply line in two places (Fig. 23).
Cap the oil lines and fittings.
NOTE: Compressor oil lines and fittings between the oil filter and compressor must be kept extremely clean to prevent obstruction of the compressor inlet bearing oil orifice. Cap all orifice lines and fittings during disassembly. The compressor inlet bearing oil orifice is located at the lubrication block on top of the compressor.
2. Disconnect the motor cooling inlet flange, the motor cooling drain flange, optional economizer vapor line flange, and bearing oil drain flange (Fig. 23). Remove the economizer muffler bracket.
3. Brace the end of the discharge pipe assembly closest to the compressor if it has not already been removed. Place an oil pan under the compressor flange to collect oil that may have accumulated in the discharge pipe assembly. Unbolt the discharge pipe assembly from the compressor. It may also be necessary to loosen the bolts that attach the discharge pipe assembly to the condenser.
4. If the cooler has been removed, rig the suction elbow and unbolt the suction elbow at the compressor and vaporizer vent line flanges (see Fig. 12). If the cooler is still in place, it may be necessary to loosen the bolts that secure the suction elbow to the cooler.
5. Carefully remove the perforated insulation cutouts that cover the compressor lifting points. See Fig. 23. Replace the lifting shackle thread protector after the compressor is re-installed to prevent insulation adhesive from fouling the threads.
6. Rig the compressor with lifting eyelets installed in the two M30 threaded holes provided in the top of the compressor housing (Fig. 23). Use only M30 forged eye bolts or M30 hoist rings with a sufficient working load limit to safely lift the compressor. The rubber vibration isolators may pull out of the compressor mounting bracket when the compressor is lifted off of the condenser. Applying leak detection soap solution to the outside of the vibration isolators will make it easier to press the isolators back into position.
7. Cover all openings.
NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secure to reduce the risk damaging them.
DISCHARGE
PIPE ASSEMBLY
BOLTING
FLANGE
ECONOMIZER
MUFFLER
BRACKET
OIL SUPPLY LINE
FITTINGS
M30 COMPRESSOR LIFTING
SHACKLE HOLES
MOTOR COOLING INLET FLANGE
ECONOMIZER VAPOR
LINE FLANGE
MOTOR COOLING
DRAIN FLANGE
SUCTION ELBOW
FLANGE
VAPORIZER VENT
LINE FLANGE
ECONOMIZER
MUFFLER
(OPTIONAL)
BEARING OIL
DRAIN FLANGE a23-1572
Fig. 23 — Compressor Removal
22
SEPARATE THE VAPORIZER FROM THE CON-
DENSER — The VFD mounting brackets (Fig. 24) extend beyond the outboard edge of the vaporizer. The vaporizer extends beyond the perimeter of the condenser tubesheet.
1. Cut the vaporizer hot gas supply line near the oil concentrator (Fig. 24).
2. Cut the vaporizer hot gas return line (Fig. 25).
3. Cut the bearing oil drain line near the oil sump (Fig. 25).
4. Unbolt the vaporizer vent line flange shown in Fig. 25.
5. Cut the oil supply line as shown in Fig. 25.
6. Cut the oil reclaim line as shown in Fig. 25.
7. Disconnect all wires and cable leads to the vaporizer assembly (see Fig. 26) including: a. oil sump temperature sensor b. oil sump pressure cable and oil pressure leaving filter cable c. oil reclaim cable d. vaporizer heater cable in the vaporizer heater junction box (Fig. 24) e. oil pump cable f. oil sump heater conduit from its junction box
(Fig. 24) g. vaporizer temperature sensor (Fig. 24)
VFD MOUNTING
BRACKETS
8. Rig the vaporizer with the lifting points on the vaporizer mounting bracket and remove the four bolts that secure it to the condenser (Fig. 24).
9. Cover all openings.
NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them.
Step 4 — Install VFD
1. Install terminal box frame mounting studs into tapped holes using short threaded end (see section E-E in
Fig. 27). Do not exceed 120 ft-lb (163 N-m).
2. Install thermal insulators, insulation frame assembly, and terminal box frame prior to attaching motor power cables.
3. Torque motor terminals to 45 to 55 ft-lb (61 to 75 N-m).
4. There may be 1 or 2 motor power cables per terminal identified as T1, T2 and T3. Position motor end lugs on terminal studs with Belleville washer located against the front terminal lug with the convex side facing toward the front terminal nut. Clinch the two cables together with wire ties before tightening terminal nuts. Install front terminal nut finger tight. Hold front terminal nut stationary while tightening rear terminal nut to 45 to 50 ft-lb
(61 to 68 N-m). (See Fig. 28.)
VAPORIZER
MOUNTING
BOLTS
VAPORIZER
REFRIGERANT
RETURN LINE
VAPORIZER
MOUNTING
BOLTS
VAPORIZER HOT
GAS SUPPLY LINE a23-1672
OIL PRESSURE
REGULATOR ISOLATION
VALVE
VAPORIZER HEATER
JUNCTION BOX
OIL RECLAIM
ACTUATOR
OIL SUMP
HEATER JUNCTION
BOX
VAPORIZER TEMPERATURE SENSOR
Fig. 24 — Oil Concentrator Removal
OIL PUMP
JUNCTION BOX (HIDDEN)
23
OIL SUPPLY
LINE
VAPORIZER
BEARING OIL
DRAIN LINE
VAPORIZER
VENT LINE
VAPORIZER HOT
GAS SUPPLY LINE
OIL PUMP
OIL FILTER a23-1574
OIL RECLAIM
LINE
OIL PRESSURE
REGULATOR VALVE
OIL SUMP
OIL PRESSURE
REGULATOR ISOLATION
VALVE
VAPORIZER HOT
GAS RETURN
LINE
Fig. 25 — Oil Reclaim Piping
OIL FILTER
SCHRADER
VALVE
OIL RECLAIM
ACTUATOR
OIL PRESSURE
LEAVING FILTER
SENSOR
OIL SUPPLY
LINE (TO
COMPRESSOR)
OIL PRESSURE
REGULATOR LINE
OIL RECLAIM
LINE ( FROM
COOLER)
VAPORIZER REFRIGERANT
RETURN ORIFICE a23-1575
OIL SUMP STRAINER
OIL PUMP/OIL FILTER
ISOLATION VALVE
OIL FILTER
OIL SUMP
PRESSURE
SENSOR
OIL SUMP
TEMPERATURE
SENSOR
OIL PUMP/OIL FILTER
ISOLATION VALVE
OIL PUMP
JUNCTION BOX
Fig. 26 — Oil Reclaim Components
24
MOTOR
TEMPERATURE
SENSOR TERMINAL
BLOCK
T1 T2
T3
TERMINAL
ENCLOSURE
FRAME
MOTOR LEADS
PROTECTIVE
EARTH (PE)
GROUND
CONNECTION
CONTROL CENTER
TERMINAL ENCLOSURE FRAME
COMPRESSOR
FOAM
INSULATION
THERMAL
INSULATOR
INSULATION
FRAME
ASSEMBLY
TERMINAL
BOX FRAME a23-1576
SECTION E-E
TERMINAL BOX MOUNTING
STUD - DO NOT EXCEED
120 FT-LB TORQUE
Fig. 27 — Motor Terminal Box
TERMINAL
ENCLOSURE
FRAME
WASHER
TERMINAL
BOX
FRAME CENTER TERMINAL ENCLOSURE
FRAME OVER TERMINAL BOX
FRAME ASSEMBLY
T2
T3
MOTOR
TERMINAL
STUD NUTS
SECTION C-C
FROM FIG. 27 a23-1577
0.38 APPROX.
FOAM
INSULATION
WIRE
TIES
MOTOR POWER CABLES
(MAY BE 1 OR 2 PER
TERMINAL)
VIEW LOOKING DOWN
INTERNAL/EXTERNAL TOOTH
LOCK WASHER
BETWEEN TERMINAL
BOX FRAME AND
PE/GROUND CABLE LUG
Fig. 28 — Motor Terminal Insulation
25
5. Check all terminal connections for proper installation.
IMPORTANT: Do not insulate terminals until wiring arrangement has been checked and approved by
Carrier start-up personnel. Motor terminals must be insulated in acceptance with national and local electrical codes.
Insulate Motor Terminals and Lead Wire Ends — Locate heat shrink tubing (RCD P/N LF33MM114) over power connections so that they are completely covered and tubing is against motor housing. Shrink into position.
Slide foam tubing (3 in. inner diameter closed cell vinyl, neoprene, or nitrile foam) part way over the heat shrink tubing. Apply adhesive for closed cell foam insulation to motor side end of the foam tubing and push tubing the rest of the way over the terminal and against the sheet insulation on the motor side. Secure the opposite end of the foam tubing with a wire tie as shown in Fig. 28.
Alternate Insulation for Motor Terminals and Lead Wire
Ends — Insulate compressor motor terminals, lead wire ends, and electrical wires to prevent moisture condensation and electrical arcing. Obtain Carrier approved insulation material from RCD (Replacement Components
Division) consisting of 3 rolls of insulation putty and one roll of vinyl tape.
a. Insulate each terminal by wrapping with one layer of insulation putty (RCD P/N 19EA411-1102).
b. Overwrap putty with 4 layers of vinyl tape.
6. Orient PE/ground lug as shown in Fig. 28. Assemble internal/external tooth lock washer between the terminal box frame and the PE/ground cable. Torque PE/ground lug nut to 55 to 65 ft-lb (75 to 89 N-m). See section H-H in Fig. 29 for PE/ground cable routing.
7. Center terminal enclosure frame over terminal box frame assembly so the space between the frames is equal within
3
/
16
-in. (5 mm) at the top and bottom. Use the slots in the terminal enclosure frame. Adjust spacing between the sides of the terminal enclosure frame and terminal box frame assemblies by moving the control center to the left or right.
8. Install O-rings on VFD refrigerant connections using silicone grease. Tighten connector using two wrenches to
27 to 33 ft-lb (37 to 45 N-m). (See Detail A in Fig. 30.)
9. Evacuate all piping between the VFD and the VFD isolation valves after assembly and tightening of VFD fittings.
Dehydration/evacuation is complete to equalize VFD piping pressure with machine pressure if machine is charged with refrigerant (see Fig. 30).
Step 5 — Install Machine Supports
IMPORTANT: Chiller housekeeping pad, anchor bolts and attachment points to be designed by others in accordance with all applicable national and local codes.
INSTALL STANDARD ISOLATION — Figures 31 and 32 show the position of support plates and shear flex pads, which together form the standard machine support system.
Service clearance under the chiller can be enhanced if the grout is not extended along the entire length of the heat exchangers.
a23-1578 a23-1579
DETAIL A
Fig. 29 — Motor Ground Cable
SEE
DETAIL A
FILTER DRIER
ISOLATION VALVE
VFD ISOLATION
VALVES (2)
VFD COOLING
LINE O-RING
FACE SEAL
COUPLINGS
Fig. 30 — VFD Refrigerant Connectors
FILTER DRIER
ISOLATION VALVE
26
a23-1534
23XRV
HEAT EXCHANGER
SIZE
30-32
35-37
40-42
45-47
50-52
55-57
A
12-10 3 /
4
14- 7 1 /
4
12-10 3 /
4
14- 7
1
/
4
12-10 3 /
4
14- 7 1 /
4
B
5-5 1 /
4
5-5 1 /
4
6-0
6-0
6-5 1 /
2
6-5 1 /
2
C
0
0
0-1 1 /
2
0-1
1
/
2
01 /
2
01 /
2
DIMENSIONS (ft-in.)
D
0-3 5 /
8
0-3 5 /
8
0-3 5 /
8
0-3
5
/
8
0-3 5 /
8
0-3 5 /
8
E
1-3 1 /
4
1-3 1 /
4
1-3 1 /
4
1-3
1
/
4
1-3 1 /
4
1-3 1 /
4
F
0-9
0-9
0-9
0-9
0-9
0-9
Fig. 31 — 23XRV Machine Footprint
.
ACCESSORY SOLEPLATE DETAIL
G
01 /
2
01 /
2
01 /
2
0-
1
/
2
01 /
2
01 /
2 a23-46
VIEW Y-Y
NOTES:
1. Dimensions in ( ) are in millimeters.
2. Isolation package includes 4 shear flex pads.
Fig. 32 — Standard Isolation
INSTALL ACCESSORY ISOLATION (if required) — Uneven floors or other considerations may dictate the use of accessory soleplates (supplied by Carrier for field installation) and leveling pads. Refer to Fig. 33.
Level machine by using jacking screws in isolation soleplates. Use a level at least 24-in. (610 mm) long.
IMPORTANT: Chiller support plates must be level within
1
/
2
in. from one end to the other end of the heat exchangers for effective oil reclaim system operation.
For adequate and long lasting machine support, proper grout selection and placement is essential. Carrier recommends that only pre-mixed, epoxy type, non-shrinking grout be used for machine installation. Follow manufacturer’s instructions in applying grout.
1. Check machine location prints for required grout thickness.
2. Carefully wax jacking screws for easy removal from grout.
3. Grout must extend above the base of the soleplate and there must be no voids in grout beneath the plates.
4. Allow grout to set and harden, per manufacturer’s instructions, before starting machine.
5. Remove jacking screws from leveling pads after grout has hardened.
27 a19-1109 a19-1110
VIEW X-X
LEGEND
HRS — Hot Rolled Steel
NOTES:
1. Dimensions in ( ) are in millimeters.
2. Accessory (Carrier supplied, field installed) soleplate package includes 4 soleplates, 16 jacking screws and leveling pads.
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 c-1½s
(38.1) to 0 c-2¼s (57) thick.
Fig. 33 — Accessory Isolation
INSTALL SPRING ISOLATION
IMPORTANT: Accessory spring isolation packages are intended solely for non-seismic applications. Seismic applications must be designed by a registered professional in accordance with all applicable national and local codes.
Spring isolation may be purchased as an accessory from
Carrier for field installation. It may also be field supplied and installed. Spring isolators may be placed directly under machine support plates or located under machine soleplates.
See Fig. 34. Consult job data for specific arrangement. Low profile spring isolation assemblies can be field supplied to keep the machine at a convenient working height.
Obtain specific details on spring mounting and machine weight distribution from job data. Also, check job data for methods to support and isolate pipes that are attached to spring isolated machines.
a23-1537
NOTE: The accessory spring isolators are supplied by Carrier for installation in the field.
Fig. 34 — 23XRV Accessory Spring Isolation
(Shown with Accessory Soleplates)
Step 6 — Connect Piping
IMPORTANT: Chiller water nozzle connections to be designed by others in accordance with all applicable national and local codes.
CAUTION
Remove cooler and condenser liquid temperature and optional pressure sensors before welding connecting piping to water nozzles. Refer to Fig. 14. Replace sensors after welding is complete.
INSTALL WATER PIPING TO HEAT EXCHANGERS —
Refer to Table 4 for nozzle sizes. Install piping using job data, piping drawings, and procedures outlined below. A typical piping installation is shown in Fig. 35.
THERMOMETER
OPENING
(OPTIONAL)
PIPE
FLANGES
LEAVING
CONDENSER
WATER
PRESSURE
GAGES
AIR VENT
PIPE HANGERS a23-1580
LEAVING CHILLED
WATER
ENTERING CHILLED
WATER
Fig. 35 — Typical Nozzle Piping
ENTERING
CONDENSER
WATER
CAUTION
Factory-supplied insulation is not flammable but can be damaged by welding sparks and open flame. Protect insulation with a wet canvas cover.
1. Offset pipe flanges to permit removal of waterbox cover for maintenance and to provide clearance for pipe cleaning. No flanges are necessary with marine waterbox option; however, water piping should not cross in front of the waterbox cover or access will be blocked.
2. Provide openings in water piping for required pressure gages and thermometers. For thorough mixing and temperature stabilization, wells in the leaving water pipe should extend inside pipe at least 2 in. (51 mm).
3. Install air vents at all high points in piping to remove air and prevent water hammer.
4. Install pipe hangers where needed. Make sure no weight or stress is placed on waterbox nozzles or flanges.
5. Water flow direction must be as specified in Fig. 36 and 37.
NOTE: Entering water is always the lower of the 2 nozzles. Leaving water is always the upper nozzle for cooler or condenser.
6. Install waterbox vent and drain piping in accordance with individual job data. All connections are 3 /
4
-in. FPT.
7. Install waterbox drain plugs in the unused waterbox drains and vent openings.
8. Install optional pumpout system or pumpout system and storage tank as shown in Fig. 38-42.
CAUTION
Never charge liquid R-134a refrigerant into the chiller if the pressure is less than 35 psig (241 kPa). Charge as a gas only, with the cooler and condenser pumps running, until
35 psig (241 kPa) is reached using the pumpdown mode on the ICVC. Terminate the pumpdown mode using the
ICVC. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.
28
NOZZLE-IN HEAD WATERBOXES
a23-1538
FRAME 3
12
11
10 a23-1581
CONDENSER
DISCHARGE END
COOLER
9
8
6
7
4
5
FRAMES 4 AND 5
COOLER
SUCTION END
CONDENSER
3
2
1
NOZZLE ARRANGEMENT CODES FOR ALL 23XRV NOZZLE-IN-HEAD WATERBOXES
PASS
In
1
2
3
7
4
8
5
7
4
*Refer to certified drawings.
COOLER WATERBOXES
Out
Arrangement
Code*
9
6
5
8
6
9
A
B
C
D
E
F
PASS
1
2
3
In
11
2
10
1
10
1
CONDENSER WATERBOXES
Out
Arrangement
Code*
2
11
12
3
3
12
P
Q
R
S
T
U
Fig. 36 — Piping Flow Data (NIH, Frames 3 Through 5)
29
MARINE WATERBOXES
a23-1539
PASS
1
2
3
In
7
4
8
5
7
4
FRAME 3
NOZZLE ARRANGEMENT CODES
COOLER WATERBOXES
Out
Arrangement
Code
9
6
5
8
6
9
A
B
C
D
E
F
In
—
—
10
1
—
—
CONDENSER WATERBOXES
Out
Arrangement
Code
—
—
12
3
—
—
—
—
R
S
—
—
MARINE WATERBOXES
a23-1540
PASS
1
2
3
In
7
4
9
6
7
4
FRAMES 4 AND 5
NOZZLE ARRANGEMENT CODES
COOLER WATERBOXES
Out
Arrangement
Code
9
6
6
9
6
9
A
B
C
D
E
F
In
—
—
10
1
—
—
CONDENSER WATERBOXES
Out
Arrangement
Code
—
—
12
3
—
—
—
—
R
S
—
—
Fig. 37 — Piping Flow Data (Marine Waterboxes, Frames 3 Through 5)
30
LEVEL GAGE
W
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
0' - 9 "
[229mm]
TYPICAL
0' - 5 1/2"
[140mm]
D
E
PRESSURE GAGE
(2) 1" NPT RELIEF
VALVE OUTLET (SEE FIELD
INSTALLATION NOTES)
R
1' - 7 "
[483mm]
T
0' - 5 7/8 "
[149mm] a23-1541
B
TOP VIEW
1/2" MALE FLARE
VAPOR CONN.
3/4" NPT
PUMPOUT CONDENSER
WATER INLET CONN.
3/4" NPT
PUMPOUT CONDENSER
WATER OUTLET CONN.
ELECTRICAL SERVICE
ACCESS SPACE
20 3/4" X 8 3/4" X 4 1/2"
(BOTH SIDES)
NOTES:
1.
Denotes center of gravity.
2. Dimensions in [ ] are in millimeters.
3. The weights and center of gravity values given are for an empty storage tank.
4. For additional information on the pumpout unit, see certified drawings.
5. Conduit knockout is located on the side of the control box.
6. 28 cubic ft storage tank weight: 2334 lb (1059 kg).
7. 52 cu ft storage tank weight:
3414 lb (1549 kg).
J
K
VAPOR
F
L
U
V
1" NPT
LIQUID CONN.
0'- 9"
[229mm]
TYPICAL
0'- 9 7/8"
[249mm]
N
M
a23-1542
G
A
FRONT VIEW
C
P
a23-1543
0'- 7 15/16"
[202mm]
(FARSIDE)
0'- 2 3/4"
[70mm]
0'- 10"
[254mm]
1'-0 3/4"
[324mm]
DIMENSIONS
ENGLISH (ft-in.)
3/8" MALE FLARE
RELIEF VALVE CONN.
1/2" DIA. K.O.
ELECTRICAL CONN.
(PUMPOUT POWER)
(FAR SIDE)
TANK
SIZE
0428
A
10- 5
0452
14-11 1 /
4
B
9-10
14- 4 1 /
2
C
4-4 1 /
4
4-8 1 /
4
S
H
TANK
SIZE
0428
0452
L
3-4
5
/
8
3-8 1 /
2
M
0-3
1
/
2
0-3 3 /
8
N
4- 9
1
/
2
6-11 5 /
8
D
2-4 3 /
4
2-8 1 /
2
E
1-2 3 /
8
1-4 1 /
4
P
1-7
7
/
8
1-8 3 /
4
R
2-0
3
/
8
2-0 5 /
8
SI (mm)
F
3-1 1 /
4
3-4 1 /
2
S
3-9
4-1
G
6 -4 3 /
16
7-2 1 /
4
H
3-11 3 /
8
4- 3 1 /
4
J
3-4 7 /
8
3-8 3 /
4
K
2-9 9 /
16
3-1 7 /
16
T
5-0
1
/
4
5-0 1 /
2
U
2-5
2-5 1 /
4
V
2-9
7
/
8
2-10 1 /
8
W
2-5
3
/
4
2-6
TANK
SIZE
0428
0452
A
3175
4553
B
2997
4381
C
1327
1429
D
730
826
E
365
413
F
946
1029
G
1935
2191
H
1203
1302
J
1038
1137
K
852
951
0'- 3 1/4"
[83mm]
TANK
SIZE
0428
0452
L
1032
1130
M
89
86
N
1451
2124
P
505
527
R
619
625
S
1143
1225
T
1530
1537
U
737
742
V
860
867
W
756
762
LEFT SIDE VIEW
Fig. 38 — Optional Pumpout Unit and Storage Tank
31
TANK SIZE
0428
0452
COOLER
TANK OD in.
24.00
27.25
mm
610
692
RATED DRY WEIGHT AND REFRIGERANT CAPACITY
DRY WEIGHT* lb
2334
3414
kg
1059
1549
R-134a MAXIMUM REFRIGERANT
CAPACITY (ANSI/ASHRAE 15) lb kg
1860
3563
844
1616
R-134a MAXIMUM REFRIGERANT
CAPACITY (UL 1963) lb kg
1716
3286
778
1491
COOLER INLET
ISOLATION VALVE
11
COOLER REFRIGERANT
PUMPOUT VALVE
7
COOLER CHARGING
VALVE
1b
CONDENSER
CHARGING
VALVE
1a
LEGEND
ANSI —
American National Standard
Institute
ASHRAE — American Society of Heating,
Refrigerating, and Air Conditioning Engineers
OD
UL
— Outside Diameter
— Underwriters Laboratories
*The above dry weight includes the pumpout condensing unit weight of 164 lb (75 kg).
CONTROL CENTER
DISCHARGE ISOLATION
VALVE (OPTIONAL)
PRESSURE
RELIEF SAFETY
VALVE
10
STORAGE
TANK LIQUID
VALVE
OIL
SEPARATOR
SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
PUMPOUT
COMPRESSOR
PUMPOUT
CONDENSER
=
SERVICE VALVE ON
PUMPOUT UNIT
=
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
2
4
3
5
PUMPOUT
CONDENSER
WATER SUPPLY
6
AND RETURN
STORAGE TANK
VAPOR VALVE a23-1634
Fig. 39 — Optional Pumpout System Piping Schematic with Storage Tank — Configured to Push
Liquid into Storage Tank (Unit with R Compressor Shown)
COOLER INLET
ISOLATION VALVE
11
COOLER REFRIGERANT
PUMPOUT VALVE
7
COOLER CHARGING
VALVE
1b
COOLER
USE CONDENSER
CHARGING
VALVE TO ADD
CHARGE
1a
CONTROL CENTER
DISCHARGE ISOLATION
VALVE (OPTIONAL)
PRESSURE
RELIEF SAFETY
VALVE
10
STORAGE
TANK LIQUID
VALVE
OIL
SEPARATOR
=
SERVICE VALVE ON
PUMPOUT UNIT
PUMPOUT
COMPRESSOR
=
SERVICE VALVE ON
CHILLER (FIELD
SUPPLIED)
= MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND
STORAGE TANK FOR SERVICE AND OPERATION WORK.
2
4
3
5
PUMPOUT
CONDENSER
PUMPOUT
CONDENSER
WATER SUPPLY
6
AND RETURN
STORAGE TANK
VAPOR VALVE a23-1544
Fig. 40 — Optional Pumpout System Piping Schematic with Storage Tank — Configured to Pull
Vapor out of Chiller or to Charge Chiller from Storage Tank (Unit with R Compressor Shown)
32
COOLER INLET
ISOLATION VALVE
11
COOLER
COOLER REFRIGERANT
PUMPOUT VALVE
7
COOLER CHARGING
VALVE
1b
CONDENSER
CHARGING
VALVE
1a
CONTROL CENTER
DISCHARGE ISOLATION
VALVE (OPTIONAL)
1a SERVICE VALVE
PRESSURE
RELIEF SAFETY
VALVE a23-1545
OIL
SEPARATOR
=
SERVICE VALVE ON
CHILLER
PUMPOUT
CONDENSER
=
SERVICE VALVE ON
PUMPOUT UNIT
PUMPOUT
COMPRESSOR
2
4
3
5
PUMPOUT
CONDENSER
WATER SUPPLY
AND RETURN
Fig. 41 — Optional Pumpout System Piping Schematic without Storage Tank — Configured to Store
Refrigerant in Cooler or Condenser (Unit with R Compressor Shown)
CONTROL
PANEL
FRAME
ASSEMBLY
VALVE
2
VALVE
4
VALVE
3
COMPRESSOR
OIL
HEATER
VALVE
5
ENTERING
WATER a23-1546
OIL FILL
FITTING
LEAVING
WATER
CONDENSER
OIL
SEPARATOR
Fig. 42 — Pumpout Unit
INSTALL VENT PIPING TO RELIEF VALVES — The
23XRV chiller is factory equipped with relief valves on the cooler and condenser shells. Refer to Fig. 43 and Table 12 for size and location of relief devices. Vent relief devices to the outdoors in accordance with ANSI/ASHRAE 15 (latest edition) Safety Code for Mechanical Refrigeration and all other applicable codes.
DANGER
Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation.
1. Dual pressure relief valves are mounted on the three-way valves in some locations to allow testing and repair without transferring the refrigerant charge. Three-way valve shafts should be turned either fully clockwise or fully counterclockwise so only one relief valve is exposed to refrigerant pressure at a time.
The flow area of discharge piping routed from more than one relief valve, or more than one heat exchanger, must be greater than the sum of the outlet areas of all relief valves that are expected to discharge simultaneously. All relief valves within a machinery room that are exposed to refrigerant may discharge simultaneously in the event of a fire. Discharge piping should lead to the point of final release as directly as possible with consideration of pressure drop in all sections downstream of the relief valves.
2. Provide a pipe plug near outlet side of each relief device for leak testing. Provide pipe fittings that allow vent piping to be disconnected periodically for inspection of valve mechanism.
3. Piping to relief devices must not apply stress to the device. Adequately support piping. A length of flexible tubing or piping near the relief device is essential on spring-isolated machines.
4. Cover the outdoor vent with a rain cap and place a condensation drain at the low point in the vent piping to prevent water build-up on the atmospheric side of the relief device.
33
UNITS WITH Q COMPRESSOR
a23-1657
WITH OPTIONAL ISOLATION
WITHOUT OPTIONAL ISOLATION
UNITS WITH R COMPRESSOR
a23-1657
WITH OPTIONAL ISOLATION
WITHOUT OPTIONAL ISOLATION
Fig. 43 — Relief Valve Arrangements
LOCATION
Discharge Pipe Assembly
Cooler
Condenser
Optional Storage Tank
FRAME
SIZE
3-5
3-5
3-5
N/A
NOTE: All valves relieve at 185 psig (1275 kPa).
Table 12 — Relief Valve Locations
RELIEF VALVE OUTLET SIZE
1 1 /
4
-in. NPT FEMALE CONNECTOR
1
1
/
4
-in. NPT FEMALE CONNECTOR
1 1 /
4
-in. NPT FEMALE CONNECTOR
1-in. NPT FEMALE CONNECTOR
QUANTITY WITHOUT
ISOLATION VALVES
1
2
2
2
QUANTITY WITH
ISOLATION VALVES
1
1
2
2
34
Step 7 — Make Electrical Connections —
Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes. Refer to Fig. 44 and
45 for typical wiring and component layout.
DANGER
Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding.
Failure to observe this precaution could result in severe bodily injury or loss of life.
WARNING
DC bus capacitors in the VFD retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait 5 minutes for the DC bus capacitors to discharge then check both the VFD DPI communications interface board status LEDs and the VFD with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER
The drive can operate at and maintain zero speed. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating or may operate at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER
Do not install modification kits with power applied to the drive. Disconnect and lockout incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.
DANGER
The drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.
CAUTION
The user is responsible for conforming with all applicable local, national and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
These instructions are intended for qualified electrical personnel familiar with servicing and installing AC drives. Any questions or problems with the products described in this manual should be directed to your local Carrier Service Office.
Wiring diagrams in this publication are for reference only and are not intended for use during actual installation; follow job specific wiring diagrams.
CAUTION
Do not attempt to start compressor (even for a rotation check) or apply test voltage of any kind while machine is under dehydration vacuum. Motor insulation breakdown and serious damage may result.
CAUTION
Low oil level may result if the oil pump is manually operated for more than a few minutes when the chiller is not running. The oil reclaim system does not return oil to the sump when the compressor is de-energized.
GROUNDING THE CONTROLS/DRIVE ENCLOSURE —
Use the following steps to ground the drive.
1. Open the left door of the control center.
2. Run a suitable equipment grounding conductor unbroken from the drive to earth ground. Tighten these grounding connections to the proper torque. See Fig. 6A, 6B and 29.
3. Close the door to the control center.
INSTALLING INPUT POWER WIRING — All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with the drive operation. Use grommets, when hubs are not provided, to guard against wire chafing.
Use the following steps to connect AC input power to the main input circuit breaker:
1. Turn off, lock out, and tag the input power to the drive.
2. Remove the input power wiring panel above the VFD circuit breaker and drill the number of openings for the
AC input leads (refer to Fig. 6A and 6B). Mount all conduit hardware on the input power wiring panel before reinstalling the input power wiring panel on the VFD enclosure. Take care that metal chips and hardware do not enter the enclosure.
3. Wire the AC input leads by routing them through the openings in the input power wiring panel.
CAUTION
Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with control and drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.
4. Connect the three-phase AC input power leads (per job specifications) to the appropriate input terminals of the circuit breaker. See Fig. 6A and 6B.
5. Tighten the AC input power terminals and lugs to the proper torque as specified on the input circuit breaker.
35
a23-1585
Fig. 44 — Typical Field Wiring Schematic
36
Fig. 44 — Typical Field Wiring Schematic (cont)
37 a23-1586
Fig. 44 — Typical Field Wiring Schematic (cont)
38
GENERAL
1.0
Variable frequency drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirements.
1.1
All field-supplied conductors, devices and the fieldinstallation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications.
1.2
The routing of field-installed conduit and conductors and the location of field-installed devices, must not interfere with equipment access or the reading, adjusting or servicing of any component.
1.3
Equipment installation and all starting and control devices, must comply with details in equipment submittal drawings and literature.
1.4
Contacts and switches are shown in the position they would assume with the circuit de-energized and the chiller shutdown.
NOTES FOR FIG. 44
CONTROL WIRING
3.0 Field-supplied control conductors to be at least 18 AWG or larger.
3.1
Ice build start/terminate device contacts, remote start/stop device contacts and spare safety device contacts, (devices not supplied by Carrier), must have 24 VAC rating. Max current is 60 mA, nominal current is 10 mA. Switches with gold plated bifurcated contacts are recommended.
3.2
Remove jumper wire between TB1-19 and TB1-20 before connecting auxiliary safeties between these terminals.
3.3
Each integrated contact output can control loads (VA) for evaporator pump, condenser pump, tower fan low, tower fan high, and alarm annunciator devices rated 5 amps at
115 VAC and up to 3 amps at 277 VAC.
CAUTION
Do not use aluminum conductors. Contractor/installer assumes all liability resulting from the use of aluminum conductors within the VFD enclosure.
CAUTION
Control wiring required for Carrier to start pumps and tower fan motors and establish flows must be provided to assure machine protection. If primary pump, tower fan and flow control is by other means, also provide a parallel means for control by Carrier. Failure to do so could result in machine freeze-up or overpressure.
POWER WIRING TO VFD
2.0
Provide a means of disconnecting branch feeder power to
VFD. Provide short circuit protection and interrupt capacity for branch feeder in compliance with all applicable codes.
2.1
If metal conduit is used for the power wires, the last 4 feet or greater should be flexible to avoid transmitting unit vibration into the power lines and to aid in serviceability.
2.2
Line side power conductor rating must meet VFD nameplate voltage and chiller minimum circuit ampacity.
2.3
Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Circuit breaker lugs will accommodate the quantity (#) and size cables (per phase) as follows:
VFD
MAX INPUT
AMPS
225A
335A
440A
520A
608A
STANDARD 65K AIC
LUG CAPACITY
(PER PHASE)
No. of
Conductors
3
3
3
3
3
Conductor
Range
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
OPTIONAL 100K AIC
LUG CAPACITY
(PER PHASE)
No. of
Conductors
2
2
2
3
3
Conductor
Range
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
2/0 — 400MCM
NOTE: If larger lugs are required, they can be purchased from the manufacturer of the circuit breaker (Cutler-Hammer or Square D).
2.4
Compressor motor and controls must be grounded by using equipment grounding lug provided inside unit mounted VFD enclosure.
Do not use control transformers in the control center as the power source for external or field-supplied contactor coils, actuator motors or any other loads.
3.4
Do not route control wiring carrying 30 V or less within a conduit or tray which has wires carrying 50 V or higher or along side wires carrying 50 V or higher.
3.5
Spare 4-20 mA output signal is designed for controllers with a non-grounded 4-20 mA input signal and a maximum input impedance of 500 ohms.
3.6
Flow devices to confirm evaporator or condenser pump flow are not required. However; if flow devices are used, wire as shown on drawing 23XRC1-1 (J3 lower). Remove jumper installed at these terminals and wire in a 4.3 K resistor in its place.
CCM
J3 (LOWER) a23-1587
The flow device and resistor must be installed in parallel at these terminals such that the resistor provides a signal when the flow device is open.
39
40 a23-1584
WIRING THE FIELD WIRING TERMINAL STRIPS FOR
LF-2 VFD — This section describes how to wire the field wiring terminal strips shown in Fig. 46A and 47A. The control terminal blocks are mounted to the inside of the enclosure, above and below the control panel.
NOTE: Up to 30 v may be measured across open contact terminals on the hazardous voltage terminal strip.
1. Turn off, lock out, and tag the input power to the drive.
Wait five minutes.
2. Verify that there is no voltage at the input terminals (L1,
L2, and L3) of the power module.
3. Verify that the status LEDs on the communications interface board are not lit. See Fig. 48A. The location of the communications interface board is shown in Fig. 6A.
4. Use a screwdriver to remove conduit twist outs in the control panel. Do not punch holes or drill into the top surface of the control center enclosure for field wiring.
Knockouts are provided in the back of the control center for field wiring connections.
5. Connect the control wiring as shown in Fig. 47A. Tighten all connections to 7 to 9 in.-lb.
WIRING THE FIELD WIRING TERMINAL STRIPS FOR
STD TIER VFD — This section describes how to wire the field wiring terminal strips shown in Fig. 46B and 47B. The control terminal blocks are mounted to the inside of the enclosure, on the right side.
NOTE: Up to 30 v may be measured across open contact terminals on the voltage terminal strip.
1. Turn off, lock out, and tag the input power to the drive.
Wait five minutes.
2. Verify that there is no voltage at the input terminals (L1,
L2, and L3) of the power module.
3. Verify that the keypad and drive status indicators
(Fig. 48B) are not lit. The location of the drive status indicator is shown in Fig. 6B.
4. Mount incoming wiring using the knockouts on the panel.
Do not drill holes into the top side of the enclosure.
5. Connect the control wiring as shown in Fig. 47B. Tighten all connections to 7 to 9 in.-lb.
CONNECT CONTROL INPUTS — Wiring may be specified for a spare safety switch, and a remote start/stop contact can be wired to the starter terminal strip. Additional spare sensors and Carrier Comfort Network
®
modules may be specified as well. These are wired to the machine control panel as indicated in Fig. 49.
CONNECT CONTROL OUTPUTS — Connect auxiliary equipment, chilled and condenser water pumps, and spare alarms as required and indicated on job wiring drawings.
CONNECT STARTER — The 23XRV chiller is equipped with a unit-mounted VFD starter (Fig. 50).
IMPORTANT: Be sure to ground the power circuit in accordance with the National Electrical Code (NEC), applicable local codes, and job wiring diagrams. Also, make sure correct phasing is observed for proper rotation.
CAUTION
Do not punch holes or drill into the top surface of the control center. Knockouts are provided in the back of the control center for wiring connections.
Remove the VFD shipping bracket shown in Fig. 16 for typical installations. For seismic units, do not remove the shipping bracket.
41
a23-1588
Fig. 46A — 23XRV Controls Schematic (LF-2 VFD)
42
a23-1589
Fig. 46A — 23XRV Controls Schematic (LF-2 VFD) (cont)
43
a23-1671
Fig. 46B — 23XRV Controls Schematic (Std Tier VFD)
44
a23-1590
Fig. 47A — Control Terminal Blocks (LF-2 VFD)
a23-1591
Fig. 47B — Control Terminal Blocks (Std Tier VFD)
45 a23-1673
DPI Communications Interface Board
Status LEDs a23-1592
Fig. 48A — Communications Interface Board Status LEDs (LF-2 VFD)
a19-1815
Allen-Bradley
4
7
1
8
5
2
9
6
3
NAME
STS (Status)
ENET
LINK
COLOR
Green
Yellow
Red
Red/Yellow
Green/Red
None (Unlit)
Red
Red/Green
Green
None (Unlit)
Green
STATE
Flashing
Steady
Flashing
DESCRIPTION
Drive ready but not running, and no faults are present.
Drive running, no faults are present.
Drive is not running. A type 2 (non-configurable) alarm condition exists and the drive cannot be started.
Steady
Flashing
Drive is not running, a type 1 alarm condition exists. The drive can be started.
A major fault has occurred. Drive cannot be started until fault condition is cleared.
Steady A non-resettable fault has occurred.
Flashing Alternately A minor fault has occurred. When running, the drive continues to run. System is brought to a stop under system control. Fault must be cleared to continue. Use parameter 950 [Minor Flt Config] to enable. If not enabled, acts like a major fault.
Flashing Alternately Drive is flash updating.
Off Adapter and/or network is not powered, adapter is not properly connected to the network, or adapter needs an IP address.
Flashing
Steady
An EtherNet/IP connection has timed out.
Adapter failed the duplicate IP address detection test.
Flashing Alternately Adapter is performing a self-test.
Flashing Adapter is properly connected but is not communicating with any devices on the network.
Steady
Off
Adapter is properly connected and communicating on the network.
Adapter is not powered or is not transmitting on the network.
Flashing
Steady
Adapter is properly connected and transmitting data packets on the network.
Adapter is properly connected but is not transmitting on the network.
NOTES:
1. A Type 1 alarm indicates that a condition exists. Type 1 alarms are user configurable.
2. A Type 2 alarm indicates that a configuration error exists and the drive cannot be started. Type 2 alarms are not configurable.
Fig. 48B — Drive Status Indicator Status LEDs (Std Tier VFD)
46
a23-1593
47
1
MAIN COMPRESSOR
MOTOR POWER
TO CHILLED WATER PUMP
TO CONDENSER WATER PUMP
TO COOLING TOWER FAN
1
6
1
7
1
8
2
9
TO
COOLING
TOWER
FROM
COOLING
TOWER
5
FROM
LOAD
4
TO
LOAD
3
DRAIN
9
SEE NOTE 4 a23-1594
LEGEND
1 —
Disconnect (Fused on VFD only) NOT by Carrier
2 —
Unit Mounted VFD/Control Center
3 —
Pressure Gages
4 —
Chilled Water Pump
5 —
Condenser Water Pump
6 —
Chilled Water Pump Starter
7 —
Condensing Water Pump Starter
8 —
Cooling Tower Fan Starter
9 —
Vents
Piping
Control Wiring
Power Wiring
IMPORTANT: Wiring and piping shown are for general point-ofconnection only and are not intended to show details for a specific installation. Certified field wiring and dimensional diagrams are available on request.
NOTES:
1. All wiring must comply with applicable codes.
2. Refer to Carrier System Design Manual for details regarding piping techniques.
3. Wiring not shown for optional devices such as:
• remote start-stop
• remote alarm
• optional safety device
• 4 to 20 mA (1 to 5 VDC) resets
• optional remote sensors
• kW output
• head pressure reference
4. Service clearance under the chiller can be enhanced if the grout is not extended along the entire length of the heat exchangers.
5. Carrier does not recommend pre-fab water piping.
6. Field-installed piping must be arranged and supported to avoid stress on the equipment and transmission of vibrations from the equipment as well as to prevent interference with routine access for the reading, adjusting and servicing of the equipment. Provisions shall be made for adjustment in each plane of the piping and for periodic and major servicing of the equipment.
7. Relief valves on the cooler and condenser must be vented to the outdoors as discharging refrigerant in closed spaces may displace oxygen and cause asphyxiation. All field-supplied refrigerant relief piping and devices must be used in accordance with ANSI/
ASHRAE standard 15.
Dual pressure relief valves are mounted on the three-way valves in some locations to allow testing and repair without transferring the refrigerant charge. Three-way valve shafts should be turned either fully clockwise or fully counterclockwise so only one relief valve is exposed to refrigerant pressure at a time.
The flow area of discharge piping routed from more than one relief valve, or more than one heat exchanger, must be greater than the sum of the outlet areas of all relief valves that are expected to discharge simultaneously. All relief valves within a machinery room that are exposed to refrigerant may discharge simultaneously in the event of a fire. Discharge piping should lead to the point of final release as directly as possible with consideration of pressure drop in all sections downstream of the relief valves.
8. Service access should be provided per standards ANSI/ASHRAE
15 and ANSI/NFPA 70 (NEC) and local safety codes. Unobstructed space adequate for inspection, servicing and rigging of all major components of the chiller is required. Shaded service areas are shown on the certified machine assembly drawing plan view and front view. See machine assembly component disassembly drawing for component removal. Space for rigging equipment and compressor removal is not shown.
9. The installation of chilled water and cooling tower water strainers should be considered to prevent debris from collecting in the waterboxes and degrading performance.
10. Flexible conduit should be used for the last few feet to the control center for vibration isolation of power wiring and control wiring.
Fig. 50 — 23XRV with Unit-Mounted VFD/Control Center
(Unit with R Compressor Shown)
48
COMPLETING THE INSTALLATION
This section provides instructions on how to perform a final check of the installation. Do not energize the VFD circuit breaker. This should only be done by qualified Carrier personnel in accordance with the 23XRV Start-Up and Service
Manual.
Checking the Installation —
Use the following procedure to verify the condition of the installation:
WARNING
DC bus capacitors in the VFD retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait 5 minutes for the DC bus capacitors to discharge then check both the VFD DPI communications interface board status LEDs and the VFD with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.
1. Turn off, lock out, and tag the input power to the drive.
Wait five minutes.
2. Verify that there is no voltage at the input terminals (L1,
L2, and L3) of the power module.
3. a. For LF-2 VFD, verify that the status LEDs on the
DPI communications interface board are not lit.
See Fig. 48A. The location of the communications interface board is shown in Fig. 6A.
b. For Std Tier VFD, verify that the keypad and drive status indicators (Fig. 48B) are not lit. The location of the drive status indicator is shown in Fig. 6B.
4. Remove any debris, such as metal shavings, from the enclosure.
5. Check that there is adequate clearance around the machine in accordance with the certified print.
6. Verify that the wiring to the terminal strip and the AC input power terminals is correct.
7. Check that the wire size is within terminal specifications and that the wires are tightened properly.
8. Check that specified branch circuit protection is installed and correctly rated.
9. Check that the incoming power is rated correctly.
10. Verify that a properly sized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the power leads. Verify that all ground leads are unbroken.
Oil Pump and Oil Heater —
The oil pump and oil heater are wired at the factory. It is not necessary to connect additional wiring to these components. See Fig. 51 and 52.
WARNING
Voltage to terminals T1 and T3 on the 1C and 6C contactors comes from a control transformer in the starter built to
Carrier specifications. Do not connect an outside source of control power to the chiller (terminals T1 and T3). An outside power source will produce dangerous voltage at the line side of the starter, because supplying voltage at the transformer secondary terminals produces input level voltage at the transformer primary terminals (see Fig. 46A,
46B, 51, and 52).
a23-1595
LEGEND
Factory Wiring
Power Panel Component Terminal
Contactor
Fig. 51 — Oil Pump Wiring
a23-1596
LEGEND
Factory Wiring
Power Panel Component Terminal
Fig. 52 — Oil Heater and Control Power Wiring
Connect Control Wiring —
All control wiring must use shielded cable. Refer to the job wiring diagrams for cable type and cable number. Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on machine control wiring label.
Carrier Comfort Network
®
Interface —
The Carrier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.
The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See
Fig. 49 for location of the CCN network connections on the terminal strip labelled CCN.
NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl,
Teflon*, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –4 F to 140 F (–20 C to 60 C) is required. See Table 13 for cables that meet the requirements.
Table 13 — Cable Manufacturers
MANUFACTURER
Alpha
American
Belden
Columbia
CABLE NO.
2413 or 5463
A22503
8772
02525
49
* Registered trademark of DuPont.
When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. See Table 14 for the recommended color codes:
Table 14 — Insulator Codes
SIGNAL TYPE
+
Ground
–
CCN BUS
CONDUCTOR
INSULATION
COLOR
Red
White
Black
CCN NETWORK
INTERFACE
(Control Panel)
+
G
–
If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network.
NOTE: This color scheme does not apply to SIO wiring between the CCM and Gateway module.
At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. See
Fig. 49. If the communication bus cable exits from one building and enters another, the shields must be connected to ground at the lightening suppressor in each building where the cable enters or exits the building (one point only).
To connect the 23XRV chiller to the network, proceed as follows (see Fig. 49):
1. Route wire through knockout in back of control panel.
2. Strip back leads.
3. Crimp one no. 8 size spring spade terminal on each conductor.
4. Attach red to “+” terminal and white to “G” terminal and black to “–” terminal of CCN Network interface located in the control panel.
BACnet* Communications Option Wiring —
The BACnet Communications option uses the UPC Open controller. The controller communicates using BACnet on an MS/
TP network segment communications at 9600 bps, 19.2 kbps,
38.4 kbps, or 76.8 kbps.
Wire the controllers on an MS/TP network segment in a daisy-chain configuration. Wire specifications for the cable are
22 AWG (American Wire Gage) or 24 AWG, low-capacitance, twisted, stranded, shielded copper wire. The maximum length is 2000 ft.
Install a BT485 terminator on the first and last controller on a network segment to add bias and prevent signal distortions due to echoing. See Fig. 53-55.
To wire the UPC Open controller to the BAS network:
1. Pull the screw terminal connector from the controller's
BAS Port.
2. Check the communications wiring for shorts and grounds.
3. Connect the communications wiring to the BAS port’s screw terminals labeled Net +, Net -, and Shield.
NOTE: Use the same polarity throughout the network segment.
4. Insert the power screw terminal connector into the UPC
Open controller's power terminals if they are not currently connected.
5. Verify communication with the network by viewing a module status report. To perform a module status report using the BACview keypad/display unit, press and hold the “FN” key then press the “.” Key.
To install a BT485 terminator, push the BT485, on to the
BT485 connector located near the BACnet connector.
NOTE: The BT485 terminator has no polarity associated with it.
To order a BT485 terminator, consult Commercial Products i-Vu
®
Open Control System Master Prices.
MS/TP WIRING RECOMMENDATIONS — Recommendations are shown in Tables 15 and 16. The wire jacket and UL temperature rating specifications list two acceptable alternatives. The Halar specification has a higher temperature rating and a tougher outer jacket than the SmokeGard specification, and it is appropriate for use in applications where the user is concerned about abrasion. The Halar jacket is also less likely to crack in extremely low temperatures.
NOTE: Use the specified type of wire and cable for maximum signal integrity.
Lead-Lag Control Wiring —
The 23XRV chiller can be wired for lead-lag operation in either series or parallel. See
Fig. 56 for applicable wiring schematics.
Install Field Insulation
CAUTION
Protect insulation from weld heat damage and weld splatter. Cover with wet canvas cover during water piping installation.
When installing insulation at the job site, insulate the following components:
• compressor
• discharge pipe assembly
• cooler shell
• cooler tube sheets
• condenser shell
• condenser tubesheets
• suction piping
• economizer
• economizer muffler
• motor cooling drain
• oil reclaim piping
• vaporizer chamber
• refrigerant liquid line to cooler
NOTE: Insulation of the waterbox covers is applied only at the job site by the contractor. When insulating the covers, make sure there is access for removal of waterbox covers for servicing. See Fig. 57A for the insulation area for units with the Q compressor. See Fig. 57B for the insulation area for units with the R compressor.
* Sponsored by ASHRAE (American Society of Heating, Refrigerating and Air Conditioning Engineers).
50
BT485
TERMINATOR
BACNET
CONNECTION
(BAS PORT)
Tx1 LED
Rx1 LED
Tx2 LED
Rx2 LED
EIA-485
JUMPERS
POWER LED
Fig. 53 — UPC Open Controller
2
3
4
6
7
8
09
1
4
6
7
8
09
1
3
2
BACNET
BAUD RATE
DIP SWITCHES
ADDRESS
ROTARY
SWITCHES
RUN LED
ERROR LED
Fig. 54 — Network Wiring
51
Fig. 55 — BT485 Terminator Installation
Table 15 — MS/TP Wiring Recommendations
SPECIFICATION
Cable
Conductor
Insulation
Color code
Twist Lay
Shielding
Jacket
DC Resistance
Capacitance
Characteristic Impedance
Weight
UL Temperature Rating
RECOMMENDATION
Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable
22 or 24 AWG stranded copper (tin plated)
Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D.
Black/White
2 in. (50.8 mm) lay on pair 6 twists/foot (20 twists/meter) nominal
Aluminum/Mylar shield with 24 AWG TC drain wire
SmokeGard Jacket (SmokeGard PVC) 0.021 in. (0.5334 mm) wall 0.175 in. (4.445 mm) O.D.
Halar Jacket (E-CTFE) 0.010 in. (0.254 mm) wall 0.144 in. (3.6576 mm) O.D.
15.2 Ohms/1000 feet (50 Ohms/km) nominal
12.5 pF/ft (41 pF/meter) nominal conductor to conductor
100 Ohms nominal
12 lb/1000 feet (17.9 kg/km)
SmokeGard 167°F (75°C)
Halar -40 to 302°F (-40 to 150°C)
300 Vac, power limited
UL: NEC CL2P, or better
Voltage
Listing
LEGEND
AWG
— American Wire Gage
CL2P
— Class 2 Plenum Cable
DC
FEP
— Direct Current
— Fluorinated Ethylene Polymer
NEC
O.D.
TC
UL
— National Electrical Code
— Outside Diameter
— Tinned Copper
— Underwriters Laboratories
Wire Type
Table 16 — Open System Wiring Specifications and Recommended Vendors
WIRING SPECIFICATIONS
Description
RECOMMENDED VENDORS AND PART NUMBERS
Connect Air
International
Belden RMCORP
Contractors
Wire and Cable
MS/TP
Network (RS-485)
22 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
24 AWG, single twisted shielded pair, low capacitance, CL2P,
TC foam FEP, plenum rated. See MS/TP Installation Guide for specifications.
Rnet
4 conductor, unshielded, CMP, 18 AWG, plenum rated.
LEGEND
AWG
— American Wire Gage
CL2P
— Class 2 Plenum Cable
CMP
FEP
TC
— Communications Plenum Rated
— Fluorinated Ethylene Polymer
— Tinned Copper
W221P-22227
W241P-2000F
—
25160PV
82841
25120-OR
W184C-2099BLB
6302UE
21450
CLP0520LC
—
CLP0442
52
a23-1597
53
a23-1598
54
55 a23-1666
56 a23-1667
Copyright 2012 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230006-01 Printed in U.S.A.
Form 23XRV-3SI Pg 58 8-12 Replaces: 23XRV-2SI
INSTALLATION START-UP REQUEST CHECKLIST
Machine Model Number: 23XRV Serial Number:
To:
Attn.:
Date
Project Name
Carrier Job Number
The following information provides the status of the chiller installation. Send a copy of this checklist to the local Carrier Service office after it has been completed and signed-off by the Purchaser and Job Site Supervisor.
YES/NO
(N/A)
DATE TO BE
COMPLETED
1. The machine is level within
1
/
2
in. end to end.
2. The machine components are installed and connected in accordance with the installation instructions.
3. The isolation package and grouting (if necessary) are installed.
4. The relief valves are piped to the atmosphere.
5. All piping is installed and supported. Direction of flow is indicated in accordance with the installation instructions and job prints.
a. Chilled water piping b. Condenser water piping c. Waterbox drain piping d. Pumpout unit condenser piping (if installed) e. Other
6. Gages are installed as called for on the job prints required to establish design flow for the cooler and condenser.
a. Water pressure gages IN and OUT b. Water temperature gages IN and OUT
7. The machine’s control center wiring is complete. The wiring is installed per installation instructions and certified prints.
a. Power wiring to VFD circuit breaker. (If chiller was disassembled during installation, motor leads must not be taped until the Carrier technician megger tests the motor.) b. Carrier controls can independently energize water pumps and tower fan.
c. Line side voltage is within ±10% of chiller nameplate voltage.
d. Other
COMMENTS:
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230006-01 Printed in U.S.A.
Form 23XRV-3SI Pg CL-1 8-12 Replaces: 23XRV-2SI
TESTING
1. The cooling tower fan has been checked for blade pitch and proper operation.
2. The chilled water and condenser water lines have been: a. Filled b. Tested c. Flushed d. Vented e. Strainers cleaned
3. The chilled water and condenser water pumps have been checked for proper rotation and flow.
4. The following cooling load will be available for start-up: a. 25% b. 50% c. 75% d. 100%
5. The refrigerant charge is at the machine.
6. Services such as electrical power and control air will be available at start-up.
7. The electrical and mechanical representatives will be available to assist in commissioning the machine.
8. The customer’s operators will be available to receive instructions for proper operation of the chiller after start-up.
Concerns about the installation/request for additional assistance:
YES/NO DATE TO BE
COMPLETED
I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.
Your contact at the job site will be _______________________________________________________________________________
Phone number ______________________________________________________________________________________________
Cell/Pager number ___________________________________________________________________________________________
Fax number ________________________________________________________________________________________________
In accordance with our contract, we hereby request the services of your technician to render start-up services per contract terms for this job on (Date). I understand that the technician’s time will be charged as extra services due to correcting items in this checklist that are incomplete.
Signature of Purchaser ________________________________________________________________________________________
Signature of Job Site Supervisor ________________________________________________________________________________
Copyright 2012 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230006-01 Printed in U.S.A.
Form 23XRV-3SI Pg CL-2 8-12 Replaces: 23XRV-2SI
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