Carrier HFC-134A User Manual

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.

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, Refrigeration and Air-Conditioning Engineers) (Safety Code for Mechanical Refrigeration). 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 to leak test. 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 voltage is present on motor leads even though the motor is not running. Open the power supply disconnect before touching motor leads or terminals.

DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and vapor) has been removed from chiller. Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.

DO NOT USE eyebolts or eyebolt holes to rig heat exchangers or the entire assembly.

DO NOT work on high-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 ILLEGAL. 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.

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.

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.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book	2	Catalog No. 532-309	Printed in U.S.A.	Form 23XRV-1SI	Pg 1	309 6-06	Replaces: New
Tab	5e

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Job Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

•INSPECT SHIPMENT

•IDENTIFY MACHINE

•INSTALLATION REQUIREMENTS

•PROVIDE MACHINE PROTECTION

Rigging the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

•RIG MACHINE ASSEMBLY

•RIG MACHINE COMPONENTS

Separate Machine Components . . . . . . . . . . . . . . . . . 13

•SEPARATE COOLER AND CONDENSER

•REMOVE THE CONTROLS/DRIVE ENCLOSURE FROM THE CONDENSER

•REMOVE THE DISCHARGE PIPE ASSEMBLY FROM THE CONDENSER

•SEPARATE THE COMPRESSOR FROM THE CONDENSER

•SEPARATE THE VAPORIZER FROM THE

CONDENSER

VFD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Install Machine Supports . . . . . . . . . . . . . . . . . . . . . . . . 22

•INSTALL STANDARD ISOLATION

•INSTALL ACCESSORY ISOLATION

•INSTALL SPRING ISOLATION

Connect Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

•INSTALL WATER PIPING TO HEAT EXCHANGERS

•INSTALL VENT PIPING TO RELIEF VALVES

Make Electrical Connections . . . . . . . . . . . . . . . . . . . . 30

•GROUNDING THE CONTROLS/DRIVE ENCLOSURE

•INSTALLING INPUT POWER WIRING

•WIRING THE FIELD WIRING TERMINAL STRIPS

•CONNECT CONTROL INPUTS

•CONNECT CONTROL OUTPUTS

•CONNECT STARTER

COMPLETING THE INSTALLATION . . . . . . . . . . . 43-47

Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . 43

Oil Pump and Oil Heater . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connect Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 43

Carrier Comfort Network Interface. . . . . . . . . . . . . . . 43

Lead-Lag Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . 44

Install Field Insulation and Lagging . . . . . . . . . . . . . 44

INSTALLATION START-UP REQUEST

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

Receiving the Machine

INSPECT SHIPMENT

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. Manufacturer 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. 1-4) — 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 job data.

a23-1547

Fig. 1 — Refrigeration Machine Nameplate

2

		S –Special
	23XRV – High Efficiency	Not Used
	Variable Speed Screw Chiller
	Cooler Size*	Voltage Code
		3 – 380-3-60
	30-32
		4 – 416-3-60
	35-37
		5 – 460-3-60
	40-42
		9 – 400-3-50
	45-47
	50-52	Drive	Rectifier Max	Inverter Max
	55-57
		Frame	Input Amps†	Output Amps†
	Condenser Size*	AA	440	442
		BA	520	442
	30-32	BB	520	520
	35-37	CC	608	608
	40-42
	45-47	Motor Code	Max Motor Amps
	50-52
	55-57	P	265
		Q	283
	Economizer Option	R	306
		S	334
	E – With Economizer	T	368
	N – No Economizer	U	421	a23-1533
		V	440

R – Compressor

*First number denotes frame size.

†Maximum limits only. Additional application limits apply that may reduce these ampacities.

Fig. 2 — Model Number Identification

Identifying the Drive by Part Number — Each LiquiFlo™ 2.0 AC drive can be identified by its part number. See Fig. 5. This number appears on the shipping label and on the VFD nameplate.

Drive Input Component Location — Figure 6 identifies the control center components.

Identifying the Power Module by I.D. Number — Each LiquiFlo 2.0 AC power module can be identified by its I.D. number. See Fig. 5. This number appears on the shipping label and on the power module’s nameplate. Power ratings are provided in Table 1.

INSTALLATION REQUIREMENTS — Certain 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 Air Flow 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.

Rigging the Machine — 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.

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 2-9B. 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.

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 5-9B for machine component weights.

3

1

21

20

19

-1548

41 40 39 38

37

-1549

4

2 3

5

6

7

8

9

10

12 11

13

14

16 15

18 17

22

23

24

25

26

36 35 34

27

33

28

32 31 30 29

45

42 43 44

46

47

48

49

50

a23-1550 51

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

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

38— Economizer

39— Motor Cooling Sight Glass

40— Motor Cooling Isolation Valve

41— Vaporizer Drain Sight Glass

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

Fig. 3 — Typical 23XRV Components

4

6

4 5

2 3

1

9

7

a23-1551 8

10	12 13
	11

14

	15
20	16
	17
a23-1552	19
	18

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)

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)

Fig. 4 — Typical 23XRV Installation (Sensor Locations)

a23-1553

Fig. 5 — VFD Nameplate

5

6

-a23
1554	21	1

19

18

17

16

1— Input Inductor Assembly

2— Capacitor Bank Assembly

3— Pre-Charge Resistor Assembly

4— AC Contactor (3)

5— Power Module Assembly

6— Terminal Block, 10-Position (2)

7— Power Module Nameplate

8— Fuse Black, 30A, 600V, Class CC

9— Fuse, Class CC, 600V, 15A (2)

10— Fuse, Class CC, 600V, 5A (1)

11— Fuse, Class CC, 600V, 20A (3)

10

	11		9		20
2	8	13	8	5	6

16	8	14	3	4	7	6
	12	15

12— Fuse, Class CC, 600V, 1A (3)

13— Transformer, 3kVA

14— Line Sync PC Board Assembly

15— Line Sync Board Cover

16— Fan, 115V (3)

17— Circuit Breaker, 600V, 15A

18— Circuit Breaker, 600V

19— Lug, Ground, 2-600 MCM

20— Communications Interface Board

21— Input Power Wiring Panel

Fig. 6 — Control Center Components

a23-1555

Fig. 7 — Machine Electrical Data Nameplate

	HEAT EXHANGER	COMPRESSOR	MAXIMUM WEIGHT	VESSEL	DIM.	CHAIN LENGTH			DIM.	DIM.
	CODE	FRAME SIZE*	(lb)	LENGTH	“A”	“B”	“C”	“D”	“E”	“F”
	30-32		19,187	12′	6′-10″	13′- 5″	13′-0″	12′- 5″	3′-11″	3′- 8″
	35-37		20,589	14′	7′- 8″	13′-10″	13′-5″	12′-10″	3′-11″	3′- 8″
	40-42	R	23,928	12′	6′-10″	13′- 6″	12′-8″	12′- 3″	4′- 1″	3′-11″
	45-47		25,167	14′	7′- 8″	13′-11″	13′-2″	12′- 8″	4′- 1″	3′-11″
	50-52		26,950	12′	6′-10″	13′-10″	12′-7″	12′- 9″	4′- 0″	4′- 4″
	55-57		28,479	14′	7′- 8″	14′- 4″	13′-1″	13′- 1″	4′- 0″	4′- 4″

*The 11th character of the chiller model number indicates the frame size of the compressor.

CHAIN “D” CHAIN “B” (SEE NOTE #2) (SEE NOTE #2)

CHAIN “C” (SEE NOTE #2)

15´-0´´ MIN. HEIGHT ABOVE FLOOR

“E”

“A”

“F”

a23-1556

MACHINE RIGGING GUIDE

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′ lifting height. Some minor adjustments may be required.

Fig. 8 — Machine Rigging Guide (Cooler Size 30 Through 57)

7

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)

0’-3”

0’-3”

4’-10” 0’-5”

MOTOR SERVICE
CLEARANCE
1’ - 10” (559 mm)	FRAME R COMPRESSOR 3’ - 0” (915mm)
	RECOMMENDED OVERHEAD SERVICE CLEARANCE

C

2’ MIN

(610 mm)

B

	A	(WIDEST POINT)
SERVICE AREA		4’ - 10” MIN
a23-1557		(1219 mm)

Fig. 9 — 23XRV Dimensions (Refer to Tables 2 and 3)

Table 1 — Drive Assembly and Power Module Ratings

			ENCLOSURE	INPUT	MAX INPUT	MAX OUTPUT
	CARRIER PART NUMBER	FRAME SIZE		VOLTAGE (V)	CURRENT	CURRENT* at 4kHZ
			TYPE
				RANGE	(AMPS)	(AMPS)
	23XRA2AA_ _ _ _ _ _ _ _ _ _ _	Frame 2AA	NEMA 1	380 to 460	440	442
	23XRA2BA_ _ _ _ _ _ _ _ _ _ _	Frame 2BA	NEMA 1	380 to 460	520	442
	23XRA2BB_ _ _ _ _ _ _ _ _ _ _	Frame 2BB	NEMA 1	380 to 460	520	520
	23XRA2CC_ _ _ _ _ _ _ _ _ _ _	Frame 2CC	NEMA 1	380 to 460	608	608

*110% output current capability for one minute, 150% output current for 5 seconds.

Table 2 — 23XRV Dimensions (Nozzle-In-Head Waterbox)

HEAT EXCHANGER		A (Length, with Nozzle-in-Head Waterbox)						B (Width)		C (Height)
	1 Pass		2-Pass*		3 Pass†
SIZE
	ft-in.	mm	ft-in.	mm	ft-in.	mm	ft-in.		mm	ft-in.	mm
30 to 32	14- 31/4	4350	13- 81/4	4172	14- 31/4	4350	6-	4	1930	7-25/8	2200
35 to 37	15-113/4	4870	15- 43/4	4693	15-113/4	4870	6-	4	1930	7-25/8	2200
40 to 42	14- 9	4496	14- 31/8	4347	14- 6	4420	6- 8½		2045	7-6½	2299
45 to 47	16- 51/2	5017	15-115/8	4867	16- 21/2	4940	6- 8½		2045	7-6½	2299
50 to 52	14-10	4521	14- 41/2	4382	14- 61/2	4432	6-113/4		2127	7-63/4	2305
55 to 57	16- 61/2	5042	16- 1	4902	16- 3	4953	6-113/4		2127	7-63/4	2305

*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, Refrigeration, 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 psi design and victaulic connections. The 300 psi design and/or flanges will add length. See certified drawings.

6.Dished head waterbox covers not available for 3 pass design.

8

Table 3 — 23XRV Dimensions (Marine Waterbox)

HEAT EXCHANGER	A (Length, Marine Waterbox — not shown)					MAXIMUM			MAXIMUM
	2-Pass*			1 or 3 Pass†			B WIDTH		C HEIGHT
SIZE
	ft-in.		mm	ft-in.	mm	ft-in.		mm	ft-in.	mm
30 to 32	14- 9		4496	16-43/4	4997	6-93/8		2067	7-25/8	2200
35 to 37	16- 51/2		5017	18-11/4	5518	6-93/8		2067	7-25/8	2200
40 to 42	15- 23/4		4642	16-81/4	5086	6-93/4		2076	7-61/2	2299
45 to 47	16-111/4		5163	18-43/4	5607	6-93/4		2076	7-61/2	2299
50 to 52	15- 31/2		4661	16-81/2	5093	7-1		2159	7-63/4	2305
55 to 57	17- 0		5182	18-5	5613	7-1		2159	7-63/4	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, Refrigeration, 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 psi design and victaulic connections. The 300 psi design and/ or flanges will add length. See certified drawings.

Table 4 — 23XRV Waterbox Nozzle Sizes

	FRAME	PRESSURE	PASS	NOMINAL PIPE SIZE (in.)		ACTUAL PIPE ID (in.)
	SIZE	psig (kPa)		Cooler	Condenser	Cooler	Condenser
		150/300	1	10	10	10.020	10.020
	3		2	8	8	7.981	7.981
		(1034/2068)
			3	6	6	6.065	6.065
		150/300	1	10	10	10.020	10.020
	4		2	8	8	7.981	7.981
		(1034/2068)
			3	6	6	6.065	6.065
		150/300	1	10	10	10.020	10.020
	5		2	8	10	7.981	10.020
		(1034/2068)
			3	6	8	6.065	7.981

Table 5 — 23XRV Compressor Weights

	ENGLISH	SI
MOTOR	Total Compressor	Total Compressor
CODE	Weight*	Weight*
	(lb)	(kg)
P
Q
R
S	4866	2207
T
U
V

*Compressor weight is comprised of compressor, stator, rotor, and end bell.

Table 6 — 23XRV Component Weights — TR Compressor

	FRAME 3			FRAME 4			FRAME 5
COMPONENT	HEAT EXCHANGER*			HEAT EXCHANGER*			HEAT EXCHANGER*
	lb		kg	lb		kg	lb		kg
Suction Elbow	179		81	237		108	232		105
Discharge Pipe Assembly	747		339	747		339	747		339
Control Center	1650		749	1650		749	1650		749
Discharge Pipe Adapter Flange	178		81	178		81	178		81
Optional Isolation Valves	70		32	70		32	115		52
Optional Unit Mounted Pumpout Unit	164		75	164		75	164		75
Vaporizer Oil Sump	700		318	700		318	700		318
Economizer	542		246	542		246	542		246

*To determine compressor frame size, refer to Fig. 2.

9

Table 7 — 23XRV Heat Exchanger Data

			ENGLISH						SI
	Dry Rigging Weight			Machine Charge			Dry Rigging Weight				Machine Charge
		(lb)*						(kg)*
CODE			Refrigerant		Liquid Weight				Refrigerant				Liquid
	Cooler	Condenser	Weight (lb)			(lb)	Cooler	Condenser	Weight (kg)			Weight (kg)
	Only	Only	With	Without	Cooler	Condenser	Only	Only	With		Without	Cooler		Condenser
			Economizer	Economizer					Economizer		Economizer
30	4148	3617	800	650	464	464	1877	1676	363		295	210		210
31	4330	3818	800	650	531	542	1959	1769	363		295	241		246
32	4522	4023	800	650	601	621	2046	1860	363		295	273		282
35	4419	4529	910	760	511	513	2000	2089	413		345	232		233
36	4627	4758	910	760	587	602	2094	2195	413		345	266		273
37	4845	4992	910	760	667	692	2193	2299	413		345	303		314
40	5008	4962	900	750	863	915	2675	2746	408		340	391		415
41	5178	5155	900	750	930	995	2758	2839	408		340	422		451
42	5326	5347	900	750	990	1074	2832	2932	408		340	449		487
45	5463	5525	1015	865	938	998	2882	3001	460		392	425		453
46	5659	5747	1015	865	1014	1088	2976	3108	460		392	460		494
47	5830	5967	1015	865	1083	1179	3061	3214	460		392	491		535
50	5827	6013	1250	1100	1101	1225	3182	3304	567		499	499		556
51	6053	6206	1250	1100	1192	1304	3294	3397	567		499	541		591
52	6196	6387	1250	1100	1248	1379	3364	3485	567		499	566		626
55	6370	6708	1430	1280	1201	1339	3429	3620	649		581	545		607
56	6631	6930	1430	1280	1304	1429	3556	3726	649		581	591		648
57	6795	7138	1430	1280	1369	1514	3636	3826	649		581	621		687

*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.

Table 8A — 23XRV Additional Data for Cooler Marine Waterboxes*

HEAT EXCHANGER		ENGLISH			SI
FRAME, PASS	Psig	Rigging Weight	Water Volume	kPa	Rigging Weight	Water Volume
		(lb) (see Note 2)	(gal)		(kg) (see Note 2)	(L)
FRAME 3, 1 AND 3 PASS	150	730	84	1034	331	318
FRAME 3, 2 PASS	150	365	42	1034	166	159
FRAME 4, 1 AND 3 PASS	150	1888	109	1034	856	413
FRAME 4, 2 PASS	150	944	54	1034	428	204
FRAME 5, 1 AND 3 PASS	150	2445	122	1034	1109	462
FRAME 5, 2 PASS	150	1223	61	1034	555	231
FRAME 3, 1 AND 3 PASS	300	860	84	2068	390	318
FRAME 3, 2 PASS	300	430	42	2068	195	159
FRAME 4, 1 AND 3 PASS	300	2162	109	2068	981	413
FRAME 4, 2 PASS	300	1552	47	2068	704	178
FRAME 5, 1 AND 3 PASS	300	2655	122	2068	1204	462
FRAME 5, 2 PASS	300	1965	53	2068	891	201

*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).

10

Table 8B — 23XRV Additional Data for Condenser Marine Waterboxes*

HEAT EXCHANGER		ENGLISH			SI
FRAME, PASS	Psig	Rigging Weight	Water Volume	kPa	Rigging Weight	Water Volume
		(lb) (see Note 2)	(gal)		(kg) (see Note 2)	(L)
FRAME 3, 1 AND 3 PASS	150	N/A	N/A	1034	N/A	N/A
FRAME 3, 2 PASS	150	365	42	1034	166	159
FRAME 4, 1 AND 3 PASS	150	N/A	N/A	1034	N/A	N/A
FRAME 4, 2 PASS	150	989	54	1034	449	204
FRAME 5, 1 AND 3 PASS	150	N/A	N/A	1034	N/A	N/A
FRAME 5, 2 PASS	150	1195	60	1034	542	227
FRAME 3, 1 AND 3 PASS	300	N/A	N/A	2068	N/A	N/A
FRAME 3, 2 PASS	300	430	42	2068	195	159
FRAME 4, 1 AND 3 PASS	300	N/A	N/A	2068	N/A	N/A
FRAME 4, 2 PASS	300	1641	47	2068	744	178
FRAME 5, 1 AND 3 PASS	300	N/A	N/A	2068	N/A	N/A
FRAME 5, 2 PASS	300	1909	50	2068	866	189

*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).

Table 9A — 23XRV Waterbox Cover Weights — English (lb)

			COOLER						CONDENSER
WATERBOX	Frame 3		Frame 4		Frame 5		Frame 3		Frame 4		Frame 5
DESCRIPTION	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged
	Nozzles		Nozzles		Nozzles		Nozzles		Nozzles		Nozzles
NIH,1 pass Cover 150 PSIG	282	318	148	185	168	229	282	318	148	185	168	229
NIH,2 pass Cover 150 PSIG	287	340	202	256	222	276	287	340	191	245	224	298
NIH,3 pass Cover 150 PSIG	294	310	472	488	617	634	294	310	503	519	628	655
NIH Plain End, 150 PSIG	243	243	138	138	154	154	225	225	138	138	154	154
MWB End Cover, 150 PSIG*	243/315	243/315	138/314	138/314	154/390	154/390	225/234	225/234	138/314	138/314	154/390	154/390
NIH,1 pass Cover 300 PSIG	411	486	633	709	764	840	411	486	633	709	764	840
NIH,2 pass Cover 300 PSIG	411	518	626	733	760	867	411	578	622	729	727	878
NIH,3 pass Cover 300 PSIG	433	468	660	694	795	830	433	468	655	689	785	838
NIH Plain End, 300 PSIG	291	291	522	522	658	658	270	270	522	522	658	658
MWB End Cover, 300 PSIG*	445/619	445/619	522/522	522/522	658/658	658/658	359/474	359/474	522/522	522/522	658/658	658/658

*Rows with two entries list nozzle end and return end weights.

Table 9B — 23XRV Waterbox Cover Weights — SI (kg)

				COOLER						CONDENSER
	WATERBOX	Frame 3		Frame 4		Frame 5		Frame 3		Frame 4		Frame 5
	DESCRIPTION
		Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged	Victaulic	Flanged
		Nozzles		Nozzles		Nozzles		Nozzles		Nozzles		Nozzles
	NIH,1 pass Cover 150 PSIG	128	144	67	84	76	104	128	144	67	84	76	104
	NIH,2 pass Cover 150 PSIG	130	154	92	116	101	125	130	154	87	111	102	135
	NIH,3 pass Cover 150 PSIG	133	141	214	221	280	288	133	141	228	235	285	297
	NIH Plain End, 150 PSIG	110	110	63	63	70	70	102	102	63	63	70	70
	MWB End Cover, 150 PSIG	110/143	110/143	63/142	63/142	70/177	70/177	102/106	102/106	63/142	63/142	70/177	70/177
	NIH,1 pass Cover 300 PSIG	186	220	287	322	347	381	186	220	287	322	346	381
	NIH,2 pass Cover 300 PSIG	186	235	284	332	344	393	186	235	282	331	330	398
	NIH,3 pass Cover 300 PSIG	196	212	299	315	361	376	196	212	297	313	356	380
	NIH Plain End, 300 PSIG	132	132	237	237	298	298	122	122	237	237	298	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.

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.

Before rigging the compressor remove control panel and control center.

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.

11

		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)
	CONDENSER
	PRESSURE
	CABLE
	WATER SENSOR CABLES
	FOR NOZZLE ARRANGEMENTS
	A,B,C,E,F,P,Q,R,T,&U
	(SAME FOR OTHER END
	OF MACHINE)
	DISCHARGE END
		CABLE TRAY CONTAINING
	DISCH. TEMP. CABLE	ENT/LVG CHILLED LIQUID CABLES
		ENT/LVG COND. LIQUID CABLES
	DISCH. PRESS. CABLE
		COND, PRESS CABLE
	DISCH. PRESS. SWITCH
		COMP’R DISCH TEMP. CABLE
		EVAP. PRESS. CABLE
	COOLER	EVAP. REFRIG. LIQUID TEMP. CABLE
		MOTOR TEMP. CABLE
	PRESSURE	VFD COOLANT SOLENOID CABLE
	CABLE	OIL PRESS. CABLE

DISCH. PRESS. SWITCH CABLE

HGBP CONDUIT (OPTIONAL)

CONTROL

PANEL

MOTOR TEMPERATURE

CABLE

SUCTION END

VFD COOLING

SOLENOID

CABLE

HGBP CONDUIT (OPTIONAL)

EVAP REFRIG. LIQUID	LEGEND
TEMP. CABLE
HGBP	— Hot Gas Bypass
HTR	— Heater

ENT/LVG — Entering/Leaving

Fig. 10 — Electrical Cable Routing (Top View)

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

		OIL PUMP			CABLE TRAY CONTAINING	OIL HEATER
		CONDUIT			VAPORIZER HEATER CONDUIT	CONDUIT
	LEGEND		OIL	OIL SUMP	OIL HTR CONDUIT	EVAPORATOR
					OIL PUMP CONDUIT	REFRIG LIQUID
				TEMPERATURE
			PRESSURE		OIL RECLAIM ACTUATOR CABLE	TEMPERATURE
HGBP	— Hot Gas Bypass		LEAVING	CABLE	OIL SUMP PRESS. CABLE	SENSOR CABLE
		OIL RECLAIM
HTR	— Heater		FILTER	OIL SUMP	OIL PRESS. CABLE
		ACTUATOR
ENT/LVG— Entering/Leaving			CABLE	PRESSURE	OIL SUMP TEMP. CABLE
		CABLE
				CABLE	HGBP CONDUIT (OPTIONAL)	a23-1559

Fig. 11 — Electrical Cable Routing (Back View)

12

Separate Machine Components — The design of the 23XRV allows for disassembly at the job site so that individual 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.

3.Cut the motor cooling refrigerant drain line.

4.Rig the suction elbow and disconnect the compressor suction line at the cooler and compressor. Remove bolts from the vaporizer vent line flange.

5.Cut the VFD cooling drain line.

6.Cut the oil reclaim line(s).

7.Cut the hot gas bypass line between the HGBP (hot gas bypass) solenoid valve and the cooler feed line.

8.Unbolt the cooler liquid feed line 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 (see Fig. 12).

	17	19
	18			1
	16
				2
	15				3
	14				4
					5
	5
					6
					5
	13	12
		11		10	7
				9
	a23-1560
				8
1	— Suction Elbow (Unbolt)		11	— VFD Cooling Drain Line
2	— Vaporizer Vent Line (Unbolt)		12	— Oil Reclaim Line (Cut)
3	— Motor Cooling Line (Unbolt)		13	— Vaporizer Hot Gas Return Line (Cut)
4	— Motor Cooling Drain Line (Cut)		14	— Discharge Isolation Valve (Optional)
5	— Tubesheet Mounting Bracket		15	— Condenser Relief Valves (Unscrew)
6	— Bearing Oil Drain Line		16	— Discharge Temperature Sensor
7	— Support Plate		17	— Discharge Pipe Assembly Relief Valve (Unscrew)
8	— In-Line Economizer Orifice Plate		18	— Discharge Pressure Sensor
9	— Cooler Liquid Feed LIne (Unbolt)		19	— Discharge Pressure Switch
10	— Hot Gas Bypass Line (Cut)

Fig. 12 — Cooler/Discharge Pipe Assembly Removal

13

9. Cut the vaporizer refrigerant return line as shown.

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.

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.

OPTIONAL

HOT GAS

BYPASS LINE

EVAPORATOR

REFRIGERANT

LIQUID

TEMPERATURE

SENSOR

COOLER

REFRIGERANT

PUMPOUT

VALVE

a23-1635

Fig. 13 — Evaporator Refrigerant Liquid Temperature Sensor on Bottom of Cooler

LEAVING CONDENSER	LEAVING CHILLED
LIQUID TEMPERATURE	LIQUID TEMPERATURE
SENSOR	SENSOR

	ENTERING CONDENSER		ENTERING CHILLED
	LIQUID TEMPERATURE	a23-1563	LIQUID TEMPERATURE
	SENSOR		SENSOR

Fig. 14 — Chiller End View

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.

Do not attempt to remove the VFD without first isolating the refrigerant charge in the condenser. Damage to one of the motor terminals during VFD removal will result in an uncontrolled refrigerant leak.

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 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. Remove any conduits that bring power to the VFD. See Fig. 16.

VFD
REFRIGERANT
COOLING
SOLENOID	SCHRADER
VALVE
VFD	VALVE
REFRIGERANT
COOLING
ISOLATION	VFD DRAIN
VALVE	ISOLATION
VFD	VALVE
REFRIGERANT
STRAINER

			MOTOR	FILTER DRIER
	FILTER DRIER	FILTER	COOLING
			SIGHT	ISOLATION VALVE
	ISOLATION VALVE	DRIER
			GLASS

a23-1564

Fig. 15 — VFD Refrigerant Isolation Valves

14

SHIPPING

BRACKET

a23-1565

Fig. 16 — VFD Shipping Bracket

3.Remove the nuts that secure the terminal box transition piece to the motor housing.

4.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.

5.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.

6.Disconnect the communication cables from the back of the ICVC (Fig. 18).

7.Disconnect the high pressure switch leads from terminal strip TB1, terminals 15 and 16 (Fig. 19).

8.Unplug connectors CN1A, CN1B, CN2, and CN3 (Fig. 19).

9.Disconnect the control panel ground wire (Fig. 19) that is located next to connectors CN1A and CN1B.

10.Disconnect the VFD cooling lines (Fig. 20) and cover all openings.

11.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.

12.Position the control panel on top of the condenser and secure it in place to prevent damage.

MOTOR TERMINALS

MOTOR TERMINAL

BOX FRAME

MOTOR

TEMPERATURE

SENSOR TERMINAL

BLOCK

MOTOR
TEMPERATURE	a23-1566
CABLE

Fig. 17 — Motor Terminals

a23-1567

Fig. 18 — ICVC Communication Cables

CONNECTOR CN2

a23-1570

	CONTROL PANEL
CONNECTOR CN1A	GROUND WIRE

CONNECTOR CN1B

HIGH

PRESSURE

SWITCH

CABLE

LOW VOLTAGE FIELD

WIRING TERMINAL STRIP

CONNECTOR CN3

Fig. 19 — Control Panel Connectors

15

OIL HEATER CONDUIT ASY

OIL PUMP CONDUIT ASY

VAPORIZER HEATER CONDUIT ASY

VFD COOLING LINE

O-RING FACE SEAL

COUPLINGS

OIL RECLAIM

ACTUATOR CABLE

VFD COOLING

SOLENOID CABLE

TEMPERATURE SENSOR CABLES

PRESSURE SENSOR a23-1571 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

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	45° MIN
	EYEBOLT

a23-1561

Fig. 21 — Control Center Lifting Points

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.)

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.

3.Disconnect the compressor discharge pressure sensor and remove the high discharge pressure switch sensor.

4.Rig the discharge pipe assembly 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.

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.

16