Screw liquid chillers are designed to provide safe and reliable service when operated within design specifications. Whenoperatingthisequipment, use good judgment
and follow 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). 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.
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 machine sections 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
center,switches, starters, or oil heater until you are sureALLPOWER
IS OFF and no residual voltage can leak from capacitors or solidstate components.
LOCK OPEN AND T AGelectricalcircuits during servicing. IF WORK
IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.
DO NOT syphon refrigerant.
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.
23XL
50/60 Hz
Hermetic Screw Liquid Chillers
With HCFC-22 and HFC-134a
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 NOTATTEMPTTO 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 VENTOR 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
Tab 5e
PC 211Catalog No. 532-303Printed in U.S.A.Form 23XL-2SIPg 19-94Replaces: 23XL-1SI
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INTRODUCTION ..............................2
General ......................................2
Job Data ....................................2
Equipment Required .........................2
INSTALLATION .............................2-34
Receiving the Machine .......................2
• INSPECT SHIPMENT
• IDENTIFY MACHINE
• PROVIDE MACHINE PROTECTION
Rigging the Machine .........................4
• RIG MACHINE ASSEMBLY
• RIG MACHINE COMPONENTS
Install Machine Supports ....................16
• INSTALL STANDARD ISOLATION
• INSTALL OPTIONAL OR ACCESSORY
ISOLATION
• INSTALL SPRING ISOLATION
Connect Piping .............................18
• INSTALL WATER PIPING
TO HEAT EXCHANGERS
• INSTALL VENT PIPING
TO RELIEF DEVICES
Make Electrical Connections .................25
• CONNECT CONTROL INPUTS
• CONNECT CONTROL OUTPUTS
• CONNECT STARTER
• INSULATE MOTOR TERMINALS
AND LEAD WIRE ENDS
• CONNECT POWER WIRE TO OIL
HEATER CONTACTOR (Frame 1 and 2)
• CONNECT COMMUNICATION AND CONTROL
WIRING FROM STARTER TO POWER PANEL
• CARRIER COMFORT NETWORK
INTERFACE
Install Field Insulation .......................30
• FACTORY-INSTALLED INSULATION
INSTALLATION START-UP REQUEST
CHECKLIST ..........................CL-1, CL-2
INSTALLATION
Receiving the Machine
INSPECT SHIPMENT
Do not open any valves or break any connections. The
standard 23XL machine is 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 the machine is still on
shipping conveyance. If the 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 the transportation company. The manufacturer is not responsible for any dam-
age 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 installation. All openings are closed with
covers or plugs to prevent dirt and debris from entering
during shipping. The 23XL is shipped with a full operating oil charge.
IDENTIFY MACHINE — The machine model number, serial number, and heat exchanger sizes are stamped on machine information plate (Fig. 1, 2, and 3). Check this information against shipping papers and job data.
INTRODUCTION
General—
and leak tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. Rigging, installation, field wiring, and field piping are
the responsibility of the contractor and/or customer. Carrier
has no installation responsibilities for the equipment.
The 23XLmachine is factory assembled, wired,
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 prints
Equipment Required
• mechanic’s tools (refrigeration)
• volt-ohmmeter and clamp-on ammeter
• leak detector (halide or electronic)
• absolute pressure manometer or wet-bulb vacuum
indicator
• portable vacuum pumps
LEGEND
VI — Volumetric Index
Fig. 1 — Model Number Identification
PROVIDE MACHINE PROTECTION — Protect machine
and starter 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.
2
FRONT VIEW
REAR VIEW
1—Power Panel
2—Local Interface Display (LID) Control Center
3—ASME Nameplate, Cooler
4—Cooler Refrigerant Isolation Valve
5—ASME Nameplate, Economizer (Hidden)
6—Service Valve
7—Take-Apart Rabbet Fit Connector (Lower)
8—Cooler Temperature Sensor
9—ASME Nameplate, Condenser
10 — Typical Waterbox Drain Port
11 — Cooler Supply/Return End
32 — Cooler Temperature Sensors
33 — Machine Identification Nameplate
Fig.3—Typical 23XL Installation (Frame 4 Machine)
Rigging the Machine — The 23XL can be rigged as
an entire assembly. It also has flanged connections that
allow the compressor, cooler, condenser, and oil separator
sections to be separated to fulfill specific installation
requirements.
RIG MACHINE ASSEMBLY — See rigging instructions
in plastic envelope attached to machine. Also refer to rigging guide (Fig. 4 and 5), physical data in Fig. 6 and 7, and
Tables 1-6. Lift machine only from the 3 points indicated inthe rigging guide. Spreader bar must be used. 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 and personal injury. Rigging equipment and procedure must be adequate for
machine weight. See Tables 1-6 for machine weights.
NOTE: These weights are broken down into component
sections for use when installing the unit in sections. For
complete machine weight, add all section components
together. Total machine weight (Table 6) is also stenciled on the cooler and condenser sections.
4
→
The compressor is heavy. To avoid bodily injury, lift
the compressor only by using cables or slings. Do not
lift thecompressor using threaded eyebolts. Metric threaded
eyebolts are provided only for lifting individual compressor castings.
Do not attempt to cut refrigeration lines or disconnect
flanges or fittings while machine is under pressure. Cutting lines or disconnecting flanges or fittings can result
in personal injury or damage to the unit. Be sure both
refrigerant and oil charge are removed from the machine before separating the components.
IMPORTANT: Only a qualified service technician
should disassemble and reassemble the machine. After
reassembly, the machine must be dehydrated and leak
tested.
RIG MACHINE COMPONENTS — Refer to instructions
below, Fig. 8-12, and Carrier certified prints for machine
disassembly.
NOTE: If the cooler and condenser vessels must be separated, the heat exchanger separation feet must be unbolted,
rotated, and rebolted in order to keep each heat exchanger
level. See Fig. 4, 5, and 8-12.
NOTE: Sensor wiring must be disconnected. Label each wire
before removal (see Carrier certified prints). Remove all transducer and thermistor wires at the sensor. Clip all wire ties
necessary to remove the wires from the heat exchangers. Remove the control wiring and oil heater wiring
(Frame 1 and 2 machines) at the power panel and the main
motor leads at the starter lugs before disconnecting the starter
from the machine.
*Carrier recommends that ‘‘I’’ Beam Spreader Bars be field supplied and installed.
NOTES:
1. Each chain must be capable of supporting the entire weight of the machine. Maximum weight of machine is 13,200 lbs (5940 Kg).
2. Chain lengths shown are typical for 15 ft (4572 mm) lifting height. Some minor
adjustment may be required.
HEAT
EXCHANGER
SIZE
10 or 113- 811171-1157211,810 5357
20 or 213-1011612- 060013,200 5940
1S12 x 31.8S30 x 464
2S10 x 35S25.4 x 511
3W12 x 22W30 x 321
4W10 x 25W25.4 x 365
ENGLISHSI
in. x lb/ftcm x N/m
NOTES:
1. Each chain must be capable of supporting the entire weight of the machine. Maximum weight of machine is 22,300 lbs (10,116 Kg).
2. Chain lengths shown are typical for 15 ft (4572 mm) lifting height. Some minor adjustment may be required.
3. [ ] indicates millimeters.
CENTER OF GRAVITY —
HEAT EXCHANGER
SIZE
40, 41, 42, or 436-419302-881322,30010,116
*Includes marine waterboxes and refrigerant charge.
APPROXIMATE DIMENSIONS
A
(Length)
ft-in.mmft-in.mm
B
(Width)
MAXIMUM WEIGHT*
lbkg
Suggested ‘‘I’’ Beam Spreader Bar†
OPTIONS
1S12 x 31.8S30 x 464
2S10 x 35S25.4 x 511
3W12 x 22W30 x 321
4W10 x 25W25.4 x 365
†Carrier recommends that ‘‘I’’ beam spreader bars be field supplied and installed.
ENGLISHSI
in. x lb/ftcm x N/m
Fig. 5 — Machine Rigging Guide
(Frame 4 Machines)
6
23-22
HEAT EXCHANGER
SIZE
10 or 11
20 or 214-1114996-11
1 Pass2 and 3 Pass*
ft-in.mmft-in.mmft-in.mmft-in.mm1-Pass2 and 3-Pass
9-528709-6
A (LENGTH)
1
⁄
2
2908
OVERALL
B (WIDTH)
1
4- 9
⁄
4
*2 and 3-pass length applies if either (or both) cooler or condenser isa2or3-pass design.
NOTES:
1. Service access should be provided per ANSI/ASHRAE 15 (American National Standards
Institute/American Society of Heating Refrigeration and Air Conditioning Engineers), Latest Edition. NFPA (National Fire Protection Association) 70 and local safety codes.
2. Allow at least 6 in. (152 mm) overhead clearance for service rigging.
3. Certified drawings available upon request.
→
Fig. 6 — 23XL Dimensions (Frame 1 and 2 Machines)
OVERALL
C (HEIGHT)
14546- 95⁄
NOZZLE PIPE SIZE
8
207366
3
⁄
8
211886
(in.)
7796
NOTES:
1. For flanged waterbox nozzles, refer to the certified drawings for length addition measurements.
2. Service access should be provided based onAmerican Society of Heating, Refrigeration, and Air Conditioning Engineers
(ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, and local safety codes.
3. A minimum 6 in. (152 mm) overhead clearance for service rigging is recommended.
4. Certified drawings are available upon request.
5. [ ] indicates millimeters.
HEAT EXCHANGER
(Cooler and
Condenser Size)
40-4313-7
*Assumes both cooler and condenser nozzles on same end of chiller.
†1 or 3 pass length applies if either (or both) cooler or condenser isa1or3pass
VI — Volumetric Index
*Total rigging weight includes HCFC-22 and water.
NOTE: Starter weight is included in total weights. Subtract 500 lbs (227 kg) if a starter is not used.
Table 6 — 23XL Machine Rigging Weights
ECONOMIZER
INDICATOR
YES
NO11,1105,039
YES
NO12,2605,561
YES
NO19,5208,855
COMPRESSOR
SIZE
C2 or C40 or 1
C60or1
D4 or D60 or 1
79610
VI TYPE
TOTAL RIGGING WEIGHT*
lbskg
11,4105,175
12,5605,697
20,0209,081
NOTE: Before proceeding with disassembly, make sure the
machine is at atmospheric pressure.
NOTE: The screw compressor uses all metric dimensions
→
and metric fasteners. The heat exchangers and oil separator
use American standard dimensions and English fasteners.
Metric wrenches are required to remove the compressor.
To Separate Cooler and Condenser (Frame 1 and 2
Machines)
1. Turn vessel separation feet to the lowered position
(Fig. 8).
2. Disconnect and/or cut the following lines:
a. cooler liquid feed (Fig. 8).
b. condenser refrigerant vapor to oil reclaim ejector
(Fig. 9).
c. motor cooling supply from condenser (Fig. 9).
d. optional hot gas bypass and associated solenoid valve
wiring (not shown).
3. Separate compressor from oil supply system by disconnecting the following:
a. discharge flange from compressor and remove check
valve (Fig. 8).
b. oil supply line to compressor and associated solenoid
valve wiring (Fig. 8).
c. oil scavenging/sump vent to compressor (Fig. 8
and 9).
4. Cover all openings.
5. Be sure all wiring is properly marked. Detach all transducers, switches, and sensor wires. Remove all wire ties
required to remove wires from the cooler to the condenser. Do not cut the wires.
6. Disconnect the rabbet fit connectors on the tube sheets
(Fig. 9).
7. Rig vessels apart.
To Separate Compressor from Cooler (Frame 1 and 2
Machines)
→
The compressor is heavy. To avoid bodily injury, lift
the compressor only by using cables or slings. Do not
lift the compressor using threaded eyebolts. The metric
threaded eyebolts are provided only for lifting individual compressor castings.
1. Unbolt the suction flange (Fig. 8).
2. Disconnect the following lines:
a. oil reclaim to compressor (Fig. 9).
b. motor cooling to motor (Fig. 9).
c. motor cooling drain (Fig. 9).
d. optional economizer gas line to compressor rotors
(Fig. 9).
3. Separate compressor from oil supply system by disconnecting the following:
a. discharge flange from compressor and remove check
valve (Fig. 8).
b. oil supply line to compressor and associated solenoid
valve wiring (Fig. 8 and 9).
c. oil scavenging/sump vent to compressor (Fig. 8
and 9).
4. Cover all openings.
5. Be sure the following electrical connections are
disconnected:
a. motor power cables from optional unit-mounted starter
lugs (not shown).
b. motor winding temperature sensor (Fig. 9).
c. slide valve increase and decrease capacity control so-
lenoid valves (Fig. 9).
d. optional variable VI solenoid valves (Fig. 9).
e. discharge (condenser) pressure transducer (Fig. 8).
6. Unbolt motor support foot (Fig. 8).
7. Rig compressor.
To Separate Oil Separator from Condenser (Frame 1 and 2
Machines)
1. Separate the compressor and oil separator by disconnecting the following:
a. discharge flange from compressor and remove check
valve (Fig. 8).
b. oil feed from separator to sump (Fig.9).
c. oil scavenging/sump vent to compressor (Fig. 8
and 9).
d. oil sump relief to separator (Fig. 8).
2. Unbolt the discharge adaptor flange from the condenser
(Fig. 9).
3. Cover all openings.
4. Be sure the following electrical connections are
disconnected:
a. high discharge pressure cutout switch (Fig. 8).
5. Unbolt the four securing bolts from the bottom of the oil
separator (Fig. 8 and 9).
6. Rig oil separator.
NOTE: Before proceeding with disassembly, make sure the
machine is at atmospheric pressure.
To Separate Cooler and Condenser (Frame 4 Machines)
→
The compressor is heavy. To avoid bodily injury, lift
the compressor only by using cables or slings. Do not
lift the compressor using threaded eyebolts. The metric
threaded eyebolts are provided only for lifting individual compressor castings.
11796
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