Carrier EVERGREEN 23XRV User Manual

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Page 1

Product

INNOVATION

AWARD

2008 AHR EXPO

23XRV

EISMICOMPLIANT

* Meets IBC 2006, ASCE-7-05, CBC 2007, and OSHPD seismic requirements.

Data

EVERGREEN

23XRV

High-Efficiency Variable Speed Screw Chiller

with FOXFIRE™ Compression Technology

50/60 Hz

HFC-134a

300 to 550 Nominal Tons (1055 to 1934 Nominal kW)

Carrier’s Evergreen® 23XRV chiller is the world’s first integrated variable speed, water-cooled, screw chiller. It incorporates significant breakthroughs in water-cooled chiller technology to provide excellent reliability and achieve superior efficiencies at true operating conditions without compromising the environment.

The 23XRV chiller provides:

• Variable speed, positive displacement screw compressor.

• Air Conditioning, Heating, and Refrigerant Institute (AHRI) certified efficiencies to 0.33 kW/ton (AHRI IPLV).

• Chlorine-free HFC-134a refrigerant.

• IEEE-519 compliance for harmonic distortion.

• An ideal solution for constant and variable flow pumping systems.

2008 AHR EXPO

INNOVATION

AWARD

WINNER – Green Building

Features/Benefits

Quality design and construction make the Evergreen 23XRV chillers the best choice for modern, efficient chilled water plants.

Product reliability

The 23XRV chiller uses proven technology from Carrier’s existing line of Evergreen chillers along with innovations that increase reliability. The 23XRV compressors are designed for extremely high reliability. The advanced tri-rotor compressor features a balanced rotor geometry and shorter screw lengths, resulting in vastly reduced compressor bearing loads and a minimum L10 compressor bearing life in excess of 500,000 hours when operated at AHRI conditions.

Page 2

Features/Benefits (cont)

Variable speed capacity control eliminates slide valves, their associated losses, and their potential failure modes. Component count (both rotating and total) has been minimized assuring maximum reliability under a wide range of operating conditions.

High efficiency

Per AHRI 550/590, chillers operate at design conditions less than one percent of the time. As a result, superior part load efficiency is required for today’s chilled water applications. The Ever-

green chiller efficiency by optimizing compressor operation. Electric power consumption drops dramatically when the motor speed slows. The 23XRV screw chiller delivers industry-leading integrated part load values (IPLV) in an extremely broad range of applications and climates.

23XRV screw chiller maximizes

Environmental leader

Carrier has long been committed to the environment and its sustainability. The Evergreen 23XRV screw chillers provide our customers with a highefficiency, chlorine-free, long-term solution unaffected by refrigerant phase outs. Carrier’s decision to utilize non-ozone depleting HFC-134a refrigerant provides our customers with a safe and environmentally sound product without compromising efficiency. In addition, HFC-134a was given an A1 safety rating by ASHRAE (American Society of Heating, Refrigerating and Air Conditioning Engineers), meaning that it is the safest refrigerant available.

Quality design

Positive displacement compression — Positive displacement com-

pression ensures stable operation under all load conditions without the possibility of compressor surge.

Superior oil management/cold condenser water operation — All

Evergreen 23XRV chillers regulate oil temperature, viscosity and pressure. A patented process assures high quality oil is delivered to the compressor bearings by a positive displacement pump. Bearing lubrication is assured, allowing continuous operation with cold condenser water at all loads. Screw chillers no longer need to rely on differential system pressure to effectively lubricate the compressor. Should the

input power to the chiller be lost, the system design assures proper lubrication of the bearings during coast down.

Small footprint — The Evergreen 23XRV chiller’s positive pressure design reduces the chiller size by up to 35% compared to negative-pressure designs. Extremely high compression efficiencies allow for compact, high-efficiency chillers that require less mechanical room floor space.

Constant or variable evaporator flow — The 23XRV chiller combines

the advantages of positive displacement compression with variable speed capacity control. This process provides a chiller that reacts substantially better than chillers equipped with inlet guide vanes or slide valves. This allows for easier transition when bringing additional chillers on line in multiple chiller plants and eliminates any possibility of surge, regardless of the changes in the system.

Low harmonic distortion — The Evergreen 23XRV chiller will generate less than 5% total harmonic distortion at the input to the VFD (variable frequency drive) without the use of any external filters or line reactors. This assures the VFD alone cannot exceed the IEEE-519 standard for distortion at the point of common coupling. Ultra-low harmonics can eliminate the need for complicated harmonic system studies.

Low starting current (inrush) —

The inrush current is limited to the chiller full load amps (rated load amperes). No other starting means can equal this level of starting current. The combination of low current and ultra low harmonics can reduce backup generator size requirements.

0.99 power factor — The Evergreen 23XRV chiller can operate at up to 0.99 displacement power factor, which helps building owners avoid power factor penalties and decreases electrical losses in cables and transformers. High power factor may also reduce KVA requirements, saving electrical system costs on new projects or freeing up electrical resources on existing systems operating near their maximum capacity.

Refrigerant-cooled VFD — Refrigerant cooling of the VFD minimizes VFD size and ensures proper cooling of the transistors for extended life. Using R-134a refrigerant instead of water also eliminates costly maintenance associated with the water cooling pump, heat exchanger and rubber tubing used with water-cooled VFDs.



Optional seismic kit — A seismic isolation package is available to meet International Building Code and ASCE 7 seismic qualification requirements in concurrence with ICC ES AC156 Acceptance Criteria for Seismic Qualification by Shake-Table Testing of Nonstructural Components and Systems.

Hermetic motor — The Evergreen 23XRV chiller utilizes motors that are hermetically sealed from the machine room. Cooling is accomplished by spraying liquid refrigerant on the motor windings. This highly efficient motor cooling method results in coolerrunning motors than could be realized with air-cooled designs of the same type.

In addition, Carrier’s hermetic de-

sign eliminates:

• Compressor shaft seals that require maintenance and increase the likelihood of refrigerant leaks.

Page

Features/Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Model Number Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6

Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

Typical Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23

Guide Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-31

910

Page 3

• Machine room cooling requirements associated with air-cooled motors, which dissipate heat to the mechanical room.

• High noise levels common with aircooled motors, which radiate noise to the machine room and adjacent areas.

• Shaft alignment problems that occur with open-drive designs during startup and operation, when equipment temperature variations cause thermal expansion.

Positive pressure design — Positive pressure designs eliminate the need for costly low pressure containment devices, reducing the initial cost of the system. The Evergreen

23XRV chiller’s positive pressure design ensures that air, moisture and other performance degrading contaminants are not sucked inside the chiller. Purge units and their associated maintenance are no longer necessary.

Optional refrigerant isolation valves — The optional refrigerant

isolation valves allow the refrigerant to be stored inside the chiller during shipment from the factory, minimizing start-up time. During servicing, the “in-chiller” storage reduces refrigerant loss and eliminates time-consuming transfer procedures. As a self-contained unit, the Evergreen 23XRV chiller does not require additional remote storage systems.

Optional pumpdown unit — Combined with the refrigerant isolation valves listed above, the optional pumpdown unit eliminates complex connections to portable transfer systems, thereby reducing service costs. The optional pumpdown compressor meets Environmental Protection Agency’s (EPA) vacuum level requirements that mandate minimizing refrigerant emissions during service.

Modular construction — The cooler, condenser, and compressor assemblies are bolted together, making Evergreen 23XRV chillers ideally suited for replacement jobs where ease of disassembly and reassembly at the jobsite are essential.

Single point power — The 23XRV chiller features internal control power transformers to provide low voltage power (115 v and 24 vdc) for machine controls. Simply connecting the three

input power leads to the VFD provides all unit power.

Marine container shipment — The compact design allows for open-top container shipment to export destinations, ensuring quality while reducing shipping cost.

Heat exchanger combinations —

The Evergreen 23XRV chillers are available with a complete line of heat exchangers, ensuring the best combination of chiller components to meet project specific tonnage and efficiency requirements. One, 2 and 3-pass arrangements are available to meet a wide variety of flow conditions. Nozzlein-head and marine waterboxes are available to meet 150 psig and 300 psig piping requirements.

Heat exchanger features

ASME certified construction — An

independent agency certifies the design, manufacture, and testing of all heat exchangers to American Society of Mechanical Engineers (ASME) standards, ensuring heat exchanger safety, reliability and long life. The ASME U-stamp is applied to the refrigerant side of the evaporator and condenser and is applied to the water side of heat exchangers when 300 psig marine water boxes are provided.

High performance tubing — Carrier’s Evergreen chillers utilize advances in heat transfer technology, providing compact, high-efficiency heat exchangers. Tubing with advanced internally and externally enhanced geometry improves chiller performance by reducing overall resistance to heat transfer while reducing fouling.

Cooler tube expansion — Cooler tube expansion at center support sheets prevents unwanted tube movement and vibration, thereby reducing the possibility of premature tube failure. Tube wall thickness is greater at the expansion location, support sheets, and end tube sheets in order to provide maximum strength and long tube life.

Double-grooved end tube sheet holes — This design provides a more

robust seal than single rolled joints, reducing the possibility of leaks between the water and refrigerant sides of the chiller.

Condenser baffle — The baffle deflects hot discharge gas before it contacts condenser tubes, reducing tube vibration and wear while distributing

refrigerant more evenly over the length of the vessel for improved efficiency.

Closely spaced intermediate support sheets — Support sheets pre-

vent tube sagging and vibration, thereby increasing heat exchanger life.

Refrigerant filter isolation valves — These valves allow filter replace-

ment without pumping down the chiller, reducing service time and expense.

FLASC (flash subcooler) — The subcooler, located in the bottom of the condenser, increases the refrigeration effect by cooling the condensed liquid refrigerant to a lower temperature, thereby reducing compressor power consumption.

AccuMeter™ system — The AccuMeter system regulates refrigerant flow according to load conditions, providing a liquid seal at all operating conditions, eliminating unintentional hot gas bypass.

Microprocessor controls features

Direct Digital Product Integrated control (PIC III) — Carrier’s PIC III

provides unmatched flexibility and functionality. Each unit integrates directly with the Carrier Comfort Network solution to controls applications.

International Chiller Visual Controller (ICVC) — The ICVC provides

an unparalleled ease of operation and can be configured to display English or metric values.

cated on the chiller VFD panel displays chiller and VFD data. The VGA 320 x 240 element LCD (liquid crystal display) features 4 menu specific softkeys. The default display offers an all-in-one glance review of key chiller operation data, simplifying the interaction between chiller and user.

languages:

•English

•Chinese

• Japanese

• Korean

Automatic capacity override —

This function unloads the compressor whenever key safety limits are approached, increasing unit life. This

(CCN) system, providing a

For convenience, a single display lo-

The display includes 4 standard

Other languages are available.

Page 4

Features/Benefits (cont)

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

Voltage Code

3 – 380-3-60

4 – 416-3-60 5 – 460-3-60 9 – 380/415-3-50

S – Special

R – Compressor

Not Used

Drive Amps Amps Code In† Out† AA 440 442 BA 520 442 BB 520 520

Motor Code P T Q U R V S

CC 608 608

ASME

‘U’ Stamp

AHRI (Air Conditioning, Heating

and Refrigeration Institute)

Performance Certified

Model number nomenclature

*First number denotes frame size.

†Maximum limits only. Additional application

limits apply that may reduce these ampacities.

a23-1648

Quality Assurance

Certified to ISO 9001:2000

EISMICOMPLIANT

* Meets IBC 2006, ASCE-7-05, CBC 2007, and OSHPD seismic requirements.

feature also allows the machine to operate at reduced capacity, rather than shut down, when key safety limits are approached.

Chilled liquid reset — Reset can be accomplished manually or automatically from the building management system. For a given capacity, reset allows operation at slower compressor speeds, saving energy when warmer chilled liquid can be used.

Demand limiting — This feature limits the power draw of the chiller during peak loading conditions. When incorporated into the Carrier Comfort Network

building automation system, a red line command holds chillers at their present capacity and prevents any other chillers from starting. If a load shed signal is received, the compressors are unloaded to avoid demand charges whenever possible.

Ramp loading — Ramp loading ensures smooth pulldown of liquid loop temperature and prevents a rapid increase in compressor power consumption during the pulldown period.

Automated controls test — The test can be executed prior to start-up to verify that the entire control system is functioning properly.

365-day real time clock — This feature allows the operator to program a yearly schedule for each week, weekends, and holidays.

Occupancy schedules — Schedules can be programmed into the controller to ensure that the chiller operates when cooling is required and remains off when not needed by the tenants or process.

Extensive service menu — Unauthorized access to the service menu

can be prevented through password protection. Built-in diagnostic capabilities assist in troubleshooting and recommend proper corrective action for preset alarms, resulting in greater working time.

Alarm file — This file maintains the last 25 time-and date-stamped alarm messages in memory. This function reduces troubleshooting time and cost.

Alert file — This file maintains the last 25 alert messages in memory. This function provides prognostic information and corrective actions that can avoid unit shutdown.

Configuration data backup —

Non-volatile memory provides protection during power failures and eliminates time consuming control reconfiguration.

Page 5

Physical data

MOTOR

SIZE

P, Q ,R , S ,

T,U ,V

Tot al

Compressor

Weight

(lb)

4866 441 229 46 2207 200 104 21

23XRV COMPRESSOR AND MOTOR WEIGHTS

ENGLISH SI

Stator

Weight

(lb)

Rotor

Weight

(lb)

Motor

Ter min al

Cover

(lb)

Compressor

Weight

(kg)

Stator

Weight

(kg)

COMPONENT WEIGHTS

Rotor

Weight

(kg)

Motor

Ter min al

Cover

(kg)

COMPONENT

FRAME 3 HEAT

EXCHANGER

FRAME 4 HEAT

EXCHANGER

FRAME 5 HEAT

EXCHANGER

lb kg lb kg lb kg Isolation Valves 70 32 70 32 115 52 Suction Elbow 179 81 237 108 232 105 Discharge Elbow/Muffler 747 339 747 339 747 339 Control Center/VFD 1650 749 1650 749 1650 749 Vaporizer and Oil Sump 700 318 700 318 700 318 Economizer 542 246 542 246 542 246

LEGEND VFD — Variable Frequency Drive

23XRV HEAT EXCHANGER WEIGHTS

ENGLISH METRIC (SI)

NUMBER

CODE

COND — Condenser

*Rigging weights are for standard tubes of standard wall thickness (EDE and Spikefin 3, 0.025-in. [0.635 mm] wall).

NOTES:

1. Cooler includes the suction elbow and

2. Condenser includes float valve and sump, discharge elbow, and 1/2 the

3. For special tubes, refer to the 23XRV Computer Selection Program.

4. All weights for standard 2-pass NIH (nozzle-in-head) design with vic-

OF TUBES

Cooler Cond.

30 200 218 4148 3617 800 650 464 464 1877 1676 363 295 210 210 31 240 266 4330 3818800 650 531 542 1959 1769 363 295 241 246 32 2823154522 4023 800 650 601 621 2046 1860 363 295 273 282 35 200 218 4419 4529 910 760 511 513 2000 2089 413 345 232 233 36 240 266 4627 4758 910 760 587 602 2094 2195 413 345 266 274 37 2823154845 4992 910 760 667 692 2193 2299 413 345 303 314 40 324 366 5008 4962 900 825 863 915 2675 2746 408 375 391 415 41 364 415 5178 5155 900 825 930 995 2758 2 42 400 464 5326 5347 900 825 990 1074 2832 2932 408 375 449 487 45 324 366 5463 5525 1015 960 938 998 2882 3001 460 436 425 453 46 364 415 5659 5747 1015 960 1014 1088 2976 3108 460 436 460 494 47 400 464 5830 5967 1015 960 1083 1179 3061 3214 460 436 491 535 50 431 507 5827 6013 1250 1100 1101 1225 3182 3304 567 499 499 556 51 4855566053 6206 1250 1100 1192 1304 3294 3397 567 499 541 591 52 519 602 6196 6387 1250 1100 1248 1379 3364 3485 567 499 566 626 55 431 507 6370 6708 1430 1280 1201 1339 3429 3620 649 581545607 56 4855566631 6930 1430 1280 1304 1429 3556 3726 649 581591648 57 519 602 6795 7138 1430 1280 1369 1514 3636 3826 649 581621687

distribution piping weight.

taulic grooves.

Dry Rigging

Weight

(lb)*

Cooler

Only

Refrigerant

Cond.

Only

/2 the distribution piping weight.

Weight (lb)

With

Economizer

Machine Charge

Without

Economizer

Liquid Weight

(lb)

Cooler Cond.

Dry Rigging

Weight

(kg)*

Cooler

Only

Cond.

Machine Charge

Refrigerant

Only

839 408 375 422 451

Weight (kg)

With

Economizer

Without

Economizer

Liquid Weight

(kg)

Cooler Cond.

Page 6

Physical data (cont)

ADDITIONAL WEIGHTS FOR 23XRV MARINE WATERBOXES*

ENGLISH (lb) SI (kg)

FRAME

NUMBER

PASSES

Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt

Cooler Condenser Cooler Condenser

1 and 3 730 700 N/A N/A 331 318 N/A N/A

2 365 350 365 350 166 159 166 159

1 and 3 1888 908 N/A N/A 856 412 N/A N/A

2 944 452 989 452 428 205 449 205

1 and 3 2445 1019 N/A N/A 1109 462 N/A N/A

2 1223 510 1195 499 555 231 542 226

150 psig (1034 kPa) MARINE WATERBOXES

300 psig (2068 kPa) MARINE WATERBOXES

FRAME

*Add to cooler and condenser weights for total weights. Cooler and condenser weights may be found in the 23XRV Heat Exchanger

Weights table on page 5. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.

NUMBER

PASSES

1 and 3 860 700 N/A N/A 390 318 N/A N/A

2 430 350 430 350 195 159 195 159

1 and 3 2162 908 N/A N/A 981 412 N/A N/A

2 1552 393 1641 393 704 178 744 178

1 and 3 2655 1019 N/A N/A 1204 462 N/A N/A

2 1965 439 1909 418891 199 866 190

Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt

Cooler Condenser Cooler Condenser

ENGLISH (lb) SI (kg)

23XRV WATERBOX COVER WEIGHTS — ENGLISH (lb)

FRAMES 3, 4, AND 5

COOLER CONDENSER

WATERBOX

DESCRIPTION

NIH,1 pass Cover 150 psig 282318 148 185168 229 282318 148 185168 229 NIH,2 pass Cover 150 psig 287 340 202 256 222 275 287 340 191 245 224 298 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 411 518 626 733 760 867 411 518 622 729 727 878 NIH,3 pass Cover 300 psig 433 468 660 694 795 830 433 468 655 689785 838 NIH Plain End, 300 psig 294 294 522 522 658 658 270 270 522 522 658 658 MWB End Cover, 300 psig* 445/619 445/619 522/522 522/522 658/658 658/658 359/474 359/474 658/658 658/658 658/658 658/658

LEGEND *Nozzle end weight/return end weight.

NIH — Nozzle-in-Head MWB — Marine Waterbox

Frame 3 Frame 4 Frame 5 Frame 3 Frame 4 Frame 5

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown on page 5.

Flanged

23XRV WATERBOX COVER WEIGHTS — SI (kg)

FRAMES 3, 4, AND 5

WATERBOX

DESCRIPTION

NIH,1 pass Cover 1034 kPa 128 144 67 8476104128 144 67 8476104 NIH,2 pass Cover 1034 kPa 130 154 92 116 101 125 130 154 87 111 102 135 NIH,3 pass Cover 1034 kPa 133 141 214 221 280288 133 141 228 235 285297 NIH Plain End, 1034 kPa 110 110 63 63 70 70 102 102 63 63 70 70 MWB End Cover, 2068 kPa* 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 2068 kPa 186220287322347381186220287322347381 NIH,2 pass Cover 2068 kPa 186235284332344393186235282331330398 NIH,3 pass Cover 2068 kPa 196 212 299 315 361 376 196 212 297 313 356 380 NIH Plain End, 2068 kPa 132 132 237 237 298 298 122 122 237 237 298 298 MWB End Cover, 2068 kPa* 202/281202/281 237/237 237/237 298/298 298/298 163/215 163/215 298/298 298/298

Frame 3Frame 4Frame 5Frame 3Frame 4Frame 5

Victaulic

Nozzles

Flanged

COOLER CONDENSER

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

298/298 298/298

Flanged

LEGEND *Nozzle end weight/return end weight.

NIH — Nozzle-in-Head MWB — Marine Waterbox

NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown on page 5.

Page 7



Options and accessories

ITEM OPTION* ACCESSORY† .028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Copper Tubing — Cooler/Condenser X .028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Cupronickel Tubing — Condenser X .028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Copper Tubing — Cooler/Condenser X .028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Cupronickel Tubing — Condenser X Flanged Cooler and/or Condenser Waterbox Nozzles** X Hinged Waterboxes X Marine Waterboxes, 150 psig (1034 kPa)†† X Marine Waterboxes, 300 psig (2068 kPa)†† X Nozzle-in Head Waterbox, 300 psig (2068 kPa) X One, 2, or 3 Pass Cooler or Condenser Waterside Construction X Seismic Kit X Zinc Anodes X 100K AIC (Amp Interrupt Capacity) High Interrupt Circuit Breaker with Shunt Trip X Analog Voltmeter and Ammeter with 3 Phase Selector Switch X BACnet*** Communications X LonWorks††† Carrier Translator X Sensor Package X Refrigerant Isolation Valves X Separate Storage Tank and Pumpout Unit X Shipped Factory Charged with Refrigerant X Stand-Alone Pumpout Unit X Unit-Mounted Pumpout Unit X Hot Gas Bypass X Soleplate Package X Spring Isolator Kit X Acoustical Sound Insulation Kit X Full Cold Surface Thermal Insulation (Except Waterbox Covers) X Customer Factory Performance Testing X Export Crating X Extended Warranty (North American Operations [NAO] only) X Service Contract X

*Factory-installed. †Field-installed. **Standard waterbox nozzles are victaulic type. Flanged nozzles are available as an option with either nozzle-in-head type waterboxes or marine waterboxes.

††Optional marine waterboxes available for 23XRV heat exchanger frames 3-5 only. Standard waterboxes for 23XRV are nozzle-in-head type, 150 psig (1034 kPa). ***Sponsored by ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers). †††Registered trademark of Echelon Corporation.

910

Page 8

(WIDEST POINT)

2’ MIN

(610 mm)

4’-10” MIN (1475 mm)

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

MOTOR SERVICE CLEARANCE 1’-10” (559 mm)

TUBE REMOVAL SPACE FOR EITHER END SIZES 30-32, 40-42 50-52 14’-3” (4343 mm) SIZES 35-37, 45-47 55-57 14’-0” (4267 mm)

SERVICE AREA

4’ MIN

(1219 mm)

23XRV DIMENSIONS

a23-1646

Dimensions

*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 Heat-

2. Allow at least 3 ft (915 mm) overhead clearance for service rigging

23XRV DIMENSIONS (NOZZLE-IN-HEAD WATERBOX)

HEAT EXCHANGER

SIZE

30 to 32 14- 31/

35 to 37 15-113/

ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm

A (Length, with Nozzle-in-Head Waterbox)

1 Pass 2-Pass* 3 Pass

4350 13- 81/

4870 15- 43/

40 to 42 14- 9 4496 14- 31/

45 to 47 16- 51/

5017 15-115/

50 to 52 14-10 4521 14- 41/

55 to 57 16- 61/

5042 16- 1 4902 16- 3 4953 6-113/

4172 14- 31/

4693 15-113/

4347 14- 6 4420 6- 81/

4867 16- 21/

4382 14- 61/

4350 6- 4 1930 7- 25/82200

4870 6- 4 1930 7- 25/82200

4940 6- 81/

4432 6-113/

B (Width) C (Height)

23XRV DIMENSIONS (MARINE WATERBOX)

HEAT EXCHANGER

SIZE

ft-in. mm ft-in. mm ft-in. mm 30 to 32 14- 9 4496 16- 4

35 to 37 16- 5

40 to 42 15- 2

45 to 47 16-11

50 to 52 15- 3

55 to 57 17- 0 518218- 5 5613 7- 1 2159

ing, Refrigerating, and Air Conditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, and local safety code.

for the compressor.

A (Length, Marine Waterbox)

5017 18-11/

4642 16- 31/

5163 18-43/

4661 16- 81/

B (Width)

3. Certified drawings available upon request.

4. Marine waterboxes may add 6 in. (152 mm), to the width of the machine. See certified drawings for details.

5. ‘A’ length and ‘B’ width dimensions shown are for standard 150 psig (1034 kPa) design and victaulic connections. The 300 psig (2068 kPa) design and/or flanges will add length. See certified drawings.

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

4997 6- 93/

5518 6- 93/

50866-9

5607 6- 93/

5093 7- 1 2159

2045 7- 61/22299

2127 7- 63/42305

2067

2076

C (Height)2-Pass* 1 or 3 Pass†

See unit certified

drawings

Page 9

Performance data

FRAME

SIZE

1-Pass 2-Pass 3-Pass 1-Pass 2-Pass 3-Pass 3 10 8 610 8 6 4 10 8 610 8 6 5 10 8 61010 8

23XRV HEAT EXCHANGER MIN/MAX FLOW RATES*

NOZZLE SIZE

NOZZLE SIZE (in.)

(Nominal Pipe Size)

Cooler Condenser

ENGLISH (GPM)

COOLER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

30 611 2,444 305 1222 204 815 31 733 2,933 367 1466 244 978

*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec);

maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.

COOLER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec);

maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.

32 855 3,422 428 1710 285 1141 35 611 2,444 305 1222 204 815 36 733 2,933 367 1466 244 978 37 855 3,422 428 1710 285 1141

40 989 3,959 495 1979 330 1320 41 1112 4,448 556 2224 371 1482 42 1222 4,888 611 2444 407 1775 45 989 3,959 495 1979 330 1320 46 1112 4,448 556 2224 371 1482 47 1222 4,888 611 2444 407 1775

50 1316 5,267 658 2634 439 1756 51 1482 5,927 741 2964 494 1976 52 1586 6,343 793 3171 529 2114 55 1316 5,267 658 2634 439 1756 56 1482 5,927 741 2964 494 1976 57 1586 6,343 793 3171 529 2114

SI (L/s)

30 38 154 19 77 13 51 31 46 18523921562 32 54 215 27 108 18 72 35 38 154 19 77 13 51 36 46 18523921562 37 54 215 27 108 18 72

40 62 249 31 125 21 83 41 70 281 35 140 23 93 42 77 307 38 154 26 112 45 62 249 31 125 21 93 46 70 281 35 140 23 93 47 77 307 38 154 26 112

50 83 332 42 166 28 111 51 93 374 47 18731125 52 100 400 50 200 33 133 55 83 332 42 166 28 111 56 93 374 47 18731125 57 100 400 50 200 33 133

CONDENSER 1 PASS 2 PASS 3 PASS Frame Size Min Max Min Max Min Max

30 646 2,582 323 1291 215 861 31 791 3,162 395 1581 263 1054

CONDENSER 1 PASS 2 PASS 3 PASS Frame Size Min Max Min Max Min Max

32 932 3,731 466 1865 311 1244 35 646 2,582 323 1291 215 861 36 791 3,162 395 1581 263 1051 37 932 3,731 466 1865 311 1244

40 1096 4,383548 2192 365 1461 41 1235 4,940 618 2470 412 1647 42 1371 5,485686 2743 457 1828 45 1096 4,383548 2192 365 1461 46 1235 4,940 618 2470 412 1647 47 1371 5,485686 2743 457 1828

50 1507 6,029 754 3015 502 2010 51 1646 6,586 823 3293 549 2195 52 1783 7,131 891 3565 594 2377 55 1507 6,029 754 3015 502 2010 56 1646 6,586 823 3293 549 2195 57 1783 7,131 891 3565 594 2377

30 41 163 20 8114 54 31 50 199 25 100 17 67 32 59 235 29 118 20 79 35 41 163 20 8114 54 36 50 199 25 100 17 67 37 59 235 29 118 20 79

40 69 277 35 138 23 92 41 78 312 39 156 26 104 42 86 346 43 173 29 115 45 69 277 35 138 23 92 46 78 312 39 156 26 104 47 86 346 43 173 29 115

50 95 38048 190 32 127 51 104 416 52 208 35 138 52 112 450 56 225 37 150 55 95 38048 190 32 127 56 104 416 52 208 35 138 57 112 450 56 225 37 150

Page 10

Electrical data

VFD FRAME SIZES

FRAME SIZE MAX INPUT CURRENT* MAX OUTPUT CURRENT*

AA 440 442

BA 520 442 BB 520 520 CC 608 608

*Maximum limits only. Additional application limits apply that will reduce these ampacities.

AUXILIARY RATINGS*

ITEM VOLTAGE

Controls, Oil Pump And Heater Circuit† 115 15 — Oil Pump 115 1.48 130 Oil Sump Heater 115 4.35 500

Oil Vaporizer Heater Circuit† 115 15 — Oil Vaporizer Heater 115 13 1500

*Factory wired to VFD. †Minimum circuit ampacity of 15 amps.

MAXIMUM

PROTECTIVE DEVICE

SIZE (AMPS)

WATTS

Page 11

Controls

Microprocessor controls

Microprocessor controls provide the safety, interlock, capacity control, indications and accessibility necessary to operate the chiller in a safe and efficient manner.

Control system

The microprocessor control on each Carrier chiller is factory-mounted, factory-wired, and factory-tested to ensure machine protection and efficient capacity control. In addition, the program logic ensures proper starting, stopping, and recycling of the chiller and provides a communication link to the Carrier Comfort Network® (CCN) system.

Features

Control system

• Component test and diagnostic check

• Programmable recycle allows chiller to recycle at optimum loads for decreased operating costs

• Menu-driven keypad interface for status display, set point control, and system configuration

• CCN system compatible

• Primary and secondary status messages

• Individual start/stop schedules for local and CCN operation modes

• Recall of up to 25 alarm messages and 25 alert messages with diagnostic help

• Two chiller lead/lag with third chiller standby is standard in the PIC III software

• Optional soft stop unloading decreases compressor speed to unload the motor to the configured amperage level prior to stopping

• Languages pre-programmed at factory for English, Chinese, Japanese, Korean

• ILT (International Language Translator) available for conversion of extended ASCII characters

Safety cutouts

• Motor high temperature*†

• Refrigerant (condenser) high pressure*†

• Refrigerant (cooler) low temperature*†

• Lube oil low pressure*

• Compressor (refrigerant) high discharge temperature*

• Under voltage**

• Over voltage**

• Cooler and condenser liquid flow

• Motor overload†

• Motor acceleration time

• Intermittent power loss**

• Motor stall protection

• Low level ground fault

• Cooler and condenser freeze prevention*

• Low oil temperature

• Line voltage imbalance**

• Line current imbalance**

• Line frequency

• Motor current imbalance

• Motor rotation reversal

• Excessive motor amps

• Motor starts limit

• VFD speed out of range

• High VFD rectifier temperature*†

• High VFD inverter temperature*†

• DC bus voltage (Low/High)

Capacity control

• Leaving chilled liquid control

• Entering chilled liquid control

• Soft loading control by temperature or load ramping

• Hot gas bypass valve (optional)

• Power (demand) limiter

• Automatic chilled liquid reset (3 methods)

• Manual speed control

Interlocks

• Manual/automatic remote start

• Starting/stopping sequence Pre-lube/post-lube Pre-flow/post-flow

• Compressor run interlock

• Pre-start check of safeties and alerts

• Low chilled liquid (load) recycle

• Monitor/number compressor starts and run hours

• Manual reset of safeties

Indications

• Chiller operating status message

•Power-on

• Pre-start diagnostic check

• Compressor motor amps

• Alert (pre-alarm)††

• Alarm

• Contact for remote alarm

• Safety shutdown messages

• Elapsed time (hours of operation)

• Chiller input kW

• Demand kW

Drive control parameters

• Compressor 100% speed (Hz)

• Rated line voltage

• Rated line amps

• Rated line kW

• Motor rated Load kW

• Motor rated Load amps

• Motor nameplate amps

• Motor nameplate RPM

• Motor nameplate kW

• Inverter PWM frequency

*Can be configured by the user to provide alert indication

at user-defined limit.

†Override protection: Causes compressor to first unload

and then, if necessary, shut down.

**Will not require manual reset or cause an alarm if auto-

restart after power failure is enabled.

††By display code only.

Page 12

Controls (cont)

CONTROL PANEL DISPLAY (Front View)

ICVC ENGLISH DISPLAY IN SI UNITS

CONTROL PANEL DISPLAY (Front View)

ICVC CHINESE DISPLAY IN METRIC UNITS

Page 13

BLACK

WHITE

RED

BLACK

WHITE

RED

DRAIN WIREDRAIN WIRE

BLACK

WHITE

RED

BLACK

WHITE

RED

DRAIN WIRE

GROUNDDRAIN WIRE

NOTE: Field-supplied terminal strip must be located in control panel.

LEGEND

CCM — Chiller Control Module

Factory Wiring

Field Wiring

CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)

a23-1649

Page 14

Controls (cont)

MACHINE SAFETIES, EVAPORATOR PUMP

CONDENSER WATER PUMP

WATER FLOWS

CHILLED WATER TEMP, CONTROL

OIL PUMP

OIL PRESSURE VERIFIED

VDF FAULT TEST COMPRESSOR, PHASE REVERSAL, COMPRESSOR AND SERVICE ONTIME

1-MINUTE STOP-T O-START TIMER (SOFTWARE VERSION 13)

15-MINUTE START-TO-START TIMER

RAMP VDF TO

TARGET SPEED

COMPRESSOR

RUNNING

IJKL

O/A

TIME

TOWER FAN

0 0

CONTROL SEQUENCE

0—Phase reversal monitored A—START INITIATED: Pre-start checks are made; evaporator pump

started

B—Condenser liquid pump started (5 seconds after A); tower fan control

enabled

C—Liquid flows verified (30 sec to 5 minutes maximum after B) D—Chilled liquid temperature checked against control point; oil pump

on.

E—Oil pressure verified (oil pressure verified 45-300 sec after D). F—VFD starts; phase reversal conditions monitored; compressor

ontime and service ontime start; 15-minute inhibit timer starts (VFD fault tests for 15 sec after F)

G—Verify average current >5% within 15 sec after VFD start, ramp to

VFD target speed.

H—Compressor reaches target speed, chiller set to running status I—Shutdown initiated: Target VFD speed to 0% (or J occurs) J—Ramp down until percent line current <

soft stop amps threshold

(0-60 sec after I)

K—Oil pump relay off (1-20 sec after J) L—Evaporator pump deenergized (60 sec after K); condenser pump

and tower fan control may continue to operate if condenser pressure is high; evaporator pump may continue if in RECYCLE mode

O/A — Restart permitted (both inhibit timers expired) (minimum of 15 min-

utes after F; minimum of 3 minutes after L)

Control sequence

To st a r t — Local start-up (manual start-up) is initiated by

pressing the LOCAL or CCN menu softkey, which is indicated on the default international chiller visual control (ICVC) screen. Time schedule 01 or 03, respectively, must be in the Occupied mode and the internal 15-minute startto-start and the 1-minute stop-to-start inhibit timers must have expired. All pre-start safeties are checked to verify that all prestart alerts and safeties are within limits (if one is not, an indication of the fault displays and the start will be delayed or is aborted). The signal is sent to start the cooler liquid pump. Five seconds later, the condenser liquid pump is energized. If satisfied, it checks the chilled liquid temperature against the control point. If the temperature is less than or equal to the chilled liquid control point, the condenser liquid pump is deenergized and the chiller goes into a recycle mode.

If the chilled liquid temperature is high enough, the startup sequence continues. The oil pump is started and waits a minimum of 45 sec to verify oil flow. Once oil flow is verified, the VFD is energized. The control will monitor for a phase reversal condition. At this time, the following occurs:

• The “start-to-stop” timer is activated.

• The “compressor on-time” and “service on-time” timers are activated.

• The “starts in 12-hour counter” advances by one.

• The “total compressor starts counter” advances by one.

Once started — If the VFD average current >5% within 15 seconds after VFD start, the machine enters run mode and speed will be ramped up to meet VFD target speed. Once the target speed is met the controls, enter the capacity control mode.

Shutdown sequence — The chiller shutdown is initiated if any of the following occur:

• The Stop button is pressed for at least one second (the alarm light blinks once to confirm the stop command).

• A recycle shutdown is initiated.

• The time schedule has gone into unoccupied mode.

• The chiller protective limit has been reached and the chiller is in alarm.

• The start/stop status is overridden to stop from the ICVC, CCN system, or building management system.

Once the controls shutdown sequence is initiated, the compressor is stopped and the VFD target speed is set to 0. If optional soft stop unloading is activated when the Stop button is pressed or the remote contacts open, motor speed decreases to a configured amperage level, and the compressor is stopped. The display indicates “Shutdown in Progress” while the motor speed decreases. Compressor ontime and service ontime timers stop once the current in all phases is <5%, indicating a VFD Stop Complete. The oil pump and cooler liquid pump are then deenergized. The condenser liquid pump shuts down when the refrigerant temperature or entering condenser liquid temperature is below pre-established limits. The 3-minute start-to-stop timer starts.

Restart — Restart is permitted after both inhibit timers have expired. If shutdown was due to a safety shutdown, the reset button must be depressed before restarting the chiller.

Page 15

Typical piping and wiring

TO CHILLED LIQUID PUMP

TO CONDENSER LIQUID PUMP

TO COOLING TOWER FAN

MAIN COMPRESSOR MOTOR POWER

FROM COOLING TOWER

FROM LOAD

TO COOLING TOWER

TO LOAD

DRAIN

LEGEND

1—Disconnect 2—Unit-Mounted VFD/Control Center 3—Pressure Gages 4—Chilled Liquid Pump 5—Condenser Liquid Pump 6—Chilled Liquid Pump Starter 7—Condenser Liquid Pump Starter 8 — Cooling Tower Fan Starter 9—Vents

Piping Control Wiring Power Wiring

NOTES:

1. Wiring and piping shown are for general point-of-connection only and are not intended to show details for a specific installation. Certified field wiring and dimensional diagrams are available on request.

2. All wiring must comply with applicable codes.

3. Refer to Carrier System Design Manual for details regarding piping techniques.

4. Wiring not shown for optional devices such as:

• remote start/stop

• remote alarms

• optional safety device

• 4 to 20 mA resets

• optional remote sensors

• kW output

• head pressure reference

5. Flow switches are NOT required.

23XRV CHILLER

Page 16

Control wiring schematic

23XRV COMPONENT ARRANGEMENT

LEGEND

CCM — Chiller Control Module CCN — Carrier Comfort Network® ICVC — International Chiller Visual Controller GND — Ground

Page 17

Application data

VESSELS

TYP. 0’-3” [76.2mm]

ACCESSORY SOLEPLATE

0’-01/2” [13mm] TYP.

VESSELS

COND.

COOLER

23XRV MACHINE FOOTPRINT

*See detail on page 18.

23XRV

HEAT EXCHANGER

SIZE

DIMENSIONS (ft-in.) DIMENSIONS (mm)

A BCDEFGABCDEFG

30-32 12-10

/45-41/4 0 0-35/81-13/40-9 0-1/23931 1632 0 92 349 229 13

35-37 14- 7

/45-41/4 0 0-35/81-13/40-9 0-1/24451 1632 0 92 349 229 13

40-42 12-10

/46-0 0-11/20-35/81-13/40-9 0-1/23931 1829 38 92 349 229 13

45-47 14- 7

/46-0 0-11/20-35/81-13/40-9 0-1/24451 1829 38 92 349 229 13

50-52 12-10

/46-51/20-1/20-35/81-13/40-9 0-1/23931 1969 13 92 349 229 13

55-57 14- 7

/46-51/20-1/20-35/81-13/40-9 0-1/24451 1969 13 92 349 229 13

a23-1650

910

Page 18

Application data (cont)

ELASTOMERIC PAD

23XRV ISOLATION WITH ACCESSORY SOLEPLATE PACKAGE

TYPICAL ISOLATION

STANDARD ISOLATION

ACCESSORY SOLEPLATE DETAIL

VIEW X-X

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Accessory soleplate package includes 4 soleplates, 16 jacking screws and leveling pads. Requires isolation package.

3. Jacking screws to be removed after grout has set.

4. Thickness of grout will vary, depending on the amount necessary to level chiller. Use only pre-mixed non-shrinking grout, Ceilcote 748 or Chemrex Embeco 636 Plus Grout, 0-1

/2 (38.1) to 0-21/4 (57) thick.

5. Service clearance under the chiller is enhanced if leveling pads are not extended along the entire length of the heat exchangers.

VIEW Y-Y

ISOLATION WITH ISO L AT IO N PA C K AG E ON LY

(STA ND A RD )

NOTE: Isolation package includes 4 elastomeric pads.

a23-1647

Page 19

23XRV NOZZLE ARRANGEMENTS

NOZZLE-IN-HEAD WATERBOXES

FRAME 3

FRAMES 4 AND 5

NOZZLE ARRANGEMENT CODES FOR ALL 23XRV NOZZLE-IN-HEAD WATERBOXES

*Refer to certified drawings.

PAS S

COOLER WATERBOXES

In Out

Arrangement

Code*

8 5A 5 8 B

79 C 46 D

76 E 49 F

PA SS

CONDENSER WATERBOXES

In Out

Arrangement

Code*

11 2 P

211 Q

10 12 R

13 S

10 3 T

112 U

DISCHARGE END SUCTION END

Page 20

Application data (cont)

23XRV NOZZLE ARRANGEMENTS (cont)

MARINE WATERBOXES

FRAME 3

NOZZLE ARRANGEMENT CODES

PAS S

COOLER WATERBOXES

PAS S

CONDENSER WATERBOXES

In Out

Arrangement

Code

In Out

Arrangement

Code

8 5A

—— —

5 8 B———

79 C

10 12 R

46 D 1 3 S

76 E

—— —

49 F — — —

FRAMES 4, AND 5

NOZZLE ARRANGEMENT CODES

PA SS

COOLER WATERBOXES

PAS S

CONDENSER WATERBOXES

In Out

Arrangement

Code

In Out

Arrangement

Code

96 A

—— —

69 B — — —

79 C

10 12 R

46 D 1 3 S

76 E

—— —

49 F — — —

DISCHARGE END SUCTION END

Page 21

23XRV WATERBOX NOZZLE SIZES (Nozzle-In-Head and Marine Waterboxes

WITH OPTIONAL ISOLATION OF DISCHARGE AND COOLER

WITH OPTIONAL ISOLATION

WITHOUT OPTIONAL ISOLATION

RELIEF VALVE ARRANGEMENTS

FRAME

SIZE

LOCATION

PRESSURE

psig (kPa)

150/300

(1034/2068)

150/300

(1034/2068)

150/300

(1034/2068)

PAS S

1 10 10 10.020 10.020 2 887.9817.981 3 6 6 6.065 6.065 1 10 10 10.020 10.020 2 887.9817.981 3 6 6 6.065 6.065 1 10 10 10.020 10.020 2 8 10 7.981 10.020 36 8 6.065 7.981

FRAME

SIZE

MUFFLER 3-5 1

COOLER 3-5 1

CONDENSER 3-5 1

OPTIONAL

STORAGE TANK

N/A 1-in. NPT FEMALE CONNECTOR 2

* Coolers without optional isolation require 2 relief valves.

NOTE: All valves relieve at 185 psig (1275 kPa).

NOMINAL PIPE SIZE (in.) ACTUAL PIPE ID (in.)

Cooler Condenser Cooler Condenser

RELIEF VALVE LOCATIONS

RELIEF VALVE

/4-in. NPT FEMALE CONNECTOR 1

/4-in. NPT FEMALE CONNECTOR 1 or 2*

/4-in. NPT FEMALE CONNECTOR 2

OUTLET SIZE

QUANTITY

Page 22

Application data (cont)

Vent and drain connections

Nozzle-in-head waterboxes have vent and drain connections on covers. Marine waterboxes have vent and drain connections on waterbox shells.

Provide high points of the chiller piping system with vents and the low points with drains. If shutoff valves are provided in the main liquid pipes near the unit, a minimal amount of system liquid is lost when the heat exchangers are drained. This reduces the time required for drainage and saves on the cost of re-treating the system liquid.

It is recommended that pressure gages be provided at points of entering and leaving liquid to measure pressure drop through the heat exchanger. Gages may be installed as shown in Pressure Gage Location table. Pressure gages installed at the vent and drain connections do not include nozzle pressure losses.

Use a reliable differential pressure gage to measure pressure differential when determining liquid flow. Regular gages of the required pressure range do not have the accuracy to provide accurate measurement of flow conditions.

PRESSURE GAGE LOCATION

NUMBER

PASSES

1 or 3 One gage in each waterbox

2 Two gages in waterbox with nozzles

GAGE LOCATION

(Cooler or Condenser)

Each heat exchanger and economizer (if equipped) is

ASME ‘U’ stamped on the refrigerant side of each vessel.

Relief valve discharge pipe sizing

See page 21 for number of relief valves.

Relief valve discharge piping size should be calculated per the current version of the ASHRAE 15, latest edition, code using the tabulated C factors for each vessel shown in the table below.

23XRV RELIEF VALVE DISCHARGE PIPE SIZING

RELIEF

VALVE

RATED C FACTOR (lb air/Min)

FIELD

CONNECTION

SIZE (FPT)

/4

HEAT

EXCHANGER

COOLER

CONDENSER

FRAME

SIZE

30 to 32 43.4 70.8 1 35 to 37 49.5 70.8 1 40 to 42 50.4 70.8 1 45 to 47 57.4 70.8 1 50 to 52 53.7 70.8 1 55 to 57 61.1 70.8 1 30 to 32 41.4 70.8 1 35 to 37 47.1 70.8 1 40 to 42 47.1 70.8 1 45 to 47 53.7 70.8 1 50 to 52 51.2 70.8 1 55 to 57 58.3 70.8 1

VESSEL

REQUIRED

C FACTOR (lb air/Min)

ASME stamping

All 23XRV heat exchangers are constructed in accordance with ASHRAE (American Society of Heating, Refrigerating, and Air Conditioning Engineers) 15 Safety Code for Mechanical Refrigeration (latest edition). This code, in turn, requires conformance with ASME (American Society of Mechanical Engineers) Code for Unfired Pressure Vessels wherever applicable.

Carrier further recommends that an oxygen sensor be installed to protect personnel. Sensor should be able to sense the depletion or displacement of oxygen in the machine room below 19.5% volume oxygen per ASHRAE 15, latest edition.

Design pressures

Design and test pressures for heat exchangers are listed below.

DESIGN AND TEST PRESSURES (23XRV)

SHELL SIDE

PRESSURES

Leak Test at Design Pressure* 185 1276 150 1034 300 2068 Hydrostatic — — 195 1344 390 2689 Proof Test* 204 1407 — — — —

*Nitrogen/Helium.

(Refrigerant)

psig kPa psig kPa psig kPa

HEAT EXCHANGER MATERIAL SPECIFICATIONS

ITEM MATERIAL SPECIFICATION

Shell HR Steel ASME SA516 GR 70 Tube Sheet HR Steel ASME SA516 GR 70 Condenser/Cooler Waterbox Cover HR Steel ASME SA516 GR 70, S A-36, or SA-285 GRC

Condenser/Cooler Waterbox Shell HR Steel

Tubes Finned Copper ASME SB359 Discharge/Suction

Pipe Steel ASME SA106 GRB Flanges Steel ASME SA105

LEGEND

ASME — American Society of Mechanical Engineers HR — Hot Rolled

STANDARD TUBE SIDE

(Liquid)

ASME SA675 GR 60, SA-516 GR70, or SA-181 CL70, SA-36, SA-675 GR70, SAE AME 7496

OPTIONAL TUBE SIDE

(Liquid)

Page 23

Insulation

23XRV MINIMUM FIELD-INSTALLED INSULATION

COMPONENT SIZE

Cooler

Misc. Liquid Lines All Sizes 21 2.0 Economizer All Sizes 20 1.9 Compressor Motor All Sizes 17 1.6

Factory insulation — Thermal insulation is factoryprovided to the following areas:

• Cooler (not including waterbox)

• Suction line

• Compressor and motor

• Oil cooling line and oil return system line (oil and refrigerant lines at or near evaporator pressure are insulated)

• VFD cooling line (oil and refrigerant lines at or near evaporator pressure are insulated)

• Motor cooling line

• Vaporizer

• Liquid line and discharge line

• Float chamber

• Optional economizer (including vent line and economizer muffler)

Factory insulation is not available for the waterboxes.

Insulation applied at the factory is closed cell and Some parts of the chiller are also treated with an outer layer of

/16-in. (5 mm) thick vinyl. The 1/2-in. (13 mm)

closed cell foam has a thermal conductivity K value of

0.28 (BTU in.)/(hr sqft °F) [0.0404 W/(m °C)] and

REQUIREMENTS

INSULATION

30-32 96 8.9 35-37 108 10.0 40-42 109 10.1 45-47 122 11.3 50-52 115 10.7 55-57 130 12.1

/2-in. (13 mm) open cell PVC-Nitrile foam.

/2-in. (13 mm) thick

conforms with Underwriters Laboratories (UL) Standard 94, Classification 94 HF-1. Both the

/16-in. vinyl layer will pass flammability test method

/2-in. foam and the

MVSS 302. Field insulation — As indicated in the Condensation vs

Relative Humidity table, the factory insulation provides excellent protection against condensation under most operating conditions. If temperatures in the equipment area exceed the maximum design conditions, extra insulation is recommended.

If the machine is to be field insulated, obtain the approximate areas from the 23XRV Minimum Field-Installed Insulation Requirements table.

Insulation of waterbox is made only in the field and this area is not included in 23XRV Minimum Field-Installed Insulation Requirements table. When insulating the covers, allow for service access and removal of covers. To estimate water-box cover areas, refer to certified drawings.

High humidity jobsite locations may require field supplied and installed insulation on the float chamber, suction housing, and the lower half of the condenser.

CONDENSATION VS RELATIVE HUMIDITY*

AMOUNT OF

CONDENSATION

None 8076 70 Slight 87 8477 Extensive 94 91 84

*These approximate figures are based on 35 F (1.7 C) saturated suction temperature. A 2° F (1.1° C) change in saturated suction temperature changes the relative humidity values by 1% in the same direction.



Minimum fluid loop volume

ROOM DRY-BULB TEMPERATURE

80 F (27 C) 90 F (32 C) 100 F (38 C)

% Relative Humidity

Minimum fluid volume must be in excess of 1.5 gal per ton (20 L per kW) for comfort cooling applications and apply 3 to 5 gal per ton (40 to 66 L per kW) fluid loop volume for process applications.

910

Page 24

Guide specifications

Variable Speed Screw Chiller

HVAC Guide Specifications

Size Range: 300 to 550 Tons (1055 to 1934 kW)

Nominal

Carrier Model Number: 23XRV Part 1 — General

1.01 SYSTEM DESCRIPTION A. Microprocessor-controlled liquid chiller shall use a

semi-hermetic screw compressor using refrigerant HFC-134a only. Chiller refrigerant shall not have a planned phase out date.

B. If a manufacturer proposes a liquid chiller using

HCFC-123 refrigerant, which has a planned phase out date, then the manufacturer shall include in the chiller price:

1. A vapor activated alarm system consisting of all alarms, sensors, safeties, and ventilation equipment as required by ANSI/ASHRAE Standard 15 Safety Code for Mechanical Refrigeration (latest edition) with the quotation. System shall be capable of responding to HCFC-123 levels of 10 ppm Allowable Exposure Limit (AEL).

2. A free-standing refrigerant storage tank and pumpout unit shall be provided. The storage vessels shall be designed per ASME Section VIII Division 1 code with 300 psig (2068 kPa) design pressure. Double relief valves per ANSI/ ASHRAE 15, latest edition, shall be provided. The tank shall include a liquid level gage and pressure gage. The pumpout unit shall use a semi-hermetic reciprocating compressor with water cooled condenser. Condenser water piping, 3-phase motor power, and 115-volt control power shall be installed at the jobsite by the installing contractor.

3. Zero emission purge unit capable of operating even when the chiller is not operating.

4. Back-up relief valve to rupture disk.

5. Factory-installed chiller pressurizing system to prevent leakage of noncondensables into the chiller during shutdown periods.

6. Plant room ventilation.

7. Removal and disposal of refrigerant at the end of the phase out period.

8. Chillers utilizing a purge unit shall include in the machine price the costs to perform the following regular maintenance procedures:

a. Weekly: Check refrigerant charge. b. Quarterly: Charge purge unit dehydrator at

least quarterly, more often if necessary. Clean foul gas strainer. Perform chemical analysis of oil.

c. Annually: Clean and inspect all valves. Drain

and flush purge shell. Clean orifices.

1.02 QUALITY ASSURANCE A. Chiller performance shall be rated in accordance

with AHRI Standard 550/590, latest edition.

B. Equipment and installation shall be in compliance

with ANSI/ASHRAE 15 (latest edition).

C. Cooler and condenser refrigerant side shall include

ASME “U” stamp and nameplate certifying compliance with ASME Section VIII, Division 1 code for unfired pressure vessels.

D. A manufacturer’s data report is required to verify

pressure vessel construction adherence to ASME vessel construction requirements. Form U-1 as required per ASME code rules is to be furnished to the owner. The U-1 Form must be signed by a qualified inspector, holding a National Board Commission, certifying that construction conforms to the latest ASME Code Section VIII, Div. 1 for pressure vessels. The ASME symbol “U” must also be stamped on the heat exchanger. Vessels specifically exempted from the scope of the code must come with material, test, and construction methods certification and detailed documents similar to ASME U-1; further, these must be signed by an officer of the company.

E. Chiller shall be designed and constructed to meet

UL and UL of Canada requirements and have labels appropriately affixed.

F. Unit shall be manufactured in a facility registered to

ISO 9001:2000 Manufacturing Quality Standard.

G. Each compressor assembly shall undergo a mechan-

ical run-in test to verify vibration levels, oil pressures, and temperatures are within acceptable limits. Each compressor assembly shall be proof tested at a minimum 204 psig (1407 kPa) and leak tested at 185 psig (1276 kPa) with a tracer gas mixture.

H. Entire chiller assembly shall be proof tested at

204 psig (1407 kPa) and leak tested at 185 psig (1276 kPa) with a tracer gas mixture on the refrigerant side. The leak test shall not allow any leaks greater than 0.5 oz per year of refrigerant. The water side of each heat exchanger shall be hydrostatically tested at 1.3 times rated working pressure.

I. Prior to shipment, the chiller automated controls

test shall be executed to check for proper wiring and ensure correct controls operation.

J. Chillers shall have factory-mounted, factory-wired

and factory-tested unit-mounted variable frequency drive (VFD). Proper VFD operation shall be confirmed prior to shipment.

1.03 DELIVERY, STORAGE AND HANDLING

A. Unit shall be stored and handled in accordance with

manufacturer’s instructions.

B. Unit shall be shipped with all refrigerant piping and

control wiring factory-installed.

C. Unit shall be shipped charged with oil and full

charge of refrigerant HFC-134a or a nitrogen holding charge as specified on the equipment schedule.

Page 25

D. Unit shall be shipped with firmly attached labels that

indicate name of manufacturer, chiller model number, chiller serial number, and refrigerant used.

E. If the unit is to be exported, the manufacturer shall

provide sufficient protection against sea water corrosion, making the unit suitable for shipment in a standard open top ocean shipping container.

F. Chiller and starter shall be stored indoors, protected

from construction dirt and moisture. Chiller shall be inspected under shipping tarps, bags, or crates to be sure water has not collected during transit. Protective shipping covers shall be kept in place until machine is ready for installation. The inside of the protective cover shall meet the following criteria:

1. Temperature is between 40 F (4.4 C) and 120 F (48.9 C)

2. Relative humidity is between 10% and 80% non-condensing.

1.04 WARRANTY Warranty shall include parts and labor for one year

after start-up or 18 months from shipment, whichever occurs first. A refrigerant warranty shall be provided for a period of 5 years.

Part 2 — Products

2.01 EQUIPMENT

A. General:

Factory-assembled, single piece, liquid chiller shall consist of compressor, motor, VFD, lubrication system, cooler, condenser, initial oil and refrigerant operating charges, microprocessor control system, and documentation required prior to start-up.

B. Compressor:

1. One variable speed, tri-rotor screw compressor of the high performance type.

2. Compressor and motor shall be hermetically sealed into a common assembly and arranged for easy field servicing.

3. The compressor motor shall be accessible for servicing without removing the compressor base from the chiller. Connections to the compressor casing shall use O-rings and gaskets to reduce the occurrence of refrigerant leakage. Connections to the compressor shall be flanged or bolted for easy disassembly.

4. Compressor bearings must have individual design life of 500,000 hours or greater.

5. Compressor shall provide capacity modulation from 100% to 15% capacity without the use of hot gas bypass or mechanical unloaders.

6. Compressor shall be provided with a factoryinstalled positive pressure lubrication system to deliver oil under pressure to bearings and rotors at all operating conditions. Lubrication system shall include:

a. Oil pump with factory-installed motor con-

tactor with overload protection.

b. Oil pressure sensor with differential readout

at main control center. c. Oil pressure regulator. d. Oil filter with isolation valves to allow filter

change without removal of refrigerant

charge. e. Oil sump heater [115 v, 50 or 60 Hz] con-

trolled from unit microprocessor. f. Oil reservoir temperature sensor with main

control center digital readout. g. All wiring to oil pump, oil heater, and con-

trols shall be pre-wired in the factory and

power shall be applied to check proper

operation prior to shipment.

7. Compressor shall be fully field serviceable. Compressors that must be removed and returned to the factory for service shall be unacceptable.

8. Acoustical attenuation shall be provided as required, to achieve a maximum (full load or part load) sound level, measured per AHRI Standard 575 (latest edition).

C. Motor:

1. Compressor motor shall be of the semihermetic, liquid refrigerant cooled, squirrel cage, induction type suitable for voltage shown on the equipment schedule.

2. If an open (air cooled) motor is provided, a compressor shaft seal leakage containment system shall be provided:

a. An oil reservoir shall collect oil and refriger-

ant that leaks past the seal.

b. A float device shall be provided to open

when the reservoir is full, directing the refrigerant/oil mixture back into the compressor housing.

c. A refrigerant sensor shall be located next to

the open drive seal to detect leaks.

3. Motors shall be suitable for operation in a refrigerant atmosphere and shall be cooled by atomized refrigerant in contact with the motor windings.

4. Motor stator shall be arranged for service or removal with only minor compressor disassembly and without removing main refrigerant piping connections.

5. Full load operation of the motor shall not exceed nameplate rating.

6. One motor winding temperature sensor (and on spare) shall be provided.

7. Should the mechanical contractor choose to provide a chiller with an air-cooled motor instead of the specified semi-hermetic motor, the contractor shall install additional cooling

Page 26

Guide specifications (cont)

equipment to dissipate the motor heat as per the following formula:

Btuh = (FLkW motor) (0.05) (3413) Btuh = (FLkW motor) (171) and, alternately Tons = Btuh/12,000 The additional piping, valves, air-handling

equipment, insulation, wiring, switchgear changes, ductwork, and coordination with other trades shall be the responsibility of the mechanical contractor. Shop drawings reflecting any changes to the design shall be included in the submittal, and incorporated into the final asbuilt drawings for the project.

8. Also, if an open motor is provided, a mechanical room thermostat shall be provided and set at 104 F (40 C). If this temperature is exceeded, the chillers shall shut down and an alarm signal shall be generated to the central Energy Management System (EMS) display module, prompting the service personnel to diagnose and repair the cause of the overtemperature condition. The mechanical contractor shall be responsible for all changes to the design, including coordination with temperature control, electrical and other trades. In addition, the electrical power consumption of any auxiliary ventilation and/or mechanical cooling required to maintain the mechanical room conditions stated above shall be considered in the determination of conformance to the scheduled chiller energy efficiency requirement.

D. Unit-Mounted Variable Frequency Drive (VFD) with

Built-In Harmonic LiquiFlo™ II Filter: The compressor shall be factory-mounted, factory-

wired and factory-tested prior to shipment by the chiller manufacturer. All interconnecting wiring and piping between the VFD and the chiller shall be factory-installed. Customer electrical connection for compressor motor power shall be limited to main power leads to the VFD, and wiring liquid pumps and tower fans to the chiller control circuit. The VFD shall incorporate the following features:

1. Design: a. The VFD shall be refrigerant cooled,

microprocessor based, pulse width modulated design. Water cooled designs are not acceptable.

b. Input and output power devices shall be

Insulated Gate Bipolar Transistors (IGBTs).

c. Rectifier shall convert incoming fixed volt-

age/frequency to fixed DC voltage.

d. Transistorized inverter and control regulator

shall convert fixed DC voltage to a sinusoidal PWM waveform.

e. Low voltage control sections and main

power sections shall be physically isolated.

f. Integrated controls shall coordinate motor

speed to optimize chiller performance over a wide variety of operating conditions.

2. Enclosure: a. Pre-painted unit mounted, NEMA 1 cabinet

shall include hinged, lockable doors and removable lifting lugs.

b. The VFD shall have a short circuit interrupt

and withstand rating of at least 65,000 amps.

c. Provisions to padlock main disconnect han-

dle in the “Off” positions shall be provided. Mechanical interlock to prevent opening cabinet door with disconnect in the “On” position or moving disconnect to the “On” position while the door is open shall be provided.

d. Provisions shall be made for top entry of

incoming line power cables.

3. Heat Sink: a. The heat sink shall be refrigerant cooled.

Heat sink and mating flanges shall be suitable for ASME design working pressure of 185 psig (1276 kPa).

b. Refrigerant cooling shall be metered to

maintain heat sink temperature within acceptable limits for ambient temperature.

4. VFD Rating: a. Drive shall be suitable for operation at name-

plate voltage ±10%.

b. Drive shall be suitable for continuous opera-

tion at 100% of nameplate amps and 150% of nameplate amps for 5 seconds.

c. Drive shall comply with applicable ANSI,

NEMA, UL and NEC standards.

d. Drive shall be suitable for operation in ambient

temperatures between 40 and 122 F (4 and 50 C), 95% humidity (non-condensing) for altitudes up to 6000 ft (1829 m) above sea level. Specific drive performance at jobsite ambient temperature and elevation shall be provided by the manufacturer in the bid.

5. User Interface: A single display shall provide interface for pro-

gramming and display of VFD and chiller parameters. Viewable parameters include:

a. Operating, configuration and fault messages b. Frequency in hertz c. Load and line side voltage and current (at the

VFD) d. kW e. IGBT temperature

6. VFD Performance: a. The VFD Voltage Total Harmonic Distortion

(THD) and Harmonic Current Total Demand Distortion (TDD) shall not exceed IEEE-519 requirements using the VFD circuit breaker

Page 27

input terminals as the point of common coupling (PCC).

b. The VFD full load efficiency shall meet or

exceed 97% at 100% VFD rated ampacity.

c. Active rectifier shall regulate unity displace-

ment power factor to 0.99 or higher.

d. Voltage boost capability to provide full motor

voltage at reduced line voltage conditions.

e. The VFD shall feature soft start, linear accel-

eration, and coast to stop capabilities.

f. Base motor frequency shall permit motor to

be utilized at nameplate voltage. Adjustable frequency range shall permit capacity control down to 15%.

g. The VFD shall have 150% instantaneous

torque generation.

7. VFD Electrical Service (single point power): a. The VFD shall have input circuit breaker

with minimum 65,000 amp interrupt capacity.

b. The VFD shall have standard branch oil

pump circuit breaker to provide power for chiller oil pump.

c. The VFD shall have standard 3 KVA control

power transformer with circuit breaker to provide power for oil heater, VFD controls and chiller controls.

d. The branch oil pump circuit breaker and

control power transformer shall be factorywired.

e. Input power shall be 380/460 vac, ±10%,

3 Phase, 50/60 Hz, ±2% Hz.

8. Discrete Outputs: 115-v discrete contact outputs shall be provided

for: a. Circuit breaker shunt trip b. Chilled water pump c. Condenser water pump d. Alarm status

9. Analog Output: An analog (4 to 20 mA) output for head pres-

sure reference shall be provided. This signal shall be suitable to control a 2-way or 3-way water regulating valve in the condenser piping.

10. Protection (the following shall be supplied): a. Under-voltage b. Over voltage c. Phase loss d. Phase reversal e. Ground fault f. Phase unbalance protection g. Single cycle voltage loss protection h. Programmable auto re-start after loss of

power

i. Motor overload protection (NEMA Class 10) j. Motor over temperature protection

11. VFD Testing: The VFD shall be factory-mounted, factory-

wired and factory-tested on the chiller prior to shipment.

E. Evaporator and Condenser:

1. Evaporator and condenser shall be of shell and tube type construction, each in separate shells. Units shall be fabricated with high-performance tubing, steel shell and tube sheets with fabricated steel waterboxes. Waterboxes shall be nozzle-in-head type with stub out nozzles having Victaulic grooves to allow for use of Victaulic couplings.

2. Tubing shall be copper, high-efficiency type, with integral internal and external enhancement unless otherwise noted. Tubes shall be nominal

/4-in. OD with nominal wall thickness of 0.025 in. measured at the root of the fin unless otherwise noted. Tubes shall be rolled into tube sheets and shall be individually replaceable. Tube sheet holes shall be double grooved for joint structural integrity. Intermediate support sheet spacing shall not exceed 36 in. (914 mm).

3. Waterboxes and nozzle connections shall be designed for 150 psig (1034 kPa) minimum working pressure unless otherwise noted. Nozzles should have grooves to allow use of Victaulic couplings.

4. The tube sheets of the cooler and condenser shall be bolted together to allow for field disassembly and reassembly.

5. The vessel shall display an ASME nameplate that shows the pressure and temperature data and the “U” stamp for ASME Section VIII, Division 1. A re-seating pressure relief valve(s) shall be installed on each heat exchanger. If a non-reseating type is used, a backup reseating type shall be installed in series.

6. Waterboxes shall have vents, drains, and covers to permit tube cleaning within the space shown on the drawings. A thermistor type temperature sensor with quick connects shall be factoryinstalled in each water nozzle.

7. Cooler shall be designed to prevent liquid refrigerant from entering the compressor. Devices that introduce pressure losses (such as mist eliminators) shall not be acceptable because they are subject to structural failures that can result in extensive compressor damage.

8. Tubes shall be individually replaceable from either end of the heat exchanger without affecting the strength and durability of the tube sheet and without causing leakage in adjacent tubes.

9. The condenser shell shall include a FLASC (Flash Subcooler) which cools the condensed

Page 28

Guide specifications (cont)

liquid refrigerant to a reduced temperature, thereby increasing the refrigeration cycle efficiency.

F. Refrigerant Flow Control:

To improve part load efficiency, liquid refrigerant shall be metered from the condenser to the cooler using a float-type metering valve to maintain the proper liquid level of refrigerant in the heat exchangers under both full and part load operating conditions. By maintaining a liquid seal at the float valve, bypassed hot gas from the condenser to the cooler is eliminated.

G. Controls, Safeties, and Diagnostics:

1. Controls: a. The chiller shall be provided with a factory-

installed and factory-wired microprocessor control center. The control center shall include a 16-line by 40-character liquid crystal display, 4 function keys, stop button, and alarm light. Other languages are available using the international language translator software.

b. All chiller and motor control monitoring shall

be displayed at the chiller control panel.

c. The controls shall make use of non-volatile

memory.

d. The chiller control system shall have the ability

to interface and communicate directly to the building control system.

e. The default standard display screen shall simul-

taneously indicate the following minimum information:

1) Date and time of day

2) 24-character primary system status message

3) 24-character secondary status message

4) Chiller operating hours

5) Entering chilled water temperature

6) Leaving chilled water temperature

7) Evaporator refrigerant temperature

8) Entering condenser water temperature

9) Leaving condenser water temperature

10) Condenser refrigerant temperature

11) Oil supply pressure

12) Oil sump temperature

13) Percent motor rated load amps (RLA)

f. In addition to the default screen, status

screens shall be accessible to view the status of every point monitored by the control center including:

1) Evaporator pressure

2) Condenser pressure

3) Compressor speed

4) Bearing oil supply temperature

5) Compressor discharge temperature

6) Motor winding temperature

7) Number of compressor starts

8) Control point settings

9) Discrete output status of various devices

10) Variable frequency drive status

11) Optional spare input channels

12) Line current and voltage for each phase

13) Frequency, kW, kWhr, demand kW

g. Schedule Function:

The chiller controls shall be configurable for manual or automatic start-up and shutdown. In automatic operation mode, the controls shall be capable of automatically starting and stopping the chiller according to a stored user programmable occupancy schedule. The controls shall include built-in provisions for accepting:

1) A minimum of two 365-day occupancy schedules.

2) Minimum of 8 separate occupied/unoccupied periods per day

3) Daylight savings start/end

4) 18 user-defined holidays

5) Means of configuring an occupancy timed override

6) Chiller start-up and shutdown via remote contact closure

h. Service Function:

The controls shall provide a password protected service function which allows authorized individuals to view an alarm history file which shall contain the last 25 alarm/alert messages with time and date stamp. These messages shall be displayed in text form, not codes.

i. Network Window Function:

Each chiller control panel shall be capable of viewing multiple point values and statuses from other like controls connected on a common network, including controller maintenance data. The operator shall be able to alter the remote controller’s set points or time schedule and to force point values or statuses for those points that are operator forcible. The control panel shall also have access to the alarm history file of all like controllers connected on the network.

j. Pump Control:

Upon request to start the compressor, the control system shall start the chilled and condenser water pumps and shall verify that flows have been established.

k. Ramp Loading:

A user-configurable ramp loading rate, effective during the chilled water temperature pulldown period, shall prevent a rapid increase in compressor power consumption. The controls shall allow configuration of the ramp loading rate in either degrees per minute of chilled water temperature pulldown or percent motor amps per minute. During the ramp loading period, a message shall be

Page 29

displayed informing the operator that the chiller is operating in ramp loading mode.

l. Chilled Water Reset:

The control center shall allow reset of the chilled water temperature set point based on any one of the following criteria:

1) Chilled water reset based on an external 4 to 20 mA signal.

2) Chilled water reset based on a remote temperature sensor (such as outdoor air).

3) Chilled water reset based on water temperature rise across the evaporator.

m. Demand Limit:

The control center shall limit amp draw of the compressor to the rated load amps or to a lower value based on one of the following criteria:

1) Demand limit based on a user input ranging from 40% to 100% of compressor rated load amps

2) Demand limit based on external 4 to 20 mA signal.

n. Controlled Compressor Shutdown:

The controls shall be capable of being configured to soft stop the compressor. The display shall indicate “shutdown in progress.”

2. Safeties: a. Unit shall automatically shut down when any

of the following conditions occur (each of these protective limits shall require manual reset and cause an alarm message to be displayed on the control panel screen, informing the operator of the shutdown cause):

1) Motor overcurrent

2) Over voltage*

3) Under voltage*

4) Single cycle dropout*

5) Low oil sump temperature

6) Low evaporator refrigerant temperature

7) High condenser pressure

8) High motor temperature

9) High compressor discharge temperature

10) Low oil pressure

11) Prolonged stall

12) Loss of cooler water flow

13) Loss of condenser water flow

14) Variable frequency drive fault

15) High variable frequency drive temperature * Shall not require manual reset or cause an

alarm if auto-restart after power failure is enabled.

b. The control system shall detect conditions

that approach protective limits and take selfcorrective action prior to an alarm occurring. The system shall automatically reduce chiller capacity when any of the following

parameters are outside their normal operating range:

1) High condenser pressure

2) High motor temperature

3) Low evaporator refrigerant temperature

4) High motor amps

5) High VFD rectifier temperature

6) High VFD inverter temperature

c. During the capacity override period, a pre-

alarm (alert) message shall be displayed informing the operator which condition is causing the capacity override. Once the condition is again within acceptable limits, the override condition shall be terminated and the chiller shall revert to normal chilled water control. If during either condition the protective limit is reached, the chiller shall shut down and a message shall be displayed informing the operator which condition caused the shutdown and alarm.

d. Internal built in safeties shall protect the

chiller from loss of water flow. Differential pressure switches shall not be allowed to be the only form of freeze protection.

3. Diagnostics and Service: a. A self diagnostic controls test shall be an

integral part of the control system to allow quick identification of malfunctioning components.

b. Once the controls test has been initiated, all

pressure and temperature sensors shall be checked to ensure they are within normal operating range. A pump test shall automatically energize the chilled water pump, condenser water pump, and oil pump. The control system shall confirm that water flow and oil pressure have been established and require operator confirmation before proceeding to the next test.

c. In addition to the automated controls test,

the controls shall provide a manual test which permits selection and testing of individual control components and inputs. A thermistor test and transducer test shall display on the ICVC screen the actual reading of each transducer and each thermistor installed on the chiller. All out-of-range sensors shall be identified. Pressure transducers shall be serviceable without the need for refrigerant charge removal or isolation.

4. Multiple Chiller Control: The chiller controls shall be supplied as stan-

dard with a two-chiller lead/lag and a third chiller standby system. The control system shall automatically start and stop a lag or second chiller on a two-chiller system. If one of the two chillers on line goes into a fault mode, the third standby chiller shall be automatically started. The two-chiller lead/lag system shall allow

Page 30

Guide specifications (cont)

manual rotation of the lead chiller and a staggered restart of the chillers after a power failure. The lead/lag system shall include load balancing if configured to do so.

H. Electrical Requirements:

1. Electrical contractor shall supply and install main electrical power line, disconnect switches, circuit breakers, and electrical protection devices per local code requirements and as indicated necessary by the chiller manufacturer.

2. Electrical contractor shall wire the chilled water pump and flow, condenser water pump and flow, and tower fan control circuit to the chiller control circuit.

3. Electrical contractor shall supply and install electrical wiring and devices required to interface the chiller controls with the building control system if applicable.

4. Electrical power shall be supplied to the unit at the voltage, phase, and frequency listed in the equipment schedule.

I. Piping Requirements — Instrumentation and Safeties:

1. Mechanical contractor shall supply and install pressure gages in readily accessible locations in piping adjacent to the chiller such that they can be easily read from a standing position on the floor. Scale range shall be such that design values shall be indicated at approximately midscale.

2. Gages shall be installed in the entering and leaving water lines of the cooler and condenser.

J. Vibration Isolation:

Chiller manufacturer shall furnish neoprene isolator pads for mounting equipment on a level concrete surface.

K. Start-Up:

1. The chiller manufacturer shall provide a factorytrained representative, employed by the chiller manufacturer, to perform the start-up procedures as outlined in the Start-Up, Operation and Maintenance manual provided by the chiller manufacturer.

2. Manufacturer shall supply the following literature:

a. Start-up, operation and maintenance

instructions. b. Installation instructions. c. Field wiring diagrams. d. One complete set of certified drawings.

L. Special Features:

1. Soleplate Package: Unit manufacturer shall furnish a soleplate

package consisting of soleplates, jacking screws, leveling pads, and neoprene pads.

2. Spring Isolators: Spring isolators shall be field furnished and

selected for the desired degree of isolation.

3. Spare Sensors with Leads: Unit manufacturer shall furnish additional tem-

perature sensors and leads.

4. Sound Insulation Kit: Unit manufacturer shall furnish a sound insula-

tion kit that covers the compressor housing, motor housing, compressor discharge pipe, suction line, evaporator, and economizer (if equipped).

5. Stand-Alone Pumpout Unit: A free-standing pumpout unit shall be provided.

The pumpout unit shall use a semi-hermetic reciprocating compressor with liquid-cooled condenser. Condenser liquid piping and 3-phase motor power shall be installed at the jobsite by the installing contractor.

6. Separate Storage Tank and Pumpout Unit: A free-standing refrigerant storage tank and

pumpout unit shall be provided. The storage vessels shall be designed per ASME Section VIII Division 1 code with 150 psig (1034 kPa) design pressure. Double relief valves per ANSI/ ASHRAE 15, latest edition, shall be provided. The tank shall include a liquid level gage and pressure gage. The pumpout shall use a hermetic reciprocating compressor with watercooled condenser. Condenser water piping and 3-phase motor power shall be installed at the jobsite by the installing contractor.

7. Building Control System Interface (LON): The chiller control system shall have the ability

to interface and communicate directly to the building control using a LON based system. The LonWorks Carrier Translator shall output data in standard LON profiles.

8. Refrigerant Charge: The chiller shall ship from the factory fully

charged with R-134a refrigerant and oil.

9. Thermal Insulation: Unit manufacturer shall insulate the cooler

shell, economizer, suction elbow, motor shell and motor cooling lines. Insulation shall be 1 in. (25.4 mm) thick with a thermal conductivity not exceeding

0.28

and shall conform to UL standard 94, classification 94 HF-1.

10. Automatic Hot Gas Bypass: Hot gas bypass valve and piping shall be

factory-furnished to permit chiller operation for extended periods of time.

(Btu · in.)

hr. Ft2 F

0.0404

(

m C

)

Page 31

11. Cooler and Condenser Tubes: Contact a local Carrier Representative for other

tube offerings.

12. Cooler and Condenser Passes: Unit manufacturer shall provide the cooler and/

or condenser with 1, 2 or 3 pass configuration on the water side.

13. Nozzle-In-Head, 300 psig (2068 kPa): Unit manufacturer shall furnish nozzle-in-head

style waterboxes on the cooler and/or condenser rated at 300 psig (2068 kPa).

14. Marine Waterboxes: Unit manufacturer shall furnish marine style

waterboxes on cooler and/or condenser rated at 150 psig (1034 kPA).

15. Marine Waterboxes: Unit manufacturer shall furnish marine style

waterboxes on cooler and/or condenser rated at 300 psig (2068 kPA).

16. Flanged Water Nozzles: Unit manufacturer shall furnish standard

flanged piping connections on the cooler and/ or condenser.

17. Hinges: Unit manufacturer shall furnish hinges on

waterboxes to facilitate tube cleaning.

18. Optional Compressor Discharge Isolation Valve and Liquid Line Ball Valve:

These items shall be factory-installed to allow isolation of the refrigerant charge in the condenser for servicing the compressor.

19. Pumpout Unit: A refrigerant pumpout system shall be installed

on the chiller. The pumpout system shall include a hermetic compressor and drive, internal piping, internal wiring, and motor. Fieldsupplied main power wiring and water piping shall be required.

20. BACnet Communication Option: Shall provide factory installed communication

capability with a BACnet MS/TP network. Allows integration with i-Vu

Open control sys-

tem or a BACnet building automation system. denser for servicing the compressor.



21. Optional Seismic Isolation Package: Package shall meet International Building Code

and ASCE 7 seismic qualification requirements in concurrence with ICC ES AC156 Acceptance Criteria for Seismic Qualification by Shake-Table Testing of Nonstructural Components and Systems. Manufacturer shall provide seismic certificate from OSHPD (California only).

910

Page 32

Section 9 Ta b 9 a

Carrier Corporation • Syracuse, New York 13221 910 5-10

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

Pg 32 Catalog No. 04-52230002-01 Printed in U.S.A. Form 23XRV-3PD

Replaces: 23XRV-2PD

Carrier EVERGREEN 23XRV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Features/Benefits

Table of contents

Model number nomenclature

Physical data

Options and accessories

Dimensions

Performance data

Electrical data

Controls

Typical piping and wiring

Control wiring schematic

Application data

Guide specifications