Carrier 23 XL User Manual

23XL 50/60 Hz Hermetic Screw Liquid Chillers

With HCFC-22 and HFC-134a

Installation Instructions

SAFETY CONSIDERATIONS

Screw liquid chillers are designed to provide safe and reliable service when operated within design speci®cations. When operating this equipment, 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 speci®ed 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 ¯ame 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 quali- ®ed electrician.

DO NOT WORK ON electrical components, including control center, switches, starters, or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solidstate components.

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, con®rm 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.

NEVER APPLY an open ¯ame 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 re®ll them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT INCINERATE.

CHECK THE REFRIGERANT TYPE before adding refrigerant to the machine. The introduction of the wrong refrigerant can cause machine damage or malfunction.

Operation of this equipment with refrigerants other than those cited herein should comply with ANSI/ASHRAE-15 (latest edition). Contact Carrier for further information on use of this machine with other refrigerants.

DO NOT ATTEMPT TO REMOVE ®ttings, covers, etc., while machine is under pressure or while machine is running. Be sure pressure is at 0 psig (0 kPa) before breaking any refrigerant connection.

CAREFULLY INSPECT all relief valves, rupture discs, and other relief devices AT LEAST ONCE A YEAR. If machine operates in a corrosive atmosphere, inspect the devices at more frequent intervals.

DO NOT ATTEMPT TO REPAIR OR RECONDITION any relief valve when corrosion or build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism. Replace the valve.

DO NOT install relief devices in series or backwards.

USE CARE when working near or in line with a compressed spring. Sudden release of the spring can cause it and objects in its path to act as projectiles.

DO NOT STEP on refrigerant lines. Broken lines can whip about and release refrigerant, causing personal injury.

DO NOT climb over a machine. Use platform, catwalk, or staging. Follow safe practices when using ladders.

USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move inspection covers or other heavy components. Even if components are light, use mechanical equipment when there is a risk of slipping or losing your balance.

BE AWARE that certain automatic start arrangements CAN ENGAGE THE STARTER, TOWER FAN, OR PUMPS. Open the disconnect ahead of the starter, tower fan and pumps. Shut off the machine or pump before servicing equipment.

USE only repaired or replacement parts that meet the code requirements of the original equipment.

DO NOT VENT OR DRAIN waterboxes containing industrial brines, liquid, gases, or semisolids without the permission of your process control group.

DO NOT LOOSEN waterbox cover bolts until the waterbox has been completely drained.

DOUBLE-CHECK that coupling nut wrenches, dial indicators, or other items have been removed before rotating any shafts.

DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread engagement.

PERIODICALLY INSPECT all valves, ®ttings, 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, speci®cations or designs without notice and without incurring obligations.

Book	2		PC 211	Catalog No. 532-303	Printed in U.S.A.	Form 23XL-2SI	Pg 1	9-94	Replaces: 23XL-1SI
Tab	5e

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

INTRODUCTION

General Ð The 23XL machine is factory assembled, wired, and leak tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. Rigging, installation, ®eld wiring, and ®eld piping are the responsibility of the contractor and/or customer. Carrier has no installation responsibilities for the equipment.

Job Data

Necessary information consists of:

·job contract or speci®cations

·machine location prints

·rigging information

·piping prints and details

·®eld wiring drawings

·starter manufacturer's installation details

·Carrier certi®ed 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

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 damage incurred in transit.

2.Check all items against shipping list. Immediately notify the nearest Carrier representative if any item is missing.

3.To prevent loss or damage, leave all parts in original packages until 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 Ð 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.

LEGEND

VI Ð Volumetric Index

Fig. 1 Ð Model Number Identi®cation

PROVIDE MACHINE PROTECTION Ð 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 ®lled.

2

FRONT VIEW

1 Ð Power Panel

2 Ð Local Interface Display (LID) Control Center

3 Ð ASME Nameplate, Cooler

4 Ð Cooler Refrigerant Isolation Valve

5 Ð ASME Nameplate, Economizer (Hidden)

6 Ð Service Valve

7 Ð Take-Apart Rabbet Fit Connector (Lower)

8 Ð Cooler Temperature Sensor

9 Ð ASME Nameplate, Condenser

10 Ð Typical Waterbox Drain Port

11 Ð Cooler Supply/Return End

Waterbox Cover

12 Ð Condenser Supply/Return End

Waterbox Cover

13 Ð Compressor Nameplate (Hidden)

REAR VIEW

14 Ð Oil Separator

15 Ð ASME Nameplate, Muffler (Hidden)

16 Ð ASME Nameplate, Oil Separator

17 Ð Cooler Relief Valves (Hidden)

18 Ð Oil Sump Filter Assembly

19 Ð Oil Charging Valve

20 Ð Vessel Separation Feet

21 Ð Float Chamber

22 Ð Condenser Isolation Valve (Option or Accessory)

23 Ð Refrigerant Charging Valve

24 Ð Condenser

25 Ð Condenser Relief Valves (Hidden)

26 Ð Take-Apart Rabbet Fit Connector (Upper)

27 Ð Unit Mounted Starter (Option)

28 Ð Machine Identi®cation Nameplate

Fig. 2 Ð Typical 23XL Installation (Frame 1 and 2 Machines)

3

FRONT VIEW

1 Ð Compressor Nameplate (Hidden)

2 Ð Power Panel

3 Ð Local Interface Display (LID) Control Center

4 Ð ASME Nameplate, Cooler

5 Ð Cooler

6 Ð Vessel Separation Feet

7 Ð Economizer Float Valve Access Cover

(Hidden)

8 Ð Refrigerant Charging Valve

9 Ð Economizer

10 Ð Oil Filter Assembly (Hidden)

11 Ð ASME Nameplate, Economizer

12 Ð Typical Waterbox Drain Port

13 Ð Take-Apart Rabbet Fit Connector

14 Ð ASME Nameplate, Condenser

15 Ð Cooler Supply/Return End Waterbox Cover

16 Ð Condenser Temperature Sensors

17 Ð Cooler Relief Valve

REAR VIEW

18 Ð Unit Mounted Starter (Option)

19 Ð ASME Nameplate, Oil Separator

20 Ð Oil Separator Relief Valves

21 Ð Oil Separator

22 Ð Oil Charging Valve

23 Ð Condenser Isolation Valve (Option or Accessory)

24 Ð Service Valve

25 Ð Cooler Refrigerant Isolation Valve

26 Ð Condenser Relief Valves and Oil Filter

27 Ð Float Chamber

28 Ð Poppet Valve Assembly

29 Ð Motor Cooling Isolation Valve

30 Ð Condenser

31 Ð Condenser Supply/Return End Waterbox Cover

32 Ð Cooler Temperature Sensors

33 Ð Machine Identi®cation Nameplate

Fig. 3 Ð Typical 23XL Installation (Frame 4 Machine)

Rigging the Machine Ð The 23XL can be rigged as an entire assembly. It also has ¯anged connections that allow the compressor, cooler, condenser, and oil separator sections to be separated to ful®ll speci®c installation requirements.

RIG MACHINE ASSEMBLY Ð 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 in the 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 speci®ed 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 the compressor using threaded eyebolts. Metric threaded eyebolts are provided only for lifting individual compressor castings.

IMPORTANT: Only a quali®ed service technician should disassemble and reassemble the machine. After reassembly, the machine must be dehydrated and leak tested.

RIG MACHINE COMPONENTS Ð Refer to instructions below, Fig. 8-12, and Carrier certi®ed prints for machine disassembly.

Do not attempt to cut refrigeration lines or disconnect ¯anges or ®ttings while machine is under pressure. Cutting lines or disconnecting ¯anges or ®ttings 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.

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 certi®ed 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 ®eld 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.	Suggested ``I'' Beam Spreader Bar*

	HEAT	CENTER OF GRAVITY Ð				MAXIMUM
		APPROXIMATE DIMENSIONS
	EXCHANGER					WEIGHT
		A (Length)		B (Width)
	SIZE
		ft-in.	mm	ft-in.	mm	lb	Kg
	10 or 11	3- 8	1117	1-11	572	11,810	5357
	20 or 21	3-10	1161	2- 0	600	13,200	5940

	OPTIONS	ENGLISH	SI
		in. x lb/ft	cm x N/m
	1	S12 x 31.8	S30 x 464
	2	S10 x 35	S25.4 x 511
	3	W12 x 22	W30 x 321
	4	W10 x 25	W25.4 x 365

Fig. 4 Ð Machine Rigging Guide (Frame 1 and 2 Machines)

5

796

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 Ð						MAXIMUM WEIGHT*
		APPROXIMATE DIMENSIONS
	HEAT EXCHANGER
			A			B
	SIZE
		(Length)			(Width)			lb	kg
		ft-in.		mm	ft-in.		mm
	40, 41, 42, or 43	6-4		1930	2-8		813	22,300	10,116

*Includes marine waterboxes and refrigerant charge.

Suggested ``I'' Beam Spreader Bar²

	OPTIONS	ENGLISH	SI
		in. x lb/ft	cm x N/m
	1	S12 x 31.8	S30 x 464
	2	S10 x 35	S25.4 x 511
	3	W12 x 22	W30 x 321
	4	W10 x 25	W25.4 x 365

²Carrier recommends that ``I'' beam spreader bars be ®eld supplied and installed.

Fig. 5 Ð Machine Rigging Guide

(Frame 4 Machines)

6

23-22

	HEAT EXCHANGER		A (LENGTH)			OVERALL		OVERALL		NOZZLE PIPE SIZE
		1 Pass		2 and 3 Pass*		B (WIDTH)		C (HEIGHT)			(in.)
	SIZE
		ft-in.	mm	ft-in.	mm	ft-in.	mm	ft-in.	mm	1-Pass	2 and 3-Pass
	10 or 11	9-5	2870	9-61¤2	2908	4- 91¤4	1454	6- 95¤8	2073	6	6
	20 or 21					4-11	1499	6-113¤8	2118	8	6

*2 and 3-pass length applies if either (or both) cooler or condenser is a 2 or 3-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.Certi®ed drawings available upon request.

→	Fig. 6 Ð 23XL Dimensions (Frame 1 and 2 Machines)

7

796

NOTES:

1.For ¯anged waterbox nozzles, refer to the certi®ed drawings for length addition measurements.

2.Service access should be provided based on American 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.Certi®ed drawings are available upon request.

5.[ ] indicates millimeters.

HEAT EXCHANGER

A (LENGTH)

OVERALL

OVERALL

NOZZLE PIPE SIZE (in.)

(Cooler and

2 Pass*

1 or 3 Pass²

B (WIDTH)

C (HEIGHT)

(Nominal Pipe Size)

Condenser Size)

ft-in.

mm

ft-in.

mm

ft-in.

mm

ft-in.

mm

1-Pass

2-Pass

3-Pass

40-43

13-73¤4

4159

14-31¤4

4350

5-107¤8

1800

7-611¤16

2303

10

8

6

HEAT EXCHANGER

A (Length With

Marine Waterbox Ð Not Shown)

(Cooler and

2 Pass*

1 or 3 Pass²

Condenser Size)

ft-in.

mm

ft.-in.

mm

40-43

14-95¤8

4512

16-51¤2

5017

*Assumes both cooler and condenser nozzles on same end of chiller.

²1 or 3 pass length applies if either (or both) cooler or condenser i s a 1 or 3 pass design.

Fig. 7 Ð 23XL Dimensions (Frame 4 Machines)

9

Table 1 Ð 23XL Compressor Weights

	23XL	COMPRESSOR SIZE	ASSEMBLY
			(Less Motor)
	UNIT	(Tons)
			lb	kg
	Frame 1	C2	2270	1029
		C4	2300	1043
	Frame 2	C6	2400	1088
	Frame 4	D4	3300	1497
		D6	3400	1542

Table 2 Ð 23XL Component Weights

	COMPONENT	FRAME 1 AND 2		FRAME 4
		lb	kg	lb	kg
	Oil Separator	1180	535	2880*	1306*
	Economizer²	296	134	560	254
	Muffler	170	77	*	*
	Discharge Piping:	44	20	Ð	Ð
	Pipe
	Isolation Valve²	30	14	30	14
	Adaptor Flange	76	34	76	34
	Power Panel	20	9	20	9
	Starter²	500	227	500	227
	Control Center	31	14	31	14

*The Frame 4 muffler is included in the oil separator weight. ²Optional.

Table 3 Ð 23XL Motor Weights*

COMPRESSOR		MAX IkW	STATOR		ROTOR			MOTOR CASING AND COVER
Size	VI Type		lb	kg	lb		kg	lb	kg
C2	0	125	230	104	58		26	310	141
C4	0	155	249	113	63		29	310	141
C4	1	195	276	125	69		31	310	141
C6	0 or 1
D4	0 or 1	280	460	208	110		49	370	167
D6	0 or 1	280	460	208	110		49	370	167

LEGEND

VI Ð Volumetric Index

*C2-C6 listed weights are for low-voltage motors (200-600 v). D4-D6 listed weights are for low-voltage motors (320-600 v).

→				Table 4 Ð 23XL Heat Exchanger Weights
					ENGLISH
		Dry Wt (lb)*					Machine Charge
	SIZE	Cooler	Cond		Refrigerant (lb)					Water (gal)
				Economizer			No Economizer
		Only²	Only							Cooler	Cond
				HCFC-22	HFC-134a		HCFC-22		HFC-134a
	10	2480	2890	650	**		600		**	34	39.2
	11	2650	3020	650	**		600		**	40	44.4
	20	2845	3250	750	**		700		**	45	49.2
	21	3000	3445	750	**		700		**	49	56.4
	40	5030	4690	1000	850		900		800	49.2	51.6
	41	5180	4835	1100	900		1000		850	54	57
	42	5345	5005	1200	950		1100		900	60	63
	43	5525	5185	1300	1000		1200		950	66	70
						SI
		Dry Wt (kg)*					Machine Charge
	SIZE	Cooler	Cond		Refrigerant (kg)					Water (L)
				Economizer			No Economizer
		Only²	Only							Cooler	Cond
				HCFC-22	HFC-134a		HCFC-22		HFC-134a
	10	1125	1310	295	**		272		**	130	150
	11	1202	1370	295	**		272		**	152	168
	20	1291	1474	340	**		318		**	170	186
	21	1361	1563	340	**		318		**	186	214
	40	2282	2127	454	385		408		363	186	195
	41	2350	2193	499	408		454		385	204	216
	42	2424	2270	544	431		499		408	227	239
	43	2506	2352	590	454		544		431	250	264

LEGEND

NIH Ð Nozzle-In-Head

*Weight based on: .035 in. wall copper Turbo-B2 tubes in cooler, Turbo chill in condenser. 2-pass, 150 psi NIH waterbox arrangements (sizes 10, 11, 20, 21) 3-pass, 300 psi NIH waterbox arrangements (sizes 40, 41, 42, 43)

²Weight of optional economizer is not included and must be added to cooler weight. **Not available.

NOTE: Standard shipment is with refrigerant charged, so be sure to add refrigerant charge to dry weight.

9

796

Table 5A Ð 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)*

HEAT EXCHANGER		WATERBOX	PSI	FRAME 1			FRAME 2
		DESCRIPTION	(kPa)	lbs		kg	lbs		kg
	NIH, 1	Pass	150	118		54	128		58
	NIH, 2	Pass (Plain)		100		46	148		67
Cooler or			(1034)
	NIH, 2	Pass (With Pipe Nozzles)		185		84	200		91
Condenser
	NIH, 3	Pass	150	166		76	180		82
			(1034)
LEGEND
NIH Ð Nozzle-In-Head

*These weights are given for reference only. They have been included in heat exchanger weights shown in Table 4.

NOTE: Add 30 lb (14 Kg) for bolts.

Table 5B Ð 23XL Waterbox Cover Weight (Frame 4 Machines)*

					ENGLISH (lb)				SI (kg)
		HEAT	WATERBOX	Frame 4,		Frame 4,		Frame 4,		Frame 4,
	EXCHANGER		DESCRIPTION	Std Nozzles		Flanged		Std Nozzles		Flanged
				150 psig	300 psig	150 psig	300 psig	1034 kPa	2068 kPa	1034 kPa	2068 kPa
			NIH, 1 Pass Cover	284	414	324	491	129	188	147	223
			NIH, 2 Pass Cover	285	411	341	523	129	187	155	237
		COOLER	NIH, 3 Pass Cover	292	433	309	469	133	197	140	213
			NIH, Plain End Cover	243	292	243	292	110	133	110	133
			MWB Cover	CS	621	CS	621	CS	282	CS	282
			Plain End Cover	CS	482	CS	482	CS	219	CS	219
			NIH, 1 Pass Cover	306	446	346	523	139	202	157	237
			NIH, 2 Pass Cover	288	435	344	547	131	197	156	248
	CONDENSER		NIH, 3 Pass Cover	319	466	336	502	145	212	153	228
			NIH, Plain End Cover	226	271	226	271	103	123	103	123
			MWB Cover	CS	474	CS	474	CS	215	CS	215
			Plain End Cover	CS	359	CS	359	CS	163	CS	163
		LEGEND
	CS	Ð Contact Syracuse
	MWB Ð Marine Waterbox
	NIH	Ð Nozzle-In-Head

*These weights are given for reference only. The 150 psig (1034 kPa) standard waterbox cover weights have been included in the heat exchanger weights shown in Table 4.

→		Table 6 Ð 23XL Machine Rigging Weights
	COOLER SIZE	CONDENSER SIZE	ECONOMIZER	COMPRESSOR	VI TYPE	TOTAL RIGGING WEIGHT*
			INDICATOR	SIZE		lbs	kg
	10 or 11	10 or 11	YES	C2 or C4	0 or 1	11,410	5,175
			NO			11,110	5,039
	20 or 21	20 or 21	YES	C6	0 or 1	12,560	5,697
			NO			12,260	5,561
	40, 41, 42, or 43	40, 41, 42, or 43	YES	D4 or D6	0 or 1	20,020	9,081
			NO			19,520	8,855

LEGEND

VI Ð 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.

796

10

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 ¯ange 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 ®t 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 ¯ange (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 ¯ange 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 solenoid 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 ¯ange 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 ¯ange 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.

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