Carrier HFC-134A User Manual

Page 1

23XRV High-Efficiency Variable Speed Screw Chiller

Installation Instructions

SAFETY CONSIDERATIONS

Screw liquid chillers are designed to provide safe and reliable service when operated within design specifications. When operating this equipment, use good judgment and safety precautions to avoid damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and safety precautions contained in the machine instructions, as well as those listed in this guide.

DO NOT VENT refrigerant relief devices within a building. Outlet from rupture disc or relief valve must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE 15 (American National Standards Institute/American Society of Heating, Refrigeration and Air-Conditioning Engineers) (Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation.

PROVIDE adequate ventilation in accordance with ANSI/ ASHRAE 15, especially for enclosed and low overhead spaces. Inhalation of high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness, or death. Intentional misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen available for breathing. Product causes eye and skin irritation. Decomposition products are hazardous.

DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose. Oxygen gas reacts violently with oil, grease, and other common substances.

DO NOT USE air to leak test. Use only refrigerant or dry nitrogen. NEVER EXCEED specified test pressures. VERIFY the allowable

test pressure by checking the instruction literature and the design pressures on the equipment nameplate.

DO NOT VALVE OFF any safety device. BE SURE that all pressure relief devices are properly installed and

functioning before operating any machine. RISK OF INJURY OR DEATH by electrocution. High voltage

is present on motor leads even though the motor is not running. Open the power supply disconnect before touching motor leads or terminals.

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

open flame produces toxic gases.

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

DO NOT work on high-voltage equipment unless you are a qualified electrician.

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

LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED, confirm that all circuits are deenergized before resuming work.

AVOID SPILLING liquid refrigerant on skin or getting it into the eyes. USE SAFETY GOGGLES. Wash any spills from the skin with soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water and consult a physician.

EVERGREEN®

with Foxfire™ Compression Technology

and PIC III Controls

50/60 Hz

HFC-134a

NEVER APPLY an open flame or live steam to a refrigerant cylinder. Dangerous over pressure can result. When it is necessary to heat refrigerant, use only warm (110 F [43 C]) water.

DO NOT REUSE disposable (nonreturnable) cylinders or attempt to refill them. It is DANGEROUS AND ILLEGAL. When cylinder is emptied, evacuate remaining gas pressure, loosen the collar, and unscrew and discard the valve stem. DO NOT INCINERATE.

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

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

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

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

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

DO NOT install relief devices in series or backwards. USE CARE when working near or in line with a compressed spring.

Sudden release of the spring can cause it and objects in its path to act as projectiles.

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

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

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

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

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

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

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

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

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

PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a build-up of condensate or rain water.

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

Book 2 Ta b 5 e

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

Page 2

CONTENTS

Page

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

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

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

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

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

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

• INSPECT SHIPMENT

• IDENTIFY MACHINE

• INSTALLATION REQUIREMENTS

• PROVIDE MACHINE PROTECTION

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

• RIG MACHINE ASSEMBLY

• RIG MACHINE COMPONENTS

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

• SEPARATE COOLER AND CONDENSER

• REMOVE THE CONTROLS/DRIVE ENCLOSURE FROM THE CONDENSER

• REMOVE THE DISCHARGE PIPE ASSEMBLY FROM THE CONDENSER

• SEPARATE THE COMPRESSOR FROM THE CONDENSER

• SEPARATE THE VAPORIZER FROM THE CONDENSER

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

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

• INSTALL STANDARD ISOLATION

• INSTALL ACCESSORY ISOLATION

• INSTALL SPRING ISOLATION

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

• INSTALL WATER PIPING TO HEAT EXCHANGERS

• INSTALL VENT PIPING TO RELIEF VALVES

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

• GROUNDING THE CONTROLS/DRIVE ENCLOSURE

• INSTALLING INPUT POWER WIRING

• WIRING THE FIELD WIRING TERMINAL STRIPS

• CONNECT CONTROL INPUTS

• CONNECT CONTROL OUTPUTS

• CONNECT STARTER

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

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

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

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

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

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

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

INSTALLATION START-UP REQUEST

CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1, CL-2

INSTALLATION

Receiving the Machine

INSPECT SHIPMENT

Do not open any valves or loosen any connections. The 23XRV machine may be shipped with a full refrigerant charge. Some machines may be shipped with a nitrogen holding charge as an option.

1. Inspect for shipping damage while machine is still on shipping conveyance. If machine appears to be damaged or has been torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufac-

turer is not responsible for any damage incurred in transit.

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

3. To prevent loss or damage, leave all parts in original packages until beginning installation. All openings are closed with covers or plugs to prevent dirt and debris from entering machine components during shipping. A full operating oil charge is placed in the oil sump before shipment.

IDENTIFY MACHINE (Fig. 1-4) — Refer to machine nameplate in Fig. 1. The machine model number, serial number, and heat exchanger sizes are stamped on the Refrigeration Machine nameplate located on the side of the VFD (variable frequency drive) enclosure. Check this information against shipping papers and job data.

INTRODUCTION

General —

wired, and leak tested. Installation (not by Carrier) consists primarily of establishing water and electrical services to the machine. The rigging, installation, field wiring, field piping, and insulation of waterbox covers are the responsibility of the contractor and/or customer. Carrier has no installation responsibilities for the equipment.

The 23XRV machine is factory assembled,

Job Data — Necessary information consists of:

• job contract or specifications

• machine location prints

• rigging information

• piping prints and details

• field wiring drawings

• starter manufacturer’s installation details

• Carrier certified print

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Fig. 1 — Refrigeration Machine Nameplate

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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

R – Compressor

*First number denotes frame size.

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

Motor Code P Q R

T U V

Fig. 2 — Model Number Identification

S – Special

Not Used

Voltage Code 3 – 380-3-60 4 – 416-3-60 5 – 460-3-60 9 – 400-3-50

Drive

Rectifier Max

Frame

Input Amps†

440

520

608

Max Motor Amps

265 283

306 334 368

421 440

Inverter Max Output Amps†

442 442 520 608

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Identifying the Drive by Part Number

— Each LiquiFlo™

2.0 AC drive can be identified by its part number. See Fig. 5. This number appears on the shipping label and on the VFD nameplate.

Drive Input Component Location

— Figure 6 identifies the

control center components. Identifying the Power Module by I.D. Number

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

INSTALLATION REQUIREMENTS — Certain requirements should be checked before continuing with the chiller’s electrical installation. Input power wire sizes, branch circuit protection, and control wiring are all areas that need to be evaluated.

Determining Wire Size Requirements

— Wire size should be determined based on the size of the conduit openings, and applicable local, national, and international codes (e.g., NEC [National Electric Code]/CEC [California Energy Commission] regulations). General recommendations are included in the Carrier field wiring drawing.

Conduit Entry Size

— It is important to determine the size of the conduit openings in the enclosure power entry plate so that the wire planned for a specific entry point will fit through the opening. Do NOT punch holes or drill into the top surface of the control center enclosure for field wiring. Do not punch holes or drill into the top surface of the control center enclosure for field wiring. Knockouts are provided in the back of the control center for field control wiring connections.

Recommended Control and Signal Wire Sizes

— The recommended minimum size wire to connect I/O signals to the control terminal blocks is 18 AWG (American Wire Gage). Recommended terminal tightening torque is 7 to 9 in.-lb (0.79 to 1.02 N-m).

Recommended Air Flow Clearances

— Be sure there is adequate clearance for air circulation around the enclosure. A 6-in. (152.4 mm) minimum clearance is required wherever vents are located in the VFD enclosure.

Match Power Module Input and Supply Power Ratings

— It is important to verify that building power will meet the input power requirements of the Machine Electrical Data nameplate

input power rating. Be sure the input power to the chiller corresponds to the chiller’s nameplate voltage, current, and frequency. Refer to machine nameplate in Fig. 7. The machine electrical data nameplate is located on the right side of the control center.

PROVIDE MACHINE PROTECTION — Protect machine and VFD enclosure from construction dirt and moisture. Keep protective shipping covers in place until machine is ready for installation.

If machine is exposed to freezing temperatures after water circuits have been installed, open waterbox drains and remove all water from cooler and condenser. Leave drains open until system is filled.

It is important to properly plan before installing a 23XRV unit to ensure that the environment and operating conditions are satisfactory. The installation must comply with all requirements in the certified prints.

Rigging the Machine — The 23XRV machine can be

rigged as an entire assembly. Large interconnecting piping has flanged connections that allow the compressor, cooler, and condenser sections to be separated and rigged individually. In addition, the VFD can be removed and rigged separately.

RIG MACHINE ASSEMBLY — See rigging instructions on label attached to machine. Also refer to rigging guide (Fig. 8), physical data in Fig. 9, and Tables 2-9B. Lift machine only from the points indicated in rigging guide. Each lifting cable or chain must be capable of supporting the entire weight of the machine.

Lifting machine from points other than those specified may result in serious damage to the unit and personal injury. Rigging equipment and procedures must be adequate for machine weight. See Fig. 8 for machine weights.

NOTE: These weights are broken down into component sections for use when installing the unit in sections. For the complete machine weight, add all component sections and refrigerant charge together. See Tables 5-9B for machine component weights.

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1—Motor Terminal Cover Plate 2—Variable Frequency Drive 3—International Chiller Visual Controller (ICVC) 4—Discharge Pipe Relief Valve 5—Condenser 6—Oil Reclaim Actuator 7—Vaporizer Sight Glass 8—Oil Filter Assembly (Hidden)

9—Vaporizer 10 — Oil Charging/Drain Valve 11 — Oil Sump 12 — Condenser Refrigerant Pumpout Valve 13 — Condenser Float Chamber 14 — Cooler Inlet Isolation Valve 15 — ASME Nameplate, Economizer (Hidden) 16 — Filter Drier 17 — Oil Sump Heater 18 — Condenser Supply/Return End Waterbox 19 — Cooler Supply/Return End Waterbox 20 — Motor Cooling Supply Line 21 — VFD Disconnect

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35 34

22 — Discharge Pipe 23 — Compressor Discharge Check Valve Access Cover 24 — Condenser Relief Valves 25 — Refrigerant Charging Valve 26 — Cooler Relief Valve 27 — Tubesheet Mounting Brackets 28 — Typical Waterbox Drain Coupling 29 — ASME Nameplate, Condenser 30 — Oil Pump 31 — Oil Pump Inlet Strainer 32 — Strainer Housing Sight Glass 33 — Discharge Isolation Valve (Option or Accessory) 34 — Refrigeration Machine Nameplate 35 — Machine Electrical Data Nameplate 36 — Oil Sump Sight Glass 37 — Filter Drier Isolation Valve with Schrader 38 — Economizer 39 — Motor Cooling Sight Glass 40 — Motor Cooling Isolation Valve 41 — Vaporizer Drain Sight Glass

42 — VFD Cold Plate Refrigeration Inlet Connection

(Outlet Hidden)

43 — VFD Cold Plate Solenoid 44 — Compressor Nameplate 45 — Compressor Lubrication Block 46 — Economizer Muffler 47 — Vaporizer Condenser Gas Isolation Valve 48 — Hot Gas Bypass Isolation and Trim Valve 49 — VFD Cooling Refrigerant Strainer 50 —

Cooler Refrigerant Pumpout Valve

51 — ASME Nameplate, Cooler

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Fig. 3 — Typical 23XRV Components

Page 5

1—Condenser Pressure 2—Evaporator Pressure 3—Compressor Discharge Temperature 4—Compressor Discharge Pressure 5—Compressor Discharge High Pressure Switch 6—Compressor Motor Winding Temperature (Hidden) 7—Evaporator Refrigerant Liquid Temperature (Hidden) 8—Condenser Liquid Temperature 9—Condenser Liquid Flow (Optional)

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10 — Inductor Temperature Switch

(Inside VFD Enclosure)

11 — VFD Rectifier Temperature

(Inside Power Module)

12 — VFD Cold Plate Temperature

(Inside VFD Enclosure)

13 — VFD Inverter Temperature

(Inside Power Module)

14 — Humidity Sensor (Inside VFD Enclosure) 15 — Oil Pressure Leaving Filter (Hidden) 16 — Oil Sump Pressure (Hidden) 17 — Oil Sump Temperature (Hidden) 18 — Vaporizer Temperature 19 — Evaporator Liquid Temperature 20 — Evaporator Liquid Flow (Optional)

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

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Fig. 5 — VFD Nameplate

Page 6

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6 1

Fig. 6 — Control Center Components

9 1

1—Input Inductor Assembly 12 — Fuse, Class CC, 600V, 1A (3)

2—Capacitor Bank Assembly 13 — Transformer, 3kVA

3—Pre-Charge Resistor Assembly 14 — Line Sync PC Board Assembly

4—AC Contactor (3) 15 — Line Sync Board Cover

5—Power Module Assembly 16 — Fan, 115V (3)

6—Terminal Block, 10-Position (2) 17 — Circuit Breaker, 600V, 15A

7—Power Module Nameplate 18 — Circuit Breaker, 600V

8—Fuse Black, 30A, 600V, Class CC 19 — Lug, Ground, 2-600 MCM

9—Fuse, Class CC, 600V, 15A (2) 20 — Communications Interface Board

10 — Fuse, Class CC, 600V, 5A (1) 21 — Input Power Wiring Panel

11 — Fuse, Class CC, 600V, 20A (3)

Page 7

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Fig. 7 — Machine Electrical Data Nameplate

HEAT EXHANGER

CODE

30-32 35-37 20,58914′ 7′- 8″ 13′-10″ 13′-5″ 12′-10″ 3′-11″ 3′- 8″ 40-42 23,928 12′ 6′-10″ 13′-6″ 12′-8″ 12′-3″ 4′-1″ 3′-11″ 45-47 25,167 14′ 7′- 8″ 13′-11″ 13′-2″ 12′- 8″ 4′-1″ 3′-11″ 50-52 26,950 12′ 6′-10″ 13′-10″ 12′-7″ 12′-9″ 4′-0″ 4′-4″ 55-57 28,479 14′ 7′- 8″ 14′-4″ 13′-1″ 13′-1″ 4′-0″ 4′-4″

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

CHAIN “B” (SEE NOTE #2)

CHAIN “C” (SEE NOTE #2)

“E”

“F”

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COMPRESSOR

FRAME SIZE*

“A”

MAXIMUM WEIGHT

(lb)

19,18712′ 6′-10″ 13′-5″ 13′-0″ 12′-5″ 3′-11″ 3′- 8″

CHAIN “D” (SEE NOTE #2)

15´-0´´

MIN. HEIGHT ABOVE FLOOR

VESSEL LENGTH

DIM.

“A”

NOTES:

1. Each chain must be capable of supporting the entire weight of the machine. See chart for maximum weights.

2. Chain lengths shown are typical for 15′ lifting height. Some minor adjustments may be required.

CHAIN LENGTH

“B” “C” “D”

DIM.

“E”

MACHINE RIGGING GUIDE

DIM.

“F”

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

Page 8

TUBE REMOVAL SPACE FOR EITHER END SIZES 30-32, 40-42, 50-52 12’-7½” (3848 mm) SIZES 35-37, 45-47, 55-57 14’-4” (4369 mm)

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

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

0’-3”

4’-10”

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0’-5”

SERVICE AREA

4’ - 10” MIN (1219 mm)

(WIDEST POINT)

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

Table 1 — Drive Assembly and Power Module Ratings

CARRIER PART NUMBER FRAME SIZE

ENCLOSURE

TYPE

INPUT

VOLTAGE (V)

RANGE 23XRA2AA_ _ _ _ _ _ _ _ _ _ _ Frame 2AA NEMA 1 380 to 460 440 442 23XRA2BA_ _ _ _ _ _ _ _ _ _ _ Frame 2BA NEMA 1 380 to 460 520 442 23XRA2BB_ _ _ _ _ _ _ _ _ _ _ Frame 2BB NEMA 1 380 to 460 520 520 23XRA2CC_ _ _ _ _ _ _ _ _ _ _ Frame 2CC NEMA 1 380 to 460 608 608

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

MAX INPUT

CURRENT

(AMPS)

CURRENT* at 4kHZ

2’ MIN (610 mm)

MAX OUTPUT

(AMPS)

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

HEAT EXCHANGER

SIZE

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

30 to 32 14- 3

35 to 37 15-11

40 to 42 14- 9 4496 14- 3

45 to 47 16- 5

50 to 52 14-10 4521 14- 4

55 to 57 16- 6

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

1 Pass 2-Pass* 3 Pass†

4350 13- 81/

4870 15- 43/

5017 15-115/

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

4172 14- 31/

4693 15-113/

4347 14- 6 4420 6- 8½ 2045 7-6½ 2299

4867 16- 21/

4382 14- 61/

4350 6- 4 1930 7-25/

4870 6- 4 1930 7-25/

4940 6- 8½ 2045 7-6½ 2299

4432 6-113/

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

†1 or 3 pass length applies if either (or both) cooler or condenser is a 1 or 3 pass design. NOTES:

1. Service access should be provided per American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, and local safety code.

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

3. Certified drawings available upon request.

4. Marine waterboxes may add 6 in. to the width of the machine. See certified drawings for details.

5. ‘A’ length dimensions shown are for standard 150 psi design and victaulic connections. The 300 psi design and/or flanges will add length. See certified drawings.

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

B (Width) C (Height)

2127 7-63/

2200

2305

Page 9

Table 3 — 23XRV Dimensions (Marine Waterbox)

HEAT EXCHANGER

SIZE

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

A (Length, Marine Waterbox — not shown)

2-Pass* 1 or 3 Pass†

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

5017 18-11/

4642 16-81/

5163 18-43/

4661 16-81/

4997 6-93/

5518 6-93/

50866-9

5607 6-93/

5093 7-1 2159 7-63/

55 to 57 17- 0 518218-5 5613 7-1 2159 7-6

MAXIMUM

B WIDTH

2067 7-25/

2076 7-61/

*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:

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

3. Certified drawings available upon request.

4. Marine waterboxes may add 6 in. to the width of the machine. See certified drawings for details.

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

Table 4 — 23XRV Waterbox Nozzle Sizes

FRAME

SIZE

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

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

Cooler Condenser Cooler Condenser

MAXIMUM C HEIGHT

2200

2299

2305

Table 5 — 23XRV Compressor Weights

MOTOR

CODE

P Q R S T U V

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

ENGLISH SI

Total Compressor

Weight*

(lb)

4866 2207

Tot a l C o m pressor

Weight*

(kg)

Table 6 — 23XRV Component Weights — TR Compressor

FRAME 3

COMPONENT

HEAT EXCHANGER*

lb kg lb kg lb kg Suction Elbow 179 81 237 108 232 105 Discharge Pipe Assembly 747 339 747 339 747 339 Control Center 1650 749 1650 749 1650 749 Discharge Pipe Adapter Flange 17881178811788 Optional Isolation Valves 70 32 70 32 115 52 Optional Unit Mounted Pumpout Unit 164 75 164 75 164 75 Vaporizer Oil Sump 700 318 700 318 700 318 Economizer 542 246 542 246 542 246

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

FRAME 4

HEAT EXCHANGER*

FRAME 5

HEAT EXCHANGER*

Page 10

Table 7 — 23XRV Heat Exchanger Data

ENGLISH SI

Dry Rigging Weight

Cooler

Only

(lb)*

Condenser

Only

With

Economizer

CODE

30 4148 3617 800 650 464 464 1877 1676 363 295 210 210 31 4330 3818800 650 531 542 1959 1769 363 295 241 246 32 4522 4023 800 650 601 621 2046 1860 363 295 273 282 35 4419 4529 910 760 511 513 2000 2089 413 345 232 233 36 4627 4758 910 760 587 602 2094 2195 413 345 266 273 37 4845 4992 910 760 667 692 2193 2299 413 345 303 314 40 5008 4962 900 750 863 915 2675 2746 408 340 391 415 41 5178 5155 900 750 930 995 2758 2839 408 340 422 451 42 5326 5347 900 750 990 1074 2832 2932 408 340 449 487 45 5463 5525 1015 8 65 938 998 2882 3001 460 392 425 453 46 5659 5747 1015 8 65 1014 1088 2976 3108 460 392 460 494 47 5830 5967 1015 865 1083 1179 3061 3214 460 392 491 535 50 5827 6013 1250 1100 1101 1225 3182 3304 567 499 499 556 51 6053 6206 1250 1100 1192 1304 3294 3397 567 499 541 591 52 6196 6387 1250 1100 1248 1379 3364 3485 567 499 566 626 55 6370 6708 1430 128 0 1201 1339 3429 3620 649 581 545 607 56 6631 6930 1430 1280 1304 1429 3556 3726 649 581 591 648 57 6795 7138 1430 128 0 1369 1514 3636 3826 649 581621687

*Rigging weights are for standard tubes of standard wall thickness (Turbo-B3 and Spikefin 2, 0.025-in. [0.635 mm] wall). NOTES:

1. Cooler includes the suction elbow and

2. Condenser includes float valve and sump, discharge stub-out, and

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

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

Machine Charge

Refrigerant

Weight (lb)

Without

Economizer

/2 the distribution piping weight.

Liquid Weight

Cooler Condenser

(lb)

/2 the distribution piping weight.

Dry Rigging Weight

(kg)*

Cooler

Only

Condenser

Only

Refrigerant Weight (kg)

With

Economizer

Machine Charge

Without

Economizer

Liquid

Weight (kg)

Cooler Condenser

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

HEAT EXCHANGER

FRAME, PASS

FRAME 3, 1 AND 3 PASS 150 730 84 1034 331 318 FRAME 3, 2 PASS 150 365 42 1034 166 159 FRAME 4, 1 AND 3 PASS 150 1888 109 1034 856 413 FRAME 4, 2 PASS 150 944 54 1034 428 204 FRAME 5, 1 AND 3 PASS 150 2445 122 1034 1109 462 FRAME 5, 2 PASS 150 1223 61 1034 555 231 FRAME 3, 1 AND 3 PASS 300 860 84 2068 390 318 FRAME 3, 2 PASS 300 430 42 2068 195 159 FRAME 4, 1 AND 3 PASS 300 2162 109 2068 981413 FRAME 4, 2 PASS 300 1552 47 2068 704 178 FRAME 5, 1 AND 3 PASS 300 2655 122 2068 1204 462 FRAME 5, 2 PASS 300 1965 53 2068891 201

*Add to heat exchanger data for total weights or volumes. NOTES:

1. Weight adder shown is the same for cooler and condenser of equal frame size.

2. For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volume).

Psig

ENGLISH SI

Rigging Weight (lb) (see Note 2)

Water Volume

(gal)

kPa

Rigging Weight

(kg) (see Note 2)

Wate r Volume

(L)

Page 11

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

HEAT EXCHANGER

FRAME, PASS

FRAME 3, 1 AND 3 PASS 150 N/A N/A 1034 N/A N/A FRAME 3, 2 PASS 150 365 42 1034 166 159 FRAME 4, 1 AND 3 PASS 150 N/A N/A 1034 N/A N/A FRAME 4, 2 PASS 150 989 54 1034 449 204 FRAME 5, 1 AND 3 PASS 150 N/A N/A 1034 N/A N/A FRAME 5, 2 PASS 150 1195 60 1034 542 227 FRAME 3, 1 AND 3 PASS 300 N/A N/A 2068 N/A N/A FRAME 3, 2 PASS 300 430 42 2068 195 159 FRAME 4, 1 AND 3 PASS 300 N/A N/A 2068 N/A N/A FRAME 4, 2 PASS 300 1641 47 2068 744 178 FRAME 5, 1 AND 3 PASS 300 N/A N/A 2068 N/A N/A FRAME 5, 2 PASS 300 1909 50 2068866 189

*Add to heat exchanger data for total weights or volumes. NOTES:

1. Weight adder shown is the same for cooler and condenser of equal frame size.

2. For the total weight of a vessel with a marine waterbox, add these values to the heat exchanger weights (or volume).

Psig

ENGLISH SI

Rigging Weight

(lb) (see Note 2)

Water Volume

(gal)

kPa

Rigging Weight

(kg) (see Note 2)

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

Wate r Volume

(L)

WATERBOX

DESCRIPTION

NIH,1 pass Cover 150 PSIG 282318 148 185168 229 282318 148 185168 229 NIH,2 pass Cover 150 PSIG 28 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 486633709764840 411 486633709764840 NIH,2 pass Cover 300 PSIG 411 518 626 733 760 867 411 578 622 729 727 8 78 NIH,3 pass Cover 300 PSIG 433 468 660 694 795 830 433 468 655 689785 8 38 NIH Plain End, 300 PSIG 291 291 522 522 658 658 270 270 522 522 658 658 MWB End Cover, 300 PSIG* 445/619 445/619 522/522 522/522 658/658 658/658 359/474 359/474 522/522 522/522 658/658 658/658

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

Victaulic Nozzles

Flanged

7 340 202 256 222 276 287340191245224298

COOLER CONDENSER

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

Victaulic Nozzles

Flanged

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

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

COOLER CONDENSER

WATERBOX

DESCRIPTION

NIH,1 pass Cover 150 PSIG 128 144 67 84 76 104 128 144 67 84 76 104 NIH,2 pass Cover 150 PSIG 130 154 92 116 101 125 130 154 87 111 102 135 NIH,3 pass Cover 150 PSIG 133 141 214 221 280288 133 141 228 235 285 297 NIH Plain End, 150 PSIG 1101106363707010210263637070 MWB End Cover, 150 PSIG 110/143 110/143 63/142 63/142 70/177 70/177 102/106 102/106 63/142 63/142 70/177 70/177 NIH,1 pass Cover 300 PSIG 186220287 322 347 381186220287 322 346 381 NIH,2 pass Cover 300 PSIG 186235284 332 344 393 186235282 331 330 398 NIH,3 pass Cover 300 PSIG 196 212 299 315 361 376 196 212 297 313 356 380 NIH Plain End, 300 PSIG 132 132 237 237 298 298 122 122 237 237 298 298 MWB End Cover, 300 PSIG 202/281 202/281 237/237 237/237 298/298 298/298

LEGEND

NIH — Nozzle-in-Head MWB — Marine Waterbox

*Rows with two entries list nozzle end and return end weights. NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included in the heat exchanger weights shown in Table 7.

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

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

163/215 163/215 237/237 237/237 298/298 298/298

Flanged

Victaulic

Nozzles

Flanged

Victaulic

Nozzles

Flanged

RIG MACHINE COMPONENTS — Refer to Fig. 10-26 and Carrier Certified Prints for machine component disassembly.

IMPORTANT: Only a qualified service technician should perform this operation.

Do not attempt to disconnect flanges while the machine is under pressure. Failure to relieve pressure can result in personal injury or damage to the unit.

Before rigging the compressor remove control panel and control center.

NOTE: Label each wire before removal when wiring must be disconnected (see Fig. 10 and 11). Clip all wire ties necessary when removing pressure and temperature sensors. Disconnect all pressure transducer wires at the sensor. Temperature sensors cannot be disconnected from their cables; remove temperature sensors from their thermowells and label as required.

Page 12

CONDENSER

PRESSURE

CABLE

CABLE TRAY CONTAINING

VAPORIZER HTR CONDUIT

OIL HEATER CONDUIT

OIL PUMP CONDUIT

OIL SUMP TEMP. CABLE

OIL SUMP PRESS. CABLE

OIL PRESS. CABLE

OIL RECLAIM ACTUATOR CABLE

HGBP CONDUIT (OPTIONAL)

CONTROL

PA NE L

MOTOR TEMPERATURE

CABLE

a23-1558

WATER SENSOR CABLES FOR NOZZLE ARRANGEMENTS A,B,C,E,F,P,Q,R,T,&U (SAME FOR OTHER END OF MACHINE)

DISCHARGE END

DISCH. TEMP. CABLE DISCH. PRESS. CABLE DISCH. PRESS. SWITCH

COOLER PRESSURE CABLE

Fig. 10 — Electrical Cable Routing (Top View)

CABLE TRAY CONTAINING OIL VAPORIZER CONDUIT

OIL HTR CONDUIT

OIL PUMP CONDUIT

OIL RECLAIM ACTUATOR CABLE

OIL SUMP PRESS. CABLE

OIL DISCH. PRESS. CABLE

OIL SUMP TEMP. CABLE

HGBP CONDUIT (OPTIONAL)

COMR’R DISCH. TEMP. CABLE

DISCH. PRESS. SWITCH

DISCH. PRESS. CABLE

CABLE TRAY CONTAINING

ENT/LVG CHILLED LIQUID CABLES

ENT/LVG COND. LIQUID CABLES

COND, PRESS CABLE

COMP’R DISCH TEMP. CABLE

EVAP. PRESS. CABLE

EVAP. REFRIG. LIQUID TEMP. CABLE

MOTOR TEMP. CABLE

VFD COOLANT SOLENOID CABLE

OIL PRESS. CABLE

DISCH. PRESS. SWITCH CABLE

HGBP CONDUIT (OPTIONAL)

VFD COOLING

SOLENOID

CABLE

EVAP REFRIG. LIQUID

VFD COOLING

SOLENOID

TEMP. CABLE

SUCTION END

HGBP CONDUIT (OPTIONAL)

LEGEND

HGBP — Hot Gas Bypass HTR — Heater ENT/LVG — Entering/Leaving

MOTOR TEMP

CABLE

COMP’R DISCHARGE

TEMP. CABLE

DISCH. PRESS. CABLE

DISCH. PRESS. SWITCH

CONDENSER

PRESSURE

CABLE

EVAPORATOR

PRESSURE

CABLE

LEGEND

HGBP — Hot Gas Bypass HTR — Heater ENT/LVG— Entering/Leaving

DISCHARGE END

OIL PUMP

CONDUIT

OIL RECLAIM

ACTUATOR

CABLE

CABLE TRAY CONTAINING

VAPORIZER HEATER CONDUIT

OIL

PRESSURE

LEAVING

FILTER

CABLE

OIL SUMP

PRESSURE

CABLE

OIL SUMP

TEMPERATURE

CABLE

OIL HTR CONDUIT OIL PUMP CONDUIT OIL RECLAIM ACTUATOR CABLE OIL SUMP PRESS. CABLE OIL PRESS. CABLE OIL SUMP TEMP. CABLE HGBP CONDUIT (OPTIONAL)

Fig. 11 — Electrical Cable Routing (Back View)

EVAPORATOR REFRIG LIQUID TEMPERATURE SENS

OR CABLE

SUCTION END

OIL HEATER

CONDUIT

a23-1559

Page 13

Separate Machine Components — The design of

the 23XRV allows for disassembly at the job site so that individual components may be moved through existing doorways. Use the following procedures to separate the machine components.

Suggested locations to cut piping will minimize the width of

the condenser/economizer assembly. SEPARATE COOLER AND CONDENSER

IMPORTANT: If the cooler and condenser vessels must be separated, the heat exchangers should be kept level by placing a support plate under the tube sheets. The support plate will also help to keep the vessels level and aligned when the vessels are bolted back together.

NOTE: For steps 1 through 13 refer to Fig. 12. The cooler has been removed from the picture to show the pipes and lines that must be cut.

Check that the holding charge has been removed from the chiller.

1. Place a support plate under each tube sheet to keep each vessel level.

2. Remove cooler relief valve and relief valve vent piping.

3. Cut the motor cooling refrigerant drain line.

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

5. Cut the VFD cooling drain line.

6. Cut the oil reclaim line(s).

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

8. Unbolt the cooler liquid feed line near the economizer or condenser float chamber at the flanged connection. Temporarily secure the in-line economizer orifice plate (economized chillers only) to the economizer flange (see Fig. 12).

a23-1560

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

10 — Hot Gas Bypass Line (Cut)

Fig. 12 — Cooler/Discharge Pipe Assembly Removal

Page 14

9. Cut the vaporizer refrigerant return line as shown.

10. Disconnect all sensors with cables that cross from the condenser side of the machine to the cooler side including:

a. Evaporator refrigerant liquid temperature sensor.

See Fig. 13.

b. Entering and leaving chiller liquid temperature

sensors. See Fig. 14.

c. Evaporator pressure sensor.

11. Disconnect the tubesheet mounting brackets from the vessel connectors on the tube cooler tubesheet.

12. Cover all openings.

13. Rig the cooler away from the condenser/compressor.

NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them.

OPTIONAL HOT GAS BYPASS LINE

Do not rig the condenser before the control center and compressor are removed. The condenser/compressor assembly has a high center of gravity and may tip over when lifted at the tubesheet rigging points, which could result in equipment damage and/or serious personal injury.

REMOVE THE CONTROLS/DRIVE ENCLOSURE FROM THE CONDENSER — Confirm that the power supply disconnect is open and all safety procedures are observed before removing the VFD. This procedure minimizes the number of sensors and cables that need to be disconnected.

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

a23-1635

Fig. 13 — Evaporator Refrigerant Liquid

Temperature Sensor on Bottom of Cooler

LEAVING CONDENSER LIQUID TEMPERATURE SENSOR

EVAPORATOR REFRIGERANT LIQUID TEMPERATURE SENSOR

COOLER REFRIGERANT PUMPOUT VALV E

LEAVING CHILLED LIQUID TEMPERATURE SENSOR

1. Close the 2 filter drier isolation valves (Fig. 15) and the 2 VFD isolation valves. Isolate the refrigerant charge into the condenser to prevent a refrigerant leak if one of the motor terminals is accidentally damaged during VFD removal or installation. Evacuate the VFD coldplate through the Schrader valve (Fig. 15) on the VFD drain isolation valve.

2. Remove the shipping bracket between the VFD and the compressor if it is still in place. Remove any conduits that bring power to the VFD. See Fig. 16.

VFD REFRIGERANT COOLING SOLENOID VALV E

VFD REFRIGERANT COOLING ISOLATION VALV E

VFD REFRIGERANT STRAINER

FILTER DRIER ISOLATION VALVE

a23-1564

FILTER DRIER

MOTOR COOLING SIGHT GLASS

FILTER DRIER ISOLATION VALVE

SCHRADER VALV E

VFD DRAIN ISOLATION VALV E

ENTERING CONDENSER LIQUID TEMPERATURE SENSOR

Fig. 14 — Chiller End View

a23-1563

ENTERING CHILLED LIQUID TEMPERATURE SENSOR

Fig. 15 — VFD Refrigerant Isolation Valves

Page 15

SHIPPING BRACKET

a23-1565

Fig. 16 — VFD Shipping Bracket

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

4. Disconnect the motor leads from the motor terminals (Fig. 17). Note the position of the motor terminal cable lugs so they can be reinstalled with sufficient clearance away from surrounding structure.

5. Remove the motor temperature sensor leads (Fig. 17), the motor ground lead, and the bolts that secure the VFD enclosure to the terminal box transition piece.

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

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

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

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

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

11. Remove the 12 screws that secure the control panel to the VFD enclosure. Tilt the control panel away from the back of the control center.

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

a23-1567

Fig. 18 — ICVC Communication Cables

CONTROL PANEL

CONNECTOR CN1A

GROUND WIRE

CONNECTOR CN1B

MOTOR TERMINALS

MOTOR TEMPERATURE SENSOR TERMINAL BLOCK

MOTOR TEMPERATURE CABLE

Fig. 17 — Motor Terminals

MOTOR TERMINAL BOX FRAME

a23-1566

CONNECTOR CN2

a23-1570

LOW VOLTAGE FIELD WIRING TERMINAL STRIP

CONNECTOR CN3

Fig. 19 — Control Panel Connectors

HIGH PRESSURE SWITCH CABLE

Page 16

OIL HEATER CONDUIT ASY

3/4 IN. - 10 x 2 IN. LIFTING EYEBOLT WITH SHOULDER OR SWIVEL HOIST RING

6000 LB (2722 KG) WORKING LOAD LIMIT TYPICAL — CHICAGO HARDWARE P/N 28 GRAINGER P/N 5ZA63

OIL PUMP CONDUIT ASY

VAPORIZER HEATER CONDUIT ASY

VFD COOLING LINE O-RING FACE SEAL COUPLINGS

OIL RECLAIM ACTUATOR CABLE

VFD COOLING SOLENOID CABLE

a23-1571

TEMPERATURE SENSOR

PRESSURE SENSOR CABLES

CABLES

Fig. 20 — Control Panel Back

Lifting the Control Center

— Care should be used to prevent damage due to dropping or jolting when moving the control center. A fork truck or similar means of lifting and transporting may be used. Sling in a manner that will equalize the load at the pickup points. Use a spreader bar if the angle of the sling is less than 45 degrees relative to horizontal. Do not jolt while lifting.

Use the following procedure to lift the control center.

1. Remove the rubber hole plugs in the top of the control center and fully thread in 4 eyebolts or swivel hoist rings (see Fig. 21). Lifting hardware must have

/4 in.-10 x 2 in. long threads and must have a working load limit of at least 6000 lb (2722 kg). Typical eyebolts are Chicago Hardware (size 28) or Grainger (P/N 5ZA63).

2. Attach a sling to the four lifting eyebolts. Make certain that the angle of the sling is not less than 45 degrees relative to horizontal.

3. Using an overhead or portable hoist (minimum 2 ton rated capacity), attach a free-fall chain to the sling secured to the drive. Take up any slack in the chain.

4. Rig the control center and remove the bolts that secure it to the VFD mounting brackets on the condenser (see Fig. 21).

5. Confirm that welding procedures comply with local Pressure Vessel Codes before removing a portion of the VFD support bracket from the condenser. Custom brackets should be fabricated if part of the VFD supports must be cut off of the condenser to reduce the width of the condenser assembly. Clamp ¼-in. plates over both sides of the VFD bracket and drill two pairs of holes that

LIFTING

EYEBOLT

45° MIN

a23-1561

Fig. 21 — Control Center Lifting Points

straddle the line along which the VFD brackets will be cut. This will allow the VFD brackets to be reinstalled and welded in their original position.

NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them. (See Fig. 22.)

REMOVE THE DISCHARGE PIPE ASSEMBLY FROM THE CONDENSER

NOTE: For steps 1 through 6 refer to Fig. 12. The condenser relief valve and relief valve vent piping should

be removed if they will interfere with discharge pipe assembly rigging.

1. Remove the discharge pipe assembly relief valve and relief valve vent piping.

2. Disconnect the compressor discharge temperature sensor.

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

4. Rig the discharge pipe assembly and remove the bolts from the compressor discharge and condenser inlet flange. Note the position and orientation of the discharge isolation valve on the condenser inlet flange.

5. Remove the discharge pipe assembly.

6. Cover all openings.

NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk of damaging them.

Page 17

TO TERMINAL J4-10 UPPER

HUMIDITY SENSOR

a23-1568

Fig. 22 — Control Panel Inputs

SEPARATE THE COMPRESSOR FROM THE CONDENSER

a23-1569

The VFD blocks access to the compressor mounting bolts. It must be removed before the compressor can be separated from the condenser. See instructions to remove the VFD from the condenser. Refer to Table 10.

Page 18

Table 10 — Compressor Fastener Identification

COMPRESSOR FASTENERS SIZE

Discharge Pipe Assembly to

Compressor Discharge Flange

Suction Elbow to Compressor Inlet

Compressor Mount to Condenser

Motor Cooling, Motor Drain, Oil Drain M 12x1.75 Grade 10.9 Socket Head

Economizer Line

Compressor Lifting Points (2) M30x3.5 Threaded Holes

Stator Housing Lifting Point M30x3.5 Threaded Hole

Discharge Housing Lifting Point M30x3.5 Threaded Hole

1 in.-8 Grade 5 Hex Head

/8 in.-9 Grade 5 Hex Head

/4 in.-10 Studs (A-449)

/8 in.-11 Grade 8 Hex Head

1. Disconnect the oil supply line in two places (Fig. 23). Cap the oil lines and fittings.

NOTE: Compressor oil lines and fittings between the oil filter and compressor must be kept extremely clean to prevent obstruction of the compressor inlet bearing oil orifice. Cap all orifice lines and fittings during disassembly. The compressor inlet bearing oil orifice is located at the lubrication block on top of the compressor.

2. Disconnect the motor cooling inlet flange, the motor cooling drain flange, optional economizer vapor line flange, and bearing oil drain flange (Fig. 23). Remove the economizer muffler bracket.

3. Brace the end of the discharge pipe assembly closest to the compressor if it has not already been removed. Place an oil pan under the compressor flange to collect oil that may have accumulated in the discharge pipe assembly. Unbolt

the discharge pipe assembly from the compressor. It may also be necessary to loosen the bolts that attach the discharge pipe assembly to the condenser.

4. If the cooler has been removed, rig the suction elbow and unbolt the suction elbow at the compressor and vaporizer vent line flanges (see Fig. 12). If the cooler is still in place, it may be necessary to loosen the bolts that secure the suction elbow to the cooler.

5. Carefully remove the perforated insulation cutouts that cover the compressor lifting points. See Fig. 23. Replace the lifting shackle thread protector after the compressor is re-installed to prevent insulation adhesive from fouling the threads.

6. Rig the compressor with lifting eyelets installed in the two M30 threaded holes provided in the top of the compressor housing (Fig. 23). Use only M30 forged eye bolts or M30 hoist rings with a sufficient working load limit to safely lift the compressor. The rubber vibration isolators may pull out of the compressor mounting bracket when the compressor is lifted off of the condenser. Applying leak detection soap solution to the outside of the vibration isolators will make it easier to press the isolators back into position.

7. Cover all openings.

NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secure to reduce the risk damaging them.

a23-1572

DISCHARGE PIPE ASSEMBLY BOLTING FLANGE

ECONOMIZER MUFFLER BRACKET

OIL SUPPLY LINE FITTINGS

Fig. 23 — Compressor Removal

M30 COMPRESSOR LIFTING SHACKLE HOLES

MOTOR COOLING INLET FLANGE

ECONOMIZER VAPOR LINE FLANGE

MOTOR COOLING DRAIN FLANGE

SUCTION ELBOW FLANGE

VAPORIZER VENT LINE FLANGE

ECONOMIZER MUFFLER (OPTIONAL)

BEARING OIL DRAIN FLANGE

Page 19

SEPARATE THE VAPORIZER FROM THE CONDENSER — The VFD mounting brackets (Fig. 24) extend beyond the outboard edge of the vaporizer. The vaporizer extends beyond the perimeter of the condenser tubesheet.

1. Cut the vaporizer hot gas supply line near the oil concentrator (Fig. 24).

2. Cut the vaporizer hot gas return line (Fig. 24).

3. Cut the bearing oil drain line near the oil sump (Fig. 25).

4. Unbolt the vaporizer vent line flange shown in Fig. 25.

5. Cut the oil supply line as shown in Fig. 25.

6. Cut the oil reclaim line as shown in Fig. 25.

7. Disconnect all wires and cable leads to the vaporizer assembly (see Fig 26) including:

a. oil sump temperature sensor b. oil sump pressure cable and oil pressure leaving

filter cable c. oil reclaim cable d. vaporizer heater cable in the vaporizer heater

junction box e. oil pump cable f. oil sump heater conduit (Fig. 24) g. vaporizer temperature sensor

8. Rig the vaporizer with the lifting points on the vaporizer mounting bracket and remove the four bolts that secure it to the condenser (Fig. 24).

9. Cover all openings.

NOTE: To reassemble, follow steps in reverse order. Connect sensors and cables after major components have been secured to reduce the risk damaging them.

VFD Installation

1. Install terminal box frame mounting studs into tapped holes using short threaded end (see section E-E in Fig. 27). Do not exceed 120 ft-lb (163 N-m).

2. Install thermal insulators, insulation frame assembly, and terminal box frame prior to attaching motor power cables.

3. Torque motor terminals to 45 to 55 ft-lb (61 to 75 N-m).

4. There may be 1 or 2 motor power cables per terminal identified as T1, T2 and T3. Position motor end lugs on terminal studs with Belleville washer located against the front terminal lug with the convex side facing toward the front terminal nut. Clinch the two cables together with wire ties before tightening terminal nuts. Install front terminal nut finger tight. Hold front terminal nut stationary while tightening rear terminal nut to 45 to 50 ft-lb (61 to 68 N-m). (See Fig. 28.)

5. Check all terminal connections for proper installation.

IMPORTANT: Do not insulate terminals until wiring arrangement has been checked and approved by Carrier start-up personnel. Motor terminals must be insulated in acceptance with national and local electrical codes.

VAPORIZER MOUNTING BOLTS

VAPORIZER HOT GAS SUPPLY LINE

a23-1573

VFD MOUNTING BRACKETS

VAPORIZER HEATER

OIL PRESSURE REGULATOR ISOLATION VALV E

OIL SUMP HEATER JUNCTION BOX

JUNCTION BOX

OIL RECLAIM ACTUATOR

Fig. 24 — Oil Concentrator Removal

VAPORIZER MOUNTING BOLTS

VAPORIZER REFRIGERANT RETURN LINE

OIL PUMP JUNCTION BOX (HIDDEN)

Page 20

OIL SUPPLY LINE

BEARING OIL DRAIN LINE

VAPORIZER VENT LINE

OIL PUMP

OIL FILTER

a23-1574

VAPORIZER

VAPORIZER HOT GAS RETURN LINE

OIL SUMP

OIL RECLAIM LINE

Fig. 25 — Oil Reclaim Piping

VAPORIZER HOT GAS SUPPLY LINE

OIL PRESSURE REGULATOR VALVE

OIL PRESSURE REGULATOR ISOLATION VALV E

a23-1575

OIL FILTER SCHRADER VALV E

VAPORIZER REFRIGERANT RETURN ORIFICE

OIL SUMP STRAINER

OIL PUMP/OIL FILTER ISOLATION VALVE

OIL PRESSURE OIL RECLAIM ACTUATOR

OIL PUMP JUNCTION BOX

LEAVING FILTER

SENSOR

OIL PUMP/OIL FILTER ISOLATION VALVE

OIL FILTER

Fig. 26 — Oil Reclaim Components

OIL SUPPLY LINE (TO COMPRESSOR)

OIL PRESSURE REGULATOR LINE

OIL RECLAIM LINE ( FROM COOLER)

OIL SUMP PRESSURE SENSOR

OIL SUMP TEMPERATURE SENSOR

Page 21

MOTOR TEMPERATURE SENSOR TERMINAL BLOCK

TERMINAL ENCLOSURE FRAME

MOTOR LEADS

PROTECTIVE

EARTH (PE) GROUND CONNECTION

CONTROL CENTER

TERMINAL ENCLOSURE FRAME

FOAM INSULATION

a23-1576

COMPRESSOR

WASHER

THERMAL INSULATOR

SECTION E-E

TERMINAL ENCLOSURE FRAME

INSULATION FRAME ASSEMBLY

TERMINAL BOX FRAME

TERMINAL BOX MOUNTING STUD - DO NOT EXCEED 120 FT-LB TORQUE

Fig. 27 — Motor Terminal Box

TERMINAL BOX FRAME

CENTER TERMINAL ENCLOSURE FRAME OVER TERMINAL BOX FRAME ASSEMBLY

MOTOR TERMINAL

STUD NUTS

SECTION C-C

FROM FIG. 27

a23-1577

INTERNAL/EXTERNAL TOOTH LOCK WASHER BETWEEN TERMINAL BOX FRAME AND PE/GROUND CABLE LUG

Fig. 28 — Motor Terminal Insulation

FOAM INSULATION

WIRE TIES

VIEW LOOKING DOWN

MOTOR POWER CABLES (MAY BE 1 OR 2 PER TERMINAL)

0.38 APPROX.

Page 22

Insulate Motor Terminals and Lead Wire Ends — Locate heat shrink tubing (RCD P/N LF33MM114) over power connections so that they are completely covered and tubing is against motor housing. Shrink into position. Slide foam tubing (3 in. inner diameter closed cell vinyl, neoprene, or nitrile foam) part way over the heat shrink tubing. Apply adhesive for closed cell foam insulation to motor side end of the foam tubing and push tubing the rest of the way over the terminal and against the sheet insulation on the motor side. Secure the opposite end of the foam tubing with a wire tie as shown in Fig. 28.

Alternate Insulation for Motor Terminals and Lead Wire Ends — Insulate compressor motor terminals, lead wire

ends, and electrical wires to prevent moisture condensation and electrical arcing. Obtain Carrier approved insulation material from RCD (Replacement Components Division) consisting of 3 rolls of insulation putty and one roll of vinyl tape.

a. Insulate each terminal by wrapping with one layer

of insulation putty (RCD P/N 19EA411-1102).

b. Overwrap putty with 4 layers of vinyl tape.

6. Orient PE/ground lug as shown in Fig. 28. Assemble internal/external tooth lock washer between the terminal box frame and the PE/ground cable. Torque PE/ground lug nut to 55 to 65 ft-lb (75 to 89 N-m). See section H-H in Fig. 29 for PE/ground cable routing.

7. Center terminal enclosure frame over terminal box frame assembly so the space between the frames is equal within

/16-in. (5 mm) at the top and bottom. Use the slots in the terminal enclosure frame. Adjust spacing between the sides of the terminal enclosure frame and terminal box frame assemblies by moving the control center to the left or right.

8. Install O-rings on VFD refrigerant connections using silicone grease. Tighten connector using two wrenches to 27 to 33 ft-lb (37 to 45 N-m). (See Detail A in Fig. 30.)

9. Evacuate all piping between the VFD and the VFD isolation valves after assembly and tightening of VFD fittings. Dehydration/evacuation is complete to equalize VFD piping pressure with machine pressure if machine is charged with refrigerant (see Fig. 30).

Install Machine Supports

IMPORTANT: Chiller housekeeping pad, anchor bolts and attachment points to be designed by others in accordance with all applicable national and local codes.

INSTALL STANDARD ISOLATION — Figures 31 and 32 show the position of support plates and shear flex pads, which together form the standard machine support system.

Service clearance under the chiller can be enhanced if the grout is not extended along the entire length of the heat exchangers.

a23-1578

a23-1579

DETAIL A

Fig. 29 — Motor Ground Cable

SEE

DETAIL A

VFD COOLING LINE O-RING FACE SEAL COUPLINGS

Fig. 30 — VFD Refrigerant Connectors

VFD ISOLATION VALV ES (2)

FILTER DRIER ISOLATION VALVE

Page 23

a23-1534

23XRV

HEAT EXCHANGER

SIZE

30-32 12-10

35-37 14- 71/

40-42 12-103/

45-47 14- 71/

50-52 12-103/

55-57 14- 71/

ABCDEFG

5-51/

6-0 0-11/

6-51/

Fig. 31 — 23XRV Machine Footprint

a23-46

VIEW Y-Y

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Isolation package includes 4 shear flex pads.

Fig. 32 — Standard Isolation

INSTALL ACCESSORY ISOLATION (if required) — Uneven floors or other considerations may dictate the use of accessory soleplates (supplied by Carrier for field installation) and leveling pads. Refer to Fig. 33.

Level machine by using jacking screws in isolation sole-

plates. Use a level at least 24-in. (610 mm) long.

DIMENSIONS (ft-in.)

0-35/

00-3

0-1/

ACCESSORY SOLEPLATE DETAIL

a19-1109

1-31/

0-9 0-1/

IMPORTANT: Chiller support plates must be level

within

/2 in. from one end to the other end of the heat

exchangers for effective oil reclaim system operation.

For adequate and long lasting machine support, proper grout selection and placement is essential. Carrier recommends that only pre-mixed, epoxy type, non-shrinking grout be used for machine installation. Follow manufacturer’s instructions in applying grout.

1. Check machine location prints for required grout thickness.

2. Carefully wax jacking screws for easy removal from grout.

3. Grout must extend above the base of the soleplate and there must be no voids in grout beneath the plates.

4. Allow grout to set and harden, per manufacturer’s instructions, before starting machine.

a19-1110

VIEW X-X

LEGEND

HRS — Hot Rolled Steel

NOTES:

1. Dimensions in ( ) are in millimeters.

2. Accessory (Carrier supplied, field installed) soleplate package includes 4 soleplates, 16 jacking screws and leveling pads.

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

4. Thickness of grout will vary, depending on the amount necessary to level chiller. Use only pre-mixed non-shrinking grout, Ceilcote 748 OR Chemrex Embeco 636 Plus Grout 0′-1½″ (38.1) to 0′-2¼″ (57) thick.

Fig. 33 — Accessory Isolation

Page 24

5. Remove jacking screws from leveling pads after grout has hardened.

INSTALL SPRING ISOLATION

IMPORTANT: Accessory spring isolation packages are intended solely for non-seismic applications. Seismic applications must be designed by a registered professional in accordance with all applicable national and local codes.

Spring isolation may be purchased as an accessory from Carrier for field installation. It may also be field supplied and installed. Spring isolators may be placed directly under machine support plates or located under machine soleplates. See Fig. 34. Consult job data for specific arrangement. Low profile spring isolation assemblies can be field supplied to keep the machine at a convenient working height.

Obtain specific details on spring mounting and machine weight distribution from job data. Also, check job data for methods to support and isolate pipes that are attached to spring isolated machines.

a23-1537

NOTE: The accessory spring isolators are supplied by Carrier for installation in the field.

Fig. 34 — 23XRV Accessory Spring Isolation

(Shown with Accessory Soleplates)

Connect Piping

THERMOMETER OPENING (OPTIONAL)

AIR VENT

PIPE HANGERS

a23-1580

LEAVING CHILLED WATER

PIPE FLANGES

ENTERING CHILLED WATER

PRESSURE GAGES

LEAVING CONDENSER WATER

ENTERING CONDENSER WATER

Fig. 35 — Typical Nozzle Piping

Factory-supplied insulation is not flammable but can be damaged by welding sparks and open flame. Protect insulation with a wet canvas cover.

1. Offset pipe flanges to permit removal of waterbox cover for maintenance and to provide clearance for pipe cleaning. No flanges are necessary with marine waterbox option; however, water piping should not cross in front of the waterbox cover or access will be blocked.

2. Provide openings in water piping for required pressure gages and thermometers. For thorough mixing and temperature stabilization, wells in the leaving water pipe should extend inside pipe at least 2 in. (51 mm).

3. Install air vents at all high points in piping to remove air and prevent water hammer.

4. Install pipe hangers where needed. Make sure no weight or stress is placed on waterbox nozzles or flanges.

5. Water flow direction must be as specified in Fig. 36 and 37.

NOTE: Entering water is always the lower of the 2 nozzles. Leaving water is always the upper nozzle for cooler or condenser.

6. Install waterbox vent and drain piping in accordance with individual job data. All connections are

/4-in. FPT.

7. Install waterbox drain plugs in the unused waterbox drains and vent openings.

8. Install optional pumpout system or pumpout system and storage tank as shown in Fig. 38-42.

IMPORTANT: Chiller water nozzle connections to be designed by others in accordance with all applicable national and local codes.

Remove cooler and condenser liquid temperature and optional pressure sensors before welding connecting piping to water nozzles. Refer to Fig. 15. Replace sensors after welding is complete.

INSTALL WATER PIPING TO HEAT EXCHANGERS — Refer to Table 4 for nozzle sizes. Install piping using job data, piping drawings, and procedures outlined below. A typical piping installation is shown in Fig. 35.

Never charge liquid 134a refrigerant into the chiller if the pressure is less than 35 psig (241 kPa). Charge as a gas only, with the cooler and condenser pumps running, until 35 psig (241 kPa) is reached using a pumpdown. Terminate the pumpdown mode using the ICVC. Flashing of liquid refrigerant at low pressures can cause tube freeze-up and considerable damage.

Page 25

a23-1538

NOZZLE-IN HEAD WATERBOXES

FRAME 3

a23-1581

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

PA SS

*Refer to certified drawings.

In Out

8 5A 5 8 B 79 C 46 D 76 E 49 F

CONDENSER

COOLER

DISCHARGE END

COOLER WATERBOXES

Arrangement

Code*

FRAMES 4 AND 5

PAS S

CONDENSER

COOLER

SUCTION END

CONDENSER WATERBOXES

In Out

11 2 P

211 Q

10 12 R

13 S

10 3 T

112 U

Arrangement

Code*

Fig. 36 — Piping Flow Data (NIH, Frames 3 Through 5)

Page 26

MARINE WATERBOXES

a23-1539

PA SS

FRAME 3

NOZZLE ARRANGEMENT CODES

COOLER WATERBOXES CONDENSER WATERBOXES

In Out

8 5A—— — 5 8 B—— — 79 C 10 12 R 46 D 1 3 S 76 E — — — 49 F — — —

Arrangement

Code

In Out

Arrangement

Code

MARINE WATERBOXES

Fig. 17 — Piping Flow Data (MWB, Frames 2 and 3)

a23-1540

PAS S

FRAMES 4 AND 5

NOZZLE ARRANGEMENT CODES

COOLER WATERBOXES CONDENSER WATERBOXES

In Out

96 A — — — 69 B — — — 79 C 10 12 R 46 D 1 3 S 76 E — — — 49 F — — —

Arrangement

Code

In Out

Arrangement

Code

Fig. 37 — Piping Flow Data (Marine Waterboxes, Frames 3 Through 5)

Page 27

LEVEL GAGE

0' - 5 1/2"

[140mm]

PRESSURE GAGE

a23-1541

3/8" MALE FLARE RELIEF VALVE CONN.

1/2" DIA. K.O. ELECTRICAL CONN. (PUMPOUT POWER)

0' - 9 "

[229mm]

TYPICAL

(2) 1" NPT RELIEF VALVE OUTLET (SEE FIELD

1' - 7 "

[483mm]

INSTALLATION NOTES)

0' - 5 7/8 "

[149mm]

TOP VIEW

NOTES:

1. Denotes center of gravity.

2. Dimensions in [ ] are in millimeters.

3. The weights and center of gravity values given are for an empty storage tank.

4. For additional information on the pumpout unit, see certified drawings.

5. Conduit knockout is located on the side of the control box.

6. 28 cubic ft storage tank weight: 2334 lb (1059 kg).

7. 52 cu ft storage tank weight: 3414 lb (1549 kg).

0'- 7 15/16"

[202mm]

(FARSIDE)

0'- 2 3/4"

[70mm]

0'- 10"

[254mm]

a23-1543

LEFT SIDE VIEW

1/2" MALE FLARE VAPOR CONN.

3/4" NPT PUMPOUT CONDENSER WATER INLET CONN.

VAP OR

a23-1542

1'-0 3/4" [324mm]

3/8" MALE FLARE RELIEF VALVE CONN.

1/2" DIA. K.O. ELECTRICAL CONN. (PUMPOUT POWER) (FAR SIDE)

0'- 3 1/4"

[83mm]

3/4" NPT PUMPOUT CONDENSER WATER OUTLET CONN.

ELECTRICAL SERVICE ACCESS SPA C E 20 3/4" X 8 3/4" X 4 1/2" (BOTH SIDES)

0'- 9 7/8"

[249mm]

1" NPT LIQUID CONN.

[229mm]

TYPICAL

FRONT VIEW

DIMENSIONS

ENGLISH (ft-in.)

TANK

SIZE 0428 10- 5 9-10 4-4

0452 14-111/414- 41/24-81/42-81/21-41/43-41/27-21/44- 31/43-83/43-17/

TANK

SIZE 0428 3-4

0452 3-81/20-33/86-115/81-83/42-05/84-1 5-01/22-51/42-101/82-6

TANK

SIZE 0428 3175 2997 1327 730 365 946 1935 1203 1038852 0452 4553 4381 1429 826 413 1029 2191 1302 1137 951

TANK

SIZE 0428 1032 89 1451 505 619 1143 1530 737 860 756 0452 1130 86 2124 527 625 1225 1537 742 867 762

ABCDEFGHJK

/42-43/41-23/83-11/46-43/163-113/83-47/82-99/

L M NPRS TUVW

/80-31/24- 91/21-77/82-03/83-9 5-01/42-5 2-97/82-53/

SI (mm)

ABCDEFGHJ K

LMNPRSTUVW

0'- 9"

Fig. 38 — Optional Pumpout Unit and Storage Tank

Page 28

RATED DRY WEIGHT AND REFRIGERANT CAPACITY

ENGLISH (lb)

TANK

SIZE

TANK OD

(in.)

DRY

WEIGHT*

(lb) 0428 24.00 2334 1860 1716 0452 27.25 3414 3563 3286

SI (kg)

TAN K

SIZE

TANK OD

(mm)

DRY

WEIGHT*

(kg) 0428 610 1059 844 778 0452 692 1549 1616 1491

LEGEND

ANSI — American National Standard Institute ASHRAE — American Society of Heating, Refrigeration,

OD — Outside Diameter UL — Underwriters Laboratories

and Air Conditioning Engineers

*The above dry weight includes the pumpout condensing unit weight of 164 lb (75 kg).

R-134a MAXIMUM REFRIGERANT CAPACITY (lb)

ANSI/ASHRAE 15 UL 1963

R-134a MAXIMUM REFRIGERANT CAPACITY (kg)

ANSI/ASHRAE 15 UL 1963

a23-1634

COOLER REFRIGERANT PUMPOUT VALVE

SERVICE VALVE ON

CHILLER (FIELD SUPPLIED)

PUMPOUT COMPRESSOR

COOLER CHARGING VALV E

CONDENSER CHARGING VALV E

PRESSURE RELIEF SAFETY VALV E

COOLER

COOLER INLET ISOLATION VALVE

CONTROL CENTER

SERVICE VALVE ON

PUMPOUT UNIT

MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND

STORAGE TANK FOR SERVICE AND OPERATION WORK.

DISCHARGE ISOLATION VALVE (OPTIONAL)

Fig. 39 — Optional Pumpout System Piping Schematic with Storage Tank

(Configured to Push Liquid into Storage Tank)

STORAG E TANK LIQUID VALV E

OIL SEPARATOR

PUMPOUT CONDENSER

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

STORAGE TANK VAP OR VALV E

Page 29

COOLER

COOLER INLET ISOLATION VALVE

CONTROL CENTER

DISCHARGE ISOLATION VALVE (OPTIONAL)

COOLER REFRIGERANT PUMPOUT VALVE

COOLER CHARGING VALV E

USE CONDENSER CHARGING VALVE TO ADD CHARGE

PRESSURE RELIEF SAFETY VALV E

STORAG E TANK LIQUID

VALV E

OIL SEPARATOR

PUMPOUT COMPRESSOR

a23-1544

SERVICE VALVE ON

PUMPOUT UNIT

MAINTAIN AT LEAST 2 FT (610mm) CLEARANCE AROUND

STORAGE TANK FOR SERVICE AND OPERATION WORK.

SERVICE VALVE ON

CHILLER (FIELD SUPPLIED)

Fig. 40 — Optional Pumpout System Piping Schematic with Storage Tank

(Configured to Pull Vapor out of Chiller or to Charge Chiller from Storage Tank)

COOLER REFRIGERANT PUMPOUT VALVE

COOLER CHARGING VALV E

CONDENSER CHARGING VALV E

COOLER

COOLER INLET ISOLATION VALVE

CONTROL CENTER

DISCHARGE ISOLATION VALVE (OPTIONAL)

PUMPOUT CONDENSER

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

STORAGE TANK VAP OR VALV E

PRESSURE RELIEF SAFETY VALV E

SERVICE VALVE ON

PUMPOUT UNIT

a23-1545

SERVICE VALVE ON

CHILLER

PUMPOUT COMPRESSOR

Fig. 41 — Optional Pumpout System Piping Schematic without Storage Tank

(Configured to Store Refrigerant in Cooler or Condenser)

SERVICE VALVE

OIL SEPARATOR

PUMPOUT CONDENSER

PUMPOUT CONDENSER WATER SUPPLY AND RETURN

Page 30

FRAME

PANEL

LEAVING

WATER

ASSEMBLY

VALVE

CONDENSER

OIL

SEPARATOR

OIL

HEATER

OIL FILL FITTING

COMPRESSOR

VALV E

ENTERING

WATER

a23-1546

CONTROL

Fig. 42 — Pumpout Unit

INSTALL VENT PIPING TO RELIEF VALVES — The 23XRV chiller is factory equipped with relief valves on the cooler and condenser shells. Refer to Fig. 43 and Table 11 for size and location of relief devices. Vent relief devices to the outdoors in accordance with ANSI/ASHRAE 15 (latest edition) Safety Code for Mechanical Refrigeration and all other applicable codes.

WITH ISOLATION VALVES

Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation.

1. Dual pressure relief valves are mounted on the three-way valves in some locations to allow testing and repair without transferring the refrigerant charge. Three-way valve shafts should be turned either fully clockwise or fully counterclockwise so only one relief valve is exposed to refrigerant pressure at a time.

The flow area of discharge piping routed from more than one relief valve, or more than one heat exchanger, must be greater than the sum of the outlet areas of all relief valves that are expected to discharge simultaneously. All relief valves within a machinery room that are exposed to refrigerant may discharge simultaneously in the event of a fire. Discharge piping should lead to the point of final release as directly as possible with consideration of pressure drop in all sections downstream of the relief valves.

2. Provide a pipe plug near outlet side of each relief device for leak testing. Provide pipe fittings that allow vent piping to be disconnected periodically for inspection of valve mechanism.

3. Piping to relief devices must not apply stress to the device. Adequately support piping. A length of flexible tubing or piping near the relief device is essential on spring-isolated machines.

4. Cover the outdoor vent with a rain cap and place a condensation drain at the low point in the vent piping to prevent water build-up on the atmospheric side of the relief device.

a23-1583

WITHOUT ISOLATION VALVES

Fig. 43 — Relief Valve Arrangements

Make Electrical Connections — Field wiring must

be installed in accordance with job wiring diagrams and all applicable electrical codes. Refer to Fig. 44 and 45 for typical wiring and component layout.

Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

Page 31

Table 11 — Relief Valve Locations

LOCATION

Discharge Pipe Assembly 3-5 1

Cooler 3-5 1

Condenser 3-5 1

Optional Storage Tank N/A 1-in. NPT FEMALE CONNECTOR 2 2

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

FRAME

SIZE

RELIEF VALVE OUTLET SIZE

/4-in. NPT FEMALE CONNECTOR 0 1

/4-in. NPT FEMALE CONNECTOR 2 1

/4-in. NPT FEMALE CONNECTOR 2 2

Do not attempt to start compressor (even for a rotation check) or apply test voltage of any kind while machine is under dehydration vacuum. Motor insulation breakdown and serious damage may result.

QUANTITY WITHOUT

ISOLATION VALVES

tions Interface Board Status LEDs and the VFD with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

Low oil level may result if the oil pump is manually operated for more than a few minutes when the chiller is not running. The oil reclaim system does not return oil to the sump when the compressor is de-energized.

The drive can operate at and maintain zero speed. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating or may operate at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

GROUNDING THE CONTROLS/DRIVE ENCLOSURE — Use the following steps to ground the drive.

1. Open the left door of the control center.

2. Run a suitable equipment grounding conductor unbroken from the drive to earth ground. Tighten these grounding connections to the proper torque. See Fig. 6 and 29.

3. Close the door to the control center.

INSTALLING INPUT POWER WIRING — All wiring should

be installed in conformance with the applicable local, national, Do not install modification kits with power applied to the drive. Disconnect and lockout incoming power before attempting such installation or removal. Failure to observe this precaution could result in severe bodily injury or loss of life.

and international codes (e.g., NEC/CEC). Signal wiring, control

wiring, and power wiring must be routed in separate conduits to

prevent interference with the drive operation. Use grommets,

when hubs are not provided, to guard against wire chafing.

Use the following steps to connect AC input power to the

main input circuit breaker:

1. Turn off, lock out, and tag the input power to the drive.

The drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

2. Remove the input power wiring panel above the VFD circuit breaker and drill the number of openings for the AC input leads (refer to Fig. 6). Mount all conduit hardware on the input power wiring panel before re-installing the input power wiring panel on the VFD enclosure. Take care that metal chips and hardware do not enter the enclosure.

3. Wire the AC input leads by routing them through the openings in the input power wiring panel.

QUANTITY WITH

The user is responsible for conforming with all applicable local, national and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

These instructions are intended for qualified electrical personnel familiar with servicing and installing AC drives. Any questions or problems with the products described in this manual should be directed to your local Carrier Service Office.

Wiring diagrams in this publication are for reference only and are not intended for use during actual installation; follow job specific wiring diagrams.

Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with control and drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

4. Connect the three-phase AC input power leads (per job specifications) to the appropriate input terminals of the circuit breaker. See Fig. 6.

5. Tighten the AC input power terminals and lugs to the proper torque as specified on the input circuit breaker.

Page 32

a23-1585

Fig. 44 — Typical Field Wiring Schematic

Page 33

Fig. 44 — Typical Field Wiring Schematic (cont)

a23-1586

Page 34

Fig. 44 — Typical Field Wiring Schematic (cont)

Page 35

NOTES FOR FIG. 44

GENERAL

1.0 Variable frequency drive (VFD) shall be designed and manufactured in accordance with Carrier engineering requirements.

1.1 All field-supplied conductors, devices and the fieldinstallation wiring, termination of conductors and devices, must be in compliance with all applicable codes and job specifications.

1.2 The routing of field-installed conduit and conductors and the location of field-installed devices, must not interfere with equipment access or the reading, adjusting or servicing of any component.

1.3 Equipment installation and all starting and control devices, must comply with details in equipment submittal drawings and literature.

1.4 Contacts and switches are shown in the position they would assume with the circuit de-energized and the chiller shutdown.

1.5

Do not use aluminum conductors. Contractor/installer assumes all liability resulting from the use of aluminum conductors within the VFD enclosure.

POWER WIRING TO VFD

2.0 Provide a means of disconnecting branch feeder power to VFD. Provide short circuit protection and interrupt capacity for branch feeder in compliance with all applicable codes.

2.1 If metal conduit is used for the power wires, the last 4 feet or greater should be flexible to avoid transmitting unit vibration into the power lines and to aid in serviceability.

2.2 Line side power conductor rating must meet VFD nameplate voltage and chiller minimum circuit ampacity.

2.3 Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required. Circuit breaker lugs will accommodate the quantity (#) and size cables (per phase) as shown in Table 12.

2.4 Compressor motor and controls must be grounded by using equipment grounding lug provided inside unit mounted VFD enclosure.

CONTROL WIRING

3.0 Field-supplied control conductors to be at least 18 AWG or larger.

Table 12 — Lug Capacity

3.1 Ice build start/terminate device contacts, remote star t/stop device contacts and spare safety device contacts, (devices not supplied by Carrier), must have 24 VAC rating. Max current is 60 mA, nominal current is 10 mA. Switches with gold plated bifurcated contacts are recommended.

3.2 Remove jumper wire between TB1-19 and TB1-20 before connecting auxiliary safeties between these terminals.

3.3 Each integrated contact output can control loads (VA) for evaporator pump, condenser pump, tower fan low, tower fan high, and alarm annunciator devices rated 5 amps at 115 VAC and up to 3 amps at 277 VAC.

Control wiring required for Carrier to start pumps and tower fan motors and establish flows must be provided to assure machine protection. If primary pump, tower fan and flow control is by other means, also provide a parallel means for control by Carrier. Failure to do so could result in machine freeze-up or over-pressure.

Do not use control transformers in the control center as the power source for external or field-supplied contactor coils, actuator motors or any other loads.

3.4 Do not route control wiring carrying 30 V or less within a conduit or tray which has wires carrying 50 V or higher or along side wires carrying 50 V or higher.

3.5 Spare 4-20 mA output signal is designed for controllers with a non-grounded 4-20 mA input signal and a maximum input impedance of 500 ohms.

3.6 Flow devices to confirm evaporator or condenser pump flow are not required. However; if flow devices are used, wire as shown on drawing 23XRC1-1 (J3 lower). Remove jumper installed at these terminals and wire in a 4.3 K resistor in its place.

CCM J3 (LOWER)

a23-1587

The flow device and resistor must be installed in parallel at these terminals such that the resistor provides a signal when the flow device is open.

VFD

MAX. INPUT

AMPS.

225A 3 3/0 — 500MCM 2 3/0 — 250MCM 338A 3 3/0 — 500MCM 2 400 — 500MCM 440A 3 3/0 — 500MCM 2 400 — 500MCM 520A 3 3/0 — 500MCM 3 3/0 — 400MCM 608A 3 3/0 — 500MCM 3 3/0 — 400MCM

NOTE: If larger lugs are required, they can be purchased from the manufacturer of the circuit breaker (Cutler-Hammer or Square D).

STANDARD 65K AIC LUG CAPACITY

(PER PHASE)

No. Conductors Conductor Range No. Conductors Conductor Range

OPTIONAL 100K AIC LUG CAPACITY

(PER PHASE)

Page 36

Fig. 45 — PIC III Control Component Layout

a23-1584

Page 37

WIRING THE FIELD WIRING TERMINAL STRIPS — This section describes how to wire the field wiring terminal strips shown in Fig. 46 and 47. The control terminal blocks are mounted to the inside of the enclosure, above and below the control panel.

NOTE: Up to 30 v may be measured across open contact terminals on the hazardous voltage terminal strip.

1. Turn off, lock out, and tag the input power to the drive. Wait five minutes.

2. Verify that there is no voltage at the input terminals (L1, L2, and L3) of the power module.

3. Verify that the status LEDs on the Communications Interface Board are not lit. See Fig. 48. The location of the Communications Interface Board is shown in Fig. 6.

4. Use a screwdriver to remove conduit twist outs in the control panel. Do not punch holes or drill into the top surface of the control center enclosure for field wiring. Knockouts are provided in the back of the control center for field wiring connections.

5. Connect the control wiring as shown in Fig. 47. Tighten all connections to 7 to 9 in-lb.

CONNECT CONTROL INPUTS — Wiring may be specified for a spare safety switch, and a remote start/stop contact can be wired to the starter terminal strip. Additional spare sensors and Carrier Comfort Network® modules may be specified as well. These are wired to the machine control panel as indicated in Fig. 49.

CONNECT CONTROL OUTPUTS — Connect auxiliary equipment, chilled and condenser water pumps, and spare alarms as required and indicated on job wiring drawings.

CONNECT STARTER — The 23XRV is equipped with a unit-mounted VFD starter (Fig. 50).

IMPORTANT: Be sure to ground the power circuit in accordance with the National Electrical Code (NEC), applicable local codes, and job wiring diagrams. Also, make sure correct phasing is observed for proper rotation.

Do not punch holes or drill into the top surface of the control center. Knockouts are provided in the back of the control center for wiring connections.

Remove the VFD shipping bracket shown in Fig. 16.

Page 38

a23-1588

Fig. 46 — 23XRV Controls Schematic

Page 39

a23-1589

Fig. 46 — 23XRV Controls Schematic (cont)

Page 40

a23-1590

a23-1591

Fig. 47 — Control Terminal Blocks

DPI Communications Interface Board

a23-1592

Status LEDs

Fig. 48 — Communications Interface Board Status Lights

Page 41

RED

WHITE

BLACK

DRAIN WIRE

RED

WHITE

BLACK

DRAIN WIRE

BLACK

WHITE

GROUND

BLACK

WHITE

DRAIN WIRE

a23-1593

RED

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

Fig. 49 — CCN Communication Wiring For Multiple Chillers (Typical)

(CCN) Interface

LEGEND

RED

WHITE

BLACK

Factory Wiring

Field Wiring

1— Carrier Comfort Network

2— Circuit Breakers

3— Chiller Control Module (CCM)

Page 42

TO CHILLED WATER PUMP

TO CONDENSER WATER PUMP

TO COOLING TOWER FAN

TO COOLING TO W ER

MAIN COMPRESSOR MOTOR POWER

TO LOAD

FROM COOLING TO W ER

FROM LOAD

a23-1594

LEGEND

1—Disconnect (Fused on VFD only) NOT by Carrier 2—Unit Mounted VFD/Control Center 3—Pressure Gages 4—Chilled Water Pump

5—Condenser Water Pump 6 — Chilled Water Pump Starter 7 — Condensing Water Pump Starter 8 — Cooling Tower Fan Starter 9 — Ven ts

Piping Control Wiring Powe r Wiri ng

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

NOTES:

1. All wiring must comply with applicable codes.

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

3. Wiring not shown for optional devices such as:

• remote start-stop

• remote alarm

• optional safety device

• 4 to 20 mA (1 to 5 VDC) resets

• optional remote sensors

• kW output

• head pressure reference

4. Service clearance under the chiller can be enhanced if the grout is not extended along the entire length of the heat exchangers.

5. Carrier does not recommend pre-fab water piping.

SEE NOTE 4

DRAIN

6. Field-installed piping must be arranged and supported to avoid stress on the equipment and transmission of vibrations from the equipment as well as to prevent interference with routine access for the reading, adjusting and servicing of the equipment. Provisions shall be made for adjustment in each plane of the piping and for periodic and major servicing of the equipment.

7. Relief valves on the cooler and condenser must be vented to the outdoors as discharging refrigerant in closed spaces may displace oxygen and cause asphyxiation. All field-supplied refrigerant relief piping and devices must be used in accordance with ANSI/ ASHRAE standard 15.

Dual pressure relief valves are mounted on the three-way valves in some locations to allow testing and repair without transferring the refrigerant charge. Three-way valve shafts should be turned either fully clockwise or fully counterclockwise so only one relief valve is exposed to refrigerant pressure at a time.

8. Service access should be provided per standards ANSI/ASHRAE 15 and ANSI/NFPA 70 (NEC) and local safety codes. Unobstructed space adequate for inspection, servicing and rigging of all major components of the chiller is required. Shaded service areas are shown on the certified machine assembly drawing plan view and front view. See machine assembly component disassembly drawing for component removal. Space for rigging equipment and compressor removal is not shown.

9. The installation of chilled water and cooling tower water strainers should be considered to prevent debris from collecting in the waterboxes and degrading performance.

10. Flexible conduit should be used for the last few feet to the control center for vibration isolation of power wiring and control wiring.

Fig. 50 — 23XRV with Unit-Mounted VFD/Control Center

Page 43

COMPLETING THE INSTALLATION

This section provides instructions on how to perform a final check of the installation. Do not energize the VFD circuit breaker. This should only be done by qualified Carrier personnel in accordance with the 23XRV Start-Up and Service Manual.

Checking the Installation — Use the following pro-

cedure to verify the condition of the installation:

a23-1595

LEGEND

Factory Wiring Power Panel Component Terminal Contactor

DC bus capacitors in the VFD retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait 5 minutes for the DC bus capacitors to discharge then check both the VFD DPI Communications Interface Board Status LEDs and the VFD with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

1. Turn off, lock out, and tag the input power to the drive. Wait five minutes.

2. Verify that there is no voltage at the input terminals (L1, L2, and L3) of the power module.

3. Verify that the status LEDs on the DPI Communications Interface Board are not lit. See Fig. 48. The location of the Communications Interface Board is shown in Fig. 6.

4. Remove any debris, such as metal shavings, from the enclosure.

5. Check that there is adequate clearance around the machine in accordance with the certified print.

6. Verify that the wiring to the terminal strip and the AC input power terminals is correct.

7. Check that the wire size is within terminal specifications and that the wires are tightened properly.

8. Check that specified branch circuit protection is installed and correctly rated.

9. Check that the incoming power is rated correctly.

10. Verify that a properly-sized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the power leads. Verify that all ground leads are unbroken.

Oil Pump and Oil Heater — The oil pump and oil

heater are wired at the factory. It is not necessary to connect additional wiring to these components. See Fig. 51 and 52.

Voltage to terminals T1 and T3 on the 1C and 6C contactors comes from a control transformer in the starter built to Carrier specifications. Do not connect an outside source of control power to the chiller (terminals T1 and T3). An outside power source will produce dangerous voltage at the line side of the starter, because supplying voltage at the transformer secondary terminals produces input level voltage at the transformer primary terminals (see Fig. 46, 51, and 52).

Fig. 51 — Oil Pump Wiring

a23-1596

LEGEND

Factory Wiring Power Panel Component Terminal

Fig. 52 — Oil Heater and Control Power Wiring

Connect Control Wiring — All control wiring must

use shielded cable. Refer to the job wiring diagrams for cable type and cable number. Make sure the control circuit is grounded in accordance with applicable electrical codes and instructions on machine control wiring label.

Carrier Comfort Network® Interface — The Car-

rier Comfort Network (CCN) communication bus wiring is supplied and installed by the electrical contractor. It consists of shielded, 3-conductor cable with drain wire.

The system elements are connected to the communication bus in a daisy chain arrangement. The positive pin of each system element communication connector must be wired to the positive pins of the system element on either side of it. The negative pins must be wired to the negative pins. The signal ground pins must be wired to the signal ground pins. See Fig. 49 for location of the CCN network connections on the terminal strip labelled CCN.

NOTE: Conductors and drain wire must be 20 AWG (American Wire Gage) minimum stranded, tinned copper. Individual conductors must be insulated with PVC, PVC/nylon, vinyl, Teflon, or polyethylene. An aluminum/polyester 100% foil shield and an outer jacket of PVC, PVC/nylon, chrome vinyl, or Teflon with a minimum operating temperature range of –4 F to 140 F (–20 C to 60 C) is required. See Table 13 for cables that meet the requirements.

Table 13 — Cable Manufacturers

MANUFACTURER CABLE NO.

Alpha 2413 or 5463

American A22503

Belden 8772

Columbia 02525

Page 44

When connecting the CCN communication bus to a system element, a color code system for the entire network is recommended to simplify installation and checkout. See Table 14 for the recommended color codes:

Table 14 — Insulator Codes

CCN BUS

SIGNAL TYPE

+ Red +

Ground White G

– Black –

CONDUCTOR

INSULATION

COLOR

CCN NETWORK

INTERFACE

(Control Panel)

If a cable with a different color scheme is selected, a similar color code should be adopted for the entire network.

NOTE: This color scheme does not apply to SIO wiring between the CCM and Gateway module.

At each system element, the shields of its communication bus cables must be tied together. If the communication bus is entirely within one building, the resulting continuous shield must be connected to ground at only one single point. See Fig. 49. If the communication bus cable exits from one building and enters another, the shields must be connected to ground at the lightening suppressor in each building where the cable enters or exits the building (one point only).

To connect the 23XRV chiller to the network, proceed as follows (see Fig. 49):

1. Route wire through knockout in back of control panel.

2. Strip back leads.

3. Crimp one no. 8 size spring spade terminal on each conductor.

4. Attach red to “+” terminal and white to “G” terminal and black to “–” terminal of CCN Network interface located in the control panel.

Lead-Lag Control Wiring — The 23XRV can be

wired for lead-lag operation in either series or parallel. See Fig. 53 for applicable wiring schematics.

Install Field Insulation and Lagging

Protect insulation from weld heat damage and weld splatter. Cover with wet canvas cover during water piping installation.

When installing insulation at the job site, insulate the fol-

lowing components:

• compressor

• discharge pipe assembly

• cooler shell

• cooler tube sheets

• condenser shell

• condenser tubesheets

• suction piping

• economizer

• economizer muffler

• motor cooling drain

• oil reclaim piping

• vaporizer chamber

• refrigerant liquid line to cooler NOTE: Insulation of the waterbox covers is applied only at the

job site by the contractor. When insulating the covers, make sure there is access for removal of waterbox covers for servicing (Fig. 54).

Page 45

a23-1597

Fig. 53 — Lead/Lag Control Wiring

Page 46

a23-1598

Fig. 53 — Lead/Lag Control Wiring (cont)

Page 47

a23-1599

Fig. 54 — 23XRV Insulation Area

FACTORY-SUPPLIED AND

INSTALLED INSULATION (IF REQUIRED)

FACTORY-INSTALLED

INSULATION

Page 48

Page 49

Page 50

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

Book 2 Ta b 5 e

Catalog No. 532-309 Printed in U.S.A. Form 23XRV-1SI Pg 50 309 6-06 Replaces: New

Page 51

INSTALLATION START-UP REQUEST CHECKLIST

Machine Model Number: 23XRV Serial Number:

To:

Attn.:

Date

Project Name

Carrier Job Number

The following information provides the status of the chiller installation. Send a copy of this checklist to the local Carrier Service office after it has been completed and signed-off by the Purchaser and Job Site Supervisor.

YES/NO DATE TO BE

(N/A) COMPLETED

1. The machine is level within

2. The machine components are installed and connected in accordance with the installation instructions.

3. The isolation package and grouting (if necessary) are installed.

4. The relief valves are piped to the atmosphere.

5. All piping is installed and supported. Direction of flow is indicated in accordance with the installation instructions and job prints.

a. Chilled water piping b. Condenser water piping c. Waterbox drain piping d. Pumpout unit condenser piping (if installed) e. Other

6. Gages are installed as called for on the job prints required to establish design flow for the cooler and condenser.

a. Water pressure gages IN and OUT b. Water temperature gages IN and OUT

7. The machine’s control center wiring is complete. The wiring is installed per installation instructions and certified prints.

a. Power wiring to VFD circuit breaker. (If chiller was disassembled during installation, motor leads must

not be taped until the Carrier technician megger tests the motor.)

b. Carrier controls can independently energize water pumps

and tower fan. c. Line side voltage is within ±10% of chiller nameplate voltage. d. Other

/2 in. end to end.

COMMENTS:

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

Book 2 Ta b 5 e

Catalog No. 532-309 Printed in U.S.A. Form 23XRV-1SI Pg CL-1 309 6-06 Replaces: New

Page 52

TESTING YES/NO DATE TO BE

COMPLETED

1. The cooling tower fan has been checked for blade pitch and proper operation.

2. The chilled water and condenser water lines have been:

a. Filled b. Tested c. Flushed d. Vented e. Strainers cleaned

3. The chilled water and condenser water pumps have been checked for proper rotation and flow.

4. The following cooling load will be available for start-up:

a. 25% b. 50% c. 75% d. 100%

5. The refrigerant charge is at the machine.

6. Services such as electrical power and control air will be available at start-up.

7. The electrical and mechanical representatives will be available to assist in commissioning the machine.

8. The customer’s operators will be available to receive instructions for proper operation of the chiller after start-up.

Concerns about the installation/request for additional assistance:

I am aware that the start-up time for a Carrier chiller can take between 2 and 6 days depending on the model of the machine and the options and accessories used with it.

Your contact at the job site will be _______________________________________________________________________________

Phone number ______________________________________________________________________________________________

Cell/Pager number ___________________________________________________________________________________________

Fax number ________________________________________________________________________________________________

In accordance with our contract, we hereby request the services of your technician to render start-up services per contract terms for this job on

(Date). I understand that the technician’s time will be charged as extra services due to correcting items in this

checklist that are incomplete.

Signature of Purchaser ________________________________________________________________________________________

Signature of Job Site Supervisor ________________________________________________________________________________

CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE

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

Book 2 Ta b 5 e

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

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Carrier HFC-134A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual