Carrier EVERGREEN 23XRV User's Manual
Contents
1. o os om os 1682 0 220 os 119 0 9 oss est 1682 0 92 220 Paton eo ote os 1494 os oss 3081 1629 229 peo ore osi 19 os ox tezo se 2 220 este o o 11 0 9 ox 1969 9 220 Die 69 0 5 ose 0 9 ove east 1969 12 92 349 220 910 17 Application data cont 23XRV ISOLATION WITH ACCESSORY SOLEPLATE PACKAGE TYPICAL ISOLATION STANDARD ISOLATION TUBE SHEET SUPPORT PLATE SUPPORT 0 3 8 10 PLATE LEVEL BASE LINE ISOLATION ELASTOMERIC PAD VIEW Y Y ISOLATION WITH ISOLATION PACKAGE ONLY JACKING ec SCREW STANDARD ACCESSORY SOLEPLATE NOTE Isolation package includes 4 elastomeric pads SOLEPLATE PACKAGE LEVELING ACCESSORY SOLEPLATE DETAIL TUBE SHEET JACKING SCREW SEE NOTE 3 SUPPORT PLATE LEVEL BASE LINE 1 25 H R S 051 3 8 35 SOLEPLATE PME 4 5 IEEE FLOOR LINE Dimensions i in are in millimeters Accessory soleplate package includes 4 soleplates 16 jacking screws and leveling pads Requires isolation package Jacking screws to be removed after grout has set Thickness of grout will vary depending on the amount necessary to leve2. NOILVOINAWWOO 13 Controls cont 14 CONTROL SEQUENCE MACHINE SAFETIES EVAPORATOR PUMP CONDENSER WATER PUMP WATER FLOWS CHILLED WATER TEMP TOWER FAN CONTROL OILPUMP OILPRESSURE VERIFIED VDF FAULT TEST COMPRESSOR PHASE REVERSAL COMPRESSOR AND SERVICE ONTIME COMPRESSOR RUNNING gt RAMP VDF TO TARGET SPEED 15 MINUE START TO START TIMER 1 MINUTE STOP TO START TIMER SOFTWARE VERSION 13 Phase reversal monitored START INITIATED Pre start checks are made evaporator pump started Condenser liquid pump started 5 seconds after A tower fan control enabled Liquid flows verified 30 sec to 5 minutes maximum after B Chilled liquid temperature checked against control point oil pump on Oil pressure verified oil pressure verified 45 300 sec after D VFD starts phase reversal conditions monitored compressor ontime and service ontime start 15 minute inhibit timer starts VFD fault tests for 15 sec after F Verify average current gt 5 within 15 sec after VFD start ramp to VFD target speed Compressor reaches target speed chiller set to running status Shutdown initiated Target VFD speed to 0 or J occurs Ramp down until percent line current lt soft stop amps threshold 0 60 sec after Oil pump relay off 1 20 sec after J Evaporator pump deenergized 60 sec after K condenser pump and tower fan control may continue to operate if condenser pressu
3. 1 Demand limit based on a user input ranging from 40 to 10096 of compres sor rated load amps 2 Demand limit based on external 4 to 20 mA signal Controlled Compressor Shutdown The controls shall be capable of being configured to soft stop the compressor The display shall indicate shutdown in progress 2 Safeties a Unit shall automatically shut down when any of the following conditions occur each of these protective limits shall require manual reset and cause an alarm message to be dis played on the control panel screen inform ing the operator of the shutdown cause 1 Motor overcurrent 2 Over voltage Under voltage Single cycle dropout Low oil sump temperature Low evaporator refrigerant temperature High condenser pressure High motor temperature High compressor discharge temperature Low oil pressure Prolonged stall Loss of cooler water flow 13 Loss of condenser water flow 14 Variable frequency drive fault 15 High variable frequency drive temperature 00 1 11 12 Shall not require manual reset or cause alarm if auto restart after power failure is enabled The control system shall detect conditions that approach protective limits and take self corrective action prior to an alarm occur ring The system shall automatically reduce chiller capacity when any of the following parameters are outside their normal operat ing range 1 High condenser pres
4. Chillers shall have factory mounted factory wired and factory tested unit mounted variable frequency drive VFD Proper VFD operation shall be con firmed prior to shipment DELIVERY STORAGE AND HANDLING Unit shall be stored and handled in accordance with manufacturer s instructions Unit shall be shipped with all refrigerant piping and control wiring factory installed Unit shall be shipped charged with oil and full charge of refrigerant HFC 134a or a nitrogen hold ing charge as specified on the equipment schedule D 1 04 Unit shall be shipped with firmly attached labels that indicate name of manufacturer chiller model num ber chiller serial number and refrigerant used If the unit is to be exported the manufacturer shall provide sufficient protection against sea water corro sion making the unit suitable for shipment in a standard open top ocean shipping container Chiller and starter shall be stored indoors protected from construction dirt and moisture Chiller shall be inspected under shipping tarps bags or crates to be sure water has not collected during transit Protec tive shipping covers shall be kept in place until machine is ready for installation The inside of the protective cover shall meet the following criteria l Temperature is between 40 F 4 4 C and 120 F 48 9 C 2 Relative humidity is between 10 and 80 non condensing WARRANTY Warranty shall include part
5. The condenser liquid pump shuts down when the refrigerant temperature or entering condenser liquid temperature is be low pre established limits The 3 minute start to stop timer starts Restart Restart is permitted after both inhibit timers have expired If shutdown was due to a safety shutdown the reset button must be depressed before restarting the chiller Typical piping and wiring TO CHILLED LIQUID PUMP TO CONDENSER LIQUID PUMP TO COOLING TOWER FAN FROM COOLING LEGEND Disconnect Unit Mounted VFD Control Center Pressure Gages Chilled Liquid Pump Condenser Liquid Pump Chilled Liquid Pump Starter Condenser Liquid Pump Starter Cooling Tower Fan Starter Vents Piping Control Wiring um Power Wiring 23XRV CHILLER MAIN COMPRESSOR MOTOR POWER NOTES 1 Wiring and piping shown are for general point of connection only and are not intended to show details for a specific installation Certified field wiring and dimensional diagrams are available on request All wiring must comply with applicable codes Referto Carrier System Design Manual for details regarding piping techniques Wiring not shown for optional devices such as remote start stop remote alarms optional safety device 4to 20 mA resets optional remote sensors kW output head pressure reference Flow switches are NOT required 15 Control wiring schematic 23XRV COMPONENT ARRANGE
6. Variable Speed Screw Chiller 1 02 HVAC Guide Specifications A Size Range 300 to 550 Tons 1055 to 1934 kW Nominal B Carrier Model Number 23XRV C Part 1 General 1 01 SYSTEM DESCRIPTION A Microprocessor controlled liquid chiller shall use a semi hermetic screw compressor using refrigerant D HFC 134a only Chiller refrigerant shall not have a planned phase out date B If manufacturer proposes a liquid chiller using HCFC 123 refrigerant which has a planned phase out date then the manufacturer shall include in the chiller price 1 A vapor activated alarm system consisting of all alarms sensors safeties and ventilation equip ment as required by ANSI ASHRAE Standard 15 Safety Code for Mechanical Refrigeration latest edition with the quotation System shall be capable of responding to HCFC 123 levels of 10 ppm Allowable Exposure Limit AEL 2 A free standing refrigerant storage tank and pumpout unit shall be provided The storage vessels shall be designed per ASME Section VIII Division 1 code with 300 psig 2068 kPa design pressure Double relief valves per ANSI F ASHRAE 15 latest edition shall be provided The tank shall include a liquid level gage and G pressure gage The pumpout unit shall use a semi hermetic reciprocating compressor with water cooled condenser Condenser water pip ing 3 phase motor power and 115 volt control power shall be installed at the jobsite by the installing contractor H
7. compressor on time and service on time timers are activated e The starts in 12 hour counter advances by one The total compressor starts counter advances by one Once started If the VFD average current gt 5 within 15 seconds after VFD start the machine enters run mode and speed will be ramped up to meet VFD target speed Once the target speed is met the controls enter the capac ity control mode Shutdown sequence The chiller shutdown is initiated if any of the following occur The Stop button is pressed for at least one second the alarm light blinks once to confirm the stop command A recycle shutdown is initiated The time schedule has gone into unoccupied mode The chiller protective limit has been reached and the chiller is in alarm The start stop status is overridden to stop from the ICVC CCN system or building management system Once the controls shutdown sequence is initiated the compressor is stopped and the VFD target speed is set to O If optional soft stop unloading is activated when the Stop button is pressed or the remote contacts open motor speed decreases to a configured amperage level and the compressor is stopped The display indicates Shutdown in Progress while the motor speed decreases Compressor ontime and service ontime timers stop once the current in all phases is 596 indicating VFD Stop Complete The oil pump and cooler liquid pump are then deenergized
8. saves on the cost of re treating the system liquid It is recommended that pressure gages be provided at points of entering and leaving liquid to measure pressure drop through the heat exchanger Gages may be installed as shown in Pressure Gage Location table Pressure gages installed at the vent and drain connections do not include nozzle pressure losses Use a reliable differential pressure gage to measure pres sure differential when determining liquid flow Regular gag es of the required pressure range do not have the accuracy to provide accurate measurement of flow conditions PRESSURE GAGE LOCATION MH GAGE LOCATION PASSES Cooler or Condenser 10r3 One gage in each waterbox 2 Two gages in waterbox with nozzles ASME stamping All 23XRV heat exchangers are constructed in accordance with ASHRAE American Society of Heating Refrigerat ing and Air Conditioning Engineers 15 Safety Code for Mechanical Refrigeration latest edition This code in turn requires conformance with ASME American Society of Mechanical Engineers Code for Unfired Pressure Ves sels wherever applicable Each heat exchanger and economizer if equipped is ASME U stamped on the refrigerant side of each vessel Relief valve discharge pipe sizing See page 21 for number of relief valves Relief valve discharge piping size should be calculated per the current version of the ASHRAE 15 latest edition code using the tabulated C factors for each vesse
9. customers with a safe and environmentally sound product without compromising effi ciency In addition HFC 134a was given 1 safety rating by ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers meaning that it is the safest refrigerant available Quality desian Positive displacement compres sion Positive displacement com pression ensures stable operation under all load conditions without the possibility of compressor surge Superior oil management cold condenser water operation All Evergreen 23XRV chillers regulate oil temperature viscosity and pressure A patented process assures high quality oil is delivered to the compressor bear ings by a positive displacement pump Bearing lubrication is assured allowing continuous operation with cold condenser water at all loads Screw chillers no longer need to rely on dif ferential system pressure to effectively lubricate the compressor Should the 2 input power to the chiller be lost the system design assures proper lubrica tion of the bearings during coast down Small footprint The Evergreen 23XRV chiller s positive pressure design reduces the chiller size by up to 3596 compared to negative pressure designs Extremely high compression efficiencies allow for compact high efficiency chillers that require less mechanical room floor space Constant or variable evaporator flow The 23XRV chiller combines the advantages o
10. extremely high reliability The ad vanced tri rotor compressor features a balanced rotor geometry and shorter screw lengths resulting in vastly re duced compressor bearing loads and a minimum L10 compressor bearing life in excess of 500 000 hours when op erated at AHRI conditions Form 23XRV 3PD Features Benefits cont Variable speed capacity control elimi nates slide valves their associated loss es and their potential failure modes Component count both rotating and total has been minimized assuring maximum reliability under a wide range of operating conditions High efficiency Per AHRI 550 590 chillers operate at design conditions less than one percent of the time As a result superior part load efficiency is required for today s chilled water applications The Ever green 23XRV screw chiller maximizes chiller efficiency by optimizing com pressor operation Electric power con sumption drops dramatically when the motor speed slows The 23XRV screw chiller delivers industry leading inte grated part load values IPLV in an ex tremely broad range of applications and climates Environmental leader Carrier has long been committed to the environment and its sustainability The Evergreen 23XRV screw chillers provide our customers with a high efficiency chlorine free long term solution unaffected by refrigerant phase outs Carrier s decision to utilize non ozone depleting HFC 134a refrig erant provides our
11. standard for distortion at the point of common coupling Ultra low harmonics can eliminate the need for complicated harmonic system studies Low starting current inrush The inrush current is limited to the chiller full load amps rated load amperes No other starting means can equal this level of starting current The combination of low current and ultra low harmonics can reduce backup generator size requirements Table of contents Features Benefits Model Number Nomenclature Physical Data Options and Accessories Dimensions Performance Data Electrical Data Controls Typical Piping and Wiring Control Wiring Schematic Application Data Guide Specifications 910 isolation package is available to meet International Building Code and ASCE 7 seismic qualification requirements in concurrence with ICC ES AC156 Ac ceptance Criteria for Seismic Qualifica tion by Shake Table Testing of Non structural Components and Systems Hermetic motor The Evergreen 23XRV chiller utilizes motors that are hermetically sealed from the machine room Cooling is accomplished by spraying liquid refrigerant on the motor windings This highly efficient motor cooling method results in cooler running motors than could be realized with air cooled designs of the same type In addition Carrier s hermetic de sign eliminates C
12. the remote controller s set points or time schedule and to force point values or statuses for those points that are operator forcible The control panel shall also have access to the alarm history file of all like con trollers connected on the network Pump Control Upon request to start the compressor the control system shall start the chilled and condenser water pumps and shall verify that flows have been established Ramp Loading A user configurable ramp loading rate effec tive during the chiled water temperature pulldown period shall prevent a rapid increase in compressor power consumption The controls shall allow configuration of the ramp loading rate in either degrees per min ute of chilled water temperature pulldown or percent motor amps per minute During the ramp loading period a message shall be displayed informing the operator that the chiller is operating in ramp loading mode Chilled Water Reset The control center shall allow reset of the chilled water temperature set point based on any one of the following criteria 1 Chilled water reset based on an external 4 to 20 mA signal 2 Chilled water reset based on a remote temperature sensor such as outdoor air 3 Chilled water reset based on water tem perature rise across the evaporator Demand Limit The control center shall limit amp draw of the compressor to the rated load amps or to a lower value based on one of the following criteria
13. 1 Soleplate Package Unit manufacturer shall furnish soleplate package consisting of soleplates jacking screws leveling pads and neoprene pads 10 Spring isolators shall be field furnished and selected for the desired degree of isolation Spring Isolators Spare Sensors with Leads Unit manufacturer shall furnish additional tem perature sensors and leads Sound Insulation Kit Unit manufacturer shall furnish a sound insula tion kit that covers the compressor housing motor housing compressor discharge pipe suction line evaporator and economizer if equipped Stand Alone Pumpout Unit A free standing pumpout unit shall be provided The pumpout unit shall use a semi hermetic reciprocating compressor with liquid cooled condenser Condenser liquid piping 3 phase motor power shall be installed at the jobsite by the installing contractor Separate Storage Tank and Pumpout Unit A free standing refrigerant storage tank and pumpout unit shall be provided The storage vessels shall be designed per ASME Section VIII Division 1 code with 150 psig 1034 kPa design pressure Double relief valves per ANSI ASHRAE 15 latest edition shall be provided The tank shall include a liquid level gage and pressure gage The pumpout shall use a hermetic reciprocating compressor with water cooled condenser Condenser water piping and 3 phase motor power shall be installed at the jobsite by the installing con
14. 3 Zero emission purge unit capable of operating even when the chiller is not operating 4 Back up relief valve to rupture disk 5 Factory installed chiller pressurizing system to prevent leakage of noncondensables into the chiller during shutdown periods 6 Plant room ventilation 7 Removal and disposal of refrigerant at the end of the phase out period 8 Chillers utilizing a purge unit shall include in the machine price the costs to perform the follow ing regular maintenance procedures a Weekly Check refrigerant charge 1 03 b Quarterly Charge purge unit dehydrator at A least quarterly more often if necessary Clean foul gas strainer Perform chemical analysis of oil c Annually Clean and inspect all valves Drain C and flush purge shell Clean orifices 24 QUALITY ASSURANCE Chiller performance shall be rated in accordance with AHRI Standard 550 590 latest edition Equipment and installation shall be in compliance with ANSI ASHRAE 15 latest edition Cooler and condenser refrigerant side shall include ASME U stamp and nameplate certifying compli ance with ASME Section VIII Division 1 code for unfired pressure vessels A manufacturer s data report is required to verify pressure vessel construction adherence to ASME vessel construction requirements Form U 1 as required per ASME code rules is to be furnished to the owner The U 1 Form must be signed by a qualified inspector holding a National B
15. 9 1769 29 241 32 282 315 4522 4023 _ 800 650 601 621 2046 1860 363 29 273 35 200 218 4419 4520 90 76 511 513 2000 2089 413 345 232 36 240 266 4627 4758 90 760 587 602 2094 2195 545 266 37 282 315 4845 4992 90 76 667 692 2193 2209 43 545 303 40 324 366 5008 4962 590 825 863 915 2675 2746 48 375 391 41 364 415 5178 5155 90 825 930 995 2758 2839 48 375 422 42 400 464 5326 5347 90 825 990 1074 2832 2932 48 375 449 45 324 366 5463 5525 1015 _ 960 938 998 2882 3001 460 436 425 46 364 415 5659 5747 1015 960 10144 1088 2976 3108 460 436 460 47 400 464 5830 5967 115 960 1083 1179 3061 3214 460 436 491 50 431 507 5827 6013 120 1100 1101 1225 3182 3304 57 499 499 51 485 556 6053 6206 1250 1100 1192 1304 3294 3397 57 499 541 52 519 602 6196 6387 120 1100 1248 1379 3364 3485 57 49 566 55 431 507 6370 6708 140 120 1201 1339 3429 3620 649 581 545 56 485 556 6631 6930 140 1280 1304 1429 3556 3726 69 581 501 57 519 602 6795 7138 140 1280 1369 1514 3636 3826 69 581 621 COND Condenser Rigging weights are fo
16. BOX NOZZLE SIZES Nozzle In Head and Marine Waterboxes FRAME PRESSURE NOMINAL PIPE SIZE in ACTUAL PIPE ID in SIZE psig kPa Condenser 10 020 10 020 0342008 1 8 7981 7 981 6 065 6 065 1 10 50 10020 10 020 4 o eae u o 7 4 1034 2068 7 981 7 981 3 6 59 6065 6 065 10 020 10 020 5 0342000 2218 590 7 10 020 s e 8a 606 7 981 RELIEF VALVE LOCATIONS RELIEF VALVE LOCATION OUTLET SIZE QUANTITY MUFFLER 11 4 FEMALE CONNECTOR 1 COOLER 11 4 NPT FEMALE CONNECTOR 1 or 2 CONDENSER 11 4 NPT FEMALE CONNECTOR 2 OPTIONAL STORAGE TANK 1 in NPT FEMALE CONNECTOR 2 Coolers without optional isolation require 2 relief valves NOTE All valves relieve at 185 psig 1275 kPa RELIEF VALVE ARRANGEMENTS WITH OPTIONAL ISOLATION OF DISCHARGE AND COOLER WITH OPTIONAL ISOLATION WITHOUT OPTIONAL ISOLATION 21 Application data cont Vent and drain connections Nozzle in head waterboxes have vent and drain connec tions on covers Marine waterboxes have vent and drain connections on waterbox shells Provide high points of the chiller piping system with vents and the low points with drains If shutoff valves are provid ed in the main liquid pipes near the unit a minimal amount of system liquid is lost when the heat exchangers are drained This reduces the time required for drainage and
17. Cover 150 psig NIH Plain End 150 psig MWB End Cover 150 psig NIH 1 pass Cover 300 psig NIH 2 pass Cover 300 psig NIH 3 pass Cover 300 psig NIH Plain End 300 psig MWB End Cover 300 psig 9 445 619 445 619 522 522 522 522 658 658 658 658 359 474 359 474 658 658 658 658 658 658 658 658 LEGEND Nozzle end weight return end weight Nozzle in Head NOTE Weight for 2 pass cover 150 psig 1034 kPa is included MWB Marine Waterbox the heat exchanger weights shown on page 5 23XRV WATERBOX COVER WEIGHTS SI ka FRAMES 3 4 AND 5 CONDENSER Frames Frame 3 Frame 4 Frame 5 _ aes Victaulic Victaulic Victaulic Flanged Flanged Flanged Nozzles Flanged Nozzles Flanged Nozzles Flanged WATERBOX DESCRIPTION NIH 1 pass Cover 1034 kPa 144 NIH 2 pass Cover 1034 kPa 154 135 NIH 3 pass Cover 1034 kPa 141 297 NIH Plain End 1034 kPa 63 0 0 102 63 63 70 70 MWB End Cover 2068 kPa 102 106 70 177 NIH 1 pass Cover 2068 kPa 220 381 NIH 2 pass Cover 2068 kPa 235 398 NIH 3 pass Cover 2068 kPa 212 380 NIH Plain End 2068 kPa 122 298 MWB End Cover 2068 kPa 202 281 202 281 237 237 237 237 298 298 298 298 163 215 163 215 298 298 298 298 298 298 298 298 LEGEND Nozzle end weight return end weight Nozzle in Head NOTE Weight for NIH 2 pass cover 150 psig 1034 kPa is included in MWB Marine W
18. MENT CONTROL PANEL Lib RESET H t CONTROLLER INPUT SEE NOTE 1 AUTO CHILLED WATER RESET CONTROLLER INPUT SEE NOTE 1 yen LEAK DETECTOR INPUT SEE NOTE 42 M 20n OUTPUT 0 100 kw SPARE TEMP 42 SEN CONMON RETURN id NOTE 3 SPARE TEMP LES CONMON SUPPLY ee NOTE 48 REMOTE TEMP RESET SENSOR SEE NOTE 45 CONTROL PANEL OPTIONAL WRING CCN COMMUNICA TION TERMINAL BLOCK OPTION LISTING CHECK 10 NETTTB SENSOR PACKAGE INSIDE PANEL DOOR LEGEND Chiller Control Module Carrier Comfort Network amp International Chiller Visual Controller Ground 16 NOTES 1 THIS FEATURE IS STANDARD IN THE 23XRV CONTROLS BUT REQUIRES A CONTROLLER WTH A NON GROUNDED 4 20mA OR 1 5Vdc OUTPUT SIGNAL NOT BY CARRIER THIS FEATURE IS STANDARD IN THE 23XRV CONTROLS BUT REQUIRES AN EXTERNAL CONTROLLER WITH NON GROUNDED 4 20mA OUTPUT SIGNAL NOT BY CARRIER THIS FEATURE IS STANDARD IN THE 23XRV CONTROLS BUT REQUIRES A SENSOR PACKAGE OPTION BY CARRIER ITEM 3 SEE OPTION LISTING PINS SHQWN FOR REFERENCE ONLY ACTUAL PIN LAYOUT NOT SHOWN CONTROL PANEL COMPONENT LAYOUT Application data 23XRV MACHINE FOOTPRINT A VESSELS a COND ACCESSORY SOLEPLATE COOLER See detail on page 18 23XRV DIMENSIONS ft in DIMENSIONS mm
19. Product EVERGREEN 23XRV Data High Efficiency Variable Speed Screw Chiller with FOXFIRE Compression Technology 50 60 Hz HFC 134a 300 to 550 Nominal Tons 1055 to 1934 Nominal kW Eve CHILLERS SEISMI Meets IBC 2006 ASCE 7 05 CBC 2007 and OSHPD seismic requirements ASHRAE INNOVATION AWARD COMPLIANT WINNER Green Building Copyright 2010 Carrier Corporation Carrier s Evergreen 23XRV chiller is the world s first integrated variable speed water cooled screw chiller It incorporates significant break throughs in water cooled chiller tech nology to provide excellent reliability and achieve superior efficiencies at true operating conditions without com promising the environment The 23XRV chiller provides Variable speed positive displacement screw compressor Air Conditioning Heating and Refrigerant Institute AHRI certified efficiencies to 0 33 kW ton AHRI IPLV Chlorine free HFC 134a refrigerant IEEE 519 compliance for harmonic distortion An ideal solution for constant and variable flow pumping systems Features Benefits Quality design and con struction make the Evergreen 23XRV chillers the best choice for modern efficient chilled water plants Product reliability The 23XRV chiller uses proven tech nology from Carrier s existing line of Evergreen chillers along with innova tions that increase reliability The 23XRV compressors are designed for
20. V MINIMUM FIELD INSTALLED INSULATION REQUIREMENTS COMPONENT INSULATION m 8 9 10 0 10 1 Cooler 113 10 7 12 1 Misc Liquid Lines Sizes 2 0 Economizer All Sizes 1 9 Compressor Motor Sizes 1 6 Factory insulation Thermal insulation is factory provided to the following areas Cooler not including waterbox Suction line Compressor and motor Oil cooling line and oil return system line oil and refrig erant lines at or near evaporator pressure are insulated VFD cooling line oil and refrigerant lines at or near evaporator pressure are insulated Motor cooling line Vaporizer Liquid line and discharge line Float chamber Optional economizer including vent line and econo mizer muffler Factory insulation is not available for the waterboxes Insulation applied at the factory is 1 2 13 mm thick closed cell and 1 2 in 13 mm open cell PVC Nitrile foam Some parts of the chiller are also treated with an outer layer of 3 16 5 mm thick vinyl The 1 2 13 mm closed cell foam has a thermal conductivity K value of 0 28 BTU in hr sqft F 0 0404 W m C and 910 conforms with Underwriters Laboratories UL Standard 94 Classification 94 HF 1 Both the 1 2 foam and the 3 16 vinyl layer will pass flammability test method MVSS 302 Field insulation As indicated in the Condensation vs Relative Humidity table the factory insulation provides ex
21. all be generated to the central Energy Management System EMS display module prompting the service personnel to diagnose and repair the cause of the overtem perature condition The mechanical contractor shall be responsible for all changes to the design including coordination with temperature control electrical and other trades In addition the electrical power consumption of any auxil iary ventilation and or mechanical cooling required to maintain the mechanical room con ditions stated above shall be considered in the determination of conformance to the scheduled chiller energy efficiency requirement D Unit Mounted Variable Frequency Drive VFD with 26 Built In Harmonic LiquiFlo II Filter The compressor shall be factory mounted factory wired and factory tested prior to shipment by the chiller manufacturer All interconnecting wiring and piping between the VFD and the chiller shall be factory installed Customer electrical connection for compressor motor power shall be limited to main power leads to the VFD and wiring liquid pumps and tower fans to the chiller control circuit The VED shall incorporate the following features 1 Design a The VFD shall be refrigerant cooled microprocessor based pulse width modu lated design Water cooled designs are not acceptable b Input and output power devices shall be Insulated Gate Bipolar Transistors IGBTs c Rectifier shall convert incoming fixed volt age frequenc
22. and testing of all heat exchangers to American Society of Mechanical Engineers ASME standards ensuring heat ex changer safety reliability and long life The ASME U stamp is applied to the refrigerant side of the evaporator and condenser and is applied to the water side of heat exchangers when 300 psig marine water boxes are provided High performance tubing Carrier s Evergreen chillers utilize advances in heat transfer technology providing compact high efficiency heat exchangers Tubing with advanced internally and externally enhanced geometry improves chiller per formance by reducing overall resistance to heat transfer while reducing fouling Cooler tube expansion Cooler tube expansion at center support sheets prevents unwanted tube move ment and vibration thereby reducing the possibility of premature tube fail ure Tube wall thickness is greater at the expansion location support sheets and end tube sheets in order to provide maximum strength and long tube life Double grooved end tube sheet holes This design provides a more robust seal than single rolled joints re ducing the possibility of leaks between the water and refrigerant sides of the chiller Condenser baffle The baffle de flects hot discharge gas before it con tacts condenser tubes reducing tube vibration and wear while distributing refrigerant more evenly over the length of the vessel for improved efficiency Closely spaced in
23. aterbox the heat exchanger weights shown on page 5 gt Options and accessories ITEM 028 or 035 in 0 711 or 0 889 mm Internally Externally Enhanced Copper Tubing Cooler Condenser 028 or 035 in 0 711 or 0 889 mm Internally Externally Enhanced Cupronickel Tubing Condenser 028 or 035 in 0 711 or 0 889 mm Smooth Bore Externally Enhanced Copper Tubing Cooler Condenser 028 or 035 in 0 711 or 0 889 mm Smooth Bore Externally Enhanced Cupronickel Tubing Condenser Flanged Cooler and or Condenser Waterbox Nozzles Hinged Waterboxes Marine Waterboxes 150 psig 1034 kPa tt Marine Waterboxes 300 psig 2068 kPa tt Nozzle in Head Waterbox 300 psig 2068 kPa One 2 or 3 Pass Cooler or Condenser Waterside Construction Seismic Kit Zinc Anodes 100K AIC Amp Interrupt Capacity High Interrupt Circuit Breaker with Shunt Trip Analog Voltmeter and Ammeter with 3 Phase Selector Switch BACnet Communications LonWorksttt Carrier Translator Sensor Package Refrigerant Isolation Valves Separate Storage Tank and Pumpout Unit Shipped Factory Charged with Refrigerant Stand Alone Pumpout Unit Unit Mounted Pumpout Unit Hot Gas Bypass Soleplate Package Spring Isolator Kit Acoustical Sound Insulation Kit Full Cold Surface Thermal Insulation Except Waterbox Covers Customer Factory Performance Testing Export Crating Extended Warranty North American Operations NAO only Service Contract Factory ins
24. be provided with a factory installed factory wired microprocessor control center The control center shall include a 16 line by 40 character liquid crystal display 4 function keys stop button and alarm light Other languages are available using the inter national language translator software b All chiller and motor control monitoring shall be displayed at the chiller control panel c The controls shall make use of non volatile memory d The chiller control system shall have the ability to interface and communicate directly to the building control system e The default standard display screen shall simul taneously indicate the following minimum information 1 Date and time of day 2 24 character primary system status message 3 24 character secondary status message Chiller operating hours Entering chilled water temperature Leaving chilled water temperature Evaporator refrigerant temperature Entering condenser water temperature Leaving condenser water temperature 10 Condenser refrigerant temperature 11 Oil supply pressure 12 Oil sump temperature 13 Percent motor rated load amps RLA f In addition to the default screen status screens shall be accessible to view the status of every point monitored by the control center including 1 Evaporator pressure 2 Condenser pressure 3 Compressor speed 4 Bearing oil supply temperature 5 Compressor discharge temperature 6 Motor winding te
25. cellent protection against condensation under most op erating conditions If temperatures in the equipment area exceed the maximum design conditions extra insulation is recommended If the machine is to be field insulated obtain the approx imate areas from the 23XRV Minimum Field Installed Insu lation Requirements table Insulation of waterbox is made only in the field and this area is not included in 23XRV Minimum Field Installed In sulation Requirements table When insulating the covers allow for service access and removal of covers To estimate water box cover areas refer to certified drawings High humidity jobsite locations may require field sup plied and installed insulation on the float chamber suction housing and the lower half of the condenser CONDENSATION VS RELATIVE HUMIDITY ROOM DRY BULB TEMPERATURE SNDENSATION 80 27 90 32 CONDENSATION 80 F 27 C 90 F 32 C 100 F 38 C Relative Humidity None 70 Slight 77 Extensive 84 These approximate figures are based on 35 F 1 7 C saturated suction temperature A 2 F 1 1 C change in saturated suction temperature changes the relative humidity values by 196 in the same direction Minimum fluid loop volume Minimum fluid volume must be in excess of 1 5 gal per ton 20 L per kW for comfort cooling applications and apply 3 to 5 gal per ton 40 to 66 L per kW fluid loop volume for process applications 23 Guide specifications
26. des prognostic informa tion and corrective actions that can avoid unit shutdown Configuration data backup Non volatile memory provides protection during power failures and eliminates time consuming control reconfiguration S Special Not Used Voltage Code 3 380 3 60 4 416 3 60 5 460 3 60 9 380 415 3 50 First number denotes frame size TMaximum limits only Additional application limits apply that may reduce these ampacities Quality Assurance Certified to ISO 9001 2000 Physical data 23XRV COMPRESSOR AND MOTOR WEIGHTS Total Motor Compressor Terminal Weight Cover Ib Compressor Weight kg Ib COMPONENT WEIGHTS FRAME 3 HEAT FRAME 4 HEAT EXCHANGER EXCHANGER Cove 21 5 EXCHANGER kg b b Isolation Valves 52 Suction Elbow 105 Discharge Elbow Muffler 747 339 747 339 747 339 Control Center VFD 1650 1650 1650 749 Vaporizer and Oil Sump 700 700 700 318 Economizer 542 246 542 542 246 LEGEND VFD Variable Frequency Drive 23XRV HEAT EXCHANGER WEIGHTS ENGLISH METRIC SI Dry Rigging Deyi Rigging NUMBER Weight Machine Charge Weight OF TUBES Ib kg CODE Cooler Machine Charge cona 77 Economizer Economizer Cooler Cond 30 zm uus se 3e 386 31 240 266 4330 3818 800 650 531 542 195
27. e VFD shall have 150 instantaneous torque generation Electrical Service single point power a The VFD shall have input circuit breaker with minimum 65 000 amp interrupt capacity b The VFD shall have standard branch oil pump circuit breaker to provide power for chiller oil pump c The VFD shall have standard 3 KVA control power transformer with circuit breaker to provide power for oil heater VFD controls and chiller controls d The branch oil pump circuit breaker and control power transformer shall be factory wired e Input power shall be 380 460 vac 10 3 Phase 50 60 Hz 2 Hz Discrete Outputs 115 v discrete contact outputs shall be provided for a Circuit breaker shunt trip b Chilled water pump c Condenser water pump d Alarm status Analog Output An analog 4 to 20 mA output for head pres sure reference shall be provided This signal shall be suitable to control a 2 way or 3 way water regulating valve in the condenser piping Protection the following shall be supplied Under voltage Over voltage Phase loss Phase reversal Ground fault Phase unbalance protection Single cycle voltage loss protection Juro Programmable auto re start after loss of power 11 i Motor overload protection NEMA Class 10 j Motor over temperature protection VFD Testing The VFD shall be factory mounted factory wired and factory tested on the chiller prior to sh
28. eplate RPM Motor nameplate kW Inverter PWM frequency Can be configured by the user to provide alert indication at user defined limit TOverride protection Causes compressor to first unload and then if necessary shut down Will not require manual reset or cause an alarm if auto restart after power failure is enabled TTBy display code only 11 Controls cont CONTROL PANEL DISPLAY Front View ICVC ENGLISH DISPLAY IN SI UNITS MANUALLY STOPPED PRESS 03 10 03 16 05 CCN OR LOCAL TO START 0 3 HOURS CHL IN CHL OUT EVAP REF 78 7 72 0 52 0 CDL IN CDL OUT COND REF 79 1 80 0 81 9 OILPRESS OIL TEMP AMPS IN 3 9 148 4 0 0 LOCAL RESET M ENU CONTROL PANEL DISPLAY Front View ICVC CHINESE DISPLAY IN METRIC UNITS 1 03 10 03 16 05 CCN 0 3 m RARE 78 7 72 0 52 0 PHA TOR 79 1 80 0 81 9 8 3 9 148 4 0 0 12 0224 ejnpo N 191149 NOD Jeued 1snuu duis perddns pjer4 3 LON 3LIHM 3LIHM ALIHM MOVE Ovid 3HIM VU 3UIMNIVHG TIU 6 TIdLIEIOW
29. f positive displace ment compression with variable speed capacity control This process provides a chiller that reacts substantially better than chillers equipped with inlet guide vanes or slide valves This allows for easier transition when bringing addi tional chillers on line in multiple chiller 0 99 power factor The Ever green 23XRV chiller can operate at up to 0 99 displacement power factor which helps building owners avoid power factor penalties and decreases electrical losses in cables and trans formers High power factor may also reduce KVA requirements saving elec trical system costs on new projects or freeing up electrical resources on exist ing systems operating near their maxi mum capacity Refrigerant cooled VFD Refrig erant cooling of the VFD minimizes VFD size and ensures proper cooling of the transistors for extended life Using R 134a refrigerant instead of water also eliminates costly mainte nance associated with the water cool ing pump heat exchanger and rubber tubing used with water cooled VFDs plants and eliminates any possibility of Optional seismic kit A seismic surge regardless of the changes in the system Low harmonic distortion The Evergreen 23XRV chiller will generate less than 5 total harmonic distortion at the input to the VFD variable frequency drive without the use of any external filters or line reactors This assures the VFD alone cannot exceed the IEEE 519
30. if cooler is a 1 or 3 pass design 4 Marine waterboxes may add 6 in 152 mm to the width of the NOTES machine See certified drawings for details 1 Service access should be provided per American Society of Heat 5 A length and width dimensions shown are for standard ing Refrigerating and Air Conditioning Engineers ASHRAE 15 150 psig Med en seson and 2 latest edition National Fire Protection Association NFPA 70 and 300 psig 2068 kPa design and or flanges will add length See cer local safety code tified drawings 2 Allow at least 3 ft 915 mm overhead clearance for service rigging 6 Dished head waterbox covers not available for the 3 pass design for the compressor 30 to 32 35 to 37 40 to 42 45 to 47 50 to 52 55 to 57 Performance data NOZZLE SIZE NOZZLE SIZE in Nominal Pipe Size 3 Pass 23XRV HEAT EXCHANGER MIN MAX FLOW RATES ENGLISH GPM COOLER 1PASS 2PASS 55 CONDENSER 1 2PASS 55 Frame Sze Min Min Mm Max Frame Size Mn Max Min f Max Max 815 861 978 1054 1141 1244 3 815 1 861 978 1051 1141 1244 1320 1461 1482 1647 4 1775 4 1828 1320 1461 1482 1647 1775 1828 1756 2010 1976 2195 5 2114 5 2377 1756 2010 1976 2195 2114 2377 Flow rates based on standard tubes in the cooler and condenser Minimum flow based on tube velocity of 3 ft sec 0 91 m sec maxi
31. ig 1034 kPA Marine Waterboxes Unit manufacturer shall furnish marine style waterboxes on cooler and or condenser rated at 300 psig 2068 Flanged Water Nozzles Unit manufacturer shall furnish standard flanged piping connections on the cooler and or condenser Hinges Unit manufacturer shall furnish hinges on waterboxes to facilitate tube cleaning 910 18 19 20 21 Optional Compressor Discharge Isolation Valve and Liquid Line Ball Valve These items shall be factory installed to allow isolation of the refrigerant charge in the con denser for servicing the compressor Pumpout Unit A refrigerant pumpout system shall be installed on the chiller The pumpout system shall include a hermetic compressor and drive inter nal piping internal wiring and motor Field supplied main power wiring and water piping shall be required BACnet Communication Option Shall provide factory installed communication capability with BACnet MS TP network Allows integration with i Vu Open control sys tem or a BACnet building automation system denser for servicing the compressor Optional Seismic Isolation Package Package shall meet International Building Code and ASCE 7 seismic qualification requirements in concurrence with ICC ES AC156 Accep tance Criteria for Seismic Qualification Shake Table Testing of Nonstructural Compo nents and Systems Manufacturer shall provide seismic certificate fro
32. ipment E Evaporator and Condenser 1 2 Evaporator and condenser shall be of shell and tube type construction each in separate shells Units shall be fabricated with high performance tubing steel shell and tube sheets with fabri cated steel waterboxes Waterboxes shall be nozzle in head type with stub out nozzles having Victaulic grooves to allow for use of Victaulic couplings Tubing shall be copper high efficiency type with integral internal and external enhance ment unless otherwise noted Tubes shall be nominal 3 4 in OD with nominal wall thickness of 0 025 in measured at the root of the fin unless otherwise noted Tubes shall be rolled into tube sheets and shall be individually replaceable Tube sheet holes shall be double grooved for joint structural integrity Intermedi ate support sheet spacing shall not exceed 36 in 914 mm Waterboxes and nozzle connections shall be designed for 150 psig 1034 kPa minimum working pressure unless otherwise noted Nozzles should have grooves to allow use of Victaulic couplings The tube sheets of the cooler and condenser shall be bolted together to allow for field disas sembly and reassembly The vessel shall display an ASME nameplate that shows the pressure and temperature data and the U stamp for ASME Section VIII Division 1 A re seating pressure relief valve s shall be installed on each heat exchanger If a non reseating type is used a backup resea
33. k This feature allows the operator to program a yearly schedule for each week week ends and holidays Occupancy schedules Schedules can be programmed into the controller to ensure that the chiller operates when cooling is required and remains off when not needed by the tenants or process Extensive service menu Unau thorized access to the service menu Model number nomenclature 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 c UL us SEISMI 23XRV 40 42 N R U ASME U Stamp 5 4 S AME CERTIFIED www ahridirectory org Water Cooled Chillers AHRI Standard 550 590 AHRI Air Conditioning Heating and Refrigeration Institute Performance Certified Meets IBC 2006 ASCE 7 05 CBC 2007 and OSHPD seismic requirements can be prevented through password protection Built in diagnostic capabili ties assist in troubleshooting and rec ommend proper corrective action for preset alarms resulting in greater working time Alarm file This file maintains the last 25 time and date stamped alarm messages in memory This function re duces troubleshooting time and cost Alert file This file maintains the last 25 alert messages in memory This function provi
34. l chiller Use only pre mixed non shrinking grout Ceilcote 748 or Chemrex Embeco 636 Plus Grout 0 11 2 38 1 to 0 21 4 57 thick Service clearance under the chiller is enhanced if leveling pads are not extended along the entire length of the heat exchangers 18 23XRV NOZZLE ARRANGEMENTS NOZZLE IN HEAD WATERBOXES DISCHARGE END SUCTION END DISCHARGE END SUCTION END FRAMES 4 AND 5 NOZZLE ARRANGEMENT CODES FOR ALL 23XRV NOZZLE IN HEAD WATERBOXES COOLER WATERBOXES CONDENSER WATERBOXES Arrangement Arrangement Refer to certified drawings 19 Application data cont 23XRV NOZZLE ARRANGEMENTS cont MARINE WATERBOXES NOTE NOTE COOLER 3 PASS NOZZLE 45 COOLER 3 PASS NOZZLE 45 NOT SHOWN SIMILIAR TO NOT SHOWN SIMILIAR TO CONDENSER 2 CONDENSER 2 55 P 2 6 Pee TET ar 55 2 on INS 2 he Al o G E m 3 3 DISCHARGE END FRAME 3 NOZZLE ARRANGEMENT CODES COOLER WATERBOXES Arrangement DISCHARGE END SUCTION END FRAMES 4 AND 5 NOZZLE ARRANGEMENT CODES COOLER WATERBOXES CONDENSER WATERBOXES Arrangement Arrangement 20 23XRV WATER
35. l shown in the table below 23XRV RELIEF VALVE DISCHARGE PIPE SIZING RELIEF HEAT VALVE FIELD REQUIRED EXCHANGER C FACTOR Factor SIZE Ib air Min Ib air Min 11 4 11 4 COOLER 11 4 11 4 11 4 114 114 11 4 11 4 Tur 11 4 11 4 Carrier further recommends that oxygen sensor be installed to protect personnel Sensor should be able to sense the depletion or displacement of oxygen in the ma chine room below 19 5 volume oxygen ASHRAE 15 latest edition Design pressures Design and test pressures for heat exchangers are listed below DESIGN AND TEST PRESSURES 23XRV PRESSURES Leak Test at Design Pressure Hydrostatic Proof Test Nitrogen Helium SHELL SIDE STANDARD TUBE SIDE Refrigerant Liquid 185 1276 150 1034 300 m 195 1344 390 204 1407 OPTIONAL TUBE SIDE Liquid HEAT EXCHANGER MATERIAL SPECIFICATIONS ITEM MATERIAL Shell HR Steel HR Steel HR Steel Tube Sheet Condenser Cooler Waterbox Cover SPECIFICATION ASME SA516 GR 70 ASME SA516 GR 70 ASME SA516 GR 70 SA 36 or SA 285 GRC ASME SA675 60 SA 516 GR70 or SA 181 CL70 SA 36 SA 675 GR70 SAE AME 7496 ASME SA106 GRB ASME SA105 Condenser Cooler Waterbox Shell HR Steel Tubes Finned Copper ASME SB359 Discharge Suction Pipe Steel Flanges Steel LEGEND ASME American Society of Mechanical Engineers HR Hot Rolled 22 Insulation 23XR
36. m California only 31 Z Carrier Carrier Corporation Syracuse New York 13221 910 5 10 A United Technologies Company Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations 9 32 Catalog 04 52230002 01 Printed in U S A Form 23XRV 3PD Tab ls Replaces 28XRV 2PD
37. mperature 7 Number of compressor starts 8 Control point settings 9 Discrete output status of various devices O Variable frequency drive status 11 Optional spare input channels 2 Line current and voltage for each phase 13 Frequency kW kWhr demand kW Schedule Function The chiller controls shall be configurable for manual or automatic start up and shutdown In automatic operation mode the controls shall be capable of automatically starting and stopping the chiller according to a stored user programmable occupancy schedule The controls shall include built in provisions for accepting 1 A minimum of two 365 day occupancy schedules Minimum of 8 separate occupied unoc cupied periods per day Daylight savings start end 18 user defined holidays Means of configuring an occupancy timed override Chiller start up and shutdown via remote contact closure 2 6 Service Function The controls shall provide a password protected service function which allows authorized individuals to view an alarm history file which shall contain the last 25 alarm alert messages with time and date stamp These messages shall be displayed in text form not codes Network Window Function Each chiller control panel shall be capable of viewing multiple point values and statuses from other like controls connected on a common network including controller main tenance data The operator shall be able to alter
38. mum flow based on tube velocity of 12 ft sec 3 66 m sec Consult the factory if variable primary flow SI L s COOLER 1PASS 2PASS 3PASS CONDENSER 1PASS 2 55 55 Frame Size Min Max Min Min Max Frame Size Min Max Min Min 51 54 62 67 72 79 51 54 62 67 72 79 83 92 93 104 4 112 4 115 93 92 93 104 112 115 111 127 125 138 133 150 5 111 157 125 138 133 150 Flow rates based on standard tubes the cooler and condenser Minimum flow based on tube velocity of 3 ft sec 0 91 m sec maximum flow based on tube velocity of 12 ft sec 3 66 m sec Consult the factory if variable primary flow Electrical data VFD FRAME SIZES FRAME SIZE MAX OUTPUT CURRENT AA 442 442 520 608 Maximum limits only Additional application limits apply that will reduce these ampacities AUXILIARY RATINGS MAXIMUM VOLTAGE PROTECTIVE DEVICE SIZE AMPS Controls Oil Pump And Heater Circuit 115 15 Oil Pump 115 1 48 Oil Sump Heater 115 4 35 Vaporizer Heater Circuitt Oil Vaporizer Heater 115 15 115 13 1500 Factory wired to TMinimum circuit ampacity of 15 amps 10 Controls Microprocessor controls Microprocessor controls provide the safety interlock ca pacity control indications and accessibility necessary to operate the chiller in a safe and efficient manner Control system The microprocessor c
39. n to the automated controls test the controls shall provide a manual test which permits selection and testing of indi vidual control components and inputs A thermistor test and transducer test shall dis play on the ICVC screen the actual reading of each transducer and each thermistor installed on the chiller All out of range sen sors shall be identified Pressure transducers shall be serviceable without the need for refrigerant charge removal or isolation 4 Multiple Chiller Control The chiller controls shall be supplied as stan dard with a two chiller lead lag and a third chiller standby system The control system shall automatically start and stop a lag or second chiller on a two chiller system If one of the two chillers on line goes into a fault mode the third standby chiller shall be automatically started The two chiler lead lag system shall allow 29 Guide specifications cont manual rotation of the lead chiller and a stag gered restart of the chillers after a power fail ure The lead lag system shall include load balancing if configured to do so H Electrical Requirements 30 1 Electrical contractor shall supply and install main electrical power line disconnect switches circuit breakers and electrical protection devices per local code requirements and as indi cated necessary by the chiller manufacturer 2 Electrical contractor shall wire the chilled water pump and flow condenser water pump and fl
40. nates complex connec tions to portable transfer systems thereby reducing service costs The op tional pumpdown compressor meets Environmental Protection Agency s EPA vacuum level requirements that mandate minimizing refrigerant emis sions during service Modular construction The cool er condenser and compressor assem blies are bolted together making Ever green 23XRV chillers ideally suited for replacement jobs where ease of disas sembly and reassembly at the jobsite are essential Single point power The 23XRV chiller features internal control power transformers to provide low voltage power 115 v 24 vdc for machine controls Simply connecting the three input power leads to the VFD provides all unit power Marine container shipment The compact design allows for open top container shipment to export destina tions ensuring quality while reducing shipping cost Heat exchanger combinations The Evergreen 23XRV chillers are available with a complete line of heat exchangers ensuring the best combi nation of chiller components to meet project specific tonnage and efficiency requirements One 2 and 3 pass arrangements are available to meet a wide variety of flow conditions Nozzle in head and marine waterboxes are available to meet 150 psig and 300 psig piping requirements Heat exchanger features ASME certified construction An independent agency certifies the design manufacture
41. nstalled motor con tactor with overload protection b Oil pressure sensor with differential readout at main control center c Oil pressure regulator d Oil filter with isolation valves to allow filter change without removal of refrigerant charge e Oil sump heater 115 v 50 or 60 Hz con trolled from unit microprocessor f Oil reservoir temperature sensor with main control center digital readout g All wiring to oil pump oil heater and con trols shall be pre wired in the factory and power shall be applied to check proper operation prior to shipment Compressor shall be fully field serviceable Compressors that must be removed and returned to the factory for service shall be unacceptable Acoustical attenuation shall be provided as required to achieve a maximum full load or part load sound level measured per AHRI Standard 575 latest edition C Motor 1 Compressor motor shall be of the semi hermetic liquid refrigerant cooled squirrel cage induction type suitable for voltage shown on the equipment schedule If an open air cooled motor is provided a compressor shaft seal leakage containment system shall be provided a An oil reservoir shall collect oil and refriger ant that leaks past the seal b A float device shall be provided to open when the reservoir is full directing the refrigerant oil mixture back into the com pressor housing c A refrigerant sensor shall be l
42. oard Commission certifying that construction conforms to the latest ASME Code Section VIII Div 1 for pressure vessels The ASME symbol U must also be stamped on the heat exchanger Vessels specifi cally exempted from the scope of the code must come with material test and construction methods certification and detailed documents similar to ASME U 1 further these must be signed by an offi cer of the company Chiller shall be designed and constructed to meet UL and UL of Canada requirements and have labels appropriately affixed Unit shall be manufactured in a facility registered to ISO 9001 2000 Manufacturing Quality Standard Each compressor assembly shall undergo a mechan ical run in test to verify vibration levels oil pressures and temperatures are within acceptable limits Each compressor assembly shall be proof tested at a mini mum 204 psig 1407 kPa and leak tested at 185 psig 1276 kPa with a tracer gas mixture Entire chiller assembly shall be proof tested at 204 psig 1407 kPa and leak tested at 185 psig 1276 kPa with a tracer gas mixture on the refriger ant side The leak test shall not allow any leaks greater than 0 5 oz per year of refrigerant The water side of each heat exchanger shall be hydro statically tested at 1 3 times rated working pressure Prior to shipment the chiller automated controls test shall be executed to check for proper wiring and ensure correct controls operation
43. ocated next to the open drive seal to detect leaks Motors shall be suitable for operation in a refrigerant atmosphere and shall be cooled by atomized refrigerant in contact with the motor windings Motor stator shall be arranged for service or removal with only minor compressor disassem bly and without removing main refrigerant piping connections Full load operation of the motor shall not exceed nameplate rating One motor winding temperature sensor and on spare shall be provided Should the mechanical contractor choose to provide a chiller with an air cooled motor instead of the specified semi hermetic motor the contractor shall install additional cooling 25 Guide specifications cont equipment to dissipate the motor heat as per the following formula Btuh motor 0 05 3413 Btuh FLkW motor 171 and alternately Tons Btuh 12 000 The additional piping valves air handling equipment insulation wiring switchgear changes ductwork and coordination with other trades shall be the responsibility of the mechan ical contractor Shop drawings reflecting any changes to the design shall be included in the submittal and incorporated into the final as built drawings for the project 8 Also if an open motor is provided a mechani cal room thermostat shall be provided and set at 104 F 40 C If this temperature is exceeded the chillers shall shut down and an alarm signal sh
44. ompressor shaft seals that require maintenance and increase the likeli hood of refrigerant leaks Machine room cooling requirements associated with air cooled motors which dissipate heat to the mechan ical room High noise levels common with air cooled motors which radiate noise to the machine room and adjacent areas Shaft alignment problems that occur with open drive designs during start up and operation when equipment temperature variations cause ther mal expansion Positive pressure design Posi tive pressure designs eliminate the need for costly low pressure contain ment devices reducing the initial cost of the system The Evergreen 23XRV chiller s positive pressure design en sures that air moisture and other per formance degrading contaminants are not sucked inside the chiller Purge units and their associated mainte nance are no longer necessary Optional refrigerant isolation valves The optional refrigerant isolation valves allow the refrigerant to be stored inside the chiller during shipment from the factory minimizing start up time During servicing the in chiller storage reduces refrigerant loss and eliminates time consuming transfer procedures As a self contained unit the Evergreen 23XRV chiller does not require additional remote storage systems Optional pumpdown unit Com bined with the refrigerant isolation valves listed above the optional pump down unit elimi
45. ontrol on each Carrier chiller is factory mounted factory wired and factory tested to ensure machine protection and efficient capacity control In addition the program logic ensures proper starting stopping and recycling of the chiller and provides a com munication link to the Carrier Comfort Network CCN system Features Control system Component test and diagnostic check Programmable recycle allows chiller to recycle at opti mum loads for decreased operating costs Menu driven keypad interface for status display set point control and system configuration CCN system compatible Primary and secondary status messages Individual start stop schedules for local and CCN opera tion modes Recall of up to 25 alarm messages and 25 alert mes sages with diagnostic help Two chiller lead lag with third chiller standby is stan dard in the PIC III software Optional soft stop unloading decreases compressor speed to unload the motor to the configured amperage level prior to stopping Languages pre programmed at factory for English Chi nese Japanese Korean International Language Translator available for conversion of extended ASCII characters Safety cutouts Motor high temperature Refrigerant condenser high pressure t Refrigerant cooler low temperature t Lube oil low pressure Compressor refrigerant high discharge temperature Under voltage Over voltage Cooler and condenser li
46. ow and tower fan control circuit to the chiller control circuit 3 Electrical contractor shall supply and install electrical wiring and devices required to inter face the chiller controls with the building control system if applicable 4 Electrical power shall be supplied to the unit at the voltage phase and frequency listed in the equipment schedule I Piping Requirements Instrumentation and Safeties 1 Mechanical contractor shall supply and install pressure gages in readily accessible locations in piping adjacent to the chiller such that they can be easily read from a standing position on the floor Scale range shall be such that design val ues shall be indicated at approximately mid scale 2 Gages shall be installed in the entering and leav ing water lines of the cooler and condenser J Vibration Isolation Chiller manufacturer shall furnish neoprene isolator pads for mounting equipment on a level concrete surface K Start Up 1 The chiller manufacturer shall provide a factory trained representative employed by the chiller manufacturer to perform the start up proce dures as outlined in the Start Up Operation and Maintenance manual provided by the chiller manufacturer 2 Manufacturer shall supply the following literature a Start up operation maintenance instructions b Installation instructions c Field wiring diagrams d One complete set of certified drawings L Special Features
47. pplicable ANSI NEMA UL and NEC standards d Drive shall be suitable for operation in ambient temperatures between 40 and 122 F 4 and 50 C 95 humidity non condensing for altitudes up to 6000 ft 1829 m above sea level Specific drive performance at jobsite ambient temperature and elevation shall be provided by the manufacturer in the bid User Interface A single display shall provide interface for pro gramming and display of VFD and chiller parameters Viewable parameters include a Operating configuration and fault messages b Frequency in hertz c Load and line side voltage and current at the VFD d kW e IGBT temperature 6 VFD Performance a The VFD Voltage Total Harmonic Distortion THD and Harmonic Current Total Demand Distortion TDD shall not exceed IEEE 519 requirements using the VFD circuit breaker 7 9 10 input terminals as the point of common cou pling PCC b The VFD full load efficiency shall meet or exceed 97 at 100 VFD rated ampacity C Active rectifier shall regulate unity displace ment power factor to 0 99 or higher d Voltage boost capability to provide full motor voltage at reduced line voltage conditions e The VFD shall feature soft start linear accel eration and coast to stop capabilities f Base motor frequency shall permit motor to be utilized at nameplate voltage Adjustable frequency range shall permit capacity con trol down to 15 Th
48. quid flow Motor overloadt Motor acceleration time Intermittent power loss Motor stall protection Low level ground fault Cooler and condenser freeze prevention Low oil temperature Line voltage imbalance Line current imbalance Line frequency Motor current imbalance Motor rotation reversal Excessive motor amps Motor starts limit VFD speed out of range High VFD rectifier temperature High VFD inverter temperature t DC bus voltage Low High Capacity control Leaving chilled liquid control Entering chilled liquid control Soft loading control by temperature or load ramping Hot gas bypass valve optional Power demand limiter Automatic chilled liquid reset 3 methods Manual speed control Interlocks Manual automatic remote start Starting stopping sequence Pre lube post lube Pre flow post flow Compressor run interlock Pre start check of safeties and alerts Low chilled liquid load recycle Monitor number compressor starts and run hours Manual reset of safeties Indications Chiller operating status message Power on Pre start diagnostic check Compressor motor amps Alert pre alarm tt Alarm Contact for remote alarm Safety shutdown messages Elapsed time hours of operation Chiller input kW Demand kW Drive control parameters Compressor 100 speed Hz Rated line voltage Rated line amps Rated line kW Motor rated Load kW Motor rated Load amps Motor nameplate amps Motor nam
49. r standard tubes of standard wall thickness EDE and Spikefin 3 0 025 in 0 635 mm wall NOTES 1 Cooler includes the suction elbow and 1 2 the distribution piping weight 2 Condenser includes float valve and sump discharge elbow and 1 2 the distribution piping weight 3 For special tubes refer to the 23XRV Computer Selection Program 4 All weights for standard 2 pass NIH nozzle in head design with vic taulic grooves Motor Terminal r Cond Weight Ib Ib Cooler Cond Weight kg 210 246 282 233 274 314 415 451 487 453 494 535 556 591 626 607 648 687 Physical data cont ADDITIONAL WEIGHTS FOR 23XRV MARINE WATERBOXES 150 psig 1034 kPa MARINE WATERBOXES NUMBER Sig OF Condenser PASSES Rigging Wat Liquid Wat 300 psig 2068 kPa MARINE WATERBOXES NUMBER Sig FRAME OF Condenser PASSES Rigging Wat Liquid Wat 195 159 744 178 7 2655 1019 1204 N A N A 1965 1909 866 190 Add to cooler and condenser weights for total weights Cooler and condenser weights may be found in the 23XRV Heat Exchanger Weights table on page 5 The first digit of the heat exchanger code first column is the heat exchanger frame size 23XRV WATERBOX COVER WEIGHTS ENGLISH lb FRAMES 3 4 AND 5 CONDENSER WATERBOX DESCRIPTION NIH 1 pass Cover 150 psig NIH 2 pass Cover 150 psig NIH 3 pass
50. re is high evaporator pump may continue if in RECYCLE mode Restart permitted both inhibit timers expired minimum of 15 min utes after F minimum of 3 minutes after L Control sequence To start Local start up manual start up is initiated by pressing the LOCAL or CCN menu softkey which is indi cated on the default international chiller visual control ICVC screen Time schedule 01 or 03 respectively must be in the Occupied mode and the internal 15 minute start to start and the 1 minute stop to start inhibit timers must have expired All pre start safeties are checked to verify that all prestart alerts and safeties are within limits if one is not an indication of the fault displays and the start will be delayed or is aborted The signal is sent to start the cooler liquid pump Five seconds later the condenser liquid pump is energized If satisfied it checks the chilled liquid temper ature against the control point If the temperature is less than or equal to the chilled liquid control point the con denser liquid pump is deenergized and the chiller goes into a recycle mode If the chilled liquid temperature is high enough the start up sequence continues The oil pump is started and waits a minimum of 45 sec to verify oil flow Once oil flow is veri fied the VFD is energized The control will monitor for a phase reversal condition At this time the following occurs The start to stop timer is activated The
51. s and labor for one year after start up or 18 months from shipment which ever occurs first A refrigerant warranty shall be provided for a period of 5 years Part 2 Products 2 01 A B EQUIPMENT General Factory assembled single piece liquid chiller shall consist of compressor motor VFD lubrication sys tem cooler condenser initial oil and refrigerant operating charges microprocessor control system and documentation required prior to start up Compressor 1 One variable speed tri rotor screw compressor of the high performance type 2 Compressor and motor shall be hermetically sealed into a common assembly and arranged for easy field servicing 3 The compressor motor shall be accessible for servicing without removing the compressor base from the chiller Connections to the com pressor casing shall use O rings and gaskets to reduce the occurrence of refrigerant leakage Connections to the compressor shall be flanged or bolted for easy disassembly 4 Compressor bearings must have individual design life of 500 000 hours or greater 5 Compressor shall provide capacity modulation from 100 to 15 capacity without the use of hot gas bypass or mechanical unloaders 6 Compressor shall be provided with a factory installed positive pressure lubrication system to deliver oil under pressure to bearings and rotors at all operating conditions Lubrication system shall include a Oil pump with factory i
52. sure 2 High motor temperature 3 Low evaporator refrigerant temperature 4 High motor amps 5 High VFD rectifier temperature 6 High VFD inverter temperature c During the capacity override period a pre alarm alert message shall be displayed informing the operator which condition is causing the capacity override Once the con dition is again within acceptable limits the override condition shall be terminated and the chiller shall revert to normal chilled water control If during either condition the protective limit is reached the chiller shall shut down and a message shall be displayed informing the operator which condition caused the shutdown and alarm d Internal built in safeties shall protect the chiller from loss of water flow Differential pressure switches shall not be allowed to be the only form of freeze protection 3 Diagnostics and Service a A self diagnostic controls test shall be an integral part of the control system to allow quick identification of malfunctioning components b Once the controls test has been initiated all pressure and temperature sensors shall be checked to ensure they are within normal operating range A pump test shall automat ically energize the chilled water pump con denser water pump and oil pump The control system shall confirm that water flow and oil pressure have been established and require operator confirmation before pro ceeding to the next test c In additio
53. talled TField installed Standard waterbox nozzles are victaulic type Flanged nozzles are available as an option with either nozzle in head type waterboxes or marine waterboxes 910 6 OPTION ACCESSORYt TTOptional marine waterboxes available for 23XRV heat exchanger frames 3 5 only Standard waterboxes for 23XRV are nozzle in head type 150 psig 1034 kPa Sponsored by ASHRAE American Society of Heating Refrigerating and Air Conditioning Engineers tttRegistered trademark of Echelon Corporation Dimensions 23XRV DIMENSIONS TUBE REMOVAL MOTOR SERVICE SPACE FOR CLEARANCE EITHER END 17 10 559 mm SIZES 30 32 40 42 50 52 14 3 4343 mm FRAME COMPRESSOR 2 0 915mm SIZES 35 37 45 47 z RECOMMENDED OVERHEAD SERVICE CLEARANCE A 55 57 14 0 4267 mm HEAT EXCHANGER C Height SIZE 5017 2867 DE 23XRV DIMENSIONS MARINE WATERBOX A Length Marine Waterbox HEAT EXCHANGER _ 1 or 3 Passt C Height frin mm f mm 301032 2496 16 407 74997 2067 35 to 37 16 51 2 5017 18 11 4 5518 2067 40 to 42 15 23 4642 16 37 5086 2076 See unit a 509 NEUE 45 to 47 16 1134 5163 18 43 4 5607 2076 drawings 50 to 52 15 31 2 4661 16 81 2 5093 2159 551057 5182 5613 2159 Assumes both cooler and condenser nozzles same end of chiller 3 Certified drawings available upon request T1 or 3 pass length applies
54. termediate sup port sheets Support sheets pre vent tube sagging and vibration there by increasing heat exchanger life Refrigerant filter isolation valves These valves allow filter replace ment without pumping down the chill er reducing service time and expense FLASC flash subcooler The subcooler located in the bottom of the condenser increases the refrigeration effect by cooling the condensed liquid refrigerant to a lower temperature thereby reducing compressor power consumption AccuMeter system The AccuMeter system regulates refrigerant flow according to load conditions providing a liquid seal at all operating conditions eliminating unintentional hot gas bypass Microprocessor controls features Direct Digital Product Integrated control PIC III Carrier s PIC III provides unmatched flexibility and functionality Each unit integrates directly with the Carrier Comfort Network CCN system providing solution to controls applications International Chiller Visual Con troller ICVC The ICVC provides an unparalleled ease of operation and can be configured to display English or metric values For convenience a single display lo cated on the chiller VFD panel displays chiller and VFD data The VGA 320 x 240 element LCD liquid crystal dis play features 4 menu specific soft keys The default display offers an all in one glance review of key chiller operation data simplif
55. ting type shall be installed in series Waterboxes shall have vents drains and covers to permit tube cleaning within the space shown on the drawings A thermistor type temperature sensor with quick connects shall be factory installed in each water nozzle Cooler shall be designed to prevent liquid refrig erant from entering the compressor Devices that introduce pressure losses such as mist eliminators shall not be acceptable because they are subject to structural failures that can result in extensive compressor damage Tubes shall be individually replaceable from either end of the heat exchanger without affect ing the strength and durability of the tube sheet and without causing leakage in adjacent tubes The condenser shell shall include a FLASC Flash Subcooler which cools the condensed 27 Guide specifications cont liquid refrigerant to a reduced temperature thereby increasing the refrigeration cycle efficiency F Refrigerant Flow Control To improve part load efficiency liquid refrigerant shall be metered from the condenser to the cooler using a float type metering valve to maintain the proper liquid level of refrigerant in the heat exchangers under both full and part load operating conditions By maintaining a liquid seal at the float valve bypassed hot gas from the condenser to the cooler is eliminated G Controls Safeties and Diagnostics 28 1 Controls a The chiller shall
56. tractor Building Control System Interface LON The chiller control system shall have the ability to interface and communicate directly to the building control using a LON based system The LonWorks Carrier Translator shall output data in standard LON profiles Refrigerant Charge The chiller shall ship from the factory fully charged with R 134a refrigerant and oil Thermal Insulation Unit manufacturer shall insulate the cooler shell economizer suction elbow motor shell and motor cooling lines Insulation shall be 1 in 25 4 mm thick with a thermal conductivity not exceeding Btu in W 0 28 hr F2 F UE mC and shall conform to UL standard 94 classifica tion 94 HF 1 Automatic Hot Gas Bypass Hot gas bypass valve and piping shall be factory furnished to permit chiller operation for extended periods of time 11 12 13 14 15 16 17 Cooler and Condenser Tubes Contact a local Carrier Representative for other tube offerings Cooler and Condenser Passes Unit manufacturer shall provide the cooler and or condenser with 1 2 or 3 pass configuration on the water side Nozzle In Head 300 psig 2068 kPa Unit manufacturer shall furnish nozzle in head style waterboxes on the cooler and or con denser rated at 300 psig 2068 kPa Marine Waterboxes Unit manufacturer shall furnish marine style waterboxes on cooler and or condenser rated at 150 ps
57. y to fixed DC voltage d Transistorized inverter and control regulator shall convert fixed DC voltage to a sinusoidal PWM waveform e Low voltage control sections and main power sections shall be physically isolated f Integrated controls shall coordinate motor speed to optimize chiller performance over a wide variety of operating conditions 2 Enclosure a Pre painted unit mounted NEMA 1 cabinet shall include hinged lockable doors and removable lifting lugs b The VFD shall have a short circuit interrupt and withstand rating of at least 65 000 amps c Provisions to padlock main disconnect han dle in the Off positions shall be provided Mechanical interlock to prevent opening cabinet door with disconnect in the position or moving disconnect to the On position while the door is open shall be provided d Provisions shall be made for top entry of incoming line power cables 3 Heat Sink a The heat sink shall be refrigerant cooled Heat sink and mating flanges shall be suit able for ASME design working pressure of 185 psig 1276 kPa b Refrigerant cooling shall be metered to maintain heat sink temperature within acceptable limits for ambient temperature 4 VFD Rating a Drive shall be suitable for operation at name plate voltage 10 b Drive shall be suitable for continuous opera tion at 100 of nameplate amps and 150 of nameplate amps for 5 seconds c Drive shall comply with a
58. ying the interac tion between chiller and user The display includes 4 standard languages English Chinese Japanese Korean Other languages are available Automatic capacity override This function unloads the compressor whenever key safety limits are ap proached increasing unit life This Features Benefits cont feature also allows the machine to operate at reduced capacity rather than shut down when key safety limits are approached Chilled liquid reset Reset can be accomplished manually or automatical ly from the building management sys tem For a given capacity reset allows operation at slower compressor speeds saving energy when warmer chilled liquid can be used Demand limiting This feature lim its the power draw of the chiller during peak loading conditions When incor porated into the Carrier Comfort Network building automation system a red line command holds chillers at their present capacity and prevents any other chillers from starting If a load shed signal is received the compres sors are unloaded to avoid demand charges whenever possible Ramp loading Ramp loading en sures smooth pulldown of liquid loop temperature and prevents a rapid increase in compressor power con sumption during the pulldown period Automated controls test The test can be executed prior to start up to verify that the entire control system is functioning properly 365 day real time cloc
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