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Carrier 23 XL Refrigerator User Manual

1. 435 110 1 f Re NI ttt ML N v RS LTEM i pdt SHOLO3NNOO I nari uaonasNvulr 3unssaud 27 4 a joOHVHOSIQ 2 SATIVA 22 3ONVH D QION310S 3sv3uoaad KL B a o 3 8 HOSN3S 3Hn VH3dW3L Ud 1000 H31VM H31002 xy HE SJ WAGIONTIOS NOLLO3NNOO 3sy3uoNI 10 NOLLOINI HOSN3S JNN Sv9 3univH3dW3L NOILO3NNOO uagonasNvul H3ZIWNONOO3 HOLOW 3unss3 d H31002 3HfiSS3Hd 3H vu3dWwaL JOUVHOSIG NOLLO3NNOO 13 NI HOLO NOI GIO HOSN3S 3uf 1 vH3d Wa H3ZINONO23 HOSS3HdWOO LYOddNS HOLOW d31VM HA 1009 14 2 Cover all openings Additional Notes For Frame 1 2 and 4 Machines 3 Be sure the switches sensor and transducers are Use silicon grease on new O rings when refitting disconnected 2 Use gasket sealant on new gaskets when refitting 4 Cut oil separator from its support foot 3 Cooler and condenser may be vertically rigged Rigging 5 Rig oil separator should be fixed to 4 corners of the cooler and condenser tube sheet TEMPERATURE SENSOR MOTOR COOLING DRAIN SUCTION FLANGE DISCHARGE FLANGE AND CHECK VALVE LOCATION i 4i 1 2 2 RABBET CONNECTIONS VESSEL SEPARATION FOOT Fig 11 Motor Cooling Drain Section Frame 4 Machines 4 OIL SEPAR
2. Code 1 J D ee 5 L L mcib 399 Jp cce M 4 ce Waterbox Nozzle Sizes NOMINAL PIPE ACTUAL PIPE FRAME SIZE in ID in Coolerand Condenser and Condenser Cooler and Condenser 6 065 1 6 065 6 065 7 981 2 6 065 6 065 LEGEND ID Inside Diameter NOTE All nozzles are nozzle in head NIH type with 150 psig 1034 kPa ASA American Standards Association flanged connections POWER PANEL Ld Fe E NETS COMPRESSOR END FRONT VIEW DRIVE END Fig 20 Piping Flow Data Frame 1 and 2 20 d pu _ 3 151 COMPRESSOR END j FRONT VIEW Cooler and Condenser Nozzle Arrangements NOZZLE ARRANGEMENT CODES Condenser Pass Code P 1 Q 2 5 Waterbox Nozzle Sizes NOMINAL PIPE ACTUAL PIPE FRAME SIZE in ID in Cooler and Condenser and Condenser Cooler and Condenser 1 L coste and Condenser 0 10 020 4 2 8 7 981 3 6 6 065 Frame 4 waterboxes are factory fabricated with bolt on covers Fig 21 Piping Flow Data Frame 4 21 PRESSURE GAGE 0 9 0 5 1 4 0 7 1 8 229 133 181 VAPOR 1 L3 D 1 8 3 43 E LEVEL GAGE RELIEF VALVES S 0 8 1 FEMALE ELECTRICAL 203 PEA ACCESS SPACE CONDENSER WATER CONN B 2 1 2 NPT FEMALE VAPOR CO
3. 16 7 41 1499 en 2118 8 2 and 3 pass length applies if either or both cooler or condenser is a 2 or 3 pass design NOTES 1 Service access should be provided per ANSI ASHRAE 15 American National Standards Institute American Society of Heating Refrigeration and Air Conditioning Engineers Lat est Edition NFPA National Fire Protection Association 70 and local safety codes 2 Allow at least 6 in 152 mm overhead clearance for service rigging 3 Certified drawings available upon request Fig 6 23XL Dimensions Frame 1 and 2 Machines 7 796 3 0 914 RECOMMENDED OVERHEAD SERVICE CLEARANCE OVERHEAD 0 6 152 MINIMUM OVERHEAD SERVICE CLEARANCE MOTOR SERVICE CLEARANCE 2 6 762 TUBE REMOVAL SPACE EITHER END 12 3 1 2 3747 2 7 3 8 2 6 MIN INCLUDES WATERBOX 762 NOZZLE LENGTH SERVICE AREA 2 0 MIN 23XL FRONT 610 NOTES 1 For flanged waterbox nozzles refer to the certified drawings for length addition measurements 2 Service access should be provided based on American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 15 latest edition National Fire Protection Association NFPA 70 and local safety codes 3 A minimum 6 in 152 mm overhead clearance for service rigging is recommended 4 Certified drawings are available upon request 5 indicates millimeters A LENGTH OVERALL OVERALL NOZ
4. Protect machine and starter from construction dirt and moisture Keep pro tective 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 re move all water from cooler and condenser Leave drains open until system is filled FRONT VIEW 1 Power Panel 2 Local Interface Display LID Control Center 3 ASME Nameplate Cooler 12 4 Cooler Refrigerant Isolation Valve 5 ASME Nameplate Economizer Hidden 11 6 Service Valve 7 Take Apart Rabbet Fit Connector Lower 8 Cooler Temperature Sensor 10 9 ASME Nameplate Condenser 10 Typical Waterbox Drain Port 9 11 Cooler Supply Return End Waterbox Cover 12 Condenser Supply Return End Waterbox Cover 13 Compressor Nameplate Hidden REAR VIEW 14 Oil Separator 15 ASME Nameplate Muffler Hidden 16 ASME Nameplate Oil Separator 17 Cooler Relief Valves Hidden 18 Oil Sump Filter Assembly 19 Oil Charging Valve 20 Vessel Separation Feet 21 Float Chamber 22 Condenser Isolation Valve Option or Accessory 23 Refrigerant Charging V
5. 10 e g DRIVE END If chiller is set on concrete pad electrical contractor is to locate conduit stub ups outside of pad Approximate location shown Fig 13 23XL Machine Footprint Frame 1 and 2 Machines 13 0 1 4 3968 3 1873 3 Sun 1873 3 6 1 3 4 3 0 914 4 0 4 3 8 111 1 OPTIONAL SOLEPLATE 5 7 7 8 2 11 1724 889 0 2 76 2 VESSELS CONDENSER _ AREIS 0 10 1 2 268 7 TYP 0 7 8 22 2 SLOT TYP 0 11 8 28 6 TYP 6 1 3 4 _ OUTSIDE EDGE OF CONDENSER TUBESHEET TYP BOTH ENDS 5 7 3 8 1724 COOLER OUTSIDE EDGE OF COOLER Quique a TUBESHEET BOTH ENDS 393 7 M 4 2 0 7 914 4 1 0 304 8 0 0 1 2 12 7 22 22 0 0 1 2 12 7 p B B COMPRESSOR END 1619 d DRIVE END NOTES 1 Dimensions in are in millimeters 2 Use grout and package components to establish the level base line 3 If chiller is set on concrete pad electrical contractor is to locate conduit stub ups outside of pad Approximate location shown 4 See Fig 15 and 16 for additional information Fig 14 23XL Machine Footprint Frame 4 Machine 16 0 1 1 2 38 17 1 0 10 330 254 0 1 1 2 38 054 1 2 0 1 1 2 0 8 0 5 VIEW 5 0 3 8 10 LEVEL BASE LINE BLrEG SR GNM EM PY CES SHEAR FLE
6. 6 Rig oil separator NOTE Before proceeding with disassembly make sure the machine is at atmospheric pressure To Separate Cooler and Condenser Frame 4 Machines A WARNING The compressor is heavy To avoid bodily injury lift the compressor only by using cables or slings Do not lift the compressor using threaded eyebolts The metric threaded eyebolts are provided only for lifting indi vidual compressor castings 796 DISCHARGE FLANGE AND CHECK VALVE LOCATION SUCTION FLANGE NOT SHOWN MOTOR SUPPORT FOOT DISCHARGE PRESSURE TRANSDUCER SOLENOID VALVE mm HIGH PRESSURE DISCHARGE CUTOUT SWITCH OIL SUPPLY LINE OIL SUMP VENT OIL SCAVENGE LINE VENT 2 SUMP SECURING BOLTS FOR OIL SEPARATOR COOLER LIQUID FEED LINE e 5 EU VESSEL SEPARATION FEET Fig 8 23XL Drive End View Frame 1 and 2 Machines Refer to Fig 10 unless otherwise specified Turn all 4 vessel separation feet to the lowered position Fig 11 Disconnect and or cut the following lines as required a cooler liquid feed 2 b motor cooling supply from condenser c liquid injection to compressor d bubble line to float chamber not shown e optional hot gas bypass and associated solenoid valve wiring not shown f motor power cables from optional unit mounted starter lugs not shown 3 Se
7. If the machine appears to be dam aged or has been torn loose from its anchorage have it examined by transportation inspectors before removal For ward claim papers directly to the transportation com pany The manufacturer is not responsible for any dam age incurred in transit 2 Check all items against shipping list Immediately notify the nearest Carrier representative if any item is missing 3 To prevent loss or damage leave all parts in original pack ages until installation All openings are closed with covers or plugs to prevent dirt and debris from entering during shipping The 23XL is shipped with a full oper ating oil charge IDENTIFY MACHINE The machine model number se rial number and heat exchanger sizes are stamped on ma chine information plate Fig 1 2 and 3 Check this infor mation against shipping papers and job data 23XL 20 21 E C6 1 1 Variable V 0 Fixed Vl Model Description Hermetic Screw Liquid Chiller Compressor Size C2 160 Tons Cooler Size 560 KW 10 11 Frame 1 C4 200 Tons 20 21 Frame2 700 kW 40 41 42 43 Frame 4 C6 250 Tons 880 KW D4 300 Tons Condenser Size 1055 kW 10 11 Frame 1 D6 350 Tons 20 21 Frame 2 40 41 42 43 Frame 4 1231 kW E Economizer N No Economizer LEGEND VI Volumetric Index Fig 1 Model Number Identification PROVIDE MACHINE PROTECTION
8. LEGEND NIH Nozzle In Head These weights are given for reference only They have been included in heat exchanger weights shown in Table 4 NOTE Add 30 Ib 14 Kg for bolts Table 5B 23XL Waterbox Cover Weight Frame 4 Machines SI kg EXCHANGER DESCRIPTION Std Nozzles Flanged Std Nozzles Flanged 150 psig 300 psig 150 psig 300 psig 1034 kPa 2068 kPa 1034 kPa 2068 kPa 223 237 COOPER 213 133 282 219 237 248 EN 228 128 215 163 LEGEND CS Contact Syracuse MWB Marine Waterbox Nozzle In Head These weights are given for reference only The 150 psig 1034 kPa standard waterbox cover weights have been included in the heat exchanger weights shown in Table 4 Table 6 23XL Machine Rigging Weights 17 um am 697 2 ae 20 020 1 LEGEND VI Volumetric Index Total rigging weight includes HCFC 22 and water NOTE Starter weight is included in total weights Subtract 500 lbs 227 kg if a starter is not used 796 10 NOTE Before proceeding with disassembly make sure the machine is at atmospheric pressure NOTE The screw compressor uses all metric dimensions and metric fasteners The heat exchangers and oil separator use American standard dimensions and English fasteners Metric wrenches are required to remove the compressor T ler an ndenser Frame 1 and 2 1 Turn vessel separation feet
9. Machine Charge SIZE Gnd Refrigerant Ib Water gal Economizer NoEconomzer n o 2480 280 oo oo 34 392 n 20 300 65 80 7 4 444 20 2845 3250 75 T 45 492 21 56 4 40 5030 4690 100 85 90 80 492 516 a 5180 no 900 100 850 54 57 a2 5345 505 120 950 no 90 60 43 xo 6 70 SI Machine Charge SIZE Cooler Cond Refrigerant kg Water L Onlyt oc Economizer NoEconomizer coe cond w p s dadas ie MB s t8 11 168 20 186 21 214 40 195 4i 216 42 239 43 264 LEGEND Nozzle In Head Weight based on 035 in wall copper Turbo B2 tubes in cooler Turbo chill in condenser 2 pass 150 psi NIH waterbox arrangements sizes 10 11 20 21 3 pass 300 psi NIH waterbox arrangements sizes 40 41 42 43 TWeight of optional economizer is not included and must be added to cooler weight Not available NOTE Standard shipment is with refrigerant charged so be sure to add refrigerant charge to dry weight 796 Table 5A 23XL Waterbox Cover Weights Frame 1 and 2 Machines WATERBOX PSI 0 1 FRAME 2 HEAT EXCHANGER DESCRIPTION kPa kg NIH 1 1 Pass xm 58 7 2 Pass Plain 1034 6 Condenser NIH 2 2 Pass With Pipe Nozzles With 2 Pass With Pipe Nozzles Nozzles 91 1034
10. N A COMPLETED The machine is level 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 starter wiring is complete The wiring is installed per installation instructions and certified prints a Power wiring to compressor motor Motor leads will not be taped until the Carrier technician megger tests the motor b Oil heater control wiring if applicable c Other 8 The motor starter has not been supplied by Carrier It has been installed according to the manufacturer s instructions 9 The motor starter has not been supplied by Carrier and it has been checked for proper operation COMMENTS CL 1 DATE BE TESTING YES NO COMPLETED 1 The cooling tower fan has been checked for blade pitch and proper operation 2 The chilled water and condenser water line
11. power to the compressor motor starter terminals LL1 and LL2 An outside power source will produce dan gerous voltage at the line side of the starter because supplying voltage at the transformer secondary termi nals produces input level voltage at the transformer primary terminals NOTE The voltage selector switch in the machine power panel is factory set for 115 v control power source When a 230 v control power source is used set the voltage selector switch at 230 v 21 1C 11 RED 230V _ 50 60 Hz eoe 22 1C 12 115 OIL HEATER 50 60 Hz amp 1200 W 23 1C 13 COM qe LEGEND Field Wiring Power Panel Component Terminal Fig 29 Oil Heater and Control Power Wiring Diagram Frame 1 and 2 Machines CONNECT COMMUNICATION AND CONTROL WIR ING FROM STARTER TO POWER PANEL Connect control wiring from main motor starter to the machine power panel All control wiring must use shielded cable Also connect the communications 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 CAUTION The optional hot gas bypass valve is factory wired for 115 volts If 230 v is used for control voltage discon nect the red wire from the piggy back terminal oil heater contactor terminal 23 and yellow wire from the piggy back on pilo
12. Columbia 02525 796 When connecting the CCN communication bus to a sys tem element a color code system for the entire network is recommended to simplify installation and checkout The fol lowing color code is recommended CCN BUS CONDUCTOR COMM1 PLUG SIGNAL TYPE INSULATION COLOR PIN NO Red 1 Ground White 2 Black 3 If a cable with a different color scheme is selected a simi lar color code should be adopted for the entire network 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 31 If the communication bus cable exits from one build ing 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 23XL chiller to the network proceed as follows Fig 31 Cut power to the PIC control center 2 Remove the COMMI plug from the processor module 3 Cut a CCN wire and strip the ends of the RED WHITE and BLACK conductors 4 Using a wirenut connect the drain wires together 5 Insert and secure the RED wire to Terminal 1 of the COMMI plug 6 Insert and secure the WHITE wire to Terminal 2 of the COMMI plug 7 Insert and secure the BLACK wire to Terminal 3 of the COMMI plug 8 Mount
13. a terminal strip in a convenient location 9 Connect the opposite ends of each conductor to separate terminals on the terminal strip 30 10 Cut another CCN wire and strip the ends of the conductors 11 Connect the RED wire to the matching location on the terminal strip 12 Connect the WHITE wire to the matching location on the terminal strip 13 Connect the BLACK wire to the matching location on the terminal strip Install Field Insulation A CAUTION Protect insulation from weld heat damage and weld splat ter Cover with wet canvas cover during water piping installation When installing insulation at the job site insulate the fol lowing components compressor motor cooler shell cooler tube sheets suction piping motor cooling drain oil reclaim piping Frame 1 and 2 machines only cooler liquid inlet piping hot gas bypass piping if applicable economizer and economizer piping if applicable Insulation of the waterbox covers is applied only at the jobsite When insulating the covers make sure there is ac cess for removal of waterbox covers for servicing Fig 32 and 33 Depending upon humidity conditions field insulation of the condenser s bottom half may be required when the ma chine is not operating FACTORY INSTALLED INSULATION OPTIONAL Op tional factory installed insulation is available for the evapo rator shell and tube sheets suction pipe compressor motor refrigerant li
14. v maximum Wiring diagrams in this publication Fig 27 31 are for reference only and are not intended for use during actual installation follow job specific wiring diagrams RELIEF VALVES 3 WAY VALVE NOTE The relief valve tree is available on all condens ers It is also applicable to Frame 4 machines with accessory isolation packages Fig 26 Typical 23XL Relief Valve Tree Table 7 Relief Device Locations LOCATION Storage Tank Optional LEGEND FPT Female Pipe Thread FL Flare Relief valve is only available when an optional factory installed or accessory field installed refrigerant isolation package is used WARNING Do not attempt to start compressor or apply test voltage of any kind while machine is under dehydration vacuum Motor insulation breakdown and serious damage may result CONNECT CONTROL INPUTS Connect the control in put wiring from the chilled and condenser water flow switches to the starter terminal strip Wiring may also 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 Control Network modules may be specified as well These are wired to the machine control center as in dicated in Fig 29 31 WARNING Connect only 24 v wiring to the control center CONNECT CONTROL OUTPUTS Connect auxiliary equipment chilled and condenser water pu
15. 23XL 50 60 Hz Hermetic Screw Liquid Chillers With HCFC 22 and HFC 134a Installation Instructions SAFETY CONSIDERATIONS Screw liquid chillers are designed to provide safe and re liable service when operated within design specifica tions When operating this equipment use good judgment and follow safety precautions to avoid damage to equip ment and property or injury to personnel Be sure you understand and follow the procedures and safety precautions contained in the machine instruc tions as well as those listed in this guide DANGER DO NOT VENT refrigerant relief devices within a building Outlet from rupture disc or relief valve must be vented outdoors in ac cordance with the latest edition of ANSI ASHRAE 15 American National Standards Institute American Society of Heating Refrigeration and Air Conditioning Engineers The accumulation of refrigerant in an enclosed space can displace oxygen and cause asphyxiation PROVIDE adequate ventilation in accordance with ANSI ASHRAE 15 especially for enclosed and low overhead spaces Inhalation of high concentrations of vapor is harmful and may cause heart ir regularities 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 De composition products are hazardous DO NOT USE OXYGEN to purge lines or to pressurize a machine for any purpose Oxyg
16. 3 x 2 25 76 x 57mm LIFTING HOLE 3 x 2 25 76 x 57 mm SUPPORT PLATE NOTES 1 Each chain must be capable of supporting the entire weight of the machine Maxi mum weight of machine is 22 300 lbs 10 116 Kg 2 Chain lengths shown are typical for 15 ft 4572 mm lifting height Some minor ad justment may be required 3 indicates millimeters CENTER OF GRAVITY APPROXIMATE DIMENSIONS A B Length Width Hmm D am 20 41 42 or 43 Includes marine waterboxes and refrigerant charge MAXIMUM WEIGHT HEAT EXCHANGER SIZE kg Suggested 1 Beam Spreader Bart ENGLISH SI OPTIONS in x lb ft cm x N m 12 x 31 8 530 x 464 10 x 35 525 4 x 511 W12 x 22 W30 x 321 W10 x 25 W25 4 x 365 AON TCarrier recommends that 41 beam spreader bars be field supplied and installed Fig 5 Machine Rigging Guide Frame 4 Machines OIL SEPARATOR SERVICE CLEARANCE 3 0 914 RECOMMENDED OVERHEAD SERVICE CLEARANCE 0 6 152 MINIMUM OVERHEAD SERVICE CLEARANCE OVERHEAD MOTOR SERVICE CLEARANCE 2 610 TUBE REMOVAL SPACE EITHER END 8 2 2515 1 8 5 8 524 mm 2 6 1 8 MIN 765 mm A INCLUDES WATERBOX NOZZLE LENGTH 1 3 MIN SERVICE AREA 381 mm 23XL FRONT VIEW NOZZLE PIPE SIZE A LENGTH OVERALL OVERALL 1Pas 2and3 Pass B WIDTH C HEIGHT in ge 2908 28454212582 2079 5
17. ATOR OIL SEPARATOR SUPPORT FOOT CONDENSER ISOLATION VALVE OPTIONAL OR ACCESSORY CONDENSER OIL LEVEL SWITCH AND CHARGING OIL TEMPERATURE VALVE SUPPLY SENSOR LINE Fig 12 Oil Separator Section Frame 4 Machines 15 796 Install Machine Supports INSTALL STANDARD ISOLATION Figures 13 18 show the position of support plates and shear flex pads that form the standard machine support system INSTALL OPTIONAL OR ACCESSORY ISOLATION if required Uneven floors or other considerations may HEAT EXCHANGER SIZE dictate the use of soleplates and leveling pads Refer to Fig 13 18 Level machine by using jacking screws in isolation sole plates Use a level at least 24 in 600 mm long DIMENSION 20 or 21 0 7 8 0 1 7 8 Win mm fim mm eza P prove mim 0 718 Q2 2 8 7 3 4 SLOT TYP 4 1 3 8 2535 4 1 3 8 1254 1254 VESSELS OUTSIDE EDGE OF CONDENSER TUBESHEET COND _ TYP BOTH ENDS OPTIONAL SOLE PLATE 0 0 1 2 13 COMPRESSOR END EAS NOTES Dimensions in are in millimeters Use grout and package components to establish the level base line See Fig 15 and 16 for additional information 0 3 76 2 OUTSIDE EDGE OF COOLER TUBESHEET TYP BOTH ENDS 0 7 178 Q COOLER 1 0 7 178 0 0 3 8
18. FC 134a HCFC 22 HFC 134a ANSI American National Standards 1080 Institute 592 1569 569 1600 1616 1481 ASHRAE American Society of Heating SER Refrigeration and Air Condition above dry weight includes the pumpout condensing unit weight of 210 Ibs 95 kg ing Engineers OD Outside Diameter UL Underwriters Laboratories Fig 22 Optional Pumpout System and or Storage Tank 796 22 CONDENSER ISOLATION SERVICE VALVES ACCESSORY MOTOR COOLING Il ISOLATION VALVE 11 I SERVICE VALVE TE Hoo ECONOMIZER OPTIONAL Ho d gm HOT GAS BYPASS OPTIONAL MET 11 INI MOTOR COOLING CHARGING ISOLATION VALVE SERVICE VALVE ii SOLATI ET VALVE OPTIONAL ll ECONOMIZER PIPING CHARGING T VALVE We m oo eens Jl COOLER STORAGE REFRIGERANT TANK ISOLATION JZ 2 VALVE T REFRIGERANT COMPRESSOR CHARGING TI T VALVE PUMPOUT te t eo SHH rr COMPRESSOR OIL SUCTION SEPARATOR VALVE ico NX 2 22 NSER EPN E 74 RT SUPPLY RE 7479 aes AND RETURN 29 7 PUMPOUT N ENSER 1 CONDENS ZY __ STORAGE LEGEND MAINTAIN LEAST 2 FT 610 mm gt VENT nasci i SERVICE CLEARANCE 2 A Field Supplied and Installed Piping F
19. NN SEE NOTE 5 1 2 FLARE ELECTRICAL SERVICE E FEMALE ACCESS SPACE SAFETY HEAD T 0 5 7 8 149 3 8 FLAREN R MALE 7 8 48 1a 1 4 337 a i J H L i Hou 5 E 1 LIQUID CONN 1 FEMALE l al 0 10 0 3 3 4 M G 0 9 254 95 229 DIMENSIONS ENGLISH ft in a e 0428 50 0452 507 SI e 428 S175 2997 1448 730 36 945 149 i8 965 39 1442 05 1550 52 4553 4582 1546 826 415 1027 2191 1215 1216 948 1064 86 2172 528 497 1118 1537 NOTES RATED DRY WEIGHT AND REFRIGERANT CAPACITY e Denotes center of gravity ENGLISH Ib Dimensions in are in millimeters The weights and center of gravity values given are for an empty storage tank TANK For additional information on the pumpout unit SIZE see certified drawings The available conduit knockout sizes are MAXIMUM REFRIGERANT CAPACITY Ib UL 1963 HFC 134a a A TRADE SIZE LOCATION top bottom SI kg 1 middle 1 4 middle MAXIMUM REFRIGERANT CAPACITY kg E ASHRAE ANSI 15 UL 1963 LEGEND HCFC 22 H
20. NNECT COMMUNICATION AND CONTROL WIRING FROM STARTER TO POWER PANEL CARRIER COMFORT NETWORK INTERFACE Install Field Insulation 30 FACTORY INSTALLED INSULATION INSTALLATION START UP REQUEST CHECKLIST 1121 char CL 1 CL 2 INTRODUCTION General The 23XL machine is factory assembled wired and leak tested Installation not by Carrier consists prima rily of establishing water and electrical services to the ma chine Rigging installation field wiring and field piping are the responsibility of the contractor and or customer Carrier has no installation responsibilities for the equipment Job Data Necessary information consists of job contract or specifications machine location prints rigging information piping prints and details field wiring drawings starter manufacturer s installation details Carrier certified prints Equipment Required mechanic s tools refrigeration volt ohmmeter and clamp on ammeter leak detector halide or electronic absolute pressure manometer or wet bulb vacuum indicator portable vacuum pumps INSTALLATION Receiving the Machine INSPECT SHIPMENT CAUTION Do not open any valves or break any connections The standard 23XL machine is shipped with a full refriger ant charge Some machines may be shipped with a nitrogen holding charge as an option 1 Inspect for shipping damage while the machine is still on shipping conveyance
21. NOTE Entering water is always the lower of the two nozzles Leaving water is always the upper nozzle for cooler or condenser 6 Water flow switches must be of vapor tight construction and must be installed on top of the pipe in a horizontal run and at least 5 pipe diameters from any bend Differential pressure type flow switches may be con nected at the nozzle of the waterbox 7 Install waterbox vent and drain piping in accordance with individual job data All connections are 34 1 8 Install waterbox drain plugs in the unused waterbox drains and vent openings 9 Install water piping to the optional pumpout system con denser storage tank as shown in Fig 20 25 STAHTER PRESSURE DIFFERENTIAL SWITCH BOX MOUNTED TO WALL MACHINE OR COLUMN COM PRESSURE CONNECTION LOW HIGH 3 8 IN COPPER OR SUITABLE LINE MACHINE WATERBOX NOZZLES FLARED FITTING FOR EASY DISCONNECT TO FLUSH BLEED AND SERVICE COPPER LINES LOW PRESSURE 7 NEEDLE TYPE VALVE FOR SWITCH MAINTENANCE HIGH PRESSURE um INLET DIFFERENTIAL PRESSURE SWITCH PIPE FLANGES THERMOMETERS OPTIONAL PRESSURE GAGES REQUIRED PIPE HANGERS Fig 19 Typical Nozzle Piping 19 COMPRESSOR END DRIVE END Cooler and Condenser Nozzle Arrangements NOZZLE ARRANGEMENT CODES Cooler Condenser Pass Lm pow 1 Code Pes omo
22. X PAD 3 8 10 THK SUPPORT PLATE NOTES 1 Dimensions in are in millimeters 2 Isolation package includes 4 shear flex pads Fig 15 Standard Isolation 7 8 9UNC 4 HOLES FOR JACKING SCREWS SOLE PLATE DETAIL SECTION A A TUBE SHEET JACKING SCREW SEE NOTE NO SUPPORT PLATE FRAMES 1 AND 2 SEE NOTE NO 2 E MEL a i 1 25 5 i SOLEPLATE ER 6 242 22 22 pM gore Se 0 8 1 2 215 9 7 8 9UNC 4 HOLES FOR JACKING SCREWS HRS Hot Rolled Steel NOTES 1 Dimensions in are in millimeters quires accessory spring vibration isolation package 3 Jacking screws to be removed after grout has set Fig 16 Accessory Isolation SUPPORT PLATE ATTACH SECURELY TO SOLEPLATE SPRING SOLEPLATE OPTIONAL RESILIENT SHEAR ISOLATOR ATTACH SECURELY FLEX PAD BONDED TO TO ISOLATOR TOP AND BOTTOM OF SPRING MOUNT NOTE The accessory spring vibration isolation package is supplied by Carrier for installation in the field Fig 17 23XL Accessory Spring Vibration Isolation Shown With Accessory Soleplates 17 LEVEL BASE LINE SEE NOTE NO 4 FLOOR LINE 2 Accessory Carrier supplied field installed soleplate package in cludes 4 soleplates 16 jacking screws and leveling pads Re FRAME 4 4 Thickness of grout will vary depending on the amount necessary to level chiller Use only pre mixed non shrinking
23. ZLE PIPE SIZE in 1 or 3 Passt B WIDTH C HEIGHT Nominal Pipe Size ftin mm ftin mm ftin mm ftin mm 1 Pass 2 Pass 3 Pass 13 794 143 800 76s 230310 98 HEAT EXCHANGER Cooler and Condenser Size A Length With Marine Waterbox Not Shown 1 or 3 Passt 14 95 4512 16 572 Assumes both cooler and condenser nozzles same end of chiller T1 or pass length applies if either or both cooler or condenser is 1 or pass design HEAT EXCHANGER Cooler and Condenser Size Fig 7 23XL Dimensions Frame 4 Machines Table 1 23XL Compressor Weights 23XL COMPRESSOR SIZE Loss Motor UNIT ee b kg 2270 2300 2400 D4 3300 De 3400 Table 2 23XL Component Weights FRAME 1 AND 2 COMPONENT FRAME 4 Oil Separator Economizert Muffler Discharge Piping Pipe Isolation Valvet Adaptor Flange Power Panel Starter Control Center Frame 4 muffler is included in the oil separator weight tOptional Table 3 23XL Motor Weights COMPRESSOR MOTOR CASING AND COVER Size Ib kg ib kg kg c2 0 15 290 14 58 26 X 30 141 0 15 249 141 C4 D4 167 06 280 460 167 LEGEND VI Volumetric Index C2 C6 listed weights are for low voltage motors 200 600 v 04 06 listed weights are for low voltage motors 320 600 v Table 4 23XL Heat Exchanger Weights ENGLISH
24. actory Supplied and Installed Piping Fig 23 Typical Optional Pumpout System Piping Schematic with Storage Tank 23 CONDENSER ISOLATION SERVICE VALVES VALVE OPTION OR ACCESSORY MOTOR COOLING ISOLATION VALVE SERVICE VALVE ECONOMIZER OPTIONAL HOT GAS BYPASS OPTIONAL MOTOR COOLING SERVICE MACHINE vM 12 ISOLATION VALVE VALVE II 1 VALVE COOLER REFRIGERANT 000000000000 ISOLATION VALVE ee COMPRESSOR 1 DISCHARGE JU PUMPOUT VALVE COMPRESSOR OIL SUCTION VALVE SEPARATOR CONDENSER c WATER SUPPLY PUMPOUT CONDENSER LEGEND Field Supplied and Installed Piping Factory Supplied and Installed Piping Fig 24 Typical Optional Pumpout System Piping Schematic without Storage Tank 24 olL RETU RN DISCHARGE VENT VALVE SERVICE CONNECTION VALVE PUMPOUT SUCTION SERVICE i us VALVE VALVE VALVE VASE PUMPOUT gt BOX VALVE WIRING BY CONTRACTOR RELIEF OIL SIGHT VALVE COMPRESSOR GLASS MTG SPRINGS PUMPOUT VLDE REFRIGERANT CONDENSER CONNECTIONS INLET VALVE FIELD INSTALLED Fig 25 Pumpout Unit INSTALL VENT PIPING TO RELIEF DEVICES The 23XL chiller is factory equipped with relief devices on the cooler and condenser shells Refer to Fig 26 and Table 7 Vent relief devices to the outdoors in accordance with ANSI ASHRAE 15 lates
25. alve 24 Condenser 25 Condenser Relief Valves Hidden 26 Take Apart Rabbet Fit Connector Upper 27 Unit Mounted Starter Option 6 25 24 28 22 24 20 28 Machine Identification Nameplate Fig 2 Typical 23XL Installation Frame 1 and 2 Machines FRONT VIEW REAR VIEW 18 19 20 21 0 0 33 EQ 0 9 0 0 p U oJ 7 1 y 32 jp 2 9 e 31 k a 12 30 29 28 27 26 8 25 22 23 24 NOORON Compressor Nameplate Hidden Power Panel Local Interface Display LID Control Center ASME Nameplate Cooler Cooler Vessel Separation Feet Economizer Float Valve Access Cover Hidden Hefrigerant Charging Valve Economizer Filter Assembly Hidden ASME Nameplate Economizer Typical Waterbox Drain Port Take Apart Rabbet Fit Connector ASME Nameplate Condenser Cooler Supply Return End Waterbox Cover Condenser Temperature Sensors Cooler Relief Valve Unit Mounted Starter Option ASME Nameplate Oil Separator Oil Separator Relief Valves Oil Separator Oil Charging Valve Condenser Isolation Valve Option or Accessory Service Valve Cooler Refrigerant Isolation Valve Condenser Re
26. ame 1 and 2 Machines Shown CUSTOMER SUPPLIED REMOTE COMPRESSOR MOTOR TERMINAL Jan 18 L X 18 H X 12 8 1670 AEN 3 PHASE GROUNDING LUGS PROVIDED d RANGE 350 800 ic dh N 2 1 SEF NOTE 2 2 COMP R MOTOR STARTER CIRCUIT BREAKER OR DISCONNECT OPTIONAL i LO 115V CRED 230V NOTE IV D Ince SEE NOTE 3 1 Daal ANNUNCIATOR DEVICE 2 SEE NOTE 3 3 lt V 1PH S0 B0HZ e CUSTOMER SUPPLIED REMOTE ALARM OPTIONAL C 3 3 IMPORTANT Wiring shown is typical and not intended to show detail for a specific installation Refer to certified field wiring diagrams for additional information Certified drawings are available upon request LEGEND Required Power Wiring Required Control Wiring Options Wiring NOTES POWER WIRING T 1 0 Starters shall be designed and manufactured in accordance with Carrier Engineer ing Requirement Z 375 All field supplied conductors devices field installation wiring and termination of conductors and devices must be in compliance with all applicable codes and job specifications The routing of field installed conduit and conductors and the location of field installed devices must not interfere with equipment access or the reading adjust ing or servicing of any component Equipment installation and all starting and cont
27. arter terminals LL1 and LL2 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 trans former primary terminals POWER WIRING BETWEEN STARTER AND COMPRESSOR MOTOR 4 0 Low voltage 600 v or less compressor motors have 12 in terminal studs lead connectors not supplied by Carrier Either 3 or 6 leads must be run between com pressor motor and starter depending on type of motor starter employed If only 3 leads are required jumper motor terminals as follows 1 to 6 2 to 4 3 to 5 Center to center distance between terminals is 2 73 inches Compressor motor starter must have nameplate stamped as to conforming with Carrier requirement Z 375 When more than one conduit is used to run conductors from starter to compressor motor terminal box one conductor from each phase must be in each conduit to prevent excessive heating 0 conductors to motor terminals 1 2 and one conduit and these to 4 5 and 6 in another Compressor motor power connections can be made through top bottom or right side of compressor motor terminal box by rotating the terminal box and using holes cut by contractor to suit conduit Flexible conduit should be used for the last few feet to the terminal box for unit vibration isolation Use of stress cones or 12 conductors larger than 500 MCM may require an oversize spec
28. e grounded by using equip ment grounding lugs provided inside starter enclosure Wye Delta starters require the assembly and the installation of a Top Hat located inside enclosure to provide the required wire bending space for incoming power leads CONTROL WIRING 3 0 3 1 3 2 3 3 3 4 Field supplied control conductors to be at least 18 AWG American Wire Gage or larger Chilled water and condenser water flow switch contacts optional re mote start device contacts and optional spare safety device contacts must have 24 vdc rating Max current is 60 ma nominal current is 10 ma Switches with gold plated bifurcated contacts are recommended Remove jumper wire between 12A and 12B before connecting auxil iary safeties between these terminals Pilot relays can control cooler and condenser pump and tower fan mo tor contactor coil loads rated 10 amps at 115 vac up to 3 amps at 600 vac Control wiring required for Carrier to start pumps and tower fan motors must be provided to assure machine protection If primary pump and tower fan motor control is by other means also provide a parallel means for control by Carrier Do not use starter control transformer as the power source for pilot relay loads Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher Fig 34 23XL Typical Field Wiring with Optional Unit Mounted Starter Fr
29. ecifications or designs without notice and without incurring obligations Book 2 PC 211 Catalog No 532 303 Printed in U S A Form 23XL 2S Pg CL 2 796 9 94 Replaces 23 151 Tab
30. en 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 WARNING DO NOT WELD OR FLAMECUT refrigerant line or vessel until all refrigerant liquid and vapor has been removed from chiller Traces of vapor should be displaced with dry air or nitrogen and the work area should be well ventilated Refrigerant in contact with an open flame produces toxic gases DO NOT USE eyebolts or eyebolt holes to rig machine sections or the entire assembly DO NOT work on high voltage equipment unless you are a quali fied electrician DO NOT WORK ON electrical components including control center switches starters or oil heater until you are sure ALL POWER IS OFF and no residual voltage can leak from capacitors or solid state components LOCK OPEN AND TAG electrical circuits during servicing IF WORK IS INTERRUPTED confirm that all circuits are deenergized be fore resuming work DO NOT syphon refrigerant AVOID SPILLING liquid refrigerant on skin or getting it into the eyes USE SAFETY GOGGLES Wash any spills from the skin with soap and wate
31. es that are attached to the spring isolated machines Connect Piping INSTALL WATER PIPING TO HEAT EXCHANGERS Install piping using job data piping drawings and proce dure outlined below A typical piping installation is shown in Fig 19 CAUTION Factory supplied insulation is not flammable but can be damaged by welding sparks and open flame Protect in sulation with a wet canvas cover A CAUTION Remove chilled and condenser water sensors before weld ing connecting piping to water nozzles Refer to Fig 2 and 3 Replace sensors after welding is complete 1 Ifthe machine is a nozzle in head arrangement offset pipe flanges to permit removal of waterbox cover for main tenance and to provide clearance for pipe cleaning No flanges are necessary with marine waterboxes however water piping should not cross in front of the waterbox or access will be blocked off 2 Provide openings in water piping for required pressure gages and thermometers Openings should be at least 6 to 10 pipe diameters from the waterbox nozzle For thor ough mixing and temperature stabilization wells in the leaving water pipe should extend inside pipe at least 2 in 50 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 information is shown in Fig 20 and 21
32. greater lead separation with less bending In addition the shape of the base of the terminal box is square with symmetrical screw holes on all sides This permits the cover assembly of the box to be oriented on the base frame so that the 45 degree surface mentioned above can be positioned on the top side or bottom for greater adaptation with respect to power lead entry direction Attach power leads to compressor terminals in accordance with job wiring drawings observing caution label in terminal box While holding bottom terminal sta tionary torque top nut to 10 15 ft Ib 13 6 20 3 Nm While holding bottom terminal nut stationary torque top nut down until washer is flat and dome portion is not recognizable 10 15 ft Ib Use only copper conductors The motor must be grounded in accordance with NEC applicable local codes and job wir ing diagrams TO CHILLED WATER PUMP TO CONDENSER WATER PUMP TO COOLING TOWER FAN LEGEND Chilled Water Pump Starter Condenser Water Pump Starter Cooling Tower Fan Starter Chilled Water Pump Condenser Water Pump Disconnect Vents Piping Control Wiring Power Wiring Eb qp qas MAIN COMPRESSOR MOTOR POWER UNIT MOUNTED STARTER s PN c a 3 aS Q P d NOTES 1 PON Wiring and piping shown are for general point of connection o
33. grout Celcote HT 648 or Master Builders 636 0 11 2 38 1 to 0 21 57 thick SIDE VIEW FRONT VIEW NOTE Afield supplied and installed low profile isolation is suggested to keep operation height low Fig 18 Typical Low Profile Isolation Assembly Field Supplied and Installed For adequate and long lasting machine support proper grout selection and placement is essential Carrier recommends that only epoxy type grout be used for machine installation Fol low 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 in structions before starting machine 5 Back jacking screws off leveling pads after grout has hardened INSTALL SPRING ISOLATION Field supplied spring isolators may be placed directly under machine support plates or located under machine soleplates See Fig 17 Consult job data for specific arrangement Low profile spring isola tion assemblies are recommended so that the machine is kept at a convenient working height inside of the tube sheet 18 Obtain specific details on spring mounting and machine weight distribution from job data Also check job data for methods for supporting and isolating pip
34. ial motor terminal box not supplied by Carrier Lead connections between 3 phase motors and their starters must not be insulated until Carrier personnel have checked compressor rotation Compressor motor frame to be grounded in accordance with the National Electrical Code NFPA 70 and applicable codes Means for grounding compressor motor is 2 Thomas and Betts pressure connectors for 350 to 800 MCM wire supplied and lgcatod in the back upper and lower right side corners of the compressor motor terminal box Do not allow motor terminals to support weight of wire cables Use cable supports and strain reliefs as required Use back up wrench when tightening lead connectors to motor terminal studs Torque to 10 15 lb ft maximum 3 5 3 6 3 7 4 4 2 4 3 44 4 5 Fig 35 23XL Typical Field Wiring with Free Standing Starter Frame 1 and 2 Machines Shown Copyright 1994 Carrier Corporation 2 Manufacturer reserves the right to discontinue or change at time specifications or designs without notice and without incurring obligations PC 211 Catalog No 532 303 Printed in U S A Form 23XL 2SI Pg 34 796 9 94 Replaces 23XL 1SI CUT ALONG DOTTED LINE INSTALLATION START UP REQUEST CHECKLIST Machine Model Number 23XL Serial Number To Date Project Name Attn Carrier Job Number The following information provides the status of the chiller installation YES NO DATE TO BE
35. ing cables or slings Do not lift the compressor using threaded eyebolts Metric threaded eyebolts are provided only for lifting individual com pressor castings WARNING Do not attempt to cut refrigeration lines or disconnect flanges or fittings while machine is under pressure Cut ting lines or disconnecting flanges or fittings can result in personal injury or damage to the unit Be sure both refrigerant and oil charge are removed from the ma chine before separating the components IMPORTANT Only a qualified service technician should disassemble and reassemble the machine After reassembly the machine must be dehydrated and leak tested RIG MACHINE COMPONENTS Refer to instructions below Fig 8 12 and Carrier certified prints for machine disassembly CHAIN LENGTH 7 6 2286 mm CHAIN LENGTH 5 0 1524 mm CHAIN LENGTH 4 11 1499 mm LIFTING HOLES 3 x 2 25 76 x 57 mm HEAT EXCHANGER SEPARATION FEET NOTE If the cooler and condenser vessels must be sepa rated the heat exchanger separation feet must be unbolted rotated and rebolted in order to keep each heat exchanger level See Fig 4 5 and 8 12 NOTE Sensor wiring must be disconnected Label each wire before removal see Carrier certified prints Remove all trans ducer and thermistor wires at the sensor Clip all wire ties necessary to remove the wires from the heat ex changers Remove the control wiring and
36. l valves fittings and piping for cor rosion rust leaks or damage PROVIDE A DRAIN connection in the vent line near each pres sure 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 PC 211 Catalog No 532 303 Printed in U S A Form 23XL 2SI Pg 1 9 94 Replaces 23 15 Tab 5e Page SAFETY CONSIDERATIONS 1 INTRODUCTION 2 General 2 Job D ta ede ton 2 Equipment Required 2 2 5 e hte RE ER 2 34 Receiving the Machine 2 INSPECT SHIPMENT IDENTIFY MACHINE e PROVIDE MACHINE PROTECTION Rigging the Machine 4 RIG MACHINE ASSEMBLY RIG MACHINE COMPONENTS Install Machine Supports 16 INSTALL STANDARD ISOLATION INSTALL OPTIONAL OR ACCESSORY ISOLATION INSTALL SPRING ISOLATION Connect Piping 18 INSTALL WATER PIPING TO HEAT EXCHANGERS INSTALL VENT PIPING TO RELIEF DEVICES Make Electrical Connections 25 CONNECT CONTROL INPUTS CONNECT CONTROL OUTPUTS CONNECT STARTER INSULATE MOTOR TERMINALS AND LEAD WIRE ENDS CONNECT POWER WIRE TO OIL HEATER CONTACTOR Frame 1 and 2 CO
37. lace 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 CAUTION 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 com ponents 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 require ments 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 al
38. late voltage and compressor motor RLA rated load amps When 3 conductors are used Minimum ampacity per conductor 1 25 x compressor RLA When 6 conductors are used Minimum ampacity per conductor 0 721 x compressor RLA EE M CONDENSER WATER FLOW SWITCH SEE NOTE 3 1 33 ER CHILLED WATER PUMP MOTOR de NOT BY CARRIER 2 1 2 2 2 3 2 4 OPTIONAL HAND QFF AUT O SW SEE NOTE 3 3 LH Erg WATER NOT BY CARRIER E S CHILLED WATER FLOW SW TCH SEE NOTE 3 1 Lug adapters may be required if installation conditions dictate that con ductors be sized beyond the minimum ampacity required Solid state starters are provided with A Two 2 0 250 MCM lugs provided per phase for power conductor terminations when compressor motor RLA is 400 amps or less B Three 3 250 500 MCM lugs provided per phase for power con ductor terminations when compressor motor RLA is more than 400 amps Wye Delta starters are provided with A Two 2 250 500 MCM lugs provided per phase for power conduc tor terminators when compressor motor RLA is 420 amps or less B Two 2 1 500 MCM lugs provided per phase for power conductor terminations when compressor motor RLA is more than 420 amps Power conductors to starter must enter through top of enclosure Flex ible conduit should be used for the last few feet to the enclosure to provide unit vibration isolation Compressor motor and controls must b
39. lief Valves and Oil Filter Float Chamber Poppet Valve Assembly Motor Cooling Isolation Valve Condenser Condenser Supply Return End Waterbox Cover Cooler Temperature Sensors Machine Identification Nameplate Fig 3 Typical 23XL Installation Frame 4 Machine Rigging the Machine The 23XL can be rigged as an entire assembly It also has flanged connections that allow the compressor cooler condenser and oil separator sections to be separated to fulfill specific installation requirements RIG MACHINE ASSEMBLY See rigging instructions in plastic envelope attached to machine Also refer to rig ging guide Fig 4 and 5 physical data in Fig 6 and 7 and Tables 1 6 Lift machine only from the 3 points indicated in the rigging guide Spreader bar must be used Each lifting cable or chain must be capable of supporting the entire weight of the machine WARNING Lifting machine from points other than those specified may result in serious damage and personal injury Rig ging equipment and procedure must be adequate for machine weight See Tables 1 6 for machine weights NOTE These weights are broken down into component sections for use when installing the unit in sections For complete machine weight add all section components together Total machine weight Table 6 is also sten ciled on the cooler and condenser sections WARNING The compressor is heavy To avoid bodily injury lift the compressor only by us
40. mps and spare alarms as required and indicated on job wiring drawings CONNECT STARTER The 23XL is available with either a unit mounted factory installed starter or a free standing field installed starter Fig 27 and 28 Attach power leads by connecting them from inside the starter cabinet to the line side circuit breaker terminals Machines with electro mechanical starters wye delta will have a top hat shipped with the machine if the RLA is greater than 432 amps The top hat is shipped in the knocked down position and must be assembled and installed on top of the starter cabinet over the line side circuit breaker During assembly remove the access plate and use it as the cover piece of the top hat The top hat provides additional wire bending space to attach line side power leads to the circuit breaker within the starter The solid state starter does not require a top hat 26 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 nding Field Install rter Assemble and in stall compressor terminal box in desired orientation and cut necessary conduit openings in conduit support plates One side of the box has a 45 degree surface next to the 90 degree surface This additional surface permits the power leads to enter the box at an angle which allows
41. nals 2 1 2 2 OPTIONAL REMOTE START DEVICE OPTIONAL SPARE SAFETY DEVICES SEE NOTE 3 1 MACHINE POWER PANEL SUPPLIED BY CARRIER 115 WIRING ONLY 30V WIRING ONLY SEE NOTE 3 5 UN 98 CHILLED WATER FLOW SWITCH SEE NOTE 3 1 CONDENSER WATER FLOW SWITCH SEE NOTE 3 1 db me VOLTAGE SELECTOR SWITCH SEE NOTE 3 5 3 3 Pilot relays can control cooler and condenser pump and tower fan motor contactor coil loads rated 10 amps at 115 vac up to 3 amps at 600 vac Control wiring required for Carrier to start pumps and tower fan motors must be provided to assure machine protection If primary pump and tower fan motor control is by other means also provide a parallel means for control by Carrier D rol trans former wer rce for pilot relay 3 4 Do not route control wiring carrying 30 v or less within a conduit which has wires carrying 50 v or higher or along side wires carrying 50 v or higher Voltage selector switch in machine power panel is factory set for 115 v control power source When 230 v control power source is used set switch to 230 v position Control wiring cables between starter and power panel must be shielded with mini mum rating of 600 v 80 C Ground shield at starter Voltage to terminals LL1 and LL2 comes from a control transformer in a starter built to Carrier specifications Do not connect an outside source of control power to the compressor motor st
42. nes oil reclaim piping hot gas bypass if ap plicable and economizer and economizer piping if appli cable The insulation is 4 in 19 mm thick GROUND DRAIN WIRE DRAIN WIRE DRAIN WIRE DRAIN WIRE BLACK BLACK p BAK BAK WHITE mw Se WHITE RED E n HR PE SEM x RED e E e Re 5179110 9 vA TU Li HET CONNECTION J5 ADDRESS SWITCHES 23XL CHILLER LEGEND Factory Wiring Field Wiring TERMINAL STRIP FIELD SUPPLIED EZX 23XL CHILLER Field supplied terminal strip must be located in the control center Fig 31 Typical COMM1 CCN Communication Wiring for Multiple Chillers 31 CHASSIS GROUND REAR UPPER NETWORK CONNECTION J5 TERMINAL STRIP 7 FIELD SUPPLIED ZJ PSIO 1 ADDRESS O 52 SWITCHES 23XL CHILLER CHASSIS GROUND REAR UPPER NETWORK CONNECTION ndicates factory installed insulation NOTE Waterbox cover insulation must be field supplied and installed Fig 32 23XL Insulation Area for Frame 1 and 2 Machines Indicates factory installed in
43. nly and are not intended to show details for a specific installation Certified field wiring and di mensional diagrams are available on request 23XL machines should be in stalled using certified drawings All wiring must comply with applicable codes Refer to Carrier System Design Manual for details regarding piping techniques Wiring not shown for optional devices such as remote start stop remote alarm optional safety device 4 to 20 mA resets optional remote sensors Fig 27 Typical 23XL with Optional Unit Mounted Starter Frame 1 and 2 Machines 27 POWER 6 Bel d i l TO MOTOR TERMINAL BOX TO CHILLED WATER PUMP 7 11 TO POWER PANEL TO CONDENSER WATER PUMP TO COOLING TOWER FAN M LEGEND NOTES 1 Wiring and piping shown are for general point of connection only and are not 2 intended to show details for a specific installation Certified field wiring and di 3 Cooling Tower Fan Sud mensional diagrams are available on request 23XL machines should be in d Waler Bum stalled using certified drawings 5 _ Chilled Water Pum 2 All wiring must comply with applicable codes 6 42 Disconnect p 3 Refer to Carrier System Design Manual for details regarding piping techniques 7 Freestanding Compressor Motor Starter 4 Wiring not shown for optional devices such as 8 Compressor Motor Terminal Box i sat Stop im Panel Hidden optional safety device dis 4 t
44. o 20 mA resets Cc Piping optional remote sensors Control Wiring Fig 28 Typical 23XL with Free Standing Starter Frame 1 and 2 Machines 28 IMPORTANT Do not insulate terminals until wiring arrangement has been checked and approved by Carrier start up personnel Also make sure correct phas ing is followed for proper motor rotation INSULATE MOTOR TERMINALS AND LEAD WIRE ENDS Insulate compressor motor terminals lead wire ends and electrical wires to prevent moisture condensation and electrical arcing Obtain insulation material from machine shipping package located inside the motor terminal box con sisting of 3 rolls of insulation putty and one roll of vinyl tape 1 Insulate each terminal by wrapping with one layer of in sulation putty 2 Overwrap putty with 4 layers of vinyl tape NOTE Installer is responsible for any damage caused by improper wiring between starter and compressor motor CONNECT POWER WIRE TO OIL HEATER CONTAC TOR FRAME 1 AND 2 Connect control power wiring between the oil heater contactor terminals Fig 29 and terminals LL1 and 112 on the field wiring strip in the compressor motor starter Refer to Fig 29 and wiring label on the chiller power panel WARNING Voltage to terminals LL1 LL2 comes from con trol transformer in a starter built to Carrier specifi cations Do not connect an outside source of control
45. oil heater wiring Frame 1 and 2 machines at the power panel and the main motor leads at the starter lugs before disconnecting the starter from the machine CHAIN LENGTH 7 6 2286 mm BEAM SPREADER LENGTH 11 0 MIN 3353 mm CHAIN LENGTH 4 6 1372 mm LIFTING HOLE 3 x 2 25 76 x 57 mm MACHINE INFORMATION PLATE LOCATION SUPPORT PLATE COOLER CONDENSER Carrier recommends that I Beam Spreader Bars be field supplied and installed NOTES 1 Each chain must be capable of supporting the entire weight of the machine Maxi mum weight of machine is 13 200 lbs 5940 Kg 2 Chain lengths shown are typical for 15 ft 4572 mm lifting height Some minor adjustment may be required CENTER OF GRAVITY APPROXIMATE DIMENSIONS A Length B Width hin mm fein mm 1 330 2 0 609 13200 MAXIMUM WEIGHT Kg 5357 5940 10 or 11 20 or 21 Suggested I Beam Spreader Bar OPTIONS ENGLISH SI in x Ib ft cm x N m 1 512 x 31 8 530 x 464 2 S10 x 35 25 4 x 511 3 W12 x 22 W30 x 321 4 W10 x 25 W25 4 x 365 Fig 4 Machine Rigging Guide Frame 1 and 2 Machines 796 CHAIN LENGTH 7 11 2413 l BEAM SPREADER BAR LENGTH 11 0 3352 8 MIN CHAIN LENGTH 7 11 2413 CHAIN LENGTH 5 7 7 8 1724 mm LIFTING HOLE 2 13 x 2 87 54 1 x 72 9 mm CHAIN LENGTH 3 10 1168 4 CHAIN LENGTH 4 7 1 2 1409 7 LIFTING HOLE
46. olt motor support foot Fig 10 7 Rig compressor T il r Machines Refer to Fig 12 unless otherwise specified 1 Separate the compressor and oil separator by disconnect ing the following a discharge flange from compressor secure the check valve See Fig 11 b oil supply line from separator to compressor are from ndenser Frame 4 pue 4 1xez 6 HOSN3S 5NIdld 3NI1SvV9 JAVA 5NI 1009 HOLON HO LON WIV103H 110 uU3ZIWONOO3 GION3 10S ASVAYONI S3A1VA QION3 10S IX TWNOLLdO 3ATVA GION310S SHOLO3NNOO o Ei SHOLO3NNOO 1 1 I388VH ADNAAVOS E 110 QVNOILdO H31HVIS Q31NnONN LINN 1 3unssaud SIS 3oONv14 HOIH 3OHVHOSIG u3ldvav 3NI1HOLO3f 3 INIV1O3H OL HOdVA HOLON 35uVvHOSId H3JSN3QONOO SYNLVHAdWAL dWns 10 LINGNOO HOLIMS ALSAVS T3A31 10 YALVSH 10 13 p 4 1Xez 01 bis HOSN3IS HOSNHS JYNLVYHAdWSAL JIN 3univH3dW3l 0334 GNVHOLIMS SNIIOOO SNITOOO H31VM H3SN3ONOO ainonuaToo9 991114 10 AL3JVS T3A31 110 HOLOW HOLOW HOSN3S 10 3univuddWa3L JN H31VM H3SN3UNOO AlddNs 10 7
47. parate compressor by disconnecting the following a discharge flange from compressor remove the check valve b oil supply line to compressor and associated solenoid valve wiring Cover all openings 5 Be sure all wiring is properly marked Detach all trans ducers switches and sensor wires Remove all wire ties required to remove wires from the cooler to the con denser Do not cut the wires 6 Disconnect the rabbet fit connectors on the tube sheets 7 Rig vessels apart To Separate Compressor from Cooler Frame 4 Machines 1 Unbolt the suction flange Fig 11 2 Disconnect the following lines a motor cooling to motor Fig 10 b motor cooling drain Fig 11 12 c optional economizer gas line to compressor rotors Fig 10 d liquid injection to compressor Fig 10 3 Separate compressor from oil supply system by discon necting the following a discharge flange from compressor and remove check valve Fig 10 b oil supply line to compressor and associated solenoid valve wiring Fig 10 Cover all openings 5 Be sure the following electrical connections disconnected a motor power cables from optional unit mounted starter lugs not shown b motor winding temperature sensor Fig 10 c slide valve increase and decrease capacity control so lenoid valves Fig 10 d optional variable VI solenoid valves Fig 10 e discharge condenser pressure transducer Fig 10 6 Unb
48. r If liquid refrigerant enters the eyes IMME DIATELY FLUSH EYES with water and consult a physician 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 ma chine is under pressure or while machine is running Be sure pres sure 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 Re p
49. rol devices must comply with de tails in equipment submittal drawings and literature Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down WARNING Do not use aluminum conductors Installer is responsible for any damage caused by improper wiring between starter and machine 1 1 1 2 1 3 1 4 1 5 1 6 TARTER 2 0 Power conductor rating must meet minimum unit nameplate voltage and compres sor motor RLA rated load amps When 3 conductors are used Minimum ampacity per conductor 1 25 x compressor RLA When 6 conductors are used Minimum ampacity per conductor 0 721 x compressor RLA Lug adapters may be required if installation conditions dictate that conductors be sized beyond the minimum ampacity required Contact starter supplier for lug information Compressor motor and controls must be grounded by using equipment grounding lugs provided inside starter enclosure CONTROL WIRING 3 0 Field supplied control conductors to be at least 18 AWG American Wire Gage or larger 3 1 Chilled water and condenser water flow switch contacts optional remote start device contacts and optional spare safety device contacts must have 24 vdc rating Max current is 60 ma nominal current is 10 ma Switches with gold plated biurcated contacts are recommended 3 2 Remove jumper wire between 12A and 12B before connecting auxiliary safeties be tween these termi
50. rotors Fig 9 11 3 Separate compressor from oil supply system by discon necting the following a discharge flange from compressor and remove check valve Fig 8 b oil supply line to compressor and associated solenoid valve wiring Fig 8 and 9 c oil scavenging sump vent to compressor Fig 8 and 9 4 Cover all openings 5 Be sure the following electrical connections are disconnected a motor power cables from optional unit mounted starter lugs not shown b motor winding temperature sensor Fig 9 c slide valve increase and decrease capacity control so lenoid valves Fig 9 d optional variable VI solenoid valves Fig 9 e discharge condenser pressure transducer Fig 8 6 Unbolt motor support foot Fig 8 7 Rig compressor To Separate Oil Separator from Condenser Frame 1 and 2 Machines 1 Separate the compressor and oil separator by disconnect ing the following a discharge flange from compressor and remove check valve Fig 8 b oil feed from separator to sump Fig 9 c oil scavenging sump vent to compressor Fig 8 and 9 d oil sump relief to separator Fig 8 2 Unbolt the discharge adaptor flange from the condenser Fig 9 3 Cover all openings 4 Be sure the following electrical connections are disconnected a high discharge pressure cutout switch Fig 8 5 Unbolt the four securing bolts from the bottom of the oil separator Fig 8 and 9
51. s 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 5096 c 7596 d 100 5 The refrigerant charge is at the machine 6 Services such as electrical power and control air will be avail able at start up 7 electrical and mechanical representatives will be available to assist in commissioning the machine 8 customer s operators will be available to receive instruc tions 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 Beeper 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 or damaged during rigging or shipping Signature of Purchaser Signature of Job Site Supervisor Copyright 1994 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time sp
52. sulation NOTE Waterbox cover insulation must be field supplied and installed Fig 33 23XL Insulation Area for Frame 4 Machines 796 32 OPTIONAL REMOTE START DEVICE SEE NOTE 3 1 OPTIONAL SPARE SAFETY DEVICES SEE NOTE 3 1 L CUSTOMER SUPPLIED REMOTE ALARM OPTIONAL SEE NOTE 3 3 IMPORTANT Refer to certified drawings for addi tional information Certified drawings are available upon request LEGEND Required Power Wiring Required Control Wiring Options Wiring NOTES l 1 0 1 1 1 2 1 3 1 4 1 5 2 0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z 375 All field supplied conductors devices field installation wiring and ter mination of conductors and devices must be in compliance with all applicable codes and job specifications 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 Equipment installation and all starting and control devices must com ply with details in equipment submittal drawings and literature Contacts and switches are shown in the position they would assume with the circuit deenergized and the chiller shut down WARNING Do not use aluminum conductors POWER WIRING TO STARTER Power conductor rating must meet minimum unit namep
53. t addition Safety Code for Mechanical Refrigeration and all other applicable codes To ensure relief valve serviceability and to fulfill ASHRAE 15 latest edition 3 way valves and redundant re lief valves are installed See Fig 26 Only one half of the total number of relief valves listed in Table 7 are in service at any time DANGER Refrigerant discharged into confined spaces can dis place oxygen and cause asphyxiation 1 If relief devices are manifolded the cross sectional area of the relief pipe must at least equal the sum of the areas required for individual relief pipes 2 Provide a pipe plug near outlet side of each relief device for leak testing Provide pipe fittings that allow vent pip ing 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 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 Make Electrical Connections Field wiring must be installed in accordance with job wiring diagrams and all applicable electrical codes 25 CAUTION Do not run 120 v wiring into the control center The control center should only be used for additional extra low voltage wiring 50
54. t relay 3C terminal No 4 Then connect the red and yellow wires together with splice connector CARRIER COMFORT NETWORK INTERFACE The Carrier Comfort Network CCN communication bus wiring is supplied and installed by the controls electrical contractor if required The wiring 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 30 for location of the CCN network connector on the processor module NETWORK SENSOR BUS CONNECTOR CONNECTOR COMM 1 COMM 3 PROCESSOR MODULE Fig 30 Carrier Comfort Network Communication Bus Wiring NOTE Conductors and drain wire must be 20 AWG American Wire Gage minimum stranded tinned cop per Individual conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 10046 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operat ing temperature range of 4 F to 140 20 C to 60 C is required See table below for cables that meet the requirements MANUFACTURER CABLE NO Alpha 2413 or 5463 American A22503 Belden 8772
55. to the lowered position Fig 8 2 Disconnect and or cut the following lines a cooler liquid feed Fig 8 b condenser refrigerant vapor to oil reclaim ejector Fig 9 c motor cooling supply from condenser Fig 9 d optional hot gas bypass and associated solenoid valve wiring not shown 3 Separate compressor from oil supply system by discon necting the following a discharge flange from compressor and remove check valve Fig 8 b oil supply line to compressor and associated solenoid valve wiring Fig 8 c oil scavenging sump vent to compressor Fig 8 and 9 4 Cover all openings 5 Be sure all wiring is properly marked Detach all trans ducers switches and sensor wires Remove all wire ties required to remove wires from the cooler to the con denser Do not cut the wires 6 Disconnect the rabbet fit connectors on the tube sheets Fig 9 7 Rig vessels apart r ler Frame 1 and 2 from WARNING The compressor is heavy To avoid bodily injury lift the compressor only by using cables or slings Do not lift the compressor using threaded eyebolts The metric threaded eyebolts are provided only for lifting indi vidual compressor castings Unbolt the suction flange Fig 8 2 Disconnect the following lines a oil reclaim to compressor Fig 9 motor cooling to motor Fig 9 motor cooling drain Fig 9 optional economizer gas line to compressor

Carrier 23 XL Refrigerator User Manual

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