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Carrier 23 XL manual

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Table of contents for the manual

  • Page 1

    Installation Instructions SAFETY CONSIDERA TIONS 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[...]

  • Page 2

    CONTENTS Page SAFETY CONSIDERA TIONS ...................1 INTRODUCTION ..............................2 General ......................................2 Job Data ....................................2 Equipment Required .........................2 INST ALLA TION ............................. 2-34 Receiving the Machine .......................2 • INSPE[...]

  • Page 3

    FRONT VIEW REAR VIEW F i g .2—T ypical 23XL Installation (Frame 1 and 2 Machines) 1— Power Panel 2— Local Interface Display (LID) Control Center 3— ASME Nameplate, Cooler 4— Cooler Refrigerant Isolation V alve 5— ASME Nameplate, Economizer (Hidden) 6— Service V alve 7— T ake-Apart Rabbet Fit Connector (Lower) 8— Cooler T emperatur[...]

  • Page 4

    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 ASSEMBL Y — See rigging instructions in plastic envelope attached to machine. Also refer to[...]

  • Page 5

    The compressor is heavy. To avoid bodily injury, lift the compressor only by using cables or slings. Do not lift the compressor using threaded eyebolts. Metric threaded eyebolts are provided only for lifting individual com- pressor castings. IMPOR T ANT : Only a qualified service technician should disassemble and reassemble the machine. After reas[...]

  • Page 6

    NOTES: 1. Each chain must be capable of supporting the entire weight of the machine. Maxi- mum weight of machine is 22,300 lbs (10,1 16 Kg). 2. Chain lengths shown are typical for 15 ft (4572 mm) lifting height. Some minor ad- justment may be required. 3. [ ] indicates millimeters. HEA T EXCHANGER SIZE CENTER OF GRA VITY — APPROXIMA TE DIMENSIONS[...]

  • Page 7

    HEA T EXCHANGER SIZE A (LENGTH) OVERALL B (WIDTH) OVERALL C (HEIGHT) NOZZLE PIPE SIZE (in.) 1 Pass 2 and 3 Pass* ft-in. mm ft-in. mm ft-in. mm ft-in. mm 1-Pass 2 and 3-Pass 10 or 1 1 9-5 2870 9-6 1 ⁄ 2 2908 4- 9 1 ⁄ 4 1454 6- 9 5 ⁄ 8 2073 6 6 20 or 21 4-1 1 1499 6-1 1 3 ⁄ 8 21 18 8 6 *2 and 3-pass length applies if either (or both) cooler o[...]

  • Page 8

    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 (NFP A) 70, and local safety codes. 3. A minimum 6 in. [...]

  • Page 9

    T able 1 — 23XL Compressor W eights 23XL UNIT COMPRESSOR SIZE (T ons) ASSEMBL Y (Less Motor) lb kg Frame 1 C2 2270 1029 C4 2300 1043 Frame 2 C6 2400 1088 Frame 4 D4 3300 1497 D6 3400 1542 T able 2 — 23XL Component W eights COMPONENT FRAME 1 AND 2 FRAME 4 lb kg lb kg Oil Separator 1 180 535 2880* 1306* Economizer† 296 134 560 254 Muff ler 170 [...]

  • Page 10

    T able 5A — 23XL W aterbox Cover W eights (Frame 1 and 2 Machines)* HEA T EXCHANGER W A TERBOX DESCRIPTION PSI (kPa) FRAME 1 FRAME 2 lbs kg lbs kg Cooler or Condenser NIH, 1 Pass 150 (1034) 1 18 54 128 58 NIH, 2 Pass (Plain) 100 46 148 67 NIH, 2 Pass (With Pipe Nozzles) 185 84 200 91 NIH, 3 Pass 150 (1034) 166 76 180 82 LEGEND NIH — Nozzle-In-H[...]

  • Page 11

    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 o Separate Cooler and Condens[...]

  • Page 12

    Refer to Fig. 10 unless otherwise specified. 1. T urn all 4 vessel separation feet to the lowered position (Fig. 1 1). 2. Disconnect and/or cut the following lines, as required: a. cooler liquid feed. b. motor cooling supply from condenser . c. liquid injection to compressor . d. bubble line to float chamber (not shown). e. optional hot gas bypas[...]

  • Page 13

    Fig. 9 — 23XL T op View (Frame 1 and 2 Machines) 13[...]

  • Page 14

    Fig. 10 — 23XL T op View (Frame 4 Machines) 14[...]

  • Page 15

    2. Cover all openings. 3. Be sure the switches, sensor , and transducers are disconnected. 4. Cut oil separator from its support foot. 5. Rig oil separator . Additional Notes For Frame 1, 2, and 4 Machines: 1. Use silicon grease on new O-rings when refitting. 2. Use gasket sealant on new gaskets when refitting. 3. Cooler and condenser may be vert[...]

  • Page 16

    Install Machine Supports INST ALL ST ANDARD ISOLA TION — Figures 13-18 show the position of support plates and shear flex pads that form the standard machine support system. INST ALL OPTIONAL OR ACCESSOR Y ISOLA TION (if required) — Uneven floors or other considerations may dictate the use of soleplates and leveling pads. Refer to Fig. 13-18.[...]

  • Page 17

    NOTES: 1. Dimensions in ( ) are in millimeters. 2. Isolation package includes 4 shear flex pads. Fig. 15 — Standard Isolation HRS — Hot Rolled Steel NOTES: 1. Dimensions in ( ) are in millimeters. 2. Accessory (Carrier supplied, field installed) soleplate package in- cludes 4 soleplates, 16 jacking screws and leveling pads. Re- quires accesso[...]

  • Page 18

    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 [...]

  • Page 19

    Fig. 19 — T ypical Nozzle Piping 19[...]

  • Page 20

    Cooler and Condenser Nozzle Arrangements NOZZLE ARRANGEMENT CODES Cooler Condenser Pass In Out Code Pass In Out Code 1 12 A 1 1 1 12 J 21 B 1 2 1 1 K 2 34 C 2 13 14 L 56 D 1 5 1 6 M 3 78 E 3 17 18 N 9 10 F 19 20 P W aterbox Nozzle Sizes FRAME P ASS NOMINAL PIPE SIZE (in.) ACTUAL PIPE ID (in.) Cooler and Condenser Cooler and Condenser 1 1 6 6.065 2 [...]

  • Page 21

    Cooler and Condenser Nozzle Arrangements NOZZLE ARRANGEMENT CODES Cooler Condenser Pass In Out Code Pass In Out Code 1 85 A 1 11 2 P 58 B 2 1 1 Q 2 79 C 2 10 12 R 46 D 1 3 S 3 76 E 3 10 3 T 4 9 F 1 12 U W aterbox Nozzle Sizes FRAME P ASS NOMINAL PIPE SIZE (in.) ACTUAL PIPE ID (in.) Cooler and Condenser Cooler and Condenser 4* 1 10 10.020 2 8 7.981 [...]

  • Page 22

    DIMENSIONS ENGLISH (ft-in.) T ANK SIZE A B C D E F G H J K L M N P R S T 0428 10- 5 9-10 4-9 2-4 3 ⁄ 4 1-2 3 ⁄ 8 3-1 3 ⁄ 16 4-1 1 3-8 1 ⁄ 8 3- 8 2-9 7 ⁄ 16 3-2 0-3 1 ⁄ 2 4-8 3 ⁄ 4 1-7 7 ⁄ 8 1-7 5 ⁄ 16 3-7 3 ⁄ 4 5-0 1 ⁄ 4 0452 14-1 1 1 ⁄ 4 14- 4 1 ⁄ 2 5-0 7 ⁄ 8 2-8 1 ⁄ 2 1-4 1 ⁄ 4 3-4 7 ⁄ 16 7- 2 1 ⁄ 4 4-0 3-1 1 7[...]

  • Page 23

    LEGEND Hidden Piping Field Supplied and Installed Piping Factory Supplied and Installed Piping Fig. 23 — T ypical Optional Pumpout System Piping Schematic with Storage T ank 23[...]

  • Page 24

    LEGEND Field Supplied and Installed Piping Factory Supplied and Installed Piping Fig. 24 — T ypical Optional Pumpout System Piping Schematic without Storage T ank 24[...]

  • Page 25

    INST ALL 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 T able 7. V ent relief devices to the outdoors in accordance with ANSI/ ASHRAE-15 (latest addition) Safety Code for Mechanical Refrigeration and all other applicable codes. T o ensure relief va[...]

  • Page 26

    CONNECT CONTROL INPUTS — Connect the control in- put wiring from the chilled and condenser water flow switches to the starter terminal strip. W iring 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 spec[...]

  • Page 27

    LEGEND 1— Chilled W ater Pump Starter 2— Condenser W ater Pump Starter 3— Cooling T ower Fan Starter 4— Chilled W ater Pump 5— Condenser W ater Pump 6— Disconnect 7— V ents Piping Control Wiring Power Wiring NOTES: 1. Wiring and piping shown are for general point-of-connection only and are not intended to show details for a specific [...]

  • Page 28

    LEGEND 1— Chilled W ater Pump Starter 2— Condenser W ater Pump Starter 3— Cooling T ower Fan Starter 4— Condenser W ater Pump 5— Chilled W ater Pump 6— Disconnect 7— Freestanding Compressor Motor Starter 8— Compressor Motor T erminal Box 9— Power Panel (Hidden) 1 0— V ents Piping Control Wiring Power Wiring NOTES: 1. Wiring and [...]

  • Page 29

    IMPOR T ANT : 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. INSULA TE MOTOR TERMINALS AND LEAD WIRE ENDS — Insulate compressor motor terminals, lead wire ends, and electrical wires to prevent moisture condensa[...]

  • Page 30

    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: SIGNAL TYPE CCN BUS CONDUCTOR INSULA TION COLOR COMM1 PLUG PIN NO. + Red 1 Ground White 2 − Black 3 If a cable with a dif ferent color scheme i[...]

  • Page 31

    LEGEND Factory Wiring Field Wiring *Field supplied terminal strip must be located in the control center . Fig. 31 — T ypical COMM1 CCN Communication Wiring for Multiple Chillers 23XL CHILLER 23XL CHILLER 23XL CHILLER 31[...]

  • Page 32

    Fig. 32 — 23XL Insulation Area for Frame 1 and 2 Machines Fig. 33 — 23XL Insulation Area for Frame 4 Machines 796 32 → →[...]

  • Page 33

    IMPOR T ANT : Refer to certified drawings for addi- tional information. Certified drawings are available upon request. LEGEND Required Power Wiring Required Control Wiring Options Wiring NOTES: I. GENERAL 1.0 Starters shall be designed and manufactured in accordance with Carrier Engineering Requirement Z-375. 1.1 All field-supplied conductors, d[...]

  • Page 34

    IMPORT ANT : 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 Options Wiring Required Control Wiring NOTES: I. GENERAL 1.0 Starters shall be designed and manufacture[...]

  • Page 35

    INST ALLA TION ST ART -UP REQUEST CHECKLIST Machine Model Number: 23XL Serial Number: To : Attn: Date Project Name Carrier Job Number The following information provides the status of the chiller installation. YES/NO (N/A) DA TE TO BE COMPLETED 1. The machine is level. 2. The machine components are installed and connected in accordance with the inst[...]

  • Page 36

    TESTING YES/NO DA TE TO BE COMPLETED 1. The cooling tower fan has been checked for blade pitch and proper operation. 2. The chilled water and condenser water lines have been: a. Filled b. T ested c. Flushed d. V ented e. Strainers cleaned 3. The chilled water and condenser water pumps have been checked for proper rotation and flow . 4. The followi[...]