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Carrier HFC-134A manual

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  • Page 1

    Manufacturer reserves the right to disco ntinue, or change at any time, specifications or de signs without notice and without inc urring obligations. Catalog No . 532-309 Printed in U. S.A. Fo rm 23XRV -1SI Pg 1 309 6-06 Replaces: New Book 2 Ta b 5 e Installation Instr uctions SAFETY CONSIDERA TIONS Screw liquid c hillers are de signed to pr o vide[...]

  • Page 2

    2 CONTENTS Page SAFETY CONSIDERA TIONS . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Job Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 3

    3 Identifying the Drive by Part Number — Each LiquiFlo™ 2.0 AC drive can be identified by its part number . See Fig. 5. This number appears on the shipping label and on the VFD nameplate. Drive Input Component Location — Figur e 6 identifies the control center components. Identifying the Power Module by I.D. Number — Each Liqui- Flo 2.0 AC [...]

  • Page 4

    4 20 19 18 17 16 15 14 1 3 12 11 10 9 8 7 6 5 4 3 2 1 21 22 23 24 25 26 27 28 29 30 32 31 33 35 34 36 37 38 39 40 41 50 49 48 47 46 45 51 44 43 42 1— Motor T erminal Cover Plate 2— V a riable F requency Dr ive 3— Internation al Chiller Visual Controller (ICVC) 4— Discharge Pipe Relief V alve 5— Condenser 6— Oil Reclaim Actuator 7— V a[...]

  • Page 5

    5 7 6 4 2 1 3 5 8 9 19 18 17 16 15 14 11 10 12 1 3 20 Fig. 4 — Typical 23XRV Installation (Sens or Locations) 1— Condenser Pressure 2— Evaporator Pressure 3— Compressor Discharge T emperature 4— Compressor Discharge Pressure 5— Compressor Discharge High Pressure Switch 6— Compressor Motor Win ding T emperature (Hidden) 7— Evaporator[...]

  • Page 6

    6 4 3 1 8 6 1 7 1 8 1 9 1 1 2 3 7 6 6 5 2 1 1 1 5 1 6 1 8 9 0 1 4 1 8 21 0 2 Fig. 6 — Control Center Components 1— Input Inductor Assembly 12 — Fuse, Class CC, 600V , 1A (3) 2— Capacitor Bank Assembly 13 — T ransformer , 3kV A 3— Pre-Charge Resistor Assembly 14 — Line Sync PC Board Assembly 4— AC Contactor (3) 15 — Line Sync Board[...]

  • Page 7

    7 CHAIN “B” ( S EE NO TE #2) CHAIN “C” ( S EE NO TE #2) CHAIN “D” ( S EE NO TE #2) 15´-0´´ MIN. HEIGHT ABO VE FLOOR “E” “F” “A” Fig. 7 — Mach ine Ele ctrical Data Nameplate *The 11th character of the chiller model numb er indicate s the fr ame siz e of the compressor . HEA T EXHANGER CODE COMPRESSOR FRAME SIZE * MAXIMUM[...]

  • Page 8

    8 Table 1 — Drive Assembly and Power Modul e Ratings *110% output current capability for one minute, 150% output current f or 5 seconds. Table 2 — 23XRV Dimensions (Nozzle-In-Head Wa terbox) *Assumes both cooler and condenser nozzles on same end of chiller . †1 or 3 pass length applies if either (or both) cooler or condenser is a 1 or 3 pass [...]

  • Page 9

    9 Table 3 — 23XRV Dimensions (Marine Waterbox) *Assumes both cooler and condenser nozzles on same end of chiller . †1 or 3 pass length applies if c ooler is a 1 or 3 pass design. NO TES: 1. Ser vice access should be provided per American Society of Heating, Refr igeration, and Air Conditioning Engineers (ASHRAE) 15, latest edition, Nati onal Fi[...]

  • Page 10

    10 Table 7 — 23XRV Heat Excha nger Data *Rigging weights are f or standard tubes of standard wall th ickness (T urbo-B3 and Spikefin 2, 0.025 -in. [0.635 mm] wall ). NO TES: 1. Cooler includes the suction elbo w and 1 / 2 the distrib ution piping w eight. 2. Condenser includes floa t valv e and sump, discharge stu b-out, and 1 / 2 the distribut i[...]

  • Page 11

    11 Table 8B — 23XRV Additional Dat a for Condenser Marine Waterbox es * *Add to heat e xchanger data f or total weights or volumes . NO TES: 1. W eight adder sho w n is the same f or cooler and condenser of equal fra me size. 2. F or the total weight of a v essel with a marine waterbox, add these v alues to the heat exchanger we ights (or volu me[...]

  • Page 12

    12 MOT OR TEMPERA TURE CABLE CONTROL PA N E L V APORIZER HTR CONDUIT OIL HEA TER CONDUIT OIL PUMP CONDUIT OIL S UMP TEMP . CABLE OIL S UMP PRE SS . CABLE OIL PRE SS . CABLE OIL RECLAIM ACTU A TOR CABLE HGBP CONDUIT (OPTIONAL) CONDEN S ER PRE SS URE CABLE W A TER S EN S OR CABLE S FOR NOZZLE ARRANGEMENT S A,B,C ,E,F ,P ,Q,R,T ,&U ( S AME FOR OTH[...]

  • Page 13

    13 Separate Mac hine Components — The design of the 23XR V allows for disassembly at the job site so that individual components may be moved through existing door- ways. Use the following procedur es to separate the machine components. Suggested locations to cut piping will minimize the width of the condenser/economizer assembly . SEPARATE COOLER[...]

  • Page 14

    14 9. Cut the vaporizer refrigerant return line as shown. 10. Disconnect all sensors with cables that cross from the condenser side of the machine to the cooler side including: a. Evaporator refrigerant liquid temperature sensor . See Fig. 13. b. Entering and l eaving chiller liquid te mperature sensors. See Fig. 14. c. Evaporator pressure sensor .[...]

  • Page 15

    15 3. Remove the nuts that secure the terminal box transition piece to the motor housing. 4. Disconnect the motor leads from the motor terminals (Fig. 17). Note the position of the motor terminal cable lugs so they can be reinstalled with suf ficient clearance away from surrounding structure. 5. Remove the motor temperature sensor leads (Fig. 17), [...]

  • Page 16

    16 Lifting the Control Center — Care should be used to prevent damage due to dropping or jolting when moving the control center . A fork truck or similar means of lifting and transporting may be used. Sling in a manner that will equalize the load at the pickup points. Use a spreader bar if the angle of the sling is less than 45 degrees relative t[...]

  • Page 17

    17 SEP ARA TE THE COMPRESSOR FROM THE CONDENSER The VFD blocks access to the compressor mounting bolts. It must be removed before th e compressor can be separated from the condenser . See instruc tions to remove the VFD from the condenser . Refer to T able 10. Do not rig the condenser before the control center and compressor are removed. The conden[...]

  • Page 18

    18 Table 10 — Comp ressor Fastener Ide ntification 1. Disconnect the oil supply line in two places (Fig. 23). Cap the oil lines and fittings. NOTE: Compressor oil lines and fittings between the oil filter and compressor must be kept extremely clean to prevent obstruction of the compressor inlet bearing oil orifice. Cap all orifice lines and fitti[...]

  • Page 19

    19 SEP ARA TE THE V APORIZE R FROM THE CON- DE NS ER — The VFD mounting brackets (Fig. 24) extend beyond the outboard edge of the vaporizer . The vaporizer extends beyond the perimeter of the condenser tubesheet. 1. Cut the vaporizer hot gas supply line near the oil concen- trator (Fig. 24). 2. Cut the vaporizer hot gas return line (Fig. 24). 3. [...]

  • Page 20

    20 OIL SUPPL Y LINE V APORIZER OIL PUMP OIL FIL TER V APORIZER HOT GAS RETURN LINE OIL RECLAIM LINE OIL SUMP OIL PRESSURE REGULA TOR ISOLA TION VA LV E OIL PRESSURE REGULA TOR V AL VE V APORIZER HOT GAS SUPPL Y LINE V APORIZER VENT LINE BEARING OIL DRAIN LINE Fig. 25 — Oil Reclaim Piping a23-1574 OIL S UMP PRE SS URE S EN S OR OIL PUMP/OIL FIL TE[...]

  • Page 21

    21 MO T OR LEAD S CONTROL CENTER TERMINAL ENCLO S URE FRAME THERMAL IN S ULA T OR IN S ULA TION FRAME A SS EMBL Y TERMINAL BO X FRAME COMPRE SS OR FOAM IN S ULA TION TERMINAL BO X MOUNTING S TUD - DO NO T EXCEED 120 FT -LB TORQUE T1 T2 T 3 TERMINAL ENCLO S URE FRAME M OTOR TEMPERA TURE S EN S OR TERMINAL BLOCK PRO TECTIVE EARTH (PE) GROUND CONNECTI[...]

  • Page 22

    22 Insulate Motor T e rminals and Lead W ire Ends — Locate heat shrink tubing (RCD P/N LF33MM1 14) over power connections so that they are completely covered and tubing is against motor housing. Shrink into position. Slide foam tubing (3 in. inner diameter closed cell vinyl, neoprene, or nitrile foam) pa rt way over the heat shrink tubing. Apply [...]

  • Page 23

    23 INST ALL ACCESSOR Y ISOLA TION (if required) — U n- even floors or other considerations may dictate the use of accessory soleplates (supplied by Carrier for field installation) and leveling pads. Refer to Fig. 33. Level machine by using jacking screws in isolation sole- plates. Use a level at least 24-in. (610 mm) long. For adequate and long l[...]

  • Page 24

    24 5. Remove jacking screws fr om leveling pads after grout has hardened. INST ALL SPRING ISOLA TIO N Spring isolation may be purchased as an accessory from Carrier for field installation. It may also be field supplied and installed. Spring isolators may be placed directly under machine support plates or located under machine soleplates. See Fig. 3[...]

  • Page 25

    25 12 11 10 9 8 7 DI S CHARGE END S UCTION END 6 5 4 3 2 1 CONDEN S ER CONDEN S ER COOLER COOLER NOZZLE-IN HEAD WATERBOXES FRAME 3 FRAMES 4 AND 5 NOZZLE ARRANGEMENT CODES FOR ALL 23XR V NOZZLE-IN-HEAD W A TERBO XES Fig. 36 — Piping Flow Data (NIH, Frames 3 Through 5) *Refer to certified drawings. PA S S COOLER W A TERBOXES In Out Arrang ement Cod[...]

  • Page 26

    26 NOZZLE ARRANGEMENT CODES PA S S COOLER W A TERBOXES CONDENSER W A TERBOXES In Out Arrangement Code In Out Arrangement Code 1 8 5A — — — 5 8 B— — — 2 79 C 1 0 1 2 R 46 D 1 3 S 3 76 E — — — 49 F — — — Fig. 17 — Piping Flow Data (MWB, Frames 2 and 3) MARINE W A TERBOXES FRAMES 4 AND 5 NOZZLE ARRANGEMENT CODES PA S S COOLER[...]

  • Page 27

    27 LEVEL GAGE 0' - 5 1/2" [140mm] PRE SS URE GAGE 3 /8" MALE FLARE RELIEF V AL VE CONN. 1/2" DIA. K.O. ELECTRICAL CONN. (PUMPOUT POWER) 1' - 7 " [48 3 mm] 0' - 5 7/8 " [149mm] (2) 1" NPT RELIEF V AL VE OUTLET ( S EE FIELD IN S T ALLA TION NOTE S ) 0' - 9 " [229mm] TYPICAL B T R E D W 0'- 9[...]

  • Page 28

    28 RA TED DR Y WEIGHT AND REFRIGERAN T CAP ACITY ENGLISH (lb) SI (kg) T ANK SIZE T ANK OD (in.) DR Y WEIGHT * (lb) R-134a MAXIMUM REFRIGERANT CAP ACITY (lb) ANSI/ASHRAE 15 UL 1963 0428 24.00 2334 1 8 60 1716 0452 27.25 3414 3563 32 8 6 TA N K SIZE T ANK OD (mm) DR Y WEIGHT * (kg) R-134a MAXIMUM REFRIGERANT CAP ACITY (kg) ANSI/ASHRAE 15 UL 1963 0428[...]

  • Page 29

    29 COOLER CONTROL CENTER COOLER REFRIGERANT PUMPOUT V AL VE COOLER CHARGING VA LV E U S E CONDEN S ER CHARGING V AL VE TO ADD CHARGE DI S CHARGE I S OLA TION V AL VE (OPTIONAL) S TOR AG E T ANK LIQUID VA LV E OIL S EP ARA TOR PUMPOUT CONDEN S ER W A TER S UPPL Y AND RETURN PUMPOUT CONDEN S ER S TORA GE T ANK VA P O R VA LV E 2 3 4 5 PRE SS URE RELI[...]

  • Page 30

    30 INST ALL VENT PIPING TO RELIEF V AL VES — T h e 23XR V chiller is factory equipped with relief valves on the cooler and condenser shells. Refe r to Fig. 43 and T able 1 1 for size and location of relief devices. V ent relief devices to the outdoors in accordance with ANSI/ASHRAE 15 (latest edition) Safety Code for Mech anical Refrigeration and[...]

  • Page 31

    31 Table 11 — Relief Valve Loc ations NO TE: All valv es reliev e at 1 8 5 psi (1275 kPa). These instructions are intended for qualified electrical per- sonnel familiar with servicing and installing AC drives. Any questions or problems with the products described in this man- ual should be directed to your local Carrier Service Office. W iring di[...]

  • Page 32

    32 Fig. 44 — Typical Fi eld Wiring Schematic a23-15 8 5[...]

  • Page 33

    33 Fig. 44 — Typical Field Wiring Schematic (cont) a23-15 8 6[...]

  • Page 34

    34 Fig. 44 — Typical Field Wiring Schematic (cont )[...]

  • Page 35

    35 NO TES FOR FIG. 44 GENERA L 1.0 V ariable frequency dr ive (VFD) shall be designed and manufa ctured in accordance with Carrier engineer ing requirements . 1.1 All field-supplied conductors, devices and the field- installation wiring, termination of co nductors and de vices, must be in compliance with all applicable codes and job specifications.[...]

  • Page 36

    36 Fig. 45 — PIC III Control Component Layout a23-15 8 4[...]

  • Page 37

    37 WIRING THE FIELD WIRING TERMINAL STRIPS — This section describes how to wire the field wiring terminal strips shown in Fig. 46 and 47. The control terminal blocks are mounted to the inside of the enclosure, above and below the control panel. NOTE: Up to 30 v may be measured across open contact terminals on the hazardous voltage terminal strip.[...]

  • Page 38

    38 Fig. 46 — 23XRV Controls Schematic a23-15 88[...]

  • Page 39

    39 Fig. 46 — 23XRV Controls Schematic (cont) a23-15 8 9[...]

  • Page 40

    40 DPI Communications Interface Board S tatus LEDs Fig. 47 — Control Terminal Blocks Fig. 48 — Communications In terface Board Sta tus Lights a23-1590 a23-1591 a23-1592[...]

  • Page 41

    41 DRAIN WIRE DRAIN WIRE DRAIN WIRE DRAIN WIRE GROUND BLACK WHITE RED BLACK WHITE RED BLACK WHITE RED BLACK WHITE RED 1 2 3 RED BLACK WHITE Fig. 49 — CCN C ommunication Wiring For Multiple Chillers (Typical) LEGEND 1— Carrier Comfor t Network ® (CCN) Interface 2— Circuit Breakers 3— Chiller Control Module (CCM) F actor y Wiring Field Wirin[...]

  • Page 42

    42 TO CHILLED WA TER PUMP TO CONDEN S ER W ATER PUMP TO COOLING TOWER FAN TO COOLING TO W E R FROM COOLING TO W E R FROM LOAD TO LOAD 3 5 4 DRAIN MAIN COMPRE SS OR MOTOR POWER 1 1 1 1 2 S EE NOTE 4 6 7 8 9 9 LEGEND 1— Discon nect (Fused on VFD only ) NO T by Carri er 2— Unit Mounted VFD/Control Center 3— Pres sure Gages 4— Chilled W ater Pu[...]

  • Page 43

    43 COMPLETING THE INST ALLA TION This section provides instructions on how to perform a final check of the installation. Do not ener gize the VFD circuit breaker . This should only be done by qualified Carrier person- nel in accordance with the 23XR V Start-Up and Service Manual. Checkin g the Installation — Use the following pro- cedure to verif[...]

  • Page 44

    44 When connecting the CCN communication bus to a system element, a color code system for the entire network is recom- mended to simplify installation and checkout. See T a ble 14 for the recommended color codes: Table 14 — Insulator Codes If a cable with a different color scheme is selected, a similar color code should be adopted for the entire [...]

  • Page 45

    45 Fig. 53 — Lead/Lag Control Wir ing a23-1597[...]

  • Page 46

    46 Fig. 53 — Lead/Lag Control Wiring (cont) a23-159 8[...]

  • Page 47

    47 F ACTOR Y -IN S T ALLED IN S ULA TION F ACTOR Y - S UPPLIED AND IN S T ALLED IN S ULA TION (IF REQUIRED) Fig. 54 — 23XRV Insulation Area a23-1599[...]

  • Page 48

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  • Page 49

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  • Page 50

    Manufacturer reserves the right to disco ntinue, or change at any time, specificatio ns or designs without notice and without inc urring obligations. Catalog No . 532-309 Printed in U .S.A. Form 23XR V -1SI Pg 50 309 6-06 Replaces: New Book 2 Ta b 5 e Copy right 2006 Carrier Cor poration[...]

  • Page 51

    Manufacturer reserves the right to disco ntinue, or change at any time, specifications or de signs without notice and without inc urring obligations. Catalog No . 532-309 Printed in U .S.A. Form 23XR V -1SI Pg CL-1 309 6-06 Replaces: New Book 2 Ta b 5 e INST ALLA TION ST ART -UP REQUEST CHECKLIST Machine Model Number: 23XR V Serial Number: To : Att[...]

  • Page 52

    Manufacturer reserves the right to disco ntinue, or change at any time, specificatio ns or designs without notice and without inc urring obligations. Catalog No . 532-309 Printed in U .S.A. Form 23XR V -1SI Pg CL-2 30 9 6-06 Replaces: New Book 2 Ta b 5 e Copy right 2006 Carrier Cor poration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - [...]