Carrier EVERGREEN HFC-134A manual

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[...]

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

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 .[...]

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), [...]

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[...]

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[...]

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[...]

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. [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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

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

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

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.[...]

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

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.[...]

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

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

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[...]

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[...]

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 Carr ier 2— Unit Mounted VFD/Control Center 3— Pres sure Gages 4— Chilled W ater Pu[...]

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[...]

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 [...]

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

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

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[...]

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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[...]

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[...]

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - [...]