Copyright 2012 Carrier Corporation Form 23XRV-4PD Carrier’s Evergreen ® 23XRV chiller is the world’s first integrated variable speed, water-cooled, screw chiller. It incorporates significant break- throughs in water-cooled chiller tech- nology to provide excellent reliability and achieve superior efficiencies at true operating conditions without com- promising the environment. The 23XRV chiller provides: • Variable speed, positive displacement screw compressor. • Air Conditioning, Heating, and Refrigerant Institute (AHRI) certified efficiencies to 0.299 kW/ton (AHRI IPLV). • Chlorine-free HFC-134a refrigerant. • IEEE-519 compliance for harmonic distortion with units equipped with the LF-2 variable frequency drive (VFD). • An ideal solution for constant and variable flow pumping systems. Features/Benefits Quality design and con- struction make the Evergreen 23XRV chillers the best choice for modern, efficient chilled water plants. Product reliability The 23XRV chiller uses proven tech- nology from Carrier’s existing line of Evergreen chillers along with innova- tions that increase reliability. The 23XRV compressors are designed for extremely high reliability. The ad- vanced tri-rotor compressor features a balanced rotor geometry and shorter screw lengths, resulting in vastly re- duced compressor bearing loads and a minimum L10 compressor bearing life in excess of 500,000 hours when op- erated at AHRI conditions. EVERGREEN ® 23XRV High-Efficiency Variable Speed Screw Chiller with FOXFIRE™ Compression Technology 50/60 Hz HFC-134a 275 to 550 Nominal Tons (967 to 1934 Nominal kW) Product Data INNOVATION INNOVATION AWARD AWARD 2008 AHR EXPO 2008 AHR EXPO ® WINNER – Green Building 23XRV SEISMICOMPLIANT * * Meets IBC 2006, ASCE-7-05, CBC 2007, and OSHPD seismic requirements. ®
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Copyright 2012 Carrier Corporation Form 23XRV-4PD
Carrier’s Evergreen® 23XRV chiller is the world’s first integrated variable speed, water-cooled, screw chiller. It incorporates significant break-throughs in water-cooled chiller tech-nology to provide excellent reliability and achieve superior efficiencies at true operating conditions without com-promising the environment. The 23XRV chiller provides:• Variable speed, positive
displacement screw compressor.• Air Conditioning, Heating, and
Refrigerant Institute (AHRI) certified efficiencies to 0.299 kW/ton (AHRI IPLV).
• Chlorine-free HFC-134a refrigerant.• IEEE-519 compliance for harmonic
distortion with units equipped with the LF-2 variable frequency drive (VFD).
• An ideal solution for constant and variable flow pumping systems.
Features/BenefitsQuality design and con-struction make the Evergreen 23XRV chillers the best choice for modern, efficient chilled water plants. Product reliabilityThe 23XRV chiller uses proven tech-nology from Carrier’s existing line of Evergreen chillers along with innova-tions that increase reliability. The 23XRV compressors are designed for extremely high reliability. The ad-vanced tri-rotor compressor features a balanced rotor geometry and shorter screw lengths, resulting in vastly re-duced compressor bearing loads and a minimum L10 compressor bearing life in excess of 500,000 hours when op-erated at AHRI conditions.
Variable speed capacity control elimi-nates slide valves, their associated loss-es, and their potential failure modes. Component count (both rotating and total) has been minimized assuring maximum reliability under a wide range of operating conditions.
High efficiencyPer AHRI 550/590, chillers operate at design conditions less than one percent of the time. As a result, superior part load efficiency is required for today’s chilled water applications. The Ever-green® 23XRV screw chiller maximizes chiller efficiency by optimizing com-pressor operation. Electric power con-sumption drops dramatically when the motor speed slows. The 23XRV screw chiller delivers industry-leading inte-grated part load values (IPLV) in an ex-tremely broad range of applications and climates.
Environmental leaderCarrier has long been committed to the environment and its sustainability. The Evergreen 23XRV screw chillers provide our customers with a high-efficiency, chlorine-free, long-term solution unaffected by refrigerant phase outs. Carrier’s decision to utilize non-ozone depleting HFC-134a refrig-erant provides our customers with a safe and environmentally sound product without compromising effi-ciency. In addition, HFC-134a was given an A1 safety rating by ASHRAE (American Society of Heating, Refrigerating and Air Conditioning Engineers), meaning that it is the safest refrigerant available.
Quality designPositive displacement compres-sion — Positive displacement com-pression ensures stable operation under all load conditions without the possibility of compressor surge.Superior oil management/cold condenser water operation — All Evergreen 23XRV chillers regulate oil temperature, viscosity and pressure. A patented process assures high quality oil is delivered to the compressor bear-ings by a positive displacement pump. Bearing lubrication is assured, allowing continuous operation with cold condenser water at all loads. Screw chillers no longer need to rely on dif-ferential system pressure to effectively lubricate the compressor. Should the
input power to the chiller be lost, the system design assures proper lubrica-tion of the bearings during coast down.Small footprint — The Evergreen 23XRV chiller’s positive pressure design reduces the chiller size by up to 35% compared to negative-pressure designs. Extremely high compression efficiencies allow for compact, high-efficiency chillers that require less mechanical room floor space.Constant or variable evaporator flow — The 23XRV chiller combines the advantages of positive displace-ment compression with variable speed capacity control. This process provides a chiller that reacts substantially better than chillers equipped with inlet guide vanes or slide valves. This allows for easier transition when bringing addi-tional chillers on line in multiple chiller plants and eliminates any possibility of surge, regardless of the changes in the system. Low harmonic distortion option (with LF-2 VFD) — The Evergreen 23XRV chiller will generate less than 5% total harmonic distortion at the in-put to the VFD (variable frequency drive) without the use of any external filters or line reactors. This assures the VFD alone cannot exceed IEEE-519 standard for distortion at the point of common coupling. Ultra-low harmon-ics can eliminate need for complicated harmonic system studies.Low starting current (inrush) —The inrush current is limited to the chiller full load amps (rated load amperes). No other starting means can equal this level of starting current. The combination of low current and ultra- low harmonics can reduce backup generator size requirements.
0.99 power factor — The Ever-green 23XRV chiller can operate at up to 0.99 displacement power factor (with LF-2 VFD), which helps building owners avoid power factor penalties and decreases electrical losses in cables and transformers. High power factor may also reduce KVA requirements, saving electrical system costs on new projects or freeing up electrical re-sources on existing systems operating near their maximum capacity.Refrigerant-cooled VFD — Refrig-erant cooling of the VFD minimizes VFD size and ensures proper cooling of the transistors for extended life. Using R-134a refrigerant instead of water also eliminates costly mainte-nance associated with the water cool-ing pump, heat exchanger and rubber tubing used with water-cooled VFDs.Optional seismic kit — A seismic isolation package is available to meet International Building Code and ASCE 7 seismic qualification requirements in concurrence with ICC ES AC156 Ac-ceptance Criteria for Seismic Qualifica-tion by Shake-Table Testing of Non-structural Components and Systems.Hermetic motor — The Evergreen 23XRV chiller utilizes motors that are hermetically sealed from the machine room. Cooling is accomplished by spraying liquid refrigerant on the motor windings. This highly efficient motor cooling method results in cooler-running motors than could be realized with air-cooled designs of the same type.
In addition, Carrier’s hermetic de-sign eliminates:• Compressor shaft seals that require
maintenance and increase the likeli-hood of refrigerant leaks.
• Machine room cooling requirementsassociated with air-cooled motors,which dissipate heat to the mechan-ical room.
• High noise levels common with air-cooled motors, which radiate noiseto the machine room and adjacentareas.
• Shaft alignment problems that occurwith open-drive designs during start-up and operation, when equipmenttemperature variations cause ther-mal expansion.
Positive pressure design — Posi-tive pressure designs eliminate the need for costly low pressure contain-ment devices, reducing the initial cost of the system. The Evergreen® 23XRV chiller’s positive pressure design en-sures that air, moisture and other per-formance degrading contaminants are not sucked inside the chiller. Purge units and their associated mainte-nance are no longer necessary.Optional refrigerant isolation valves — The optional refrigerant isolation valves allow the refrigerant to be stored inside the chiller during shipment from the factory, minimizing start-up time. During servicing, the “in-chiller” storage reduces refrigerant loss and eliminates time-consuming transfer procedures. As a self-contained unit, the Evergreen 23XRV chiller does not require additional remote storage systems.Optional pumpdown unit — Com-bined with the refrigerant isolation valves listed above, the optional pump-down unit eliminates complex connec-tions to portable transfer systems, thereby reducing service costs. The op-tional pumpdown compressor meets Environmental Protection Agency’s (EPA) vacuum level requirements that mandate minimizing refrigerant emis-sions during service.Modular construction — The cool-er, condenser, and compressor assem-blies are bolted together, making Ever-green 23XRV chillers ideally suited for replacement jobs where ease of disas-sembly and reassembly at the jobsite are essential.Single point power — The 23XRV chiller features internal control power transformers to provide low voltage power (115 v and 24 vdc) for machine controls. Simply connecting the three
input power leads to the VFD provides all unit power.Marine container shipment — The compact design allows for open-top container shipment to export destina-tions, ensuring quality while reducing shipping cost.Heat exchanger combinations — The Evergreen 23XRV chillers are available with a complete line of heat exchangers, ensuring the best combi-nation of chiller components to meet project specific tonnage and efficiency requirements. One, 2 and 3-pass arrangements are available to meet a wide variety of flow conditions. Nozzle-in-head and marine waterboxes are available to meet 150 psig and300 psig piping requirements.
Heat exchanger featuresASME certified construction — An independent agency certifies the design, manufacture, and testing of all heat exchangers to American Society of Mechanical Engineers (ASME) standards, ensuring heat ex-changer safety, reliability and long life. The ASME U-stamp is applied to the refrigerant side of the evaporator and condenser and is applied to the water side of heat exchangers when 300 psig marine water boxes are provided.High performance tubing — Carrier’s Evergreen chillers utilize advances in heat transfer technology, providing compact, high-efficiency heat exchangers. Tubing with advanced internally and externally enhanced geometry improves chiller per-formance by reducing overall resistance to heat transfer while reducing fouling.Cooler tube expansion — Cooler tube expansion at center support sheets prevents unwanted tube move-ment and vibration, thereby reducing the possibility of premature tube fail-ure. Tube wall thickness is greater at the expansion location, support sheets, and end tube sheets in order to provide maximum strength and long tube life.Double-grooved end tube sheet holes — This design provides a more robust seal than single rolled joints, re-ducing the possibility of leaks between the water and refrigerant sides of the chiller.Condenser baffle — The baffle de-flects hot discharge gas before it con-tacts condenser tubes, reducing tube vibration and wear while distributing
refrigerant more evenly over the length of the vessel for improvedefficiency.Closely spaced intermediate sup-port sheets — Support sheets pre-vent tube sagging and vibration, there-by increasing heat exchanger life.Refrigerant filter isolation valves — These valves allow filter replace-ment without pumping down the chill-er, reducing service time and expense.FLASC (flash subcooler) — The subcooler, located in the bottom of the condenser, increases the refrigeration effect by cooling the condensed liquid refrigerant to a lower temperature, thereby reducing compressor power consumption.AccuMeter™ system — The AccuMeter system regulates refrigerant flow according to load conditions, providing a liquid seal at all operating conditions, eliminating unintentional hot gas bypass.
Microprocessor controls featuresDirect Digital Product Integrated control (PIC III) — Carrier’s PIC III provides unmatched flexibility and functionality. Each unit integrates directly with the Carrier Comfort Network® (CCN) system, providing a solution to controls applications.International Chiller Visual Con-troller (ICVC) — The ICVC provides an unparalleled ease of operation and can be configured to display English or metric values.
For convenience, a single display lo-cated on the chiller VFD panel displays chiller and VFD data. The VGA 320 x 240 element LCD (liquid crystal dis-play) features 4 menu specific soft-keys. The default display offers an all-in-one glance review of key chiller operation data, simplifying the interac-tion between chiller and user.
The display includes 4 standardlanguages:• English• Chinese• Japanese• Korean
Other languages are available.Automatic capacity override —This function unloads the compressor whenever key safety limits are ap-proached, increasing unit life. This
4
feature also allows the machine to operate at reduced capacity, rather than shut down, when key safety limits are approached.Chilled liquid reset — Reset can be accomplished manually or automatical-ly from the building management sys-tem. For a given capacity, reset allows operation at slower compressor speeds, saving energy when warmer chilled liquid can be used. Demand limiting — This feature lim-its the power draw of the chiller during peak loading conditions. When incor-porated into the Carrier Comfort Network® building automation system, a red line command holds chillers at their present capacity and prevents anyother chillers from starting. If a load shed signal is received, the compres-sors are unloaded to avoid demand charges whenever possible.
Ramp loading — Ramp loading en-sures smooth pulldown of liquid loop temperature and prevents a rapid increase in compressor power con-sumption during the pulldown period.Automated controls test — The test can be executed prior to start-up to verify that the entire control system is functioning properly.365-day real time clock — This feature allows the operator to program a yearly schedule for each week, week-ends, and holidays.Occupancy schedules — Schedules can be programmed into the controller to ensure that the chiller operates when cooling is required and remains off when not needed by the tenants or process.Extensive service menu — Unau-thorized access to the service menu
can be prevented through password protection. Built-in diagnostic capabili-ties assist in troubleshooting and rec-ommend proper corrective action for preset alarms, resulting in greater working time.Alarm file — This file maintains the last 25 time-and date-stamped alarm messages in memory. This function re-duces troubleshooting time and cost.Alert file — This file maintains the last 25 alert messages in memory. This function provides prognostic informa-tion and corrective actions that can avoid unit shutdown. Configuration data backup — Non-volatile memory provides protection during power failures and eliminates time consuming control reconfiguration.
Features/Benefits (cont)
23XRV – High EfficiencyVariable Speed Screw Chiller
Cooler Size*30-3235-3740-4245-4750-5255-57
Condenser Size* 30-3235-3740-4245-4750-5255-57
Economizer OptionE – With EconomizerN – No Economizer
Voltage Code3 – 380-3-604 – 416-3-605 – 460-3-609 – 380/415-3-50
S – Special
R – Compressor
Motor CodeP TQ UR VS
Compressor Option0 – Full Load Optimized1 – Part Load Optimized
Drive Code†AA – LF-2, 440 Amps In, 442 Amps OutBA – LF-2, 520 Amps In, 442 Amps OutR3 – Std Tier, 335 Amps In, 335 Amps OutR4 – Std Tier, 445 Amps In, 445 Amps Out
23XRV 40 42 N R V AA 5 0 S
ASME‘U’ Stamp
AHRI (Air Conditioning, Heating and Refrigeration Institute)
Model number nomenclature
*First number denotes frame size.†Maximum limits only. Additional applicationlimits apply that may reduce these ampacities.
*Rigging weights are for standard tubes of standard wall thickness(EDE and Spikefin 3, 0.025-in. [0.635 mm] wall).NOTES:
1. Cooler includes the suction elbow and 1/2 the distribution piping weight.2. Condenser includes float valve and sump, discharge elbow, and 1/2 the
distribution piping weight.3. For special tubes, refer to the 23XRV Computer Selection Program.4. All weights for standard 2-pass NIH (nozzle-in-head) design with vic-
*Add to cooler and condenser weights for total weights. Cooler and condenser weights may be found in the 23XRV Heat Exchanger Weights table on page 5. The first digit of the heat exchanger code (first column) is the heat exchanger frame size.
23XRV WATERBOX COVER WEIGHTS — ENGLISH (lb)FRAMES 3, 4, AND 5
LEGEND *Nozzle end weight/return end weight.NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included inthe heat exchanger weights shown on page 5.
23XRV WATERBOX COVER WEIGHTS — SI (kg)FRAMES 3, 4, AND 5
LEGEND *Nozzle end weight/return end weight.NOTE: Weight for NIH 2-pass cover, 150 psig (1034 kPa), is included inthe heat exchanger weights shown on page 5.
FRAMENUMBER
OFPASSES
ENGLISH (lb) SI (kg)Cooler Condenser Cooler Condenser
*Factory-installed.†Field-installed.**Standard waterbox nozzles are victaulic type. Flanged nozzles areavailable as an option with either nozzle-in-head type waterboxes ormarine waterboxes.
††Optional marine waterboxes available for 23XRV heat exchangerframes 3-5 only. Standard waterboxes for 23XRV are nozzle-in-headtype, 150 psig (1034 kPa).***Sponsored by ASHRAE (American Society of Heating, Refrigerating,and Air Conditioning Engineers).†††Registered trademark of Echelon Corporation.
ITEM OPTION* ACCESSORY†Std Tier VFD XFreestanding 5% Line Reactor (for use with Std Tier VFD only) X.028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Copper Tubing — Cooler/Condenser X.028 or .035 in. (0.711 or 0.889 mm) Internally/Externally Enhanced Cupronickel Tubing — Condenser X.028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Copper Tubing — Cooler/Condenser X.028 or .035 in. (0.711 or 0.889 mm) Smooth Bore/Externally Enhanced Cupronickel Tubing — Condenser XFlanged Cooler and/or Condenser Waterbox Nozzles** XHinged Waterboxes XMarine Waterboxes, 150 psig (1034 kPa)†† XMarine Waterboxes, 300 psig (2068 kPa)†† XNozzle-in Head Waterbox, 300 psig (2068 kPa) XOne, 2, or 3 Pass Cooler or Condenser Waterside Construction XSeismic Kit XZinc Anodes X100K AIC (Amp Interrupt Capacity) High Interrupt Circuit Breaker XAnalog Voltmeter and Ammeter with 3 Phase Selector Switch (LF-2 Only) XDigital Meter Kit (Std Tier VFD Only) XBACnet*** Communications XLonWorks††† Carrier Translator XSensor Package XRefrigerant Isolation Valves XSeparate Storage Tank and Pumpout Unit XShipped Factory Charged with Refrigerant XStand-Alone Pumpout Unit XUnit-Mounted Pumpout Unit XHot Gas Bypass XSoleplate Package XSpring Isolator Kit XAcoustical Sound Insulation Kit XFull Cold Surface Thermal Insulation (Except Waterbox Covers) XCustomer Factory Performance Testing XExport Crating XExtended Warranty (North American Operations [NAO] only) XService Contract X
Options and accessories
8
23XRV DIMENSIONS (NOZZLE-IN-HEAD WATERBOX)
23XRV DIMENSIONS (MARINE WATERBOX)
*Assumes both cooler and condenser nozzles on same end of chiller. †1 or 3 pass length applies if cooler is a 1 or 3 pass design.NOTES:
1. Service access should be provided per American Society of Heat-ing, Refrigerating, and Air Conditioning Engineers (ASHRAE) 15,latest edition, National Fire Protection Association (NFPA) 70, andlocal safety code.
2. Allow at least 3 ft (915 mm) overhead clearance for service riggingfor the compressor.
3. Certified drawings available upon request.4. Marine waterboxes may add 6 in. (152 mm), to the width of the
machine. See certified drawings for details.5. ‘A’ length and ‘B’ width dimensions shown are for standard
150 psig (1034 kPa) design and victaulic connections. The300 psig (2068 kPa) design and/or flanges will add length. See cer-tified drawings.
6. Dished head waterbox covers not available for the 3-pass design.
HEAT EXCHANGERSIZE
A (Length, with Nozzle-in-Head Waterbox)B (Width) C (Height)1 Pass 2-Pass* 3 Pass
ft-in. mm ft-in. mm ft-in. mm30 to 32 14- 31/4 4350 13- 81/4 4172 14- 31/4 4350
See unitcertifieddrawings
35 to 37 15-113/4 4870 15- 43/4 4693 15-113/4 4870
*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec); maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.
SI (L/s)
*Flow rates based on standard tubes in the cooler and condenser. Minimum flow based on tube velocity of 3 ft/sec (0.91 m/sec); maximum flow based on tube velocity of 12 ft/sec (3.66 m/sec). Consult the factory if variable primary flow.
Microprocessor controlsMicroprocessor controls provide the safety, interlock, ca-pacity control, indications and accessibility necessary tooperate the chiller in a safe and efficient manner.
Control systemThe microprocessor control on each Carrier chiller isfactory-mounted, factory-wired, and factory-tested toensure machine protection and efficient capacity control.In addition, the program logic ensures proper starting,stopping, and recycling of the chiller and provides a com-munication link to the Carrier Comfort Network® (CCN)system.
FeaturesControl system• Component test and diagnostic check• Programmable recycle allows chiller to recycle at opti-
mum loads for decreased operating costs• Menu-driven keypad interface for status display, set
point control, and system configuration• CCN system compatible• Primary and secondary status messages• Individual start/stop schedules for local and CCN opera-
tion modes• Recall of up to 25 alarm messages and 25 alert mes-
sages with diagnostic help• Two chiller lead/lag with third chiller standby is stan-
dard in the PIC III software• Optional soft stop unloading decreases compressor
speed to unload the motor to the configured amperagelevel prior to stopping
• Languages pre-programmed at factory for English, Chi-nese, Japanese, Korean
• ILT (International Language Translator) available forconversion of extended ASCII characters
Safety cutouts• Motor high temperature*†• Refrigerant (condenser) high pressure*†• Refrigerant (cooler) low temperature*†• Lube oil low pressure*• Compressor (refrigerant) high discharge temperature*• Under voltage**• Over voltage**• Cooler and condenser liquid flow• Motor overload†• Motor acceleration time• Intermittent power loss**• Motor stall protection• Low level ground fault• Cooler and condenser freeze prevention*• Low oil temperature• Motor current imbalance• Motor rotation reversal• Excessive motor amps• Motor starts limit• VFD speed out of range• High VFD inverter temperature*†• DC bus voltage (Low/High)
Capacity control• Leaving chilled liquid control• Entering chilled liquid control• Soft loading control by temperature or load ramping• Hot gas bypass valve (optional)• Power (demand) limiter• Automatic chilled liquid reset (3 methods)• Manual speed controlInterlocks• Manual/automatic remote start• Starting/stopping sequence
Pre-lube/post-lubePre-flow/post-flow
• Compressor run interlock• Pre-start check of safeties and alerts• Low chilled liquid (load) recycle• Monitor/number compressor starts and run hours• Manual reset of safetiesIndications• Chiller operating status message• Power-on• Pre-start diagnostic check• Compressor motor amps• Alert (pre-alarm)††• Alarm• Contact for remote alarm• Safety shutdown messages• Elapsed time (hours of operation)• Chiller input kW• Demand kWDrive control parameters• Compressor 100% speed (Hz)• Motor rated Load kW• Motor rated Load amps• Motor nameplate amps• Motor nameplate RPM• Motor nameplate kW• Inverter PWM (pulse width modulation) frequency
*Can be configured by the user to provide alert indicationat user-defined limit.
†Override protection: Causes compressor to first unloadand then, if necessary, shut down.
**Will not require manual reset or cause an alarm if auto-restart after power failure is enabled.
††By display code only.
Controls
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Controls (cont)
CONTROL PANEL DISPLAY (Front View)
ICVC ENGLISH DISPLAY IN SI UNITS
CONTROL PANEL DISPLAY (Front View)
ICVC CHINESE DISPLAY IN METRIC UNITS
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a23-1649
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Control sequenceTo start — Local start-up (manual start-up) is initiated bypressing the LOCAL or CCN menu softkey, which is indi-cated on the default international chiller visual control(ICVC) screen. Time schedule 01 or 03, respectively, mustbe in the Occupied mode and the internal 15-minute start-to-start and the 1-minute stop-to-start inhibit timers musthave expired. All pre-start safeties are checked to verifythat all prestart alerts and safeties are within limits (if one isnot, an indication of the fault displays and the start will bedelayed or is aborted). The signal is sent to start the coolerliquid pump. Five seconds later, the condenser liquid pumpis energized. If satisfied, it checks the chilled liquid temper-ature against the control point. If the temperature is lessthan or equal to the chilled liquid control point, the con-denser liquid pump is deenergized and the chiller goes intoa recycle mode.
If the chilled liquid temperature is high enough, the start-up sequence continues. The oil pump is started and waits aminimum of 45 sec to verify oil flow. Once oil flow is veri-fied, the VFD is energized. The control will monitor for aphase reversal condition. At this time, the following occurs:• The “start-to-stop” timer is activated.• The “compressor on-time” and “service on-time” timers
are activated.• The “starts in 12-hour counter” advances by one.• The “total compressor starts counter” advances by one.Once started — If the VFD average current >5% within15 seconds after VFD start, the machine enters run modeand speed will be ramped up to meet VFD target speed.Once the target speed is met the controls, enter the capac-ity control mode.Shutdown sequence — The chiller shutdown is initiatedif any of the following occur:• The Stop button is pressed for at least one second (the
alarm light blinks once to confirm the stop command).• A recycle shutdown is initiated.• The time schedule has gone into unoccupied mode.• The chiller protective limit has been reached and the
chiller is in alarm.• The start/stop status is overridden to stop from the
ICVC, CCN system, or building management system.Once the controls shutdown sequence is initiated, the
compressor is stopped and the VFD target speed is set to 0.If optional soft stop unloading is activated when the Stopbutton is pressed or the remote contacts open, motorspeed decreases to a configured amperage level, and thecompressor is stopped. The display indicates “Shutdown inProgress” while the motor speed decreases. Compressorontime and service ontime timers stop once the current inall phases is <5%, indicating a VFD Stop Complete. The oilpump and cooler liquid pump are then deenergized. Thecondenser liquid pump shuts down when the refrigeranttemperature or entering condenser liquid temperature is be-low pre-established limits. The 3-minute start-to-stop timerstarts.Restart — Restart is permitted after both inhibit timershave expired. If shutdown was due to a safety shutdown,the reset button must be depressed before restarting thechiller.
ontime and service ontime start; 15-minute inhibit timer starts (VFDfault tests for 15 sec after F)
G — Verify average current >5% within 15 sec after VFD start, ramp toVFD target speed.
H — Compressor reaches target speed, chiller set to running statusI — Shutdown initiated: Target VFD speed to 0% (or J occurs)J — Ramp down until percent line current < soft stop amps threshold
(0-60 sec after I)K — Oil pump relay off (1-20 sec after J)L — Evaporator pump deenergized (60 sec after K); condenser pump
and tower fan control may continue to operate if condenser pressureis high; evaporator pump may continue if in RECYCLE mode
O/A — Restart permitted (both inhibit timers expired) (minimum of 15 min-utes after F; minimum of 3 minutes after L)
NOTES:1. Wiring and piping shown are for general point-of-connection only and are not
intended to show details for a specific installation. Certified field wiring anddimensional diagrams are available on request.
2. All wiring must comply with applicable codes.3. Refer to Carrier System Design Manual for details regarding piping techniques.4. Wiring not shown for optional devices such as:
• remote start/stop• remote alarms• optional safety device• 4 to 20 mA resets• optional remote sensors• kW output• head pressure reference
5. Flow switches are NOT required.6. Carrier suggests vibration spring isolation for chillers installed in upper floors.
Carrier suggests that a structural engineer be consulted if the transmission ofvibrations from mechanical equipment is of concern.
23XRV CHILLER
16
Control wiring schematic
23XRV COMPONENT ARRANGEMENT
LEGENDCCM — Chiller Control ModuleCCN — Carrier Comfort Network®
ICVC — International Chiller Visual ControllerGND — Ground
NOTES:1. Dimensions in ( ) are in millimeters.2. Accessory soleplate package includes 4 soleplates, 16 jacking screws and leveling
pads. Requires isolation package.3. Jacking screws to be removed after grout has set.4. Thickness of grout will vary, depending on the amount necessary to level chiller. Use
only pre-mixed non-shrinking grout, Ceilcote 748 or Chemrex Embeco 636 PlusGrout, 0-11/2 (38.1) to 0-21/4 (57) thick.
5. Service clearance under the chiller is enhanced if leveling pads are not extendedalong the entire length of the heat exchangers.
VIEW Y-Y
ISOLATION WITH ISOLATION PACKAGE ONLY(STANDARD)
NOTE: Isolation package includes 4 elastomeric pads.
a23-1647
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23XRV NOZZLE ARRANGEMENTS
NOZZLE-IN-HEAD WATERBOXES
FRAME 3
FRAMES 4 AND 5
NOZZLE ARRANGEMENT CODES FOR ALL 23XRV NOZZLE-IN-HEAD WATERBOXES
*Refer to certified drawings.
PASSCOOLER WATERBOXES
In Out ArrangementCode*
18 5 A5 8 B
27 9 C4 6 D
37 6 E4 9 F
PASSCONDENSER WATERBOXES
In Out ArrangementCode*
111 2 P
2 11 Q
210 12 R
1 3 S
310 3 T
1 12 U
DISCHARGE END SUCTION END
DISCHARGE END SUCTION END
20
Application data (cont)
23XRV NOZZLE ARRANGEMENTS (cont)
MARINE WATERBOXES
FRAME 3NOZZLE ARRANGEMENT CODES
PASSCOOLER WATERBOXES
PASSCONDENSER WATERBOXES
In Out ArrangementCode In Out Arrangement
Code
18 5 A
1— — —
5 8 B — — —
27 9 C
210 12 R
4 6 D 1 3 S
37 6 E
3— — —
4 9 F — — —
FRAMES 4, AND 5
NOZZLE ARRANGEMENT CODES
PASSCOOLER WATERBOXES
PASSCONDENSER WATERBOXES
In Out ArrangementCode In Out Arrangement
Code
19 6 A
1— — —
6 9 B — — —
27 9 C
210 12 R
4 6 D 1 3 S
37 6 E
3— — —
4 9 F — — —
DISCHARGE END SUCTION END
DISCHARGE END SUCTION END
21
23XRV WATERBOX NOZZLE SIZES (Nozzle-In-Head and Marine Waterboxes)
RELIEF VALVE LOCATIONS
* Coolers without optional isolation require 2 relief valves.
NOTE: All valves relieve at 185 psig (1275 kPa).
FRAMESIZE
PRESSUREpsig (kPa) PASS
NOMINAL PIPE SIZE (in.) ACTUAL PIPE ID (in.)Cooler Condenser Cooler Condenser
WITH OPTIONAL ISOLATION WITHOUT OPTIONAL ISOLATION
RELIEF VALVE ARRANGEMENTS
22
Vent and drain connectionsNozzle-in-head waterboxes have vent and drain connec-tions on covers. Marine waterboxes have vent and drainconnections on waterbox shells.
Provide high points of the chiller piping system with ventsand the low points with drains. If shutoff valves are provid-ed in the main liquid pipes near the unit, a minimal amountof system liquid is lost when the heat exchangers aredrained. This reduces the time required for drainage andsaves on the cost of re-treating the system liquid.
It is recommended that pressure gages be provided atpoints of entering and leaving liquid to measure pressuredrop through the heat exchanger. Gages may be installedas shown in Pressure Gage Location table. Pressure gagesinstalled at the vent and drain connections do not includenozzle pressure losses.
Use a reliable differential pressure gage to measure pres-sure differential when determining liquid flow. Regular gag-es of the required pressure range do not have the accuracyto provide accurate measurement of flow conditions.
PRESSURE GAGE LOCATION
ASME stampingAll 23XRV heat exchangers are constructed in accordancewith ASHRAE (American Society of Heating, Refrigerat-ing, and Air Conditioning Engineers) 15 Safety Code forMechanical Refrigeration (latest edition). This code, inturn, requires conformance with ASME (American Societyof Mechanical Engineers) Code for Unfired Pressure Ves-sels wherever applicable.
Each heat exchanger and economizer (if equipped) isASME ‘U’ stamped on the refrigerant side of each vessel.
Relief valve discharge pipe sizingSee page 21 for number of relief valves.
Relief valve discharge piping size should be calculatedper the current version of the ASHRAE 15, latest edition,code using the tabulated C factors for each vessel shown inthe table below.
23XRV RELIEF VALVE DISCHARGE PIPE SIZING
Carrier further recommends that an oxygen sensor beinstalled to protect personnel. Sensor should be able tosense the depletion or displacement of oxygen in the ma-chine room below 19.5% volume oxygen per ASHRAE15, latest edition.
Design pressuresDesign and test pressures for heat exchangers are listedbelow.
DESIGN AND TEST PRESSURES (23XRV)
*Nitrogen/Helium.
HEAT EXCHANGER MATERIAL SPECIFICATIONS
LEGEND
NUMBEROF
PASSES
GAGE LOCATION(Cooler or Condenser)
1 or 3 One gage in each waterbox2 Two gages in waterbox with nozzles
HEATEXCHANGER
FRAMESIZE
VESSELREQUIREDC FACTOR(lb air/Min)
RELIEFVALVERATED
C FACTOR(lb air/Min)
FIELDCONNECTION
SIZE (FPT)
COOLER
30 to 32 43.4 70.8 11/435 to 37 49.5 70.8 11/440 to 42 50.4 70.8 11/445 to 47 57.4 70.8 11/450 to 52 53.7 70.8 11/455 to 57 61.1 70.8 11/4
CONDENSER
30 to 32 41.4 70.8 11/435 to 37 47.1 70.8 11/440 to 42 47.1 70.8 11/445 to 47 53.7 70.8 11/450 to 52 51.2 70.8 11/455 to 57 58.3 70.8 11/4
Factory insulation — Thermal insulation is factory-provided to the following areas:• Cooler (not including waterbox)• Suction line• Compressor and motor• Oil cooling line and oil return system line (oil and refrig-
erant lines at or near evaporator pressure are insulated)• VFD cooling line (oil and refrigerant lines at or near
evaporator pressure are insulated)• Motor cooling line• Vaporizer• Liquid line and discharge line• Float chamber• Optional economizer (including vent line and econo-
mizer muffler)Factory insulation is not available for the waterboxes.Insulation applied at the factory is 1/2-in. (13 mm) thick
closed cell and 1/2-in. (13 mm) open cell PVC-Nitrile foam.Some parts of the chiller are also treated with an outerlayer of 3/16-in. (5 mm) thick vinyl. The 1/2-in. (13 mm)closed cell foam has a thermal conductivity K value of0.28 (BTU in.)/(hr sq ft °F) [0.0404 W/(m °C)] and
conforms with Underwriters Laboratories (UL) Standard94, Classification 94 HF-1. Both the 1/2-in. foam and the3/16-in. vinyl layer will pass flammability test methodMVSS 302.Field insulation — As indicated in the Condensation vsRelative Humidity table, the factory insulation providesexcellent protection against condensation under most op-erating conditions. If temperatures in the equipment areaexceed the maximum design conditions, extra insulation isrecommended.
If the machine is to be field insulated, obtain the approx-imate areas from the 23XRV Minimum Field-Installed Insu-lation Requirements table.
Insulation of waterbox is made only in the field and thisarea is not included in 23XRV Minimum Field-Installed In-sulation Requirements table. When insulating the covers,allow for service access and removal of covers. To estimatewater-box cover areas, refer to certified drawings.
High humidity jobsite locations may require field sup-plied and installed insulation on the float chamber, suctionhousing, and the lower half of the condenser.
CONDENSATION VS RELATIVE HUMIDITY*
*These approximate figures are based on 35 F (1.7 C) saturated suction temperature. A 2° F (1.1° C) change in saturated suction temperature changes the relative humidity values by 1% in the same direction.
Minimum fluid loop volumeMinimum fluid volume must be in excess of 1.5 gal per ton(1.6 L per kW) for comfort cooling applications and apply3 to 5 gal per ton (3.2 to 5.4 L per kW) fluid loop volumefor process applications.
Variable Speed Screw Chiller HVAC Guide SpecificationsSize Range: 275 to 550 Tons (967 to 1934 kW)
NominalCarrier Model Number: 23XRVPart 1 — General1.01 SYSTEM DESCRIPTION
A. Microprocessor-controlled liquid chiller shall use asemi-hermetic screw compressor using refrigerantHFC-134a only. Chiller refrigerant shall not have aplanned phase out date.
B. If a manufacturer proposes a liquid chiller usingHCFC-123 refrigerant, which has a planned phaseout date, then the manufacturer shall include in thechiller price:
1. A vapor activated alarm system consisting of allalarms, sensors, safeties, and ventilation equip-ment as required by ANSI/ASHRAE Standard15 Safety Code for Mechanical Refrigeration(latest edition) with the quotation. System shallbe capable of responding to HCFC-123 levelsof 10 ppm Allowable Exposure Limit (AEL).
2. A free-standing refrigerant storage tank andpumpout unit shall be provided. The storagevessels shall be designed per ASME Section VIIIDivision 1 code with 300 psig (2068 kPa)design pressure. Double relief valves per ANSI/ASHRAE 15, latest edition, shall be provided.The tank shall include a liquid level gage andpressure gage. The pumpout unit shall use asemi-hermetic reciprocating compressor withwater cooled condenser. Condenser water pip-ing, 3-phase motor power, and 115-volt controlpower shall be installed at the jobsite by theinstalling contractor.
3. Zero emission purge unit capable of operatingeven when the chiller is not operating.
4. Back-up relief valve to rupture disk.5. Factory-installed chiller pressurizing system to
prevent leakage of noncondensables into thechiller during shutdown periods.
6. Plant room ventilation.7. Removal and disposal of refrigerant at the end
of the phase out period.8. Chillers utilizing a purge unit shall include in the
machine price the costs to perform the follow-ing regular maintenance procedures:a. Weekly: Check refrigerant charge.b. Quarterly: Charge purge unit dehydrator at
least quarterly, more often if necessary.Clean foul gas strainer. Perform chemicalanalysis of oil.
c. Annually: Clean and inspect all valves. Drainand flush purge shell. Clean orifices.
1.02 QUALITY ASSURANCEA. Chiller performance shall be rated in accordance
with AHRI Standard 550/590, latest edition.B. Equipment and installation shall be in compliance
with ANSI/ASHRAE 15 (latest edition).C. Cooler and condenser refrigerant side shall include
ASME “U” stamp and nameplate certifying compli-ance with ASME Section VIII, Division 1 code forunfired pressure vessels.
D. A manufacturer’s data report is required to verifypressure vessel construction adherence to ASMEvessel construction requirements. Form U-1 asrequired per ASME code rules is to be furnishedto the owner. The U-1 Form must be signed by aqualified inspector, holding a National BoardCommission, certifying that construction conformsto the latest ASME Code Section VIII, Div. 1 forpressure vessels. The ASME symbol “U” must alsobe stamped on the heat exchanger. Vessels specifi-cally exempted from the scope of the code mustcome with material, test, and construction methodscertification and detailed documents similar toASME U-1; further, these must be signed by an offi-cer of the company.
E. Chiller shall be designed and constructed to meetUL and UL of Canada requirements and have labelsappropriately affixed.
F. Unit shall be manufactured in a facility registered toISO 9001 Manufacturing Quality Standard.
G. Each compressor assembly shall undergo a mechan-ical run-in test to verify vibration levels, oil pressures,and temperatures are within acceptable limits. Eachcompressor assembly shall be proof tested at a mini-mum 204 psig (1407 kPa) and leak tested at185 psig (1276 kPa) with a tracer gas mixture.
H. Entire chiller assembly shall be proof tested at204 psig (1407 kPa) and leak tested at 185 psig(1276 kPa) with a tracer gas mixture on the refriger-ant side. The leak test shall not allow any leaksgreater than 0.5 oz per year of refrigerant. Thewater side of each heat exchanger shall be hydro-statically tested at 1.3 times rated working pressure.
I. Prior to shipment, the chiller automated controlstest shall be executed to check for proper wiring andensure correct controls operation.
J. Chillers shall have factory-mounted, factory-wiredand factory-tested unit-mounted variable frequencydrive (VFD). Proper VFD operation shall be con-firmed prior to shipment.
1.03 DELIVERY, STORAGE AND HANDLINGA. Unit shall be stored and handled in accordance with
manufacturer’s instructions.B. Unit shall be shipped with all refrigerant piping and
control wiring factory-installed.C. Unit shall be shipped charged with oil and full
charge of refrigerant HFC-134a or a nitrogen hold-ing charge as specified on the equipment schedule.
Guide specifications
25
D. Unit shall be shipped with firmly attached labels thatindicate name of manufacturer, chiller model num-ber, chiller serial number, and refrigerant used.
E. If the unit is to be exported, the manufacturer shallprovide sufficient protection against sea water corro-sion, making the unit suitable for shipment in astandard open top ocean shipping container.
F. Chiller and starter shall be stored indoors, protectedfrom construction dirt and moisture. Chiller shall beinspected under shipping tarps, bags, or crates to besure water has not collected during transit. Protec-tive shipping covers shall be kept in place untilmachine is ready for installation. The inside of theprotective cover shall meet the following criteria:
1. Temperature is between 40 F (4.4 C) and120 F (48.9 C)
2. Relative humidity is between 10% and 80%non-condensing.
1.04 WARRANTYWarranty shall include parts and labor for one yearafter start-up or 18 months from shipment, which-ever occurs first. A refrigerant warranty shall beprovided for a period of 5 years.
Part 2 — Products2.01 EQUIPMENT
A. General:Factory-assembled, single piece, liquid chiller shallconsist of compressor, motor, VFD, lubrication sys-tem, cooler, condenser, initial oil and refrigerantoperating charges, microprocessor control system,and documentation required prior to start-up.
B. Compressor:1. One variable speed, tri-rotor screw compressor
of the high performance type.2. Compressor and motor shall be hermetically
sealed into a common assembly and arrangedfor easy field servicing.
3. The compressor motor shall be accessible forservicing without removing the compressorbase from the chiller. Connections to the com-pressor casing shall use O-rings and gaskets toreduce the occurrence of refrigerant leakage.Connections to the compressor shall be flangedor bolted for easy disassembly.
4. Compressor bearings must have individualdesign life of 500,000 hours or greater.
5. Compressor shall provide capacity modulationfrom 100% to 15% capacity without the use ofhot gas bypass or mechanical unloaders.
6. Compressor shall be provided with a factory-installed positive pressure lubrication system todeliver oil under pressure to bearings and rotorsat all operating conditions. Lubrication systemshall include:a. Oil pump with factory-installed motor con-
tactor with overload protection.
b. Oil pressure sensor with differential readoutat main control center.
c. Oil pressure regulator.d. Oil filter with isolation valves to allow filter
change without removal of refrigerantcharge.
e. Oil sump heater [115 v, 50 or 60 Hz] con-trolled from unit microprocessor.
f. Oil reservoir temperature sensor with maincontrol center digital readout.
g. All wiring to oil pump, oil heater, and con-trols shall be pre-wired in the factory andpower shall be applied to check properoperation prior to shipment.
7. Compressor shall be fully field serviceable.Compressors that must be removed andreturned to the factory for service shall beunacceptable.
8. Acoustical attenuation shall be provided asrequired, to achieve a maximum (full loador part load) sound level, measured per AHRIStandard 575 (latest edition).
C. Motor:1. Compressor motor shall be of the semi-
hermetic, liquid refrigerant cooled, squirrelcage, induction type suitable for voltage shownon the equipment schedule.
2. If an open (air cooled) motor is provided, acompressor shaft seal leakage containmentsystem shall be provided:a. An oil reservoir shall collect oil and refriger-
ant that leaks past the seal.b. A float device shall be provided to open
when the reservoir is full, directing therefrigerant/oil mixture back into the com-pressor housing.
c. A refrigerant sensor shall be located next tothe open drive seal to detect leaks.
3. Motors shall be suitable for operation in arefrigerant atmosphere and shall be cooled byatomized refrigerant in contact with the motorwindings.
4. Motor stator shall be arranged for service orremoval with only minor compressor disassem-bly and without removing main refrigerantpiping connections.
5. Full load operation of the motor shall notexceed nameplate rating.
6. One motor winding temperature sensor (and onspare) shall be provided.
7. Should mechanical contractor choose to pro-vide a chiller with an air-cooled motor instead ofthe specified semi-hermetic motor, the contrac-tor shall install additional cooling equipment todissipate the motor heat.
26
The following formula applies:Btuh = (FLkW motor) (0.05) (3413)Btuh = (FLkW motor) (171)and, alternatelyTons = Btuh/12,000The additional piping, valves, air-handlingequipment, insulation, wiring, switchgearchanges, ductwork, and coordination with othertrades shall be the responsibility of the mechan-ical contractor. Shop drawings reflecting anychanges to the design shall be included in thesubmittal, and incorporated into the final as-built drawings for the project.
8. Also, if an open motor is provided, a mechani-cal room thermostat shall be provided and setat 104 F (40 C). If this temperature isexceeded, the chillers shall shut down and analarm signal shall be generated to the centralEnergy Management System (EMS) displaymodule, prompting the service personnel todiagnose and repair the cause of the overtem-perature condition. The mechanical contractorshall be responsible for all changes to thedesign, including coordination with temperaturecontrol, electrical and other trades. In addition,the electrical power consumption of any auxil-iary ventilation and/or mechanical coolingrequired to maintain the mechanical room con-ditions stated above shall be considered in thedetermination of conformance to the scheduledchiller energy efficiency requirement.
D. Evaporator and Condenser:1. Evaporator and condenser shall be of shell and
tube type construction, each in separate shells.Units shall be fabricated with high-performancetubing, steel shell and tube sheets with fabri-cated steel waterboxes. Waterboxes shall benozzle-in-head type with stub out nozzles havingVictaulic grooves to allow for use of Victauliccouplings.
2. Tubing shall be copper, high-efficiency type,with integral internal and external enhance-ment unless otherwise noted. Tubes shall benominal 3/4-in. OD with nominal wall thicknessof 0.025 in. measured at the root of the finunless otherwise noted. Tubes shall be rolledinto tube sheets and shall be individuallyreplaceable. Tube sheet holes shall be doublegrooved for joint structural integrity. Intermedi-ate support sheet spacing shall not exceed36 in. (914 mm).
3. Waterboxes and nozzle connections shall bedesigned for 150 psig (1034 kPa) minimumworking pressure unless otherwise noted.Nozzles should have grooves to allow use ofVictaulic couplings.
4. The tube sheets of the cooler and condensershall be bolted together to allow for field disas-sembly and reassembly.
5. The vessel shall display an ASME nameplatethat shows the pressure and temperature dataand the “U” stamp for ASME Section VIII,Division 1. A re-seating pressure relief valve(s)shall be installed on each heat exchanger. If anon-reseating type is used, a backup reseatingtype shall be installed in series.
6. Waterboxes shall have vents, drains, and coversto permit tube cleaning within the space shownon the drawings. A thermistor type temperaturesensor with quick connects shall be factory-installed in each water nozzle.
7. Cooler shall be designed to prevent liquid refrig-erant from entering the compressor. Devicesthat introduce pressure losses (such as misteliminators) shall not be acceptable becausethey are subject to structural failures that canresult in extensive compressor damage.
8. Tubes shall be individually replaceable fromeither end of the heat exchanger without affect-ing the strength and durability of the tube sheetand without causing leakage in adjacent tubes.
9. The condenser shell shall include a FLASC(Flash Subcooler) which cools the condensedliquid refrigerant to a reduced temperature,thereby increasing the refrigeration cycleefficiency.
E. Refrigerant Flow Control:To improve part load efficiency, liquid refrigerantshall be metered from the condenser to the coolerusing a float-type metering valve to maintain theproper liquid level of refrigerant in the heatexchangers under both full and part load operatingconditions. By maintaining a liquid seal at the floatvalve, bypassed hot gas from the condenser to thecooler is eliminated.
F. Controls, Safeties, and Diagnostics:1. Controls:
a. The chiller shall be provided with a factory-installed and factory-wired microprocessorcontrol center. The control center shall includea 16-line by 40-character liquid crystal display,4 function keys, stop button, and alarm light.Other languages are available using the inter-national language translator software.
b. All chiller and motor control monitoring shallbe displayed at the chiller control panel.
c. The controls shall make use of non-volatilememory.
d. The chiller control system shall have the abilityto interface and communicate directly to thebuilding control system.
e. The default standard display screen shall simul-taneously indicate the following minimuminformation:
1) Date and time of day2) 24-character primary system status
message
Guide specifications (cont)
27
3) 24-character secondary status message4) Chiller operating hours5) Entering chilled water temperature6) Leaving chilled water temperature7) Evaporator refrigerant temperature8) Entering condenser water temperature9) Leaving condenser water temperature
f. In addition to the default screen, statusscreens shall be accessible to view the statusof every point monitored by the controlcenter including:
1) Evaporator pressure2) Condenser pressure3) Compressor speed4) Bearing oil supply temperature5) Compressor discharge temperature6) Motor winding temperature 7) Number of compressor starts8) Control point settings9) Discrete output status of various devices
10) Variable frequency drive status11) Optional spare input channels12) Line current and voltage for each phase13) Frequency, kW, kWhr, demand kW
g. Schedule Function:The chiller controls shall be configurable formanual or automatic start-up and shutdown.In automatic operation mode, the controlsshall be capable of automatically starting andstopping the chiller according to a storeduser programmable occupancy schedule.The controls shall include built-in provisionsfor accepting:1) A minimum of two 365-day occupancy
schedules. 2) Minimum of 8 separate occupied/unoc-
cupied periods per day3) Daylight savings start/end 4) 18 user-defined holidays 5) Means of configuring an occupancy
timed override 6) Chiller start-up and shutdown via remote
contact closureh. Service Function:
The controls shall provide a passwordprotected service function which allowsauthorized individuals to view an alarmhistory file which shall contain the last25 alarm/alert messages with time and datestamp. These messages shall be displayed intext form, not codes.
i. Network Window Function:Each chiller control panel shall be capable ofviewing multiple point values and statusesfrom other like controls connected on acommon network, including controller main-tenance data. The operator shall be able toalter the remote controller’s set points ortime schedule and to force point values orstatuses for those points that are operatorforcible. The control panel shall also haveaccess to the alarm history file of all like con-trollers connected on the network.
j. Pump Control:Upon request to start the compressor, thecontrol system shall start the chilled andcondenser water pumps and shall verify thatflows have been established.
k. Ramp Loading:A user-configurable ramp loading rate, effec-tive during the chilled water temperaturepulldown period, shall prevent a rapidincrease in compressor power consumption.The controls shall allow configuration of theramp loading rate in either degrees per min-ute of chilled water temperature pulldown orpercent motor amps per minute. During theramp loading period, a message shall bedisplayed informing the operator that thechiller is operating in ramp loading mode.
l. Chilled Water Reset:The control center shall allow reset of thechilled water temperature set point based onany one of the following criteria:1) Chilled water reset based on an external
4 to 20 mA signal.2) Chilled water reset based on a remote
temperature sensor (such as outdoorair).
3) Chilled water reset based on water tem-perature rise across the evaporator.
m. Demand Limit:The control center shall limit amp draw ofthe compressor to the rated load amps or toa lower value based on one of the followingcriteria:1) Demand limit based on a user input
ranging from 40% to 100% of compres-sor rated load amps
2) Demand limit based on external 4 to20 mA signal.
n. Controlled Compressor Shutdown:The controls shall be capable of beingconfigured to soft stop the compressor. Thedisplay shall indicate “shutdown in progress.”
28
2. Safeties:a. Unit shall automatically shut down when any
of the following conditions occur (each ofthese protective limits shall require manualreset and cause an alarm message to be dis-played on the control panel screen, inform-ing the operator of the shutdown cause):
1) Motor overcurrent2) Over voltage*3) Under voltage*4) Single cycle dropout* (LF-2 VFDs only)5) Low oil sump temperature6) Low evaporator refrigerant temperature7) High condenser pressure8) High motor temperature9) High compressor discharge temperature
10) Low oil pressure11) Prolonged stall12) Loss of cooler water flow13) Loss of condenser water flow14) Variable frequency drive fault15) High variable frequency drive temperature* Shall not require manual reset or cause an
alarm if auto-restart after power failure isenabled.
b. The control system shall detect conditionsthat approach protective limits and take self-corrective action prior to an alarm occur-ring. The system shall automatically reducechiller capacity when any of the followingparameters are outside their normal operat-ing range:1) High condenser pressure2) High motor temperature3) Low evaporator refrigerant temperature4) High motor amps5) High VFD inverter temperature
c. During the capacity override period, a pre-alarm (alert) message shall be displayedinforming the operator which condition iscausing the capacity override. Once the con-dition is again within acceptable limits, theoverride condition shall be terminated andthe chiller shall revert to normal chilledwater control. If during either condition theprotective limit is reached, the chiller shallshut down and a message shall be displayedinforming the operator which conditioncaused the shutdown and alarm.
d. Internal built in safeties shall protect thechiller from loss of water flow. Differentialpressure switches shall not be allowed to bethe only form of freeze protection.
3. Diagnostics and Service:a. A self diagnostic controls test shall be an
integral part of the control system to allowquick identification of malfunctioningcomponents.
b. Once the controls test has been initiated, allpressure and temperature sensors shall bechecked to ensure they are within normaloperating range. A pump test shall automat-ically energize the chilled water pump, con-denser water pump, and oil pump. Thecontrol system shall confirm that water flowand oil pressure have been established andrequire operator confirmation before pro-ceeding to the next test.
c. In addition to the automated controls test,the controls shall provide a manual testwhich permits selection and testing of indi-vidual control components and inputs. Athermistor test and transducer test shall dis-play on the ICVC screen the actual readingof each transducer and each thermistorinstalled on the chiller. All out-of-range sen-sors shall be identified. Pressure transducersshall be serviceable without the need forrefrigerant charge removal or isolation.
4. Multiple Chiller Control:The chiller controls shall be supplied as stan-dard with a two-chiller lead/lag and a thirdchiller standby system. The control system shallautomatically start and stop a lag or secondchiller on a two-chiller system. If one of the twochillers on line goes into a fault mode, the thirdstandby chiller shall be automatically started.The two-chiller lead/lag system shall allowmanual rotation of the lead chiller and a stag-gered restart of the chillers after a power fail-ure. The lead/lag system shall include loadbalancing if configured to do so.
G. Electrical Requirements:1. Electrical contractor shall supply and install
main electrical power line, disconnect switches,circuit breakers, and electrical protectiondevices per local code requirements and as indi-cated necessary by the chiller manufacturer.
2. Electrical contractor shall wire the chilled waterpump and flow, condenser water pump andflow, and tower fan control circuit to the chillercontrol circuit.
3. Electrical contractor shall supply and installelectrical wiring and devices required to inter-face the chiller controls with the building controlsystem if applicable.
4. Electrical power shall be supplied to the unit atthe voltage, phase, and frequency listed in theequipment schedule.
H. Piping Requirements — Instrumentation and Safeties:1. Mechanical contractor shall supply and install
pressure gages in readily accessible locations inpiping adjacent to the chiller such that they canbe easily read from a standing position on thefloor. Scale range shall be such that design val-ues shall be indicated at approximately mid-scale.
Guide specifications (cont)
29
2. Gages shall be installed in the entering and leav-ing water lines of the cooler and condenser.
I. Vibration Isolation:Chiller manufacturer shall furnish neoprene isolatorpads for mounting equipment on a level concretesurface.
J. Start-Up:1. The chiller manufacturer shall provide a factory-
trained representative, employed by the chillermanufacturer, to perform the start-up proce-dures as outlined in the Start-Up, Operationand Maintenance manual provided by thechiller manufacturer.
2. Manufacturer shall supply the followingliterature:a. Start-up, operation and maintenance
instructions.b. Installation instructions.c. Field wiring diagrams.d. One complete set of certified drawings.
K. Special Features:1. Soleplate Package:
Unit manufacturer shall furnish a soleplatepackage consisting of soleplates, jackingscrews, leveling pads, and neoprene pads.
2. Spring Isolators:Spring isolators shall be field furnished andselected for the desired degree of isolation.
3. Spare Sensors with Leads:Unit manufacturer shall furnish additional tem-perature sensors and leads.
4. Sound Insulation Kit:Unit manufacturer shall furnish a sound insula-tion kit that covers the compressor housing,motor housing, compressor discharge pipe,suction line, evaporator, and economizer (ifequipped).
5. Stand-Alone Pumpout Unit:A free-standing pumpout unit shall be provided.The pumpout unit shall use a semi-hermeticreciprocating compressor with liquid-cooledcondenser. Condenser liquid piping and3-phase motor power shall be installed at thejobsite by the installing contractor.
6. Separate Storage Tank and Pumpout Unit:A free-standing refrigerant storage tank andpumpout unit shall be provided. The storagevessels shall be designed per ASME Section VIIIDivision 1 code with 150 psig (1034 kPa)design pressure. Double relief valves per ANSI/ASHRAE 15, latest edition, shall be provided.The tank shall include a liquid level gage andpressure gage. The pumpout shall use ahermetic reciprocating compressor with water-
cooled condenser. Condenser water piping and3-phase motor power shall be installed at thejobsite by the installing contractor.
7. Building Control System Interface (LON):The chiller control system shall have the abilityto interface and communicate directly to thebuilding control using a LON based system. TheLonWorks Carrier Translator shall output datain standard LON profiles.
8. Refrigerant Charge:The chiller shall ship from the factory fullycharged with R-134a refrigerant and oil.
9. Thermal Insulation:Unit manufacturer shall insulate the coolershell, economizer, suction elbow, motor shelland motor cooling lines. Insulation shall be 1 in.(25.4 mm) thick with a thermal conductivity notexceeding
and shall conform to UL standard 94, classifica-tion 94 HF-1.
10. Automatic Hot Gas Bypass:Hot gas bypass valve and piping shall befactory-furnished to permit chiller operation forextended periods of time.
11. Cooler and Condenser Tubes:Contact a local Carrier Representative for othertube offerings.
12. Cooler and Condenser Passes:Unit manufacturer shall provide the cooler and/or condenser with 1, 2 or 3 pass configurationon the water side.
13. Nozzle-In-Head, 300 psig (2068 kPa):Unit manufacturer shall furnish nozzle-in-headstyle waterboxes on the cooler and/or con-denser rated at 300 psig (2068 kPa).
18. Optional Compressor Discharge Isolation Valveand Liquid Line Ball Valve:These items shall be factory-installed to allowisolation of the refrigerant charge in the con-denser for servicing the compressor.
19. Pumpout Unit:A refrigerant pumpout system shall be installedon the chiller. Pumpout system shall include ahermetic compressor and drive, internal piping,internal wiring, and motor. Field-supplied mainpower wiring and water piping shall berequired.
20. BACnet Communication Option:Shall provide factory installed communicationcapability with a BACnet MS/TP network.Allows integration with i-Vu® Open control sys-tem or a BACnet building automation system.
21. Optional Seismic Isolation Package: Package shall meet International Building Codeand ASCE 7 seismic qualification requirementsin concurrence with ICC ES AC156 Accep-tance Criteria for Seismic Qualification byShake-Table Testing of Nonstructural Compo-nents and Systems. Manufacturer shall provideseismic certificate from OSHPD (Californiaonly).
22. Unit-Mounted Variable Frequency Drive (VFD)with Built-In Harmonic LiquiFlo™ II Filter:a. Design:
1) The VFD shall be refrigerant cooled,microprocessor based, pulse width mod-ulated design. Water cooled designs arenot acceptable.
2) Input and output power devices shall beInsulated Gate Bipolar Transistors(IGBTs).
3) Rectifier shall convert incoming fixedvoltage/frequency to fixed DC voltage.
4) Transistorized inverter and control regu-lator shall convert fixed DC voltage to asinusoidal PWM waveform.
5) Low voltage control sections and mainpower sections shall be physically iso-lated.
6) Integrated controls shall coordinatemotor speed to optimize chiller perfor-mance over a wide variety of operatingconditions.
b. Enclosure:1) Pre-painted unit mounted, NEMA 1 cab-
inet shall include hinged, lockable doorsand removable lifting lugs.
2) The VFD shall have a short circuit inter-rupt and withstand rating of at least65,000 amps.
3) Provisions to padlock main disconnecthandle in “Off” positions shall be pro-vided. Mechanical interlock to prevent
opening cabinet door with disconnect inthe “On” position or moving disconnectto the “On” position while the door isopen shall be provided.
4) Provisions shall be made for top entry ofincoming line power cables.
c. Heat Sink:1) The heat sink shall be refrigerant
cooled. Heat sink and mating flangesshall be suitable for ASME design work-ing pressure of 185 psig (1276 kPa).
2) Refrigerant cooling shall be metered tomaintain heat sink temperature withinacceptable limits for ambient tempera-ture.
d. VFD Rating:1) Drive shall be suitable for operation at
nameplate voltage ±10%.2) Drive shall be suitable for continuous
operation at 100% of nameplate ampsand 150% of nameplate amps for 5 sec-onds.
3) Drive shall comply with applicableANSI, NEMA, UL and NEC standards.
4) Drive shall be suitable for operation inambient temperatures between 40 and122 F (4 and 50 C), 95% humidity (non-condensing) for altitudes up to 6000 ft(1829 m) above sea level. Specific driveperformance at jobsite ambient temper-ature and elevation shall be provided bythe manufacturer in the bid.
e. User Interface:A single display shall provide interface forprogramming and display of VFD and chillerparameters. Viewable parameters include:1) Operating, configuration and fault mes-
sages2) Frequency in hertz3) Load and line side voltage and current
(at the VFD)4) kW5) IGBT temperature
f. VFD Performance:1) The VFD Voltage Total Harmonic Dis-
tortion (THD) and Harmonic CurrentTotal Demand Distortion (TDD) shall notexceed IEEE-519 requirements usingthe VFD circuit breaker input terminalsas the point of common coupling (PCC).
2) The VFD full load efficiency shall meetor exceed 97% at 100% VFD ratedampacity.
3) Active rectifier shall regulate unity dis-placement power factor to 0.99 orhigher.
4) Voltage boost capability to provide fullmotor voltage at reduced line voltageconditions.
Guide specifications (cont)
31
5) The VFD shall feature soft start, linearacceleration, and coast to stop capabili-ties.
6) Base motor frequency shall permitmotor to be utilized at nameplate volt-age. Adjustable frequency range shallpermit capacity control down to 15%.
7) The VFD shall have 150% instanta-neous torque generation.
g. VFD Electrical Service (single point power):1) The VFD shall have input circuit breaker
with minimum 65,000 amp interruptcapacity.
2) The VFD shall have standard branch oilpump circuit breaker to provide powerfor chiller oil pump.
3) The VFD shall have standard 3 KVAcontrol power transformer with circuitbreaker to provide power for oil heater,VFD controls and chiller controls.
4) The branch oil pump circuit breaker andcontrol power transformer shall be fac-tory-wired.
5) Input power shall be 380/460 vac,±10%, 3 Phase, 50/60 Hz, ±2% Hz.
h. Discrete Outputs:115-v discrete contact outputs shall be pro-vided for:1) Circuit breaker shunt trip2) Chilled water pump3) Condenser water pump4) Alarm status
i. Analog Output:An analog (4 to 20 mA) output for headpressure reference shall be provided. Thissignal shall be suitable to control a 2-way or3-way water regulating valve in the con-denser piping.
j. Protection (the following shall be supplied):1) Under-voltage2) Over voltage3) Phase loss4) Phase reversal5) Ground fault6) Phase unbalance protection7) Single cycle voltage loss protection8) Programmable auto re-start after loss of
power9) Motor overload protection (NEMA Class
10)10) Motor over temperature protection
k. VFD Testing:The VFD shall be factory-mounted, factory-wired and factory-tested on the chiller priorto shipment.
23. Unit-Mounted Variable Frequency Drive (VFD)without Built-In Harmonic Filter:a. Design:
1) VFD shall be refrigerant cooled, micro-processor based, pulse width modulateddesign. Water cooled designs are notacceptable.
2) Output power devices shall be insulatedgate bipolar transistors (IGBTs).
3) Converter section with full-wave fixeddiode bridge rectifier shall convertincoming fixed voltage/frequency tofixed DC voltage.
4) DC link shall filter and smooth the con-verted DC voltage.
5) Transistorized inverter and control regu-lator shall convert fixed DC voltage to asinusoidal PWM waveform.
6) Integrated controls shall coordinate themotor speed and the guide vane posi-tion to optimize chiller performanceover a wide variety of operating condi-tions.
7) Surge prevention and surge protectionalgorithms shall take action to preventsurge and move chiller operation awayfrom surge.
b. Enclosure:1) Pre-painted unit mounted, NEMA 1 cab-
inet shall include hinged, lockable doorsand removable lifting lugs.
2) VFD shall have a short circuit interruptand withstand rating of at least 100,000amps.
3) Provisions to padlock main disconnecthandle in the “Off” positions shall beprovided. Mechanical interlock to pre-vent opening cabinet door with discon-nect in the “On” position or movingdisconnect to the “ON” position whilethe door is open shall be provided.
4) Provisions shall be made for top entry ofincoming line power cables.
c. Heat Sink:1) The heat sink shall be refrigerant
cooled. Heat sink and mating flangesshall be suitable for ASME design work-ing pressure of 185 psig (1276 kPa).
2) Refrigerant cooling shall be metered byintegrated standard controls to maintainheat sink temperature within acceptablelimits for ambient temperature.
d. VFD Rating:1) Drive shall be suitable for nameplate
voltage ±10%.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.Pg 32 Catalog No. 04-52230003-01 Printed in U.S.A. Form 23XRV-4PD
Replaces: 23XRV-3PDSection 9Tab 9a
Carrier Corporation • Syracuse, New York 13221 2-12
2) Drive shall be suitable for continuousoperation at 100% of nameplate ampsand 150% of nameplate amps for 3seconds.
3) Drive shall comply with applicable UL,CE, and NEMA standards.
4) Drive shall be suitable for operation inambient temperatures between 40 and104 F, 95% humidity (non-condensing)for altitudes up to 3300 feet (1006 m)above sea level. Specific drive perfor-mance at jobsite ambient temperatureand elevation shall be provided by themanufacturer in the bid.
e. User Interface:Displays shall provide interface for pro-gramming and display of VFD and chillerparameters. Viewable parameters include:1) Operating, configuration and fault
messages2) Frequency in hertz3) Load side voltage and current (at the
VFD)4) kW (on the VFD interface)
f. VFD Performance:1) VFD full load efficiency shall meet or
exceed 97% at 100% VFD RatedAmpacity.
2) Base motor frequency shall be either50 or 60 hertz.
g. VFD Electrical Service: (single pointpower):1) VFD shall have input circuit breaker
with minimum 65,000 amp interruptcapacity.
2) VFD shall have standard 15 ampbranch oil pump circuit breaker to pro-vide power for chiller oil pump.
3) VFD shall have standard 3 kva controlpower transformer with circuit breakerprovides power for oil heater, VFDcontrols and chiller controls.
4) The branch oil pump circuit breakerand control power transformer shall befactory wired.
5) Input power shall be 380/480 vac,±10 percent, 3 phase, 50/60 Hz,±3 Hz.
h. Discrete Outputs:115-v discrete contact outputs shall be pro-vided for:1) Chilled water pump2) Condenser water pump3) Alarm status.
i. Analog Output:An analog (4 to 20 mA) output for headpressure reference shall be provided. Thissignal shall be suitable to control a 2-wayor 3-way water regulating valve in the con-denser piping.
j. Protection (the following shall be supplied):1) Under-voltage2) Over voltage3) Phase loss4) Phase unbalance protection5) Programmable auto re-start after loss
of power6) Motor overload protection (NEMA
Class 10)7) Motor over temperature protection
k. VFD Testing:The VFD shall be factory mounted, wireand tested on the chiller prior to shipment.