Carrier Evergreen 23Xrv Users Manual 3pd Reprint 910

23XRV to the manual 2f5066a0-4e7a-4acf-85c9-ade2ef55a790

2015-01-24

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Features/Benefits
Table of Contents
Model Number Nomenclature
Physical Data
Options and Accessories
Dimensions
Performance Data
Electrical Data
Controls
Typical Piping and Wiring
Control Wiring Schematic
Application Data
Guide Specifications

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 0.33 kW/ton (AHRI

IPLV).

• Chlorine-free HFC-134a refrigerant.

• IEEE-519 compliance for harmonic

distortion.

• 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

300 to 550 Nominal Tons (1055 to 1934 Nominal kW)

Product

Data

INNOVATION

AWARD

2008 AHR EXPO

2008 AHR EXPO®

WINNER – Green Building

23XRV

EISMI

OMPLIANT*

* Meets IBC 2006, ASCE-7-05, CBC 2007, and OSHPD seismic requirements.

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 efficiency

Per 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 leader

Carrier 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 design

Positive 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 — The

Evergreen 23XRV chiller will generate

less than 5% total harmonic distortion

at the input to the VFD (variable

frequency drive) without the use of

any external filters or line reactors.

This assures the VFD alone cannot

exceed the IEEE-519 standard for

distortion at the point of common

coupling. Ultra-low harmonics can

eliminate the 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,

which helps building owners avoid

power factor penalties and decreases

electrical losses in cables and trans-

formers. High power factor may also

reduce KVA requirements, saving elec-

trical system costs on new projects or

freeing up electrical resources on exist-

ing systems operating near their maxi-

mum 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.

Features/Benefits (cont)

Table of contents

Page

Features/Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Model Number Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5, 6

Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14

Typical Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-23

Guide Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-31



910

• Machine room cooling requirements

associated with air-cooled motors,

which dissipate heat to the mechan-

ical room.

• High noise levels common with air-

cooled motors, which radiate noise

to the machine room and adjacent

areas.

• Shaft alignment problems that occur

with open-drive designs during start-

up and operation, when equipment

temperature 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 and

300 psig piping requirements.

Heat exchanger features

ASME 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 improved

efficiency.

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

features

Direct 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 standard

languages:

•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

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 any

other 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 Efficiency

Variable Speed Screw Chiller

Cooler Size*

30-32

35-37

40-42

45-47

50-52

55-57

Condenser Size*

30-32

35-37

40-42

45-47

50-52

55-57

Economizer Option

E – With Economizer

N – No Economizer

Voltage Code

3 – 380-3-60

4 – 416-3-60

5 – 460-3-60

9 – 380/415-3-50

S – Special

R – Compressor

Not Used

Drive Amps Amps

Code In† Out†

AA 440 442

BA 520 442

BB 520 520

Motor Code

P T

Q U

R V

CC 608 608

ASME

‘U’ Stamp

AHRI (Air Conditioning, Heating

and Refrigeration Institute)

Performance Certified

Model number nomenclature

*First number denotes frame size.

†Maximum limits only. Additional application

limits apply that may reduce these ampacities.

a23-1648

Quality Assurance

Certified to ISO 9001:2000

EISMI

OMPLIANT*

* Meets IBC 2006, ASCE-7-05, CBC 2007, and OSHPD seismic requirements.

23XRV COMPRESSOR AND MOTOR WEIGHTS

COMPONENT WEIGHTS

LEGEND

23XRV HEAT EXCHANGER WEIGHTS

COND — Condenser

*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-

taulic grooves.

MOTOR

SIZE

ENGLISH SI

Total

Compressor

Weight

(lb)

Stator

Weight

(lb)

Rotor

Weight

(lb)

Motor

Terminal

Cover

(lb)

Compressor

Weight

(kg)

Stator

Weight

(kg)

Rotor

Weight

(kg)

Motor

Terminal

Cover

(kg)

P, Q , R , S ,

T,U,V 4866 441 229 46 2207 200 104 21

COMPONENT

FRAME 3 HEAT

EXCHANGER

FRAME 4 HEAT

EXCHANGER

FRAME 5 HEAT

EXCHANGER

lb kg lb kg lb kg

Isolation Valves 70 32 70 32 115 52

Suction Elbow 179 81 237 108232 105

Discharge Elbow/Muffler 747 339 747 339 747 339

Control Center/VFD 1650 749 1650 749 1650 749

Vaporizer and Oil Sump 700 318700 318700 318

Economizer 542 246 542 246 542 246

VFD — Variable Frequency Drive

CODE

NUMBER

OF TUBES

ENGLISH METRIC (SI)

Dry Rigging

Weight

(lb)*

Machine Charge

Dry Rigging

Weight

(kg)*

Machine Charge

Cooler

Only

Cond.

Only

Refrigerant

Weight (lb)

Liquid Weight

(lb) Cooler

Only

Cond.

Only

Refrigerant

Weight (kg)

Liquid Weight

(kg)

Cooler Cond. With

Economizer

Without

Economizer Cooler Cond. With

Economizer

Without

Economizer Cooler Cond.

30 200 21841483617 800 650 464 464 1877 1676 363 295 210 210

31 240 266 4330 3818800 650 531 542 1959 1769 363 295 241 246

32 2823154522 4023 800 650 601 621 2046 1860 363 295 273 282

35 200 2184419 4529 910 760 511 513 2000 2089 413 345 232 233

36 240 266 4627 4758910 760 587 602 2094 2195 413 345 266 274

37 2823154845 4992 910 760 667 692 2193 2299 413 345 303 314

40 324 366 50084962 900 825 863 915 2675 2746 408375 391 415

41 364 415 51785155 900 825 930 995 27582839 408375 422 451

42 400 464 5326 5347 900 825 990 1074 2832 2932 408375 449 487

45 324 366 5463 5525 1015 960 9389982882 3001 460 436 425 453

46 364 415 5659 5747 1015 960 1014 1088 2976 3108460 436 460 494

47 400 464 5830 5967 1015 960 1083 1179 3061 3214 460 436 491 535

50 431 507 5827 6013 1250 1100 1101 1225 3182 3304 567 499 499 556

51 4855566053 6206 1250 1100 1192 1304 3294 3397 567 499 541 591

52 519 602 6196 6387 1250 1100 12481379 3364 3485 567 499 566 626

55 431 507 6370 67081430 1280 1201 1339 3429 3620 649 581545607

56 4855566631 6930 1430 1280 1304 1429 3556 3726 649 581591648

57 519 602 6795 71381430 1280 1369 1514 3636 3826 649 581621687

Physical data

ADDITIONAL WEIGHTS FOR 23XRV MARINE WATERBOXES*

150 psig (1034 kPa) MARINE WATERBOXES

300 psig (2068 kPa) MARINE WATERBOXES

*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 in

the 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 in

the heat exchanger weights shown on page 5.

FRAME

NUMBER

PASSES

ENGLISH (lb) SI (kg)

Cooler Condenser Cooler Condenser

Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt

31 and 3 730 700 N/A N/A 331 318N/A N/A

2 365 350 365 350 166 159 166 159

41 and 3 1888 908N/A N/A 856 412 N/A N/A

2 944 452 989 452 428205 449 205

51 and 3 2445 1019 N/A N/A 1109 462 N/A N/A

2 1223 510 1195 499 555 231 542 226

FRAME

NUMBER

PASSES

ENGLISH (lb) SI (kg)

Cooler Condenser Cooler Condenser

Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt Rigging Wgt Liquid Wgt

31 and 3 860 700 N/A N/A 390 318N/A N/A

2 430 350 430 350 195 159 195 159

41 and 3 2162 908N/A N/A 981 412 N/A N/A

2 1552 393 1641 393 704 178744 178

51 and 3 2655 1019 N/A N/A 1204 462 N/A N/A

2 1965 439 1909 418891 199 866 190

WATERBOX

DESCRIPTION

COOLER CONDENSER

Frame 3 Frame 4 Frame 5 Frame 3 Frame 4 Frame 5

Victaulic

Nozzles Flanged Victaulic

Nozzles Flanged

NIH,1 pass Cover 150 psig 282318148185168229 282318148185168229

NIH,2 pass Cover 150 psig 287 340 202 256 222 275 287 340 191 245 224 298

NIH,3 pass Cover 150 psig 294 310 472 488 617 634 294 310 503 519 628655

NIH Plain End, 150 psig 243 243 138138154 154 225 225 138138154 154

MWB End Cover, 150 psig*243/315 243/315 138/314 138/314 154/390 154/390 225/234 225/234 138/314 138/314 154/390 154/390

NIH,1 pass Cover 300 psig 411 486 633 709 764 840 411 486 633 709 764 840

NIH,2 pass Cover 300 psig 411 518626 733 760 867 411 518622 729 727 878

NIH,3 pass Cover 300 psig 433 468660 694 795 830 433 468655 689785838

NIH Plain End, 300 psig 294 294 522 522 658658270 270 522 522 658658

MWB End Cover, 300 psig*445/619 445/619 522/522 522/522 658/658658/658359/474 359/474 658/658658/658658/658658/658

NIH — Nozzle-in-Head

MWB — Marine Waterbox

WATERBOX

DESCRIPTION

COOLER CONDENSER

Frame 3Frame 4Frame 5Frame 3Frame 4Frame 5

Victaulic

Nozzles Flanged Victaulic

Nozzles Flanged

NIH,1 pass Cover 1034 kPa 128144 67 8476104128144 67 8476104

NIH,2 pass Cover 1034 kPa 130 154 92 116 101 125 130 154 87 111 102 135

NIH,3 pass Cover 1034 kPa 133 141 214 221 280288 133 141 228235 285297

NIH Plain End, 1034 kPa 110 110 63 63 70 70 102 102 63 63 70 70

MWB End Cover, 2068 kPa*110/143 110/143 63/142 63/142 70/177 70/177 102/106 102/106 63/142 63/142 70/177 70/177

NIH,1 pass Cover 2068 kPa 186220287322347381186220287322347381

NIH,2 pass Cover 2068 kPa 186235284332344393186235282331330398

NIH,3 pass Cover 2068 kPa 196 212 299 315 361 376 196 212 297 313 356 380

NIH Plain End, 2068 kPa 132 132 237 237 298298122 122 237 237 298298

MWB End Cover, 2068 kPa*202/281202/281 237/237 237/237 298/298298/298163/215 163/215 298/298298/298298/298298/298

NIH — Nozzle-in-Head

MWB — Marine Waterbox

Physical data (cont)

*Factory-installed.

†Field-installed.

**Standard waterbox nozzles are victaulic type. Flanged nozzles are

available as an option with either nozzle-in-head type waterboxes or

marine waterboxes.

††Optional marine waterboxes available for 23XRV heat exchanger

frames 3-5 only. Standard waterboxes for 23XRV are nozzle-in-head

type, 150 psig (1034 kPa).

***Sponsored by ASHRAE (American Society of Heating, Refrigerating,

and Air Conditioning Engineers).

†††Registered trademark of Echelon Corporation.

ITEM OPTION*ACCESSORY†

.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 X

Flanged Cooler and/or Condenser Waterbox Nozzles** X

Hinged Waterboxes X

Marine Waterboxes, 150 psig (1034 kPa)†† X

Marine Waterboxes, 300 psig (2068 kPa)†† X

Nozzle-in Head Waterbox, 300 psig (2068 kPa) X

One, 2, or 3 Pass Cooler or Condenser Waterside Construction X

Seismic Kit X

Zinc Anodes X

100K AIC (Amp Interrupt Capacity) High Interrupt Circuit Breaker with Shunt Trip X

Analog Voltmeter and Ammeter with 3 Phase Selector Switch X

BACnet*** Communications X

LonWorks††† Carrier Translator X

Sensor Package X

Refrigerant Isolation Valves X

Separate Storage Tank and Pumpout Unit X

Shipped Factory Charged with Refrigerant X

Stand-Alone Pumpout Unit X

Unit-Mounted Pumpout Unit X

Hot Gas Bypass X

Soleplate Package X

Spring Isolator Kit X

Acoustical Sound Insulation Kit X

Full Cold Surface Thermal Insulation (Except Waterbox Covers) X

Customer Factory Performance Testing X

Export Crating X

Extended Warranty (North American Operations [NAO] only) X

Service Contract X

Options and accessories

910



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, and

local safety code.

2. Allow at least 3 ft (915 mm) overhead clearance for service rigging

for 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. The

300 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 EXCHANGER

SIZE

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. mm ft-in. mm ft-in. mm

30 to 32 14- 31/44350 13- 81/44172 14- 31/44350 6- 4 1930 7- 25/82200

35 to 37 15-113/44870 15- 43/44693 15-113/44870 6- 4 1930 7- 25/82200

40 to 42 14- 9 4496 14- 31/84347 14- 6 4420 6- 81/22045 7- 61/22299

45 to 47 16- 51/25017 15-115/84867 16- 21/24940 6- 81/22045 7- 61/22299

50 to 52 14-10 4521 14- 41/24382 14- 61/24432 6-113/42127 7- 63/42305

55 to 57 16- 61/25042 16- 1 4902 16- 3 4953 6-113/42127 7- 63/42305

HEAT EXCHANGER

SIZE

A (Length, Marine Waterbox) B (Width) C (Height)2-Pass*1 or 3 Pass†

ft-in. mm ft-in. mm ft-in. mm

30 to 32 14- 9 4496 16- 43/44997 6- 93/82067

See unit

certified

drawings

35 to 37 16- 51/25017 18-1

1/455186- 93/82067

40 to 42 15- 23/44642 16- 31/450866-9

3/42076

45 to 47 16-113/45163 18-4

3/45607 6- 93/42076

50 to 52 15- 31/24661 16- 81/25093 7- 1 2159

55 to 57 17- 0 518218- 5 5613 7- 1 2159

(WIDEST POINT)

2’ MIN

(610 mm)

4’-10” MIN

(1475 mm)

FRAME R COMPRESSOR 3’-0” (915mm)

RECOMMENDED OVERHEAD SERVICE CLEARANCE

MOTOR SERVICE

CLEARANCE

1’-10” (559 mm)

TUBE REMOVAL

SPACE FOR

EITHER END

SIZES 30-32, 40-42

50-52

14’-3” (4343 mm)

SIZES 35-37, 45-47

55-57

14’-0” (4267 mm)

SERVICE AREA

4’ MIN

(1219 mm)

23XRV DIMENSIONS

a23-1646

Dimensions

NOZZLE SIZE

23XRV HEAT EXCHANGER MIN/MAX FLOW RATES*

ENGLISH (GPM)

*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.

FRAME

SIZE

NOZZLE SIZE (in.)

(Nominal Pipe Size)

Cooler Condenser

1-Pass 2-Pass 3-Pass 1-Pass 2-Pass 3-Pass

310 8610 86

410 8610 86

510 861010 8

COOLER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

30 611 2,444 305 1222 204 815

31 733 2,933 367 1466 244 978

32 855 3,422 4281710 285 1141

35 611 2,444 305 1222 204 815

36 733 2,933 367 1466 244 978

37 855 3,422 4281710 285 1141

40 989 3,959 495 1979 330 1320

41 1112 4,448556 2224 371 1482

42 1222 4,888 611 2444 407 1775

45 989 3,959 495 1979 330 1320

46 1112 4,448556 2224 371 1482

47 1222 4,888 611 2444 407 1775

50 1316 5,267 6582634 439 1756

51 1482 5,927 741 2964 494 1976

52 1586 6,343 793 3171 529 2114

55 1316 5,267 6582634 439 1756

56 1482 5,927 741 2964 494 1976

57 1586 6,343 793 3171 529 2114

CONDENSER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

30 646 2,582 323 1291 215 861

31 791 3,162 395 1581 263 1054

32 932 3,731 466 1865 311 1244

35 646 2,582 323 1291 215 861

36 791 3,162 395 1581 263 1051

37 932 3,731 466 1865 311 1244

40 1096 4,383 5482192 365 1461

41 1235 4,940 6182470 412 1647

42 1371 5,485686 2743 457 1828

45 1096 4,383 5482192 365 1461

46 1235 4,940 6182470 412 1647

47 1371 5,485686 2743 457 1828

50 1507 6,029 754 3015 502 2010

51 1646 6,586823 3293 549 2195

52 1783 7,131 891 3565 594 2377

55 1507 6,029 754 3015 502 2010

56 1646 6,586823 3293 549 2195

57 1783 7,131 891 3565 594 2377

COOLER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

30 38154 19 77 13 51

31 46 18523921562

32 54 215 27 1081872

35 38154 19 77 13 51

36 46 18523921562

37 54 215 27 1081872

40 62 249 31 125 21 83

41 70 281 35 140 23 93

42 77 307 38154 26 112

45 62 249 31 125 21 93

46 70 281 35 140 23 93

47 77 307 38154 26 112

50 83 332 42 166 28111

51 93 374 47 18731125

52 100 400 50 200 33 133

55 83 332 42 166 28111

56 93 374 47 18731125

57 100 400 50 200 33 133

CONDENSER 1 PASS 2 PASS 3 PASS

Frame Size Min Max Min Max Min Max

30 41 163 20 8114 54

31 50 199 25 100 17 67

32 59 235 29 11820 79

35 41 163 20 8114 54

36 50 199 25 100 17 67

37 59 235 29 11820 79

40 69 277 35 13823 92

41 78312 39 156 26 104

42 86 346 43 173 29 115

45 69 277 35 13823 92

46 78312 39 156 26 104

47 86 346 43 173 29 115

50 95 38048190 32 127

51 104 416 52 20835 138

52 112 450 56 225 37 150

55 95 38048190 32 127

56 104 416 52 20835 138

57 112 450 56 225 37 150

Performance data

VFD FRAME SIZES

*Maximum limits only. Additional application limits apply that will reduce these ampacities.

AUXILIARY RATINGS*

*Factory wired to VFD.

†Minimum circuit ampacity of 15 amps.

FRAME SIZE MAX INPUT CURRENT*MAX OUTPUT CURRENT*

AA 440 442

BA 520 442

BB 520 520

CC 608608

ITEM VOLTAGE

MAXIMUM

PROTECTIVE DEVICE

SIZE (AMPS)

WATTS

Controls, Oil Pump And Heater Circuit† 115 15 —

Oil Pump 115 1.48130

Oil Sump Heater 115 4.35 500

Oil Vaporizer Heater Circuit† 115 15 —

Oil Vaporizer Heater 115 13 1500

Electrical data

Microprocessor controls

Microprocessor controls provide the safety, interlock, ca-

pacity control, indications and accessibility necessary to

operate the chiller in a safe and efficient manner.

Control system

The microprocessor control on each Carrier chiller is

factory-mounted, factory-wired, and factory-tested to

ensure 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.

Features

Control 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 amperage

level prior to stopping

• Languages pre-programmed at factory for English, Chi-

nese, Japanese, Korean

• ILT (International Language Translator) available for

conversion 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

• Line voltage imbalance**

• Line current imbalance**

• Line frequency

• Motor current imbalance

• Motor rotation reversal

• Excessive motor amps

• Motor starts limit

• VFD speed out of range

• High VFD rectifier temperature*†

• 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 control

Interlocks

• Manual/automatic remote start

• Starting/stopping sequence

Pre-lube/post-lube

Pre-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 safeties

Indications

• 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 kW

Drive control parameters

• Compressor 100% speed (Hz)

• Rated line voltage

• Rated line amps

• Rated line kW

• Motor rated Load kW

• Motor rated Load amps

• Motor nameplate amps

• Motor nameplate RPM

• Motor nameplate kW

• Inverter PWM frequency

*Can be configured by the user to provide alert indication

at user-defined limit.

†Override protection: Causes compressor to first unload

and 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

Controls (cont)

CONTROL PANEL DISPLAY (Front View)

ICVC ENGLISH DISPLAY IN SI UNITS

CONTROL PANEL DISPLAY (Front View)

ICVC CHINESE DISPLAY IN METRIC UNITS

BLACK

WHITE

RED

BLACK

WHITE

RED

DRAIN WIREDRAIN WIRE

BLACK

WHITE

RED

BLACK

WHITE

RED

DRAIN WIRE

GROUNDDRAIN WIRE

NOTE: Field-supplied terminal strip must be located in control panel.

LEGEND

CCM — Chiller Control Module

Factory Wiring

Field Wiring

CCN COMMUNICATION WIRING FOR MULTIPLE CHILLERS (TYPICAL)

a23-1649

Control sequence

To start — Local start-up (manual start-up) is initiated by

pressing 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, must

be in the Occupied mode and the internal 15-minute start-

to-start and the 1-minute stop-to-start inhibit timers must

have expired. All pre-start safeties are checked to verify

that all prestart alerts and safeties are within limits (if one is

not, an indication of the fault displays and the start will be

delayed or is aborted). The signal is sent to start the cooler

liquid pump. Five seconds later, the condenser liquid pump

is energized. If satisfied, it checks the chilled liquid temper-

ature against the control point. If the temperature is less

than or equal to the chilled liquid control point, the con-

denser liquid pump is deenergized and the chiller goes into

a recycle mode.

If the chilled liquid temperature is high enough, the start-

up sequence continues. The oil pump is started and waits a

minimum of 45 sec to verify oil flow. Once oil flow is veri-

fied, the VFD is energized. The control will monitor for a

phase 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% within

15 seconds after VFD start, the machine enters run mode

and 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 initiated

if 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 Stop

button is pressed or the remote contacts open, motor

speed decreases to a configured amperage level, and the

compressor is stopped. The display indicates “Shutdown in

Progress” while the motor speed decreases. Compressor

ontime and service ontime timers stop once the current in

all phases is <5%, indicating a VFD Stop Complete. The oil

pump and cooler liquid pump are then deenergized. The

condenser liquid pump shuts down when the refrigerant

temperature or entering condenser liquid temperature is be-

low pre-established limits. The 3-minute start-to-stop timer

starts.

Restart — Restart is permitted after both inhibit timers

have expired. If shutdown was due to a safety shutdown,

the reset button must be depressed before restarting the

chiller.

Controls (cont)

MACHINE SAFETIES,

EVAPORATOR PUMP

CONDENSER WATER

PUMP

WATER FLOWS

CHILLED WATER

TEMP,

CONTROL

OIL PUMP

OIL PRESSURE

VERIFIED

VDF FAULT TEST

COMPRESSOR, PHASE

REVERSAL,

COMPRESSOR AND

SERVICE ONTIME

1-MINUTE

STOP-T O-STAR T

TIMER (SOFTWARE

VERSION 13)

15-MINUTE

START-TO-START

TIMER

RAMP VDF TO

TARGET SPEED

COMPRESSOR

RUNNING

ABCDEFGHIJ

KLO/A

TIME

TOWER FAN

0 0

CONTROL SEQUENCE

0—Phase reversal monitored

A—START INITIATED: Pre-start checks are made; evaporator pump

started

B—Condenser liquid pump started (5 seconds after A); tower fan control

enabled

C—Liquid flows verified (30 sec to 5 minutes maximum after B)

D—Chilled liquid temperature checked against control point; oil pump

on.

E—Oil pressure verified (oil pressure verified 45-300 sec after D).

F—VFD starts; phase reversal conditions monitored; compressor

ontime and service ontime start; 15-minute inhibit timer starts (VFD

fault tests for 15 sec after F)

G—Verify average current >5% within 15 sec after VFD start, ramp to

VFD target speed.

H—Compressor reaches target speed, chiller set to running status

I—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 pressure

is 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)

Typical piping and wiring

111

TO CHILLED LIQUID PUMP

TO CONDENSER LIQUID PUMP

TO COOLING TOWER FAN 2

MAIN COMPRESSOR

MOTOR POWER

FROM

COOLING

TOWER FROM

LOAD

COOLING

TOWER

LOAD

DRAIN

LEGEND

1—Disconnect

2—Unit-Mounted VFD/Control Center

3—Pressure Gages

4—Chilled Liquid Pump

5—Condenser Liquid Pump

6—Chilled Liquid Pump Starter

7—Condenser Liquid Pump Starter

8—Cooling Tower Fan Starter

9—Vents

Piping

Control Wiring

Power Wiring

NOTES:

1. Wiring and piping shown are for general point-of-connection only and are not

intended to show details for a specific installation. Certified field wiring and

dimensional 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.

23XRV CHILLER

Control wiring schematic

23XRV COMPONENT ARRANGEMENT

LEGEND

CCM — Chiller Control Module

CCN — Carrier Comfort Network®

ICVC — International Chiller Visual Controller

GND — Ground

Application data

YY*

VESSELS

TYP.

0’-3”

[76.2mm]

ACCESSORY

SOLEPLATE

0’-01/2”

[13mm]

TYP.

XX*

VESSELS

COND.

COOLER

23XRV MACHINE FOOTPRINT

*See detail on page 18.

23XRV

HEAT EXCHANGER

SIZE

DIMENSIONS (ft-in.) DIMENSIONS (mm)

A BCDEFGABCDEFG

30-32 12-103/45-41/4 0 0-35/81-13/40-9 0-1/23931 1632 0 92 349 229 13

35-37 14- 71/45-41/4 0 0-35/81-13/40-9 0-1/24451 1632 0 92 349 229 13

40-42 12-103/46-0 0-11/20-35/81-13/40-9 0-1/23931 1829 3892 349 229 13

45-47 14- 71/46-0 0-11/20-35/81-13/40-9 0-1/24451 1829 3892 349 229 13

50-52 12-103/46-51/20- 1/20-35/81-13/40-9 0-1/23931 1969 13 92 349 229 13

55-57 14- 71/46-51/20- 1/20-35/81-13/40-9 0-1/24451 1969 13 92 349 229 13

a23-1650

910

Application data (cont)

ELASTOMERIC PAD

23XRV ISOLATION WITH ACCESSORY SOLEPLATE PACKAGE

TYPICAL ISOLATION STANDARD ISOLATION

ACCESSORY SOLEPLATE DETAIL

VIEW X-X

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 Plus

Grout, 0-11/2 (38.1) to 0-21/4 (57) thick.

5. Service clearance under the chiller is enhanced if leveling pads are not extended

along the entire length of the heat exchangers.

VIEW Y-Y

ISOLATION WITH ISO L AT IO N PAC K A G E O N LY

(STA N DA R D )

NOTE: Isolation package includes 4 elastomeric pads.

a23-1647

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.

PASS

COOLER WATERBOXES

In Out Arrangement

Code*

185A

58B

279 C

46 D

376 E

49 F

PAS S

CONDENSER WATERBOXES

In Out Arrangement

Code*

111 2 P

211 Q

210 12 R

13 S

310 3 T

112 U

DISCHARGE END SUCTION END

Application data (cont)

23XRV NOZZLE ARRANGEMENTS (cont)

MARINE WATERBOXES

FRAME 3

NOZZLE ARRANGEMENT CODES

PASS

COOLER WATERBOXES

PASS

CONDENSER WATERBOXES

In Out Arrangement

Code In Out Arrangement

Code

85A 1—— —

58B———

279 C 210 12 R

46 D 1 3 S

376 E 3—— —

49 F — — —

FRAMES 4, AND 5

NOZZLE ARRANGEMENT CODES

PAS S

COOLER WATERBOXES

PASS

CONDENSER WATERBOXES

In Out Arrangement

Code In Out Arrangement

Code

196 A 1—— —

69 B — — —

279 C 210 12 R

46 D 1 3 S

376 E 3—— —

49 F — — —

DISCHARGE END SUCTION END

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).

FRAME

SIZE

PRESSURE

psig (kPa) PASS NOMINAL PIPE SIZE (in.) ACTUAL PIPE ID (in.)

Cooler Condenser Cooler Condenser

3150/300

(1034/2068)

1 10 10 10.020 10.020

2887.9817.981

3 6 6 6.065 6.065

4150/300

(1034/2068)

1 10 10 10.020 10.020

2887.9817.981

3 6 6 6.065 6.065

5150/300

(1034/2068)

1 10 10 10.020 10.020

2810 7.981 10.020

36 86.065 7.981

LOCATION FRAME

SIZE

RELIEF VALVE

OUTLET SIZE QUANTITY

MUFFLER 3-5 11/4-in. NPT FEMALE CONNECTOR 1

COOLER 3-5 11/4-in. NPT FEMALE CONNECTOR 1 or 2*

CONDENSER 3-5 11/4-in. NPT FEMALE CONNECTOR 2

OPTIONAL

STORAGE TANK N/A 1-in. NPT FEMALE CONNECTOR 2

WITH OPTIONAL ISOLATION OF DISCHARGE AND COOLER

WITH OPTIONAL ISOLATION WITHOUT OPTIONAL ISOLATION

RELIEF VALVE ARRANGEMENTS

Vent and drain connections

Nozzle-in-head waterboxes have vent and drain connec-

tions on covers. Marine waterboxes have vent and drain

connections on waterbox shells.

Provide high points of the chiller piping system with vents

and the low points with drains. If shutoff valves are provid-

ed in the main liquid pipes near the unit, a minimal amount

of system liquid is lost when the heat exchangers are

drained. This reduces the time required for drainage and

saves on the cost of re-treating the system liquid.

It is recommended that pressure gages be provided at

points of entering and leaving liquid to measure pressure

drop through the heat exchanger. Gages may be installed

as shown in Pressure Gage Location table. Pressure gages

installed at the vent and drain connections do not include

nozzle 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 accuracy

to provide accurate measurement of flow conditions.

PRESSURE GAGE LOCATION

ASME stamping

All 23XRV heat exchangers are constructed in accordance

with ASHRAE (American Society of Heating, Refrigerat-

ing, and Air Conditioning Engineers) 15 Safety Code for

Mechanical Refrigeration (latest edition). This code, in

turn, requires conformance with ASME (American Society

of Mechanical Engineers) Code for Unfired Pressure Ves-

sels wherever applicable.

Each heat exchanger and economizer (if equipped) is

ASME ‘U’ stamped on the refrigerant side of each vessel.

Relief valve discharge pipe sizing

See page 21 for number of relief valves.

Relief valve discharge piping size should be calculated

per the current version of the ASHRAE 15, latest edition,

code using the tabulated C factors for each vessel shown in

the table below.

23XRV RELIEF VALVE DISCHARGE PIPE SIZING

Carrier further recommends that an oxygen sensor be

installed to protect personnel. Sensor should be able to

sense the depletion or displacement of oxygen in the ma-

chine room below 19.5% volume oxygen per ASHRAE

15, latest edition.

Design pressures

Design and test pressures for heat exchangers are listed

below.

DESIGN AND TEST PRESSURES (23XRV)

*Nitrogen/Helium.

HEAT EXCHANGER MATERIAL SPECIFICATIONS

LEGEND

NUMBER

PASSES

GAGE LOCATION

(Cooler or Condenser)

1 or 3 One gage in each waterbox

2Two gages in waterbox with nozzles

HEAT

EXCHANGER

FRAME

SIZE

VESSEL

REQUIRED

C FACTOR

(lb air/Min)

RELIEF

VALVE

RATED

C FACTOR

(lb air/Min)

FIELD

CONNECTION

SIZE (FPT)

COOLER

30 to 32 43.4 70.811/4

35 to 37 49.5 70.811/4

40 to 42 50.4 70.811/4

45 to 47 57.4 70.811/4

50 to 52 53.7 70.811/4

55 to 57 61.1 70.811/4

CONDENSER

30 to 32 41.4 70.811/4

35 to 37 47.1 70.811/4

40 to 42 47.1 70.811/4

45 to 47 53.7 70.811/4

50 to 52 51.2 70.811/4

55 to 57 58.3 70.811/4

PRESSURES

SHELL SIDE

(Refrigerant)

STANDARD TUBE SIDE

(Liquid)

OPTIONAL TUBE SIDE

(Liquid)

psig kPa psig kPa psig kPa

Leak Test at Design Pressure*185 1276 150 1034 300 2068

Hydrostatic — — 195 1344 390 2689

Proof Test*204 1407 — — — —

ITEM MATERIAL SPECIFICATION

Shell HR Steel ASME SA516 GR 70

Tube Sheet HR Steel ASME SA516 GR 70

Condenser/Cooler Waterbox Cover HR Steel ASME SA516 GR 70, SA-36, or SA-285 GRC

Condenser/Cooler Waterbox Shell HR Steel ASME SA675 GR 60, SA-516 GR70, or SA-181 CL70,

SA-36, SA-675 GR70, SAE AME 7496

Tube s Finned Copper ASME SB359

Discharge/Suction

Pipe Steel ASME SA106 GRB

Flanges Steel ASME SA105

ASME — American Society of Mechanical Engineers

HR — Hot Rolled

Application data (cont)

Insulation

23XRV MINIMUM FIELD-INSTALLED INSULATION

REQUIREMENTS

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 outer

layer of 3/16-in. (5 mm) thick vinyl. The 1/2-in. (13 mm)

closed cell foam has a thermal conductivity K value of

0.28 (BTU in.)/(hr sqft °F) [0.0404 W/(m °C)] and

conforms with Underwriters Laboratories (UL) Standard

94, Classification 94 HF-1. Both the 1/2-in. foam and the

3/16-in. vinyl layer will pass flammability test method

MVSS 302.

Field insulation — As indicated in the Condensation vs

Relative Humidity table, the factory insulation provides

excellent protection against condensation under most op-

erating conditions. If temperatures in the equipment area

exceed the maximum design conditions, extra insulation is

recommended.

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 this

area 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 estimate

water-box cover areas, refer to certified drawings.

High humidity jobsite locations may require field sup-

plied and installed insulation on the float chamber, suction

housing, 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 volume

Minimum fluid volume must be in excess of 1.5 gal per ton

(20 L per kW) for comfort cooling applications and apply 3

to 5 gal per ton (40 to 66 L per kW) fluid loop volume for

process applications.

COMPONENT SIZE INSULATION

ft2m2

Cooler

30-32 96 8.9

35-37 10810.0

40-42 109 10.1

45-47 122 11.3

50-52 115 10.7

55-57 130 12.1

Misc. Liquid Lines All Sizes 21 2.0

Economizer All Sizes 20 1.9

Compressor Motor All Sizes 17 1.6

AMOUNT OF

CONDENSATION

ROOM DRY-BULB TEMPERATURE

80 F (27 C) 90 F (32 C) 100 F (38 C)

% Relative Humidity

None 8076 70

Slight 878477

Extensive 94 91 84

910



Variable Speed Screw Chiller

HVAC Guide Specifications

Size Range: 300 to 550 Tons (1055 to 1934 kW)

Nominal

Carrier Model Number: 23XRV

Part 1 — General

1.01 SYSTEM DESCRIPTION

A. Microprocessor-controlled liquid chiller shall use a

semi-hermetic screw compressor using refrigerant

HFC-134a only. Chiller refrigerant shall not have a

planned phase out date.

B. If a manufacturer proposes a liquid chiller using

HCFC-123 refrigerant, which has a planned phase

out date, then the manufacturer shall include in the

chiller price:

1. A vapor activated alarm system consisting of all

alarms, sensors, safeties, and ventilation equip-

ment as required by ANSI/ASHRAE Standard

15 Safety Code for Mechanical Refrigeration

(latest edition) with the quotation. System shall

be capable of responding to HCFC-123 levels

of 10 ppm Allowable Exposure Limit (AEL).

2. A free-standing refrigerant storage tank and

pumpout unit shall be provided. The storage

vessels shall be designed per ASME Section VIII

Division 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 and

pressure gage. The pumpout unit shall use a

semi-hermetic reciprocating compressor with

water cooled condenser. Condenser water pip-

ing, 3-phase motor power, and 115-volt control

power shall be installed at the jobsite by the

installing contractor.

3. Zero emission purge unit capable of operating

even 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 the

chiller 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 chemical

analysis of oil.

c. Annually: Clean and inspect all valves. Drain

and flush purge shell. Clean orifices.

1.02 QUALITY ASSURANCE

A. 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 for

unfired pressure vessels.

D. A manufacturer’s data report is required to verify

pressure vessel construction adherence to ASME

vessel construction requirements. Form U-1 as

required per ASME code rules is to be furnished

to the owner. The U-1 Form must be signed by a

qualified inspector, holding a National Board

Commission, certifying that construction conforms

to the latest ASME Code Section VIII, Div. 1 for

pressure vessels. The ASME symbol “U” must also

be stamped on the heat exchanger. Vessels specifi-

cally exempted from the scope of the code must

come with material, test, and construction methods

certification and detailed documents similar to

ASME U-1; further, these must be signed by an offi-

cer of the company.

E. Chiller shall be designed and constructed to meet

UL and UL of Canada requirements and have labels

appropriately affixed.

F. Unit shall be manufactured in a facility registered to

ISO 9001:2000 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. Each

compressor assembly shall be proof tested at a mini-

mum 204 psig (1407 kPa) and leak tested at

185 psig (1276 kPa) with a tracer gas mixture.

H. Entire chiller assembly shall be proof tested at

204 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 leaks

greater than 0.5 oz per year of refrigerant. The

water side of each heat exchanger shall be hydro-

statically tested at 1.3 times rated working pressure.

I. Prior to shipment, the chiller automated controls

test shall be executed to check for proper wiring and

ensure correct controls operation.

J. Chillers shall have factory-mounted, factory-wired

and factory-tested unit-mounted variable frequency

drive (VFD). Proper VFD operation shall be con-

firmed prior to shipment.

1.03 DELIVERY, STORAGE AND HANDLING

A. 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

D. Unit shall be shipped with firmly attached labels that

indicate name of manufacturer, chiller model num-

ber, chiller serial number, and refrigerant used.

E. If the unit is to be exported, the manufacturer shall

provide sufficient protection against sea water corro-

sion, making the unit suitable for shipment in a

standard open top ocean shipping container.

F. Chiller and starter shall be stored indoors, protected

from construction dirt and moisture. Chiller shall be

inspected under shipping tarps, bags, or crates to be

sure water has not collected during transit. Protec-

tive shipping covers shall be kept in place until

machine is ready for installation. The inside of the

protective cover shall meet the following criteria:

1. Temperature is between 40 F (4.4 C) and

120 F (48.9 C)

2. Relative humidity is between 10% and 80%

non-condensing.

1.04 WARRANTY

Warranty shall include parts and labor for one year

after start-up or 18 months from shipment, which-

ever occurs first. A refrigerant warranty shall be

provided for a period of 5 years.

Part 2 — Products

2.01 EQUIPMENT

A. General:

Factory-assembled, single piece, liquid chiller shall

consist of compressor, motor, VFD, lubrication sys-

tem, cooler, condenser, initial oil and refrigerant

operating 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 arranged

for easy field servicing.

3. The compressor motor shall be accessible for

servicing without removing the compressor

base from the chiller. Connections to the com-

pressor casing shall use O-rings and gaskets to

reduce the occurrence of refrigerant leakage.

Connections to the compressor shall be flanged

or bolted for easy disassembly.

4. Compressor bearings must have individual

design life of 500,000 hours or greater.

5. Compressor shall provide capacity modulation

from 100% to 15% capacity without the use of

hot gas bypass or mechanical unloaders.

6. Compressor shall be provided with a factory-

installed positive pressure lubrication system to

deliver oil under pressure to bearings and rotors

at all operating conditions. Lubrication system

shall include:

a. Oil pump with factory-installed motor con-

tactor with overload protection.

b. Oil pressure sensor with differential readout

at main control center.

c. Oil pressure regulator.

d. Oil filter with isolation valves to allow filter

change without removal of refrigerant

charge.

e. Oil sump heater [115 v, 50 or 60 Hz] con-

trolled from unit microprocessor.

f. Oil reservoir temperature sensor with main

control center digital readout.

g. All wiring to oil pump, oil heater, and con-

trols shall be pre-wired in the factory and

power shall be applied to check proper

operation prior to shipment.

7. Compressor shall be fully field serviceable.

Compressors that must be removed and

returned to the factory for service shall be

unacceptable.

8. Acoustical attenuation shall be provided as

required, to achieve a maximum (full load

or part load) sound level, measured per AHRI

Standard 575 (latest edition).

C. Motor:

1. Compressor motor shall be of the semi-

hermetic, liquid refrigerant cooled, squirrel

cage, induction type suitable for voltage shown

on the equipment schedule.

2. If an open (air cooled) motor is provided, a

compressor shaft seal leakage containment

system 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 the

refrigerant/oil mixture back into the com-

pressor housing.

c. A refrigerant sensor shall be located next to

the open drive seal to detect leaks.

3. Motors shall be suitable for operation in a

refrigerant atmosphere and shall be cooled by

atomized refrigerant in contact with the motor

windings.

4. Motor stator shall be arranged for service or

removal with only minor compressor disassem-

bly and without removing main refrigerant

piping connections.

5. Full load operation of the motor shall not

exceed nameplate rating.

6. One motor winding temperature sensor (and on

spare) shall be provided.

7. Should the mechanical contractor choose to

provide a chiller with an air-cooled motor

instead of the specified semi-hermetic motor,

the contractor shall install additional cooling

equipment to dissipate the motor heat as per

the following formula:

Btuh = (FLkW motor) (0.05) (3413)

Btuh = (FLkW motor) (171)

and, alternately

Tons = Btuh/12,000

The additional piping, valves, air-handling

equipment, insulation, wiring, switchgear

changes, ductwork, and coordination with other

trades shall be the responsibility of the mechan-

ical contractor. Shop drawings reflecting any

changes to the design shall be included in the

submittal, 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 set

at 104 F (40 C). If this temperature is

exceeded, the chillers shall shut down and an

alarm signal shall be generated to the central

Energy Management System (EMS) display

module, prompting the service personnel to

diagnose and repair the cause of the overtem-

perature condition. The mechanical contractor

shall be responsible for all changes to the

design, including coordination with temperature

control, electrical and other trades. In addition,

the electrical power consumption of any auxil-

iary ventilation and/or mechanical cooling

required to maintain the mechanical room con-

ditions stated above shall be considered in the

determination of conformance to the scheduled

chiller energy efficiency requirement.

D. Unit-Mounted Variable Frequency Drive (VFD) with

Built-In Harmonic LiquiFlo™ II Filter:

The compressor shall be factory-mounted, factory-

wired and factory-tested prior to shipment by the

chiller manufacturer. All interconnecting wiring and

piping between the VFD and the chiller shall be

factory-installed. Customer electrical connection for

compressor motor power shall be limited to main

power leads to the VFD, and wiring liquid pumps

and tower fans to the chiller control circuit. The

VFD shall incorporate the following features:

1. Design:

a. The VFD shall be refrigerant cooled,

microprocessor based, pulse width modu-

lated design. Water cooled designs are not

acceptable.

b. Input and output power devices shall be

Insulated Gate Bipolar Transistors (IGBTs).

c. Rectifier shall convert incoming fixed volt-

age/frequency to fixed DC voltage.

d. Transistorized inverter and control regulator

shall convert fixed DC voltage to a sinusoidal

PWM waveform.

e. Low voltage control sections and main

power sections shall be physically isolated.

f. Integrated controls shall coordinate motor

speed to optimize chiller performance over a

wide variety of operating conditions.

2. Enclosure:

a. Pre-painted unit mounted, NEMA 1 cabinet

shall include hinged, lockable doors and

removable lifting lugs.

b. The VFD shall have a short circuit interrupt

and withstand rating of at least 65,000 amps.

c. Provisions to padlock main disconnect han-

dle in the “Off” positions shall be provided.

Mechanical interlock to prevent opening

cabinet door with disconnect in the “On”

position or moving disconnect to the “On”

position while the door is open shall be

provided.

d. Provisions shall be made for top entry of

incoming line power cables.

3. Heat Sink:

a. The heat sink shall be refrigerant cooled.

Heat sink and mating flanges shall be suit-

able for ASME design working pressure of

185 psig (1276 kPa).

b. Refrigerant cooling shall be metered to

maintain heat sink temperature within

acceptable limits for ambient temperature.

4. VFD Rating:

a. Drive shall be suitable for operation at name-

plate voltage ±10%.

b. Drive shall be suitable for continuous opera-

tion at 100% of nameplate amps and 150%

of nameplate amps for 5 seconds.

c. Drive shall comply with applicable ANSI,

NEMA, UL and NEC standards.

d. Drive shall be suitable for operation in ambient

temperatures between 40 and 122 F (4 and

50 C), 95% humidity (non-condensing) for

altitudes up to 6000 ft (1829 m) above sea

level. Specific drive performance at jobsite

ambient temperature and elevation shall be

provided by the manufacturer in the bid.

5. User Interface:

A single display shall provide interface for pro-

gramming and display of VFD and chiller

parameters. Viewable parameters include:

a. Operating, configuration and fault messages

b. Frequency in hertz

c. Load and line side voltage and current (at the

VFD)

d. kW

e. IGBT temperature

6. VFD Performance:

a. The VFD Voltage Total Harmonic Distortion

(THD) and Harmonic Current Total Demand

Distortion (TDD) shall not exceed IEEE-519

requirements using the VFD circuit breaker

Guide specifications (cont)

input terminals as the point of common cou-

pling (PCC).

b. The VFD full load efficiency shall meet or

exceed 97% at 100% VFD rated ampacity.

c. Active rectifier shall regulate unity displace-

ment power factor to 0.99 or higher.

d. Voltage boost capability to provide full motor

voltage at reduced line voltage conditions.

e. The VFD shall feature soft start, linear accel-

eration, and coast to stop capabilities.

f. Base motor frequency shall permit motor to

be utilized at nameplate voltage. Adjustable

frequency range shall permit capacity con-

trol down to 15%.

g. The VFD shall have 150% instantaneous

torque generation.

7. VFD Electrical Service (single point power):

a. The VFD shall have input circuit breaker

with minimum 65,000 amp interrupt

capacity.

b. The VFD shall have standard branch oil

pump circuit breaker to provide power for

chiller oil pump.

c. The VFD shall have standard 3 KVA control

power transformer with circuit breaker to

provide power for oil heater, VFD controls

and chiller controls.

d. The branch oil pump circuit breaker and

control power transformer shall be factory-

wired.

e. Input power shall be 380/460 vac, ±10%,

3 Phase, 50/60 Hz, ±2% Hz.

8. Discrete Outputs:

115-v discrete contact outputs shall be provided

for:

a. Circuit breaker shunt trip

b. Chilled water pump

c. Condenser water pump

d. Alarm status

9. Analog Output:

An analog (4 to 20 mA) output for head pres-

sure reference shall be provided. This signal

shall be suitable to control a 2-way or 3-way

water regulating valve in the condenser piping.

10. Protection (the following shall be supplied):

a. Under-voltage

b. Over voltage

c. Phase loss

d. Phase reversal

e. Ground fault

f. Phase unbalance protection

g. Single cycle voltage loss protection

h. Programmable auto re-start after loss of

power

i. Motor overload protection (NEMA Class 10)

j. Motor over temperature protection

11. VFD Testing:

The VFD shall be factory-mounted, factory-

wired and factory-tested on the chiller prior to

shipment.

E. 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-performance

tubing, steel shell and tube sheets with fabri-

cated steel waterboxes. Waterboxes shall be

nozzle-in-head type with stub out nozzles having

Victaulic grooves to allow for use of Victaulic

couplings.

2. Tubing shall be copper, high-efficiency type,

with integral internal and external enhance-

ment unless otherwise noted. Tubes shall be

nominal 3/4-in. OD with nominal wall thickness

of 0.025 in. measured at the root of the fin

unless otherwise noted. Tubes shall be rolled

into tube sheets and shall be individually

replaceable. Tube sheet holes shall be double

grooved for joint structural integrity. Intermedi-

ate support sheet spacing shall not exceed

36 in. (914 mm).

3. Waterboxes and nozzle connections shall be

designed for 150 psig (1034 kPa) minimum

working pressure unless otherwise noted.

Nozzles should have grooves to allow use of

Victaulic couplings.

4. The tube sheets of the cooler and condenser

shall be bolted together to allow for field disas-

sembly and reassembly.

5. The vessel shall display an ASME nameplate

that shows the pressure and temperature data

and the “U” stamp for ASME Section VIII,

Division 1. A re-seating pressure relief valve(s)

shall be installed on each heat exchanger. If a

non-reseating type is used, a backup reseating

type shall be installed in series.

6. Waterboxes shall have vents, drains, and covers

to permit tube cleaning within the space shown

on the drawings. A thermistor type temperature

sensor 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. Devices

that introduce pressure losses (such as mist

eliminators) shall not be acceptable because

they are subject to structural failures that can

result in extensive compressor damage.

8. Tubes shall be individually replaceable from

either end of the heat exchanger without affect-

ing the strength and durability of the tube sheet

and without causing leakage in adjacent tubes.

9. The condenser shell shall include a FLASC

(Flash Subcooler) which cools the condensed

liquid refrigerant to a reduced temperature,

thereby increasing the refrigeration cycle

efficiency.

F. Refrigerant Flow Control:

To improve part load efficiency, liquid refrigerant

shall be metered from the condenser to the cooler

using a float-type metering valve to maintain the

proper liquid level of refrigerant in the heat

exchangers under both full and part load operating

conditions. By maintaining a liquid seal at the float

valve, bypassed hot gas from the condenser to the

cooler is eliminated.

G. Controls, Safeties, and Diagnostics:

1. Controls:

a. The chiller shall be provided with a factory-

installed and factory-wired microprocessor

control center. The control center shall include

a 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 shall

be displayed at the chiller control panel.

c. The controls shall make use of non-volatile

memory.

d. The chiller control system shall have the ability

to interface and communicate directly to the

building control system.

e. The default standard display screen shall simul-

taneously indicate the following minimum

information:

1) Date and time of day

2) 24-character primary system status

message

3) 24-character secondary status message

4) Chiller operating hours

5) Entering chilled water temperature

6) Leaving chilled water temperature

7) Evaporator refrigerant temperature

8) Entering condenser water temperature

9) Leaving condenser water temperature

10) Condenser refrigerant temperature

11) Oil supply pressure

12) Oil sump temperature

13) Percent motor rated load amps (RLA)

f. In addition to the default screen, status

screens shall be accessible to view the status

of every point monitored by the control

center including:

1) Evaporator pressure

2) Condenser pressure

3) Compressor speed

4) Bearing oil supply temperature

5) Compressor discharge temperature

6) Motor winding temperature

7) Number of compressor starts

8) Control point settings

9) Discrete output status of various devices

10) Variable frequency drive status

11) Optional spare input channels

12) Line current and voltage for each phase

13) Frequency, kW, kWhr, demand kW

g. Schedule Function:

The chiller controls shall be configurable for

manual or automatic start-up and shutdown.

In automatic operation mode, the controls

shall be capable of automatically starting and

stopping the chiller according to a stored

user programmable occupancy schedule.

The controls shall include built-in provisions

for accepting:

1) A minimum of two 365-day occupancy

schedules.

2) Minimum of 8 separate occupied/unoc-

cupied periods per day

3) 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 closure

h. Service Function:

The controls shall provide a password

protected service function which allows

authorized individuals to view an alarm

history file which shall contain the last

25 alarm/alert messages with time and date

stamp. These messages shall be displayed in

text form, not codes.

i. Network Window Function:

Each chiller control panel shall be capable of

viewing multiple point values and statuses

from other like controls connected on a

common network, including controller main-

tenance data. The operator shall be able to

alter the remote controller’s set points or

time schedule and to force point values or

statuses for those points that are operator

forcible. The control panel shall also have

access to the alarm history file of all like con-

trollers connected on the network.

j. Pump Control:

Upon request to start the compressor, the

control system shall start the chilled and

condenser water pumps and shall verify that

flows have been established.

k. Ramp Loading:

A user-configurable ramp loading rate, effec-

tive during the chilled water temperature

pulldown period, shall prevent a rapid

increase in compressor power consumption.

The controls shall allow configuration of the

ramp loading rate in either degrees per min-

ute of chilled water temperature pulldown or

percent motor amps per minute. During the

ramp loading period, a message shall be

Guide specifications (cont)

displayed informing the operator that the

chiller is operating in ramp loading mode.

l. Chilled Water Reset:

The control center shall allow reset of the

chilled water temperature set point based on

any 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 outdoor

air).

3) Chilled water reset based on water tem-

perature rise across the evaporator.

m. Demand Limit:

The control center shall limit amp draw of

the compressor to the rated load amps or to

a lower value based on one of the following

criteria:

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 to

20 mA signal.

n. Controlled Compressor Shutdown:

The controls shall be capable of being

configured to soft stop the compressor. The

display shall indicate “shutdown in progress.”

2. Safeties:

a. Unit shall automatically shut down when any

of the following conditions occur (each of

these protective limits shall require manual

reset and cause an alarm message to be dis-

played on the control panel screen, inform-

ing the operator of the shutdown cause):

1) Motor overcurrent

2) Over voltage*

3) Under voltage*

4) Single cycle dropout*

5) Low oil sump temperature

6) Low evaporator refrigerant temperature

7) High condenser pressure

8) High motor temperature

9) High compressor discharge temperature

10) Low oil pressure

11) Prolonged stall

12) Loss of cooler water flow

13) Loss of condenser water flow

14) Variable frequency drive fault

15) High variable frequency drive temperature

* Shall not require manual reset or cause an

alarm if auto-restart after power failure is

enabled.

b. The control system shall detect conditions

that approach protective limits and take self-

corrective action prior to an alarm occur-

ring. The system shall automatically reduce

chiller capacity when any of the following

parameters are outside their normal operat-

ing range:

1) High condenser pressure

2) High motor temperature

3) Low evaporator refrigerant temperature

4) High motor amps

5) High VFD rectifier temperature

6) High VFD inverter temperature

c. During the capacity override period, a pre-

alarm (alert) message shall be displayed

informing the operator which condition is

causing the capacity override. Once the con-

dition is again within acceptable limits, the

override condition shall be terminated and

the chiller shall revert to normal chilled

water control. If during either condition the

protective limit is reached, the chiller shall

shut down and a message shall be displayed

informing the operator which condition

caused the shutdown and alarm.

d. Internal built in safeties shall protect the

chiller from loss of water flow. Differential

pressure switches shall not be allowed to be

the 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 allow

quick identification of malfunctioning

components.

b. Once the controls test has been initiated, all

pressure and temperature sensors shall be

checked to ensure they are within normal

operating range. A pump test shall automat-

ically energize the chilled water pump, con-

denser water pump, and oil pump. The

control system shall confirm that water flow

and oil pressure have been established and

require operator confirmation before pro-

ceeding to the next test.

c. In addition to the automated controls test,

the controls shall provide a manual test

which permits selection and testing of indi-

vidual control components and inputs. A

thermistor test and transducer test shall dis-

play on the ICVC screen the actual reading

of each transducer and each thermistor

installed on the chiller. All out-of-range sen-

sors shall be identified. Pressure transducers

shall be serviceable without the need for

refrigerant 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 third

chiller standby system. The control system shall

automatically start and stop a lag or second

chiller on a two-chiller system. If one of the two

chillers on line goes into a fault mode, the third

standby chiller shall be automatically started.

The two-chiller lead/lag system shall allow

manual rotation of the lead chiller and a stag-

gered restart of the chillers after a power fail-

ure. The lead/lag system shall include load

balancing if configured to do so.

H. Electrical Requirements:

1. Electrical contractor shall supply and install

main electrical power line, disconnect switches,

circuit breakers, and electrical protection

devices per local code requirements and as indi-

cated necessary by the chiller manufacturer.

2. Electrical contractor shall wire the chilled water

pump and flow, condenser water pump and

flow, and tower fan control circuit to the chiller

control circuit.

3. Electrical contractor shall supply and install

electrical wiring and devices required to inter-

face the chiller controls with the building control

system if applicable.

4. Electrical power shall be supplied to the unit at

the voltage, phase, and frequency listed in the

equipment schedule.

I. Piping Requirements — Instrumentation and Safeties:

1. Mechanical contractor shall supply and install

pressure gages in readily accessible locations in

piping adjacent to the chiller such that they can

be easily read from a standing position on the

floor. Scale range shall be such that design val-

ues shall be indicated at approximately mid-

scale.

2. Gages shall be installed in the entering and leav-

ing water lines of the cooler and condenser.

J. Vibration Isolation:

Chiller manufacturer shall furnish neoprene isolator

pads for mounting equipment on a level concrete

surface.

K. Start-Up:

1. The chiller manufacturer shall provide a factory-

trained representative, employed by the chiller

manufacturer, to perform the start-up proce-

dures as outlined in the Start-Up, Operation

and Maintenance manual provided by the

chiller manufacturer.

2. Manufacturer shall supply the following

literature:

a. Start-up, operation and maintenance

instructions.

b. Installation instructions.

c. Field wiring diagrams.

d. One complete set of certified drawings.

L. Special Features:

1. Soleplate Package:

Unit manufacturer shall furnish a soleplate

package consisting of soleplates, jacking

screws, leveling pads, and neoprene pads.

2. Spring Isolators:

Spring isolators shall be field furnished and

selected 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 (if

equipped).

5. Stand-Alone Pumpout Unit:

A free-standing pumpout unit shall be provided.

The pumpout unit shall use a semi-hermetic

reciprocating compressor with liquid-cooled

condenser. Condenser liquid piping and

3-phase motor power shall be installed at the

jobsite by the installing contractor.

6. Separate Storage Tank and Pumpout Unit:

A free-standing refrigerant storage tank and

pumpout unit shall be provided. The storage

vessels shall be designed per ASME Section VIII

Division 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 and

pressure gage. The pumpout shall use a

hermetic reciprocating compressor with water-

cooled condenser. Condenser water piping and

3-phase motor power shall be installed at the

jobsite by the installing contractor.

7. Building Control System Interface (LON):

The chiller control system shall have the ability

to interface and communicate directly to the

building control using a LON based system. The

LonWorks Carrier Translator shall output data

in standard LON profiles.

8. Refrigerant Charge:

The chiller shall ship from the factory fully

charged with R-134a refrigerant and oil.

9. Thermal Insulation:

Unit manufacturer shall insulate the cooler

shell, economizer, suction elbow, motor shell

and motor cooling lines. Insulation shall be 1 in.

(25.4 mm) thick with a thermal conductivity not

exceeding

and shall conform to UL standard 94, classifica-

tion 94 HF-1.

10. Automatic Hot Gas Bypass:

Hot gas bypass valve and piping shall be

factory-furnished to permit chiller operation for

extended periods of time.

0.28 (Btu · in.) (0.0404 W)

hr. Ft2 F m C

Guide specifications (cont)

11. Cooler and Condenser Tubes:

Contact a local Carrier Representative for other

tube offerings.

12. Cooler and Condenser Passes:

Unit manufacturer shall provide the cooler and/

or condenser with 1, 2 or 3 pass configuration

on the water side.

13. Nozzle-In-Head, 300 psig (2068 kPa):

Unit manufacturer shall furnish nozzle-in-head

style waterboxes on the cooler and/or con-

denser rated at 300 psig (2068 kPa).

14. Marine Waterboxes:

Unit manufacturer shall furnish marine style

waterboxes on cooler and/or condenser rated

at 150 psig (1034 kPA).

15. Marine Waterboxes:

Unit manufacturer shall furnish marine style

waterboxes on cooler and/or condenser rated

at 300 psig (2068 kPA).

16. Flanged Water Nozzles:

Unit manufacturer shall furnish standard

flanged piping connections on the cooler and/

or condenser.

17. Hinges:

Unit manufacturer shall furnish hinges on

waterboxes to facilitate tube cleaning.

18. Optional Compressor Discharge Isolation Valve

and Liquid Line Ball Valve:

These items shall be factory-installed to allow

isolation of the refrigerant charge in the con-

denser for servicing the compressor.

19. Pumpout Unit:

A refrigerant pumpout system shall be installed

on the chiller. The pumpout system shall

include a hermetic compressor and drive, inter-

nal piping, internal wiring, and motor. Field-

supplied main power wiring and water piping

shall be required.

20. BACnet Communication Option:

Shall provide factory installed communication

capability with a BACnet MS/TP network.

Allows integration with i-Vu® Open control sys-

tem or a BACnet building automation system.

denser for servicing the compressor.

21. Optional Seismic Isolation Package:

Package shall meet International Building Code

and ASCE 7 seismic qualification requirements

in concurrence with ICC ES AC156 Accep-

tance Criteria for Seismic Qualification by

Shake-Table Testing of Nonstructural Compo-

nents and Systems. Manufacturer shall provide

seismic certificate from OSHPD (California

only).

910



Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Pg 32 Catalog No. 04-52230002-01 Printed in U.S.A. Form 23XRV-3PD

Replaces: 23XRV-2PD

Section 9

Ta b 9 a

Carrier Corporation • Syracuse, New York 13221 910 5-10

Carrier Evergreen 23Xrv Users Manual 3pd Reprint 910

23XRV to the manual 2f5066a0-4e7a-4acf-85c9-ade2ef55a790

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