Carrier AquaEdge 23XRV Start-Up, Operation And Maintenance Instructions Manual
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Carrier AquaEdge 23XRV Start-Up, Operation And Maintenance Instructions Manual

High-efficiency variable speed screw chiller with greenspeed intelligence and pic6 controls
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Start-Up, Operation and Maintenance
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ABBREVIATIONS AND EXPLANATIONS . . . . . . . . . . 4
23XRV CHILLER FAMILIARIZATION. . . . . . . . . . . . . . 4
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . 4
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor-Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . 11
REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . 12
MOTOR COOLING CYCLE . . . . . . . . . . . . . . . . . . . . . 15
LUBRICATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . 15
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
PIC6 System Components . . . . . . . . . . . . . . . . . . . . 17
Local Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . 23
Shutdown Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 23
BEFORE INITIAL START-UP . . . . . . . . . . . . . . . . . . . 24
Job Data Required . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove Shipping Packaging . . . . . . . . . . . . . . . . . . 24
Open Oil Circuit Valves . . . . . . . . . . . . . . . . . . . . . . . 24
Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tighten All Gasketed Joints . . . . . . . . . . . . . . . . . . . 24
Check Chiller Tightness . . . . . . . . . . . . . . . . . . . . . . 25
Refrigerant Tracer . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Leak Test Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chiller Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect Liquid Piping. . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect Refrigerant Cooling Lines . . . . . . . . . . . . . . 32
Check Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Identify the VFD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Check Control Center . . . . . . . . . . . . . . . . . . . . . . . . 34
Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53230017-01
High-Efficiency Variable Speed Screw Chiller
with Greenspeed
Instructions
Page
Printed in U.S.A.
Form 23XRV-8SS
®
Intelligence and PIC6 Controls
Checking the Installation . . . . . . . . . . . . . . . . . . . . . .34
Inspect Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Ground Fault Troubleshooting . . . . . . . . . . . . . . . . .35
CCN Interface and LEN Interface. . . . . . . . . . . . . . . .35
Software Configuration . . . . . . . . . . . . . . . . . . . . . . .36
Input the Design Set Points . . . . . . . . . . . . . . . . . . . .36
Input the Local Occupancy Schedule . . . . . . . . . . . .36
Input Configurations. . . . . . . . . . . . . . . . . . . . . . . . . .37
Perform a Control Test . . . . . . . . . . . . . . . . . . . . . . . .37
High Altitude Locations . . . . . . . . . . . . . . . . . . . . . . .38
Charge Refrigerant into Chiller . . . . . . . . . . . . . . . . .38
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
To Prevent Accidental Start-Up . . . . . . . . . . . . . . . . .41
Check Chiller Operating Condition . . . . . . . . . . . . . .41
Instruct the Customer Operator . . . . . . . . . . . . . . . .41
OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . .42
Operator Duties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Prepare the Chiller for Start-Up . . . . . . . . . . . . . . . . .42
To Start the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Check the Running System . . . . . . . . . . . . . . . . . . . .42
To Stop the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . .42
After Limited Shutdown . . . . . . . . . . . . . . . . . . . . . . .43
Preparation for Extended Shutdown. . . . . . . . . . . . .43
After Extended Shutdown . . . . . . . . . . . . . . . . . . . . .43
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . .43
Refrigeration Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
TRANSFER PROCEDURES . . . . . . . . . . . . . . . . . .45
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Operating the Optional Pumpout Unit . . . . . . . . . . .45
Chillers with Storage Tanks. . . . . . . . . . . . . . . . . . . .46
GENERAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . .52
Refrigerant Properties . . . . . . . . . . . . . . . . . . . . . . . .52
Adding Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . .52
Adjusting the Refrigerant Charge . . . . . . . . . . . . . . .52
Refrigerant Leak Testing . . . . . . . . . . . . . . . . . . . . . .52
Refrigerant Leak Rate. . . . . . . . . . . . . . . . . . . . . . . . .53
Standing Vacuum Test. . . . . . . . . . . . . . . . . . . . . .53
Trim Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . .53
Pg 1
®
AquaEdge
23XRV
50/60 Hz
R-134a
6-22
Replaces: 23XRV-7SS

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Summary of Contents for Carrier AquaEdge 23XRV

  • Page 1: Table Of Contents

    ® AquaEdge 23XRV High-Efficiency Variable Speed Screw Chiller ® with Greenspeed Intelligence and PIC6 Controls 50/60 Hz R-134a Start-Up, Operation and Maintenance Instructions CONTENTS Checking the Installation ..... .34 Inspect Wiring .

  • Page 2: Safety Considerations

    instructions or manuals, be alert to the potential for personal WEEKLY MAINTENANCE..... . 53 injury. Check the Lubrication System ....53 Understand the signal words DANGER, WARNING, CAUTION, SCHEDULED MAINTENANCE .
  • Page 3 ANSI/ASHRAE 15 (latest contamination when timely repairs cannot be completed. edition). Contact Carrier for further information on use of this Chiller must be installed in an indoor environment where the machine with other refrigerants.

  • Page 4: Introduction

    ABBREVIATIONS AND EXPLANATIONS Frequently used abbreviations in this manual include: CAUTION ® — Carrier Comfort Network — Counterclockwise This unit uses a microprocessor control system. Do not short — Chillervisor System Manager or jumper between terminations on circuit boards or modules;...
  • Page 5 23XRV 40 – – – – Standard S – Special 23XRV – High Efficiency – – Not Used Variable Speed Screw Chiller Compressor Option Evaporator Size* 0 – Full Load Optimized A1-A6 1 – Part Load Optimized B1-B6 30-32 Voltage Code 35-37 3 –...
  • Page 6 1 — Discharge Pipe 2 — Variable Frequency Drive 3 — Cooler Relief Valve 4 — Compressor Discharge Pipe 5 — PIC6 Controller 6 — Refrigerant Charging Valve 7 — ASME Nameplate, Evaporator 8 — Condenser Relief Valves 9 — Tubesheet Mounting Brackets 10 —...
  • Page 7 1 — Motor Terminal Cover Plate 2 — Variable Frequency Drive 3 — PIC6 Controller 4 — Discharge Pipe Relief Valve 5 — Condenser 6 — Oil Reclaim Actuator 7 — Vaporizer Sight Glass 8 — Oil Filter Assembly 9 — Oil Sump Temperature (hidden) 10 —...
  • Page 8 1 — Motor Terminal Cover Plate 2 — Variable Frequency Drive 3 — PIC6 Controller 4 — Discharge Pipe Relief Valve 5 — Condenser 6 — Oil Reclaim Actuator 7 — Vaporizer Sight Glass 8 — Oil Filter Assembly 9 — Oil Sump Temperature 10 —...
  • Page 9 1 — Compressor Motor Winding Temperature (Hidden) 2 — Vaporizer Temperature 3 — Evaporator Return Liquid Temperature (Hidden) 4 — Oil Sump Pressure 5 — Oil Sump Temperature 6 — Supply Oil Pressure 7 — Condenser Liquid Temperature (Hidden) 8 — Evaporator Liquid Flow (Optional) 9 —...
  • Page 10 1 — Condenser Pressure 2 — Evaporator Pressure 3 — Compressor Discharge Temperature 4 — Compressor Discharge Pressure 5 — Compressor Discharge High Pressure Switch 6 — Compressor Motor Winding Temperature (Hidden) 7 — Evaporator Refrigerant Liquid Temperature (Hidden) 8 — Condenser Liquid Temperature 9 —...

  • Page 11: Cooler

    • provides access to other Carrier Comfort Network ® devices • provides machine protection Motor-Compressor...

  • Page 12: Refrigeration Cycle

    DISCHARGE MOTOR TERMINAL COMPRESSOR LUBRICATION BLOCK ACCESS COVER MOTOR TERMINALS ECONOMIZER PORT MOTOR COOLING INLET FLANGE a23-1619 MOTOR COOLING DRAIN Fig. 8 — Compressor (Typical, R Compressor Shown) liquid seal to keep FLASC chamber vapor from entering the REFRIGERATION CYCLE cooler.
  • Page 13 REFRIGERANT VAPOR REFRIGERANT LIQUID REFRIGERANT LIQUID/VAPOR a23-1668 Fig. 9 — Refrigerant Flow Schematic, Q and R Compressors (Without Optional Flash Economizer)
  • Page 14 a23-1727 Fig. 10 — Refrigerant Flow Schematic, P Compressor (Without Optional Economizer) REFRIGERANT VAPOR REFRIGERANT LIQUID REFRIGERANT LIQUID/VAPOR a23-1669 Fig. 11 — Refrigerant Flow Schematic, Q and R Compressors (With Optional Flash Economizer)

  • Page 15: Motor Cooling Cycle

    a23-1728 Fig. 12 — Refrigerant Flow Schematic, P Compressor (With Optional Economizer) MOTOR COOLING CYCLE LUBRICATION CYCLE For Q and R compressors, one half of the motor is cooled by suc- Summary tion gas while the other half is cooled by liquid refrigerant taken The 23XRV chiller requires an oil pump.
  • Page 16 Oil is supplied to the compressor through two separate inlets. One sufficient oil pressure is not established or maintained the chiller inlet leads to the suction bearings, the other leads to the discharge will shut down. An oil pressure delta P sensor fault will be de- bearings.

  • Page 17: Oil Reclaim System

    Oil Reclaim System General The oil reclaim system recovers oil from the cooler, removes the The 23XRV hermetic screw liquid chiller contains a touch screen refrigerant, filters and returns the oil back to the compressor. microprocessor-based control center that monitors and controls all One or more oil reclaim nozzles are positioned along the length operations of the chiller.
  • Page 18 CCN LABEL LEN LABEL Fig. 16 — PIC6 Wiring FUSE FUSE DESCRIPTION CLASS CC, 1A/600V CLASS CC, 1A/600V CLASS CC, 1A/600V 150A/600V 150A/600V 150A/600V CLASS CC, 20A/600V CLASS CC, 20A/600V CLASS CC, 20A/600V FU10 CLASS CC, 5A/600V FU11A&B CLASS CC, 25A/600V A2–F1 3AG SLO–BLO LEGEND...
  • Page 19 FRONT VIEW – DOORS REMOVED LEGEND 1 — Input Circuit Breaker 2 — Power Module 3 — Control Relays (CR1 - CR6) 4 — Location of Control Panel Assembly - see expanded view 5 — Drive Status Indicator 6 — Ground Lug 7 —...
  • Page 20 a23-1627 11 8 Door Open Door Closed LEGEND 1 — Wire Harness Assembly, Gate Driver 14 — Wire Harness Assembly, DC Bus Bleeder Resistors 2 — Current Feedback Device, 1000 A 15 — Wire Harness Assembly, Line Sync 3 — Wire Harness Assembly, Power Supply, Logic 16 —...
  • Page 21 1. Cable 2. Glass Seal 3. Motor Housing 4. Stepper Motor 5. Bearing 6. Lead Screw 7. Insert 8. Valve Piston 9. Valve Seat 10. Valve Port ECONOMIZER EXV (OPTION) MAIN EXV Fig. 21 — Cutaway Views of Electronic Expansion Valves (EXV) (P Compressor Only) FIELD WIRING TERMINAL BLOCK (7TB) Table 2 —...

  • Page 22: Start-Up/Shutdown/Recycle Sequence

    POWER SUPPLY (PS) START-UP/SHUTDOWN/RECYCLE SEQUENCE The 115VAC to 24VDC power supply provides power to the cel- See Fig. 22 for control sequence. lular modem used for remote connectivity of the chiller. MODEM The 23XRVchiller with PIC6 controls is provided with a standard remote connectivity option which, when enabled, communicates chiller performance parameters via a cellular modem to the cloud.

  • Page 23: Local Start/Stop Control

    Local Start/Stop Control Table 3 — Prestart Alert/Alarm Conditions Local start-up (or manual start-up) is initiated by pressing the gray Start/Stop icon on the PIC6 Home Screen. See Fig. 23. Prestart Check Alert Condenser flow not detected during flow verification time Evaporator flow not detected during flow verification time Recycle Restarts in last 4 hours >...

  • Page 24: Before Initial Start-Up

    • digital volt-ohmmeter (DVM) If oil is added, it must conform to Carrier’s specification for screw • clamp-on ammeter compressor use as described in the Oil Specification section.

  • Page 25: Check Chiller Tightness

    Table 5 — Bolt Torque Requirements, Foot Pounds Check Chiller Tightness (Metric Bolts) Figure 26 outlines the proper sequence and procedures for leak testing. The 23XRV chillers are shipped with a full refrigerant and oil CLASS 8.8 CLASS 10.9 BOLT SIZE charge.
  • Page 26 TABLES*) ADD REFRIGERANT GAS UNTIL PRESSURE IS ABOVE 35 PSIG (241 kPa) FOR HFC-134a *See Tables 6 and 7. Fig. 26 — 23XRV Leak Test Procedure...

  • Page 27: Refrigerant Tracer

    Plainly mark any leaks which are found. Refrigerant Tracer d. Release the pressure in the system. Carrier recommends the use of an environmentally acceptable re- frigerant tracer for leak testing with an electronic detector or ha- e. Repair all leaks.
  • Page 28 3/8" MALE FLARE RELIEF VALVE CONN. LEVEL GAGE 0' - 9 " 1/2" DIA. K.O. [229mm] ELECTRICAL CONN. TYPICAL (PUMPOUT POWER) 0' - 5 1/2" [140mm] (2) 1 1/4" NPT RELIEF VALVE OUTLET (SEE FIELD PRESSURE GAGE INSTALLATION NOTES) 1' - 7 " [483mm] a23-1736 0' - 5 7/8 "...
  • Page 29 RATED DRY WEIGHT AND REFRIGERANT CAPACITY ENGLISH (lb) R-134a MAXIMUM REFRIGERANT CAPACITY (lb) TANK TANK OD WEIGHT* SIZE (in.) ANSI/ASHRAE 15 UL 1963 (lb) 0428 24.00 2334 1860 1716 0452 27.25 3414 3563 3286 SI (kg) R-134a MAXIMUM REFRIGERANT CAPACITY (kg) TANK TANK OD WEIGHT*...
  • Page 30 COOLER INLET ISOLATION VALVE 11 COOLER REFRIGERANT COOLER CHARGING PUMPOUT VALVE 7 VALVE 1a COOLER USE CONDENSER CHARGING VALVE TO ADD CHARGE 1b CONTROL CENTER DISCHARGE ISOLATION VALVE (OPTIONAL) SHIPPING BRACE (REMOVE PRIOR TO START-UP) PRESSURE RELIEF SAFETY VALVE STORAGE TANK LIQUID VALVE SEPARATOR...
  • Page 31 Table 6 — R-134a Pressure — Temperature (F) Table 7 — R-134a Pressure — Temperature (C) TEMPERATURE (F) PRESSURE (psig) TEMPERATURE (C) PRESSURE (kPa) 6.50 -18.0 44.8 7.52 -16.7 51.9 8.60 -15.6 59.3 9.66 -14.4 66.6 10.79 -13.3 74.4 11.96 -12.2 82.5 13.17...

  • Page 32: Chiller Dehydration

    Carrier assumes no responsibility for chiller damage resulting from CAUTION untreated or improperly treated water.

  • Page 33: Identify The Vfd

    400 v / 50 Hz NOTE(S): a. All voltage and current combinations listed may not be available for sale. Please review Carrier Marketing literature for latest offering. b. 110% output current capability for one minute, 150% output current for 5 seconds.

  • Page 34: Check Control Center

    Check that specified branch circuit protection is installed and Check Control Center correctly rated. Check that the incoming power is within ± 10% of chiller CAUTION nameplate voltage. BE AWARE that certain automatic start arrangements can 10. All wiring should be installed in conformance with the appli- engage the VFD.

  • Page 35: Ground Fault Troubleshooting

    Divide the 60-second resistance reading by the 10-second ation. The power for the 4 KVA transformer which powers all Carrier controls is pulled from upstream of the main circuit break- reading. The ratio, or polarization index, must be one or er.

  • Page 36: Software Configuration

    Do not assume the values in the chiller are correct. They should match the chiller labels and data sheets for the selection. If you have questions contact the Carrier Techni- cal Service Manager or Service Engineering. Consult the 23XRV with PIC6 Controls Operation and Trouble- shooting manual for controls-related issues.

  • Page 37: Input Configurations

    User (1111) • Service (3333) • Factory; Access via authorized Carrier SmartService OR PIC6 enabled Special User. Initial static Factory password is time dependent (4444), and will cease to work after 48 hours of power-up and a power recycle. User password can be modified in Main Menu, System Configu- ration, User Password Change and can be changed with a pass- word of choice of up to 23 characters.

  • Page 38: Check Optional Pumpout System Controls And Compressor

    Check Optional Pumpout System Controls and Compressor Controls include an on/off switch, a 0.5-amp fuse for the second- ary side of the transformer, 0.25-amp fuses for the primary side of the transformer, the compressor overloads, an internal thermostat, a compressor contactor, refrigerant low pressure cutout and a re- frigerant high pressure cutout.
  • Page 39 The top valve tee on a unit-mounted pumpout is connected to the condenser and the bottom valve tee is connected to the cooler. CAUTION This is different from unit-mounted installations on other Carrier chillers. Always operate the condenser and chilled liquid pumps when- ever charging, transferring, or removing refrigerant from the chiller to prevent damage to the heat exchanger tubes.
  • Page 40 Table 10 — Refrigerant Charges, Frame Sizes 3-5 CHARGE AMOUNT (R-134a, R-513A) COOLER FRAME SIZE LENGTH COOLER CODE WITH ECONOMIZER WITHOUT ECONOMIZER FT (M) lb (± 25 lb) kg (± 11 kg) lb (± 25 lb) kg (± 11 kg) (3.6) (4.3) (3.6)

  • Page 41: Initial Start-Up

    INITIAL START-UP WARNING IMPORTANT: Start-up engineer must be properly certified Do not permit liquid or brine that is warmer than 110°F (43°C) for the VFD being started up, or extended VFD warranty to flow through the cooler or condenser. Refrigerant overpres- may be affected.

  • Page 42: Operating Instructions

    SAFETY DEVICES AND PROCEDURES (14 kPad). The level in the oil sump is generally very stable. Changes in the oil level occur very slowly. Electrical disconnects, relief device inspection, and handling re- When the compressor is running, the liquid level should be frigerant.

  • Page 43: After Limited Shutdown

    Consult the minimum), the operator or tower control should automatically cy- water treatment company for details. Carrier is not responsible for cle the cooling tower fans off to keep the temperature up. Piping waterside corrosion.
  • Page 44 TEMP OUTPUT DELTA P TEMP TEMP CURRENT VOLTAGE CURRENT REMARKS: Indicate shutdowns on safety controls, repairs made, oil or refrigerant added or removed, operating hours, and start counts. Include amounts. Fig. 47 — Refrigeration Log: Carrier 23XRV Hermetic Screw Refrigeration...

  • Page 45: Pumpout And Refrigerant Transfer Procedures

    PUMPOUT AND REFRIGERANT Operating the Optional Pumpout Unit TRANSFER PROCEDURES Be sure that the suction and the discharge service valves on the optional pumpout compressor are open (backseated) Preparation during operation. Rotate the valve stem fully counterclock- The 23XRV chiller may come equipped with an optional pumpout wise to open.

  • Page 46: Chillers With Storage Tanks

    e. Open valve 8 and 10 to let higher pressure in the recov- Chillers with Storage Tanks ery tank push liquid refrigerant into the condenser float In the Valve/Condition tables that accompany these instructions, chamber and heat exchangers until the refrigerant pres- the letter “C”...
  • Page 47 a. Turn on pumpout condenser water. e. Start the chiller water pumps (condenser and cooler), establishing water flow. At this point, turn on the pum- b. Open valves 3 and 4, and place valves in the following pout compressor in auto until the vacuum switch is satis- positions: fied.
  • Page 48 RELIEF a23-1737 PUMPOUT VALVE COMPRESSOR CONDENSER SEPARATOR PUMPOUT CONDENSER CHECK COOLER VALVE Fig. 51 — Pumpout System Piping Schematic without Storage Tank for 23XRV Units with P Compressor h. Close pumpout valves 2 and 5 while opening valve 3 and Transfer Refrigerant from Cooler to Condenser 4 to prepare for removal of remaining refrigerant vapor a.
  • Page 49 q. Turn off pumpout condenser water. Return Chiller to Normal Operating Conditions Turn off chiller water pumps, and lockout chiller com- Vapor Pressure Equalization: pressor. a. Ensure that the chiller vessel that was exposed to ambi- Transfer Refrigerant from Condenser to Cooler ent has been evacuated.
  • Page 50 b. Open valve 2. c. Close charging valves 7 and 10. d. Turn off the pumpout compressor. VALVE 1A 1B e. To prepare for removal of remaining refrigerant vapor in CONDITION storage tank, close pumpout valves 3 and 4 and open c.
  • Page 51 g. Start the chiller water pumps (condenser and cooler), m. With service valve 1A closed, shut down pumpout com- establishing water flow. At this point, turn on the pum- pressor (if still running). pout compressor in auto until the vacuum switch is satis- n.

  • Page 52: General Maintenance

    p. Turn off pumpout condenser water. d. Run the pumpout compressor until the storage tank pres- sure reaches 5 psig (34 kPa), 18 in. Hg vacuum (41 kPa q. Turn off chiller water pumps, and lock out chiller absolute) in Manual or Automatic mode. compressor.

  • Page 53: Refrigerant Leak Rate

    REFRIGERANT TRACER lons (38 L). Use an environmentally acceptable refrigerant as a tracer for leak The oil must meet Carrier’s specifications for the 23XRV chillers. test procedures. Refer to Changing Oil and Oil Filter section. Any oil that is added should be logged by noting the amount and date in Fig.

  • Page 54: Changing Oil And Oil Filter

    Oil Specification The 23XRV oil pump and filter can be isolated to change the If oil is to be added, it must meet Carrier specifications: oil filter and oil while the refrigerant remains inside the chiller. Use the following procedures to change the oil and oil filter (if •...

  • Page 55: Refrigerant Filter/Drier

    Refrigerant Filter/Drier Compressor Inlet Bearing Oil Orifice A refrigerant filter/drier, located on the motor cooling line, should The oil line leading to the compressor lubrication block is con- be changed once every two years, or as necessary, if the condition nected to the inlet bearing oil orifice.
  • Page 56 VENT LINE (TO COMPRESSOR SUCTION) VAPORIZER SUPPLY GAS VAPORIZER HEATER COMPRESSOR VAPORIZER HEAT TRANSFER DRAIN TUBES VAPORIZER TEMPERATURE OIL PRESSURE SENSOR REGULATOR THERMOWELL 2-STAGE ISOLATION VALVE OIL HEATER VAPORIZER DRAIN OIL PRESSURE SIGHT REGULATOR GLASS Fig. 53 — Oil Reclaim Cross Section (Q,R Compressors Shown) FILTER DRIER ISOLATION VALVE MOISTURE INDICATOR...

  • Page 57: Inspect Variable Frequency Drive

    Excessive bearing wear can be detected through increased vibra- • Test to ground (line and link reactors if applicable). tion. Carrier recommends that periodic vibration analysis be per- • Inspect, clean, and test harmonic filter (if applicable). formed as part of compressor preventative maintenance program.

  • Page 58: Inspect The Heat Exchanger Tubes

    19XR Positive Pressure Storage System Installation, Start-Up, and potential of tubing damage due to corrosion, scaling, erosion, Service Instructions. and algae. Carrier assumes no responsibility for chiller dam- age resulting from untreated or improperly treated water/brine. Verify Thermistor Readings If required, the cooler water side thermistors should be verified after a completed pressure recalibration.

  • Page 59: Ordering Replacement Chiller Parts

    Checking Display Messages Additionally check that any 4-20mA field input to the Carrier con- The first area to check when troubleshooting the 23XRV chiller is trols has not accidentally been grounded or are receiving a differ- the HMI display.

  • Page 60: Quick Test

    To calibrate these transducers: transducer wires. Unscrew the transducer from the Schrader fit- Shut down the compressor, cooler, and condenser pumps. ting. When installing a new transducer, do not use pipe sealer (which can plug the sensor). Put the plug connector back on the NOTE: There should be no flow through the heat sensor and snap into place.
  • Page 61 Table 12 — Thermistor Temperature (F) vs Resistance/Voltage Drop PIC6 PIC6 PIC6 TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE VOLTAGE VOLTAGE VOLTAGE (OHMS) (OHMS) (OHMS) DROP (V) DROP (V) DROP (V) –25 4.700 97,706 2.565 6,568 0.630 –24 4.690 94,549 2.533 6,405 0.619 –23...
  • Page 62 Table 13 — Thermistor Temperature (C) vs Resistance/Voltage Drop PIC6 PIC6 TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE VOLTAGE VOLTAGE (OHMS) (OHMS) DROP (V) DROP (V) –33 4.722 105 616 1.338 2 272 –32 4.706 99 640 1.300 2 184 –31 4.688 93 928 1.263 2 101 –30...

  • Page 63: Control Modules

    NET B STATUS INDICATOR Control Modules Turn controller power off before servicing controls. This ensures This green LED indicates the transmit status of the adapter as safety and prevents damage to the controller. shown in Table 16. The PIC6 control system, including SIOB and IOBs, performs Table 16 —...
  • Page 64 MOD STATUS INDICATOR EXV cross-section diagrams. See Fig. 58 and 59 for disassembly and assembly instructions. This red/green bicolor LED indicates the status of the adapter as Check EXV Motor Windings Resistance shown in Table 18. To check the resistance of the EXV motor windings, remove the Table 18 —...

  • Page 65: End Of Life And Equipment Disposal

    CAUTION COIL B Do not attempt to disconnect flanges while the machine is COIL A under pressure. Failure to relieve pressure can result in per- sonal injury or damage to the unit. CAUTION Before rigging the compressor, disconnect all wires entering the power panel to avoid damage to the panel.
  • Page 66 Table 19 — 23XRV Cooler Frame Size A1-A6, B1-B6 Heat Exchanger Weights ENGLISH METRIC (SI) FRAME STEEL COPPER REFRIG. SHIP WT WATER OPER. STEEL COPPER REFRIG. SHIP WT WATER OPER. SIZE RIGGING RIGGING WT (lb) WT (lb) WT (lb) (lb) VOL (Gal) WT (lb) WT (kg)
  • Page 67 Table 22 — 23XRV Compressor and Motor Weights ENGLISH (lb) SI (kg) COMPRESSOR MOTOR Total Motor Total Motor Stator Rotor Stator Rotor TYPE SIZE Compressor Terminal Compressor Terminal Weight Weight Weight Weight Weight Cover Weight Cover 3036 1377 4090 1855 P,Q,R,S,T,U,V,X 4866 2207...
  • Page 68 Table 25 — 23XRV Waterbox Cover Weights, Frames 3,4,5 — English (lb) COOLER CONDENSER WATERBOX Frame 3 Frame 4 Frame 5 Frame 3 Frame 4 Frame 5 DESCRIPTION Victaulic Victaulic Victaulic Victaulic Victaulic Victaulic Flanged Flanged Flanged Flanged Flanged Flanged Nozzles Nozzles Nozzles...
  • Page 69 Table 27 — 23XRV Waterbox Cover Weights, Frames A/B — English (lb) COOLER FRAMES A AND B CONDENSER FRAMES A AND B WATERBOX DESCRIPTION Victaulic Nozzles Flanged Victaulic Nozzles Flanged NIH,1-Pass Cover 150 psig NIH,2-Pass Cover 150 psig NIH,3-Pass Cover 150 psig NIH/Marine Plain End, 150 psig MWB Cover, 150 psig NIH,1-Pass Cover 300 psig...
  • Page 70 Table 31 — 23XRV Compressor Torque Specification Chart TORQUE LOCATION/USAGE DESCRIPTION PART NO. lb-ft Hermetic Term, Outlet Casing Sub-Assembly Motor Side Seal Installation M5 X 0.8 X 16LG SHCS GR 12.9 8TR0115 M5 X 0.8 X 30LG SHCS GR 12.9 8TR0116 Inlet Seal Installation M5 X 0.8 X 60LG SHCS GR 12.9...
  • Page 71 Fig. 62 — 23XRV Controls Schematic...
  • Page 72 FROM 2000767952, SHEET 3 Fig. 62 — 23XRV Controls Schematic (cont)
  • Page 73 Fig. 62 — 23XRV Controls Schematic (cont)
  • Page 74 NOTE: DO NOT USE TB1 FOR PIC6 FIELD CONNECTIONS. USE 7TB TERMINAL BLOCK AS INDICATED ON WIRING DIAGRAM. NOTE: DO NOT USE TB2 FOR PIC6 FIELD CONNECTIONS. USE 7TB TERMINAL BLOCK AS INDICATED ON WIRING DIAGRAM. Fig. 63 — 23XRV VFD Schematic (LF-2)
  • Page 75 NOTE: DO NOT USE TB4 FOR PIC6 FIELD CONNECTIONS (SPARE SAFETY, EVAP AND COND PUMPS, TOWER FAN LOW/HIGH). USE 7TB TERMINAL BLOCK AS INDICATED ON WIRING DIAGRAM. Fig. 64 — 23XRV VFD Schematic (Rockwell Standard Tier VFD)
  • Page 76 FROM PREVIOUS PAGE Fig. 64 — 23XRV Controls Schematic (Rockwell Standard Tier VFD Shown) (cont)
  • Page 77 DRAIN WIRE GROUND DRAIN WIRE DRAIN WIRE DRAIN WIRE BLACK BLACK BLACK BLACK WHITE WHITE WHITE WHITE R COMPRESSOR Q COMPRESSOR P COMPRESSOR LEGEND NOTE: Field-supplied terminal strip must be located in control panel. Factory Wiring Field Wiring Fig. 65 — CCN Communication Wiring for Multiple Chillers (Typical)
  • Page 78 CONTROL PANEL CHILLER #2 CCN (+,G, -) CCN (+,G, -) CONTROL PANEL CHILLER #1 Fig. 66 — Lead/Lag Control Wiring (Parallel Flow Unit with R Compressor Shown)
  • Page 79 CCN (+,G, -) CCN (+,G, -) CONTROL PANEL CHILLER #2 CONTROL PANEL CHILLER #1 Fig. 67 — Lead/Lag Control Wiring, Series Flow Application (Unit with R Compressor Shown)

  • Page 80: Structure

    APPENDIX A — PIC6 SCREEN AND MENU STRUCTURE CHOOSE OPERATING MODE HOME MAIN MENU LOG IN / LOG OUT CONFIRM STOP ALARM MENU Fig. A — Screen Structure, Basic Level (All) Access (No Password Required) HOME MAIN MENU LOG IN / LOG OUT CHOOSE OPERATING MODE CONFIRM STOP ALARM MENU...
  • Page 81 APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE (cont) HOME MAIN MENU LOG IN / LOG OUT CHOOSE OPERATING MODE CONFIRM STOP ALARM MENU Fig. C — Screen Structure, Service Level Access (Service Password 1234 or 3333 Required) HOME MAIN MENU LOG IN / LOG OUT CHOOSE OPERATING MODE...
  • Page 82 APPENDIX A — PIC 6 SCREEN AND TABLE STRUCTURE (cont) Main Menu Description ICON DISPLAYED TEXT LOWEST ACCESS LEVEL ASSOCIATED TABLE Inputs Menu Basic Inputs Menu Outputs Basic OUTPUTS Status Basic Status Runtime Basic RUNTIME Control Algo Menu User Control Algorithm Menu Setpoint Basic SETPOINT...

  • Page 83: Appendix B - Maintenance Summary And Log Sheets

    APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS Always check the Optional Extended Warranty for specific maintenance requirements pertaining to that warranty. 23XRV Maintenance Interval Requirements WEEKLY Check Oil Level. Review Alarm/Alert History. Compressor Controls None. None. Cooler Starter None. None.
  • Page 84 APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS (CONT) 23XRV Weekly Maintenance Log Plant ___________________________Machine Serial No. ________________________________ Machine Model No. ________________Refrigerant Type __________________________________ CHECK ALARMS OPERATOR DATE OIL LEVEL REMARKS / FAULTS INITIALS NOTE: Equipment failures caused by lack of adherence to the Maintenance Interval Requirements are not covered under warranty.
  • Page 85 APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS (CONT) 23XRV Maintenance Log for Monthly, Quarterly, and Annual Checks MONTH DATE OPERATOR UNIT SECTION ACTION UNIT ENTRY Change Oil Charge yes/no Record Oil Temperature °F COMPRESSOR Send Oil Sample Out for Analysis yes/no Perform Vibration Analysis yes/no...
  • Page 86 APPENDIX B — MAINTENANCE SUMMARY AND LOG SHEETS (CONT) 23XRV Seasonal Shutdown Log MONTH DATE OPERATOR UNIT SECTION ACTION ENTRY Isolate and Drain Waterbox COOLER Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes Isolate and Drain Waterbox CONDENSER Remove Waterbox Cover from One End Use Compressed Air to Clean Tubes...

  • Page 87: Index

    Before initial start-up Local start-up Refrigerant leak testing 24-40 Carrier Comfort Network Interface Lubrication cycle Refrigerant properties ® 15-17 Carrier Comfort Network communication Lubrication cycle (details) Refrigerant (removing) wiring Lubrication cycle (summary) Refrigerant tracer Capacity control Lubrication system (check) Refrigeration cycle 12-15...
  • Page 88 © 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53230017-01 Printed in U.S.A. Form 23XRV-8SS Pg 88 6-22 Replaces: 23XRV-7SS...

  • Page 89: Initial Start-Up Checklist

    REFRIGERANT: Type: Charge   CARRIER OBLIGATIONS: Assemble....Yes   Leak Test ....Yes ...
  • Page 90 COMPRESSOR MOTOR AND CONTROL CENTER MUST BE PROPERLY AND INDIVIDUALLY CONNECTED BACK TO THE EARTH GROUND IN THE STARTER (IN ACCORDANCE WITH CERTIFIED DRAWINGS). Water/Brine Pump Control Can the Carrier controls independently start the pumps? Yes  No  Condenser Liquid Pump Yes ...
  • Page 91 F: Call your Carrier factory representative to report chiller start-up. NOTE: To extend drive warranty, startup should be performed by a Certified Technician as applicable. G: Return a copy of this completed checklist to the local Carrier Service office. SIGNATURES: CARRIER...
  • Page 92 © 2022 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53230017-01 Printed in U.S.A. Form 23XRV-8SS Pg CL-2 6-22 Replaces: 23XRV-7SS...

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