Carrier 23XL Specifiche

Start-Up, Operation, and MaintenanceInstructionsSAFETY CONSIDERATIONSScrew liquid chillers are designed to provide safe and reli-able service when ope

LEGENDHGBP — Hot Gas BypassRefrigerant Liquid FlowRefrigerant Vapor FlowOil and Refrigerant Vapor FlowOil FlowFig. 4 — Refrigerant Oil Flow Schematic

Fig. 61 — Typical Machine Power Panel, Starter Assembly, and Motor (Frame 4 Machines)100

Fig. 62 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic101

Fig. 62 — Typical Wye-Delta Unit Mounted Starter Wiring Schematic (cont)102

INDEX23XL Machine Familiarization, 4Abbreviations and Explanations, 4Adding Refrigerant, 63Adjusting the Refrigerant Charge, 63After Extended Shutdown

To Stop the Machine, 58Tower-Fan Relay, 31Troubleshooting Guide, 68Unit Mounted Solide-State Starter, 11Unit Mounted Wye Delta Starter, 12Using The Op

In addition, the PIC Controls minimize oil loss to the cooleronce the rotor inlet temperature sensor detects hot oil drain-ing down the suction pipe.I

These starters operate by reducing the starting voltage. Thestarting torque of a motor at full voltage is typically 125%to 175% of the running torque.

CONTROLSControls DefinitionsANALOG SIGNAL — An analog signal varies in propor-tion to the monitored source. It quantifies values betweenoperating limits

*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components).Fig. 11 — 23XL Control and Senso

*Some 23XL machines will have both an oil temperature sensor and an oil level safety switch (two separate components).Fig. 12 — 23XL Control and Senso

Fig. 13 — Control Sensors (Temperature)Fig. 14 — Control Sensors(Pressure Transducer, Typical)LEGEND1—LID 4—5-Volt TransducerPower Supply2—PSIO 5—6-Pa

LOCAL INTERFACE DEVICE (LID) — The LID is mountedin the control center and allows the operator to interface withthe PSIO or other CCN devices. It is t

MENU STRUCTURE — To perform any of the operationsdescribed below, the PIC must be powered up and have suc-cessfully completed its self test.• Press NE

Fig. 20 — 23XL Menu Structure19

CONTENTSPageSAFETY CONSIDERATIONS ...1INTRODUCTION ...4ABBREVIATIONS AND EXPLANATIONS ...423XL MACHINE

Fig. 21 — 23XL Service Menu Structure20

For Discrete Points — Press START or STOP to se-lect the desired state.For Analog Points — Press INCREASE orDECREASEto select the desired value.3. Pre

9. Either return to Step 4 to select another period or override or press EXITagain to leave the current timeschedule screen and save the changes.10. H

The proportional band can be viewed/modified on the LID.There are two response modes, one for temperature re-sponse above the control point, the other

Table 3 — LID ScreensIMPORTANT: The following notes apply to all Table 3examples:1. Only 12 lines of information will appear on the LID screen at anyg

EXAMPLE3—STATUS03 DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press STATUS.3. Scroll down to highlight STATUS03.

Table 3 — LID Screens (cont)EXAMPLE 6 — LEAD/LAG CONFIGURATION DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press

EXAMPLE 8 — SERVICE2 DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press SERVICE.3. Scroll down to highlight EQUIP

Table 3 — LID Screens (cont)EXAMPLE 11 — MAINTENANCE (MAINT02) DISPLAY SCREENTo access this display from the LID default screen:1. Press MENU.2. Press

Ramp Loading Control — The ramp loading controlslows down the rate at which the compressor loads up. Thiscontrol can prevent the compressor from loadi

CONTENTS (cont)PageInput the Local Occupied Schedule(OCCPC01S) ...52Selecting Refrigerant Type ...53• TO CO

Table 4 — Protective Limits and Control SettingsMONITORED PARAMETER LIMIT APPLICABLE COMMENTSTEMPERATURE SENSORSOUT OF RANGE−40 to 245 F (−40 to 118.3

Table 5 — Capacity OverridesOVERRIDECAPACITYCONTROLVIEW/MODIFYON LIDTABLEFIRST STAGE SETPOINTSECOND STAGESET POINTOVERRIDETERMINATIONDefaultValueConfig

Water/Brine Reset — Three types of chilled water orbrine reset are available and can be viewed or modified onthe Equipment Configuration menu Config tabl

Lead/Lag ControlIMPORTANT: Lead/lag control is only available onmachines with PSIO Software Version 13 or higher.Lead/lag is a control system process

Standby Chiller Configuration and Operation — The con-figured standby chiller is identified as such by having theLEAD/LAG SELECT configured to the value o

ICE BUILD INITIATION — The Ice Build Time Scheduleprovides the means for activating ice build. The ice buildtime table is named OCCPC02S.If the Ice Bu

CHANGING REFRIGERANT TYPES — To select refrig-erant type, go to the Control Test table. Whenever the re-frigerant type is changed, the ATTACH TO NETWO

4. Press NEXT until Holidef is highlighted. This isthe Holiday Definition table.5. Press SELECT to enter the Data Table Select screen.This screen lists

Shutdown Sequence — Shutdown of the machine canoccur if any of the following events happen:• the STOP button is pressed for at least one second (theal

When the machine is in RECYCLE mode, the chilled wa-ter pump relay remains energized so that the chilled watertemperature can be monitored for increas

CONTENTS (cont)Control Test ...69Control Modules ...80• RED LED• GREEN LEDsNotes on Module Opera

Leak Test Machine — Due to regulations regarding re-frigerant emissions and the difficulties associated with sepa-rating contaminants from refrigerant

Fig. 30 — 23XL Leak Test Procedures41

Fig. 31 — Typical Optional Pumpout System Piping Schematic with Storage Tank (Frame 1 and 2 Machines)42

Fig. 32 — Typical Optional Pumpout System Piping Schematic With Storage Tank (Frame 4 Machines)43

Fig. 33 — Typical Optional Pumpout System Piping Schematic Without Storage Tank(Frame 1 and 2 Machines)44

Fig. 34 — Typical Optional Pumpout System Piping Schematic Without Storage Tank(Frame 4 Machines)45

Table 6A — HCFC-22 Pressure — Temperature (F)TEMPERATURE (F)PRESSURE (psi)Absolute Gage-50 11.67 6.154*-48 12.34 4.829*-46 13.00 3.445*-44 13.71 2.002

Table 6C — HFC-134a Pressure — Temperature (F)TEMPERATURE, F PRESSURE (psig)0 6.502 7.524 8.606 9.668 10.7910 11.9612 13.1714 14.4216 15.7218 17.0620

Standing Vacuum Test — When performing the stand-ing vacuum test or machine dehydration, use a manometeror a wet bulb indicator. Dial gages cannot ind

Inspect WiringDo not apply any kind of test voltage if the machine isunder a dehydration vacuum. Insulation breakdown andserious damage may result.1.

FRONT VIEW1—Power Panel2—Local Interface Display (LID) Control Center3—ASME Nameplate, Cooler4—Cooler Refrigerant Isolation Valve5—ASME Nameplate, Eco

MECHANICAL-TYPE STARTERS1. Check all field wiring connections for tightness, clear-ance from moving parts, and correct connection.2. Check the contacto

CUTLER-HAMMERt SOLID-STATE STARTERSThis equipment is at line voltage when ac power is con-nected. Pressing the STOP button does not remove volt-age. U

Table 7 — Potentiometer AdjustmentDIALADJUSTMENT RANGEFUNCTIONFACTORYSETTINGMinimum(CCW)Maximum(CW)Starting Current 100% 400% Sets initial startingcur

Selecting Refrigerant Type — The 23XL control mustbe configured for the refrigerant being used, either HCFC-22or HFC-134a.TO CONFIRM REFRIGERANT TYPE —

Minimum Load DT1:46.5 −44 = 2.5 F (8.1 −6.7 = 1.4 C)Minimum Load DP1:121 − 73 = 45 psid (834 - 503 = 331 kPad)To avoid unnecessary opening of the hot

Table 8 — Control Test Table FunctionsTESTS TO BE PERFORMED DEVICES TESTED1. Automated Tests* Operates the second through seventh tests2. PSIO Thermis

Table 9 — Refrigerant ChargesCOOLER SIZE ECONOMIZERREFRIGERANTHCFC-22 HFC-134alb kg lb kg10,11NO 600 272 * *YES 650 295 * *20,21NO 700 318 * *YES 750

If rotation is proper , allow the compressor to come up tospeed.NOTE: Starters may have phase protection and will not al-low a start if the phase is n

OPERATING INSTRUCTIONSOperator Duties1. Become familiar with refrigeration machine and relatedequipment before operating the machine.2. Prepare the sy

Carefully make all regular preliminary and running sys-tem checks. Perform a Control Test before start-up. If the oillevel appears abnormally high, th

FRONT VIEW1—Compressor Nameplate (Hidden)2—Power Panel3—Local Interface Display (LID) Control Center4—ASME Nameplate, Cooler5—Cooler6—Vessel Separatio

Plant MACHINE MODEL NO. MACHINE SERIAL NO. REFRIGERANT TYPEDATE COOLER CONDENSER COMPRESSOROPER-ATORINITIALSREMARKSTIMERefrigerant Water Refrigerant W

PUMPOUT AND REFRIGERANTTRANSFER PROCEDURESPreparation —The 23XL may come equipped with iso-lation valves and/or a pumpout system/optional storage tank

d. Gradually crack open valve 5 to increase machine pres-sure to 68 psig (469 kPa) [35 psig (141 kPa)]. Slowlyfeed refrigerant to prevent freeze up.e.

g. Turn off pumpout condenser water.VALVE 1a1b2345811121314151617CONDITION C C CCCCC C CCCCCCh. Proceed to Pumpdown test on the LID to turn off ma-chi

Refrigerant Leak Rate — ASHRAE recommends thatmachines should be immediately taken off line and repairedif the refrigerant leakage rate for the entire

Change the oil after the first year of operation. Then, changethe oil at least every three years, or as needed. However, ifa continuous oil monitoring

Oil Specification — If oil is to be added, it must meetthe following Carrier specifications:• Carrier Part Number ...PP23BZ104• Oil type

Hard scale may require chemical treatment for its pre-vention or removal. Consult a water treatment specialistfor proper treatment.Water Leaks — Water

Ordering Replacement Chiller Parts — When or-dering Carrier specified parts, the following information mustaccompany an order.• machine model number an

If the transducer value does not move to 0 psig (0 kPa),the transducer will return to the original reading. If thepressure is within the allowed range

Cooler — This vessel (also known as the evaporator) islocated underneath the compressor. The cooler is main-tained at low temperature/pressure so that

LEGEND FOR TABLE 10, A - N1CR AUX — 1CR Compressor Start ContactCA P— Compressor CurrentCDFL — Condenser Water FlowCHIL S S— Chiller Start/StopCHWS —

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)D. PRE-START FAILURESPRIMARY MESSAGE SE

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)F. START-UP FAILURESPRIMARY MESSAGE SEC

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)G. COMPRESSOR JUMPSTART AND REFRIGERANT

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)I. NORMAL RUN OVERRIDES ACTIVE (ALERTS)

K. MACHINE PROTECT LIMIT FAULTSExcessive numbers of the same fault can lead to severemachine damage. Seek service expertise.PRIMARY MESSAGE SECONDARY

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)L. MACHINE ALERTSPRIMARY MESSAGE SECOND

Table 10 — LID Primary and Secondary Messages and Custom Alarm/Alert Messageswith Troubleshooting Guides (cont)N. ADDITIONAL TROUBLESHOOTING INFORMATI

Table 11 — Thermistor Temperature (F) vs Resistance/Voltage DropTEMPERATURE VOLTAGE RESISTANCE(F) DROP (V) (OHMS)−25.0 4.821 98010−24.0 4.818 94707−23

Table 12 — Thermistor Temperature (C) vs Resistance/Voltage DropTEMPERATURE VOLTAGE RESISTANCE(C) DROP (V) (Ohms)−40 4.896 168 230−39 4.889 157 440−38

• positions the slide valve for capacity control. The slide valveis connected to a piston via a rod. The position of the pis-ton, which rides in a cyl

Control ModulesTurn controller power off before servicing controls. Thisensures safety and prevents damage to controller.The Processor module (PSIO),

Processor Module (PSIO) (Fig. 46)INPUTS — Each input channel has 3 terminals; only 2 ofthe terminals are used. Application of machine determineswhich

Terminal block connections are provided on the optionsmodules. All sensor inputs are field wired and installed. Op-tions module number 1 can be factory

Solid-State Starters — Troubleshooting guides per-taining to the operation of the solid-state starters may be foundin Fig. 49-55 and Tables 13 and 14.

ELECTRONIC PROTECTION RELAY (EPR) — On Cutler-Hammer solid state starters, the EPR is designed to providean alternative to conventional motor protecti

Table 13 — Benshaw, Inc. Solid-State Starter Troubleshooting GuidePROBLEM PROBABLE CAUSES AREA OF CORRECTIONBIPCRS6AK board phase correctnot on.1. L1

Table 14 — Cutler-HammerT Solid-State Starter Troubleshooting GuidePROBLEM PROBABLE CAUSE AREA OF CORRECTION(CB) trips (electrically operateddisconnec

SCR — Silicon Control RectifierFig. 54 — Typical Solid-State Starter, General Operation Troubleshooting Guide87

Fig. 55 — Typical Solid-State Starter, Starter Fault (Motor Will Not Start) Troubleshooting Guide88

Physical Data — For operator convenience during trouble-shooting, additional details regarding compressor torque speci-fications, physical data, electr

LEGENDHGBP — Hot Gas BypassRefrigerant Liquid FlowRefrigerant Vapor FlowOil and Refrigerant Liquid FlowOil and Refrigerant Vapor FlowOil FlowFig. 3 —

Table 18 — Optional Storage Tank and/or Pumpout System Physical DataUNITSIZETANK OUTSIDEDIAMETERDRY WEIGHTMAXIMUM REFRIGERANT CAPACITYASHRAE/ANSI 15 A

Table 20A — 23XL Waterbox Cover Weights (Frame 1 and 2 Machines)*HEAT EXCHANGERWATERBOXDESCRIPTIONPSI(kPa)FRAME 1 FRAME 2lbs kg lbs kgCooler orCondens

Table 21 — 23XL Compressor Torque Specification Chart for Metric and American FastenersITEMCAP SCREWSIZE AND TYPEGRADE ASSEMBLY LOCATIONTORQUENm Lb-Ft

IMPORTANT: Refer to certified drawings for addi-tional information. Certified drawings are available uponrequest.LEGENDRequired Power WiringRequired Con

IMPORTANT: Refer to certified drawings for addi-tional information. Certified drawings are available uponrequest.LEGENDRequired Power WiringRequired Con

Fig. 58 — Typical Electronic PIC Controls Wiring Schematic (Frame 1 and 2 Machines)95

Fig. 58 — Typical Electronic PIC Controls Wiring Schematic (Frame 1 and 2 Machines) (cont)96

Fig. 59 — Typical Electronic PIC Controls Wiring Schematic (Frame 4 Machines)97

Fig. 59 — Typical Electronic PIC Controls Wiring Schematic (Frame 4 Machines) (cont)98

Fig. 60 — Typical Machine Power Panel, Starter Assembly, and Motor (Frame 1 and 2 Machines)99