2
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1,2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ABBREVIATIONS AND EXPLANATIONS. . . . . . . . . . 5
23XRV CHILLER FAMILIARIZATION . . . . . . . . . . . 5-13
Chiller Identification Nameplate . . . . . . . . . . . . . . . . . . 5
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor-Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Storage Vessel (Optional) . . . . . . . . . . . . . . . . . . . . . . . 12
REFRIGERATION CYCLE. . . . . . . . . . . . . . . . . . . . . 13-15
MOTOR COOLING CYCLE. . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICATION CYCLE. . . . . . . . . . . . . . . . . . . . . . . . 16-18
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil Reclaim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-60
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
• ANALOG SIGNAL
• DIGITAL SIGNAL
General Controls Overview. . . . . . . . . . . . . . . . . . . . . . 18
PIC III System Components . . . . . . . . . . . . . . . . . . . . . 18
• INTERNATIONAL CHILLER VISUAL
CONTROLLER (ICVC)
• CHILLER CONTROL MODULE (CCM)
• VFD POWER MODULE
• VFD GATEWAY MODULE
• OIL HEATER CONTACTOR (1C)
• OIL PUMP CONTACTOR (2C)
• HOT GAS BYPASS CONTACTOR RELAY (3C)
(Optional)
• SECOND STAGE OIL HEATER (5C)
• VAPORIZER HEATER CONTACTOR (6C)
• CONTROL TRANSFORMERS (T1, T2, T4)
• EXV CONTROL MODULE (PD4-EXV)
• AUXILIARY CONTROL MODULE (PD4-AUX1)
• ELECTRONIC EXPANSION VALVE
• CONDENSER LEVEL SENSOR
WARNING
Operation of this equipment with refrigerants other than
those cited herein should comply with ANSI/ASHRAE 15
(latest edition). Contact Carrier for further information on
use of this machine with other refrigerants.
DO NOT ATTEMPT TO REMOVE fittings, covers, etc.,
while machine is under pressure or while machine is run-
ning. Be sure pressure is at 0 psig (0 kPa) before breaking
any refrigerant connection.
CAREFULLY INSPECT all relief valves, rupture discs,
and other relief devices AT LEAST ONCE A YEAR. If
machine operates in a corrosive atmosphere, inspect the
devices at more frequent intervals.
DO NOT ATTEMPT TO REPAIR OR RECONDITION
any relief valve when corrosion or build-up of foreign
material (rust, dirt, scale, etc.) is found within the valve
body or mechanism. Replace the valve.
DO NOT install relief devices in series or backwards.
USE CARE when working near or in line with a com-
pressed spring. Sudden release of the spring can cause it
and objects in its path to act as projectiles.
SOME MODELS MAY EXCEED 85 dBA. Hearing pro-
tection should be worn when working in the vicinity of
such chillers.
CAUTION
Failure to follow these procedures may result in personal
injury or damage to equipment.
DO NOT STEP on refrigerant lines. Broken lines can whip
about and release refrigerant, causing personal injury.
DO NOT climb over a machine. Use platform, catwalk, or
staging. Follow safe practices when using ladders.
USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to
lift or move inspection covers or other heavy components.
Even if components are light, use mechanical equipment
when there is a risk of slipping or losing your balance.
BE AWARE that certain automatic start arrangements
CAN ENGAGE THE STARTER, TOWER FAN, OR
PUMPS. Open the disconnect ahead of the starter, tower
fan, and pumps. Shut off the machine or pump before ser-
vicing equipment.
USE only repaired or replacement parts that meet the code
requirements of the original equipment.
DO NOT VENT OR DRAIN waterboxes containing
industrial brines, liquid, gases, or semisolids without the
permission of your process control group.
DO NOT LOOSEN waterbox cover bolts until the water-
box has been completely drained.
DOUBLE-CHECK that coupling nut wrenches, dial indi-
cators, or other items have been removed before rotating
any shafts.
DO NOT LOOSEN a packing gland nut before checking
that the nut has a positive thread engagement.
PERIODICALLY INSPECT all valves, fittings, and piping
for corrosion, rust, leaks, or damage.
PROVIDE A DRAIN connection in the vent line near each
pressure relief device to prevent a build-up of condensate
or rain water.
DO NOT re-use compressor oil or any oil that has been
exposed to the atmosphere. Dispose of oil per local codes
and regulations.
CAUTION
DO NOT leave refrigerant system open to air any longer
than the actual time required to service the equipment. Seal
circuits being serviced and charge with dry nitrogen to pre-
vent oil contamination when timely repairs cannot be
completed.
CAUTION
Chiller must be installed in an indoor environment where
the ambient temperature is between 40 to 104 F (4 to 40 C)
with a relative humidity (non-condensing) of 95% or less.
To ensure that electrical components operate properly and
to avoid equipment damage, do not locate chiller in an area
exposed to dust, dirt, corrosive fumes, or excessive heat
and humidity.
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