30GX080-176 30HX076-271 Minimum Load Control Accessory 50/60 Hz
Installation Instructions
Part Nos. 30HX-900---008, 30GX-900---004
(60 Hz Ð 115-v Control)
Part Nos. 30HX-900---009, 30GX-900---005
(50 or 60 Hz Ð 230-v Control)
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Step 1 Ð Examine Package Contents . . . . . . . . . 1
Step 2 Ð Install Piping . . . . . . . . . . . . . . . . . . . . . . . 2
·REMOVE MINIMUM LOAD PORT PLUGS AND INSTALL FITTINGS
·INSTALL PIPING
·INSTALL BALL AND SOLENOID VALVES
·CONNECT PIPING
Step 3 Ð Dehydrate and Recharge Circuit . . . . . 3 Step 4 Ð Install Control Wiring . . . . . . . . . . . . . . . 4
·30HX UNITS
·30GX UNITS
·ALL UNITS
Step 5 Ð Con®gure Unit for Minimum
Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 6 Ð Test Minimum Load Relay
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 7 Ð Adjust Setting of Minimum Load
Ball Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air-conditioning equipment can be hazardous due to system pressures, electrical components, and equipment location.
Only trained, quali®ed installers and service technicians should install, start up, and service this equipment.
When working on air-conditioning equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.
Follow all safety codes. Wear safety glasses and work gloves. Use care in handling equipment.
Be sure power to equipment is shut off before performing maintenance or service.
IMPORTANT: When removing refrigerant, use an approved refrigerant recovery device. Do not vent refrigerant into the atmosphere.
INTRODUCTION
The minimum load control accessory allows 30HX and 30GX chillers to have their capacities decreased below the standard fully unloaded condition. The accessory provides more precise control of leaving ¯uid temperature during light load conditions.
The 30GX and 30HX chillers have a dual-circuit design. Each minimum load control accessory package contains the items required for both circuits. Because of an automatic lead/ lag feature on the chillers, the accessory should be installed on both circuits.
INSTALLATION
Step 1 Ð Examine Package Contents Ð Package includes solenoid valves, ball valves, Swagelokt connectors, and instructions. The kit for 30GX units also contains a junction box, junction box cover, and conduit. Examine each item. If any part is damaged or missing, ®le a claim immediately with the shipper. See Table 1 for accessory package contents and ®eld-supplied material.
Table 1 Ð Accessory Package Contents and Field-Supplied Material
ACCESSORY PACKAGE |
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ACCESSORY PART NUMBER |
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COMPONENTS |
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30HX-900---008 |
30HX-900---009 |
30GX-900---004 |
30GX-900---005 |
Solenoid Valve |
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(2) EF23JX212 |
(2) EF23JX231 |
(2) EF23JX212 |
(2) EF23JX231 |
Ball Valve |
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(2) EP71BA201 |
(2) EP71BA201 |
(2) EP71BA201 |
(2) EP71BA201 |
Swagelok Connector |
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(4) DC09CA307 |
(4) DC09CA307 |
(2) DC09CA307 |
(2) DC09CA307 |
Junction Box |
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Ð |
Ð |
HX30FZ001 |
HX30FZ001 |
Junction Box Cover |
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Ð |
Ð |
HX38ZZ001 |
HX38ZZ001 |
Watertight Conduit |
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Ð |
Ð |
99CD2121AC028 |
99CD2121AC028 |
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FIELD SUPPLIED MATERIAL Ð REQUIRED PARTS (Ordered Separately) |
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5¤8-in. OD Copper Tubing, Wiring, Conduit, |
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Field Supplied |
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Thread Sealant, Electrical Supplies |
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Manufacturer reserves the right to discontinue, or change at any time, speci®cations or designs without notice and without incurring obligations.
Book |
2 |
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PC 903 |
Catalog No. 563-056 |
Printed in U.S.A. |
Form 30GX,HX-2SI |
Pg 1 |
1-97 |
Replaces: New |
Tab |
5c |
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Step 2 Ð Install Piping
Shut off all power to the unit, then lock out and safetytag all disconnects before proceeding with installation.
Remove refrigerant charge from circuits using an approved refrigerant recovery device before proceeding with installation.
NOTE: The units have 2 circuits. Perform all of the following piping installation procedures on both A and B circuits.
REMOVE MINIMUM LOAD PORT PLUGS AND INSTALL FITTINGS Ð Plugs must be removed from these ports and replaced with Swagelokt ®ttings. Note that plugs were factory-installed with Loctitet refrigerant-compatible sealant. Fittings should be installed with similar sealant on threads.
30GX Ð Cut plug end off of minimum load port braze nipple on discharge line, located between oil separator and condenser. Remove plug from minimum load port on cooler shell. See Fig. 1. Using thread sealant, install Swagelok ®tting in minimum load port on cooler. Port on nipple in discharge line is reserved for a brazed connection.
30HX Ð Remove plugs from minimum load ports on the cooler shell and the condenser shell (30HXC) or oil separator (30HXA). See Fig. 2. Using thread sealant, install Swagelok ®ttings in minimum load ports.
INSTALL PIPING Ð On 30GX units, install ®eld-supplied 5¤8-in. OD copper tubing between the Swagelok ®tting on the cooler shell and the brazed nipple on the discharge line. On 30HX units, install ®eld-supplied 5¤8-in. OD copper tubing between the ®ttings on the cooler shell and condenser (30HXC) or oil separator (30HXA). Do not tighten ®ttings or braze tubing yet.
TOP VIEW
Fig. 1 Ð Installing Fittings, 30GX (Typical)
2
INSTALL BALL AND SOLENOID VALVES Ð Using good piping practice, braze ball valve and solenoid valve into 5¤8-in. minimum load piping. Fig. 2 shows a typical 30HX installation and Fig. 3 shows a typical 30GX installation, including valve locations and orientation. Ensure that ball valve is fully open, and that both the ball and solenoid valve are protected from excess heat during brazing process. Wrap wet cloths around valve bodies during brazing to prevent damage to the valves from heat.
IMPORTANT: When installing solenoid valve, make sure that ¯ow direction arrow on valve body points towards the cooler. The minimum load control will not function correctly if this valve is installed backwards.
CONNECT PIPING Ð Check the ends of the tubes where they will be inserted into the Swagelokt ®ttings. To avoid leaks, tube ends must be round and free of burrs, nicks, and grooves.
Insert tube ends into ®ttings as far as they will go. When tube bottoms out, tighten the compression nut ®nger-tight while holding the ®tting body. Use backup wrench to hold ®tting body and tighten compression nut another 11¤4 turns.
IMPORTANT: Do NOT overtighten the ®ttings. Overtightening the ®ttings can deform the tube ends and cause leaks.
30GX UNITS ONLY Ð Using good brazing practice, braze the 5¤8-in. minimum load tubing to the copper nipple on the discharge line (minimum load port) between the condenser coil and oil separator. See Fig. 1 and 3.
Step 3 Ð Dehydrate and Recharge Circuit
Ð When piping has been completed, leak test the assembly. If one of the Swagelok ®ttings leaks, slowly tighten the compression nut until the leak stops. If this does not ®x the leak, the connection must be reinstalled using a new ferrule and backup ring in the ®tting. Contact your Carrier representative for assistance in locating these parts.
After leak testing, evacuate, dehydrate, and recharge the circuit using an approved refrigerant recovery device. Correct type and amount of refrigerant are listed on unit nameplate and in base unit documentation.
Fig. 2 Ð Installing Fittings and Valves, 30HX (Typical)
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