Carrier R080-528, 30GXN User Manual
Minimum Load Control Accessory
Installation Instructions
Part No. 30GX-900---048,
(60 Hz — 115-v Control)
Part No. 30GX-900---049
(50 or 60 Hz — 230-v Control)
30GXN,R080-528
30HX076-271
50/60 Hz
CONTENTS
Page
SAFETY CONSIDERATIONS
INTRODUCTION
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Step 1 — Examine Package Contents
Step 2 — Install Piping
. . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
• REMOVE MINIMUM LOAD PORT PLUGS
AND INSTALL FITTINGS
• INSTALL PIPING
• INSTALL BALL AND SOLENOID VALVES
• CONNECT PIPING
• 30GXN,R UNITS ONLY
Step 3 — Dehydrate and Recharge Circuit
Step 4 — Install Control Wiring
. . . . . . . . . . . . . . . . . . . 3
. . . . . . . . 3
• 30HX UNITS
• 30GXN,R UNITS
• ALL UNITS
Step 5 — Configure Unit for Minimum
Load Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 6 —Test Minimum Load Relay
Outputs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 7 — Adjust Setting of Minimum
Load Ball Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SAFETY CONSIDERATIONS
Installing, starting up, and servicing air-conditioning equip-
ment can be hazardous due to system pressures, electrical components, and equipment location.
Only trained, qualified installers and service technicians
should install, start up, and service this equipment.
When working on air-conditioning equipment, observe pre-
cautions 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.
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
30GXN,R chillers to have their capacities decreased below the
standard fully unloaded condition. The accessory provides
more precise control of leaving fluid temperature during light
load conditions.
The 30GXN,R and 30HX chillers have a dual-circuit
design. Each minimum load control accessory package contains the items required for both circuits. Because of a n automatic lead/lag feature on the chillers, the accessory should be
installed on both circuits.
INSTALLATION
Step 1 — Examine Package Contents —
age includes solenoid valves, ball valves, O-ring seal fittings,
and instructions. Examine each item. If any part is damaged or
missing, file a claim immediately with the shipper and notify
your Carrier representative. See Table 1 for accessory package
contents and field-supplied material.
Table 1 — Accessory Package Contents
and Field-Supplied Material
ACCESSORY PACKAGE
COMPONENTS
Solenoid Valve (2) EF23JX212 (2) EF23JX231
Ball Valve (2) EP71BA201 (2) EP71BA201
O-Ring Seal Fitting (4) 30GX503492 (4) 30GX503492
Tu be A s s e m b l y (2) 30GX503487 (2) 30GX503457
Tube Assembly (Condenser
Oil Separator)
FIELD SUPPLIED MATERIAL — REQUIRED PARTS
5
/8-in. OD Copper Tubing, Wiring, Conduit,
Thread Sealant, Electrical Supplies
(Ordered Separately)
ACCESSORY PART NUMBER
30GX-900---048 30GX-900---049
(2) 30HX402343 (2) 30HX402343
Pack-
Field Supplied
Be sure power to equipment is shut off before performing
maintenance or service.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Ta b 5 c
PC 903 Catalog No. 533-00009 Printed in U.S.A. Form 30GX,HX-14SI Pg 1 102 7-00 Replaces: 30GX,HX-7SI
Step 2 — Install Piping
Shut off all power to the unit, then lock out and safety-tag
all disconnects before proceeding with installation.
Remove refrigerant charge from circuits using an approved refrigerant recovery device before proceedi ng with
installatio n.
NOTE: The units have 2 circuits. Perform all of the followi ng
piping installation procedures on both A and B circuits.
REMOVE MINIMUM LOAD PORT PLUGS AND INSTALL FITTINGS — Plugs must be removed from these
ports and replaced with O-ring seal fittings. Note that plugs
were factory-installed with Loctitet 554 or equivalent
refrigerant-compatible sealant. Fittings should be installed with
similar sealant on threads.
30GXN,R
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 O-ring seal fitting in
minimum load port on cooler. Port on nipple in discharge line
is reserved for a brazed connection.
30HX
er shell and the condenser shell (30HXC) or oil separator
(30HXA). See Fig. 2. Using thread sealant, i nstall O-ring seal
fittings in minimum load ports.
— Cut plug end off of minimum load port braze
— Remove plugs from minimum load ports on the cool-
INSTALL PIPING — On 30GXN,R units, carefully thread the
cooler tube assemblies (P/N 30GX503487) on the O-ring seal
fittings installed in the cooler port. Do not tighten. Install fieldsupplied
5
/8-in. OD copper tubing between the tube assembly
and the brazed nipple on the discharge line.
On 30HX units, carefully thread the cooler tube assemblies
(P/N 30GX503487) and the condenser oil separator tube assembly (P/N 30HX402343) on the O-ring seal fittings installed
in the cooler and condenser/oil separator ports. Do not tighten.
Install field-supplied
5
/8-in. OD copper tubing between the
tube assemblies on the cooler shell and condenser (30HXC) or
oil separator (30HXA).
INSTALL BALL AND SOLENOID VALVES — Using good
piping practice, braze ball valve and sole noid valve into
5
/8-in.
minimum load piping. Fig. 2 shows a typical 30HX installation
and Fig. 3A and 3B show a typical 30GXN,R 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 and tube assembly locking nuts
during brazing to prevent damage to the valves and O-rings
from heat.
CONNECT PIPING — Lubricate O-rings with a light coating
of polyalphaolefin lubricant suitable for R-134a systems.
Thread tube assembly nuts onto the O-ring seal fittings until
they are finger-tight. Lightly snug the nut with a wrench;
DO NOT OVER TIGHTEN. Y ou s hould be able to feel the Oring compress on the last
1
/4-turn.
IMPORTANT: DO NOT over tighten the O-ring seal
nut. Damage will occ ur to t he se al, r esult ing in le aks.
→
102
Fig. 1 — Installing Fittings, 30GXN,R (Typical Size 080-150, 160 Shown)
2
Fig. 2 — Installing Fittings and Valves, 30HX (Typical)
30GXN,R UNITS ONLY — 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, 3A and 3B.
Step 3 — Dehydrate and Recharge Circuit —
When piping has been completed, leak test the assembly. If
one of the O-ring seal fittings leaks, slowly tighten the O-ring
nut until the leak stops. If this does not fix the leak, the connection must be reinstalled using a new O-ring in the fitting. 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.
Step 4 — Install Control Wiring
Be sure all power to the unit is off before proceeding. Lock
out and safety-tag all disconnects.
Wires between field-installed components and unit control
box must be enclosed in field-supplied conduit. Follow all local
codes and NEC (National Electrical Code, U.S.A.). Wire size
must be no. 16 AWG (American Wire Gage) (1.5 mm
2
) mini-
mum. See Fig. 4 and 5 for field wiring.
30HX UNITS — Remove the screws holding the right-side
access panel to the unit control box. Open the right-side access
panel.
Route wires through field-supplied conduit and attach the
conduit to the unit control box, using a suitable conduit fitting
and one of the available
7
/8-in. knockout openings. Attach the
other end of the conduit to the solenoid valve, using a suitabl e
fitting. Repeat for the other circuit. See Fig. 4.
30GXN,R UNITS —Route the field-supplied water proof conduit from the solenoid valves to the control box at the e nd of
the unit. See Fig. 4 and 5.
ALL UNITS — Using good wiring practice, connec t a white
wire from the solenoid valve on circuit A to a white wire from
the solenoid valve on circuit B. Connect both wires to TB2-9
(30HX) or TB4-2 (30GX).
Connect a pink wire to the solenoid valve on circuit A.
Connect a gray wire to the solenoid valve on circuit B. Con-
nect both the pink and gray wires to TB5-9 for all units.
Figure 4 shows the correct location of the wiring connection
points on the chiller.
3
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