Carrier 30GX080-176, 30HX076-271 User Manual
Minimum Load Control Accessory
Installation Instructions
Part Nos. 30HX-900---008, 30GX-900---004
(60 Hz — 115-v Control)
Part Nos. 30HX-900---009, 30GX-900---005
(50 or 60 Hz — 230-v Control)
30GX080-176
30HX076-271
50/60 Hz
CONTENTS
Page
SAFETY CONSIDERATIONS ...................1
INTRODUCTION ..............................1
INSTALLATION ............................. 1-6
Step 1 — Examine Package Contents .........1
Step 2 — Install Piping .......................2
• REMOVE MINIMUM LOAD PORT PLUGS AND
INSTALL FITTINGS
• INSTALL PIPING
• INSTALL BALL AND SOLENOID VALVES
• CONNECT PIPING
Step 3 — Dehydrate and Recharge Circuit .....3
Step 4 — Install Control Wiring ...............4
• 30HX UNITS
• 30GX UNITS
• ALL UNITS
Step 5 — Configure Unit for Minimum
Load Control ..............................6
Step6—TestMinimum Load Relay
Outputs ...................................6
Step 7 — Adjust Setting of Minimum Load
Ball Valve ..................................6
SAFETY CONSIDERATIONS
Installing, startingup,and servicing air-conditioning equipment 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-conditioningequipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment.
Follow all safety codes. W earsafetyglasses 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 fluid 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 anautomatic 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, 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, file a claim
immediately with the shipper.See Table 1 for accessory package contents and field-supplied material.
Pack-
Table 1 — Accessory Package Contents and Field-Supplied Material
ACCESSORY PACKAGE
COMPONENTS
Solenoid Valve (2) EF23JX212 (2) EF23JX231 (2) EF23JX212 (2) EF23JX231
Ball Valve (2) EP71BA201 (2) EP71BA201 (2) EP71BA201 (2) EP71BA201
Swagelok Connector (4) DC09CA307 (4) DC09CA307 (2) DC09CA307 (2) DC09CA307
Junction Box — — HX30FZ001 HX30FZ001
Junction Box Cover — — HX38ZZ001 HX38ZZ001
Watertight Conduit — — 99CD2121AC028 99CD2121AC028
5
⁄8-in. OD Copper Tubing, Wiring, Conduit,
Thread Sealant, Electrical Supplies
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 2
Tab 5c
PC 903 Catalog No. 563-056 Printed in U.S.A. Form 30GX,HX-2SI Pg 1 1-97 Replaces: New
30HX-900---008 30HX-900---009 30GX-900---004 30GX-900---005
FIELD SUPPLIED MATERIAL — REQUIRED PARTS (Ordered Separately)
ACCESSORY PART NUMBER
Field Supplied
Step 2 — 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 devicebefore 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 — Plugs must be removed from these
ports and replaced with Swagelokt fittings. Note that plugs
were factory-installed with Loctitet refrigerant-compatible
sealant. Fittings should be installed with similar sealant on
threads.
30GX — Cut plug end of fof 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 fitting in
minimum load port on cooler. Port on nipple in discharge
line is reserved for a brazed connection.
30HX — 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 fittings in minimum load ports.
INSTALL PIPING — On 30GX units, install field-supplied
5
⁄8-in. OD copper tubing between the Swagelok fitting on
the cooler shell and the brazed nipple on the discharge line.
On 30HX units, install field-supplied5⁄8-in. OD copper tubing between the fittings on the cooler shell and condenser
(30HXC) or oil separator (30HXA). Do not tighten fittings
or braze tubing yet.
TOP VIEW
Fig. 1 — Installing Fittings, 30GX (Typical)
2
INSTALL BALLAND SOLENOID VALVES — 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. Wrapwet
cloths around valve bodies during brazing to prevent damage to the valves from heat.
IMPORTANT: When installing solenoid valve, make
sure that flow 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 — Check the ends of the tubes where
they will be inserted into the Swagelokt fittings. To avoid
leaks, tube ends must be round and free of burrs, nicks, and
grooves.
Insert tube ends into fittings as far as they will go. When
tube bottoms out, tighten the compression nut finger-tight
while holding the fitting body. Use backup wrench to hold
fitting body and tighten compression nut another 1
1
⁄4turns.
IMPORTANT: Do NOTovertighten the fittings. Overtightening the fittings can deform the tube ends and
cause leaks.
30GX UNITS ONLY— Using good brazing practice, braze
the5⁄8-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 — Dehydrate and Recharge Circuit
When piping has been completed, leak test the assem-
—
bly. If one of the Swagelok fittings leaks, slowly tighten the
compression nut until the leak stops. If this does not fix the
leak, the connection must be reinstalled using a new ferrule
and backup 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.
Fig. 2 — Installing Fittings and Valves, 30HX (Typical)
3
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