Carrier MINIMUM LOAD CONTROL ACCESSORY 30RB060-390, 00EFN900000100A, 30RBA315, 30RBA330, 30RBA345 Installation Instructions Manual
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Minimum Load Control Accessory
Installation Instructions
Part No: 00EFN900000100A
30RB060-390
SAFETY CONSIDERATIONS
Installing, starting up, 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-conditioning equipment, observe
precautions in the literature, on tags, stickers, and labels
attached to the equipment.
Follow all safety codes. Wear safety glasses and work
gloves. Use care in handling equipment.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation. There
may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work
is completed.
GENERAL
IMPORTANT: This accessory can only be used on units
configured for Cooler Fluid Type (Configuration
SERVFLUD = 1 [Water]). The minimum load control
accessory (HGBP) is not allowed on units configured for
Cooler Fluid Type (Configuration
[Brine]).
This control accessory reduces 30RB chiller capacities below the standard lowest capacity step. This capacity reduction
provides more precise control of leaving fluid temperature
during light load conditions.
The solenoid valve limits the amount of gas that can be
bypassed from the condenser without impacting oil return.
One accessory package is required for 30RB060-190 units
and for each module of duplex units 30RB315-390. Two
accessory packages are required for 30RB210-300 units to
accommodate connections for all three refrigerant circuits. See
Table 1 for modular unit combinations.
Table 1 — Modular Unit Combinations
UNIT SIZE MODULE A MODULE B
30RBA315 30RBA160 30RBA160
30RBA330 30RBA170 30RBA160
30RBA345 30RBA170 30RBA170
30RBA360 30RBA190 30RBA170
30RBA390 30RBA190 30RBA190
NOTE: An “A” in the model number indicates the design series.
SERVFLUD = 2
INSTALLATION
Examine the package contents for correct part numbers. If
any of the components are damaged, file a claim with the
shipping company and notify a Carrier representative.
See Table 2 for package contents. See Fig. 1 for dimensional
drawings of tubes included in the kit.
The following material is field supplied:
1
•
/2 in. OD copper tubing
• standard
1
/2 in. copper tube elbows and couplings as required
Install the Solenoid Valve
WARNING
Shut off all power to the unit. Lock out and safety-tag all
disconnects. Remove refrigerant charge from the circuits
using an approved refrigerant recovery device before
proceeding with this installation. Follow good piping
practices. Severe personal injury could result.
1. Shut off power to the unit.
2. Remove refrigerant charge from the unit.
3. Locate the factory-supplied stub on the discharge line for
each circuit. Locate the
blank end of the cooler for 30RB110 circuit B and
for both circuits A and B on 30RB060-300 units. See
Fig. 2.
4. Remove the
1
/2 in. NPT pipe plugs from the blank end
of the cooler. Use an appropriate thread sealing
compound and install one 1 in. — 14 O-ring seal
adapter for each circuit. Lightly lubricate each O-ring
and attach a
5
/8 in. O-ring seal tube assembly to each
adapter. This nut should be torqued to 30 ft-lb (40 Nm). For 30RB110 circuit A size only, use a tubing cutter to cut off the end of the stub tube. See Fig. 3.
5. Assemble the hot gas bypass line in the following order:
a. Remove the discharge stub tube and braze the cor-
rect beaded tube in place.
b. Braze the ball valve to the beaded tube.
c. Braze the solenoid valve into the line.
d. Using field-supplied tubing, connect the solenoid
valve to the low side connection, either the cooler
or the liquid line.
e. Clamp the
5
/8-in. tube to the rail. See Fig. 4 and 5.
Use field-supplied
tings (as required) to plumb from the solenoid valve
outlet to either the adapter tube in the cooler or stub
tube in the liquid line depending on unit size. Tube
support brackets and
with the kit. Install brackets to the bottom of the coil
bases to support tubing.
1
/2 in. NPT pipe plugs at the
1
/2 in. OD copper tubing and fit-
1
/2 in. tubing clamps are provided
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300047-01 Printed in U.S.A. Form 30RB-16SI Pg 1 3-10 Replaces: 30RB-4SI
Table 2 — Contents of Accessory Kit
R31.75
[1.25]
152.40
[6.00]
1in.-14 ORS NUT MUST
MATE CORRECTLY
WITH CARRIER
ADAPTER
30GX503492
65.77
[2.59]
126.73
[4.99]
12.33
[0.49]
MIN.
Ø 12.7 [.50] SWAGE
R25.40
[1.00]
20.11 MIN.
[0.79]
BEAD
5.60
[0.22]
50.80
[2.00]
126.73
[4.99]
12.33
[0.49]
MIN.
Ø 12.7 [.50] SWAGE
BEAD
R25.40
[1.00]
5.60
[0.22]
58.16
[2.21]
20.11 MIN.
[0.79]
00PSN500023900A
00PSN500024400AA
00PPN500000600A
NOTE: DIMENSIONS ARE IN MM [IN].
BEAD
00PSN500024000A
Ø 12.7 [.50] SWAGE
5.60
[0.22]
123.98
[4.88]
222.98
[8.78]
12.33
[0.49]
MIN.
NOTE: Dimensions are in mm [in.].
Fig. 1 — Dimensions of Tubes Provided in Accessory Kit
PART NUMBER QUANTITY DESCRIPTION USAGE
5
00PPN500000600A 2
00PPN50001000A 2
00PSN500023900A 2
00PSN500024000A 1
00PSN500024400A 2
/8 in. tube assembly with 90-degree
bend and 1 in. — 14 O-ring seal nut
Solenoid valve with
1
/2 in.
ODF connections
5
/8 in. beaded tube with 1/2 in. swage
(used with 1
5
/8 in. beaded tube with 1/2 in. swage 30RB060,070 circuit B
5
/8 in. beaded tube with 1/2 in. swage
(used with 15/8 in. discharge lines)
1
/8 in. discharge lines)
00PSN500023600A 4 Tube support bracket
Blank end of the cooler except in
30RB110 circuit A
All
30RB060,070,110,120, circuit A and
30RB080-100 circuits A and B
30RB110,120 circuit B and
30RB130-390 all circuits
30RB060-110, circuit A (1 required)
30RB120,130 (2 required)
30RB150 (3 required)
30RB160-390 (4 required)
00PPN500000302A 8 M6 screw All, mount tube support brackets
00PPN500000401A 7 No. 10 screw All, mount tube clamps
EP71BA181 2
1
/2 in. ball valve
30GX503492 2 1 in. — 14 ORS by
KA66AA050 5
KA66AA062 2
1
/2 in. tube clamp
5
/8 in. tube clamp All, one per circuit just before solenoid
1
/2 in. NPT adapter
All, put in discharge line after solenoid
valve so circuit can be isolated
All at blank end of cooler except
30RB110 circuit A
30RB060-110 (1 required)
30RB120,130 (2 required)
30RB150 (3 required)
30RB160,170,190, 315-390* (4 required)
30RB210-300* (5 required)
SF703318 2 Cable assembly All, one per circuit
*Requires two kits.
2
DISCHARGE STUB
Fig. 2 — Typical Stub Tube View
COOLER STUB
Fig. 3 — Stub Tube for Circuit A of Size 110
BALL VALVE
Fig. 4 — Typical View of 5/8 in. Swage Tube,
5
/8 in. Clamp and Solenoid Valve Installed
ESCAPE
ENTER
ENTER
ENTER
.
IMPORTANT: The valve is direction specific and must
have the arrow pointing toward the cooler. The solenoid
valve will not properly seat if installed backwards.
6. Dehydrate and recharge each circuit.
7. Restore power to the unit.
NOTE: When piping is completed, leak test the assembly.
Then evacuate, dehydrate, and recharge the circuit using
approved refrigeration practices. Be sure to use the correct
type and amount of refrigerant listed in the nameplate data
and base unit documentation.
Install Control Wiring (See Fig. 6 and 7)
1. One control wire harness is supplied per circuit.
Secure the DIN connector end on the solenoid valve
coil with the screw in the connector. Verify the square
rubber gasket is in place to ensure connection remains
watertight.
2. Route the other end of the cable to the main control panel
(where the display is located). For the circuit A solenoid,
connect leads to TB5-7 and TB5-13. For the B circuit
solenoid, connect leads to TB5-8 and TB5-13. For the
C circuit solenoid (30RB210-300 only), connect the leads
to TB5-6 and TB5-13. In all cases the black wire from the
solenoid must be connected to TB5-13 to ensure correct
polarity. Incorrect polarity will damage the control
boards.
3. For 30RB250-300 units only, locate fan board 3 (FB3) in
the C circuit power control panel. Route the C circuit
solenoid cable to the panel. Locate the orange and brown
wires from channel 7 of connector J3 on this board.
Connect the red wire from the solenoid to the orange wire
from the board. Connect the black wire from the solenoid
to the brown wire from the board.
Configure Unit for Minimum Load Control —
The control must be configured for the minimum load control
operation. Use the scrolling marquee display to configure the
system.
IMPORTANT: This accessory can only be used on units
configured for Cooler Fluid Type (Configuration
SERVFLUD = 1 [Water]). The minimum load control
accessory (HGBP) is not allowed on units configured for
Cooler Fluid Type (Configuration
SERVFLUD = 2
[Brine]).
1. Set the Enable/Off/Remote switch to OFF position.
2. Press until the screen is blank and use the
arrow key to select the Configuration mode LED (light
emitting diode).
3. Press , then use arrow key to select the
sub-mode ‘UNIT’, then press Enter key.
4. Press the down arrow key until ‘HGBP’ is displayed.
5. Press key twice. The word ‘PASS’ and
‘WORD’ will flash.
6. Press 0 1 1 1 then key so that ‘0’ flashes.
7. Use arrow keys to change value to one of the following
configurations:
CONFIGURATION DESCRIPTION
1 Used during chiller start-up only
2
3
Used during start-up and for close
control of leaving fluid temperature
Used during start-up, for close control
of the leaving fluid temperature and for
high ambient unloading
3
8. Press the key.
ENTER
ESCAPE
00PPN500000600A
TUBE ASSEMBLY
5/8 IN.
TUBING CLAMP
(TYPICAL)
BALL VALVE
SOLENOID VALVE
FIELDSUPPLIED
TUBING
BALL VALVE
SOLENOID VALVE
5/8 IN.
TUBING CLAMP
(TYPICAL)
CIRCUIT A
CIRCUIT B
30RB110
Fig. 5 — Typical Piping Brackets
30RB060-100
9. Press the key until ‘DISP’ is displayed. Wait
10 seconds and cycle the control power using the On/Off
switch.
The chiller is now configured for minimum load valve control.
Test Minimum Load Relay Output — Use the Scroll-
ing Marquee display, the instructions given in the Controls,
Start-Up, Operation Service and Troubleshooting manual and
the Service Test mode to verify proper operation of the
solenoid(s) (illuminate the Service Test LED, enter the TEST
mode, enable the test request, ‘T.REQ’ and test outputs
‘HGB.A,’ ‘HGB.B’ and for 30RB210-300 only, ‘HGB.C.’
Once the outputs have been tested, the installation is complete.
Return the Enable/Off/Remote contact switch to the desired
position.
TUBE SUPPORT BRACKET
1/2 IN. TUBING
CLAMP
(TYPICAL)
CIRCUIT A
SOLENOID VALVE
BALL VALVE
4
SOLENOID VALVE
BALL VALVE
FIELD-SUPPLIED
TUBING
CIRCUIT B
00PPN500000600A
TUBE ASSEMBLY
TUBE SUPPORT
BRACKETS
SOLENOID VALVE
FIELD-SUPPLIED
TUBING
00PPN500000600A
TUBE ASSEMBLY
SOLENOID VALVE
BALL VALVE
BA L L VA LVE
CIRCUIT A
CIRCUIT B
SOLENOID VALVE
SOLENOID VALVE
FIELD-SUPPLIED
TUBING
1/2 IN.
TUBING CLAMP (TYPICAL)
TUBE SUPPORT BRACKETS
TUBE SUPPORT BRACKETS
FIELD-SUPPLIED
TUBING
FIELD-SUPPLIED
TUBING
5/8 IN.
TUBING CLAMP
(TYPICAL)
SOLENOID VALVE
00PPN500000600A
TUBE ASSEMBLY
BALL VALVE
BALL VALVE
1/2 IN. CLAMP (TYPICAL)
BALL VALVE
CIRCUIT C
CIRCUIT B
CIRCUIT A
30RB210-300
Fig. 5 — Typical Piping Brackets (cont)
30RB120-190
5
Fig. 6 — Main Base Board Wiring for
Circuits A and B, 30RB060-300
Fig. 7 — Fan Board 3 Wiring for Circuit C, 30RB210-300
LEGEND
MLV — Minimum Load Valve
TB — Terminal Block
LEGEND
MLV — Minimum Load Valve
TB — Terminal Block
6
Copyright 2010 Carrier Corporation
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300047-01 Printed in U.S.A. Form 30RB-16SI Pg 8 3-10 Replaces: 30RB-4SI
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