Carrier 30GX080-176 Manuale utente

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)

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, 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 at-

tached 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 perform-

ing maintenance or service.

IMPORTANT: When removing refrigerant, use an

approved refrigerant recovery device. Do not vent re-

frigerant 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 an automatic lead/

lag feature on the chillers, the accessory should be installed

on both circuits.

INSTALLATION

Step 1 — Examine Package Contents — Pack-

age includes solenoid valves, ball valves, Swageloktcon-

nectors, and instructions. The kit for 30GX units also con-

tains 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 pack-

age contents and ﬁeld-supplied material.

Table 1 — Accessory Package Contents and Field-Supplied Material

ACCESSORY PACKAGE

COMPONENTS ACCESSORY PART NUMBER

30HX-900---008 30HX-900---009 30GX-900---004 30GX-900---005

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

FIELD SUPPLIED MATERIAL — REQUIRED PARTS (Ordered Separately)

⁄

-in. OD Copper Tubing, Wiring, Conduit,

Thread Sealant, Electrical Supplies Field Supplied

30GX080-176

30HX076-271

Minimum Load Control Accessory

50/60 Hz

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

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 ap-

proved refrigerant recovery device before proceeding with

installation.

NOTE: The units have 2 circuits. Perform all of the follow-

ing piping installation procedures on both A and B circuits.

REMOVE MINIMUM LOAD PORT PLUGS AND IN-

STALL FITTINGS — Plugs must be removed from these

ports and replaced with Swageloktﬁttings. Note that plugs

were factory-installed with Loctitetrefrigerant-compatible

sealant. Fittings should be installed with similar sealant on

threads.

30GX — Cut plug end off of minimum load port braze nipple

on discharge line, located between oil separator and con-

denser. 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 sepa-

rator (30HXA). See Fig. 2. Using thread sealant, install

Swagelok ﬁttings in minimum load ports.

INSTALL PIPING — On 30GX units, install ﬁeld-supplied

⁄

-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-supplied

⁄

-in. OD copper tub-

ing 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)

INSTALL BALLAND SOLENOID VALVES — Using good

piping practice, braze ball valve and solenoid valve into

⁄

-in. minimum load piping. Fig. 2 shows a typical 30HX

installation and Fig. 3 shows a typical 30GX installation, in-

cluding 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 dam-

age 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 Swageloktﬁttings. 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

⁄

turns.

IMPORTANT: Do NOT overtighten the ﬁttings. Over-

tightening the ﬁttings can deform the tube ends and

cause leaks.

30GX UNITS ONLY — Using good brazing practice, braze

the

⁄

-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 repre-

sentative for assistance in locating these parts.

After leak testing, evacuate, dehydrate, and recharge the

circuit using an approved refrigerant recovery device. Cor-

rect type and amount of refrigerant are listed on unit name-

plate and in base unit documentation.

Fig. 2 — Installing Fittings and Valves, 30HX (Typical)

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

)

minimum. See Fig. 4 for ﬁeld wiring.

30HX UNITS — Remove the screws holding the right-side

access panel to the unit control box. Remove the right-side

access panel and store in a safe area.

Route wires through ﬁeld-supplied conduit and attach the

conduit to the unit control box, using a suitable conduit ﬁt-

ting and one of the available

⁄

-in. knockout openings. At-

tach the other end of the conduit to the solenoid valve, using

a suitable ﬁtting. Repeat for the other circuit.

30GX UNITS — Install the accessory junction box included

with this kit in the position shown on the 30GX chiller in

Fig. 3. Route the waterproof conduit included with this kit

between the accessory junction box and the factory-installed

junction box. See Fig. 3 and 4. Route ﬁeld-supplied conduits

from the solenoid valves to the accessory junction box.

ALLUNITS — Using good wiring practice, connect 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

the white wire in the factory-installed junction box (30GX),

or unit wiring harness labelled ‘‘MLC-A& B’’(30HXA, HXC).

Connect a pink wire from the solenoid valve on circuit A

to the pink wire in the factory-installed junction box (30GX),

or unit wiring harness labelled MLC-A (30HXA, HXC).

Connect a gray wire from the solenoid valve on circuit B

to the gray wire in the factory-installed junction box (30GX),

or unit wiring harness labelled MLC-B (30HXA, HXC).

Figure 4 shows the correct wiring for the minimum load

control and the location of the wiring connection points on

the chiller.

Fig. 3 — Installing Valves, 30GX

30GX080-176

30HX076-271

LEGEND

MLC — Minimum Load Control

TB — Terminal Block

NOTE: See Fig. 3 for locations of junction

boxes on unit. Fig. 4 — Minimum Load Control Wiring

Step 5 — Conﬁgure Unit for Minimum Load Con-

trol — Once the piping installation and wiring installation

are complete, the chiller must be conﬁgured for minimum

load control operation. This may be done using the unit key-

pad (HSIO-2). Set the LOCAL/OFF switch in the OFF

position.

1. Press on the keypad.

2. Press the down arrow until the display reads:

MIN. LOAD VALVE SELECT

DISABLE

3. To enable the minimum load valve feature, press

4. The display may read as follows. (If not, skip to Step 7.)

PASSWORD PROTECTED FUNCTION

ENTER PASSWORD

5. Press .

6. The HSIO-2 again displays the following:

MIN. LOAD VALVE SELECT

DISABLE

7. Press . The display changes to:

MIN. LOAD VALVE SELECT

ENABLE

The chiller is now conﬁgured for minimum load valve

control.

Step6—TestMinimum Load Relay Outputs

—After the accessory components are installed and the unit

is recharged and reconﬁgured, test the operation of the relay

and solenoid valve using the Quick Test software function.

Test Circuit A as follows (the LOCAL/OFF switch must be

in the OFF position):

1. Press on the HSIO-2 keypad.

2. Press the down arrow until the display reads:

MIN. LOAD VALVE A

RELAY IS OFF

3. Press .

4. The display may read as follows. (If not, skip to Step 7.)

PASSWORD PROTECTED FUNCTION

ENTER PASSWORD

5. Press .

6. The HSIO-2 again displays the following:

MIN. LOAD VALVE A

RELAY IS OFF

7. Press to energize the relay. The display reads:

MIN. LOAD VALVE A

RELAY IS ON

An audible click will be heard. Verify that the solenoid

valve for Circuit A is energized.

8. Press to turn off the minimum load valve relay

for Circuit A.

To check the operation of the solenoid valve on Circuit B,

follow the same procedure as the preceding, but enter

enter in Step 1, instead of . The display

screens will be for Circuit B instead of A.

After testing is complete, recheck all electrical connec-

tions for proper location and tightness. For 30HX units, re-

place and secure the access panels for the unit control box.

For 30GX units, secure the junction box covers to the junc-

tion boxes.

Step 7 — Adjust Setting of Minimum Load Ball

Valve — Before the installation is complete, the mini-

mum load ball valve must be adjusted to suit the application.

Calibrate one circuit at a time as follows:

1. Adjust the ball valve so that it is approximately half open.

2. Operate the chiller in Manual Control mode, with one cir-

cuit operating, and all compressor loaders deenergized.

NOTE: Operation of the chiller in Manual Control mode is

described in the Controls, Start-Up, Operation, and Trouble-

shooting Guide that is included with the 30GX,HX

Ecologic™ chillers.

3. Record the cooler DT (the difference between cooler en-

tering ﬂuid temperature and cooler leaving ﬂuid tempera-

ture) at this fully unloaded condition.

4. Use the Manual Control feature to enable the minimum

load valve for the circuit that is operating.

5. Observe and record the cooler DTwith the minimum load

valve energized.

6. Adjust the minimum load ball valve until the cooler tem-

perature difference reading from Step 5 is equal to half of

the temperature difference reading from Step 3.

7. Open the ball valve to decrease the temperature differ-

ence or close the ball valve to increase the temperature

difference (DT). When the valve is adjusted correctly,

the difference between cooler entering and leaving ﬂuid

temperatures when the minimum load control is ener-

gized must be at least half of the temperature difference

when the minimum load control is deenergized. For ex-

ample, if the difference between the cooler entering and

leaving water temperature is 3° F with the valve deen-

ergized, then the difference between cooler entering and

leaving water temperature must be at least 1.5° F with the

valve energized.

Once the outputs have been tested and the ball valve ad-

justed, the installation is complete.

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 8 1-97 Replaces: New

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