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30GXN,R080-528 30HX076-271 Minimum Load Control Accessory 50/60 Hz

Brochure 80 to 450 Tons 30GXN-2PD Keywords: 100 QUALITY USED CHILLERS FOR SALE. Carrier Air-Cooled Chiller Model 30GXN/GXR Brochure 80 to 450 Tons 30GXN-2PD Created Date Product Data ECOLOGIC™ Air-Cooled Carrier Manuals. Search for: Toggle navigation Folders. Installation Manuals; Owners Manuals; Parts.

Installation Instructions

Part No. 30GX-900---048,

(60 Hz — 115-v Control)

Part No. 30GX-900---049

(50 or 60 Hz — 230-v Control)

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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

•30GXN,R UNITS ONLY

Step 3 — Dehydrate and Recharge Circuit. . . . . . . . 3 Step 4 — Install Control Wiring. . . . . . . . . . . . . . . . . . . 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 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 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 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 an automatic lead/lag feature on the chillers, the accessory should be installed on both circuits.

INSTALLATION

Step 1 — Examine Package Contents — Package 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

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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 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 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 — 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 O-ring seal 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 O-ring seal fittings in minimum load ports.

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 solenoid 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. You should be able to feel the O- ring compress on the last 1/4-turn.

IMPORTANT: DO NOT over tighten the O-ring seal nut. Damage will occur to the seal, resulting in leaks.

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 mm2) minimum. See Fig. 4 and 5 for field wiring.

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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 suitable 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 end of the unit. See Fig. 4 and 5.

ALL UNITS — 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 TB2-9 (30HX) or TB4-2 (30GX).

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Connect a pink wire to the solenoid valve on circuit A.

Connect a gray wire to the solenoid valve on circuit B. Connect both the pink and gray wires to TB5-9 for all units.

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Figure 4 shows the correct location of the wiring connection points on the chiller.