Carrier Refrigerator 30GXN User Manual

30GXN,R080-528  
30HX076-271  
Minimum Load Control Accessory  
50/60 Hz  
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  
IMPORTANT: When removing refrigerant, use an  
approved refrigerant recovery device. Do not vent refrig-  
erant into the atmosphere.  
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  
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 con-  
tains the items required for both circuits. Because of an auto-  
matic lead/lag feature on the chillers, the accessory should be  
installed on both circuits.  
• 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  
INSTALLATION  
Step 1 — Examine Package Contents Pack-  
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.  
SAFETY CONSIDERATIONS  
Table 1 — Accessory Package Contents  
and Field-Supplied Material  
Installing, starting up, and servicing air-conditioning equip-  
ment can be hazardous due to system pressures, electrical com-  
ponents, 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.  
ACCESSORY PART NUMBER  
ACCESSORY PACKAGE  
COMPONENTS  
30GX-900---048  
(2) EF23JX212  
(2) EP71BA201  
(4) 30GX503492  
(2) 30GX503487  
30GX-900---049  
(2) EF23JX231  
(2) EP71BA201  
(4) 30GX503492  
(2) 30GX503457  
Solenoid Valve  
Ball Valve  
O-Ring Seal Fitting  
Tube Assembly  
Tube Assembly (Condenser  
Oil Separator)  
(2) 30HX402343  
(2) 30HX402343  
Follow all safety codes. Wear safety glasses and work  
gloves. Use care in handling equipment.  
FIELD SUPPLIED MATERIAL — REQUIRED PARTS  
(Ordered Separately)  
5/8-in. OD Copper Tubing, Wiring, Conduit,  
Field Supplied  
Thread Sealant, Electrical Supplies  
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.  
PC 903 Catalog No. 533-00009 Printed in U.S.A. Form 30GX,HX-14SI Pg 1 102 7-00 Replaces: 30GX,HX-7SI  
Book 2  
Tab 5c  
 
Fig. 2 — Installing Fittings and Valves, 30HX (Typical)  
30GXN,R UNITS ONLY — Using good brazing practice,  
codes and NEC (National Electrical Code, U.S.A.). Wire size  
must be no. 16 AWG (American Wire Gage) (1.5 mm2) 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 suitable  
fitting. Repeat for the other circuit. See Fig. 4.  
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 connec-  
tion must be reinstalled using a new O-ring in the fitting. Con-  
tact your Carrier representative for assistance in locating these  
parts.  
30GXN,R UNITS —Route the field-supplied water proof con-  
duit 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).  
After leak testing, evacuate, dehydrate, and recharge the cir-  
cuit 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  
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.  
Be sure all power to the unit is off before proceeding. Lock  
out and safety-tag all disconnects.  
Figure 4 shows the correct location of the wiring connection  
points on the chiller.  
Wires between field-installed components and unit control  
box must be enclosed in field-supplied conduit. Follow all local  
3
 
MINIMUM LOAD  
CONTROL PORTS  
SOLENOID VALVE (TYP)  
BALL VALVE (TYP)  
CIRCUIT A (080-138)  
CIRCUIT B (150, 160)  
O-RING SEAL FITTING  
AND ADAPTER (TYP)  
CIRCUIT B (080-138)  
CIRCUIT A (150, 160)  
Fig. 3A Typical Piping and Valve Installation 30GXN,R080-178  
and Associated Modular Sizes (080-150, 160 Shown)  
SEE DETAIL C  
O-RING SEAL  
FITTING  
SOLENOID  
VALVE  
DETAIL C  
FIELD INSTALLED  
PIPING TO  
CIRCUIT B DISCHARGE  
LINE  
BALL  
VALVE  
MINIMUM LOAD PORT  
CIRCUIT B  
MINIMUM LOAD PORT  
CIRCUIT A  
FIELD INSTALLED PIPING  
TO CIRCUIT A DISCHARGE LINE  
Fig. 3B Typical Piping and Valve Installation 30GXN,R204-350  
and Associated Modular Sizes (204-268 Shown)  
102  
4
 
30GXN,R080-178*  
MLC-B  
CONDUIT  
MLC-A  
CONDUIT  
30HX076-186  
LEGEND  
C
Contactor Compressor  
Circuit Breaker  
GND  
LR  
Ground  
SPT  
Suction Pressure  
Transducer  
CB  
CCP  
Loader Relay  
ComfortLinkCompressor  
Protection  
MLC  
OPC  
PL  
Minimum Load Control  
Oil Pump Contactor  
Plug Assembly  
Primary  
Screw Compressor  
Board  
Sensor (Toroid)  
TB  
TRAN  
Terminal Block  
Transformer  
CLHR  
EMM  
EQUIP  
EXV  
Cooler Heater Relay  
Energy Management Module  
Equipment  
Terminal Block Connection  
PRI  
SCB  
Unmarked Splice  
Factory Wiring  
Electronic Expansion Valve  
Fuse Block  
FB  
SN  
FR  
Fan Relay  
GFI-CO  
Ground Fault Interrupter Convenience Outlet  
*And associated modular sizes.  
Fig. 4 Typical Minimum Load Control Wiring  
5
102  
 
MLC-B  
CONDUIT  
MLC-A  
CONDUIT  
30HX206-271  
30GXN,R204-350*  
*And associated modular sizes.  
Fig. 4 Typical Minimum Load Control Wiring (cont)  
102  
6
 
Fig. 4 Typical Minimum Load Control Wiring (cont)  
ROUTE CONDUITS THROUGH TRAY  
AND ATTACH TO BOTTOM OF SHELF  
ON TB-4 SIDE OF CONTROL BOX  
Fig. 5 Routing Field-Supplied Wiring and Conduit (30GXN,R Shown)  
7
 
Step 5 Configure Unit for Minimum Load  
Control Once the piping installation and wiring installa-  
tion are complete, the chiller must be configured for minimum  
load control operation. This may be done using the Navigator.  
Set the Enable/Off/Remote/Contact switch in the OFF position.  
ENTER  
6. Press the  
display reads:  
MLV ON  
and  
key to energize the relays. The  
An audible click will be heard. Verify that the solenoid  
valves for both circuits are energized.  
ESCAPE  
1. Press  
key until display reads ‘SELECT A MENU  
ENTER  
ENTER  
7. Press the  
,
and  
keys to turn the solenoids  
ITEM.’ Press  
key to light up Configuration mode.  
off. When finished, exit the Service Test mode (change  
‘TEST ON’ to ‘TEST OFF’). Put the Enable/Off/Remote  
Contact switch in the desired position.  
ENTER  
Press  
Press  
. Press key to select sub-mode ‘OPT1’.  
ENTER  
.
After testing is complete, recheck all electrical connections  
for proper location and tightness. Replace and secure the access  
panels for the unit control box.  
2. Press the down arrow  
key to select MLVS NO.  
3. To enable the minimum load valve feature, press the  
Step 7 Adjust Setting of Minimum Load Ball  
Valve Before the installation is complete, the minimum  
load ball valve must be adjusted to suit the application. Cali-  
brate one circuit at a time as follows:  
1. Adjust the ball valve so that it is approximately half open.  
2. Operate the chiller in Service Test mode, with one circuit  
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 30GXN,GXR,HX  
ComfortLink™ chillers.  
3. Record the cooler T (the difference between cooler en-  
tering fluid temperature and cooler leaving fluid tempera-  
ture) at this fully unloaded condition.  
ENTER  
key.  
4. The display may read as follows. (If not, skip to Step 7.)  
ENTER PASSWORD  
ENTER  
5. Press 1 1 1 1 then  
key.  
6. The Navigator again displays the following:  
MLVS NO  
ENTER  
7. Press  
MLVS YES  
The chiller is now configured for minimum load valve  
key and The Navigator displays:  
control.  
Step 6 Test Minimum Load Relay Out-  
puts After the accessory components are installed and the  
unit is recharged and reconfigured, test the operation of the re-  
lay and solenoid valve using the Service Test software func-  
tion. Test both circuits as follows:  
4. Use the Service Test feature to enable the minimum load  
valve output.  
5. Observe and record the cooler T with 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.  
ESCAPE  
1. Press the  
key until the Navigator displays ‘SE-  
LECT A MENU ITEM.’ Press the  
key and light up  
7. Open the ball valve to decrease the temperature differ-  
ence or close the ball valve to increase the temperature  
difference (T). When the valve is adjusted correctly, the  
difference between cooler entering and leaving fluid tem-  
peratures when the minimum load control is energized  
must be at least half of the temperature difference when  
the minimum load control is deenergized. For example, if  
the difference between the cooler entering and leaving  
water temperature is 3° F with the valve deenergized,  
then the difference between cooler entering and leaving  
water temperature must be at least 1.5° F with the valve  
energized.  
ENTER  
ENTER  
the Service Test mode. Press the  
key. Press the  
key and ‘TEST OFF’ will be displayed with ‘OFF’ flash-  
ENTER  
ing. Press the  
key then  
key and the Navigator  
displays ‘TEST ON.’ Switch the Enable/Off/Remote  
contact switch to the Enable position.  
2. The display may read as follows. (If not, skip to Step 4.)  
ENTER PASSWORD  
ENTER  
3. Press 1 1 1 1 then  
key.  
key to select the ‘COMP’ sub-  
key and key to display MLV  
4. Press the down arrow  
Once the outputs have been tested and the ball valve ad-  
justed, the installation is complete.  
ENTER  
mode. Press the  
OFF.  
ENTER  
5. Press the  
key.  
Copyright 2000 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 903 Catalog No. 533-00009 Printed in U.S.A. Form 30GX,HX-14SI Pg 8 102 7-00 Replaces: 30GX,HX-7SI  
Book 2  
Tab 5c  
 

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