Carrier 38AKS014-024 User's Manual
Contents
1. 38AKS014 024 30GT015 035 Accessory Hot Gas Bypass 50 60 Hz Installation Instructions Part No 30G1T911054 GENERAL These installation instructions cover field installation of the accessory hot gas bypass valve pilot valve and hot gas sole noid For 30GT units these instructions are intended for units with a starting serial number of 2294F or higher The hot gas bypass package is not required on 30GT015 50 Hz units or on 30GT020 60 Hz units since these 2 units have hot gas bypass installed as standard from the factory See table below for a list ing of package contents NOTE Since the 30GT015 035 and 38AKS014 024 units are single circuit units only one accessory package is required per unit ACCESSORY PACKAGE CONTENTS ITEM QUANTITY PART NO Pilot Valve EF11BS038 Hot Gas Solenoid With Clip eae Hot Gas Bypass In addition the following parts will need to be field supplied e in refrigerant grade copper tubing amount will vary with application e 3 in refrigerant grade copper tubing amount will vary with application e gt in refrigerant grade copper tubing amount will vary with application e For 30GT units one manual shut off valve for gt g in line e One 3 way tee with an internal branch OR one standard 3 way tee depending on application see Pilot Valve and Hot Gas Solenoid section for more information e For 38AKS indoor coil split system an auxiliary side connector may be requi2. NOTE Hot Gas Relay HGR use Part No HN61KK324 Fig 5 38AKS014 024 Hot Gas Bypass Wiring ACCESSORY OPERATION AND ADJUSTMENT Adjustment The hot gas bypass valve is set to begin opening when the suction pressure falls to approximately 62 psig 427 kPa The pressure corresponds to a chilled water set point of approximately 44 F 6 C If the chilled water set point is lower than 44 F 6 C the bypass setting must be de creased The opposite is true if the chilled water setting is above 44 F 6 C Condensing temperature also affects the setting of the bypass valve and a change may be required To adjust the setting of the bypass valve a in hex wrench is required Remove the cap on the valve and turn the adjustment nut with the hex wrench Turning in a clockwise direction increases the setting and turn ing in a counterclockwise direction decreases the setting Operation The hot gas bypass accessory operates as fol lows When a call for cooling is received the compressor start circuit is energized along with the hot gas solenoid HGS and all unloaders Once the HGS circuit is completed the solenoid valve opens allowing the hot gas bypass valve HGBV to sense suction pressure and respond accordingly If the suction pressure is below the HGBP hot gas bypass valve setting the valve begins to open The valve continues to open until it either reaches an equilibrium or the maximum open position Discharge gas i
3. Wiring ee A WARNING f NLA i Be sure all power to the unit is off before proceeding and a TTI EE that all disconnects are open and tagged F ea LIQUID STUB Follow all local codes and NEC National Electrical Code b U S A when installing control wiring All wire must be a min imum of 16 AWG American Wire Gage U S A gt Connect control wires as shown in Fig 3 At hot gas sole Fig 2 30GT Stub Locations noid HGS connect to brown and orange wires as shown TC2 com HGS o ne ORN BRN Q ut LEGEND COM Common NC Normally Closed TC Temperature Controller HGS Hot Gas Solenoid NO Normally Open U1 Unloader 1 Fig 3 30GT Hot Gas Solenoid Wiring INSTALLATION IN 38AKS014 024 INDOOR FAN COIL CONSTANT VOLUME SPLIT SYSTEM COMBINATION Step 1 Install Piping See Fig 4 A WARNING Shut off all power to the unit and remove refrigerant charge using an approved refrigerant recovery device before pro ceeding with installation Failure to do so may result for personal injury IMPORTANT Do not bury refrigerant piping underground 1 In applications where the air handler refrigerant distribu tor is not equipped with a side outlet connection it 1s rec ommended that a Sporlan in line auxiliary side connector with standard distributor be used Refer to the installation instructions for the indoor fan coil to obtain nozzle size and distribut
4. TOR LL CONDENSER LIQUID LINE TO COMPRESSOR SUCTION SERVICE VALVE SOLENOID PILOT VALVE n Uf u 4 00 I 3 8 SWEAT CONNECTION l i Mes AB aeons VALVE 5 8 OD CONN WN a a ee A ae LEGEND a FIELD SUP TXV Thermostatic Expansion BEE eer LIEU BIPASS CINE AUXILIARY Valve SKETCH A AUXILIARY HOT GAS IN Pilot valve connects directly to bypass valve per sketch A SIDE CONNECTOR Fig 4 38AKS Hot Gas Bypass Piping Step 2 Install Control Wiring See Fig 5 1 Install a field supplied relay with a 24 v coil and normal ly closed contacts rated for 20 va at 125 vac inductive load Mount this relay in the 38AKS control box NOTE This relay is identified in Fig 5 as HGR hot gas relay 2 For 38AKS014 024 a Connect a field supplied wire between TB2 3 and the L1 side of the HGR coil b Connect a field supplied wire between TB2 9 and the L2 side of the HGR coil c Connect a field supplied wire between TB2 2 and HGR 4 one of the normally closed NC contacts d Connect one leg of the hot gas pilot solenoid valve to HGR 6 the other NC contact e Connect the other leg of the hot gas pilot solenoid valve to C2 Step 3 Restore Refrigerant Charge Charge unit in accordance with 38AKS Charging Chart found on unit TC2 TB2 TB2 POOF Daan TB2 gt BLU Hot Gas LEGEND Pilot Solenoid Valve HGR Hot Gas Relay LLS Liquid Line Solenoid TB Terminal Block TC Thermostat Cooling
5. l the field supplied shut off valve in the bypass line as close to the discharge line as possible The shut off valve will aid in the pumpdown of the low side when closed HOT GAS BYPASS VALVE Install the valve in the bypass line near the shut off valve installed in the Bypass Line section above The bypass valve has g in ODF inlet and outlet one each and a 3 g in ODM equalizer port sweat connection To ensure proper operation the valve should be installed in a hori zontal section of the bypass line and the pilot valve should be installed above bypass valve body PILOT VALVE AND HOT GAS SOLENOID Install the hot gas solenoid onto the pilot valve The solenoid fits over the stem of the valve and attaches with the supplied clip on the top over the coil Install the pilot valve solenoid assembly in the external equalizer line of the bypass valve 3 in ODF equalizer port The pilot valve has a 3 g in ODF inlet and a in SAE Society of Automotive Engineers U S A connection to the TXV thermostatic expansion valve equalizer line IMPORTANT Be sure the sweat connection on the hot gas bypass valve is facing the pilot valve solenoid assembly in the equalizer line See Fig 1 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 2 4 PC 111 Catalog No 533 00067 Tab Sal5c 2a Printed in U S A F
6. or connection size Select the auxiliary side connector based on this information The side connector must be installed on refrigerant circuit no 1 first stage of cooling of the fan coil being used 38AKS CONDENSING UNIT EXTERNAL EQUALIZER _ PORT HOT GAS PILOT SOLENOID VALVE BYPASS SHUT OFF N HOT GAS BYPASS VALVE 5 8 TUBE E a C DISCHARGE P gt COMPRESSOR Install a field supplied in NPT to in flare fitting on the gage connection port of the compressor suction service valve Sweat the pilot solenoid valve supplied in the hot gas ac cessory package directly to the hot gas bypass valve on the 3 in ODF external equalizer port Install field supplied in copper tube flared with a nut on each end between the compressor suction valve and the hot gas pilot solenoid valve Connect a field supplied 5 4 in OD copper tube between the discharge line process tube hot gas stub and a field supplied manual shutoff service valve avoiding any traps in piping Connect another field supplied gt g in OD copper tube be tween the manual shutoff valve outlet and the hot gas by pass valve inlet Connect a field supplied g in OD copper tube between the leaving side of the hot gas bypass valve and the Sporlan auxiliary side connector distributor side connector INDOOR FAN COIL EXTERNAL EQUALIZER SOLENOID VALVE DISTRIBU
7. orm 30GT 38AKS 1SI Pg 1 1 05 Replaces 30GT 35SI 3 SUCTION LINE COOLER TXV 1 4 EQUALIZER LINE 3 e LIQUID LINE CIRCUIT NO 1 HOT GAS SOLENOID AND PILOT VALVE Hh op 5 3 8 SWEAT CONNECTION STUB 1 SEALED FROM 1 HOT GAS BYPASS VALVE 5 8 OD CONN SEE NOTE ey oe ee E pal fo meh FIELD SUPPLIED BYPASS LINE Lea I Z SHUT OFF VALVE FIELD SUPPLIED EQUALIZER LINE FIELD SUPPLIED STUB BYPASS LINE SEALED FROM Y FACTORY 5 8 OD LEGEND f HOT GAS DISCHARGE TXV Thermostatic Expansion Valve Pe gt Factory Piping czz Jq Field Piping CONDENSER COMPRESSOR NOTE The bypass valve in this package has in connections and can be used directly on 30GT015 035 units Fig 1 30GT Piping Schematic Install the field supplied in OD tubing from the SAE connection to the TX V equalizer line If the connection is made directly to the TXV use the field supplied 3 way tee with an internal branch install horizontally in the line with the internal branch attaching directly to the TXV If the connection is made into the equalizer line use the field supplied standard 3 way tee Step 2 Dehydrate and Recharge the Cir cuit When piping is completed leak test the assembly and DISCHARGE replace the filter drier cores Then evacuate dehydrate and re TIEN charge the circuit using approved refrigeration practices Step 3 Install Control
8. red Examine Package Contents Examine each item in the package If any part is damaged or missing file a claim immediately with the shipper See table above for accessory package contents 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 A WARNING Be sure power to equipment is shut off before performing maintenance or service functions Electrical shock may cause personal injury INSTALLATION IN 30GT AIR COOLED CHILLERS Step 1 Install Piping A WARNING Shut off all power to the unit and remove refrigerant charge before continuing with this accessory installation Failure to do so may result in personal injury See Fig 1 for a schematic of the unit piping BYPASS LINE Install the g in field supplied line between the factory supplied stubs in the discharge line from the compressor and in the liquid line between the expansion valve and cooler See Fig 2 NOTE The stubs are sealed as shipped from the factory Instal
9. s bypassed into the mixed phase line between the expansion valve and the cooler This condition continues until the suction pressure rises above the HGBP valve setting a second stage of temperature control is called for or the unit cycles off TROUBLESHOOTING PROBLEM Hot Gas Bypass Valve Fails to Open 3 External equalizer not connected or equalizer line is pinched shut 1 Dirt or foreign material in valve 2 Diaphragm failure Hot Gas Bypass Valve Fails to Close Copyright 2005 Carrier Corporation PROBABLE CAUSE 1 Dirt or foreign material in valve 2 Equalizer passageway clogged SOLUTION 1 Disassemble and clean valve 2 Disassemble and clean valve 3 Connect or replace equalizer line Check solenoid valve 1 Disassemble and clean valve 2 Replace element only Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 2 4 PC 111 Printed in U S A Tab 3a 5c 2a Catalog No 53833 00067 Form 30GT 38AKS 1SI Pg 4 1 05 Replaces 30GT 35SI
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