Carrier 30XA080-500 Air Conditioner User Manual
Contents
1. 30XA080 500 Minimum Load Control Accessory Installation Instructions Part No OOEFN900002700A OOEFN900002800A OOEFN900002900A SAFETY CONSIDERATIONS 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 precautions 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 to avoid electrocution Lock out and safety tag all disconnects There may be more than one disconnect GENERAL This control accessory reduces 30XA chiller capacities be low the standard lowest capacity step This capacity reduction provides more precise control of leaving fluid temperature during light load conditions The minimum load control solenoid valve limits the amount of gas that can be bypassed from the condenser without impacting oil return One accessory package is required for 30XA080 350 units Two accessory packages are required for 30XA400 500 units to accommodate connections for three refrigerant circuits See Table 1 for accessory package usage Table 12. TB11 X2 30XA080 120 200 230 v and 30XA140 500 all voltages See Fig 7 Using harness TH70400864 provided in the kit connect TBS pins 6 30XA400 500 only 7 8 and 13 to HGBP Pump board J2 CH3 CH4 and J3 CH5 30XA400 500 only Use the pins inside TB5 See Fig 5 For 30XA080 120 200 230 v 380 v and 30XA140 500 all voltages disconnect the 3 pin plug on MBB J9B or EMM board J9A for communication and plug it in to the HGBP Pump board J9 Use the additional communica tion cable assembly TH70400852 provided in the kit to connect between HGBP Pump board J9 and MBB J9B or EMM board J9A when EMM board exists The com munication cable in the TH70400864 harness will not be used For 30XA080 120 460 v 575 v connect the 3 pin plug of the communication cable in the TH70400864 harness to the HGBP Pump board J9 and splice the other end of the cable to the communication network using the wire nuts provided in the kit Be sure to splice the wires with same color together to ensure correct polarity EM E NM JI 1 8 3 4 9 6 7 8 Fig 5 HGBP Pump Board Address Switch and Wiring for Minimum Load Solenoid Output TB11 X2 1 X 2 WIREDUCT MAIN BASE BOARD MOUNTED DN 1 2 STANDOFF S 11 8 X e WIREDUCT 1 X 2 WIREDUCT HGBP PUMP PUMP BDARD ISDL ISUL ISUL VLV A VLV B VLVC Fig 6A HGBP Pump Board and CB14 Mounting Location 30XA080 120 200 v 230 v 380 v and 30XA140 500 a
3. 5 Press the Home button on the bottom line of the dis play A save confirmation menu will display Press the OK button to confirm the action 6 Wait 10 seconds and cycle the control power using the Emergency On Off switch SW2 The chiller is now configured for minimum load valve control Complete the following steps to configure minimum load con trol with the Navigator display 1 Set the Enable Off Remote switch to the Off position 2 Press until the screen is blank and use the arrow key to select the Configuration mode LED 3 Press ENTER then use the arrow key to select the sub mode UNIT then press ENTER key 4 Press the down arrow key until HGBP is displayed 5 Press the ENTER key If the login menu is displayed log in with the password The default password is 0 1 1 1 Use the arrow keys to change each number s value Press the ENTER key after each number until finished Press the ENTER key so that No flashes Use the arrow keys to change the value to Yes Press the key Press the key until DISP is displayed Wait 10 seconds and cycle the control power using the Emer gency On Off switch SW2 The chiller is now configured for minimum load valve control Test Minimum Load Relay Output Use the Touch Pilot or Navigator display s service test mode and the instruc tions given in their Controls Start Up Operation Service and Troubleshooting manuals to verify pr
4. Accessory Package Usage 30XA UNIT SIZE ACCESSORY PART NO 080 240 OOEFN9000002700A 260 300 OOEFN9000002800A 325 350 OOEFN9000002900A 400 OOEFN9000002700A OOEFN9000002800A CIT ae 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 your Carrier representative See Table 2A 2B or 2C for package contents See Fig 1 for dimensional drawings of tubes included in the kit The following material is field supplied gt in OD copper tubing g in OD copper tube elbows and couplings as required e Loctite 554 thread sealing compound Parker Super O lube O ring lubricant Install the Solenoid Valve Tube Assembly 1 Remove refrigerant charge from the circuits using an approved refrigerant recovery device before proceeding with this installation Follow good piping practices 2 Locate the discharge manifold for minimum load piping on the side of the coil V for each circuit as shown in Fig 2 Locate the in NPT pipe plugs on the top of the cooler for each circuit See Fig 3 3 Remove the 2 in NPT pipe plugs from the top of the cooler Use the thread sealing compound and install one 1 in 14 O ring seal ORS x in NPT adapter for each circuit Lightly lubricate each O ring with O lube and attach the tube assembly to each adapter See Fig 3 Be sure to attach the correct tube assembly to the
5. Once the outputs have been tested the installation is com plete Return the Touch Pilot to Local Off operating mode For the Navigator display t 2 Set the Enable Off Remote switch to the Off position Press until the screen is blank and use the arrow key to select the Service Test mode LED Press ENTER then use the arrow key to select the sub mode QUIC then press the ENTER key 4 Press the down arrow key until HGP A is displayed 5 Press the ENTER key If the login menu is displayed uo 10 11 log in with the password The default password is 0 1 1 1 Use the arrow keys to change each number s value Press the ENTER key after each number until finished Press the ENTER key so that Off flashes Use the arrow keys to change the value to On Press ENTER key Verify that the Cir A minimum load valve MLV solenoid is energized Proceed to HGP B and HGP C 30XA400 500 only and repeat Steps 4 9 for Cir B MLV and Cir Once the outputs have been tested the installation is com plete Return the Enable Off Remote contact switch to the desired position Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53300010 01 Printed in U S A Book 2 Tab 5c Form 65 Pg8 12 06 Replaces New
6. peo unuiuriy 104 uoreoo7 piopuen 2 z 080 4ZIS LINN SPJOJIUBW JO uomneoo eui sejouep Bale zZ epis J9 009 eu VX0 suiejDelq d 19 V DID SALON AINO A0 2 002 10U1N02 X08 1081N02 83N0d uoneoo pjopuew Sip SIU ui ea eze1q L noo LAD Xog onuo Gd QIN3931 0cL 060 3ZIS LINN 00S OS 3ZIS LINN g 10 g 10 V 1 5 O 10 ANO A0 2 002 XOG 1081 02 X08 1081N02 83N0d U3MOd U3MOd 094 OtL 3ZIS LINN oor 3ZIS LINN DANKA 002 081 3ZIS LINN OSE 626 3ZIS LINN A INO 0 2 002 g LMO V LMO X08 43MOd X08 43MOg s Ci AINO ADE 002 X08 3 04 1 2 IN NPT A CIRCUIT B CIRCUIT 1 2 IN NPT Fig 3 Typical Solenoid Valve Tube Assembly Installation SS BRAZE THE TEE IN THIS LOCATION CUT 1 1 2 IN OFF THE DISCHARGE MANIFOLD REMOVE TRIM PANEL TO ACCESS Fig 4 Discharge Manifold Modification and Tee Brazing Install HGBP Pump Board and Control Wiring 1 Attach the solenoid coil assembly to the solenoid valve plunger on the tube assembly for each circuit One cable assembly TH70400410 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 A CAUTION Take care connect
7. 0432E TH70400864 HH83ZB001 A6X10004352 A6X10004434 TH70400852 HY89TB010 LEGEND Table 2A Contents of Accessory Kit Part No OOEFN900002700A QUANTITY DESCRIPTION USAGE One per circuit circuit A and B for 30XA400 Tube assembly including solenoid valve MN ball valve and 90 degree bend tube assembly IURE te 1 in 14 ORS x 1 2 NPT adapter One per circuit Cooler shell minimum load port One per circuit Plug onto solenoid valve stub EE col Assembly on 00PSN500171700A tube assembly Secure minimum load piping to the frame 5 in tube clamp as required One per circuit Discharge manifold on the side 1 1 x 1 sin x 5 Tee ol condenser coil V One per circuit Connect to solenoid coil Cable assembly assembly and terminal block TB5 in control box No 10 Screw Mount tube clamps HGBP Pump board Mount in control box Harness assembly Wiring between TB5 and HGBP Pump board ae 24 v circuit breaker CB14 Mount on display bracket in control box Mount HGBP Pump board Mount HGBP Pump board 30XA140 240 400 Board mounting standoff all voltages and 30XA080 120 200 230 v 380 v Communication cable assembly 55 105010 00030 COXA cable um HGBP Hot Gas Bypass ORS O Ring Seal TB Terminal Block PART NUMBER 00PSN500171700A 30GX5034892 0OPPG000011600A KA66AA062 DE40BA705 TH70400410 00PPN500000401A 32GB500432E TH704008
8. 64 HH83ZB001 A6X10004352 A6X10004434 TH70400852 HY89TB010 LEGEND Table 2B Contents of Accessory Kit Part No OOEFN900002800A USAGE One per circuit circuit A and B for 30XA400 assembly including solenoid valve Cooler shell minimum load port connect to ball valve and 90 degree bend tube assembly 30GX5034892 adapter 1 in 14 ORS x 1 2 in NPT adapter One per circuit Cooler shell minimum load port One per circuit Plug onto solenoid valve stub SC Sel Ocoee ny on 00PSN500171700A tube assembly Secure minimum load piping to the frame 5 g in tube clamp as required One per circuit Discharge manifold on the side One per circuit Connect to solenoid coil Cable assembly assembly and terminal block TB5 in control box No 10 Screw Mount tube clamps 1 HGBP Pump board Mount in control box Harness assembly Wiring between TB5 and HGBP Pump board EE HEN 24 v circuit breaker CB14 Mount on display bracket in control box 4 No8scew MountHGBP Pump board Mount HGBP Pump board 30XA260 300 400 450 Board mounting standoff 500 all voltages Communication cable assembly 30XA260 300 400 450 500 all voltages Splice communication cable HEN HGBP Hot Gas Bypass ORS O Ring Seal TB Terminal Block Table 2C Contents of Accessory Kit Part No OOEFN900002900A PART NUMBER QUANTITY DESCRIPTION USAGE One per circuit Circuit A and B for 30XA325 350 00PSN5001
9. 75200A see eg solenoid valve circuit A and C for 30XA450 500 Cooler shell g minimum load port connect to 30GX5034892 adapter 30GX5034892 1 in 14 ORS x 1 2 in NPT adapter One per circuit Cooler shell minimum load port One per circuit Plug onto solenoid valve stub 00PPGO000011600A Solenoid coil assembly on 00PSN500171700A tube assembly KA66AA062 4 tihe ciam Secure minimum load piping to the frame as required DE40BA705 11 in x 11 8 in x 5 in Tee TH70400410 2 Cutis asambl One per circuit Connect to solenoid coil y assembly and terminal block TB5 in control box 32GB500432E Mount in control box TH70400864 Wiring between TB5 and HGBP Pump board HH83ZB001 Mount on display bracket in control box A6X10004352 4 o No8screw Mount HGBP Pump board A6X10004434 Board mounting standoff board 325 350 450 500 TH70400852 Communication cable assembly 30XA325 350 450 500 all voltages HY89TBO10 Splice communication cable LEGEND HGBP Hot Gas Bypass ORS O Ring Seal TB Terminal Block SOLENOID VALVE BALL VALVE O RING SEAL SURFACE 398 05 15 61 TUBE ASSEMBLY 00PSN500175200A SOLENOID VALVE BALL VALVE 84 03 REF 2091 O RING SEAL SURFACE 382 39 30 15 05 TUBE ASSEMBLY 00PSN500171700AA NOTE Dimensions are in mm in Fig 1 Dimensions of Tube Assemblies Provided in Accessory Kit UNIDAD Huldig
10. cooler Refer to the usage column in Tables 2A 2B and 2C for tube assembly part number correspond ing to the unit size and circuit The nut on the tube assembly should be torqued to 30 ft lb 40 N m 4 Remove the trim panel on the discharge manifold for minimum load piping on the side of the coil V Use a tubing cutter to cut 1 5 in out from the discharge mani fold for each circuit See Fig 4 Braze a tee in between the gap and depending on the routing of the hot gas bypass tubing have the tee s remaining port facing either left or right 5 Use field supplied s in OD copper tubing and fittings as required to pipe from the solenoid valve outlet to the gt g in port of the tee on the discharge manifold Use the provided gt in tubing clamps to secure the tubing to the unit frame as necessary 6 When piping is completed leak test the assembly 7 Evacuate dehydrate and recharge each circuit Be sure to use the correct type and amount of refrigerant listed in the nameplate data and base unit documentation 8 Restore power to the unit Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Printed in U S A Book 2 Catalog No 04 53300010 01 Tab 5c Form 30XA 6SI Pg 1 12 06 Replaces New PART NUMBER 00PSN500171700A 30GX5034892 0OPPG000011600A KA66AA062 DE40BA705 TH70400410 00PPN500000401A 32GB50
11. ing leads to terminal blocks Incorrect polarity will damage the control boards 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 30XA400 500 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 Set the board address of the HGBP Pump Board by posi tioning the dual in line package DIP switches to the correct settings See Fig 5 Mount the HGBP Pump board in the main control panel with the No 8 screws provided mounting standoffs required for 30XA080 120 200 v 230 v 380 v and 30XA 140 500 all voltages See Fig 6A and 6B for the board mounting location Mount the 24 v circuit breaker CB14 in the CB14 mounting hole on the display bracket See Fig 6A and 6B for the mounting hole location Connect the 24 v power from TB10 X1 30XA080 120 460 v 575 v only or TB11 X1 30XA080 120 200 230 v and 30XA140 500 all voltages to 4 with the provided red wire in the harness assembly Find two 2 pin plugs marked J1 11 12 with red and brown wires in the harness assembly Connect the plug to the HGBP Pump board J1 with the red wire connected to CB14 and the brown wire connected to TB10 X2 30XA080 120 460 v 575 v only
12. ll voltages HGBP PUMP BOARD Fig 6B HGBP Pump Board and CB14 Mounting Location 30XA080 120 460 v 575 v TB10 X2 OR TB11 X2 3 2 AMPS TB10 X1 OR TB11 X1 Fig 7 HGBP Pump Board 24 v Power Wiring Configure Unit for Minimum Load Control The controls must be configured for the minimum load control operation Use the Touch Pilot or the Navigator display to configure the system Refer to the 30XA Controls Start Up Operation Service and Troubleshooting manual for additional information Complete the following steps to configure minimum load con trol with the Touch Pilot display 1 Ensure the unit is in Local Off operating mode by looking at the upper left hand corner of the group display If the unit is not in Local Off mode press the Start Stop button to switch to the Local Off operating mode 2 Press the main menu button 233 on the bottom line of the display and then select Service Factory to navigate to the factory table 3 Scroll down the screen by pressing the Scroll Down button or the Page Down button until Hot Gas Bypass Select is displayed on the screen Press Hot Gas Bypass Select to display the Point Data dialog 4 Press the Modify button fez If the login menu is dis played log in with the password The default password is 3333 Press the OK button v to confirm the input The value of hgbp sel will display Select Yes and press the OK button to confirm the input
13. oper operation of the solenoid s oe a Copyright 2006 Carrier Corporation 10 11 12 For the Touch Pilot display 1 Ensure the unit is in Local Off operating mode by looking at the upper left hand corner of the group display If the unit is not in the Local Off mode press the Start Stop but ton to switch to the Local Off operating mode Press the Main Menu button 223 on the bottom line of the display and then select Status Quick Test Enable Press the Force button If the login menu is dis played log in with the password The default password is 3333 Press the OK button vl to confirm the input The value of qck test will display Select On and press the OK button 24 to confirm the input Scroll down the screen by pressing the scroll down button 4 or the page down X button until Cir A Hot Gas Bypass is displayed on the screen Press Cir A Hot Gas Bypass Select to display the Point Data dialog Press the Force button 4 Select On and press OK button to confirm input Verify that the Cir A minimum load valve MLV sole noid is energized Proceed to Cir B Hot Gas Bypass and Cir C Hot Gas By pass 30XA400 500 only by pressing the page down button Repeat Steps 5 7 for Cir MLV and Cir Use page up button to return to the top of the ta ble and select Quick Test Enable Press the Force button 7 Select Off and press the OK button vl to disable Quick Test
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