Carrier 30GXN Refrigerator User Manual
Contents
1. And associated modular sizes 102 ComfortLink a q g RFit ge 30GXN R204 350 Fig 4 Typical Minimum Load Control Wiring cont MLC B MLC A CONDUIT CONDUIT SOO OB A i SO EQUIP i ComfortLink Comfortlink ets D 9 g al Tt i te ee Sa o j o o o js mj o 2 cee Q O TB4 Hr Ti HA P2. MLC B MLC A CONDUIT CONDUIT 0000 O ComfortLink 2 O amp o o ly ela i gt a o EL o o la 5 o o ly E o c o Ss O E o oO S Tele C BI 5 ols C Al Sl p oO o ja amp o ja Eo q o E o Elo uP CCP o R e o R G o ola D o a D o EE ea P 2 jf Jf a o 2 o o 7 s 4 hom 3 SN BI SN AI 3 e e o o Lej o a i O Ill Wil M q o o o 30HX076 186 LEGEND Contactor Compressor GND Ground SPT Suction Pressure Circuit Breaker LR Loader Relay Transducer ComfortLink Compressor MLC Minimum Load Control TB Terminal Block Protection OPC Oil Pump Contactor TRAN Transformer Cooler Heater Relay PL Plug Assembly Energy Management Module PRI Primary Terminal Block Connection Equipment SCB Screw Compressor Electronic Expansion Valve Board Unmarkad Splice Fuse Block SN Sensor Toroid Factory Wiring Fan Relay Ground Fault Interrupter Convenience Outlet And associated modular sizes Fig 4 Typical Minimum Load Control Wiring 102
3. Y of er er PL5 PL6 TB4 P gG PS el ole PLOPLI3 PLIO PLI4 EQUIP GND ComfortLink ComfortLink Navigator ijji PRI PRI PRI TRAN E TRAN TRANS LS LS o o dl F g P AA lesa al 8 a sl al il PLIIPL3 30GXN RO80 178
4. 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 Page SAFETY CONSIDERATIONS 1 INTRODUCTION 1 INSTALLATION 1 8 Step 1 Examine Package Contents 1 Step 2 Install Piping 2 e REMOVE MINIMUM LOAD PORT PLUGS AND INSTALL FITTINGS e INSTALL PIPING e INSTALL BALL AND SOLENOID VALVES e CONNECT PIPING e 30GXN R UNITS ONLY Step 3 Dehydrate and Recharge Circuit 3 Step 4 Install Control Wiring 3 e 30HX UNITS e 30GXN R UNITS e ALL UNITS Step 5 Configure Unit for Minimum Load Control ooooocooooccoooo o 8 Step 6 Test Minimum Load Relay OULDUNG lt ocnesssnerrdp rre 8 Step 7 Adjust Setting of Minimum Load Ball Valve 8 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 pre cautions in the literature and on tags stickers and labels attached to the equipment Follow all safety codes Wear safety glasse
5. 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 cool er 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 REMOVE PLUG AND INSTALL O RING SEAL ORS FITTING AND COOLER TUBE ASSEMBLY HERE CIRCUIT A CEN Vai Al L 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 field supplied 5 3 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 as sembly P N 30HX402343 on the O ring seal fittings installed in the cooler and condenser oil separator ports Do not tighten Install field supplied g 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 gt g in minimum load piping Fig 2 shows a typical 30HX installation and Fig 3A and 3B show a typical 30GXN R installation 1n cluding valve locations and orientation Ensure that ball valve
6. is fully open and that both the ball and solenoid valve are pro tected 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 4 turn a a ma 7 7 REMOVE PLUG AND i INSTALL O RING SEAL Foo l ORS FITTING AND H COOLER TUBE ASSEMBLY HERE CIRCUIT B aem I HL 97 FIELD INSTALLED ty CUT PLUG END OFF OF BRAZE NIPPLE Fig 1 Installing Fittings 30GXN R Typical Size 080 150 160 Shown 102 INSTALL O RING SEAL FITTING AND TUBE ASSEMBLY HERE BALL VALVE B INSTALL O RING SEAL FITTING AND TUBE ASSEMBLY HERE SOLENOID VALVE B BALL VALVE A INSTALL O RING SEAL FITTING AND TUBE ASSEMBLY HERE S SOLENOID VALVE A ial ea lo HH a o es un 01 at ima CASA O Saro 1 IN MA dl O ee eel om A O RING SEAL FITTING SHOWN INSTALLED Fig 2 Installing Fittings and Valves 30HX Typical 30GXN R UNITS ONLY Using good brazing practice braze the gt g in minimum load tubing to the copper nipple on the discharge lin
7. load valve feature press the key 4 The display may read as follows If not skip to Step 7 ENTER PASSWORD 5 Press 1 1 1 1 then key 6 The Navigator again displays the following MLVS NO 7 Press key and The Navigator displays MLVS YES The chiller is now configured for minimum load valve 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 1 Press the key until the Navigator displays SE LECT A MENU ITEM Press the key and light up the Service Test mode Press the key Press the key and TEST OFF will be displayed with OFF flash 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 3 Press 1 1 1 1 then key 4 Press the down arrow key to select the COMP sub mode Press the key and key to display MLV OFF 5 Press the key Copyright 2000 Carrier Corporation 6 Press the and key to energize the relays The display reads MLV ON An audible click will be heard Verify that the solenoid valves for both circuits are energized 7 Press the and keys to turn the solenoids off When finished exit the
8. solenoid valve using a suitable fitting Repeat for the other circuit See Fig 4 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 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 Figure 4 shows the correct location of the wiring connection points on the chiller 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 O RING SEAL FITTING SOLENOID LL DETAIL C VALVE FIELD INSTALLED BALL A PIPING TO VALVE CIRCUIT B DISCHARGE INE 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 GFI CO
9. Assembly Condenser 2 30HX402343 Oil Separator 2 30HX402343 FIELD SUPPLIED MATERIAL REQUIRED PARTS Ordered Separately 5 g in OD Copper Tubing Wiring Conduit Thread Sealant Electrical Supplies Field Supplied 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 PC 903 Catalog No 533 00009 Tab 5c Form 30GX HX 14SI Pg 1 102 7 00 Replaces 30GX HX 7SI Step 2 Install Piping A WARNING Shut off all power to the unit then lock out and safety tag all disconnects before proceeding with installation A WARNING 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 following 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 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 con denser Remove plug from minimum load port on cooler shell See Fig 1 Using thread sealant install
10. Service Test mode change TEST ON to TEST OFF Put the Enable Off Remote Contact switch in the desired position After testing is complete recheck all electrical connections for proper location and tightness Replace and secure the access panels for the unit control box 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 AT the difference between cooler en tering fluid temperature and cooler leaving fluid tempera ture at this fully unloaded condition 4 Use the Service Test feature to enable the minimum load valve output 5 Observe and record the cooler AT 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 7 Open the ball valve to decrease the temperature differ ence or close the ball valve to increase the temp
11. a o la o ola 5 o J5 9 2 lo S C Bl Gl o b a lo 3 C A2 Sle b o a S o o la S o i ol Ej o ol T o el al T o R K o o R Bl o ll T T o la D o ola sio E i J TE D z a ef e 0 e a oo en SN BI 3 SN A2 o lo e le lo e le el TRANA TRAN3 TRAN2 TRAN 7 I T T T m a si D o 30HX206 271 FIELD SUPPLIED CONDUIT MLC B MLC A EXE s TO TB5 9 T pue WIRE NUT TO TB4 2 30GX TO TB2 9 30HX FIELD SUPPLIED CONDUIT A Fig 4 Typical Minimum Load Control Wiring cont id ey A B 009 e e O eel 9 s o e O gt es ojo o 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 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 1 Press key until display reads SELECT A MENU ITEM Press key to light up Configuration mode Press Press key to select sub mode OPT 1 Press 2 Press the down arrow key to select MLVS NO 3 To enable the minimum
12. e 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 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 A WARNING 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 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 g in knockout openings Attach the other end of the conduit to the
13. erature difference AT 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 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 Printed in U S A Book 2 PC 903 Catalog No 533 00009 Tab 5c Form 30GX HX 14SI Pg 8 102 7 00 Replaces 30GX HX 7SI
14. s and work gloves Use care in handling equipment A WARNING 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 refrig erant 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 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 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 Table 1 Accessory Package Contents and Field Supplied Material ACCESSORY PACKAGE ACCESSORY PART NUMBER COMPONENTS 30GX 900 048 30GX 900 049 Solenoid Valve 2 2 EF23JX231 Ball Valve 2 EP71BA201 O Ring Seal Fitting 4 30GX503492 Tube Assembly 2 30GX503457 Tube
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