Carrier Air Conditioner 30XA080 500 User Manual

30XA080-500  
Minimum Load Control Accessory  
Installation Instructions  
Part No: 00EFN900002700A, 00EFN900002800A, 00EFN900002900A  
SAFETY CONSIDERATIONS  
INSTALLATION  
Installing, starting up, and servicing air-conditioning equip-  
ment can be hazardous due to system pressures, electrical com-  
ponents, and equipment location.  
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.  
Only trained, qualified installers and service technicians  
should install, start up, and service this equipment.  
See Table 2A, 2B, or 2C for package contents. See Fig. 1 for  
dimensional drawings of tubes included in the kit.  
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.  
The following material is field supplied:  
5/8 in. OD copper tubing  
5/8 in. OD copper tube elbows and couplings  
(as required)  
• 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.  
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.  
2. Locate the discharge manifold for minimum load  
piping on the side of the coil V for each circuit as  
1
shown in Fig. 2. Locate the /2 in. NPT pipe plugs on  
GENERAL  
the top of the cooler for each circuit. See Fig. 3.  
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.  
3. Remove the 1/2 in. NPT pipe plugs from the top of the  
cooler. Use the thread sealing compound and install  
1
one 1 in.-14 O-ring seal (ORS) x /2 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 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 11/2 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.  
Table 1 — Accessory Package Usage  
30XA UNIT SIZE  
080-240  
ACCESSORY PART NO.  
00EFN9000002700A  
00EFN9000002800A  
00EFN9000002900A  
260-300  
325, 350  
5
5. Use field-supplied /8 in. OD copper tubing and fittings  
00EFN9000002700A,  
00EFN9000002800A  
400  
(as required) to pipe from the solenoid valve outlet to the  
5/8 in. port of the tee on the discharge manifold. Use the  
provided 5/8 in. tubing clamps to secure the tubing to the  
unit frame as necessary.  
00EFN9000002800A,  
00EFN9000002900A  
450, 500  
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.  
Catalog No. 04-53300010-01 Printed in U.S.A. Form 30XA-6SI Pg 1 12-06 Replaces: New  
Book 2  
Tab 5c  
 
Table 2C — Contents of Accessory Kit, Part No. 00EFN900002900A  
PART NUMBER  
QUANTITY  
DESCRIPTION  
USAGE  
One per circuit (Circuit A and B for 30XA325, 350,  
circuit A and C for 30XA450, 500). Cooler shell  
minimum load port, connect to 30GX5034892 adapter.  
Tube assembly including solenoid valve,  
ball valve, and 90 degree bend tube assembly  
00PSN500175200A  
2
30GX5034892  
2
2
1 in. - 14 ORS x 1/2 in. NPT adapter  
Solenoid coil assembly  
One per circuit. Cooler shell minimum load port.  
One per circuit. Plug onto solenoid valve stub  
on 00PSN500171700A tube assembly.  
00PPG000011600A  
Secure minimum load piping to the frame  
as required.  
KA66AA062  
DE40BA705  
TH70400410  
4
2
2
5/8 in. tube clamp  
11/8 in. x 11/8 in. x 5/8 in. Tee  
Cable assembly  
One per circuit. Discharge manifold on the side  
of condenser coil V.  
One per circuit. Connect to solenoid coil  
assembly and terminal block TB5 in control box.  
00PPN500000401A  
32GB500432E  
TH70400864  
HH83ZB001  
A6X10004352  
4
1
1
1
4
No. 10 screw  
HGBP/Pump board  
Harness assembly  
24V circuit breaker (CB14)  
No. 8 screw  
Mount tube clamps  
Mount in control box  
Wiring between TB5 and HGBP/Pump board  
Mount on display bracket in control box  
Mount HGBP/Pump board  
Mount HGBP/Pump board (325,350,450,500:  
all voltages)  
A6X10004434  
4
Board mounting standoff  
TH70400852  
HY89TB010  
1
3
Communication cable assembly  
Wire nut  
30XA325,350,450,500: all voltages.  
Splice communication cable  
LEGEND  
HGBP — Hot Gas Bypass  
ORS — O-Ring Seal  
TB  
Terminal Block  
SOLENOID VALVE  
BALL VALVE  
a30-4499  
TUBE ASSEMBLY 00PSN500175200A  
SOLENOID VALVE  
BALL VALVE  
a30-4500  
TUBE ASSEMBLY 00PSN500171700AA  
NOTE: Dimensions are in mm [in.].  
Fig. 1 — Dimensions of Tube Assemblies Provided in Accessory Kit  
3
 
a30-4498  
4
 
1/2 IN. NPT  
A CIRCUIT  
B CIRCUIT  
1/2 IN. NPT  
TUBE ASSEMBLIES  
a30-4501  
Fig. 3 — Typical Solenoid Valve Tube Assembly Installation  
BRAZE THE TEE IN THIS LOCATION  
CUT 1-1/2 IN. OFF THE DISCHARGE MANIFOLD  
REMOVE TRIM PANEL  
TO ACCESS  
a30-4502  
Fig. 4 — Discharge Manifold Modification and Tee Brazing  
5
 
575 v only) or TB11-X2 (30XA080-120: 200/230 v and  
30XA140-500: all voltages). See Fig. 7.  
6. Using harness TH70400864 provided in the kit, connect  
TB5 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.  
7. 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.  
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.  
Take care connecting 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.  
3. 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 30XA140-500: all voltages). See Fig. 6A  
and 6B for the board mounting location.  
4. 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.  
5. 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 CB14 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,  
a30-4503  
Fig. 5 — HGBP/Pump Board Address Switch and  
Wiring for Minimum Load Solenoid Output  
CB14  
HGBP/PUMP  
BOARD  
a30-4504  
Fig. 6A — HGBP/Pump Board and CB14 Mounting Location  
(30XA080-120: 200 v, 230 v, 380 v and 30XA140-500: all voltages)  
6
 
TOUCH  
PILOT  
DISPLAY  
HGBP/PUMP  
BOARD  
CB14  
a30-4505  
Fig. 6B — HGBP/Pump Board and CB14 Mounting Location  
(30XA080-120: 460 v, 575 v)  
BRN  
TB10-X2 OR TB11-X2  
FIOP/ACCESSORY  
J1  
CB14  
HGBP/  
2
1
3.2 AMPS  
12  
11  
BRN  
RED  
PUMP  
BOARD  
a30-4506  
RED  
TB10-X1 OR TB11-X1  
Fig. 7 — HGBP/Pump Board 24 v Power Wiring  
7
 
For the Touch Pilot display:  
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.  
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  
2. Press the Main Menu button  
the display and then select StatusQuick Test Enable.  
3. 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 to confirm the input.  
4. The value of qck_test1 will display. Select On and press  
the OK button to confirm the input.  
5. Scroll down the screen by pressing the scroll down button  
or the page down button until Cir. A Hot Gas  
to switch to the Local Off operating mode.  
on the bottom line of  
2. Press the main menu button  
on the bottom line of the  
display, and then select ServiceFactory to navigate to  
the factory table.  
3. Scroll down the screen by pressing the Scroll Down  
Bypass is displayed on the screen. Press Cir. A Hot Gas  
Bypass Select to display the Point Data dialog.  
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.  
6. Press the Force button  
. Select On and press the OK  
button to confirm input.  
4. Press the Modify button  
played, log in with the password. The default password is  
3333. Press the OK button to confirm the input. The  
value of hgbp_sel will display. Select Yes and press  
the OK button to confirm the input.  
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.  
. If the login menu is dis-  
7. Verify that the Cir. A minimum load valve (MLV) sole-  
noid is energized.  
8. Proceed to Cir. B Hot Gas Bypass and Cir. C Hot Gas By-  
pass (30XA400-500 only) by pressing the page down  
button  
MLV.  
. Repeat Steps 5-7 for Cir. B MLV and Cir. C  
9. Use the page up button  
ble and select Quick Test Enable.  
10. Press the Force button  
to return to the top of the ta-  
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:  
11. Select Off and press the OK button  
Test.  
to disable Quick  
12. Once the outputs have been tested, the installation is com-  
plete. Return the Touch Pilot to Local Off operating  
mode.  
For the Navigator display:  
1. Set the Enable/Off/Remote switch to the Off position.  
1. Set the Enable/Off/Remote switch to the Off position.  
2. Press  
until the screen is blank and use the  
ESCAPE  
arrow key to select the Configuration mode LED.  
3. Press , then use the arrow key to select the  
ENTER  
sub-mode ‘UNIT’, then press the  
key.  
2. Press  
until the screen is blank and use the  
ENTER  
4. Press the down arrow key until ‘HGBP’ is displayed.  
5. Press the key. If the login menu is displayed,  
ESCAPE  
arrow key to select the Service Test mode LED.  
3. Press , then use the arrow key to select the  
ENTER  
sub-mode ‘QUIC’, then press the  
ENTER  
key.  
ENTER  
4. Press the down arrow key until ‘HGP.Ais displayed.  
5. Press the 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  
key after each number until finished.  
ENTER  
ENTER  
6. Press the  
key so that ‘No’ flashes.  
ENTER  
log in with the password. The default password is 0 1 1 1.  
7. Use the arrow keys to change the value to ‘Yes.’  
Use the arrow keys to change each number’s value. Press  
8. Press the  
9. Press the  
key.  
the  
key after each number until finished.  
ENTER  
ENTER  
key until ‘DISP’ is displayed. Wait  
ESCAPE  
6. Press the  
key so that ‘Off’ flashes.  
ENTER  
7. Use the arrow keys to change the value to ‘On.’  
8. Press the key.  
10 seconds and cycle the control power using the Emer-  
gency On/Off switch (SW2).  
ENTER  
The chiller is now configured for minimum load valve control.  
9. Verify that the Cir. A minimum load valve (MLV)  
solenoid is energized.  
10. Proceed to ‘HGP.B’ and ‘HGP.C’ (30XA400-500 only)  
and repeat Steps 4-9 for Cir. B MLV and Cir. C. MLV.  
11. Once the outputs have been tested, the installation is com-  
plete. Return the Enable/Off/Remote contact switch to the  
desired position.  
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 proper operation of the  
solenoid(s).  
Copyright 2006 Carrier Corporation  
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. Form 30XA-6SI Pg 8 12-06 Replaces: New  
Book 2  
Tab 5c  
 

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