30GT
K,HL
HEATING
SAFETY CONSIDERATIONS
INTRODUCTION
These instructions cover field installation of the Acces-
Installing, starting-up and servicing air conditioning
equipment can be hazardous due to system pressures,
electrical components and equipment location,
sory Hot Gas
B y ass Valve and solenoid pilot valve on
the following chi lers:
through 060 (50 and 60 Hz)
Only trained, qualified installers and service techni-
cians 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 attached to the equipment.
(60 Hz), Flotronic’”
(50 Hz), Flotronic’”
through 200 (50 and 60 Hz), Flotronic’”
(60 Hz)
(50 Hz)
Follow all safety codes. Wear safety glasses and work
gloves. Use care in handling equipment.
On Flotronic chillers with no unloaders or 2 unloaders,
the accessory hot gas bypass must be added to both
circuits because of
automatic lead-lag feature.
INSTALLATION
Examine e Contents
Step 1
Pack-
age includes hot gas bypass va ve, solenoid pilot valve
and instructions. Examine each item. If any part is
damaged or missing, file a claim immediately with the
shipping agent.
Step 2
Install Piping
SUCTION LINE
C O O L E R
LINE (CIRCUIT
I
STUB
I
(SEALED FROM
FACTORY
BYPASS VALVE
SEE N O T E
2
SEE NOTE I
FROM FACTORY
FIELD-SUPPLIED BYPASS LINE
HOT GAS DISCHARGE
C O N D E N S E R
TXV
TH ER MOSTATI.C EXPANSION VALVE
FACTORY PIPING
PIPING
- - -
- - - a
NOTES:
1. %-in. OD for
and 30GT;
this package has %-in. connections and can be used directly on
to must be made either at the valve or at the stubs.
OD for 30GB.
2. The bypass valve
and 30GT units.
3. On 30GB units, a change from
Fig.
1
Schematic Piping;
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
P C 1 1 1 Catalog No. 533-039
Replaces:
Printed in U.S.A.
Form
SI
2-89
UNITS,
(See Fig. 2.)
UNITS
and
(See Fig. 1.)
Bypass Line
Install field-supplied line between the
Line
Connect the field-supplied line to the
header on inlet side of lead coil and the entrance to the
cooler. Two factory-sealed stubs are provided in each
circuit, one on the lead coil header and one on the liquid
line between the Flotronic expansion valve (EXV) and
the cooler.
factory-provided stubs in the discharge line
the
circuit no. 1 compressor and in the
no.
line,
between expansion valve and cooler (stubs are sealed
from factory).
Bypass Valve
Install the valve in the
line as
liquid
NOTE: The 30GB 1
units have 2 stubs in the high
close to the cooler as possible. This
side of each circuit, one on each lead coil header; it is
storage between valve and cooler when valve is closed
and prevents flood of liquid refrigerant when the valve
opens. To ensure proper closing, install the bypass valve
in a horizontal section of the bypass line, with the pilot
valve installed vertically (coil on top).
necessary to connect piping to only one of these stubs.
Bvpass Valve
Install the valve in the bypass line as
close to the cooler as possible. This minimizes liquid
storage between the valve and cooler when valve is
closed and prevents flood of liquid refrigerant when the
valve opens. To ensure proper closing, install the by ass
Solenoid Pilot Valve Install on the bypass valve at the
external equalizer
OD sweat connection). The
outlet side of the pilot valve is a
OD tube from this connection to the thermo-
static expansion valve (TXV) equalizer line, If the
SAE thread. Run
valve in
a
horizontal section of the bypass line, wit the
a
pilot valve installed vertically (coil on top).
Solenoid Pilot Valve
Install on the bypass valve at
connection is made directly to the TXV, use a
FL
the external equalizer. The outlet side of the pilot valve is
x
female flare tee. If the connection is made into
a
SAE thread. Run a
OD tube from this
the equalizer line, use a standard FL tee.
connection to the suction valve of the lead compressor
in the circuit.
SUCTION LINE VALVE
EXV- ELECTRONIC EXPANSION VALVE
TXV- THERMOSTATIC EXPANSION VALVE
PIPING
PIPING
NOTE: Circuit
2
should be piped same as circuit 1. The
tube should be connected to the lead compressor in both circuits.
CKT
CKT
CKT
CKT
CKT
CKT
CKT
CKT
0 6 0
CKT
q2p☺
090, 100
110,125
0 7 5 , 0 8 0
CKT
CKT
qma
ql2☺lml-g
2 0 0
Compressor numbers, viewed facing compressor side of unit.
Fig. 2
Schematic Piping;
with Electronic Controls (Flotronic)
2
Step 3
Dehydrate and Recharge Circuit
W h e n piping has been completed, leak test the assembly
and replace the filter drier, or core(s) for circuit no. 1.
On single-compressor chillers
for 60 Hz, 020,025 for 50 Hz; 30GT) the filter drier itself
must be replaced.
15,025 and 030
TIME DELAY
MODULE
After core (or drier) replacement, evacuate, dehydrate
and recharge the circuit. Procedures for evacuation,
dehydration and charging are detailed in Carrier Stand-
ard Service Techniques Manual, Chapter 1, Refrig-
erants, Sections 6 and 7.
6 0 0 K
RESISTOR
HGS
RI
R2
TIME DELAY
MODULE
Step 4
Install Control Wiring
T B 2
4
I
Be sure all power to the unit is off before proceeding.
c
l
c
c
l
l
1
T B 2
2
q
Fig. 4
Hot Gas Solenoid Wiring, Units with
No Unloaders or Two Unloaders
Wires between field-installed components and unit
control box must be enclosed in conduit. Wire size is
no. 16 AWG minimum. Wire-end terminals required on
field wires are indicated in the Combined Legend for
Fig. 3 8.
UNITS
Fig. 3.)
THROUGH 070 FLOTRONIC (See
Control logic allows the hot gas bypass to be
energized only on the first stage of capacity.
A unit with 2 unloaders has the automatic lead/lag
feature which allows starting of either circuit, and
thus must have 2 hot gas bypass packages, one per circuit
(see Fig. 4).
On the 040-060 units, R3 should energize with com-
pressor no. 2. On the 070 unit. R3 energizes with com-
pressor no. 3. In both instances, it is the lead compressor
on circuit no. 2 (see Fig. 5.)
RI and R2 Coil Wiring, All Units
Fig. 5
Connect R2 in parallel with lead compressor in circuit 2:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comp 2
. . . . . . . . . . . . . . . . . , . . . . . . . . . .
. . . . . . . . . Comp 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . Comp 4
.
. . . . . . . , .
. . . . . . . . . . . . . . . . .
.
Comp 5
(Refer to Fig. 2 for compressor locations.)
The time delay module must be set for a one-minute
delay by connecting a
resistor between the
center terminals of the module (see Fig. 6). (One second
of time delay results from each
of resistance.)
6 0 0 K
RESISTOR
HGS
NOTES:
RI
1. Relays R 1 and R2 apply to all units.
2. R3 applies only to units with a single unloader. Units
with no unloaders or 2 unloaders do not require R3.
3. 30GB 175 and 200 units do not use unloaders.
Gas Solenoid Wiring,
Fig. 6
Hot
Single Unloader Units
FLOTRONIC’” UNITS,
THROUGH 070
Drill a hole to accommodate a standard conduit fitting
RELAY
BOARD
in bottom of control box at
entrance hole for control
end, adjacent to existing
Locate HGR Gas
J 6
FIELD SPLICE
Bypass Relay) in right side of control box adjacent to
existing relays. Using the HGR base as a template, mark
,
,
mountmg hole
and drill appropriate hole. Run
PIN
4
CKT NO.21
I
conduit from the bypass valve to the control box and wire
relays into control circuit as shown in Fig. 4. Relays
and Time
Module should be installed in the upper
left corner of the control box, above the transformer.
T B 4
FLOTRONIC UNITS, THROUGH 200
2 holes in the bottom right of the control box, next
to the compressor conduit holes, to accommodate stand-
ard conduit fittings. Run conduit from the bypass valve
to the control box and wire relays into control circuit
as shown in Fig. 4.
NOTE: 3063175,200
R3 DOES NOT APPLY.
Fig. 3
R3 Coil Wiring (R3 used only with
units having a single unloader)
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