Carrier Fan 30GT015 035 User Manual

38AKS014-024  
30GT015-035  
Accessory Hot Gas Bypass  
50/60 Hz  
Installation Instructions  
Part No. 30GT911054  
Follow all safety codes. Wear safety glasses and work  
gloves. Use care in handling equipment.  
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.  
Be sure power to equipment is shut off before performing  
maintenance or service functions. Electrical shock may  
cause personal injury.  
NOTE: Since the 30GT015-035 and 38AKS014-024 units are  
single-circuit units, only one accessory package is required per  
unit.  
INSTALLATION IN 30GT  
AIR-COOLED CHILLERS  
Step 1 — Install Piping  
ACCESSORY PACKAGE CONTENTS  
ITEM  
Pilot Valve  
Hot Gas Solenoid  
With Clip  
Hot Gas Bypass  
Valve  
QUANTITY  
PART NO.  
EF11BS038  
1
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.  
1
1
EF19XS024  
EA52DC421  
See Fig. 1 for a schematic of the unit piping.  
5
In addition, the following parts will need to be  
field-supplied:  
BYPASS LINE — Install the /8 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.  
1/4-in. refrigerant grade copper tubing (amount will vary  
with application)  
3/8-in. refrigerant grade copper tubing (amount will vary  
with application)  
NOTE: The stubs are sealed as shipped from the factory.  
Install 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 5/8 in. ODF inlet and outlet (one  
each), and a 3/8 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.  
5/8-in. refrigerant grade copper tubing (amount will vary  
with application)  
• For 30GT units, one manual shut-off valve for 5/8-in. line  
• 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)  
• For 38AKS/indoor coil split system, an auxiliary side  
connector may be required.  
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.  
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).  
SAFETY CONSIDERATIONS  
Install the pilot valve/solenoid assembly in the external  
equalizer line of the bypass valve (3/8 in. ODF equalizer port).  
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.  
3
1
The pilot valve has a /8 in. ODF inlet and a /4 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.  
PC 111 Catalog No. 533-00067 Printed in U.S.A. Form 30GT/38AKS-1SI Pg 1 1-05 Replaces: 30GT-35SI  
Book 1  
2
4
Tab 3a 5c 2a  
 
2. Install a field-supplied 1/4 in. NPT to 1/4 in. flare fitting on  
the gage connection port of the compressor suction  
service valve.  
3. Sweat the pilot solenoid valve supplied in the hot gas ac-  
cessory package directly to the hot gas bypass valve on  
the 3/8 in. ODF external equalizer port.  
INSTALLATION IN 38AKS014-024/INDOOR  
FAN COIL (CONSTANT VOLUME)  
SPLIT SYSTEM COMBINATION  
Step 1 — Install Piping (See Fig. 4)  
4. Install field-supplied 1/4 in. copper tube (flared with a nut  
on each end) between the compressor suction valve and  
the hot gas pilot solenoid valve.  
5. Connect a field-supplied 5/8 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.  
6. Connect another field-supplied 5/8 in. OD copper tube be-  
tween the manual shutoff valve outlet and the hot gas by-  
pass valve inlet.  
7. Connect a field-supplied 5/8 in. OD copper tube between  
the leaving side of the hot gas bypass valve and the Sporlan  
auxiliary side connector (distributor-side connector).  
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 is 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 distributor 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.  
LEGEND  
TXV  
Thermostatic Expansion  
Valve  
*Pilot valve connects directly to  
bypass valve per sketch A.  
Fig. 4 — 38AKS Hot Gas Bypass Piping  
3
 
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:  
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).  
a. Connect a field-supplied wire between TB2-3 and  
the L1 side of the HGR coil.  
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 5/16 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.  
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.  
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 is 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.  
Step 3 — Restore Refrigerant Charge — Charge  
unit in accordance with 38AKS Charging Chart found on unit.  
TB2  
9
TC2  
TB2  
3
LLS  
HGR  
TB2  
C2  
BLU  
YEL  
Hot Gas  
HGR  
Pilot Solenoid Valve  
LEGEND  
HGR  
LLS  
TB  
Hot Gas Relay  
Liquid Line Solenoid  
Ter minal Block  
TC  
Thermostat Cooling  
NOTE: Hot Gas Relay (HGR) use Part No. HN61KK324.  
Fig. 5 — 38AKS014-024 Hot Gas Bypass Wiring  
TROUBLESHOOTING  
PROBLEM  
PROBABLE CAUSE  
SOLUTION  
Hot Gas Bypass Valve Fails to Open.  
1. Dirt or foreign material in valve.  
2. Equalizer passageway clogged.  
1. Disassemble and clean valve.  
2. Disassemble and clean valve.  
3. External equalizer not connected or  
equalizer line is pinched shut.  
3. Connect or replace equalizer line.  
Check solenoid valve.  
Hot Gas Bypass Valve Fails to Close.  
1. Dirt or foreign material in valve.  
2. Diaphragm failure.  
1. Disassemble and clean valve.  
2. Replace element only.  
Copyright 2005 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 111 Catalog No. 533-00067 Printed in U.S.A. Form 30GT/38AKS-1SI Pg 4 1-05 Replaces: 30GT-35SI  
Book 1  
2
4
Tab 3a 5c 2a  
 

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