Carrier 30RC065-150 Brazed Plate Heat Exchanger Instruction Manual

30RC065-150 R-410A Units
Remote Evaporator
(Brazed Plate Heat Exchanger Only)
Mounting Accessory
Installation Instructions
Part No. 30RC70000201

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags and labels attached to the unit, and other safety precautions that may apply.
Follow all safety codes, including ANSI (American National Standards Institute) Z223.1. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.
It is important to recognize safety information. This is the safetyalert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices, which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.
WARNING
DO NOT USE TORCH to remove any component. System contains oil and refrigerant under pressure.
To remove a component, wear protective gloves and goggles and proceed as follows:
Shut off electrical power to unit.
Recover refrigerant to relieve all pressure from system using both high- pressure and low pressure ports.
Traces of vapor should be displaced with nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame produces toxic gases.
Cut component connection tubing with tubing cutter and remove component from unit. Use a pan to catch any oil that may come out of the lines and as a gauge for how much oil to add to the system.
Carefully un-sweat remaining tubing stubs when necessary.
Oil can ignite when exposed to torch flame.
Failure to follow these procedures may result in personal injury or death.
WARNING
Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation and service.
There may be more than one disconnect switch. Tag all disconnect locations to alert others not to restore power until work is completed.

GENERAL

This accessory is only applicable for 30RC units equipped with R-410A refrigerant and shall not be used for units with A2L refrigerant. The remote evaporator accessory allows for indoor relocation of the evaporator as another means of freeze protection. When the evaporator is located in the heated space, an antifreeze solution is not needed and the performance degradation associated with the antifreeze solution can be avoided. With the evaporator in the interior space, ASHRAE (American Society of Heating, Refrigeration and Air Conditioning Engineers) 15 considerations are required. Maximum separation of the 30RC base unit and evaporator is limited to:

• Plate fin coils: 75 linear ft (22 m) of piping.
• Microchannel coils: 50 linear ft (15 m) of piping. Maximum condensing section elevation above the evaporator is limited to 50 ft (15.2 m).

Maximum evaporator elevation above the condensing section is limited to 15 ft (4.5 m). Relocating the evaporator introduces minimal line losses if correct piping practices are followed. See Table 1 for accessory package contents. In addition to the parts supplied with the accessory package, the following material must be field-supplied:

• Refrigerant grade liquid, hot gas bypass, and suction line piping (length determined by installation)
• Water piping and fittings
• Suction and water line tubing insulation (length determined by installation). Minimum R-value of 25 (m deg. K/W) recommended.
• Electrical conduit (length determined by installation)
• Assorted refrigerant grade fittings according to site re- quirements (elbows, tees, refrigerant pipe couplings, etc.)

CAUTION
This system uses R-410A. No other refrigerant may be used in this system. Suction tubing design pressure is 445 psig (3068 kPa) and liquid tubing design pressure is 656 psig (4522 kPa). Failure to use gauge set, hoses, and recovery systems designed to handle R-410A refrigerant may result in personal injury and equipment damage. If unsure about equipment, consult the equipment manufacturer.
Table 1 — 30RC70000201 Accessory Package Contents for 30RC065-150 R-410A Units

INSTALLATION

Perform the following to install the remote evaporator mounting accessory:

1. Inspect package contents for any missing or damaged parts. File a claim with the shipping agency if parts are damaged. Notify your Carrier representative if any item is missing.

2. Determine the new location for the evaporator. Ensure that the new location supports the evaporator weight. See Fig. 1 and 2 for evaporator dimensions and Table 2 for evaporator weight.

3. Turn off the electrical power to the unit using the optional dis- connect or the field-installed disconnect and lock off using proper lockout and tag-out procedures.

4. Recover refrigerant charge from all circuits using standard refrigeration practices before cutting any refrigerant lines. Refer to unit nameplate or installation instructions for refrigerant quantities.

5. Disconnect evaporator heater conduit and wiring, if equipped.

6. Remove entering and leaving chilled water temperature thermistors. Make sure to label thermistors as they are removed. Label entering water thermistor as EWT (entering water temperature) and leaving water thermistor as LWT (leaving water  temperature).

7. Disconnect field-supplied water piping. The factory-installed water piping, thermistor well, and strainer can remain with the evaporator.
   NOTE: The cone strainer will be loose once the fieldsupplied piping is removed.

8. Disconnect flow switch cable from flow switch located on factory-installed leaving water piping. The flow switch can remain in the water piping.

9. Disconnect EXV (electronic expansion valve) cables from EXVs. Make sure to label the cables as they are removed.

10. Because the 30RC units use polyolester (POE) oil, which can absorb moisture, it is important to minimize the amount of time that the system interior is left exposed to the atmosphere. Minimizing the exposure time of the oil to the atmosphere will minimize the amount of moisture that needs to be removed during evacuation.

11.  Cut suction, liquid, and hot gas bypass lines (if equipped) in area shown in Fig. 3. Remove evaporator as well as the filter drier, EXV, and service valve assembly from unit. It is not recommended to separate the filter drier, EXV, and service valve assembly from the evaporator. Cut the liquid line in a convenient location to allow installation of the liquid line service valve included in the accessory kit.

12. Transport the evaporator, factory-installed water piping assembly, filter drier, EXV, and service valve assembly to the new location using lifting holes shown in Fig. 1 and 2, and bolt it in place. Make sure the new location can support the weight of the evaporator while operating. Install evaporator vertically as shown in Fig. 3. If the filter drier, EXV, and service valve assemblies were separated from the BPHE, ensure there is enough room to install them at new location. Refer to Fig. 4 for filter drier, EXV, and service valve assembly dimensions.
    IMPORTANT: On some units, the EXV size is different between circuit A and circuit
    B. Label each filter drier, EXV, and service valve assembly if they are to be separated. Ensure that each assembly is reinstalled with the original circuit.

13. If separated, reinstall the filter drier, EXV, and service valve assembly at the evaporator. Keep the location of the EXVs as close to the evaporator as possible but no further than 24 in. away. See Fig. 5.

14. Following Carrier recommended piping practices, install field-supplied liquid and suction lines to reconnect the evaporator with the base unit. If the evaporator is located below the base unit, then double suction risers must be installed to ensure proper oil return at part load conditions. See Fig. 6 for suction riser and speed riser piping diagram. Refer to Tables 2-3 for refrigerant pipe sizing information and Table 4 for double suction riser line sizing. As shown in Fig. 5, the pressure relief valves included in the kit must be installed on the new liquid lines between the service valves as required by local codes.

15. Prior to brazing the suction and liquid line, remove the following parts from the suction and liquid line to avoid damage:
    a. Suction pressure transducer(s) and Schrader core(s) from the fitting(s)
    b. Schrader core(s) and cap(s) from pressure tap fittings
    c. Return gas thermistor and insulation
    d. High flow Schrader port(s) and cap(s)
    e. Fusible plug(s) on suction piping and filter drier
    f. Low side and high side pressure relief valves, if equipped.
    Be sure all wires are clear of the brazing operation to avoid damage.
    WARNING
    Do not shut off both service valves in either liquid line. Pressure can build within the trapped area. To avoid the possibility of personal injury or property damage, the pressure relief valves included in the kit must be installed in each liquid line between the two shutoff valves. See Fig. 5.
    The dimensions shown are without the evaporator insulation installed.
    Evaporator is shipped with factory-installed insulation that is 19.1 mm (3/4 in.) thick.
    Add/subtract insulation thickness as necessary to determine actual dimensions.*The dimensions shown are without the evaporator insulation installed.
    Evaporator is shipped with factory-installed insulation that is 19.1 mm (3/4 in.) thick.
    Add/subtract insulation thickness as necessary to determine actual dimensions. Table 2 — Evaporator Connection Dimensions** UNIT 30RC| CARRIER P/N| WATER CONNECTIONS (VICTAULIC) INLET/OUTLET (in.)| REFRIGERANT CONNECTIONS LIQUID INLET (IDS) (in.)| REFRIGERANT CONNECTIONS SUCTION OUTLET (IDS) (in.)| EMPTY WEIGHT (lb)| EMPTY WEIGHT (kg)| OPERATING WEIGHT (lb)| OPERATING WEIGHT (kg)
    ---|---|---|---|---|---|---|---|---
    Ckt A| Ckt B| Ckt A| Ckt B
    065| LL01LV060| 3| 5/8| 5/8| 1-5/8| 1-5/8| 134.3| 60.9| 178.6| 81.0
    070| LL01LV070| 3| 5/8| 5/8| 2-1/8| 2-1/8| 153.6| 69.7| 204.3| 92.7
    080 C| LL01LV080| 3| 5/8| 5/8| 2-1/8| 2-1/8| 176.2| 79.9| 234.5| 106.3
    080| LL01LV080| 3| 5/8| 5/8| 2-1/8| 2-1/8| 176.2| 79.9| 234.5| 106.3
    090| LL01LV080| 3| 5/8| 5/8| 2-1/8| 2-1/8| 176.2| 79.9| 234.5| 106.3
    100| LL01LV100| 5| 1-3/8| 1-3/8| 2-1/8| 2-1/8| 242.6| 110.0| 330.7| 150.0
    110| LL01LV110| 5| 1-3/8| 1-3/8| 2-5/8| 2-5/8| 302.9| 137.4| 414.8| 188.1
    120 C| LL01LV110| 5| 1-3/8| 1-3/8| 2-5/8| 2-5/8| 302.9| 137.4| 414.8| 188.1
    120| LL01LV110| 5| 1-3/8| 1-3/8| 2-5/8| 2-5/8| 302.9| 137.4| 414.8| 188.1
    130| LL01LV130| 5| 1-3/8| 1-3/8| 2-5/8| 2-5/8| 337.8| 153.2| 463.4| 210.2
    150**| LL01LV150| 5| 1-3/8| 1-3/8| 2-5/8| 2-5/8| 381.4| 173.0| 524.0| 237.6

LEGEND
IDS — Inside Diameter (Solde)![Carrier 30RC065-150 Brazed Plate Heat Exchanger

• Fig1](https://manuals.plus/wp-content/uploads/2024/01/Carrier-30RC065-150 -Brazed-Plate-Heat-Exchanger-Fig1.jpg)

NOTE: Dimensions are in millimeters.

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Table 3 — Recommended Refrigerant Line Sizing****

LIQUID LINE AFTER EXV DIAMETER (in.) a
Ckt A| Ckt B| Ckt A| Ckt B| Ckt A| Ckt B
065| 2-1/8| 2-1/8| 7/8| 7/8| 5/8| 5/8
070| 2-1/8| 2-1/8| 7/8| 7/8| 5/8| 5/8
080 C| 2-1/8| 2-1/8| 7/8| 7/8| 5/8| 5/8
080| 2-1/8| 2-1/8| 7/8| 7/8| 5/8| 5/8
090| 2-1/8| 2-1/8| 1-1/8| 1-1/8| 5/8| 5/8
100| 2-1/8| 2-1/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8
110| 2-5/8| 2-1/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8
120 C| 2-1/8| 2-5/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8
120| 2-1/8| 2-5/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8
130| 2-5/8| 2-5/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8
150| 2-5/8| 2-5/8| 1-1/8| 1-1/8| 1-3/8| 1-3/8

NOTE(S):
a. Removal of EXV assembly from heat exchanger is not recommended.
LEGEND
EXV — Electronic Expansion Valve
Table 4 — Remote Evaporator Double Suction Riser Line Dimensions

16. Use a nitrogen purge while brazing refrigerant lines. Be careful to route piping to proper refrigerant circuit. It is required that liquid line filter driers be installed between the condenser(s) and expansion device(s) to capture any foreign debris and provide additional moisture removal capacity.
17. If hot gas bypass valve is used in remote applications, the line size should be kept to a minimum to reduce the amount of liquid refrigerant that can condense in the line during the off cycle. Liquid refrigerant in the hot gas bypass line can result in a liquid slug entering the compressor at start-up. Line size is not as critical as if sizing for discharge lines, therefore 5/8 in. OD (outside dimensions) line size is recommended for all applications. It is important to loop the hot gas bypass line over the compressor to help reduce the chance of the hot gas bypass line filling with liquid in the off cycle. The hot gas bypass valve should remain with the outdoor portion of the unit. If hot gas bypass valve is installed as a factory-installed option, cut the line outlet of the valve and run the hot gas bypass line to the remote evaporator. Leave the hot gas bypass control solenoid valve where it is already located.
18. Once all brazing is complete, re-install the devices removed in Step 15.
19. Once all of the piping connections are complete, leak test the unit and then pull a deep dehydration vacuum. Connect the vacuum pump to the charging valve in the suction line and to the liquid line service valve. For best results, it is recommended that a vacuum of at least 500 microns be obtained. Afterwards, to ensure that no moisture is present in the system, perform a standing vacuum-rise test. With the unit in deep vacuum (500 microns or less), isolate the vacuum pump from the system. Observe the rate-of-rise of the vacuum in the system. If the vacuum rises by more than 50 microns in a 30-minute time period, then continue the dehydration process. Maintain a vacuum on the system until the standing vacuum requirement is met. This will ensure a dry system. By following these evacuation and dehydration procedures, the amount of moisture present in the system will be minimized.
20. Insulate evaporator with original insulation or suitable alternative if needed. Removal of insulation is not recommended.
21. Install new field-supplied water piping as well as reinstall the strainer in the factory-installed inlet piping.
22. Route the flow switch extension cable included in the kit from the flow switch on the factory-installed water piping to the unit. Plug the extension cable into the original flow switch cable assembly at the unit, which was previously disconnected. Coil excess cable and wire tie in a convenient location.
23. Label and cut EWT (entering water temperature) and LWT (leaving water temperature) thermistors approximately 1 ft from the SIOB-A-J25 connector. See Fig. 7.
24. The junction box supplied with the accessory is for splicing the thermistor leads from the evaporator with the 5-wire jacketed cable from the base unit. Mount the junction box near the liquid refrigerant connection end of evaporator with the M6 screws provided. One or two knockouts can be used. Remove a knockout from bottom of the junction box and install HW60EA001 conduit connector for strain relief at the knockout hole. If using conduit to provide mechanical protection to the wires between the junction box and the base unit, remove another knockout. Follow local codes.
25. Install thermistors into thermistor wells in the factoryinstalled entering and leaving water piping. Run the labeled thermistor leads from the evaporator into the junction box and tighten the strain relief. Strip back the lead jackets to expose the 2 wires in each lead.
26. A 100 ft (30.5 m) 5-wire jacketed cable is provided to con- nect the thermistor leads in the junction box back to the base unit. Each wire in the jacketed cable is a different color. Strip back the jacket of the jacketed cable on both ends to expose the 5 wires. Pick any 2 wires and label both ends of each wire “EWT.” Pick another pair of wires and label both ends of each “LWT.” One wire is not used.
27. Run one end of the jacketed cable(s) into the junction box and splice the cable wires to the identically tagged thermistor leads. Solder the splices and insulate them to prevent shorting. Tighten the strain relief for the cable(s) and secure the junction box cover with the supplied M6 screws. Splicing for leads is shown in Fig. 8.
28.  Run the other end of the jacketed cable back to the base unit and into the control box. Tie cables to piping or run cables in conduit; follow local codes. Splice each wire in the control box to the appropriate thermistor lead. Solder the splices and insulate them to prevent short circuiting. Connect the wires to those cut from the SIOB-A-J25 plug, previously labeled EWT and LWT.
29. Label each end of one of the EXV extension cable assemblies supplied with the accessory “EXV A.” Label the ends of the other assemblies “EXV B.” Plug the electrical connectors of the appropriate EXV cable assemblies into the EXVs. Run the other end of  the cable assemblies to the base unit. Plug the accessory EXV cable assemblies into the corresponding EXV leads located at the base unit where the EXV assemblies were removed. Coil excess cables and wire tie in a convenient location.
30. The 30RC units are shipped from the factory with the operat- ing charge of a packaged system. Additional refrigerant is required for the machine to operate properly and depends upon the separation between the evaporator and the base unit, the line sizes, and the operating conditions. Table 5 provides an estimate for suction line charge and liquid line charge per 100 ft for different pipe sizes. The estimated additional refrigerant charge will be the sum of the calculated suction line charge and liquid line charge. To correct for saturated temperatures other than those shown in Table 5, multiply by the factors shown in Table 6. Actual charge should be determined at the time of start up.
31. Initially charge the machine with refrigerant using nameplate charge amount. Add additional charge according to Step 30. Charge at the liquid line. Do not charge into suction line or compressor damage will occur. Charge the machine per the Controls, Start-Up, Operation, Service and Troubleshooting manual and adjust charge as necessary. Record the final charge amount for each circuit.
32. Reference the Controls, Start-Up, Operation, Service and Troubleshooting manual for pre-start-up and start-up procedure. The Controls, Start-Up, Operation, Service and Troubleshooting manual also provides a procedure for adjusting oil charge if necessary. If, after adjusting oil charge the level remains low, check the piping system for proper design for oil return; also, check the system for leaks. If checking the oil level with unit running in part load, let unit run one hour, then run at full load for 10 minutes. If oil does not return to acceptable sight glass levels, check for correct suction piping and line sizing. Oil must be added if the oil level does not meet requirements.
33. When unit is operating correctly and the suction lines have been cleared of any leaks, install field-supplied insulation on suction lines between the unit and the evaporator.
34. Replace filter drier or filter drier core if pressure drop becomes excessive after 24 hours of operation.

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Table 5 — Estimated Additional Refrigerant Charge
R-410A WEIGHT LB (kg) OF REFRIGERANT PER 100 ft (30.48 m) OF TUBING

NOMINAL SIZE (in.)| SUCTION LINE 40°F (4.4°C)| LIQUID LINE 100°F (43.3°C)
---|---|---
5/8| 0.4 (0.2)| 9.7 (4.4)
7/8| 0.7 (0.3)| 20.1 (9.1)
1-1/8| 1.3 (0.6)| 34.3 (15.6)
1-3/8| 1.9 (0.9)| 52.3 (23.8)
1-5/8| 2.7 (1.2)| 74.2 (33.7)
2-1/8| 4.7 (2.1)| 128.6 (58.5)
2-5/8| 7.3 (3.3)| 198.0 (90.0)

Table 6 — Temperature Correction Factors
R-410A CORRECTION FACTORS — ALL TEMPERATURES ARE SATURATED TEMPERATURES °F (°C)

(48.9)**
0.83| 1.19| 1.10| 1.04| 0.96

© 2023 Carrier
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53300235-01 Printed in U.S.A.
Form No. 30RC-1ASI
Rev A. Pg 12 9-23
Replaces: NEW

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