Carrier 30RAP010-150 Remote Evaporator Mounting Accessory Instruction Manual

Carrier 30RAP010-150 Remote Evaporator Mounting Accessory

Product Information

Specifications

• Product Name : 30RAP010-150 Remote Evaporator Mounting Accessory
• Part Numbers : 30RA-900—060, 30RA-900—068 through 30RA-900—075
• Manufacturer: Not specified
• Refrigerant: R-410A
• Safety Standards: ANSI Z223.1
• Design Pressures:
  • Suction Tubing: 445 psig (3068 kPa)
  • Liquid Tubing : 656 psig (4522 kPa)

Product Usage Instructions

Safety Considerations

• Installation and servicing of this air-conditioning equipment should only be carried out by trained and qualified personnel due to the potential hazards involved.
• Untrained personnel can perform basic maintenance functions like cleaning coils and filters, but all other operations should be done by trained service personnel.
• Always follow safety codes and wear appropriate safety gear like safety glasses and work gloves. Have a fire extinguisher available for brazing operations.

Installation Steps

1. Shut off electrical power to the unit.
2. Recover refrigerant to relieve all pressure from the system using both high-pressure and low-pressure ports.
3. Displace traces of vapor with nitrogen and ensure good ventilation in the work area.
4. Cut component connection tubing with a tubing cutter and remove the component from the unit.
5. Carefully un-sweat remaining tubing stubs if necessary.
6. Consult the equipment manufacturer if unsure about handling R-410A refrigerant.

General Caution
This system uses R-410A refrigerant with higher pressures than R-22. No other refrigerant should be used in this system to prevent personal injury and equipment damage.

FAQ

• Can untrained personnel perform all maintenance functions on this product?
  Untrained personnel can perform basic maintenance functions like cleaning coils and filters, but all other operations should be done by trained service personnel.

• What refrigerant is used in this system?
  This system uses R-410A refrigerant, and no other refrigerant should be used in it.

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 operation s 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 safety-alert 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 hazard s 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

• The remote evaporator accessory allows for indoor relocation of the evaporator as another means of freeze protection. Maximum separation of the 30RAP base unit and evaporator is limited to:
  • Plate fin coils: 75 ft (22 m) of piping. For more information, refer to the Carrier Piping Design manual.
  • Microchannel coils: 50 ft (15 m) of piping. For more information, refer to the Carrier Piping Design manual.
• Maximum evaporator elevation above the condensing section is limited to 15 ft (4.5m). Relocating the evaporator introduces minimal line losses if correct piping practices are followed. See Tables 1-9 for accessory package usage and 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)
  • electrical conduit (length determined by installation)
  • assorted refrigerant grade fittings according to site requirements (elbows, tees, refrigerant pipe couplings, etc.)
  • 90°C appliance wire 16 AWG if evaporator heater installation is required. (Length determined by installation).
  • 1/2 in. strain reliefs
    CAUTION
    This system uses R-410A, which has higher pressures than R-22 and other refrigerants. 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 gage 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 — 30RA-900—060 Accessory Package Contents for 30RAP070-150

Table 2 — 30RA-900—068 Accessory Package Contents for 30RAP010, 015, 018-060 with RTPF Coil

ga, 4 Cond (BLK/BRN/RED/ORN)
30RA500358| 2| Sensor Well
32GB404694| 3| Flow Switch and EXV Extension Cable, 95 ft (29.0 m)
HY69DS045| 6| Terminal, Male
RM02EJ115| 150| Thermistor Cable, 2 Conductor 22 ga

Table 3 — 30RA-900—069 Accessory Package Contents for 30RAP010, 30RAP015 with MCHX Coil All Voltages STD Interrupt, 30RAP018-030 with MCHX Coil 380-575V STD Interrupt

ga, 4 Cond (BLK/BRN/RED/ORN)
30RA500358| 2| Sensor Well
32GB404694| 2| Flow Switch and EXV Extension Cable, 95 ft (29.0 m)
99MH7504GC204210| 2| Wire, BLK, 42 in. (1066 mm), 10 AWG
99MZ7504GC204210| 2| Wire, YEL, 42 in. (1066 mm), 10 AWG
HY69DS045| 6| Terminal, Male
RM02EJ115| 150| Thermistor Cable, 2 Conductor 22 ga
HN53AB036| 4| Auxiliary Compressor Contactor for Crankcase Heaters
38APHACBTW-A00| 1| Wire Harness, Aux to FB
38APHACBTW-A10| 2| Wire Harness, CCH to Control Box Harness
HT32BH943| 2| Crankcase Heater (See Table 13 for usage details.)
HT32BH948| 2| Crankcase Heater (See Table 13 for usage details.)
HT32BH941| 2| Crankcase Heater (See Table 13 for usage details.)
HY93NH069| 2| Bushing

Table 4 — 30RA-900—070 Accessory Package Contents for 30RAP010-030 with MCHX Coil All Voltages High Interrupt, 30RAP018-030 with MCHX Coil 208/230V STD Interrupt

ga, 4 Cond (BLK/BRN/RED/ORN)
30RA500358| 2| Sensor Well
32GB404694| 2| Flow Switch and EXV Extension Cable, 95 ft (29.0 m)
99MH7504GC204210| 2| Wire, BLK, 42 in. (1066 mm), 10 AWG
99MZ7504GC204210| 2| Wire, YEL, 42 in. (1066 mm), 10 AWG
HY69DS045| 6| Terminal, Male
RM02EJ115| 150| Thermistor Cable, 2 Conductor 22 ga
HN59AD001| 2| Auxiliary Compressor Contactor for Crankcase Heaters
38APHACBTW-A00| 1| Wire Harness, Aux to FB
38APHACBTW-A10| 2| Wire Harness, CCH to Control Box Harness
38APHMCCTJ-A00| 4| Wire Harness, Aux Adapter
HT32BH943| 2| Crankcase Heater (See Table 13 for usage details.)
HT32BH948| 2| Crankcase Heater (See Table 13 for usage details.)
HT32BH941| 2| Crankcase Heater (See Table 13 for usage details.)
HY93NH069| 2| Bushing

Table 5 — 30RA-900—071 Accessory Package Contents for 30RAP011 and 016 with RTPF Coil

Table 6 — 30RA-900—072 Accessory Package Contents for 30RAP011, 30RAP016 with MCHX Coil All Voltages STD Interrupt

Table 7 — 30RA-900—073 Accessory Package Contents for 30RAP011, 30RAP016 with MCHX Coil All Voltages High Interrupt

Table 8 — 30RA-900—074 Accessory Package Contents for 30RAP035-060 with MCHX Coil All Voltages High Interrupt, 30RAP035-060 with MCHX Coil 208/230V STD Interrupt

ga, 4 Cond (BLK/BRN/RED/ORN)
30RA500358| 2| Sensor Well
32GB404694| 3| Flow Switch and EXV Extension Cable, 95 ft (29.0 m)
99MH7504GC204210| 4| Wire, BLK, 42 in. (1066 mm), 10 AWG
99MZ7504GC204210| 4| Wire, YEL, 42 in. (1066 mm), 10 AWG
HY69DS045| 6| Terminal, Male
RM02EJ115| 150| Thermistor Cable, 2 Conductor 22 ga
HN59AD001| 4| Auxiliary Compressor Contactor for Crankcase Heaters
38APHACBTW-A00| 1| Wire Harness, Aux to FB
38APHLCLTW-A00| 1| Wire Harness, Aux to FB
38APHACBTW-A10| 4| Wire Harness, CCH to Control Box Harness
38APHMCCTJ-A00| 8| Wire Harness, Aux Adapter
HT32BH943| 4| Crankcase Heater (See Table 13 for usage details.)
HT32BH948| 4| Crankcase Heater (See Table 13 for usage details.)
HT32BH941| 4| Crankcase Heater (See Table 13 for usage details.)
HY93NH069| 4| Bushing

Table 9 — 30RA-900—075 Accessory Package Contents for 30RAP035-060 with MCHX Coil 380-575V STD Interrupt

ga, 4 Cond (BLK/BRN/RED/ORN)
30RA500358| 2| Sensor Well
32GB404694| 3| Flow Switch and EXV Extension Cable, 95 ft (29.0 m)
99MH7504GC204210| 4| Wire, BLK, 42 in. (1066 mm), 10 AWG
99MZ7504GC204210| 4| Wire, YEL, 42 in. (1066 mm), 10 AWG
HY69DS045| 6| Terminal, Male
RM02EJ115| 150| Thermistor Cable, 2 Conductor 22 ga
HN53AB036| 8| Auxiliary Compressor Contactor for Crankcase Heaters
38APHACBTW-A00| 1| Wire Harness, Aux to FB
38APHLCLTW-A00| 1| Wire Harness, Aux to FB
38APHACBTW-A10| 4| Wire Harness, CCH to Control Box Harness
HT32BH943| 4| Crankcase Heater (See Table 13 for usage details.)
HT32BH941| 4| Crankcase Heater (See Table 13 for usage details.)
HY93NH069| 4| Bushing

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. Turn off the electrical power to the unit using the optional disconnect or the field-installed disconnect and lock off using proper lockout and tag-out procedures.
3. Recover holding charge or refrigerant charge from all circuits using standard refrigeration practices before cutting any refrigerant lines.
4. Disconnect water lines, thermistors, flow switch, EXV (electronic expansion valve) cable(s) and evaporator heater wiring.
5. Because the 30RAP 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.
6. Cut suction, liquid and hot gas bypass (if equipped) lines in area shown in Fig. 1-6. Remove evaporator/EXV assembly from unit.

7. Install evaporator heater if necessary; if evaporator will be located in area with ambient temperature above 40°F or applied with fluid suitably treated for freeze protection, then evaporator heater is not required. Refer to the power schematic located inside the control box for heater connection detail and follow the local electrical code. Carefully note refrigerant and water connections. Install evaporator in suitable location that can support the weight of the evaporator while operating. Install evaporator vertically as shown in Fig. 1-6. For 070-150, reposition filter drier as necessary.
   IMPORTANT: For sizes 035-060, circuit A liquid line is on the lower left corner and circuit B liquid line is on the lower right corner. See Fig. 8. For sizes 070-150, circuit A liquid line is on the lower right corner and circuit B liquid line is on the lower left corner. See Fig. 9.

8. Install field-supplied suction lines, hot gas bypass lines (if required), and liquid refrigerant lines from unit to evaporator according to Fig. 7-10 and Tables 10-12, using standard refrigeration practices.

9. Prior to brazing the suction line, remove the following parts from the suction line to avoid damage:

   • Suction pressure transducer(s) and Schrader core(s) from the fitting(s).
   • Schrader core(s) and cap(s) from pressure tap fittings.
   • Return Gas Thermistor and insulation.
   • High Flow Schrader port(s) and cap(s). Be sure all wires are clear of the brazing operation to avoid damage.

10. Use a nitrogen purge while brazing refrigerant lines. Be carefulto route piping to proper refrigerant circuit. It is required that liquid line filter driers be installed between the condenser(
    and the expansion device(s) to capture any foreign debris and provide additional moisture removal capacity.

11. Double suction riser is required on some units if refrigerant flow is up. See Table 12 for required units and piping details. Refer to Fig. 11 for suction riser and speed riser piping diagram.

12. 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 line size is recommended for all applications. For 30RAP010-060, dual circuit units should use circuit “A” hot gas bypass only. For 30RAP070-150, use both circuits hot gas bypass. 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 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.

13. Once all brazing is complete, re-install the devices removed in Step 9.

1-1/4
015| 20-3/4| 4-11/16| 18-1/2| 2-1/2| 1| 4.7| 1/4| 13/4| 1| 2-3/8| 8-7/8| 1-1/4
016| 20-3/4| 4-11/16| 18-1/2| 2-1/2| 1| 6.5| 1/4| 13/4| 1| 2-3/8| 8-7/8| 1-1/4
018| 20-3/4| 4-11/16| 18-1/2| 2-1/2| 1| 5.6| 1/4| 13/4| 1| 2-3/8| 8-7/8| 1-1/4
020| 20-3/4| 4-11/16| 18-1/2| 2-1/2| 1| 7.4| 1/4| 13/4| 1| 2-3/8| 8-7/8| 1-1/4
025| 20-3/4| 4-11/16| 18-1/2| 2-1/2| 1| 9.0| 1/4| 13/4| 1| 2-3/8| 8-7/8| 1-1/4
030| 20-3/4| 9-9/16| 18| 6-7/8| 1| 8.0| 1/8| 21/8| 1-3/8| 4| 5-1/2| 1-5/8

30RAP

| REFRIGERANT LINES
---|---
Suction Line Diameter (in.)| Liquid Line

Before EXV Diameter (in.)

| Liquid Line

After EXV Diameter (in.) b

Ckt A| Ckt B| Ckt A| Ckt B| Ckt A| Ckt B
010| 1-3/8| —| 5/8| —| 1/2| —
011| 1-3/8| —| 5/8| —| 1/2| —
015| 1-3/8| —| 5/8| —| 1/2| —
016| 1-3/8| —| 5/8| —| 1/2| —
018| 1-5/8| —| 5/8| —| 1/2| —
020| 1-5/8| —| 5/8| —| 1/2| —
025| 1-5/8| —| 5/8| —| 5/8| —
030| 1-5/8| —| 5/8| —| 5/8| —
035| 1-5/8| 1-5/8| 5/8| 5/8| 1/2| 1/2
040| 1-5/8| 1-5/8| 5/8| 5/8| 1/2| 1/2
045| 1-5/8| 1-5/8| 5/8| 5/8| 1/2| 1/2
050| 1-5/8| 1-5/8| 5/8| 5/8| 5/8| 5/8
055| 1-5/8| 1-5/8| 5/8| 5/8| 5/8| 5/8
060| 1-5/8| 1-5/8| 5/8| 5/8| 5/8| 5/8
070| 1-5/8| 2-1/8| 7/8| 7/8| 1-1/8| 1-1/8
080| 2-1/8| 2-1/8| 7/8| 7/8| 1-1/8| 1-1/8
090| 2-1/8| 2-1/8| 7/8| 7/8| 1-3/8| 1-3/8
100| 2-5/8| 2-5/8| 7/8| 1-1/8| 1-3/8| 1-3/8
115| 2-5/8| 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):

  * Shading indicates double suction risers required. Refer to Table 12 and Fig. 11 for double suction risers/speed riser piping designations.
  * Removal of EXV assembly from heat exchanger is not recommended.  

UNIT 30RAP

| WATER CONNECTIONS (VICTAULIC)

INLET/OUTLET (in.)

| REFRIGERANT CONNECTIONS LIQUID

INLET (IDS)

| REFRIGERANT CONNECTIONS SUCTION

OUTLET (IDS)

| BPHE CARRIER

P/N

| EMPTY WEIGHT

(lb)

| OPERATING WEIGHT

(lb)

| EMPTY WEIGHT

(kg)

| OPERATING WEIGHT

(kg)

---|---|---|---|---|---|---|---|---
010| 1-1/2| 1/2| 1-3/8| LL01SZ010| 22| 27| 10| 12
011| 1-1/2| 1/2| 1-3/8| LL01SZ010| 22| 27| 10| 12
015| 1-1/2| 1/2| 1-3/8| LL01SZ015| 27| 34| 12| 15
016| 1-1/2| 1/2| 1-3/8| LL01SZ018| 32| 39| 14| 18
018| 1-1/2| 1/2| 1-5/8| LL01SZ018| 32| 39| 14| 18
020| 1-1/2| 1/2| 1-5/8| LL01SZ020| 40| 50| 18| 23
025| 1-1/2| 5/8| 1-5/8| LL01SZ025| 46| 58| 21| 26
030| 2| 5/8| 1-5/8| LL01SZ032| 80| 96| 36| 44
035| 2-1/2| 1/2| 1-5/8| LL01LB035| 98| 125| 44| 57
040| 2-1/2| 1/2| 1-5/8| LL01LB040| 118| 145| 53| 66
045| 2-1/2| 1/2| 1-5/8| LL01LB045| 125| 155| 57| 70
050| 2-1/2| 5/8| 1-5/8| LL01LB050| 137| 172| 62| 78
055| 2-1/2| 5/8| 1-5/8| LL01LB055| 160| 202| 73| 92
060| 2-1/2| 5/8| 1-5/8| LL01LB055| 160| 202| 73| 92
070| 3| 1-1/8| 2-1/8| LL01SB070| 197| 279| 89| 127
080| 3| 1-1/8| 2-1/8| LL01SB080| 228| 323| 103| 147
090| 3| 1-3/8| 2-1/8| LL01SB090| 245| 351| 111| 159
100| 3| 1-3/8| 2-5/8| LL01SB100| 267| 385| 121| 175
115| 3| 1-3/8| 2-5/8| LL01SB110| 304| 440| 138| 200
130| 3| 1-3/8| 2-5/8| LL01SB130| 334| 485| 152| 220
150| 3| 1-3/8| 2-5/8| LL01SB150| 378| 551| 171| 250
UNIT 30RAP| CIRCUIT| RECOMMENDED LINE SIZE (in.)| DOUBLE SUCTION RISER LINE SIZING (in.)| SPEED RISER (in.)
---|---|---|---|---
SUCTION| LIQUID| A| B| C| D
011| A| 1-3/8| 5/8| 7/8| 1-1/8| 1-3/8| 7/8
070| A| 1-5/8| 7/8| —| —| —| —
B| 2-1/8| 7/8| 1-3/8| 1-5/8| 2-1/8| 1-3/8
080| A| 2-1/8| 7/8| 1-3/8| 1-5/8| 2-1/8| 1-3/8
B| 2-1/8| 7/8| 1-3/8| 1-5/8| 2-1/8| 1-3/8
090| A| 2-1/8| 7/8| 1-3/8| 1-5/8| 2-1/8| 1-3/8
B| 2-1/8| 7/8| 1-3/8| 1-5/8| 2-1/8| 1-3/8
100| A| 2-5/8| 7/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
B| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
115| A| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
B| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
130| A| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
B| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
150| A| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8
B| 2-5/8| 1-1/8| 1-5/8| 2-1/8| 2-5/8| 1-5/8

14. 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.

15. Install evaporator heater (if necessary). If evaporator will be located in an area with ambient temperatures above 40°F (4.4°C) or applied with fluid suitably treated for freeze protection, then the evaporator heater is not required.

16. Insulate evaporator with original insulation or suitable alternative if needed. Removal of insulation is not recommended.

17. Remove water strainer from unit and reinstall in new water inlet piping within 10 ft (3 m) of the evaporator. Install remainder of water piping.

18. Install entering and leaving water thermistor wells (included in kit). Thermistors should be located within 1 ft (0.3 m) of the evaporator inlet and outlet.

19. Install a 1/4 NPT fitting for the flow switch. Flow switch should be installed with at least 2 pipe diameters of straight tube in front of and behind switch and no water-side service valves between the flow switch and the evaporator. Flow switch should be installed near evaporator. Piping containing switch should be no smaller in diameter than field-supplied water lines. Remove water flow switch from the unit and reinstall in new piping. Route flow switch extension cable from the flow switch to the unit and plug it into the flow switch cable assembly, which was previously disconnected. Coil excess cable and wire tie in a convenient location.

20. Label and cut EWT (entering water temperature) and LWT(leaving water temperature) thermistors approximately 1 ft from the MBB (main base board) connector. For 30RAP010-060 units with a Packard Weather-Pack1 EXV connector cable, label and cut EXV cable(s) approximately 1 ft from EXV board connector. For 30RAP010-060 with an M12 EXV connector cable and all 30RAP070-090 units, label and disconnect the existing cable.

21. The junction box supplied with the accessory is for splicing the thermistor leads and EXV Packard Weather-Pack EXV connector leads (30RAP010-060) from the evaporator with the cables from the base unit. Mount the junction box near the liquid refrigerant connection end of evaporator. One or two knockouts can be used. Remove a knockout from the 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.

22. Install thermistors into thermistor wells in 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.

23. A 150 ft (45.7 m), 2-conductor jacketed cable is provided to connect the thermistor leads in the junction box back to the base unit. Cut the cable in half. Label both ends of one cable “EWT.” Label both ends of the other cable “LWT.” Run one end of the jacketed cables into the junction box and splice the cable wires to the identically tagged thermistor leads. Solder the splices and insulate them to prevent shorting.

24. For 30RAP010-060 units with the Packard Weather-Pack EXV connector:

    • A 150 ft (45.7 m), 4-wire jacketed cable is provided to connect the EXV leads in the junction box back to the base unit. Each wire in the jacketed cable is a different color. Cut the cable in half. Label each end of one of the EXV cable “EXV A.”
      Third-party trademarks and logos are property of their respective owners.

    • Label the ends of the other cable “EXV B” (if present).

    • Run one end of the jacketed cable(s) into the junction box and splice the cable wires to the identically tagged EXV cable. Solder the splices and insulate them to prevent shorting.

    • Tighten the strain relief for the cables and secure the junction box cover with the supplied 8B-18 x 3/8-in. screw.

    • Coil excess cables and wire tie in a convenient location.
      For 30RAP010-060 with M12 EXV connectors and 30RAP070-150 units:

    • 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.

25. For 30RAP010-060 units with MCHX coils only:
    For 30RAP010-060 MCHX units with Eaton or Hongfa compressor contactors:

    • Install crankcase heaters, one per compressor.

    • Install included auxiliary compressor contactors onto compressor contactors in the control box. For each Eaton auxiliary compressor contactor, install two Aux Adapter Harnesses. Connect the ferule end of one harness to the auxiliary compressor contactor terminals 11 and 21. Connect the ferule end of another harness to the auxiliary compressor contactor terminals 21 and 22.

    • Install the CCH to Control Box Harness. Insert a plastic bushing in the bottom of the compressor junction box and make the following connections within the junction box. Connect harness male ends labeled CCH-L1 and CCH-L2 to crankcase heater female terminals. Connect harness female ends labeled CCH-AUX-L1 and CCHAUX- L2 to terminals 12 and 22 of auxiliary compressor contactor. Connect the compressor ground wire to the grounding stud within the compressor junction box.

    • Install AUX to FB Harness.
      Connect ends labeled FB1-21 and FB1-22 to FB1 terminals 21 and 22 respectively.
      For Hongfa auxiliary compressor contactors, connect AUX to FB Harness terminals labeled CA1-AUX L1 and CA2-AUX L1 (if CA2 is present) to the respective auxiliary compressor contactors terminal 11. Then connect AUX to FB Harness terminals labeled CA1-AUX L2 and CA2-AUX L2 (if CA2 is present) to the respective auxiliary compressor contactor terminals 21. For Eaton auxiliary compressor contactors, connect AUX to FB Harness terminals labeled CA1-AUX L1 and CA2-AUX L1 (if CA2 is present) to the respective male Aux Adapter Harnesses labeled CCH-AUX L1. Then connect AUX to FB Harness terminals labeled CA1-AUX L2 and CA2-AUX L2 (if CA2 is present) to the respective male Aux Adapter Harnesses labeled CCH-AUX L2.
      For 30RAP010-060 MCHX units with compressor contactors other than Hongfa and Eaton:

    • Use included black and yellow wires and male terminals to connect crankcase heaters to line side of compressor contactors terminals 11 and 13.

    • For the connection from the black and yellow wires to the crankcase heater and the crankcase heater ground connection, insert a bushing into the bottom of the compressor junction box and make the connections within.
      See Table 13-15 for heater part numbers. See Fig. 12-17 for heater locations.

26. Charge machine with refrigerant using nameplate charge amount. Add charge according length of interconnecting piping.
    Charge at the liquid line. Do not charge into suction line or compressor damage will occur. Charge per unit installation instructions. Note the final charge amount for each circuit when complete on the unit.
    Preliminary charge is based on 25 ft (7.6 m) of interconnecting liquid line piping between indoor and outdoor units. For liquid line piping longer than 25 ft (7.6 m), use the following information:

    • 1/2 in. (12.7 mm) liquid line — 0.6 lb per 10 linear ft (0.27 kg per 3 m)
    • 5/8 in. (15.9 mm) liquid line — 1.0 lb per 10 linear ft (0.45 kg per 3 m)
    • 7/8 in. (22.2 mm) liquid line — 2.0 lb per 10 linear ft (0.91 kg per 3 m)
    • 1-1/8 in. (28.6 mm) liquid line — 3.5 lb per 10 linear ft (1.59 kg per 3 m)
    • 1-3/8 in. (34.9 mm) liquid line — 5.1 lb per 10 linear ft (2.32 kg per 3 m)

27. Check suction gas superheat for both circuits during steady operation. Increase set point if required, to account for suction line pressure drop and heat gain so that there is an 8°F (4.4°C) superheat leaving the evaporator when measured at the evaporator. Inspect the compressor oil sump during steady operation to ensure that oil is not foaming due to liquid flooding.

28. Check operation according to unit Controls, Start-Up, Operation, Service and Troubleshooting manual and adjust oil and refrigerant charge as necessary. After adjusting the refrigerant charge, allow each circuit to run fully loaded for 20 minutes. Stop the compressors and check the oil level. Oil level should be 1/8 to 3/8 up on the sight glass. Add oil only if necessary to bring the oil into view in the sight glass. If oil is added, run the circuit for an additional 10 minutes, then stop and check oil level. If 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 the requirements.

29. Replace filter drier or filter drier core if pressure drop becomes excessive after 24 hours of operation.
    Table 13 — 30RAP010,015,018-060 Crankcase Heater Part Numbers MODEL NUMBER| VOLTAGE| PART NUMBER
    ---|---|---

    ---

30RAP010, 30RAP015, 30RAP018-060

| 460| HT32BH943
208/230| HT32BH948
575| HT32BH941
380| HT32BH943

Table 14 — 30RAP011, 016 Crankcase Heater Part Numbers

30RAP011

| 460| HT32TC705(1)| HT32TC743(1)
208/230| HT32TC205(1)| HT32TC243(1)
575| HT32TC905(1)| HT32TC943(1)
380| HT32TC705(1)| HT32TC743(1)

30RAP016

| 460| HT32TC705(2)| —
208/230| HT32TC205(2)| —
575| HT32TC905(2)| —
380| HT32TC705(2)| —

Table 15 — Crankcase Heater Location

14. 38RAP040| ZP120 (Fig. 14)| ZP120 (Fig. 14)| ZP137 (Fig. 14)| ZP137 (Fig.

15. 38RAP045| ZP137 (Fig. 14)| ZP137 (Fig. 14)| ZP154 (Fig. 15)| ZP154 (Fig.

16. 38RAP050| ZP154 (Fig. 15)| ZP154 (Fig. 15)| ZP154 (Fig. 15)| ZP154 (Fig.

17. 38RAP055| ZP154 (Fig. 15)| ZP154 (Fig. 15)| ZP182 (Fig. 15)| ZP182 (Fig.

18. 38RAP060| ZP182 (Fig. 15)| ZP182 (Fig. 15)| ZP182 (Fig. 15)| ZP182 (Fig.

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