Hi-Velocity RBM I Refrigerant Base Module Instruction Manual
- June 12, 2024
- Hi-Velocity
Table of Contents
Hi-Velocity RBM I Refrigerant Base Module
Product Information
RBM-I Refrigerant Base Module
The RBM-I Series cooling coil is a module designed for use with HVS-24, HVS-36, and HVS-60 Variable Speed Heat Pumps. It can be installed in the vertical or horizontal position on the return air side of the air handler. The RBM-I comes with T-mounting brackets, access port(s), an external freeze stat, and additional components for air sealing. All Energy Saving Products R-Series modules come standard with R-410A refrigerant components. This module does not come with a thermal expansion valve (TXV) as it is designed to be used with heat pumps that have internal EXVs. When installing the RBM-I Modules, it is important not to install with TXVs. The RBM-I module includes access port(s) for reading refrigerant pressures/temperatures at the Evaporator (RBM-I). The approximate installation locations for these components are shown in Fig. 01. The RBM-I module can be installed as a stand (return air base) for the air handler or as a side-mounted coil. It can be adapted to different orientations, such as left to up/right or right to up/left. Please refer to page 3 for steps on how to adapt the coil to up/left orientation.
There are four different configurations in which the RBM-I module can be installed:
- A: Entering air in through the left, leaving through the top.
- B: Entering air in through the left, leaving through the right.
- C: Entering air in through the right, leaving through the top.
- D: Entering air in through the right, leaving through the left.
It is important to note that the Freeze Stat (anti-ice control) must be used at all times to prevent severe icing of the coil in the event of an undercharge or low load. Failure to properly install the freeze stat will result in RBM-I-related warranty issues being voided.
Note: Do not remove the protective bubble wrap from the Freeze Stat.
Product Usage Instructions
- Determine the desired air inlet side for installation (left or right).
- Choose the appropriate configuration (A, B, C, or D) based on the desired air inlet and outlet directions.
- If necessary, adapt the RBM-I module to the up/left orientation by following the steps provided on page 3 of the manual.
- Install the RBM-I module on the return air side of the air handler, either vertically or horizontally, using the included T-mounting brackets.
- Ensure that the access port(s) are properly installed to allow for reading refrigerant pressures and temperatures at the Evaporator (RBM-I).
- Connect the RBM-I module to the appropriate HVS-24, HVS-36, or HVS-60 Inverter Heat Pump Condensing Unit.
- Make sure to use R-410A refrigerant components when connecting the RBM-I module to any R-410A condensing unit.
- If using the RBM-I module with heat pumps other than HVS-24, HVS-36, or HVS-60, ensure that a thermal expansion valve (TXV) is installed in addition to the RBM-I module.
- Properly seal the RBM-I module for air sealing using the additional components provided.
- Test the RBM-I module to ensure proper functionality and adjust as necessary.
For use with HVS-24, HVS-36 & HVS-60 Variable Speed Heat Pumps
- RBM-I-50 (1.5-2 Tons)
- RBM-I-70 (2.5-3 Tons)
- RBM-I-100 (3.5-5 Tons)
Refrigerant Base Modules (RBM-I)
- The RBM-I Series cooling coil comes as a module and can be installed in the vertical or horizontal position on the return air side of the air handler. The RBM-I comes with T-mounting brackets, access port(s), an external freeze stat*, and additional components for air sealing.
- RBM-I modules can be used on any R-410A condenser if R-410A refrigerant components are used. All Energy Saving Products R-Series modules come standard with R-410A refrigerant components.
- This module is for use with HVS-24, HVS-36 and HVS-60 Inverter Heat Pump Condensing Units. It does not come with thermal expansion valve, as there are internal EXVs inside the Heat Pump. When installing the RBM-I Modules, DO NOT INSTALL WITH TXVs.
- The module will come with access port(s) that will need to be installed to read refrigerant pressures/temperatures at the Evaporator (RBM-I). ( Fig. 01) shows approximate installation locations for these components.
- RBM-I Modules were designed to be used with the HVS-24, HVS-36, and HVS-60 Heat Pumps but can be used on any R-410A condensing unit, as long as a TXV is installed as well. All Energy Saving Products cooling modules come standard with R-410A refrigerant components.
IMPORTANT : The Freeze Stat (anti-ice control) serves the purpose of
preventing severe icing of the coil in the event of an undercharge or low load
on the coil. This piece of equipment must be used at all times. Failure to
properly install the freeze stat will result in RBM-I-related warranty issues
being voided
1) Liquid line
- High-side access port (if applicable)
3) Refrigerant distributor
4) Distributor tubes
| 5) Suction line
- Low-side access port
7) Freeze Stat (Anti-ice Control)
---|---
Coil Configuration
The RBM-I module can be installed as a stand (return air base) for the air handler or as a side-mounted coil. When the desired air inlet side has been determined, the module can be adapted. The module comes ready as left to up/right orientation (Fig. 02) but can easily be changed to a right-to- up/left orientation. (Fig. 03) See page 3 for steps to adapt the coil to up/left.
The RBM-I Module can be installed in four different configurations:
- A: Entering air in through the left, leaving through the top.
- B: Entering air in through the left, leaving through the right
OR (WITH ADAPTATION) - C: Entering air in through the right, leaving through the top.
- D: Entering air in through the right, leaving through the left.
RBM-I Change Configuration
To change from an up/right (standard) configuration to an up/left
configuration, follow the steps below
- Remove the front door from the module. (Fig. 04)
- Remove the drain pan by sliding it out from the bottom of the coil casing, ensuring that the foam air dam is also (Figs. 05a, 05b)
- Rotate the entire unit 90 deg. clockwise. (Fig. 06)
- Position the blue horse hair filter in front of the drain line inlets, to filter condensate and prevent any air from bypassing under the coil through the gap in the drain pan’s air dam. (Figs. 07a, 07b)
- Replace the drain pan in the (new) bottom location. (Fig. 08)
- Ensure the foam air dam is re-installed under the corner of the coil to prevent air from bypassing the coil. (Fig. 09)
- Remove round knockouts on the door to fit drain lines. Plug previously used drain holes with provided plugs. (Fig. 10)
- Replace the front door on the module. (Fig. 11)
Return Air Cutouts
Once the RBM-I coil configuration and placement of the return air ducting
have been decided, the return air knockout(s) can be cut. The pre-measured
guide cuts supplied with the RBM-I coil should always be used to make the
first cut. For this first cut, do not use a saw blade longer than 5” (125mm),
or damage to the coil can occur.
TO AVOID DAMAGE : After the first initial cut using the return air knockout(s) a metal shear must be used to make the return air cutout opening match more closely to the filter or return air ducting size to maximize flow capacity. Use this cut method for both coil inlet and outlet.
Mounting Brackets
Mounting the cooling coil to the air handler can be done with the T
brackets supplied (Fig. 12) , ensure that no screws puncture the drain pan
or coil. Use the provided mounting tape to air seal the RBM-I to the air
handler. See the specifications page for the dimensions of the air handler
units and cooling modules.
Access Ports
When refrigerant lines are connected to the RBM-I coil, access port(s) must be connected as well. (Fig. 01 – reference 2 & 6) With the use of a tee and reducer, this process is simplified. The access ports are required for system startup and for future troubleshooting or service. When reading refrigerant pressures/ temperatures, always read them at the evaporator access port.
Drain Connections, P – Trap & Secondary Drain Pan
Important : Piping the condensate lines on a return side cooling coil can be dramatically different, be sure to read the info below.
The primary condensate drain must have a minimum 3” P-Trap installed (Fig.
15). The drain line must run at a slope of ¼” per foot in the direction of
the drain. RBM-I modules come with a ¾” male CPVC primary and secondary
outlet. It is good
practice to install a cleanout right above the P-Trap. Using a “tee fitting”
and cap in the P-Trap’s construction can be usedas thee clean out and as a way
to prime the P-Trap if it ever dries out. A wet P-Trap is important. A dry
P-Trap can be detrimental to proper drainage. If the code requires a secondary
drain line, run the secondary line using the same method as the primary.
Otherwise, capping off the secondary drain line is acceptable. Do not run the
secondary drain line to the secondary drain pan or use it as a vent to the
atmosphere! An equipment stand/riser or rubber equipment mat may be necessary
to elevate the module off of the ground to allow for a P-Trap.
Any installation that has the potential of property damage due to condensate must have a secondary drain pan installed. If the unit is installed in a high heat and/or high humidity location, extra insulation around the unit casing may be required. This will prevent excessive condensate from forming on the outer surface of the casing.
Piping the RBM-I
Only refrigerant-grade pipe and fittings are to be used with the RBM-I Module. Plumbing fittings may contain wax or other contaminants which are detrimental to the proper operation of the system. Insulate the suction line with a minimum of 3/8” insulation. For inverter heat pump applications, insulating both suction and liquid lines is mandatory. In high heat areas, a minimum of 1/2” insulation may be needed. Support the pipe every 5 feet, or whatever local code states.
Run the pipes in the most direct route possible, taking into account structural integrity, building details, and local building codes. The minimum refrigerant pipe length is 16ft (6m). If going less than 16 ft, coil the additional copper pipe up in horizontal loops to ensure proper oil return. If the evaporator is located above the condenser, slope any horizontal runs toward the condenser. If the condenser is located above the evaporator, a P-trap must be installed at the bottom of the vertical riser. For long vertical risers, additional P-traps must be installed for every twenty feet. Lines running over 213’ (65m) are not recommended.
Freeze Stat
The RBM Series cooling module comes with a freeze stat (anti-ice control).
This freeze stat serves the purpose of preventing severe icing of the coil in
the event of an undercharge or low load on the coil.
NOTE : Do not remove protective bubble wrap from Freeze-Stat.
Important : The Freeze Stat (anti-ice control) must be used at all times. Failure to do so may void the warranty.
During start-up, it is acceptable to jump across the freeze stat. This will prevent the freeze stat from shutting the system off while charging a new system that may be low on refrigerant. Once charged and running, this jumper must be removed and the freeze stat connected to the FZ and FZ terminals on the Printed Circuit Board. Should wiring needs arise in which the outdoor unit is controlled through another means of wiring, the freeze stat should be connected in series on the input side of the control wiring. See fthe reeze stat install location on page 2 (Fig. 01).
Pipe Sizing
Refer to the charts below and Module HVS – Variable Speed Heat Pump Manual
for pipe sizing.
Minimum pipe sizes, maximum length, and maximum lift
Model| Liquid Line| Suction Line| Maximum Length|
Maximum Lift
---|---|---|---|---
HVS-24| 3/8” (9.5 mm)| 5/8” (15.9 mm)| 164.5’ (50 m)| 82’ (25 m)
HVS-36| 3/8” (9.5 mm)| 5/8” (15.9 mm)| 213.25’ (65 m)| 98.4’ (30 m)
HVS-60| 3/8” (9.5 mm)| 3/4” (19 mm)| 213.25’ (65 m)| 98.4’ (30 m)
The HVS Variable Speed Heat Pump comes with a factory charge. An additional charge will only be needed on line sets longer than 25 ft. (See table below)
Minimum pipe sizes, factory charge, and additional refrigerant required
Model
| ****
Liquid Line
| ****
Suction Line
| ****
Factory Charge (kg)
| Add extra refrigerant for line sets
over 25 ft (7.5 m)
---|---|---|---|---
HVS-24| 3/8” (9.5 mm)| 5/8” (15.9 mm)| 5.18 lbs (2.35 kg)| 1 oz/ 3 ft
HVS-36| 3/8” (9.5 mm)| 5/8” (15.9 mm)| 6.75 lbs (3.06 kg)| 1 oz/ 3 ft
HVS-60| 3/8” (9.5 mm)| 3/4” (19 mm)| 10.15 lbs (4.6 kg)| 1 oz/ 3 ft
Outdoor Unit Installation
Locate the outdoor unit in a suitable location, as close as possible to the air handler. Maintain the clearances recommended by the HVS Variable Speed Heat Pump manual to ensure proper airflow. The outdoor unit must be installed level, in a properly supported location. If proper refrigerant piping techniques are used, a liquid line bi-directional filter/drier is not needed. More information can be found in module HVS – Variable Speed Heat Pump Manual.
Wiring – Outdoor Unit
Make all connections to the outdoor unit with rain-tight conduit and
fittings. Most building codes require a rain-tight disconnect switch at the
outdoor unit as well (always check local codes). Run the proper size copper
wires to the unit, and connect as per the manufacturer’s recommendations.
Evacuating
The system must be brazed under a nitrogen purge to prevent oxidation of
the pipe during the brazing process. After the piping is installed and all
components have been brazed together, a vacuum pump must be used to properly
evacuate the system from both of the access ports to 1500 microns, to ensure
the system is free of contaminants. Add refrigerant to the system to bring the
pressure above zero psig. After allowing the refrigerant to absorb moisture,
repeat the above procedure. Evacuate the system to 500 microns on the second
evacuation, and ensure that the system holds at the vacuum pressure. If not
check for leaks and evacuate again. If the vacuum holds, add refrigerant to
raise the pressure to 2 psig. At this point open service valves on pre-charged
condensing units. The use of an electronic leak detector is recommended, as it
is more sensitive to small leaks under low pressures.
Charging
Once the system has been determined clean and ready for charging,
refrigerant can be added. The service valves on the condenser must be open at
this time. By referring to page 5 in the HVS Heat Pump Manual, if additional
refrigerant is needed, weigh in the recommended amount. Truly, the only way to
tell if the system is properly charged is by pulling out all refrigerant, then
weighing it back in based on the factory charge listed on the rating plate,
plus any additional refrigerant needed based on page 5 of Module HVS –
Variable Speed Heat Pump Manual.
The RBM-I coil can operate at a level that is different from most other conventional system coils. This coil is supplied refrigerant by a variable speed condenser/compressor, so refrigerant pressures and temperature can vary as well. Temperature and pressure rreadingsaren’t as important for a refrigeration technician to know in a variable-speed heat pump condensing unit.
Important : Failure to follow the proper evacuating and charging procedures may void the warranty.
Important : Return Air must be filtered before entering the cooling module.
Return Air
When designing the return air for a Hi-Velocity System, there are a few things
to consider. It is common to use centralized return air with systems that have
rooms that are within a common area. Separate floors or rooms that have high
loads and require a large amount of supply airflow should have their return
air, or be tied into the centralized return air to allow the air to return to
the air handler. Rooms or areas that cannot be tied into the return air should
have an air transfer grill to allow the air to escape the room and flow back
to centralized return air.
Duct Sizing
The Return Air is to be sized on a 0.15 static pressure (37 pa) as compared
to 0.10 static pressure (25 pa) for conventional forced air systems. The
maximum length for an individual return air duct is fifty feet (15.24m).
Please note : It is VERY important NOT to undersize the return air, as this will create noise, increase motor power consumption, reduce airflow, and increase the possibility of condensate carry-over.
Important : When connecting a round Return Air duct to the RBM-I coil, a round-to-rectangular transition is required.
Table 03 – Return Air Duct Sizes
Unit
|
Rigid Ø
|
Flex Ø
| Min Sq. Inches (Sq. cm)
---|---|---|---
50/51/52| 12”
(305mm)
| 14”
(356mm)
| 120
(774cm)
70/71| 12”
(305mm)
| 14” (356mm)| 120 (774cm)
100/101| 14” (356mm)| 16” (406mm)| 168 (1084cm)
Remember : When using flexible ducts for return air, use one duct size larger due to the higher friction loss. Where allowed by local codes, a single return air grill may be used.
Note : Return air grill must have an equal minimum of free air area to return air.
Important : When using flexible ducts for return air, use one duct size larger due to the higher friction loss.
Table 03 has recommended return air sizes for round and rectangular ducts. A variance of +20% is allowable for sizing return ducts that connect to the RBM-I or Hi-Velocity Systems unit.
| Specifications | RBM-I-50 | RBM-I-70 | RBM-I-100 |
|---|---|---|---|
| Part Number | 41090303050 | 41090303070 | 41090303100 |
Matching Air Handler
| HE-Z/HE-B/HE/HV-50/51 CU-51
LV-Z/LV-B-750/751 LV-50
| HE-Z/HE-B/HE/HV-70/71 LV-Z/LV-B-1050/1051
LV-70
| HE-Z/HE-P/HE-B/HE/ HV-100/101
HE-P-240/241 (x2 Coils)
Matching Inverter Heat Pump| HVS-24| HVS-24, HVS-36| HVS-24, HVS-36, HVS-60
Tons(1)| 1.5 – 2.0 (5.3 – 7.0 kW)| 2.5 – 3.0 (8.8 – 10.6 kW)| 3.5 – 5.0 (12.3
– 17.6 kW)
Refrigerant Type| R-410A| R-410A| R-410A
TX Cooling MBH(2)| 18-24 (5.3-7.0 kW)| 30-36 (8.8-10.6 kW)| 42-60 (12.3-17.6
kW)
Latent Cooling MBH| 6.8-8.9 (2.0-2.6 kW)| 11.7-13.7 (3.4-4.0 kW)| 16.0-22.2
(4.7-6.5 kW)
Fin Material| Aluminum| Aluminum| Aluminum
Tubing Material| Copper| Copper| Copper
Type of Fins| .006 Al (0.1524mm)| .006 Al (0.1524mm)| .006 Al (0.1524mm)
Connection Sizes
| Liquid Line (Lq)| 1/2” (13mm)| 1/2” (13mm)| 1/2” (13mm)
Suction Line (S)| 7/8” (22.3mm)| 7/8” (22.3mm)| 7/8” (22.3mm)
Drain Connection| 3/4” M CPVC (19mm)| 3/4” M CPVC (19mm)| 3/4” M CPVC (19mm)
Freeze Stat| Yes| Yes| Yes
Access Port(s)| Yes| Yes| Yes
Shipping Weight| 35 lbs (15.9 kg)| 45 lbs (20.4 kg)| 55 lbs (24.9 kg)
Module Size (L x W x H)| 14 1⁄2” x 18 1⁄4” x 18 1⁄4”
(368mm x 464mm x 464mm)
| 19 1⁄2” x 18 1⁄4” x 18 1⁄4”
(495mm x 464mm x 464mm)
| 25 1⁄2” x 18 1⁄4” x 18 1⁄4”
(648mm x 464mm x 464mm)
- Minimum of four HE outlets per ton of cooling is needed. (2” Duct = Minimum eight outlets per ton)
- Smaller condensers may be matched to the air handler when needed (match TXV to condenser size)
- MBH: Thousand British Thermal Units per Hour
- TX: Thermal Expansion
- TXV : Thermal Expansion Valve
RBM Series Sizing
Item| Length| Width| Height| Liquid Line|
Suction Line| Drain Conn.
---|---|---|---|---|---|---
Refrigerant Modules| B| C| A| D| E| F
RBM-I-50| 14 1⁄2” (368mm)| 18 1⁄4” (464mm)| 18 1⁄4” (464mm)| 1/2” o.d.|
7/8” o.d.| 3/4” M CPVC
RBM-I-70| 19 1⁄2” (495mm)| 18 1⁄4” (464mm)| 18 1⁄4” (464mm)| 1/2” o.d.|
7/8” o.d.| 3/4” M CPVC
RBM-I-100| 25 1⁄2” (648mm)| 18 1⁄4” (464mm)| 18 1⁄4” (464mm)| 1/2” o.d.|
7/8” o.d.| 3/4” M CPVC
WARRANTY
Energy Saving Products Ltd. is proud to offer a limited warranty. This warranty applies strictly to the first purchaser at the wholesale level and only to the Air Handler unit and module. It does not include connections, attachments, and other products or materials furnished by the installer.
This warranty excludes any damages caused by changes, relocation to, or installation in a new site. This warranty does not cover any defects caused by failure to follow the installation and operating instructions furnished with the Air Handler. This warranty does not cover defects caused by failing to adhere to local building codes and following good industry standards. Failure to correctly install the Air Handler, or material related to the unit, may result in improper system performance and/or damages and will void this warranty. This warranty does not cover material installed in or exposed to a corrosive environment. This warranty does not cover products subjected to abnormal use, misuse, improper maintenance, or alteration of the product. Using the Air Handler and/or module as a source of temporary heating/cooling during construction will void this warranty.
A Five (5) Year Limited Warranty is extended on all components in products manufactured exclusively by Energy Saving Products. These components include Motors, WEG Controllers, Circuit Boards, Dampers, Zoning Controls, Blowers, Motor & Blower Assemblies, Heating Coils, Chilled Water Coils, and Air Conditioning Coils. Note: If any product is installed in or exposed to a corrosive environment, the warranty will be void. A Three (3) Year Limited Warranty is extended on Electric Strip Heaters. A (1) Year Limited Warranty is extended on replacement parts. Products sold by Energy Saving Products but manufactured by others will carry the original manufacturer’s warranty.
TERMS & CONDITIONS
- Warranty will not be considered unless a contractor has contacted Energy Saving Products Ltd. Technical Support department for assistance, and received a tech code.
- Any repair performed under warranty must be approved by Energy Saving Products Ltd. for this warranty to be valid.
- The liability of Energy Saving Products Ltd. is limited to and shall not exceed the cost of pre-approved replacement parts.
- This warranty does not cover shipping costs to and from the factory, labor costs, or any other cost associated with the installation of the replacement part.
- Inoperative parts must be returned to Energy Saving Products Ltd. with an ESP RMA Form that includes model, serial number, and a detailed description of the entire problem. Inoperative parts must be returned in testable condition.
- Energy Saving Products is not liable for any other damages, personal injury, or any other losses of any nature.
Follow these steps for Service or Repair:
- Contact the installer of the product or a licensed service company
- Contact the distributor
- Contact Energy Saving Products Mon-Fri 8 am – 4:30 pm MT 1-888-652-2219
This warranty replaces all other warranties expressed or implied. www.hi- velocity.com
Energy Saving Products Ltd, established in 1983, manufactures the Hi-Velocity SystemsTM product line for residential, commercial, and multi-family markets. Our facilities house Administration, Sales, Design, Manufacturing, as well as Research & Development complete with an in-house test lab. Energy Saving Products prides itself on Customer Service and provides design services and contractor support.
For all of your Heating, Cooling, and Indoor Air Quality needs, the Hi- Velocity System is the right choice for you!
Small Duct Heating, Cooling, and IAQ Systems
Build Smart, Breathe Easy
Hi-Velocity HE-Z Air Handlers, Green Technology
- Phone : 780-453-2093
- Fax : 780-453-1932
- Toll – Free : 1-888-652-2219
References
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