Hi-Velocity RCM-I Refrigerant Module Instruction Manual

Hi-Velocity RCM-I Refrigerant Module

Product Information

Specifications:

• Product Name : RCM-I Refrigerant Module
• Compatibility: HVS Series Variable Speed Heat Pumps
• Models Available : RCM-I-50 (1.5-2 Tons), RCM-I-70 (2.5-3 Tons), RCM-I-100 (3.5-5 Tons)
• Included Components : Service/Access Ports, Freeze Stat, L-Mounting Brackets, Mounting Tape, Carry-Over Screen

Product Usage Instructions

Mounting Brackets Installation:

The RCM-I cooling coil must be installed horizontally on the return air side of the air handler using the provided L mounting brackets. Ensure no screws puncture the drain pan or coil during installation.

Refrigerant Compatibility:

RCM-I modules can be used with any R-410A condenser if R-410A refrigerant components are used. They are specifically designed for use with HVS Series Inverter Heat Pump Condensing Units.

Access Ports Installation:

When connecting refrigerant lines to the RCM-I coil, install access ports for reading refrigerant pressures/temperatures at the evaporator. Access ports are necessary for system startup, troubleshooting, and servicing.

Freeze Stat Installation:

Install the Freeze Stat above the center line of the suction line and connect the wires to the designated terminals on the air handler circuit board. Ensure proper insulation and do not over-tighten.

FAQ

• Q: What is the purpose of the Freeze Stat?
  • A : The Freeze Stat serves to prevent severe icing of the coil in case of an undercharge or low load on the coil. It must be installed correctly to avoid warranty issues.

Refrigerant Modules (RCM-I)

The RCM-I cooling coil comes as a module and must be installed in the horizontal position on the return air side of the air handler. RCM-I modules come with two L mounting brackets, access port(s), carry-over screen, external freeze stat*, and additional components for air sealing.

RCM-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 specifically designed for use with HVS Series Inverter Heat Pump Condensing Units. It does not come with a thermal expansion valve, as there are internal EXVs inside the Heat Pump. When installing the RCM-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 (RCM-I). Fig. 01 shows approximate installation locations for these components.

RCM-I Modules were designed to be used with the HVS Series 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.

1. Liquid line
2. High-side access port (if applicable)
3. Refrigerant distributor
4. Distributor tubes
5. Suction line
6. Low-side access port
7. Suction line temperature port
8. Middle coil temperature port

Note : 7 & 8 coil temperature ports are explained in Module HVS – Heat Pump Manual

Mounting Brackets

Mounting the cooling coil to the air handler can be done with the L brackets supplied (Fig. 02), ensuring that no screws puncture the drain pan or coil. Page 8 has the dimensions of the cooling modules.

When refrigerant lines are connected to the RCM-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 port(s) are required for system startup and for future troubleshooting or service. When reading refrigerant pressures/ temperatures, always read them at the evaporator access ports.

Freeze Stat

Install the anti-ice control (Freeze-Stat) above the center line of the suction line and connect the wires to the Freeze-Stat terminals on the air handler circuit board.
Ensure that the anti-ice control is fastened securely and are well insulated. Do not use a self-tightening clamp on the anti-ice control, as the control may be damaged by excessive tightening.

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 RCM-I-related warranty issues being voided.

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. 05). The drain line must run at a slope of ¼” per foot in the direction of the drain. RCM-I modules come with a ¾” male CPVC primary and secondary outlet. It is good practice to install a clean-out right above the P-Trap. Using a “tee fitting” and cap in the P-Trap’s construction can be used as the 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 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.

Pipe Sizing

Refer to the charts below and Module HVS – Variable Speed Heat Pump Manual for pipe sizing

Piping the RCM-I

Only refrigerant-grade pipe and fittings are to be used with the RCM-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. When using the HVS Variable Speed Heat Pump, 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 Variable Speed Heat Pump, 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.

Important : Return air must be filtered before entering the cooling module.

Minimum Pipe Sizes, Maximum Length and Maximum Lift

The HVS Variable Speed Heat Pump comes with a factory charge. Additional charge will only be needed on line sets longer
than 25 ft. (See table below)

Outdoor Unit Installation

Locate the outdoor unit in a suitable location, as close as possible to the air handler. Maintain the clearances recommended  in 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 precharged condensing units.

The use of an electronic leak detector is recommended, as it is more sensitive to small leaks under the 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 RCM-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 readings aren’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.

Carry-Over Screen

All RCM-I refrigerant cooling modules come supplied with a nylon mesh carry- over screen and six stand-off plugs. The Hi-Velocity units have a very high humidity removal rate, the airflow across the coil can grab moisture off the fins and carry it into the unit. With the carry-over screen in place, it reduces the chance of moisture being carried into the unit. Ensure that the nylon mesh is placed on the exiting air side of the cooling module (Fig. 4)

Installation Instructions

The carry-over screen is placed on the air handler side of the cooling module (Fig. 04).

On the air handler side of the cooling module, attach three plastic stand-offs down each side of the cooling coil (Fig. 05).

Place the nylon wire mesh over the stand-offs, ensuring the screen touches the drain pan. Then snap the screen over the plastic stand-offs (Fig. 06).

Return Air

When sizing the return air ducts, keep in mind that if they are too small they can create noise, but if they are too large,the air handler cannot build up proper pressure. Table 03 has recommended return air sizes for round and rectangular ducts. A variance of plus 20% is allowable for sizing return ducts that connect to the Hi-Velocity Systems unit.

Note : It is recommended to us a grill that is 10-20% larger than R/A duct size.

It is recommended to install a grill that is 10 – 20% larger than specifications require, this will ensure that there is no air velocity noise at the grill. Where allowed by local codes, a single centralized return air grill may be used. When using a flexible duct for return air, use one duct size larger due to the higher friction loss.

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 RCM-I coil, a round-to-rectangular transition is required.
• 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 RCM-I or Hi-Velocity Systems unit.

Remember : When using a flexible duct 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 a flexible duct for return air, use one duct size larger due to the higher friction loss.

Return Cutout

Fig. 07 shows the different locations the return air can be installed on Hi- Velocity air handlers. Table 04 contains the dimensions needed for the return. All air handlers are equipped with return air knockout cuts and can be used as a proper return air size.

Notes:

• DO NOT cut past the center plate or electrical box (Dim A & B).
• 100 and 140 Units CANNOT use return air “C” (RA-C).
• This drawing is NOT to scale.

Specifications

• (1) A minimum of four HE outlets per ton of cooling is needed. (2″ Duct = Minimum eight outlets per ton)
• (2) 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

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 One (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 Ltd. is not liable for any other damages, personal injury, or any other losses of any nature.

Follow these steps for Service or Repair:

1. Contact the installer of the product or a licensed service company
2. Contact the distributor
3. Contact Energy Saving Products Ltd. 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 Systems™ 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!

Build Smart, Breathe Easy

Hi-Velocity HE-Z Air Handlers, Green Technology

PRODUCTS LTD

• Phone : 780-453-2093
• Fax : 780-453-1932
• Toll Free : 1-888-652-2219
•   www.hi-velocity.com

References

• velocity.com
• Energy Saving Products LTD.

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