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Instruction Manual for Hi-Velocity models including: RBM I Refrigerant Base Module, RBM I, Refrigerant Base Module, Base Module
14.5" x 18.25" x 18.25", R-410A, 1.5 to 2 Ton, Aluminum Fin, Copper Tubing, Vertical/Horizontal Mount, Multi-Position, Cooling Refrigerant Base Module for Variable Speed Heat Pump | Design Air
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. ... 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 ...
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DocumentDocumentSmall Duct High Velocity Heating, Cooling and Home Comfort Systems RBM-I Refrigerant Base Module Installation Manual 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) Includes: Freeze Stat Drain Pan Service/ Access Port(s) T-Mounting Brackets Mounting Tape Hole Plugs (2) Manufactured By Manual-RBM-I-Refrigerant-Cooling-Coil-Installation-120121 www.hi-velocity.com Module RBM-I RBM-I Refrigerant Base Module Installation 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. 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. A *IMPORTANT: The Freeze Stat (anti-ice control) serves B 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 A or B related warranty issues being voided. NOTE: Do not remove protective bubble wrap from Freeze Stat 4 3 2 1 Fig. 02 - Up/Right Orientation 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. C D 67 5 Fig. 01 - Coil Assembly 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) Freeze Stat (Anti-ice Control) -2- C or D Fig. 03 - Up/Left Orientation © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com RBM-I Change Configuration Module RBM-I RBM-I Refrigerant Base Module Installation To change from up/right (standard) configuration to up/left configuration, follow the steps below. 1) Remove front door from module. (Fig. 04) 5) Replace the drain pan in (new) bottom location. (Fig. 08) Fig. 08 Fig. 04 2) Remove drain pan by sliding it out from the bottom of the coil casing, ensuring that the foam air dam is also removed. (Figs. 05a, 05b) 6) Ensure the foam air dam is re-installed under the corner of the coil to prevent air from bypassing under the coil. (Fig. 09) Fig. 09 Fig. 05a 3) Rotate entire unit 90 deg. clockwise. (Fig. 06) Fig. 05b 7) Remove round knock- outs on the door to fit drain lines. Plug previously used drain holes with provided plugs. (Fig. 10) Fig. 06 4) 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) Insert Plugs Fig. 10 Remove Knock-Outs Air dam gap to fill with horse hair filter Air dam built into drain pan Fig. 07a Fig. 07b 8) Replace front door on module. (Fig. 11) Return Air Knock-Out Fig. 11 -3- © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com Return Air Cutouts Module RBM-I RBM-I Refrigerant Base Module Installation Once the RBM-I coil configuration and placement of the return air ducting has 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. Step 1: First cuts (using pre-measured guide cuts) can be made with a power tool (no longer than a 5" blade) Step 2: Second cuts (to match more closely to filter or R/A ducting size) must be made with a metal shear to avoid damage to the coil Pre-Measured Guide Cuts 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 specifications page for the dimensions of the air handler units and cooling modules. Fig. 12 -45- © 1995-2022 Energy Saving Products Ltd. Access Ports www.hi-velocity.com Module RBM-I RBM-I Refrigerant Base Module Installation Piping the RBM-I 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 trouble shooting 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 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 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 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 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. Primary Drain Secondary Drain Capped Cleanout 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 minumum 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. 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 warranty. During start-up, it is acceptable to jumper 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 freeze stat install location on page 2 (Fig. 01). P-Trap Stand/Riser Fig. 15 - Example of Recommended Condensate Piping -5- © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com Pipe Sizing Module RBM-I RBM-I Refrigerant Base Module Installation 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. 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 HVS-24 HVS-36 HVS-60 Liquid Line 3/8" (9.5 mm) 3/8" (9.5 mm) 3/8" (9.5 mm) Suction Line 5/8" (15.9 mm) 5/8" (15.9 mm) 3/4" (19 mm) Factory Charge (kg) 5.18 lbs (2.35 kg) 6.75 lbs (3.06 kg) 10.15 lbs (4.6 kg) Add extra refrigerant for line sets over 25 ft (7.5 m) 1 oz/ 3 ft 1 oz/ 3 ft 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 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 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 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 reading 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 warranty. Important: Return Air must be filtered before entering the cooling module. -6- © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com Module RBM-I RBM-I Refrigerant Base Module Installation 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 air flow should have their own return air, or be tied into the centralized return air to allow the air to return back 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 a centralized return air. 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 Min Sq. Unit Rigid Ø Flex Ø Inches (Sq. cm) 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). 50/51/52 70/71 100/101 12" (305mm) 12" (305mm) 14" (356mm) 14" (356mm) 14" (356mm) 16" (406mm) 120 (774cm) 120 (774cm) 168 (1084cm) 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. Remember: When using 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 equal minimum of free air area to return air. 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. Important: When using flexible duct for return air, use one duct size larger due to the higher friction loss. Specifications Part Number Matching Air Handler Matching Inverter Heat Pump Tons(1) RBM-I-50 41090303050 HE-Z/HE-B/HE/HV-50/51 CU-51 LV-Z/LV-B-750/751 LV-50 HVS-24 1.5 - 2.0 (5.3 - 7.0 kW) RBM-I-70 41090303070 HE-Z/HE-B/HE/HV-70/71 LV-Z/LV-B-1050/1051 LV-70 HVS-24, HVS-36 2.5 - 3.0 (8.8 - 10.6 kW) RBM-I-100 41090303100 HE-Z/HE-P/HE-B/HE/ HV-100/101 HE-P-240/241 (x2 Coils) HVS-24, HVS-36, HVS-60 3.5 - 5.0 (12.3 - 17.6 kW) Refrigerant Type TX Cooling MBH(2) R-410A 18-24 (5.3-7.0 kW) R-410A 30-36 (8.8-10.6 kW) R-410A 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 Connection Sizes Liquid Line (Lq) Suction Line (S) Drain Connection .006 Al (0.1524mm) 1/2" (13mm) 7/8" (22.3mm) 3/4" M CPVC (19mm) .006 Al (0.1524mm) 1/2" (13mm) 7/8" (22.3mm) 3/4" M CPVC (19mm) .006 Al (0.1524mm) 1/2" (13mm) 7/8" (22.3mm) 3/4" M CPVC (19mm) Freeze Stat Yes Yes Yes Access Port(s) Yes Yes Yes Shipping Weight Module Size (L x W x H) 35 lbs (15.9 kg) 14 1/2" x 18 1/4" x 18 1/4" (368mm x 464mm x 464mm) 45 lbs (20.4 kg) 19 1/2" x 18 1/4" x 18 1/4" (495mm x 464mm x 464mm) 55 lbs (24.9 kg) 25 1/2" x 18 1/4" x 18 1/4" (648mm x 464mm x 464mm) (1) Minimum of four HE outlets per ton of cooling 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) -7- MBH - Thousand British Thermal Units per Hour TX - Thermal Expansion TXV - Thermal Expansion Valve © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com RBM Series Sizing Module RBM-I RBM-I Refrigerant Base Module Installation Item Refrigerant Modules RBM-I-50 RBM-I-70 RBM-I-100 Length B 14 1/2" (368mm) 19 1/2" (495mm) 25 1/2" (648mm) Width C 18 1/4" (464mm) 18 1/4" (464mm) 18 1/4" (464mm) Height A 18 1/4" (464mm) 18 1/4" (464mm) 18 1/4" (464mm) Liquid Line D 1/2" o.d. 1/2" o.d. 1/2" o.d. Suction Line E 7/8" o.d. 7/8" o.d. 7/8" o.d. Drain Conn. F 3/4" M CPVC 3/4" M CPVC 3/4" M CPVC C A B D E F -8- © 1995-2022 Energy Saving Products Ltd. www.hi-velocity.com Module RBM-I RBM-I Refrigerant Base Module Installation WARRANTY Energy Saving Products Ltd. is proud to offer a limited warranty. This warranty applies strictly to the first purchaser at 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 Controller, 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, 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 -9- © 1995-2022 Energy Saving Products Ltd. 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! TM 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 www.hivelocity.com