RCM-I Refrigerant Module Installation Manual
For use with HVS Series Variable Speed Heat Pumps
Models: RCM-I-50 (1.5-2 Tons), RCM-I-70 (2.5-3 Tons), RCM-I-100 (3.5-5 Tons)
Includes: Service/Access Ports, Freeze Stat, L-Mounting Brackets, Mounting Tape, Carry-Over Screen
Manufactured By: Energy Saving Products Ltd.
Refrigerant Modules (RCM-I) and Mounting
The RCM-I cooling coil is a module designed for horizontal installation on the return air side of the air handler. RCM-I modules include two L mounting brackets, access port(s), a carry-over screen, an external freeze stat [footnote], and components for air sealing.
These modules can be used with any R-410A condenser, provided R-410A refrigerant components are used. All Energy Saving Products R-Series modules are equipped with R-410A refrigerant components.
This module is specifically designed for HVS Series Inverter Heat Pump Condensing Units. It does not include a thermal expansion valve (TXV) as the heat pump already has internal EXVs. DO NOT INSTALL WITH TXVs when using RCM-I Modules with HVS Series Heat Pumps.
The module comes with access port(s) that must be installed to read refrigerant pressures/temperatures at the Evaporator (RCM-I). Figure 01 shows approximate installation locations for these components.
RCM-I Modules are designed for HVS Series Heat Pumps but can be used with any R-410A condensing unit, provided a TXV is also installed. All Energy Saving Products cooling modules feature R-410A refrigerant components.
Figure 01 - Coil Assembly: This diagram illustrates the coil assembly and identifies key 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: Ports 7 & 8 are detailed in the HVS - Heat Pump Manual.
Mounting Brackets: Mount the cooling coil to the air handler using the supplied L brackets (Figure 02). Ensure no screws penetrate the drain pan or coil. Refer to page 8 for module dimensions.
Figure 02 - Mounting brackets: This illustration shows the L-shaped mounting brackets being attached to the refrigerant module for installation onto an air handler.
Access Ports and Freeze Stat Installation
When connecting refrigerant lines to the RCM-I coil, access port(s) must also be connected (refer to Figure 01, points 2 & 6). Using a tee and reducer simplifies this process. Access ports are essential for system startup and future troubleshooting or service. Always read refrigerant pressures/temperatures at the evaporator access ports.
Freeze Stat: Install the anti-ice control (Freeze-Stat) above the center line of the suction line. Connect its wires to the Freeze Stat terminals on the air handler circuit board.
Ensure the anti-ice control is securely fastened and well insulated. Avoid using a self-tightening clamp, as it may damage the control through excessive tightening.
IMPORTANT: The Freeze Stat (anti-ice control) is critical for preventing severe coil icing due to undercharge or low load conditions. This component must be used at all times. Improper installation of the freeze stat will void RCM-I related warranty issues.
NOTE: Do not remove the protective bubble wrap from the Freeze Stat.
Drain Connections, P-Trap & Secondary Drain Pan
Piping condensate lines for a return side cooling coil can differ significantly; review the following information carefully.
The primary condensate drain must include a minimum 3-inch P-trap (Figure 05). The drain line should slope at 1/4 inch per foot towards the drain. RCM-I modules are equipped with 3/4-inch male CPVC primary and secondary outlets. It is good practice to install a cleanout directly above the P-trap. A tee fitting with a cap can serve as a cleanout and help prime the P-trap if it dries out. A wet P-trap is important; a dry one can impede proper drainage.
If local codes require a secondary drain line, install it using the same method as the primary. Alternatively, the secondary drain line can be capped off. Do not connect the secondary drain line to the secondary drain pan or use it as a vent to atmosphere.
An equipment stand/riser or a rubber equipment mat may be necessary to elevate the module, allowing space for the P-trap.
Any installation where condensate could cause property damage requires a secondary drain pan. In locations with high heat and/or humidity, additional insulation around the unit casing might be needed to prevent excessive condensate formation on the outer surface.
Figure 05 - Secondary drain pan: This diagram illustrates the setup for secondary drain pan connections, including the primary and secondary drain lines and a capped cleanout.
Pipe Sizing and Piping the RCM-I
Refer to the charts below and the Module HVS - Variable Speed Heat Pump Manual for specific pipe sizing recommendations.
Only refrigerant-grade pipe and fittings are to be used with the RCM-I Module. Plumbing fittings may contain wax or other contaminants that can harm system operation.
Insulate the suction line with a minimum of 3/8-inch insulation. For inverter heat pump applications, insulating both suction and liquid lines is mandatory. In high-heat areas, 1/2-inch insulation may be required.
Support the pipe every 5 feet, or as dictated by local codes. Run pipes via the most direct route, considering structural integrity, building details, and local codes.
When using the HVS Variable Speed Heat Pump, the minimum refrigerant pipe length is 16 feet (6m). If the length is less than 16 feet, coil the additional copper pipe into horizontal loops to ensure proper oil return. If the evaporator is located above the Variable Speed Heat Pump, slope any horizontal runs towards the condenser. If the condenser is above the evaporator, install a P-trap at the bottom of the vertical riser. For long vertical risers, install additional P-traps every twenty feet. Lines exceeding 213 feet (65m) are not recommended.
Important: Return air must be filtered before entering the cooling module.
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 includes a factory charge. Additional charge is only needed for 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, Wiring, Evacuating, Charging, and Carry-Over Screen
Outdoor Unit Installation: Locate the outdoor unit close to the air handler, maintaining recommended clearances from the HVS Variable Speed Heat Pump manual for proper airflow. The unit must be installed level and securely supported. If proper refrigerant piping techniques are followed, a liquid line bi-directional filter/drier is not required. Consult the HVS - Variable Speed Heat Pump Manual for more details.
Wiring - Outdoor Unit: Use rain-tight conduit and fittings for all connections to the outdoor unit. Building codes typically require a rain-tight disconnect switch at the outdoor unit; always verify local codes. Use appropriately sized copper wires and connect them according to the manufacturer's recommendations.
Evacuating: Braze the system under a nitrogen purge to prevent pipe oxidation. After piping installation and brazing, use a vacuum pump to evacuate the system from both access ports to 1500 microns to remove contaminants. Add refrigerant to bring the pressure above zero psig. After allowing the refrigerant to absorb moisture, repeat the evacuation to 500 microns, ensuring the system holds vacuum. If leaks are detected, re-evacuate. If the vacuum holds, add refrigerant to reach 2 psig. Then, open the service valves on pre-charged condensing units.
An electronic leak detector is recommended for its sensitivity to small leaks at low pressures.
Charging: Once the system is clean and ready, add refrigerant. Ensure the condenser service valves are open. Refer to page 5 of the HVS Heat Pump Manual for the correct amount of additional refrigerant needed. The most accurate method is to recover all refrigerant, then weigh it back in based on the rating plate's factory charge, plus any additional required.
The RCM-I coil can operate at different levels than conventional coils. Since it is supplied by a variable speed condenser/compressor, refrigerant pressures and temperatures may vary. These readings are less critical for technicians working with variable speed heat pumps.
Carry-Over Screen: All RCM-I refrigerant cooling modules include a nylon mesh carry-over screen and six stand-off plugs. Hi-Velocity units have high humidity removal rates, which can cause airflow to carry moisture off the fins into the unit. The carry-over screen reduces this possibility.
Ensure the nylon mesh is placed on the exiting air side of the cooling module (Figure 04).
Installation Instructions (Carry-Over Screen):
The carry-over screen is positioned on the air handler side of the cooling module (Figure 04).
Figure 04 - Screen on the air handler side: This diagram shows the carry-over screen being placed on the air handler side of the cooling module.
Attach three plastic stand-offs down each side of the cooling coil on the air handler side (Figure 05).
Figure 05 - Attach stand-off plugs: This illustration depicts the attachment of plastic stand-off plugs to the cooling coil.
Place the nylon wire mesh over the stand-offs, ensuring it touches the drain pan. Snap the screen over the plastic stand-offs (Figure 06).
Figure 06 - Attach screen to coil: This diagram shows the nylon mesh screen being secured over the stand-offs.
Important: Failure to follow proper evacuating and charging procedures may void the warranty.
Return Air and Duct Sizing
When sizing return air ducts, consider that undersized ducts can cause noise, while oversized ducts may prevent the air handler from building adequate pressure. Table 03 provides recommended return air sizes for round and rectangular ducts. A variance of plus 20% is permissible for sizing return ducts connecting to Hi-Velocity Systems units.
Note: It is recommended to use a grill that is 10-20% larger than the R/A duct size to prevent air velocity noise at the grill.
Where local codes permit, a single, centralized return air grill may be used. Ensure the grill has an equal minimum free air area to the return air duct.
When using flexible duct for return air, select one duct size larger to account for higher friction loss.
Duct Sizing: Return air should be sized based on 0.15 static pressure (37 Pa), 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. Doing so will create noise, increase motor power consumption, reduce airflow, and increase the likelihood of condensate carry-over.
Important: When connecting a round Return Air duct to the RCM-I coil, a round to rectangular transition is required.
Return Cutout: Figure 07 illustrates the various locations for return air installation on Hi-Velocity air handlers. Table 04 lists the required dimensions for the return. All air handlers are equipped with return air knockout cuts that can serve as a proper return air size.
Figure 07 - Return air cutout sizing: This diagram shows different return air cutout locations (RA-A, RA-B, RA-C) on an air handler, with dimensions A, B, C, and D indicated.
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 duct for return air, use one duct size larger due to the higher friction loss.
Table 04 - Return Air Cutouts
| Unit | A | B | C | D |
|---|---|---|---|---|
| 50/51 | 3" | 17" | 10" | 14" |
| 70/71 | 3" | 17" | 15" | 15" |
| 100/101 | 3" | 17" | 22" | 15" |
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.
RCM-I Specifications
The following table details the specifications for the RCM-I Refrigerant Cooling Module series.
RCM-I Specifications
| Specifications | RCM-I-50 | RCM-I-70 | RCM-I-100 |
|---|---|---|---|
| Matching Air Handler | HE-Z/HE-B/HE/HV-50/51 LV-50 | HE-Z/HE-B/HE/HV-70/71 LV-70 | HE-Z/HE-B/HE-P/HE/HV-100/101 |
| Matching Inverter Heat Pump | HVS-24 | HVS-24, HVS-36 | HVS-24, HVS-36, HVS-60 |
| Part Number | 10090203050 | 10090203070 | 10090203100 |
| Tons(1) | 1.5 - 2.0 (5.3 - 7 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) |
| Hydronic Connection Sizes | Liquid Line (Lq): 1/2" (13mm) Suction Line (S): 7/8" (22.3mm) Drain Connection: 3/4" M CPVC (19mm) | 1/2" (13mm) 7/8" (22.3mm) 3/4" M CPVC (19mm) | 1/2" (13mm) 7/8" (22.3mm) 3/4" M CPVC (19mm) |
| Access Ports | Yes | Yes | Yes |
| Shipping Weight | 21 lbs (9.5kg) | 34 lbs (15.4 kg) | 47 lbs (21.31 kg) |
| Module Size (L x W x H) | 14 3/8" x 10 1/8" x 18 1/2" (365mm x 257mm x 470mm) | 19 3/8" x 10 1/8" x 18 1/2" (492mm x 257mm x 470mm) | 25 3/8" x 10 1/8" x 18 1/2" (645mm x 257mm x 470mm) |
(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)
MBH - Thousand British Thermal Units per Hour
TX - Thermal Expansion
TXV - Thermal Expansion Valve
Warranty
Energy Saving Products Ltd. offers a limited warranty that applies strictly to the original purchaser at wholesale level and only to the Air Handler unit and module. It does not cover connections, attachments, or other products/materials supplied by the installer.
This warranty excludes damages resulting from changes, relocation, or installation at a new site. It does not cover defects arising from failure to follow the installation and operating instructions provided with the Air Handler, or from non-compliance with local building codes and industry standards. Incorrect installation of the Air Handler or related materials may lead to improper system performance, damages, and voiding of the warranty. The warranty also does not cover materials installed in or exposed to corrosive environments, nor products subjected to abnormal use, misuse, improper maintenance, or alteration. Using the Air Handler and/or module for temporary heating/cooling during construction will void this warranty.
A Five (5) Year Limited Warranty covers all components manufactured exclusively by Energy Saving Products, including Motors, WEG Controller, Circuit Boards, Dampers, Zoning Controls, Blowers, Motor & Blower Assemblies, Heating Coils, Chilled Water Coils, and Air Conditioning Coils. If any product is installed in or exposed to a corrosive environment, the warranty will be void.
A Three (3) Year Limited Warranty is provided for Electric Strip Heaters.
A One (1) Year Limited Warranty covers replacement parts.
Products sold by Energy Saving Products but manufactured by third parties will carry the original manufacturer's warranty.
Terms & Conditions
- Warranty claims require a contractor to contact Energy Saving Products Ltd. Technical Support for assistance and obtain a tech code.
- Any repair performed under warranty must be approved by Energy Saving Products Ltd. to be valid.
- The liability of Energy Saving Products Ltd. is limited to the cost of pre-approved replacement parts.
- This warranty does not cover shipping costs (to/from the factory), labor costs, or any other costs associated with replacement part installation.
- Inoperative parts must be returned to Energy Saving Products Ltd. with an ESP RMA Form, including model, serial number, and a detailed problem description. Parts must be returned in testable condition.
- Energy Saving Products Ltd. is not liable for any other damages, personal injury, or 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 Ltd. (Mon-Fri 8 am - 4:30 pm MT) at 1-888-652-2219.
This warranty supersedes all other expressed or implied warranties.
Visit: www.hi-velocity.com
Company Information
Energy Saving Products Ltd., established in 1983, manufactures the Hi-Velocity Systems™ product line for residential, commercial, and multi-family markets. Their facilities house Administration, Sales, Design, Manufacturing, and Research & Development, complete with an in-house test lab. Energy Saving Products emphasizes Customer Service and provides design services and contractor support.
For all Heating, Cooling, and Indoor Air Quality needs, the Hi-Velocity System is presented as the ideal choice.
Hi-Velocity Systems™
Small Duct Heating, Cooling and IAQ Systems
Build Smart, Breathe Easy
Hi-Velocity HE-Z Air Handlers, Green Technology
Energy Saving Products Ltd.
Phone: 780-453-2093
Fax: 780-453-1932
Toll Free: 1-888-652-2219
Website: www.hi-velocity.com
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Energy Saving Products LTD.