EarthLinked CC Series Compressor Unit R-410A Quik-Start Instructions

EarthLinked CC Series Compressor Unit R-410A Quik-Start Instructions CONTENTS PAGE Pre-Installation 3 Placement & Mechanical Information 4 System Application Options 11 Desuperheater Kit 15 Anti-Freeze Protection 19 Electrical and Sound Data 20 230-1-60 Internal Wiring 21 230-3-60 Internal Wiring 23 Field Wiring Diagram 25 System Start-Up 27 Evacuation 27 Initial Charge 27 Final Charge 32 Cooling Mode Start-Up 34 CC-410-QS (09/17) Inc. Copyright 2017 Earthlinked Technologies,

Disclaimer Proper installation and servicing of the EarthLinked Heating and Cooling System is essential to its reliable performance. All EarthLinked systems must be installed and serviced by an authorized, trained technician who has successfully completed the training class and passed the final examination. Installation and service must be made in accordance with the instructions set forth in this manual and the current EarthLinked Heating and Cooling Installation, Operation and Maintenance Manual. Failure to provide installation and service by an authorized, trained installer in a manner consistent with the subject manuals will void and nullify the limited warranty coverage for the system. READ THE CURRENT EarthLinked Heating and Cooling Installation, Operation and Maintenance Manual FOR COMPLETE INSTALLATION DETAILS. Earthlinked Technologies shall not be liable for any defect, unsatisfactory performance, damage or loss, whether direct or consequential, relative to the design, manufacture, construction, application or installation of the field specified components. CC-410-QS (09/17) Inc. Copyright 2017 Earthlinked Technologies,

Earthlinked Technologies, Inc. 4151 South Pipkin Road Lakeland, Florida 33811 tel. 863-701-0096 fax 863-701-7796 info@earthlinked.com www.earthlinked.com CSI # 23 80 00 CC-410-QS (09/17)

Pre-Installation Upon receipt of the equipment, carefully check the shipment against the bill of lading. Reference EarthLinked matching system component model numbers in Figure 1. Make sure all units have been received and model numbers are the same as those ordered. Compressor Unit 1 Air Handler Cased Coil CCS COOL ONLY Applications Hydronic Water Module Desuperheater Water Heating Hybrid Cooling Module 3 Earth Loop 2-024 0024-C* 0024-C* -024 HWM-1836-036 0036-C* 0036-C* -036-048 0048-C* 0048-C* HWM-4248 HRM-1872 HCM-1860C -048-060 0060-C* 0060-C* -060 HWM-5472-068 0068-CV NA -072 1. For CC compressor units: Contained in each compressor package: compressor unit four L-shaped hold down brackets service valves-liquid and vapor adapters for service valves and earth loop line set product literature 2. All series Earth Loops: V1, D1, V1.5, D1.5, V2, D2, H1B 3. HCMs are for CC compressor units. Note: Desuperheater EarthLinked thermostats can be utilized throughout capacity range. Figure 1. Model Numbers Cathodic Protection System EPS-KIT Guidelines for the general layout of the system components are shown in Figure 2. Before placing the compressor unit (outside or indoors), review the guidelines in Figure 2. CC-410-QS (09/17) Page 4

Figure 2. General System Layout Placement and Mechanical Information EarthLinked compressor units may be located outside or inside the building, following these guidelines. OUTSIDE Locate compressor unit: On a standard HVAC condensing unit pad, resting on firm, level, settled ground. Same as for INSIDE placement. See below. INSIDE Locate compressor unit: On a solid, level hard surface. If compressor unit is to be fastened, see Figure 3 for bracket installation. Where compressor unit sound and vibration will not disturb human activities. Compressor unit may be located in garage, basement, crawl space or utility room. Avoid placing compressor unit in kitchen, bedroom, family/living/dining room areas. In a condensate pan. On vibration pads. CC-410-QS (09/17) Page 5

Attic installations, where necessary, must include a drip pan, anti-vibration pads and are to be suspended from the rafters with suspension isolators. Where suggested clearance is 3 feet on both sides, top and front, for access. However, local codes and applicable regulations take precedence. Clearance from back panel to wall and minimum side clearance should be at least one foot. See Figure 4 for details. Where the total length of refrigerant line sets (from manifolds to compressor and from compressor to air handler) do not exceed 125 feet, as shown in Figure 2. Where the compressor unit is no more than 20 feet higher than the earth loop manifolds. Compressor unit may be located lower than the earth loop manifolds. See Figure 2. If the compressor unit or other refrigerant-containing system components are located indoors, they shall be in a location which (1) is an unoccupied space, or (2) is served by the circulating air system, or (3) provides 280 cu. ft. of open space per nominal ton of rated system capacity. The 2012 International Mechanical Code defines residential occupancy as including permanent provisions for living, sleeping, eating, cooking, and sanitation. Consult local code authorities to define unoccupied space for the specific installation. Figure 3. Compressor Unit Bracket Installation Figure 4. Compressor Unit Clearance CC-410-QS (09/17) Page 6

Compressor units are shipped from the factory with a low pressure nitrogen holding charge. Carefully relieve the holding charge when the compressor unit is being prepared to connect refrigerant system piping. The compressor unit package contains a service valve kit and an adapter kit. The two service valves are to be installed on the earth loop vapor and liquid connections of the compressor unit, using the adapters to right-size to the proper earth loop line set. Installation of the service valves will provide isolation of the earth loop system from the compressor unit and provide easy access to the refrigerant system. The service valve configuration provided is illustrated in Figure 4a. The valve stem is accessed by removing the cap. The service port is equipped with a Schrader valve insert. Figure 4a. Service Valve Orientation Complete service valve installation instructions are contained in the Service Valve Kit Installation Manual, included with the service valves. CC-410-QS (09/17) Page 7

CC-410-QS (09/17) Page 8

Figure 5. CC Connections for R-410A CC-410-QS (09/17) Page 9

System Application Options Figure 8. CC Air Heating CC-410-QS (09/17) Page 10

Figure 8a. CC Air Cooling (Chilled Water Air Handler) CC-410-QS (09/17) Page 11

Figure 8b. CC Air Cooling; Domestic Hot Water by Field-Installed Desuperheater Kit CC-410-QS (09/17) Page 12

Figure 8c. CC Air Cooling (Chilled Water Air Handler) and Domestic Hot Water by Field Installed Desuperheater Kit CC-410-QS (09/17) Page 13

Desuperheater Kit The field installed ETI Desuperheater Kit Model DSH-1872 equips the CC Series Compressor Unit with supplemental water heating capability during cooling mode operation. Typical water piping installed with an existing or new standard storage water heater is illustrated in Figure 8d. Water piping for the desuperheater installed with an ETI Model GSTE Storage Water Heater is illustrated in Figure 8e. The GSTE Series Storage Water Heater is available in 60, 80 and 119 gallon capacities with water piping connections built into the top of the storage water heater specifically for use with the desuperheater. All GSTE Series models are equipped with a 4.5 kw electric heater and provide the following hot water recovery rates in gallons per hour, for a range of water temperature increases, in degrees Fahrenheit. ΔT 30 40 50 60 70 80 90 GPH 62 46 37 31 26 23 21 *ΔT in ºF; GPH in U.S. Gallons per hour. Field wiring for the DSH-1872 Kit is illustrated in Figure 8f for water heating during cooling system operation. See the EarthLinked Model DSH-1872 Desuperheater Installation Manual for the SC and CC Compressor Units, for complete installation details. CC-410-QS (09/17) Page 14

Figure 8d. Desuperheater Installed with Existing or New Standard Storage Water Heater CC-410-QS (09/17) Page 15

Figure 8e. Desuperheater installed with GSTE Storage Water Heater. CC-410-QS (09/17) Page 16

Figure 8f. Field Wiring for Desuperheater Kit CC-410-QS (09/17) Page 17

Antifreeze Protection When HWM hydronic water modules are applied to chilled water cooling systems, the water circulating system must be protected from potential damage due to freeze-up by utilizing an adequate antifreeze solution. The antifreeze protection is provided by the installer prior to the EarthLinked system start-up. Propylene-glycol antifreeze solution with an inhibitor is the type of antifreeze solution required for Earthlinked products utilized in radiant panel hydronic heating and/or chilled water cooling systems. These systems shall be freeze protected consistent with the application -specific minimum temperature, as shown in the table below. Propylene-glycol antifreeze solutions should always be in the range of 20% to 50% by volume, as indicated in the table. WATER SOLUTION MULTIPLIER FACTOR (WSMF) 18 20 x 1.03 8 30 x 1.07-7 40 x 1.11-29 50 x 1.16 Propylene Glycol Freeze Protection Table TEMPERATURE, F PROPYLENE GLYCOL, % Propylene-glycol can be purchased in the straight form and mixed with an inhibitor prior to filling the system, or it can be purchased as inhibited propylene-glycol. The following are examples of manufacturers for the above: Straight propylene-glycol: Chemical Specialties, Inc. (www.chemicalspec.com/spg.html) Inhibitor: Nu-Calgon Products, Ty-lon B20 (www.nucalgon.com/products) Inhibited propylene-glycol: Houghton Chemical Corp., SAFE-T-THERM, www.houghton.com/fluids/safe-t-therm/index.html) CC-410-QS (09/17) Page 18

General guidelines for introducing propylene glycol into the water circulating system follow. The manufacturer s specific instructions and industry standards always take precedence when introducing propylene-glycol to the system. Calculate the quantity of inhibited propylene-glycol (fluid) required to achieve the desired results. Introduce a sufficient quantity of water to the system and pressure check to ensure a sealed system. Drain some water from the system to provide enough volume for the calculated amount of fluid. Add the correct amount of fluid and any water needed to completely refill the system, allowing for liquid expansion due to operating temperature. Circulate the inhibited propylene-glycol antifreeze solution for at least 24 hours to ensure complete mixing. Check the liquid concentration to assure that the correct mixture is obtained. Electrical and Sound Data Compressor Unit - Model Compressor Model Voltage/ Phase/ Hz Voltage Min. Max. LRA RLA MCA MFS Sound Pressure Level * @10 ft, db(a) -024-1C ZP24K5E-PFV 230-1-60 207 253 64.0 14.3 18.0 30 57.0-024-2C ZP24K5E-TF5 230-3-60 207 253 58.0 9.3 11.0 20 60.0-036-1C ZP36K5E-PFV 230-1-60 207 253 112.0 20.0 25.0 40 59.0-036-2C ZP36K5E-TF5 230-3-60 207 253 88.0 15.1 19.0 30 62.0-048-1C ZP49K5E-PFV 230-1-60 207 253 134.0 27.9 34.0 50 59.0-048-2C ZP49K5E-TF5 230-3-60 207 253 110.0 17.7 22.0 35 62.0-060/-068-1C ZP57K5E-PFV 230-1-60 207 253 178.0 28.3 34.8 50 63.0-060/-068-2C ZP57K5E-TF5 230-3-60 207 253 136.0 19.2 23.9 40 64.0 LRA = Locked Rotor Amps RLA = Rated Load Amps MCA = Minimum Circuit Ampacity MFS = Maximum Fuse or HACR Circuit Breaker Size (External) AWG = Consult NEC and Local Codes *Data Source is published Copeland Compressor Sound Power Levels converted to Sound Pressure Level in db(a) at 10 Feet, having two reflective surfaces. Effects of ETI compressor unit cabinet and components not included. Figure 9. Compressor Unit Electrical and Sound Data CC-410-QS (09/17) Page 19

Figure 10. CC Electrical Ladder Diagram (230-1-60) CC-410-QS (09/17) Page 20

Figure 11. CC Electrical Schematic (230-1-60) CC-410-QS (09/17) Page 21

Figure 12. CC Series 230-3-60 Electrical Ladder Diagram CC-410-QS (09/17) Page 22

Figure 13. CC Series 230-3-60 Electrical Schematic CC-410-QS (09/17) Page 23

Figure 14. (Part 1 of 2) CC Field Wiring Diagram CC-410-QS (09/17) Page 24

Figure 14. (Part 2 of 2) CC Field Wiring Diagram CC-410-QS (09/17) Page 25

System Start-up 1) System Leak Check After all indoor and outdoor refrigerant bearing components of the system have been installed and joints have been nitrogen brazed, pressurize the system prior to evacuation to leak test the system. Do not exceed 150 psig when pressure testing the compressor unit and indoor system components. Test for leaks with a sensitive electronic leak detector and bubble solution. Repair leaks as appropriate prior to evacuation. CAUTION! During the Evacuation and Initial Charging processes, be sure that ALL power to the EarthLinked System is OFF. This includes the compressor unit, air handler and all other electrically powered system components. Failure to do so will cause lockout on start-up. CC-410-QS (09/17) Page 26

2) Evacuation 1) Carefully vent the nitrogen charge from the compressor unit. 2) It is recommended to use two Schrader core removal tools. One installed on the suction port located on the ¼ line between the TXV and the accumulator, and the other installed on the discharge line of the compressor. Removal of the Schrader cores will greatly reduce the time to achieve the desired vacuum. 3) Attach a good quality manifold gauge and hose set to the Schrader core removal tools. The low-side hose should be attached to the pre-charge port and the high-side hose to the discharge port. The same manifold gauge and hose set will later be used in this position for pre-charging the system as well 4) Attach a good quality micron gauge to the charging hose of your manifold gauge set using either one with a pass through design or a Tee. 5) Using another hose, attach the micron gauge to a well maintained, high quality vacuum pump with an isolation valve, 7 CFM or greater is recommended. If your vacuum pump does not have an isolation valve, you will need to install one between the vacuum pump and micron gauge. Ensure that the vacuum pump oil has been changed prior to initiating the evacuation process to avoid contamination. 6) Open both valves of your manifold gauge set. Open the vacuum pump isolation valve and start the pump. Evacuate the system down to 400 MICRONS or less as read on the micron gauge. IMPORTANT! DO NOT ENERGIZE THE COMPRESSOR WHILE THE SYSTEM IS UNDER VACUUM. THIS WILL CAUSE DAMAGE TO THE COMPRESSOR. CC-410-QS (09/17) Page 27

After 400 microns or less has been achieved, close the isolation valve between the micron gauge and vacuum pump and wait 5 minutes before reading the micron gauge. The system pressure must not exceed 500 MICRONS WITHIN 5 MINUTES. If it does, continue the evacuation to remove any remaining non-condensibles in the system. A dry system will hold 500 microns for 5 minutes. A procedure often used to evacuate a system, known as the triple evacuation method, is detailed in the section of this manual entitled Triple Evacuation. Local codes may require other evacuation criteria, in which case the local codes take precedence over the evacuation requirements described above. IMPORTANT! DO NOT CHARGE THE SYSTEM UNTIL THE CONDITIONS OF STEP #6 ARE COMPLETED! 7) When the system has been successfully evacuated, valve off your manifold gauge set and move on to the charging procedure. DO NOT remove the manifold gauge or hoses prior to pre-charging as air will be drawn into the system, defeating the vacuum process. Only after the system is under refrigerant pressure by pre-charging should you remove the CC-410-QS (09/17) Page 28

3) Initial Charge 1) With your manifold gauge set still connected to the Schrader core removal tools, connect your refrigerant drum to the charging hose of your manifold gauge set. Never remove or change hoses while a unit is under vacuum. WARNING! Inhalation of high concentrations of refrigerant gas vapor is harmful and may cause heart irregularities or death. Vapor reduces oxygen available for breathing and is heavier than air. Decomposition products are hazardous. Liquid contact can cause frostbite. Avoid contact of liquid with eyes and prolonged skin exposure. Liquid and gas are under pressure. Deliberate inhalation of refrigerant gas is extremely dangerous. Asphyxiation can occur without warning due to lack of oxygen. Before using, read the material safety data sheet. Use proper safety measures when charging the system, especially when warming the refrigerant container. Do not overheat. 2) Open your refrigerant drum s valve and place the drum upside down (or oriented to deliver liquid refrigerant) - with the refrigerant valve at the bottom so as to charge refrigerant in a liquid state - and place it on a refrigerant scale. 3) Purge the charging hose by loosening it at the manifold end, until refrigerant is released. Re-tighten the charging hose and zero out your refrigerant scale. 4) Open the low-side valve of your manifold gauge set, this sends liquid refrigerant to the pre-charge port on the rail assembly only. Continue to add refrigerant until 3 lbs. per system ton has been added. In cold weather, it may be necessary to warm the refrigerant container to charge to 3 pounds per ton. CC-410-QS (09/17) Page 29

4) Final Charge 1) Start the air handler while keeping the compressor off and verify that the airflow meets the design target of 400 CFM/ton 2) Place a temperature clamp or probe securely to the air handler/cased coil vapor line at the rear of the compressor unit approximately 6 inches away from the rear. Check and record both the suction pressure and the air handler/cased coil suction line temperature. Use a pressure-temperature chart and verify the unit is operating with 6 to 12 degrees of superheat while in cooling mode. If the superheat is higher than 12 degrees, add refrigerant slowly until the superheat falls between 6 and 12 degrees. If the superheat is lower than 6 degrees, remove refrigerant slowly until the superheat rises between 6 and 12 degrees. Please note that there is an inline site glass prior to the unit s TXV. While in cooling mode, this inline sight glass may never clear. This is normal and no more refrigerant should be added. Should the inline sight glass clear while suction superheat is still over 12 degrees, the TXV will need adjustment. At this time, do not add more refrigerant and follow the next step. 3) Remove the cap from over the TXV adjustment nut. Using a refrigerant wrench, turn the TXV one full counter-clockwise turn and wait 5 minutes. Recheck the suction superheat. Adjust again in a counter-clockwise rotation if needed, waiting 5 minutes between each turn. No more than 3 counter-clockwise turn should be needed to set the suction superheat. 4) If any issues arise during any of these procedures, or, suction superheat is not correct after 3 counter-clockwise turns of the TXV, please contact EarthLinked Technical Support for assistance. 5) The system is now fully charged and operational in heating and cooling modes. Document the weight of the Total refrigerant charge in the system. Write it down on the Warranty Registration Card and inside the compressor unit on the electrical diagram, for future reference. CC-410-QS (09/17) Page 30

TEMPERATURE ( F) PRESSURE (psig) -20 26.1-15 30.8-10 35.9-5 41.5 0 47.5 5 54.1 10 61.2 15 68.8 20 77.1 25 86.0 30 95.5 35 105.7 40 116.6 45 128.3 50 140.8 55 154.1 60 168.2 65 183.2 70 199.2 75 216.1 80 234.0 85 253.0 90 273.0 95 294.1 100 316.4 105 339.9 110 364.6 115 390.5 120 417.7 125 446.3 130 476.3 135 507.6 140 540.5 145 574.8 150 610.6 Pressure-Temperature for R-410A CC-410-QS (09/17) Page 31