EarthLinked SHC-410-CP User manual

SHC-410-CP (01/13)Copyright 2013 Earthlinked Technologies, Inc.
EarthLinked®
CHARGING PROCESS
for
R-410A
Heating and Cooling Systems

SHC-410-CP (01/13)
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.
EarthlinkedTechnologies 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.
Earthlinked Technologies, Inc.
4151 South Pipkin Road
Lakeland, Florida 33811
tel. [phone] ● fax [phone]
[e-mail] ● www.earthlinked.com

SHC-410-CP (01/13)Page 3
System Start-up
Evacuation/Charging
SC, SD and SCW Models
Refer to Figure 1 and the following description:
Evacuation and Initial Charge
WARNING
This compressor unit is equipped with POE lubricant. POE lubricant absorbs
significant amounts moisture from the air very rapidly. Exposure of POE lubricant
to air must be minimized. Even a few minutes of exposure to air can be harmful to
the system.
After the initial nitrogen holding charge has been released from the compressor
unit, it is critical that air not be allowed to enter the compressor unit during the
process of preparing compressor unit refrigerant connections (tube cutting
deburring, cleaning, brazing, etc.).
To ensure air does not enter the compressor unit while preparing refrigerant
connections, “trickle” dry nitrogen through the compressor unit, entering at the
access port nearest Active Charge Control (ACC), to keep airborne moisture out
of the compressor unit and the POE lubricant.
Complete preparing and brazing all compressor unit refrigerant connections at
one setting to minimize exposure of open connections to air.
Failure to implement the above precautions will result in an extended period of
time to effectively evacuate the system, and may adversely affect system
performance and cause system failure.
1. Carefully vent the nitrogen charge from the compressor unit.
2. After installing and nitrogen brazing the HVAC system components and
compressor unit service valves, turn the Service Valves to Full Open and
pressurize the HVAC components to 150 psig with dry nitrogen and a trace of
refrigerant. Valve off the nitrogen Tank from the HVAC system components and

SHC-410-CP (01/13)Page 4
check joints with a sensitive Electronic Leak Detector to ensure they are sealed.
Repair any leaks and re-test as appropriate.
3. After venting the pressurized system, connect the Gage Block, Refrigerant
Container and Hoses as shown in Figure 1. LP and HP valves are fully open.
Both Service Valves are fully opened.
4. As illustrated in Figure 1, connect a good quality Digital Micron Gage to the Liquid
Line Service Valve Access Port with an Isolation Hose/Valve. Connect a quality
Vacuum Pump (at least 6 CFM capacity) to the Gage Block.
5. Connect the Refrigerant Hose from the Refrigerant Container to the Charging
Port.
6. Initiate the system evacuation. Evacuate the system down to 230 MICRONS as
read on the digital micron gage. After 230 microns has been achieved, turn off the
LP and HP valves and turn “OFF” the vacuum pump. Reading the digital micron
gage, the system pressure must not exceed 280 MICRONS WITHIN 5
MINUTES. If pressure rises to greater than 280 microns, open LP and HP valves,
crack the refrigerant valve and allow just enough refrigerant into the system until
20 inches of Hg vacuum is read on the LP gage. Close the refrigerant valve, and
initiate the evacuation process again and until the above conditions are met.

SHC-410-CP (01/13)Page 5
Figure 1. Typical Evacuation & Initial Charge Set-up for SC, SD and SCW Compressor
Models (SC model shown).
7. Close the LP and HP valves on the gage block. Disconnect the vacuum pump
and the utility hose from the gage block. Isolate/protect the Digital Micron Gage
from the liquid Earth Loop Service Valve until the initial refrigerant charge is
complete.
8. Open the refrigerant container valve and inject liquid refrigerant into the
charging port as shown in Figure 1.
9. Charge with liquid refrigerant until 3 pounds of refrigerant per ton of system
capacity, has entered the system.
Liquid entering the system at the charging port goes directly to the system earth
loops. It does not go to the compressor. Should the pressures equalize and

SHC-410-CP (01/13)Page 6
prevent the intended charge from entering completely, terminate the process of
initial charging. Note and document the amount of refrigerant.
10. When the initial refrigerant charge (see step 9 above) has entered the system,
close the refrigerant container valve and disconnect the refrigerant hose from the
charging port. Note and document the amount of refrigerant.
11. The system has now been initially charged. Disconnect the Digital Micron Gage.
Final Charge
It is critical to control the conditions under which the compressor unit operates while
final charging the system. Final charging must be done in HEAT mode.
Air Handler Systems
If AIR heating is provided by one of the following DX air handler systems, as
listed in Figure 2, the return air to the air handler during the final charging is to
be maintained in the range of 70°F to 80°F. If necessary, the air can be warmed
with electric supplemental heat in the air handler. (Shunt “R” to “W2” at the terminal
block.)
Item
Comp
. Unit Air Htg.
Hydro
nic
Htg.
Air
Clg
Domesti
c Wtr.
Htg.
System Functions
1. SC Yes Yes Air heating and cooling
2. SC Yes Yes Yes1Air heating and cooling, domestic hot water by field
installed desuperheater
3. SD Yes Yes Yes1Air heating and cooling, domestic hot water by
desuperheater
1
Includes Desuperheater Model DSH-1872 to supplement water heating.
Figure 2. Systems with DX Air Handlers
Hydronic Systems
If heating is provided through the SCW compressor unit or a hydronic water
module, HWM, as listed in Figure 3, the circulating water in the primary circuit (see
Figures 4 and 5) for the hydronic system is to be maintained in the 95°F to 105°F
range.
Item
Comp.
Unit
Air
Htg.
Hydroni
c Htg.
Air
Clg
Domestic
Wtr. Htg.
System Functions
1. SC Yes2Yes2Radiant panel hydronic heating and air cooling
(chilled water handler)
2. SC Yes2Yes2Yes1Radiant panel hydronic heating and air cooling
(chilled water handler); and domestic hot water by
field installed desuperheater
3. SD Yes2Yes2Yes1Radiant panel hydronic heating and air cooling
(chilled water handler); and domestic hot water by
desuperheater
4. SCW Yes3Yes3Radiant panel hydronic heating and air cooling
(chilled water air handler)
1
Includes Desuperheater Model DSH-1872 to supplement water heating.
2Hydronic (radiant floor) water heating provided with separately purchased Series HWM Hydronic Water
Module.
3Has internal refrigerant/water heat exchanger. Requires field supplied water circulating pump.
Figure 3. Systems with Hydronic Heat Exchangers

SHC-410-CP (01/13)Page 7
Figure 4. Primary Circuit with Hydronic Water Module (HWM)
Figure 5. Primary Circuit with Compressor Unit Heat Exchanger

SHC-410-CP (01/13)Page 8
Final charging is done in the HEAT mode as follows, with the charging set up described in
Figure 6:
1. Continue measuring the refrigerant charge weight as shown in Figure 6.
2. Be sure that air entering the air handler is between 70°F and 80°F. If the system is a
hydronic primary circuit, circulating water is to be held between 95°F and 105°F.
3. Close the HP valve. Then turn the system on in the HEAT mode.
4. Initiate final charging by opening the refrigerant container valve and the gage manifold
LP valve to allow liquid refrigerant to enter the system SLOWLY as shown in Figure 6.
The ACC will not allow liquid refrigerant to enter the compressor.
5. Adding liquid refrigerant will raise the liquid level in the ACC. Continue to add liquid
refrigerant to the system until the liquid level has reached the middle sight glass, as
shown in Figure 7.
6. When the liquid level is at the middle sight glass, as shown in Figure 7, turn the
refrigerant container valve OFF.
7. When the system has run for 20 minutes (in HEAT mode), read the evaporating
temperature and condensing temperature.
The evaporating temperature can be read by attaching a thermocouple lead to the
Earth Loop Vapor Line with electrical tape, then wrapped with ½” thick insulation. The
condensing temperature can be read by attaching a thermocouple lead to the Air
Handler/CC/HWM liquid line coming into the compressor unit with electrical tape, then
wrapped with ½” thick insulation. Use an accurate temperature indicator.
In Figure 8, locate the evaporating temperature on the horizontal axis. The
corresponding condensing temperature reading should fall between the upper and
lower parallel lines in Figure 8.
The temperature profile in Figure 8 is valid for the air handler systems with an
air flow of 400CFM per Ton. If condensing temperature is above acceptable range,
the air flow is low. If condensing temperature is below the acceptable range, air flow is
too high. Adjust air flow as appropriate.

SHC-410-CP (01/13)Page 9
Figure 6. Typical Final Charge Set-up for SC, SD and SCW Compressor Units
(SC Model shown).
8. Check the suction saturation temperature to verify that it is within ±3°F for the
measured suction pressure. The suction temperature should be approximately 15 to
20°F lower than the local earth temperature.

SHC-410-CP (01/13)Page 10
Figure 7. Charge at Middle Sight Glass
Figure 8. EarthLinked®Performance Parameters

SHC-410-CP (01/13)Page 11
9. If the system is to operate in Heat Only mode, write the final refrigerant charge on
the Warranty registration Card and on the inside of the compressor unit on the
electrical diagram for future reference. This is the full system charge. For Heat Only
operation, do not adjust the Thermostatic Expansion Valve (TXV) or the Cooling
Assist Valve (CAV). These valves have been factory set and are not to be adjusted by
the installer. The system is fully operational and needs no further adjustment.
10. If the system is to operate in Heat/Cool or Cool Only mode: While the system is
still operating in HEAT mode, add refrigerant to the system to bring the liquid
refrigerant level up to the top sight glass on the ACC. See Figure 9. Document the
total weight of the refrigerant charge to the system.
Figure 9. Charge at Top Sight Glass
11. The following additional steps in the system start-up process are required if the
system is to operate in Heat/Cool or Cool Only modes. These following steps
require that the system be run in COOL mode.
IMPORTANT
If site conditions prevent maintaining an air handler return air temperature
between 70°F and 80°F, the cooling system start-up steps can be completed at a
later time. If the cooling mode start-up process is delayed, the system can run in
heat mode only and the cooling mode must be disable until the cooling mode
start-up process is initiated. If the cooling mode start-up process is initiated after
running the system in Heat Only mode, the system should remain OFF for 48
hours after running in the Heat mode to allow the earth temperature surrounding
the earth loops to stabilize.

SHC-410-CP (01/13)Page 12
Cooling Mode Start-Up Process
These following steps are to be followed if the system is to be run in Heat/Cool or Cool
Only. The process flow chart for these steps is illustrated in Figure 15. Be sure the
cooling mode for the system is enabled. Start the system in COOL mode and run system
until the suction pressure stabilizes.
1. Determine what the liquid refrigerant level is in the ACC by viewing it through the
sight glasses. If the liquid level is at or above the lowest sight glass, wait 10
minutes and check it again. The liquid level should be dropping with time. Repeat
the 10 minute cycle observations until the liquid is below the lowest sight glass or
until 2 hours pass. After 2 hours, if the liquid level has not dropped below the
lowest sight glass, call ETI Technical services at 1-863-701-0096.
2. When the liquid refrigerant level drops below the ACC lowest sight glass,
observe the INLINE sight glass (not the ACC sight glasses) for the status of the
refrigerant flow. There are three possibilities:
A. INLINE sight glass is CLEAR:As illustrated in Figure 10, a clear sight
glass means the refrigerant flow is liquid. Remove 1 pound of refrigerant
from the system, wait 10 minutes, and observe again. Continue this until
bubbles appear in the sight glass.
Figure 10. Clear-Inline Sight Glass
B. INLINE sight glass has MANY BUBBLES: This is illustrated in Figure 11.
Wait 10 minutes and observe the sight glass again. If many bubbles are still
present, repeat the 10 minute wait cycle until the bubbles become few, or
you have waited 2 hours. After a 2 hour wait, and many bubbles still exist in
the sight glass, the process is done. No further adjustment in cool mode is
required, and the system is operational.
Figure 11. Many Bubbles-Inline Sight Glass

SHC-410-CP (01/13)Page 13
C. INLINE sight glass has FEW BUBBLES: This is illustrated in Figure 12.
When this condition exists, the next steps are to check the superheat and
adjust the TXV as necessary. SWC compressor units are not equipped
with a TXV. A system equipped with an SCW compressor unit is now
fully operational and needs no further adjustment. Go to item #9.
Figure 12. Few Bubbles-Inline Sight Glass
3. The TXV is to be adjusted to provide 10ºF to 15ºF superheat while running in
cooling mode. The first step is to utilize the access port and LP gage in Figure 13
to measure suction pressure. Next, apply a thermocouple at the compressor
suction port as shown in Figure 13 by attaching the thermocouple lead with
electrical tape, and wrapping with ½” thick insulation.
Figure 13. Superheat Measurements for SC, SD and SCW Compressor Units
(SC Model shown).

SHC-410-CP (01/13)Page 14
4. Using an accurate temperature indicator, read the suction temperature at
the compressor suction port. Read the suction pressure at the access port on
the LP gage.
5. Enter the Pressure-Temperature Table in Figure 14 and for the suction pressure
read on the LP gage, determine the saturation temperature (evaporating
temperature) from the chart, interpolating if necessary.
SATURATION
TEMPERATURE
(°F)
SUCTION
PRESSURE
(psig)
SATURATION
TEMPERATURE
(°F)
SUCTION
PRESSURE
(psig)
-20 26.1 70 199.2
-15 30.8 75 216.1
-10 35.9 80 234.0
-5 41.5 85 253.0
0 47.5 90 273.0
5 54.1 95 294.1
10 61.2 100 316.4
15 68.8 105 339.9
20 77.1 110 364.6
25 86.0 115 390.5
30 95.5 120 417.7
35 105.7 125 446.3
40 116.6 130 476.3
45 128.3 135 507.6
50 140.8 140 540.5
55 154.1 145 574.8
60 168.2 150 610.6
65 183.2
Figure 14. Pressure-Temperature for R-410A
6. To determine the degrees of Superheat, subtract the saturation temperature from
the suction temperature read at the compressor suction port thermocouple. The
difference in the temperatures is the superheat.
(Superheat, °F) = (Suction Temp., °F) -(Saturation temp., °F)
7. If superheat is greater than 20°F, decrease the superheat by adjusting the
setting on the TXV in the counter clockwise direction.
8. See Figure 15 and follow the guidelines to bring the superheat into the 100F to
150F range. When superheat is adjusted to within this range, the system is fully
operational and needs no further adjustment.
9. Document the net weight of the refrigerant charge in the system. Net weight is
equal to the final refrigerant charge minus refrigerant removed from the
system. Write it down on the Warranty Registration Card and inside the
compressor unit on the electrical diagram, for future reference. This is the full
system charge.

SHC-410-CP (01/13)Page 15
Figure 15. Cooling Mode Start-Up Process
NOTE!
TXV ADJUSTMENT DOES
NOT APPLY TO SCW SERIES
COMPRESSOR UNITS