EarthLinked CCA Series User manual

CCA-410-IM (03/15) Page 1
EarthLinked®
CCA Series Cased Coils
Installation Manual

CCA-410-IM (03/15) Page 2
Table of Contents
Model Nomenclature ........................................................................................................................ 4
Safety............................................................................................................................................... 5
Equipment Manuals ......................................................................................................................... 5
Installation........................................................................................................................................ 6
Component Matching................................................................................................................... 6
Cased Coil Placement ................................................................................................................. 7
Refrigeration ................................................................................................................................ 9
Line Set.................................................................................................................................. 9
TXV Kit................................................................................................................................. 11
Airflow ............................................................................................................................................ 20
Appendix A – CCA Series (CE) Supplemental Installation Instructions........................................... 21
Appendix B – CCA Series (CE) Parts List ...................................................................................... 24

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List of Figures
Figure 1. Heat/Cool and Cool Only Component Matchup......................................................................... 6
Figure 2. Heat Only Component Matchup ................................................................................................ 6
Figure 3. General Layout of System Components................................................................................... 7
Figure 4. General Air Handler Physical Dimensions................................................................................ 8
Figure 5. Line Set Sizes .......................................................................................................................... 9
Figure 6. Cased Coil and Air Handler Line Set Separation..................................................................... 10
Figure 7. TXV Control ............................................................................................................................ 11
Figure 8a. TXV Control installed near Cased Coil (Vertical Application)................................................ 12
Figure 8b. TXV Control installed near Cased Coil (Horizontal Application)............................................ 13
Figure 8c. TXV Control Box Dimensions ............................................................................................... 14
Figure 8d. TXV Control Box Mounting Positions.................................................................................... 15
Figure 9. Positioning the Pressure Equalizer Tee.................................................................................. 16
Figure 10. Thermal Bulb Positioning ..................................................................................................... 17
Figure 11. Clamping the Thermal Bulb.................................................................................................. 18
Figure 12. Insulating the Thermal Bulb.................................................................................................. 18
Figure 13. TXV Liquid Line Connections ............................................................................................... 19
Figure 14. Airflow Vs. Pressure Drop .................................................................................................... 20

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Model Nomenclature
Disclaimer
Proper installation and service of EarthLinked®Heating and Cooling System Components is essential to
reliable performance. All EarthLinked®components must be installed and serviced by a technician
authorized by Earthlinked Technologies. Installation and service must be in accordance with the
instructions set forth in this manual. Failure to provide installation and service by an authorized, trained
installer in a manner consistent with this manual will void the limited warranty coverage for the system.
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.
EarthLinked Technologies, Inc.
4151 South Pipkin Road
Lakeland, Florida 33811
tel. [phone] ● fax [phone]
[e-mail] ● www.earthlinked.com
CSI # 23 80 00

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Safety
Warning, Caution and Important notices appear throughout the manual. Read these items carefully
before attempting installation, servicing or troubleshooting the equipment.
Equipment Manuals
The following is a listing of the equipment installation manuals that are provided with each component
specified for this EarthLinked®system.
Series SC, SD, HC, HW or CC Quick-Start Instructions (as appropriate)
Model TR94, TR97, TE54 Thermostats by manufacturer
CAUTION!
Indicates a potentially hazardous situation or an unsafe practice, which
if not avoided, may result in injury, or equipment or property damage.
IMPORTANT!
Notification of installation, operation or maintenance information which
is important, but which is not hazardous.
IMPORTANT!
Read and follow all installation instructions in these manuals,
appropriate for the EarthLinked®system being installed, BEFORE
initiating the Start-Up procedure.
WARNING!
Indicates a hazardous situation, which if not avoided will result in serious
injury or death, or equipment or property damage.

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Installation
Component Matching
CCA Series Cased Coils are ready for vertical installation as shipped. Field conversion to horizontal
requires no additional components. The CCA Series Cased Coils are manufactured for vertical and
horizontal applications.
Heat/Cool and Cool Only (Model CCA-00XX): These cased coils are equipped with a distributor
designed for providing optimum performance in the cooling mode and the heating mode. In addition, this
cased coil includes a TXV Kit that is field installed external to the cased coil and is required to make the
system operational in the cooling mode when matched with the appropriate model EarthLinked®
compressor unit as shown in Figure 1.
COMPRESSOR UNIT
MODEL/CAPCITY
CASED COIL
MODEL TXV-KIT MODEL**
-018 (1.5 Tons) CCA – 0018 TXV-018A
-024 (2.0 Tons) CCA – 0024 TXV-024A
-030 (2.5 Tons) CCA – 0030 TXV-030A
-036 (3.0 Tons) CCA – 0036 TXV-036A
-042 (3.5 Tons) CCA – 0042 TXV-042A
-048 (4.0 Tons) CCA – 0048 TXV-048A
-054 (4.5 Tons) CCA – 0054 TXV-054A
-060 (5.0 Tons) CCA – 0060 TXV-060A
*TXV Kit is included with air handler for field installation
Figure 1. Heat/Cool and Cool Only Component Matchup
Heat Only (Model CCA-XXXX): These cased coils are to be matched with the appropriate model
EarthLinked®Compressor unit model shown in Figure 2.
COMPRESSOR UNIT
MODEL/CAPCITY
CASED COIL
MODEL
-018 (1.5 Tons) CCA – 1824
-024 (2.0 Tons) CCA – 1824
-030 (2.5 Tons) CCA – 3036
-036 (3.0 Tons) CCA – 3036
-042 (3.5 Tons) CCA – 4248
-048 (4.0 Tons) CCA – 4248
-054 (4.5 Tons) CCA – 5460
-060 (5.0 Tons) CCA – 5460
Figure 2. Heat Only Component Matchup

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Cased Coil Placement
Guidelines for the cased coil (or air handler) placement relative to the compressor unit and other
EarthLinked®system components are shown in Figure 3.
Figure 3. General Layout of System Components
WARNING!
WEAR ADEQUATE PROTECTIVE CLOTHING AND PRACTICE ALL
APPLICABLE SAFETEY PRECAUTIONS WHILE INSTALLING THIS
EQUIPMENT. FAILURE TO DO SO MAY RESULT IN EQUIPMENT
AND/OR PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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Dimensions for the cased coils are illustrated and listed in Figure 4.
Compressor
Unit Model
Heat/Cool,
Cool Only
Model
Heat Only
Model
Cainet
H x W x D
Inches
LIQ/VAP
OD
Inches
OUTLET
W1 x D1
Inches
NLET
W2 x D2
Inches
-018 CCA – 0018 CCA-1824 23 x 14 x 21.5 3/8 x 3/4 12.5 x 20 13.25 x 20.75
-024 CCA – 0024
-030 CCA – 0030 CCA-3036 27 x 17 x 21.5 3/8 x 3/4 15.5 x 20 16.25 x 20.75
-036 CCA – 0036
-042 CCA – 0042 CCA-4248 30 x 21 x 21.5 3/8 x 7/8 19.5 x 20 20.25 x 20.75
-048 CCA – 0048
-054 CCA – 0054 CCA-5460 30 x 24.5 x 23 3/8 x 7/8 23 x 21.5 23.75 x 22.25
-060 CCA – 0060
*Outlet and Inlet are reversed for Downflow and Horizontl Left Applications
Figure 4. General Air Handler Physical Dimensions
Specific instructions for the mechanical installation of the cased coil are provided in Appendix A of this
manual.

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Refrigeration
Line Set
Line set sizes for CCA Series Cased Coils connecting to the matching compressor units are listed in
Figure 5. Line set liquid and vapor lines are to be insulated with Armaflex®, Insul-Lock®or equivalent
tubing insulation at least ½” wall thickness. For interior living areas, thicker walled insulation will reduce
sound level.
LINE SET ADAPTERS REQUIRED FOR THE AIR HANDLER, CASED COIL, HYDRONIC WATER
MODULE AND DOMESTIC WATER MODULE ARE FIELD SUPPLIED. CHECK ALL
APPROPRIATE COMPRESSOR UNIT STUB-OUT TUBING SIZES FOR REQUIRED FIELD
SUPPLIED ADAPTERS!
EARTHLOOP, AIR HANDLER, CASED COIL LINE SETS HWM/DWM LINE SETS
COMPRESSOR
UNIT SIZE
LINE SET O.D., INCHES HWM
MODEL
LINE SET O.D., INCHES
LIQUID* VAPOR* LIQUID* VAPOR*
1.5 Tons (-018) 3/8 5/8 -018C/-1836 3/8 1/2
2.0 Tons (-024) 3/8 5/8 -024C/-1836 3/8 1/2
2.5 Tons (-030) 3/8 3/4 -030C/-1836 3/8 1/2
3.0 Tons (-036) 1/2 3/4 -036C/-1836 3/8 1/2
3.5 Tons (-042) 1/2 3/4 -042C/-4248 1/2 5/8
4.0 Tons (-048) 1/2 7/8 -048C/-4248 1/2 5/8
4.5 Tons (-054) 1/2 7/8 -054C/-5472 1/2 3/4
5.0 Tons (-060) 1/2 7/8 -060C/-5472 1/2 3/4
*Liquid and Vapor lines must BOTH be insulated with Armaflex® or equivalent with at least 1/2” wall thickness for
the full length of the line set.
Figure 5. Line Set Sizes
Both liquid and vapor lines running between the compressor unit and the cased coil must be separated
by an air space, as illustrated in Figure 6, to ensure system performance. The lines shall not be
“bundled” by tying them together or by running both lines together, in contact with one another, within a
single conduit, such as PVC pipe.

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Figure 6. Cased Coil and Air Handler Line Set Separation

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TXV Kit Introduction
CCA Series cased coils that are intended for HEAT ONLY application are ready to install and make the
refrigeration line set connection to the cased coil as shipped.
CCA Series cased coils that are intended for HEAT/COOL or COOL ONLY applications, are shipped
with the matching TXV Kit that must be field installed to enable operation of the system in the
cool mode.
The following procedure is for the installation of the TXV Kit which must be done prior to making the line
set connections to the cased coil.
Figure 7 illustrates the TXV Kit as shipped with the external parts for field installation identified. The TXV
(thermal expansion valve), CAV (cooling assist valve) and interconnecting tubing are located inside the
control box to ensure performance.
Figure 7. TXV Control

CCA-410-IM (03/15) Page 12
The TXV control box is field positioned external to the vertical (upflow or downflow) cased coil and
fastened to a solid mounting surface immediately adjacent to the cased coil as shown typically in Figure
8a. Locate the TXV control box to allow a service access of at least 12 inches in front of the box to
adjust the TXV control.
Figure 8a. TXV Control installed near Cased Coil (Vertical Application)
Important!
The TXV control box must be located no more than 3-1/2 feet from the
suction tube stub out on the air handler. The TXV control box must be
mounted above the cased coil tubing stub outs as shown.

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For horizontal cased coil applications (left or right air flow), the TXV control box is field positioned
external to the cased coil and can be fastened to a solid mounting surface immediately adjacent to the
cased coil as shown typically in Figure 8b.
Figure 8b. TXV Control installed near Cased Coil (Horizontal Application)
Important!
The TXV control box must be located no more than 3-1/2 feet from the
suction tube stub out on the cased coil. The TXV control box must be
mounted above the cased coil tubing stub outs as shown.

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For mounting purposes, the physical dimensions for the TXV Control Box are shown in figure 8c. The
preferred mounting position for the TXV Control Box is vertical with the liquid line tube connections on
the bottom. However, as shown in Figure 8d, the Control Box can be mounted from vertical to any angle
up to 90 degrees (horizontal).
Figure 8c. TXV Control Box Dimensions

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Figure 8d. TXV Control Box Mounting Positions
The following steps and positioning requirements apply to installing the TXV Control to the cased coil for
vertical and horizontal applications. The vertical installation provides an illustrated example.
Step 1: Relieve the nitrogen holding charge on the air handler using the valve on the liquid line stub out.
Locate the TXV Control box within the 3-1/2 feet of the suction line stub out on the cased coil. Fasten
the TXV control box above the suction line stub out.

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Step 2: Position the Pressure Equalizer Tee on the suction tube at least 10 inches downstream from
the 90° ell as shown in Figure 9. Remove the core from Schrader valve on the Tee.
Figure 9. Positioning the Pressure Equalizer Tee

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Step 3: The Thermal Bulb must be positioned and clamped to the suction tube as shown in the
example illustrated in Figure 10. The Thermal Bulb and suction tube must be horizontal regardless
of the cased coil application (vertical or horizontal).
The Thermal Bulb must be positioned at the 3:00, 4:00, 8:00 or 9:00 positions on the suction tube, as
illustrated in Figure 10.
Figure 10. Thermal Bulb Positioning
Step 4: Clamp the thermal bulb firmly against the clean suction tube extension and parallel to it, as
shown in Figure 11.
Isolate the Thermal Bulb from with a cold wet cloth while Nitrogen brazing the joints on the suction line.
After the suction line has cooled, apply the supplied cork tape insulation around the Thermal Bulb to
completely isolate it from the surrounding air, as shown in Figure 12.

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Figure 11. Clamping the Thermal Bulb
Figure 12. Insulating the Thermal Bulb

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Step 5: Measure and cut copper tubing to connect the liquid line from the TXV control box to the liquid
line stub out on the cased coil as shown in Figures 7 and 13. Run the other liquid line from the
connection on the TXV control box to the compressor unit, also shown in Figure 13. Nitrogen braze the
joints.
Step 6: Replace the core in the Schrader valve and connect the pressure equalizer tube to the Schrader
valve. Tighten the flare connection firmly. Wrap the liquid and vapor tubing including the liquid line
tubing to the TXV control box, with Armaflex®, Insul-Tube®or equivalent insulation of at least ½”
wall thickness, between the cased coil and compressor unit.
Figure 13. TXV Liquid Line Connections

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Airflow
CCA Cased Coils are designed to operate at 400 cfm/Ton, nominal capacity.
For system design purposes, Figure 14 provides the airflows for each CCA cased coil model and the
associated coil pressure drops.
Cased Coil Model Airflow, cfm Coil Pressure Drop,
in W.C.
CCA-0018
CCA-0024
CCA-1824
400 0.14*
600 0.20*
800 0.27
CCA-0030
CCA-0036
CCA-3036
800 0.15*
1000 0.23*
1200 0.30
CCA-0042
CCA-0048
CCA-4248
1200 0.15*
1400 0.23*
1600 0.31
CCA-0054
CCA-0060
CCA-5460
1600 0.15*
1800 0.24*
2000 0.32
*Projected pressure drop based on similar cased coils
Figure 14. Airflow Vs. Pressure Drop