EarthLinked HWM-18B Instruction manual

HWM-407CH-IOM (09/13) Copyright 2013 Earthlinked Technologies, Inc
EarthLinked®
Hydronic Water Module
Installation, Operation & Maintenance Manual
for
R-407C Heat/Cool and Cool Only Systems

HWM-407CH-IOM (09/13) Page 2
Disclaimer
This manual contains instructions for the EarthLinked®Hydronic Water Module which is
combined with other EarthLinked®system components, field specified hydronic heating
and chilled water cooling components, thermostats, storage water heaters, storage water
tanks and associated fittings, controls and piping.
EarthLinked®Technologies manufactures and sells only the EarthLinked®system
components and the performance information contained herein is based on performance
of EarthLinked®Technologies’ supplied Products.
Therefore, 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 above mentioned field
specified items.
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 nullify the limited warranty coverage for the system.
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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Table of Contents
1. Inspection/Pre-Installation........................................................................................................5
A. Inspection...........................................................................................................................5
B. Pre-Installation...................................................................................................................6
2. General System Layout............................................................................................................7
3. Applications .............................................................................................................................8
4. The Primary Circuit ................................................................................................................10
A. Plumbing..........................................................................................................................10
B. Antifreeze Protection........................................................................................................11
C. Water Quality ...................................................................................................................13
D. Storage Water Heater Sizing and Connections ................................................................14
E. Circulating Pump, Piping, Strainer and Flowmeter ...........................................................15
F. Refrigerant Piping ............................................................................................................17
5. Controls and Electrical...........................................................................................................18
A. Hydronic Heating and Chilled Water Cooling....................................................................18
B. Chilled Water Cooling.......................................................................................................19
C. HWM Freeze Protection Thermostat................................................................................21
6. Start-Up .................................................................................................................................22
7. Heat Exchanger Maintenance................................................................................................24
8. Tools and Equipment.............................................................................................................28
Index .......................................................................................................................................29

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List of Figures
Figure 1. Matching Component Model Numbers................................................................................5
Figure 2. General System Layout ......................................................................................................7
Figure 3. Typical Chilled Water Cooling and Radiant Panel Hydronic Heating System ......................8
Figure 4. Typical Chilled Water Cooling System ................................................................................9
Figure 5. Primary Circuit for EarthLinked®System with HWM..........................................................10
Figure 6. Typical HWM Primary Circuit Plumbing.............................................................................11
Figure 7. Propylene Glycol Freeze Protection Table.......................................................................12
Figure 8a. Hydronic System Water Quality Parameters...................................................................13
Figure 8b. Storage Tank Capacities and Pipe Sizes ........................................................................14
Figure 8c. Typical HWM Piping Illustration.......................................................................................15
Figure 9. Hydronic Water Module (HWM) ........................................................................................16
Figure 10a. Minimum Water Pipe, Fitting and Strainer Sizes to Storage Water Heater.................... 17
Figure 10b. Flowmeter Kit................................................................................................................17
Figure 10c. (Part 1 of 2) Electrical Field Wiring –
Hydronic Heating and Chilled Water Cooling (HWM)..........................................................18
Figure 10c. (Part 2 of 2) Electrical Field Wiring –
Hydronic Heating and Chilled Water Cooling (HWM)..........................................................19
Figure 10d. (Part 1 of 2) Electrical Field Wiring – Chilled Water Cooling (HWM)............................. 20
Figure 10d. (Part 2 of 2) Electrical Field Wiring – Chilled Water Cooling (HWM)..............................20
Figure 10e. Three-Step Electrical Installation for Freeze Protection Thermostat.............................. 21
Figure 11. Maximum Operating Conditions (R-407C) ......................................................................23
Figure 12. Minimum Heat Exchanger Water Flow Rates..................................................................24
Figure 13. Minimum Heat Exchanger Propylene Glycol/Water Solution Flow Rates ........................25
Figure 14. HWM Heat Exchanger Cleaning Set-up..........................................................................26

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1. Inspection/Pre-Installation
A. Inspection
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
MODEL/CAPACITY
R-407C
HYDRONIC WATER
MODULE MODEL
-018 (18,000 BTUH)
HWM-18B
-024 (24,000 BTUH)
HWM-24B
-030 (30,000 BTUH)
HWM-30B
-036 (36,000 BTUH)
HWM-36B
-042 (42,000 BTUH)
HWM-42B
-048 (48,000 BTUH)
HWM-48B
-060 (60,000 BTUH)
HWM-60B
-072 (72,000 BTUH)
HWM-72B
Figure 1. Matching Component Model Numbers
Inspect the carton or crating of each unit, and inspect each unit for damage. Assure the
carrier makes proper notation of any shortages or damage on all copies of the freight bill
and he completes a common carrier inspection report. Concealed damage not discovered
during unloading must be reported to the carrier within 15 days of receipt of shipment. If not
filed within 15 days, the freight company can deny the claim without recourse. Note: it
is the responsibility of the purchaser to file all necessary claims with the carrier.

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Equipment should be stored in its packaging in a clean, dry area. Store equipment in an
upright position at all times. Equipment is to be stacked in accordance with the notation on
the packaging. DO NOT remove equipment from shipping cartons until equipment is
required for installation.
Cover equipment on the job site with either shipping cartons, vinyl film or an equivalent
protective covering. In areas where painting, plastering and/or spraying has not been
completed, all due precautions must be taken to avoid physical damage to the equipment
and contamination by foreign material. Physical damage and contamination may prevent
proper start-up and may result in costly equipment clean up. Examine all equipment before
installing.
B. Pre-Installation
Prior to installing the Hydronic Water Module and other EarthLinked®space heating and
cooling system above-ground components, you will need tools and equipment listed in
Section 8 to properly install the system.
Installation of the Hydronic Water Module must be done in accordance with this manual and
the EarthLinked®Technical Manual.
Prepare the Hydronic Water Module (HWM) for installation as follows:
1. Compare the data on the unit nameplate or packaging with ordering and shipping
information to verify the correct unit has been shipped (See Figure 1.)
2. Keep the HWM covered with the packaging until installation is begun and all plastering,
painting, etc. is finished.
3. Verify refrigerant tubing is free of kinks or dents.
4. Inspect all electrical connections. Connections must be clean and tight at the terminals.

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2. General System Layout
Guidelines for the general layout of the Hydronic Water Module and other EarthLinked®
system components are shown in Figure 2.
Figure 2. General System Layout

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3. Applications
A typical application of the Hydronic Water Module to a chilled water cooling and radiant
panel hydronic heating system is illustrated in Figures 3.
Figure 3. Typical Chilled Water Cooling and Radiant Panel Hydronic Heating System

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A typical application of the Hydronic Water Module to a chilled water cooling system is
illustrated in Figures 4.
Figure 4. Typical Chilled Water Cooling System

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4. The Primary Circuit
A. Plumbing
The primary circuit in a typical HWM installation is shown in Figure 5.
Figure 5. Primary Circuit for EarthLinked®System with HWM
The Hydronic Water Module primary circuit water solution plumbing must be installed
consistent with local codes and industry practice. At a minimum, the HWM should have the
fittings as shown in Figure 6. The minimal fittings shown in Figure 6 will facilitate maintaining
and servicing the Hydronic Water Module. Additional fittings may be required to satisfy local
codes and other hydronic system requirements.

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Figure 6. Typical HWM Primary Circuit Plumbing
B. Antifreeze Protection
When the HWM hydronic water module is applied to radiant panel hydronic heating and
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.

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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 Figure 7.
TEMPERATURE, °F PROPYLENE GLYCOL, %
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
Figure 7. Propylene Glycol Freeze Protection Table
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)
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.

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•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.
C. Water Quality
Water quality in hydronic systems is important to the life and efficiency of the system.
Water of poor quality can cause a decrease in heat transfer ability and cause leaks.
Ensuring proper quality water is a key step in the installation of the hydronic water module
(HWM) and circulating water system.
Water quality parameters and the recommended ranges are listed in Figure 8a. The
antifreeze manufacturer’s water quality requirements take precedence over the ranges
listed in Figure 8a.
Parameter Optimal Conditions Comments
Glycol Freeze Protection 20% to 50% Below 20% can promote the growth of bacteria. Concentrations
higher than 50% will dramatically reduce the heat transfer
ability. Glycol seepage can occur at o-rings and seals.
Corrosion inhibitor
Molybdate inhibitor
or
Nitrite inhibitor
100-150ppm
800-1200ppm
Without the addition of Nitrite or Molybdate inhibitors, corrosion
of the metallic components will begin and eventually lead to
leaks.
pH 9-10.5 pH units A pH below 9.0 will allow the corrosion of steel and above 10.5
will allow the corrosion of brass and copper.
Conductivity 700-3200µS/cm Conductivity above 3500µS/cm will cause the water to become physically abrasive and damage the o-rings. Addition of
chemicals to the water will raise the conductivity.
Hardness 100-300ppm Artificially soft water can be aggressive to the system. The use
of unsoftened water is recommended. Do not use distilled or
purified water.
Bacteria/Mold No Bacteria or
Mold
The growth of bacteria will cause erosion of seals and the
deposit of a bacterial slime will clog the system. Bacteria can
attack the o-rings and cause premature failure. Glycol above
20% will kill any bacteria.
Figure 8a. Hydronic System Water Quality Parameters

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D. Storage Water Heater Sizing and Connections
Storage water heaters are necessary with EarthLinked®radiant panel hydronic heating and
chilled water cooling systems, as illustrated in Figures 3, 5 and 6.
ETI Models 60, 80 or 119 GSTE storage water heaters are configured specifically for
hydronic heating and chilled water cooling and meet all requirements for these applications.
Recommended water storage heater capacities are shown in Figure 8b, based on the
nominal tonnage of the compressor unit specified. Typical water heater plumbing
connections are illustrated in Figure 8c.
Compressor Unit
Model/Capacity, BTUH HWM Model ETI Storage
Water Heater Size,
US Gallons
ETI Storage
Water Heater
Element Rating, kW
Minimum Nominal
Type L Hard Copper
Pipe & Fittings, inches
-018/18,000 -18B 60* 4.5 3/4
-024/24,000 -24B 60* 4.5 3/4
-030/30,000 -30B 60* 4.5 1
-036/36,000 -36B 60* 4.5 1
-042/42,000 -42B 80 4.5 1-1/2
-048/48,000 -48B 80 4.5 1-1/2
-060/60,000 -60B 80 4.5 1-1/2
-072/72,000 -72B 80 4.5 1-1/2
* NOTE: These sizes are valid only for hydronic heating. If chilled water cooling is to
be provided, 80 gallon ETI Model 80 GST storage water tank is required.
Figure 8b. Storage Tank Capacities and Pipe Sizes

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Figure 8c. Typical HWM Piping Illustration
E. Circulating Pump, Piping, Strainer and Flowmeter
The HWM system primary circuit piping arrangements for chilled water (to air) cooling and
radiant panel hydronic heating are illustrated in Figures 3 and 4.

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The Hydronic Water Module physical dimensions as well as water solution piping
connections are illustrated in Figure 9.
Figure 9. Hydronic Water Module (HWM)

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Figure 10a lists the minimum nominal Type L hard copper pipe and fitting sizes, and the
strainer required for the primary circuit between the hot water module (HWM) and the
storage water heater.
Compressor Unit Size
& Capacity, BTUH HWM Models Minimum Nominal Type L
Hard Copper Pipe and
Fittings, Inches
ETI Strainer
Model, Size
-018 (18,000) -18B 3/4
ST-1836
1in FPT
-024 (24,000) -24B 3/4
-030 (30,000) -30B 1
-036 (36,000) -36B 1
-042 (42,000) -42B 1-1/2 ST-4272
1-1/2in FPT
-048 (48,000) -48B 1-1/2
-060 (60,000) -60B 1-1/2
-072 (72,000) -72B 1-1/2
Figure 10a. Minimum Water Pipe, Fitting and Strainer Sizes to Storage Water Heater
The flow meter illustrated in Figure 5 is an important component of the system to (1)
commission the performance of the system at startup and (2) determine when maintenance
to the system strainer and/or HWM heat exchanger is required. (See Maintenance in
Section 7.)
ETI part number ETI-A1-116000-1 flowmeter kit has a range of 5-50 GPM and can be field
calibrated for the appropriate antifreeze mixture for the specific application. The kit includes
the flowmeter and the 5 gallon calibration container.
The flow meter kit (see Figure 10b) may be purchased at http://www.buygpi.com/eti-a1-
116000-1.aspx.
Figure 10b. Flowmeter Kit
F. Refrigerant Piping
Refrigerant piping connections and line set sizes are listed in Figure 9.

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5. Controls and Electrical
A. Hydronic Heating and Chilled Water Cooling
Figures 3 and 5 illustrate a typical hydronic heating and chilled water cooling primary circuit
configurations. The use of a three-way valve is shown in these illustrations. For heating,
the valve is normally open with the flow from the HWM directed DOWNWARD providing
heated water to the storage water heater. When cooling is called for, the valve is energized
and directs chilled water UPWARD to the hydronic circulating pump.
The electrical field wiring for the HHK-1872 hydronic hot water temperature controller and
the electric heating element/thermostat; and the CWK-1872 chilled water temperature
controller is illustrated in Figure 10c (Part 1 of 2) and 10c (Part 2 of 2).
Figure 10c. (Part 1 of 2) Electrical Field Wiring
– Hydronic Heating and Chilled Water Cooling (HWM)

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Figure 10c. (Part 2 of 2) Electrical Field Wiring
– Hydronic Heating and Chilled Water Cooling (HWM)
B. Chilled Water Cooling
The electrical field wiring for the CWK-1872 chilled water temperature controller is
illustrated in Figure 10d (Part 1 of 2) and 10d (Part 2 of 2).

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Figure 10d. (Part 1 of 2) Electrical Field Wiring
– Chilled Water Cooling (HWM)
Figure 10d. (Part 2 of 2) Electrical Field Wiring – Chilled Water Cooling (HWM)