Marstair 526 HL, 527 HLR Technical Manual

Download

Page 1

-1-

TECHNICAL MANUAL

for HL/HLR WALL MOUNTED

SPLIT SYSTEMS

(with CEILING MOUNTED OPTION)

This manual provides technical and installation information for HL/HLR WALL MOUNTED split systems comprising:

INDOOR UNIT 526 series HL

527 series HLR

MATCHED WITH 550 series MCU or MCU+ condensing units

551 series MHPUE heat pump units.

INDEX PAGE

GENERAL Part numbers, dimensions and weights 2 - 3

Unit features/accessories 3

SELECTION Unit combinations, performance data 4

Airflows, sound pressure levels 5

ELECTRICAL Electrical data, recommended fuse sizes 6 - 7 UNIT HL/HLR 8

INSTALLATION MCU(+) and MHPUE units 9 - 10

Pipework, restrictors 10 - 12 Condensate removal, air deflection 12 HLR remote controller 13 Electrical connections 14 HLR conversion to air conditioner mode 14 Evacuating and charging 15

WIRING HL/HLR units 16 DIAGRAMS MCU(+) 17 - 18

MHPUE 19 - 20 Interconnection 21 - 23

OPERATION HL/HLR 24 - 25 MAINTENANCE User maintenance 25 HL/HLR KITS Ceiling mounting 26

Condensate pump 27 - 28 LPHW coil 29 De-ice thermostat 30

FAULT FINDING All units 31

TEV Ltd., Armytage Road, Brighouse, West Yorkshire. HD6 1QF, UK. Tel: +44 (0) 1484 405600 Fax: +44 (0) 1484 405620 52708017-06 Email: [email protected]

Page 2

-2-

TEV LIMITED - HL/HLR SPLIT SYSTEMS

The HL/HLR range of split systems comprises the 526 series HL indoor unit with in-built electromechanical controls, the 527 series HLR indoor unit with hard wired remote control, the 550 series outdoor condensing units and the 551 series heat pump outdoor units.

By choosing appropriate combinations, the installer can provide:

AIR CONDITIONERS with a cooling range of 7.9 - 13.8 kW,

or HEAT PUMP systems with a cooling range of 7.9 - 12.8 kW, and a heating range of 9.1 - 13.2 kW with an outdoor

temperature of 7°C

PART NUMBERS

526/527 Series HL/HLR INDOOR UNITS

HL Models 380 460 540 Part Number

52600010 52600009 52600007

HLR Models 380 460 540 Part Number

52700020 52700021 52700022

550 Series CONDENSING UNITS (MCU/MCU+)

MCU 1Ph

Scroll

MCU 90

MCU 3Ph

Scroll

MCU 90 MCU 100 MCU 130 MCU 165

R407C

55022052

R407C

55022058 55022059 55022060 55022062

R22

55022073

R22

55022079 55022080 55022081

55022083

MCU+ 1Ph

Scroll

MCU+ 90

MCU+ 3Ph

Scroll

MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165

R407C

55022009

R407C

55022016 55022017 55022018 55022020

R22

55022031

R22

55022037 55022038 55022039 55022041

551 Series HEAT PUMP UNITS (MHPUE)

MHPUE 1Ph

Scroll

MHPUE 90

MHPUE 3Ph

Scroll

MHPUE 90 MHPUE 100 MHPUE 130

R407C

55122008

R407C

55199014 55199015 55199016

R22

55122026

R22

55199032 55199033 55199034

UNPACKED DIMENSIONS AND WEIGHTS

HL/HLR INDOOR UNITS

Model HL/HLR

380 460 540

HEIGHT mm

786 786 786

WIDTH mm

1170 1320 1520

DEPTH mm

288 288 288

WEIGHT kg

58 62 69

CONDENSING UNITS

Model MCU(+) 90 MCU(+) 100 MCU(+) 130 MCU(+) 165 HEIGHT mm

820 820 1070 1070

WIDTH mm

1000 1000 1000 1000

DEPTH mm

350 350 425 425

WEIGHT kg

73 (76*) 81 101 103

* Single phase

HEAT PUMP OUTDOOR UNITS

Model MHPUE 90 MHPUE 100 MHPUE 130 HEIGHT mm

680 820 1070

WIDTH mm

905 1000 10001000

DEPTH mm

350 425 425

WEIGHT kg

75 (77*) 101 102

* Single phase

PACKED DIMENSIONS AND WEIGHTS

Page 3

-3-

HL/HLR INDOOR UNITS

Model HL/HLR

380 460 540

HEIGHT mm

850 850 850

WIDTH mm

1210 1360 1560

DEPTH mm

305 305 305

WEIGHT kg

63 74 82

CONDENSING UNITS

Model MCU(+) 90 MCU(+) 100 MCU(+) 130 MCU(+) 165 HEIGHT mm

820 820 1080 1080

WIDTH mm

109 1090 1090 1090

DEPTH mm

390 390 465 465

WEIGHT kg

75 (78*) 83 105 107

* Single phase

HEAT PUMP OUTDOOR UNITS

Model MHPUE 90 MHPUE 100 MHPUE 130 HEIGHT mm

820 1080 1080

WIDTH mm

1090 1090 1090

DEPTH mm

390 465 465

WEIGHT kg

77 (79*) 105 106

* Single phase

FEATURES/ACCESSORIES

INDOOR UNITS

HL HLR

Manual air deflection

De-ice thermostat

3 fan speeds

STD STD

Remote hard wired control

*STD

Programmable timer

Condensate pump

Ceiling mounting kit

Floor mounting kit

LPHW coil

Long life washable filter

STD STD

Fresh air inlet facility

STD STD

Air deflectors

OUTDOOR UNITS

MCU MCU+ MHPUE

CSR hard start (1 phase)

** *

PTC hard start (1 phase)

** *

Fan speed head pressure control

*STDSTD

LP cutout auto

*STDSTD

HP cutout auto

* STD ---

HP cutout auto (with manual

--- --- STD

Isolator

** *

3 minute start time delay

*STDSTD

Wall mounting brackets

** *

Contactor

STD STD STD

Overload (standard on 3Ph)

** *

MHPUE condensate drain

--- --- *

Low ambient start

--- --- STD

Volt free relay

** *

Key: * = site option. STD = standard. --- = not available

Page 4

-4-

PRODUCT SELECTION

Combinations of indoor unit and condensing/heat pump unit can be chosen to give either air conditioning or heat pump systems.

UNIT COMBINATIONS

Air Conditioning Systems Heat Pump Systems

HL/HLR MCU(+) HL/HLR MCU(+) HLR MHPUE

380 100 380 90 380 90 460 130 460 100 460 100 540 165 540 130 540 130

AIR CONDITIONER PERFORMANCE DATA (All duties in kW)

UK CONDITIONS ROOM 21°C/15°C

AMBIENT 27°C/19°C

EUROVENT (NEMA)

ROOM 27°C/19°C

AMB 35°C/24°C

TROPICAL

ROOM 29°C/19°C

AMB 46°C/24°C

MODEL

COMBINATIONLOW MIN SPEED MAX SPEED MAX SPEED EVAP MAX SPEED EVAP

HL/HLR+ MCU(+) TO SHR SENS TOT SH SEN TOTAL SHR SENS TOTAL SHR SENS

380 + 90 6.95 0.75 5.19 7.39 0.83 6.14 7.9 0.83 6.6 7.00 1.00 7.00 380 + 100 7.16 0.74 5.29 7.69 0.82 6.27 8.5 0.80 6.8 7.47 1.00 7.47 460 + 100 8.49 0.71 6.05 9.37 0.82 7.64 10.0 0.82 8.2 8.73 1.00 8.73 460 + 130 10.4 0.68 7.02 11.48 0.75 8.60 12.3 0.78 9.6 10.86 0.93 10.04 540 + 130 11.0 0.69 7.63 12.02 0.79 9.46 12.8 0.83 10.6 11.15 0.92 10.27 540 + 165 11.9 0.68 8.14 13.19 0.76 10.00 13.8 0.80 11.0 12.26 0.95 11.66

For medium speed duties, interpolate between minimum speed and maximum speed duties. Rating conditions are to BS2852: Part 1: 1982: UK condition C; NEMA condition A; Tropical condition B.

HEAT PUMP PERFORMANCE DATA

a. Cooling, (kW, max speed outdoor unit fan).

UK CONDITIONS EUROVENT (NEMA)

ROOM 21°C/15°C

AMBIENT 27°

C/19°C ROOM 27°C/19°C AMBIENT 35°C/24°C

MIN SPEED INDOOR FAN MAX SPEED INDOOR FAN MAX SPEED INDOOR FAN

HL/HLR TOTAL SHR SENS TOTAL SHR SENS TOTAL SHR SENS

380 6.95 0.75 5.19 7.39 0.83 6.14 7.9 0.83 6.6 460 8.49 0.71 6.05 9.37 0.82 7.64 10.0 0.82 8.2 540 11.02 0.69 7.63 12.02 0.79 9.46 12.8 0.83 10.6

b. Heating, (Room 20°C/12°C with outdoor unit fan running at maximum speed).

HEATING OUTPUT AT 7°C AMBIENT HEATING OUTPUT AT -1°C AMBIENT

MAX SPEED INDOOR FAN MAX SPEED INDOOR FAN

HL/HLR kW COP kW COP

380 9.1 2.9 7.8 3.0 460 11.6 3.7 10.0 3.5 540 13.2 4.0 10.6 3.4

Page 5

-5-

AIRFLOWS HL/HLR UNITS

Minimum Medium Maximum

HL/HLR CFM m

/s CFM m3/s CFM m3/s

380 805 0.38 1000 0.47 1145 0.54 460 850 0.40 1100 0.52 1400 0.66 540 1000 0.47 1290 0.61 1650 0.78

AIRFLOWS OUTDOOR UNITS

MIN Speed MAX Speed

Model CFM m

/s CFM m3/s

MCU(+) 90 --

1440 0.68 2420 1.14

MCU(+) 100 MHPUE 90

1440 0.68 2420 1.14

MCU(+) 130 MHPUE 100

2840 1.34 3690 1.74

MCU(+) 165 MHPUE 130

2840 1.34 3690 1.74

SOUND PRESSURE LEVELS HL/HLR UNITS

Sound Pressure Levels

MODEL Speed dBA NC

380

Min

50 42

Med

53 47

Max

57 51

460

Min

47 41

Med

53 47

Max

59 53

540

Min

48 42

Med

53 48

Max

59 53

Sound Pressure Levels are dB relative to 2 x 10

-5

N/m2 and are calculated from the results under anechoic conditions and are

quoted as an average of all points on a hemisphere of a radius of 3m away from the centre of the unit.

SOUND POWER and SOUND PRESSURE LEVELS

550/551 SERIES MCU, MCU+ and MHPUE

MAXIMUM SPEED

SOUND POWER LEVELS

SOUND PRESSURE

LEVELS

Frequency Hz

MCU(+) MHPUE Compressor 125 250 500 1K 2K 4K dBA dBA NC

90 90

Scroll 81.8 71.8 69.2 68.6 63.1 57.4 72.8 52.3 47

100 --

Scroll 79.4 73.7 71.5 68.5 63.8 58.1 73.4 52.9 47

-- 100

Scroll 79.0 69.7 68.6 65.9 61.2 55.2 71.0 50.5 44

130 130

Scroll 73.0 70.3 70.0 68.8 65.0 56.7 72.6 52.1 47

165 --

Scroll 73.1 70.3 70.1 68.9 65.5 57.5 73.1 57.2 51

MINIMUM SPEED

SOUND POWER LEVELS

SOUND PRESSURE

LEVELS

Frequency Hz

MCU(+) MHPUE Compressor 125 250 500 1K 2K 4K dBA dBA NC

90 90

Scroll 79.0 65.4 64.9 61.5 58.5 53.7 67.6 47.1 40

100 --

Scroll 75.3 69.4 70.9 63.7 59.7 53.6 70.4 49.9 46

-- 100

Scroll 67.1 67.9 65.0 61.2 56.3 51.0 66.9 46.4 40

130 130

Scroll 65.4 66.7 68.1 66.1 63.1 53.0 70.0 49.5 44

165 --

Scroll 65.5 66.9 67.3 65.1 64.2 54.0 72.6 52.6 47

Sound Power Levels were obtained in full accordance with the direct method of ISO 3741: 1988. Quantities are shown in dB with a standard reference of 1 pW. Sound Pressure Levels are dB relative to 2 x 10

-5

N/m2 and are calculated from the results under free field conditions and are quoted as an average of all points on a sphere of a radius of 3m away from the centre of the unit (in cooling mode); (add 3dBA or 3NC for units at an intersection of a wall, add 1dBA or 1NC for high level wall mounted units).

Page 6

-6-

ELECTRICAL DATA (Cooling Data rated at EUROVENT (NEMA) conditions)

(Heating Data rated at 20°C/12°C indoor; 7°C/6°C ambient)

a) R22 Air Conditioning Systems

Single Phase Supply 230Volts - 50Hz Three Phase Supply 400 Volts - 50Hz

MODEL

COMBINATION

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

Cooling Cooling Cooling Cooling

HL/HLR + MCU(+) kW AMPS AMPS kW A/PH A/PH

380 + 90 4.3 17.5 116 4.3 8.3 50 380 + 100 -- -- -- 4.3 8.4 53 460 + 100 -- -- -- 4.3 8.5 53 460 + 130 -- -- -- 4.9 9.0 64 540 + 130 -- -- -- 4.9 9.2 64 540 + 165 -- -- -- 6.3 11.1 73

b) R22 Heat Pump Systems

Single Phase Supply 230Volts - 50Hz Three Phase Supply 400 Volts - 50Hz

MODEL

COMBINATION

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

STD.

MODEL

STD.

MODEL

STD.

MODEL

STD.

MODEL

HL/HLR + MHPUE kW AMPS AMPS kW A/PH A/PH

380 + 90 4.3 17.5 114 4.3 8.3 60 460 + 100 -- -- -- 4.3 8.7 63 540 + 130 -- -- -- 4.9 9.2 74

c) R407C Air Conditioning Systems

Single Phase Supply 230Volts - 50Hz Three Phase Supply 400 Volts - 50Hz

MODEL

COMBINATION

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

Cooling Cooling Cooling Cooling

HL/HLR + MCU(+) kW AMPS AMPS kW A/PH A/PH

380 + 90 4.4 18.2 116 4.4 8.4 50 380 + 100 -- -- -- 4.6 8.5 53 460 + 100 -- -- -- 4.6 8.6 53 460 + 130 -- -- -- 4.9 9.1 64 540 + 130 -- -- -- 4.9 9.3 64 540 + 165 -- -- -- 6.5 11.1 73

d) R407C Heat Pump Systems

Single Phase Supply 230Volts - 50Hz Three Phase Supply 400 Volts - 50Hz

MODEL

COMBINATION

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

INPUT FULL LOAD AMPS

SYSTEM

MAX.

STARTING

CURRENT

STD.

MODEL

STD.

MODEL

STD.

MODEL

STD.

MODEL

HL/HLR + MHPUE kW AMPS AMPS kW A/PH A/PH

380 + 90 4.4 18.2 114 4.4 8.4 60 460 + 100 -- -- -- 4.6 8.7 63 540 + 130 -- -- -- 4.9 9.3 74

Page 7

-7-

Electrical Loads (At 230 Volts 50 Hz 1Ph or 400 Volts 50 Hz 3PhN)

HL/HLR

380 460 540

FAN MOTOR

1.3 1.4 1.6

MCU(+)

90 100 130 165

FAN MOTOR

1.0 1.0 1.2 1.2

R407C COMPRESSOR (1 PHASE) NOMINAL FLA

15.9------

R407C COMPRESSOR (3 PHASE) NOMINAL FLA

6.1 6.2 6.7 8.5

R22 COMPRESSOR (1 PHASE) NOMINAL FLA

15.2------

R22 COMPRESSOR (3 PHASE) NOMINAL FLA

6.0 6.1 6.4 8.3

MHPUE

90 100 130

FAN MOTOR

1.0 1.2 1.2

R407C COMPRESSOR (1 PHASE) NOMINAL FLA

15.9 -- --

R407C COMPRESSOR (3 PHASE) NOMINAL FLA

6.1 6.2 6.7

R22 COMPRESSOR (1 PHASE) NOMINAL FLA

15.2 -- --

R22 COMPRESSOR (3 PHASE) NOMINAL FLA

6.0 6.1 6.4

Recommended Fuse Sizes (R22 and R407C systems)

The system and its supply/interconnecting wiring must be protected by fuses, preferably High Rupture Current (HRC) motor rated types (to EN 60269) or miniature circuit breakers (to EN 60898) or local codes having similar time lag characteristics, that allow starting of the compressor yet still afford close overcurrent protection under running conditions. The ratings below are for HRC motor rated fuses.

Air Conditioners

HL/HLR + MCU(+) 380 + 90 380 + 100 460 + 100 460 + 130 540 + 130 540 + 165 1 Phase cool only

32 -- -- -- -- --

3 Phase cool only

16 16 16 16 16 20

Heat Pumps

HL/HLR + MHPUE 380 + 90 460 + 100 540 + 130 1 Phase cool only

32 -- --

3 Phase cool only

16 16 20

Page 8

-8-

HL/HLR Installation

An envelope containing important user information is supplied with the indoor unit. Please pass this to the end user.

Indoor Unit Cabinet Removal

1. Press the filter tray at both sides to spring it and the filter out (Fig.1).

2. Remove the two outer self tap screws then release the quarter turn fasteners.

3. Pivot the cabinet forward from the bottom and lift upwards to clear the

chassis top flange and remove, this will reveal the polystyrene fan scrolls which should NOT be removed.

Fig. 1

Weight (kg)

HL/HLR 380

HL/HLR 460

HL/HLR 540

4. The unit is shipped with a bracket to protect the motor during transit. Remove and discard

the bracket, and fit the motor wiring plug and

socket as shown.

Mounting

1. It is generally easier to fit kits prior to mounting the unit and brazing the pipework.

2. Ensure that the wall or ceiling will accept the operating weight of the unit.

3. Mark off the mounting holes as Fig.2 and drill holes to suit M6 rawlbolt shields or equivalent fasteners.

Allow 130mm minimum from ceiling to holes for cabinet removal on wall mounted units. Allow 150mm at the base plate (wall or ceiling mounted) to maintain design airflows.

4. If a fresh air facility is required, apertures must be prepared as shown in Fig.2. This must be suitably lined and screened on the internal wall to prevent brick dust from entering the unit, (apertures are 35mm high), filters are fitted as standard.

5. Mount the unit and secure the fixings. On ceiling mounted uni ts t wo extra holes are provided for screws to prevent movement on the keyhole slots.

6. Check the unit is square and level. Use the extra self tap screws to additionally secure ceiling mounted cabinets.

Fig. 2

Model 'A' 'B' 'C' 'D'

No. of

air inlets

No. of

spaces

HL/HLR 380

961 921 461 250 2 1

HL/HLR 460

1111 1071 536 300 2 1

HL/HLR 540

1311 1271 626 240 3 2

Page 9

-9-

MOUNTING HOLES

550 Series CONDENSING UNITS and 551 Series HEAT PUMP OUTDOOR UNITS INSTALLATION

These outdoor units are for use in systems which use expansion devices.

MCU = standard condensing unit MCU+ = standard condensing unit + FSC + LP MHPUE = electronic heat pump outdoor unit

Some units are supplied with a number of loose restrictors which may be required, depending on the indoor unit it is matched with and whether the unit is to be run in NEMA conditions; refer to page 11.

The installer needs:

2 open ended spanners for securing the flare fittings A 4 or 5mm Allen Key for the valves (dependant on valve type).

Note: It is easier to fit kits prior to mounting the unit.

These units are designed to stand on a flat surface. If the unit is to be wall mounted the following kits are available. (TEV cannot accept liability for installers own mounting arrangements).

Model MCU(+) 90 - 100/MHPUE 90 MCU(+) 130 - 165/MHPUE 100 - 130 Mounting Bracket Kit

55021100 55021101

Whether floor or wall mounted, it is essential that the mounting surface is capable of supporting the unit weight (shown over). Leave space around the unit for air circulation and access for installation and maintenance.

MOUNTING: MCU(+) 90 - 100 and MHPUE 90

All dimensions are in millimetres.

MODEL ABCDEFGH

Weight (kg)

1 Ph 3

MCU(+) 90

1000 350 760 495 250 70 345 325 76 73

MCU(+) 100

1000 350 760 495 250 70 345 325 -- 81

MHPUE 90

1000 350 760 495 250 70 345 325 77 75

Page 10

-10-

A10

MOUNTING HOLES

417

397

425

MOUNTING: MCU(+) 130 - 165 and MHPUE 100 - 130

All dimensions are

in millimetres.

MODEL A B C D E Weight (kg) MCU(+) 130

1000 1020 495 251 100 101

MCU(+) 165

1000 1020 495 251 100 103

MHPUE 100

1000 1020 495 251 100 101

MHPUE 130

1000 1020 495 251 100 102

APPLICATION

1. To maximise performance, pipe runs should be kept as short as possible, avoiding sharp bends. However,

individual pipe runs to a maximum of 80m, including 20m lift, are permissible provided good refrigeration practice is followed.

Published performance duties are based on 7.5m pipe runs. Correctly sized pipes for each installation, and fitting the correct expansion orifice (restrictor) will result in no significant loss of capacity on extended pipe runs.

a) Pipe sizes are based on:-

Minimum of 3.8 m/s (750 fpm) suction gas velocity for horizontal or downflow. Minimum of 7.6 m/s (1500 fpm) suction gas velocity for upflow. Maximum of 15.2 m/s (3000 fpm) suction gas.

b) Where vertical risers exceed 3m, oil traps must be formed in the pipe. This will help ensure that oil returns to

the compressor. Typically fit an oil trap every 3m with a trap at the bottom of the riser.

2. Add 25 grams of refrigerant oil (Polyolester Oil) for every 350 grams of charge added to systems with pipe runs

exceeding 25m, up to a maximum of 300 grams; preferably by slowly pumping into the suction side with the unit running, after charging the system.

3. The maximum pipe lengths to be used for each pipe size and outdoor unit are shown in the table opposite. Use of

these sizes and lengths is recommended in order to achieve optimum system performance.

Page 11

-11-

MAXIMUM EQUIVALENT LENGTH OF

SUCTION LINE

PIPES (M)

EXPANSION

LINES

UNIT 3/8 1/2 5/8 3/4 7/8 1-1/8 1-3/8 3/8 1/2 5/8 3/4 MCU(+) 90

10 25 55 80 20 80

MCU(+) 100

7.52245 80 1580

MCU(+) 130

15 30 80 12 60 80

MCU(+) 165

8 18 60 80 7.5 40 80

MHPUE 90

25 55 80 20 60 80

MHPUE 100

22 45 80 15 50 80

MHPUE 130

15 30 80 12 60 80

RESTRICTORS

Outdoor units are supplied with cooling restrictors fitted in an expansion assembly; refer to the following tables for any restrictor changes: those ticked do not require changing. Where appropriate,the alternative restrictor is supplied in either the indoor or the outdoor unit. A capillary is fitted to HLR units for refrigerant control during a heat pump heating cycle.

RESTRICTOR MATCHES

AIR CONDITIONING AT UK CONDITIONS AIR CONDITIONING AT NEMA CONDITIONS

3 = NO RESTRICTOR CHANGE NEEDED RESTRICTOR CHANGE NEEDED

MCU(+)

Restrictor

Fitted

HL/HLR

MCU(+)

Restrictor

Fitted

HL/HLR

380 460 540 380 460 540

63 066

100

68 071 71

130

0.071

130

71 74 074

165

79 083

HEAT PUMP COOLING AT UK CONDITIONS HEAT PUMP COOLING AT NEMA CONDITIONS

3 = NO RESTRICTOR CHANGE NEEDED RESTRICTOR CHANGE NEEDED

MHPUE

Restrictor

Fitted

HL/HLR

MHPUE

Restrictor

Fitted

HL/HLR

380 460 540 380 460 540

67 070

100

68 71

130

76 080

3 = no change needed

4. In calculating equivalent lengths of pipe runs, the effect of bends and fittings mu st b e taken into account. The table

below covers the fittings most likely to be encountered in this type of installation. The equivalent lengths of all the fittings in a pipe run must be added together and the total added to the actual length of pipe in the run, in order to calculate the total equivalent length.

Pipe Size (outside diameter in inches) Fitting 3/8 1/2 5/8 3/4 7/8 1-1/8 45° Bend

0.12 0.15 0.18 0.21 0.24 0.3

90° Bend R/d = 1

0.37 0.43 0.49 0.55 0.61 0.79

90° Bend R/d = 1.5

0.24 0.27 0.30 0.37 0.43 0.52

180° Bend C/d = 1.5

0.73 0.91 1.10 1.28 1.46 1.83

180° Bend C/d = 2.5

0.46 0.55 0.64 0.76 0.85 1.07

90° Elbow

0.67 0.85 1.04 1.25 1.46 1.89

R = Radius of bend d = Diameter of tube C = Centres of bend

Fitting losses, in equivalent straight lengths of pipe (metres).

5. Use the shortest possible route, avoiding sharp bends.

6. Fully insulate both the suction and expansion lines, including the expansion device, since both lines may sweat.

Page 12

-12-

Refrigeration Installation

1. The refrigerant connections are terminated on the left hand side of the indoor coil and the lower front of the right end

panel on outdoor units; (indoor units are brazed connections, outdoor units are flare fittings). Units are supplied with the following pipes: (HL are the same as HLR models; MCU+ are the same as MCU models).

HLR 380 HLR 460 HLR 540 MCU 90 MCU 100 MCU 130 MCU 165 MHPUE 90 MHPUE 100 MHPUE 130

Expansion

1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"

Suction

5/8" 5/8" 5/8" 5/8" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4"

2. Using a tube cutter, remove sealed ends of suction and expansion pipes on the indoor unit. This will release a small holding charge of dry nitrogen.

3. Pipe exit will normally be via knockouts in the base or cutouts in the back panel. Alternatives are: For top left hand exit, turn your pipework through 180° and exit via the gap provided in the back panel. The cabinet will need to be locally notched as Fig. 3 - do not completely cut away as this will weaken the structure.

BOTTOM RIGHT HAND EXIT can be achieved by running pipework underneath the scroll attached to the back panel. Remove the lower grille (4 screws) for access, fit suitable lengths of insulation to the pipework and braze in. It is recommended that the liquid and suction lines be kept to ½" and 5/8" respectively until exit, when the full pipe size can be run. Exit is preferably made via notches to be cut to suit in the right hand side panel.

4. It is recommended that the drip tray is removed during brazing to prevent if being melted. Remove the top two screws on the front scroll, and remove drip tray and the support bracket together.

5. Connect pipework between units ensuring: a) Only refrigeration quality copper is used. b) The ends are capped on tubes and parts when not working on them to prevent moisture or dirt entering the

system.

c) If pipes are brazed, use a copper phosphorous alloy containing 5% silver, ensuring that dry nitrogen is passed

through the components involved to prevent oxidation.

d) The suction and expansion lines are fully insulated, including inside the cabinet of the indoor unit up to the drip

deflector. Bend pipework back to ensure it is over the drip tray; if in doubt, use non-drip tape.

e) The system is leak tested and evacuated before final charging.

6. If a sight glass is fitted to aid charging it must be positioned before the expansion device on the outdoor unit.

Condensate Drain

The condensate drain connection is at the left hand end of the drain tray. A ½" O.D. plastic drain pipe is provided in the drain tray sump for connection with non-kink plastic tubing secured with a suitable clip. Should it be necessary for the drain pipe to go through the bottom of the unit a knockout is provided at the left hand end of the base plate. The drain line must have a constant fall to open drain using a ''U' trap if required. Check that the water will run freely and that there are no leaks. Details of ceiling mounted drain and fitting of optional condensate pump are provided on pages 25 to 27.

Discharge Grille position

The discharge grille is supplied for front down discharge. The alternatives are achieved by:

i) Remove and retain grille and blanking panel screws (12 in total). ii) Slacken but do not remove all other fixing screws. iii) Remove blanking panel. iv) Remove grille. v) Slide blanking panel into new position and fix. vi) Clip panel location bracket under return edge of blanking panel and screw down into return edge of front panel.

Page 13

-13-

Page 14

-14-

ELECTRICAL CONNECTIONS

Supply, control and connecting cables are fitted by the installer. Installer wiring should be carried out in accordance with local and national codes. Cables must be size compatible with the recommended fuse for a given system. (see page 7 for fuse ratings). A double pole isolator switch should be positioned adjacent to the indoor unit. The equipment must be earthed. Systems should have the supply taken to the outdoor unit; a single phase supply (L1), is run back to the indoor unit. Power should be connected to the outdoor unit for 4 hours to allow the lubricating oil to be heated prior to compressor start up.

INDOOR UNIT WIRING

The connections for internal wiring for indoor units are made at the right hand side of the unit. Mains supply should be routed to the terminal blocks in the unit through the slots behind the fan motor if brought from below. Cable grips are provided above the terminal block to give a secure installation.

Note that the electrics assembly can be quickly removed if required by removing 2 screws from the evaporator flange and springing the electrics mounting plate free of locating slots in the rear panel. These screws and washers form the earth connection to the air handler and must be securely re-fitted.

Make sure all connections are secure and all wires are clear of rotating parts. Interconnect as shown on pages 21 to 23.

CONVERSION OF HLR INDOOR UNIT FOR AIR CONDITIONER USE

The HLR indoor unit is supplied wired for use as a heat pump.

For air conditioner mode, remove the pink link between relay 1 terminal 14 and relay 2 terminal 22.

OUTDOOR UNIT WIRING

Cable entry for the outdoor unit electrics is through the cabinet to a terminal block.

MCU+, MHPUE and DCUE units are supplied wired via a head pressure controller to give maximum control. Ensure that all connections are secure and that both units are earthed.

MCU unit fan motors have a high speed (black) wire and a low speed (red) wire; the speed not being used is w ired into a dummy terminal. They are supplied wired for low fan speed, which is suitable for temperate climates. If continuous running is expected at ambient temperatures of 35°C or higher, change to high speed by interchanging the black and red wires, i.e. black to fused terminal, red to terminal 4 (single fan units) or terminals 4 and 8 (double fan units).

SCROLL COMPRESSOR ROTATION

On 3 Phase units it is possible for the scroll compressor to run backwards. This becomes obvious on start u p; the compressor will not develop a normal running pressure differential and the top will not become warm. It may be excessively noisy. If this happens, switch off the mains power and exchange any two of the phases supplying the unit. This will correct the rotation of the compressor.

DATA PLATES

Because of the ability to match indoor and outdoor units, the data plates only give information on either an indoor or outdoor unit. To obtain the system details, input power and currents from indoor and outdoor units should be added.

FIRE LINK

In order to automatically switch off the fan in the event of a fire, it is necessary to fit an external switch (240V, 3A, closed to run, volt free contact) to:-

HLR units

: in the installer wire between terminal block terminal 2 and the Marstair remote control thermostat terminal

2(96000320) or L (97200211)

HL units

: in the internal (black) wire between the fuse and rotary switch terminal 'd'. This external switch should be

operated by the building's fire alarm or BMS system.

Page 15

-15-

EVACUATING

Connect a vacuum pump to the service ports on the outdoor unit valves and evacuate the interconnecting pipework and indoor unit to 1000 microns (1 Torr) or better and allow to be held for a minimum of 15 minutes.

After evacuating the indoor unit and interconnecting pipework, open the outdoor unit valves using a 5mm Allen key. The high and low side pressures should equalise within a minute.

Run the system for a few minutes to allow it to stabilize. If a manual HP cutout is fitted, ensure that the reset button is depressed (in the compressor compartment, outdoor unit).

MHPUE units: if no extra refrigerant is to be added REMOVE link JP6 (in the electrics box, outdoor unit, identified by a white label), otherwise the unit will always run at full speed.

ADDING REFRIGERANT

Each outdoor unit is charged with refrigerant, as below:-

MCU(+)90 MCU(+) 100 MCU(+) 130 MCU(+) 165 MHPUE 90 MHPUE 100 MHPUE 130

FACTORY CHARGE (g) (sufficient for up to 7.5m runs at UK conditions)

R407C 2060 2520 4170 4540 2260 3380 4470

R22 1960 2400 3970 4320 2330 3490 4610

1. Ensure the refrigerant being added is the same refrigerant that the system was originally charged with.

2. Refrigerant should be introduced with the system in the AIR CONDITIONING MODE (including heat pumps).

3. Refrigerant should be charged through the Schrader valve on the indoor unit, or the service port on the suction

service valve on the outdoor unit.

4. Indoor and outdoor units should be run at maximum fan speed during charging:

Set the indoor unit to operate in cooling mode at maximum speed. MHPUE are supplied with link JP6 fitted on the outdoor unit pcba; this is only for charging, overriding alarms

and running the MHPUE fan at maximum speed during the charging process.

(Do not forget to remove it once charging is complete: see 10) MCU+ outdoor units are fitted with head pressure control; before charging, isolate the unit and transfer the

blue wire on the head pressure control from terminal 4 to terminal 1. (Do not forget to transfer it back once charging is complete: see 10)

5. All systems with pipe runs longer than 7.5m (UK or NEMA) require added refrigerant.

As a guide, add:- 1/2" Expansion line add 30 g/m; 5/8" Expansion line add 48 g/m.

6. Further refrigerant needs to be added if the system is to be run at NEMA conditions (27°C/19°C indoor, 35°C

ambient) :-

MCU(+)90 MCU(+) 100 MCU(+) 130 MCU(+) 165 MHPUE 90 MHPUE 100 MHPUE 130

Extra refrigerant required for NEMA conditions (g)

R407C 115 145 250 200 180 250 200

R22 110 140 240 190 190 260 210

7. Run the system for a few minutes to allow it to stabilize.

8. If a sight glass is fitted, it should be just clear of bubbles (flooded).

9. Indications of incorrect charge are:-

Undercharged unit: The top few tubes of the evaporator are dry and there are (possibly) slight signs of

frosting at the inlet to the evaporator coil.

Overcharged unit: The suction line 'sweats' all the way back to the compressor.

10. MHPUE units: once refrigerant has been added, REMOVE link JP6 (in the electrics box, outdoor unit, identified by a

white label), otherwise the unit will always run at full speed. MCU(+) units: once refrigerant has been added, transfer the blue wire on the head pressure control back

from terminal 1 to terminal 4.

11. MHPUE units: a random start delay of up to 1 minute occurs when mains is first applied. A 3 minute delay occurs

between successive compressor operations on all systems incorporating MHPUE units, or MCU(+) units fitted with a 3 minute timer kit.

Page 16

-16-

HL WIRING DIAGRAM

HLR WIRING DIAGRAM

Page 17

-17-

MCU WIRING DIAGRAMS

1 Phase MCU 90 3 Phase MCU 90 to 100

3 Phase MCU 130 to 165

Page 18

-18-

MCU+ WIRING DIAGRAMS

1 Phase MCU+ 90 3 Phase MCU+ 90 to 100

3 Phase MCU+ 130 to 165

Page 19

-19-

MHPUE WIRING DIAGRAMS

1 Phase MHPUE 90

3 Phase MHPUE 90

Page 20

-20-

3 Phase MHPUE 100 to 130

Page 21

-21-

HL INTERCONNECTING WIRING DIAGRAMS

HL 380 + 1 Phase MCU(+) 90

HL 380 to 460 + 3 Phase MCU(+) 90 to 100

Page 22

-22-

HL 460 to 540 + 3 Phase MCU(+) 130 to 165

HLR INTERCONNECTING WIRING DIAGRAMS

HLR 380 + 1 Phase MCU(+) 90 HLR 380 to 460 + 3 Phase MCU(+) 90 to 100

Page 23

-23-

HLR 380 + 1 Phase MHPUE 90 HLR 380 to 460 + 3 Phase MHPUE 90 to 100

HLR 460 to 540 + 3 Phase MCU(+) 130 to 165 HLR 540 + 3 Phase MHPUE 130

Page 24

-24-

HL OPERATING INSTRUCTIONS (using Speed Selector Switch and Thermostat)

The switches to operate the fan speed and thermostat control are located on the right hand side.

The upper knob selects temperature, which is automatically controlled by an internal thermostat that senses return room air.

Lower room temperatures can be maintained by turning the knob clockwise, further towards the snow flake. (Minimum is approximately 19°C room temperature).

Similarly, higher room temperatures can be maintained by turning the knob anticlockwise, further towards the sun.

The lower knob selects the fan speed required, or the Off position.

Knob Position

Effect

Upper Lower

Any

Unit Switched Off

Set

Minimum fan speed with auto control for normal room temperature and lowest sound level

Set

Medium fan speed with auto control

Set

Maximum fan speed giving rapid change of room temperature

HLR OPERATING INSTRUCTIONS FOR 97200211 (RCC30)

Page 25

-25-

HLR OPERATING INSTRUCTIONS FOR 96000320 (7204)

REMOTE CONTROLLER

Controls to operate the fan speeds and thermostat are on the front face of the controller.

ON/OFF AND FAN SPEEDS

The switches on the left hand side control the ON/OFF and fan speed operations. The lower left hand switch is the ON/OFF control. The green neon is lit when the switch is 'ON'. The upper left hand switch operates the fan speeds. The fan speed switch gives minimum fan speed at position , medium fan speed at position and maximum fan speed at position .

TEMPERATURE CONTROL

The right hand knob selects temperature, which is automatically controlled by the thermostat in the remote control housing; the range is factory set from 17°C to 30°C. By turning anti-clockwise, lower room temperatures are maintained; by turning clockwise, higher temperatures. The white neon is lit when the unit is in cooling mode. The amber neon is lit when the unit is in heating mode (if the system includes a heat pump outdoor unit). Neither neon is lit when the thermostat is between cooling and heating.

User Maintenance

Isolate at the mains before commencing any maintenance work. In order to maintain maximum efficiency it is important that the filter behind the return grille is cleaned regularly; this will

normally be every two to three weeks.

SWITCH OFF THE UNIT AND ALLOW THE FAN TO STOP

Remove the filter from the housing. Wash the filter (in tepid water) and dry before use. Alternatively tap the filter gently to remove dust or vacuum

clean.

THE UNIT SHOULD ALWAYS BE USED WITH A FILTER. FAILURE TO DO SO WILL CAUSE A DECLINE IN UNIT PERFORMANCE AND MAY RESULT IN MALFUNCTION.

We recommend that in order to prolong the life and maintain performance of your 'Marstair' units you arrange a regular service contract with your TEV Ltd. installer/dealer.

Page 26

-26-

CEILING MOUNTING KITS - 52600230 to 233

This kit converts HL (526) and HLR (527) indoor units for ceiling mounting.

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

1 1 Ceiling Mounting Drip Tray 5 1 No. 10 x 1/2" Screw 2 1 Left Hand Sealing Plate 6 1 Sensor Bracket 3 1 Right Hand Sealing Plate 4 2 Latch for Filter Carrier

Ceiling mounted units can only have top discharge on the air off grille.

1 Remove the filter tray, release the fasteners and lift off the cabinet. 2 Remove and keep the 4 off No. 10 x 3/8" screws securing the insulation plate to the sealing plates and the 6 off No.

10 x 3/8" screws securing the sealing plates to the coil. Transfer the six grommets from the old sealing plates to the new sealing plates.

3 With the black faces of the new sealing plates innermost, secure them to the coil using 6 off No. 10 x 3/8" screws.

Fig. 1.

Fig. 2.

4 Remove the three No. 10 x 3/4" screws from the ends of the drip tray support bracket and extract the plastic drip tray. 5 Secure the indoor unit in position and braze all pipework 6 Fit the drip tray so that the rear flange is held in position by the drip tray support bracket and refit the three No. 10 x 3/4"

drip tray support bracket screws, (Fig. 1).

7 Use two of th e r e t ained No. 10 x 3/8" screws to secure the drip tray to the lugs at the front of the sealing plates. Use

the No. 10 x 1/2" screw provided in the kit to secure the centre of the rear flange to the centre of the drip tray support bracket, (Fig. 1).

8 If a gravity drain is to be used, pull off the plastic cap from the drain spout, ensure that the drain pipe is kept as low as

possible within the unit and has a constant fall to an open drain. A knockout is provided in the filter tray for cabinet exit.

9 Using four No. 6 x 3/8" screws, secure the two filter carrier retention latches to the rear of the filter carrier, (Fig. 2). 10 Leak test the drip tray and ensure the effectiveness of the gravity drain, (if fitted), before refitting the cabinet; use the

quarter turn fasteners and self tapping screws for additional security. Press the latches towards the filter to fit/release the filter tray

Page 27

-27-

CONDENSATE PUMP KIT 52600240

This kit is for use on all HL/HLR units for the removal of condensate where gravity drain is not practicable or desirable. The pump is capable of overcoming a resistance equivalent to 5 metres lift. The sensor is arranged so that residual condensate in the sump is kept to a minimum. The kit includes an overflow protection circuit which will prevent further cooling and condensate production if a high

condensate level occurs.

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

1 PUMP ASSEMBLY CONSISTING OF: 2 C O N TR O L B O ARD ASSEMBLY

CONSISTING OF:

1Pump 2 Grommet 1 Control Board 2 Hose 4 Mounting Foot 1 Green/Yellow Cable 1 Plastic Cover 1 Bracket

4 Cable Tie

1 Connector

2 No. 6 Screw

2 Cable Tie

1 Sensor Block (with filter)

It is preferable to fit this kit prior to installing the unit; the following instructions refer to bench fitting.

ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTA LLATION OF THIS KIT

WALL MOUNTED UNITS 1 Remove the filter tray, release the fasteners and remove the cabinet,

(Fig. 1).

2 Locate and secure the pcb assembly in the left hand hanger bracket,

(Fig. 2).

3 Remove the rubber boots from the black and blue cables running

across the front of the unit and connect to the pcb, black to L, blue to N.

4 Cut the loop of the red cable (brown on HL u nits) running across the

front of the unit, bare back by 5mm and connect to terminal TB1 on the pcb.

5 Using 2 x No. 6 screws, supplied loose, secure the pump/bracket

assembly to the left hand hanger bracket at the angle shown in Fig. 2.

Use one of the screws to con nect the earth (green/yellow) cable ring terminal between the pump bracket and the hanger bracket.

6 Ease off the edge clips and remove the sensor bracket from the drip

tray. The sensor/filter assembly is supplied fitted to a transition bracket.

a If the unit has been supplied with a sensor bracket w ith screws

fitted, align the holes in the transition bracket with those in the

sensor bracket and connect together with the No. 6 screws (Fig. 3a).

b If the unit has been supplied with a sensor bracket with notches

(no screws) fitted, unhook the sensor/filter from the transition

bracket and discard the transition bracket. Hook the sensor/filter to the unit sensor bracket (Fig. 3b).

Refit the sensor bracket.

7 Push the bottom hose from the pump onto one of the sensor spouts. 8 Connect the red cables from the pump onto the pcb terminals P/L and

P/N. Secure the plastic pcb cover to the red cables.

9 The pump top hose is supplied fitted with a connector suitable for

joining to 8mm bore plastic hose to give condensate outlet. If 1/4" diameter copper is to be used, the connector should be discarded and the hose pushed directly onto the copper for at least 20mm, and be secured with a cable tie.

NOTE: If the condensate outlet pipe bore is less than 8mm and the outlet is below the level of the sump, syphoning may occur which will lead to noise on pumping. To ensure quiet running fit an air break no further than 200mm below the level of the drain tray by pumping into a larger diameter pip e than that from the pump.

10 See opposite for application and testing.

Fig. 1.

Fig. 2.

Fig. 3a. Fig. 3b.

Page 28

-28-

CEILING MOUNTED UNITS 1 Remove the filter tray, release the fasteners and remove the cabinet,

(Fig. 1).

2 Locate and secure the pcb assembly in the left hand hanger bracket,

(Fig. 4).

3 Remove the rubber boots from the black and blue cables running

across the front of the unit and connect to the pcb, black to L, blue to N.

4 Cut the lo op of the red cable (brown on HL units) running across the

front of the unit, bare back by 5mm and connect to terminal TB1 on the pcb.

5 Using 2 x No. 6 screws, supplied loose, secure the pump/bracket

assembly to the left hand hanger bracket at the angle shown in Fig. 4.

Use one of the screws to connect the earth (green /yellow) cable ring terminal between the pump bracket and the hanger bracket.

6 Remov e the sensor bracket from the ceiling mounted drip tray. The

sensor block is supplied fitted to a transition bracket. Hook this bracket onto the two screws in the sensor bracket and fasten the screw s. Refit the sensor block to the drip tray.

7 Push the bottom hose from the pump onto the sensor spout. 8 Connect the red cables from the pump onto the pcb terminals P/L and

P/N. Secure the plastic pcb cover to the red cables.

9 The pump top hose is supplied fitted with a connector suitable for

Fig. 4.

Fig. 5.

TESTING THE PUMP AND CONTROL a Connect a suitably fused supply to the unit (refer to the unit installation instructions). Allow approximately one

minute for the controls and sensor to stabilize.

b Slowly add water to the condensate tray sump until the pump runs. Initially the pump will be noisy until the air

in the hose has been expelled. It is possible that, on this first cycle, the pump will run dry for a short period

(indicated by noise).

c Add more water to the sump and the pump will cycle in the normal manner. d With the system in cooling mode, continue adding water to the sump until it reaches the higher of the sensor

probes. The cooling cycle will shut down, and the pump continue to run, until the water has dropped below the level of this probe.

NOTE: Whenever the electr ical supply to a unit fitted with a condensate pump and controls is interrupted, a delay of

up to 1 minute will occur before the compressor or the pump will start when the supply is reinstated.

TROUBLE SHOOTING Unit will not cool No mains supply to the control board. Pump does not run Fuse on control board blown (315 mA x 20mm)

Sensor disconnected from control board

Cooling is interrupted Restriction in pump flow allowing level to rise and trip overflow circuit

Check for blockage or kink in hoses. Condensate at high level -- tripping overflow circuit Filter blocked -- remove and clean

Excessive pump noise Air leak in hoses and/or joints

Pumping without water in sump -- control board fault Loose connection between sensor and control board Loose fuse, intermittent mains supply to control board. Debris in pump or bottom hose Water syphoning due to lack of air break

Application Notes

1 The pump will work against a 5m head. Flow rate is highest with minimum head. 2 Long lengths of drain pipe should not be exposed to the outdoor ambient, otherwise freezing of condensate may occur

during winter operation.

3 It is not advisable to have the outlet of the drain well below the position of the pump, otherwise the syphon effect may

open the pump valves.

4 For normal applications, i.e., where the drain is level or above the pump or within 3 feet below it, no extra check valves

are needed; the pump has its own internal check valves.

5 Ensure that no hose is kinked, as this could seriously affect the pump performance.

Page 29

-29-

LOW PRESSURE HOT WATER COIL KIT

This kit provides LPHW heating for HL (526) and HLR (527) indoor units. A control valve is not provided in this kit. Since the coil is upstream of the evaporator, a de-ice thermostat is not necessary on the LPHW coil. It is, however, highly recommended to fit a de-ice thermostat to the evaporator to protect the LPHW coil.

UNIT SIZE KIT PART NUMBER Item Qty Description

HL/HLR 380 52600227 1 1 LPHW coil assembly HL/HLR 460 52600226 2 7 Grommet strip HL/HLR 540 52600224

Fitting the LPHW coil is best done prior to installing the unit.

1 Remove the unit cabinet and lay the unit on its backpanel. 2 Remove the three No. 10 electrics tray retaining screws and spring the tray free. 3 Remove the four No. 10 evaporator coil retaining screws and lift the coil away complete with sealing plates and the

insulation plate.

4 Remove and discard the blanking plate from the left hand hanger bracket. 5 Remove the tape covering the slots in the right hand hanger bracket and fit the grommet strips in place, (Fig. 1). 6 Position the end of the LPHW coil into these slots and secure the left hand end plate to the left hand hanger bracket,

(Fig. 2).

Fig. 1. Fig. 2.

7 Replace the evaporator assembly and electrics plate. 8 If a valve is to be fitted, connect to the indoor unit as shown in either Fig. 3, (HL) or Fig. 4, (HLR).

Fig. 3 526 Models Fig. 4 527 Models.

Page 30

-30-

EVAPORATOR DE-ICE THERMOSTAT KIT 52600242

This kit stops the compressor running during cooling mode if the indoor coil starts to ice up, (due to lack of charge, blocked filter or over condensing). This kit MUST be fitted to all HL/HLR units w ith LPHW coils fitted, to provide protection against the hot water system freezing.

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

1 De-ice Thermostat

10 x 3/8 Screw

1 Mounting Bracket

2 Cable Tie

1 Red Cable

2 Cable Clamp

ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT.

1 Remove the filter tray (Fig. 1), release the cabinet retaining screws and remove the cabinet. 2 Screw the thermostat to the left hand hanger bracket using the 2 x N

10 x 3/8 Screws.

3 Insert the thermostat phial into the hole in the left hand end of the fin block to a depth of at least 150mm; neatly coil the

excess capillary without kinking it.

4 Route the cables along the ledge beneath the drip tray using the self adhesive cable clamps to secure them; pass the

cables through the flexi-grommetted hole into the electrics tray.

5 The cables are supplied to suit HL/HLR 540 models. On all other models, gather the exc ess c able and secure neatly

with a cable tie.

6 For HL units: Refer to Fig. 3. Remove and discard the red cable between the heat/cool thermostat terminal 5 and

the terminal block. Cut the termination off the end of one of the de-ice thermostat cables and bare back by approximately 10mm to allow it to fit terminal 3. Connect the other cable to the heat/cool thermostat terminal 5.

7 For HLR units: Refer to Fig. 4. Remove and discard the black cable as indicated. Connect the de-ice thermostat

cables across the vacated terminals.

Fig. 1. Fig. 2.

Fig. 3. Fig. 4.

Page 31

-31-

FAULT FINDING

CONDITION POSSIBLE CAUSE ACTION

A Indoor fan motor will not run

No electric supply at socket or switched fuse box

Check fuse rating and replace if necessary.

Check for loose electrical connections Unit wiring fault Check wiring and connections Fan motor capacitor defective Replace if faulty Fan motor defective Replace if faulty Internal fuse blown Clear fault and replace fuse

B Inadequate cooling or heating

Dirty evaporator fins/filter Clean if blocked Evaporator motor not running As in section A

Refrigerant shortage or excess

Check for leaks. Repair, evacuate and

recharge or check for high head pressure and

recover refrigerant if necessary Faulty thermostat or incorrectly set Replace if faulty Dirty condenser Clean if necessary Faulty compressor Replace LP cutout circuit open (if fitted) Check as refrigerant shortage or excess

Compressor and outdoor fan motor will not run

LP cutout circuit open (if fitted) Check as above No electric supply at socket or switch fuse box

Check fuse rating and replace if necessary.

Check for loose electrical connection. Unit wiring fault Check wiring and connections Capacitor, thermostat, relay or overload

defective

Replace if faulty Compressor failure Replace if faulty

Controls not set properly Check and rectify Off cycle delay operating If applicable, wait 3 minutes High condensate level detected See G

System runs for long periods and will not cycle

Unit underrated for conditioned area Check heat load against capacity Thermostat not operating correctly Check wiring, position of phial and operation Refrigerant shortage

Check for leaks. Recover, repair, evacuate

and recharge

Indoor coil dry or partly sweating Dirty condenser Clean fins if necessary

E Indoor coil frosting

Refrigerant shortage

Check for leaks. Recover, repair, evacuate

and recharge Dirty evaporator fins/filter Clean if blocked Running in cool ambient without a head

pressure controller

Fit head pressure controller

If room temperature is also low Thermostat set too low or cooling permanentlyReset or replace

F Noisy unit

Fan fouling cowl (outdoor unit) Realign fan Worn motor bearing Replace motor Casing or piping vibration Check cause and rectify Loose parts or mounting Find and tighten Bent fan blade Replace fan

G Water leaking from unit

Blocked drain Clear obstruction

Units with condensate pump No supply to pump or loose connection Secure the supply

Fouled sensor Clean sensor Pumping slowly Check drain pipes; if clear, replace pump Pump windings shorted Replace pump

H Pump always runs

Faulty sensor or pcb Replace sensor or pcb

No heating (Heat pump systems only)

Controls not set for heating Reset Unit wiring fault Check wiring and connections

Dirty evaporator fins/filter Clean Faulty thermostat Check for signal; replace if faulty Reversing valve jammed A light tap may free it; preferably replace

Overload tripped on three phase units

High voltage supply Max rated voltage 254v -- check supply Compressor failure Replace Fuses blown

Replace fuses and investigate reason for

fuses blowing