Highcool 2007 Series
Contents
1. SC187 ro Ls a ia Fan Motor Capacitor zl L ae AES Water M S Pump sa ve 2 eas CO oa Da BK BUI Cm Se odoo O oj siy RU a 2 Te sz S z7L zw SS Su a flee lt ON oe mmm 123 Control ON OFF Pei e o SWI mee DISPAL Y GNDAB IVE IAB EPT PPLT ROON er rf DAZ sere so l TERRE 3 heel el he E Control Panel Technique Parameter Transformer ie Float switch SWI SW 00 Standby Duct Ceiling amp Floor 18kBtu 110 D1 HEAT HOT WATER Cassette 18kBtu 110 ote dotted line part in the frame may not be used fe ene wisi anne tie Electric connection diagram indoor unit SC247 amp SC427 ro Ls es ee 4 ia Fan Motor Capacitor mle gt L Water MI __ 2 PUMP A m 2 Y G CO 2 aa BK BUI i C mm Sees O O lt BNIRDI lt S S be eee a 5 Lu uu uu ON gt a Control immm IE ON OFF EO al e reer i Swi s S ajaa DISPALY GNDAB1V AB EPT PPT ROOK WATER PSE Step Motor 123 epep ese e rene2. AUX Highcool 2007 Series Installation amp Operation Manual Built In Cassette Heat Pump Systems Installation should only be carried out by fully trained amp qualified technicians For your convenience please read this manual thoroughly and follow its instructions carefully Please keep this manual in good condition for your reference Cassette Heat Pumps R410a Introduction Thank you for choosing this AUX Highcool series cassette air conditioner This unit is designed to provide many years of en ergy efficient and reliable operation if installed and operated correctly according to the instructions in this manual Highcool series cassette air conditioners are designed for in Stallation by Trained and Qualified personnel and are not suit able for DIY projects In particular High Voltage Electrics and High Pressure Refrigerant Gas as well as moving parts pre sent many potential hazards to health This manual is designed to provide a suitably qualified and trained Installation Professional with the specialist information required to install and operate the unit in the manner for which it was designed Applicable Models Highcool series cassette systems are supplied in three sepa rate boxes for assembly on site These contain the indoor unit supplied complete with a remote wired controller outdoor unit and grille This manual refers to the following models which are designed to work together and should not
3. Due to the dangers inherent in brazing we cannot give any advice which may be used by unqualified personnel The Vilkan Lokring jointing system should be considered for joining pipes in place of brazing in places where hot works are not permitted or where staff are untrained in brazing pipe 26 Cutting Copper Tube Never use a hacksaw to cut refrigerant copper tube Always use a purpose designed copper tube cutter and ensure it is properly deburred afterwards Your local Climate Center carries these in stock as well as spare blades and tools for deburring Ensure the blade is sharp Connections at Indoor and Outdoor Your Highcool system is provided with flared connections at both the indoor and outdoor unit Flaring is a reliable and safe method of connection provided it is carried out correctly by trained and qualified professionals N CAUTION The refrigerant used in this system R410a runs at extremely high pressures Up to 42 Bar or 610 Psi Conventional flaring kits will not give satisfactory results with this refrigerant and specially designed products designed for use with R410a are available at your local branch of Climate Center We particularly recommend the 689646 concentric flaring tool Always use a torque wrench we recommend model 688507 when connecting flare nuts to their joints Always use a spanner to hold the joint steady while connecting the flare nut with the torque wrench Before making the flare on the copper tube
4. tThis is used to switch between operating modes You can use this to select Automatic Cool ing Only Heating Only Dehumidification or Fan Only operation for your air conditioner Heater This function is used to control an optional electric heater element if one is fitted Your Highcool air conditioner does not include this device but uses the outdoor unit to generate heat in heating mode Fan This is used to set the fan speed and pressing it will scroll between low medium high and automatic fan speeds Option Pressing this allows the user to use the temperature up amp down buttons to interrogate the various temperature sensors in the indoor and outdoor units Reset This can be used when you are in any programming mode to return to standard operational mode Pressing and holding this button allows the keyboard lock to be set Understanding the Display RETETE EEO B ROH TE WED THU PRI SAT SUH The Clock Area shows the Date Time and Day of the week Pressing and holding the CLOCK button with the unit off allows these parameters to be scrolled through and changed using the TIME UP amp DOWN buttons to increase and decrease the setting and the CLOCK button to scroll to the next function After setting the date time and day of the week press RESET to leave the programming mode Al 3 e The Mode Area shows which mode the unit is currently set to work in This is set using the MODE button on the controller 20 te Automa
5. Discomfort or damage to health can result Do not operate with wet hands risk of electric shock Do not use for storing items such as artworks or other special purposes ai Use a correctly sized fuse or circuit breaker Using wire can start a fire OF Do not use kettles near units or controllers Steam can cause mal function or damage A N WARNING Do not poke sticks or other items into the air grilles The fans run at high speeds and this poses a danger of injury and damage Do not wash with wa ter Isolate electrically before cleaning Danger of electric shock SO m Do not use gas fires where the airflow can interfere with combustion O GRE Do not use the power switch to start amp stop the unit Danger of Fire Regularly check that unit supports are not damaged Danger of Injury or Death Never operate the air con ditioner with protective grilles removed Do not sit on the air condi tioner or place objects that may fall off on it Ensure the room is ade quately ventilated Do not place containers with liquids on top of the air con ditioner Water entry can cause damage or injury A N WARNING If you experience abnormal sounds and or odours for example a burn ing smell stop the unit isolate it elec trically immediately and contact your installer Continued operation risks breakdown electric shock or fire CG Do not place sprays on
6. 00pm stop with Monday to Friday set to ON and Saturday and Sunday set to OFF Enabling or Disabling the Time Clock If a start or stop time is shown in the Timer Display section the time clock is active If it is not then it is inac tive Press TIMER to enable or disable the time clock Operating the System Manually 1 Ensure the time clock is disabled by pressing TIMER if there is a start or stop time displayed in the Timer Display LCD section 2 Press OPERATION ON OFF in the top right hand corner of the controller to switch the unit on or off 3 If the unit is on then the display LED will glow green If it is off then it will glow red What do you want the unit to do Pressing the mode button scrolls between automatic cooling dry fan only and heating modes Choose the mode most appropriate to your needs Automatic will engage whichever mode is necessary to maintain the set temperature Cooling will cool the room down to the set temperature Dry will remove moisture and cool the room down Fan Only will give air movement in the room without heating and cooling Heating will heat the room up to the set temperature Note the unit will only be able to reach the set temperature if it is powerful enough to do so Your air conditioner is not designed to cool a room down to 20C or less for long periods or heat it up to 25C or more for long periods Depending upon the heating or cooling requirements of your room the unit may be unable to
7. 10 If the unit operates in cooling dehumidification or automatic modes in high humidity conditions water droplets may form on the air outlets Run the fan at high speed to alleviate this 11 Air outlet temperature is low in heating mode During very low outdoor temperatures the amount of heat able to be produced is much lower and the air temperature leaving the unit will be lower than normal 12 The outdoor fan slows down or stops This is normal and happens in both cooling and heating modes to match the capacity of the outdoor heat exchanger with the capacity of the indoor 16 Recommended Service amp Maintenance Regime The following is a list of the checks we recommend in order to get the best from you Highcool cassette system This list is not exhaustive and many service companies follow a more rigor ous schedule We recommend taking out a service contract with the company who installed your Highcool system for you at the time of purchase Weekly Checks to carry out yourself Check the condition of the Air Filter and clean if necessary Check no visible interference of vandalism has occurred to any part of the system Check the unit is performing correctly in the mode required at that time A thermometer will confirm this by measuring the temperature of the air going into the unit and the air coming out when the unit is cool ing or heating the temperature difference between the air in and out should be at least 10C Che
8. 3 note elite As Control Panel Technique Parameter Transformer Float switch ep Motor Swi SW UII Standby Duct Ceiling amp Floor 24k 48kBruf 111 01 HEAT HOT WATER Cassette 24k 48kBtu 1 ofe dotted line part in the frame may not be used E l F dia goes T And it may changed without further notice PA e CONNECTION Ce UI lt MN WOO UN Appendix 4 Outdoor Unit Wiring Diagrams OC187 amp OC247 Low pressure switch Four road valve Pa Pressure switch High pressure switch Lrankcase heater f Pressure switch ransformer Durdoor PLD Temperature sensor _ Q Jemperature Sensor 5 s Contactorla c e ompressor Y p D ave E S GABI Nel NIG Capacitor D Lees aa J Note dotted line part in the frame may not be used or ee a gR an And it may changed without further notice To indoor unt fo power supply lectric connection diagram outdoor unit OC427 Low pressure Switch Fan motor ean ai Four road valve a Geer z Sale amp a D High pressure swi
9. C ostean ss sc c oo i 38 Time Operation Parameters are set by use of the time up and down buttons Win SwingAnge sos PCPS Comp Delay OD Fan so4 Ssecs GOsecs tseo Lob Liton Faure o 10secs s0secs secs Auto Mode terval _Sc08 f0mins 30mns Omns Temperature Protection Parameters are set by use of the temperature up and down buttons CoolingModeDe ee eo 20 wc see Cooling Mode Overload o2 eoc sc sce Backi OnTime scos secs 60secs Ssecs Le iton Query soor secs 30secs sses Auto Mode ntervai scos 10mins 30mins Omns Time Protection Parameters are set by use of the time up and down buttons Comp Start Proiecton E 3mins mns imn Winimum Comp Run Time E02 3mins 10mins imn C veain E tsecs 120secs Osecs Wax Fan Delay On eat E004 15secs 120secs Osecs Outdoor Failure Delay E005 2mins 5mins Oses Defrost Operation Parameters are set by use of the temperature up and down buttons for temperature parameters and time up and down buttons for time pa T PC01 PC02 PC05 PCO7 Each system has four temperature sensors These are 37 0K 74 0K PC01 Indoor Air Sensor Type A 226K 226K 226K 45 2K PCO2 Indoor Pipe Sensor Type A PC05 Outdoor Pipe Sensor Type A See rei ac teea ee eee er aad The chart above shows the temperature resistance values at
10. Low Humidity set temperature higher Low Gas Charge Investigate Dirty Outdoor Coil Clean Non Condensibles in Refrigerant Recharge Excess Gas Charge Recharge Dirty Filter or indoor coil clean Set temperature too high set lower Non Condensibles in Refrigerant Recharge Excess Gas Charge Recharge 42 Commissioning Sheet Fill in during commissioning and retain a copy for your records Leave this with the end user Name Company End User Grille Type Date Po Cooling Heating Indoor Inet Air Temp fJ Indoor Outlet Air Temp J IndoorCoilTemp _ J Outdoor Inet Air Temp J Oudoor Outlet Air Temp Outdoor Disch Pipe Temp Outdoor CoilTemp J Outdoor Gas Pipe Temp Outdoor Liq Pipe Temp Sketch Pipe Layout Below Comments I confirm I have explained the workings of the machine to the user and carried out the commissioning tests required in this manual Signed Date 43 For further information telephone 01743 466333 Ss Medal Or visit our website at www medalaircon co uk Aircon Accessories Ltd Whilst every care has been taken to ensure that the information included in this docu ment was accurate at the time of printing we reserve the right to change specifications at any time The photographs reproduced in this publication are within the constraints of the printing process and are NOT to be used for matching purposes E amp OE AUX DE COMMISSIONING DISMANTLING amp DISPOS
11. Release all OFN from system ver Connect Vacuum Pump to Manifold amp turn on Set Connect Low pressure manifold line to unit service valve service Open low pressure manifold valve Connect Vacuum Gauge to high pressure manifold line yey Open high pressure manifold valve Turn Vacuum Gauge on and monitor process E e p N Once 700 micron 0 7 Torr is reached isolate vacuum pump and turn off Evacuation is complete if the vacuum holds under 1000 micron 1 Torr for 1 hour oS eo Se a To speed up the evacuation process if it is taking a long time halt the evacuation process and purge with OFN ensuring the vacuum pump and gauge are isolated Failure to hold below 2000 micron 2 torr indicates a leak or water Failure to hold between 1000 amp 2000 micron 1 amp 2 Torr indicates the presence of moisture Shut off the high pressure manifold valve and remove the Vacuum Gauge after evacuation is complete 29 Charging with Refrigerant A N WARNING Wear gloves and eye protection at all times during the handling of refrigerant due to the dan ger of frost bite and pressurised gas release Never vent refrigerant or allow it to escape to atmosphere Always catalogue your use of refrigerant as evidence that leakage or venting has not taken place in case of prosecution Ensure the workplace is well ventilated to avoid as phyxiation in the event of a leak Once the system has been evacuated and can hold below 1000 micron 1 Torr for an hour th
12. be used for any other model or combination Class Indoor Unit Outdoor Unit Grille 5KW SC 187 OC187 SG187 KW SC247 OC247 SG247 12KW S0427 OC42 S6427 If you have any queries please contact Medal Aircon Accesso ries on 01743 466333 Table of Contents Technical Data 4 Safety Precautions 5 7 Grille 7 System Components 8 Wired Controller 8 13 Service amp Maintenance 14 17 Indoor amp Outdoor Installation 18 25 Pipe work Connections 25 30 Electrical Connections 31 32 Installing the Controller 33 Commissioning 33 Appendixes 34 42 Commissioning Sheet 43 Model References SC 24 7 Unit Type Model Year S Split Indoor 7 2007 O Split Outdoor P Packaged System Reference Capacity kbtu hr W Wall 18 18 000 btu hr C Cassette 24 24 000 btu hr G Grille 42 42 000 btu hr M Mobile 1KW 3 412 btu hr warning This Manual is designed for experienced and qualified Installation and Service Engineers and not for the General Public It does not contain specific warning or cautionary information for non technical individuals Attempts to install or service this system by unqualified personnel carries the risk of seri ous injury or death This air conditioner is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible
13. ensure the flare nut has been slid onto the tube first as this cannot be done afterward Always use a little refrigerant oil to coat the inside and outside of your flare Always check the pipe is cut correctly first The following table shows the required tightening torque and machining dimensions for each size of copper pipe Pipe Diamm_ Torque Nm Dim Amm 114 635 15to19 9 10 i 3 40 8 TEE 3 8 9 52 35t040 13 20 S Thm 1 2 12 70 50 to 60 16 60 IS 4 einai 5 8 15 88 62to76 20 00 Ww 3 4 19 05 98 to 120 24 00 Good and Bad Cuts Bad Flares Ra A x X x x TILTED UNEVEN BURRS SVK X x cee ign O Baines Always Leave the pipes capped until the last moment Bleed OFN through any open pipes As soon as the pipe work has been completed purge and then pressurise the system with OFN prior to the leak test 27 Piping between the Indoor and Outdoor Unit When forming the pipe work between the indoor and outdoor unit ensure that the limitations shown on the preceding pages are followed Never exceed the maximum length or vertical lift and do not add these two figures together Always ensure that moisture or air does not enter the pipes and that pipe ends are always capped when not being worked upon This particu larly applies when they are held upright and when passing through a wall Making the Connections It is recommended that the suction large pipe at the outdoor unit is connected first This allows an OFN
14. for their safety Children should be supervised to ensure they do not play with the air conditioner or remote control ler Technical Data Energy Class Cooling B 6 c a a Indoor Air Flow m3 hr 900 1300 1800 Outdoor Noise dBA 52 56 60 Panel WeightKg 3 M s M s 1 AUX products are subject to continual improvement and data may change without notice 2 Ifthe data on the product nameplate differs from the above then the data on the nameplate shall be taken as correct 3 Errors and Omissions Excepted 4 Cooling Performance is measured at 27 19 C db wb air entering the indoor unit and 35C db outdoor temperature with High Fan Speed 5 Heating Performance is based upon 20C db air entering the indoor unit and 7 6C db wb outdoor temperature with High Fan Speed Safety Precautions Before starting the Air Conditioner ensure you have read the Safety Precautions in order to ensure correct operation of the system Allow 8 hours after connection of electrical power before operating this air conditioner After reading this manual please keep it in good condition for reference If the air conditioner is ever sold or transferred to others then this manual should be trans ferred along with it The following symbols are used in this manual for your protection WARNING CAUTION Please do as Danger of Serious Danger of Serious Instructed Personal Injury or Accident Death 1 Installation Precautions N WARNI
15. hook B maintain its structural integrity for the lifetime of the units installation Fix the unit directly to the ceiling as shown or install 1 Suspension bolts additional brackets and hang the unit from these 20 Sloping Ceiling If the unit is mounted in a sloping suspended ceiling then the unit must be installed level and a gasket installed between the exposed cassette body and the grille as shown below Cassette a Ceiling Grille Gasket Mounting the Indoor Unit Suspension bolt 1 Adjust the relative positions of the suspension hooks to ensure the indoor unit is level in all direc ring shim tions Use a spirit level to ensure this 2 Tighten the nuts and ensure that the hooks are tightly connected to the nuts and shims 3 Ensure the unit is tightly secured 4 Ensure the centre of the unit is at the centre of the hole in the ceiling Suspension hook Drain Pipe Installation Drain pipe work can be run in either hard Polyvinyl pipe type VP25 connected directly to the unit drain connector or the accessory drain tube used to connect to flexible hose of ID 16mm Either way follow the regulations below 1 Thermal insulation is recommended for the drain pipe work to avoid moisture forming on the outside 2 Pipes should be run in a straight line with a 1 50 to 1 100 slope to allow the water to drain away The pipe should not rise at any point 3 Itis permissible to raise the height of the drain pipe to
16. louvers can be set to operate continually or set to supply air in a direction and then stopped We recom mend for your best comfort setting these in a direction which is comfortable and leaving them there Our recommendations are shown below IMPORTANT Do not attempt to operate the swing louvers by hand or damage to the mechanism may result Cooling As cold air falls best results in cooling come from setting the louvers to direct the air hori zontally across the ceiling Heating As hot air rises best results in heating come from set ting the louvers to direct the air down toward the floor 13 Service amp Maintenance Check Prior to Use The Earth wire is securely connected and not broken The Air Filter is clean and installed correctly The air inlet and outlet of both indoor and outdoor units are not obstructed e Electrical power is present securely connected and power has been supplied to the system for 8 hours Optimal Operation To get the most from your Highcool air conditioner pay attention to the following 1 During cooling operation avoid excessive energy consumption by using blinds to limit solar radiation and check to ensure the no heating system is operating as well as the air conditioner Close doors and windows to avoid excessive heat gains or losses to the room Ensure the room is adequately ventilated Ensure no objects are placed in a position where they obstruct the airflow of indoor or outdo
17. minutes after it has stopped and will run for a minimum of 3 minutes once it has started 2 Anti Draft Function In heating mode the fan will not operate unless heat is being produced to avoid cold drafts 3 Defrost Function In heating the outdoor heat exchanger gets very cold and will build up ice The defrost function operates to clear this During defrost the symbol DEF is present on the controller the indoor and outdoor fans stop and the compressor operates to remove any ice 4 Mist may be produced from the air conditioner when the unit is cooling or dehumidifying during high hu midity conditions or the unit commences heating after either cooling dehumidification or defrost opera tion 5 When the compressor is running or has just stopped operation you may hear glugging or whooshing sounds as refrigerant moves through the system 6 When the system changes from cooling to heating or vide versa or during defrost a short whooshing sound may be heard 7 When the unit is operating or has just ceased operation you may hear creaking due to the expansion or contraction of components 8 If the unit produces odours it can be because it has taken those odours in during operation has un trapped drains or has a build up of bacteria inside it Your service contractor can disinfect it for you if re quired 9 No cooling or heating when the unit has reached its set temperature cooling or heating will cease until it is required again
18. system information It can also display faults be used to program system set tings and also contains a time clock to operate the unit according to a time program General Description Status LED Operation IR Receiver Flap Closed Flap Open The controller has a Backlit Liquid Crystal Display Section Status LED and Operation Switch mounted on the top half The lower half is covered by a swing open flap Opening the flap reveals the control buttons These are used to operate the unit The buttons with a yellow border control the timer operation and the others control the units other functions Please Ensure Do not operate the controller with wet hands Do not press multiple buttons simultaneously Do not press the buttons with sharp objects Ensure the Correct Button is Pressed Ensure all settings are in accordance with the Units User Manual Do not get the controller wet Wired Controller aA BWN Re sae ee Opening the panel on the front of the controller reveals the controller buttons which allow you to control the functions of the air conditioner Display Section ETETE EEI K AH TUE WES THU FR SAT SUH AR E E A P o opak 2 og oa fo N BOW oo 0 O1 N Display Segments Clock Area Displaying the date time and day of the week Mode Display Showing your choice of Automatic Cooling Dry Fan Only and Heating Modes Timer Area Displaying the next Timer Occurr
19. to form on the air outlets and louvers Select high fan speed to alleviate this A N WARNING Prior to commencing Service Maintenance or Cleaning run the unit for a short time in fan only mode with a high speed fan setting then turn the unit off and disconnect the electrical power In the event of the following conditions switch off the power supply and contact your service contractor for immediate investigation Repeated Minor Fault Codes or any Major Fault Code Frequently tripping fuses or MCBs Indoor or Outdoor Unit giving loud abnormal noises Excessive Vibration or signs that the unit is not held firmly in position Water Leakage Less than 10C difference between supply and return air temperature in cooling or heating Other Abnormal Conditions 14 Cleaning the Air Filter Regular cleaning of the air filter is vital for correct operation of your air conditioner Failure to do this will result in loss of performance malfunction and eventual component failure To Clean the Air Filter Press the two access buttons located on the underside of the cassette grille Swing the access panel down so it hangs at around 90 degrees to the grille or remove completely Remove the Air Filter from the grille and wash thoroughly Dry the air Filter completely Replace the Filter Swing the access panel back into position ensuring it is securely fastened Ove eee Access Buttons Fault Codes In the event of a failure a fault code on the
20. AL This product contains refrigerant under pressure rotating parts and electrical connections which may be a danger amp cause injury All work must only be carried out by competent persons using suitable protective clothing and safety precautions cE AY RoHS A Read the Manual Risk of Electric Shock Unit is Remotely controlled amp may start without warning 1 Isolate all sources of electrical supply to the unit including any control system supplies switched by the unit Ensure that all points of electrical and gas isolation are secured in the OFF position The supply cables and gas pipe work may then be disconnected and removed For points of connection refer to unit installation instructions 2 Remove all refrigerant from each system of the unit into a suitable container using a refrigerant reclaim or recovery unit This refrigerant may then be reused if appropriate or returned to the manufacturer for disposal Under No cir cumstances should refrigerant be vented to atmosphere Where appropriate drain the refrigerant oil from each system into a suitable container and dispose of according to local laws and regulations governing disposal of oily wastes 3 Packaged units can generally be removed in one piece after disconnection as above Any fixing down bolts should be removed and then unit lifted from position using the points provided and equipment of adequate lifting capacity Reference MUST be made to the unit installation instruct
21. Box To Connect the Outdoor Unit 1 Open the outdoor unit electrical access panel 2 Use the straps provided to secure the Power Mains Connecting and Control Cables 3 Connect the Control Cable to the Control Cable Terminals 4 Connect the Mains and Power Cable to their terminals 5 Check all cables are connected safely securely and correctly 6 Close the electrical terminal box Finishing Off After all connections have been made and checked the pipe work has been leak tested and charged and the drain pipe work tested then the pipes and cables should be bound together as follows Locate the drain pipe at the bottom along with the control cable Place the insulated refrigerant pipes on top Place the mains cable on top of these Bind carefully with tape Ensure the drain pipe is not damaged Liquid Pipe Take the drain to a safe drainage point Mains Cable Insulation for Gas Pipe OE a a a E Gas Pipe Insulation for Liquid Pipe Drain Pipe Control Cable 32 Fitting the Controller N CAUTION Use the screws provided with the controller to avoid damage to the casing When running the control cable avoid any High Voltage cables or sources of electromag netic radiation Do not mount the controller near sources of steam or heat or where water can drip on it Do not mount the controller near radios televisions or other electronic devices The controller is provided with a connector and this connects to a factory supplied
22. CB has two spade terminals marked ALARM Normally there is no conti nuity between these two terminals but in the event of a fault condition a relay oper ates to give continuity between these two terminals It is possible therefore to use a maximum 240V feed to one side of the ALARM ter minals to give a fault signal from the other side It is recommended that a low Volt age 12V or 24V is used and this signal is only designed to operate a control signal operating a relay Indoor PCB Layout Remote Fault Contacts COMP VALVE E F AN Paar me Feil RL N TH ae a WATER PI a ja WO Ce F Mei E Ly UUU LARAJ A peT rE ort reas mat g Mia ae oss CI OISPRLY ta ai Pg we A t t go A E OM E P T H Lri 35 euBIs HO UO aJoWEY Appendix 3 Indoor Unit Wiring Diagrams
23. NG This system is designed for comfort cooling for offices shops and light commercial premises It is not designed for workshops or operation in arduous conditions This system contains refrigerant gas under pressure Leakage of gas con stitutes a potential health hazard due to frostbite or asphyxiation and vio lates COSHH legislation N CAUTION T g Ae Install Earth Leakage Circuit Breaker maximum 30mA Install Isolator within arms reach of indoor amp Outdoor Unit Read amp Follow the Installation amp Consider Leak Detection Operation Instructions for small rooms Install Drains Correctly to avoid wa ter leakage Do not drink the con densate water produced Drains must be trapped In the event of a gas leak ventilate the af fected area Do not ex pose gas to naked flame Install an Earth Connection Installation by qualified trained and experienced service personnel only Not suitable for DIY installations Electrical Installation by qualified Elec trical Installation Engineers Only Follow the IET regulations Confirm the system is properly Earthed in accor dance with National amp Lo cal Requirements Danger of Injury or Death Ensure units pipes and cables are securely fixed Securely attach all covers Check noth ing is loose 1 Operation Precautions Do not set the temperature too low or stay in the cold air stream for long periods
24. Oxygen Free Nitrogen cylinder with appropriate manifold to be connected to the access port on the suction line service valve in order to pressurise the pipe with OFN or bleed nitrogen through gently if the pipe must be uncapped for any reason or brazing is tak ing place Connect the suction large pipe to the indoor unit next then the liquid small pipe to the indoor unit and finally purge the pipe work with OFN before connecting the liquid small pipe to the outdoor unit To make each connection remove the nut from the flare connector slip this over the copper pipe and discard the copper bonnet on the flare connector Use an R410a compatible flare tool to flare the copper pipe lubricate the flare with refrigerant oil and tighten the flare nut back onto the flare connector Always check the flare has been made correctly before con necting and always hold the flare connector firmly in place with a spanner while using a torque wrench to tighten the flare nut to the correct torque Once all pipes are in place and securely connected pressurize the whole system with OFN as soon as possible Ensure all pipes and connectors except service valves are insulated 28 Pressure Testing Evacuating and Charging A N WARNING This process in particular should only be attempted by trained and qualified professionals Working with high pressure gases is hazardous and should not be attempted by anyone not fully conversant with the dangers involved and wear
25. arate fan is used to boost the airflow This fan should have its own separate on off Switch Branch Ducts There are four large rectangular branch duct Knockouts one on each side of the cassette These knockouts are 405mm wide and either 95mm high SC247 or 150mm high SC427 The knockouts may be removed using snips and the polystyrene casing behind cut with a knife Spigot plates can then be connected to the side of the unit to allow ductwork to be connected and air to be ducted away All ductwork should be thermally and acoustically insu lated A maximum of 5 metres of duct is recommended Branch Duct Openings Fresh Air Duct Opening 34 Appendix 2 External Interfaces It is possible to operate the Unit remotely from an external control signal and also to send a signal to a remote panel in the event of a unit fault In both cases a two core signal cable ideally 1mm CY type earthed at one end is required Remote Operation The Indoor control PCB has two spade terminals marked PCOM and ON OFF If operation feature SA10 is enabled On using the OPTION feature on the remote controller then bridging between these two terminals will cause the unit to run and breaking the bridge will cause the unit to start If SA10 is enabled but no connection is made externally then the unit cannot run Only connecting between these two terminals will allow the unit to operate when SA10 is enabled Remote Fault Alarm The indoor P
26. both indoors and outdoors rather than yourself to be sure bare wires 31 Electrical Connections at the Indoor amp Outdoor Units CAUTION Ensure that the power cable to the outdoor unit is supplied via a weatherproof mains isolator mounted within arms reach of the electrical panel of the outdoor unit so it can be turned off in case of an accident or emergency Ensure that the mains interconnecting cable is taken through an isolating switch mounted within arms reach of the electrical panel of the indoor unit so it can be turned off in the case of an accident or emergency Ensure that the mains interconnecting cable is not connected inadvertently to the con trol cable terminals marked G A amp B or expensive damage may be caused to the in door and outdoor PCBs and controller j Earthing Power connecting cables of indoor and outdoor ynit eg a Baffle S Signal connecting cpbles of Pa Wye ind i al k Pa i z I jaa aoe z SL TE E T h l oe z 7 fe ian oor and outdoor unit a i 3 Fi X oe To connect the Indoor Unit D g 1 Open the cover of the Terminal Box Aena Y heat insulation material 2 Use the straps provided to secure the mains and control connecting cables 3 Connect the Control Cable to the Con trol Cable terminals 4 Connect the Mains Cable to the Mains Cable Terminals er Check all cables are connected safely securely and correctly 6 Close the Terminal
27. ck the unit is not making any unusual noises and there is no burning smell Contact the maintenance contractor immediately in the event of a failure or a fault condition Quarterly Checks by the Maintenance Contractor Check the condition of the Air Filter Clean or Replace if necessary Check for Vandalism interference or wear and tear on any part of the system Check the cooling and heating performance of the unit Investigate and repair if necessary Check the condition of the indoor and outdoor heat exchangers and drain pan Clean if necessary Check for odours at the indoor unit Treat the heat exchanger and drain pan if necessary Check that condensate is able to drain freely Six Monthly Inspection by the Maintenance Contractor Carry out all of the checks for the quarterly schedule above Clean the Float Switch Clean the contacts of any temperature sensors Check PCBs for moisture damage Check and clean indoor and outdoor unit drain pans Clean the Return Air Grille of the indoor and outdoor units Clean the Indoor and Outdoor Heat Exchangers Check the electrical supply Voltage and also compressor running current Twelve Monthly Service by the Maintenance Contractor Carry out all of the requirements of the six monthly inspection Check sensor resistances and make sure all are operating correctly Check drain hoses and condensate connections for signs of aging or cracks replace if necessary Blow through drains to clear any debris Ensur
28. control ca ble which also connects to the indoor unit Do not extend this cable l Remove the controller from the back plate using the point of a small screwdriver 2 Locate the back plate on the wall and use the screws provided to fix it securely and level 3 Clip the controller back onto the back plate 4 Connect the controller to the control cable provided 5 Connect the other end of the control cable to the plug provided in the indoor unit 6 Enclose the control cable in trunking Commissioning 1 Turn on the Power Supply and switch the mains isolators on indoors and out 2 Check the LED on the controller is lit it should glow red 3 Press the Operation On Off button on the controller The LED on the controller should now glow green 4 Select cooling operation on the controller and set the temperature to 16C and the fan to high speed 5 Wait for 5 minutes and check the controller The pump compressor and outdoor fan symbols should be displayed 6 Press the SWING button and check the louver is operating Set it in an appropriate posi tion for the time of year using the SWING button 7 Check the system is performing correctly in cooling with all indoor fan speed settings 8 Select Heating operation on the controller with a setting of 30C and the fan on high speed 9 Wait for 5 minutes and check the controller The compressor outdoor fan and reversing valve symbols should be displayed 10 Check the system is performi
29. controller will usually advise the nature of the problem Fault codes are divided into two groups E codes are major faults and require the system to be manually reset P codes are minor faults and will reset themselves in the event of the fault condition resolving itself Sensor Failure P codes will allow the unit to run in emergency mode for 50 minutes with limited functionality before halting operation if the failure is not cleared All fault codes should be investigated by an engineer although Pr03 and Pr08 should be investigated by the user by cleaning the filter and checking the operating temperature first 15 Trouble Shooting In the event of there not being a fault code present but the unit not performing correctly the following checks can be carried out yourself Unit will not switch on Poor Cooling or Heating Indoor or Outdoor air is restricted Clear the obstruction Performance Close doors and windows Too high cooling or heating demand Check for abnormal sources Blinds are open Close the blinds i Three minute protection device Wait for 3 minutes No Cooling or Heating Penonnance Improper Mode setting Reset the Mode Warning Do not attempt to repair the air conditioner yourself call a professional Warning Do not use the mains switch to turn the unit on and off Symptoms Not indicating a Fault Condition The following symptoms do not indicate a fault 1 Compressor Protection The compressor cannot operate for 3
30. ctronic Thermo hygrometer Electronic Anemometer Electronic Multimeter and Clamp Tester R410a refrigerant comparator Electronic Vacuum Gauge 19 Installing the Indoor Unit The dimensions in mm required for installation of the indoor unit are shown below Model SC187 SC247 C427 Indoor Unit Height 255 240 280 Minimum Ceiling Height 310 295 295 fe nenaneian Waal USAR 150 150 Suspension Hook Height 175 950 x 950 Grille Size 650 x 650 950 x 950 650 panel size _600 630 opening on the ceiling size _ __600 suspension hook size 70 unit size Refrigerant pipe Suspension hole 950 panel size 860 910 opening on the ceiling size _ 840 unit size 780 suspension hook size 650 panel size T 400 suspension hook size 570 unit size _ a 600 63 0 opening on the ceiling size E Ee l Ceiling _V SC187 SC247 amp SC427 See the diagram on page 18 for installation spaces required In addition please allow at least 1500mm from the grille centre to the nearest light fitting 2000mm from the grille centre to an extract duct or extract fan 4000mm from the grille centre to another cassette unit Suspending the Indoor Unit The suspension structure must be firm reliable and P On DA capable of suspending at least 200kg 1 Rebars It must be capable of resisting vibration and able to 1 Built in
31. d copper pipe must be used and this must be insulated to prevent heat loss and condensation Uninsulated soft drawn copper pipe is stocked at all branches of Climate Center nationwide in handy 15 metre and 30 metre coils with separate Armacell Armaflex 9mm wall insulation ma terial available in 2m lengths and longer boxed coils Pre insulated Armacell Duosplit copper is also available in 20 metre lengths Always use genuine Climate Center pipe amp insulation Limitations of Refrigerant Pipe work The table below shows the maximum pipe separation and vertical lift and also the maximum number of bends for your Highcool air conditioner Always keep pipe separation and the num ber of bends to a minimum C187 SC247 SC427 Pipe Liquid _ Size Max Length m Max Height m Max Bend ay o 6 8 amp 8 10 25 Making the pipe work correctly N WARNING It is essential for the correct operation of your unit that the pipe work is correctly installed and connected and is of the correct type and size and that the work follows the design guide lines and limitations in this manual Failure to do so will result in malfunction failure refriger ant gas leaks and possible hazard to health N CAUTION Handling Refrigerant Pipe It is essential when handling refrigerant pipe that moisture or air do not enter the tube Pipe is sold capped to prevent this and when the tube is open to atmosphere for more than a few seconds it m
32. d to structures that can support its operating weight Electrical cables must comply with both the instructions and IET regulations All electrical works must be carried out by qualified electricians Please ensure personal safety during installation including the use of Personal Safety Equipment Do not switch on the power supply until the installation is completed and checked Ensure adequate ventilation is available in case of refrigerant leakage After installation ensure the end user is fully instructed in the use of their air conditioner and has a copy of all relevant user manuals to operate his air conditioner correctly and safely This unit must not be installed where volatile oils including machine oil or acidic gases are present as these will cause the unit to malfunction Ensure an Earth Leakage Circuit breaker is used Ensure the unit is correctly Earthed If the unit is installed on a metal part of a building ensure good electrical insulation is provided complying with local and national standards and also best practice Selecting the Indoor Unit Location Ensure the following conditions are satisfied and confirm the position with the customer Ensure there is enough space to service and maintain the unit Ensure a maintenance hatch is provided at the pipe connection side Ensure the installation position is able to take four times the unit weight The indoor unit must be away from sources of heat or steam and way from
33. different temperatures showing Resis tance in KiloOhms 39 Appendix 7 Trouble Shooting No Display On Controller Controller operates but no compressor symbol displayed Controller Operates amp Compressor Symbol Displayed TEE oles Sea am ee a enema Compressor Runs Continuously 40 aati tiene trades eee ae mere Faulty Installation Check Source Compressor Noisy Compressor Vibrating Excess Gas Charge Penne oe ee Dirty Filter Heating Clean Suction Too High acai 41 Appendix 8 Common Reasons for Fault Codes These are common reasons for seeing the various fault codes and methods for resolving them Fault Meaning Eo00 or ErO8 Comms Failure Eo03 Phase Problem Er04 High Pressure Er05 Low Pressure Er06 High Discharge Er07 Overcurrent Eri1 or Prii Drain Problem Pr01 2 50or6 Pipe Sensor Problem Pr03 De Ice Pr04 Overload Pr08 Heating High Temp Suggestion Usually a broken cable or faulty connection Sometimes Interference try screened cable Lost Phase Check all 3 phases Swapped Phase Try swapping 2 phases Probably excess refrigerant or dirty filters coils Usually low or no gas or a refrigerant circuit blockage Usually low gas or a refrigerant circuit blockage Usually a blocked condenser coil or overloaded unit Usually blocked drains Clean the sensor connections Dirty filter or indoor coil clean Set temperature too low set higher
34. do so at all Setting the Set Temperature Use TEMPERATURE UP amp DOWN to increase or decrease the set temperature to the required level We rec ommend between 22C amp 24C for an optimum comfort level Setting the Auto Swing Louver Press SWING while the unit is operating to start or stop this function Setting the Indoor Fan Speed Press FAN while the unit is running to increase or decrease the indoor fan speed or choose automatic fan speed to let the unit choose the most appropriate Setting the Keyboard Lock Press and hold RESET for six seconds to turn the keyboard lock on and off 12 Advanced Settings Remote Start amp Stop YES NO It is possible to provide the unit with a remote over ride switch to turn the unit on or off remotely using a cen tral time clock or switch Check with your installer whether this has been done and for future reference make a note above if this is the case It is still possible to operate the unit using the time clock on the unit while this function is operating but the remote switch will always take priority over any local setting Temporary Start Stop If the unit is operating in time clock mode then pressing the OPERATION button will temporarily advance the operation The unit will stop if it is running or start if it is off The Timer Display will change to the next on or off period and at this time will resume time clock operation Temporary Timer Pressing TIMER when not in time clock mod
35. e condensate can run freely Thoroughly clean all heat exchangers Treat indoor coil and drain tray with bactericide Check for leaks in refrigerant circuit paying particular attention to flared joints Repair if necessary Check refrigerant and electrical circuits in all modes for correct performance Check electrical connections for corrosion and integrity Remake if necessary Check PCBs for corrosion dust or moisture damage Clean or replace if necessary Check operation of indoor and outdoor fans Clean any attached ductwork and grilles Fully clean both indoor and outdoor units Lubricate the swing louver mechanism and ensure correct operation Following this schedule will ensure many years of reliable operation and will protect your in vestment Please be aware that failure to have your Highcool unit maintained to this schedule may in validate its warranty 17 Installation Before Installation please read all of the Safety Precautions Please follow the instructions in this manual and any relevant local or national legislation During Installation please follow industry Best Practice Please read the unit labels and this manual carefully before installation N WARNING The unit must be installed by a competent trained and qualified engineer Do not install yourself Any changes to the building structure required by the installation must comply with local and national leg islation The indoor and outdoor unit must be fixe
36. e increased or decreased using the TEMPERATURE UP amp DOWN buttons In order to achieve the best results we recommend that a setting of between 22C and 24C will give the best results in terms of room comfort Constant changes in set temperature will not give better comfort but will increase energy consumption Operating the unit with an abnormally low set temperature in cooling or abnormally high set temperature in heating for extended periods may also cause erro neous operation oo yH g rl cy T Py T uf i a tyga Sg E The Fan amp Louver Display Area shows the fan speed and also whether the automatic swing louver is opera tional To start or stop the swing louver mechanism press the SWING button All four louvers operate simultaneously and can not be con trolled individually This function can only be set when the unit is running To change the fan speed press the FAN button when the unit is running This will scroll between high medium low and automatic fan speeds Cc 2 zo a a Co c e m m 2 ean PUES MOS g H eon o aan a Swing Louver Low Fan Speed Medium Fan Speed High Fan Speed Automatic Fan Speed is shown by the display continually changing from low to medium to high fan speed In order to prevent malfunction it is recommended not to use the low or medium fan speed settings when using the unit in cooling or automatic modes with a set temperature below 21C or in heating or automatic modes above 25C U
37. e system can be charged Your Highcool cassette system is delivered with sufficient refrigerant R410a for a 10 metre pipe length from the outdoor to the indoor unit s If the pipe length is less than this then no additional charging is necessary The two ser vice valves on the outdoor unit can be opened to release the refrigerant and the caps tightly replaced Your system is now charged If the pipe length is less than 3 metres then additional pipe must be installed and looped within the false ceiling or the unit will be overcharged If the pipe length is greater than 10 metres then additional refrigerant must be weighed into the evacuated pipe work A N CAUTION Always weigh the refrigerant accurately Do not guess or charge by pressure Do not use the compressor to pump the refrigerant in Always decant the refrigerant into the evacuated pipe work Ensure the gas bottle is situated so charging is with liquid refrigerant not gas Ensure the bottle is high enough so liquid refrigerant can be decanted into the pipe The table on the right shows the Charging Data for your unit Do not exceed the Maximum pipe run or charge SAIR ARUN ue 2 x The charging process is shown below Maximum Charge g 1800 3300 5800 Place the cylinder on the scales safely and se curely in a position that allows for decanting Disconnect the yellow charging hose from the vacuum pump Connect the charging hose of the manifo
38. e will allow a temporary on or off time to be set This is set in a similar manner to setting the time clock and once the time is set pressing RESET will allow the unit to function under this temporary setting Alternatively pressing TIMER will cancel the temporary timer setting and press ing it again will resume time clock operation Service Engineers Pressing OPTION will allow you to interrogate the various temperature sensors in the indoor and outdoor unit by scrolling through them using the TEMPERATURE UP amp DOWN buttons The sensor reference is shown in the Error Display Segment PCO1 is the indoor unit air temperature sensor PCO2 is the indoor pipe temperature sensor PCO4 is not used and always shows 0 PCO5 is the outdoor coil tem perature sensor and PCO7 the compressor discharge sensor Pressing and holding OPTION will allow you to enter Engineer Setup mode Details are available in the Service Manual Parameters in the Engineer Setup mode should only be changed by suitably qualified personnel with a copy of the Service Manual to hand If you enter En gineer Setup mode by mistake press RESET to leave without changing any important system parameters Air Direction The unit has four air outlets each of which has a direction louver These are linked and operate together they cannot be operated individually They are operated by the SWING button on the controller when the fan is operating Press to start and press again to stop The
39. e within reach of both indoor and outdoor unit Both indoor and outdoor unit contain a control PCB with a fuse The specification of this fuse is 5x20 TSD 3 15A 250V If Steel Wire Armoured SWA cable is used then it must be correctly glanded Control Low Voltage cable should be run separately to the mains cable and be routed SO exposure to High Voltage cable and electromagnetic radiation is avoided If shielded cable is used for the Control cable then the shielding should be earthed at the outdoor unit only Do NOT earth at both ends Electrical Connections Models SC187 0C187 amp SC247 0C247 Model SC427 0C427 tf nlel efa B elne ela le o a a CONTROL CABLE ess M a ihk Ho ELE twee we ola fe urfuzfes njele je ola fe Power Supply Power Supply 220 240V 50Hz 380 415V 3N 50Hz Model Ref SC OC E T oor ene Power 3x40 3x60 5x40 ower yabe i Supply See tee uence t a E ee Control Connecting HO5VV F or CY flex Connecting Mains mm 3X1 5 3X1 5 3X1 5 Cable 3X1 0 3X1 0 3X1 0 Fuse Slow Blow All the above along with all electrical acces E sories are available at your local branch of Control Cable run in CY flex should have the shielding earthed Electric Center at the outdoor end only Do NOT earth at both ends Power Cable sizes are given as a guide only To maintain electrical connection integrity ALWAYS use and may vary with distance Please check crimped connections
40. ence and whether the unit will turn On or Off at this time If this is not displayed then the unit is not in Timer Mode Error Code Display Area This displays any applicable error conditions Temperature Display Area This displays the Temperature as measured by the unit Set Temperature Display Area This displays the temperature the unit is trying to achieve Fan and Louver Display Area This shows the current fan setting and whether the swing louver is operational Output Device Display Area This shows which output devices are operational These include water pump reversing valve outdoor fan motor compressor electric heater and defrost It also displays whether the keyboard lock has been set Control Buttons Operation Switch amp Status LED 6 7 0 ON OFF g 9 10 Press the operation switch to turn the unit on and off The status LED glows red for off and green for on In brief this page describes their main functions 1 a ey 10 Timer Pressing this button turns the timer function on and off Pressing and holding with the unit off allows the timer to be set Clock Pressing and holding with the unit off allows the date time and day of the week to be set Time Up amp Down These can be used to set the time in Clock Set or Timer Set modes Temperature Up amp Down These can be used to increase or decrease the set temperature Swing This is used to enable or disable the swing louver Mode
41. entrances The indoor unit position must allow for easy drainage The indoor unit position must allow for easy connection to the outdoor unit The position must allow the air to not be obstructed The position must allow the airflow to reach every part of the room The indoor unit must be at least 3m away from any sources of electrical interference and cables should be run in steel conduit If the unit is to be installed more than 3m high select use the white HIGH fan speed connection plug in the indoor unit wiring loom in place of the red LOW speed connector installed at the factory ee et ee ee pa S09 or less 1000 or more Unit mmi Unit mir 18 Selecting the outdoor unit location Ensure the following conditions are satisfied and confirm the position with the customer 1 2 3 4 5 6 7 Ensure there is enough space for service and maintenance Select a place where inlet and outlet are not obstructed and the unit is not subject to strong wind Select a dry well ventilated place Select a place where the unit can be installed correctly will support the units weight and will not trans mit vibration Select a place where the operating noise of the outdoor unit will not affect neighbours Ensure there are no gas pipes flue pipes or potential flammable gas leaks nearby Select a place which allows for easy installation N CAUTION Installation in the following places may cause malfunction injury o
42. g the Outdoor Unit Overall Dimensions in millimetres FRONT VIEW SIDE VIEW TOP VIEW A f 590 690 940 B 800 800 950 D 540 540 580 Installation Clearances in millimetres Minimum allowed space between the unit and the nearest obstacle to allow for adequate airflow and mainte nance access 500 300 500 1500 lt gt 300 lt P Very high or low temperatures will affect the performance of the unit Ensure adequate airflow and avoid air recirculation Ensure adequate drainage from the outdoor unit Check the unit is level A slope of 5 degrees or more can cause malfunction or failure Ensure the unit is adequately secured Do not allow the air from one outdoor unit blow directly onto another Positioning the Outdoor Unit ee i I 23 Lifting the Outdoor Unit Use two slings to lift the unit Use spacers to protect the surface and heat ex changers of the unit Avoid contact with the heat exchanger surface Sharp fins can cause injury Pao pany ae SY LI oe ZS ZS AVL gt SHINN Cry ei err lt 4 Roag WARNING A ZA SY es WZ E SS ZENS i th gt Poe A Ca ay QS er ma To Installation of the Outdoor Unit 1 Use the drain connector provided with the unit to connect drain pipe work Ensure adequate drainage Ensure the unit is secured properly a
43. he following Ensure that the unit is used according to the instructions contained in this manual or malfunc tion may occur Pay particular attention to the instructions for setting the air conditioner Using an incorrect temperature setting can cause discomfort health problems and also malfunction Electromagnetic Radiation can affect the operation of the unit and cause it to malfunction If this occurs then the unit can be restarted by disconnecting the power supply for three minutes and then restarting It is important that the air inlet and outlet for both indoor and outdoor unit are kept free of obstructions Do not operate the indoor unit in abnormally high humidity Condensation can result The Air Filter in the indoor unit grille must be cleaned regularly to prevent malfunction and ensure optimum performance Note The system contains both liquid and gas refrigerant under pressure Occasional sounds such as whoosh or glug glug are normal and an indication the system is operating correctly System Components ye Indoor Unit Pipe Work and Cable Drain Pipe Outdoor Unit Li E Pale Air Inlet Air Outlet ae rn i PTTL Electrical Breaker Supplied Locally Hh p ees Remote Controller Air Inlet Air Outlet Operating the Air Conditioner A wired remote controller is used to operate the unit and also display the status of the system and important
44. ing personal safety equipment Failure to leak test adequately can lead to loss of refrigerant danger to health and potential prosecution Failure to remove contaminants can cause malfunction and high system running pressures Failure to charge system correctly will cause incorrect performance and may cause malfunction or failure Pressure and Leak Testing Before charging with refrigerant pressure test the pipe work and indoor heat exchanger for integrity amp leaks with OFN Oxygen Free Nitrogen Ensure that the two service valves are fully shut and only increase OFN pressure gradually to avoid nitrogen passing through the service valves and contaminating the refrigerant 1 Pressurise to 3 Bar 42psi to find large leaks 2 Pressurise to 15 Bar 213psi to find small leaks 3 Pressurise to 28 Bar 398psi to find very small leaks and perform full system pressure test We recommend testing for 24 hours at this pressure Repair any leaks at once and then restart the test process until you are sure that the system is fully gas tight and secure Evacuation Process The presence of moisture or air in the pipe work will cause malfunction or failure to your sys tem and must be removed thoroughly before the valves can be opened and your system op erated Using an accurate electronic vacuum gauge to monitor this process and then test the state of vacuum will ensure that this is done quickly and accurately Electronic Vacuum Gauge
45. ions for unit weight and correct methods of lifting Note that any residual or spilt refrigerant oil should be mopped up and disposed of as described above 4 After removal from position the unit parts may be disposed of according to local laws and regulations 5 Meaning of crossed out wheeled dustbin Do not dispose of electrical appliances as unsorted municipal waste use separate collection facilities Contact your local government for information regarding the collection systems available If electrical appliances are disposed of in landfills or dumps hazardous substances can leak into the groundwater and get into the food chain damaging your health and well being When replacing old appliances with new ones the retailer is legally obligated to take back your old appliance for disposals at least free of charge Ref AUX Highcool Cassette Manual 44
46. ld to the cylinder Purge any air from the hose Open the low pressure manifold valve and watch the scales Add the required quantity of refrigerant to the system Shut off the low pressure manifold valve Shut off the R410a cylinder disconnect and remove Open both system service valves amp replace the caps tightly 0 Mark the extra R410a added on the unit nameplate Cylinder set for liquid Manifold Yellow Hose me ete a Blue Hose The system is now charged with refrigerant Before operating the system remove the blue low pressure manifold hose and replace it with the red high pressure hose Never operate the system with the low pressure manifold gauge in case the system starts to operate in heating as this will damage the low pressure gauge m Electrical Wiring A WARNING All electrical works must be carried out amp checked by a qualified electrician and must ad here to the IET regulations local and national legislation and industry best practice Check to ensure the power supply meets the requirements of your unit is stable and for model SC427 all three phases are balanced correctly The power supply to your air conditioner should have its own unique power circuit All wiring should be secured correctly and each cable should not touch one another The system should be correctly fused and Earth Leakage circuit breakers should be used A method of switching the mains supply off should b
47. ler When it is lit none of the keys on the con troller can be used This allows the operator to set the units operating mode and start stop times then prevent others from interfering with the operation of the system It is enabled or disabled by pressing and holding the RESET button for six seconds 11 Getting Started Setting the Time Date amp Day of the Week Press and hold CLOCK until a beep is heard One of the segments of the Time Display will flash Use TIME UP amp DOWN to set that segment Use CLOCK to scroll to the next segment Use RESET to finish when the time date and day of the week have been set See eee Setting the Time Clock Each day has a start time stop time and whether the time clock is active for that day of the week The time clock is only activated if a start or stop time is shown in the Timer Display segment of the LCD Display This must be done with the unit off 1 Press and hold TIMER until a beep is heard 2 The Timer Display will be shown as well as a day of the week and a large ON or OFF One of the seg ments will flash Use TEMPERATURE UP amp DOWN to set whether the unit will run that day or not Use TIME UP amp DOWN to change the flashing segment to the desired setting Use TIMER to scroll to the next segment When the day of the week changes go back to step 3 When each day has a start and stop time and has been set to on or off press RESET Ot Typical settings are 8 00am start and 5
48. nd free from vibration Ensure the unit is bolted down correctly and the surface it is attached to is secure and stable We recommend using plastic mounting feet for floor mounted installations We recommend using wall brackets for wall mounted installations Use protective cages to protect the unit from damage and passers by from harm when mounting the unit in a public space If mounting on the floor where no firm surface is available create a concrete base or use paving slabs to create one Ensure mounting bolts protrude upward for at least 20mm N CAUTION Ensure adequate drainage The outdoor unit will produce water If drain pipe work is not used then utilise a drainage ditch or other method of removing condensate water NOTICE The installation position must be well ventilated to ensure correct operation The installation position must be firm enough to take the weight of the unit and ab sorb any vibration The installation position must be adequately drained so rain and condensate water does not accumulate The installation position must not be subject to becoming immersed in snow The air outlet must not point in the direction of strong winds The installation position must not be subject to accumulation of rubbish or airborne contaminants 24 Examples of Correct and Incorrect Installation Refrigerant Pipe work The indoor and outdoor unit are connected by refrigerant pipe work Special refrigeration quality dehydrate
49. nder certain conditions the units internal controls may over ride the fan speed selected by the user GB Wt elo EF gy z ce a4 The Output Device Display Area is designed to show which of your systems internal components are operat ing at that moment in time except for the Indoor Fan and Swing Louver which are shown separately in the Fan amp Louver Display Area It can also display if the keyboard lock is set The Internal Drain Pump is used to remove condensate water produced during cooling automatic and dry modes from the indoor unit The Reversing Valve is used to reverse the flow of refrigerant in order to allow the unit to heat instead of cool This is lit in heating mode The Outdoor Fan is used to reject heat from the room in cooling or dry modes or collect heat from outside in heating mode The compressor is used to pump refrigerant around the system to allow the unit to heat or cool It is located in the out door unit The electric heat symbol is used to show when an optional electric heater device is energised Your Highcool unit does not have this heater and if it is displayed you can cancel it using the HEATER button It has no effect on your unit The Defrost Symbol shows when the unit is in heating but has stopped to melt any ice formed on the outdoor heat ex changer This will happen from time to time to allow the system to operate efficiently The Keyboard Lock is used to prevent unauthorised access to the control
50. ng correctly in heating with all indoor fan speed settings 11 Check the drain operates correctly If necessary introduce water into the indoor unit drain tray 12 Check the outdoor drains operate correctly 13 Program the date and time on the controller with the unit off 14 Agree start and stop times for each day for the time clock and whether the unit will run that day with the end user Program these into the Controller and note them in the Con troller Operation Manual 15 Instruct the End User in operation of the Controller and the air conditioner 16 Fill in the commissioning report on Page 43 17 Give this manual to the end user along with the Controller Manual Thank you for installing Highcool air conditioners 33 Appendix 1 Fresh Air amp Branch Ducts Models SC247 and SC427 but not SC187 are able to be connected to fresh air ducts in order to ventilate the room They are also able to connect to short lengths of branch ductwork to take conditioned air into small separate rooms or give better air distribution in an awkwardly shaped room Fresh Air Ducts The corner opposite the pipe entry has a 75mm knock out for introducing fresh air This can be removed using a pair of snips and a 75mm or 100mm spigot connected to the side of the unit to allow a circular insulated fresh air duct to be connected to outside While a very small quantity of fresh air will be induced using the cassettes own fan it is recommended that a sep
51. or units Clean the Air Filter regularly This is vitally important for correct operation of your unit Keep the room clean Dust and dirt will clog the air filter and cause the unit to emit odours Do not operate the unit when the room is excessively humid A comfortable temperature is between 22 amp 24C Setting the temperature too low or too high will increase energy consumption be uncomfortable and may cause the unit to malfunction P E ae Please note the operating conditions for this unit Dehumidi cation Please be aware that in cooling dehumidification or automatic operation these are guidelines assuming average humidity conditions Low humidity will increase the minimum indoor temperature and high humid ity decrease the maximum indoor temperature in cooling For this reason we do not suggest operating the air conditioner for long periods with a room temperature of less than 21C or more than 27C in cooling or these modes Operating the unit for short periods on start up with the temperature below the minimum permissible in door temperature in heating is allowed but prolonged operation at this level will cause malfunction These conditions assume high fan speed The minimum room temperature in cooling dehumidification or automatic modes will increase and maximum room temperature in heating or automatic will decrease if automatic low or medium fan speed is selected Excessively high humidity will cause water droplets
52. ou can then set a start and stop time for every day of the week using the TIME UP amp DOWN buttons to increase or decrease the time and the TIMER button to scroll be tween the settings For every day of the week you can select the unit to either run or not Use the TEMPERATURE UP amp DOWN buttons to scroll between ON and OFF for that day of the week Press RESET to leave programming mode If you wish to operate the unit manually without time clock operation press the TIMER button until there is no display in the Timer Area To resume press the TIMER button to show the Timer Area foe GGBB The Error Code Display Area is lit when there is a fault which must be rectified Depending upon the nature of the fault the unit may continue to operate or shut down On seeing an Error Code you should immediately inform your service engineer and give them the fault code An explanation of these fault codes are shown in the appendix of this manual sH i HASi The Temperature Display Area shows the temperature of the room as measured at the units Air Inlet Pressing the OPTION button allows the temperatures of the other temperature sensors to be displayed here using the TEMPERATURE UP amp DOWN buttons to scroll through them The sensor reference is shown in the Error Code Display Area Press RESET to leave this mode 10 983 The Set Temperature Display Area shows the temperature the unit is set to achieve when operating This temperature can b
53. r death Places with oil in the atmosphere By the sea or where the atmosphere contains salt In hot spring or other areas where there are acidic gases In automobiles or cabins where there is the risk of serious vibration or shock damage Places with strong electromagnetic radiation In kitchens or other places where these is steam gas or oil in the atmosphere Places where acidic or alkaline liquids evaporate Explosive environments Required for Installation The following are required for installing your Highcool air conditioner Approved installation items for use with your Highcool system are available from Medal Aircon on 01743 466333 Four M10 bolts for suspending the indoor unit PVC drain pipe Refrigeration quality copper tube and insulation we recommend 9mm wall Vidoflex Vidoflex insulation tape Outdoor power cable and interconnecting cable Outdoor Unit Mounting Bracket or Mounting Feet Indoor Unit electrical isolation switch Outdoor Unit Mains Isolator Cable Tray Extra R410a refrigerant if pipe separation extends beyond 10 metres Oxygen Free Nitrogen with regulating valve and manifold The following specialist tools will be required to complete the installation in addition to normal engineers tools Core drill Torque Drive Set Concentric Flaring Tool R410a Service Manifold with hoses Vacuum Pump with non return and shut off valves R410a Refrigerant Recovery Unit R410a Reclaim Cylinder Electronic Thermometer Ele
54. ry set Do not modify these or failure will result When fitting a new PCB ensure that the settings on the new PCB are set the same as to the old PCB System Function Parameters in Software These are set by entering System Function Select mode on the controller This is entered by turning the system off and pressing and holding the OPTION button Pressing the OPTION button will then scroll through the pa rameters and the TEMPERATURE UP DOWN and TIME UP DOWN buttons are used to change the settings of those parameters System Function Parameters are set by use of the time up and down buttons e e e CSCC system E oi __SystemType _SA02_ On O Seat Pump O C Fanse sa On 3Fan Speeds Defrost Type saa On Compressor On Mode Change during Operation SAO7 Mowa C AwoResat O sa ooo O abe C Repeattmer sao o oooO OO Enabled Remote Start Stop smo ow Enabled Swing Patten s2 on o Angle Pattern Swing Direction ss On Cocwse a BS Temperature Set Back Parameters are set by use of the temperature up and down buttons C Senso Coe Factory Mn vex Canco Discharge Poe Poor o e e i Temperature Operation Parameters are set by use of the temperature up and down buttons Please note electric heat is not available C Deanna so se oe 3c x Bes eat on a a8 e E rat Reventon E a 350 ne 306 Post Heatran so 20 sc 200 SS
55. tch or j Pressure Switch no rankcase heater Mm Pressure Switch Transformer Outdoor PLB Temperature sensor g lemperature Sensor a7 Compressor Y G pi K V a oH Sa Aaa ane GA IB IL IN IG ILVL2ZIL3 IN Contactor a c pol oi Ae a eg Note dotted line part in the frame may not be used Grr a Ri a And it may changed without further notice To Indoor unt To power supply lectric connection diagram outdoor unit Appendix 5 System Settings A N CAUTION The system settings should only be modified by a trained and qualified professional as incorrect settings may cause malfunction or have unintended consequences Do not modify these settings unless you are clear that you know what you are doing and are prepared to accept any consequences of doing so Amending the system set tings may invalidate the systems warranty Indoor amp Outdoor Unit DIP Switches These are facto
56. the air conditioner Never spray into the air conditioner Do not let the unit blow directly onto children animals or plants Do not operate elec tronic devices within 1 metre of your system After a long period without electrical power do not operate for 8 hours when power is restored With the exception of the filter which must be cleaned regularly this air conditioner contains no user service able parts Do not attempt to service or repair this system yourself Regular Service amp Preventative Maintenance by a qualified professional is essential for correct operation and failure to have this carried out may cause fail ure and invalidate the warranty 3 Moving amp Repair Precautions N CAUTION Do not attempt to repair the air condi Do not attempt to move reinstall or Q tioner yourself Q decommission the air conditioner your self All service work must be carried out by This work must be carried out by a quali a qualified and trained professional fied and trained professional Panel Components Display Panel H Optional iin Panel Body Panel Frame Air Inlet Grille Air Guide Louver 2 LN i I Hi a S Access Button Access to the Filter for cleaning requires depression of the 2 Access Buttons and lowering of the air inlet grille We recommend checking the state of the filter weekly A CAUTION For correct use of this air conditioner please ensure t
57. tic mode allows the unit to automatically select heating or cooling in order to maintain the desired room tempera A ture For your comfort we recommend setting the temperature to between 22 amp 24C in automatic mode Cooling Mode allows cooling to be used to prevent the room temperature exceeding the set temperature during summer time use For your comfort we recommend not setting the desired temperature below 22C in cooling mode Dry or Dehumidification Mode uses the units cooling function to reduce the humidity in the room It is designed to make l the room comfortable with reduced energy consumption compared with cooling mode Fan Only Mode uses the indoor fan to generate air movement within the room but without cooling or heating the room It is often used to prevent a room getting stuffy aale Heating Mode allows heating to be used to prevent the room temperature dropping below the set temperature during win a m S C ter use For your comfort we recommend not setting the temperature above 24C in heating mode Om wid aU The Timer Area is only lit during timer operation and shows the time when the timer will next turn the unit on or off If the unit is in timer operation and the OPERATION button is pressed then the timer area will advance to the next applicable setting as the OPERATION button over rides the current setting Setting the timer can only be carried out when the unit is off Press and hold the TIMER button Y
58. up to 750mm from the false ceil ing provided this is done within 300mm of the unit 4 When connecting the drain pipes from multiple units the common drain must be at least 100mm below each units drain outlet 5 The drain pipe should be supported every metre of its length Lt Lt Lb GOOD BAD lt 300mm gt 100mm co tft fp Rise to 750mm within 300mm At least 100mm drop to common drains 21 Installing the Return Air Grille Three models of return air grille are available The SG187 grille is used with indoor unit SC187 SG247 is used with SC247 and SG427 is used with SC427 Grilles SG247 and SG427 are physically identical The smaller SG187 is much easier to lift than the larger SG247 and SG427 For this reason the larger size grilles are equipped with suspension hooks Installation of the grille involves the following 1 2 3 4 J Remove the centre filter access panel and any corner access panels Locate the swing louver control cable on one corner of the grille this corner should be installed at the corner of the unit where the refrigerant pipe work connections are For model SG187 offer up the grille to the unit and fix using the four mounting bolts For models SG247 and SG427 offer up the grille to the unit and first connect the four guide hooks before fixing using the four mounting bolts Replace the filter access panel and corner access panels Connection of SG247 SG427 is shown below 22 Installin
59. ust be either recapped or otherwise resealed Never allow water to enter the tube or store where water can collect Pay particular attention with any vertical pipes because of the potential for rain dust and other contaminants to enter the pipe work Always purge pipes that have been open for more than a few seconds with OFN Oxygen Free Nitrogen Tube that is to be left unconnected for several weeks or more should be pinched off and brazed shut to prevent contamination For lesser periods PVC tape may be used to secure the cap that covered the pipe work when purchased or used as below to secure the pipe j Wrap PVC tape Flatten a short Bend the flattened Wrap more tape around the tube length of tape at part over and hold around the pipe and the end of the tube against the pipe cut off at the end Bending the Tube It is essential that any bends in the pipe offer as little resistance to refrigerant flow as possi ble Bends should be as wide as practical and there should never be more bends than the quantity allowed in the chart on page 25 Always use a bending machine or bending spring to make any bends Brazing Do Not braze pipe if unqualified and untrained to do so Do not use soft solder and always bleed Oxygen Free Nitrogen through any pipe being brazed to avoid oxidisation In most cases brazing should be unnecessary to install a Highcool cassette system Always use Oxya cetylene or similar systems to ensure a hot enough flame
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