temperzone ISD 950KBX-P Reverse Cycle Ducted Split Systems Instruction Manual

Instruction Manual for temperzone models including: ISD 950KBX-P Reverse Cycle Ducted Split Systems, ISD 950KBX-P, Reverse Cycle Ducted Split Systems, Cycle Ducted Split Systems, Ducted Split Systems, Split Systems

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ISD 950KBX-P / OSA 950RKTBG (UC8)

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ISD-OSA 840-950G-P UC8 ECO IM 1022

ISD/OSA 840,950 REVERSE CYCLE DUCTED SPLIT SYSTEMS (ECO Series) c/w UC8 - R410A Installation & Maintenance

CONTENTS

Page

1. General ................................................................1 2. Installation............................................................1 3. Refrigeration System......................................... 2 4. Wiring.................................................................. 2 5. Start-Up Procedure........................................... 3 6. Operation............................................................ 5 7. Controls............................................................... 5 8. Maintenance....................................................... 7 9. Troubleshooting.................................................. 7 10. Warranty............................................................ 8 Table 1: UC8 Display Information........................ 8 Appendix I : Protection Features......................... 9 Appendix II: Air Handling Performance..............11 Commissioning Checklist.................................... 12

1. GENERAL
Temperzone ISD/OSA Air Cooled Split Systems.
Follow these instructions to ensure the optimum performance, reliability and durability.
Units must be installed in accordance with all national and regional regulations and bylaws. National Health and Safety regulations must be followed to avoid personal injuries.
The appropriate local permits must be acquired and adhered to.
Local regulations on maximum boundary noise need to be considered when positioning the unit.
Seismic restraints must be fitted if required. This appliance 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 for their safety. Children should be supervised to ensure that they do not play with the appliance.

GENERAL

2. INSTALLATION
2.1 Indoor unit ISD
2.1.1 Positioning & Mounting
Line length restrictions between indoor and outdoor unit are given in the Specification sheet. Clearances for servicing are shown in the Dimension diagrams on the supplied Specifications sheet. Filter slide rails are built into the return air spigot. Access for filter replacement should be considered. Mount unit level as drain tray has a built-in slope. Access to fixing centres beneath the return air spigot can be made via the removable bungs in the spigots base.
Flexible duct connections are recommended between the supply and return ducts and the unit.
2.1.2 Drains
Main drain tray drain pipe to be installed as per figure 1 diagram below.

100 mm APPROX.
100 mm 200 mm MINIMUM APPROX.
'U' TRAP

VENT PIPE FOR LONG CONDENSATE DRAIN RUNS
OPEN DRAIN

MINIMUM SLOPE 20 mm PER m (1 IN 50)

Figure 1 Condensate Drain
2.2 Outdoor Unit OSA 2.2.1 Positioning a. Clearances for optimum airflow and access for servicing are shown in figure 3 and the Dimension diagram on the supplied Specifications Sheet

1000 MIN. CLEARANCE 1000 MIN. CLEARANCE

ELECTRICAL ACCESS PANEL

500 MIN. CLEARANCE
OUTDOOR AIR FLOW

FAN ACCESS PANEL

OUTDOOR AIR FLOW 500 MIN. CLEARANCE 2000 MIN. CLEARANCE
P

I N S TA L L AT I O N

Figure 2 Outdoor Unit Clearances
b. Consideration should be given to the piping route to the Indoor unit as well as power and control cabling.
c. The Outdoor unit noise levels need to be considered in respect to boundary noise limits. Change the Outdoor unit position if necessary or erect an acoustic barrier.
d. If multiple units are to be placed side-by-side then allow at least 2m between coil faces.
e. Units are designed to be sited outdoors. If siting in a plant room or enclosed space, ensure discharge air is not forced to recirculate back through the coil/s, reducing performance.
003-000-287 10/22

I N S TA L L AT I O N

2.2.2 Mounting.
a. For base mounting, fasten the unit to a solid level base using the four mounting points in the feet.
b. Some commercial rubber pads between the Outdoor unit feet and the base can minimise transmission of vibration.
c. Units are designed to be sited outdoors. If siting in a plant room or enclosed space, ensure discharge air is not forced to recirculate back through the coil/s, reducing performance.

2.2.3 Drains
The condensate drain pipe to be installed as per figure 1 diagram.
The optional Drain Connection Adaptors 25/13mm (x4) (p/n 060-000-039), can be used to assist in the drainage of water and condensate from the base of the Outdoor unit if necessary. For a totally drip free installation (eg plant room) mount the unit in a separate drain tray.

REFRIGERATION SYSTEM

3. REFRIGERATION SYSTEM
3.1 General
All refrigeration pipe brazing, evacuation and charging shall be performed by a technician with a current Refrigerant Handling Licence.
Hot Work Permits should be acquired where necessary before work commences.
Follow the Refrigerant Handling Code of Practice guidelines.
3.2 Piping and Brazing
a. The Outdoor unit has shut off valves and uses swaged pipe connections. It is shipped with a pre-charge of R410A refrigerant.
b. The Indoor unit is shipped from the factory with pressured nitrogen.
c. Immediately before removing the brazed pipe seals from the Indoor and Outdoor units, relieve the pressure to atmosphere after first ensuring the Outdoor unit shut off valves are closed.
d. Refer to supplied Specification Sheet for pipe sizing. e. Use clean sealed refrigeration grade piping designed
for R410A. f. Before brazing any pipe connections, ventilate the pipe
concerned with low pressure nitrogen. g. Use pipe cutters to avoid swarf. h. Use long radius bends (2x pipe dia.). i. Insulate both suction (gas) and liquid lines; seal all
insulation joints. j. Ensure open pipe ends are sealed until the final
connection is made. k. If the outdoor unit is to be installed above the indoor
unit, then the suction riser should be trapped at the bottom of the vertical rise and then again at 8 m (maximum) intervals. This is to ensure oil return to the compressor. The trap should be a `swan-neck' curve in the pipe, with no change in the pipe size. Refer figure 2.
3.3 Evacuation and Charging
a. Evacuate Indoor Unit and interconnecting pipework to a vacuum pressure of 500 microns and hold for 15 minutes.
b. The OSA Outdoor unit is supplied with R410A refrigerant sufficient for 10m line length.
c. Calculate additional refrigerant to suit your line length; refer supplied Specification sheet. · Do not exceed the maximum refrigerant charge specified · For line lengths less than the pre-charge distance stated above, deduct excess refrigerant at the rate specified, or coil excess pipe out of sight.

d. If needed, add refrigerant via the Schraeder connection on the smaller of the Outdoor unit's two service valves. Note: Refrigerant can cause suffocation in high concentrations. Increasing the refrigerant charge, increases the minimum room size to be served by the system. Refer Specification Sheet for minimum floor area. Options to reduce concentration may include: leak detection sensors, forced ventilation, safety shut-off valves and/or overflow rooms.
e. Record the total amount of refrigerant on the label provided on the electrical box.
f. Open the service valve at the Outdoor unit to allow refrigerant to flow throughout the system.
g. For long line lengths, oil (of the correct type) should be added to the refrigerant system at the rate shown in the Specification Data table.
h. Leak check all brazed and fitted joints.

Design

OUTDOOR UNIT

INDOOR UNIT

Suction line recommendation for long line lengths

INDOOR UNIT

slope

Figure 2 Oil Traps.

8 m maximum

20 m maximum

OUTDOOR UNIT
Oil trap in suction line

- 2 -

WIRING

4. WIRING
4.1 Electrical Requirements Electrical power wiring must be fitted and certified by persons with appropriate qualifications and certification. A signed electrical `Certificate of Compliance' must be left with the unit for insurance purposes.
DO NOT install wiring in contact with refrigeration piping. See figures 4 & 5 on page 11 for power wiring and control wiring schematics and positioning.
4.2 Power to Outdoor Unit OSA
All power wiring is to be done to the appropriate electrical standard of the country in which the unit is being installed.
The person installing the wiring is responsible for the correct selection of wiring size and auxiliary components.
See the Specification Sheet for supply voltage range, frequency, phase, maximum operating current and RCD type. Wire the outdoor unit directly from the Electrical Distribution Board.
The unit shall have its own dedicated circuit breaker on the Distribution Board.
A lockable Isolator Switch shall be fitted adjacent to but not on the outdoor unit (as per AS/NZS 3000).
4.3 Power to Indoor Unit ISD
Three phase mains power wiring to the indoor unit shall be taken from the connection on the outdoor unit.
A 24 hour power supply to the compressor crank case heaters is required, otherwise the warranty is void.
4.4 Control
4.4.1 Indoor Outdoor
a.The Outdoor unit is fitted with a unit controller (UC8) which communicates with an Indoor Unit Controller (IUC) in the Indoor unit.
b.Communication wiring between indoor and outdoor unit shall be shielded twisted pair cable, wire gauge 22 to 26 AWG (optional Temperzone part).
c. Communications wiring shall be connected to the indoor and outdoor units as per diagram, refer fig.4 page 6.
d.It is recommended that communications cabling not be laid directly adjacent to any high voltage 230 or 400 VAC power cables for more than 1m. To minimise signal interference, it is preferable to keep the communication cable at least 300mm away from the mains cable as much as possible and only coming together through wall penetrations and other narrow passages. Note: Use the clips provided to keep cables clear of the Gas line.
4.4.2 Room Temperature Controller
Various options are available to control the air conditioning unit operation. a.Temperzone TZT-100 Wall Thermostat, which is
shown in the ISD/OSA wiring diagrams. It can be wired directly to the indoor unit or the outdoor unit. (Refer to www.temperzone.biz for full features and details; model search `TZT-100'. Separate `Installer' and `User' instructions are supplied with the TZT-100 for installation and operation.)

b.BMS Control via dry contact and analog inputs: both the Outdoor unit controller (UC8) and the Indoor unit controller (IUC) offer facilities to connect a BMS system via a series of no-voltage contacts and 0-10V dc analog signals. Note: 0-10V indoor fan speed control input is only on UC8.
c. BMS control via Modbus over RS485. For a full list of the Modbus control setup, settings and read/write parameters. Contact Temperzone for details, or visit www.temperzone.biz; model search `BMS'.
Refer Section 7.0 for more details on Control settings. 4.5 Remote on/off
The UC8 has an input for a remote on/off function on terminal `On', signal return is terminal `0V'. When used the remote on/off terminals should connect to a voltagefree relay contact. When not used the remote on/off terminals should be shorted (`looped'). 4.6 Capacity control OSA ECO units offer the following capacity control options: · Automatic control when the unit connects to the
TZT-100 wall thermostat. · 0-10V control signal via terminal `VC' on the UC8 circuit
board, signal return is terminal `0V'. · Control by a building management system via Modbus
RTU or BACnet-IP serial communications.
4.7 Unit Controller (UC8)
LCD Display
Push button
The temperzone Unit Controller 8 (UC8) is the successor to the UC6 controller. Each dual compressor OSA unit utilises two UC8 Controllers, one for each refrigeration system. The UC8 controllers receive requests such as `Unit On/Off', `Start compressors', `Activate HEAT (Reverse Cycle)' and transfer the requests to the outputs after enforcing safety timers. The Unit Controller provides several system protection functions. These are covered in Appendix I (p.9). For additional information, refer to the UC8 Controller label on the unit or www.temperzone.biz for operation & fault diagnostics information; model search `UC8'. References available: UC8 Operation Manual : Air-to-Air Units UC8 Fault & Display Messages (as per unit label) UC8 Quick Reference and Operation Fault Diagnosis UC8 Troubleshooting Guide UC8 Modbus Communications UC8 BACnet Communications UC8 Master-Slave Connection

- 3 -

START-UP PROCEDURE

5. START-UP PROCEDURE
5.1 Before starting the compressor 1. Before working on the unit remove mains power from the unit by opening the mains isolating switch.
2. Remove the shipping blocks from beneath each compressor. Check that each compressor is securely mounted.
3. Check the thermostat and/or other controls are correctly wired to the unit.
4. Check tightness of electrical connections.
5. Check the air filters have been correctly installed, if present.
6. Check that all indoor fan motors can freely rotate.
7. Apply mains power to the unit by closing the mains isolating switch.
8. Check the supply voltage between each phase and neutral.
9. Check air diffusers are open.
10. Before starting the compressors a four hour delay period is required to allow the crankcase heaters to drive any liquid refrigerant out of the compressor oil. Mains power must be switched on during this four hour delay period.
5.2 Commissioning After the four hour delay period has expired (see step 10 in section 5.1) complete the following procedure. You can use the Commissioning Sheet (supplied with the unit) to help you.
1. Place the UC8 master controller in commissioning mode by holding down the SW3 push button on the circuit board (see Section 4.5) until the display shows: `0' [release] `1' [long press] `t'; [short press] repeat to find `c', then [long press] to select. This Commissioning mode `c' reduces the waiting times at start-up and between cycles.for the next half hour, or until the controller is reset by removing power.
2. Start compressor number 1 in cooling mode. Note: Compressors are directional. If a compressor rotates incorrectly it will not pump, be noisy and draw minimal current. If this is the case switch the unit off and check for correct mains phase connections at the main power terminals and recheck.
3. Check the outdoor fan motors run smoothly. Note: Outdoor fans do not necessarily start rotating immediately after the compressor is started. The fans may run-on for a short period after the compressor stops. Outdoor fans stop during outdoor coil de-ice cycles.
4. Measure the current draw on each phase to the compressor motor and to each fan motor. Check the readings against the specified values in the wiring diagram or specification sheet.
5. The display and pushbutton on the UC8 can be used to check temperatures and pressures. Short presses on the pushbutton cycles through the available options. Table 1 on page 8 shows, in sequence, what information is available with examples.
Alternatively use a set of pressure gauges suitable for R410A refrigerant.

6. Repeat steps 2 to 5 for each compressor.
7. Test operation of the compressors when operating in heating mode.
8. Check for desired supply air flow rate at each outlet. 9. Touch up any outdoor unit paintwork damage to
prevent corrosion.
10. Sign the check label.
5.3 Commissioning of variable speed (EC) indoor plug fans A unit equipped with variable speed (EC) indoor plug fans allows adjustment of the fan speeds to obtain the desired indoor supply airflows. Using TZT-100 option If the unit is controlled with a temperzone TZT-100 wall thermostat then adjustments are made as follows:
1. Stop all compressors. The UC8 display should show a flashing dot ( ).
2. Hold down the SW3 push button on the circuit board until the display shows: `0' [release] `1' [long press] `t'; [short press] repeat to find `H', then [long press] to select. The indoor fan will start and run at High speed. The display shows the fan control voltage for the
Highspeed setting, factory default value is 8.0V.
3. Each following button press increases the control voltage in steps of 0.5V. The maximum is 10V. Pressing the button when the maximum of 10V is reached causes the control voltage to step down to the minimum of 3V, where-after subsequent presses once again raise the control voltage in steps of 0.5V.
4. When the desired High speed control voltage is displayed, [long press] to select and save. The controller then exits the menu and the fan stops.
5. From the flashing dot ( ), hold down the SW3 push button on the circuit board until the display shows: `0' [release] `1' [long press] `t'; [short press] repeat to find `L', then [long press] to select. The indoor fan will start and run at the Low speed setting. The factory default value is 5.0V
6. Repeat steps 3 and 4 to adjust the fan Low speed setting. The minimum control voltage for Low speed is 1V and the maximum control voltage for Low speed is 8V. (Note: A `low' control voltage of less than 2V is not recommended.) If `low' is set higher than `high', the `high' is made equal to `low'.
Using Alternative Thermostats Follow same procedure as for TZT-100.
Note:
If fan speed selections are different from the factory default values then the procedure above must be carried out for each UC8 controller in the unit.
It is allowed to make the control voltages for low and high fan speed equal. This makes the indoor fan act as a fixed speed fan.
It is allowed to control the indoor fan speed by an external source, independent of the UC8 controller. It is then the responsibility of the system-designer

- 4 -

START-UP PROC.

and installer to ensure proper and safe operation of the indoor fan, and the system as a whole, under all operating conditions.
Setting the indoor fan speed too low can bring risk of frost forming on the indoor coil with potential nuisance frost protection trips on cooling, possibly even unit lockout, and/or HP trips on heating.
Setting the indoor fan speed too high can bring a risk of blowing moisture off the fins of the indoor coil and into the supply air duct. Water could then start leaking from the supply air vents and diffusers and corrosion of ducting may occur.

Setting the indoor fan speed too high can also bring a
risk of `over-condensing' (when the unit is heating) which in turn could cause the unit to perform more outdoor coil
de-ice cycles than necessary.

6. OPERATION
6.1 Safety timers
The UC8 receives control signals and transfers the signals to the outputs after enforcing safety timers and other protection functions. If the compressor is held off, or held on, by a safety timer then the display shows message `H-O-L-d'.
Normal durations of safety timers are: · Minimum off time 3 minutes · Minimum run time 1.5 minutes · Min. cycle time 6 minutes (up to 10 compressor
starts per hour) · Min. mode change-over time
10 minutes (cooling to heating or vice-versa)

6.2 Variable Capacity
OSA 840/950G units are equipped with two compressors where the first compressor is variable capacity (ie digital scroll type); the second fixed capacity. DIP switch 14 on the UC8 circuit board can be used to select one of two operating modes:

DIP switch 14 OFF ON

Capacity control mode Standard capacity control Close capacity control

Compressor operating capacities and 0-10V control voltages are:

Compressor

Minimum

type

Standard

control

Nominal

Fixed duty

100%

Digital scroll 16% (1.6V) 40% (4V) 100% (10V)

Note:

At any time, when operating conditions dictate, safety functions can restrict unit operating capacity.

Unless the application requires close control it is recommended to operate OSA ECO units in standard capacity control mode.

When a capacity signal is presented that is lower than
the minimum capacity (for example 0V on input `VC') then the compressor operates on minimum duty.

If a unit operates on low capacity for extended periods then the unit may periodically perform oil flush cycles. Under such operating conditions compressor lubricating
oil may slowly settle in parts of the refrigeration system
other than the compressor; oil flush cycles help to return the lubricating oil to the compressor. During an oil flush cycle compressor capacity is increased to a certain
minimum. The duration of an oil flush cycle is 1 minute.7. Controls

O P E R AT I O N

CONTROLS

7. CONTROLS
7.1 General The control details shown in this document relate to the operation of a unit with a single digital compressor (Stage 1: variable capacity controlled) and a fixed capacity compressor (Stage 2: on/off controlled).

7.2 TZT-100 wall thermostat When the unit is controlled with a TZT-100 wall thermostat then it is necessary to configure the UC8 controllers in the unit as a master and a slave. Follow these steps:

1. On the master UC8:

DIP switch 11 OFF

switch 12 OFF

2. On the slave UC8:

DIP switch 11 ON

switch 12 OFF

3. The thermostat connects to the master UC8 as shown below.

4. The Master-Slave communications cable (factory supplied and connected) must stay connected between individual UC8's (refer wiring schematic sheet 1, grid reference 5-E to 8-E).
To connect the thermostat to the unit it is recommended to use shielded twisted pair type cable, suitable for RS485 communications. Signals A and B should form one twisted pair.

- 5 -

Note: The cable shield should connect to terminal `0V' on the UC8 controller only. Do not connect at both ends. Connect the thermostat as follows:

CONTROLS
Capacity

Note: Capacity Staging. A TZT-100 must be configured for two-stage operation.
TZT-100 has its own DIP switches that must be set as follows: DIP switch 2 ON Equipment type = Heat Pump DIP switch 3 ON Equipment stages = Two DIP switch 4 ON Reverse cycle valve on = Heating

7.3 Communications format for TZT-100

Communications format must be set as per recommended Modbus RTU:

· Baud rate (bd or br) 19200

· Data bits

· Parity

Even

· Stop bits (Pa)

· TZT-100 address (Ad) 7

TZT-100: The procedure to check and adjust these settings is: 1. Press and hold the O/RIDE button until the display shows the PIN 2. Use the UP & DOWN buttons to select PIN code 88:21, then press O/RIDE in installer mode. 3. Use the O/RIDE and PROG buttons to cycle through the various installer settings. If necessary, refer TZT-100 User Manual for more detail.

7.4 Control using switched and 0-10V signals

An external controller that provides 24V AC switched signals or has a set

OSA Terminals

of voltage-free relay contacts should be connected as per the diagram
below. UC8 inputs `VF' and `VC' will accept a 0-10V capacity control signals. If no capacity control signal is available then link UC8 terminals `VF' and `5' and `VC' and `12'.

*If using the unit's internal 12V dc from UC8, add this loop

It is necessary to configure the UC8 controllers in the unit as master and slave; refer Section 7.2 and follow steps 1, 2 & 4.

7.5 Control via Modbus RTU communications

0V COMP 0-10V FAN 0-10V
COMP1 COMP2 HEAT ON COM COM
24V LOW IN

OSA ECO units can be fully monitored and controlled via Modbus RTU serial communications. The following is typical for most installations:

MED IN HIGH IN

BMS / external controller
0V 0-10V Comp. 0-10V Fan
COMP1 COMP2 HEAT
LOW MEDIUM HIGH

· Set DIP switches 11 and 12 OFF on all UC8 controllers. · Connect BMS terminal A / TX+ to terminal A1 on all UC8 controllers. · Connect BMS terminal B / TX- to terminal B1 on all UC8 controllers.

24V ac COM or 0V

24V ac/dc or 12V ac/dc*

It is recommended to `daisy-chain' the A&B connections using shielded twisted pair type cable, suitable for RS485 communications. Signals A and B should form one twisted pair. The cable shield should connect to terminal `0V' on the UC8 controller. The Master/Slave communications cable connected between the UC8 controllers must be removed. DIP switch 11 must be set to OFF on both UC8 controllers.

· To avoid collisions of messages on the RS485 serial communications cable it is necessary to ensure each connected UC8 controller has a unique Modbus device address. Refer to section 7.6 for the procedure.

Example:

- 6 -

CONTROLS

For detailed information about monitoring and control via Modbus RTU refer to document "UC8 Modbus communications", available free on the temperzone internet website.
7.6 Setting the UC8 Modbus device address To view or change the Modbus device address of a UC8 follow these steps:
· Power up the unit but leave the compressors off.
· Hold down the SW3 pushbutton on the UC8 circuit board until the display shows: `0' [release] `1' short press to `2,' [long press] A, [long press]
· The display will show the current Modbus device address. The factory default address is `44'. [Short press] the button to select higher numbers, for example press once to change the address to 45, press twice for address 46 and so forth. [Long press] to save the chosen address. After address 99 the number returns back to 1.
· The controller returns to the default state (_).

MAINTENANCE

8. MAINTENANCE
WARNING HAZARDOUS VOLTAGE. ENSURE ALL POWER SUPPLIES ARE ISOLATED BEFORE PERFORMING MAINTENANCE. FAILURE TO ISOLATE POWER CAN LEAD TO SERIOUS INJURY.
8.1 Monthly 1. Check air filters, if fitted, and vacuum or wash clean as necessary.
2. Check condensate drain for free drainage.
3. Check compressor compartment for oil stains indicating refrigerant leaks.
4. Check system operating pressures via the UC8 (refer Section 5.2.5).
8.2 Six Monthly 1. Check the tightness of electrical connections.
2. Check for signs of corrosion on electrical connections in high salt atmospheres; replace where necessary.
3. Check the tightness of all fans, motor mountings
4. Check system operating pressures via the UC8 (refer Section 5.2.5).

5. Check and/or replace indoor air filters 6. Check condensate drain for free drainage.
8.3 Yearly 1. Check all refrigerant piping for chafing and vibration. 2. Check the operation of electric heaters, if fitted 3. Check air supply at all diffusers 4. Check for excessive noise and vibration and correct as necessary. 5. Check for insulation and duct damage and repair as necessary. 6. Check system operating pressures via the UC8 (refer Section 5.2.5). 7. Remove lint and dust accumulation from outdoor coil fins with soft brush or low pressure water spray. 8. Touch up any paintwork damage to prevent corrosion.

TROUBLESHOOTING

9. TROUBLESHOOTING 9.1 Room temperature varies significantly from its
setting · Unit may have been incorrectly sized for the building.
· Drafts from wrongly placed supply air diffusers or from the back of the wall plaque could be affecting the temperature sensor built into the wall plaque.
· Poor air circulation in the room can cause incorrect temperature readings.
· If using a BMS, check it has been correctly wired to control the compressor capacity.
9.2 Air conditioner does not seem to deliver the heating when most needed · Heating capacity at design conditions may be incorrect. As the outside temperature falls, heat losses through the walls, floor and ceiling increase. · Check the unit's brochure for information on the minimum/ maximum operating temperatures.
9.3 When heating, units have de-icing cycles built in to remove ice on the outdoor coil. · This usually means reversing the cycle for a few minutes during which time there is no heating and in fact a little cooling can occur.

9.4 In a new building, why does it take some days before the air conditioning heat hump unit seems to work properly · Many new buildings, especially a commercial buildings, have a large amount of concrete and other structural materials that are generally cold and full of moisture. This is most evident in the winter when trying to heat the building from scratch.
9.5 Unit is leaking water · Check the drain trap/vent/slope. · Water carry-over: Reduce the maximum fan speed.
9.6 Air conditioner runs excessively the temperature remains too hot in summer or too cold in winter. · Windows or doors may be opened to non conditioned areas. · Keep doors to unconditioned areas closed. · Leaves, papers or other items blocking air flow over the outdoor unit coil. · Location of wall controller or remote temperature sensor is incorrect. · Check for leaks in supply or return air ductwork.

- 7 -

TROUBLESHOOTING

9.7 Outdoor unit displays an error code:
· Refer to UC8 Controller label on the unit for operation & fault diagnostics information or visit www.temperzone.biz; model search `UC8'.

WA R R A N T Y

10. WARRANTY Please refer to the separate warranty document supplied with the unit, or visit www.temperzone.biz for details.

Australia: warranty@temperzone.com.au spares@temperzone.com.au Telephone: 1800 21 1800

New Zealand: customerservices@temperzone.co.nz Telephone: 0800 TZWARRANTY (899 2777)

Table
1,
Information
available
on
the
UC8
display.

Item

Unit
Abbreviation
Examples

Compressor
suction
line
pressure
kPa
SLP

Suction
line
pressure
1034
kPa

Evaporating
temperature

°C
Et

Evaporating
temperature
12°C

Compressor
suction
line
temperature

°C
SLt

Suction
line
temperature
18°C

Compressor
suction
side
superheat
K

SSH

Suction
side
superheat
6K

Compressor
discharge
line
pressure
kPa
dLP

Discharge
line
pressure
2447
kPa

Condensing
temperature

°C
Ct

Condensing
temperature
42
°C

Compressor
discharge
line
temperature

°C
dLt

Discharge
line
temperature
70°C

Compressor
discharge
side
superheat

dSH

Discharge
side
superheat
28K

De--ice
sensor
temperature

°C
ICEt

(located
on
fins
of
the
outdoor
coil)

De--ice
sensor
temperature
39°C

Capacity

%
CAP

Capacity
100%

Expansion
valve
1
opening

%
EE1

Expansion
valve
1

75%
open

Expansion
valve
2
opening

%
EE2

- 8 -

Expansion
valve
2

75%
open

APPENDIX I PROTECTION FUNCTIONS

APPENDIX I

The display shows the message `Hi-t'

PROTECTION FUNCTIONS

when protection is active.

The UC8 implements system protection functions such as indoor coil frost, extreme high and low pressures, rapid on-off cycling of the compressors, loss of refrigerant and more.
The following applies to all protection functions except where otherwise indicated:

5 High discharge superheat protection
Discharge superheat is defined as the difference between the compressor discharge gas temperature and the condensing temperature. When this temperature differential becomes very high it is an indication that the compressor is being starved of refrigerant gas. Common reasons for this could be a lack of refrigerant

Unit operating capacity may automatically be reduced

(under-charged or loss-of-charge) or a problem with

before a protection function is activated. Such a

the expansion device (for example a stuck accurator or

reduction may be sufficient to prevent an actual trip from

loose wiring to an EEV).

occurring.

The protection is activated when discharge superheat

When a compressor is stopped by a protection function

exceeds 45K for longer than 30 minutes.

it is held off for a period of 3 minutes, after which it is allowed to restart (provided the cause of the trip has cleared).
When a protection function is active and when a unit is locked out the alarm relay output "FLT" is active.

The display shows the message `Hi-dSH' when protection is active. 6 Low discharge superheat protection Discharge superheat is defined as the difference between the compressor discharge gas temperature

More detailed information about protection functions and

and the condensing temperature. When this temperature

troubleshooting refer to document "UC8 troubleshooting

differential stays very low it can be an indication that

information", available for free download from the temperzone internet website.

the compressor is being flooded with liquid refrigerant. Common reasons for this could be an excess of

1 High pressure protection (HP) Some OSA ECO units may be fitted with high pressure switches. These switches connect to UC8 inputs IN#1.

refrigerant (over-charged) or a problem with the expansion device (for example a stuck accurator or loose wiring to an EEV).

When a high pressure switch activates (the electrical

The protection is activated when discharge superheat

circuit opens) then the compressor is stopped.

remains below the threshold for longer than 15 minutes.

Most OSA ECO units are fitted with high pressure transducers connected to UC8 input HPT. A compressor is switched off when the discharge line pressure reading

The threshold varies linearly from 0K at standard mode minimum capacity (40%) to 10K at nominal capacity (100%).

exceeds 4238 kPa.

This protection function is disabled when a compressor

The display shows the letters `HP' when protection is active.

operates at less than standard mode minimum capacity (< 40%).

2 Low pressure protection (LP)
Some OSA ECO units may be fitted with low pressure switches. These switches connect to UC8 inputs IN#2. When a low pressure switch activates (the electrical

The threshold for a variable speed compressor operated in boost mode (capacity above 100%) is fixed at 10K.
The display shows the message `LO-dSH' when protection is active.

circuit opens) then the compressor is stopped.

7 High evaporation temperature / high suction line

Most OSA ECO units are fitted with low pressure transducers connected to UC8 input LPT. A compressor is switched off when the suction line pressure reading falls below 228 kPa.
The display shows the letters `LP' when protection is active.
3 Indoor coil frost protection
When the unit is cooling the evaporating temperature in the indoor coil should remain above -8°C. If this temperature falls below -8°C then ice (frost) likely will form on the indoor coil. If the low temperature persists for longer than 6 minutes then the protection function activates.

temperature protection
When the unit has a low pressure transducer connected to the compressor suction line then the controller calculates the evaporating temperature from the suction line pressure reading. If the unit does not have a low pressure transducer then the controller finds the evaporating temperature via a coil temperature sensor (input IC when the unit is cooling, input OC when the unit is heating, yellow wires). Additionally the controller monitors the compressor suction line temperature via a sensor connected to input `SL' (white wires).
The protection function stops the compressor when:
· The evaporating temperature remains above 27.5°C for longer than 15 minutes.

When indoor coil frost protection is activated the compressor is stopped for 6 minutes, after which it is allowed to restart.
4 High discharge line temperature protection

· The suction line temperature remains above 30°C for longer than 15 minutes.
The display shows the message `Hi-SL' when protection is active.

The controller monitors the compressor discharge line temperature via a sensor connected to input `DL' (red wires). The compressor is stopped when:

8 Other alarms
The controller performs many other protection functions. For example:

· The temperature rises above 110°C for longer than 30 minutes.

· Signals from sensors and transducers must remain inside normal operating range.

· The temperature rises above 120°C (immediate action).

- 9 -

PROTECTION FUNCTIONS

· Modbus RTU communications with connected devices (e.g. TZT-100 or SAT-3 thermostat, a Carel Power+ inverter) must continue uninterrupted.
· Modbus RTU communications with a controller such as a BMS that is controlling the unit must continue uninterrupted.
Refer to document `UC8 Troubleshooting Guide' for details.
9 Lock-out
Each protection function has a trip counter. A trip counter is reset to 0 whenever the compressor run request is removed. Any trip that has occurred more than 12 hours ago is removed from the trip count. For some protection functions, when the trip counter reaches value 3 (i.e. three consecutive trips occur) then the unit is "locked out".

When a unit is locked out the compressor is not allowed to start. Lock-out is designed to protect the compressor from repeatedly starting when a serious fault exists that requires the attention of a service technician.
The display shows the code of the fault that caused the lock-out condition.
A unit that is locked out can be unlocked using any one of the following methods:
· Remove mains power from the unit for at least 3 seconds, then restore power.
· Issue an `unlock' command via Modbus RTU serial communications.
· Reset the controller via Modbus RTU serial communications.

APPENDIX II

AIR HANDLING PERFORMANCE Note: Airflows are for a dry coil. Reduce airflow by 10% in wet coil conditions. In a free blow or low resistance application, beware of exceeding indoor fan motor's full load amp limit (refer Specifications document). As filters are optional, the fan air flows given are for units installed without filters.

ISD 840KXY-P
l/s - Pa 500

7.2

9.0

Amps
ISD 950KXY-P

l/s - Pa

500

7.2

8.7

6.0 400
300 4.5

10V
8.9 9V

5.7 400
300 4.5

10V 9V

8.9

200

7.0

6V 100

AVAILABLE EXTERNAL PRESSURE (Pa)

2.7

4.0

5.4

3000 3500 4000 4500 5000 5500

NOMINAL

AIR FLOW (l/s)

2.5 m/s Face Velocity

2.8

4.0

5.4

6.9

3000 3500 4000 4500 5000 5500

NOMINAL

AIR FLOW (l/s)

2.5 m/s Face Velocity

APPENDIX II PERFORMANCE DATA AVAILABLE EXTERNAL PRESSURE (Pa)

- 10 -

temperzone.biz

Figure 3. CONNECTING ALTERNATIVE THERMOSTATS or BMS

A non-Temperzone alternative thermostat (non-communicating contact switching type) can be connected to: 1. UC8 on the outdoor unit, or 2. IUC on the indoor unit, or

3. A communicating BMS via Modbus over RS485.

NOTE: DO NOT try to connect an alternative thermostat to both the IUC on the indoor unit and the UC8 on the outdoor unit. It is one or the other, not both.

OSA Outdoor Unit

ISD Indoor Unit

B2 A2 0V
HI ME LO C1 CP1 CP2 HT C2 5 VF UC8 0V 12 VC 0V
On 0V
B1 A1 0V

screen (Earth at UC8 end only)

Option 1 Low level

HIGH MED LOW

COMP1 COMP2 HEAT
010V dc Indoor Fan speed Ref Common

Alternative compatible
3 speed t/stat or BMS
(independently powered)

010V dc Comp. Capacity Ref

Remote On/Off (optional; if used remove existing link)
Option 3 High Level
BMS RS485/Modbus NB Connection
wires to pass through ferrite
provided.
Control - shielded twisted pair - 2 core + screen (Earth at both ends)

12 B A 0V
12 IUC On
0V
Dy Qu 0V CP1 RV Hi IUC Me Lo 0V V+ V-

Remote On/Off (optional; if used remove existing link)
NB Connection wires to pass twice through ferrite provided.

Option 2 Low level

DRY

Modes

QUIET (optional)

COMP HEAT HIGH MED LOW Relay common
010V dc E

Alternative compatible
3 speed t/stat or BMS
(independently powered)
NB Connection wires to pass twice through ferrite provided.

Figure 4. OSA CONNECTION WIRING PATH
Recommended electrical wiring path shown below. Use cable ties supplied. IMPORTANT! Don't run low and high voltage wiring in parallel; separate where possible. Beware! Potential high temperatures on pipework

Communications cable

Power cable
- 11 -

INSTALLER TO COMPLETE
Commissioning Check List
Site Name/address: .......................................................................................................................................................................... Installing Company ...................................................................................................... Date: .......................................................... Serviceman: ............................................................................................................... Tel: ............................................................ Model ..................................................................... Serial No..................................... Site Ref. ....................................................

Unit mounted level? Temperzone recommended drain trap fitted? Water drain tested okay? (panels on, fan running) Does unit have adequate safe access? All electrical terminals are tight? Return air filters fitted? Removed compressor shipping blocks? Refrigeration leak checked? Is air flow set and balanced? Thermostat type:

Y / N

Supply voltage checked?

Y / N Y / N

External electrical isolator fitted? Compressor overload settings

Y / N

Indoor Plug fan set voltage

Y / N Y / N

Are temperature controller's parameters set? Checked for excessive noise & vibration of unit?

Y / N

Has client had controls demo?

Y / N Y / N

Electrical Certificate Of Compliance issued?

BMS / TZT-100 / Other? (name):

Y / N Y / N
A V Y / N Y / N Y / N Y / N

Mark UC8 dip switch positions with an 'X' SW1
12345678 On Off

SW2 9 (1) 10 (2) 11 (3) 12 (4) 13 (5) 14 (6) 15 (7) 16 (8) On Off

Record the following UC8 monitored conditions using push button SW3 (repeat to scroll through list). IMPORTANT: Digital compressors must be operating at 100% for at least 10 minutes when taking these readings.

System 1

System 2

Cool Cycle: Low Pressure:

SLP

kPa

kPa Outdoor Ambient temperature:

°C

Evap temperature:

°C

°C Indoor Return air temperature:

°C

Suction Line temperature:

SLt

°C

°C Indoor Supply air temperature:

°C

Suction Superheat:

SSH

K Indoor fan amps :

Discharge Line Pressure:

dLP

kPa

kPa Fresh Air introduced :

l/s

Condensing temperature:

°C

°C Compressor 1 amps :

Discharge Line temperature: dLt

°C

°C Compressor 2 amps :

Discharge Superheat:

dSH

De-ice Sensor temperature: ICEt

°C

Required Capacity:

CAP

Expansion Valve 1:

EE1

Expansion Valve 2:

EE2

Heat Cycle: Low Pressure:

SLP

kPa

kPa Outdoor Ambient temperature:

°C

Evaporating temperature:

°C

°C Indoor Return air temperature:

°C

Suction Line temperature:

SLt

°C

°C Indoor Supply air temperature:

°C

Suction Superheat:

SSH

K Indoor fan amps :

Discharge Line Pressure:

dLP

kPa

kPa Fresh Air introduced :

l/s

Condensing temperature:

°C

°C Compressor 1 amps :

Discharge Line temperature: dLt

°C

°C Compressor 2 amps :

Discharge Superheat:

dSH

De-ice Sensor temperature: ICEt

°C

Required Capacity:

CAP

Expansion Valve 1:

EE1

Expansion Valve 2:

EE2

NOTE: This document to be kept with the unit. Failure to provide this completed page on request by Temperzone may effect unit

warranty.

References

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