MRCOOL VERSA PRO MVP-48-HP-230-00 (01) PDF MANUAL

MRCOOL VERSA PRO MVP-48-HP-230-00 (01) PDF SUMMARY:

What should I read carefully before installation, and where should I keep it?

Read this manual carefully before installation and keep it where the operator can easily find it for future reference.

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What does a warning indicate?

Indicates a medium level of risk which, if not avoided, may result in death or serious injury.

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What does a caution indicate?

Indicates a low degree of risk which, if not avoided, may result in minor or moderate injury.

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What does a notice indicate?

Indicates important information but not danger.

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Who should perform the installation?

INSTALLATION MUST BE PERFORMED BY AN AUTHORIZED DEALER OR SPECIALIST. Defective installation can cause water leakage, electrical shock, or fire.

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Who must complete electrical work?

ELECTRICAL WORK MUST BE COMPLETED BY A QUALIFIED ELECTRICAL TECHNICIAN.

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Where should I not install the unit?

DO NOT install the unit in a location that may be exposed to combustible gas leaks. If combustible gas accumulates around the unit, it could cause fire.

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When should I turn on the power?

DO NOT turn on the power until the installation and all work has been completed.

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What should I do if the unit operates abnormally?

If the unit operates abnormally (emits strange noises or a burning smell), immediately turn off the unit and disconnect the power in order to avoid electric shock, fire, and/or injury. Call your local dealer, or MRCOOL® tech support at (270) 366-0457, for further assistance.

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What should I do if the air conditioner is used together with burners or other heating devices?

If the air conditioner is used together with burners or other heating devices, thoroughly ventilate the room in order to avoid an oxygen deficiency.

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What should I do before cleaning the unit?

Turn off the device and disconnect the power before cleaning. Failure to do this could result in electrical shock.

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What should I make sure of if water condensation occurs?

Make sure that water condensation can drain smoothly and unhindered from the unit.

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What should I do with the unit and the power if it will not be used for an extended period of time?

Turn off the unit and disconnect the power if the unit will not be used for an extended period of time.

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What should I do when handling the unit and any of its accessories?

As with any mechanical equipment, contact with sharp metal edges can result in personal injury. Ensure care is taken when handling the unit and any of its accessories by wearing gloves and protective clothing.

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What is required to avoid static or image distortion?

Install the indoor and outdoor units, cables, and wires at least 3.2 ft (1 m) away from televisions or radios to prevent static or image distortion. Depending on the appliances, a 3.2ft (1m) distance may not be sufficient.

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What is required to avoid water damage?

Install the drainage piping according to the instructions in this PDF. Improper drainage could cause water damage to your home and/or property.

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What should be done to moving or relocating the air conditioner?

When moving or relocating the air conditioner, consult experienced service technicians for disconnection and re-installation of the unit.

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What is the Excessive Weight Hazard?

Excessive Weight Hazard: Use two or more people when moving and installing the unit. Failure to do this could result in personal injury.

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What should be done to ensure a tight seal between the bottom of the air handler and the return air plenum?

There must be an airtight seal between the bottom of the air handler and the return air plenum. In order to achieve this, use fiberglass sealing strips, foil duct tape, caulking, or an equivalent sealing method to ensure a tight seal.

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Where should return air NOT be drawn from?

Return air must not be drawn from a room where the air handler or any gas-fueled appliance (ex: water heater), or carbon monoxide-producing device (ex: wood fireplace) is installed.

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What should be done around any places where wires, refrigerant piping, and condensate piping enter the air handler cabinet?

Be sure to apply sealant around any places where wires, refrigerant piping, and condensate piping enter the air handler cabinet.

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What should be used to seal any space around the holes where condensate piping exits the cabinet?

Use duct tape and/or Permagum to seal any space around the holes where condensate piping exits the cabinet. Warm air must not be allowed to enter through any gaps or holes in the cabinet.

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What should be removed before installation?

Remove all accessories and packing from the air outlet before installation.

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What should be checked to verify that the drain opening is fully clear and free of any debris?

After removing the drain pan plug(s), check the drain hole(s) to verify that the drain opening is fully clear and free of any debris. Also check to ensure no debris has fallen into the drain pan during installation that could plug the drain opening.

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What should be applied around the exiting drain pipe and the liquid and suction lines?

Apply sealant around the exiting drain pipe and the liquid and suction lines to prevent the infiltration of humid air.

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What must be installed in the condensate drain lines?

On units of this type in which the blower “draws” in air rather than “blows” air through the coil, traps must be installed in the condensate drain lines (primary and auxiliary, if used). Traps prevent the blower from drawing air through the drain lines into the air supply.

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What is required near the unit?

The unit operates with a negative pressure at the drain connections and a drain trap is required. The trap must be installed as close to the unit as possible. Make sure the top of the trap is below the connection to the drain pan to allow complete drainage of the pan.

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What is needed for horizontal runs to eliminate air trapping?

Horizontal runs must also have an anti-siphon air vent (standpipe) installed ahead of the horizontal run to eliminate air trapping.

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What should the drainpipe outlet be?

The drainpipe outlet should be at least 1.9 in (5 cm) above the ground.

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What could happen if the drainpipe outlet touches the ground?

If it touches the ground, the unit may become blocked and malfunction.

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What should be ensured when installing the refrigeration system?

When installing the refrigeration system, ensure that air, dust, moisture, or foreign substances do not enter the refrigerant circuit. Contamination in the system may cause poor operating capacity, high pressure in the refrigeration cycle, explosion, or injury.

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What should be done if there is refrigerant leakage during the installation?

Ventilate the area immediately if there is refrigerant leakage during the installation. Leaked refrigerant gas is both toxic and may be flammable. Ensure there is no refrigerant leakage after completing the installation work.

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What should be taken when preparing refrigerant pipes?

When preparing refrigerant pipes, take extra care to cut and flare them properly. This will ensure efficient operation and minimize the need for future maintenance.

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What should be applied when connecting the flare nuts?

When connecting the flare nuts, apply a thin coat of refrigeration oil to the flared ends of the pipes.

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What should be wrapped around the piping?

Be sure to wrap insulation around the piping. Direct contact with the bare piping may result in burns or frostbite.

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What should be done to make sure the pipe is properly connected?

Make sure the pipe is properly connected. Over tightening may damage the bell mouth and under tightening may lead to leakage.

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What should be used to prevent damage to the system?

Use both a spanner and a torque wrench when connecting or disconnecting pipes to/from the unit.

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What should be done after connecting the copper pipes to the indoor unit?

After connecting the copper pipes to the indoor unit, wrap the power cable, signal cable, and the piping together with binding tape.

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What should be done to all the piping?

Insulate all the piping, including the valves of the outdoor unit.

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What should be checked after completing installation work?

Check to make sure there is no refrigerant leak after completing installation work. If there is a refrigerant leak, ventilate the area immediately and evacuate the system (refer to Air Evacuation section of this PDF).

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What should be confirmed after the electric heating wiring is connected and before powering on?

After the electric heating wiring is connected, please confirm the following before powering on:

• Check and ensure a secure connection of all wiring.
• Ensure that wire size is properly selected per NEC or local codes.

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What should be followed when installing the unit?

Install the unit by following local switch regulations. These may differ slightly between different regions.

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What should be done in cold climates to ensure swift water drainage?

In cold climates, make sure that the drain hose is as vertical as possible to ensure swift water drainage. If water drains too slowly, it can freeze inside the hose and flood the unit.

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What are the wiring warnings before performing any electrical work?

BEFORE PERFORMING ANY ELECTRICAL OR WIRING WORK, TURN OFF THE MAIN POWER TO THE SYSTEM.

All wiring must comply with local and national electrical codes, regulations, and must be installed by a licensed electrician.

All electrical connections must be made according to the Electrical Connection Diagram located on the panels of the indoor and outdoor units.

If there is a serious safety issue with the power supply, stop work immediately. Do not resume the install until the safety issue is properly resolved.

Power voltage should be within 90-110% of rated voltage. Insufficient power supply can cause malfunction, electrical shock, or fire.

Installation of an external surge suppressor at the outdoor disconnect is recommended.

If connecting power to fixed wiring, a switch or circuit breaker that disconnects all poles and has a contact separation of at least 1/8in (3mm) must be incorporated in the fixed wiring. The qualified technician must use an approved circuit breaker or switch.

Only connect the unit to an individual branch circuit. Do not connect another appliance to that circuit.

Make sure to properly ground the unit.

Every wire must be firmly connected. Loose wiring can cause the terminal to overheat, resulting in product malfunction and possible fire.

Do not let wires touch or rest against refrigerant tubing, the compressor, or any moving parts within the unit.

To avoid getting electric shock, never touch the electrical components soon after the power supply has been turned off. After turning off the power, always wait 10 minutes or more before you touch the electrical components.

Ensure electrical wiring does not cross with signal wiring. This may cause distortion, interference, or possibly damage the circuit boards.

No other equipment should be connected to the same power circuit.

Connect the outdoor wires before connecting the indoor wires.

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What should be chosen according to local electrical switches and regulations?

Choose the cable type according to the local electrical switches and regulations.

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What should be chosen according to the Minimum Circuit Ampacity indicated on the nameplate of the unit?

Choose the right cable size according to the Minimum Circuit Ampacity indicated on the nameplate of the unit.

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What does the caution indicate while connecting the wires?

While connecting the wires, strictly follow the wiring diagram.

The refrigerant circuit can become very hot. Keep the interconnection cable away from the copper tube.

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What is isolated by the strain relief and keep power supply away from communication leads?

ISOLATE POWER SUPPLY LEADS AND COMMUNICATION LEADS BY THE STRAIN RELIEF AND KEEP POWER SUPPLY AWAY FROM COMMUNICATION LEADS.

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What should be done when opening valve stems?

When opening valve stems, turn the hexagonal wrench until it hits against the stopper. Do not try to force the valve open further.

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What should be checked before performing evacuation?

Before Performing Evacuation:

• Check to ensure the connective pipes between the indoor and outdoor units are connected properly.
• Check to make sure all wiring is connected properly.

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What should be done to valve caps on all three valves?

Tighten valve caps on all three valves (service port, high pressure, and low pressure) by hand. Tighten it further using a torque wrench if needed.

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What should not be mixed?

DO NOT mix refrigerant types.

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What should be recorded?

Length of the piping and additional refrigerant capacity have been recorded.

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What should be referred to if the unit malfunctions or does not operate according to expectations?

If the unit malfunctions or does not operate according to expectations, refer to the Troubleshooting section of the Service Manual before calling customer service.

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How to perform a vertical down and horizontal right installation?

Follow these steps to perform a vertical down and horizontal right installation:

• Step 1: Open the upper cover.
• Step 2: Open the cover of the electronic control box.
• Step 3: Connect the wire according to the wiring diagram.
• Step 4: Connect the pipes and install drainage pipes.

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How to perform a vertical down and horizontal right installation?

Follow these steps to perform a vertical down and horizontal right installation:

• Step 1: Open the upper cover.
• Step 2: Open the cover of the electronic control box.
• Step 3: Connect the wire according to the wiring diagram.
• Step 4: Connect the pipes and install drainage pipes.

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What are the steps to follow for wire connection preparation?

Prepare the cable for connection Step 1:

1. You must first choose the right cable size.
2. Using wire strippers, strip the rubber jacket from both ends of the signal cable to reveal approximately 5.9in (15cm) of wire.
3. Strip the insulation from the ends.
4. Stranded wire requires u-lugs or ring terminals to be crimped onto the ends of the wire.

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What are the steps to follow for wire connection?

Step 3:

1. Match the wire colors/labels with the labels on the terminal block. Firmly screw the u-lug of each wire to its corresponding terminal.
2. Clamp down the cable with the cable clamp.
3. Insulate unused wires with electrical tape. Keep them away from any electrical or metal parts.
4. Reinstall the cover of the electrical control box.

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How to prepare the cable for connection?

Indoor Unit Wiring Step 1: Prepare the cable for connection.

1. Using wire strippers, strip the rubber jacket from both ends of the signal cable to reveal about 5.9in (15cm) of the wire.
2. Strip the insulation from the ends of the wires.

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What is the indoor unit wiring procedure?

Indoor Unit Wiring

• Step 1: Prepare the cable for connection.
  1. Using wire strippers, strip the rubber jacket from both ends of the signal cable to reveal about 5.9in (15cm) of the wire.
  2. Strip the insulation from the ends of the wires.
• Step 2: Open the front panel.
  1. Open the front panel of the indoor unit. Using a screwdriver, remove the cover of the electric control box on your indoor unit.
• Step 3: Connect the wires to the terminals.
  1. Thread the power cable and the signal cable through the wire outlet.
  2. Match the wire colors/labels with the labels on the terminal block. Firmly screw the wires of each wire to its corresponding terminal. Refer to the Serial Number and Wiring Diagram located on the cover of the electric control box.

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How to connect pipes?

Step 4: Connect Pipes

• Connect the copper pipes to the indoor unit first, then connect it to the outdoor unit. First connect the low-pressure pipe, then the high pressure pipe.
• When connecting the flare nuts, apply a thin coat of refrigeration oil to the flared ends of the pipes.
• Align the center of the two pipes that you will connect.
• Tighten the flare nut snugly by hand.
• Using a wrench, grip the nut on the unit tubing.
• While firmly gripping the nut, use a torque wrench to tighten the flare nut according to the torque valves in the table above.

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How to flare pipe ends?

Step 3: Flare Pipe Ends

• Clamp flare form on the end of the pipe. The end of the pipe must extend beyond the flare form.
• Place flaring tool onto the form.
• Turn the handle of the flaring tool clockwise until the pipe is fully flared.
• Remove the flaring tool and flare form, then inspect the end of the pipe for cracks and even flaring.

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How to remove burrs?

Step 2: Remove Burrs

• Hold the pipe at a downward angle to prevent burrs from falling into the pipe.
• Using a reamer or deburring tool, remove all burrs from the cut section of the pipe.

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How to cut pipes?

Step 1: Cut Pipes

• Measure the distance between the indoor and outdoor units.
• Using a pipe cutter, cut the pipe a little longer than the measured distance.
• Make sure that the pipe is cut at a perfect 90° angle.

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How to install the electric auxiliary heat module and wiring operation?

Electric Auxiliary Heat Module Installation and Wiring Operation:

• Step 1: Open the upper cover.
• Step 2: Use tools to remove the knock-out holes of the upper cover.
• Step 3: Remove the terminal block and power wires, loosen the screws, and remove the electric auxiliary heating cover.
• Step 4: Install the electric auxiliary heating assembly through the front, and note that the support assembly must lock into the support holes in the back of the cabinet.
• Step 5: Tighten the mounting screws.
• Step 6: Wire according to the wiring nameplate. Apply the wiring diagram to the inside cover for future reference and maintenance.
• Step 7: Install the upper cover and the silicone breaker cover.
• Step 8: After installing the electric auxiliary heat module, apply the circuit breaker label near the silicone breaker cover previously installed.

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How to Install the Drain Fitting?

7. 2 Drain Fitting Installation

• Step 1: Find the base pan hole on the outdoor unit.
• Step 2:
  • Fit the rubber seal on the end of the drain fitting that will connect to the outdoor unit.
  • Insert the drain fitting into the hole in the base pan of the unit. The drain fitting will click into place.
  • Connect a drain hose extension (not included) to the drain fitting to redirect water from the unit during heating mode.

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How do you anchor the outdoor unit if installing the unit on the ground or concrete mounting platform?

If installing the unit on the ground or concrete mounting platform, do the following:

• Mark the positions for four expansion bolts based on the dimensions chart.
• Pre-Drill holes for expansion bolts.
• Place a nut on the end of each expansion bolt.
• Hammer expansion bolts into the pre-drilled holes.
• Remove the nuts from expansion bolts, and place the outdoor unit on bolts.
• Put a washer on each expansion bolt, then replace the nuts.
• Using a wrench, tighten each nut until snug.

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How do you anchor the outdoor unit if installing the unit on a wall-mounted bracket?

If installing the unit on a wall-mounted bracket, do the following:

• Mark the position of the bracket holes based on the dimensions chart.
• Pre-Drill holes for expansion bolts.
• Place a washer and nut on the end of each expansion bolt.
• Thread expansion bolts through the holes in the mounting brackets, put mounting brackets into position, and hammer the expansion bolts into the wall.
• Check that the mounting brackets are level.
• Carefully lift the unit and place its mounting feet on brackets.
• Bolt the unit firmly to the brackets.
• If allowed, install the unit with rubber isolator pads to reduce vibrations and noise.

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How to connect a humidifier?

To connect a humidifier, utilize the passive signal “WORK” output (CN23) port as well as the G and C wires on the controller, and wire the humidistat and humidifier per above wiring diagram. When the fan is running, the CN23 relay will be closed, which will allow power to the humidifier when the humidistat is below the humidity setpoint. If the thermostat or zone controller has an HUM interface, connect the humidifier directly to the HUM and C ports.

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What are the Air Evacuation Instructions?

10. 2 Evacuation Instructions

• Connect the charge hose of the manifold gauge to service port on the outdoor unit’s low pressure valve.
• Connect another charge hose from the manifold gauge to the vacuum pump.
• Open the low pressure side of the manifold gauge. Keep the high pressure side closed.
• Turn on the vacuum pump to evacuate the system.
• Run the vacuum for at least 15 minutes, or until the compound meter reads -750 Microns (-105Pa).
• Close the low pressure side of the manifold gauge, and turn off the vacuum pump.
• Wait for 5 minutes, then check that there has been no change in system pressure.
• If there is a change in system pressure, refer to the Gas Leak Check section for information on how to check for leaks. If there is no change in system pressure, unscrew the cap from the packed valve (high pressure valve).
• Insert hexagonal wrench into the packed valve (high pressure valve) and open the valve by turning the wrench in a 1/4 counter clockwise turn. Listen for gas to exit the system, then close the valve after 5 seconds.
• Watch the pressure gauge for one minute to make sure that there is no change in pressure. The pressure gauge should read slightly higher than atmospheric pressure.
• Remove the charge hose from the service port.
• Using a hexagonal wrench, fully open both the high pressure and low pressure valves.
• Tighten valve caps on all three valves (service port, high pressure, and low pressure) by hand. Tighten it further using a torque wrench if needed.

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How can the additional refrigerant to be charged be calculated?

The additional refrigerant to be charged can be calculated using the following formula:

R410A: (metering device in the indoor unit)

cj>6.35(1/4") (Total pipe length -standard pipe length) x30g(0.32oZ)/m(ft)

R410A: (Total pipe length – (metering device in the outdoor unit} standard pipe length) xl Sg(0. 16oZ)/m(ft)

Liquid Side Diameter

cj>9.52(3/8") (Total pipe length -standard pipe length) x65g(0.69oZ)/m(ft)

(Total pipe length -standard pipe length) x30g(0.32oZ)/m(ft)

cj>12.7(1/2") (Total pipe length -standard pipe length) xl 1 Sg(1.23oZ)/m(ft)

(Total pipe length -standard pipe length) x65g(0.69oZ)/m(ft)

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What points should be confirmed before performing the test?

A test run must be performed after the entire system has been completely installed. Confirm the following points before performing the test:

• Indoor and outdoor units are properly installed.
• Piping and wiring are properly connected.
• No obstacles near the inlet and outlet of the unit that might cause poor performance or product malfunction.
• Refrigeration system does not leak.
• Drainage system is unimpeded and draining to a safe location.
• Insulation of piping and duct is properly installed.
• Grounding wires are properly connected.
• Length of the piping and additional refrigerant capacity have been recorded.
• Power voltage is the correct voltage for the system.

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What are the test run instructions?

12. 2 Test Run Instructions 1. Open both the liquid and gas service valves. 2. Turn on the main power switch and allow the unit to warm up. 3. Set the unit to COOL mode. 4. For the Indoor Unit
    1. Double check to see if the room temperature is being registered correctly.
    2. Ensure the manual buttons on the indoor unit work properly.
    3. Check to see that the drainage system is unimpeded and draining smoothly.
    4. Ensure there is no vibration or abnormal noise during operation.

5.  For the Outdoor Unit
    1.  Check for any leaks from the refrigeration system.
    2.  Make sure there is no vibration or abnormal noise during operation.
    3.  Ensure the wind, noise, and water generated by the unit do not disturb individuals nearby or pose a safety hazard.
6.  Drainage Test
    1.  Ensure the drainpipe flows smoothly. New buildings should perform this test before finishing the ceiling.
    2.  Turn on the main power switch and run the unit in COOL mode.
    3.  Check to see that the water is discharged. It may take up to one minute before the unit begins to drain depending on the drainpipe.
    4.  Make sure that there are no leaks in any of the piping.
    5.  Stop the unit. Turn off the main power switch and reinstall the test cover.