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Installation and Maintenance Manual

IM818
Group: Unitary Part Number: IM818 Date: March 2005

MCK Ceiling Cassette Ductless Split Type Air Conditioner

Indoor Unit

Wireless Remote Control (Standard)

Outdoor Unit

Wired Wall Control (Optional)

2005 McQuay International

IM 818

Page 1

Table of Contents
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cooling Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cooling/Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Indoor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Outdoor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . 5 Installation Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation of Outdoor Unit . . . . . . . . . . . . . . . . . . . . . 5 Installation of the Indoor Unit. . . . . . . . . . . . . . . . . . . . 5 Drain Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Drain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Condensate Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Water Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Intake Grille Installation . . . . . . . . . . . . . . . . . . . . . 7 Refrigerant Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tubing Length & Elevation . . . . . . . . . . . . . . . . . . . . . 8 Tubing Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tubing Connection To Units . . . . . . . . . . . . . . . . . . . . 8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . 9 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Evacuating and Charging. . . . . . . . . . . . . . . . . . . . Evacuating the tubing and the indoor unit. . . . . . . . . Additional charge . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge operation . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Controller Operation Guide . . . . . . . . . . . Wired Wall Control (Optional) . . . . . . . . . . . . . . . . Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . Dry mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat mode (heat pump only) . . . . . . . . . . . . . . . . . . Overheating protection (heat pump only) . . . . . . . . . Frost prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan speed and rated cooling capacity . . . . . . . . . . . Operating Conditions . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . IR signal receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . Wireless Remote Control . . . . . . . . . . . . . . . . . . . . . Mode and Diagnostic Chart . . . . . . . . . . . . . . . . . . . Startup After Extended Shutdown . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . Service and Maintenance . . . . . . . . . . . . . . . . . . . 17 17 17 17 18 19 20 20 20 20 20 20 20 20 20 21 21 21 21 22 22 23

Model Numbers
Cooling Only
Indoor Unit MCK20A MCK25A MCK30A MCK40A MCK50A Outdoor Unit MLC20B MLC25B MLC30C MLC40C MLC50C Nominal Cooling - BTUH 21,000 25,000 30,000 40,000 50,000

Cooling/Heat Pump
Indoor Unit MCK20AR MCK25AR MCK30AR MCK40AR MCK50AR Outdoor Unit MLC20BR MLC25BR MLC30CR MLC40CR MLC50CR Nominal Cooling - BTUH 20,000 25,000 30,000 40,000 48,000 Nominal Heating - BTUH 20,000 25,000 31,000 41,000 50,000

Page 2

IM 818

General Information
This manual provides the installation procedures so your air conditioner unit operates properly and provides you the service it was designed to provide. Special adjustment may be necessary to suit local requirements. Before using your air conditioner, please read this instruction manual carefully and keep it for future reference. CAUTION Use copper conductors only. Unit terminals are not designed to accept other types of conductors. Failure to do so can cause damage to the equipment.

Safety Precautions
Before installing the air conditioner unit, please read the following safety precautions carefully. . WARNING The installer must determine and follow all applicable codes and regulations. This equipment presents hazards of electricity, rotating parts, sharp edges, heat and weight. Failure to read and follow these instructions can cause property damage, equipment damage, severe personal injury or death. This equipment must be installed by experienced, trained personnel only. Do not allow flammable fumes near unit or areas sharing ventilation. Installation and maintenance must be performed by qualified persons who are familiar with local code and regulation, and experienced with this type of appliance. All field wiring must be done in accordance with industry standards and local codes. Inspect the unit nameplate to be certain the voltage is the same as the voltage that will be delivered to the unit. Improper electrical wiring can cause property damage, sever personal energy or death. The unit must be GROUNDED. Make sure wiring does not touch refrigerant piping, compressor, or any moving parts of the fan motors. Confirm that the power supply is switched OFF before installing or servicing the unit. CAUTION Do not install in a laundry room. Humidity and laundry chemicals can corrode unit components. Do not install the unit where leakage of flammable gas may occur. If gas leaks and accumulates around the unit, it can cause a fire. Connect drainage piping properly. If drainage piping is not connected properly, water leakage can cause property damage. Do not overcharge the unit. This unit is factory precharged. Overcharge will cause over-current or damage to the compressor. Keep panel closed. Unsecured panels will cause the unit to operate noisily.

NOTICE This product was carefully packed and thoroughly inspected before leaving the factory. Responsibility for its safe delivery was assumed by the carrier upon acceptance of the shipment. Claims for loss or damage sustained in transit must therefore be made upon the carrier, as follows: VISIBLE LOSS OR DAMAGE Any external evidence of loss or damage must be noted on the freight bill or carriers receipt, and signed by the carriers agent. Failure to adequately describe such external evidence of loss or damage may result in the carries refusing to honor a damaged claim. The form required to file such a claim will be supplied by the carrier. CONCEALED LOSS OR DAMAGE Concealed loss or damage means loss or damage which does not become apparent until the product has been unpacked. The contents may be damaged in transit due to rough handling even though the carton may not show external damages. When the damage is discovered upon unpacking, make a written request for inspection by the carriers agent within fifteen (15) days of the delivery date. File a claim with the carrier since such damage is the carriers responsibility.

WARNING Hazardous Voltage! Disconnect all electrical power including remote disconnects before servicing. Failure to disconnect power before servicing can cause severe personal injury or death.

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Unit Dimensions
Indoor Unit
Model: MCK20, 25, 30, 40, 50 A/AR
Note: See Figure 3 For More Detail

32 1/4

Frame
32 1/4

14 3/4 13 3/4

36 5/8

Front Panel

Frame and Front Panel

36 5/8

Outdoor Unit
Model: MLC20 & 25B/BR, MLC30, 40 & 50C/CR
G F

H B

E Electrical Access Panel w/ 7/8 Knockout

K Refrigerant Piping Connections J D


20 & 25 B/BR 16" 33" 25 1/2" 2 1/4" 13 1/4" 23 1/4" 4 7/8" 5/8" 3/4" 2" 30, 40 & 50C/CR 19 1/4" 40 1/2" 33 1/2" 3 1/2" 15 3/4" 29 3/8" 5 1/2" 3/4" 1" 2"

Model MLC A B C D E F G H J K

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IM 818

Installation Guidelines
Installation Diagram
"L" 3/4" OD Drain Connection INDOOR UNIT Frame IR Receiver and LED Indicator Lights Line Voltage Wiring Air Intake Grille Refrigerant Tubing and Insulation Front Panel Air Filter (Behind the grille) Air Discharge Louver (4) Optional Wired Wall Control Wireless IR Remote Control

Installation of the Indoor Unit


Electrical wiring and installation must conform to all national and local codes. Voltage supply fluctuation must not exceed 10% of rated voltage. Ensure that the location is convenient for wiring, piping and drainage. The indoor unit must be installed near the center of the room with no obstacles in path of the discharge or return air. See Figure 2 for minimum clearances. The suspending structure must be stronge enough to avoid amplifying noise and vibration. The height above the finished ceiling must be 13 3/4" minimum (See Figure 4). Avoid excessive heat. Do not install close to steam or hot water pipes. Figure 2. Indoor Unit Minimum Clearances

Air Intake

Front Panel
Air Intake

20" Min. 40" Min. 120" Max.

Air Discharge Nozzle

OUTDOOR UNIT

Obstacle Floor

Installation of Outdoor Unit


Install the outdoor unit in a manner to prevent mixing hot discharged air with return air flow. Also, the unit should be a suitable distance from obstructions (See Figure 1) for installation clearances. Double the dimensions shown if surroundings are more than 72" tall, or if there is an obstruction on top. Select the coolest possible place where intake air temperature is not greater than the outside air temperature (maximum 113F). Figure 1. Outdoor Unit Minimum Clearances
12"
Intake Air

Locate and install four (4) 3/8" threaded hanging rods per dimensions shown in Figure 3. Each rod must be able to support 50 lbs. minumum. The dimensions of the cardboard template match Figure 3. Figure 3. Looking Up at Unit in Ceiling
5 1/4" 2" 24 1/2" (Hanging Rods) 5 1/4" 2"

40"
Discharge Air

Obstacle

Obstacle

31" (Hanging Rods)

12"
Intake Air

20"
Service Access

Obstacle

Obstacle

2" 5 1/4" 24 1/2" (Hanging Rods) 35" (Ceiling Opening) 5 1/4"

32 1/4" (Unit Size)

2"

IM 818

Page 5

35" (Ceiling Opening)

31" (Hanging Rods)

32 1/4" (Unit Size)

Hang the unit on the rods using washers and locknuts. Adjust the unit height to 1" above the finished ceiling surface and level in all directions (See Figure 4). Figure 4. Unit Hanging
1 1/2" Drain Line Liquid Line Gas Line 10 1/2" 8" 6 1/2"

Water Level Switch


This normally closed switch will open and turn off the compressor if the condensate level gets to high. If it closes within 5 minutes, the compressor will turn back on. If the switch does not close for more than 5 minutes, the system will warn user regarding the fault and the compressor is not allowed to cut in. If the switch is confirmed opened twice within 30 minutes, the compressor will stay off and indicator lights will show fault (See Mode and Diagnostic Chart, page 21).

13 3/4"

Front Panel Installation


1" Finished Ceiling Surface

Drain Piping
Drain pipe must be pitched away from the unit for good drainage (See Figure 5). The outside diameter of the drain connection is 3/4". Use flexable coupling with 3/4" ID (See Figure 6) . Insulate drain pipe to prevent sweating. Figure 5. Drain Piping

Open the air intake grille by pulling back the latches and remove it together with the filter from the panel (See Figure 7). Attach the front panel to the indoor unit with 4 screws. Make sure the seals contact the indoor unit to prevent air leakage (See Figure 9). Figure 7. Front Panel Installation

Indoor Unit

Pipe Clamp

OPEN
BAD

GOOD

Drain Test
Connect the flexible coupling to the drain pipe. Bend coupling upward and pour water in to check the piping for leakage (See Figure 6). When the test is completed, connect the flexible coupling to the drain connection on the indoor unit. Figure 6. Drain Test
Pour Water In Here

Drain Pipe

Flexible Coupling

Condensate Pump
The condensate pump will be on whenever compressor is on. The pump will remain on for at least 5 minutes after the compressor stops. Max head is 27" H2O.
SCREW

Page 6

IM 818

Plug the 2 electrical cords from the front panel into the 2 matching connections inside the control box (See Figure 8). Figure 8. Electrical Connection Front Panel to Control Box
Control Box LED Connectors

Figure 9. Prevent Discharge Air Leakage


C o o l A ir

In d o o r U n it

C e ilin g B o a r d

P a n e l
From Front Panel

G O O D IN S T A L L A T IO N

In d o o r U n it
Air Swing Connectors

C o o l A ir A ir L e a k

A ir L e a k

C e ilin g B o a r d

P a n e l B A D IN S T A L L A T IO N

Air Intake Grille Replacement


Reattach the air intake grille and filter to the front panel. The grille can swing in 4 directions. Position the grille to maximize accessibility when open (See Figure 7).

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Page 7

Refrigerant Tubing
Tubing Length & Elevation
Copper tubing to connect the indoor and outdoor units is supplied by others or it can be ordered from the factory. See Table 1 for requirements. Table 1: Refrigeration Tubing Requirements
Model Indoor Model Outdoor Max. Length, "L"- Ft. Max. elevation-Ft. Max. no. of bends Liq. tube size - OD Gas tube size - OD MCK20A MCK25A MCK30A MCK40A MCK50A MLC20B MLC25B MLC30C MLC40C MLC50C 49 26 10 1/4" 5/8" 49 26 10 3/8" 5/8" 115 49 10 3/8" 5/8" 115 49 10 3/8" 3/4" 115 49 10 3/8" 3/4"

Table 2: Tube Flaring Dimensions


Tube Diameter - OD Inch
1/4 3/8 5/8

X (in.) Imperial
.051 .063 .087

Rigid
.028 .039 .067

Tubing Connection To Units


Connect the copper tubing to both the indoor and outdoor units (See Figure 11). Torque each flare nut to specifications (See Table 3). Cover both tubes individually with 3/8" minimum wall thickness foam insulation.
Tube Size (in.)
1/4 3/8 5/8

Note: The refrigerant pre-charged in the outdoor unit is for tubing length "L" up to 25 ft. See "Installation Diagram" page 5. See Table 6 on page 17 for additional R-22 refrigerant required on longer runs.

Table 3: Flare Nut Torque Specifications


Torque (ft./lb.)
13.3 31.0 48.0

Tubing Preparation
Do not use contaminated or damaged copper tubing. Do not remove plastic, rubber plugs or brass nuts from the valves, fittings, tubings and coils until you are ready to connect suction or liquid line into valves or fittings. If any brazing work is required, ensure that the nitrogen gas is passed through coil and joints while the brazing work is done. This will eliminate soot formation on the inside wall of the copper tubing. Cut the copper tubing with a tube cutter (See Figure 10). Remove burrs from cut ends by holding tubing downwards to prevent metal chips from entering the tubing. Slide flare nut on tubing. Flare the tubing as shown in Figure 10, Figure 11 and Table 2. The flare must be even and not cracked or scratched. Figure 10. Cutting and Flaring Tube
Cutrting Copper Tube

Figure 11: Flare Tubing Connection

Flared Tube

Unit Fitting

Flare Nut

1/4 Tube

Copper Tube See Table 2 Flaring Tool X

Page 8

IM 818

Electrical Connections
WARNING Improper installation can cause severe personal injury o r death . Wi rin g mu st b e d one by a qual ifi ed technician in compliance with local codes. Wiring must be in accordance with all applicable electrical codes. Wires must not touch the refrigerant piping, compressor or any moving part. All electrical field wiring must be clamped at both the indoor unit and the outdoor unit. Field install 10A fuse in blue wire of outdoor unit as shown in wire diagrams for unit sizes 30, 40, and 50.

Table 4: Wire, Fuse/Breaker Requirements - Cooling Only


Unit Size
Voltage - 60Hz. 1 Ph. Power supply wire size No. of 12 ga. wires between units Fuse/Breaker size 12 ga. 2 + gnd. 20 amp. 10 ga. 2 + gnd 25 amp.

20

25

30
208/230 8 ga. 3 + gnd 35 amp.

40
8 ga. 3 + gnd 40 amp.

50
6 ga. 3 + gnd 55 amp.

Table 5: Wire, Fuse/Breaker Requirements - Heat Pump Only


Unit Size
Voltage - 60Hz. 1 Ph. Power supply wire size No. of 12 ga. wires between units* Fuse/Breaker size 12 ga. 5 + gnd. 20 amp. 10 ga. 5 + gnd 25 amp.

20

25

30
208/230 8 ga. 6 + gnd 35 amp.

40
8 ga. 6 + gnd 40 amp.

50
6 ga. 6 + gnd 55 amp.

Note:

See Table 4 and 5 for the number of wires, wire gage and fuse/circuit breaker size required. NEC requires an approved electrical disconnect within sight of the unit so that anyone working on the unit can turn off the power and see that its not accidently turned back on. This will require two disconnects, one by the outdoor unit and one by the indoor unit.

* Not including the low voltage OD coil sensor cable.

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Wiring Diagrams
MODEL MCK 020/025A INDOOR UNIT- (COOLING ONLY)
RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID TO OUTDOOR DEFROST SENSOR OD CN4 CN6 L WIRED REMOTE CONTROLLER WIRELESS REMOTE CONTROLLER COMP. 4WV
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

NOTE: DISCONNECT CN6 IF CN4 IS USED PURPLE ORANGE BROWN BLACK G/Y
BLACK

HIGH

WTP

FH FM FL

PURPLE

RED

RED

RED

AS BLUE BLACK BLACK KEY: ---- - FIELD SUPPLY WIRING AS - AIRSWING MOTOR DP - DRAIN PUMP (CONDENSATE) COMP.L/L1 N/L2 N/L2 GREEN/YELLOW DP BLUE

WHITE

RED

A.C. MC

I.C.

GREEN/YELLOW

FAN MOTOR L2 208/230V 60Hz L1

12 GA. WIRE

MODEL MLC / M4L020/025B OUTDOOR UNIT


WHITE

C S CM R RED CAPACITOR BLUE BLUE

GREEN/YELLOW BLUE FAN MOTOR RED BLUE BROWN

KEY: ---- - FIELD SUPPLY WIRING CM - COMPRESSOR MOTOR WITH INTERNAL OVERLOAD PROTECTOR

COMP. N

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IM 818

MODEL MCK 030A INDOOR UNIT- (COOLING ONLY)


RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID TO OUTDOOR DEFROST SENSOR OD CN4 CN6 L WIRED WALL CONTROLLER WIRELESS REMOTE CONTROLLER COMP. 4WV
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

NOTE: DISCONNECT CN6 IF CN4 IS USED PURPLE ORANGE BROWN RED AS BLUE DP BLUE BLACK
BLACK

HIGH

WTP

FH FM FL

PURPLE

RED

RED

WHITE

RED

KEY: ---- - FIELD SUPPLY WIRING AS - AIRSWING MOTOR DP - DRAIN PUMP (CONDENSATE)

GREEN/YELLOW COMP. L/L1 N/L2

A.C. MC

I.C.

GREEN/YELLOW

FAN MOTOR

12 GA. WIRE 208-230V 1 PH

L2 L1

*NOTE: FIELD INSTALL 10A FUSE IN BLUE WIRE AS SHOWN

N BLUE

COMP. *10A

BLUE G/Y

RED RED REDREDRED A C R/L1S/L2 T/L3 A1 MAGNETIC 1 CONTACTOR 2 U/T1V/T2 W/T3 A2 BLUE REDRED RED WHITE

RED 10A
HIGH / LOW PRESSURE SWITCH

RED RED
GREEN/YELLOW

RED BLUE BLUE BLACK WHITE

BLUE

MODEL MLC / M4L030C OUTDOOR UNIT

IM 818

RED

RED R S RED BROWN C FAN G/Y COMPRESSOR CRANKCASE MOTOR HEATER BROWN R S

Page 11

MODEL MCK 40A/50A - (COOLING ONLY)


RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID OD CN4 CN6 L WIRED WALL CONTROLLER WIRELESS REMOTE CONTROLLER COMP. 4WV
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

NOTE: DISCONNECT CN6 IF CN4 IS USED WHITE BLUE YELLOW RED AS BLUE BLACK KEY: ---- - FIELD SUPPLY WIRING AS - AIRSWING MOTOR DP - DRAIN PUMP (CONDENSATE) GREEN/YELLOW COMP. L/L1 N/L2 FAN MOTOR A.C. MC I.C. GREEN/YELLOW DP BLUE BLACK
BLACK

HIGH

WTP

FH FM FL

PURPLE

RED

RED

WHITE
N/L2

208-230V 1 PH 60Hz

L2 L1

12 GA. WIRE

*NOTE: FIELD INSTALL 10A FUSE IN BLUE WIRE AS SHOWN

L/L1

N/L2 *10A BLUE BLUE RED RED 10A RED PURPLE BLUE A1 A2 RED 2 BLUE BLACK

COMP. L/L1

BLACK PURPLE

RED

GREEN/YELLOW

RED
GREEN/YELLOW

RED RED RED 1L1 3L2 5L3 1 2T1 4T2 6T3 2 RED RED

HIGH LOCK OUT PRESSURE SWITCH RELAY BLUE RED

LOW PRESSURE SWITCH BLACK WHITE

WHITE

C
COMPRESSOR BLUE

RED RED CRANKCASE HEATER

BROWN FAN G/Y MOTOR BROWN

BLUE

MODEL MLC 40C/50C

Page 12

RED

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MODEL MCK 020/025AR INDOOR UNIT- (HEAT PUMP)


RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID OD CN4 CN6 L WIRED WALL CONTROLLER WIRELESS REMOTE CONTROLLER 4WV NOTE: DISCONNECT CN6 IF CN4 IS USED COMP.
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

HIGH

WTP

PURPLE

BROWN

BLUE

RED

RED

RED

PURPLE ORANGE BROWN BLACK G/Y


BLACK

FH FM FL

AS BLUE BLACK BLACK 4WV OF COMP.L/L1 N/L2 N/L2 KEY: ---- - FIELD SUPPLY WIRING AS - AIRSWING MOTOR DP - DRAIN PUMP (CONDENSATE) GREEN/YELLOW DP BLUE

WHITE

RED

A.C. MC

I.C.

GREEN/YELLOW

FAN MOTOR

LOW VOLTAGE CABLE TO OUTDOOR COIL SENSOR

12 GA. WIRE L1 L2

BLACK BLACK

4WV OF COMP.

N
GREEN/YELLOW BLUE

TH2

BLACK BROWN

GREEN/YELLOW

FAN MOTOR

RED BROWN

BLUE WHITE C CM S BLUE BLACK 4V R RED

WHITE

BLACK

KEY: ---- - FIELD SUPPLY WIRING CM -COMPRESSOR MOTOR 4V - 4 WAY VALVE TH2 - OUTDOOR THERMISTOR

MODEL MLC / M4L020/025BR OUTDOOR UNIT (HEAT PUMP)

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BLUE

Page 13

MODEL MCK 030AR INDOOR UNIT- (HEAT PUMP)


RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID OD TO OUTDOOR DEFROST SENSOR CN4 CN6 L WIRED WALL CONTROLLER WIRELESS REMOTE CONTROLLER COMP. 4WV
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

NOTE: DISCONNECT CN6 IF CN4 IS USED PURPLE ORANGE BROWN RED AS


WHITE

HIGH

WTP

FH FM FL

BROWN

PURPLE

BLACK

BLUE

RED RED

BLACK

KEY: ---- - FIELD SUPPLY WIRING AS - AIRSWING MOTOR DP - DRAIN PUMP (CONDENSATE)

BLUE BLACK

DP

BLUE BLACK

RED

G/Y N/L2

GREEN/YELLOW

A.C. MC

I.C.

GREEN/YELLOW

A 4WV OF COMP. L/L1 N/L2

FAN MOTOR

LOW VOLTAGE CABLE TO OUTDOOR COIL SENSOR

12 GA. WIRE

208-230V 1 PH 60Hz

L2 L1

L
RED

N BLUE *10A

*NOTE: FIELD INSTALL 10A FUSE IN BLUE WIRE AS SHOWN A 4WV OF COMP. L N G/Y BLUE
BLACK

GREEN/YELLOW RED 10A


BLACK

RED

4WV
BLACK

O/D COIL SENSOR

BLUE

WHITE

WHITE

22 T1 T2 T3 14 RED RED WHITE

A2

BLUE

BROWN

BROWN

C COMPRESSOR
BLUE RED

BLACK

FAN MOTOR

MODEL MLC / M4LC030CR OUTDOOR UNIT (HEAT PUMP)

Page 14

WHITE

CRANKCASE HEATER

HIGH PRESSURE SWITCH

BLUE

REDREDRED 21 L1 L2 L3 13

A1

WHITE

BLUE

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MODEL MCK 040AR/50AR INDOOR UNIT (HEAT PUMP)


RETURN AIR SENSOR ROOM INDOOR COIL SENSOR ID OD TO OUTDOOR DEFROST SENSOR CN4 CN6 L WIRED WALL CONTROLLER WIRELESS REMOTE CONTROLLER COMP. 4WV
DDH

JH RMODE
CN3

WATER LEVEL SWITCH

TRANSFORMER

N2 LIVE N1

AS

LOW MED

NOTE: DISCONNECT CN6 IF CN4 IS USED WHITE BLUE YELLOW RED AS


WHITE

HIGH

WTP

FH FM FL

BROWN

PURPLE

BLACK

BLUE

RED RED

BLACK

KEY: ---- - FIELD SUPPLY WIRING AS - AIR SWING MOTOR DP - DRAIN PUMP (CONDENSATE)

BLUE

DP

BLUE BLACK

RED

A.C. GREEN/YELLOW MC A 4WV OF COMP. L L1 N L2

I.C.

GREEN/YELLOW

FAN MOTOR

LOW VOLTAGE CABLE TO OUTDOOR COIL SENSOR

12 GA. WIRE

208-230V 1 PH 60Hz

L2 L1

L
RED

N BLUE *10A

4WV

OF

COMP. L L1 N L2 G/Y

*NOTE: FIELD INSTALL 10A FUSE IN BLUE WIRE AS SHOWN

BLUE
BLACK

GREEN/YELLOW RED 10A


BLACK

RED

RED

RED

RED

4WV
BLACK

O/D COIL SENSOR

BLUE

WHITE

WHITE

2T14T2 6T3 2 RED RED


WHITE

A2

BLUE

BROWN

BROWN

C COMPRESSOR
BLUE RED

BLACK

FAN MOTOR

MODEL MLC040CR/50CR

IM 818

WHITE

CRANKCASE HEATER

HIGH PRESSURE SWITCH

BLUE

1L1 3L2 5L3 1

A1

WHITE

BLUE

Page 15

MODEL : MLC 20B - 25B OUTDOOR UNIT - COOLING ONLY OPTIONAL LOW AMBIENT KIT
WHITE OL C CM S CAPACITOR R BLUE GREEN/YELLOW BLUE RED BROWN YELLOW ORANGE BLUE CAPACITOR FM BLUE RED WHITE

OUTDOOR COIL SENSOR

1 2

3 4 FSCM

COMP

KEY CM - COMPRESSOR MOTOR FM - OUTDOOR FAN MOTOR FSCM - FAN SPEED CONTROL MODULE 12 GA. WIRE BY OTHERS

(TO INDOOR UNIT)

MODEL : MLC20BR - 25BR OUTDOOR UNIT - HEAT PUMP OPTIONAL LOW AMBIENT KIT
KEY FM - FAN MOTOR CM - COMPRESSOR MOTOR 4V - 4 WAY VALVE TH2 - OUTDOOR THERMISTOR FSCM - FAN SPEED CONTROL MODULE 12 GA. WIRE BY OTHERS (TO INDOOR UNIT)

BLACK TH2 BLACK 4V OF COMP. N

BROWN

BLUE

BLUE

4 3
YELLOW BROWN ORANGE

2 1

FSCM

WHITE

C FM RED R
BLACK

RED CM S
WHITE

BLUE BLUE BLACK

BLUE BLACK

4V

Page 16

BLACK

GREEN/YEL

BROWN

BLACK

BLUE

BLUE

IM 818

Evacuating and Charging


Evacuating the tubing and the indoor unit
The outdoor unit is pre-charged with refrigerant R-22. The indoor unit and the refrigerant connection tubing must be evacuated as follows: 1. 2. 3. 4. 5. 6. Remove the 3 caps from the valves on the outdoor unit. Connect the center of the charging gauge to the vacuum pump. Connect the charging gauge to the service port of the 3-way valve (See Figure 13). Start the pump and evacuate to -760 mm Hg (-29.9" Hg). Close the valve of the changing gauge and stop the vacuum pump. On the outdoor unit, open both valves using a 4 mm Allen wrench. (See Figure 12.) Table 6: Additional R-22 ounces per ft. (when tubing length "L" is more than 25 feet - see Installation Diagram on page 5)
Model 20A 25A 30A 40A 50A 20AR 25AR 30AR 40AR 50AR Oz. Per Ft. .16 .40 .53 .55 .55 .16 .50 .53 .55 .55 Max. Length "L"-Ft. 49 49 115 115 115 49 49 115 115 115

Charge operation
Figure 12. 3-way Suction Valve on Outdoor Unit

Hex Socket for 4 mm Allen wrench

Flare Nut

Refrigerant Tubing

This operation must be done by weighing the R-22 being added thru the service port on the 3 way suction valve. (See Table 6 and Figure 14.) 1. 2. Remove the service port cap. Connect the low pressure side of the charging gauge to the suction service port center of the cylinder tank and close the high pressure side of the gauge. Purge the air from the service hose (See Figure 14). Start the air conditioner unit. Open the gas cylinder and low pressure charging valve. When the required refrigerant quantity is pumped into the unit, close the low pressure side and the gas cylinder valve. Disconnect the service hose from service port. Put back the service port cap.

Service Port

Outdoor Unit 3-way Valve

3. 4. 5.

6. Figure 13 Evacuation Schematic


Indoor Unit Liquid side Outdoor Unit Discharge Valve Close

Figure 14. Charging Schematic


Indoor Unit Liquid side Outdoor Unit Discharge Valve

Gas side Suction Valve Vacuum Pump High Low Press. Press. Close
Gas side Suction Valve

Low Press.

High Press.

Additional charge
The refrigerant is pre-charged in the outdoor unit. If the tubing length ("L") between the indoor and outdoor unit is no more than 25 ft., additional charge after evacuation is not necessary. If the tubing length ("L") is more than 25 ft., use additional R-22 as indicated in Table 6. (See Installation Diagram on page 5).
IM 818 Page 17

Remote Controller Operation Guide


Transmission source
The source where the signal is transmitted.

Signal Transmission Indication


Blinks to confirm the last setting was sent to the unit.

Temperature Setting
Set the desired room temperature by pressing the buttons to increase or decrease the set temperature. The temperature setting range is from 60F to 86F. Press both buttons simultaneously to toggle the temperature setting between C and F.

On/Off Button
Press once to start the air conditioner. Press again to stop the air conditioner.

Operation mode
Press the MODE button to select the type of operating mode. For cooling only unit, the available modes are : COOL, DRY & FAN. For heat pump unit, the available modes are: AUTO, COOL, DRY, FAN & HEAT.

Fan Speed Selection


Press the button until the desired fan option displays (auto, low, med. or high). "Auto" automatically selects high fan until room temperature is within 2oF of setting, then switches to low speed. Fan runs continuous in Cool and cycles in Heat.

OFF Timer Setting


Press the SET button will activate the off timer function. Set the desired off time by pressing the SET button continuously. Press the CLR button to cancel the off timer setting.

ON Timer Setting
Press the SET button will activate the on timer function. Set the desired on time by pressing the SET button continuously. If the timer is set to 7.30am, the air conditioner will turn on at 7.30 sharp. Press the CLR button to cancel the on timer setting.

Sleep mode setting


Press the button to activate sleep mode. This function is available under COOL, HEAT & AUTO mode. In COOL mode, the set temperature will increase 1.0F after 30 minutes, 2F after 1 hour and a total of 4F after 2 hours. In HEAT mode, the set temperature will decrease 2F after 30 minutes, 4F after 1 hour and a total of 5F after 2 hours.

Automatic Air Swing


Press the SWING button to activate the automatic air swing function. To distribute the air to a specific direction, press the SWING button and wait until the air conditioner baffle swings to the desired direction. Press the button again to hold it.

Clock Time Setting


Press button + or - to increase or decrease the clock time.

Symbol Identification
Auto low med high

Cool

Dry

Fan

Heat

Sleep

Power

Timer

Auto

Fan Speed

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IM 818

Netware 2 - Wired Wall Control (Optional)


Features: 1. Modes - Cool, Heat, Auto, Dry, Fan and Off.
AUTO
SET CLOCK

SLEEP DRY AUTO COOL HEAT FAN SWING

MON TUE WED THU FRI SAT SUN

AM PM
TIME ACTIVATE SET TIMER

ON OFF
SET CLOCK

COOL TEMP. HEAT TEMP. ROOM TEMP.

F C
ON/OFF

SLEEP

FAN

MODE

SET TEMP

SWING

ON TIMER

OFF TIMER

CLOCK

HOLD

DAY

HOUR

MINUTE

Temperature Range: 60 F to 86 F. (Press both arrows simultaneously to convert from C to F or F to C). 3. Timer - Seven day clock capable of a different On/Off time for each day of the week. Note: Hold button is used to temporarily override timer. 4. Shows time of day. 5. Electronic lockout to prevent tampering. 6. Fan Speeds - Low, medium, high and auto. 7. Sleep - Sets temperature back for sleeping. 8. Swing - Swings or positions air baffle for better air distribution. 9. Display normally shows room temperature. (Momentarily shows set point when a change is made.) 10. Heat symbol ( ) blinks while outdoor coil defrosts (heat pump only). 11. Error codes blink on display: E1 - Room sensor loose or defective. E2 - Indoor coil sensor loose or defective. E3 - Outdoor coil sensor loose or defective. E4 - Compressor cycling on overload. E5 - Low refrigerant charge. For more detail, see manual that ships with the Wall Control.

2.

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Page 19

Special Features
Dry mode
Select this mode when the standard Cool mode does not provide sufficient dehumidification. The compressor and indoor low fan will cycle together and will operate for longer periods of timeto provide the increased rate of dehumidification. As a result, the room temperature differential may increase slightly. When the unit is switched on from cold start or defrosting cycle, the indoor fan will start to operate only after the coil warms up. When the set temperature is achieved, the indoor fan will operate until the coil cools down. In case the coil overheats (145F), the compressor will cut out. If the indoor coil starts to frost, an LED light will blink to indicate that the unit is in defrost. The rated cooling capacity is provided at high indoor fan speed. The cooling capacity is slightly lower when the unit is operating at MEDIUM and LOW fan speed.

Heating (heat pump only)


Temperature
Minimum Indoor Maximum Indoor Minimum Outdoor Maximum Outdoor

Ts F
61 86 16 75

Th F
21 64

Heat mode (heat pump only)

Ts = Dry Bulb Temperature, Th = Wet Bulb Temperature

Overall Checking
Ensure that: 1. The unit has been mounted properly. 2. Refrigerant tubing connections have been checked for leaks. 3. Proper wiring and circuit breakers have been installed. Drainage check: Check condensate drain for leaks and proper flow. See Drain Test, page 6. Test run: Check the following items: Are all electrical plugs firmly inserted into there receptcales? Is there any abnormal sound from the unit? Is there any abnormal vibration on the unit itself or piping? Confirm that: 1. Condenser fan is running, with warm/cold air blowing off the outdoor unit. (Cooling only/Heat Pump) 2. Evaporator blower is running and discharge cool/warm air. (Cooling only/Heat Pump) Note: The control incorporates a 3 minute randum start delay in the circuit. Thus, it requires about 3 minutes before the outdoor unit will start.

Overheating protection (heat pump only)

Frost prevention

Fan speed and rated cooling capacity


Operating Conditions
Cooling
Temperature
Minimum Indoor Maximum Indoor Minimum Outdoor Maximum Outdoor

Ts (dry bulb) F
61 90 66* 114

Th (wet bulb) F
52 73 24 75

* 32F on size 20 and 25, 23F on size 30, 40 and 50 with optional Low Ambient Kit.

Page 20

IM 818

Unit Indicator Lights


IR signal receiver
When an infrared remote control operating signal is transmitted, the signal receiver on the indoor unit beeps and indicator lights confirm acceptance of the signal transmission. Figure 15. Indicator Lights Location - Indoor Unit
IR Receiver, LED Indicator Lights and On/Off Switch

Wireless Remote Control


Cooling: LED Indicator Lights Heat Pump: LED Indicator Lights

SLEEP

TIMER

POWER

HEAT

TIMER

POWER

Mode and Diagnostic Chart


POWER TIMER SLEEP HEAT

Mode or Fault
ON ON ON Blink Continuously Once every 3 sec. Twice every 3 sec. 3 times every 3 sec. 4 times every 3 sec. ON ON ON ON or OFF

Action or Possible Cause

Timer on Sleep mode on Heat mode Defrosting outdoor coil Heating will resume after coil is defrosted

Compressor cycling on over- Low OD air flow, dirty coil, load defective comp. or overload Condensate pump not working - water level too high Gas leak Room/indoor/outdoor coil sensor loose or defective Defective pump or blocked drain Repair leak in refrigeration system Attach or replace

Note: The main ON/OFF push button switch is located above the LED Indicator Lights.

IM 818

Page 21

Startup After Extended Shutdown


Inspect thoroughly and clean indoor and outdoor units. Clean or replace air filter. Clean condensate drain line. Clean clogged indoor and outdoor coils. Check fan imbalance before operation. Tighten all wire connections. Check for refrigerant leakage. The crankcase heater should be energized for at least 6 hours before starting the unit.

Note:

Troubleshooting
When any malfunction is noted, immediately switch off the power supply to the unit. Some simple trouble shooting tips are listed below. Trouble
The compressor does not operate.

Possible cause/treatment
Protection against frequent starting. Wait for 3 to 4 minutes for the compressor to start operating. Power failure. Check fuse or circuit breaker. Power supply is disconnected. Delay timer may be set incorrectly. Dirty air filters.

Fans and compressor do not operate.

Air flow too low or insufficient cooling/heating capacity.

Doors or windows may be open. Adjust thermostat setting. Smoke, perfume, etc. may have collected on the indoor coil. Clean coil. Use dry mode. High humidity in conditioned space. Temperature set too low. Increase temperature setting and operate unit at high fan speed. Condensate drain plugged. Refrigerant fluid flowing into the evaporator coil. Operate for a while to see if sound goes away.

Discharge air flow has bad odor.

Condensation on the return air grille of the indoor unit.

Condensate leaking into room. Hissing sound from the unit during operation.

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IM 818

Service and Maintenance


WARNING Disconnect the main power supply before performing any service, maintenance or troubleshooting. The unit is designed to give long life operation with minimum maintenance required. However, it should be regularly
Item

checked and the following items should be given due attention.


Frequency

Maintenance Procedures

Indoor Unit Air Filters

1. Remove the filter before cleaning it. 2. Remove the dust adhering on the filter by using a vacuum cleaner or wash with lukewarm water (below 40C/104F) with neutral detergent solution. At least once a month. 3. Rinse well and dry the filter before placing it back onto the unit. Note. Do not use gasoline, volatile substances or chemicals to clean the filter. Clean the grille and panel by wiping it using soft cloth soaked in lukewarm water (below 40C/104F) with neutral detergent solution. Note. Do not use gasoline, volatile substances or chemicals to clean the unit. Check and clean if necessary. Check for abnormal noise. Clean the louvers and coil. Be careful not to bend or flatten the aluminium fins. DO NOT use cleaning fluids that might corrode the coil. 1. Check the running current and voltage for indoor and outdoor units. 2. Check the electrical wiring and tighten the terminals. No maintenance needed if refrigerant circuit remains sealed. However, check for refrigerant leaks at joints and fittings. Oil is factory charged. Not necessary to add oil if circuit remains sealed. All motors are pre-lubricated and sealed at factory. Every year.

Indoor Unit Condense Drain Pan and Pipe Indoor Fan Indoor/Outdoor Coil Power Supply Compressor Compressor Oil Fan Motor Oil

Every year. Every year. Every year. Every year. Every year. No maintenance required. No maintenance required.

IM 818

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This document contains the most current product information as of this printing. For the most up-to-date product information, please go to www.mcquay.com.

2004 McQuay International www.mcquay.com 800-432-1342

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IM 818