HERON 2.2 User manual

1
Figure 1
INSTALLATION INSTRUCTIONS FOR HERON 2.2
The Heron 2.2 is suitable for installation in most caravans & motorhomes.
Installation in Commercial and Industrial vehicles and equipment should be
referred to AIRCOMMA D AUST for assessment of suitability.
The capacity of the airconditioner to adequately cool or heat a van, is dependent on:
•The size of the van
•The thickness and quality of thermal insulation installed in the van
•The expected outside or ambient conditions.
The HERO 2.2 is recommended for vans up to 5.2 m overall, but assumes that
wall and ceilings are insulated with a minimum of 25 mm of insulation, wool or
foam. Windows should all have shades or curtains as a minimum.
If the van is to be used mainly in extreme conditions (40°C plus), then be
conservative, i.e. ensure the best insulation is installed, consider double glazed
windows, and size the airconditioner down to 4.8 m maximum.
315
440
460
235
Condenser

AIRHANDLER A/H
FACIA
2
DESCRIPTION OF THE HERON 2.2 SYSTEM
The HERO 2.2 is a split system, utilizing a condenser set (referred to throughout
this text as a CO /SET) and an airhandler (referred to as an A/H).
The Con/set is designed for installation beneath a bunk, settee, or in the bottom of
a floor cupboard. Refer fig. 1 for dimensions.
The A/H is designed for fitment into an overhead cupboard or similar, and comes
complete with facia and controls. See fig. 2.
The A/H and CO /SET are coupled by means of a pair of refrigerant lines, and a
control cable. The pipework is not supplied with the unit, but a standard 5 m
control cable is.
Before proceeding with the installation, consider a number of important details
that must be complied with in the following description.
220
380
DRAIN RECOMMEND 70 MM TO FLOOR
OF CUPBOARD FOR ADAQUATE
"FALL" OF DRAIN
215
MUSTALLOW
90 MM SPACE
FOR AIR FLOW
TO FAN
270
12
490
Figure 2

3
Choosing a position for the con/set
Generally, avoid installation on the left hand side (annex side), as the condenser
set will discharge hot air into this space.
It is usual to install the con/set on the right hand side, either under a bunk, settee,
or at the bottom of a floor cupboard.
NOTE: Ensure that wherever the con/set is installed, reasonable access to the
top of the unit is always available, for service, and any shelving etc. above, must
be easily removed. Also, the two line valves on the back of the unit must be easily
accessed.
The maximum length of pipework between the Con/set and the A/H is 5 metres.
Installations exceeding this may require extra refrigerant to be added to the
system.
Figure 3
372
237 107
390
265
180
50
10
178
Comp.
well
Normally install condenser
set opposite to annexe

4
nstalling the Condenser set
Marking out the floor
Use the floor template as provided (or refer to fig. 3). Both, or either end of the
con/set may be hard against a wall or panel, but the back of the unit must have
sufficient clearance to allow easy access to the line valves (see fig. 4). Once a
convenient position has been decided upon, place the template, side marked
“Inside Wall”, hard against the inside skin of the van, and mark out the six 114mm
diameter (4 1/2”) condenser air inlet holes, and the square compressor well hole
(see fig. 3).
Note: Check to see if any structural floor members will interfere with any of these
holes. It is essential that the compressor well is unimpeded.
The air inlet holes will tolerate some obstruction. However the total area must not
be less than 75% of the inlet holes in the chassis.
We recommend that a hole saw be used to cut out the six round holes. If a
structural member is beneath, then the complete cut out can be removed. The gap
between the top of the structural member and the underside of the unit (i.e. the
floor thickness) will help in overcoming the restriction of the member.
Clips
Line Valves
Figure 4

5
Marking out the wall
ow mark out the hole in the wall for the condenser discharge grille (see fig. 5).
Mark out the position and size of the air outlet hole, from inside the van, using the
floor as reference.
Witness holes can be drilled at the four corners, and the hole cut out from the
outside. It is essential to box up this hole to give a firm seal to the air outlet from
the con/set and to stop any discharge air from entering the wall space.
Positioning of the Con/set
Lay down a generous bead of silicone on the floor to match the perimeter of the
Con/set. ow, lift the Con/set into position, and check that the compressor well
does not interfere and prevent the chassis from sitting firmly on the floor.
Push the Con/set hard up against the wall.
t is vital that the Con/set seals hard against the inside wall to ensure no hot air
leakage during operation.
To secure the Con/set in position, use the two hold down clips provided (see fig. 4).
These clip over the edge of the chassis. At least one clip should be installed on the
back edge to ensure the good airseal is maintained against the inside wall.
Screw the clips firmly to the floor.
Condenser air outlet
Air handler
15
440
15
140
80 Floor
Figure 5

6
90 mm min.
75 mm between pan of unit and
bottom to allow for drain fall
Refrig. pipes cross
back of enclosure
and come round on
LH. side to give flexibility
2 return air filter
assy. inset to bottom
of cupboard
Refrig. lines, drain hose,
electrical cable
(cover with moulding)
Refrig. liner
Return air filter
Drain
Facia
Section Detail
Figure 6
PIPE INSTALLATION & CONTROL WIRING
The pipe work consists of a 1/4” tube (liquid line), and a 3/8” tube (return gas)
running between the Con/set and the A/H. The 3/8” line must be insulated with 10x
10 mm foam rubber insulation.
Connection is made at the back of the Con/set. Pipe work may be run internally to
the A/H, or may be run through holes in the floor and run externally to a
convenient re-entry point, or the pipes may be built into the wallspace during van
construction. N.B. Pipework installed in walls must be well insulated to avoid
“sweating” and possible long term moisture damage.
The control wiring will normally follow the pipework and be taped to it. N.B. If
the control cable is to be run externally, then it must be run in a suitable conduit.
ow refer to the A/H installation, after which we return to the Con/set to open up
the refrigeration circuit and fit the louvre panel.

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AIR HANDLER INSTALLATION
The A/H needs to be installed in as central as possible position, such that no short
cycling of discharge air will occur. See figs. 6 & 7.
3 most important points that must be satisfied
1. The distance from the back of the cupboard to the back of the A/H must not be
less than 90 mm to allow proper air entry to the fan.
2. Two separate return air grilles/filters are supplied, and must be installed. If
only one is used, this will reduce the air flow back to the fan.
3. The A/H has a condensate drain underneath. This drain must continuously
“fall” from the outlet. It is recommended that the bottom of the A/H be 70 mm
above the bottom of the cupboard, to allow adequate fall.
A lesser amount is ok, provided much care is exercised to avoid “humps” that will
result in airlocks and the backup & overflow of condensate.
Air flow
Refrig. pipes run through
floor and up rear of wardrobe
Return air
filter assy.
False ceiling
N.B. unit may sit hard on
ceiling as condensate drain
can be run vertically.
Figure 7

8
Refer to figs 8a & 8b and the full size template provided in the kit
The following describes the procedure for a cupboard with a full front that can be
removed. For cupboards that cannot be disassembled (retrofitting) see pp.5.
Set up the paper template on the front panel of cupboard and position it such that:
1. The facia panel will be centrally located on the cupboard if possible.
2. The connection side of the A/H needs to be a min of 110mm from the LHS wall
of the cupboard to allow the 3/8pipe to be bent around and flared (fig. 8a & 9).
3. The bottom of the A/H will be located so as to give sufficient fall for the drain.
Using adhesive tape stick down the template and drill pilot holes to mark the
cutouts. Also drill the 4 screw holes for the A/H retaining screws, & countersink
or counterbore so that the screw heads will be flush with the surface.
Figure 8b
Figure 8a
CUTTING TEMPLATE - AIR HANDLER
PART NO. 4002063
CUT OUT FOR AIR REGISTERS
DRILL 4 HOLES - 5 DIAMETER
OUTSIDE OF AIR HANDLER CABINET
CUT OUT FOR CONTROL BOX
MINIMUM 110 MM
TO SIDE WALL OF
CUPBOARD TO ALLOW
PIPEWORK TO BE
CONNECTED
DRAIN

9
From the template the height of the two support rails may be measured. Ref. to fig. 10
to make the two support rails. ote that the rails are cut out to assist air flow into
the cupboard.
Install the 2 return air grilles frames, usually equispaced along the under side of
the cupboard. Some installations will allow the return grilles to be placed in
possibly more convenient positions. eg Pop top vans may allow the grilles to be
fitted on top of the cupboard. Installation in corner cupboards would allow one or
more return grilles to be fitted on the side.
The support rails can now be fitted.
nstalling the copper pipe in the cupboard
ormally the two pipes coming from the Con/set will enter the cupboard on the
right hand side, go to the top of the cupboard, bend to the left and run to the left
side and be bent to come forward to line up with the connection nipples of the A/H.
This system will allow the maximum flexibility after connection. The 3/8” pipe
must be fully insulated and normally tape the control cable to it also.
t is important to run the pipes along
the top of, and hard to the back of the
cupboard to minimize interference to
the airflow to the fan.
The final 90° bend back to the nipple on
the A/H normally needs to be as tight as
possible. Use a hand tube bender to obtain
a good tight radiused bend (ref fig. 9).
FITTING THE DRAIN
Use 12 mm hose or semi rigid irrigation
tube (poly).
Run the hose vertically downwards from
either back corner of the cupboard, and
drain through the floor. Use the 90° elbow
(provided) at back of cupboard.
ow measure and cut the tube to run from
the special elbow at unit drain outlet
grommet to the corner elbow. See fig. 11. Figure 9

10
POWER SUPPLY
The unit is designed to plug into a normal GPO.
If there is not a convenient outlet available, then one should be installed either
within the cupboard or in close proximity.
NOW TO INSTALL THE AIRHANDLER
Sit the A/H on the rails and adjust its position as per the cutting out template, the
front being flush with back of front panel when fitted.
The surplus pipe can now be cut off, the pipe angles generally adjusted to line up
with the A/H nipples.
Unscrew both flare nuts from the A/H and knock out the sealing bonnets, before
slipping them onto their respective tubes. ow flare both tubes, and connect them
to the A/H. Tighten both nuts firmly. See fig. 9.
h
16210
20
20
SUGGESTED RAIL DIMENSION
Figure 10

11
CONNECTING THE DRAIN
With the special elbow connected to the tube running to back corner, moisten the
vertical leg and insert it into the drain grommet with rotating motion. Now check
that the drain runs downhill all the way! (fig. 11)
FIT THE FRONT PANEL OF THE CUPBOARD
1. Screw the panel to the cupboard (original fastenings).
2. To fasten the A/H to the front panel, use 4 self tapping screws, 32 long x no 6.
Insert through the front of the panel & pick up the prepunched holes in front of
the A/H. See fig. 12. Screw up until A/H forms a firm seal against the back of
the front panel.
ow return to the Con/set to complete the refrigerant circuit.
Figure 11 1DRAIN HOSE TO VERTICAL DRAIN (NOTE - FALLS ALL THE WAY)
2GROMMET
3SPECIAL ELBOW
4FLOOR OF CUPBOARD
2
3
4
1

12
INSTALLING AN AIRHANDLER INTO AN EXISTING CUPBOARD,
THE FRONT PANEL OF WHICH IS NOT EASILY REMOVED
This is often the case with retrofits.
Please note: The installation requires that there be a minimum of 16mm between the
front of the A/H and the back of the front panel, to allow sufficient room for the
turning vanes on the facia to be accommodated.
f there is a 3 to 5 mm front panel, then a frame 16mm thick will need to be installed.
The cupboard door is removed, and the cutting template applied to the cupboard
front.
Firstly, however, refer to fig. 13 which shows a modified template. Draw the “New
Cutting Line” as described in fig. 13 onto the full sized template.
This hole will now measure 240 mm high, and include the control box cutout.
Apply the marked up template to the cupboard front, adjust for symmetry etc. tape
down, and drill the witness or pilot holes at the corners. Proceed then to cut out.
An adaptor frame is now constructed. See fig. 14.
The cutting template can be layed over this frame, the right end line “outside of
airhandler cabinet” is layed flush with the end of the frame. The same line is 10 mm
inside the top and bottom cutout. Mark and drill the 4x5 mm dia. holes used to pick
up the prepunched holes on the front of the A/H.
Figure 12 1“P” SADDLE FOR THERMOSTAT BULB
2CLAMPING SCREWS 4 OFF - COUNTER SINK.
THESE SCREWS PICK UP PREPUNCHED HOLES IN THE FRONT OF A/H.
MAX LENGTH SCREWS No.6 X 32M.
2
1

13
ow screw the frame to the A/H, using the 32 x no 6 screws provided (ensure they
are countersunk flush with the surface of the frame). See fig. 12 & 13.
Cut out the holes for the two return air grilles and install them. ow fit the two
support rails. The support rail height is best measured by initially inserting the A/H
(complete with timber sub frame fitted), and measure from underneath through a
return air frame. This way will give the correct height you need to make the two
rails. See fig. 10 & 15.
Install the drain as described in pp. 8 & 9.
ow run the pipework as pp. 4 & 8.
The A/H assy. can now be fitted with the subframe being screwed to the front
panel of the cupboard. See fig. 15.
Note: If the front panel is just 3 to 10 mm plywood, then extra framing will need
to be installed, so that the sub frame attached to the A/H can be screwed back to
it.
CUTTING TEMPLATE - AIR HANDLER
PART NO. 4002063
CUT OUT FOR AIR REGISTERS
DRILL 4 HOLES - 5 DIAMETER
NEW CUTTING LINE
10
10
OUTSIDE OF AIR HANDLER CABINET
CUT OUT FOR CONTROL BOX
Figure 13

14
To summarize
Before fitting the A/H:
1. Install copper pipework
2. Fit the drain
3. Provide the power supply (GPO)
ow fit the A/H with the sub frame into the cupboard.
4. Screw the subframe into the cupboard front panel
5. Connect the drain (pp 9)
6. Connect up the refrigeration pipes (pp 8 & 9)
7. Open up the refrigeration circuit (pp 13)
8. Leak test (pp 15)
9. Install facia (pp 7)
10. Test (pp 19).
30
240
16 min
GLUE & STAPLE
ALL JOINTS
380
CLAMP SCREW HOLES (COUNTERSUNK)
SUB FRAME
Figure 14

15
CHARGING THE SYSTEM
The condenser set is factory precharged, but the airhandler and connecting
pipework needs to be purged or evacuated of non-condensables.
PLEASE NOTE:
State laws re the handling of prescribed refrigerants may prohibit the purging
method. Such laws take precedence.
Method 1 (Purging)
1. Make sure all connections are tight at the A/H.
2. Tighten firmly both flare nuts at Con/set.
3. Then ease off the 3/8nut one turn at the Con/set.
4. Remove both valve stem caps. See fig. 16.
5. With a 5 mm allen key, insert into stem of the 1/4” valve and undo 1/8of a
turn.
6. Gas will be heard to be purging thru the eased off 3/8flarenut.
7. Allow to purge for 6 Secs, and tighten up the 3/8f/nut.
8. ow wind out both the 1/4& 3/8valve stems with the allen key until fully
back seated.
9. Put on the valve stem caps and tighten up.
10. Now check for leaks: See paragraphs following on leak testing.
AIR HANDLER
90
min
SCREW BACK INTO
CUPBOARD FRONT
SUBFRAME
SUPPORT RAIL
CUT OUT FOR 3 RETURNAIR GRILLES
BACK OF
CUPBOARD
Figure 15

16
Method 2 (Use a vacuum pump to remove non-condensable from A/H and pipe
work.)
1. Tighten all flare nut connections on both Con/set & A/H.
2. Remove schrader valve caps and connect vac. pump hoses, preferably to
both valves. (Make sure valve depressors are set OK.)
3. If both hoses are fitted, evacuate for 10 mins. If only one is fitted then
evacuate for 15 mins.
4. Check that pump retains a high vacuum.
5. Remove the stem caps, then isolate the vac. pump, and then turn on both
valve stems. Fully backseat both & refit caps.
6. Disconnect vacc. pump hoses & replace caps.
7. Check for leaks.
Figure 16
LINE VALVE
Valve stem
Schrader valve
Valve stem cap
Refrigerant pipe
Use 5 mm allen key
to open valve (fully backseat)

17
LEAK TESTING
It is of the utmost importance that a leak check be made on the 4 flare nut
connections. Aleak however small will result in the aircon system loosing capacity
and endanger the compressor.
1. Use either soapy water or a proprietary leak test solution.
Paint on each flare nut (particularly the neck) and inspect carefully for any
telltail bubbles. Use a torch to improve visibility, particularly in the A/H area.
Any leak will generally be remedied by further tightening of the particular flare
nut.
In the event of a faulty flare, the line valves must be turned off, the A/H
pumped out and the flare remade.
2. Use an ELECTRO IC leak detector. Test initially on low sensitivity,
examining in particular the neck of each flarenut. Increase the sensitivity until
you are confident that no leak exists.
nstall bituminous tape on 3/8” flare nuts
To avoid “sweating” and the dripping of water off the return gas line, with the
bituminous tape provided, wrap the 3/8flare nut at both the A/H and the Con/set.

FITTING OF AIRHANDLER FACIA
With leak testing of the A/H flare nuts completed, the Facia may be fitted.
1. Feed the service lead into the cupboard and plug in to GPO but leave turned
off.
2. ow plug in the Con/set control cable to back of switch box (6 pin). Plug in the
A/H cable (9 pin). See fig. 17.
3. Take the thermostat bulb, stretch out the capillary approx 150mm and fit the
bulb into the “p” saddle on the side of the A/H. See fig. 12.
It may be more convenient to fit this after the facia is installed by reaching up
thru a return air frame.
4. ow push the facia fully into the cupboard frontpanel. Square up and using the
c/s chipboard screws (supplied) screw facia in 4 places. Use the white plastic
buttons provided to cover screw heads.
5. Check that turning vanes are free to rotate.
6. Turn on power to system.
7. Fit the 2 return air filters by springing them into their frames.
18
Figure 17
THERMOSTAT
CAPILLARY
9 PIN PLUG
6 PIN PLUG

19
Figure 18
THERMOSTAT
FAN SPEED
SELECTOR
HIGH SPEED
COOLING
MODE
SELECTOR
OFF
MEDIUM
COOLING
LOW COOLING
SPEED
HEATING SPEED
HEATING
COOLING
FAN ONLY
(VENTILATION)

Test to be carried out by the nstaller prior to delivery
Refer to fig. 18.
COOL NG:
N.B. The unit will not run on cooling if the inside temperature is much below
20°C.
1. Turn fan speed selector to (Hi speed cooling)
2. Turn mode to (Cooling)
3. Adjust the thermostat counter clockwise until the Con/set is heard to start.
Ensure that cold air is being discharged, and there are no pipe rattles etc. After
about 15 mins. of running, and providing the inside temperature is above 23°C,
then the discharge air should be 12°C or cooler than the return air.
HEAT NG (ref fig. 18)
N.B. The unit will not heat if the inside temperature is much above 28°C.
1. Turn the speed selector to (Heating Speed)
2. Turn mode selector to (Heating)
3. Adjust the thermostat to maximum clockwise position.
There will be approximately 30 secs. delay before heating is apparent.
4. After about 15 mins. the discharge air will be approx. 25°C more than the
return air.
20