Marstair CXE Series User manual

55908039-06
CXE SPLIT SYSTEMS
TECHNICAL MANUAL

2 55908039-06
INDEX
CONTENTS
PAGE
PART NUMBERS, OPTIONS, UNIT COMBINATIONS, DIMENSIONS & WEIGHTS
3-4
PERFORMANCE DATA & AIR FLOW
4
SOUND POWER AND SOUND PRESSURE LEVELS
5
ELECTRICAL DATA
6
CXE
DIMENSIONS
7
INSTALLATION: CONTENTS & PIPEWORK
8
ELECTRICAL: FUSES & WIRING DIAGRAMS
9
CONTROLLER SETTINGS
10
CKC
INSTALLATION: DIMENSIONS
11
PIPEWORK
12
ELECTRICAL
13 -14
R407C REFRIGERANT
15 -17
END OF LIFE REQUIREMENTS
17
COMPONENT IDENTIFICATION
CXE UNITS
18
CKC UNITS
19
1. TEV Ltd recommend that personnel working on this equipment be skilled and fully conversant with
the appropriate Air Conditioning, Refrigeration and Electrical practices and have sound knowledge
of current Industrial Safe Working practices.
2. CXE models are electronic control units that use R407C refrigerant; they provide cooling within
the range of 2.8 –6.8 kW. These units are matched with MCU+ outdoor units to complete a
system.
3. These units contain live electrical components, moving parts and refrigerant under pressure.
Always site out of reach of children and protect from vandalism.
4. The data plate only gives information for the CXE unit. For system details add input power and
current of indoor and outdoor unit, including any heater load.
5. Expansion device is fitted to the indoor unit. For pipe runs longer than 20m the expansion
device needs to be removed from the indoor unit and fitted onto the suction line on the
outdoor unit.
GENERAL

3 55908039-06
MODEL
Part No.
CXE30
MASTER
55917026
CXE50
MASTER
55917028
CXE70
MASTER
55917029
CXE30
SLAVE
55917056
CXE 50
SLAVE
55917058
CXE70
SLAVE
55917059
Evaporators
Condensing unit
2 x CXE30
CKC 50
2 x CXE50
CKC 80
2 x CXE50
CKC 90
2 x CXE50
CKC 100
2 x CXE70
CKC 100
2 x CXE70
CKC 130
2 x CXE70
CKC150
3 x CXE50
CKC 100
3 x CXE50
CKC 130
3 x CXE50
CKC 150
3 x CXE50
CKC 165
3 x CXE70
CKC 100
3 x CXE70
CKC 130
3 x CXE70
CKC 150
3 x CXE70
CKC 165
3 x CXE70
CKC 180
3 x CXE70
CKC 200
If heater is to be fitted to a slave it must also be fitted to the master.
MODEL
Part No.
1ph
3ph
CKC 50
55020722
55020776
CKC 80
55020723
55020724
CKC 90
55020771
55020778
CKC 100
-
55020779
CKC 130
-
55020780
CKC 150
-
55020781
CKC 165
-
55020782
CKC 180
-
55020783
CKC 200
-
55020784
OPTIONAL KITS
PART NUMBER
DESCRIPTION
55900721
3kW heater (MASTER)
55900722
3kW heater (SLAVE)
OPTIONS
UNIT COMBINATIONS
PART NUMBERS

4 55908039-06
Evaporators
Condensing unit
Duty at
8ºC kW
Duty at
12.7ºC kW
2 x CXE30
CKC 50
3.90
4.80
2 x CXE50
CKC 80
5.60
6.90
2 x CXE50
CKC 90
6.40
7.30
2 x CXE50
CKC 100
7.30
8.20
2 x CXE70
CKC 100
7.60
8.80
2 x CXE70
CKC 130
8.40
10.00
2 x CXE70
CKC 150
9.50
11.00
3 x CXE50
CKC 100
7.70
9.10
3 x CXE50
CKC 130
8.50
10.20
3 x CXE50
CKC 150
9.80
11.30
3 x CXE50
CKC 165
10.80
12.50
3 x CXE70
CKC 100
8.00
10.00
3 x CXE70
CKC 130
8.90
11.10
3 x CXE70
CKC 150
10.0
11.50
3 x CXE70
CKC 165
11.00
12.70
3 x CXE70
CKC 180
12.50
14.00
At 27°C External Ambient
MODEL
UNPACKED
PACKED
CKC
HEIGHT
WIDTH
DEPTH
WEIGHT
1ph
WEIGHT
3ph
HEIGHT
WIDTH
DEPTH
WEIGHT
1ph
WEIGHT
3ph
50
720
1000
350
64
62
720
1080
340
66
64
80
720
1000
350
66
64
720
1080
340
68
66
90
820
1000
350
76
73
820
1090
390
78
75
100
820
1000
350
-
81
820
1090
390
-
83
130
1080
1000
425
-
101
1080
1090
465
-
105
150
1080
1000
425
-
103
1080
1090
465
-
107
165
1080
1000
425
-
103
1080
1090
465
-
107
180
1275
1100
425
-
118
1280
1215
465
-
123
200
1275
1100
425
-
173
1280
12515
465
-
178
MODEL
UNPACKED
PACKED
CXE
HEIGHT
WIDTH
DEPTH
WEIGHT
HEIGHT
WIDTH
DEPTH
WEIGHT
30
483
845
320
18
530
950
370
21
50
483
845
320
20
530
950
370
23
70
483
845
320
23
530
950
370
26
PERFORMANCE DATA (kW)
DIMENSIONS & WEIGHTS

5 55908039-06
AIR FLOWS
INDOOR UNIT
MAXIMUM
SPEED
SOUND POWER LEVELS
SOUND PRESSURE
LEVELS
SPEED
Frequency Hz
125
250
500
1K
2K
4K
dB(A)
NC
CXE 30
69.1
67.7
67.6
65.6
62.2
56.0
55
48
CXE 50
71.7
69.2
69.1
67.1
63.2
58.5
56
50
CXE 70
70.1
68.2
68.6
66.1
63.2
57.5
56
49
Sound Power Levels were obtained in full accordance with the direct method of BS EN ISO3174:2000.
Levels are shown in dB with a standard reference of 1 pW.
Sound Pressure Levels in dB(A) refer to semi-hemispherical radiation (wall or ceiling mounted) at a distance
of 1.5m from the front of the unit, with the fan operating at full speed.
OUTDOOR UNIT
MAXIMUM
SPEED
SOUND POWER LEVELS
SOUND PRESSURE
LEVELS
SPEED
Frequency Hz
125
250
500
1K
2K
4K
dB(A)
NC
CKC 50
74
68
67
66
61
54
49
44
CKC 80
71
69
68
65
60
54
49
43
CKC 90
82
72
69
69
63
57
52
47
CKC 100
79
74
72
69
64
58
53
47
CKC 130
73
70
70
69
65
57
52
47
CKC 165
73
70
70
69
66
58
57
51
CKC 150
73
70
70
69
66
58
57
51
CKC 180
73
72
72
69
66
58
59
53
Sound Power Levels were obtained in full accordance with the direct method of ISO 3741: 1988. Levels are
shown in dB with a standard reference of 1 pW.
Sound Pressure Levels in dB(A) refer to semi-hemispherical radiation (wall or floor mounted) at a distance
of 3m from the front of the unit, with the fan operating at full speed; (add 3dBA or 3NC for units at an
intersection of a wall, add 1dBA or 1NC for high level wall mounted units).
MODEL
m³/s
CXE 30
0.61
CXE 50
0.66
CXE 70
0.58
MODEL
m³/s
CKC 50
0.97
CKC 80
0.97
CKC 90
0.97
CKC 100
0.97
CKC 130
1.85
CKC 150
1.85
CKC 165
1.85
CKC 180
1.85
SOUND POWER AND SOUND PRESSURE LEVELS

6 55908039-06
PERFORMANCE DATA
UNIT ELECTRICAL LOADS [230V 50Hz 1Ph (A) or 400V 50Hz 3Ph (A/Ph)]
MODEL
FAN MOTOR
HEATER
CXE 30
0.8
13.0
CXE 50
0.8
13.0
CXE 70
0.8
13.0
MODEL
1ph
3ph
Power
(nominal)
(kW)
Starting
current
LRA
(A)
Nominal
current
FLA
(A)
Power
(nominal)
(kW)
Starting
current
LRA
(A)
Nominal
current
FLA
(A)
CKC 50
2.0
58
8.9
1.9
26
4.2
CKC 80
3.0
76
11.5
3.0
40
4.9
CKC 90
4.2
114
16.9
4.1
48
7.1
CKC 100
-
-
-
4.3
51
7.2
CKC 130
-
-
-
4.4
62
7.7
CKC 165
-
-
-
5.3
68
8.7
CKC 150
-
-
-
6.0
71
9.5
CKC 180
-
-
-
7.0
71
11.9
ELECTRICAL DATA

7 55908039-06
CXE DIMENSIONS

8 55908039-06
The unit may be mounted on a wall or solid ceiling using brackets supplied. It should be matched with the
appropriately sized outdoor unit; this instruction should be used in conjunction with the outdoor unit
installation instructions.
1. Fit all kits prior to installing the unit. (Heater kit is easier to fit when unit has been mounted).
2. Ensure that the mounting surface will support the operating weight of the unit (see table below).
3. Mark out the mounting positions and drill holes to suit 6mm rawlbolt shields or equivalent strength
fasteners (ensure that the unit is positioned to give sufficient access (min 0.5m) to the electrics access
side).
4. Fix the mounting brackets to the unit in the correct
position for wall or ceiling mounting.
5. Raise the unit into position and secure the fixings,
ensuring that it is square and level.
6. Remove the drain tray then fit the drain stub, nut &
gasket (Fig.1). Refit the drain tray.
Fig.1
CXE PIPEWORK
NITROGEN CHARGE
The unit contains a small charge of dry nitrogen, which should be discharged into the atmosphere. This is a
non-toxic, non-ozone depleting gas with no global warming potential.
PIPE CONNECTIONS
Pipework is terminated with 2 flare nuts & bonnets. Access is via the rear right hand side. Pipes exit the unit
through holes in the back panel.
INDOOR UNIT
CXE 30
CXE 50
CXE 70
LIQUID / EXPANSION
3/8"
3/8"
1/2"
SUCTION
1/2 "
1/2 "
5/8"
CONDENSATE DRAIN
Push fit connections are widely available for the 7/8” (22mm) OD condensate drain and 3/4"(19mm) ID drain
stub adaptor. Alternatively 7/8” (22mm) bore plastic tubing may be fitted directly to the stub/adaptor with a
hose clamp. Take care not to overtighten hose clamps as this could damage the stub pipe.
CONTENTS
PARTS DESCRIPTION
ACTION
Envelope containing operating
instructions and Declaration of
Conformity
Pass to the end user.
Drain Stub/Nut/Gasket
Fitted by installer.
Drain stub adaptor
Convert to ¾" drain if required.
Mounting brackets plus fixings
Use to hang unit.
DRAIN TRAY
GASKET
NUT
DRAIN STUB
CXE INSTALLTION

9 55908039-06
•Cables are routed to the terminal block via the cable cord grips at the rear of the unit and then through
the back of the electrics box (see page 2).
•Cables MUST be size compatible with the recommended system fuse.
FUSES
Note: On 3 ph systems the supply must go to the MCU+ outdoor unit and then to the CXE indoor unit.
For fuse sizing with electric heating contact Marstair technical department.
WIRING DIAGRAM
MASTER (Also shows optional heater)
SLAVE (Also shows optional heater)
1PH FUSE SIZE (Cooling Only Systems)
CKC
15
20
30
40
50
60
80
90
100
130
150
165
180
200
FUSE
16
16
16
20
16
20
25
32
-
-
-
-
-
-
3PH FUSE SIZE (Cooling Only Systems)
CKC
30
40
50
60
80
90
100
130
150
165
180
200
FUSE
10
10
10
10
10
16
16
16
20
20
25
32
CXE ELECTRICAL CONNECTIONS

10 55908039-06
TEMPERATURE CONTROL (Do not set the controller below 4°C.)
The SET temperature is factory set at 12⁰C.
The digital display normally displays the return air temperature.
To change the SET temperature, press and hold down the SET button. If no alarms
active, the ‘St1’ label appears and the current value is shown on the screen and will flash.
To change the Setpoint value, press ▲ and ▼ keys within 60 seconds.
The display will revert to the return air temperature after 60 seconds.
The fitted de-ice thermostat will activate a de-ice cycle when there is a build up of ice on
the evaporator coil.
Cellarators will only heat a room if the electric heater option is fitted.
WARNING
The following actions could damage your system:
1. Switching the unit OFF and ON quickly
2. Setting the unit to HEAT and then back to COOL quickly
NB: Allow at least 3 minutes between the above actions.
CONTROLLER SETTINGS

11 55908039-06
MOUNTING
Whether floor or wall mounted, it is essential that the mounting surface is capable of supporting the unit
weight. Leave space around the unit for air circulation and access for installation and maintenance.
CKC 50-100 (Dimensions in mm.)
MODEL
A
B
C
D
E
F
G
H
G1
H1
Weight (kg)
1 Ph
3 Ph
CKC 50
1000
350
660
570
213
60
383
358
345
325
64
62
CKC 80
1000
350
660
570
213
60
383
358
345
325
66
64
CKC 90
1000
350
760
495
250
70
383
358
345
325
76
73
CKC 100
1000
350
760
495
250
70
383
358
345
325
--
81
1500 min air off
100 min 100 min
600 min
CKC INSTALLATION
CKC DIMENSIONS

12 55908039-06
CKC 130 –180 (Dimensions in mm.)
MODEL
A
B
C
D
E
Weight (kg)
CKC 130
1000
1020
495
251
100
101
CKC 150
1000
1020
495
251
100
103
CKC 165
1000
1020
495
251
100
103
CKC 180
1100
1215
675
211
95
118

13 55908039-06
1. Individual pipe runs to a maximum of 20m, including 7.5m lift, are permissible with liquid lines, 80m
with expansion lines, provided good refrigeration practice is followed.
Performance is based on 7.5m pipe runs. Correctly sized pipes for each installation will result in no
significant loss of capacity on extended pipe runs.
a) Pipe sizes are based on:-
Minimum of 3.8 m/s (750 fpm) suction gas velocity for horizontal or downflow.
Minimum of 7.6 m/s (1500 fpm) suction gas velocity for upflow.
Maximum of 15.2 m/s (3000 fpm) suction gas.
b) Where vertical risers exceed 3m, oil traps must be formed in the pipe. This will help ensure that oil
returns to the compressor. Typically fit an oil trap every 3m with a trap at the bottom of the riser.
2. In calculating equivalent lengths of pipe runs, the effect of bends and fittings must be taken into
account. The table below covers the fittings most likely to be encountered in this installation.
The equivalent lengths of all the fittings in a pipe run should be added together and the total added to
the actual pipe length in order to calculate the total equivalent length.
3. Use the shortest possible route, avoiding sharp bends.
4. Completely insulate the suction line, fully over the indoor unit drain tray.
CKC PIPEWORK

14 55908039-06
USING SUCTION AND EXPANSION LINES
The expansion assembly must be removed from the indoor unit and connected to the outdoor unit allowing a
pipe run of up to 80m, including a maximum lift of 20m.
Fully insulate both the suction and expansion lines, including the expansion device: ensure the pipes are
insulated well over the drain tray at the indoor unit.
MODEL
MAXIMUM LENGTH OF EQUIVALENT
SUCTION LINE PIPE (m)
SUCTION LINE PIPE SIZES
EXPANSION LINES
PIPE SIZES
UNIT SIZE
TYPE
⅜
½
⅝
¾
⅞
1⅛
1⅜
⅜
½
⅝
¾
50
Common
7.5
18
50
80
7.5
50
80
Twin
7.5
23
80
80
80
Common
11
30
80
50
80
Twin
15
50
80
50
80
90
Common
10
25
55
80
20
80
Twin
10
36
80
7.5
80
100
Common
7.5
22
45
80
15
80
Twin
7.5
18
50
80
7.5
50
80
Triple
15
50
80
50
80
130
Common
15
30
80
12
60
80
Twin
7.5
18
50
80
7.5
50
80
Triple
10
36
80
7.5
80
150
Common
12
27
80
8
50
80
Twin
14
36
80
7.5
50
80
Triple
10
36
80
7.5
80
165
Common
8
18
60
80
7.5
40
80
Triple
7.5
18
50
80
7.5
50
80
180
Common
7.5
16
55
80
7.5
35
80
Triple
7.5
18
50
80
7.5
50
80

15 55908039-06
PIPE CONNECTIONS
Units are supplied with the following male flare connections (sizes in inches):
Model
CKC
Size
50
80
90
100
130
150
165
180
Expansion
3/8
1/2
1/2
1/2
1/2
1/2
1/2
1/2
Suction
1/2
5/8
5/8
3/4
3/4
3/4
3/4
7/8*
CONNECTING THE UNITS
1. Ensure both service valves on the unit are closed (clockwise) before
commencing installation.
2. If a expansion assembly requires cleaning:
a. Remove the entire expansion assembly from the outdoor unit.
b. Split the expansion assembly in the middle and remove the existing
restrictor.
c. Drop the new restrictor vertically into the field connector.
d. Reassemble in the vertical plane (field connector lowest) when
reassembled the restrictor can be heard to be free to move if the
assembly is shaken.
e. Refit the expansion assembly.
3. Connecting the pipework
a. Remove the flare nuts from the suction service valve and the
expansion device as appropriate.
b. Ensure that both the suction and expansion lines are fully insulated.
c. Place the flare nuts over the incoming pipework and flare the pipe ends.
d. Connect the pipework between the units. Do not leave pipes ends, valves
etc open to the atmosphere. Always use 2 spanners when tightening the flare nuts to
avoid twisting the pipes. Use a small amount of refrigerant oil on the mating surfaces.
e. Sight glasses and filters driers are not necessary, but if required should be fitted between
the out door unit liquid shut off valve and the expansion device on the CKC units.
f. CKC 180 has a ⅞¨ suction pipe with brazed connections. Use a protective shield to avoid
scorching the side panel.
EVACUATING
With the valves closed, connect a vacuum pump to the service ports on the outdoor unit valves. Evacuate the
interconnecting pipework and indoor unit to 1000 microns (1 Torr) or better. Allow this to be held for a minimum
of 15 minutes
BRANCH LINE LENGTH
All branch lines must have the same equivalent lengths to ensure that the system is correctly balanced.

16 55908039-06
CKC ELECTRICAL
•The installer supplies mains, control and interconnecting cables: equipment must be earthed.
•Wiring must be carried out in accordance with local and national codes.
•Mains supply cables must be size compatible with the recommended fuse.
•An all pole isolator switch should be positioned within easy reach of the indoor/outdoor unit
dependant on which receives the fuse supply.
•Cable clamps for use with stranded cables are supplied and should be used to secure
incoming/outgoing cables. Installers must supply a method of securing solid sheathed cables.
3PH CKC
On 3 PH CKC it is possible for the scroll compressor to run backwards.
This becomes obvious on start up - the compressor will not develop a normal running pressure differential
and the top will not become warm: it may be excessively noisy. If this happens, switch off the mains power
and exchange the two supply phases not connected to the indoor unit. This will correct the rotation.
ISOLATOR SWITCHES
On a 3 phase system, ensure that the neutral contact of the isolator switch is an early make, late break type.
This applies to all switches in the supply line. If in doubt, do not switch the neutral but connect it solidly.
WIRING
•Cable entry for the outdoor unit electrics is through the cabinet to a terminal block.
•Ensure that all connections are secure and that both units are earthed.
•CKC fan motors have a single speed and are ready for use at all outdoor temperatures.
NOTE: The CKC wiring diagram can be found on the inside of the front panel.

17 55908039-06
INTERCONNECTING WIRING
REFRIGERANT

18 55908039-06
R407C REFRIGERANT
Charging the System:
1. Evacuate the system and interconnecting pipework ensuring the service valves are fully open.
2. Allow the evacuated system to draw in the majority of the refrigerant charge.
3. The final charge should be adjusted with the system running.
4. All units are fitted with head pressure control. The link wire across the orange terminals allows
the fan to operate at full speed. THIS SHOULD BE REMOVED AFTER CHARGING
5. A random start delay of up to 1 minute occurs when mains is first applied. A 3 minute delay occurs
between successive compressor operations on all systems.
6. Refrigerant and polyolester oil should be introduced through the Schrader valve in the service port on
the suction service valve on the outdoor unit. Ensure the refrigerant is the correct type, as shown
on the rating plate. R407C must always be added in the liquid state. See indoor installation
instruction for refrigerant charge weight.
7. Run the system for a few minutes to allow it to stabilize. Where possible, charge to a sweat
line on the evaporator. Typical suction pressures on short lines at UK conditions, with high
speed evaporator fan, high speed condenser fan, should be; low temperature system
approx 4.4 bar (65 psig).
8. Systems should not be overcharged, to avoid liquid return to the compressor
9. HEAD PRESSURE CONTROL ALCO (FSY-42S)
The head pressure controller is factory set to suit the refrigerant. It may be necessary to adjust this to
suit site conditions, to raise or lower the nominal head pressure.
ALCO (FSY-42S)
a. With the system switched off, connect a high pressure gauge to the liquid line service valve.
b. Switch on the system, and run for a few minutes to stabilise.
c. The head pressure should be approximately:
Min fan speed (0 rpm) and fan cut in pressure 200 psig (13.8 barg) are factory set and not adjustable.
NOTE: The condenser fan may stop if the operating pressure drops below 200 psig (13.8 barg)
R407C: 270-280 psig (18.9-19.6barg) to achieve this remove sealing plug and insert 2mm or 5/64”
allen key into setting screw. Turn allen key clockwise (+) or counter clockwise (-) to readjust the
setting.
Do not turn setting screw more than 3 turns clockwise (+3). Use following table as a quick
guideline for setting:
Pressure changes per turn of adjusting screw:
Pressure change: 9.2 … 21.2 bar:
Clockwise ~ +2,5 bar, counter clockwise ~ -2,5 bar
After adjustment, re-insert sealing plug and make sure that it is properly fitted. IP65 protection
requires firmly sealed plug
NOTES:
Tolerances for condensing temperatures setpoint: ±2K

19 55908039-06
END OF LIFE REQUIREMENTS
Refrigerant must be recovered by a certificated technician before the plant is dismantled. Modern
refrigerant recovery machines should be able to remove well over 95% of the refrigerant in an old
system.
All recovered HFC refrigerants can either be:
a) Sent for destruction by incineration at a licenced waste facility
b) Sent to a specialist plant that can re-process the old refrigerant into a gas with properties
identical to virgin refrigerant, to create “reclaimed refrigerant”
c) Given a basic cleaning process, to create “recycled refrigerant”
Given the HFC supply shortage that will be created by the phase down process, it is worth trying to
send the old refrigerant for reclamation as it may have a good residual value. If the old refrigerant
is too contaminated it cannot be reclaimed and must be sent for destruction. It is important not to
mix different gases in the same recovery cylinder –as this would render them unsuitable for
reclamation.
Reclaimed refrigerant can be used in any refrigeration equipment. Recycled refrigerant must
always be used with care as it may be contaminated or of unknown composition. The use of
recycled refrigerant with a GWP above 2,500 is restricted to either (a) the organisation owning the
plant from which the gas was recovered or (b) the organisation that carried out the recovery.

20 55908039-06
1
Grille
9
De-ice stat (option)
2
Fan / motor
10
Heater assembly (option)
3
Case
11
Drain stub adaptor
4
Wall / ceiling mounting brackets
12
Drain tray
5
Heater bracket
13
Side access panel
6
Coil assembly
14
Electrics box door
7
Thermostat bulb & bracket
15
Digital display (option)
8
Restrictor assembly / extended pipe (option)
CXE INDOOR UNIT COMPONENT IDENTIFICATION