Marstair WM 60 User manual

1
TECHNICAL MANUAL
WM: CO2 EVAPORATOR
GENERAL Part numbers 2
Dimensions and weights 2
Kits 2
Features/accessories 3
PRODUCT Optional electric heating 3
SELECTION Airflows, air throws 3
Sound power and pressure levels 3
Performance data 4
Fuses 4
Electrical data 4
INSTALLATION Removing the case & Fitting filters 5
Hanging the unit 6
Pipework and restrictors 7
Gravity drain; cable routing 7
Remote controller WM 60 (RCC30) 8
WIRING WM 60 10
DIAGRAMS
WM(L)(E) KITS Remote return air sensor (for WM RCC30 controller) 11
Programmable timer (for WM) 11
5m high condensate pump 12
Fitting new condensate pump 13
TROUBLE WM 60 15
SHOOTING
COMPONENT Exploded view of chassis with component identification 16
IDENTIFICATION Exploded view of case 17
Marstair Division, TEV Ltd.,
Armytage Road, Brighouse,
West Yorkshire, HD6 1QF, UK. 55699116-03
Tel: [phone]
Fax: [phone]
Email: sa[email protected]m

2
PART NUMBERS
WM UNITS
WM
Cool Only
WM 60
55600069
KITS
DESCRIPTION
PART NUMBER
LHPW Coil FFO
97300523
Electric Heater Kit
55600401
Condensate Pump (5m head - with
flow protection ) Kit
97300446
Programmable Timer Kit
52500151
Return Air Sensor Kit
97200212
UNPACKED DIMENSIONS AND WEIGHTS
MODEL
WM 60
HEIGHT mm
350
WIDTH mm
1200
DEPTH mm
223
WEIGHT kg
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. These units are supplied with a holding charge of oxygen free nitrogen.
Do not open the valves until the system is fully installed.
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 indoor unit.
5. Evaporator tested to 90 bar pressure.
6. Max operating pressure 60 bar
7. Appropriate safety devices must be fitted to ensure maximum operating pressure is not exceeded.
GENERAL

3
FEATURES/ACCESSORIES
INDOOR UNITS
WM
Top air discharge
STD
Adjustable air deflection
STD
Long life washable filter
STD
3 fan speeds
STD
De-ice thermostat
STD
Electric heating
*
Remote hard wired control
STD
Remote temperature sensor
0
*
Programmable timer
*
Gravity drain
STD
5m high condensate pump
*
*
OPTIONAL ELECTRIC HEATING (kW)
WM (L) (E)
230V 50Hz
240V 50Hz
60
1.2
1.3
AIRFLOWS
WM (L) (E)
LOW SPEED
MEDIUM SPEED
HIGH SPEED
m3/s
m3/s
m3/s
60
0.17
0.19
0.28
AIR THROWS
SOUND POWER and SOUND PRESSURE LEVELS
556 SERIES WM (L) (E)
SOUND POWER LEVELS
SOUND PRESSURE LEVELS
Frequency Hz
MODEL
SPEED
125
250
500
1K
2K
4K
dBA
dBA
NC
60
MIN
36.8
37
39.1
38.8
34.4
31.7
43
25
19
MED
41
43.4
45.8
45.1
39.6
35.4
49
31
25
MAX
46.7
48.6
50.6
50.4
46.6
39
54
37
31
Sound Power Levels obtained in conformance with BS 4196: Part 5: 1981. Values are shown in dB with a standard
reference of 1 pW.
Sound Pressure Levels are dB relative to 2 x 10-5N/m2and are calculated from results measured in anechoic
conditions. Values relate to a position 3m away from the centre line of the unit, 1m down.
ELECTRICAL LOADS: Amps (230V 50Hz 1Ph) or A/Ph (400V 50Hz 3PhN)
WM (L) (E)
60
Fan Motor
0.4
Electric heater
5.2

4
TECHNICAL INFORMATION –CO2
MODEL
Airflow
l/s
EVAPORATING TEMPERATURE °C
2.5
5
7.5
Capacity kW
Capacity kW
Capacity kW
Total
Latent
Sensible
Total
Latent
Sensible
Total
Latent
Sensible
WM 60
@ 23°C Air
ON
170
4.60
1.55
3.06
3.84
1.17
2.68
3.05
0.69
2.36
190
4.90
1.63
3.27
4.11
1.24
2.87
3.26
0.72
2.55
280
5.96
1.89
4.07
5.02
1.43
3.60
4.03
0.75
3.28
Heating Duty at Air 20°C (kW)
Water Temperatures °C
60 - 30
60-40
65 - 40
50 - 30
82-71
0.21
0.33
0.34
0.19
1.46
ELECTRICAL SUPPLY
1. Mains, control and interconnecting cables must be supplied and fitted by the installer. Follow local and national
wiring regulations.
2. Cables must be size compatible with the recommended system fuse size.
3. Position an isolator switch within easy reach of the indoor unit.
4. Ensure the equipment is earthed.
FUSE RATING
WM E
S
H
60 E
5
10

5
CASE REMOVAL AND FILTER CHANGE

6
HANGING RAIL
FIXING THE HANGING RAIL
HANGING THE CHASSIS
WM 60

7
REFRIGERATION PIPEWORK
GRAVITY DRAIN
CABLE ROUTING

8
RCC 30 REMOTE CONTROLLER 97200211 - NEW INSTALLATION
The position of the thermostat should account for specific site application:-
i) Mount on a flat surface within the area conditioned by the unit to which it is connected.
ii) Avoid draughts, heat from radiators, proximity to hot/cold water pipes, direct sunlight.
iii) Avoid corners of the room where air is likely to stagnate.
iv) Avoid direct air discharge from the unit onto the thermostat.
v) Avoid positions where the thermostat may be covered or obscured.
vi) If the room contains pillars, mount on the side of the pillar furthest away from the unit.
Using a flat-bladed screwdriver in the slot at the bottom of the casing, lever off the cover.
Mount the backpanel directly to a wall or onto a plinth, using the fasteners supplied.
The thermostat should be wired with 7 cores of double insulated cable, 0.5mm2minimum, preferably in plastic conduit
for good appearance. Connections are shown on the table on page 2.
The temperature range is factory set to 17C - 30C: it is recommended that this is maintained, but if adjustment is
needed (eg. to save energy, a range of 21C - 25C might be desired) carefully prise off the rotary dial and reset the
stops to suit.
Heating is possible only if the system includes a heat pump outdoor unit, or if electric heaters or a Low Pressure Hot
Water coil (CW) has been fitted.
RCC 30 optional return air sensor 97200212 can detect return air temperature at the unit rather than the controller. It
should be wired between B1 and M on the RCC 30.
The KLRe 52552 return air sensor is not suitable for use with the RCC 30 thermostat: use 97200212 return air sensor.
DIP switches at the bottom rear of the controller are factory set as shown below: these are the recommended settings.
DIP switch
Function
ON position
OFF position
1
Fan control
Fan control is temperature dependent in all
operating modes
Fan control in normal operation is
temperature independent
2
Operating mode changeover via
external switch
Changeover between normal operation and
energy saving mode
Changeover between normal operation and
standby
3
Action of switch for externally
operated mode changeover
Changeover activated when contact of
switch is closed
Changeover activated when contact of
switch is open
4
Standby
Frost protection disabled
Frost protection enabled
5
Switching differential
1K in heating mode, 0.5K in cooling mode
4K in heating mode, 2K in cooling mode
6
Dead zone in normal operation
2K
5K
= factory settings

9
OPERATING INSTRUCTION RCC 30 REMOTE CONTROLLER
ON / OFF AND FAN SPEEDS
The slider controls the fan speeds as shown above: in its lowest position the unit is in standby ie. the air conditioner has
power supplied to it but does not operate.
TEMPERATURE CONTROL
The desired room temperature is set using the rotary switch.
Normally the range is restricted to 17°C - 30°C, although the installer may have set the minimum higher or the maximum
lower
(eg 20°C - 25°C) to conserve energy.
After resetting the temperature, there may be a short delay (2-3 minutes) before the system operates in its new mode. The
air conditioner will then attempt to satisfy the set temperature.
Heating is possible only if the system includes a heat pump outdoor unit or if electric heaters have been fitted (DX systems),
or if an LPHW coil is fitted or the unit is supplied from a reverse cycle chiller (CW systems).
For specified low temperature systems : the range is restricted from between 10°C and 16°C.
This adjustment can be made by
carefully prising off the rotary dial and re-setting the stops as required.

10
WM WIRING DIAGRAM

11
If, as a result of fitting this kit, more than one supply is taken into a unit, that unit must be marked:-
"Two, (or more if applicable), supplies are taken into this equipment.
Isolate both, (all), before undertaking any maintenance work."
RETURN AIR SENSOR 97200212 (FOR RCC 30 REMOTE CONTROLLER 97200211)
The sensor can be fitted to the return air inlet to an air conditioning unit to improve operation eg. if the wall thermostat is
placed outside the space being conditioned, or if there is considerable stratification in a room with a high ceiling, where
the wall thermostat would not measure a representative temperature.
ITEM
QTY
DESCRIPTION
1
1
Sensor (2.4m lead)
2
2
Tie wrap
ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THE
SENSOR
1. Cut off the faston terminals on the cables and strip back.
2. Connect the sensor to terminals B1 and M , as shown (polarity is unimportant).
Changeover to the remote sensor is automatic on power up of the controller.
3. Tie wrap the sensor to a suitable place in the return airflow, where it will soak in a
representative temperature.
4. After installation, adjust the thermostat to confirm satisfactory operation.
5. Sensor input B1-M carries mains potential.
If the sensor cable needs to be extended, the cables used must be suitable for mains
voltage.
PROGRAMMABLE TIMER KIT 52500151
This kit can be used to give ON/OFF switching of the mains voltage control circuits of WM units where the total current
does not exceed 3 Amps.
ELECTRIC HEATER CURRENTS CANNOT BE SWITCHED DIRECTLY.
It is not required for WM L units which have built in timers.
ITEM
QTY
DESCRIPTION
1
1
7 Day Programmable Timer
2
1
In Line Fuse Carrier
3
1
5 Amp Fuse, 1" x 1/4"
4
1
Terminal
PROGRAMMER SPECIFICATION: Selection Switch
Type: Digital electronic 230V, 50Hz "OFF",
Programme: 7 day "TMD " (TIMED)
Setting Resolution: 1 minute "CON " (CONSTANT ON)
Max. Switched Current: 3 A (fan load) "ADV " (ADVANCE)
The timer will accommodate 0.75mm2to 2.5mm2wires.
Three core cable is required between the timer and the air conditioning unit.
The timer motor must be connected to an uninterrupted supply source.
TIMER MOUNTING
1. Carefully unpack and identify the components.
2. If the unit is to be surface wired, remove the appropriate knockouts in the backplate. Screw the backplate to the wall
with No. 8 wood screws through the fixing holes.
3. If the backplate is to be fixed to a BS4662 single gang plaster depth box, use 3.5mm machine screws.
WIRING FOR ON/OFF SWITCHING
1.a) Wire timer terminal 'L' to unit terminal 2.
b) Use the terminal provided to connect terminal 4 to live (terminal L, remote controller RCC 30 [97200211]).
c) Wire timer terminal 'N' to unit terminal N
2.Discard the in-line fuse carrier.
3.Plug in the unit and secure the screws.
4.Program as described in the separate timer instructions.

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5m HIGH CONDENSATE PUMP KIT FOR WM UNITS
This kit is for use on all versions of CWM and CWM L units and is for condensate removal where a lift of up to 5m
is required.
The pump runs on demand.
A high level alarm will switch off the cooling signal until condensate has dropped below a pre-set level.
It is easier to fit this kit before installing the unit.
IF THE UNIT HAS BEEN INSTALLED, ISOLATE THE SYSTEM BEFORE FITTING THE KIT.
This external condensation replacement kit is for use on all versions of CWM indoor units and is suitable for
condensateremoval where a lift of up to a maximum 5m is required. The pump will run on demand. There is a built in
high level alarmwhich will switch off the cooling signal if there is a build up of condensate. The unit will remain off until
the condensate hasdropped below a preset level.
CONTENTS OF KIT CHECKLIST
Item
CONDENSATION PUMP KIT 97100476
1
Condensatepump
1
2
Condensate pump bkt
1 Supplied assembled to pump
3
Pump vibrationsleeve
1 Supplied assembled to pump
4
Floatswitch
1
5
Clear PlasticTube
1 piece to be cut to size
6
Mains sensor wireharness
1
7
Adhesive pad
2
8
Cable tiesmall
6
9
Cable tielarge
1
10
Preformedelbow pipe
1
11
Installation instruction
1
12
Float switchbracket
1 Supplied fitted tofloat valve
13
Earth EdgeClip
1 Not shown
It iseasiest to fit this kit prior to installing the unit if possible, but isnot
essential.
IMPORTANT
ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION
OF THISKIT

13
1 : CASINGREMOVAL
Cabinet Removal
FittingNewCondensationPump
1. Before fitting the replacement condensation pump any condensation in the drain tray must be safely
collected.
2. On the back edge of the drain tray is a drain point fitted with a short piece of pipe and a rubber adaptor
remove short pieceof pipe leaving rubber adaptor in position and collect any condensation remaining in
the drain tray.
3. Fit the pre formed elbow pipe to float valve and secure with large cable tie.
4. Fit one of the self adhesive pads to the back of thefloat valve mounting bracket.
5. Cut two pieces of the 6 mm dia clear plastic tube to180 mm long and fix on to the float
valve on
the same size as the preformed elbow and one on the opposite side, securein position
using a small cable ties.
6.The small black plastic cap should befitted on the outlet connection below the vent pipe.
7. Secure other end of pre formed pipe to drain plug on drain tray using
rubber adaptor alreadyfitted on to drain tray to form a tight fit then secure
in position using a large cable tie.
8. Fit the Float switch intoits retaining bracket [the bracket only fits one way] then usingthe
adhesive pad on the back of the bracket, stick the bracket in position. Leave a 7 mm gap between
the bottom of the float switch bracket and the bottom return flange ofthe backplate.
Adhesive pad on back
Black blanking plug
Outlet pipe secured in position with small
cable tie 180 mm long
Vent pipe secured in
position whit a small cable
tie. 180 mm long
Pre Formed Elbow secured in
position with large a cable tie
Float switch / bracket
Pipe connection on back ofthe drain tray,
secure using a large cable tie.

14
9. Fit a self adhesive pad on to the back ofcondensation pumpbracket.
10. Position the bracket on the right hand side of the backplate
approximately 60 mm from the bottom and 10mminfrom the side
using the self adhesive padto holdit in position.
12. Connect the other end of the outlet pipe off thefloat valve to
the condensation pump and secure using a smallcabletie.
13. From the outlet pipe fitted with the anti siphon valve connect
to the condensationdrain pipe.
14. Secure the vent pipe to the back plate using the small self adhesive pad and a smallcable
tie ensure that the vent pipe terminates higher than the drain tray.
ELECTRICAL CONNECTIONS
a] Connect wiring harness from the float valve to the connection on condensation pump, this can only fit one way.
b] Connect the mains / High Level Alarm wiring harness plug to the condensation pump [this harness as two cables one
Mains supply cable and High Level Alarm cable as a purple, black and white wire.
c] Connect mains cable to permanent live and neutral use the earth edge clip supplied with the kit to provide an earth
connection to the steelpanel work.
d] Connect black and white wires in the high level alarm harness to the same terminals on the terminal connector that
thepreviously removed red wires were connectedto.
e] The purple wire is supplied connected to a 2 way block to make it electrically safe. This wire is the normally open wire
and is not used, in a high level alarm situation voltage will be present on this wire so it is important that it is kept
electrically safe.
f] Make tidy any loose wiringusing cable ties
g] Switch on mains supply to unit; ensure controls are calling for cooling then pour some water slowly in to the black
draintray until the float switch rises; once the float switch rises it will activate the condensation pump and discharged
water into the common drain. Check all pipe connections for any leaks.
h] Refit fascia panels.
Float switch fixed in position under drain tray on R/H side of unit.
Vent Pipe
Outlet pipe with anti siphon valve
Direction
of
flow

15
TROUBLE SHOOTING
Unit will not cool No mains supply to the unit.
Pump does not run Sensor wires disconnected from terminal connector block.
Cooling is interrupted Restriction in pump flow allowing level to
Rise and trip overflow circuit. Check for blockage or kink in hoses.
Condensate at high level - tripping overflow circuit
Pump and filter blocked - remove and clean.Loose
wiring harness connections check plugs on wiring
harnesses from float chamber andcondensation
pump.
Pump runs all thetime Is the float position in the reservoir locatedfirmly
And the float located inside the reservoir around the
sensor column?
Is there any sludge inside the reservoir preventing the
float from resting on the bottom? clean with antibacterial
wash.
Excessive pump noise Air leak in hoses and/or joints.
Pumping without water in sump –Float valve stuck in
alarm position –clean out float chamber.
APPLICATION NOTES
1The pump will work against a 5m head. [for units with latent duty of 4 kW Flow rate is highest with minimum head.
2Long lengths of drain pipe should not be exposed to the outdoor ambient, otherwise freezing of condensate may
occur during winter operation.
3It is not advisable to have the outlet of the drain well below the position of the pump; otherwise the siphon effect mayopen
the pumpvalves.
4For normal applications, i.e. where the drain outlet is level or above the pump or within 1m below it, no extra check
valves are needed; the pump has its own internal checkvalves.
5Ensure that no hoses are kinked, as this could seriously affect the pump performance.
6 Always ensure the float chamber is sitting flat and horizontal.
7 Do not run the pumpdry.
SERVICE /MAINTENANCE
1 Every sixmonths the reservoirshould be removed taking careto clean thefilter,float and reservoir
thoroughly prior to re assembly
2 Use a chemically compatible anti bacterial wash.
3 Take great care to ensure the float magnet is always positioned with the magnet facing upwards.

16
EXPLODED VIEW OF WM (L) (E) with COMPONENT IDENTIFICATION
Back panel
16
Heater elements
31
Main PCB (WM L)
2
Condensate pump PCB
17
Heater coil retaining clip
32
Main PCB (WM E)
3
Condensate pump bracket
18
Heater cutout bracket
33
Terminals (WM L, E)
4
Condensate pump
19
Heater cutout
34
Terminal mounting bracket
5
Scroll
20
Return air sensor (WM L, E)
35
Electrics panel
6
Case fixing bracket
21
Coil sensor (WM E)
36
Capacitor (WM L, E)
7
Drain tray clip
22
Coil sensor (WM L)
37
IR PCB mounting bracket
8
Coil (rear)
23
Air flow cut-off
38
Fan guard
9
Fan
24
L/H coil support bracket
39
Capacitor (WM)
10
R/H coil support bracket
25
Resistor
40
Terminals (WM)
11
Condensate pump sensor/filter
26
Motor
41
De-ice thermostat (WM)
12
Sensor bracket
27
Fan support bracket
42
Heater relay (WM)
13
Drain tray
28
IR receiver PCB (WM E)
43
Wall mounting bracket
14
Coil (front)
29
IR receiver PCB (WM L)
15
Heater coil
30
Blanking plate (WM L, E)

17
EXPLODED VIEW OF CASE
1
Cover ( L/H)
5
Vertical air deflection vane
9
Horizontal air deflector vane (lower)
2
Cover (centre)
6
Grille (R/H)
10
Horizontal air deflector vane (upper)
3
Cover (R/H)
7
Grille (centre)
11
Connecting rod
4
Filter
8
Grille (L/H)
12
Blank (WM): IR lens (WM L, WM E)
12
1
2
3
4
5
6
7
8
9
10
11