Cool Stream installation manual by raa13961


									NuVision Energy                                                                                  Queensgate House
                                                                                                    48 Queen Street
Energy through innovation                                                                                  EX43SR
                                                                                                TEL: (01392) 247880
                                                                                                FAX: (01392) 410436

                  Installation Instructions (Model A)

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  The CoolStream can only save you money on running costs if the air-conditioning unit (A/C) is operating correctly.
  The most important indicator of a healthy A/C is the minimum achievable supply air temperature which should be
  15 deg. C below the set point, but a reduction of 10 deg. C is acceptable. However, for this unit which switches the
  compressor ON at 20 deg. C, if the minimum achievable supply air temperature is greater than 12 deg. C then
  postpone any Energy Saver installation until the refrigerant levels have been topped up and the indoor unit
  filters have been cleaned.

  Electrical Connections

  Please follow the following steps:

  Step1.       Isolate the main electrical supply to the evaporator unit and remove outer casing.

  Step 2.     Identify the compressor control cable either from the internal wiring diagram or with the A/C unit
              running, locate the connection between the room thermostat and the compressor contactor. Using a
              current clamp record the contactor 'ON' current. If this value exceeds 3 amps in normal operation then
              please ensure that an auxiliary relay with normally open contacts is used to drive the contactor (see
              below). Please note this should only be carried out by experienced personnel.

  Step 3.     Isolate the A/C unit at the appropriate circuit breaker. For a split system ensure that the outdoor
              compressor supply is also isolated.

  Step 4.     Mount the CoolStream adjacent to the A/C unit, ensuring that its position does not interfere with
              future A/C unit cover removal.

  NuVision Energy Cool Stream Air-con Energy Saver
Step 5.      Connect electrical power to the CoolStream using the WHITE COLOURED cable. If possible
             use the same power supply outlet as the A/C unit. The colour codes for the CoolStream
             WHITE COLOURED three core cable are:
             Green/Yellow - Earth
             Blue        - Neutral
             Brown       - Live
             If a new cable is used this must be secured using the supplied cable clamp and retaining

Step 6.      Disconnect the wire connecting the room thermostat with the compressor contactor
             identified in Step 1 above. If the current measured in Step 1 was 3 amps or less then proceed
             to Step 7. If this current exceeded 3 amps then install and auxiliary relay and proceed to Step

Step 7.      Direct Connection. Connect the two wire GREY CoolStream Control Cable with the wire
             disconnected in Step 5 above. You may disregard the blue/brown colour coding of this GREY
             CoolStream Control Cable.
          Direct Connection              Sensor Cable


                                                                                               Room thermostat control

                  Grey Control
                                                                                        Compressor relay
                                                                                        Maximum Cool Stream
              White Power Cable                                                         Load 3 amps ac.
              220/230volt ac. supply   L E N   Note:
                                               Any control loads over 3amp
                                               Must have an isolation relay installed
                                               Please see full installation manual

NuVision Energy Cool Stream Air-con Energy Saver
                                              Sensor Cable
   Indirect installation

                                                                    220/230 volt

                       Grey Control
                                                                                          Optional Manual
                                                                                          Override Switch

                  White Power Cable                                                                         Compressor internal
                  220/230volt ac. supply   L E N          Isolating relay 10/20 amp                         relay
                                                          Depending on control load
                                                          Installed next to Cool Stream

 Step 8.     Auxiliary Relay Connection.

 i) Select a suitably sized auxiliary relay (10 or 20 amps is usually sufficient) for use with mains power.
               ii) Locate this auxiliary relay in a suitably sized plastic enclosure, with holes drilled for ventilation.
               iii) Provide a NEUTRAL power source to one side of the auxiliary relay's coil.
               iv) Connect the LIVE power supply to the BROWN core of the GREY CoolStream Control Cable.
               v) Connect the BLUE core of the GREY CoolStream Control cable to the other side of the auxiliary
               relay's coil.
               vi) Connect one side of the wire connecting the room thermostat with the compressor contactor
               from Step 5 to the auxiliary relay's COMMON terminal. Connect the other side of this wire to the
               auxiliary relay's NORMALLY OPEN terminal.
               vii) Optional, but recommended. Connect a BYPASS SWITCH across the auxiliary relay's COMMON
               and NORMALLY OPEN terminals [this will allow A/C operation in the event of any failure].

NuVision Energy Cool Stream Air-con Energy Saver
Advanced Installation of Cool Stream Air-con Power Saver into AC
units using AC’s own sensor control
Increasingly air-conditioning units are equipped with their own control systems that have fairly
sophisticated interlocks to prevent incorrect operation. Rather than working around these interlocks and
alarm systems we have come up with a fairly simple approach that uses the air-conditioning unit’s own
control system to turn the compressor on and off under Energy Saver direction.

Using nothing more than thin telephone wire, spring-loaded connectors, shrink fit insulation and resistors
(making for a discreet installation) this approach effectively presents wrong temperature information to
the air-conditioner’s control system thereby influencing when the compressor will be switched off.
Unfortunately, it is not easy to describe graphically so here is a step by step process:

Energy Saver Connection with Advanced Aircon Control Systems

For air-conditioning units equipped with their own thermistor-based temperature sensors and control
systems the following is the process:

   1. Turn off power to the air-conditioner
   2. Locate the air-conditioning unit’s own RETURN AIR temperature sensor and its connection to the
      control circuit board. This unit connects to the circuit board using a plug with female
      connections.[NOTE – some air-conditioning controls system also have a evaporator coil
      temperature sensor which should be ignored]
   3. Unplug the RETURN AIR temperature sensor from the pins protruding from the circuit board
   4. Using a Meter, measure the electrical resistance of the RETURN AIR temperature sensor at room
      temperature, noting its value
      (typical values at 23°C are 18,000 Ohms for Daikin and 9,000 Ohms for Mitsubishi air-conditioning
   5. Confirm that the RETURN AIR temperature sensor is a negative temperature coefficient device
      (electrical resistance increases with decreasing temperature) by measuring the RETURN AIR
      temperature sensor resistance in the presence of ice. Electrical resistance values should have
      approximately doubled
      (typical values at 0°C are 34,000 Ohms for Daikin and 18,000 Ohms for Mitsubishi air-conditioning
   6. Select electrical resistors equivalent to approximately half the observed difference in resistance.
      Note that this does not have to be accurate, so a value of 10,000 Ohms is probably the most useful
      (typical electrical resistance values are 10,000 Ohms for the Daikin example above, and 5,000 Ohms
      for the Mitsubishi example)
   7. Connect the selected electrical resistor across the Energy Savers control connections
   8. Using thin telephone wire, connect one side of the Energy Saver control connection to one of the
      RETURN AIR connections on the air-conditioning unit’s control board using a female push fit
   9. Using thin telephone wire, connect the other side of the Energy Saver control connection to one
      side of air-conditioner’s RETURN AIR temperature sensor

NuVision Energy Cool Stream Air-con Energy Saver
    10. Using thin telephone wire, connect the other side of the air-conditioner’s RETURN AIR temperature
        sensor to the air-conditioner’s control circuit board
    11. Reposition the air-conditioner’s RETURN AIR temperature sensor and check the continuity of all
        electrical connections made in the above steps
    12. Power up the air-conditioner and check the operation of the Energy Saver through two complete
        compressor cycles, ensuring that
            a. The supply air temperature reduces to a minimum value, confirming that the compressor is
                operating correctly
            b. The Energy Saver detects a minimum supply air temperature, its relay energizes and
                presents the additional electrical resistance to the air-conditioner’s own control circuit
                (indicating a temperature that is below the setpoint) and that the control circuit turns off
                the compressor
            c. With the compressor off, the supply air temperature increases to a switching point (typically
                20°C) at which the Energy Saver will de-energize its relay to present a correct RETURN AIR
                temperature reading to the air-conditioner’s own control circuit. This should turn the
                compressor back on, resulting in a decrease in the supply air temperature

    Installation using internal AC sensor

                     Sensor Cable

                                                    type cable

                                                                                            Connection blocks

                           Grey Control                 Resistors
                                                                        AC internal PCB
                                                                        Control board
                                     L E N
                                    White Power Cable
                                    220/230volt ac. supply

                                                                                              AC internal
                                                                                              Return air sensor

                                                                              Cool Stream

NuVision Energy Cool Stream Air-con Energy Saver
 Temperature Sensor Installation
 Step 9.     Route the Temperature Sensor Cable through the A/C indoor unit chassis and into the cold supply air
             chamber (the location where you have measured the minimum supply air temperature at the start
             the process). Avoid placing the sensor cable in a position where it may be trapped when any A/C
             covers are replaced.

 Step 10.    Fix the Temperature Sensor bead (encased in metal) using a cable tie into a position where it can
             sense the coldest supply air temperature. Ideally this should be between 30 and 300 mm from the
             supply air cooling coil, ensuring that is not actually touching the cooling coil.
             Note: If the indoor unit is equipped with automatic shutoff or air stream direction grille blades,
             ensure that the sensor cable does not restrict the action of the grille blades.
             Where the sensor is to be mounted in ducting, placing it in the centre of the air flow important. To
             make this possible fasten the sensor to a stiff piece of wire which passes right through the ducting
             but leaves the sensor suspended in the centre of the duct.

     30 - 300 mm
     Between the evaporator                                                              Sensor
     And sensor

                                                     Cool Stream

 Step 11.    Replace all removable filters, A/C unit covers and turn on power to the A/C unit.

 Step 12.    Witness two complete cycles of the compressor and verify that the compressor (and associated
             auxiliary relay, if applicable) energizes and de-energizes and that the cold supply air temperature
             cycles correctly in accordance with the following green LED flashing sequence:

 Flashing Sequence                Indication

 NO LED                       -   CoolStream initialization        Random Startup Delay (5 – 15 seconds)

 ON/OFF every 0.5 seconds -       Compressor ON for first 30 seconds

 ON every 3 seconds           -   Compressor ON     (Seeking Minimum Temperature)

 ON every 7 seconds           -   Compressor OFF (Seeking Compressor ON point)

 Rapid ON/OFF                 -   Minimum Energy Saving (For a heavily loaded A/C unit)

 The Cool Stream Air-con Power Saver is fitted with a normally closed relay. Power failure to the unit or sensor
 damage should not affect the air conditioning unit operation

 NuVision Energy
 Energy through innovation                                                                                         6
NuVision Energy Cool Stream Air-con Energy Saver

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