TECHNICAL MANUAL FOR CD3 (929 SERIES) CHILLED WATER AIR HANDLING UNITS AND CD3 (929 SERIES)

DX AIR HANDLING UNITS FOR USE IN SPLIT SYSTEMS

This manual covers installation and technical aspects of IMI Air Conditioning Ltd. CD3 range, (929 series), chilled water air handling units and DX indoor units for use in conjunction with 550 series MCU+ condensing units or 542 series DCUE ducted condensing units.

INDEX
GENERAL
Introduction General description and part numbers - DX upflow package electronic - DX upflow package electromechanical - DX upflow/downflow configurable electronic - DX upflow/downflow configurable electromechanical - CW upflow/downflow configurable - Condensing units CD3 Configurable options Dimensions and weights Unit combinations Performance data DX Performance data CW Airflows - outdoor/ducted units Sound levels - CD3 units, outdoor/ducted units Airflow options Indoor unit MCU+ 30 - 100 MCU+ 130 - 200 DCUE 30 - 80 Pipe sizing and application Refrigeration installation Electrical data Fuses Evacuating,factory charge Adding refrigerant Condensate drain CD3 MCU+ DCUE Interconnecting wiring diagrams Electromechanical control (thermostat, humidistat and fan speed control) Electronic control Exploded views of units with component identification
IMI Air Conditioning Ltd. Armytage Road, Brighouse, West Yorkshire. HD6 1QF. Tel: (01484) 405600 Fax: (01484) 721949 e-mail: sales@imi-airconditioning.co.uk

2 2 3 3 4 4 5 6 8 9 9 11 11 12 13 14 16 17 18 20 21 22 24 24 25 25 26 28 29 30 32 36 45

SELECTION

INSTALLATION

APPLICATION

WIRING DIAGRAMS

OPERATION and COMMISSIONING COMPONENT IDENTIFICATION

A subsidiary company of IMI plc 92908127-03

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INTRODUCTION
The standard indoor units in the CD3-range are available as direct expansion split systems or chilled water air handlers. Options can provide the close control of temperature and humidity demanded by computer rooms, laboratories, banks, offices etc.. Indoor units are ordered as either upflow or downflow. The CD3 range of DX air handling units matches with the IMI Air Conditioning range of MCU+ and DCUE outdoor/ducted condensing units NOTE: The DCUE range is only available up to size 80.

CD3-RANGE - GENERAL DESCRIPTION DX UPFLOW PACKAGE - electronic controls

* NORMALLY SUPPLIED EX-STOCK
008 92900072 92900060 010 92900073 92900061 015 92900074 92900062 020 92900075 92900063

MODEL Single Circuit Twin Circuit

ELECTRONIC PACKAGE UNITS INCLUDE:

* * * * * * * * * Electronically controlled fan speeds * Four pole mains isolator Class 'O' thermal and acoustic insulation * Electronic controls Washable filters * Alarm options: humidity/temperature out of limits Discharge plenum * Switches: Off/standby, unit run, high/low fan speed Single or twin circuit coils * De-ice thermostat Electric heating * Dehumidification Humidifier with electronic control Display of temperature and humidity (return air or set point - user selected) Indication: cooling/heating on, hum/dehum on, change cylinder

KITS AVAILABLE FOR FIELD FITTING TO ELECTRONIC PACKAGE UNITS:

Condensate pump (hot or cold, 5m lift) Fresh air spigot 100mm dia. Fresh air spigot 160mm dia. Fresh air fan and filter 93m3/h Fresh air fan and filter 186m3/h Top ducted discharge spigot ALL ALL ALL ALL ALL 008 010, 015 020 INDOOR UNIT AUTO-CHANGEOVER PANELS (Supplied loose) Changeover on alarm Changeover on set time and/or 2 stage to 1 stage conversion 2 stage to 1 stage conversion 2 stage to 1 stage conversion 2 stage to 1 stage conversion 3 Ph to 1 Ph conversion ALL ALL 008 010 015 020 008/1 + 80 92900820 92900821 92911102 92911103 92911104 92911105 92911124 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 92911002 92911062 92911063 92911003 92911004 92911059 92911060 92911061 Disposable filter (replaces washable filter) Double deflection grille 008 Floor stand plinth 75mm high 010, 015 020 008 010, 015 020 008 010, 015 020 008 Sound attenuation section 010, 015 020 008/2 + 50 008/2 + 30 010/2 + 50 010/2 + 60 015/2 + 80 020/2 + 90 92911032 92911033 92911034 92911094 92911095 92911096 92911038 92911039 92911040 92911075 92911076 92911077 92911125 92911126 92911127 92911128 92911129 92911130

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DX UPFLOW PACKAGE -- electromechanical controls

* NORMALLY SUPPLIED EX-STOCK 008 92900076 92900064 010 92900077 92900065 015 92900078 92900066 020 92900079 92900067 MODEL Single Circuit Twin Circuit

ELECTROMECHANICAL PACKAGE UNITS INCLUDE:

* * * * * * Class 'O' thermal and acoustic insulation Washable filters Discharge plenum Twin circuit coils Electric heating Indication: Cooling/heating on * * * * * Switches: Off/standby, unit run, high/low fan speed Electromechanical controls 4 stage thermostat De-ice thermostat Four pole mains isolator

KITS AVAILABLE FOR FIELD FITTING TO ELECTROMECHANICAL PACKAGE UNITS:

Condensate pump (hot or cold, 5m lift) Fresh air spigot 100mm dia. Fresh air spigot 160mm dia. Fresh air fan and filter 93m /h Fresh air fan and filter 186m3/h Top ducted discharge spigot
3

ALL ALL ALL ALL ALL 008 010, 015 020

92911001 92911062 92911063 92911003 92911004 92911059 92911060 92911061

008 Floor stand plinth 75mm high 010, 015 020 008 Double deflection grille 010, 015 020 Disposable filter (replaces washable filter) 008 010, 015 020 008 Sound attenuation section 010, 015 020 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 3 Ph to 1 Ph conversion 008/2 + 50 008/2 + 30 010/2 + 50 010/2 + 60 015/2 + 80 020/2 + 90

92911032 92911033 92911034 92911094 92911095 92911096 92911038 92911039 92911040 92911075 92911076 92911077

INDOOR UNIT AUTO-CHANGEOVER PANELS (Supplied loose) Changeover on alarm Changeover on set time and/or 2 stage to 1 stage conversion 2 stage to 1 stage conversion 2 stage to 1 stage conversion 2 Stage to 1 stage conversion 3 Ph to 1 Ph conversion ALL ALL 008 010 015 020 92900820 92900821 92911102 92911103 92911104 92911105

9291112
92911126 92911127 92911128 92911129 92911130

008/1 + 80 92911124

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DX UPFLOW/DOWNFLOW CONFIGURABLE - electronic controls

* CUSTOMER CONFIGURABLE
COOLING 1 2 1 2 8 92900001 92900009 92900005 92900013 10 92900002 92900010 92900006 92900014 15 92900003 92900011 92900007 92900015 20 92900004 92900012 92900008 92900016

MODEL UPFLOW DOWNFLOW

ELECTRONIC CONFIGURABLE UNIT FEATURES:

* * * * * * * 4 capacity sizes in 3 cabinets * Upflow and downflow systems available Class 'O' thermal and acoustic insulation * Electronic controls Washable filters * Electronically controlled fan speeds Discharge plenum (Upflow only) * Switches: Off/standby, unit run, high/low fan speed Single and twin circuit systems available Display of temperature and humidity (Return air or set point - user selected) Indication: Cooling/heating on, Hum/dehum on, change cylinder

Factory fitted options for electronic configurable units - see pages 6 and 7
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DX UPFLOW/DOWNFLOW CONFIGURABLE -- electromechanical controls

* CUSTOMER CONFIGURABLE COOLING 1 2 1 2 8 92900026 92900034 92900030 92900038 10 92900027 92900035 92900031 92900039 15 92900028 92900036 92900032 92900040 20 92900029 92900037 92900033 92900041 MODEL UPFLOW DOWNFLOW

ELECTROMECHANICAL CONFIGURABLE UNIT FEATURES:

* * * * * * 4 capacity sizes in 3 cabinets * Upflow and downflow systems available Class 'O' thermal and acoustic insulation * Electromechanical controls Washable filters * Electronically controlled fan speeds Discharge plenum (Upflow only) * Switches: Off/standby, unit run, high/low fan speed Single and twin circuit systems available Indication: Cooling/heating on, Hum/dehum on, change cylinder

Factory fitted options for electromechanical configurable units - refer to pages 6 and 7
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CW UPFLOW/DOWNFLOW CONFIGURABLE -- electronic or electromechanical controls

* CUSTOMER CONFIGURABLE
CONTROLS Electronic Electromechanical Electronic Electromechanical 8 92900017 92900042 92900021 92900046 10 92900018 92900043 92900022 92900047 15 92900019 92900044 92900023 92900048 20 92900020 92900045 92900024 92900049

MODEL UPFLOW DOWNFLOW

CHILLED WATER ELECTRONIC/ELECTROMECHANICAL CONFIGURABLE UNIT FEATURES:

* * * * * * 4 capacity sizes in 3 cabinets * Upflow and downflow systems available Class 'O' thermal and acoustic insulation * Electronic or Electromechanical controls Washable filters * Electronically controlled fan speeds Discharge plenum (Upflow only) * Switches: Off/standby, unit run, high/low fan speed Indication: Cooling/heating on, Hum/dehum on, change cylinder Display of temperature and humidity (return air or set point - user selected); electronic control only
MODEL 008, 010, 015 020 008, 010, 015 020 ALL 008, 010, 015 020 FACTORY 92900428 92900429 92900430 92900431 92900491 92900492 92900493 KITS 92911028 92911029 92911030 92911031 92911091 92911092 92911093

CHILLED WATER VALVES 2 way motorised 3 way motorised Modulating controller * Modulating 3 port valve (controller must be used with valve)

* NOTE: ONLY ONE CONTROLLER IS REQUIRED FOR TWO VALVES (i.e., CW and LPHW)

Other factory fitted options for chilled water configurable units - refer to pages 6 and 7
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MCU+ CONDENSING UNITS

* NORMALLY SUPPLIED EX-STOCK
MCU+ 30 55099157 55099004 MCU+ 30 55099032 55099011 MCU+ 50 55099028 55099006 MCU+ 50 55099034 55099013 MCU+ 40 55099158 55099005 MCU+ 40 55099033 55099012 MCU+ 60 55099029 55099007 MCU+ 60 55099035 55099014 MCU+ 80 55099030 55099008 MCU+ 80 55099036 55099015 MCU+ 90 55099031 55099009 MCU+ 90 55099037 55099016 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200 55099038 55099017 55099039 55099018 55099041 55099020 55099042 55099021 55099043 55099022

MCU+ 1Ph Recip R22 R407C MCU+ 3Ph Recip R22 R407C MCU+ 1Ph Scroll R22 R407C MCU+ 3Ph Scroll R22 R407C

DCUE DUCTED CONDENSING UNITS (fitted with reciprocating compressors)

DCUE 1Ph R22 R407C DCUE 3Ph R22 R407C DCUE 30 54200004 54200029 DCUE 30 54200015 54200035 DCUE 50 54200006 54200031 DCUE 50 54200017 54200037 DCUE 60 54200007 54200032 DCUE 60 54200018 54200038 DCUE 80 54200008 54200033 DCUE 80 54200019 54200039

STANDARD FEATURES AND OPTIONS, MCU+, DCUE

MCU+ = standard condensing unit + head pressure control + loss of gas switch DCUE = electronic controlled ducted condensing unit + head pressure control + HP and LP switches
CONDENSING UNIT MODEL Easy access for installation and service Suction and liquid service valves Expansion device (orifice type) Pre-charged with refrigerant (R22 or R407C) Heat pump version available Ducted air inlet and/or discharge Ceiling suspendible Capacitor start relay (1 phase) (MCU+ 30 - 40, ALL DCUE) PTC resistor (1 phase) Head pressure control LP cut-out HP cut-out Isolator 3 minute start time delay Wall mounting brackets Contactor Overload (standard on 3ph) Low ambient start MCU+ --* * * * * --DCUE * * * * *

= Standard Feature, * = Option

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CD3 CONFIGURABLE ACCESSORIES

DESCRIPTION MODEL Electronic Configured Electromechanical Configured Chilled Water Configured Factory Fitted Part Number 92900468 92900469 92900470 92900471 92900472 92900473 92900474 92900451 92900452 92900453 92900454 92900455 92900464 92900465 92900466 92900423 92900424 92900424 92900425 92900426 92900427 92900410 92900444 92900445 92900446 92900447 92900448 92900449 92900401 92900402 92900462 92900463 92900403 92900404 92900459 92900460 92900461 92900475 92900476 92900477 92900432 92900433 92900434 92900435 92900436 92900437 92900481 92900482 92900483 92900484 92900485 92900486 92900494 92900495 92900496 92900438 92900439 92900440 92900441 92900442 92900443 92900478 92900479 92900480 92900456 92900457 92900458

THERMOSTATIC EXPANSION VALVE

ELECTRIC HEATERS - SINGLE STAGE (For 2 stage heaters add kits together ie, 8kW + 6kW = 14kW). Max. heater loads: 008 = 12kW, 010 = 14kW 015 = 16kW, 020 = 20kW HEATER RAIL (must be used with electric heaters on downflow units only) LPHW COIL (Add de-ice stat with DX systems) 7.52kW 10.50kW 14.94kW 18.40kW LPHW VALVE 2 WAY (motorised) 3 WAY DE-ICE THERMOSTAT (one per DX circuit) HUMIDIFIER 0-4kg/h (For hum and dehum controlssee next page)

CONDENSATE PUMP (no alarm interface CONDENSATE PUMP (alarm interface fitted) FRESH AIR SPIGOT 100mm dia FRESH AIR SPIGOT 160mm dia FRESH AIR FAN AND FILTER 93m3/h FRESH AIR FAN AND FILTER 186m3/h TOP DUCTED DISCHARGE SPIGOT
(when used as return air spigot on downflow units a plenum is required for access to disposable filters).

SOUND ATTENUATION SECTION

FLOOR STAND PLINTH 75mm high (Recommended for use with all floor standing units and for side entry of services)

DOWNFLOW PLINTH 300mm high

Front discharge Front discharge Front discharge Rear discharge Rear discharge Rear discharge DOUBLE DEFLECTION GRILLE (Upflow only) DISPOSABLE FILTER (Replaces washable filter) 50mm

HIGH EFFICIENCY FILTERS

100mm

(Includes additional plenum section) ISOLATOR 63A

008/1 U U 010/1 U 015/1 U 020/1 U 008/2 - 010/2 U 015/2 U 020/2 2 kW U U 4 kW U 6 kW U 8 kW U 10kW U 008D U 010D, 015D U 020D 008 U/D U U 010 U/D U 015 U/D U 020 U/D ALL U U ALL ALL U 008U U U 010U, 015U U 020U U 008D U 010D, 015D U 020D ALL U ALL U ALL U ALL U ALL U ALL U 008 U U 010, 015 U 020 008 U U U 010U, 015U U 020U 008U U U 010U, 015U U 020U U 008D U 010D, 015D U 020D 008D U 010D, 015D U 020D U 008D U 010D, 015D U 020D U 008U U U 010U, 015U U 020U 008U U U 010U, 015U U 020U U 008D U 010D, 015D U 020D 008U/D U U 010U/D, 015U/D U 020U/D 008U/D U U 010U/D, 015U/D U 020U/D U = UPFLOW D = DOWNFLOW

U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U = OPTION

Y Y Y Y Y Y Y U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U U Y = NOT APPLICABLE

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DESCRIPTION

MODEL

Electronic Configured

Electromechanic al Configured

Chilled Water Configured

Factory Fitted Part Number

CONTROLS Electronic Humidity Only Control (and bottle change indication) Hum and Dehum Control (and bottle change indication) Dehum Control (No Humidifier) Dehum Override Electromechanical 4 Stage Thermostat Electromechanical Humidity Control (1 hum + 1 dehum control) Remote Control Panel (includes 6m ribbon cable) -supplied loose
ALL

U U U U Y Y U U U

Y U U U U U U U U

Y U Y Y Y U U U U

92900405 92900418 92900416 92900417 92900490 92900489 92911815 92911816 92911817

ALL ALL ALL ALL ALL 008 010, 015 020

ALARMS
Alarm Interface Board 1 High water level
(This board allows the fitting of any combination of the following alarm function options) ALL ALL ALL ALL DX only 2 circuit DX only ALL ALL ALL ALL ALL ALL ALL

U U U U U U U
Standard with pcb

U U U U U U Y Y U U U U U

U U U U Y Y U
Standard with pcb

92900407 92900412 92900411 92900408 92900413 92900414 92900421 92900487 92900488 92900409 92900621 92900622

2 Water spillage 3 Fan failure 4 5 6 7 Condensing unit 1 trip Condensing unit 2 trip Humidity out of limits Temperature out of limits

Control status board Alarm status board Dirty filter indication Dirty filter indication - volt free relay Hum bottle change indication - volt free relay

U U U U U

U U U U U

INDOOR UNIT AUTO-CHANGEOVER PANELS (Supplied loose) Changeover on alarm Changeover on set time and/or alarm
DX only DX only U = UPFLOW

U U
D =DOWNFLOW

U U U = OPTION

Y Y Y = NOT APPLICABLE

92900820 92900821

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UNPACKED DIMENSIONS AND WEIGHTS CD3 INDOOR UNITS (no plenums fitted)
Model HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg CD3 008 1165 1230 430 124 010 1165 1380 430 142 015 1165 1380 430 151 020 1165 1580 430 160

MCU+ CONDENSING UNITS

Model HEIGHT mm WIDTH mm DEPTH mm 1 Ph kg 3 Ph kg
MCU+ 30 MCU+ 40 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200

620 904 304 48 48

620 904 304 53 53

720 1004 304 64 62

720 1004 304 65 63

720 1004 304 66 64

820 1004 354 76 73

820 1004 354 81

1080 1004 429 101

1080 1004 429 103

1275 1104 429 118

1275 1104 429 173

DCUE DUCTED CONDENSING UNITS

Model HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg
DCUE 30 DCUE 50 DCUE 60 DCUE 80

560 1075 565 70

625 1245 565 81

625 1245 565 81

625 1245 565 84

--o--o--O--O--O--o--o--

PACKED DIMENSIONS AND WEIGHTS CD3 INDOOR UNITS (no plenums fitted)
Model HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg CD3 008 1300 1250 455 141 010 1300 1400 455 160 015 1300 1400 455 169 020 1300 1600 455 184

MCU+ CONDENSING UNITS

Model HEIGHT mm WIDTH mm DEPTH mm 1 Ph kg 3 Ph kg
MCU+ 30 MCU+ 40 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200

620 980 340 50 50

620 980 340 55 55

720 1080 340 66 64

720 1080 340 67 65

720 1080 340 68 66

820 1090 390 78 75

820 1090 390 83

1080 1090 465 105

1080 1090 465 107

1280 1215 465 123

1280 1215 465 178

DCUE DUCTED CONDENSING UNITS

Model HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg
DCUE 30 DCUE 50 DCUE 60 DCUE 80

580 1090 610 76

650 1270 610 86

650 1270 610 86

650 1270 610 90

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PRODUCT SELECTION
Combinations of indoor unit and (ducted) condensing unit can be chosen to give either comfort cooling or cooling with higher sensible heat ratios

CD3 COMBINATIONS AND CAPACITIES

MODEL AIRFLOW (max) m3/s CIRCUITS MCU+ / DCUE (HIGH SENS) MCU+ / DCUE (STANDARD) 1 1 x 80 1 x 100 008 0.78 2 2 x 30 2 x 50 1 1 x 100 1 x 130 010 1.04 2 2 x 50 2 x 60 1 1 x 165 1 x 180 015 1.23 2 2 x 80 2 x 100 1 1 x 180 1 x 200 020 1.51 2 2 x 90 2 x 130

DX PERFORMANCE DATA HIGH SENSIBLE MATCHES

NOMINAL COOLING CAPACITIES AT AMBIENT 30/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 80 7.20 7.20 7.46 7.46 7.75 7.75 2 x 30 7.36 7.36 7.74 7.74 8.09 8.09 1 x 100 10.63 10.58 11.23 10.86 11.89 11.13 2 x 50 11.08 10.77 11.62 11.01 12.13 11.22 1 x 165 13.56 13.44 14.23 13.76 14.87 14.03 2 x 80 13.86 13.57 14.44 13.84 14.98 14.07 1 x 180 16.76 16.56 17.60 16.96 18.40 17.29 2 x 90 18.05 17.11 19.05 17.54 20.04 17.91

NOMINAL COOLING CAPACITIES AT AMBIENT 35/C DCUE / MCU+ 1 x 80 6.86 6.86 7.11 7.11 ----2 x 30 7.17 7.17 7.39 7.39 ----1 x 100 10.11 10.11 10.60 10.60 11.22 10.88 2 x 50 10.56 10.55 11.15 10.83 11.64 11.04 1 x 165 12.97 12.97 13.62 13.52 14.22 13.79 2 x 80 13.19 13.19 13.72 13.56 14.22 13.79 1 x 180 16.03 16.03 16.78 16.63 17.79 17.07 2 x 90 17.20 16.75 18.05 17.14 19.00 17.52

NOMINAL COOLING CAPACITIES AT AMBIENT 40/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 80 6.57 SENS 6.79 6.79 ----2 x 30 6.63 6.57 6.98 6.98 ----1 x 100 9.43 6.63 9.93 9.93 10.42 10.42 2 x 50 10.15 9.43 10.60 10.60 11.05 10.82 1 x 165 12.28 10.15 12.85 12.85 13.43 13.43 2 x 80 12.62 12.28 13.08 13.08 13.49 13.49 1 x 180 15.22 12.62 16.00 16.00 16.79 16.70 2 x 90 15.83 15.22 16.78 16.63 17.54 16.98

NOMINAL COOLING CAPACITIES AT AMBIENT 45/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 80 ------------2 x 30 6.21 6.21 6.46 6.46 ----1 x 100 8.79 8.79 9.24 9.24 9.73 9.73 2 x 50 9.75 9.75 10.20 10.20 10.65 10.65 1 x 165 11.52 11.52 12.09 12.09 12.73 12.73 2 x 80 ------------1 x 180 14.33 14.33 15.11 15.11 15.83 15.83 2 x 90 14.88 14.88 15.59 15.59 16.31 16.31

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STANDARD MATCHES
MODEL AIRFLOW (max) m3/s 008 .778 010 1.038 015 1.225 020 1.510

NOMINAL COOLING CAPACITIES AT AMBIENT 30/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 100 9.84 8.80 10.40 9.01 10.96 9.20 2 x 50 10.26 8.98 10.79 9.17 11.32 9.34 1 x 130 11.67 11.02 12.30 11.29 12.92 11.52 2 x 60 11.81 11.08 12.53 11.38 13.08 11.58 1 x 180 15.98 14.48 16.84 14.82 17.69 15.11 2 x 100 18.78 15.72 19.98 16.13 21.20 16.49 1 x 200 18.88 17.49 19.91 17.89 21.04 18.30 2 x 130 21.90 18.80 23.13 19.22 24.36 19.59

NOMINAL COOLING CAPACITIES AT AMBIENT 35/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 100 9.31 8.57 9.90 8.81 10.45 9.00 2 x 50 9.84 8.80 10.35 9.00 10.88 9.17 1 x 130 11.08 10.77 11.77 11.08 12.37 11.31 2 x 60 11.30 10.86 11.85 11.11 12.45 11.34 1 x 180 15.17 14.13 16.10 14.51 16.92 14.81 2 x 100 17.91 15.33 19.01 15.72 20.12 16.06 1 x 200 17.95 17.07 19.05 17.54 19.92 17.87 2 x 130 20.91 18.36 22.11 18.80 23.41 19.22

NOMINAL COOLING CAPACITIES AT AMBIENT 40/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 100 8.67 8.29 9.19 8.52 9.76 8.74 2 x 50 9.44 8.63 9.94 8.83 10.45 9.00 1 x 130 10.46 10.46 11.07 10.80 11.64 11.04 2 x 60 10.78 10.64 11.31 10.89 11.89 11.13 1 x 180 14.33 13.77 15.13 14.12 16.02 14.46 2 x 100 16.76 14.82 17.65 15.15 18.81 15.54 1 x 200 16.65 16.52 17.71 17.00 18.76 17.43 2 x 130 19.77 17.86 20.93 18.31 22.10 18.71

NOMINAL COOLING CAPACITIES AT AMBIENT 45/C RETURN AIR TEMPERATURE 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS MCU+ / DCUE 1 x 100 8.02 8.02 8.57 8.27 9.08 8.48 2 x 50 9.06 8.46 9.55 8.67 10.04 8.85 1 x 130 9.84 9.84 10.38 10.38 10.88 10.75 2 x 60 ------------1 x 180 13.47 13.40 14.23 13.76 15.08 14.11 2 x 100 15.35 14.21 16.56 14.70 17.50 15.03 1 x 200 15.63 15.63 16.47 16.47 17.54 16.98 2 x 130 18.47 17.29 19.70 17.80 20.82 18.21

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CD3 CAPACITIES
CHILLED WATER PERFORMANCE DATA
MODEL AIRFLOW (max) m3/s 008 0.78 010 1.04 015 1.23 020 1.51

NOMINAL COOLING CAPACITIES CHILLED WATER 5/C - 10.5/C 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS 8.75 8.33 12.19 9.77 15.57 11.07 12.40 11.34 16.48 13.03 20.57 14.60 16.81 14.84 22.11 17.05 27.45 19.09 22.06 18.87 28.25 21.43 34.62 23.85

NOMINAL COOLING CAPACITIES CHILLED WATER 6/C - 11/C 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS 8.19 8.09 11.56 9.50 14.88 10.78 11.49 10.95 15.51 12.62 19.54 14.16 15.59 14.31 20.82 16.49 26.07 18.50 20.37 18.12 26.48 20.66 32.84 23.08

NOMINAL COOLING CAPACITIES CHILLED WATER 7/C - 12.5/C 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS 6.80 6.80 9.01 8.45 12.54 9.83 9.50 9.50 12.62 11.42 16.83 13.05 12.49 12.49 17.13 14.94 22.60 17.06 16.17 16.17 22.36 18.90 28.75 21.36

NOMINAL COOLING CAPACITIES CHILLED WATER 6/C - 11/C 22/C 50% RH 24/C 50% RH 26/C 50% RH TOTAL SENS TOTAL SENS TOTAL SENS 5.07 5.07 6.95 6.95 9.24 8.55 7.48 7.48 9.61 9.61 12.81 11.48 9.86 9.86 12.64 12.64 17.42 15.00 13.03 13.03 16.28 16.28 22.63 18.91

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AIRFLOWS
CD3
Model 008 010 015 020 Min m/s 0.42 0.67 0.72 0.92 Max m/s 0.78 1.04 1.23 1.51 Model MCU+ 30 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200

MCU+
Min CFM 1720 1660 1660 1660 2420 2420 3690 3690 3690 3690 Max m/s 0.81 0.78 0.78 0.78 1.14 1.14 1.74 1.74 1.74 1.74 Model DCUE 30 DCUE 50 DCUE 60 DCUE 80

DCUE
Min. speed CFM 685 885 885 740 m/s 0.32 0.42 0.42 0.34 Max. speed CFM 885 1115 1115 1040 m/s 0.42 0.53 0.53 0.48

Note: Maximum external resistance at maximum speed = 75 Pa

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-11-

SOUND PRESSURE LEVELS -- CD3 UNITS

UPFLOW Top Discharge and Front Return Front Discharge with Plenum and Front Return Front Discharge and Front Return DOWNFLOW Standard High NC dBA FAN SPEED High High High NC dBA NC dBA NC dBA

008 59 66.5 49 58.5 60 67

010 60 67 49 58.5 58 65

015 58 65 48 57 58 65

020 61 68 50 58 60 67

44 53

45 54

45 54

48 56

SOUND POWER and SOUND PRESSURE LEVELS 550 SERIES MCU+

MAXIMUM SPEED
MCU+ 30 40 30 40 50 60 80 90 100 130 165 180 200 Compressor Rotary Rotary Recip Recip Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll 125 68.8 68.5 77.4 77.3 73.6 72.9 70.9 81.8 79.4 73.0 73.1 72.5 73.0

SOUND POWER LEVELS

Frequency Hz 500 1K 65.9 64.6 66.2 65.1 68.5 64.8 68.6 64.7 67.1 65.5 67.8 66.4 68.1 65.3 69.2 68.6 71.5 68.5 70.0 68.8 70.1 68.9 71.7 68.9 71.5 70.1 2K 60.6 59.1 60.2 60.1 61.1 61.9 59.5 63.1 63.8 65.0 65.5 66.0 66.1

SOUND PRESSURE LEVELS

dBA 48.1 48.1 50.0 49.3 49.2 49.8 49.2 52.3 52.9 52.1 57.2 59.2 61.8 NC 43 43 44 44 44 45 43 47 47 47 51 53 55

250 66.4 67.3 67.5 67.4 68.2 67.7 68.6 71.8 73.7 70.3 70.3 71.9 71.8

4K 56.7 53.0 53.8 53.9 54.3 54.1 53.8 57.4 58.1 56.7 57.5 58.2 58.3

dBA 68.6 68.6 69.8 69.8 69.7 70.3 69.7 72.8 73.4 72.6 73.1 75.5 75.7

LEVELS Frequency Hz MCU+ Compressor 125 250 500 1K 2K 4K dBA dBA NC Rotary 64.3 60.6 60.4 57.7 54.4 54.2 62.7 42.2 36 30 Rotary 63.8 61.7 60.6 61.0 52.8 46.1 63.6 43.1 40 40 Recip 65.6 61.3 65.0 58.5 53.3 47.6 64.5 43.7 40 30 Recip 65.5 61.2 65.1 58.4 53.2 47.7 64.5 43.7 40 40 Scroll 67.4 64.1 66.0 63.6 58.7 51.8 67.7 47.2 42 50 Scroll 67.4 64.3 67.1 66.8 60.7 51.7 69.7 49.2 45 60 Scroll 69.4 66.5 66.9 62.1 56.1 51.6 67.5 47.0 41 80 Scroll 79.0 65.4 64.9 61.5 58.5 53.7 67.6 47.1 40 90 Scroll 75.3 69.4 70.9 63.7 59.7 53.6 70.4 49.9 46 100 Scroll 65.4 66.7 68.1 66.1 63.1 53.0 70.0 49.5 44 130 Scroll 65.5 66.9 67.3 65.1 64.2 54.0 72.6 52.6 47 165 Scroll 65.7 35.9 67.1 61.3 65.3 55.1 73.2 53.7 49 180 Scroll 66.5 66.1 67.9 66.7 66.0 57.2 75.6 55.6 51 200 Sound Power Levels were obtained in full accordance with the direct method of ISO 3741: 1988. Quantities are shown in dB with a standard reference of 1 pW. Sound Pressure Levels are dB relative to 2 x 10-5N/m2 and are calculated from the results under anechoic conditions and are quoted as an average of all points on a sphere of a radius of 3m away from the centre of the unit (in cooling mode); (add 3dBA or 3NC for units at an intersection of a wall, add 1dBA or 1NC for high level wall mounted units).

MINIMUM SPEED

SOUND POWER LEVELS

SOUND PRESSURE

DUCTED CONDENSING UNITS

Measurement Point 3m from unit in void Unit Size DCUE 30 DCUE 50, 60, 80 DCUE 30 Office area DCUE 50, 60, 80 DCUE 30 3m from discharge grille DCUE 50, 60, 80 Fan Speed Max Min Max Min Max Min Max Min Max Min Max Min dBA 52 35 54 44 37 30 42 32 52 34 52 40 NC 46 28 48 31 26 15 28 17 46 27 44 28

Sound Pressure Levels are dB relative to 2x10-5N/m2. All readings taken from a typical application of a unit suspended in a ceiling void complete with 5m of insulated ducting, conditioning an office directly below.

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CD3 AIRFLOW OPTIONS

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-13-

CD3 SERIES AIR HANDLING UNIT INSTALLATION

An envelope containing important user information is supplied with the indoor unit. Please pass this to the end user. 1 2 The standard unit is supplied configured for the correct airflow as ordered by the customer. The central panel, with control panel inset, MUST be removed first using the two keys provided.

UNIT ACCESS AND CABINET STRIP DOWN

1 2 3 If a door interlock isolator is fitted, ensure that the switch is turned to the OFF position. Using the keys provided, unlock the electrics access panel. Remove the panel by easing outwards and down. The side panels can be removed by releasing the two swell latches located through the side bulkheads within the electrics compartment and carefully pulling outwards until they are clear of the upper and lower grabber catches. Access to the fan section, (and coil section in the downflow mode), can be gained by releasing the appropriate swell latches located through the cutouts to the front of the side bulkheads and removing the panel. The return air grille can be removed by turning the 4 retaining screws anticlockwise until a click is heard and pulling the grille outwards.

4 5

MOUNTING
1 2 It is recommended that ALL field fit kits are installed prior to mounting the unit and brazing the pipework. Ensure that the wall or floor will accept the operating weight of the unit;the weights shown below include the plenum.
Model Weight (kg) 08 144 10 165 15 165 20 187

NOTE:-When wall mounting, the unit should be lifted into position using the pallet provided. 3 Mark off the mounting holes as shown and drill holes to suit M6 Rawlbolt shields or equivalent fasteners.

UPFLOW SERVICE AND FIXING HOLE CENTRES (excluding discharge plenum)

Note: Plenum not shown is 430mm high

UNIT SIZE 008 010 / 015 020

DIMENSION 'A' 1230 1380 1580

DIMENSION 'B' 690 790

-14-

DOWNFLOW SERVICE AND FIXING HOLE CENTRES

UNIT 08 10/15 20

DIMENSION 'A' 1230 1380 1580

DIMENSION 'B' -690 790

4 5 6

If a fresh air facility is required, apertures must be prepared as shown above/opposite. This must be suitably lined and screened on the internal wall to prevent brick dust entering the unit. Mount the unit and secure the fixings. Check that the unit is square and level, (failure to do so will result in misalignment of the cabinet panels).

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-15-

INSTALLATION of 550 Series CONDENSING UNITS

MCU+ = standard condensing unit + fan speed control and low pressure switch Note: It is easier to fit kits prior to mounting the unit.

These units are designed to stand on a flat surface. If the unit is to be wall mounted the following kits are available. (IMI Air Conditioning cannot accept liability for installers own mounting arrangements).
Model Mounting Bracket Kit MCU+ 30 - 80 55000844 MCU+ 90 - 100 55000845 MCU+ 130 - 200 55000846

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.

MOUNTING:

MCU+ 15 - 100

Dimensions in mm.
MODEL MCU+ 30 MCU+ 40 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 A 904 904 1004 1004 1004 1004 1004 B 304 304 304 304 304 354 354 C 560 560 660 660 660 760 760 D 290 290 290 290 290 340 E 185 185 213 213 213 250 F 527 527 571 571 571 497 G 260 260 260 260 260 310 H 60 60 60 60 60 70 Weight (kg) 1 Ph 46 (41*) 53 (45*) 64 65 66 76 3 Ph 48 53 62 63 64 73

340 250 497 310 70 81 * Obsolete R407C Models and R22 models fitted with a rotary compressor

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-16-

MOUNTING:

MCU+ 130 - 200

Dimensions in mm.
MODEL MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200 A 1004 1004 1104 1104 B 429 429 429 429 C 1020 1020 1215 1215 D 415 415 415 415 E 251 251 211 211 F 495 495 675 675 G 385 385 385 385 H 70 70 95 95 Weight 101 103 118 173

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-17-

INSTALLING 542 SERIES DUCTED CONDENSING UNITS

MOUNTING
Units are supplied with a polystyrene packing piece supporting the blower assembly, this MUST be removed prior to commissioning. Ducted Units are designed to be hung on a wall (kit available), suspended from a ceiling (installer supplied fittings), or to stand on a flat surface. Whichever method is used it is essential that the mounting surface is capable of supporting the units weight.

DIMENSIONS

Model DCUE 30 DCUE 50 DCUE 60 DCUE 80

A 930 1100 1100 1100

B 510 510 510 510

C 495 560 560 560

D 1004 1174 1174 1174

E 490 490 490 490

F 65 65 65 65

G 65 65 65 65

H 210 240 240 240

J 317 392 392 392

K 717 865 865 865

Spigot dia. 354 404 404 404

Weight (kg) 70 81 81 84

FLOOR MOUNTING

Using the appropriate side of the packing carton as a template, (centres marked A), mark out and drill 4 holes to suit maximum M8 bolts (also see opposite). Secure the unit to the floor. Discard the stabilizing brackets.

Dimensions in mm.
Model 30 50 to 80 A 930 1100 B 510 510

-18-

SUSPENSION MOUNTING
The installer must supply 4 x M8 threaded rods with 16 nuts and washers to suit. IMPORTANT:The stabilizing brackets provided MUST be used when suspending a unit. Fit the stabilizing brackets to the top corners of the backpanel and front face using the No. 10 screws provided, (2 per bracket). If these brackets are omitted the unit will be subject to unacceptable movement on compressor start. Where long drops of M8 rod are used, it is advisable to incorporate flexible pipes in the suction and expansion lines to absorb any movement of the unit. Using the template printed on the side of the packing carton, (centres marked A), mark out the ceiling and drill 4 holes to suit M8 screwed rod. Raise the unit to the required height and pass the screwed rods through the mounting holes in the units feet and stabilizing brackets. Secure the unit with a nut and washer on either side of each stabilizing bracket and two nuts and washers underneath each foot mounting hole, (as shown).

WALL MOUNTING
Brackets to enable ducted units to be wall mounted are available as an optional kit (53200407).

DUCTWORK
Each unit is supplied with air inlet and discharge spigots, models 30 to 40 - 354mm (14") dia., models 50 to 80 - 404mm (16") dia. These may be used for connecting installers ducting or used with the optional Duct, Plenum and Grille kits. Please refer to the kit instruction for installation methods. The front face of the units are also fitted with M6 rivnuts to accept installer supplied square ducting, see dimensions below. Maximum flange width is 25mm and fixing holes should be central within them. NOTE:It is essential that ducting is adequately insulated to prevent sweating. An insulation thickness of at least 45mm is recommended.

Dimensions mm. A B C

Model 30 to 40 400 300 100 50 to 80 450 350 100

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-19-

APPLICATION
1 To maximise performance, pipe runs should be kept as short as possible, avoiding sharp bends. However, individual pipe runs to a maximum of 45m on air conditioners, (except for 1 Phase models with rotary compressors, i.e., up to and including size 40, which have a maximum run of 15m), are permissible provided good refrigeration practice is followed. Published performance duties are 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 Add 25 grams of refrigerant oil (Polyolester Oil for all units except those fitted with rotary compressors which contain mineral oil) for every 350 grams of charge added to systems with pipe runs exceeding 25m, up to a maximum of 300 grams; preferably by slowly pumping into the suction side with the unit running, after charging the system. For systems with capillary control at the indoor unit; the table below shows the suggested pipe sizes (in inches).
Equivalent length of run 0 - 7.5m UNIT MCU+ 30* MCU+ 40* MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 7/8 5/8 5/8 5/8 3/4 3/4 3/4 7/8 7/8 7/8 1 1/8 5/8 5/8 3/4 3/4 3/4 3/4 7/8 7/8 7/8 1 1/8 5/8 3/4 3/4 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1/2 1/2 5/8 5/8 5/8 5/8 3/4 3/4 3/4 1 1/8 1/4 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 1/2 5/8 5/8 5/8 5/8 5/8 Suction Line Size Horizontal or Downflow 7.5 - 15m 15 - 21m 21 - 45m Upflow Up to 15m 0 - 21m 21 - 45m Liquid Line Size

7/8 1 1/8 1 1/8 1 3/8 1 1/8 1/2 MCU+ 200 * Units with 1 Phase rotary compressors should not be used on pipe runs exceeding 20m.

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 type of installation. The equivalent lengths of all the fittings in a particular pipe run must be added together and the total added to the actual length of pipe in the run, in order to calculate the total equivalent length.

FITTING LOSSES, in equivalent straight lengths of pipe (m).

Pipe Size (outside diameter in inches) Fitting 45/ Bend 90/ Bend R/d = 1 90/ Bend R/d = 1.5 180/ Bend C/d = 1.5 180/ Bend C/d = 2.5 90/ Elbow R = Radius of bend 3/8 0.12 0.37 0.24 0.73 0.46 0.67 1/2 0.15 0.43 0.27 0.91 0.55 0.85 5/8 0.18 0.49 0.30 1.10 0.64 1.04 3/4 0.21 0.55 0.37 1.28 0.76 1.25 7/8 0.24 0.61 0.43 1.46 0.85 1.46 1-1/8 0.3 0.79 0.52 1.83 1.07 1.89

d = Diameter of tube

C = Centres of bend

5 6

Use the shortest possible route, avoiding sharp bends. Fully insulate the suction line, (or suction and liquid line if run together, or separately if the system is a heat pump).

CHILLED WATER UNITS

008 and 010 units are supplied with 22mm dia. copper water pipe, 015 and 020 units are supplied with 28mm dia. copper water pipe.

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-20-

REFRIGERATION INSTALLATION
1 Units are supplied with the following pipes (in inches):Model Liquid Suction 08S 3/8 3/4 08T 3/8 1/2 10S 3/8 3/4 10T 3/8 1/2 15S 1/2 7/8 15T 3/8 5/8 20S 1/2 7/8 20T 3/8 5/8

NOTE: On two stage units, the lower half of the coil is the first stage. 2 3 4 Using a tube cutter, remove sealed ends of suction and liquid pipes. This will release a small holding charge of nitrogen. Discard the expansion device on the condensing unit. Pipe exit positions are shown on pages 14 and 15. It is recommended that the liquid and suction lines be kept at the supplied size until exit, when the full pipe size can be run. Connect pipework between units noting the following:a) b) c) d) e) 5 6 Use only refrigeration quality copper tube/pipe, supported every 2 metres. Use tube cutters to avoid forming swarf. If brazing, use copper phosphorus alloy with 5% silver, and purge the system with dry nitrogen to avoid oxidation and build up of scale. Do not leave pipe ends, valves, driers etc. open to the atmosphere longer than necessary. Fully insulate the suction line, or suction and liquid if run together.

A strainer is fitted in the liquid line just prior to the capillary on the air handler. It is recommended that a liquid line filter drier is fitted. If a sight glass is fitted to assist charging, position this in the liquid line as near to the air handler as practicable, downstream of drier. --o--o--O--O--O--o--o--

ELECTRICAL CONNECTIONS
The installation wiring should be carried out in accordance with I.E.E. regulations and/or local codes. A mains isolator should be used and the system suitably fused, (see page 24). Supply cables and connecting cables are provided by the installer.

INDOOR UNIT WIRING

The connections for the internal wiring are made within the electrics enclosure at the left hand side of the unit. The mains cable should be via a fused switch and routed through the knockouts in the bottom left hand corner of the coil section. The wires are then routed through an access hole in the bottom left hand side of the electrics compartment to the mains terminal block. The earth wire is connected to an earth stud at the right hand side of the mains terminal block. Connect the supply and any interconnecting cables ensuring that the cable size used is correct to that of the electrical rating of the unit. Make sure that all connections are secure and all wires are clear of any rotating parts.

AIR CONDITIONER CONNECTION

On single or three phase units, wire the mains supply to the indoor unit and then link to the outdoor/ducted unit via a three pole circuit breaker

DATA PLATES
Because of the ability to mix-match indoor and outdoor units, the data plates only give information on an indoor unit with maximum possible running current.

3 PHASE COMPRESSOR ROTATION

On 3 Phase unit sizes 50 to 165 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 any two of the phases supplying the unit. This will correct the rotation of the compressor. --o--o--O--O--O--o--o--

-21-

ELECTRICAL DATA
R22 SYSTEMS
1 Ph 230V 50Hz Model Combination Full Load Amps 3 Ph 400V 50Hz System Full Load Amps System Max. Max. Cooling Cool & Cool/Heat/ Starting Cooling Cool & Cool/Heat/ Starting Only Heat* Hum/Dehum Current Only Heat** Hum/Dehum Current Amps HS 08 CD08 + MCU+/DCUE 80 16.4 -17.8 22.4 --22.0 27.2 --31.0 ---41.8 -S 08 S CD08 + MCU+ 100 HS 08 T CD08 + 2 x MCU+/DCUE 30 S 08 T CD08 + 2 x MCU+/DCUE 50 HS 10 CD10 + MCU+ 100 S 10 S CD10 + MCU+ 130 HS 10 T CD10 + 2 x MCU+/DCUE 50 S 10 T CD10 + 2 x MCU+/DCUE 60 HS 15 CD15 + MCU+ 165 S 15 S CD15 +MCU+ 180 HS 15 T CD15 + 2 x MCU+/DCUE 80 S 15 T CD15 +2 x MCU+ 100 HS 20 CD20 + MCU+ 180 S 20 S CD20 + MCU+ 200 HS 20 T CD20 + 2 x MCU+ 90 S 20 T CD20 + 2 x MCU+ 130 Amps 38.7 -38.7 38.7 --40.7 40.7 --41.3 ---41.8 -Amps ----------------Amps 82.0 -44.5 72.5 --50.3 78.9 --96.6 ---140.6 -A/PH 9.9 12.5 12.6 13.4 14.5 15.0 17.0 15.6 18.5 20.6 18.0 23.2 21.0 24.0 23.4 24.6 A/PH 22.1 22.1 22.1 22.1 25.0 25.0 25.0 25.0 33.3 33.3 33.3 33.3 33.3 33.3 33.3 33.3 A/PH 38.1 38.1 38.1 38.1 32.1 32.6 34.6 33.2 39.8 44.9 42.3 47.3 47.1 47.9 47.3 48.5 A/PH 63.1 74.1 44.6 52.7 84.4 95.6 60.1 69.1 114.5 115.3 87.4 101.6 115.7 161.7 99.1 113.9

System

NOTE 1:-

*Single phase models are available for twin circuit direct expansion and chilled water systems where the electric heating requirement is 8kW or less. **The electric heating loads shown are based on maximum amounts of heating which are:CD 08 = 12kW CD 10 = 14kW CD 15 = 16kW CD 20 = 20kW
1 Ph 230V 50Hz Model Combination Full Load Amps 3 Ph 400V 50Hz

R407C SYSTEMS
System Full Load Amps System Max. Max. Cooling Cool & Cool/Heat/ Starting Cooling Cool & Cool/Heat/ Starting Only Heat* Hum/Dehum Current Only Heat** Hum/Dehum Current Amps HS 08 CD08 + MCU+/DCUE 80 18.9 -21.6 23.2 --27.8 27.0 --32.0 ---43.2 -S 08 S CD08 + MCU+ 100 HS 08 T CD08 + 2 x MCU+/DCUE 30 S 08 T CD08 + 2 x MCU+/DCUE 50 HS 10 CD10 + MCU+ 100 S 10 S CD10 + MCU+ 130 HS 10 T CD10 + 2 x MCU+/DCUE 50 S 10 T CD10 + 2 x MCU+/DCUE 60 HS 15 CD15 + MCU+ 165 S 15 S CD15 +MCU+ 180 HS 15 T CD15 + 2 x MCU+/DCUE 80 S 15 T CD15 +2 x MCU+ 100 HS 20 CD20 + MCU+ 180 S 20 S CD20 + MCU+ 200 HS 20 T CD20 + 2 x MCU+ 90 S 20 T CD20 + 2 x MCU+ 130 Amps 38.7 -38.7 38.7 --39.7 39.7 --41.3 ---43.2 -Amps ----------------Amps 82.0 -50.4 72.9 --68.5 78.8 --97.1 ---141.3 -A/PH 10.3 12.6 12.6 14.0 14.6 15.3 17.0 15.8 18.7 20.9 18.8 23.4 21.3 24.4 23.6 25.2 A/PH 22.1 22.1 22.1 22.1 25.0 25.0 25.0 25.0 33.3 33.3 33.3 33.3 33.3 33.3 33.3 33.3 A/PH 38.1 38.1 38.1 38.1 32.2 32.9 34.6 33.4 43.0 45.2 43.1 47.7 45.2 48.3 47.5 49.1 A/PH 63.1 74.1 44.6 52.7 84.4 95.6 60.1 69.1 114.5 115.3 87.4 101.6 115.7 161.7 99.1 113.9

System

NOTE 1:- *Single phase models are available for twin circuit direct expansion and chilled water systems where the electric heating requirement is 8kW or less. **The electric heating loads shown are based on maximum amounts of heating which are:CD 08 = 12kW CD 10 = 14kW CD 15 = 16kW CD 20 = 20kW

-22-

CHILLED WATER AIR HANDLERS

1 Ph 230V 50Hz Air Handler Full Load Amps Cooling Only Amps CW 08 CW 10 CW 15 CW 20 5.4 7.4 9.0 9.4 Cooling Only A/PH 5.4 7.4 9.0 9.4 3 Ph 400V 50Hz Full Load Amps Cool & Heat A/PH 22.1 25.0 33.3 33.3 Cool/Heat/ Hum/Dehum A/PH 38.1 25.0 33.3 33.3

The electric heating loads shown for three phase models are based on maximum amounts of heating which are:CW 08 = 12kW CW 15 = 16kW CW 10 = 14kW CW 20 = 20kW --o--o--O--O--O--o--o--

CURRENT RATINGS
CD3 HEATING (1 PHASE)
CURRENT RATING (Amps) 8.3 16.7 25.0 33.3 UNIT SIZE 008 1 STAGE O O O O 2 STAGE O O O O O O 010 1 STAGE 2 STAGE O O O O O O 015 1 STAGE 2 STAGE O O O O O O 020 1 STAGE 2 STAGE O O

HEATING 2kW 4kW 6kW 8kW

CD3 HEATING (3 PHASE)

CURRENT RATING AMPS/PHASE HEATING 2kW 4kW 6kW 8kW 10kW 12kW 14kW 16kW 18kW 20kW O L1 8.3 8.3 8.3 16.7 16.7 16.7 25.0 25.0 25.0 33.3 L2 --8.3 8.3 8.3 16.7 16.7 16.7 25.0 25.0 25.0 L3 ----8.3 8.3 8.3 16.7 16.7 16.7 25.0 25.0 1 O O O O O O O O O O UNIT SIZE 008 2 1 O O O O O O O O O O O 010 2 1 O O O O O O O O O O O O O O 015 2 1 O O O O O O O O O O O O 020 2

= HEATING OPTIONS
UNIT SIZE 008 010 6.4A 2 370W 2A 16A 015 8.0A 2 330W 020 8.4A 2 550W

CD3 FANS

RUNNING CURRENT NUMBER OF FANS POWER RATING CONTROL CIRCUIT HUMIDIFIER

4.4A 1 550W

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-23-

FUSES
The system and its supply/interconnecting wiring must be protected by fuses, preferably H.R.C. motor rated types to EN60269 or miniature circuit breakers to EN60898 or local codes having similar time lag characteristics that allow starting of the compressor yet still afford close overcurrent protection under running conditions. The ratings below are for H.R.C. motor rated or semi-enclosed wire fuses.

STANDARD COOLING (R22 and R407C models)

System 1 Phase Cool Only 1 Phase Cool and Heat 3 Phase Cool Only 3 Phase Cool and Heat 3 Phase Cool/Heat/Hum/Dehum S 08 S --20 32 50 S 08 T 32 50 20 32 50 S 10 S --25 40 50 S 10 T 40 50 25 40 50 S 15 S --32 50 63 S 15 T --32 50 63 S 20 S --35 50 63 S 20 T --40 50 63

HIGH SENSIBLE COOLING (R22 and R407C models)

System 1 Phase Cool Only 1 Phase Cool and Heat 3 Phase Cool Only 3 Phase Cool and Heat 3 Phase Cool/Heat/Hum/Dehum HS 08 S 25 50 16 32 50 HS 08 T 25 50 20 32 50 HS 10 S --20 40 50 HS 10 T 32 63 25 40 50 HS 15 S --30 50 63 HS 15 T 40 63 30 50 63 HS 20 S --32 50 63 HS 20 T 63 63 40 50 63

CHILLED WATER AIR HANDLERS

Air Handler 1 Phase 3 Phase CW 08 10 10 CW 10 16 16 CW 15 16 16 CW 20 16 16

--o--o--O--O--O--o--o--

EVACUATING AND CHARGING

When the compressor is first started in the field, the bearing surfaces are susceptible to damage if not properly lubricated. Care should be taken when the bearings are being run in to ensure that:a) The compressor is not started the first time with excessive refrigerant charge. b) The system is not overcharged, in which case liquid return to the compressor could result. Evacuate the air handler and interconnecting pipework by connecting a vacuum pump to the Schrader valves on both suction and discharge valves on the condensing unit, (DO NOT OPEN THE VALVES), and evacuate to 1000 microns (1 Tor) or better.

FACTORY CHARGE OF REFRIGERANT

Each outdoor unit is charged with refrigerant, detailed in the tables below.
MCU(+) 30 40 50 60 80 90 100 130 165 180 200 R22 charge gms 950 1180 1610 1900 1800 1960 2400 3970 4320 4420 5220 R407C charge gms 1000 1240 1690 2000 1880 2060 2520 4170 4540 4640 5480 DCUE 30 50 60 80 R22 charge gms 930 1250 1140 1400 R407C charge gms 990 1240 1190 1480

-24-

ADDING REFRIGERANT
Additional refrigerant may be necessary for the product match, or when pipe runs are more than 7.5m. Typically add the following for longer pipe runs:Expansion line size. Additional R22/R407C (g/m). Additional oil. 1/4 7 3/8 16 1/2 30 5/8 48

25g per 350g of additional R22/R407C to a maximum of 300g

The preferred method of adding charge is :1 Start the unit, (on the highest evaporator fan setting and appropriate outdoor unit speed), and allow the compressor to run for a few seconds.

2 Any additional charge needed should be introduced through the Schrader valve on the suction side of the compressor.
3 The correct unit charge may be determined by examining the condition of the evaporator coil during the charging process, (with the system running in cooling). Refrigerant enters the coil at the bottom left hand side and leaves at the top left hand side. A properly charged unit should show signs of 'sweating' all the way up the coil. 'Sweating' should be reduced at the coil outlet as it enters the suction line, which should be completely dry a few inches before it enters the compressor. If a sight glass is fitted, position this in the liquid line as near to the air handler as possible. Charge should be added to the unit, (with the system running), until the sight glass is just clear of bubbles, (flooded).

Undercharged Unit - The top few tubes of the evaporator are dry and there are, (possibly), slight signs of frosting at the inlet to the evaporator coil. Overcharged Unit The suction line 'sweats' all the way back to the compressor. IMPORTANT: If a manual HP cutout is fitted, ensure that the reset button is depressed.

--o--o--O--O--O--o--o--

CONDENSATE DRAIN
The condensate drain connection is at the left hand end of the drain tray. A 15mm O.D. copper drain pipe is provided in the drain sump for connection with non-kink plastic tubing secured with a suitable clip. Should it be necessary for the drain pipe to go through the back or base of the unit, a knockout is provided in the backpanel or base plate. The drain line must have a constant fall to open drain using a 'U' trap if required. Check that the water will run freely and that there are no leaks.

--o--o--O--O--O--o--o--

WHEN INSTALLATION HAS BEEN COMPLETED - CHECK :1 2 3 4 All pipe work and joints for leakage. All pipe work and fittings for insulation. All bolts are secure and that fan rotates freely. If a manual low pressure cutout is fitted, that the reset button is depressed before switching on.

--o--o--O--O--O--o--o--

-25-

POWER WIRING DIAGRAM

-26-

CD3 008 to 020 COOL ONLY, CONTROL WIRING DIAGRAM

-27-

MCU+ WIRING DIAGRAMS

1 Phase MCU+ 30 to 90

3 Phase MCU+ 30 to 100

3 Phase MCU+ 130 to 180

3 Phase MCU+ 200

-28-

ELECTRONIC DCUE WIRING DIAGRAMS

1 Phase DCUE 30 - 60

1 Phase DCUE 80

3 Phase DCUE 30 to 80
-29-

CD3 008 to 020 WITH MCU+ - INTERCONNECTING WIRING DIAGRAMS

CD3/2 008 - 010 and 1 Phase MCU+ 30 - 60 CD3/1 008 and 1 Phase MCU+ 80 CD3/2 015 - 020 and 1 Phase MCU+ 80 - 90

CD3/1 008 - 010 and 3 Phase MCU+ 100 CD3/2 008 - 020 and 3 Phase MCU+ 30 - 100

CD3/1 010 - 020 and 3 Phase MCU+ 130 - 200 CD3/2 020 and 3 Phase MCU+ 130

-30-

CD3 008 to 020 + DCUE, INTERCONNECTING WIRING DIAGRAMS

THREE PHASE

SINGLE PHASE

-31-

ELECTROMECHANICAL CONTROL
The controller in its basic form has 4 parts :1 Power board - fitted inside the air conditioner - this houses the main power terminal block and output switching relays. The input to the power board is 24V AC which is rectified to provide the low voltage supplies to dc power and relay coils and the main control board. Control board - this is attached to the fascia plate and performs the logic conversion, temperature measurement and control functions, as well as providing indication of actual and set point values of temperature, indication of output relay functions and the controller status. Membrane keypad - provides external control for the user and is connected to the controller via the 11 way membrane keypad tail. 16 way ribbon cable - connected to the power board. NOTE:-During commissioning work, all access panels except the electrics compartment access panel should remain in situ unless otherwise stated.

3 4

Fig. 2. Electromechanical control

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CD3-SERIES ELECTROMECHANICAL OPERATING INSTRUCTIONS

MEMBRANE KEYPAD, (ELECTROMECHANICAL)

KEYPAD SYMBOL

FUNCTION
OFF (STAND-BY) ON LOW FAN

OPERATION
Press to stop the unit and put into stand-by mode.

Press to start unit.

Press to select low fan speed.

HIGH FAN MUTE HEAT

Press to select high fan speed.

Press to mute alarm sounder, (if alarm interface fitted). When lit indicates heating operation.

COOL HUMIDIFY DEHUMIDIFY MODULATED HEATING

When lit indicates cooling operation.

When lit indicates humidifier operating, (if humidifier is fitted). When lit indicates dehumidification, (if humidifier is fitted). When lit indicates operation of modulating heating valve, (electronic models only). Brightness of symbol shows status of valve, i.e. Dim = Valve just beginning to open. Bright = Valve fully open. When lit indicates operation of modulating cooling valve, (electronic models only). Brightness of symbol shows status of valve i.e. Dim = Valve just beginning to open. Bright = Valve fully open. When lit indicates blocked or dirty filter, (if pressure switch is fitted). When lit indicates humidifier bottle requires changing, (if humidifier fitted).

MODULATED COOLING

FILTER CLOG CYLINDER CHANGE

-33-

ELECTROMECHANICAL CONTROL
SETTING THE THERMOSTAT
The control thermostat is located in the electrics panel. The type used depends upon the control requirements. Units are wired to one of the variations shown below.

2 STAGE THERMOSTAT

3 or 4 STAGE THERMOSTAT

SETTING THE 2 STAGE HBCC HUMIDISTAT

With an increase in humidity over the set point Xs, the circuit across terminals 4 and 5 is broken and across 5 and 6 is made (switching B). With a decrease of humidity below the switching differential Xsh, the circuit across terminals 1 and 3 is broken and across 1 and 2 is made (switch A). The upper switching point of switch A is set by the set point knob (E). The switching differential Xsh is set by the screw (N) and the auxiliary scale (F). The factory setting of Xsh is approx. 5% RH. RECALIBRATION In case of deviations of the measured humidity from the set point, a recalibration by means of the nut (S) is recommended: If the actual value is higher than the set point, turn nut (S) anticlockwise. If the actual value is lower than the set point, turn nut (S) clockwise.
Set point 1/6 turn = 20% 15% 40% 15% 60% 11% 70% 8% 80% 5%

MAINTENANCE

Solid sensing elements can be cleaned by dipping the stem in soapy water or water with washing powder (max. 80/C). When drying, the stem must remain tensioned, i.e., the set point knob is set to approx. 0% RH. Drying time will be approx 24 hours. If necessary, recalibrate the humidistat.

-34-

C. SETTING THE FAN SPEED CONTROLLER (THIS ALSO APPLIES TO ELECTRONIC UNITS)
One control is used on electromechanical CD3 units, each having a switch for selecting top speed (high or boost) as shown in the diagram below. The boost position should be selected for:ALL DOWNFLOW systems Upflow systems requiring ductwork on the supply or return air OR when high efficiency filters are fitted. The High position should be selected for standard 'Free Blow' Upflow systems. Units are despatched with the low speed set on minimum. This speed can be increased by turning the low speed potentiometer clockwise. This adjustment will give between approximately 50% to 100% of the selected top speed.

--o--o--O--O--O--o--o--

-35-

ELECTRONIC CONTROL
The control in its basic form has 6 parts :1 Power board fitted inside the air conditioner - this houses the main power terminal block and output switching relays. The input to the power board is 24V AC which is rectified to provide the low voltage supplies to dc power and relay coils and the main control board. this is attached to the fascia plate and performs the logic conversion, temperature measurement and control functions, as well as providing indication of actual and set point values of temperature, indication of output relay functions and the controller status. provides external control for the user and is connected to the controller via the 11 way membrane keypad tail.

Control board

3 4 5 6

Membrane keypad

20 way ribbon cable - connected to the power board. 26 way ribbon cable - connected to the hum board. Temperature sensor - connected via 2 way cable to controller.

NOTE:-During commissioning work, all access panels except the electrics compartment access panel should remain in situ unless otherwise stated.

Fig. 1. Electronic control

-36-

CD3-SERIES OPERATING INSTRUCTIONS

MEMBRANE KEYPAD, (ELECTRONIC)

KEYPAD SYMBOL

FUNCTION
OFF (STAND-BY)

OPERATION
Press to stop the unit and put into stand-by mode.

ON

Press to start unit.

LOW FAN HIGH FAN INTERROGATE

Press to select low fan speed. Press to select high fan speed. Press to display actual room temperature and humidity, (electronic models only). (Defaults to set point display).

MUTE HEAT COOL HUMIDIFY

Press to mute alarm sounder, (if alarm interface fitted). When lit indicates heating operation.

When lit indicates cooling operation.

When lit indicates humidifier operating, (if humidifier is fitted). When lit indicates dehumidification, (if humidifier is fitted). When lit indicates operation of modulating heating valve, (electronic models only). Brightness of symbol shows status of valve, i.e. Dim = Valve just beginning to open. Bright = Valve fully open. When lit indicates operation of modulating cooling valve, (electronic models only). Brightness of symbol shows status of valve i.e. Dim = Valve just beginning to open. Bright = Valve fully open. When lit indicates blocked or dirty filter, (if pressure switch is fitted). When lit indicates humidifier bottle requires changing, (if humidifier fitted). -37-

DEHUMIDIFY MODULATED HEATING

MODULATED COOLING

FILTER CLOG

CYLINDER CHANGE

ELECTRONIC CONTROL
A. SETTING THE THERMOSTAT
The temperature display on the controller is factory set to display the set point temperature. The links on LK5 are fitted horizontally as shown in figure 2a. The temperature set point is altered by rotating the potentiometer, denoted RV3 TMP/SP, accessed from the rear of the board, until the required temperature shows on the digital read-out. Temperature can be set between 9/C and 32/C with a recommended minimum of 18/C. Also refer to the Fan Speed Control setting up instruction on page 35.

B. SETTING THE ELECTRONIC HUMIDISTAT

The lower digital display shows relative humidity. The display is factory set to display the set point relative humidity using LK5 as described above. The relative humidity set point is altered by rotating the potentiometer, denoted RV5 HUM/SP, accessed from the rear of the board, until the required RH shows on the lower digital read-out. The controller can be set to display set point temperature and set point relative humidity or actual temperature and actual relative humidity using the links on LK5. When positioned horizontally as shown in figure 2a, set point values are displayed. When positioned vertically as shown in figure 2b, actual values are displayed. The other state from the default state may be displayed by pressing the interrogate button marked '?' on the membrane keypad.

Fig. 2a.

Fig. 2b.

C. ADJUSTING THE TEMPERATURE INTERSTAGE DIFFERENTIAL

The interstage differential is set by adjustment of the potentiometer, denoted 'RV2 DIFF' which is accessible from the rear of the controller. 0.5 to 3/C X X SET POINT X X 0.5 to 3/C

X - adjustable interstage differential The increase/decrease of H1/H2 and C1/C2 is symmetrical about the set point. H3 and C3 are available with an alarm interface board. Reference should be made to sections L and M to set these. Increasing the differential between the stages increases the dead band between 'heat' and 'cool'. Temperature is factory calibrated to +/- 0.1/C. Field calibration is not possible. Temperature displayed is rounded to the nearest lower integer e.g. 20.8 is displayed as 20.

D. ELECTRONIC HUMIDITY CONTROL

The humidity control board is fitted inside the unit and connected via a 26 way ribbon cable to the electronic controller. The sensor, which is mounted in the return air, is connected by a 3-way cable. The humidity set point is adjustable between 25% to 75%. The minimum interstage differential is factory set at 3% and is variable up to 9%. It should be set to the required level by means of the differential potentiometer on the PCB, see fig. 3. Do not adjust the upper potentiometers, (which are factory set and sealed), otherwise calibration will be lost.

Note:-

Increasing the differential between stages also increases the 'dead band' between hum and dehum, and consequently reduces the mean room RH.

Humidity is factory calibrated and field recalibration is not recommended. Adjustment of the humidity display for example if the room condition is offset to that of the sensor, is m a d e using the 'display cal' potentiometer on the humidity c o n t r o l board.

Fig. 3.

-38-

E. POWER UP STATUS (ELECTROMECHANICAL AND ELECTRONIC)

The unit is biased to it's 'ON' state when power is switched on. It can be biased to it's 'OFF' state by fitting a link to LK1 as shown in figure 4. On power up it is also biased to 'high fan'. Again it may be biased to 'low fan' by connecting a link to LK2, as shown in figure 4.

Fig.4. F. COOLING AND HEATING INDICATION, (ELECTRONIC)

The cool indicator (LED6) on the controller lights when the unit is in its cool mode. This indicator can be disabled by connecting a link to LK3. Similarly, when in heat mode the heat indicator (LED7) on the controller lights. This may be disabled by connecting a link to LK4. These links are only required when modulating valves are fitted. To fit these links it is necessary to remove the electronic controller, PCB 1, from the fascia plate to gain access, see Figure 4.

G. CONNECTIONS TO THE CONTROLLER

Three connections are necessary to the controller together with one extra if the optional hum board is installed, (all connections are fully polarised and latching), see Figure 1 for positions. 1 2 3 4 An 11 way connection from the membrane keypad. A 2 way connection from the temperature sensor, (not electromechanical versions). A 20 way ribbon cable from the power board, (16 way ribbon cable on electromechanical versions). A 26 way ribbon cable to the hum board if installed, (not electromechanical versions).

The ribbon cables are connected by spreading the two side arms of the connector header apart on the controller. The socket connected to the ribbon cable is then inserted so that the side arms close and 'click' in position to hold the socket firmly. To release the connector the side arms are pushed apart simultaneously.

H. PRESSURE SWITCHES (OPTIONAL) for fan fail and filter clog

Fan fail is only available when an alarm interface is fitted. Pressure switches are factory fitted and tested to ensure that they function. Adjustment and final setting, especially of Filter Clog, is carried out during commissioning and the following notes are issued for guidance only. FAN FAIL In this application the pressure switch is used to verify that the fan is operating. Should the fan fail the pressure switch will operate and the 'fan fail' warning indicator (digit 3) will flash. The sounder will operate (if enabled) and the unit will shut down after approximately 12 seconds. NOTE:- ISOLATE THE UNIT PRIOR TO STARTING THE TEST. Test by:1 2 Disable the fan by removing the live feed, L1, from the fan speed controller, PCB 3, leaving one fan running if two are fitted. Switch on the unit and select low fan. After approximately 12 seconds the fan fail indication should be displayed and the unit should shut down as detailed above.

FILTER CLOG In this application the pressure switch is used to verify that the change in pressure due to dirty filters, is detected at a level to suit environmental requirements. This level is determined and set by the commissioning engineer. Test for Filter Clog indicator operation. Note:- after every adjustment of the filter clog switch it is important that cabinet access panels are returned to position to ensure that correct pressures are achieved before testing.

-39-

1 2 3

Ensure that cabinet access panels are in position. Switch unit on and select low fan speed - check that the filter clog indicator does not light up. If the indicator illuminates, increase the set point pressure by turning the graduated dial to a higher set point until the light goes off. Block off the return air grille, (by 75%, from the right), with a piece of cardboard or similar - the filter clog indicator should illuminate. If the indicator does not light up, lower the set point pressure by making a small adjustment to the graduated dial. Recheck and repeat if necessary.

J. ALARM SYSTEM
Supplied as an optional kit, the alarm system comprises an alarm interface and an alarm indication board.

K. ALARM INTERFACE
The alarm interface is capable of processing 7 additional alarms :1 2 3 4 5 6 7 High water condition in the drip tray. Water spill condition. Fan failure. Compressor 1. trip. Compressor 2. trip. Humidity out of limits. Temperature out of limits.

Alarm 7 is standard and requires no further equipment for its operation. The remaining alarms require kits to be installed and interfaced to the alarm interface via the connections shown in the relevant kit wiring diagram. Alarms 1, 2 and 3 will cause the unit to shut down, 1 will operate immediately, 2 and 3 after approximately 12 seconds. If the appropriate links of LK1 are still fitted as shown in figure 5, then that alarm status will cause a common alarm relays contacts to close and the sounder of the alarm indication board to sound.

Fig. 5.
Pressing the mute button will mute the sounder and open the contacts of the common alarm relay. Connections are made to the alarm interface as shown in the relevant kit wiring diagram. To allow the maintenance engineer to discern which alarm conditions are present other than that currently displayed, a push button, (yellow), is provided on the alarm interface P.C.B. designated SW1, see Figure 5. Depressing this switch repeatedly allows the engineer to index through active alarms.

L. SETTING OF H3, C3 and HUM, DEHUM ALARM LEVELS

To obtain this facility an alarm interface board is required. A set point is set up on the controller together with the interstage differentials as described in sections A, B and C. The links on LK5 are now positioned vertically to display the 'actual' values of temperature and relative humidity. The push-button, SW2, on the alarm interface is pressed and held to replace the actual sensors by two dummy sensors whose values can be altered by rotating the potentiometer denoted 'TEMP' for temperature alarm and 'HUM' for humidity alarm. The HUM alarm is preset and is not adjustable.

M. TO SET H3 and C3
The 'TEMP' pot is rotated until the digital read-out of temperature displays the value required for the C3 alarm, (while holding SW2 in). The alarm set H3/C3 pot on the controller is now rotated until the alarm LED on the power board lights (see figure 5).

-40-

N. THE ALARM INDICATOR BOARD

The alarm indicator board is connected to the alarm interface via a 14 way ribbon cable (Fig 1). It is also connected to the membrane keypad via the 4 way tail. This board gives visual and audio indication of an alarm condition via a digital read-out and sounder respectively. The indication of a specific alarm is given by a digital read-out between 1 and 7 inclusively :-

DIGITAL READ-OUT 1 2 3 4 5 6 7

ALARM High water Water spill Fan failure Compressor 1 trip Compressor 2 trip Humidity out of limits Temperature out of limits

The sounder may be muted after it has sounded by pressing the 'mute' button on the membrane keypad. If another alarm(s) occurs the sounder will re-sound and alarm(s) may be identified by pressing the yellow push button on the alarm interface, within the electrics tray, to index the digital read-out.

P. VOLT FREE RELAY BOARDS ALARM STATUS

The volt free relay board connects to the alarm interface via a 10 way ribbon cable. A signal via this cable opens/closes the contacts of a relay associated with the alarm condition, and will open/close the common alarm relay contacts on the volt free relay board. Depending upon the function that is required, equipment may be either connected into the normally closed or normally open sides of the relay. Each alarm condition has a relay associated with it: see Fig. 6 for outputs.

Fig 6 Connections for alarm status VFRB

CONTROL STATUS
This connects to the electronic power board via a 10 way ribbon cable and indicates the air handler status from the outputs as numbered below. 1 Cylinder Change. 2 Heat. 3 Humidification. 4 On/Off. 5 Hi/Low Fan. 6 Filter Clog. 7 Dehumidification. 8 Cooling. Note Hi/Low Fan and On/Off use 1 relay for both indications, therefore the equipment can only be connected to one output. If used as a control status board to differentiate between high and low fan, then it is recommended that this relay is supplied via the ON (N/O) side of the ON/OFF control status relay, (output 4). for outputs see Figure 7.

Fig 7 Connections for control status VFRB

Q. CONDENSATE PUMP (OPTIONAL)

The alarm interface incorporates a drive facility for a condensate pump to remove excess water from the drip tray. This requires a float switch connection and a 240V AC feed to the board as shown in the optional kit wiring diagram. If the alarm interface is not used, then a condensate pump control board may be fitted to control the water level. This has the same input requirements as described above and connections are shown in the wiring diagram in the optional kit. This board is also used for high water shut down which lights an LED on the condensate pump control board. This LED can not be observed from outside the unit. Off/Power (Stand-by), On, High Fan and Low Fan buttons are all standard on the membrane key pad as is read-out of Temperature and Humidity, (actual or set point). All other symbols are secret until lit.

-41-

R. CD3 SYSTEM HUMIDIFIER

DESCRIPTION The CD3 system OEM humidifier is an electrode boiler-type steam generator with electronically controlled vapour output, and water filling and draining sequences. The disposable, injection-moulded polypropylene cylinder containing the electrodes is designed to be replaced periodically, as the accumulation of salts on the electrodes eventually renders it inoperative. The control system automatically signals when a change of cylinder is necessary. INSTALLATION Water supply Pre-treatment of water fed to the humidifier is unnecessary, the unit being designed to operate on a wide range of water qualities, covering most types of piped water supplies. The humidifier is not suitable for connection to fully de-mineralised water supplies. The Nordmann system OEM incorporates an air break in the water feed as required by some local regulations. Direct connection may be made to water supplies operating at pressures between 0.1 and 1 MPa (14 to 145 psig). Connection to supplies at higher pressures must be through a pressure regulator set at 0.4 to 0.6 MPa (60 to 90 psig). Plumbing connections The water feed connection is a 1/8" BSPF fitting. It is recommended that a water stop valve and a strainer are fitted in the supply line adjacent to, or inside, the unit. Control solenoid valves are supplied. The humidifier waste water is dumped directly into the drain tray in the base of the coil section, so the drain connection should be made in the normal condensate drain position. The drain pipe should be run in piping suitable for use with water at 60/C and for short periods with 100/C water. Free drainage can usually be achieved by the use of 35mm piping with a minimum slope of 5% (1 in 20) and an air break at the entry. Condensate pumps, (if other than the IMI version), should be selected for use with temperatures up to 90/C. COMMISSIONING Pre-start checks Ensure the drain line is connected and that water flows away freely. This can be carried out by filling and then draining the cylinder using the manual drain switch.

HUMIDIFIER CONTROL UNIT

Check the position of the setting switches on the humidifier control unit. This is situated inside the humidifier electrics box sited to the right of the coil in the coil section.

The humidifier output may be set to 100%, 68%, 55% or 30% of its full power by setting switches 1 and 2 on the control unit to the positions shown above. Ensure that the rubber hose is securely connected at both the steam distribution pipe and cylinder ends.

-42-

START UP
On first switching the humidifier on, with an empty steam cylinder, the feed valve will open and the drain valve will remain closed. Water will flow into the cylinder until it reaches the level sensing electrode, when the feed valve closes. Initially, the electrode current will be well below the normal operating level; however, this small current will cause the water to heat up gradually and, eventually, boil. As the water boils it's level will fall and after a short period it will break contact with the level sensing electrode. This will cause the feed valve to open, filling the cylinder with fresh water until the level sensing electrode is once more immersed, whereupon it will close again. This process of repeatedly boiling water away and topping up with feed water will continue during the operation of the humidifier. The electrode current at the end of each successive feed is slightly higher than before, because the fresh water entering the cylinder contains dissolved minerals, whereas the water leaving the cylinder as steam carries no minerals away with it. Consequently, the concentration of dissolved minerals in the water, and it's electrical conductivity, steadily increases. The electrode current will also rise steadily and will eventually reach the operating value to give the required steam output. This process is entirely automatic and may take from a few minutes to several hours, depending on the mineral content of the feed water. If this is low (very pure water) start up will be slow, whereas if it is high (less pure or hard water) start up will be faster. During the start up period, whenever the actual electrode current is less than 70% of the set operating level, the 'change cylinder' lamp will light. This is normal and should be ignored. After the output has risen above 70% of the set output, the 'change cylinder' lamp will not light again until the cylinder life is finished or some other fault has developed which may prevent the unit from giving its required steam output. It should be noted that this start up process occurs only once, when a new steam cylinder is fitted. On all subsequent starts, full output will be generated within a short period of switching on, provided that the water has not been manually drained from the cylinder. Delay on start up can be eliminated by the introduction of a 'start up tablet' or a teaspoon of table salt into a new or refilled cylinder. This has the effect of increasing the conductivity of the water and hence the initial electrode current.

NORMAL OPERATION
During normal operation, the conductivity of the cylinder water, dictated by its mineral content, is maintained at the desired level by controlled draining of mineral rich water and dilution with fresh feed water, the operation of the drain and feed solenoid valves being automatically controlled by the system's electronics. After the start up period, the unit will operate automatically throughout the steam cylinder's life at substantially constant output, regardless of any changes in the mineral content of the feed water. If the feed water has a high mineral content, the drain periods will occur more frequently than if the mineral content of the feed water is low. During the life of the steam cylinder, electrodes gradually become encrusted with scale and their conductivity to the water will reduce. The system compensates for this by allowing the conductivity of the cylinder water to rise, so that the electrode current always stays at the preset value. As this progresses, the drain periods (of constant water volume) each carry away more minerals and so fewer are needed. The system therefore becomes more efficient as the cylinder life progresses. Eventually, as the electrodes become excessively scaled, the increase of the water conductivity can no longer compensate for the decrease of the electrode conductivity. When this occurs the drain periods cease altogether and the electrode current falls off quite rapidly. This situation is signalled by the illumination of the 'change cylinder' lamp on the control fascia.

-43-

MAINTENANCE
Prior to carrying out maintenance on the humidifier system, the cylinder should be drained, by operating the manual switch, and the system isolated from the electrical supply. STEAM CYLINDER REPLACEMENT Access to the steam cylinder and solenoid valves is via the bottom section doors on all upflow units and the small left hand side door on downflow models. The humidifier control unit is situated either inside the full length control panel, where fitted, or in the internal panel on upflow units, and inside the slide out panel on downflow models. Before switching off the supply to the humidifier, isolate the water supply and drain the cylinder using the manual drain switch. Remove the discharge hose from the top of the steam cylinder, and the power and cylinder-full connectors. The electrical connectors are removed by pulling upwards. Lift the cylinder support clear of the outlet spigot: this should slide up easily but, if it becomes stiff, it can be sprung upwards and backwards. The cylinder can then be withdrawn from the feed/drain manifold assembly and a new one inserted. The hose and electrical connectors are then replaced, ensuring that the same positions are maintained. Whenever the cylinder is replaced it is advisable to clean the feed/drain manifold and check the "O" ring seal, replacing it if necessary. The drainage strainer (382 60 06), which is fitted to protect the outlet solenoid valve, should also be cleaned or replaced as necessary. Cleaning or replacing this removable item may extend the useful life of the cylinder. Remember to reinstate the water supply and return the electrical supply to automatic. After replacing a cylinder, observe the unit during its initial start-up period and ensure that the operating current is correct. REPLACEMENT STEAM CYLINDERS These can be obtained from IMI by quoting the following part numbers. Steam output kg/h Nordmann ref IMI Part Number 4 TYPE 1422 04406614S

GENERAL MAINTENANCE
Annually, or more frequently if service conditions dictate, clean the feed water strainer and drain solenoid valve. Check hoses for wear and flush out the drain pipe.

--o--o--O--O--O--o--o--

-44-

CD 3 EXPLODED DIAGRAM (DISCHARGE SPIGOT NOT SHOWN)

1 2

Coil (DX or chilled water) Drain tray Access panel Terminal Contactor Circuit breaker Condensate pump De-ice thermostat Expansion valve Heater element (2kW) Side panel assembly Swell latch End stop Terminal Heater cutout

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Blower assembly Fresh air fan Filter Transformer Discharge grille Alarm interface Relay 6 stage control Fan speed control Humidity control pcb Pressure switch Grabber Alarm indicator Touch control Humidifier assembly

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Membrane key pad Humidifier bottle Terminal Panel surround Electrics access Washable filter Return air grille Humidity sensor Isolator Temperature sensor Vice latch Volt free pcb Float switch High water level assembly Relay

3
4 5 6 7 8 9 10 11 12 13 14 15

-45-

MCU+ 30 - 100 COMPONENT IDENTIFICATION

1 2 3 4 5 6 7 8 9 10 11 12 13

Lid LP switch Contactor Overload Heat exchanger Rear access panel Mains terminal cover HP switch manual Fan capacitor Switch bracket Bulkhead panel Expansion assembly (inc. restrictor) Service valve (Suction)

14 15 16 17 18 19 20 21 22 23 24 25 26

Service valve (Liquid) Valve panel Base Mounting foot Compressor Handle Front access panel Fan guard Fascia panel Corner panel Support bracket Motor Fan

27 28 29 30 31 32 33 34 35 36 37

Motor bracket End clamp Terminal (screw - screw) Fuse Fuse terminal Terminal (4 way) Earth terminal Head pressure control 3 minute timer pcb Compressor capacitor Electrics box

-46-

MCU+ 130 - 200 COMPONENT IDENTIFICATION

1 2 3 4 5 6 7 8 9 10 11 12 13

Lid Fuse terminal Fuse Terminal (screw - screw) Terminal (4 way) Contactor Terminal (screw - screw) Earth terminal Overload Heat exchanger Rear electrics panel Fan capacitor HP switch manual

14 15 16 17 18 19 20 21 22 23 24 25 26

Switch bracket LP switch Switch bracket Bulkhead panel Expansion assembly (inc. restrictor) Service valve (Suction) Service valve (Liquid) Valve panel Base Mounting foot Compressor Handle Front access panel

27 28 29 30 31 32 33 34 35 36

Fan guard Fascia panel Support bracket Fan Corner panel Motor Motor bracket Head pressure control 3 minute timer pcba Electrics box

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DCUE COMPONENT IDENTIFICATION

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Lid Blower assembly Right hand access panel Spire clip LP Switch auto HP Switch auto 4 way terminal Fused terminal Compressor Crankcase heater Expansion assembly (including restrictor) Liquid service valve

13 14 15 16 17 18 19 20 21 22 23

Electrics access panel Handle Suction service valve Isolator End clamp Terminal Power board pcba Overload (3PH) Contactor Fan capacitor Compressor capacitor (1PH)

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