IMI CD3 MCU Tech Manual.pdf

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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 airhandling units and DX indoor units for use in conjunction with 550 series MCU+ condensing units or 542 series DCUEducted condensing units.

INDEX

GENERAL Introduction 2General description and part numbers

- DX upflow package electronic 2- DX upflow package electromechanical 3- DX upflow/downflow configurable electronic 3- DX upflow/downflow configurable electromechanical 4- CW upflow/downflow configurable 4- Condensing units 5

CD3 Configurable options 6Dimensions and weights 8

SELECTION Unit combinations 9Performance data DX 9Performance data CW 11Airflows - outdoor/ducted units 11Sound levels - CD3 units, outdoor/ducted units 12

INSTALLATION Airflow options 13Indoor unit 14MCU+ 30 - 100 16MCU+ 130 - 200 17DCUE 30 - 80 18

APPLICATION Pipe sizing and application 20Refrigeration installation 21Electrical data 22Fuses 24Evacuating,factory charge 24Adding refrigerant 25Condensate drain 25

WIRING CD3 26DIAGRAMS MCU+ 28

DCUE 29Interconnecting wiring diagrams 30

OPERATION Electromechanical control 32and (thermostat, humidistat and fan speed control)COMMISSIONING Electronic control 36

COMPONENT Exploded views of units with 45IDENTIFICATION component identification

IMI Air Conditioning Ltd.Armytage Road, Brighouse,West Yorkshire. HD6 1QF.Tel: (01484) 405600Fax: (01484) 721949 A subsidiary company of IMI plce-mail: [email protected]

92908127-03

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INTRODUCTIONThe 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/ductedcondensing 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

MODEL 008 010 015 020Single Circuit 92900072 92900073 92900074 92900075Twin Circuit 92900060 92900061 92900062 92900063

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) ALL 92911002

Floor stand plinth 75mm high008 92911032010, 015 92911033

Fresh air spigot 100mm dia. ALL 92911062 020 92911034Fresh air spigot 160mm dia. ALL 92911063

Double deflection grille008 92911094

Fresh air fan and filter 93m3/h ALL 92911003 010, 015 92911095Fresh air fan and filter 186m3/h ALL 92911004 020 92911096

Top ducted discharge spigot008 92911059

Disposable filter(replaces washable filter)

008 92911038010, 015 92911060 010, 015 92911039020 92911061 020 92911040

INDOOR UNIT AUTO-CHANGEOVER PANELS (Supplied loose) Sound attenuation section

008 92911075010, 015 92911076

Changeover on alarm ALL 92900820 020 92911077Changeover on set time and/or ALL 92900821 3 Ph to 1 Ph conversion 008/2 + 50 929111252 stage to 1 stage conversion 008 92911102 3 Ph to 1 Ph conversion 008/2 + 30 929111262 stage to 1 stage conversion 010 92911103 3 Ph to 1 Ph conversion 010/2 + 50 929111272 stage to 1 stage conversion 015 92911104 3 Ph to 1 Ph conversion 010/2 + 60 929111282 stage to 1 stage conversion 020 92911105 3 Ph to 1 Ph conversion 015/2 + 80 929111293 Ph to 1 Ph conversion 008/1 + 80 92911124 3 Ph to 1 Ph conversion 020/2 + 90 92911130

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DX UPFLOW PACKAGE -- electromechanical controls* NORMALLY SUPPLIED EX-STOCK

MODEL 008 010 015 020Single Circuit 92900076 92900077 92900078 92900079Twin Circuit 92900064 92900065 92900066 92900067

ELECTROMECHANICAL PACKAGE UNITS INCLUDE:

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

KITS AVAILABLE FOR FIELD FITTING TO ELECTROMECHANICAL PACKAGE UNITS:

Condensate pump(hot or cold, 5m lift) ALL 92911001

Floor stand plinth 75mm high008 92911032010, 015 92911033

Fresh air spigot 100mm dia. ALL 92911062 020 92911034Fresh air spigot 160mm dia. ALL 92911063

Double deflection grille008 92911094

Fresh air fan and filter 93m3/h ALL 92911003 010, 015 92911095Fresh air fan and filter 186m3/h ALL 92911004 020 92911096

Top ducted discharge spigot008 92911059

Disposable filter(replaces washable filter)

008 92911038010, 015 92911060 010, 015 92911039020 92911061 020 92911040

INDOOR UNIT AUTO-CHANGEOVER PANELS(Supplied loose) Sound attenuation section

008 92911075010, 015 92911076

Changeover on alarm ALL 92900820 020 92911077Changeover on set time and/or ALL 92900821 3 Ph to 1 Ph conversion 008/2 + 50 92911122 stage to 1 stage conversion 008 92911102 3 Ph to 1 Ph conversion 008/2 + 30 929111262 stage to 1 stage conversion 010 92911103 3 Ph to 1 Ph conversion 010/2 + 50 929111272 stage to 1 stage conversion 015 92911104 3 Ph to 1 Ph conversion 010/2 + 60 929111282 Stage to 1 stage conversion 020 92911105 3 Ph to 1 Ph conversion 015/2 + 80 929111293 Ph to 1 Ph conversion 008/1 + 80 92911124 3 Ph to 1 Ph conversion 020/2 + 90 92911130

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DX UPFLOW/DOWNFLOW CONFIGURABLE - electronic controls* CUSTOMER CONFIGURABLE

MODEL COOLING 8 10 15 20

UPFLOW1 92900001 92900002 92900003 929000042 92900009 92900010 92900011 92900012

DOWNFLOW1 92900005 92900006 92900007 929000082 92900013 92900014 92900015 92900016

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

MODEL COOLING 8 10 15 20

UPFLOW1 92900026 92900027 92900028 929000292 92900034 92900035 92900036 92900037

DOWNFLOW1 92900030 92900031 92900032 929000332 92900038 92900039 92900040 92900041

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

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

CW UPFLOW/DOWNFLOW CONFIGURABLE -- electronic or electromechanical controls* CUSTOMER CONFIGURABLE

MODEL CONTROLS 8 10 15 20

UPFLOWElectronic 92900017 92900018 92900019 92900020

Electromechanical 92900042 92900043 92900044 92900045

DOWNFLOWElectronic 92900021 92900022 92900023 92900024

Electromechanical 92900046 92900047 92900048 92900049

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

CHILLED WATER VALVES MODEL FACTORY KITS

2 way motorised008, 010, 015 92900428 92911028

020 92900429 92911029

3 way motorised008, 010, 015 92900430 92911030

020 92900431 92911031Modulating controller * ALL 92900491 92911091

Modulating 3 port valve(controller must be usedwith valve)

008, 010, 015 92900492 92911092

020 92900493 92911093

* 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+ 1PhRecip MCU+ 30 MCU+ 40

R22 55099157 55099158R407C 55099004 55099005

MCU+ 3PhRecip MCU+ 30 MCU+ 40

R22 55099032 55099033R407C 55099011 55099012

MCU+ 1PhScroll MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90

R22 55099028 55099029 55099030 55099031R407C 55099006 55099007 55099008 55099009

MCU+ 3PhScroll MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200

R22 55099034 55099035 55099036 55099037 55099038 55099039 55099041 55099042 55099043R407C 55099013 55099014 55099015 55099016 55099017 55099018 55099020 55099021 55099022

DCUE DUCTED CONDENSING UNITS (fitted with reciprocating compressors)

DCUE 1Ph DCUE 30 DCUE 50 DCUE 60 DCUE 80R22 54200004 54200006 54200007 54200008

R407C 54200029 54200031 54200032 54200033

DCUE 3Ph DCUE 30 DCUE 50 DCUE 60 DCUE 80R22 54200015 54200017 54200018 54200019

R407C 54200035 54200037 54200038 54200039

STANDARD FEATURES AND OPTIONS, MCU+, DCUEMCU+ = standard condensing unit + head pressure control + loss of gas switchDCUE = electronic controlled ducted condensing unit + head pressure control + HP and LP switches

CONDENSING UNIT MODEL MCU+ DCUEEasy 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 -- �

� = Standard Feature, * = Option

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CD3 CONFIGURABLE ACCESSORIES

DESCRIPTION MODEL ElectronicConfigured

ElectromechanicalConfigured

Chilled WaterConfigured

Factory Fitted PartNumber

THERMOSTATIC EXPANSION VALVE 008/1 � � � 92900468010/1 � � � 92900469015/1 � � � 92900470020/1 � � � 92900471008/2 - 010/2 � � � 92900472015/2 � � � 92900473020/2 � � � 92900474

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

2 kW � � � 929004514 kW � � � 929004526 kW � � � 929004538 kW � � � 9290045410kW � � � 92900455

HEATER RAIL(must be used with electric heaters ondownflow units only)

008D � � � 92900464010D, 015D � � � 92900465020D � � � 92900466

LPHW COIL 7.52kW 008 U/D � � � 92900423(Add de-ice stat with 10.50kW 010 U/D � � � 92900424DX systems) 14.94kW 015 U/D � � � 92900424

18.40kW 020 U/D � � � 92900425LPHW VALVE 2 WAY ALL � � � 92900426(motorised) 3 WAY ALL � � � 92900427DE-ICE THERMOSTAT (one per DX circuit) ALL � � � 92900410HUMIDIFIER 0-4kg/h

(For hum and dehum controlssee next page)

008U � � � 92900444010U, 015U � � � 92900445020U � � � 92900446008D � � � 92900447010D, 015D � � � 92900448020D � � � 92900449

CONDENSATE PUMP (no alarm interface ALL � � � 92900401CONDENSATE PUMP (alarm interface fitted) ALL � � � 92900402FRESH AIR SPIGOT 100mm dia ALL � � � 92900462FRESH AIR SPIGOT 160mm dia ALL � � � 92900463FRESH AIR FAN AND FILTER 93m3/h ALL � � � 92900403FRESH AIR FAN AND FILTER 186m3/h ALL � � � 92900404

TOP DUCTED DISCHARGE SPIGOT (when used as return air spigot on downflow units aplenum is required for access to disposable filters).

008 � � � 92900459010, 015 � � � 92900460020 � � � 92900461

SOUND ATTENUATION SECTION 008 U � � � 92900475010U, 015U � � � 92900476020U � � � 92900477

FLOOR STAND PLINTH

75mm high(Recommended for use with all floor standingunits and for side entry of services)

008U � � � 92900432010U, 015U � � � 92900433020U � � � 92900434008D � � � 92900435010D, 015D � � � 92900436020D � � � 92900437

DOWNFLOW PLINTH Front discharge 008D � � � 92900481300mm high Front discharge 010D, 015D � � � 92900482

Front discharge 020D � � � 92900483Rear discharge 008D � � � 92900484Rear discharge 010D, 015D � � � 92900485Rear discharge 020D � � � 92900486

DOUBLE DEFLECTION GRILLE

(Upflow only)

008U � � � 92900494010U, 015U � � � 92900495020U � � � 92900496

DISPOSABLE FILTER 50mm

(Replaces washable filter)

008U � � � 92900438010U, 015U � � � 92900439020U � � � 92900440008D � � � 92900441010D, 015D � � � 92900442020D � � � 92900443

HIGH EFFICIENCY FILTERS 100mm

(Includes additional plenum section)

008U/D � � � 92900478010U/D, 015U/D � � � 92900479020U/D � � � 92900480

ISOLATOR 63A 008U/D � � � 92900456010U/D, 015U/D � � � 92900457020U/D � � � 92900458U = UPFLOW D = DOWNFLOW � = OPTION � = NOT APPLICABLE

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DESCRIPTION MODEL ElectronicConfigured

Electromechanical Configured

Chilled WaterConfigured

Factory FittedPart Number

CONTROLS

Electronic Humidity Only Control(and bottle change indication) ALL � � � 92900405

Hum and Dehum Control(and bottle change indication) ALL � � � 92900418

Dehum Control (No Humidifier) ALL � � � 92900416Dehum Override ALL � � � 92900417Electromechanical 4 Stage Thermostat ALL � � � 92900490

Electromechanical Humidity Control(1 hum + 1 dehum control) ALL � � � 92900489

Remote Control Panel(includes 6m ribbon cable)-supplied loose

008 � � � 92911815010, 015 � � � 92911816

020 � � � 92911817

ALARMSAlarm Interface Board (This board allows the fitting of any combinationof the following alarm function options)

ALL � � � 92900407

1 High water level ALL � � � 92900412 2 Water spillage ALL � � � 92900411 3 Fan failure ALL � � � 929004084 Condensing unit 1 trip DX only � � � 929004135 Condensing unit 2 trip 2 circuit DX only � � � 929004146 Humidity out of limits ALL � � � 929004217 Temperature out of limits ALL Standard with pcb � Standard with pcb

Control status board ALL � � � 92900487Alarm status board ALL � � � 92900488Dirty filter indication ALL � � � 92900409Dirty filter indication - volt free relay ALL � � � 92900621

Hum bottle change indication - voltfree relay ALL � � � 92900622

INDOOR UNIT AUTO-CHANGEOVER PANELS (Supplied loose)Changeover on alarm DX only � � � 92900820Changeover on set time and/or alarm DX only � � � 92900821

U = UPFLOW D =DOWNFLOW � = OPTION � = NOT APPLICABLE

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UNPACKED DIMENSIONS AND WEIGHTS

CD3 INDOOR UNITS (no plenums fitted)

ModelCD3

008 010 015 020HEIGHT mm 1165 1165 1165 1165WIDTH mm 1230 1380 1380 1580DEPTH mm 430 430 430 430WEIGHT kg 124 142 151 160

MCU+ CONDENSING UNITSModel MCU+ 30 MCU+ 40 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200HEIGHT mm 620 620 720 720 720 820 820 1080 1080 1275 1275WIDTH mm 904 904 1004 1004 1004 1004 1004 1004 1004 1104 1104DEPTH mm 304 304 304 304 304 354 354 429 429 429 4291 Ph kg 48 53 64 65 66 76 - - - - -3 Ph kg 48 53 62 63 64 73 81 101 103 118 173

DCUE DUCTED CONDENSING UNITS

Model DCUE 30 DCUE 50 DCUE 60 DCUE 80

HEIGHT mm 560 625 625 625WIDTH mm 1075 1245 1245 1245DEPTH mm 565 565 565 565WEIGHT kg 70 81 81 84

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PACKED DIMENSIONS AND WEIGHTS

CD3 INDOOR UNITS (no plenums fitted)

ModelCD3

008 010 015 020HEIGHT mm 1300 1300 1300 1300WIDTH mm 1250 1400 1400 1600DEPTH mm 455 455 455 455WEIGHT kg 141 160 169 184

MCU+ CONDENSING UNITSModel MCU+ 30 MCU+ 40 MCU+ 50 MCU+ 60 MCU+ 80 MCU+ 90 MCU+ 100 MCU+ 130 MCU+ 165 MCU+ 180 MCU+ 200

HEIGHT mm 620 620 720 720 720 820 820 1080 1080 1280 1280WIDTH mm 980 980 1080 1080 1080 1090 1090 1090 1090 1215 1215DEPTH mm 340 340 340 340 340 390 390 465 465 465 4651 Ph kg 50 55 66 67 68 78 - - - - -3 Ph kg 50 55 64 65 66 75 83 105 107 123 178

DCUE DUCTED CONDENSING UNITS

Model DCUE 30 DCUE 50 DCUE 60 DCUE 80

HEIGHT mm 580 650 650 650WIDTH mm 1090 1270 1270 1270DEPTH mm 610 610 610 610WEIGHT kg 76 86 86 90

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PRODUCT SELECTION

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

CD3 COMBINATIONS AND CAPACITIES

MODEL 008 010 015 020

AIRFLOW (max) m3/s 0.78 1.04 1.23 1.51

CIRCUITS 1 2 1 2 1 2 1 2MCU+ / DCUE (HIGH SENS) 1 x 80 2 x 30 1 x 100 2 x 50 1 x 165 2 x 80 1 x 180 2 x 90MCU+ / DCUE (STANDARD) 1 x 100 2 x 50 1 x 130 2 x 60 1 x 180 2 x 100 1 x 200 2 x 130

DX PERFORMANCE DATAHIGH SENSIBLE MATCHES

NOMINAL COOLING CAPACITIES AT AMBIENT 30�CRETURN AIRTEMPERATURE

MCU+ / DCUE1 x 80 2 x 30 1 x 100 2 x 50 1 x 165 2 x 80 1 x 180 2 x 90

22�C 50% RHTOTAL 7.20 7.36 10.63 11.08 13.56 13.86 16.76 18.05SENS 7.20 7.36 10.58 10.77 13.44 13.57 16.56 17.11

24�C 50% RH TOTAL 7.46 7.74 11.23 11.62 14.23 14.44 17.60 19.05SENS 7.46 7.74 10.86 11.01 13.76 13.84 16.96 17.54

26�C 50% RH TOTAL 7.75 8.09 11.89 12.13 14.87 14.98 18.40 20.04SENS 7.75 8.09 11.13 11.22 14.03 14.07 17.29 17.91


DCUE / MCU+1 x 80 2 x 30 1 x 100 2 x 50 1 x 165 2 x 80 1 x 180 2 x 90

22�C 50% RHTOTAL 6.86 7.17 10.11 10.56 12.97 13.19 16.03 17.20SENS 6.86 7.17 10.11 10.55 12.97 13.19 16.03 16.75

24�C 50% RH TOTAL 7.11 7.39 10.60 11.15 13.62 13.72 16.78 18.05SENS 7.11 7.39 10.60 10.83 13.52 13.56 16.63 17.14

26�C 50% RH TOTAL --- --- 11.22 11.64 14.22 14.22 17.79 19.00SENS --- --- 10.88 11.04 13.79 13.79 17.07 17.52



22�C 50% RHTOTAL 6.57 6.63 9.43 10.15 12.28 12.62 15.22 15.83

SENS 6.57 6.63 9.43 10.15 12.28 12.62 15.22

24�C 50% RH TOTAL 6.79 6.98 9.93 10.60 12.85 13.08 16.00 16.78SENS 6.79 6.98 9.93 10.60 12.85 13.08 16.00 16.63

26�C 50% RH TOTAL --- --- 10.42 11.05 13.43 13.49 16.79 17.54SENS --- --- 10.42 10.82 13.43 13.49 16.70 16.98



22�C 50% RHTOTAL --- 6.21 8.79 9.75 11.52 --- 14.33 14.88SENS --- 6.21 8.79 9.75 11.52 --- 14.33 14.88

24�C 50% RH TOTAL --- 6.46 9.24 10.20 12.09 --- 15.11 15.59SENS --- 6.46 9.24 10.20 12.09 --- 15.11 15.59

26�C 50% RH TOTAL --- --- 9.73 10.65 12.73 --- 15.83 16.31SENS --- --- 9.73 10.65 12.73 --- 15.83 16.31

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STANDARD MATCHES

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



22�C 50% RHTOTAL 9.84 10.26 11.67 11.81 15.98 18.78 18.88 21.90SENS 8.80 8.98 11.02 11.08 14.48 15.72 17.49 18.80

24�C 50% RH TOTAL 10.40 10.79 12.30 12.53 16.84 19.98 19.91 23.13SENS 9.01 9.17 11.29 11.38 14.82 16.13 17.89 19.22

26�C 50% RH TOTAL 10.96 11.32 12.92 13.08 17.69 21.20 21.04 24.36SENS 9.20 9.34 11.52 11.58 15.11 16.49 18.30 19.59



22�C 50% RHTOTAL 9.31 9.84 11.08 11.30 15.17 17.91 17.95 20.91SENS 8.57 8.80 10.77 10.86 14.13 15.33 17.07 18.36

24�C 50% RH TOTAL 9.90 10.35 11.77 11.85 16.10 19.01 19.05 22.11SENS 8.81 9.00 11.08 11.11 14.51 15.72 17.54 18.80

26�C 50% RH TOTAL 10.45 10.88 12.37 12.45 16.92 20.12 19.92 23.41SENS 9.00 9.17 11.31 11.34 14.81 16.06 17.87 19.22



22�C 50% RHTOTAL 8.67 9.44 10.46 10.78 14.33 16.76 16.65 19.77SENS 8.29 8.63 10.46 10.64 13.77 14.82 16.52 17.86

24�C 50% RH TOTAL 9.19 9.94 11.07 11.31 15.13 17.65 17.71 20.93SENS 8.52 8.83 10.80 10.89 14.12 15.15 17.00 18.31

26�C 50% RH TOTAL 9.76 10.45 11.64 11.89 16.02 18.81 18.76 22.10SENS 8.74 9.00 11.04 11.13 14.46 15.54 17.43 18.71



22�C 50% RHTOTAL 8.02 9.06 9.84 --- 13.47 15.35 15.63 18.47SENS 8.02 8.46 9.84 --- 13.40 14.21 15.63 17.29

24�C 50% RH TOTAL 8.57 9.55 10.38 --- 14.23 16.56 16.47 19.70SENS 8.27 8.67 10.38 --- 13.76 14.70 16.47 17.80

26�C 50% RH TOTAL 9.08 10.04 10.88 --- 15.08 17.50 17.54 20.82SENS 8.48 8.85 10.75 --- 14.11 15.03 16.98 18.21

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CD3 CAPACITIES

CHILLED WATER PERFORMANCE DATA

MODEL 008 010 015 020AIRFLOW (max) m3/s 0.78 1.04 1.23 1.51

NOMINAL COOLING CAPACITIES CHILLED WATER 5�C - 10.5�C

22�C 50% RHTOTAL 8.75 12.40 16.81 22.06SENS 8.33 11.34 14.84 18.87

24�C 50% RH TOTAL 12.19 16.48 22.11 28.25SENS 9.77 13.03 17.05 21.43

26�C 50% RH TOTAL 15.57 20.57 27.45 34.62SENS 11.07 14.60 19.09 23.85

NOMINAL COOLING CAPACITIES CHILLED WATER 6�C - 11�C

22�C 50% RHTOTAL 8.19 11.49 15.59 20.37

SENS 8.09 10.95 14.31 18.12

24�C 50% RH TOTAL 11.56 15.51 20.82 26.48SENS 9.50 12.62 16.49 20.66

26�C 50% RH TOTAL 14.88 19.54 26.07 32.84SENS 10.78 14.16 18.50 23.08

NOMINAL COOLING CAPACITIES CHILLED WATER 7�C - 12.5�C

22�C 50% RHTOTAL 6.80 9.50 12.49 16.17

SENS 6.80 9.50 12.49 16.17

24�C 50% RH TOTAL 9.01 12.62 17.13 22.36SENS 8.45 11.42 14.94 18.90

26�C 50% RH TOTAL 12.54 16.83 22.60 28.75SENS 9.83 13.05 17.06 21.36

NOMINAL COOLING CAPACITIES CHILLED WATER 6�C - 11�C

22�C 50% RHTOTAL 5.07 7.48 9.86 13.03

SENS 5.07 7.48 9.86 13.03

24�C 50% RH TOTAL 6.95 9.61 12.64 16.28SENS 6.95 9.61 12.64 16.28

26�C 50% RH TOTAL 9.24 12.81 17.42 22.63SENS 8.55 11.48 15.00 18.91

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AIRFLOWS

CD3 MCU+ DCUE

ModelMin Max

ModelMin Max

ModelMin. speed Max. speed

m³/s m³/s CFM m³/s CFM m³/s CFM m³/s008 0.42 0.78 MCU+ 30 1720 0.81 DCUE 30 685 0.32 885 0.42010 0.67 1.04 MCU+ 50 1660 0.78 DCUE 50 885 0.42 1115 0.53015 0.72 1.23 MCU+ 60 1660 0.78 DCUE 60 885 0.42 1115 0.53020 0.92 1.51 MCU+ 80 1660 0.78 DCUE 80 740 0.34 1040 0.48

Note: Maximum externalresistance at maximum

speed = 75 Pa

MCU+ 90 2420 1.14MCU+ 100 2420 1.14MCU+ 130 3690 1.74MCU+ 165 3690 1.74MCU+ 180 3690 1.74MCU+ 200 3690 1.74

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-12-

SOUND PRESSURE LEVELS -- CD3 UNITSUPFLOW FAN SPEED 008 010 015 020Top Dischargeand FrontReturn

High NC 59 60 58 61dBA 66.5 67 65 68

Front Dischargewith Plenumand FrontReturn

HighNC 49 49 48 50

dBA 58.5 58.5 57 58Front Dischargeand FrontReturn

High NC 60 58 58 60dBA 67 65 65 67

DOWNFLOW

Standard High NC 44 45 45 48dBA 53 54 54 56

SOUND POWER and SOUND PRESSURE LEVELS 550 SERIES MCU+MAXIMUM SPEED SOUND POWER LEVELS SOUND PRESSURE

LEVELSFrequency HzMCU+ Compressor 125 250 500 1K 2K 4K dBA dBA NC

30 Rotary 68.8 66.4 65.9 64.6 60.6 56.7 68.6 48.1 4340 Rotary 68.5 67.3 66.2 65.1 59.1 53.0 68.6 48.1 4330 Recip 77.4 67.5 68.5 64.8 60.2 53.8 69.8 50.0 4440 Recip 77.3 67.4 68.6 64.7 60.1 53.9 69.8 49.3 4450 Scroll 73.6 68.2 67.1 65.5 61.1 54.3 69.7 49.2 4460 Scroll 72.9 67.7 67.8 66.4 61.9 54.1 70.3 49.8 4580 Scroll 70.9 68.6 68.1 65.3 59.5 53.8 69.7 49.2 4390 Scroll 81.8 71.8 69.2 68.6 63.1 57.4 72.8 52.3 47100 Scroll 79.4 73.7 71.5 68.5 63.8 58.1 73.4 52.9 47130 Scroll 73.0 70.3 70.0 68.8 65.0 56.7 72.6 52.1 47165 Scroll 73.1 70.3 70.1 68.9 65.5 57.5 73.1 57.2 51180 Scroll 72.5 71.9 71.7 68.9 66.0 58.2 75.5 59.2 53200 Scroll 73.0 71.8 71.5 70.1 66.1 58.3 75.7 61.8 55

MINIMUM SPEED SOUND POWER LEVELS SOUND PRESSURELEVELSFrequency Hz

MCU+ Compressor 125 250 500 1K 2K 4K dBA dBA NC30 Rotary 64.3 60.6 60.4 57.7 54.4 54.2 62.7 42.2 3640 Rotary 63.8 61.7 60.6 61.0 52.8 46.1 63.6 43.1 4030 Recip 65.6 61.3 65.0 58.5 53.3 47.6 64.5 43.7 4040 Recip 65.5 61.2 65.1 58.4 53.2 47.7 64.5 43.7 4050 Scroll 67.4 64.1 66.0 63.6 58.7 51.8 67.7 47.2 4260 Scroll 67.4 64.3 67.1 66.8 60.7 51.7 69.7 49.2 4580 Scroll 69.4 66.5 66.9 62.1 56.1 51.6 67.5 47.0 4190 Scroll 79.0 65.4 64.9 61.5 58.5 53.7 67.6 47.1 40100 Scroll 75.3 69.4 70.9 63.7 59.7 53.6 70.4 49.9 46130 Scroll 65.4 66.7 68.1 66.1 63.1 53.0 70.0 49.5 44165 Scroll 65.5 66.9 67.3 65.1 64.2 54.0 72.6 52.6 47180 Scroll 65.7 35.9 67.1 61.3 65.3 55.1 73.2 53.7 49200 Scroll 66.5 66.1 67.9 66.7 66.0 57.2 75.6 55.6 51

Sound Power Levels were obtained in full accordance with the direct method of ISO 3741: 1988. Quantities are shown indB 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 andare 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).

DUCTED CONDENSING UNITSMeasurementPoint

UnitSize

FanSpeed dBA NC

3m fromunit in void

DCUE 30 Max 52 46Min 35 28

DCUE 50, 60, 80 Max 54 48Min 44 31

Officearea

DCUE 30 Max 37 26Min 30 15

DCUE 50, 60, 80 Max 42 28Min 32 17

3m fromdischarge grille

DCUE 30 Max 52 46Min 34 27

DCUE 50, 60, 80 Max 52 44Min 40 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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-13-

CD3 AIRFLOW OPTIONS

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-14-

CD3 SERIES AIR HANDLING UNIT INSTALLATIONAn envelope containing important user information is supplied with the indoor unit. Please pass this to the end user.

1 The standard unit is supplied configured for the correct airflow as ordered by the customer.

2 The central panel, with control panel inset, MUST be removed first using the two keys provided.

UNIT ACCESS AND CABINET STRIP DOWN

1 If a door interlock isolator is fitted, ensure that the switch is turned to the OFF position.

2 Using the keys provided, unlock the electrics access panel. Remove the panel by easing outwards and down.

3 The side panels can be removed by releasing the two swell latches located through the side bulkheads withinthe electrics compartment and carefully pulling outwards until they are clear of the upper and lower grabbercatches.

4 Access to the fan section, (and coil section in the downflow mode), can be gained by releasing the appropriateswell latches located through the cutouts to the front of the side bulkheads and removing the panel.

5 The return air grille can be removed by turning the 4 retaining screws anticlockwise until a click is heard andpulling the grille outwards.

MOUNTING

1 It is recommended that ALL field fit kits are installed prior to mounting the unit and brazing the pipework.

2 Ensure that the wall or floor will accept the operating weight of the unit;the weights shown below include theplenum.

Model 08 10 15 20Weight (kg) 144 165 165 187

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 DIMENSION 'A' DIMENSION 'B'008 1230 -

010 / 015 1380 690020 1580 790

-15-

DOWNFLOW SERVICE AND FIXING HOLE CENTRES

UNIT DIMENSION 'A' DIMENSION 'B'08 1230 --

10/15 1380 69020 1580 790

4 If a fresh air facility is required, apertures must be prepared as shown above/opposite. This must be suitably linedand screened on the internal wall to prevent brick dust entering the unit.

5 Mount the unit and secure the fixings.

6 Check that the unit is square and level, (failure to do so will result in misalignment of the cabinet panels).

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-16-

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 MCU+ 30 - 80 MCU+ 90 - 100 MCU+ 130 - 200Mounting Bracket Kit 55000844 55000845 55000846

Whether floor or wall mounted, it is essential that the mounting surface is capable of supporting the unit weight. Leavespace around the unit for air circulation and access for installation and maintenance.

MOUNTING: MCU+ 15 - 100

Dimensions in mm.

MODEL A B C D E F G H Weight (kg)1 Ph 3 Ph

MCU+ 30 904 304 560 290 185 527 260 60 46 (41*) 48MCU+ 40 904 304 560 290 185 527 260 60 53 (45*) 53MCU+ 50 1004 304 660 290 213 571 260 60 64 62MCU+ 60 1004 304 660 290 213 571 260 60 65 63MCU+ 80 1004 304 660 290 213 571 260 60 66 64MCU+ 90 1004 354 760 340 250 497 310 70 76 73MCU+ 100 1004 354 760 340 250 497 310 70 - 81

* Obsolete R407C Models and R22 models fitted with a rotary compressor

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-17-

MOUNTING: MCU+ 130 - 200

Dimensions in mm.

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

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-18-

INSTALLING 542 SERIES DUCTED CONDENSING UNITS

MOUNTING

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

DIMENSIONS

Model A B C D E F G H J K Spigot dia. Weight (kg)DCUE 30 930 510 495 1004 490 65 65 210 317 717 354 70DCUE 50 1100 510 560 1174 490 65 65 240 392 865 404 81DCUE 60 1100 510 560 1174 490 65 65 240 392 865 404 81DCUE 80 1100 510 560 1174 490 65 65 240 392 865 404 84

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

Dimensions in mm.

Model A B30 930 510

50 to 80 1100 510

Andy

Andy

Andy

Andy

Andy

Andy

-19-

SUSPENSION MOUNTINGThe 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 screwsprovided, (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 toabsorb any movement of the unit.

Using the template printed on the side of thepacking carton, (centres marked A), mark outthe ceiling and drill 4 holes to suit M8 screwedrod. Raise the unit to the required height andpass the screwed rods through the mountingholes in the units feet and stabilizing brackets.Secure the unit with a nut and washer on eitherside of each stabilizing bracket and two nuts andwashers underneath each foot mounting hole,(as shown).

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

DUCTWORKEach 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 toaccept installer supplied square ducting, see dimensions below. Maximum flange width is 25mm and fixing holes shouldbe central within them.

NOTE:It is essential that ducting is adequately insulated to prevent sweating. An insulation thickness of at least 45mmis recommended.

Dimensionsmm.

Model30 to 40 50 to 80

A 400 450B 300 350C 100 100

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-20-

APPLICATION1 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 refrigerationpractice is followed.Published performance duties are based on 7.5m pipe runs. Correctly sized pipes for each installation will result inno 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 thecompressor. 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 containmineral oil) for every 350 grams of charge added to systems with pipe runs exceeding 25m, up to a maximum of 300grams; preferably by slowly pumping into the suction side with the unit running, after charging the system.

3 For systems with capillary control at the indoor unit; the table below shows the suggested pipe sizes (in inches).

Equivalentlength of run

Suction Line Size Liquid Line SizeHorizontal or Downflow Upflow

0 - 7.5m 7.5 - 15m 15 - 21m 21 - 45m Up to 15m 0 - 21m 21 - 45mUNITMCU+ 30* 1/2 5/8 5/8 5/8 1/2 1/4 3/8MCU+ 40* 1/2 5/8 5/8 3/4 1/2 3/8 3/8MCU+ 50 1/2 5/8 3/4 3/4 5/8 3/8 1/2MCU+ 60 5/8 3/4 3/4 7/8 5/8 3/8 1/2MCU+ 80 5/8 3/4 3/4 7/8 5/8 3/8 1/2MCU+ 90 5/8 3/4 3/4 7/8 5/8 3/8 1/2MCU+ 100 3/4 7/8 7/8 1 1/8 3/4 1/2 5/8MCU+ 130 3/4 7/8 7/8 1 1/8 3/4 1/2 5/8MCU+ 165 3/4 7/8 7/8 1 1/8 3/4 1/2 5/8MCU+ 180 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1/2 5/8MCU+ 200 7/8 1 1/8 1 1/8 1 3/8 1 1/8 1/2 5/8

* Units with 1 Phase rotary compressors should not be used on pipe runs exceeding 20m.

4 In calculating equivalent lengths of pipe runs, the effect of bends and fittings must be taken into account. The tablebelow covers the fittings most likely to be encountered in this type of installation. The equivalent lengths of all thefittings in a particular pipe run must be added together and the total added to the actual length of pipe in the run, inorder to calculate the total equivalent length.

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

Pipe Size (outside diameter in inches)Fitting 3/8 1/2 5/8 3/4 7/8 1-1/845� Bend 0.12 0.15 0.18 0.21 0.24 0.390� Bend R/d = 1 0.37 0.43 0.49 0.55 0.61 0.7990� Bend R/d = 1.5 0.24 0.27 0.30 0.37 0.43 0.52180� Bend C/d = 1.5 0.73 0.91 1.10 1.28 1.46 1.83180� Bend C/d = 2.5 0.46 0.55 0.64 0.76 0.85 1.0790� Elbow 0.67 0.85 1.04 1.25 1.46 1.89

R = Radius of bend d = Diameter of tube C = Centres of bend

5 Use the shortest possible route, avoiding sharp bends.

6 Fully insulate the suction line, (or suction and liquid line if run together, or separately if the system is a heat pump).

CHILLED WATER UNITS008 and 010 units are supplied with 22mm dia. copper water pipe, 015 and 020 units are supplied with 28mm dia. copperwater pipe.

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-21-

REFRIGERATION INSTALLATION

1 Units are supplied with the following pipes (in inches):-

Model 08S 08T 10S 10T 15S 15T 20S 20TLiquid 3/8 3/8 3/8 3/8 1/2 3/8 1/2 3/8Suction 3/4 1/2 3/4 1/2 7/8 5/8 7/8 5/8

NOTE: On two stage units, the lower half of the coil is the first stage.

2 Using a tube cutter, remove sealed ends of suction and liquid pipes. This will release a small holding charge ofnitrogen. Discard the expansion device on the condensing unit.

3 Pipe exit positions are shown on pages 14 and 15. It is recommended that the liquid and suction lines be kept at thesupplied size until exit, when the full pipe size can be run.

4 Connect pipework between units noting the following:-

a) Use only refrigeration quality copper tube/pipe, supported every 2 metres.

b) Use tube cutters to avoid forming swarf.

c) If brazing, use copper phosphorus alloy with 5% silver, and purge the system with dry nitrogen to avoid oxidationand build up of scale.

d) Do not leave pipe ends, valves, driers etc. open to the atmosphere longer than necessary.

e) Fully insulate the suction line, or suction and liquid if run together.

5 A strainer is fitted in the liquid line just prior to the capillary on the air handler. It is recommended that a liquid linefilter drier is fitted.

6 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.

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ELECTRICAL CONNECTIONSThe 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 WIRINGThe 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 thecoil section. The wires are then routed through an access hole in the bottom left hand side of the electrics compartmentto 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 andany 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 CONNECTIONOn single or three phase units, wire the mains supply to the indoor unit and then link to the outdoor/ducted unit via athree pole circuit breaker

DATA PLATESBecause of the ability to mix-match indoor and outdoor units, the data plates only give information on an indoor unit withmaximum 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 startup; the compressor will not develop a normal running pressure differential and the top will not become warm. It may beexcessively 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.

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-22-

ELECTRICAL DATA

R22 SYSTEMS1 Ph 230V 50Hz 3 Ph 400V 50Hz

SystemModel

Combination

Full Load Amps SystemMax.

StartingCurrent


StartingCurrentCooling

OnlyCool &Heat*

Cool/Heat/Hum/Dehum

CoolingOnly

Cool &Heat**

Cool/Heat/Hum/Dehum

Amps Amps Amps Amps A/PH A/PH A/PH A/PH

HS 08 CD08 + MCU+/DCUE 80 16.4 38.7 -- 82.0 9.9 22.1 38.1 63.1S 08 S CD08 + MCU+ 100 -- -- -- -- 12.5 22.1 38.1 74.1

HS 08 T CD08 + 2 x MCU+/DCUE 30 17.8 38.7 -- 44.5 12.6 22.1 38.1 44.6S 08 T CD08 + 2 x MCU+/DCUE 50 22.4 38.7 -- 72.5 13.4 22.1 38.1 52.7

HS 10 CD10 + MCU+ 100 -- -- -- -- 14.5 25.0 32.1 84.4S 10 S CD10 + MCU+ 130 -- -- -- -- 15.0 25.0 32.6 95.6


HS 15 CD15 + MCU+ 165 -- -- -- -- 18.5 33.3 39.8 114.5S 15 S CD15 +MCU+ 180 -- -- -- -- 20.6 33.3 44.9 115.3

HS 15 T CD15 + 2 x MCU+/DCUE 80 31.0 41.3 -- 96.6 18.0 33.3 42.3 87.4S 15 T CD15 +2 x MCU+ 100 -- -- -- -- 23.2 33.3 47.3 101.6

HS 20 CD20 + MCU+ 180 -- -- -- -- 21.0 33.3 47.1 115.7S 20 S CD20 + MCU+ 200 -- -- -- -- 24.0 33.3 47.9 161.7

HS 20 T CD20 + 2 x MCU+ 90 41.8 41.8 -- 140.6 23.4 33.3 47.3 99.1S 20 T CD20 + 2 x MCU+ 130 -- -- -- -- 24.6 33.3 48.5 113.9

NOTE 1:- *Single phase models are available for twin circuit direct expansion and chilled water systems wherethe 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 = 14kWCD 15 = 16kW CD 20 = 20kW

R407C SYSTEMS1 Ph 230V 50Hz 3 Ph 400V 50Hz

SystemModel

Combination


StartingCurrent


StartingCurrentCooling

OnlyCool &Heat*

Cool/Heat/Hum/Dehum

CoolingOnly

Cool &Heat**

Cool/Heat/Hum/Dehum

Amps Amps Amps Amps A/PH A/PH A/PH A/PH

HS 08 CD08 + MCU+/DCUE 80 18.9 38.7 -- 82.0 10.3 22.1 38.1 63.1S 08 S CD08 + MCU+ 100 -- -- -- -- 12.6 22.1 38.1 74.1


HS 10 CD10 + MCU+ 100 -- -- -- -- 14.6 25.0 32.2 84.4S 10 S CD10 + MCU+ 130 -- -- -- -- 15.3 25.0 32.9 95.6


HS 15 CD15 + MCU+ 165 -- -- -- -- 18.7 33.3 43.0 114.5S 15 S CD15 +MCU+ 180 -- -- -- -- 20.9 33.3 45.2 115.3

HS 15 T CD15 + 2 x MCU+/DCUE 80 32.0 41.3 -- 97.1 18.8 33.3 43.1 87.4S 15 T CD15 +2 x MCU+ 100 -- -- -- -- 23.4 33.3 47.7 101.6

HS 20 CD20 + MCU+ 180 -- -- -- -- 21.3 33.3 45.2 115.7S 20 S CD20 + MCU+ 200 -- -- -- -- 24.4 33.3 48.3 161.7

HS 20 T CD20 + 2 x MCU+ 90 43.2 43.2 -- 141.3 23.6 33.3 47.5 99.1S 20 T CD20 + 2 x MCU+ 130 -- -- -- -- 25.2 33.3 49.1 113.9

NOTE 1:- *Single phase models are available for twin circuit direct expansion and chilled water systems where theelectric 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 = 14kWCD 15 = 16kW CD 20 = 20kW

-23-

CHILLED WATER AIR HANDLERS

1 Ph 230V 50Hz 3 Ph 400V 50Hz

AirHandler

Full Load Amps Full Load AmpsCooling

OnlyCooling

OnlyCool &Heat

Cool/Heat/Hum/Dehum

Amps A/PH A/PH A/PHCW 08 5.4 5.4 22.1 38.1CW 10 7.4 7.4 25.0 25.0CW 15 9.0 9.0 33.3 33.3CW 20 9.4 9.4 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 10 = 14kWCW 15 = 16kW CW 20 = 20kW

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CURRENT RATINGS

CD3 HEATING (1 PHASE)CURRENTRATING(Amps)

UNIT SIZE008 010 015 020

HEATING 1 STAGE 2 STAGE 1 STAGE 2 STAGE 1 STAGE 2 STAGE 1 STAGE 2 STAGE2kW 8.3 O O O O O O O O4kW 16.7 O O O O O O O O6kW 25.0 O O O O8kW 33.3 O O O O

CD3 HEATING (3 PHASE)CURRENT RATING

AMPS/PHASEUNIT SIZE

008 010 015 020HEATING L1 L2 L3 1 2 1 2 1 2 1 2

2kW 8.3 --- --- O O O O4kW 8.3 8.3 --- O O O O O O O O6kW 8.3 8.3 8.3 O O O O O O O O8kW 16.7 8.3 8.3 O O O O O O O O

10kW 16.7 16.7 8.3 O O O O O O O O12kW 16.7 16.7 16.7 O O O O14kW 25.0 16.7 16.7 O O O16kW 25.0 25.0 16.7 O O18kW 25.0 25.0 25.0 O20kW 33.3 25.0 25.0 O

O = HEATING OPTIONS

CD3 FANSUNIT SIZE

008 010 015 020RUNNING CURRENT 4.4A 6.4A 8.0A 8.4ANUMBER OF FANS 1 2 2 2POWER RATING 550W 370W 330W 550WCONTROL CIRCUIT 2AHUMIDIFIER 16A

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-24-

FUSESThe system and its supply/interconnecting wiring must be protected by fuses, preferably H.R.C. motor rated types toEN60269 or miniature circuit breakers to EN60898 or local codes having similar time lag characteristics that allowstarting of the compressor yet still afford close overcurrent protection under running conditions. The ratings below arefor H.R.C. motor rated or semi-enclosed wire fuses.

STANDARD COOLING (R22 and R407C models)

System S 08 S S 08 T S 10 S S 10 T S 15 S S 15 T S 20 S S 20 T1 Phase Cool Only -- 32 -- 40 -- -- -- --1 Phase Cool and Heat -- 50 -- 50 -- -- -- --3 Phase Cool Only 20 20 25 25 32 32 35 403 Phase Cool and Heat 32 32 40 40 50 50 50 503 Phase Cool/Heat/Hum/Dehum 50 50 50 50 63 63 63 63

HIGH SENSIBLE COOLING (R22 and R407C models)

System HS 08 S HS 08 T HS 10 S HS 10 T HS 15 S HS 15 T HS 20 S HS 20 T1 Phase Cool Only 25 25 -- 32 -- 40 -- 631 Phase Cool and Heat 50 50 -- 63 -- 63 -- 633 Phase Cool Only 16 20 20 25 30 30 32 403 Phase Cool and Heat 32 32 40 40 50 50 50 503 Phase Cool/Heat/Hum/Dehum 50 50 50 50 63 63 63 63

CHILLED WATER AIR HANDLERS

Air Handler CW 08 CW 10 CW 15 CW 201 Phase 10 16 16 163 Phase 10 16 16 16

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EVACUATING AND CHARGING

When the compressor is first started in the field, the bearing surfaces are susceptible to damage if not properlylubricated. 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 bothsuction 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(+)R22 charge R407C charge

DCUER22 charge R407C charge

gms gms gms gms30 950 1000 30 930 99040 1180 1240 50 1250 124050 1610 1690 60 1140 119060 1900 2000 80 1400 148080 1800 188090 1960 2060100 2400 2520130 3970 4170165 4320 4540180 4420 4640200 5220 5480

-25-

ADDING REFRIGERANTAdditional 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. 1/4 3/8 1/2 5/8Additional R22/R407C (g/m). 7 16 30 48Additional oil. 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 compressorto 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, (withthe system running in cooling). Refrigerant enters the coil at the bottom left hand side and leaves at the top left hand side. Aproperly charged unit should show signs of 'sweating' all the way up the coil. 'Sweating' should be reduced at the coil outlet as itenters the suction line, which should be completely dry a few inches before it enters the compressor.

4 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 DRAINThe 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 witha 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 thebackpanel 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 andthat there are no leaks.

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

WHEN INSTALLATION HAS BEEN COMPLETED - CHECK :-1 All pipe work and joints for leakage.

2 All pipe work and fittings for insulation.

3 All bolts are secure and that fan rotates freely.

4 If a manual low pressure cutout is fitted, that the reset button is depressed before switching on.

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

-26-

POWER WIRING DIAGRAM

-27-

CD3 008 to 020 COOL ONLY, CONTROL WIRING DIAGRAM

-28-

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

-29-

ELECTRONIC DCUE WIRING DIAGRAMS

1 Phase DCUE 30 - 60

1 Phase DCUE 80

3 Phase DCUE 30 to 80

-30-

CD3 008 to 020 WITH MCU+ - INTERCONNECTING WIRING DIAGRAMSCD3/1 008 and 1 Phase MCU+ 80

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

CD3/1 008 - 010 and 3 Phase MCU+ 100 CD3/1 010 - 020 and 3 Phase MCU+ 130 - 200CD3/2 008 - 020 and 3 Phase MCU+ 30 - 100 CD3/2 020 and 3 Phase MCU+ 130

-31-

CD3 008 to 020 + DCUE, INTERCONNECTING WIRING DIAGRAMS

THREE PHASE

SINGLE PHASE

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ELECTROMECHANICAL CONTROLThe 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.

2 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.

3 Membrane keypad - provides external control for the user and is connected to the controller via the 11 way membrane keypad tail.

4 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.

Fig. 2. Electromechanical control

-33-

CD3-SERIES ELECTROMECHANICAL OPERATING INSTRUCTIONS

MEMBRANE KEYPAD, (ELECTROMECHANICAL)

KEYPAD SYMBOL FUNCTION OPERATION

OFF (STAND-BY) Press to stop the unit and put into stand-by mode.

ON Press to start unit.

LOW FAN Press to select low fan speed.

HIGH FAN Press to select high fan speed.

MUTE Press to mute alarm sounder, (if alarm interfacefitted).

HEAT When lit indicates heating operation.

COOL When lit indicates cooling operation.

HUMIDIFY When lit indicates humidifier operating, (if humidifier is fitted).

DEHUMIDIFY When lit indicates dehumidification, (if humidifier is fitted).

MODULATED When lit indicates operation of modulating HEATING heating valve, (electronic models only).

Brightness of symbol shows status of valve,i.e. Dim = Valve just beginning to open. Bright = Valve fully open.

MODULATED When lit indicates operation of modulating COOLING cooling valve, (electronic models only).

Brightness of symbol shows status of valvei.e. Dim = Valve just beginning to open. Bright = Valve fully open.

FILTER CLOG When lit indicates blocked or dirty filter, (if pressure switch is fitted).

CYLINDER When lit indicates humidifier bottle requires changing,CHANGE (if humidifier fitted).

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ELECTROMECHANICAL CONTROL

SETTING THE THERMOSTAT

The control thermostat is located in the electrics panel. The type used depends upon the control requirements. Unitsare 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, thecircuit across terminals 4 and 5 is broken and across 5and 6 is made (switching B). With a decrease of humiditybelow the switching differential Xsh, the circuit acrossterminals 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 setpoint 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.

RECALIBRATIONIn case of deviations of the measured humidity from theset point, a recalibration by means of the nut (S) isrecommended:

If the actual value is higher than the set point, turnnut (S) anticlockwise.If the actual value is lower than the set point, turn nut(S) clockwise.

Set point 20% 40% 60% 70% 80%1/6 turn = 15% 15% 11% 8% 5%

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

-35-

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) asshown 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 speedpotentiometer clockwise. This adjustment will give between approximately 50% to 100% of the selected top speed.

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

-36-

ELECTRONIC CONTROLThe 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 thelow voltage supplies to dc power and relay coils and the main control board.

2 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 pointvalues of temperature, indication of output relay functions and the controller status.

3 Membrane keypad - provides external control for the user and is connected to the controller via the 11 way membrane keypad tail.

4 20 way ribbon cable - connected to the power board.

5 26 way ribbon cable - connected to the hum board.

6 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

-37-

CD3-SERIES OPERATING INSTRUCTIONS

MEMBRANE KEYPAD, (ELECTRONIC)

KEYPAD SYMBOL FUNCTION OPERATION

OFF (STAND-BY) Press to stop the unit and put into stand-by mode.

ON Press to start unit.

LOW FAN Press to select low fan speed.

HIGH FAN Press to select high fan speed.

INTERROGATE Press to display actual room temperature and humidity, (electronic models only).(Defaults to set point display).

MUTE Press to mute alarm sounder, (if alarm interfacefitted).

HEAT When lit indicates heating operation.

COOL When lit indicates cooling operation.

HUMIDIFY When lit indicates humidifier operating, (if humidifier is fitted).

DEHUMIDIFY When lit indicates dehumidification, (if humidifier is fitted).

MODULATED When lit indicates operation of modulating HEATING heating valve, (electronic models only).

Brightness of symbol shows status of valve,i.e. Dim = Valve just beginning to open. Bright = Valve fully open.

MODULATED When lit indicates operation of modulating COOLING cooling valve, (electronic models only).

Brightness of symbol shows status of valvei.e. Dim = Valve just beginning to open. Bright = Valve fully open.

FILTER CLOG When lit indicates blocked or dirty filter, (if pressure switch is fitted).

CYLINDER When lit indicates humidifier bottle requires changing,CHANGE (if humidifier fitted).

-38-

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, denotedRV3 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 SpeedControl 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 humidityusing LK5 as described above. The relative humidity set point is altered by rotating the potentiometer, denoted RV5HUM/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 andactual relative humidity using the links on LK5. When positioned horizontally as shown in figure 2a, set point valuesare 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 therear of the controller.

SET POINT� 0.5 to 3�C � X � X � 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 alarminterface board. Reference should be made to sections L and M to set these. Increasing the differential between thestages 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 tothe 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 isvariable up to 9%. It should be set to the required levelby means of the differential potentiometer on the PCB, see fig.3. Do not adjust the upper potentiometers, (which arefactory set and sealed), otherwise calibration will be lost.

Note:- Increasing the differential between stages alsoincreases the 'dead band' between hum anddehum, and consequently reduces the mean roomRH.

Humidity is factory calibrated and field recalibration is notrecommended. Adjustment of the humidity display for exampleif the room condition is offset to that of the sensor, is m a d eusing the 'display cal' potentiometer on the humidity cont ro lboard.

Fig. 3.

-39-

E. POWER UP STATUS (ELECTROMECHANICAL AND ELECTRONIC)

The unit is biased to it's 'ON' state when power is switched on. It can be biasedto it's 'OFF' state by fitting a link to LK1 as shown in figure 4. On power up itis also biased to 'high fan'. Again it may be biased to 'low fan' by connectinga 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 byconnecting a link to LK3. Similarly, when in heat mode the heat indicator (LED7) on the controller lights. This may bedisabled by connecting a link to LK4. These links are only required when modulating valves are fitted. To fit these linksit 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, (allconnections are fully polarised and latching), see Figure 1 for positions.

1 An 11 way connection from the membrane keypad.

2 A 2 way connection from the temperature sensor, (not electromechanical versions).

3 A 20 way ribbon cable from the power board, (16 way ribbon cable on electromechanical versions).

4 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. Thesocket connected to the ribbon cable is then inserted so that the side arms close and 'click' in position to hold thesocket 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, especiallyof 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 switchwill operate and the 'fan fail' warning indicator (digit 3) will flash. The sounder will operate (if enabled) and the unit willshut down after approximately 12 seconds.

NOTE:- ISOLATE THE UNIT PRIOR TO STARTING THE TEST.

Test by:-

1 Disable the fan by removing the live feed, L1, from the fan speed controller, PCB 3, leaving one fan running iftwo are fitted.

2 Switch on the unit and select low fan. After approximately 12 seconds the fan fail indication should be displayedand 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 ata 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 positionto ensure that correct pressures are achieved before testing.

-40-

1 Ensure that cabinet access panels are in position.2 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 goesoff.

3 Block off the return air grille, (by 75%, from the right), with a piece of cardboard or similar - the filter clog indicatorshould illuminate. If the indicator does not light up, lower the set point pressure by making a small adjustmentto 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 High water condition in the drip tray.

2 Water spill condition.

3 Fan failure.

4 Compressor 1. trip.

5 Compressor 2. trip.

6 Humidity out of limits.

7 Temperature out of limits.

Alarm 7 is standard and requires no further equipment for itsoperation. The remaining alarms require kits to be installed andinterfaced to the alarm interface via the connections shown in therelevant kit wiring diagram.

Alarms 1, 2 and 3 will cause the unit to shut down, 1 will operateimmediately, 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 contactsto 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 theinterstage differentials as described in sections A, B and C. The links on LK5 are now positioned vertically to displaythe 'actual' values of temperature and relative humidity. The push-button, SW2, on the alarm interface is pressed andheld to replace the actual sensors by two dummy sensors whose values can be altered by rotating the potentiometerdenoted '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, (whileholding SW2 in). The alarm set H3/C3 pot on the controller is now rotated until the alarm LED on the power boardlights (see figure 5).

-41-

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 connectedto the membrane keypad via the 4 way tail. This board gives visual and audio indication of an alarm condition via adigital read-out and sounder respectively. The indication of a specific alarm is given by a digital read-out between 1and 7 inclusively :-

DIGITAL READ-OUT ALARM1 High water2 Water spill3 Fan failure4 Compressor 1 trip5 Compressor 2 trip6 Humidity out of limits7 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 buttonon 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 relaycontacts on the volt free relay board.

Depending upon the function that is required, equipment may be either connected into the normally closed or normallyopen 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 theoutputs 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 oneoutput.If used as a control status board to differentiate between high and low fan, then it is recommended that this relay issupplied 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. Thishas the same input requirements as described above and connections are shown in the wiring diagram in the optionalkit. This board is also used for high water shut down which lights an LED on the condensate pump control board. ThisLED 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-outof Temperature and Humidity, (actual or set point). All other symbols are secret until lit.

-42-

R. CD3 SYSTEM HUMIDIFIER

DESCRIPTION

The CD3 system OEM humidifier is an electrode boiler-type steam generator with electronically controlled vapouroutput, and water filling and draining sequences. The disposable, injection-moulded polypropylene cylindercontaining the electrodes is designed to be replaced periodically, as the accumulation of salts on the electrodeseventually 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 ofwater qualities, covering most types of piped water supplies. The humidifier is not suitable for connection to fullyde-mineralised water supplies. The Nordmann system OEM incorporates an air break in the water feed as requiredby some local regulations. Direct connection may be made to water supplies operating at pressures between 0.1 and1 MPa (14 to 145 psig). Connection to supplies at higher pressures must be through a pressure regulator set at 0.4to 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 fittedin 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 drainconnection should be made in the normal condensate drain position. The drain pipe should be run in piping suitablefor 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 airbreak 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 thendraining 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 electricsbox 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 thecontrol unit to the positions shown above.

Ensure that the rubber hose is securely connected at both the steam distribution pipe and cylinder ends.

-43-

START UP

On first switching the humidifier on, with an empty steam cylinder, the feed valve will open and the drain valve willremain closed. Water will flow into the cylinder until it reaches the level sensing electrode, when the feed valvecloses.

Initially, the electrode current will be well below the normal operating level; however, this small current will cause thewater 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 oncemore immersed, whereupon it will close again. This process of repeatedly boiling water away and topping up withfeed 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 waterentering the cylinder contains dissolved minerals, whereas the water leaving the cylinder as steam carries nominerals away with it. Consequently, the concentration of dissolved minerals in the water, and it's electricalconductivity, steadily increases. The electrode current will also rise steadily and will eventually reach the operatingvalue to give the required steam output.

This process is entirely automatic and may take from a few minutes to several hours, depending on the mineralcontent of the feed water. If this is low (very pure water) start up will be slow, whereas if it is high (less pure or hardwater) 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 theset output, the 'change cylinder' lamp will not light again until the cylinder life is finished or some other fault hasdeveloped 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 waterhas 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 orrefilled 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 thedesired level by controlled draining of mineral rich water and dilution with fresh feed water, the operation of the drainand 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 substantiallyconstant 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 contentof the feed water is low.

During the life of the steam cylinder, electrodes gradually become encrusted with scale and their conductivity to thewater will reduce. The system compensates for this by allowing the conductivity of the cylinder water to rise, so that the electrodecurrent always stays at the preset value. As this progresses, the drain periods (of constant water volume) each carry away more minerals and so fewer areneeded. 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 longercompensate 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.

-44-

MAINTENANCE

Prior to carrying out maintenance on the humidifier system, the cylinder should be drained, by operating the manualswitch, 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 smallleft hand side door on downflow models. The humidifier control unit is situated either inside the full length controlpanel, 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 manualdrain 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: thisshould 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 andelectrical 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 orreplaced 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 iscorrect.

REPLACEMENT STEAM CYLINDERS

These can be obtained from IMI by quoting the following part numbers.

Steam output kg/h 4Nordmann ref TYPE 1422IMI Part Number 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--

-45-

CD 3 EXPLODED DIAGRAM (DISCHARGE SPIGOT NOT SHOWN)

1 Coil (DX or chilled water) 16 Blower assembly 31 Membrane key pad2 Drain tray 17 Fresh air fan 32 Humidifier bottle3 Access panel 18 Filter 33 Terminal4 Terminal 19 Transformer 34 Panel surround5 Contactor 20 Discharge grille 35 Electrics access6 Circuit breaker 21 Alarm interface 36 Washable filter7 Condensate pump 22 Relay 37 Return air grille8 De-ice thermostat 23 6 stage control 38 Humidity sensor9 Expansion valve 24 Fan speed control 39 Isolator

10 Heater element (2kW) 25 Humidity control pcb 40 Temperature sensor11 Side panel assembly 26 Pressure switch 41 Vice latch12 Swell latch 27 Grabber 42 Volt free pcb13 End stop 28 Alarm indicator 43 Float switch14 Terminal 29 Touch control 44 High water level assembly15 Heater cutout 30 Humidifier assembly 45 Relay

-46-

MCU+ 30 - 100 COMPONENT IDENTIFICATION

1 Lid 14 Service valve (Liquid) 27 Motor bracket2 LP switch 15 Valve panel 28 End clamp3 Contactor 16 Base 29 Terminal (screw - screw)4 Overload 17 Mounting foot 30 Fuse5 Heat exchanger 18 Compressor 31 Fuse terminal6 Rear access panel 19 Handle 32 Terminal (4 way)7 Mains terminal cover 20 Front access panel 33 Earth terminal8 HP switch manual 21 Fan guard 34 Head pressure control9 Fan capacitor 22 Fascia panel 35 3 minute timer pcb

10 Switch bracket 23 Corner panel 36 Compressor capacitor11 Bulkhead panel 24 Support bracket 37 Electrics box12 Expansion assembly (inc. restrictor) 25 Motor13 Service valve (Suction) 26 Fan

-47-

MCU+ 130 - 200 COMPONENT IDENTIFICATION

1 Lid 14 Switch bracket 27 Fan guard2 Fuse terminal 15 LP switch 28 Fascia panel3 Fuse 16 Switch bracket 29 Support bracket4 Terminal (screw - screw) 17 Bulkhead panel 30 Fan5 Terminal (4 way) 18 Expansion assembly (inc. restrictor) 31 Corner panel6 Contactor 19 Service valve (Suction) 32 Motor7 Terminal (screw - screw) 20 Service valve (Liquid) 33 Motor bracket8 Earth terminal 21 Valve panel 34 Head pressure control9 Overload 22 Base 35 3 minute timer pcba

10 Heat exchanger 23 Mounting foot 36 Electrics box11 Rear electrics panel 24 Compressor12 Fan capacitor 25 Handle13 HP switch manual 26 Front access panel

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DCUE COMPONENT IDENTIFICATION

1 Lid 13 Electrics access panel2 Blower assembly 14 Handle3 Right hand access panel 15 Suction service valve4 Spire clip 16 Isolator5 LP Switch auto 17 End clamp6 HP Switch auto 18 Terminal7 4 way terminal 19 Power board pcba8 Fused terminal 20 Overload (3PH)9 Compressor 21 Contactor

10 Crankcase heater 22 Fan capacitor11 Expansion assembly (including restrictor) 23 Compressor capacitor (1PH)12 Liquid service valve

Documents

IMI CD3 MCU Tech Manual.pdf