Marstair 929, CD3 Technical Manual

TECHNICAL MANUAL L

CD3 (929 SERIES) PACKAGED DX CLOSE CONTROL UNITS.

FOR USE IN SPLIT SYSTEMS

This manual details technical, installation and operating information for the CD3 range (929 series)

DX indoor units for use in conjunction with 550 series CKC condensing units or 542 series DCU ducted condensing units. Remove the expansion device from the outdoor condensing unit if the

CD3 unit has capillaries or expansion valves fitted.

INDEX L

GENERAL General description and part numbers 3

- DX upflow package units 3

- DX configured units 4

- Condensing units 4

- DX configurable accessories 5 Dimensions and weights 6

SELECTION Unit combinations 7

Performance data DX 7 Airflows 8

INSTALLATION Airflow options 9

APPLICATION Pipe sizing and application 16

Fuses 19 Fan speed controller 20

WIRING CD3 21

DIAGRAMS CKC 24

DCU 25

ACCESSORIES Condensate pump 27 Humidifier 27 Auto change over 28

OPERATION pCONet Parameters 29 and Microprocessor control 33 COMMISSIONING

COMPONENT Exploded views of units with 42 IDENTIFICATION component identification

Sound levels - CD3 units, outdoor/ducted units 8

Indoor unit 10 CKC 80 - 200 13 DCU 30 - 80 14

Refrigeration installation 17 Evacuating, factory charge 17 Adding refrigerant 17 Electrical data 18

Condensate drain 20

Interconnecting wiring diagrams 26

2

92908135-17

MODEL CD3

008

010

015

020

Twin Circuit upflow

92918001

92918002

92918003

92918004

Condensate pump, including high water level indication.

(hot or cold, 5m lift)

ALL

92919077

Floor stand plinth 75mm high 008

92911032

010, 015

92911033

020

92911034

Fresh air spigot 100mm dia.

ALL

92911062

Double deflection grille 008

92911094

Fresh air spigot 160mm dia.

ALL

92911063

010, 015

92911095

Fresh air fan and filter 93m

3

/h

ALL

92911003

020

92911096

Fresh air fan and filter 186m

3

/h

ALL

92911004

Disposable filter

(replaces washable filter) 008

92911038

Top ducted discharge spigot 008

92911059

010, 015

92911039

010, 015

92911060

020

92911040

020

92911061

Sound attenuation section 008

92911075

Master/slave, run/standby, duty assist and unit sequencing

are available using a pLAN network

010, 015

92911076

020

92911077

Changeover on alarm

ALL

92900820

3 phase to 1phase conversion

kit

008/2 + 50

92911125

Changeover on set time and/or alarm

ALL

92900821

008/2 + 30

92911126

Two circuit to single circuit pipe work

conversion kit 008

92911102

010/2 + 50

92911127

010

92911103

010/2 + 60

92911128

015

92911104

015/2 + 80

92911129

020

92911105

020/2 + 90

92911130

BACnet Controls

pCONET BMS BACnet Control

ALL

92919134

USB to RS485 Connector

ALL

92919136

GENERAL L

INTRODUCTION

The CD3 range of direct expansion units is designed to provide the close control of temperature and humidity demanded by computer rooms, laboratories, banks, offices etc.. All units are fitted with programmable microprocessor controls.

CD3 indoor units are available in upflow or downflow configurations, matching with the Marsatair range of CKC and DCU outdoor/ducted condensing units using R407C refrigerant. There is a range of 4 capacities in 3 cabinet sizes for both upflow and downflow units. Packaged units are available in upflow versions only.

CD3-RANGE - GENERAL DESCRIPTION

DX UPFLOW PACKAGE UNITS

Twin circuit, packaged upflow units are normally supplied ex-stock. A field fit kit is available for converting from twin circuit to single circuit if required.

PACKAGE UNITS INCLUDE:

* Electronically controlled fan speeds * Four pole mains isolator * Class 'O' thermal and acoustic insulation * Microprocessor controls * Washable filters * Display giving access to set points and alarms

* Discharge plenum and grille * Alarms: humidity/temperature out of limits

* Twin circuit coils * Switches: Off/standby, unit run * Electric heating (2 stage) * De-ice thermostat * Humidifier with modulating control * Dehumidification

KITS AVAILABLE FOR FIELD FITTING TO PACKAGE UNITS:

3

92908135-17

MODEL

COOLING CIRCUITS

CD3 008

CD3 010

CD3 015

CD3 020

UPFLOW

1

92918006

92918008

92918010

92918012

2

92918007

92918009

92918011

92918013

DOWNFLOW

1

92918014

92918016

92918018

92918020

2

92918015

92918017

92918019

92918021

CKC 30

1ph

CKC 30

3ph

CKC 40

1ph

CKC 40

3ph

CKC 50

1ph

CKC 50

3ph

CKC 60

1ph

CKC 60

3ph

55017730

55017774

55017741

55017775

55023722

55017776

55017740

55017777

CKC 80

1ph

CKC 80

3ph

CKC 90

1ph

CKC 90

3ph

CKC 100

3ph

CKC 130

3ph

CKC 165

3ph

CKC 180

3ph

CKC 200

3ph

55017723

55017724

55017771

55023778

55017779

55017780

55017782

55017783

55017784

DCU 30

1ph

DCU 30

3ph

DCU 50

1ph

DCU 50

3ph

DCU 60

1ph

DCU 60

3ph

DCU 80

1ph

DCU 80

3ph

54224029

54224035

54224031

54224037

54224032

54224038

54224033

54224039

CONDENSING UNIT MODEL

CKC

DCU

Suction and liquid service valves

Standard

Expansion device (fixed orifice type)

Not available

Standard

Pre-charged with refrigerant (R407C)

Not available

Standard

Ducted air inlet and/or discharge

Not available

Standard

Ceiling suspendible

Not available

Standard

Capacitor start relay (1 phase) (CKC 30 - 40, All DCU)

Option

PTC resistor (1 phase)

Option

Fan speed/head pressure control

Standard

LP cut-out - Auto

Standard

HP cut-out - Auto

Standard

HP cut-out - Manual

Option

Not available

Isolator

Option

3 minute start delay timer and low ambient start

Standard

Wall mounting brackets

Option

Contactor

Standard

Overload (standard on 3ph)

Not available

Option

DX UPFLOW & DOWNFLOW CONFIGURED UNITS

CONFIGURABLE UNIT FEATURES

* Electronically controlled fan speeds * Microprocessor controls * Class 'O' thermal and acoustic insulation * Display giving access to set points and alarms * Washable filters * Alarms: humidity/temperature out of limits

* Discharge plenum and grille * Switches: Off/standby, unit run

* Single and twin circuit coils * Upflow and downflow units available

CKC CONDENSING UNITS (For use with R407C refrigerant)

CKC 30 and 40 units are fitted with reciprocating compressors. All other CKC units are fitted with scroll compressors. DCU DUCTED CONDENSING UNITS (for use with R407C)

All DCU units are fitted with reciprocating compressors.

STANDARD FEATURES AND OPTIONS, CKC, DCU

CKC = standard condensing unit + head pressure control + HP and LP switch and timers DCU = electronic controlled ducted condensing unit + head pressure control + HP and LP switches and timers

4

92908135-17

Description

Model

Factory

Fitted

Part No.

Description

Model

Factory

Fitted

Part No.

THERMOSTATIC EXPANSION VALVE

008/1

92900468

ALARMS

010/1

92900469

High water level

ALL

92919064

015/1

92900470

Water spillage indication (no pump)

ALL

92919067

020/1

92900471

Water spillage indication (with pump)

ALL

92919066

008/2

92900472 Fan failure

ALL

92919069

010/2

Dirty filter indication

ALL

92919071

015/2

92900473

Condensing unit 1 trip

ALL

92919073

020/2

92900474

Condensing unit 2 trip

ALL

92919075

2kW

92919001

Common alarm (volt free relay)

ALL

92919056

ELECTRIC HEATERS - Upflow

4kW

92919002

008

92900456

Single stage

6kW

92919003

ISOLATOR 63A

010, 015

92900457

8kW

92919004

020

92900458

10kW

92919005

FRESH AIR SPIGOT 100mm dia.

ALL

92900462

2kW

92919011

160mm dia.

ALL

92900463

ELECTRIC HEATERS - Upflow

4kW

92919012

FRESH AIR FAN + FILTER 93m³/h

ALL

92900403

Second stage

6kW

92919013

186m³/h

ALL

92900404

8kW

92919014

TOP DUCTED DISCHARGE SPIGOT (If used for return air on

downflow units add plenum for disposable filter access)

008

92900459

10kW

92919015

010, 015

92900460

HEATER RAIL - Upflow

008

92919021

020

92900461

Required for all heater kits

010, 015

92919024

008U

92900475

020

92919026

SOUND ATTENUATOR SECTION

010/015U

92900476

2kW

92919006

020U

92900477

ELECTRIC HEATERS - Downflow

4kW

92919007

008U

92900432

Single stage

6kW

92919008

FLOOR STAND PLINTH

010015U

92900433

8kW

92919009

75mm high

020U

92900434

10kW

92919010

(Recommended for all floor standing

008D

92900435

2kW

92919016

Units and for side entry of services)

010/015D

92900436

ELECTRIC HEATERS – Downflow

4kW

92919017

020D

92900437

Second stage

6kW

92919018

DOWNFLOW PLINTH

008

92900481

8kW

92919019

300mm high Font discharge

010/015

92900482 10kW

92919020

020

92900483

HEATER RAIL - Downflow

008

92919022

008

92900484

Required for all heater kits

010, 015

92919025

300mm high Rear discharge

010/015

92900485

020

92919027

020

92900486

LPHW HEATING 7.52kW

008

92900423

DOUBLE DEFLECTION GRILLE

008

92900494

(Add de-ice stat 10.50kW

010

92900424

(Upflow only)

010, 015

92900495

For all units) 14.94kW

015

92900424

020

92900496

18.40kW

020

92900425

008U

92900438

LPHW VALVE Motorised 2 port

ALL

92919048

010/015U

92900439

3 port

ALL

92919049

DISPOSABLE FILTER 50mm

020U

92900440

Modulating

ALL

92919050

(Replaces standard washable filter)

008D

92900441

DE-ICE THERMOSTAT (1 per circuit)

ALL

92900410

010/015D

92900442

008U

92919028

020D

92900443

010/015U

92919029

008

92900478

HUMIDIFIER 03kg/h

020U

92919030

HIGH EFFICIENCY FILTER

100mm

010,015

92900479

008D

92919031

020

92900480

010/015D

92919032

REMOTE CONTROL PANEL

008

92919078

020D

92919033

Supplied separately

010, 015

92919079

CONDENSATE PUMP (With alarm interface)

ALL

92919054 (Includes 6m ribbon cable)

020

92919080

BACnet Controls

pCONET BMS BACnet Control

ALL

92919133

CD3 DX UNIT CONFIGURABLE ACCESSORIES

(All options are factory fitted or supplied loose for site fitting during installation)

5

92908135-17

DIMENSIONS AND WEIGHTS

UPFLOW UNITS (With plenum fitted)

UNPACKED

PACKED

Model

008

010

015

020

008

010

015

020

HEIGHT mm

1595

1755

WIDTH mm

1230

1380

1580

1250

1400

1600

DEPTH mm

430

455

WEIGHT kg

142

162

171

182

163

185

194

211

DOWNFLOW UNITS

UNPACKED

PACKED

Model

008

010

015

020

008

010

015

020

HEIGHT mm

1165

1300

WIDTH mm

1230

1380

1580

1250

1400

1600

DEPTH mm

430

455

WEIGHT kg

124

142

151

160

141

160

169

184

UNPACKED

Model

CKC

30

CKC

40

CKC

50

CKC

60

CKC

80

CKC

90

CKC

100

CKC

130

CKC

165

CKC

180

CKC

200

HEIGHT mm

620

720

820

1080

1275

WIDTH mm

904

1004

1104

DEPTH mm

304

354

429

1 Ph kg

48

53

64

65

66

76 - - - -

-

3 Ph kg

48

53

62

63

64

73

81

101

103

118

173

PACKED

Model

CKC

30

CKC

40

CKC

50

CKC

60

CKC

80

CKC

90

CKC

100

CKC

130

CKC

165

CKC

180

CKC

200

HEIGHT mm

620

720

820

1080

1280

WIDTH mm

980

1080

1090

1215

DEPTH mm

340

390

465

1 Ph kg

50

55

66

67

68

78 - - - - - 3 Ph kg

50

55

64

65

66

75

83

105

107

123

178

UNPACKED

PACKED

Model

DCU

30

DCU

50

DCU

60

DCU

80

DCU

30

DCU

50

DCU

60

DCU

80

HEIGHT mm

560

625

580

650

WIDTH mm

1075

1245

1090

1270

DEPTH mm

565

565565

610

WEIGHT kg

66

70

81

8184

76

86

90

CD3 INDOOR UNITS

CKC CONDENSING UNITS

DCU DUCTED CONDENSING UNITS

6

92908135-17

SELECTION L

CD3 MODEL

008

010

015

020

AIRFLOW (maximum) ³/s

0.78

1.04

1.23

1.51

HIGH SENSIBLE COOLING SYSTEMS

CKC/DCU

1 x 80

2 x 30

1 x 100

2 x 50

1 x 165

2 x 80

1 x 180

2 x 90

Return air

EXTERNAL AMBIENT 30°C

22°C 50%RH

Total

7.20

7.36

10.63

11.08

13.56

13.86

16.76

18.05

Sensible

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

19.05

Sensible

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

20.04

Sensible

7.75

8.09

11.13

11.22

14.03

14.07

17.29

17.91

Return air

EXTERNAL AMBIENT 35°C

22°C 50%RH

Total

6.86

7.17

10.11

10.56

12.97

13.19

16.03

17.20

Sensible

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

18.05

Sensible

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

17.79

19.00

Sensible

---

10.88

11.04

13.79

17.07

17.52

Return air

EXTERNAL AMBIENT 40°C

22°C 50%RH

Total

6.57

6.63

9.43

10.15

12.28

12.62

15.22

15.83

Sensible

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

16.78

Sensible

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

17.54

Sensible

---

10.42

10.82

13.43

13.49

16.70

16.98

Return air

EXTERNAL AMBIENT 45°C

22°C 50%RH

Total

---

6.21

8.79

9.75

11.52

---

14.33

14.88

Sensible

---

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

15.59

Sensible

---

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

16.31

Sensible

---

9.73

10.65

12.73

---

15.83

16.31

STANDARD COOLING SYSTEMS

CKC/DCU

1 x 100

2 x 50

1 x 130

2 x 60

1 x 180

2 x 100

1 x 200

2 x 130

Return air

EXTERNAL AMBIENT 30°C

22°C 50%RH

Total

9.84

10.26

11.67

11.81

15.98

18.78

18.88

21.90

Sensible

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

23.13

Sensible

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

24.36

Sensible

9.20

9.34

11.52

11.58

15.11

16.49

18.30

19.59

Return air

EXTERNAL AMBIENT 35°C

22°C 50%RH

Total

9.31

9.84

11.08

11.30

15.17

17.91

17.95

20.91

Sensible

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

22.11

Sensible

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

23.41

Sensible

9.00

9.17

11.31

11.34

14.81

16.06

17.87

19.22

Return air

EXTERNAL AMBIENT 40°C

22°C 50%RH

Total

8.67

9.44

10.46

10.78

14.33

16.76

16.65

19.77

Sensible

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

20.93

Sensible

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

22.10

Sensible

8.74

9.00

11.04

11.13

14.46

15.54

17.43

18.71

Return air

EXTERNAL AMBIENT 45°C

22°C 50%RH

Total

8.02

9.06

9.84

---

13.47

15.35

15.63

18.47

Sensible

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

19.70

Sensible

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

20.82

Sensible

8.48

8.85

10.75

---

14.11

15.03

16.98

18.21

PRODUCT SELECTION

Systems can be selected to provide either comfort cooling or cooling with higher sensible heat ratios

CD3 COMBINATIONS AND DX PERFORMANCE DATA (nominal cooling capacities in kW)

7

92908135-17

Model

008

010

015

020

Fan speed

Min

Max

Min

Max

Min

Max

Min

Max

Airflow

0.42

0.78

0.67

1.04

0.72

1.23

0.92

1.51

Model

30

50

60

80

90

100

130

165

180

200

Airflow m³/s

0.81

0.78

1.14

1.74

Model

30

50

60

80

Fan speed

Min

Max

Min

Max

Min

Max

Min

Max

Airflow m³/s

0.32

0.42

0.53

0.42

0.53

0.34

0.48

UNIT

008

010

015

020

UPFLOW

Fan speed

Min

Max

Min

Max

Min

Max

Min

Max

Top discharge and front return air

NC

43

59

46

60

47

58

48

61

dBA

52

66.5

55

67

56

65

57

68

Front discharge with standard plenum and front return air

NC

43

60

44

58

47

58

48

60

dBA

52

67

52.5

65

56

65

58.5

67

Front discharge with additional attenuator and front return air

NC

38

49

41

49

41

48

43

50

dBA

47

58.5

50

58.5

50

57

52

58

DOWNFLOW

Top return and bottom discharge air (supplied as

NC

31

44

37

45

37

45

39

48

dBA

41

53

46

54

46

54

48

56

CKC

SOUND POWER LEVELS

SOUND PRESSURE

LEVELS

Frequency Hz

dBA

125

250

500

1k

2k

4k dBA

NC

30

77.4

67.5

68.5

64.8

60.2

53.8

69.8 50.0

44

50

73.6

68.2

67.1

65.5

61.1

54.3

69.7 49.2

44

60

72.9

67.7

67.8

66.4

61.9

54.1

70.3 49.8

45

80

70.9

68.6

68.1

65.3

59.5

53.8

69.7 49.2

43

90

81.8

71.8

69.2

68.6

63.1

57.4

72.8 52.3

47

100

79.4

73.7

71.5

68.5

63.8

58.1

73.4 52.9

47

130

73

70.3

70.0

68.8

65.0

56.7

72.6 52.1

47

165

73.1

70.3

70.1

68.9

65.5

57.5

73.1 57.2

51

180

72.5

71.9

71.7

68.9

66.0

58.2

75.5 59.2

53

200

73.0

71.8

71.5

70.1

66.1

58.3

75.7 61.8

55

Measurement point

Unit

Fan speed

dBA

NC

3m from unit in void

DCU 30

Max

52

46

Min

35

28

DCU 50, 60, 80

Max

54

48

Min

44

31

Office area

DCU 30

Max

37

26

Min

30

15

DCU 50, 60, 80

Max

42

28

Min

32

17

3m from discharge grille

DCU 30

Max

52

46

Min

34

27

DCU 50, 60, 80

Max

52

44

Min

40

28

AIRFLOWS (m³/s) CD3

Note: Maximum external resistance at the maximum speed = 150Pa

CKC (Maximum fan speed)

Note: All CKC units are fitted with fan speed control that will allow the fan to stop during normal operation.

DCU

Note: All DCU units are fitted with fan speed control, modulating the airflow according to system conditions.

SOUND PRESSURE LEVELS – CD3 UNITS

Note: CD3 Sound Pressure Levels were calculated from measurements taken at 3m from the front of the unit in an office installation and should be used for guidance only.

SOUND POWER AND SOUND PRESSURE LEVELS – 550 SERIES CKC UNITS (Maximum fan speed)

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 , calculated from the results under anechoic conditions and 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 UNITS

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.

8

92908135-17

INSTALLATION L

CD3 AIRFLOW OPTIONS

9

92908135-17

MODEL

WEIGHT (kg)

Upflow units with plenum fitted

CD3

142

CD3

162

CD3

171

CD3

182

Downflow units CD3

124

CD3

142

CD3

151

CD3

160

CD3 SERIES CLOSE CONTROL UNIT INSTALLATION

An envelope containing important user information is supplied with the indoor unit. Please pass to the end user.

1. The Packaged units are supplied for Upflow operation with front return air and top discharge. Configured units are supplied for Upflow or Downflow operation. Standard upflow units are supplied with front return

air and top discharge; Downflow units with top return air and front discharge. Units may be ordered with other airflow configurations or altered on site. Other configurations include:

Upflow: (wall mounted) with bottom return air. with front or top discharge, wall or floor mounted.

Downflow: with top return air and under floor discharge. See page 9 for all available configurations.

Note:- The required airflow arrangement must be configured prior to installation.

2. The chassis is made up of removable panels. 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 within the

electrics compartment and carefully pulling outwards until they are clear of the upper and lower grabber catches.

4 Access to the fan section, (and coil section in the downflow mode), can be gained by releasing the appropriate swell

latches located through the cut outs to the front of the side bulkheads and removing the panel.

5 The return air grille is removed by turning the 4 retaining screws anticlockwise, until a click is heard, and pulling the

grille outwards.

MOUNTING

1 It is recommended that ALL field fit kits are installed prior to mounting the unit and brazing the pipe work. 2 Ensure that the wall or floor will accept the operating weight of the unit; weights shown below include the plenum.

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. 4 If a fresh air facility is required, the appropriate apertures must be prepared to match up with the positions of the

unit fresh air inlets as shown in the diagrams following. Any opening in the external wall must be suitably lined and

screened to prevent brick dust entering the unit during installation and operation. 5 Mount the unit as required and secure all fixing bolts 6 Check that the unit is square and level. Failure to do so will result in misalignment of the cabinet access panels and

possible operational problems.

10

92908135-17

UNIT SIZE

DIMENSION 'A'

DIMENSION 'B'

008 1230 -

010 / 015

1380 690 020 1580 790

COIL SECTION

Note: Plenum (not shown) is 430mm high

UPFLOW SERVICE AND FIXING HOLE CENTRES (excluding discharge plenum)

11

92908135-17

DOWNFLOW SERVICE AND FIXING HOLE CENTRES

UNIT

DIMENSION 'A'

DIMENSION 'B'

008 1230 -- 010/015

1380

690

020 1580

790

12

92908135-17

INSTALLATION of 550 Series CKC CONDENSING UNITS

Model

CKC 30 - 80

CKC 90 - 200

Mounting Bracket Kit

55021100

55021101

MODEL

A B C D E F G

H

Weight (kg)

1 Ph

3 Ph

CKC 30

900

300

560

525

185

60

333

308

48

CKC 50

1000

300

660

570

213

60

333

308

64

62

CKC 60

1000

300

660

570

213

60

333

308

65

63

CKC 80

1000

300

660

570

213

60

333

308

66

64

CKC 90

1000

350

760

495

250

70

383

358

76

73

CKC 100

1000

350

760

495

250

70

383

358 - 81

CKC 130

1000

425

1020

495

251

100

458

433

-

101

CKC 165

1000

425

1020

495

251

100

458

433

-

103

CKC 180

1100

425

1215

675

211

95

458

433

-

118

CKC 200

1100

425

1215

675

211

95

458

433

-

173

CKC units include fan speed control, high & low pressure switches with low ambient and compressor delay start timers.

Note: It is easier to fit any kits prior to mounting the unit. The units are designed to stand on a flat surface. If they are to be wall mounted the following kits are available.

(TEV Ltd cannot accept liability for installers own mounting arrangements).

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: CKC 15 – 100 CKC 130 - 200

Dimensions in mm.

13

92908135-17

INSTALLING 542 SERIES DUCTED CONDENSING UNITS

A D

B

PLAN VIEW

E

C

G

F

J

K

H

SPIGOT DIAMETERS:-

DCUE 30 - 40 = 354 DCUE 50 - 80 = 404

Model A B C D E F G H J K

Spigot dia.

Weight (kg)

DCU 30

930

510

495

1004

490

65

210

317

717

354

70

DCU 50

1100

510

560

1174

490

65

240

392

865

404

81

DCU 60

1100

510

560

1174

490

65

240

392

865

404

81

DCU 80

1100

510

560

1174

490

65

240

392

865

404

84

DCU A B

30

930

510

50-80

1100

510

B

A

PLAN VIEW

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

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

14

92908135-17

Dimensions

mm.

Model

30

50-80

A

400

450 B 300

350

C

100

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 back panel 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.

15

92908135-17

APPLICATION L

UNIT

SIZE

MAXIMUM LENGTH OF EQUIVALENT

SUCTION LINE PIPE SIZES (m)

LIQUID LINE

⅜ ½ ⅝ ¾ ⅞

1⅛

1⅜ ⅜ ½

⅝

20

7.5

20

30

15

45

40

10

36

45 7.5

45

50

7.5

18

45 7.5

45 60

14

36

45

7.5

45

80

11

30

45 45

90

10

25

45 20

45

100

7.5

22

45 15

45

130

15

30

45

12

45

150

12

27

45 8 45

165

8 18

45

7.5

45

180

7.5

16

45

7.5

45

200

15

45

7.5

45

Fitting

Pipe Size (outside diameter in inches)

3/8

1/2

5/8

3/4

7/8

1-1/8

45° Bend

0.12

0.15

0.18

0.21

0.24

0.3

90° Bend R/d = 1

0.37

0.43

0.49

0.55

0.61

0.79

90° Bend R/d = 2

0.24

0.27

0.30

0.37

0.43

0.52

180° Bend C/d = 1

0.73

0.91

1.10

1.28

1.46

1.83

180° Bend C/d = 2

0.46

0.55

0.64

0.76

0.85

1.07

90° 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

APPLICATION

1 To maximise performance, pipe runs should be kept as short as possible, avoiding sharp bends. Individual pipe

runs to a maximum of 45m are allowed for air conditioners, providing pipe work is sized and installed correctly.

Performance ratings are based on 6m pipe runs but there will be no significant loss of capacity on extended pipe runs

for correctly sized pipes.

a) Pipe sizes are based on: Minimum of 3.8 m/s (750fpm) suction gas velocity for horizontal or down flow. Minimum of 7.6 m/s (1500 fpm) suction gas velocity for up flow. 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 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.

R407C : Use polyolester oil - L’Unite 181-023, ICI Emkarate RL32S,RL32CF,Mobil Artic EAL22 or EAL22CC

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

4 In calculating equivalent lengths of pipe runs, the effect of bends and fittings must be taken into account. Information

5 Use the shortest possible route, avoiding sharp bends. 6 Fully insulate the suction line, (or suction and liquid line if run together).

relating to the equivalent lengths of line fittings and bends etc. is generally available to the design engineer. 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 its total equivalent length.

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

16

92908135-17

Model

008S

008T

010S

010T

015S

015T

020S

020T

Liquid

3/8

1/2

3/8

1/2

3/8

Suction

3/4

1/2

3/4

1/2

7/8

5/8

7/8

5/8

Single circuit

systems

CD3

Outdoor unit

CKC charge (g)

Twin circuit

systems

CD3

Outdoor units

CKC charge (g)

R407C

S 08 S

008

CKC 90

1422

S 08 T

008

2 x CKC 50

1167*

S 10 S

010

CKC 130

3075

S 10 T

010

2 x CKC 60

1477*

S 15 S

015

CKC 180

3389

S 15 T

015

2 x CKC 100

1882*

S 20 S

020

CKC 200

4229

S 20 T

020

2 x CKC 130

3075*

HS 08 S

008

CKC 80

1357

HS 08 T

008

2 x CKC 30

761*

HS 10 S

010

CKC 100

1882

HS 10 T

010

2 x CKC 40

807*

HS 15 S

015

CKC 165

3445

HS 15 T

015

2 x CKC 80

1357*

HS 20 S

020

CKC 180

3389

HS 20 T

020

2 x CKC 90

1422*

REFRIGERATION INSTALLATION

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

S = Single Circuit T = Twin Circuit NOTE: On twin circuit units, the lower half of the coil is the first circuit.

2 Using a tube cutter, remove sealed ends of suction and liquid pipes. This will release a small holding charge of

dry nitrogen. Discard the expansion device on the condensing unit.

3 Pipe exit positions are shown on pages 3 and 4. 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.

4 Connect pipe work 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

oxidation and 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 line filter 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, and downstream of the liquid line filter/drier.

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, which could result in liquid return to the compressor.

Evacuate the air handler and interconnecting pipe work by connecting a vacuum pump to the Schrader connections on both suction and discharge service valves on the condensing unit (DO NOT OPEN THE VALVES) and evacuate to 1000 microns (1 Torr) or better and hold for a minimum of 15 minutes.

REFRIGERANT CHARGE

* = per circuit

The table above shows the base charge for R407C The base charge will generally be sufficient for 3m pipe runs at room 22°C 50% RH, ambient 27°C 50% RH.

Typical charge to be added for longer liquid lines:- 3/8" OD add 50 g/m; 1/2" OD add 80 g/m; 5/8" OD add 110 g/m.

The preferred method of adding refrigerant is:-

1. Start the unit (on highest fan setting ) and allow the compressor to run for a few seconds.

2. Additional charge 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.

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).

17

92908135-17

Undercharged Unit - the top few tubes of the evaporator are dry and there are, (possibly), slight signs of frosting

Single Phase Supply 230 Volts - 50 Hz

Three Phase Supply 400 Volts - 50 Hz

System

Model

Combination Full Load Amps

System

max. starting current

Full Load Amps

System

max.

starting

current

Cool Only

Cool &

Heat

Cool/Heat/

Hum/Dehum

If DCU

fitted

Cool Only

Cool &

Heat

Cool/Heat/

Hum/Dehum

If DCU

fitted

Amps

A/PH*

A/PH

S 08 S

CD008 + CKC 100

- - - - -

12.5

16.7

32.7

-

69.0

S 10 S

CD010 + CKC 130

- - - - -

15.75

16.7

32.7

-

89.3

S 15 S

CD015 + CKC 180

- - - - -

22.1

33.0

47.1

-

139.6

S 20 S

CD020 + CKC 200

- - - - -

23.91

33.4

49.3

-

138.0

HS 08 S

CD008 + CKC 80 / DCU 80

19.9

**38.7

-

+1.0

82.5

10.3

16.7

32.7

+2.0

57.8

HS 10 S

CD010 + CKC 100

- - - - -

14.5

23.1

32.7

-

75.4

HS 15 S

CD015 + CKC 165

- - - - -

19.4

33.0

44.6

-

109.2

HS 20 S

CD020 + CKC 180

- - - - -

22.5

33.4

49.3

-

140.0

S 08 T

CD008 +2x CKC 50 / DCU 50

26.8

**38.7

-

+1.0

75.2

13.7

16.7

32.7

+4.0

43.8

S 10 T

CD010 +2x CKC 60 / DCU 60

35.5

**40.7

-

+1.0

83.0

16.3

23.1

32.7

+5.0

56.2

S 15 T

CD015 +2x CKC 100

- - - - -

25.1

33.0

41.0

-

85.3

S 20 T

CD020 +2x CKC 130

- - - - -

27.1

33.4

49.3

-

99.6

HS 08 T

CD008 +2x CKC 30 / DCU 30

21.9

**38.7

-

+4.0

51.0

11.8

16.7

32.7

+4.0

36.1

HS 10 T

CD010 +2x CKC 50 / DCU 50

28.8

**40.7

-

+1.0

77.2

15.9

23.1

32.7

+4.0

50.2

HS 15 T

CD015 +2x CKC 80 / DCU 80

38.5

**42.3

-

+1.0

100.9

19.7

33.0

41.0

+4.0

74.1

HS 20 T

CD020 +2x CKC 90

44.7

**44.7 - -

129.4

22.5

33.4

49.3

-

81.7

at the inlet to the evaporator coil. Overcharged Unit - the suction line 'sweats' all the way back to the compressor.

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 7). Supply cables and inter-connecting cables

are to be provided by the installer.

INDOOR UNIT WIRING

Connections for internal wiring are made within the electrics enclosure accessed by removing the centre front cover. Disconnect the connecting cable from the display panel before moving the cover away from the unit.

Mains cables should be connected via a fused switch and routed through knockouts in the bottom left hand corner of the unit, then through an access hole in the bottom left hand side of the electrics compartment to the mains terminal block.

System Interconnecting Wiring

On single or three phase systems, connect the incoming mains supply to the indoor unit and then link to the condensing unit via a three pole circuit breaker.

The earth wire is connected to an earth stud at the right hand side of the mains terminal block. All mains and interconnecting cable must be sized to suit the electrical rating of the unit and the length of cable run.

Make sure that all connections are secure and all wires are clear of any rotating parts.

Data Plates

Because indoor and outdoor units can be mix-matched, the data plates only give information relevant to the indoor unit with maximum possible running currents. To determine the full system details please refer to the Technical Manual for more specific information.

ELECTRICAL DATA

* Max. Phase **Single phase models are available for twin circuit dx systems where electric heating requirement is 8kW or less.

The electric heating loads shown are based on maximum amounts of heating which are:-

CD 008 = 8kW (4+4) CD 010 = 10kW (4+6) CD 015 = 16kW (8+8) CD 020 = 20kW (10+10)

18

92908135-17

Typical control panel and terminal layout

System

S 08 S

S 10 S

S 15 S

S 20 S

S 08 T

S 10 T

S 15 T

S 20 T

1 Phase Cool Only

- - - - 40

40 - -

1 Phase Cool and Heat

- - - - 50

50 - -

3 Phase Cool Only

20

25

35

40

16

20

32

35

3 Phase Cool and Heat

20

32

40

20

32

40

3 Phase Cool/Heat/Hum/Dehum

40

63

40

50

63

System

HS 08 S

HS 10 S

HS 15 S

HS 20 S

HS 08 T

HS 10 T

HS 15 T

HS 20 T

1 Phase Cool Only

32 - - - 32

40

50

63

1 Phase Cool and Heat

50 - - - 50

50

63

3 Phase Cool Only

16

20

32

40

16

20

25

32

3 Phase Cool and Heat

20

32

40

20

32

40

3 Phase Cool/Heat/Hum/Dehum

40

63

40

50

63

RECOMMENDED FUSE SIZES

The system and its supply/interconnecting wiring must be protected by fuses, preferably H.R.C. motor rated types to BS60269 or miniature circuit breakers to BS60898 or local codes having similar time lag characteristics that allow starting of the compressor yet still afford close over current protection under running conditions. The ratings below are for H.R.C. motor rated or semi-enclosed wire fuses.

Standard Cooling

High Sensible Cooling

19

92908135-17

Pico Controller *

Setting

High/Boost Switch

Potentiometer

Unit Fan Speed

High

No Adjustment

Possible

No Adjustment

Possible

Unit Fan Speed

Low

Select High or

Boost

Adjust for

De-Hum Low SP

50% to 100%

* See Page 4 of 92908131 Operator Instructions if the Pico

Controller is set at high. Low speed will automatically be

selected during de-hum

CONDENSATE DRAIN

The condensate drain connection is at the left hand end of the condensate 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 back

panel 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.

IMPORTANT: If a humidifier is fitted the drain pipe must be capable of carrying water at 60°C.

FAN SPEED CONTROLLER

One control is used on each CD3 unit, and has a switch for selecting high or boost speed (see diagram below). These can only be selected if the Pico Controller is set at low.

SETTING

The boost speed should be selected for:-

The High speed should be selected for standard 'Free Blow' Upflow units. Units are despatched with the low speed set on 50%. The fan speed may be adjusted between 50% and 100% of

the selected top speed by turning the low speed potentiometer clockwise.

 ALL DOWNFLOW units  Upflow units requiring ductwork on the supply or return air  When high efficiency filters are fitted.

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.

20

92908135-17

WIRING DIAGRAMS L

POWER WIRING DIAGRAM – Sheet 1

21

92908135-17

POWER WIRING DIAGRAM – Sheet 2

22

92908135-17

CONTROL WIRING DIAGRAM

For HUMIDIFIER wiring diagram see page 27.

23

92908135-17

To indoor unit

CKC WIRING DIAGRAMS

1 PHASE CKC 30 to 90 3 PHASE CKC 30 to100

3 PHASE CKC 130 to 180 3 PHASE CKC 200

24

92908135-17

DCU WIRING DIAGRAMS DCU 30 to 80 1 phase

DCU 15 to 80 3 phase

INTERCONNECTING WIRING DIAGRAMS

25

92908135-17

1 phase units

Ø

( mm )

3.5

4

5.5

6

(mm²)

2.5

4

6

10

3 phase units

WAGO terminals

26

92908135-17

ACCESSORIES L

CONDENSATE PUMP (OPTIONAL)

An optional condensate pump is available, providing a 5m lift where gravity drain is not an option. The full assembly comprises a condensate pump (suitable for hot and cold water removal), a control board, a float switch to activate the pump and a second float switch to provide a high water level alarm. The high level alarm disables cooling until the condensate in the tray has fallen to a safe level.

WATER SPILL SENSOR (OPTION) Can be connected to the condensate pump board providing an alarm in the event of

CD3 SYSTEM HUMIDIFIER (OPTIONAL)

Plumbing connections

HUMIDIFIER WIRING DIAGRAM

condensate spillage.

DESCRIPTION

The humidifier is an electrode steam boiler, electronically controlled. The steam bottle will require replacing periodically. The humidifier is fitted with bottle change indication and the frequency of change is dependent upon the condition of the water feeding the humidifier.

INSTALLATION Water supply

The humidifier operates with a range of water qualities; pre-treated water is preferable, extending the bottle life (fully de-mineralised water is not suitable). The humidifier system incorporates an air break in the water feed to meet local regulations. Connect directly to a water supply operating at pressures between 0.1 and 1 MPa (14 to 145 psig). For supplies at higher pressures fit a pressure regulator set at 0.4 to 0.6 MPa (60 to 90 psig).

The inlet connection is a 15mm pipe. A stop valve and strainer should be fitted ahead of the control solenoid valve that is fitted to the inlet of the humidifier. Waste water is drained into the unit condensate tray. The drainpipe should be suitable for use with water at 60C . Drain pipes should be correctly sized with a minimum slope of 5% (1 in 20) and an air break at the entry.

27

92908135-17

Setting the capacity limitation “Sx%”

Jumper Positions

POS

With Jumper

Without Jumper

Fi

Connection to a mains supply with ground fault circuit interrupter

Connection to a mains supply without ground fault circuit interrupter *

DRN

Increased drain operation factor

Regular drain operation factor *

CDY

Low water conductivity (<125 µS/cm)

Normal water conductivity (≤125 µS/cm) *

DSP

Exchangeable steam cylinder *

Cleanable steam cylinder

K

Fault No.4 “steam cylinder maintenance due”: the

unit triggers a warning only *

Fault No.4 “steam cylinder maintenance due”: 72

hours after the warning an error is triggered and the unit is switched off

L

Fault No.3 “Fill time”: a warning is triggered after

20 minutes filling time exceeded. After 220 minutes filling time exceedance an error is triggered and the unit is switched off *

Fault No.3 “Fill time”: the unit directly triggers an error

after 20 minutes filling time exceedance. However, the unit is switched off after 220 minutes filling time exceedance.

Z, M, N

No function (spare)

Use the potentiometer “Sx%” to set the capacity limitation in % of the minimum capacity (setting range: 25…100%,

factory setting: 100%).

Setting the humidity setpoint value “%rH”

Use the potentiometer “%rH” to set the humidity setpoint value for the internal controller in % relative humidity (setting range: 0…100%, factory setting: 100%).

General Settings

With the jumpers on the jumper blocs “JP1” and “JP2” you can set different unit parameters.

* Factory settings

COMMISSIONING

Pre-start check

Ensure the drain line is connected and that water flows away freely. Do this by filling and draining the bottle using the manual drain switch.

HUMIDIFIER START UP

On initial start up the feed valve will open to fill the bottle and the drain valve will remain closed. The initial current draw will be below the normal operating level as the bottle is filled with fresh water. This will

increase as the humidifier continues to operate until reaching it’s full value (this may take several operations depending upon the condition of the water and the length of time it is operating). The bottle will continue to fill and drain automatically on demand.

During the start up period, whenever the current is less than 70% of the set operating level, the 'bottle change’ indication will be active. This is normal and the indication will go off once the current has risen above 70% of the set output. The 'bottle change' indication will not appear again until the bottle requires changing.

NOTE: The start up process described above occurs only when a new bottle has been fitted. Adding a teaspoon of table salt into the new bottle before connecting up may reduce the start-up time after a bottle

change.

NORMAL OPERATION

After the start up period, the unit will operate automatically, at a constant output until the bottle requires changing. The frequency of the drain and fill sequence will depend upon the quality of the water.

There will be a short delay from the unit receiving a humidifier on signal and the steam being generated as the water is brought up to temperature.

HUMIDIFIER MAINTENANCE

Prior to carrying out maintenance on the humidifier, the cylinder should be drained by operating the manual switch. The system should also be isolated from the electrical supply.

STEAM BOTTLE REPLACEMENT Access to the bottle and solenoid valves is from the front and left hand side of the unit.

1. Before switching off the power to the humidifier, isolate the water supply and drain the bottle using the manual drain switch.

28

92908135-17

SETTINGS

CONFIGURATION

pCONET BMS CONTROL KIT 92919134

OPERATION AND COMMISSIONING

2. Remove the discharge hose from the top of the bottle.

3. Remove the electrical connectors pulling upwards.

4. Lift the bottle support bracket clear of the outlet spigot.

5. Remove and replace the bottle.

6. Replace the hose and electrical connectors.

7. When replacing the bottle clean the feed/drain manifold and check the "O" ring seal, replacing if necessary. Check and clean the strainer protecting the outlet solenoid valve

8. Reconnect the water supply and switch on the electrical supply.

After replacing the bottle check that the operating current is correct (see start up).

ENSURE THE ELECTRICAL SUPPLY IS DISCONNECTED

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, before fully removing the panel, release the cable from the keypad.

3. Remove the “Serial card” cover from the pCO3, insert pCO net into the plug in connector and make sure it is fully inserted.

4. Insert the required Jumper (see Carel pCO net instruction supplied for more information)

5. Fit the cover supplied with pCO net

The pCO3 has been configured for the BACnet MS/TP network as from January 2016 Comm. Speed 19200 bps (RS485) NOTE: For CD3 systems supplied before January 2016 contact Marstair for further assistance.

Procedure for configuring the pCOnet parameters for correct communication over an MS/TP network

 Connect pCOnet via RS485 to a computer: during configuration, the CAREL RS485 converter (CVSTDMOR0)

for USB ports can be used, Marstair part number 92919136. USB converters should not be used in the installation due to the large volume of data transmitted across a complex BACnet network.

 Install the CAREL ”BACset” configuration tool, available free of charge at ksa.carel.com. You need to create a

free of charge account to access the software download sections. Navigate through the following menu’s:-

Software and support pCONet BacSet.

29

92908135-17

DATABASE OF THE SUPERVISOR

Address

Description

Type

Communication type

1

Compressor 1 general alarm digital input

Digital

Reading

2

Compressor 2 general alarm digital input

Digital

Reading

8

ON/OFF remote

Digital

Reading

11

fire / smoke alarm digital input

Digital

Reading

12

Dehumidification

Digital

Reading

13

ON /OFF unit

Digital

Reading

18

3p cold valve opening contact (CW) / Cooling 1 DX

Digital

Reading

19

3p cold valve closing contact (CW) / Cooling 2 DX

Digital

Reading

20

3p warm valve opening contact (CW) / Electric Heating

Digital

Reading

21

3p warm valve closing contact (CW)

Digital

Reading

22

General alarm

Digital

Reading

23

Compressor 1 general alarm

Digital

Reading

24

Compressor 2 general alarm

Digital

Reading

31

Fire / smoke alarm

Digital

Reading

32

Air filter alarm / Filter Clog

Digital

Reading

33

Ambient high temperature alarm

Digital

Reading

34

Ambient temperature alarm

Digital

Reading

35

Ambient high humidity alarm

Digital

Reading

36

Ambient low humidity alarm

Digital

Reading

55

Humidity probe enabling

Digital

Writing / Reading

58

Inlet water probe enabling

Digital

Writing / Reading

61

Cold modulating valve 0/10V enabling

Digital

Writing / Reading

63

Enabling of simultaneous operation of compressors with

Digital

Writing / Reading

64

Warm 0/10V modulating valve enabling

Digital

Writing / Reading

66

Compressor rotation enabling

Digital

Writing / Reading

67

Compressor 1dehumidification enabling

Digital

Reading

68

Compressor 2 dehumidification enabling

Digital

Reading

73

ON/OFF from supervisor enabling

Digital

Writing / Reading

74

3p cold valve enabling

Digital

Reading

75

3p warm valve enabling

Digital

Reading

The variables reported below will be transmitted between pCO and supervisor only if all the following conditions will be met:

- the serial card is inserted into the proper connector that is found on the interface

- the supervisory function is enabled in the M_MANUF_CONF1.window protected by manufacturer’s password

- the address of the unit is properly selected with reference to the supervisory network in the M_PARAM_USER12 window protected by user password.

- the equipments have been correctly connected to the network (supervisor and pCO)

Digital Variables

30

92908135-17

Whole Variables

Address

Description

Type

Communication type

01

Delay common alarm relay

Whole

Writing / Reading

10

Cold 0/10V valve ramp start

Whole

Writing / Reading

11

Cold 0/10V valve ramp end

Whole

Writing / Reading

12

Warm 0/10V valve ramp start

Whole

Writing / Reading

13

Warm 0/10V valve ramp end

Whole

Writing / Reading

16

Compressor 1 step without energy saving

Whole

Writing / Reading

17

Compressor 1 hysteresis without energy saving

Whole

Writing / Reading

18

Compressor 2 step without energy saving

Whole

Writing / Reading

19

Compressor 2 hysteresis without energy saving

Whole

Writing / Reading

26

Time interval between same compressor switching on

Whole

Writing / Reading

28

Low pressure delay alarm

Whole

Writing / Reading

29

Stop minimum time compressors

Whole

Writing / Reading

30

Time interval between different compressor switching on

Whole

Writing / Reading

33

High / low temperature / humidity alarm delay

Whole

Writing / Reading

34

Start-up delay between heaters

Whole

Writing / Reading

48

Integration time P+1 ONLY

Whole

Writing / Reading

54

Cold 3p valve ramp start

Whole

Writing / Reading

55

Cold 3p valve ramp end

Whole

Writing / Reading

56

Warm 3p valve start ramp

Whole

Writing / Reading

57

Warm 3p valve end ramp

Whole

Writing / Reading

58

3p valve complete opening time

Whole

Writing / Reading

59

Fan switching on delay

Whole

Writing / Reading

61

Cold valve ramp limit

Whole

Reading

62

Warm valve ramp limit

Whole

Reading

Address

Description

Type

Communication type

1

Ambient temperature

Analog

Reading

2

Ambient humidity

Analog

Reading

5

Supply air temperature

Analog

Reading

6

Dead zone in temperature

Analog

Writing / Reading

7

Ambient humidity band

Analog

Writing / Reading

8

Ambient humidity set

Analog

Writing / Reading

9

Low temperature alarm offset

Analog

Writing / Reading

10

High temperature alarm offset

Analog

Writing / Reading

11

Low humidity alarm offset

Analog

Writing / Reading

12

High humidity alarm offset

Analog

Writing / Reading

13

Ambient temperature set

Analog

Writing / Reading

18

Water low temperature limit

Analog

Writing / Reading

19

Water high temperature limit

Analog

Writing / Reading

23

Cooling valve position

Analog

Reading

24

Heating valve position

Analog

Reading

Analog Variables

31

92908135-17

GND TX/RX+ TX/RX-

GENERAL MAINTENANCE

12 MONTHLY (or more frequently if conditions dictate)

1. Clean the feed water strainer and drain solenoid valve. Check hoses for wear and flush out the drain pipe.

2. Check all electrical connections are tight.

3. Check and clean the drain tray to prevent a build up of deposits.

CD3 AUTO CHANGEOVER

It is possible to connect two CD3 units to allow them to operate in Run/Standby operation, changing over on alarm or on a timer to equalise component wear. One unit will be configured as the run unit, the second as the standby unit.

UNIT 1 UNIT 2

RUN STANDBY

STANDBY RUN

UNIT 1 starts as the run unit with UNIT 2 in standby mode. One of the following will cause the units to change modes.

1. Run time: If programmed, units will switch between run and standby on a timer basis to ensure even running of fans and compressors. This is factory set at 168hrs and is factory adjustable by TEV Ltd.

2. Unit assist: The standby unit will switch on in the event the room load exceeds the running unit capacity.

3. Alarm: If the run unit is disabled by alarm or power loss (including switching off) the standby unit will take over.

4. Network: If communication is broken.

Critical alarms are set in the Engineering Level mask (see operating Instructions page 5of 9) note that only AL01 and ALO2 are used with Marstair condensing units. AL03, AL04, AL32 and AL33 are not available.

WIRING

WARNING !! Units can start automatically, isolate both units before beginning work.. Connections J11 J11

CAUTION:

Do not cross the polarity of the connections.

UNIT 1 UNIT 2

Units are connected in parallel using a twisted pair shielded cable (min AWG20/22, 0.75/0.5mm²) via J11 on the controllers. Communication is via an RS485 connection. Using correct shielded cable, units may be up to 200m apart.

32

92908135-17

UNIT ASSIST

In this mode the stand-by unit is enabled if the room temperature drifts out of limits, subject to a 3 Minute delay. This allows the run unit to control the temperature, and not respond to fast transients.

Low temp alarm High temp alarm

Unit Run unit Run unit Unit Assist heating cooling Assist Heating cooling

1ºC 1ºC 1 ºC 1ºC 1ºC 1ºC Dead band 1ºC

Unit assist on Unit assist on

SETPOINT 20°C

This is a typical example: values will change for the run unit between one and two stage cooling, one and two stage heating, L.P.H.W. and any combination depending upon conditions.

OPERATING INSTRUCTIONS

DESCRIPTION OF CONTROLS

All CD3 units are fitted with a microprocessor controller and display keypad, providing the functionality necessary for all applications. Each unit is delivered tested, fully programmed and ready to run.

USER INTERFACE

The user interface is divided into 3 parts:

1. FIRST USER LEVEL, not protected by password, which allows the user to view monitored items, e.g. running hours, display active /stored alarms and temperature /humidity set points.

2. SECOND USER LEVEL, protected by a password, which allows an authorised user to select various control parameters including; set point limits, differentials and dead zones.

3. ENGINEERING LEVEL, protected by a password, allowing the commissioning/service/maintenance engineers access to the time functions and hours run counters. This level also provides the facility for calibrating the attached sensors and manually operating the fans, the cooling mode, the heating mode and the humidification and de-humidification sequences during commissioning.

A fourth MANUFACTURES LEVEL, protected by password, is for configuring and programming the controller. This level is only available to TEV and any changes to the operating software, which may be required for an individual application, must be carried out by an TEV engineer.

PASSWORDS

A document is enclosed separately in the unit containing the passwords for the second level user and engineering levels. This should be held by the installer and passed to the relevant person once the unit has been installed and commissioned. Passwords may be altered by the user or Engineer, if changes are made ensure that a record of the new passwords is kept in a safe location. Should passwords be lost, contact TEV Ltd. for assistance.

DISPLAY AND KEYPAD

The display/keypad is mounted on the front of the unit, connected by a 1.5m cable. It is fixed to the front panel of the unit and if the panel is removed, the cable should be disconnected before moving the panel away from the unit.

33

92908135-17

00:00 00/00/00 Unit 1 Temperature 00.0 °C Humidity 00.0% Unit On

KEYPAD FUNCTIONS

KEY

FUNCTION

KEY

FUNCTION

1. Displays measured values.

2. Returns operator to the main mask window.

Setting of operating parameters and safety thresholds.

Displays working hours and allows counter re-set.

Displays the version of the application programme loaded into the controller.

Not used.

Unit ON/OFF button. The green LED is lit when the unit is ON.

Displays current status of inputs and outputs.

1. Displays alarm status.

2. Mute and reset alarms.

Red LED lit when alarm is present.

Allows the time clock functions to be displayed and programmed.

Confirms data entry. Yellow LED is lit when there is power to the unit.

For setting and adjusting setpoints.

1. Toggle between display screens.

2. Raise or lower set values.

Each function button has a green LED in the top left hand corner that is lit when the particular function button is operated. This does not apply to the ON/OFF, ALARM and ENTER buttons that have LEDs as defined above.

34

92908135-17

Current time Date Mask Number

Actual Temperature and Humidity

Unit status

OPERATING SEQUENCE

00:00 00/00/00 M:01

TEMPERATURE 00.0°C

HUMIDITY 00.0%

UNIT ON

WORKING MODE COOLING HEATING HUMID DEHUMID FAN HIGH LOW AUTO RESTART

ACTUAL SET POINT

TEMPERATURE 21.0°C HUMIDITY 50%

USER PASSWORD

0000

SET POINT TEMPERATURE 21.0°C

HUMIDITY 50%

When the unit is first powered up the display will show; SELF TEST - PLEASE WAIT. Once the self test has been completed the MAIN MASK will be displayed. This is the default screen.

The default screen will always be displayed during normal operation. To view the current operating mode of the unit:

Press or to toggle between the MAIN MASK and the WORKING MODE MASK.

SECOND USER LEVEL ACCESS (Password required)

SET BUTTON MENU

Press

To change parameters To change screen

35

92908135-17

AUTO RESTART AFTER BLACKOUT YES

ENABLE REMOTE ON/OFF YES

NEW USER PASSWORD

0000

UNIT FAN SPEED HIGH

SERVICE PASSWORD

0000

LIMITS SET POINT TEMPERATURE: MIN 15°C

MAX 30°C

LIMITS SET POINT HUMIDITY MIN 20%

MAX 80%

TEMPERATURE COOL DIFFER. 1.0°C

HEAT DIFFER. 1.0°C DEAD BAND 0.5°C

HUMIDITY BAND 7.5%

ENGINEERING LEVEL ACCESS (Password required)

PROGRAMME BUTTON MENU

Press

36

92908135-17

ALARM

DESCRIPTION

ALARM

DESCRIPTION

AL01

Compressor 1 General alarm

AL20

Return Air Temperature Probe Fault

AL02

Compressor 2 General alarm

AL21

Not used

AL03

Low Pressure Circuit 1

AL22

Not used

AL04

Low Pressure Circuit 2

AL23

Not used

AL05

Fan Fail (Serious alarm) Unit OFF

AL24

Return Air Humidity Probe Fault

AL06

Fan Overload (Serious alarm) Unit OFF

AL25

Not used

AL07

Heater 1 & 2 Over temperature

AL26

Not used

AL08

Not used

AL27

Not used

AL09

Smoke/Fire (Serious alarm) Unit OFF

AL28

Alarm E06 – Humidifier High Current

AL10

Filter Clog

AL29

Alarm E09 – Humidifier Low Water

TEMPERATURE ALARM LOW OFF SET 5.0°C

HIGH OFF SET 5.0°C

HUMIDITY ALARM LOW OFF SET 20%

HIGH OFF SET 20%

SEL. TYPE ALARM S = SERIOUS N = NOT SERIOUS AL01: NNNNS AL06: NNNS AL10: NSSSS AL15: NNNN

SEL. TYPE ALARM S = SERIOUS N = NOT SERIOUS AL19: NSNNN AL24: SNNN AL28: NNNNN AL33: NNSN

SEL. TYPE ALARM S = SERIOUS N = NOT SERIOUS AL37: N---- AL42: --- AL46: ------ AL51: ----

NEW USER PASSWORD

0000

IDENTIFICAT. NUMBER FOR THE SUPERVISORY: 001

The values shown in the above screen masks are the default settings when the unit leaves the factory.

ALARM DESCRIPTIONS

37

92908135-17

AL11

High Return Air temperature

AL30

Alarm E10 – Humidifier Low Current

AL12

Low Return Air temperature

AL31

Clock alarm

AL13

High Return Air humidity

AL32

High Pressure Circuit 1

AL14

Low Return Air humidity

AL33

High Pressure Circuit 2

AL15

Not used

AL34

Not used

AL16

Not used

AL35

Water Spill (Serious alarm) Unit OFF

AL17

Hours Run Compressor 1

AL36

Condensate High Level Cooling OFF

AL18

Hours Run Compressor 2

AL37

Humidifier Bottle Change

AL19

Hours run Fan

SERVICE PASSWORD

0000

ENABLE AUTOMATIC TEMPERATURE SET POINT VARIATION NO

TEMPERATURE TIME ZONE N.1

START HOUR 00:00 SET POINT 00.0°C

TEMPERATURE TIME ZONE N.2

START HOUR 00:00 SET POINT 00.0°C

TEMPERATURE TIME ZONE N.3

START HOUR 00:00 SET POINT 00.0°C

TEMPERATURE TIME ZONE N.4

START HOUR 00:00 SET POINT 00.0°C

REGULATION CLOCK HOUR 00:00 DATE 00/00/00 DAY MONDAY

CLOCK BUTTON MENU

Press

38

92908135-17

ENABLE AUTOMATIC HUMIDITY SET POINT VARIATION

HUMIDITY TIME ZONE N.1

START HOUR 00:00 SET POINT 000.0%

HUMIDITY TIME ZONE N.2

START HOUR 00:00 SET POINT 000.0%

HUMIDITY TIME ZONE N.3

START HOUR 00:00 SET POINT 000.0%

HUMIDITY TIME ZONE N.4

START HOUR 00:00 SET POINT 000.0%

ANALOGUE INPUTS RETURN AIR TEMPERATURE 21.0°C

RETURN AIR HUMIDITY 50.0%

DIGITAL INPUTS C = CLOSE O = OPEN

01: CCCCC 06: CCCCC 11: -CCC

ANALOGUE OUTPUTS COOL VALVE 00.0V

HEAT VALVE 00.0V

DIGITAL OUTPUTS C = CLOSE O = OPEN

01: OOO 04: OOO 07: OOO 10: OOOO

Press to return to the MAIN MASK

INPUT /OUTPUT BUTTON MENU

Press

Only available when modulating

valves are fitted

39

92908135-17

WORK HOURS FAN 000000

COMPRESSOR 1 000000 COMPRESSOR 2 000000

HISTORY ALARM 000 AL00 00:00 00/00/00

SET T: 00.0 T: 00.0 SET H : 000.0 H: 000.0

SERVICE PASSWORD

0000

FAN H. THRESHOLD 100 x 1000

RESET No 000000

COMPRESSOR 1 H. THRESHOLD 100 x 1000

RESET No 000000

COMPRESSOR 2 H. THRESHOLD 100 x 1000

RESET No 000000

PROBES SETTING RETURN AIR HUMIDITY 00.0%

PROBES SETTING RETURN AIR TEMPERATURE 00.0°C

MANUAL PROCEDURE

WILL ONLY WORK IN CONJUNCTION

WITH THE MAIN FAN

Press to return to the MAIN MASK

MAINTENANCE BUTTON MENU

Press

40

92908135-17

The manual operating procedure may only be activated when the unit is in standby mode.

MANUAL PROCEDURE

MAIN FAN NO ENERGY SAVING NO

MANUAL PROCEDURE

DE-HUMIDIFIER NO HUMIDIFIER NO

MANUAL PROCEDURE

COMP 1 / CW OPEN NO COMP 2 / CW CLOSE NO

MANUAL PROCEDURE

HEAT 1 / LPHW OPEN NO HEAT 2 / LPHW CLOSE NO

MANUAL PROCEDURE

COOL VALVE 00.0V HEAT VALVE 00.0V

In this mode the ON/OFF button is in OFF.

Press to return to the MAIN MASK

NOTE:

Alarms and conditions referring to compressors, low pressure and high pressure are not relevant to Chilled Water units unless an alternative Chilled Water option is displayed.

41

92908135-17

COMPONENT IDENTIFICATION L

1

Coil 18

Filter 35

Electrics access

2

Drain tray

19

Transformer

36

Washable filter

3

Access panel

20

Discharge grille

37

Return air grille

4

Terminal

22

Relay 38

Humidity sensor

5

Contactor

24

Fan speed control

39

Isolator

6

Circuit breaker

25

Humidity control pcb

40

Temperature sensor

7

Condensate pump

26

Pressure switch

41

Vice latch

10

Heater element (2kW)

27

Grabber 42

Volt free pcb

11

Side panel assembly

28

Alarm indicator

43

Float switch

12

Swell latch

29

Touch control

44

High water level assembly

13

End stop

30

Humidifier assembly

45

Relay

14

Terminal

31

Membrane key pad

15

Heater cut out

32

Humidifier bottle

16

Blower assembly

33

Terminal 17

Fresh air fan

34

Panel surround

Note: The position of some of the controls shown in this diagram may vary from those in the unit delivered.

42

92908135-17

DCU

ITEM No.

DESCRIPTION

ITEM No.

DESCRIPTION

1

Lid 13

Electrics access panel

2

Fan assembly

14

Handle

3

Right hand access panel

15

Suction service valve

4

Spire clip

16

Isolator

5

LP switch auto

17

End clamp

6

HP switch auto

18

Terminal

7

4 way terminal

19

Power board PCBA

8

Fused terminal

20

Overload (3 phase)

9

Compressor

21

Contactor

10

Crankcase heater

22

Fan capacitor

11

Expansion assembly (including restrictor)

23

Compressor capacitor (1 phase only)

12

Liquid service valve

COMPONENT IDENTIFICATION

43

92908135-17

CKC 30 – 100

ITEM No.

DESCRIPTION

ITEM No.

DESCRIPTION

ITEM No.

DESCRIPTION

1

Lid 15

Service valve

27

Motor

2

LP switch auto

16

Service valve

28

Fan

3

Contactor

17

Valve panel

30

Terminal end clamp

4

Overload (3 phase)

18

Base 31

Terminal

5

Heat exchanger

19

Mounting foot

32

Fuse

6

Rear access panel

20

Compressor

33

Fuse terminal

7

Mains terminal cover

21

Handle 34

Terminal 4 way

8

HP switch auto

22

Front access panel

35

Earth terminal

9

Fan capacitor

23

Fan guard

36

Fan speed controller

10

Switch bracket

24

Fascia panel

37

3 minute timer

11

Bulkhead panel

25

Corner panel

38

Compressor capacitor (1 ph)

14

Expansion assembly

26

Support bracket

39

Electrics box

Note: The fan, motor and fan guard are supplied as a single assembly.

44

92908135-17

ITEM No.

DESCRIPTION

ITEM No.

DESCRIPTION

ITEM No.

DESCRIPTION

1

Lid 13

HP switch auto

26

Handle

2

Fuse terminal

14

Switch bracket

27

Front access panel

3

Fuse 15

LP switch auto

28

Fan guard

4

Terminal

16

Switch bracket

29

Fascia panel

5

Terminal 4 way

17

Bulkhead panel

30

Support bracket

6

Contactor

19

Expansion assembly

31

Fan

7

Terminal

20

Service valve

32

Corner panel

8

Earth terminal

21

Service valve

33

Motor

9

Overload

22

Valve panel

35

Fan speed controller

10

Heat exchanger

23

Base 36

3 minute timer

11

Rear access panel

24

Mounting foot

37

Electrics box

12

Fan capacitor

25

Compressor

CKC 130 to 200

Note: The fan, motor and fan guard are supplied as a single assembly.

45

92908135-17

Marstair 929, CD3 Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual