Heronhill - for all your Airking requirements TECHNICAL MANUAL. for CWR CHILLED WATER CEILING MOUNTED/RECESSED SYSTEMS.

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1 TECHNICAL MANUAL for CWR CHILLED WATER CEILING MOUNTED/RECESSED SYSTEMS. This manual provides technical and installation information for CWR 968 series CHILLED WATER CEILING MOUNTED/RECESSED indoor units. INDEX PAGE GENERAL Part numbers, dimensions and weights 2 Unit features/accessories 2 SELECTION Control valves, airflows, discharge velocities 3 Chilled water duties 4 LPHW duties, 6 Hydraulic resistance 7 Optional electric heating 7 Sound pressure levels 7 Coil water volumes 7 UNIT CWR mounting 8 INSTALLATION Pipework and electrical connections 9 CWR remote controller 12 Condensate removal, air deflection 11 WIRING CWR units 13 DIAGRAMS OPERATION CWR 14 KITS Remote sensor kit 15 Condensate pump kit 18 Electric heater kit 22 3 port diverting valve 24 Pipe thermostat 25 MAINTENANCE CWR units 25 COMPONENT Exploded view of unit with 26 IDENTIFICATION component Identification IMI Air Conditioning Ltd. Armytage Road, Brighouse, West Yorkshire. HD6 1QF Tel: (01484) Fax: (01484) sales@imi-airconditioning.co.uk A subsidiary company of IMI plc

2 IMI AIR CONDITIONING LIMITED CWR CHILLED WATER CEILING MOUNTED/RECESSED UNITS The CWR range consists of 968 series chilled water ceiling mounted/recessed indoor units. CWR CHILLED WATER INDOOR UNITS Models CWR 25 CWR 45 CWR 65 CWR 85 Part Number DIMENSIONS AND WEIGHTS (Unpacked) CWR CHILLED WATER UNITS Model CWR HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg DIMENSIONS AND WEIGHTS (Packed) CWR CHILLED WATER UNITS Model CWR HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg FEATURES/ACCESSORIES FEATURE CWR Manual air deflection Return air sensor (incl electronic thermostat) STD * Electric heating * 3 fan speeds STD Remote hard wired control STD Pendant control cable * Condensate pump * Long life washable filter STD Remote temperature sensor STD Valve options ** Control Options ** LPHW Coil heating ** Key: * = factory/site option. ** = factory fitted option STD = standard. NOTE:If using valves other than those specified by IMI Air Conditioning Ltd., ensure that there is electrical continuity through the valve in all positions, otherwise the indicator lights on the remote control will remain on at all times. For group control systems, contact IMI Air Conditioning Ltd. Technical Sales Department. -2-

3 OPTIONAL CONTROL VALVES 2 port on/off valves or 3 port diverting valves are available as factory fitted options. Chilled water valves are supplied with valve drain trays. (4 port modulating valves are also available - contact IMI Air Conditioning Technical Sales Department). 2 pipe cool only systems require one valve per fan coil. 2 pipe heat/cool systems (supplied from a reverse cycle chiller, or chiller + boiler) require one valve: if using an auto changeover thermostat, they also need a means of signalling heating or cooling status of the flow eg a pipe thermostat (kit shown on page 41). 4 pipe systems require two valves or one modulating valve (but no pipe thermostat is needed). AIRFLOWS Minimum Speed Medium Speed Maximum Speed CWR CFM m 3 /h m 3 /s CFM m 3 /h m 3 /s CFM m 3 /h m 3 /s DISCHARGE VELOCITIES The air discharge vanes are manually adjustable both vertically and horizontally to allow a larger choice of angle of airthrow and direction. It is suggested that, in cooling mode, the discharge is directed horizontally along the ceiling. In heating mode vanes can be moved to a 30 downward discharge. It is also possible to move the air off boxes to a 90 downward discharge, creating an air curtain. -3-

4 CHILLED WATER DUTIES (kw) CWR 25 Air Entering Dry Bulb (Wet Bulb) 21 C (15 C) 24 C (17 C) 27 C (19 C) 29 C (19 C) Air Flow m 3 /h In C Out C DUTY Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible CWR 45 Air Entering Dry Bulb (Wet Bulb) 21 C (15 C) 24 C (17 C) 27 C (19 C) 29 C (19 C) Air Flow m 3 /h In C Out C DUTY Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible

5 CWR 65 Air Entering Dry Bulb (Wet Bulb) 21 C (15 C) 24 C (17 C) 27 C (19 C) 29 C (19 C) Air Flow m 3 /h In C Out C DUTY Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible CWR 85 Air Entering Dry Bulb (Wet Bulb) 21 C (15 C) 24 C (17 C) 27 C (19 C) 29 C (19 C) Air Flow m 3 /h In C Out C DUTY Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible Total Sensible

6 LOW PRESSURE HOT WATER COIL DUTIES (kw) CWR 25 Air Entering, Dry Bulb 10 C 15 C 20 C 25 C Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max Air Flow m 3 /h In C Out C Heating Capacity kw kw kw kw kw kw CWR 45 Air Entering, Dry Bulb 10 C 15 C 20 C 25 C Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max Air Flow m 3 /h In C Out C Heating Capacity kw kw kw kw kw kw CWR 65 Air Entering, Dry Bulb 10 C 15 C 20 C 25 C Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max Air Flow m 3 /h In C Out C Heating Capacity kw kw kw kw kw kw CWR 85 Air Entering, Dry Bulb 10 C 15 C 20 C 25 C Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max Air Flow m 3 /h In C Out C Heating Capacity kw kw kw kw kw kw

7 HYDRAULIC RESISTANCES CHILLED WATER LPHW OPTIONAL ELECTRIC HEATING (kw) CWR 240V 50Hz 230V 50Hz SOUND LEVELS CWR UNITS Sound Pressure Levels Sound Power Levels MODEL Speed dba NC 63Hz 125Hz 250Hz 500Hz 1kHz 2kHz 4kHz 8kHz Min Med Max Min Med Max Min Med Max Min Med Max Sound Pressure Levels (SPL) at 3m distance, 1m below units running in free field conditions, (db re: 2x10-5 N/m 2 ). Sound Power Levels (SWL) in db re: 1pW. COIL WATER VOLUMES (LITRES) Model Chilled Coil LPHW Coil

8 CWR CHILLED WATER CEILING MOUNTED/RECESSED UNIT The CWR chilled water ceiling mounted/recessed unit may be installed either within a suspended ceiling or mounted directly onto a solid ceiling. The installer supplies: * Either 4 lengths of screwed rod (M8) with 12 nuts and washers (suspended false ceiling), or 4 bolts (M8) and washers (solid ceiling). * Method of securing screwed rod to solid ceiling e.g. rawlbolt shields. * Insulated pipework. * Mains wiring with suitable isolation. * Remote thermostat (available separately, part number ). * Condensate drain (12mm bore diameter tube). * Interconnecting wires for remote thermostat; 2 screws to secure the remote thermostat. * Method for securing solid sheathed cable if these are used. UNPACKING Carefully unfasten the banding and lift off the box sleeve. The following are supplied: * CWR unit (in protective sleeve, held between two polystyrene end caps). * Ceiling tile support rail and securing screws. * 2 cable clamps suitable for flexible, pre-sheathed cable. * Envelope containing end user operating instructions to be left with the end user. 1 Remove and discard the wooden supports (Not CWR 25). 2 Remove the cable clamps and place in a safe location until required. 3 Lift the CWR unit from the box complete with the end caps; (this will require 2 people for sizes 45 to 85). 4 Remove the two polystyrene end caps and the protective sleeve. PREPARATION FOR MOUNTING It is necessary to remove both end panels, the hinged grille, the corrugated cardboard beneath the grille, the filter and the fascia panel prior to installation. Remove the end panels, first opening the grey screw covers and removing the screws (two on each end panel). Unhook the panels from the chassis. Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some resistance will be felt. Lift the filter over the retaining lug and slide it out (Fig. 2). Fig. 1. Fig. 2. Fig. 3. Insert a screwdriver between the grilles and disengage the grille retaining catches (Fig. 3). Swing the grille away and unhook from the chassis. Remove and retain all the fascia support bracket fixing screws and remove the bracket and fascia from the unit. Store the fascia in a safe location until required. -8-

9 CHASSIS MOUNTING NOTE: It is generally easier to fit kits prior to mounting the unit and connecting the pipework. CWR can be fitted into a suspended false ceiling (Fig. 4) or onto a solid ceiling (Fig. 5). Fig. 4. Fig. 5. Location of the unit will depend on the room shape, load and number of units installed. Typical options are: PIPE AND CABLE EXITS CWR units allow a choice of two pipes exits for greater flexibility of installation. 1 Determine the position for the unit allowing at least 450mm clearance below the air inlet. Also ensure that the position does not interfere with light fittings, sprinkler heads, etc.. 2 Identify the type of ceiling and ensure that the mounting surface will support the operating weight of the unit. MODEL CWR 25 CWR 45 CWR 65 CWR 85 OPERATING WEIGHT (kg)

10 MOUNTING CENTRES CWR A B C D E F G H J K L M If fitting the unit in a suspended ceiling after the ceiling has been installed, remove ceiling tiles to accept the chassis, plus adjacent tiles on each side for general access. Use the ceiling tile support rail when the unit is positioned some distance from the wall; the rail should be secured to the rear of the unit chassis prior to hanging the unit. 4 The chassis should be supported by four (M8) bolts, or screwed rods and 12 nuts (M8 OD) on a suspended ceiling, supplied by the installer. On plasterboard suspended ceilings, remove sufficient of the ceiling to give clearance for the unit to be fitted, and for access to pipework and electrics; trap doors should be left for service access to electrics and pipework. On reinforced concrete ceilings use Rawlbolt shields or equivalent. On wooden ceilings use battens for a mounting frame. 5 Suspend the chassis, using either 4 bolts and 4 washers (solid ceiling) or 12 nuts and 8 washers (suspended false ceiling). NOTE: The mounting holes are keyhole slots and therefore the Rawlbolts should be installed prior to offering up the unit. -10-

11 PIPE CONNECTIONS CWR UNITS Pipework is terminated with end caps, adjacent to the access panel at the left hand side. All pipework is 15mm copper water pipe. ELECTRICAL CONNECTIONS Mains, control and interconnecting cables must be supplied and fitted by the installer. Installer wiring must be carried out in accordance with IEE regulations and local codes. Cables must be size compatible with the recommended fuse for a given system. An isolator switch should be positioned within easy reach of the indoor unit. The equipment MUST be earthed. Cables may enter the CWR unit at the top, back, left or right hand side. If the left hand side is used, sufficient cable length should be allowed to run the full length inside the unit. Ensure that the cable is secured to the chassis flange along the length of the unit and to the holes provided in both hanger brackets. Cable glands suitable for stranded cables are supplied and should be used to secure all cables. Installers must supply a method of securing any solid sheathed cable. FUSES (A) MODEL CWR 25 CWR 45 CWR 65 CWR 85 Without Electric With Electric Heaters CONDENSATE REMOVAL Condensate is collected in a drain tray incorporated within the fascia panel. An outlet connection is provided at the back/right hand side of the unit for connection to a 12mm bore flexible pipe. Run the outlet pipe to gravity drain ensuring that there are no kinks or blockages. An optional condensate pump kit is available with 5m lift. FASCIA MOUNTING Electrically isolate the unit. Once the chassis has been installed, the fascia should be refitted, (Fig. 6). When complete, refit the grille, filter and end panels: fit the fascia support bracket with No.10 screws, (Fig. 7). AIR DEFLECTION Fig. 6. Fig. 7. The air off vanes are manually adjustable to allow horizontal and downward air deflection. It is suggested that, in cooling mode, the discharge is directed horizontally along the ceiling. In heating mode, vanes can be moved to a 30 downward discharge. Refer to page 3 for discharge velocities. It is also possible (by reversing the discharge boxes) to move the air off vanes to a 90 downward discharge, creating an air curtain. -11-

12 INSTALLATION OF A REMOTE THERMOSTAT The thermostat should be wired with 7 cores of double insulated cable, 0.5mm 2 minimum, preferably in plastic conduit for good appearance. Select a position to mount the thermostat taking into account the following comments: a b c d e f The thermostat must be mounted on a flat surface within the area conditioned by the unit to which it is connected. Avoid draughts, heat from radiators, temperature variations from hot/cold water pipes and direct sunlight. Avoid corners of the room where air is likely to stagnate. Avoid direct air discharge from the unit nto the controller. Avoid positions where the thermostat may be covered or obscured. If the room contains pillars, mount on the side of the pillar furthest away from the unit. IMI REMOTE CONTROL (7204) Carefully prise off the push-fit dial on the remote controller, unscrew the retaining screw and remove the control cover. Mount the controller directly to a wall or onto a plinth, using two suitable fasteners, (not supplied). Wire between the remote controller and the unit using multi-core cable, as shown in the wiring diagram (page 34). SETTING INSTRUCTIONS: The cooling differential (cool in to cool out) is fixed at 1.8 C +/- 0.5 C. The heating differential (heat in to heat out) is fixed at 1.5 C +/- 0.5 C. The deadband is fixed at 1.2 +/- 0.7 C. The set point limits can be adjusted on the back of the push fit dial. The set point is factory set for a range from 17 C to 30 C: it is recommended that the minimum setting is kept at 17 C or above. IMI REMOTE CONTROL (RCC 30) Using a flat-bladed screwdriver in the slot at the bottom of the casing, lever off the cover. Mount the backpanel directly to a wall or onto a plinth, using the fasteners supplied. Wire between the remote controller and the unit as shown. OPERATION RETURN AIR SENSOR NEUTRAL LIVE HEAT COOL MAX MED MIN RCC 30 B1, M N L Y11 Y21 Q3 Q2 Q1 CWR * *Optional return air sensor can detect return air temperature at the unit rather than the controller. (Heating is possible if the system includes a heat pump outdoor unit, or if electric heaters have been fitted). -12-

13 DIP switches at the bottom rear of the controller can be set on site to suit the application. DIP switch Function ON position OFF position 1 Fan control Fan control is temperature dependent in all operating modes 2 Operating mode changeover via external switch 3 Action of switch for externally operated mode changeover Changeover between normal operation and energy saving mode Changeover activated when contact of switch is closed Fan control in normal operation is temperature independent Changeover between normal operation and standby Changeover activated when contact of switch is open 4 Standby Frost protection disabled Frost protection enabled 5 Switching differential 1K in heating mode, 0.5K in cooling mode 4K in heating mode, 2K in cooling mode 6 Dead zone in normal operation 2K 5K = factory settings CWR 25 TO 85 WIRING DIAGRAM B Brown H Heat/heater R Red SH Heater supplementary O Orange EH Heater electric Y Yellow TP1 Thermal protector G Green TP2 Thermal fuse BL Blue RL Relay V Violet T1 Thermostat de-ice GRY Grey T2 Thermostat supplementary W White LK Link BK Black PCB1 Condensate control P Pink RT Remote thermostat T Turquoise F Fuse HT High temperature S1 Condensate sensor M1 Motor fan C Capacitor M2 Pump V1 Valve cool M3 Vane motor V2 Valve heat AC Air conditioner CC Control HP Heat pump RV Reversing valve --- Not supplied -13-

14 TEMPERATURE CONTROL The temperature range is factory set 17 C - 30 C. Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures. The white neon is lit when the unit is in cooling mode. The amber neon is lit when the unit is in heating mode (if heating is fitted). Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted. Neither neon is lit when the thermostat is between cooling and heating. OPERATING INSTRUCTIONS (RCC 30 ELECTRONIC) TEMPERATURE CONTROL The temperature range is factory set 17 C - 30 C. Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures. Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted. OBSOLETE ELECTRONIC REMOTE CONTROLLER This may have been used in place of (7204 electromechanical), allowing the use of a return air sensor ( , shown opposite) to sense air temperature at the CWR unit. TEMPERATURE CONTROL The temperature range is factory set 17 C - 30 C. Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures. The amber neon is lit when the unit is in cooling mode. The red neon is lit when the unit is in heating mode (if heating is fitted). Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted. Neither neon is lit when the thermostat is between cooling and heating. -14-

15 REMOTE SENSOR KIT This kit may be used on CWR models to sense the temperature at the return air grille. Item Qty Description 1 1 Electronic remote control 2 1 Sensor assembly with 4m lead 3 1 Retaining clip ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT 1 Fit the retaining clip to the drip tray support bracket, (Fig. 1), with the open end of the clip to the room side of the bracket. 2 Clip in the sensor with the lead towards the electrics end of the unit. 3 Route the sensor lead into the electrics box. Use the plastic cable clamp to secure any spare cable within the electrics area, ensuring that it cannot foul on the fan or touch the electric heater (if fitted) 4 Exit the electrics box through one of the cable glands used for the interconnecting cable and route the lead to the remote controller position. NOTE: The cable may be extended up to a maximum of 50 metres. Ensure that all joints and insulation are capable of withstanding mains voltage. 5 Carefully prise off the push-fit dial on the remote controller, unscrew the retaining screw and remove the control cover, (Fig. 2) Fig. 1. Fig Locate the wire link Br.1 in the wall mounted thermostat, on the right hand side of the white adjustment potentiometer P1, and cut the link, (Fig. 3). 7 Locate the sensor, R15, on the left hand side of the adjustment potentiometer P1, and gently pull it out of the mounting sockets (Fig. 3). 8 Connect the lead from the remote sensor to terminals 11 and 12 in the remote controller Fig. 3. (Fig. 3). -15-

16 9 Route the remote controller cable from terminals 1 to 7 in the CWR unit, (Fig. 1), along with the existing wires from the unit and connect to the remote controller as shown in the table below. Secure all cables inside the unit to ensure that they do not foul the fan or touch the electric heater, (if fitted). CWR ELECTRONIC THERMOSTAT FUNCTION 1 4 NEUTRAL 2 1 LIVE 3 22 BOOST SPEED 4 21 HIGH SPEED 5 20 LOW SPEED 6 6 COOL 7 2 HEAT 10 (If an IMI Air Conditioning electromechanical controller was previously used, the connections in the original controller are numbered the same as the terminals in the CWR unit). 11 Setting instructions: The cooling differential (cool in to cool out) is fixed at 1.5C. The heating differential (heat in to heat out) is fixed at 0.5C. The square, black potentiometer, (P3, Fig. 3), adjusts dead zone; fully anti-clockwise gives 0.5K, fully clockwise (through 270 ) gives 7.5K (as shown on the printed circuit board). The set point limits can be adjusted on the back of the push-fit dial; DO NOT SET THE LOWER SET POINT BELOW 15 C. On cool only units, turn the potentiometer, P3, fully anti-clockwise (dead zone 0.5K). TYPICAL SETTINGS: REMOTE SENSOR KIT (FOR RCC 30 REMOTE CONTROLLER ) This instruction is also applicable to return air sensor spare S The sensor can be fitted to the return air inlet to an air conditioning unit to improve operation eg. if the wall thermostat is placed outside the space being conditioned, or if there is considerable stratification in a room with a high ceiling, where the wall thermostat would not measure a representative temperature. ITEM QTY DESCRIPTION 1 1 Sensor (4m lead) 2 2 Tie wrap ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THE SENSOR Connect the sensor to terminals B1 and M, as shown (polarity is unimportant). Tie wrap the sensor to a suitable place in the return airflow, where it will soak in a representative temperature. After installation, adjust the thermostat to confirm satisfactory operation, noting that DX units may experience a three minute delay if the compressor has recently run. -16-

17 PROGRAMMABLE TIMER KIT This kit can be used to give ON/OFF switching of the mains voltage control circuits of CWR units where the total current does not exceed 3 Amps. ELECTRIC HEATER CURRENTS CANNOT BE SWITCHED DIRECTLY. It is not required for 'L' products which have built in timers. ITEM QTY DESCRIPTION Day Programmable Timer 2 1 In Line Fuse Carrier Amp Fuse, 1" x 1/4" 4 1 Terminal PROGRAMMER SPECIFICATION: Type: Digital electronic 230V, 50Hz Programme: 7 day Setting Resolution: 1 minute Selection Switch: "OFF", "TMD (TIMED)" "CON (CONSTANT ON)" "ADV (ADVANCE)" Max. Switched Current: 3 A (fan load) The timer will accommodate 0.75mm 2 to 2.5mm 2 wires. Three core cable is required between the timer and the air conditioning unit. The timer motor must be connected to an uninterrupted supply source. TIMER MOUNTING 1 Carefully unpack and identify the components. 2 If the unit is to be surface wired, remove the appropriate knockouts in the backplate. Screw the backplate to the wall with No. 8 wood screws through the fixing holes. 3 If the backplate is to be fixed to a BS4662 single gang plaster depth box, use 3.5mm machine screws. WIRING FOR ON/OFF SWITCHING 4 a) Wire timer terminal 'L' to unit terminal 2. b) Connect timer terminal 4 to either:- Remote controller 7204 ( ) : terminal 2 Remote controller RCC 30 ( ): terminal L c) Wire timer terminal 'N' to unit terminal N 5 Discard the in-line fuse carrier. 6 Plug in the unit and secure the screws. 7 Program as described in the separate timer instructions. If, as a result of fitting this kit, more than one supply is taken into a unit, that unit must be marked:- "Two, (or more if applicable), supplies are taken into this equipment. Isolate both, (all), before undertaking any maintenance work." -17-

18 CONDENSATE PUMP KIT This kit is for use on 539 series IMPULSE and 968 series CWR units for the removal of condensate where gravity drain is not practicable or desirable. The pump is capable of overcoming a resistance equivalent to 5 metres lift. The sensor is arranged so that residual condensate in the sump is kept to a minimum. The kit includes an overflow protection circuit, which will prevent further cooling and condensate production if a high condensate level occurs. ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 PUMP ASSEMBLY CONSISTING OF: 4 1 Grommet A 1 Pump 5 1 Wire Support B 1 Grommet 6 4 No. 8 Screw C 1 Hose 7 1 Cable Tie D 1 Green/Yellow Cable 8 2 No. 6 Screw E 1 Cable Tie 9 1 Sensor Block 2 1 Control Board 10 1 Sensor Bracket 3 4 Mounting Foot It is preferable to fit this kit prior to installing the unit; the following instructions/diagrams refer to bench fitting. ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THIS KIT 1 Remove both side panels (2 screws each side behind the plastic caps):- WARNING: IF THE UNIT IS ALREADY INSTALLED IN THE CEILING, THE SIDE PANELS WILL DROP IMMEDIATELY UPON RELEASING THE SCREWS. 2 Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some resistance will be felt. 3 Lift the filter over the retaining lug and slide it out (Fig. 2). Fig. 1. Fig. 2. Fig Insert a screwdriver between the grilles and disengage the grille retaining catches (Fig. 3). Swing the grille away and unhook from the chassis. 5 Remove and retain all the fascia support bracket fixing screws (Fig. 4) and remove the bracket and fascia from the unit. Store the fascia in a safe location until required. Fig The condensate drain connector is already fitted to the pipework end of the unit, (Fig. 5). Fig

19 Fig Fit the loose pump grommet in the kit onto the hose (supplied as part of the unit) at the electrics end (Fig. 6). 8 Push the hose (referred to in 7) fully onto the condensate pump outlet and secure as far onto the outlet as possible with the 4" cable tie (Figs. 6 and 7). 9 Secure the green/yellow cable and pump support wire to the coil hanger bracket with No. 8 screws (Fig. 6). 10 Push the grommets on the hose into the pump support wire; the arrows on the pump must point towards the motor (Fig. 6). Fig The sensor/filter assembly is supplied fitted to a transition bracket. a If the unit has been supplied with a sensor bracket fitted, align the holes in the transition bracket with those in the sensor bracket and connect together with the No. 6 screws (Fig. 7). b If the unit has been supplied without a sensor bracket fitted, disengage the sensor from the transition bracket, align the holes in the transition bracket with those in the coil hanger bracket and secure together using the No. 8 screws. Refit the sensor to the bracket (Fig. 7). 12 Push the hose from the pump onto the sensor pick up spout (Fig. 7). Route the hose to avoid kinking. 13 Push the control board mounting feet into the four holes on the electrics plate (Fig. 6) and mount the control board. 14 Remove and discard the terminal covers from the black and blue wires, remove and retain the curly lok cable tie and make the following connections to the control board (wiring diagram below). a Black cable to terminal L. b Blue cable to terminal N. c Pump cable to terminal PL. d Pump cable to terminal PN. e Sensor block flying lead plug to the six pin connector (CON 1). f Cut the looped red cable, (Fig. 6), bare back each half by 6mm and connect to the plug-in screw terminal block TB1. g Use the curly lok cable tie to secure the wires and the sensor lead to the condensate outlet pipe above the transformer. -19-

20 15 Refit the drip tray/fascia. Disconnect the gravity drain (if previously fitted) and either block off the pipe or ensure that the outlet is above the level of the drip tray by placing the pipe up behind the grille. 16 Connect a 12mm (0.5") OD drain tube to the drain connector (Fig. 5), and route together with the refrigeration/chilled water pipes to a suitable outlet. NOTE: Use of a 12mm OD drain tube should reduce the possibility of syphoning, but if the drain outlet is below the level of the base of the drip tray, syphoning may occur, creating noise on pumping. If this occurs, fit an air break, e.g., by pumping into a larger diameter pipe than that from the pump, no further than 200mm below the level of the base of the unit. 17 Refit the grille and filter. 18 TESTING THE PUMP AND CONTROL a b c d Connect a suitably fused supply to the unit (refer to the unit installation instructions). Allow approximately one minute for the controls and sensor to stabilize. Slowly add water to the condensate tray until the pump runs. Initially the pump will be noisy until the air in the hose has been expelled. It is possible that, on this first cycle, the pump will run dry for a short period (indicated by noise). Add more water to the tray and the pump will cycle in the normal manner. With the system in cooling mode, continue adding water to the sump until it reaches the higher of the sensor probes. The cooling cycle will shut down, and the pump continue to run, until the water has dropped below the level of this probe. 19 Refit the side panels. NOTE: Whenever the electrical supply to a unit fitted with a condensate pump and controls is interrupted, a delay of up to 1 minute will occur before the compressor or the pump will start when the supply is reinstated CONDENSATE PUMP WIRING DIAGRAM -20-

21 TROUBLE SHOOTING Pump does not run Fuse on control board blown (315 ma) Sensor disconnected from control board Cooling is interrupted Excessive pump noise Restriction in pump flow allowing level to rise and trip overflow circuit Check for blockage or kink in hoses. Condensate at high level -- tripping overflow circuit Filter is blocked (remove and clean) Air leak in hoses and/or joints Pumping without water in sump -- control board fault Loose connection between sensor and control board Loose fuse, intermittent mains supply to control board. syphoning due to lack of air break APPLICATION NOTES 1 The pump will work against a 5m head. Flow rate is highest with minimum head. 2 Long lengths of drain pipe should not be exposed to the outdoor ambient, otherwise freezing of condensate may occur during winter operation. 3 It is not advisable to have the outlet of the drain well below the position of the pump, otherwise the syphon effect may open the pump valves. 4 For normal applications, i.e., where the drain is level or above the pump or within 3 feet below it, no extra check valves are needed; the pump has its own internal check valves. 5 Ensure that no hose is kinked, as this could seriously affect the pump performance. 6 Clean the filter at regular intervals. -21-

22 ELECTRIC HEATER KITS for CWR CHILLED WATER UNITS CWR MODEL KIT PART NUMBER RATING (kw at 240V) ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 Heater Assembly 2 1 Blue Wire 1 Safety Cutout 3 1 Relay Assembly 1 Cutout Bracket 1 Black Wire 2 Grommet 1 Blue Wire 3 Brown Glasslap Wire 1 Orange Wire 1 Earth Wire and clip 4 1 Heater Support Bracket 1 Cable Tie 5 3 No. 8 Screw 6 2 Cable Tie 7 1 Thermal Fuse 8 2 No.6 Screw It is preferable to fit this kit prior to installing the unit; the following instructions/diagrams refer to bench fitting. ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THIS KIT 1 Remove both side panels (2 screws each side behind the plastic caps):- WARNING:IF THE UNIT IS ALREADY INSTALLED IN THE CEILING, THE SIDE PANELS WILL DROP IMMEDIATELY UPON RELEASING THE SCREWS. 2 Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some resistance will be felt. 3 Lift the filter over the retaining lug and slide it out (Fig. 2). Fig. 1. Fig. 2. Fig Insert a screwdriver between the grilles and disengage the grille retaining catches (Fig. 3). Swing the grille away and unhook from the chassis. 5 Loosen the drip tray screws and slide the drip tray to gain access to the electrics. 6 Remove the two grommets from the electrics end hanger bracket. 7 Fit the heater support bracket onto the inside of the pipe end hanger bracket using 2 off No. 8 screws, (Fig. 4). 8 WARNING: The thermal fuse MUST be secured to the heater cutout bracket using the 2 off No.6 screws provided. IMPORTANT: DO NOT TOUCH THE HEATER CUTOUT BLADE. 9 Connect both brown glass lap wire flag terminations to the thermal fuse terminals. Fig

23 10 Remove the nuts and washers from the heater element. IMPORTANT: DO NOT TOUCH THE HEATER CUTOUT BLADE. Slide the heater terminals through the electric end hanger bracket leaving the cutout assembly between the heater and the backpanel. Ensure that the elements are not crossed and the heater end is supported on the bracket. Refit the washers then nuts and tighten to secure. 11 Fit the grommet supplied on the heater assembly wires into the slot on the hanger bracket, as shown in Fig Fit the remaining No. 8 screw to the terminal end of the relay. Locate the tab at the other end of the relay into the slot behind the 7 way terminal and secure the relay with the screw, (Fig. 5). 13 Refer to the wiring diagram below, and the one supplied on the unit side panel. Fig. 5. Connect the following wires:- Orange (O) - to 7 way terminal block, terminal 7. Blue (Bl) - to capacitor neutral piggyback. Black (Bk) - to mains terminal, live. Earth (G/Y) - to main earth terminal Brown glasslap (B) - (shorter wire) to heater element. Brown glasslap (B) - (longer wire) to relay terminal 14. Blue wire (Bl) - from heater element to mains terminal, neutral. (supplied loose) Secure with the tie wraps supplied. -23-

24 3 PORT DIVERTING VALVE ASSEMBLY - CHILLED WATER and 407 LPHW and 417 These valves are supplied to control the flow of chilled and low pressure hot water onto CWR units. The valve by-pass port (A) is fitted with an orifice disc to minimise flow fluctuations when the unit is in dead zone and the valve goes to by-pass. TYPE Chilled Chilled LPHW LPHW UNIT KIT No ITEM QTY DESCRIPTION 1 1 Valve assembly 2 2 Copper extension piece 3 3 Tie wrap These instructions assume that the unit is installed when the valve assembly is being fitted. ISOLATE THE SYSTEM PRIOR TO INSTALLATION OF THIS KIT 1 Remove the side panels and drain tray from the unit to expose the coil headers. 2 Cut the cap off the appropriate outlet header stub leaving a length of 45mm, (see Fig. 1). Similarly cut off the 90 elbow connecting the inlet pipe to the inlet header stub again leaving 45mm. De-burr both cut pipes. NOTE: For early units fitted with headers which have shorter stubs, cut the cap and elbow off leaving a length of 30mm. Braze to these stubs the swaged copper pipes supplied loose to re-establish the 45mm length, (see Fig. 2).. 3 Offer the valve assembly up to the stubs on the inlet and outlet headers with the valve motor uppermost. Tighten the valve compression nuts. 4 Feed the valve motor leads through the rectangular hole at the air on end of the unit into the electrics compartment, (Fig. 3). Secure along its length with tie wraps. Connect the valve motor leads as shown in Fig. 4. Fig. 3. Fig

25 PIPE THERMOSTAT KIT This kit is for fan coils on 2 pipe systems supplied from a reverse cycle chiller (or chiller + boiler) and fitted with an auto changeover thermostat, to enable a single valve to operate in both heating and cooling modes. It prevents the room thermostat calling for cooling and the valve being opened when the flow is hot water, and vice versa. The thermostat must measure the flow temperature from the reverse cycle chiller and should be sited as below. ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 1 Pipe thermostat 4 1 Plastic banding 2 1 Sachet of heat sink paste 5 2 Plastic clips 3 1 Spring band 6 1 Capacitor (7204 thermostat only) ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THIS KIT 1 The pipe thermostat should be secured to the hot/chilled water pipe using the spring clip, or plastic banding plus clips: typically set to 40 C. Use the heat sink paste to ensure a good thermal bond with the pipe 2 Connect pipe thermostat terminal 2 to the cooling signal, (either from the unit or room thermostat). Connect pipe thermostat terminal 3 to the heating signal, (either from the unit or room thermostat). Connect pipe thermostat terminal 1 to the live on the valve and the neutral valve terminal to mains neutral. 3 Electromechanical 7204 thermostat only (not RCC 30): connect the suppressor capacitor 'C' (where shown) to avoid the cooling indicator glowing when in dead band. USING 7204 E/M WIRED THERMOSTAT USING RCC 30 ELECTRONIC WIRED THERMOSTAT MAINTENANCE ISOLATE THE UNIT ELECTRICALLY BEFORE COMMENCING ANY MAINTENANCE WORK. In order to maintain efficiency of this unit, it is important that the filters behind the return air grilles are cleaned regularly. To remove filters; 1 Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some resistance will be felt. 2 Lift the filter over the retaining lug and slide it out (Fig. 2). Fig. 1. Fig Wash the filter and dry it before use; alternatively, tap the filter gently to remove dust or vacuum clean. 4 Replace the filter ensuring that it is held in position by the retaining lug. 5 Push the grille back into position until it spring locks. THE UNIT SHOULD ALWAYS BE USED WITH A FILTER, FAILURE TO DO SO WILL CAUSE A DECLINE IN UNIT PERFORMANCE AND MAY RESULT IN MALFUNCTION. -25-

26 INDOOR UNIT ASSEMBLY DRAWING AND COMPONENT IDENTIFICATION 1 Top box assembly 14 Condensate pump sensor 2 Side panel fixing position 15 Fuse cover 3 Fan motor 16 Fuse (2A) 4 Fascia and drip tray assembly 17 Heater cutout assembly 5 Fan motor capacitor 18 Heater element 6 Relay (only when electric heater is fitted) 19 Chilled water coil 7 Filter 20 LPHW coil 8 Condensate drain connector 21 Condensate drain connector 9 Return air grille 22 End bearing housing 10 Right hand side cover 23 Left hand side cover 11 Condensate pump PCB 24 Impeller 12 Fuse (315mA) 25 Intermediate bearing 13 Condensate pump 26 Impeller spring -26-