INSTALLATION & MAINTENANCE MANUAL

Condensing Units CU 1-1.5 CUH 1-1.5 CUS 2-12 CUHS 2-12 CFCUS 5-10

CU/CFCU

Condensing Units

About Airedale Products & Customer Services

WARRANTY, COMMISSIONING & MAINTENANCE
As standard, Airedale guarantees all non consumable parts only for a period of 24 months, variations tailored to suit product and application are also available, please contact Airedale for full terms and details. To further protect your investment in Airedale products, we have introduced Airedale Service, who can provide full commissioning services, comprehensive maintenance packages and service cover 24 hours a day, 365 days a year (UK mainland). For a free quotation contact our Airedale Service or your local Sales Engineer.

CAUTION

Warranty cover is not a substitute for Maintenance. Warranty cover is conditional to maintenance being carried out in accordance with the recommendations provided during the warranty period. Failure to have the maintenance procedures carried out will invalidate the warranty and any liabilities by Airedale International Air Conditioning Ltd. A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our Spares department on request. As well as our comprehensive range of products, Airedale offers a modular range of Refrigeration and Air Conditioning Training courses, for further information please contact our Training Co-ordinator.

SPARES TRAINING

AIAC Ltd endeavours to ensure that the information in this document is correct and fairly stated, but none of the statements are to be relied upon as a statement or representation of fact. AIAC Ltd does not accept liability for any error or omission, or for any reliance placed on the information contained in this document. The development of Airedale products and services is continuous and the information in this document may not be up to date. It is important to check the current position with AIAC Ltd at the address stated. This document is not part of a contract or licence unless expressly agreed. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or information storage and retrieval systems, for any purpose other than the purchaser's personal use, without the express written permission of AIAC Ltd. 2003 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.

CUSTOMER SERVICES
Customer Services

For further assistance, please e-mail: enquiries@airedale.com or telephone: UK Sales Enquiries International Enquiries Spares Hot Line Airedale Service Technical Support Training Enquiries + 44 (0) 113 238 7789 + 44 (0) 113 239 1000 + 44 (0) 113 238 7878 + 44 (0) 113 239 1000 + 44 (0) 113 239 1000 + 44 (0) 113 239 1000 uk.sales@airedale.com enquiries@airedale.com spares@airedale.com service@airedale.com tech.support@airedale.com marketing@airedale.com

For information, visit us at our Web Site: www.airedale.com

Condensing Units
Installation & Maintenance Manual : 904-038 IM E 11/00/C

Condensing Units
Contents
DESCRIPTION
Standard Features Optional Extras

CU/CFCU

4 5

GENERAL STATEMENT WARRANTY LOOSE ITEMS LIST SITE INSTALLATION

Lifting Positioning Wall Mounting Technical Data Dimensions / Positioning / Weights Refrigerant Pipework Schematics Unit Charge Pipe Sizing Guide Pipework Installation Pressure Testing Evacuation Alternative Refrigerants Electrical Data CU./CUH. 1 - 4 Electrical Data CUS/CUHS 5 12 Electrical Data - CFCUS 5 10 Interconnecting Wiring Pre-Start Checks Control Circuit Checks Refrigerant Charging Adding Oil Running Checks

6 7 8 8
8 8 8

MECHANICAL INFORMATION

9 10

REFRIGERATION INFORMATION

13 13 13 13 14 14 14

13

ELECTRICAL INFORMATION

15 15 16 16

15

COMMISSIONING

18 19 20 20 21

18

TROUBLESHOOTING MAINTENANCE

22 26

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Description
GENERAL

Condensing Units

The condensing units comprise a compact housing incorporating all the necessary components and associated controls required. The compressor and controls are fitted in the weatherproof end section. Airedale certify that the equipment detailed in this manual conforms with the following EC Directives: Electromagnetic Compatibility Directive (EMC) Low Voltage Directive (LVD) Machinery Directive (MD) Pressure Equipment Directive (PED) 89/336/EEC 73/23/EEC 89/392/EEC in the version 98/37/EC 97/23/EC

CE DIRECTIVE

To comply with these directives appropriate national & harmonised standards have been applied. These are listed on the Declaration of Conformity, supplied with each product.

STANDARD FEATURES FAN & MOTOR UNITS

CU./CUH. 1 - 4 Axial flow fan assembly with low noise sickle type blades. The external rotor motor allows the use of a low power output single phase speed controllable motor to power the fan. The motor has inbuilt thermal overload protection and the assembly is protected against accidental contact by an integral punched finger guard. CUS/CUHS 5 - 12 Axial flow fan assembly with low noise paddle type blades and inlet ring. The external rotor motor allows the use of a low power output single phase speed controllable motor to power the fan. The motor has inbuilt thermal overload protection and the assembly is supplied complete with a finger guard for protection. CFCUS 5 - 10 Comprises a forward curved centrifugal fan, belt driven by a totally enclosed 3 phase motor, mounted on a slide base allowing ease of belt tensioning.

COMPRESSORS CU./CUH. 1 - 1.5

CUS/CUHS 2 - 12 & CFCU 5 - 10 Fully hermetic reciprocating compressor fitted as standard with Internal thermal motor protection. Compressor(s) are mounted to the base via the use of vibration isolators. Hermetic scroll compressors fitted as standard with: Internal thermal motor protection. Internal pressure relief valve. Compressor(s) are mounted to the base via the use of vibration isolators. Oil type may vary depending upon the refrigerant type, refer to Technical Data.

SERVICE VALVES
CU./CUH. 1 - 7.5 Units are provided with suction and liquid line shut-off valves fitted with Schrader connectors to facilitate connection of a service gauge manifold (except the CUS 5 - 7.5, which have no Schrader connection on the suction valve). Units are provided with liquid line shut off valves and rotalock valves fitted in the suction line. Manual reset high and low pressure cut-out switches are fitted in the compressor end compartment as standard.

CUS/CUHS 10 - 12

SAFETY PRESSURE SWITCHES

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Description
HEAT PUMP UNITS

CU/CFCU

Heat pump units are equipped with a reversing valve, crankcase heater and suitably sized accumulator. A factory set defrost sensor is also fitted to defrost the outdoor coil when the unit is operating in heat pump mode. Equipped with a bi-directional expansion valve. Fitted with an expansion valve, check valve and sight glass. The control panel is equipped with the necessary PCBs, MCBs, contactors and other items to provide fully automatic safe operation.

CUHS 1 - 4 CUHS 5 - 12

CONTROLS

HEAD PRESSURE CONTROL

CU./CUH.1 - 12 Head pressure is maintained by a factory fitted, pressure actuated, head pressure controller which varies the speed of the fan(s) to provide optimum control under varying ambient conditions. Head pressure is maintained by a factory fitted set of pressure actuated opposed blade dampers which modulate to provide optimum control under varying ambient conditions.

CFCUS 5 - 10

OPTIONAL EXTRAS Epoxy Coated Coils Wall Brackets

In atmospheres where high corrosion is anticipated epoxy coated aluminium finned coils can be supplied. Of a single multi-fit design in matching material and colour. Ready to assemble on site. A trace heated stainless steel defrost drain tray can be fitted to units. For low load applications a hot gas bypass valve and in-line solenoid valve can be factory fitted to CUS 5 - 12 and CFCUS 7.5 - 10 (supplied loose on units CFCUS 5 - 6 and CUS 1 - 4).

(CU./CUH. 1 4)

Defrost Drain Tray

(CUH/CUHS 1 4)

Hot Gas Bypass

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General Statement
IMPORTANT

Condensing Units

The information contained in this manual is critical to the correct operation and maintenance of the unit and should be read by all persons responsible for the installation, commissioning and maintenance of this Airedale unit. The equipment has been designed and manufactured to meet international safety standards but, like any mechanical/electrical equipment, care must be taken if you are to obtain the best results. 1 2 Service and maintenance of Airedale equipment should only be carried out by skilled personnel. When working with any air conditioning units ensure that the electrical isolator is switched off prior to servicing or repair work and that there is no power to any part of the equipment. Also ensure that there are no other power feeds to the unit such as fire alarm circuits, BMS circuits etc. Electrical installation commissioning and maintenance work on this equipment should be undertaken by competent and trained personnel in accordance with local relevant standards and codes of practice. Refrigerant used in this range of products is classified under the COSHH regulations as an irritant, with set Occupational Exposure Levels (OEL) for consideration if this plant is installed in confined or poorly ventilated areas. A full hazard data sheet in accordance with COSHH regulations is available should this be required.

SAFETY

3 4

SPARES

For ease of identification when ordering spares or contacting Airedale about your unit, please quote the unit type, unit serial number and the date of manufacture. This information can be found on the unit serial plate. An area has been provided on the front cover of this manual for this information to be recorded. A spares list for 1, 3 and 5 years will be supplied with every unit and is also available from our Spares department on request.

SERIAL PLATE EXAMPLE

AIREDALE INTERNATIONAL AIR CONDITIONING LTD , LEEDS LS19 6JY UNIT TYPE CUS 4HI 81543668-001 (63091072) UNIT SERIAL No. U60801-01-02 DATE OF MANUFACTURE 01/02/03 ELECTRICAL SUPPLY 380 V 3 PH 50 Hz COMPRESSOR 1 3.8 FLA 23.0 LRA CONDENSER FAN 0.7 FLA 1 PH 0.15 kW SUPPLY FUSE RATING 10.0 A REFRIGERANT TYPE & CHARGE R407C FACTORY TEST PRESSURE HIGH SIDE 440 PSIG LOW SIDE 200 PSIG

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Warranty
GENERAL

CU/CFCU

To be read in conjunction with Airedale International Air Conditioning Ltd standard Conditions of Sale. The equipment carries Airedales standard warranty for a period of 24 months from the date of despatch or of invoice which ever is the sooner in respect of non-consumable parts only and does not include for the cost of labour incurred during the investigation or replacement of a defective item.

WARRANTY IS ONLY VALID IN THE EVENT THAT:

1 2

The equipment is serviced and maintained by Airedale or an approved Airedale company in accordance with the Installation & Maintenance manual provided, during the Warranty Period. Commissioning is carried out by Airedale or an approved Airedale company.

3
4

Commissioning documents have been completed and returned to Airedale within 28 days of the date of commissioning.
Replaced faulty parts have been returned to Airedale within 21days of replacement for evaluation.

Any spare part supplied by Airedale under the warranty shall be warranted for the unexpired period of the warranty or 3 months from delivery whichever period is the longer, with the exception of compressors on which a further 12 months warranty is granted.

PROCEDURE

When a component part fails a replacement part should be obtained through our Spares department. If the part is considered to be under warranty, the following details are required to process this requirement.
To be filled in and attached complete to faulty component

Full description of part required, including Airedale's part number, if known The original equipment serial number An appropriate purchase order number

Faulty Component Return Tag

CUSTOMER ADDRESS AIREDALE U/No TYPE OF UNIT COMPONENT DESCRIPTION SERIAL No (where applicable) FAULTY DESCRIPTION (Faulty or Defective not sufficient) DATE OF INVOICE DATE OF INSTALLATION DATE OF FAILURE
Airedale International Air Conditioning Limited Leeds Road, Rawdon, Leeds LS19 6JY Tel: 0113 239 1000 Fax: 0113 250 7219 700-006

No

28401

DATE CUST. O/No Ex G/S No

1. Original Equipment 2. Component (if different)

CUSTOMER COPY

A spares order will be raised under our warranty system and the replacement part will be despatched, usually within 24 hours should they be in stock. When replaced, the faulty part must be returned to Airedale with a suitably completed and securely attached "Faulty Component Return" (FCR) tag. FCR tags are available from Airedale and supplied with each Warranty order. On receipt of the faulty part, suitably tagged, Airedale will pass to its Warranty department, where it will be fully inspected and tested in order to identify the reason for failure, identifying at the same time whether warranty is justified or not. On completion of the investigation of the returned part, a full "Report on Goods Returned" will be issued. On occasion the release of this complete report may be delayed as component manufacturers become involved in the investigation. When warranty is allowed, a credit against the Warranty invoice will be raised. Should warranty be refused the Warranty invoice becomes payable on normal terms.

EXCLUSIONS

Warranty may be refused for the following reasons: Misapplication of product or component Incorrect site installation Incomplete commissioning documentation Inadequate site installation Inadequate site maintenance Damage caused by mishandling Replaced part being returned damaged without explanation Unnecessary delays incurred in return of defective component All faulty components returned under warranty are analysed on a monthly basis as a means of verifying component and product reliability as well as supplier performance. It is important that all component failures are reported correctly.

RETURNS ANALYSIS

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Loose Items List
LIQUID LINE FILTER DRIER

Condensing Units

Matched to the refrigeration duty of the compressor, shipped in the compressor compartment.

Site Installation
LIFTING
Whenever a condensing unit is lifted, it should be from the base and, where possible, with all packing and protection in position. If any type of slinging is used, due care should be taken to ensure that the slings do not crush the casework or coil. Due note should also be made of the fact that the compressor is at one end of the unit, and therefore the centre of gravity will also be towards that end. If the unit is dropped, it should immediately be checked for damage. NOTE: Keep all pipes capped during installation to prevent pipework contamination.

POSITIONING

The condensing unit should be positioned on a stable and even base. This base should be levelled to ensure that the compressor operates correctly without uneven internal stresses being transmitted to the compressor support springs. Pipework sizes and routes should be set in accordance with good refrigeration practice. Pipework and electrical connections are readily accessible. Where multiple units are installed, due care should be taken to avoid the discharge air from each unit adversely affecting other units in the vicinity.

WALL MOUNTING
(CU./CUH. 1-4)

When condensing units are wall-mounted due care should be taken to choose a position such that there will be an uninterrupted airflow over the coil under all normal operating conditions. It is recommended that a defrost drain tray be fitted where heat pump condensing units are to be wall mounted to prevent ice from falling.

DEFROST DRAIN TRAY

(CUH/CUHS 1 4 OPTIONAL)

Attach the optional defrost drain tray to the wall mounting brackets by first attaching the 2 drain tray brackets to the wall mounting brackets using 2 M6 screws, nuts and washers. Then attach the rear of the defrost drain tray to the wall mounting brackets using 2 M6 screws and washers. Attach the front of the defrost drain tray to the drain tray bracket using 2 M6 screws and washers.

Wall Mounting Bracket

Condensing Unit

Defrost Drain Tray Bracket

Defrost Drain Tray

SERVICES

Refer to the Technical Data, Dimensions / Positioning / Weights & Electrical Information.

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Mechanical Information
TECHNICAL DATA
CU./CUH. Nominal Capacity - Cooling Nom. Airflow Max. Fan Speed Refrigerant Unit Refrigerant Charge Oil Charge/Compressor Liquid Line Conn. Suction Line Conn. Hot Gas Stub Operating Weight (nom) CUS Operating Weight (nom) CUHS CUS/CUHS Nominal Capacity - Cooling (1) Nominal Airflow Max. Fan Speed Refrigerant Design Type Unit Refrigerant Charge Oil Charge/Compressor Liquid Line Conn. Suction Line Conn. Hot Gas Stub Weight: Operating (nom) CUS5 12 Operating (nom) CUHS5 12 CFCUS Nominal Capacity - Cooling Nominal Airflow Nom Speed @ 100Pa ESP Refrigerant Design Type Unit Refrigerant Charge Oil Charge/Compressor Liquid Line Suction Line Operating Weight (nom) (1) (1) kW m/s rpm Kg l in in in kg kg 1 3.30 840 0.85 0.60 F 1/4 F 1/2 1/2 1.5 4.50 840 1.00 1.20 F 1/4 F 1/2 1/2 2 5.10 840 0.60 1.00 F 1/4 F 5/8 1/2 60.2 61.8 7.5 21.00 2.25 930 R407C 3.63 3.25 F 5/8 S 1 1/8 7/8 208.5 222.5 2.5S 7.60 2.5T 7.60

CU/CFCU

0.80

0.80

0.80

0.80

0.80

0.80
840

3 8.70

3.5 10.80

1.45
840

4 13.10

1.80
840

51.0 53.0

59.0 61.0

840 840 R407C 1.30 1.30 1.10 1.10 F 3/8 F 3/8 F 3/4 F 3/4 1/2 1/2 75.7 75.7 78.4 10 27.40 4.45 930 4.76 3.80 F 7/8 S 1 1/8 7/8 261.0 272.0 10 32.30 3.20 1014 4.80 3.8 7/8 1 1/8 330 78.4 12 35.70 4.45 930 4.76 4.00 F 7/8 S 1 3/8 7/8 266.0 277.0

1.50 1.10 F 3/8 F 3/4 1/2 88.1 83.6

1.50 1.90 F 3/8 F 3/4 1/2 101.6 106.0

1.50 1.60 F 1/2 F 3/4 1/2 104.1 109.4

kW m/s rpm kg l in in in kg kg

5 13.70 2.00 930 2.40 1.55 F 1/2 F 7/8 5/8 141.0 168.0 5 14.80 1.89 937 2.40 1.55 1/2 7/8 241

6 17.90 2.00 930 2.40 1.65 F 5/8 S 1 1/8 5/8 144.0 171.0

F= S=

Flare Sweat

(1)

kW m/s rpm kg L in in kg

6 7.5 19.70 24.80 2.08 2.89 994 951 R407C 2.40 4.80 1.65 3.25 5/8 5/8 1 1/8 1 1/8 248 325

Nominal Capacity based on 5C mean evaporating temperature and a 35C ambient.

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Mechanical Information
DIMENSIONS / POSITIONING / WEIGHTS CU. / CUH. 1 - 4

Condensing Units

150mm

AIRFLOW

600mm B 150mm 500mm 76 87 10mm Fixing Slots MINIMUM CLEARANCE 140 657 A 140 325 369 C 25 50

Models CU1 CU1.5 CUS2 CUS2.5S & T CUS3 CUS3.5 CUS4 CUH1 CUH1.5 CUHS2 CUHS2.5S & T CUHS3 CUHS3.5 CUHS4
1 2

Dimensions mm mm mm mm mm mm mm mm mm mm mm mm mm mm

A 937 937 937 937 937 937 937 937 937 937 937 937 937 937

B 843 843 843 843 1130 1130 1130 843 843 843 843 1130 1130 1130

C Operating Weights 395 51.0 kg 395 59.0 kg 395 60.2 kg 395 75.7 kg 395 88.1 kg 395 101.6 kg 395 104.1 kg 395 53.0 kg 395 61.0 kg 395 61.8 kg 395 78.4 kg 395 83.6 kg 395 106.0 kg 395 109.4 kg

Incoming Electrical Service holes (3 x 20mm ) to rear of unit. Models CUS3 has 1 vertically aligned condenser fan.

OPTIONAL WALL MOUNTING BRACKET

Self-assembly, Multi-fit Construction

10

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Mechanical Information
DIMENSIONS / POSITIONING / WEIGHTS CUS/CUHS 5 - 7.5
1

CU/CFCU

500mm

AIRFLOW

MINIMUM CLEARANCE

500mm

500mm

Models CUS5 CUS6 CUS7.5 CUHS5 CUHS6 CUHS7.5 1 2

CUS/CUHS 10 - 12

Models CUS10 CUS12 CUHS10 CUHS12 1

B D E A F G C 12.7mm Fixing Slots

600mm

Dimensions mm mm mm mm mm mm

A 865 865 996 996 996 996

B 699 699 699 699 699 699

C 1213 1213 1441 1441 1441 1441

D 213 213 193 193 193 193

E 457 457 610 610 610 610

F 195 195 193 193 193 193

G Operating Weights 1181 141.0 kg 1181 144.0 kg 1409 208.5 kg 1409 168.0 kg 1409 171.0 kg 1409 222.5 kg

Coil to this face on the CUS/CUHS 7.5 model only. Incoming Electrical Service holes (3 x 20mm ) to rear of unit.

AIRFLOW

MINIMUM CLEARANCE

500mm

500mm

B D E A F G C 12.7mm Fixing Slots 600mm

Dimensions mm mm mm mm

A 865 865 865 865

B 953 953 953 953

C 1770 1770 1770 1770

D 204 204 204 204

E 457 457 457 457

F 203 203 203 203

G Operating Weights 1738 261.0 kg 1738 266.0 kg 1738 272.0 kg 1738 277.0 kg

Incoming Services: Connections to left hand side of unit compressor compartment.

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Mechanical Information
DIMENSIONS / POSITIONING / WEIGHTS CFCUS 5 - 10

Condensing Units

B N M D E

AIR IN

ACCESS FOR MOTOR ADJUSTMENT

MASTER DOOR ACCESS TO COMPRESSOR AIR IN

L C

4 Slots 35 x 12.7 mm

WEIGHTS
500 mm COIL

CFCUS 5 CFCUS 6 CFCUS 7.5 CFCUS 10

500 mm

kg kg kg kg

Machine 238.0 245.0 320.0 325.0

Operating 241.0 248.0 325.0 330.0

COIL 500 mm

CFCUS A B C D E F G H J K L M N P 1 2 3

mm mm mm mm mm mm mm mm mm mm mm mm mm mm

5 717 1173 1016 575 45 557 16 1238 1206 203 610 161 560 160

6 717 1173 1016 575 45 557 16 1238 1206 203 610 161 560 160

7.5 985 1459 1148 560 30 824 19 1524 1486 224 701 194 700 160

10 985 1459 1148 560 30 824 19 1524 1486 224 701 194 700 160

Incoming Services: Connections to left hand side of unit compressor compartment. Airflow and Maintenance Clearance: Please allow 500mm around the unit for airflow and maintenance purpose. Dimensions D, E, M, N and P apply for units fitted with Head Pressure Control only, therefore dimensions will vary if Head Pressure Control is not fitted.

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Refrigeration Information
REFRIGERANT PIPEWORK SCHEMATICS CU. 1 - 12/CFCUS 5 - 10
OUTDOOR UNIT

CU/CFCU

CUH. 1 - 12

OUTDOOR UNIT
Check Valve Expansion Valve

Narrow Tube Service valve Condenser

Narrow Tube Service valve Condenser Accumulator

HP LP

Wide Tube Service valve

Compressor

Cooling Mode

UNIT CHARGE
CU./CUH. 1 - 4 CUS/CUHS 5 12 Units are shipped with a charge of R407C for a pipe run up to 7 metres (equivalent length). The units are shipped with a holding charge of inert gas to guard against contamination or moisture during shipping and storage. The charge should be check to indicate if leaks are present prior to evacuation. If the charge appears to be either partially or totally lost, then the unit should be carefully checked for signs of physical damage.

PIPE SIZING GUIDE

It is important that the correct size refrigeration pipework is used to keep the system pressure drop to a minimum and promote correct oil return. Pipework sizes and routes should be set in accordance with good refrigeration practice.

PIPEWORK INSTALLATION
CUS/CUHS 1 - 12 The suction line should be insulated. Liquid lines should be insulated in areas of high temperature or when exposed to direct sunlight.

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Compressor

LP

Optional Hot Gas By-Pass

HP

Wide Tube Service valve

13

CU/CFCU
Refrigeration Information
PIPEWORK INSTALLATION
General

Condensing Units

Special consideration should be given to vertical pipe runs and heat pump installation. Unit performance will reduce if there are vertical rises of above 5m. Please consult Airedale Service for risers above 10m. When insulating refrigerant lines, cut approximately 30 - 50cm longer than the distance between the units to ensure the insulation goes right upto the unit. Leave connections uncovered for leak testing. Remove burrs to the ends of the copper tube, holding the tube downward to avoid allowing dirt to contaminate the tube. Where applicable insert flare nuts removed from the pipework terminations and make a flare at the end of the copper tube to conform with the following: Inside surface is glossy and smooth Tapered sides are of uniform length Refrigeration lubrication is applied to matching surfaces

The installation of a sight glass close to the indoor unit is recommended. Where applicable braze incoming pipe to rotalock service valve.

PRESSURE TESTING

When installation is complete, the system should be pressure tested. Fill the system with dry nitrogen to a pressure of between 17 bar/250psig and 34bar/ 500 psig. NOTE: The LP switch if fitted must be disconnected for pressures above 17bar/250 psig. Record the pressure over a minimum of 60 minutes to detect major leaks (a 24 hour period should preferably be allowed). If a reduction in pressure is detected, trace the leak and repair before conducting a further pressure test and charging.

EVACUATION

Evacuation for systems operating with R407C refrigerant to be carried out as follows (for alternative refrigerants please refer to Airedale). Use a high vacuum pump and connect to the high and low pressure sides of the system via a gauge manifold fitted with compound gauges. A high vacuum gauge should be fitted to the system at the furthest point from the vacuum pump. Triple evacuation should be used to ensure that all contaminants are removed. Operate the vacuum pump until a pressure of 1.5 torr (200 Pa) absolute pressure is reached, then stop the vacuum pump to break the vacuum using oxygen free Nitrogen until the pressure rises above zero. The above operation should be repeated a second time. The system should then be evacuated a third time but this time to 0.5 torr absolute pressure. Break with the correct refrigerant, until pressures equalise between the charging bottle and the system.

ALTERNATIVE REFRIGERANTS

If an alternative refrigerant is to be used, this must be with the approval of Airedale International Air Conditioning Ltd in order for the warranty to be valid. Care must be taken to ensure that the refrigerant and compressor oil are compatible.

14

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Electrical Information
GENERAL

CU/CFCU

A fused and isolated electrical supply of the appropriate phase, frequency and voltage should be installed. As standard the equipment is designed for 230V, 1 Phase, 50Hz or 400V, 3 Phase, 4 wire 50Hz to all relevant IEE regulations, British standards and IEC requirements. All mains and interconnecting wiring should be carried out to National and Local codes. Wires should be capable of carrying the maximum load current under non-fault conditions at the stipulated voltage. Avoid large voltage drops on cable runs, particularly low voltage wiring. Once the refrigeration pipework is complete the electrical supply can be connected by routing the cable through the appropriate casing hole and connecting the cables as per the wiring diagram supplied with each unit. Power to the indoor unit is normally taken from the outdoor unit. Should there be a separate supply for each unit, a control neutral must be fitted between the indoor and outdoor units.

ELECTRICAL DATA CU./CUH. 1 - 4

Unit Data Nominal Run Amps Maximum Start Amps Control Circuit Mains Supply Rec. Mains Fuse Max Incoming Mains Compressor Motor Rating Nominal Run Amps Locked Rotor Amps Crankcase Heater Rating (2) Type of Start Condenser Fan Motor Rating Full Load Amps Locked Rotor Amps 1 (1) A A VAC V A mm kW A A W 6.0 35.0 230 16 6 1.1 5.5 37.5 1.5 2 2.5S 14.3 78.6 230 20 6 2.5 13.6 76.0 40 2.5T 6.4 39.1 230 16 6 2.5 5.7 36.5 40 3.0 3.5 4.0 9.5 67.0 230 20 6 4.0 8.2 61.8 65 9.7 10.3 59.0 49.6 230 230 230/1/50 16 16 6 6 1.7 9.4 61.0 1.7 9.6 47.0 40 7.1 8.8 46.6 56.7 230 230 400/3/50 16 16 6 6 2.9 6.4 44.0 40 3.7 7.8 51.0 65

(1)

24

24

Direct on Line kW A A

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

0.15 0.65 2.60

ELECTRICAL DATA CUS/CUHS 5 12

Unit Data Nominal Run Amps Maximum Start Amps Control Circuit (CUS) Mains Supply Rec. Mains Fuse Max Incoming Mains Compressor Motor Rating Nominal Run Amps Locked Rotor Amps Crankcase Heater Rating Type of Start Condenser Fan Motor Rating Full Load Amps Locked Rotor Amps (1) (2) 5 (1) A A VAC V A mm kW A A W kW A A 11.4 68.3 230 20 10 4.5 8.9 62.5 65 0.55 2.50 5.80 6 13.5 100.8 230 25 10 5.9 11.0 95.0 65 0.55 2.50 5.80 7.5 15.2 103.8 230 400/3/50 32 10 6.9 12.7 98.0 50 Direct on Line 0.55 2.50 5.80 10 21.1 131.6 230 40 10 8.9 16.1 120.0 50 0.55 2.50 5.80 12 26.6 146.6 230 40 10 11.6 21.6 135.0 50 0.55 2.50 5.80

(1) (2)

Nominal data based on 5C evaporating temperature and a 35C ambient. Heat pumps only.

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Electrical Information
ELECTRICAL DATA - CFCUS 5 10
Unit Data Nominal Run Amps Maximum Start Amps Control Circuit Mains Supply Rec. Mains Fuse Max Incoming Mains Compressor Motor Rating Nominal Run Amps Locked Rotor Amps Crankcase Heater Rating Type of Start Condenser Fan Motor Rating Full Load Amps Locked Rotor Amps (1) 5 (1) A A VAC V A mm kW A A W kW A A 14.0 91.7 24 25 10 4.50 8.90 62.50 65 2.20 5.10 29.15

Condensing Units

6 16.1 124.2 24 400/3/50 32 10 5.90 11.00 95.00 65 Direct on Line 2.20 5.10 29.15

7.5 19.3 119.9 24 35 10 8.14 12.73 98.00 50 3.00 6.70 41.40

10 24.5 168.3 24 40 10 9.70 16.10 120.00 50 4.00 8.40 48.30

(1)

Nominal data based on 5C evaporating temperature and a 30C ambient.

INTERCONNECTING WIRING Microprocessor Controlled (AD05)

L1 N E S1A S1B COOL COM HEAT A3 A3 DS1 DS2 CCA CA1 CA2 ! ! ! " ! ! ! ! " " " " " " " Mains Incoming 230/1/50 Communication Connection To Indoor Unit (Microprocessor Only) External Control of Cool/Heat mode (Volt Free) Optional Auxiliary Alarm Volt Free Input (Normally Closed = Healthy) Defrost Status Indication Volt Free Contact (Normally Closed = Defrosting) Common Normally Closed Contact Normally Open Contact
L1 N E !" !" S1A S1B
(1)

CONDENSING UNIT

Common Alarm Changeover Volt Free Contacts

System Field Connections for AD05 Controlled Units

(1)

INDOOR UNIT

L1 N E S1A S1B

AD05 CONTROLLED OUTDOOR UNIT

The microprocessor (AD05) controlled condensing unit may be matched to non Airedale indoor air handling units. A contact can be closed across either the Cool and Common or Heat and Common terminals. Ensure that the cooling and heating cannot be initialised simultaneously.

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Electrical Information
INTERCONNECTING WIRING Electro-Mechanically Controlled Units CU.1-4
L1 L2 L3 N E CU.1 - 4 34 576 577 589 502 N1 "

CU/CFCU

Mains Incoming 230/1/50 or 400/3/50

" " "

Compressor Signal From Indoor Unit Cooling Signal From 24vac controlled Indoor Unit

" "

589/502 Volt Free Contact for Unit Trip Indication Control Neutral (if required)

CUH.1-4

L1 L2 L3 N E 34 CUH. 1 - 4 35 36 589 502 N1

"

Mains Incoming 230/1/50 or 400/3/50

" " "

Compressor Signal From Indoor Unit Cooling Signal From Indoor Unit Defrost Signal From Indoor Unit 589/502 Volt Free Contact for Unit Trip Indication Control Neutral (if required)

" "

CUS5 12 & CFCUS 5 - 10

CUS 5 - 12 & CFCUS 5 - 10

L1 L2 L3 N E 576 577 502 589

Mains Incoming 400/3/50

! ! "

Cooling Signal From AHU (24 Vac) Volt Free Contacts for unit Trip Indicator

CUHS5 12

L1 L2 L3 N E CUHS 5 - 12 504 515 517 523 500 502 589

Mains Incoming 400/3/50

! ! ! " ! ! "

Cooling Signal From AHU (24 Vac) Heating Signal From AHU (24 Vac) Fan Running Signal From AHU (24 Vac) Defrost Signal to AHU (24 Vac) 0 VAC Volt Free Contacts for unit Trip Indicator

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CU/CFCU
Commissioning
GENERAL PRE-START CHECKS GENERAL ELECTRICAL

Condensing Units

The following commissioning information is based on a complete matched Airedale system using R407C. Once the whole system has been installed it is most important that the following pre-start checks are made:1 2 1 2 3 4 5 6 The unit condition is satisfactory. All pipework is complete and insulated where necessary. All electrical connections (both mains and control) are properly terminated. The power supply is of the correct voltage and frequency. External fuses/circuit breakers are of the correct rating. The units are properly earthed in accordance with current regulations. All pipework is earth bonded as required. Check that there is a supply to the crankcase heater (if fitted) and ensure this is switched on for a minimum of 2 hours prior to the unit operation. The unit condition is satisfactory. All pipework is complete and insulated where necessary. All fans are able to rotate freely. The system has been evacuated correctly. Check the operation of the high and low pressure switch settings (if fitted). These should be as follows:HIGH PRESSURE SWITCH - 27 Bar ( 400 psi ) - CUT OUT LOW PRESSURE SWITCH - 0.5 Bar ( 7 psi ) - CUT OUT 2.5 Bar ( 37 psi ) - CUT IN 6 The low pressure switch is automatically reset. The high pressure switch must be reset by either switching the unit off/on at the isolator, or de-energising the compressor signal from the indoor unit.

REFRIGERATION

1 2 3 4 5

FAN SPEED / HEAD PRESSURE CONTROL

CUS/CUHS 1 - 4

The head pressure control (if fitted), allows control to be achieved in ambients down to -20C. Head pressure can be controlled by setting the fan speed to the desired range and operating in the Cut off mode, whereby the voltage output to the fan is varied between 0-100%. To adjust the fan speed, turn the slot headed screw on the transducer to the desired output.

DEFROST CONTROL
(CU.1-4)

Defrost is controlled by a factory set defrost timer via a coil temperature sensor.

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Commissioning
CONTROL CIRCUIT CHECKS Cooling Only & Heat Pump

CU/CFCU

Please refer to the Airedale matched indoor unit manual for further details.

1 2

Disconnect the compressor power wiring from the compressor contactor. Switch on mains power. Check status of the Alarm LEDs on the microprocessor, refer to information provided with unit. Under normally stand alone operation LED 4 will flash at 1 second intervals when the compressor anti-cycle delay is active.

3 4 5 6 7 8

After 4 minutes LED 4 will cease flashing and remain constant. Select Cooling mode on the indoor unit and check for continuity between the COOL and COM terminals on the microprocessor. The compressor should switch on. De-select Cooling mode on the indoor unit and check for no continuity between the COOL and COM terminals on the microprocessor. The compressor should switch off. Switch off mains power and reconnect compressor power wiring.

Heat Pump Units

Follow steps 1-7 above and then check heating operation as described below: 1 2 Select heating mode on the indoor unit and check for continuity between the HEAT and COM terminals on the microprocessor. Check status of the Alarm LEDs on the microprocessor, refer to information provided with unit. Under normally stand alone operation LED 4 will flash at 1 second intervals when the compressor anti-cycle delay is active. 3 4 5 6 7 After 4 minutes LED 4 will cease flashing and remain constant. The compressor should switch on. De-select heating mode on the indoor unit and check for no continuity between the HEAT and COM terminals on the microprocessor. The compressor should switch off. Switch off mains power and reconnect compressor power wiring.

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CU/CFCU
Commissioning
REFRIGERANT CHARGING

Condensing Units

The following information is based on a complete Airedale matched system and indicates the approximate amount of refrigerant charge required. It is also assumed that the system has been designed within operating parameters and to good refrigeration practice. NOTE: It is important that the system is charged with the correct amount of refrigerant. Remember, a seriously over or undercharged system may lead to major component failure. The final refrigerant charge level should be set by the design evaporating and condensing pressures, together with a full or nearly full sight glass. The suction and discharge pressures should be constantly monitored whilst charging is in progress. NOTE:- The sight glass level must be checked in the COOLING MODE ONLY.

ADDING REFRIGERANT
CU./CUH. 1 4 CUS/CUHS 5 12 & CFCUS 5 10 Supplied pre-charged for up to 7m pipe runs (equivalent length), please refer to the table below for additional charging guidance. Supplied with a holding charge, the charge in the Technical Data tables is based on approximately 30m pipe runs (equivalent length). The following approximate amounts should be added to the system for every additional metre of pipe run above the standard charge: System CU/CUH 1 1.5 CUS/CUHS 2 CUS/CUHS 2.5 3.5 CUS/CUHS. 4 CUS/CUHS & CFCUS 5 CUS/CUHS & CFCUS 6 7.5 CUS/CUHS & CFCU 10 CUS/CUHS 12 Additional Grams Per Metre Pipe Run 24g 28g 67g 119g 125g 210g 384g 384g

ADDING OIL
CU/CUH 1 1.5 CUS/CUHS 2 12 & CFCUS 5 10 The initial oil charge in the compressor is suitable for pipe runs up to 20m (equivalent length). The initial oil charge in the compressor is suitable for pipe runs up to 30m (equivalent length). For longer pipe runs add 26 g of oil for every ADDITIONAL 0.45 kg of refrigerant added up to the maximum permissible equivalent pipe runs stated. Please consult Airedale for further details.

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Commissioning
SYSTEM READINGS

CU/CFCU

NOTE :- The sight glass should only be used as an assistance to charging as the charge level showing in the glass will vary according to different operating conditions. This is especially noticeable with the heat pump units where the system may appear to be undercharged in the heating mode. Evaporating temperature (suction gauge) should read approximately 2C. to 3C. with a room (return air temperature) of approximately 22 C. Condensing temperature (as read on the discharge gauge) should be in the region of 45 to 46 C. with an external ambient temperature of 30C (Condensing is normally 15 C. above ambient).

RUNNING CHECKS

Once the system has been charged, the following running checks should be carried out:Check the operation of the fan speed controller by observing an increase in fan speed if the outdoor coil is temporarily partially blocked. If the system is a heat pump option, check that the reversing valve switches over from cooling to heating and vice-versa. NOTE: Head pressure control also operates in heating mode by slowing down the outdoor unit fan as the system pressure rises. This can be checked by partially blocking the inlet grilles of the indoor unit and observing the outdoor unit fan slowing down.

IMPORTANT ALARM DIAGNOSTIC OPERATION

(CU./CUH.1-4)

FINALLY AND MOST IMPORTANT - Fill in the commissioning sheet and return a copy to the factory to ensure that the warranty on the unit will be valid. Unit control is via a microprocessor board found inside the control panel of the unit. The board features 4 Red LED alarm indicators to indicate specific outdoor controller alarms which should be checked when troubleshooting. During situations when there is more than one alarm present the LEDs will only indicate one alarm based on a priority sequence shown below. Priority 1 2 3 4 5 1 2 1 2 3 4 Alarm Description A1 Low Pressure Fault A2 High Pressure Fault A3 Auxiliary Alarm A4 or A5 Outdoor Fan Fault T2 Coil Sensor Fault Compressor Delay Active S1 Communications Fault LED 1 On On ALARM LED 2 LED 3 On On Flashing On Flashing On LED 4

LED4 will operate independently of the other alarm LEDs and will follow its own priority sequence, as indicated in the table. LED 4 will also flicker intermittently when the controller is communicating with the indoor board. The Airedale matched indoor units can be configured to a Master/Slave function, refer to indoor unit manuals for details. Master/Slave control refers to a number of indoor units in one area being controlled at one designated indoor unit by one command. This does not refer to connection to a proprietary commercial BMS system.

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CU/CFCU
Troubleshooting (CU./CUH. 1 4 Only)
FAULT CRITICAL ALARMS: Aux. Alarm (LED 3 On) Outdoor Fan Fault (LED 1 & 2 On) Coil Sensor Fault (LED 2 flashing 1 Hz) No Cooling/Heating (LED 4 flashing 1 Hz) Auxiliary Trip. Fan Trip. Faulty Sensor. Compressor Protection Delay. POSSIBLE CAUSE

Condensing Units

REMEDY/ACTION Check operation of customer-added alarm function. Check and (if necessary) replace fan. Replace sensor. Wait for a maximum of 10 minutes then re-check. Clean condenser. Remove excess refrigerant from system.

Head Pressure too high/HP Condenser coil clogged or dirty. cut-out operated Overcharge of refrigerant. Normally (LED 2 On) troublesome in warm weather.

Air or other non-condensable gas in system. Evacuate system and re-charge with new refrigerant. Head pressure controller faulty. Check fan speed controller - if faulty - replace.

Fan not operating or operating inefficiently. Check motor - if faulty - replace. Compressor short cycles or LP switch faulty (if fitted). LP cut-out operated (LED 1 On) Dirty indoor unit filters. Dirty or icing evaporator (reduced airflow). Lack of refrigerant (bubbles in sight glass only as indication). Clogged filter drier (pressure/temperature drop across it). Condenser fan running at full speed in winter (full airflow). Start up problems in very low ambients or when long pipe runs are experienced. Check cut out pressure and replace if necessary. Replace. Defrost and/or clean. Check gas charge and expansion valve. Check for leaks - repair and recharge system. Replace. Check fan speed controller setting - if faulty - replace. Check for low suction pressures on start-up and fit a low ambient start kit if required, or check operation of system if already fitted.

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Troubleshooting
FAULT Unit Will Not Start POSSIBLE CAUSE No power. Wired incorrectly. Loose wires. CU./CUH. 1- 4 Only Microprocessor failure. REMEDY/ACTION

CU/CFCU

Check power supply to the controller. Check wire connections in accordance with wiring diagram on control box lid. Check all wires, connections, terminals etc. If fans can be operated by bypassing the microprocessor, then the microprocessor is faulty and requires replacing/investigation. Check isolator, fuses, MCBs, contactor and control circuit wiring Repair leak and recharge system - if completely out evacuate before charging. Investigate and correct.

Compressor not operating

No power to compressor Low pressure switch operated (if fitted) (large or complete loss of refrigerant charge). Condenser fan thermal trip open circuit.

Seized compressor, possibly due to lack of Replace compressor - investigate oil oil (piston/crank seizure) broken valve reed trapping and general installation. jamming piston etc). Defective compressor motor. Check winding resistances - replace compressor. If burnt out follow burn out procedure using suction line burn-out drier. Ensure feeler bulb is tight on suction and superheat is correct (normally 5 to 6C). Replace power assembly or valve as necessary. Repair leaks if any, add oil if required but not too much. Investigate pipe system and trapping. If no oil still, drain compressor and measure in correct quantity.

Noisy Compressor

Expansion valve malfunction (abnormally cold suction Iine).

Lack of oil.

Broken or damaged compressor valve reed Replace compressor (possible other (compressor knocking). symptom is that it will have high suction pressure). Worn or scored compressor bearing. (excessive knocking). Replace compressor.

Head Pressure too high/HP Condenser coil clogged or dirty. Clean condenser. cut-out operated Overcharge of refrigerant. Normally Remove excess refrigerant from system. troublesome in warm weather. Air or other non-condensable gas in system. Evacuate system and re-charge with new refrigerant. Head pressure controller faulty. Check fan speed controller - if faulty - replace. Free off and lubricate. Check fan speed controller adjustment - if faulty - replace.

Fan not operating or operating inefficiently. Check motor - if faulty - replace. CFCUS Units - Head pressure damper seized. Head pressure too low Fan operating too fast in low ambient conditions.

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CU/CFCU
Troubleshooting
FAULT POSSIBLE CAUSE

Condensing Units

REMEDY / ACTION Check cut out pressure and replace if necessary. Replace. Defrost and/or clean. Check gas charge and expansion valve. Check for leaks - repair and recharge system. Replace. Check fan speed controller setting - if faulty - replace. Check for low suction pressures on start-up and fit a low ambient start kit if required, or check operation of system if already fitted. Check fan motors, belts and drives. Investigate for refrigerant leaks, repair and re-charge system.

Compressor short cycles or LP switch faulty (if fitted). LP cut-out operated Dirty indoor unit filters. Dirty or icing evaporator (reduced airflow). Lack of refrigerant (bubbles in sight glass only as indication). Clogged filter drier (pressure/temperature drop across it). Condenser fan running at full speed in winter (full airflow). Start up problems in very low ambients or when long pipe runs are experienced. Suction Pressure too low Low evaporator airflow. Flash gas (bubbles in sight glass) at expansion valve.

Clogged filter drier (pressure / temperature Replace. drop across it). Obstruction in liquid line solenoid valve. Obstruction in expansion valve. Defrost cycle not initiating Unit set for cooling only. Inspect, clean or replace. Inspect, clean or replace. Check links. Check power supply at circuit breaker. Check voltage at motor terminals. Isolate unit and check free rotation of motor/fan assembly. If faulty - replace. Carry out continuity check at terminals TK in motor terminal box. If tripped and motor hot - check bearings. If tripped and motor cold - replace motor. Motor humming would indicate fault in motor or capacitor. Check windings for continuity and if OK replace capacitor. Adjust head pressure controller to suit. Check electrical connections are secure at controller and pressure sensor. Replace controller and sensor (as they are matched sets). Link wires line and load to bypass controller. If motor runs full speed replace unit.

Condenser fan not operating Power supply failure. - power on Wiring to motor. Motor / fan assembly jammed. Motor internal overheat protector tripped.

Faulty motor windings/capacitor.

Minimum speed set too low. Faulty pressure sensor.

Faulty Fan Speed Controller.

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Troubleshooting
FAULT POSSIBLE CAUSE REMEDY / ACTION Condenser fan runs too fast High ambient condition or excessive recirculation of air around condenser coil. Minimum set speed setting incorrect. Incorrect pressure sensor setting. Faulty Fan Speed Controller. Faulty pressure sensor. Condenser fans runs only slowly Incorrect pressure setting. Faulty Controller. Faulty Pressure sensor. Motor/capacitor faulty.

CU/CFCU

Check installation against design. Adjust as necessary. Adjust sensor screw as necessary. Replace controller and sensor (as they are matched sets). Replace controller and sensor (as they are matched sets). Adjust sensor screw as necessary. Replace controller and sensor (as they are matched sets). Replace controller and sensor (as they are matched sets). Replace.

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CU/CFCU
Maintenance
IMPORTANT ACCESS

Condensing Units

The equipment contains live electrical and moving parts, isolate all electrical equipment before any work is carried out. Access to the compressor and control panel area is gained by removing the securing screws from the cover of the condensing unit casing and lifting the cover off. Access is gained to the fan(s) through the top of the unit by removing the top cover.

MAINTENANCE SCHEDULE 3 MONTHS Fan & Motor Assembly

CU./CUH. 1-12 1 2 3 CFCUS5 - 10 Examine the fan and motor assembly for lateral and end play in the bearings. Examine the electrical gland plate to ensure that no water is entering the motor. Examine the fan blades for damage and corrosion. At every service visit the following checks should be carried out:-

Check condition, tension and alignment of drive belt(s). Adjust or replace as necessary. Lubricate damper pivots if required. 1 2 Visually examine pipework and components for damage, wear and tear and oil patches, the latter being indicative of a system leak. Check the suction and discharge pressures using a service gauge manifold and compare them with the commissioning sheet. If there is any significant variation, then the fault should be found and corrected. Refer to Troubleshooting. Check that the high and low pressure switches (if fitted) are cutting out the compressor(s) at the commissioned settings. Ensure the fan head pressure controller is controlling the head pressure at the required setting as indicated on the commissioning sheets provided.

Refrigeration Circuits

3 4

The gauges can then be removed from the system. Do not forget to replace the security caps on the Schrader valves.

Condenser coil

Clean the condenser coil with a stiff bristled hand brush. If dirt has accumulated over a long period, or tends to be greasy or sticky, then it may be necessary to use a water hose or chemical pressure hose. Take care not to damage the fins and comb out if they have become damaged in any way. Do not use steam for cleaning condenser coils otherwise damage or danger may result from excessive internal pressures Wash down cabinet using a mild detergent. Treat any paint damage or rust as necessary. 1 2 Check all electrical connections for signs of overheating or arcing. Check all cables for signs of chafing or physical damage.

IMPORTANT Cabinet Electrical 12 MONTHS

As per 3 months plus: 1 2 Check all electrical connections for security. Check all refrigeration connections with a leak detector.

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Notes:

CU/CFCU

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Head Office:
Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY United Kingdom Tel: Fax: e-mail: website: +44 (0) 113 239 1000 +44 (0) 113 250 7219 enquiries@airedale.com www.airedale.com

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Manufacturing Facility Also

PART NO: 904-038 IM E

ISSUE A B C

DATE 01/11/00 01/01/03 01/03/03

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Customer Services

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