AIREDALE CUS Series Maintenance and service guide

i n s t a l l a t i o n
&
ma i n t e n a n c e
C O N D E N S I N G U N I T S
C U S 1 5 ²6 0 / H C U 2 0 ²3 0 D

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
2
About Airedale
WARRANTY,
COMMISSIONING &
MAINTENANCE
Our standard warranty package guarantees all parts for 24 months. Additional
customised warranty packages are also available for periods of 12 to 36 months
covering either parts only or parts and labour.
Having chosen your Airedale product, a full commissioning service is now available on
all products and is charged on a daily rate variable by location.
To further protect your investment in Airedale products, we have also introduced our
own Planned Maintenance Service. This includes nation-wide service cover 24 hours
a day, 365 days a year, plus regular planned maintenance visits. For a free quotation
contact our Field Service Department or your Local Sales Engineer.
TRAINING
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.
CUSTOMER SERVICES
For further assistance, please e-mail: [e-mail] or telephone:
CUSTOMER SERVICES
UK Sales Enquiries
+ 44 (0) 113 238 7789
[e-mail]
International Enquiries
+ 44 (0) 113 239 1000
[email protected]
Spares Hot Line
+ 44 (0) 113 238 7878
[e-mail]
Airedale Service
+ 44 (0) 113 239 1000
[e-mail]
Technical Support
+ 44 (0) 113 239 1000
[e-mail]
Training Enquiries
+ 44 (0) 113 239 1000
[email protected]
For information, visit us at our Web Site: www.airedale.com
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.
¤2014 Airedale International Air Conditioning Limited. All rights reserved.
Printed in the UK.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
3
Description
Page 4
General
Safety
Page 5
Spares
Page 5
Serial Plate
Page 5
Warranty
Main Terms
Page 6
Procedures
Page 6
Returns Analysis
Page 7
Loose Items List
Page 7
Component Location / Description
Page 8
Site Installation Guide
Lifting / Positioning / Levelling
Page 9
Mechanical Information
Technical Data Sheet
Page 10
Dimensions
Page 11
Refrigeration System
Refrigeration Pipework Schematics
Page 14
System Holding Charge
Page 15
Pipework Sizing / Oil Addition
Page 15
Pressure Testing
Page 15
Evacuation
Page 15
Refrigerants
Page 15
Electrical Information
Electrical information - Control panel components
Page 16
Electrical Data Sheet
Page 17
Terminal Blocks - External Connections
Page 18
Commissioning Procedures
Commissioning Sheet - Example
Page 19
Pre-Start Checks
Page 20
Refrigeration Circuits - Charging
Page 20
Head Pressure Controller Adjustment
Page 20
Troubleshooting Tables
Page 22
Maintenance Requirements
Periodic Maintenance Schedule
Page 25

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
4
Description
INTRODUCTION
The condensing units comprise a compact housing incorporating all the necessary
components and associated controls required.
The multiple condenser fan and motor assemblies provide an even airflow across the
condenser coils and then discharge vertically upwards. The condenser coils are in a
³9´IRUPDWLRQRQXQLWVLQWKHUDQJH&86WR'DQGLQDWZLQYHUWLFDOIRUPDWLRQRQunits in the range CUS 40 to 60D and HCU 20 to 30D.
COMPRESSORS
CUS 15 - 30D AND HCU 20 - 30D
Three phase hermetic scroll compressors are used in this range of condensing units.
They are fitted with an internal thermal protector to protect the compressor from
damage against high motor winding and discharge gas temperatures.
CUS 40 - 60D
Three phase fully hermetic twin scroll compressors are used enabling each of the two
circuits to operate at 50% or 100% duty according to demand. Each twin compressor
is fitted with a thermistor protector module to protect the compressor from an overheat
condition.
REFRIGERATION
Each circuit is fitted with a liquid line shut-off valve to allow for isolation of the
condensing unit during service or maintenance, and this is fitted with a schraeder
access connector to facilitate connection of a service gauge manifold.
The suction line connection is capped and sealed ready for customer connection.
A large capacity filter drier is supplied loose for on-site installation.
A manual high pressure and automatic low pressure cut-out switch is fitted on each
circuit for system safety.
All units are configured to operate without pump-down.
CONTROL PANEL
7KHFRQWUROSDQHOLVHTXLSSHGZLWKWKHQHFHVVDU\0&%¶VFRQWDFWRUVDQGRWKHULWHPVto provide fully automatic safe operation. It is divided into mains and control sections
thereby ensuring voltage integrity between mains (400/230V) and controls (24V).
OPTIONS
1. When specified, the condenser fan is electronically speed controlled to ensure
that a stable head pressure can be achieved during all seasons.
2. A weatherproof mains isolator can be fitted to ensure mains isolation of the
electrical panel during adjustment and maintenance.
3. A soft start option may be fitted to compressors on the CUS 15 to 25D range.
This consists of a resistor bank which is inserted in the compressor circuit for 0.3
of a second to reduce current inrush.
4. In atmospheres where high corrosion is anticipated phenolic coated aluminium
finned coils can be supplied.
5. A large open mesh coil protection guard can be supplied for sites where coil
damage might be a problem (HCU20-30D only).
6. Compressors can be supplied charged with Ester oil suitable for use with the
environmentally friendly refrigerant R407C.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
5
General Statement
IMPORTANT
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 equipment.
SAFETY
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 Service and maintenance of Airedale equipment should only be carried out
by skilled personnel.
2 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.
3 Also ensure that there are no other power feeds to the unit such as fire alarm
circuits, BMS circuits, etc.
4 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.
5 Refrigerant No 22 and 407C 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.
6 A full hazard data sheet in accordance with COSHH regulations is available
should this be required.
SPARES
A recommended spares list is included in the unit documentation pouch located inside
the unit. For ease of identification when ordering spares or contacting Airedale about
your Condensing unit, please quote the unit type, unit serial number and the date of
manufacture. This information can be found on the serial plate attached to the unit.
An area has been provided on the front cover of this manual for this information to be
recorded.
SERIAL PLATE
EXAMPLE
Airedale International
Air Conditioning Ltd.
UK OFFICE
Tel: [phone]
Fax: [phone]
UNIT/GERÄT/UNITE
CUS10HI
SERIAL/SERIE/SERIE
U60179
MANUFACTURED/HERGESTELLT/FABRIQUE
4/11/98
SUPPLY/SPANNUNG/ALIMENTATION
400V 3PH 50Hz
FUSE/HAUPTSICHERUNG/FUSIBLES
40.0 A
REFRIGERANT & CHARGE
R407C
KÄLTEMITTEL & LADUNG
REFRIGERANT & CHARGE
TEST PRESSURE
20.0 BAR
DRUCKPRÜFUNG
35(66,21'¶(66$,
DEUTSCHES BÜRO
TEL : [phone]
FAX : [phone]
BUREAU FRANCAIS
TEL : [phone]
FAX : [phone]

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
6
Warranty
IMPORTANT
For the warranty to be valid, copies of the relevant commissioning sheets must
be fully completed and returned to Airedale, Leeds, within 28 days of
commissioning the equipment. Failure to submit the commissioning sheets
within the specified time period will invalidate any future warranty claims.
MAIN TERMS
The following warranty conditions are subject to the Airedale equipment being
regularly serviced and maintained in accordance with the installation and maintenance
documents by a competent and qualified installation and maintenance company,
approved by Airedale during the warranty period.
Airedale will respect warranty cover on all component parts for a period of 24 months
commencing from despatch of equipment from the Airedale factory. Extended
warranty to afford 24 months cover from commissioning of plant can be supplied upon
written request.
Airedale warranty cover is appropriate to component parts only and does not include
any allowance for labour costs or other expenses involved in the replacement of faulty
parts, within the warranty period.
Replaced faulty parts should be returned to Airedale within 21 days for full evaluation.
Parts fitted under warranty shall be warranted for the unexpired period of warranty of
the equipment or 3 months from delivery whichever period is the longer. This
excludes 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.
xFull description of part required, including Airedale's part number, if known.
xThe original equipment serial (U) number.
xAn appropriate purchase order number.
A spares order will be raised under our "G" number system and the replacement part
will be despatched, usually within 24 hours.
When replaced, the faulty part must be returned to Airedale with a suitably completed
and securely attached "Faulty Component Return" (FCR) tag, supplied with each
component. FCR tags are available from Airedale Spares Department and supplied
with each "G" order.
On receipt of the faulty part, suitably tagged, Airedale will pass it 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.
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Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
7
Warranty
PROCEDURE
When warranty is allowed, a credit against the "G" number invoice will be raised.
Should warranty be refused the "G" number invoice becomes payable on normal
terms.
Warranty may be refused for the following reasons:
xMisapplication of product or components.
xReplaced part being returned damaged without explanation.
xUnnecessary delays incurred in return of defective component.
RETURNS ANALYSIS
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.
Loose Items List
FILTER DRIER
A suitably sized liquid line filter drier is shipped loose in the refrigeration compartment
of the condensing unit. This has been chosen to match the required refrigeration duty
of the compressor. To access this item, remove the service cover at the electrical
panel end by undoing the catches and lifting off.

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
8
Component Location
COMPRESSORS
HCU 20 - 30D
The compressors are located in the centre of the unit and are accessed by key
operated lockable covers.
CUS 15 - 30D
The compressors are housed in the enclosed compartment which is at one end of the
condensing unit and accessible by a series of key operated lockable covers.
CUS 40 - 60D
The compressors are housed between the condenser coils and are accessible via
lockable access covers located at the opposite end of the unit from the control panel.
CONTROL PANEL
HCU 20 -30D
This is mounted at one end of the unit. It contains all the necessary breakers,
contactors and terminals required to operate the unit.
CUS 15 -30D
This is mounted above the compressor in the same compartment. It carries all the
necessary breakers, contactors and terminals required to operate the unit
CUS 40 - 60D
This is mounted in the enclosed end of the unit. It carries all the necessary breakers,
contactors and terminals required to operate the unit.
CONDENSER FAN AND
MOTOR UNITS
These are integral fan / motor units and are mounted so as to give a vertical discharge
of air from the condensing units.
COMPRESSOR ANTI-
CYCLE TIMERS
(STANDARD FITMENT)
These are fitted on the control panel and wired in to the control system. It is normally
recommended that this be set to a ten minute interval.
HEAD PRESSURE
CONTROLLER (WHEN
FITTED)
CUS 15 -30D AND HCU 20 ±30D
This fan speed controller is a single controller with the two sensors connected to it. It
operates to sense both circuits at the same time and will sense whichever circuit has a
head pressure that is requiring controlling and will vary the fan speeds accordingly.
CUS 40 -60D
A separate fan speed controller is fitted to each circuit and will vary the fan speeds for
each circuit accordingly.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
9
Site Installation Guide
LIFTING
Whenever a condensing unit is lifted, lifting should be from the base. Where possible,
all packing and protection should be left 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.
Spreader bars shall be used to ensure that any slings or chains used in the lifting
process do not crush the framework of the unit or damage the coil faces.
Due note shall 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 shall immediately be checked for damage.
POSITIONING AND
LEVELLING
The condensing unit shall be positioned on a stable load bearing and even base. This
base shall be levelled to ensure that the compressor operates correctly without
uneven internal stresses being transmitted to the compressor support.

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
10
Mechanical Information
CUS 15 - 60D
CUS
15D
20D
25D
30D
40D
50D
60D
Nominal Capacity
kW
41.8
50.2
71.1
80.7
104.0
131.4
161.4
Nominal Airflow
m³/sec
4.00
4.80
6.80
6.80
9.60
13.60
13.00
Max.Fan Speed
rpm
930
930
930
930
930
930
930
Refrigerant
R407C
R407C
R407C
R407C
R407C
R407C
R407C
Refrigerant Charge/Circ
kg
6.5
9.0
9.0
9.0
10.5
10.5
11.8
Oil Charge
l
4.0
4.0
4.0
6.6
9.9
9.9
9.9
Liquid Line Connection
ins
5/8
5/8
5/8
5/8
1 1/8
1 1/8
1 1/8
Suction Line Connection
ins
1 1/8
1 1/8
1 1/8
1 3/8
1 5/8
2 1/8
2 1/8
Machine Weight
Kg
440
540
550
695
978
1119
1356
Notes:
1 Based on 5°C evaporating and a 30°C ambient.
2 Refrigeration charge is for information purposes only. The units do not leave the factory charged.
3 All terminations are suitable for sweat connections.
HCU 20 - 30D
HCU
20D
25D
30D
Nominal Capacity
kW
58.6
69.5
81.0
Nominal Airflow
m³/sec
6.80
6.80
6.80
Max. Fan Speed
rpm
930
930
930
Refrigerant
R407C
R407C
R407C
Refrigerant Charge/Circ
kg
10.1
10.3
10.5
Oil Charge
l
4.0
4.0
6.6
Suction Line Connection
ins
1 1/8
1 1/8
1 3/8
Liquid Line Connection
ins
5/8
5/8
5/8
Notes:
1 Based on 5°C evaporating and a 35°C ambient
2 Refrigeration charge is for information purposes only. The units do not leave the factory charged.
3 All terminations are suitable for sweat connections.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
11
Dimensions: CUS 15D - 30D
+ A1
+ F1
+ B1 + C1
+ E1 + D1
C
A
B
F E D
H
Z
Y
G
6 Fixing Holes Ø 14mm
A
B
C
D
E
F
G
H
CUS 15D
mm
1438
2300
1100
200
-
-
25
1050
CUS 20D
mm
1438
2900
1100
200
1250
1250
25
1050
CUS 25D
mm
1438
2900
1100
200
1250
1250
25
1050
CUS 30D
mm
1438
3000
1100
200
1300
1300
25
1050
Point Loadings (kg)
Centre of Gravity (mm)
A1
B1
C1
D1
E1
F1
Y
Z
CUS 15D
146
-
101
101
-
156
1330
560
CUS 20D
130
120
56
56
121
140
1770
560
CUS 25D
130
122
57
57
123
141
1765
560
CUS 30D
174
140
78
77
138
179
1785
550
Notes:
1 Suction and liquid connections terminate underneath the condenser coil.
2 Allow 500mm around the unit for airflow and maintenance clearance.

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
12
Dimensions: CUS 40D - 60D
A
CB
+A1
+ F1
C1+
D1+
Y
F
Z
G
ED
SUCTION
LIQUID
6 Fixing Holes Ø 14mm
+
+F
E
K
J
H
2 Holes Ø 75mm
2 Knockouts Ø 32mm
B1
E1
D
55mm² Lifting Holes
ISOLATOR
ACCESS TO
COMPRESSOR
AIRFLOW
A
B
C
D
E
F
G
H
J
K
CUS 40D
mm
1693
2440
1800
200
1020
75
1650
155
595
100
CUS 50D
mm
1693
2440
1800
200
1020
75
1650
155
595
100
CUS 60D
mm
1693
2440
1800
200
1020
75
1650
155
595
100
Point Loadings (kg)
Centre of Gravity (mm)
A1
B1
C1
D1
E1
F1
Y
Z
CUS 40D
148
174
174
174
174
149
1169
896
CUS 50D
157
206
206
208
206
156
1136
900
CUS 60D
180
254
254
258
255
180
1116
900
Note: Allow 500mm around the unit for airflow and maintenance clearance.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
13
Dimensions: HCU 20 - 30D
A
Y
CE
B
G
Z
F
4 Fixing Holes Ø 14mm
DD
A1
D1
B1
C1
CIRCUIT 1
Liquid Line Suction Line
CIRCUIT 2
Liquid Line
Suction Line
HCU
A
B
C
D
E
F
G
20D
mm
1993
2280
805
30
2370
150
505
25D
mm
1993
2280
805
30
2370
150
505
30D
mm
1993
2280
805
30
2370
150
505
Point Loadings (kg)
Centre of Gravity (mm)
HCU
A1
B1
C1
D1
Y
Z
20D
140
157
139
131
1088
391
25D
140
157
139
131
1088
390
30D
186.2
206.7
155.7
151.4
1098
372
1 Suction and liquid connections terminate on the opposite side of the unit to the condenser coil face.
2 Allow 1000mm clearance on the coil side for airflow and 500mm clearance on the 3 other sides for maintenance

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
14
Refrigeration System
REFRIGERATION PIPEWORK SCHEMATICS
COIL
SHUT OFF
VALVE
CONDENSING UNIT
COMPRESSOR
SOLDER
CONNECTIONS
LIQUID
STUB
PIPE
SUCTION
IN-LINE PRESSURE
SWITCHES
P
P
Notes:
1 Compressor connections are diagrammatic only - not actual.
2 For clarity only one circuit is shown although all units are twin circuit.

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
15
Refrigeration System
HOLDING CHARGE
All units are shipped with a holding charge of dry nitrogen. This is to ensure that there
is no risk of internal contamination or moisture entering the units during shipping or
storage.
Before the units are evacuated prior to the charging process, the condensing unit
should be checked to see that the holding charge has been retained. If it appears to
be either partially or totally lost, then the unit concerned should be carefully checked
for signs of physical damage.
PIPEWORK SIZING/OIL
ADDITION.
It is MOST IMPORTANT that the correct size refrigeration pipework is used to ensure
that the pressure drop in the system is kept to a minimum, and also so that proper oil
return will take place under all normal operating conditions.
Accepted Good Practice should be followed in the design and installation of the
refrigeration pipework system.
Oil should be added to the pipework installation in accordance with the compressor
manufacturers recommendations where applicable.
PRESSURE TESTING
When installation is complete, fill the system with dry nitrogen to a pressure of 17
bar/250 psig. Record the pressure over a period of time (a minimum period of 60
minutes should be sufficient to detect any major leaks, however, ideally 24 hours
should be allowed). If there is any reduction in pressure, trace the leak and repair
before conducting a further pressure test.
EVACUATION
Evacuation should be carried out with a high vacuum pump. The pump should be
connected 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 or at
least reduced to significantly low proportions.
There are no hard and fast rules when applying this method. However, the following
has proved effective for general installation and service work.
1. Recover system charge and pressure test.
2. Replace filter drier.
3. Evacuate to (10 Torr) 13 mBar and maintain for 20 minutes.
4. Break vacuum with OXYGEN FREE dry nitrogen to 0.5 Bar (7psi) and hold for 15
minutes.
5. Evacuate to (5 Torr) 7mBar and maintain for 20 minutes.
6. Break vacuum with OXYGEN FREE dry nitrogen to 0.5 Bar (7psi) and hold for 15
minutes.
7. Evacuate to (½ Torr) 0.65 mBar and maintain for 1 hour.
The plant should now be sufficiently dehydrated and suitable for recharging.
Note: During installation keep all pipes capped to prevent dirt and moisture
ingress. If polyolester oil becomes contaminated with moisture then it is
advisable to change the oil and filter drier.
ALTERNATIVE
REFRIGERANTS
There are now an increasing number of transitional refrigerants as well as the
traditional ones and if any refrigerant other than R 22 is used care must be taken in all
aspects of installation and charging.
This is especially important with regard to the type of compressor oil used, and care must
be taken to ensure that the correct oil is used with the correct refrigerant.
IMPORTANT:- If an alternative refrigerant is used, then this must be with the
approval of Airedale International Air Conditioning Ltd. Use of an alternative
refrigerant without the approval of AIAC Ltd could invalidate the warranty.

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
16
Electrical Information
CONTROL PANEL
Standard Wiring
Diagram
The condensing units are designed to operate in conjunction with other Airedale units,
and are also suitable for matching to other air handling units. A wiring diagram is
supplied with each unit and should be referred to when carrying out the installation.
Components
CUS 15 - 30D AND HCU 20 - 30D
7KHIROORZLQJ0&%¶VDUHILWWHGDVVWDQGDUG
1 Single phase control circuit breakers (mains and control voltage).
2 Three phase compressor circuit breakers.
The following contactors/overloads are fitted:
1 CP1 and CP2 - Main compressor contactors.
2 Compressor thermal overload (CU 30D only).
3 CD1 - Condenser Fan Contactor.
The following relays are fitted, some are option dependent:
1 R1 - Delay Start Relay - Circuit No 1.
2 R2 - Delay Start Relay - Circuit No 2.
3 R3 - HP/LP Trip Relay - Circuit No 2
4 R4 - Relay - Circuit No 1.
5 R5 - Relay - Circuit No 2.
6 R6 - HP/LP Trip Relay - Circuit No 1
Other components are as follows, some are option dependent:
1 Compressor Sequence Switch
2 T1 - Delay Start Timer - Circuit No 1
3 T2 - Delay Start Timer - Circuit No 2
4 In-line pressure switches (HP 2 off, LP 2 off).
5 Electronic pressure operated condenser fan speed controller (One Off)
CUS 40 - 60D
7KHIROORZLQJ0&%¶VDUHILWWHGDVVWDQGDUG-
1 Single phase control circuit breakers (mains and control voltage)
2 Three phase compressor circuit breakers
The following contactors/overloads are fitted:-
1 CP1 to CP4 - Main compressor contactors
2 Compressor thermal overloads
3 CD1 and CD2 - Condenser Fan Contactors
The following relays are fitted, some are option dependent:
1 R1 and R3 - Delay Start Relay - Dual Compressor - Circuit No 1
2 R4 and R6 - Delay Start Relay - Dual Compressor - Circuit No 2
3 R2 and R5 - HP/LP Trip Relays
Other components are as follows, some are option dependent:
1 Compressor Sequence Switch
2 T1 and T2 - Delay Start Timer - Dual Compressor - Circuit No 1
3 T4 and T5 - Delay Start Timer - Dual Compressor - Circuit No 2
4 In-line pressure switches (HP 2 off, LP 2 off).
5 Electronic pressure operated condenser fan speed controller (Two Off)

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
17
Electrical Information
ELECTRICAL DATA
CUS
15D
20D
25D
30D
40D
50D
60D
Unit Data
Nominal Run Amps (1)
A
30.4
35.6
47.2
53.0
62.8
82.9
97.5
Maximum Start Amps
A
115.7
140.2
202.3
205.0
149.5
164.8
220.5
Control Circuit
V
24VAC
Mains Supply
V
400/3/50
Permanent Supply
V
230/1/50
Rec Mains Fuse
A
50
50
80
80
100
100
125
Rec. Permanent Fuse(2)
A
4
4
4
4
4
4
4
Max Incoming ) Mains
mm²
25
25
35
35
50
50
95
Cable Size ) Perm
mm²
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Compressor
Motor Rating
kW
6.9
8.9
11.6
13.4
8.9
8.9/13.4
13.4
Nominal Run Amps (1)
A
12.7
15.2
19.8
22.5
15.2
15.2/22.5
22.5
Locked Rotor Amps
A
98
120.0
175.0
175.0
120.0
120.0//175.0
175.0
Oil Sump Heater Rating
W
50
50
50
75
50
50/75
75
Type of Start
Direct on Line
Condenser Fan
Motor Rating
kW
0.55
0.55
0.55
0.55
0.55
0.55
0.55
Full Load
A
2.50
2.50
2.50
2.50
2.50
2.50
2.50
Locked Rotor Amps
A
5.80
5.80
5.80
5.80
5.80
5.80
5.80
(1) Nominal Run Amps based on 5°C evaporating and a 35°C ambient.
(2) CUS40-60 units do not require a separate permanent fused supply.
HCU
20D
25D
30D
Unit Data
Nominal Run Amps (1)
A
38
46
56
Maximum Start Amps
A
127.4
157
207
Control Circuit
V
24VAC
Mains Supply
V
400/3/50
Permanent Supply
V
230/1/50
Rec Mains Fuse
A
50
80
80
Rec. Permanent Fuse
A
4
4
4
Max Incoming ) Mains
mm²
25
35
35
Cable Size ) Perm
mm²
2.5
2.5
2.5
Compressor
Motor Rating
kW
13.3
16.7
13.4
Nominal Run Amps (1)
A
14.9
19.2
24.2
Locked Rotor Amps
A
105
130
175.0
Oil Sump Heater Rating
W
18-38
18-38
75
Type of Start
Direct on Line
Condenser Fan
Motor Rating
kW
0.55
0.55
0.55
Full Load
A
2.50
2.50
2.50
Locked Rotor Amps
A
5.80
5.80
5.80
(1) Nominal Run Amps based on 5°C evaporating and a 35°C ambient.

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
18
Field Connections
CUS 15-30
&
HCU 20-30 UNITS
L1
{
L2
{
L3
{
Î
Mains Incoming
N
{
400/3/50
E
{
L4
{
Î
L4-N1 Permanent Supply
N1
{
230/1/50
500
{
Î
0V
502
{
Î
9$&&XVWRPHU¶V&RQWURO
530
{
Î
502-530 Stage Two Cool - Customer's Control
535
{
Î
502-535 Stage One Cool - Customer's Control
531
{
Î
531-500 Liquid Line Solenoid - Circuit 2
Customer
Supply
532
{
Î
532-500 Liquid Line Solenoid - Circuit 1
526
{
Î
526-527 Common Volt Free Alarm N/O Contact
527
{
CUS 40-60 UNITS
L1
{
L2
{
L3
{
Î
Mains Incoming
N
{
400/3/50
E
{
L4
{
Î
L4-N1 Permanent Supply
N1
{
230/1/50
500
{
Î
0V
502
{
Î
24VAC - &XVWRPHU¶V&RQWURO
506
{
Î
502-506 Stage One Cool - Customer's Control
513
{
Î
502-513 Stage Two Cool - Customer's Control
522
{
Î
522-552 Stage Three Cool - Customer's Control
552
{
523
{
Î
523-555 Stage Four Cool - Customer's Control
555
{
507
{
Î
507-500 Liquid Line Solenoid 1 - Circuit 1
Customer
Supply
514
{
Î
514-500 Liquid Line Solenoid 2 - Circuit 2
507
{
Î
507-500 Liquid Line Solenoid 1 - Comp 1, Circuit 1
514
{
Î
514-500 Liquid Line Solenoid 2 - Comp 1, Circuit 2
522
{
Î
522-500 Liquid Line Solenoid 3 - Comp 2, Circuit 1
523
{
Î
523-500 Liquid Line Solenoid 4 - Comp 2, Circuit 2
526
{
Î
526-527 Common Volt Free Alarm N/O Contact
527
{

Condensing Units
CUS 15 - 60 / HCU 20 ²30D
Chillers & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07/14
19
Commissioning Procedure ±Example
CONDENSERS/CONDENSING
UNITS - C/CUS/CUHS/HCU/CFCUS
Ai r e d a l e I n t e rn a t i o n a l
Ai r C o n d i t i o n i n g L t d
TO BE COMPLETED IN CONJUNCTION WITH COMMISSIONING PROCEDURE
RETURN WHITE COPY TO AIREDALE/RETAIN PINK COPY
Leeds Road, Rawdon, Leeds
LS19 6JY ENGLAND
Tel: [phone]
Fax: [phone]
Engineer: Company: Date:
Model: Serial No: Site Ref:
1 Pre Commissioning Checklist
1.1 Unit Condition Satisfactory
Comment:
1.2 Holding charge retained
Circ 1
Yes/No
Circ 2
Yes/No
1.3 Electrical connections tight
V
1.4 Voltage at mains supply
L1-L2
V
L2-L3
V
L3-L1
V
1.5 System pressure test:
I Initial test pressure
Circ 1 Barg
Circ 2 Barg
ii Final test pressure
Circ 1 Barg
Circ 2 Barg
iii Test duration
Circ 1 Hrs
Circ 2 Hrs
2 Commissioning Checklist
2.1 Final system vacuum
Circ 1 mBar
Circ 2 mBar
2.2 Vacuum hold time
Circ 1 Min
Circ 2 Min
2.3 Refrigerant type
2.4 Refrigerant charge
Circ 1 kg
Circ 2 kg
2.5 Timer settings correct and operational (if fitted)
Low pressure override - 3mins
Circ 1 Mins
Circ 2 Mins
Defrost - 30 mins
Circ 1 Mins
Circ 2 Mins
Anti cycle timer -10 mins
Circ 1 Mins
Circ 2 Mins
2.6 Head pressure control set
Circ 1 Barg
Circ 2 Barg
2.7 HP/LP switch cut outs:
Circ 1 Barg
Circ 2 Barg
I LP cut out - 2.0 barg
LP Cut Out Barg
LP Cut Out Barg
ii LP cut in - 3.0 barg
LP Cut In Barg
LP Cut In Barg
iii HP cut out - 27.0 barg
HP Cut Out Barg
HP Cut Out Barg
2.8 HGBP valve setting (if fitted)
Circ 1 Barg
Circ 2 Barg
2.9 Superheat at compressor
Circ 1 °C
Circ 2 °C
2.10 Added oil volume (if applicable)
Circ 1 Lt
Circ 2 Lt
2.11 Operating conditions:
i Suction pressure
Circ 1 Barg
Circ 2 Barg
ii Discharge pressure
Circ 1 Barg
Circ 2 Barg
2.12 Compressor Amps (CU & CFCU)
L1 Amps
L1 Amps
L2 Amps
L2 Amps
L3 Amps
L3 Amps
2.13 Condenser Fan Amps
/ / Amps
/ / Amps
3 Other comments
IMPORTANT: THIS IS AN IMPORTANT WARRANTY DOCUMENT AND WARRANTY COULD BE
INVALIDATED SHOULD AIREDALE NOT HOLD A COPY ON FILE.
QTYENG 10 - 08/98

CUS 15 - 60 / HCU 20 ²30D
Condensing Units
Chiller & Condensing Units
Installation & Maintenance:Part No: 6259592 IM 07\14
20
Commissioning Procedure
REFRIGERATION CIRCUIT -PRE-START CHECKS
Electrical
1 Check all electrical connections are tight, including contactor and all terminal
connections.
2 Check supply is available at the correct voltage and that any external fuses /
circuit breakers are the correct rating.
3 Check that there is a proper earth connection to the condensing unit.
4 Check that there is a supply to the oil sump heater.
IMPORTANT
Scroll compressors in range CU30 to 60D and HCU30D condensing units:- Check
phase rotation of electrical supply prior to running compressor as compressor is
direction sensitive.
Refrigeration
1 Check that there is a holding charge of refrigerant in the system.
2 Check the high and low pressure switch settings. These should be as
follows:-
HIGH PRESSURE SWITCH 27 Bar (400 psi ) - CUT OUT
LOW PRESSURE SWITCH 0.5 Bar (7 psi ) - CUT OUT
3.8 Bar (55 psi ) - CUT IN
REFRIGERATION CIRCUIT - CHARGING
Procedure
The system should be charged in accordance with accepted good practice and the
suction and discharge pressures should be constantly monitored whilst charging is in
progress.
At the same time the compressor current should be monitored.
The system should be charged to the relevant suction and discharge pressures,
together with the correct suction superheat (normally 5 °C to 6 °C).
Once this has been done, all the readings taken should be recorded on the
commissioning sheets and a copy returned to Airedale for warranty purposes.
HEAD PRESSURE
CONTROLLER
ADJUSTMENT
CUS 15 - 30D AND HCU 20 - 30D
The head pressure is controlled by a single head pressure controller fitted with two
pressure transducers - one to each circuit.
The fan speeds will increase if either head pressure goes above the preset level as
the fans are common to both condenser coils.
Access to the controls for this head pressure controller is achieved by removal of the
plastic cover which is secured by four screws.