Dunham-Bush Cougar Guide

Cougar Fan Coil Unit
Installation, Operation & Maintenance Instructions
Dunham-Bush Ltd, Downley Road, Havant, Hants PO9 2JD
Document Ref:
Tel: [phone]
Email: [e-mail]
127-000-001-B
UK:www.dunham-bush.co.uk
Global:www.dunham-bush.com
June 2018
INTRODUCTION
This booklet provides guidance to identify, handle,
install and commission Dunham-Bush Cougar fan coil
units as well as guidance for operation and
maintenance.
These instructions are to be read in conjunction
with the wiring diagram supplied with the unit.
The instructions apply to units from the standard range
only. Please study the instructions carefully before
commencing any installation work.
IDENTIFICATION
The fan coil unit serial number, description and figure
number (size) are displayed on a label found on the
unit discharge plenum. If specified, a stencil reference
may also be marked on the discharge plenum for on-
site identification.
DESCRIPTION
Dunham-Bush Cougar fan coil unit comprises a self-
finished galvanised sheet steel casing with multiple
access panels to each part of the fan coil unit,
including fans, motors, air filter, dual purpose
heating/cooling coil, electrical connections box and
discharge plenum. Fan coil units are designed for
continuously variable fan speed, with fan speed set by
a 0-10VDC signal.
STANDARD RANGE MODELS & SIZES
Cougar is a horizontal basic chassis fan coil unit,
available in seven sizes, figs 1 to 7 inclusive
Diagram 1 - Cougar Fig 3 LH connections with octagonal discharge plenum
NOTE: PLEASE LEAVE COPIES OF THESE INSTRUCTIONS AND ANY WIRING DIAGRAMS
AND OTHER RELEVENT LITERATURE WITH THE END USER.
Electrical connections
and controls box
Fan speed and on/off switches
Discharge spigot
Drip tray drain
connection
Valves and actuators
(coil connections)
Coil/drip tray access panel
Filter access
panel
Fan/motor access panel
Discharge plenum access panel

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Diagram 2: Range of standard sizes with octagonal discharge plenum
ACCESSORIES
Standard controls
Dunham-Bush Cougar fan coil units are available with
accessories for fitted stand alone or remote control.
These include fitted or remote setpoint adjusters,
remote room air sensors and remote fan speed
controllers. Refer to the wiring diagram included with
the fan coil unit for details on installation and wiring of
remote controls.
Discharge Configuration
The standard configuration is for an octagonal
discharge plenum with up to eight spigots (depending
on size/figure number). Spigots can be fitted up to
Ø160mm, and can be removed and repositioned to
suit duct connections on site. Spigots that are not
required have an acoustically lined blanking plate
fixed with self-tapping screws.
CONSTRUCTION
Delivery
The purchaser is responsible for off-loading, and must
examine the fan coil units promptly upon receipt. Any
claims for damage will only be accepted if, at the time
of delivery, the consignment note is endorsed with the
details and counter- signed by the transport driver.
Each fan coil unit is marked to show the model, figure
number, serial number and stencil reference if
specified.
Handling and Storage
Fan coil units are individually packed, and two/three
persons can usually handle the heaviest unit. When a
significant quantity of fan coils is delivered, they may
be palletised and shrink-wrapped, so a fork-lift or
similar will be required for lifting. The fan coil unit
must not be dropped or suffer impact in any
circumstances and should never be lifted or handled
by their coil connections.
Fan coil units should be stored in clean, dry
conditions. Any packaging should not be removed
until the fan coil unit is required for installation.
Packaging should only be removed if damage is
suspected at the time of delivery.

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WARNING: Cougar fan coil units are designed with minimal sharp edges on the chassis. Some internal
components on the fan coil may have sharp edges. Care must be taken when handling the product; protective
gloves should be worn.
FIGURE
1
2
3
4
5
6
7
Dry mass of basic unit with discharge
spigot plenum only (kg)
43
60
65
81
86
103
108
Table 1: Approximate masses of Cougar fan coil units
INSTALLATION
General
Before removing any packaging, check the identity of
the fan coil unit against the stencil reference marked
on the access panel. Packaging should be retained to
protect the fan coil unit from damage by other works
after installation.
Fitting
1. Prepare drop rods to accept the fan coil. M6, M8
or M10 drop rods are recommended, with
appropriate washers. Refer to diagram 2 for
positions of fixings.
2. Suspend the fan coil unit and ensure it is level
in both directions. Use a spirit level on the
casing. (The drip tray is graded internally to
ensure drainage of condensate).
3. Connect ductwork to the fan coil unit. Flexible
duct connections are recommended where
sheet metal ductwork is used. Do not suspend
any ductwork from the fan coil unit alone. Refer
to diagram 4 for spigot positions.
4. Connect pipework as shown in Diagram 5.
5. Connect a suitable drain to the drip tray.
6. Connect electrical supply and control
accessories as shown in wiring diagrams
enclosed with the fan coil unit.
7. After filling the hot and chilled water systems,
check for leaks (refer to Commissioning).
8. Ensure condensate pump is installed in
accordance with the manufacturer’s
requirements and see Diagrams 3a and 3b
below.
Pipework Connections
1. The coil is a dual-purpose coil with OD15mm
copper tube tails at 40mm centres between flow
and return connections. Always observe the
correct direction of flow. (see Diagram 5)
2. Local isolating and regulating valves are
recommended, as well as strainers to filter out
foreign matter in the water.
3. The installer must provide any fittings to
connect pipework to fitted 2 or 4 port valves.
4. The drip tray has an OD22mm tube connection,
suitable for a compression fitting or similar, to
be supplied by the installer.
Electrical connections and controls
1. The electrical connections box is located on the
side of the fan coil unit, and incorporates a
hinged access door, fastened with a
self-tapping screw.
2. Connect a 230V/1ph/50Hz supply to the flying
lead fitted to the electrical connections box.
3. Fit any remote accessories in their appropriate
locations and connect terminal block inside the
electrical connections box.
Refer to the wiring diagram enclosed with the
fan coil unit for specific wiring details.
4. All wiring should comply with IEE regulations
(BS 7671) and local bye-laws.
Diagram 3a Diagram 3b

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Diagram 4: Standard spigot sizes and positions
Diagram 5: Pipework connections, as viewed on header/connection end of coil

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Diagram 6: Inlet and filter Diagram 7: Fan access panel
COMMISSIONING
1. Ensure that the fan coil unit is clean, and the
filter especially is clean and free from dust.
Check the fastness of all access panels and
ductwork connections.
2. Check that all electrical connections are correct
and comply with BS7671 and local bye-laws.
Refer to the wiring diagram supplied with the
fan coil unit
3. Check the coil connections and drip tray
connections for leaks. Refer to Table 3 for coil
test and working pressures.
4. Purge air from both heating and cooling
sections of the coil using the manual air vents
fitted.
5. Balance the water flow rate through both hot
and chilled water systems following accepted
practice to achieve the specified flow rates.
6. On AC motor units, there are two fan speed
switches - one to give three main speeds, and
the other to provide a ‘fine-adjust’ to each
speed. Set the switches to the specified design
settings, as highlighted on the label fixed to the
plenum access panel.
(Refer to diagram 8 for fan switch settings)
7. On EC motor units, adjust potentiometer to
ensure air volume to design specification. If
using a BMS controller with a 0-10V output,
adjust the fan via the remote interface to ensure
air volume and external static resistance are
both to design specification.
8. If fitted, set any remote switches and/or controls
to the specified settings.
9. Check the operation of controls in accordance
with control manufacturer’s instructions.
10. Check the operation of any remote fan speed or
remote thermal controls.
11. If supplied/fitted, check the operation of the
condensate pump by pouring a small quantity of
water into the drip tray; ensure the pump clears
any water and operates any alarms etc.
12. Leave this document and the wiring diagrams
with the end user.
For further information on any fan coil unit - contact Dunham-Bush, quoting the serial number on the label on
the access panel.

Page 6 of 12
Size
Cooling coil valve Kv
Heating coil valve Kv
Figure 1
1.0
0.6
Figure 2 & 3
1.0
0.6
Figure 4 & 5
1.0
0.6
Figure 6 & 7
1.0
0.6
Table 2 - 4 port valves; recommended Kv values to match coils
Coil Section
Maximum test pressure
Recommended working pressure
Cooling
20 bar gauge
7 bar gauge
Heating
20 bar gauge
7 bar gauge
Table 3 - Maximum test and working pressures
WARNING
Air vents should not be operated during pressure tests. Recommended working pressure is limited to 7 bar
gauge to ensure safe operation of manual air vents.
Size
Cooling section content (l)
Heating section content (l)
Figure 1
1.70
0.20
Figure 2 & 3
2.55
0.28
Figure 4 & 5
3.68
0.40
Figure 6 & 7
4.53
0.51
Table 4 - Water content of cooling and heating sections of coil
Diagram 8: Fan switch speed settings; also shown as label affixed to fan coil unit (AC motor units only)

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Diagram 9: Typical wiring diagram –Basic AC motor speed Control –Refer to wiring diagram supplied with unit.

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Diagram 10: Typical wiring diagram –Basic EC motor speed Control - Refer to wiring diagram supplied with unit

Page 9 of 12
OPERATION
Cougar fan coils provide cooling and heating of air
when used in conjunction with chilled water and/or low
temperature hot water systems. They are designed for
mounting in a ceiling or roof void, connected to
ductwork.
When running, the fan draws air from the room and the
primary air supply, through an inlet filter and over the
finned tubes of a heating/cooling coil. The air is then
discharged through spigots, along ductwork and
through grilles or diffusers to the room space.
Alternative options include chilled water cooling only,
and intake through ductwork and spigots.
Fans normally run continuously, with an automatic
control system varying the flow rates of chilled water
and hot water through the coil (waterside control), thus
varying the cooling and heating outputs. Depending
upon the particular type of controls fitted, user control
is provided by 0-10VDC signal and/or temperature
control.
CONTROLS
Cougar fan coil units are fitted with a waterside control
system, which typically comprises the following
elements: -
Fitted fan on/off switch
Fan speed change switches (AC motor units)
Fan speed potentiometer (EC motor units)
Fan coil controller
Return air sensor
Valve actuators (Two or four port valves)
Additional optional accessories include: -
Remote room air sensor
Remote setpoint adjuster
Remote fan on/off and speed switches
Fitted relays for master/slave or BMS control
Dunham-Bush also fit non-standard controls supplied
by others; refer to the wiring diagram supplied with the
unit.
CLEANING
Cleaning and maintenance must be carried out by
competent persons
Inspection
The frequency of cleaning and inspection depends
upon the conditions in which the fan coil unit
operates. Initially, it is suggested that the air filter
and drip tray are inspected after 6-8 weeks normal
operation.
Access
There are four access panels - filter, drip tray/coil,
fans/motors and discharge plenum. All access
panels can be opened by removing screws and
turning quarter-turn fasteners.
The filter can be removed by sliding it out from its
mounting on the fan coil inlet, or from below by
removing its access panel .
Cleaning
1. Air filters can be cleaned by tapping out
excess dust and washing in warm water (up
to 40°C), using detergent if necessary. The
filter must be rinsed and allowed to dry
naturally before replacing. Do not use a
vacuum cleaner, as it can damage the filter
media. Filters should be replaced after
approximately 20 washes.
2. The drip tray can be cleaned with warm,
soapy water. Ensure the drip tray drains
freely.
3. If a condensate pump is fitted, check any
sensors are clean and wiped dry. Test the
operation of the pump by pouring clean water
into the drip tray.
Because the air filter retains most of the dusty
particles, it will only be necessary to clean the fans,
motors and coil annually. An industrial vacuum
cleaner can be used to clean the inside of the fan
coil, in particular the coil and fans, with the air being
sucked through the coil in the opposite direction to
normal air flow. All accessible surfaces can be
cleaned with a cloth.

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MAINTENANCE
1. Purge any air from both cooling and heating
sections of the coil using the manual air vents
(using a suitable key).
2. The fan motor has ‘sealed for life’ bearings
which do not require any maintenance, other
than visual inspection
3. The electrical connections box incorporates a 5A
fuse.
4. Each fan coil unit is supplied with a wiring
diagram applicable for the particular controls
and accessories (Refer to pages 7 and 8).
Further copies are available on request.
Please quote the serial number on the label
on the main access panel.
5. Check the operation of all controls by varying
their settings to achieve the desired effect on
the fan.
WARNING
1. Prior to undertaking any cleaning or maintenance, ensure that the fan coil unit and any
controls are disconnected from the electrical supply at the local isolator.
2. Some internal components may have sharp edges. Care must be taken when working on the
fan coil unit, and protective gloves should be worn.

Page 11 of 12

Page 12 of 12
SPARES/SERVICE
PLEASE WRITE THE DETAILS OF THE UNIT HERE.
These details will be required when ordering spares for you Dunham-Bush Cougar Fan Coil Unit
UNIT TYPE AND MODEL INFORMATION
SERIAL NUMBER
DATE OF INSTALLATION
Spare parts/service –Please contact our office, contact information shown below.
Manufacturer reserves the right to change any product specification without notice.
Dunham-Bush Ltd, Downley Road, Havant, Hants, PO9 2JD
Sales and Technical Support
Spare Parts and Service
Tel: [phone] Fax: [phone]
Tel: [phone] Fax: [phone]
Email: [e-mail]
Email: [email protected].uk