Marstair 929 Series User manual

TECHNICAL MANUAL L
CD3 (929 SERIES) PACKAGED DX CLOSE CONTROL UNITS.
FOR USE IN SPLIT SYSTEMS
This manual details technical, installation and operating information for the CD3 range (929 series)
DX indoor units for use in conjunction with 550 series CKC condensing units or 542 series DCU
ducted condensing units. Remove the expansion device from the outdoor condensing unit if the
CD3 unit has capillaries or expansion valves fitted.

2 92908135-17
INDEX L
GENERAL General description and part numbers 3
- DX upflow package units 3
- DX configured units 4
- Condensing units 4
- DX configurable accessories 5
Dimensions and weights 6
SELECTION Unit combinations 7
Performance data DX 7
Airflows 8
Sound levels - CD3 units, outdoor/ducted units 8
INSTALLATION Airflow options 9
Indoor unit 10
CKC 80 - 200 13
DCU 30 - 80 14
APPLICATION Pipe sizing and application 16
Refrigeration installation 17
Evacuating, factory charge 17
Adding refrigerant 17
Electrical data 18
Fuses 19
Condensate drain 20
Fan speed controller 20
WIRING CD3 21
DIAGRAMS CKC 24
DCU 25
Interconnecting wiring diagrams 26
ACCESSORIES Condensate pump 27
Humidifier 27
Auto change over 28
OPERATION pCONet Parameters 29
and Microprocessor control 33
COMMISSIONING
COMPONENT Exploded views of units with 42
IDENTIFICATION component identification

3 92908135-17
GENERAL L
INTRODUCTION
The CD3 range of direct expansion units is designed to provide the close control of temperature and humidity demanded
by computer rooms, laboratories, banks, offices etc.. All units are fitted with programmable microprocessor controls.
CD3 indoor units are available in upflow or downflow configurations, matching with the Marsatair range of CKC and DCU
outdoor/ducted condensing units using R407C refrigerant. There is a range of 4 capacities in 3 cabinet sizes for both
upflow and downflow units. Packaged units are available in upflow versions only.
CD3-RANGE - GENERAL DESCRIPTION
DX UPFLOW PACKAGE UNITS
Twin circuit, packaged upflow units are normally supplied ex-stock. A field fit kit is available for converting from twin
circuit to single circuit if required.
MODEL CD3
008
010
015
020
Twin Circuit upflow
92918001
92918002
92918003
92918004
PACKAGE UNITS INCLUDE:
* Electronically controlled fan speeds * Four pole mains isolator
* Class 'O' thermal and acoustic insulation * Microprocessor controls
* Washable filters * Display giving access to set points and alarms
* Discharge plenum and grille * Alarms: humidity/temperature out of limits
* Twin circuit coils * Switches: Off/standby, unit run
* Electric heating (2 stage) * De-ice thermostat
* Humidifier with modulating control * Dehumidification
KITS AVAILABLE FOR FIELD FITTING TO PACKAGE UNITS:
Condensate pump, including high
water level indication.
(hot or cold, 5m lift)
ALL
92919077
Floor stand plinth 75mm high
008
92911032
010, 015
92911033
020
92911034
Fresh air spigot 100mm dia.
ALL
92911062
Double deflection grille
008
92911094
Fresh air spigot 160mm dia.
ALL
92911063
010, 015
92911095
Fresh air fan and filter 93m3/h
ALL
92911003
020
92911096
Fresh air fan and filter 186m3/h
ALL
92911004
Disposable filter
(replaces washable filter)
008
92911038
Top ducted discharge spigot
008
92911059
010, 015
92911039
010, 015
92911060
020
92911040
020
92911061
Sound attenuation section
008
92911075
Master/slave, run/standby, duty assist and unit sequencing
are available using a pLAN network
010, 015
92911076
020
92911077
Changeover on alarm
ALL
92900820
3 phase to 1phase conversion
kit
008/2 + 50
92911125
Changeover on set time and/or alarm
ALL
92900821
008/2 + 30
92911126
Two circuit to single circuit pipe work
conversion kit
008
92911102
010/2 + 50
92911127
010
92911103
010/2 + 60
92911128
015
92911104
015/2 + 80
92911129
020
92911105
020/2 + 90
92911130
BACnet Controls
pCONET BMS BACnet
Control
ALL
92919134
USB to RS485 Connector
ALL
92919136

4 92908135-17
DX UPFLOW & DOWNFLOW CONFIGURED UNITS
MODEL
COOLING
CIRCUITS
CD3 008
CD3 010
CD3 015
CD3 020
UPFLOW
1
92918006
92918008
92918010
92918012
2
92918007
92918009
92918011
92918013
DOWNFLOW
1
92918014
92918016
92918018
92918020
2
92918015
92918017
92918019
92918021
CONFIGURABLE UNIT FEATURES
* Electronically controlled fan speeds * Microprocessor controls
* Class 'O' thermal and acoustic insulation * Display giving access to set points and alarms
* Washable filters * Alarms: humidity/temperature out of limits
* Discharge plenum and grille * Switches: Off/standby, unit run
* Single and twin circuit coils * Upflow and downflow units available
CKC CONDENSING UNITS (For use with R407C refrigerant)
CKC 30
1ph
CKC 30
3ph
CKC 40
1ph
CKC 40
3ph
CKC 50
1ph
CKC 50
3ph
CKC 60
1ph
CKC 60
3ph
55017730
55017774
55017741
55017775
55023722
55017776
55017740
55017777
CKC 80
1ph
CKC 80
3ph
CKC 90
1ph
CKC 90
3ph
CKC 100
3ph
CKC 130
3ph
CKC 165
3ph
CKC 180
3ph
CKC 200
3ph
55017723
55017724
55017771
55023778
55017779
55017780
55017782
55017783
55017784
CKC 30 and 40 units are fitted with reciprocating compressors. All other CKC units are fitted with scroll compressors.
DCU DUCTED CONDENSING UNITS (for use with R407C)
DCU 30
1ph
DCU 30
3ph
DCU 50
1ph
DCU 50
3ph
DCU 60
1ph
DCU 60
3ph
DCU 80
1ph
DCU 80
3ph
54224029
54224035
54224031
54224037
54224032
54224038
54224033
54224039
All DCU units are fitted with reciprocating compressors.
STANDARD FEATURES AND OPTIONS, CKC, DCU
CKC = standard condensing unit + head pressure control + HP and LP switch and timers
DCU = electronic controlled ducted condensing unit + head pressure control + HP and LP switches and timers
CONDENSING UNIT MODEL
CKC
DCU
Suction and liquid service valves
Standard
Standard
Expansion device (fixed orifice type)
Not available
Standard
Pre-charged with refrigerant (R407C)
Not available
Standard
Ducted air inlet and/or discharge
Not available
Standard
Ceiling suspendible
Not available
Standard
Capacitor start relay (1 phase) (CKC 30 - 40, All DCU)
Option
Option
PTC resistor (1 phase)
Option
Option
Fan speed/head pressure control
Standard
Standard
LP cut-out - Auto
Standard
Standard
HP cut-out - Auto
Standard
Standard
HP cut-out - Manual
Option
Not available
Isolator
Option
Option
3 minute start delay timer and low ambient start
Standard
Standard
Wall mounting brackets
Option
Option
Contactor
Standard
Standard
Overload (standard on 3ph)
Not available
Option

5 92908135-17
CD3 DX UNIT CONFIGURABLE ACCESSORIES
(All options are factory fitted or supplied loose for site fitting during installation)
Description
Model
Factory
Fitted
Part No.
Description
Model
Factory
Fitted
Part No.
THERMOSTATIC EXPANSION
VALVE
008/1
92900468
ALARMS
010/1
92900469
High water level
ALL
92919064
015/1
92900470
Water spillage indication (no pump)
ALL
92919067
020/1
92900471
Water spillage indication (with
pump)
ALL
92919066
008/2
92900472
Fan failure
ALL
92919069
010/2
Dirty filter indication
ALL
92919071
015/2
92900473
Condensing unit 1 trip
ALL
92919073
020/2
92900474
Condensing unit 2 trip
ALL
92919075
2kW
92919001
Common alarm (volt free relay)
ALL
92919056
ELECTRIC HEATERS - Upflow
4kW
92919002
008
92900456
Single stage
6kW
92919003
ISOLATOR 63A
010, 015
92900457
8kW
92919004
020
92900458
10kW
92919005
FRESH AIR SPIGOT 100mm
dia.
ALL
92900462
2kW
92919011
160mm
dia.
ALL
92900463
ELECTRIC HEATERS - Upflow
4kW
92919012
FRESH AIR FAN + FILTER
93m³/h
ALL
92900403
Second stage
6kW
92919013
186m³/h
ALL
92900404
8kW
92919014
TOP DUCTED DISCHARGE
SPIGOT (If used for return air on
downflow units add plenum for
disposable filter access)
008
92900459
10kW
92919015
010, 015
92900460
HEATER RAIL - Upflow
008
92919021
020
92900461
Required for all heater kits
010, 015
92919024
008U
92900475
020
92919026
SOUND ATTENUATOR SECTION
010/015U
92900476
2kW
92919006
020U
92900477
ELECTRIC HEATERS - Downflow
4kW
92919007
008U
92900432
Single stage
6kW
92919008
FLOOR STAND PLINTH
010015U
92900433
8kW
92919009
75mm high
020U
92900434
10kW
92919010
(Recommended for all floor
standing
008D
92900435
2kW
92919016
Units and for side entry of services)
010/015D
92900436
ELECTRIC HEATERS –Downflow
4kW
92919017
020D
92900437
Second stage
6kW
92919018
DOWNFLOW PLINTH
008
92900481
8kW
92919019
300mm high Font
discharge
010/015
92900482
10kW
92919020
020
92900483
HEATER RAIL - Downflow
008
92919022
008
92900484
Required for all heater kits
010, 015
92919025
300mm high Rear
discharge
010/015
92900485
020
92919027
020
92900486
LPHW HEATING 7.52kW
008
92900423
DOUBLE DEFLECTION GRILLE
008
92900494
(Add de-ice stat 10.50kW
010
92900424
(Upflow only)
010, 015
92900495
For all units) 14.94kW
015
92900424
020
92900496
18.40kW
020
92900425
008U
92900438
LPHW VALVE Motorised 2 port
ALL
92919048
010/015U
92900439
3 port
ALL
92919049
DISPOSABLE FILTER 50mm
020U
92900440
Modulating
ALL
92919050
(Replaces standard washable filter)
008D
92900441
DE-ICE THERMOSTAT (1 per circuit)
ALL
92900410
010/015D
92900442
008U
92919028
020D
92900443
010/015U
92919029
008
92900478
HUMIDIFIER 0-
3kg/h
020U
92919030
HIGH EFFICIENCY FILTER
100mm
010,015
92900479
008D
92919031
020
92900480
010/015D
92919032
REMOTE CONTROL PANEL
008
92919078
020D
92919033
Supplied separately
010, 015
92919079
CONDENSATE PUMP
(With alarm interface)
ALL
92919054
(Includes 6m ribbon cable)
020
92919080
BACnet Controls
pCONET BMS BACnet Control
ALL
92919133

6 92908135-17
DIMENSIONS AND WEIGHTS
CD3 INDOOR UNITS
UPFLOW UNITS (With plenum fitted)
UNPACKED
PACKED
Model
008
010
015
020
008
010
015
020
HEIGHT mm
1595
1595
1595
1595
1755
1755
1755
1755
WIDTH mm
1230
1380
1380
1580
1250
1400
1400
1600
DEPTH mm
430
430
430
430
455
455
455
455
WEIGHT kg
142
162
171
182
163
185
194
211
DOWNFLOW UNITS
UNPACKED
PACKED
Model
008
010
015
020
008
010
015
020
HEIGHT mm
1165
1165
1165
1165
1300
1300
1300
1300
WIDTH mm
1230
1380
1380
1580
1250
1400
1400
1600
DEPTH mm
430
430
430
430
455
455
455
455
WEIGHT kg
124
142
151
160
141
160
169
184
CKC CONDENSING UNITS
UNPACKED
Model
CKC
30
CKC
40
CKC
50
CKC
60
CKC
80
CKC
90
CKC
100
CKC
130
CKC
165
CKC
180
CKC
200
HEIGHT mm
620
620
720
720
720
820
820
1080
1080
1275
1275
WIDTH mm
904
904
1004
1004
1004
1004
1004
1004
1004
1104
1104
DEPTH mm
304
304
304
304
304
354
354
429
429
429
429
1 Ph kg
48
53
64
65
66
76
-
-
-
-
-
3 Ph kg
48
53
62
63
64
73
81
101
103
118
173
PACKED
Model
CKC
30
CKC
40
CKC
50
CKC
60
CKC
80
CKC
90
CKC
100
CKC
130
CKC
165
CKC
180
CKC
200
HEIGHT mm
620
620
720
720
720
820
820
1080
1080
1280
1280
WIDTH mm
980
980
1080
1080
1080
1090
1090
1090
1090
1215
1215
DEPTH mm
340
340
340
340
340
390
390
465
465
465
465
1 Ph kg
50
55
66
67
68
78
-
-
-
-
-
3 Ph kg
50
55
64
65
66
75
83
105
107
123
178
DCU DUCTED CONDENSING UNITS
UNPACKED
PACKED
Model
DCU
30
DCU
50
DCU
60
DCU
80
DCU
30
DCU
50
DCU
60
DCU
80
HEIGHT mm
560
625
625
625
580
650
650
650
WIDTH mm
1075
1245
1245
1245
1090
1270
1270
1270
DEPTH mm
565
565
565
565565
610
610
610
610
WEIGHT kg
66
70
81
8184
76
86
86
90

7 92908135-17
SELECTION L
PRODUCT SELECTION
Systems can be selected to provide either comfort cooling or cooling with higher sensible heat ratios
CD3 COMBINATIONS AND DX PERFORMANCE DATA (nominal cooling capacities in kW)
CD3 MODEL
008
010
015
020
AIRFLOW (maximum) ³/s
0.78
1.04
1.23
1.51
HIGH SENSIBLE COOLING SYSTEMS
CKC/DCU
1 x 80
2 x 30
1 x 100
2 x 50
1 x 165
2 x 80
1 x 180
2 x 90
Return air
EXTERNAL AMBIENT 30°C
22°C 50%RH
Total
7.20
7.36
10.63
11.08
13.56
13.86
16.76
18.05
Sensible
7.20
7.36
10.58
10.77
13.44
13.57
16.56
17.11
24°C 50%RH
Total
7.46
7.74
11.23
11.62
14.23
14.44
17.60
19.05
Sensible
7.46
7.74
10.86
11.01
13.76
13.84
16.96
17.54
26°C 50%RH
Total
7.75
8.09
11.89
12.13
14.87
14.98
18.40
20.04
Sensible
7.75
8.09
11.13
11.22
14.03
14.07
17.29
17.91
Return air
EXTERNAL AMBIENT 35°C
22°C 50%RH
Total
6.86
7.17
10.11
10.56
12.97
13.19
16.03
17.20
Sensible
6.86
7.17
10.11
10.55
12.97
13.19
16.03
16.75
24°C 50%RH
Total
7.11
7.39
10.60
11.15
13.62
13.72
16.78
18.05
Sensible
7.11
7.39
10.60
10.83
13.52
13.56
16.63
17.14
26°C 50%RH
Total
---
---
11.22
11.64
14.22
14.22
17.79
19.00
Sensible
---
---
10.88
11.04
13.79
13.79
17.07
17.52
Return air
EXTERNAL AMBIENT 40°C
22°C 50%RH
Total
6.57
6.63
9.43
10.15
12.28
12.62
15.22
15.83
Sensible
6.57
6.63
9.43
10.15
12.28
12.62
15.22
15.83
24°C 50%RH
Total
6.79
6.98
9.93
10.60
12.85
13.08
16.00
16.78
Sensible
6.79
6.98
9.93
10.60
12.85
13.08
16.00
16.63
26°C 50%RH
Total
---
---
10.42
11.05
13.43
13.49
16.79
17.54
Sensible
---
---
10.42
10.82
13.43
13.49
16.70
16.98
Return air
EXTERNAL AMBIENT 45°C
22°C 50%RH
Total
---
6.21
8.79
9.75
11.52
---
14.33
14.88
Sensible
---
6.21
8.79
9.75
11.52
---
14.33
14.88
24°C 50%RH
Total
---
6.46
9.24
10.20
12.09
---
15.11
15.59
Sensible
---
6.46
9.24
10.20
12.09
---
15.11
15.59
26°C 50%RH
Total
---
---
9.73
10.65
12.73
---
15.83
16.31
Sensible
---
---
9.73
10.65
12.73
---
15.83
16.31
STANDARD COOLING SYSTEMS
CKC/DCU
1 x 100
2 x 50
1 x 130
2 x 60
1 x 180
2 x 100
1 x 200
2 x 130
Return air
EXTERNAL AMBIENT 30°C
22°C 50%RH
Total
9.84
10.26
11.67
11.81
15.98
18.78
18.88
21.90
Sensible
8.80
8.98
11.02
11.08
14.48
15.72
17.49
18.80
24°C 50%RH
Total
10.40
10.79
12.30
12.53
16.84
19.98
19.91
23.13
Sensible
9.01
9.17
11.29
11.38
14.82
16.13
17.89
19.22
26°C 50%RH
Total
10.96
11.32
12.92
13.08
17.69
21.20
21.04
24.36
Sensible
9.20
9.34
11.52
11.58
15.11
16.49
18.30
19.59
Return air
EXTERNAL AMBIENT 35°C
22°C 50%RH
Total
9.31
9.84
11.08
11.30
15.17
17.91
17.95
20.91
Sensible
8.57
8.80
10.77
10.86
14.13
15.33
17.07
18.36
24°C 50%RH
Total
9.90
10.35
11.77
11.85
16.10
19.01
19.05
22.11
Sensible
8.81
9.00
11.08
11.11
14.51
15.72
17.54
18.80
26°C 50%RH
Total
10.45
10.88
12.37
12.45
16.92
20.12
19.92
23.41
Sensible
9.00
9.17
11.31
11.34
14.81
16.06
17.87
19.22
Return air
EXTERNAL AMBIENT 40°C
22°C 50%RH
Total
8.67
9.44
10.46
10.78
14.33
16.76
16.65
19.77
Sensible
8.29
8.63
10.46
10.64
13.77
14.82
16.52
17.86
24°C 50%RH
Total
9.19
9.94
11.07
11.31
15.13
17.65
17.71
20.93
Sensible
8.52
8.83
10.80
10.89
14.12
15.15
17.00
18.31
26°C 50%RH
Total
9.76
10.45
11.64
11.89
16.02
18.81
18.76
22.10
Sensible
8.74
9.00
11.04
11.13
14.46
15.54
17.43
18.71
Return air
EXTERNAL AMBIENT 45°C
22°C 50%RH
Total
8.02
9.06
9.84
---
13.47
15.35
15.63
18.47
Sensible
8.02
8.46
9.84
---
13.40
14.21
15.63
17.29
24°C 50%RH
Total
8.57
9.55
10.38
---
14.23
16.56
16.47
19.70
Sensible
8.27
8.67
10.38
---
13.76
14.70
16.47
17.80
26°C 50%RH
Total
9.08
10.04
10.88
---
15.08
17.50
17.54
20.82
Sensible
8.48
8.85
10.75
---
14.11
15.03
16.98
18.21

8 92908135-17
AIRFLOWS (m³/s)
CD3
Model
008
010
015
020
Fan speed
Min
Max
Min
Max
Min
Max
Min
Max
Airflow
m³/s
0.42
0.78
0.67
1.04
0.72
1.23
0.92
1.51
Note: Maximum external resistance at the maximum speed = 150Pa
CKC (Maximum fan speed)
Model
30
50
60
80
90
100
130
165
180
200
Airflow m³/s
0.81
0.78
0.78
0.78
1.14
1.14
1.74
1.74
1.74
1.74
Note: All CKC units are fitted with fan speed control that will allow the fan to stop during normal operation.
DCU
Model
30
50
60
80
Fan speed
Min
Max
Min
Max
Min
Max
Min
Max
Airflow m³/s
0.32
0.42
0.42
0.53
0.42
0.53
0.34
0.48
Note: All DCU units are fitted with fan speed control, modulating the airflow according to system conditions.
SOUND PRESSURE LEVELS –CD3 UNITS
UNIT
008
010
015
020
UPFLOW
Fan speed
Min
Max
Min
Max
Min
Max
Min
Max
Top discharge and front return
air
NC
43
59
46
60
47
58
48
61
dBA
52
66.5
55
67
56
65
57
68
Front discharge with standard
plenum and front return air
NC
43
60
44
58
47
58
48
60
dBA
52
67
52.5
65
56
65
58.5
67
Front discharge with additional
attenuator and front return air
NC
38
49
41
49
41
48
43
50
dBA
47
58.5
50
58.5
50
57
52
58
DOWNFLOW
Top return and bottom
discharge air (supplied as
standard)
NC
31
44
37
45
37
45
39
48
dBA
41
53
46
54
46
54
48
56
Note: CD3 Sound Pressure Levels were calculated from measurements taken at 3m from the front of the unit in an office
installation and should be used for guidance only.
SOUND POWER AND SOUND PRESSURE LEVELS –550 SERIES CKC UNITS (Maximum fan speed)
CKC
SOUND POWER LEVELS
SOUND PRESSURE
LEVELS
Frequency Hz
dBA
125
250
500
1k
2k
4k
dBA
NC
30
77.4
67.5
68.5
64.8
60.2
53.8
69.8
50.0
44
50
73.6
68.2
67.1
65.5
61.1
54.3
69.7
49.2
44
60
72.9
67.7
67.8
66.4
61.9
54.1
70.3
49.8
45
80
70.9
68.6
68.1
65.3
59.5
53.8
69.7
49.2
43
90
81.8
71.8
69.2
68.6
63.1
57.4
72.8
52.3
47
100
79.4
73.7
71.5
68.5
63.8
58.1
73.4
52.9
47
130
73
70.3
70.0
68.8
65.0
56.7
72.6
52.1
47
165
73.1
70.3
70.1
68.9
65.5
57.5
73.1
57.2
51
180
72.5
71.9
71.7
68.9
66.0
58.2
75.5
59.2
53
200
73.0
71.8
71.5
70.1
66.1
58.3
75.7
61.8
55
Sound Power Levels were obtained in full accordance with the direct method of ISO 3741: 1988. Quantities are shown in dB
with a standard reference of 1 pW.
Sound Pressure Levels are dB relative to 2 x 10-5N/m2, calculated from the results under anechoic conditions and quoted as
an average of all points on a sphere of a radius of 3m away from the centre of the unit (in cooling mode); (add 3dBA or 3NC for
units at an intersection of a wall, add 1dBA or 1NC for high level wall mounted units).
DUCTED CONDENSING UNITS
Measurement point
Point
Unit
Size
Fan speed
Speed
dBA
NC
3m from
unit in void
DCU 30
Max
52
46
Min
35
28
DCU 50, 60, 80
Max
54
48
Min
44
31
Office
area
DCU 30
Max
37
26
Min
30
15
DCU 50, 60, 80
Max
42
28
Min
32
17
3m from
discharge grille
DCU 30
Max
52
46
Min
34
27
DCU 50, 60, 80
Max
52
44
Min
40
28
Sound Pressure Levels are dB relative to 2x10-5N/m2. All readings taken from a typical application of a unit suspended in a ceiling void
complete with 5m of insulated ducting, conditioning an office directly below.

9 92908135-17
INSTALLATION L
CD3 AIRFLOW OPTIONS

10 92908135-17
CD3 SERIES CLOSE CONTROL UNIT INSTALLATION
An envelope containing important user information is supplied with the indoor unit. Please pass to the end user.
1. The Packaged units are supplied for Upflow operation with front return air and top discharge.
Configured units are supplied for Upflow or Downflow operation. Standard upflow units are supplied with front return
air and top discharge; Downflow units with top return air and front discharge.
Units may be ordered with other airflow configurations or altered on site. Other configurations include:
Upflow: (wall mounted) with bottom return air.
with front or top discharge, wall or floor mounted.
Downflow: with top return air and under floor discharge.
See page 9 for all available configurations.
Note:- The required airflow arrangement must be configured prior to installation.
2. The chassis is made up of removable panels. The central panel, with control panel inset, MUST be removed first
using the two keys provided.
UNIT ACCESS AND CABINET STRIP DOWN
1 If a door interlock isolator is fitted, ensure that the switch is turned to the OFF position.
2 Using the keys provided, unlock the electrics access panel. Remove the panel by easing outwards and down.
3 The side panels can be removed by releasing the two swell latches located through the side bulkheads within the
electrics compartment and carefully pulling outwards until they are clear of the upper and lower grabber catches.
4 Access to the fan section, (and coil section in the downflow mode), can be gained by releasing the appropriate swell
latches located through the cut outs to the front of the side bulkheads and removing the panel.
5 The return air grille is removed by turning the 4 retaining screws anticlockwise, until a click is heard, and pulling the
grille outwards.
MOUNTING
1 It is recommended that ALL field fit kits are installed prior to mounting the unit and brazing the pipe work.
2 Ensure that the wall or floor will accept the operating weight of the unit; weights shown below include the plenum.
MODEL
WEIGHT
(kg)
Upflow units with plenum
fitted
CD3
142
CD3
162
CD3
171
CD3
182
Downflow units
CD3
124
CD3
142
CD3
151
CD3
160
NOTE:-When wall mounting, the unit should be lifted into position using the pallet provided.
3 Mark off the mounting holes as shown and drill holes to suit M6 Rawlbolt shields or equivalent fasteners.
4 If a fresh air facility is required, the appropriate apertures must be prepared to match up with the positions of the
unit fresh air inlets as shown in the diagrams following. Any opening in the external wall must be suitably lined and
screened to prevent brick dust entering the unit during installation and operation.
5 Mount the unit as required and secure all fixing bolts
6 Check that the unit is square and level. Failure to do so will result in misalignment of the cabinet access panels and
possible operational problems.

11 92908135-17
UPFLOW SERVICE AND FIXING HOLE CENTRES (excluding discharge plenum)
UNIT SIZE
DIMENSION 'A'
DIMENSION 'B'
008
1230
-
010 / 015
1380
690
020
1580
790
COIL SECTION
Note: Plenum (not
shown) is 430mm high

12 92908135-17
DOWNFLOW SERVICE AND FIXING HOLE CENTRES
UNIT
DIMENSION 'A'
DIMENSION 'B'
008
1230
--
010/015
1380
690
020
1580
790

13 92908135-17
INSTALLATION of 550 Series CKC CONDENSING UNITS
CKC units include fan speed control, high & low pressure switches with low ambient and compressor delay start timers.
Note: It is easier to fit any kits prior to mounting the unit.
The units are designed to stand on a flat surface. If they are to be wall mounted the following kits are available.
(TEV Ltd cannot accept liability for installers own mounting arrangements).
Model
CKC 30 - 80
CKC 90 - 200
Mounting Bracket Kit
55021100
55021101
Whether floor or wall mounted, it is essential that the mounting surface is capable of supporting the unit weight. Leave
space around the unit for air circulation and access for installation and maintenance.
MOUNTING: CKC 15 –100 CKC 130 - 200
Dimensions in mm.
MODEL
A
B
C
D
E
F
G
H
Weight (kg)
1 Ph
3 Ph
CKC 30
900
300
560
525
185
60
333
308
48
48
CKC 50
1000
300
660
570
213
60
333
308
64
62
CKC 60
1000
300
660
570
213
60
333
308
65
63
CKC 80
1000
300
660
570
213
60
333
308
66
64
CKC 90
1000
350
760
495
250
70
383
358
76
73
CKC 100
1000
350
760
495
250
70
383
358
-
81
CKC 130
1000
425
1020
495
251
100
458
433
-
101
CKC 165
1000
425
1020
495
251
100
458
433
-
103
CKC 180
1100
425
1215
675
211
95
458
433
-
118
CKC 200
1100
425
1215
675
211
95
458
433
-
173

14 92908135-17
INSTALLING 542 SERIES DUCTED CONDENSING UNITS
MOUNTING
Units are supplied with a polystyrene packing piece supporting the blower assembly, this MUST be removed prior to
commissioning.
Ducted Units are designed to be hung on a wall (kit available), suspended from a ceiling (installer supplied fittings), or to
stand on a flat surface. Whichever method is used it is essential that the mounting surface is capable of supporting the
units weight.
DIMENSIONS
A
D
B
PLAN VIEW
E
C
G
F
JK
H
SPIGOT DIAMETERS:-
DCUE 30 - 40 = 354
DCUE 50 - 80 = 404
Dimensions in mm
Model
A
B
C
D
E
F
G
H
J
K
Spigot dia.
Weight (kg)
DCU 30
930
510
495
1004
490
65
65
210
317
717
354
70
DCU 50
1100
510
560
1174
490
65
65
240
392
865
404
81
DCU 60
1100
510
560
1174
490
65
65
240
392
865
404
81
DCU 80
1100
510
560
1174
490
65
65
240
392
865
404
84
FLOOR MOUNTING
Using the appropriate side of the packing carton as a template, (centres marked A), mark out and drill 4 holes to suit
maximum M8 bolts (also see opposite). Secure the unit to the floor. Discard the stabilizing brackets.
Dimensions in mm
DCU
A
B
30
930
510
50-80
1100
510
B
A
PLAN VIEW

15 92908135-17
SUSPENSION MOUNTING
The installer must supply 4 x M8 threaded rods with 16 nuts and washers to suit.
IMPORTANT: The stabilizing brackets provided MUST be used when suspending a unit.
Fit the stabilizing brackets to the top corners of the back panel and front face using the No. 10 screws
provided, (2 per bracket).
If these brackets are omitted the unit will be subject to unacceptable movement on compressor start.
Where long drops of M8 rod are used, it is advisable to incorporate flexible pipes in the suction and expansion lines to
absorb any movement of the unit.
Using the template printed on the side of the packing
carton, (centres marked A), mark out the ceiling and
drill 4 holes to suit M8 screwed rod. Raise the unit to
the required height and pass the screwed rods
through the mounting holes in the units feet and
stabilizing brackets. Secure the unit with a nut and
washer on either side of each stabilizing bracket and
two nuts and washers underneath each foot mounting
hole, (as shown).
WALL MOUNTING
Brackets to enable ducted units to be wall mounted are available as an optional kit (53200407).
DUCTWORK
Each unit is supplied with air inlet and discharge spigots, models 30 to 40 - 354mm (14") dia., models 50 to 80 - 404mm
(16") dia. These may be used for connecting installers ducting or used with the optional Duct, Plenum and Grille kits.
Please refer to the kit instruction for installation methods. The front face of the units are also fitted with M6 rivnuts to
accept installer supplied square ducting, see dimensions below. Maximum flange width is 25mm and fixing holes should
be central within them.
NOTE: It is essential that ducting is adequately insulated to prevent sweating. An insulation thickness of at least 45mm
is recommended.
Dimensions
mm.
Model
30
50-80
A
400
450
B
300
350
C
100
100

16 92908135-17
APPLICATION L
APPLICATION
1 To maximise performance, pipe runs should be kept as short as possible, avoiding sharp bends. Individual pipe
runs to a maximum of 45m are allowed for air conditioners, providing pipe work is sized and installed correctly.
Performance ratings are based on 6m pipe runs but there will be no significant loss of capacity on extended pipe runs
for correctly sized pipes.
a) Pipe sizes are based on:-
Minimum of 3.8 m/s (750fpm) suction gas velocity for horizontal or down flow.
Minimum of 7.6 m/s (1500 fpm) suction gas velocity for up flow.
Maximum of 15.2 m/s (3000 fpm) suction gas.
b) Where vertical risers exceed 3m, oil traps must be formed in the pipe. This will help ensure that oil returns to the
compressor. Typically fit an oil trap every 3m with a trap at the bottom of the riser.
2 Add 25 grams of refrigerant oil for every 350 grams of charge added to systems with pipe runs exceeding 25m, up to
a maximum of 300 grams; preferably by slowly pumping into the suction side with the unit running, after charging the
system.
R407C : Use polyolester oil - L’Unite 181-023, ICI Emkarate RL32S,RL32CF,Mobil Artic EAL22 or EAL22CC
3 For systems with capillary control at the indoor unit; the table shows the suggested pipe sizes (in inches).
UNIT
SIZE
MAXIMUM LENGTH OF EQUIVALENT
SUCTION LINE PIPE SIZES (m)
LIQUID LINE
⅜
½
⅝
¾
⅞
1⅛
1⅜
⅜
½
⅝
20
7.5
20
30
15
45
45
40
10
36
45
7.5
45
50
7.5
18
45
7.5
45
60
14
36
45
7.5
45
80
11
30
45
45
90
10
25
45
20
45
100
7.5
22
45
15
45
130
15
30
45
12
45
150
12
27
45
8
45
165
8
18
45
7.5
45
180
7.5
16
45
7.5
45
200
15
45
7.5
45
4 In calculating equivalent lengths of pipe runs, the effect of bends and fittings must be taken into account. Information
relating to the equivalent lengths of line fittings and bends etc. is generally available to the design engineer. The table
below covers the fittings most likely to be encountered in this type of installation. The equivalent lengths of all the
fittings in a particular pipe run must be added together and the total added to the actual length of pipe in the run, in
order to calculate its total equivalent length.
FITTING LOSSES, in equivalent straight lengths of pipe (metres).
Fitting
Pipe Size (outside diameter in inches)
3/8
1/2
5/8
3/4
7/8
1-1/8
45° Bend
0.12
0.15
0.18
0.21
0.24
0.3
90° Bend R/d = 1
0.37
0.43
0.49
0.55
0.61
0.79
90° Bend R/d = 2
0.24
0.27
0.30
0.37
0.43
0.52
180° Bend C/d = 1
0.73
0.91
1.10
1.28
1.46
1.83
180° Bend C/d = 2
0.46
0.55
0.64
0.76
0.85
1.07
90° Elbow
0.67
0.85
1.04
1.25
1.46
1.89
R = Radius of bend
d = Diameter of tube
C = Centres of bend
5 Use the shortest possible route, avoiding sharp bends.
6 Fully insulate the suction line, (or suction and liquid line if run together).

17 92908135-17
REFRIGERATION INSTALLATION
1 Units are supplied with the following pipe connections (in inches):-
Model
008S
008T
010S
010T
015S
015T
020S
020T
Liquid
3/8
3/8
3/8
3/8
1/2
3/8
1/2
3/8
Suction
3/4
1/2
3/4
1/2
7/8
5/8
7/8
5/8
S = Single Circuit T = Twin Circuit
NOTE: On twin circuit units, the lower half of the coil is the first circuit.
2 Using a tube cutter, remove sealed ends of suction and liquid pipes. This will release a small holding charge of
dry nitrogen. Discard the expansion device on the condensing unit.
3 Pipe exit positions are shown on pages 3 and 4. It is recommended that the liquid and suction lines be kept at the
supplied size until exit, when the full pipe size can be run.
4 Connect pipe work between units noting the following:-
a) Use only refrigeration quality copper tube/pipe, supported every 2 metres.
b) Use tube cutters to avoid forming swarf.
c) If brazing, use copper phosphorus alloy with 5% silver, and purge the system with dry nitrogen to avoid
oxidation and build up of scale.
d) Do not leave pipe ends, valves, driers etc. open to the atmosphere longer than necessary.
e) Fully insulate the suction line, or suction and liquid if run together.
5. A strainer is fitted in the liquid line just prior to the capillary on the air handler. It is recommended that a liquid line
filter drier is fitted.
6. If a sight glass is fitted to assist charging, position this in the liquid line as near to the air handler as practicable, and
downstream of the liquid line filter/drier.
EVACUATING AND CHARGING
When the compressor is first started in the field, the bearing surfaces are susceptible to damage if not properly
lubricated. Care should be taken when the bearings are being run in to ensure that:-
a) The compressor is not started the first time with excessive refrigerant charge.
b) The system is not overcharged, which could result in liquid return to the compressor.
Evacuate the air handler and interconnecting pipe work by connecting a vacuum pump to the Schrader connections on
both suction and discharge service valves on the condensing unit (DO NOT OPEN THE VALVES) and evacuate to 1000
microns (1 Torr) or better and hold for a minimum of 15 minutes.
REFRIGERANT CHARGE
Single circuit
systems
CD3
Outdoor unit
CKC charge (g)
Twin circuit
systems
CD3
Outdoor units
CKC charge (g)
R407C
R407C
S 08 S
008
CKC 90
1422
S 08 T
008
2 x CKC 50
1167*
S 10 S
010
CKC 130
3075
S 10 T
010
2 x CKC 60
1477*
S 15 S
015
CKC 180
3389
S 15 T
015
2 x CKC 100
1882*
S 20 S
020
CKC 200
4229
S 20 T
020
2 x CKC 130
3075*
HS 08 S
008
CKC 80
1357
HS 08 T
008
2 x CKC 30
761*
HS 10 S
010
CKC 100
1882
HS 10 T
010
2 x CKC 40
807*
HS 15 S
015
CKC 165
3445
HS 15 T
015
2 x CKC 80
1357*
HS 20 S
020
CKC 180
3389
HS 20 T
020
2 x CKC 90
1422*
* = per circuit
The table above shows the base charge for R407C
The base charge will generally be sufficient for 3m pipe runs at room 22°C 50% RH, ambient 27°C 50% RH.
Typical charge to be added for longer liquid lines:-
3/8" OD add 50 g/m; 1/2" OD add 80 g/m; 5/8" OD add 110 g/m.
The preferred method of adding refrigerant is:-
1. Start the unit (on highest fan setting ) and allow the compressor to run for a few seconds.
2. Additional charge should be introduced through the Schrader valve on the suction side of the compressor.
3. The correct unit charge may be determined by examining the condition of the evaporator coil during the charging
process (with the system running in cooling). Refrigerant enters the coil at the bottom left hand side and leaves
at the top left hand side. A properly charged unit should show signs of 'sweating' all the way up the coil. 'Sweating'
should be reduced at the coil outlet as it enters the suction line, which should be completely dry a few inches before
it enters the compressor.
4. If a sight glass is fitted, position this in the liquid line as near to the air handler as possible. Charge should be
added to the unit, (with the system running), until the sight glass is just clear of bubbles (flooded).

18 92908135-17
Undercharged Unit - the top few tubes of the evaporator are dry and there are, (possibly), slight signs of frosting
at the inlet to the evaporator coil.
Overcharged Unit - the suction line 'sweats' all the way back to the compressor.
ELECTRICAL CONNECTIONS
The installation wiring should be carried out in accordance with I.E.E. regulations and/or local codes.
A mains isolator should be used and the system suitably fused, (see page 7). Supply cables and inter-connecting cables
are to be provided by the installer.
INDOOR UNIT WIRING
Connections for internal wiring are made within the electrics enclosure accessed by removing the centre front cover.
Disconnect the connecting cable from the display panel before moving the cover away from the unit.
Mains cables should be connected via a fused switch and routed through knockouts in the bottom left hand corner of the
unit, then through an access hole in the bottom left hand side of the electrics compartment to the mains terminal block.
System Interconnecting Wiring
On single or three phase systems, connect the incoming mains supply to the indoor unit and then link to the condensing
unit via a three pole circuit breaker.
The earth wire is connected toan earth stud at the right hand side of themains terminal block. Allmains and interconnecting
cable must be sized to suit the electrical rating of the unit and the length of cable run.
Make sure that all connections are secure and all wires are clear of any rotating parts.
Data Plates
Because indoor and outdoor units can be mix-matched, the data plates only give information relevant to the indoor unit
with maximum possible running currents. To determine the full system details please refer to the Technical Manual for
more specific information.
ELECTRICAL DATA
Single Phase Supply 230 Volts - 50 Hz
Three Phase Supply 400 Volts - 50 Hz
System
Model
Combination
Full Load Amps
System
max.
starting
current
Full Load Amps
System
max.
starting
current
Cool
Only
Cool &
Heat
Cool/Heat/
Hum/Dehum
If DCU
fitted
Cool
Only
Cool &
Heat
Cool/Heat/
Hum/Dehum
If DCU
fitted
Amps
Amps
Amps
Amps
Amps
A/PH*
A/PH*
A/PH*
A/PH
A/PH
S 08 S
CD008 + CKC 100
-
-
-
-
-
12.5
16.7
32.7
-
69.0
S 10 S
CD010 + CKC 130
-
-
-
-
-
15.75
16.7
32.7
-
89.3
S 15 S
CD015 + CKC 180
-
-
-
-
-
22.1
33.0
47.1
-
139.6
S 20 S
CD020 + CKC 200
-
-
-
-
-
23.91
33.4
49.3
-
138.0
HS 08 S
CD008 + CKC 80 / DCU 80
19.9
**38.7
-
+1.0
82.5
10.3
16.7
32.7
+2.0
57.8
HS 10 S
CD010 + CKC 100
-
-
-
-
-
14.5
23.1
32.7
-
75.4
HS 15 S
CD015 + CKC 165
-
-
-
-
-
19.4
33.0
44.6
-
109.2
HS 20 S
CD020 + CKC 180
-
-
-
-
-
22.5
33.4
49.3
-
140.0
S 08 T
CD008 +2x CKC 50 / DCU 50
26.8
**38.7
-
+1.0
75.2
13.7
16.7
32.7
+4.0
43.8
S 10 T
CD010 +2x CKC 60 / DCU 60
35.5
**40.7
-
+1.0
83.0
16.3
23.1
32.7
+5.0
56.2
S 15 T
CD015 +2x CKC 100
-
-
-
-
-
25.1
33.0
41.0
-
85.3
S 20 T
CD020 +2x CKC 130
-
-
-
-
-
27.1
33.4
49.3
-
99.6
HS 08 T
CD008 +2x CKC 30 / DCU 30
21.9
**38.7
-
+4.0
51.0
11.8
16.7
32.7
+4.0
36.1
HS 10 T
CD010 +2x CKC 50 / DCU 50
28.8
**40.7
-
+1.0
77.2
15.9
23.1
32.7
+4.0
50.2
HS 15 T
CD015 +2x CKC 80 / DCU 80
38.5
**42.3
-
+1.0
100.9
19.7
33.0
41.0
+4.0
74.1
HS 20 T
CD020 +2x CKC 90
44.7
**44.7
-
-
129.4
22.5
33.4
49.3
-
81.7
* Max. Phase
**Single phase models are available for twin circuit dx systems where electric heating requirement is 8kW or less.
The electric heating loads shown are based on maximum amounts of heating which are:-
CD 008 = 8kW (4+4) CD 010 = 10kW (4+6) CD 015 = 16kW (8+8) CD 020 = 20kW (10+10)

19 92908135-17
Typical control panel and terminal layout
RECOMMENDED FUSE SIZES
The system and its supply/interconnecting wiring must be protected by fuses, preferably H.R.C. motor rated types to
BS60269 or miniature circuit breakers to BS60898 or local codes having similar time lag characteristics that allow
starting of the compressor yet still afford close over current protection under running conditions. The ratings below are for
H.R.C. motor rated or semi-enclosed wire fuses.
Standard Cooling
System
S 08 S
S 10 S
S 15 S
S 20 S
S 08 T
S 10 T
S 15 T
S 20 T
1 Phase Cool Only
-
-
-
-
40
40
-
-
1 Phase Cool and Heat
-
-
-
-
50
50
-
-
3 Phase Cool Only
20
25
35
40
16
20
32
35
3 Phase Cool and Heat
20
32
40
40
20
32
40
40
3 Phase Cool/Heat/Hum/Dehum
40
40
63
63
40
40
50
63
High Sensible Cooling
System
HS 08 S
HS 10 S
HS 15 S
HS 20 S
HS 08 T
HS 10 T
HS 15 T
HS 20 T
1 Phase Cool Only
32
-
-
-
32
40
50
63
1 Phase Cool and Heat
50
-
-
-
50
50
50
63
3 Phase Cool Only
16
20
32
40
16
20
25
32
3 Phase Cool and Heat
20
32
40
40
20
32
40
40
3 Phase Cool/Heat/Hum/Dehum
40
40
63
63
40
40
50
63

20 92908135-17
CONDENSATE DRAIN
The condensate drain connection is at the left hand end of the condensate drain tray.
A 15mm O.D. copper drain pipe is provided in the drain sump for connection with non-kink plastic tubing secured with
a suitable clip.
Should it be necessary for the drain pipe to go through the back or base of the unit, a knockout is provided in the back
panel or base plate.
The drain line must have a constant fall to open drain using a 'U' trap if required. Check that the water will run freely
and that there are no leaks.
IMPORTANT: If a humidifier is fitted the drain pipe must be capable of carrying water at 60°C.
FAN SPEED CONTROLLER
One control is used on each CD3 unit, and has a switch for selecting high or boost speed (see diagram below).
These can only be selected if the Pico Controller is set at low.
SETTING
The boost speed should be selected for:-
ALL DOWNFLOW units
Upflow units requiring ductwork on the supply or return air
When high efficiency filters are fitted.
The High speed should be selected for standard 'Free Blow' Upflow units.
Units are despatched with the low speed set on 50%. The fan speed may be adjusted between 50% and 100% of
the selected top speed by turning the low speed potentiometer clockwise.
WHEN INSTALLATION HAS BEEN COMPLETED - CHECK:-
1. All pipe work and joints for leakage.
2. All pipe work and fittings for insulation.
3. All bolts are secure and that fan rotates freely.
Pico Controller *
Setting
High/Boost Switch
Potentiometer
Unit Fan Speed
High
No Adjustment
Possible
No Adjustment
Possible
Unit Fan Speed
Low
Select High or
Boost
Adjust for
De-Hum Low SP
50% to 100%
*See Page 4 of 92908131 Operator Instructions if the Pico
Controller is set at high. Low speed will automatically be
selected during de-hum