-1-
TECHNICAL MANUAL
for CWR CHILLED WATER
CEILING MOUNTED/RECESSED SYSTEMS.
This manual provides technical and installation information for
CWR
968 series
CHILLED WATER CEILING
MOUNTED/RECESSED
indoor units.
INDEX PAGE
GENERAL
Part numbers, dimensions and weights 2
Unit features/accessories 2
SELECTION
Control valves, airflows, discharge velocities 3
Chilled water duties 4
LPHW duties, 6
Hydraulic resistance 7
Optional electric heating 7
Sound pressure levels 7
Coil water volumes 7
UNIT
CWR mounting 8
INSTALLATION
Pipework and electrical connections 9
CWR remote controller 12
Condensate removal, air deflection 11
WIRING
CWR units 13
DIAGRAMS
OPERATION
CWR 14
KITS
Remote sensor kit 15
Condensate pump kit 18
Electric heater kit 22
3 port diverting valve 24
Pipe thermostat 25
MAINTENANCE
CWR units 25
COMPONENT
Exploded view of unit with 26
IDENTIFICATION
component Identification
IMI Air Conditioning Ltd.
Armytage Road, Brighouse,
West Yorkshire. HD6 1QF
Tel: (01484) 405600
Fax: (01484) 721949 A subsidiary company of IMI plc
email: sales@imi-airconditioning.co.uk
96808003-03
Heronhill - for all your Airking requirements
Tel: 01823 665660
www.heronhill.co.uk
Fax: 01823 665807
-2-
IMI AIR CONDITIONING LIMITED
CWR CHILLED WATER CEILING MOUNTED/RECESSED UNITS
The
CWR
range consists of 968 series chilled water ceiling mounted/recessed indoor units.
CWR CHILLED WATER INDOOR UNITS
Models CWR 25 CWR 45 CWR 65 CWR 85
Part Number 96800001 96800002 96800003 96800004
DIMENSIONS AND WEIGHTS (Unpacked)
CWR CHILLED WATER UNITS
Model CWR
25 45 65 85
HEIGHT mm 189 189 189 189
WIDTH mm 630 930 1230 1530
DEPTH mm 761 761 761 761
WEIGHT kg 20 25 30 36
DIMENSIONS AND WEIGHTS (Packed)
CWR CHILLED WATER UNITS
Model CWR
25 45 65 85
HEIGHT mm 280 280 280 280
WIDTH mm 740 1040 1340 1640
DEPTH mm 900 900 900 900
WEIGHT kg 26 36 47 55
FEATURES/ACCESSORIES
FEATURE CWR
Manual air deflection STD
Return air sensor
(incl electronic thermostat)
*
Electric heating *
3 fan speeds STD
Remote hard wired control STD
Pendant control cable *
Condensate pump *
Long life washable filter STD
Remote temperature sensor STD
Valve options **
Control Options **
LPHW Coil heating **
Key: * = factory/site option. ** = factory fitted option STD = standard.
NOTE:
If using valves other than those specified by IMI Air Conditioning Ltd., ensure that there is electrical continuity
through the valve in all positions, otherwise the indicator lights on the remote control will remain on at all times.
For group control systems, contact IMI Air Conditioning Ltd. Technical Sales Department.
Heronhill - for all your Airking requirements
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-3-
OPTIONAL CONTROL VALVES
2 port on/off valves or 3 port diverting valves are available as factory fitted options. Chilled water valves are supplied
with valve drain trays. (4 port modulating valves are also available - contact IMI Air Conditioning Technical Sales
Department).
2 pipe cool only systems require one valve per fan coil.
2 pipe heat/cool systems (supplied from a reverse cycle chiller, or chiller + boiler) require one valve: if using an auto
changeover thermostat, they also need a means of signalling heating or cooling status of the flow eg a pipe
thermostat (kit shown on page 41).
4 pipe systems require two valves or one modulating valve (but no pipe thermostat is needed).
AIRFLOWS
CWR Minimum Speed Medium Speed Maximum Speed
CFM m3/h m3/s CFM m3/h m3/s CFM m3/h m3/s
25 125 205 0.06 160 270 0.08 200 340 0.09
45 255 430 0.12 290 490 0.14 420 710 0.20
65 350 595 0.17 415 700 0.19 660 1120 0.31
85 440 750 0.21 715 1215 0.34 850 1440 0.40
DISCHARGE VELOCITIES
The air discharge vanes are manually adjustable both vertically and horizontally to allow a larger choice of angle of
airthrow and direction. It is suggested that, in cooling mode, the discharge is directed horizontally along the ceiling.
In heating mode vanes can be moved to a 30
/
downward discharge.
It is also possible to move the air off boxes to a 90
/
downward discharge, creating an air curtain.
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-4-
CHILLED WATER DUTIES (kW)
CWR 25
Air Entering
Dry Bulb (Wet Bulb) 21/C (15/C) 24/C (17/C) 27/C (19/C) 29/C (19/C)
Air Flow m3/h 205 270 340 205 270 340 205 270 340 205 270 340
Water
In /C
Water
Out /CDUTY
59
Total 0.83 1.00 1.20 1.20 1.40 1.70 1.50 1.90 2.20 1.60 1.90 2.20
Sensible 0.67 0.84 1.00 0.86 1.10 1.30 1.00 1.30 1.50 1.20 1.40 1.70
511
Total 0.65 0.73 0.82 0.88 0.99 1.20 1.20 1.50 1.70 1.30 1.50 1.80
Sensible 0.59 0.71 0.82 0.72 0.87 1.00 0.88 1.10 1.30 1.00 1.30 1.50
513
Total 0.54 0.64 0.72 0.75 0.84 0.93 1.00 1.10 1.20 1.00 1.10 1.30
Sensible 0.54 0.64 0.72 0.67 0.80 0.93 0.79 0.95 1.10 0.91 1.10 1.30
711
Total 0.59 0.68 0.83 0.93 1.10 1.30 1.30 1.60 1.80 1.30 1.60 1.80
Sensible 0.57 0.68 0.83 0.74 0.92 1.10 0.92 1.10 1.30 1.00 1.30 1.50
713
Total 0.51 0.60 0.68 0.69 0.78 0.89 0.94 1.20 1.40 0.96 1.20 1.40
Sensible 0.51 0.60 0.68 0.64 0.78 0.89 0.77 0.96 1.20 0.89 1.10 1.30
715
Total 0.44 0.52 0.59 0.59 0.69 0.79 0.80 0.89 0.99 0.84 0.99 1.10
Sensible 0.44 0.52 0.59 0.59 0.69 0.79 0.72 0.87 0.99 0.84 0.99 1.10
913
Total 0.47 0.56 0.64 0.63 0.79 0.94 1.00 1.30 1.40 1.10 1.30 1.50
Sensible 0.47 0.56 0.64 0.62 0.78 0.94 0.81 1.00 1.20 0.93 1.20 1.40
915
Total 0.41 0.48 0.54 0.55 0.66 0.75 0.74 0.83 0.97 0.80 0.97 1.20
Sensible 0.41 0.48 0.54 0.55 0.66 0.75 0.69 0.83 0.97 0.80 0.97 1.20
917
Total 0.34 0.40 0.45 0.49 0.58 0.65 0.64 0.75 0.86 0.74 0.87 0.99
Sensible 0.34 0.40 0.45 0.49 0.58 0.65 0.64 0.75 0.86 0.74 0.87 0.99
CWR 45
Air Entering
Dry Bulb (Wet Bulb) 21/C (15/C) 24/C (17/C) 27/C (19/C) 29/C (19/C)
Air Flow m3/h 430 490 710 430 490 710 430 490 710 430 490 710
Water
In /C
Water
Out /CDUTY
59
Total 1.90 2.00 2.50 2.50 2.80 3.50 3.20 3.50 4.50 3.30 3.60 4.50
Sensible 1.40 1.60 2.10 1.80 2.00 2.60 2.10 2.40 3.10 2.40 2.60 3.50
511
Total 1.20 1.30 1.60 1.80 2.10 2.70 2.70 2.90 3.80 2.70 3.00 3.80
Sensible 1.20 1.30 1.60 1.50 1.70 2.20 1.90 2.10 2.80 2.10 2.40 3.20
513
Total 1.00 1.10 1.40 1.40 1.50 1.80 1.80 1.90 2.80 1.90 2.00 2.90
Sensible 1.00 1.10 1.40 1.30 1.40 1.80 1.50 1.70 2.40 1.80 2.00 2.80
711
Total 1.30 1.40 1.80 2.00 2.20 2.80 2.70 3.00 3.80 2.80 3.00 3.80
Sensible 1.20 1.30 1.80 1.60 1.70 2.30 1.90 2.10 2.80 2.20 2.40 3.20
713
Total 0.97 1.10 1.30 130 1.40 1.90 2.10 2.30 3.00 2.20 2.40 3.10
Sensible 0.97 1.10 1.30 1.30 1.40 1.90 1.70 1.80 2.50 1.90 2.10 2.80
715
Total 0.84 0.91 1.10 1.10 1.20 1.50 1.50 1.50 1.90 1.60 1.80 2.40
Sensible 0.84 0.91 1.10 1.10 1.20 1.50 1.40 1.50 1.90 1.60 1.80 2.40
913
Total 0.91 1.00 1.40 1.40 1.60 2.00 2.20 2.40 3.00 2.20 2.50 3.10
Sensible 0.91 1.00 1.40 1.30 1.50 2.00 1.70 1.90 2.50 1.90 2.10 2.80
915
Total 0.78 0.84 1.00 1.10 1.20 1.50 1.40 1.60 2.10 1.70 1.90 2.50
Sensible 0.78 0.84 1.00 1.10 1.20 1.50 1.40 1.60 2.10 1.70 1.90 2.50
917
Total 0.65 0.70 0.85 0.94 1.00 1.20 1.20 1.30 1.60 1.40 1.50 2.00
Sensible 0.65 0.70 0.85 0.94 1.00 1.20 1.20 1.30 1.60 1.40 1.50 2.00
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-5-
CWR 65
Air Entering
Dry Bulb (Wet Bulb) 21/C (15/C) 24/C (17/C) 27/C (19/C) 29/C (19/C)
Air Flow m3/h 595 700 1120 595 700 1120 595 700 1120 595 700 1120
Water
In /C
Water
Out /CDUTY
59
Total 2.50 2.80 3.80 3.40 3.80 5.20 4.40 4.90 6.60 4.40 5.00 6.70
Sensible 1.90 2.20 3.20 2.40 2.80 3.90 2.90 3.30 4.60 3.20 3.70 5.20
511
Total 1.60 1.70 2.40 2.50 2.90 4.00 3.70 4.10 5.60 3.70 4.20 5.60
Sensible 1.60 1.70 2.40 2.00 2.30 4.00 2.60 2.90 4.20 2.90 3.30 4.70
513
Total 1.40 1.50 1.90 1.80 1.90 2.50 2.40 2.60 4.20 2.50 2.70 4.30
Sensible 1.40 1.50 1.90 1.80 1.90 2.50 2.10 2.30 3.60 2.40 2.70 4.20
711
Total 1.70 1.90 2.70 2.70 3.10 4.10 3.70 4.10 5.60 3.80 4.20 5.60
Sensible 1.60 1.80 2.70 2.10 2.40 3.40 2.60 2.90 4.10 2.90 3.30 4.70
713
Total 1.30 1.40 1.80 1.70 1.90 2.90 2.90 3.30 4.40 3.00 3.40 4.50
Sensible 1.30 1.40 1.80 1.70 1.90 2.90 2.30 2.60 3.70 2.60 3.00 4.30
715
Total 1.10 1.20 1.60 1.50 1.70 2.10 1.90 2.10 3.00 2.20 2.40 3.60
Sensible 1.10 1.20 1.60 1.50 1.70 2.10 1.90 2.10 3.00 2.20 2.40 3.60
913
Total 1.20 1.40 2.10 2.00 2.20 3.00 3.00 3.30 4.40 3.10 3.40 4.50
Sensible 1.20 1.40 2.10 1.80 2.00 3.00 2.30 2.60 3.70 2.60 3.00 4.30
915
Total 1.00 1.10 1.50 1.40 1.60 2.30 1.80 2.20 3.20 2.20 2.60 3.80
Sensible 1.00 1.10 1.50 1.40 1.60 2.30 1.80 2.20 3.20 2.20 2.60 3.80
917
Total 0.87 0.95 1.20 1.30 1.40 1.70 1.60 1.80 2.30 1.90 2.10 3.10
Sensible 0.87 0.95 1.20 1.30 1.40 1.70 1.60 1.80 2.3 1.90 2.10 3.10
CWR 85
Air Entering
Dry Bulb (Wet Bulb) 21/C (15/C) 24/C (17/C) 27/C (19/C) 29/C (19/C)
Air Flow m3/h 750 1215 1440 750 1215 1440 750 1215 1440 750 1215 1440
Water
In /C
Water
Out /CDUTY
59
Total 3.20 4.50 4.90 4.40 6.00 6.60 5.50 7.60 8.40 5.60 7.60 8.40
Sensible 2.50 3.60 4.10 3.10 4.40 4.90 3.60 5.20 5.80 4.10 5.80 6.50
511
Total 2.00 3.20 3.60 3.60 4.90 5.50 4.80 6.60 7.30 4.90 6.70 7.40
Sensible 1.90 3.00 3.50 2.70 3.90 4.40 3.30 4.80 5.40 3.70 5.40 6.10
513
Total 1.70 2.20 2.40 2.30 3.20 3.80 3.90 5.50 6.00 4.00 5.50 6.10
Sensible 1.70 2.20 2.40 2.20 3.20 3.80 2.90 4.30 4.80 3.30 4.90 5.50
711
Total 2.40 3.30 3.60 3.50 4.80 5.30 4.70 6.40 7.10 4.80 6.50 7.10
Sensible 2.10 3.10 3.50 2.70 3.90 4.40 3.30 4.70 5.20 3.70 5.30 5.90
713
Total 1.60 2.40 2.80 2.60 3.60 4.00 3.90 5.40 6.00 4.00 5.50 6.00
Sensible 1.60 2.40 2.80 2.30 3.40 3.80 2.90 4.20 4.80 3.40 4.90 5.50
715
Total 1.40 1.80 2.00 1.90 2.50 3.00 2.40 4.00 4.50 2.80 4.30 4.90
Sensible 1.40 1.80 2.00 1.90 2.50 3.00 2.30 3.70 4.20 2.80 4.30 4.90
913
Total 1.70 2.50 2.80 2.60 3.60 3.90 3.80 5.20 5.70 3.90 5.30 5.70
Sensible 1.70 2.50 2.80 2.30 3.40 3.80 2.90 4.20 4.70 3.30 4.80 5.40
915
Total 1.30 1.70 1.80 1.80 2.80 3.20 3.00 4.10 4.50 3.10 4.30 4.90
Sensible 1.30 1.70 1.80 1.80 2.80 3.20 2.50 3.70 4.20 3.00 4.30 4.90
917
Total 1.10 1.40 1.50 1.60 2.00 2.20 2.00 3.10 3.50 2.40 3.70 4.30
Sensible 1.10 1.40 1.50 1.60 2.00 2.20 2.00 3.10 3.50 2.40 3.70 4.30
Heronhill - for all your Airking requirements
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-6-
LOW PRESSURE HOT WATER COIL DUTIES (kW)
CWR 25
Air Entering, Dry Bulb 10/C15/C20/C25/C
Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max
Air Flow m3/h 205 270 340 205 270 340 205 270 340 205 270 340
Water
In /C
Water
Out /C
Heating
Capacity
90 80 kW 1.7 2.0 2.3 1.6 1.9 2.1 1.5 1.7 2.0 1.3 1.6 1.8
90 75 kW 1.6 1.9 2.1 1.5 1.7 2.0 1.3 1.6 1.8 1.2 1.4 1.6
80 70 kW 1.5 1.7 2.0 1.3 1.6 1.8 1.2 1.4 1.6 1.1 1.3 1.5
80 65 kW 1.3 1.5 1.8 1.2 1.4 1.6 1.0 1.2 1.4 0.9 1.1 1.2
65 55 kW 1.0 1.2 1.4 0.9 1.1 1.2 0.8 0.9 1.0 0.6 0.7 0.9
65 50 kW 0.8 0.9 1.1 0.7 0.8 0.9 0.6 0.7 0.8 0.5 0.6 0.7
CWR 45
Air Entering, Dry Bulb 10/C15/C20/C25/C
Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max
Air Flow m3/h 430 490 710 430 490 710 430 490 710 430 490 710
Water
In /C
Water
Out /C
Heating
Capacity
90 80 kW 3.7 4.0 5.0 3.4 3.7 4.6 3.2 3.4 4.3 2.9 3.1 3.9
90 75 kW 3.5 3.8 4.7 3.2 3.5 4.3 3.0 3.2 4.0 2.7 2.9 3.6
80 70 kW 3.2 3.4 4.3 2.9 3.2 3.9 2.6 2.9 3.6 2.4 2.6 3.2
80 65 kW 3.0 3.2 4.0 2.7 2.9 3.6 2.4 2.6 3.3 2.2 2.3 2.9
65 55 kW 2.3 2.5 3.1 2.0 2.2 2.7 1.8 1.9 2.4 1.5 1.7 2.0
65 50 kW 2.0 2.2 2.7 1.7 1.9 2.4 1.5 1.6 2.0 1.2 1.3 1.7
CWR 65
Air Entering, Dry Bulb 10/C15/C20/C25/C
Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max
Air Flow m3/h 595 700 1120 595 700 1120 595 700 1120 595 700 1120
Water
In /C
Water
Out /C
Heating
Capacity
90 80 kW 5.4 5.9 7.8 5.0 5.5 7.3 4.6 5.1 6.7 4.2 4.7 6.1
90 75 kW 5.1 5.6 7.4 4.7 5.2 6.9 4.3 4.8 6.3 4.0 4.4 5.8
80 70 kW 4.6 5.1 6.7 4.3 4.7 6.2 3.9 4.3 5.6 3.5 3.8 5.1
80 65 kW 4.4 4.8 6.3 4.0 4.4 5.8 3.6 4.0 5.2 3.2 3.6 4.7
65 55 kW 3.3 3.7 4.8 2.9 3.3 4.3 2.6 2.9 3.8 2.2 2.5 3.3
65 50 kW 3.0 3.4 4.4 2.6 3.0 3.9 2.3 2.6 3.4 1.9 2.2 2.8
CWR 85
Air Entering, Dry Bulb 10/C15/C20/C25/C
Fan Speed Min Med Max Min Med Max Min Med Max Min Med Max
Air Flow m3/h 750 1215 1440 750 1215 1440 750 1215 1440 750 1215 1440
Water
In /C
Water
Out /C
Heating
Capacity
90 80 kW 7.0 9.4 10.3 6.5 8.7 9.6 6.0 8.0 8.8 5.5 7.4 8.1
90 75 kW 6.7 8.9 9.8 6.2 8.2 9.1 5.7 7.6 8.4 5.2 6.9 7.6
80 70 kW 6.0 8.1 8.9 5.5 7.4 8.4 5.0 6.7 7.4 4.5 6.1 6.7
80 65 kW 5.7 7.6 8.4 5.2 7.0 7.7 4.7 6.3 6.9 4.2 5.6 6.2
65 55 kW 4.4 5.5 6.3 3.9 4.9 5.6 3.4 4.3 4.9 3.0 3.7 4.3
65 50 kW 4.0 5.1 5.8 3.6 4.5 5.1 3.1 3.9 4.5 2.6 3.3 3.8
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www.heronhill.co.uk
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-7-
HYDRAULIC RESISTANCES
CHILLED WATER LPHW
OPTIONAL ELECTRIC HEATING (kW)
CWR 240V 50Hz 230V 50Hz
25 0.9 0.84
45 1.75 1.63
65 2.6 2.43
85 3.5 3.27
SOUND LEVELS CWR UNITS
Sound Pressure Levels Sound Power Levels
MODEL Speed dBA NC 63Hz 125Hz 250Hz 500Hz 1kHz 2kHz 4kHz 8kHz
25
Min 27 22 38 45 50 48 46 41 32 29
Med 34 28 40 49 55 52 52 48 41 32
Max 40 35 47 55 59 57 58 55 49 42
45
Min 32 25 40 48 52 52 48 44 35 28
Med 35 29 42 51 54 55 52 49 41 31
Max 42 37 48 58 60 59 60 56 51 42
65
Min 31 25 40 47 51 53 46 41 32 29
Med 37 30 43 54 56 57 53 50 42 34
Max 46 42 53 62 65 63 64 61 56 49
85
Min 33 27 42 53 53 54 48 44 33 28
Med 41 35 48 59 60 60 58 55 48 39
Max 46 43 52 61 63 63 65 61 54 47
Sound Pressure Levels (SPL) at 3m distance, 1m below units running in
free field conditions, (dB re: 2x10
-5
N/m
2
).
Sound Power Levels (SWL) in dB re: 1pW.
COIL WATER VOLUMES (LITRES)
Model 25456585
Chilled Water Coil 0.642 1.103 1.565 2.026
LPHW Coil 0.345 0.510 0.675 0.840
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-8-
CWR CHILLED WATER CEILING MOUNTED/RECESSED UNIT
The
CWR
chilled water ceiling mounted/recessed unit may be installed either within a suspended ceiling or mounted
directly onto a solid ceiling.
The installer supplies:
*
Either 4 lengths of screwed rod (M8) with 12 nuts and washers (suspended false ceiling), or 4 bolts (M8) and
washers (solid ceiling).
* Method of securing screwed rod to solid ceiling e.g. rawlbolt shields.
* Insulated pipework.
* Mains wiring with suitable isolation.
* Remote thermostat (available separately, part number 96000320).
* Condensate drain (12mm bore diameter tube).
* Interconnecting wires for remote thermostat; 2 screws to secure the remote thermostat.
* Method for securing solid sheathed cable if these are used.
UNPACKING
Carefully unfasten the banding and lift off the box sleeve.
The following are supplied:
*
CWR unit (in protective sleeve, held between two polystyrene end caps).
* Ceiling tile support rail and securing screws.
* 2 cable clamps suitable for flexible, pre-sheathed cable.
* Envelope containing end user operating instructions to be left with the end user.
1
Remove and discard the wooden supports (Not CWR 25).
2
Remove the cable clamps and place in a safe location until required.
3
Lift the CWR unit from the box complete with the end caps; (this will require 2 people for sizes 45 to 85).
4
Remove the two polystyrene end caps and the protective sleeve.
PREPARATION FOR MOUNTING
It is necessary to remove both end panels, the hinged grille, the corrugated cardboard beneath the grille, the filter and
the fascia panel prior to installation.
Remove the end panels, first opening the grey screw covers and removing the screws (two on each end panel).
Unhook the panels from the chassis.
Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some resistance
will be felt.
Lift the filter over the retaining lug and slide it out (Fig. 2).
Fig. 1. Fig. 2. Fig. 3.
Insert a screwdriver between the grilles and disengage the grille retaining catches (Fig. 3). Swing the grille away and
unhook from the chassis.
Remove and retain all the fascia support bracket fixing screws and remove the bracket and fascia from the unit. Store
the fascia in a safe location until required.
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-9-
CHASSIS MOUNTING
NOTE:
It is generally easier to fit kits prior to mounting the unit and connecting the pipework.
CWR can be fitted into a suspended false ceiling (Fig. 4) or onto a solid ceiling (Fig. 5).
Fig. 5.
Fig. 4.
Location of the unit will depend on the room shape, load and number of units installed. Typical options are:
PIPE AND CABLE EXITS
CWR units allow a choice of two pipes exits for greater flexibility of installation.
1
Determine the position for the unit allowing at least 450mm clearance below the air inlet. Also ensure that the
position does not interfere with light fittings, sprinkler heads, etc..
2
Identify the type of ceiling and ensure that the mounting surface will support the operating weight of the unit.
MODEL CWR 25 CWR 45 CWR 65 CWR 85
OPERATING WEIGHT (kg) 22 28 34 41
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-10-
MOUNTING CENTRES
CWR A B C D E F G H J K L M
25 170 199 568 510 600 761 46 70 100 65 300 50
45 470 199 868 510 900 761 46 90 200 56 450 50
65 770 199 1168 510 1200 761 46 120 300 41 600 50
85 1070 199 1468 510 1500 761 46 130 400 36 750 50
3
If fitting the unit in a suspended ceiling after the ceiling has been installed, remove ceiling tiles to accept the
chassis, plus adjacent tiles on each side for general access. Use the ceiling tile support rail when the unit is
positioned some distance from the wall; the rail should be secured to the rear of the unit chassis prior to hanging
the unit.
4
The chassis should be supported by four (M8) bolts, or screwed rods and 12 nuts (M8 OD) on a suspended
ceiling, supplied by the installer.
On plasterboard suspended ceilings, remove sufficient of the ceiling to give clearance for the unit to be fitted, and for
access to pipework and electrics; trap doors should be left for service access to electrics and pipework.
On reinforced concrete ceilings use Rawlbolt shields or equivalent.
On wooden ceilings use battens for a mounting frame.
5
Suspend the chassis, using either 4 bolts and 4 washers (solid ceiling) or 12 nuts and 8 washers (suspended
false ceiling).
NOTE:
The mounting holes are keyhole slots and therefore the Rawlbolts should be installed prior to offering up the
unit.
--o--o--O--O--O--o--o--
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-11-
PIPE CONNECTIONS
CWR UNITS
Pipework is terminated with end caps, adjacent to the access panel at the left hand side. All pipework is 15mm copper
water pipe.
ELECTRICAL CONNECTIONS
Mains, control and interconnecting cables must be supplied and fitted by the installer.
Installer wiring must be carried out in accordance with IEE regulations and local codes.
Cables must be size compatible with the recommended fuse for a given system.
An isolator switch should be positioned within easy reach of the indoor unit.
The equipment
MUST
be earthed.
Cables may enter the CWR unit at the top, back, left or right hand side. If the left hand side is used, sufficient cable
length should be allowed to run the full length inside the unit. Ensure that the cable is secured to the chassis flange
along the length of the unit and to the holes provided in both hanger brackets.
Cable glands suitable for stranded cables are supplied and should be used to secure all cables. Installers must supply
a method of securing any solid sheathed cable.
FUSES (A)
MODEL CWR 25 CWR 45 CWR 65 CWR 85
Without Electric 555 5
With Electric Heaters 5101616
CONDENSATE REMOVAL
Condensate is collected in a drain tray incorporated within the fascia panel.
An outlet connection is provided at the back/right hand side of the unit for connection to a 12mm bore flexible pipe.
Run the outlet pipe to gravity drain ensuring that there are no kinks or blockages.
An optional condensate pump kit is available with 5m lift.
FASCIA MOUNTING
Electrically isolate the unit. Once the chassis has been installed, the fascia should be refitted, (Fig. 6). When complete,
refit the grille, filter and end panels: fit the fascia support bracket with No.10 screws, (Fig. 7).
Fig. 6. Fig. 7.
AIR DEFLECTION
The air off vanes are manually adjustable to allow horizontal and downward air deflection.
It is suggested that, in cooling mode, the discharge is directed horizontally along the ceiling. In heating mode, vanes
can be moved to a 30
/
downward discharge. Refer to page 3 for discharge velocities.
It is also possible (by reversing the discharge boxes) to move the air off vanes to a 90
/
downward discharge, creating
an air curtain.
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-12-
INSTALLATION OF A REMOTE THERMOSTAT
The thermostat should be wired with 7 cores of double insulated cable, 0.5mm
2
minimum, preferably in plastic conduit
for good appearance.
Select a position to mount the thermostat taking into account the following comments:
a
The thermostat must be mounted on a flat surface within the area conditioned by the unit to which it is
connected.
b
Avoid draughts, heat from radiators, temperature variations from hot/cold water pipes and direct sunlight.
c
Avoid corners of the room where air is likely to stagnate.
d
Avoid direct air discharge from the unit nto the controller.
e
Avoid positions where the thermostat may be covered or obscured.
f
If the room contains pillars, mount on the side of the pillar furthest away from the unit.
--o--o--O--O--O--o--o--
IMI REMOTE CONTROL 96000320 (7204)
Carefully prise off the push-fit dial on the remote controller, unscrew the retaining screw and remove the control cover.
Mount the controller directly to a wall or onto a plinth, using two suitable fasteners, (not supplied).
Wire between the remote controller and the unit using multi-core cable, as shown in the wiring diagram (page 34).
SETTING INSTRUCTIONS:
The cooling differential (cool in to cool out) is fixed at 1.8
/
C +/- 0.5
/
C.
The heating differential (heat in to heat out) is fixed at 1.5
/
C +/- 0.5
/
C.
The deadband is fixed at 1.2 +/- 0.7
/
C.
The set point limits can be adjusted on the back of the push fit dial. The set point is factory set for a range from 17
/
C
to 30
/
C: it is recommended that the minimum setting is kept at 17
/
C or above.
--o--o--O--O--O--o--o--
IMI REMOTE CONTROL 97200211 (RCC 30)
Using a flat-bladed screwdriver in the slot at the bottom of the casing, lever off the cover.
Mount the backpanel directly to a wall or onto a plinth, using the fasteners supplied.
Wire between the remote controller and the unit as shown.
OPERATION RETURN AIR SENSOR NEUTRAL LIVE HEAT COOL MAX MED MIN
RCC 30 B1, M N L Y11 Y21 Q3 Q2 Q1
CWR *97200212 1 276345
*Optional return air sensor 97200212 can detect return air temperature at the unit rather than the controller.
(Heating is possible if the system includes a heat pump outdoor unit, or if electric heaters have been fitted).
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-13-
DIP switches at the bottom rear of the controller can be set on site to suit the application.
DIP switch Function ON position OFF position
1Fan control Fan control is temperature dependent in all
operating modes
Fan control in normal operation is
temperature independent
2Operating mode changeover via
external switch
Changeover between normal operation and
energy saving mode
Changeover between normal operation and
standby
3Action of switch for externally
operated mode changeover
Changeover activated when contact of
switch is closed
Changeover activated when contact of
switch is open
4Standby Frost protection disabled Frost protection enabled
5Switching differential 1K in heating mode, 0.5K in cooling mode 4K in heating mode, 2K in cooling mode
6Dead zone in normal operation 2K 5K
= factory settings
--o--o--O--O--O--o--o--
CWR 25 TO 85 WIRING DIAGRAM
B Brown H Heat/heater
R Red SH Heater supplementary
O Orange EH Heater electric
Y Yellow TP1 Thermal protector
G Green TP2 Thermal fuse
BL Blue RL Relay
V Violet T1 Thermostat de-ice
GRY Grey T2 Thermostat supplementary
W White LK Link
BK Black PCB1 Condensate control
P Pink RT Remote thermostat
T Turquoise F Fuse
HT High temperature S1 Condensate sensor
M1 Motor fan C Capacitor
M2 Pump V1 Valve cool
M3 Vane motor V2 Valve heat
AC Air conditioner CC Control
HP Heat pump RV Reversing valve
--- Not supplied
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-14-
TEMPERATURE CONTROL
The temperature range is factory set 17/C - 30/C.
Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures.
The white neon is lit when the unit is in cooling mode.
The amber neon is lit when the unit is in heating mode (if heating is fitted).
Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted.
Neither neon is lit when the thermostat is between cooling and heating.
--o--o--O--O--O--o--o--
OPERATING INSTRUCTIONS 97200211 (RCC 30 ELECTRONIC)
TEMPERATURE CONTROL
The temperature range is factory set 17/C - 30/C.
Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures.
Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted.
--o--o--O--O--O--o--o--
OBSOLETE ELECTRONIC REMOTE CONTROLLER 53900428
This may have been used in place of 96000320 (7204 electromechanical), allowing the use of a return air sensor
(53900428, shown opposite) to sense air temperature at the CWR unit.
TEMPERATURE CONTROL
The temperature range is factory set 17/C - 30/C.
Turning anti-clockwise for lower room temperatures, turn clockwise for higher room temperatures.
The amber neon is lit when the unit is in cooling mode.
The red neon is lit when the unit is in heating mode (if heating is fitted).
Heating is possible if the system includes a heat pump outdoor unit, or electric heaters have been fitted.
Neither neon is lit when the thermostat is between cooling and heating.
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-15-
REMOTE SENSOR KIT 53900428
This kit may be used on CWR models to sense the temperature at the return air grille.
Item Qty Description
1 1 Electronic remote control
2 1 Sensor assembly with 4m lead
3 1 Retaining clip
ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT
1
Fit the retaining clip to the drip tray support bracket, (Fig. 1), with the open end of the clip to the room side of the
bracket.
2
Clip in the sensor with the lead towards the electrics
end of the unit.
3
Route the sensor lead into the electrics box. Use the
plastic cable clamp to secure any spare cable within
the electrics area, ensuring that it cannot foul on the
fan or touch the electric heater (if fitted)
4
Exit the electrics box through one of the cable glands
used for the interconnecting cable and route the lead
to the remote controller position.
NOTE:
The cable may be extended up to a
maximum of 50 metres. Ensure that all joints
and insulation are capable of withstanding
mains voltage.
5
Carefully prise off the push-fit dial on the remote
controller, unscrew the retaining screw and remove
the control cover, (Fig. 2)
Fig. 1.
Fig. 2.
6
Locate the wire link Br.1 in the wall mounted
thermostat, on the right hand side of the white
adjustment potentiometer P1, and cut the link,
(Fig. 3).
7
Locate the sensor, R15, on the left hand side
of the adjustment potentiometer P1, and gently
pull it out of the mounting sockets (Fig. 3).
8
Connect the lead from the remote sensor to
terminals 11 and 12 in the remote controller
Fig. 3.
(Fig. 3).
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-16-
9
Route the remote controller cable from terminals 1 to 7 in the CWR unit, (Fig. 1), along with the existing wires from
the unit and connect to the remote controller as shown in the table below. Secure all cables inside the unit to ensure
that they do not foul the fan or touch the electric heater, (if fitted).
CWR ELECTRONIC THERMOSTAT FUNCTION
1 4 NEUTRAL
21LIVE
3 22 BOOST SPEED
4 21 HIGH SPEED
5 20 LOW SPEED
6 6 COOL
7 2 HEAT
10
(If an IMI Air Conditioning electromechanical controller was previously used, the connections in the original controller
are numbered the same as the terminals in the CWR unit).
11
Setting instructions:
The cooling differential (cool in to cool out) is fixed at 1.5C.
The heating differential (heat in to heat out) is fixed at 0.5C.
The square, black potentiometer, (P3, Fig. 3), adjusts dead zone; fully anti-clockwise gives 0.5K, fully clockwise
(through 270
/
) gives 7.5K (as shown on the printed circuit board). The set point limits can be adjusted on the back
of the push-fit dial;
DO NOT SET THE LOWER SET POINT BELOW 15
/
C.
On cool only units, turn the potentiometer, P3, fully anti-clockwise (dead zone 0.5K).
TYPICAL SETTINGS:
--o--o--O--O--O--o--o--
REMOTE SENSOR KIT 97200212 (FOR RCC 30 REMOTE CONTROLLER 97200211)
This instruction is also applicable to return air sensor spare 04000012S
The sensor can be fitted to the return air inlet to an air conditioning unit to improve operation eg. if the wall thermostat
is placed outside the space being conditioned, or if there is considerable stratification in a room with a high ceiling, where
the wall thermostat would not measure a representative temperature.
ITEM QTY DESCRIPTION
1 1 Sensor (4m lead)
2 2 Tie wrap
ISOLATE THE SYSTEM ELECTRICALLY
PRIOR TO INSTALLATION OF THE SENSOR
Connect the sensor to terminals B1 and M , as shown (polarity is unimportant).
Tie wrap the sensor to a suitable place in the return airflow, where it will soak
in a representative temperature.
After installation, adjust the thermostat to confirm satisfactory operation, noting
that DX units may experience a three minute delay if the compressor has
recently run.
--o--o--O--O--O--o--o--
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Fax: 01823 665807
-17-
If, as a result of fitting this kit, more than one supply is taken into a unit, that unit must be marked:-
"Two, (or more if applicable), supplies are taken into this equipment.
Isolate both, (all), before undertaking any maintenance work."
PROGRAMMABLE TIMER KIT 52500151
This kit can be used to give
ON/OFF
switching of the mains voltage control circuits of CWR units where
the total
current does not exceed 3 Amps.
ELECTRIC HEATER CURRENTS CANNOT BE SWITCHED DIRECTLY
.
It is not required for 'L' products which have built in timers.
ITEM QTY DESCRIPTION
1 1 7 Day Programmable Timer
2 1 In Line Fuse Carrier
3 1 5 Amp Fuse, 1" x 1/4"
4 1 Terminal
PROGRAMMER SPECIFICATION:
Type:
Digital electronic 230V, 50Hz
Programme:
7 day
Setting Resolution:
1 minute
Selection Switch:
"OFF",
"TMD (TIMED)"
"CON (CONSTANT ON)"
"ADV (ADVANCE)"
Max. Switched Current:
3 A (fan load)
The timer will accommodate 0.75mm
2
to 2.5mm
2
wires.
Three core cable is required between the timer and the air conditioning unit.
The timer motor must be connected to an uninterrupted supply source.
TIMER MOUNTING
1
Carefully unpack and identify the components.
2
If the unit is to be surface wired, remove the appropriate knockouts in the backplate. Screw the backplate to the
wall with No. 8 wood screws through the fixing holes.
3
If the backplate is to be fixed to a BS4662 single gang plaster depth box, use 3.5mm machine screws.
WIRING FOR ON/OFF SWITCHING
4
a) Wire timer terminal 'L' to unit terminal 2.
b) Connect timer terminal 4 to either:-
Remote controller 7204 (96000320) : terminal 2
Remote controller RCC 30 (97200211): terminal L
c) Wire timer terminal 'N' to unit terminal N
5
Discard the in-line fuse carrier.
6
Plug in the unit and secure the screws.
7
Program as described in the separate timer instructions.
--o--o--O--O--O--o--o--
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-18-
CONDENSATE PUMP KIT 53900410
This kit is for use on 539 series IMPULSE and 968 series CWR units for the removal of condensate where gravity drain is
not practicable or desirable.
The pump is capable of overcoming a resistance equivalent to 5 metres lift.
The sensor is arranged so that residual condensate in the sump is kept to a minimum.
The kit includes an overflow protection circuit, which will prevent further cooling and condensate production if a high
condensate level occurs.
ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
1 PUMP ASSEMBLY CONSISTING OF: 4 1 Grommet
A1Pump 51Wire Support
B1 Grommet 64 No. 8 Screw
C1Hose 71 Cable Tie
D1 Green/Yellow Cable 82 No. 6 Screw
E1 Cable Tie 91 Sensor Block
21 Control Board 10 1 Sensor Bracket
34 Mounting Foot
It is preferable to fit this kit prior to installing the unit; the following instructions/diagrams refer to bench
fitting.
ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THIS KIT
1
Remove both side panels (2 screws each side behind the plastic caps):-
WARNING: IF THE UNIT IS ALREADY INSTALLED IN THE CEILING, THE SIDE PANELS WILL DROP
IMMEDIATELY UPON RELEASING THE SCREWS.
2
Open the grille by pulling the handles at the top edge of the grille (Fig. 1); the grille is spring loaded and some
resistance will be felt.
3
Lift the filter over the retaining lug and slide it out (Fig. 2).
Fig. 1. Fig. 2. Fig. 3.
4
Insert a screwdriver between the grilles and disengage the grille retaining catches
(Fig. 3). Swing the grille away and unhook from the chassis.
5
Remove and retain all the fascia support bracket fixing screws (Fig. 4)
and remove the bracket and fascia from the unit. Store the fascia in a safe
location until required.
Fig. 4.
6
The condensate drain connector is already fitted to
the pipework end of the unit, (Fig. 5).
Fig. 5.
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-19-
Fig. 6.
7
Fit the loose pump grommet in the kit onto the hose (supplied as part of the unit) at the electrics end (Fig. 6).
8
Push the hose (referred to in 7) fully onto the condensate pump outlet and secure as far onto the outlet as possible
with the 4" cable tie (Figs. 6 and 7).
9
Secure the green/yellow cable and pump support wire to the coil hanger bracket with No. 8 screws (Fig. 6).
10
Push the grommets on the hose into the pump support wire; the arrows on the pump must point towards the motor
(Fig. 6).
Fig. 7.
11
The sensor/filter assembly is supplied fitted to a transition bracket.
a
If the unit has been supplied with a sensor bracket fitted, align the holes in the transition bracket with those in
the sensor bracket and connect together with the No. 6 screws (Fig. 7).
b
If the unit has been supplied without a sensor bracket fitted, disengage the sensor from the transition bracket,
align the holes in the transition bracket with those in the coil hanger bracket and secure together using the No.
8 screws. Refit the sensor to the bracket (Fig. 7).
12
Push the hose from the pump onto the sensor pick up spout (Fig. 7). Route the hose to avoid kinking.
13
Push the control board mounting feet into the four holes on the electrics plate (Fig. 6) and mount the control board.
14
Remove and discard the terminal covers from the black and blue wires, remove and retain the curly lok cable tie and
make the following connections to the control board (wiring diagram below)
.
a
Black cable to terminal L.
b
Blue cable to terminal N.
c
Pump cable to terminal PL
.
d
Pump cable to terminal PN
.
e
Sensor block flying lead plug to the six pin connector (CON 1)
.
f
Cut the looped red cable, (Fig. 6), bare back each half by 6mm and connect to the plug-in screw terminal block
TB1.
g
Use the curly lok cable tie to secure the wires and the sensor lead to the condensate outlet pipe above the
transformer.
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-20-
15 Refit the drip tray/fascia. Disconnect the gravity drain (if previously fitted) and either block off the pipe or ensure
that the outlet is above the level of the drip tray by placing the pipe up behind the grille.
16 Connect a 12mm (0.5") OD drain tube to the drain connector (Fig. 5), and route together with the refrigeration/chilled
water pipes to a suitable outlet.
NOTE: Use of a 12mm OD drain tube should reduce the possibility of syphoning, but if the drain outlet is below
the level of the base of the drip tray, syphoning may occur, creating noise on pumping. If this occurs, fit
an air break, e.g., by pumping into a larger diameter pipe than that from the pump, no further than 200mm
below the level of the base of the unit.
17 Refit the grille and filter.
18 TESTING THE PUMP AND CONTROL
aConnect a suitably fused supply to the unit (refer to the unit installation instructions). Allow approximately one
minute for the controls and sensor to stabilize.
bSlowly add water to the condensate tray until the pump runs. Initially the pump will be noisy until the air in the
hose has been expelled. It is possible that, on this first cycle, the pump will run dry for a short period (indicated
by noise).
cAdd more water to the tray and the pump will cycle in the normal manner.
dWith the system in cooling mode, continue adding water to the sump until it reaches the higher of the sensor
probes. The cooling cycle will shut down, and the pump continue to run, until the water has dropped below the
level of this probe.
19 Refit the side panels.
NOTE: Whenever the electrical supply to a unit fitted with a condensate pump and controls is interrupted, a
delay of up to 1 minute will occur before the compressor or the pump will start when the supply is
reinstated
CONDENSATE PUMP WIRING DIAGRAM
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