TECHNICAL MANUAL. for 540 SERIES CONDENSING UNITS. and 542 SERIES DUCTED CONDENSING UNITS. from IMI AIR CONDITIONING LTD.

Transcription

1 TECHNICAL MANUAL for 540 SERIES CONDENSING UNITS and 542 SERIES DUCTED CONDENSING UNITS from IMI AIR CONDITIONING LTD. This manual provides technical and installation information for the 540 series Condensing Units and 542 series Ducted Condensing Units. INDEX PAGE GENERAL Specification Details 2 Features and Options 2 Part Numbers, Dimensions and Weights 3 SELECTION Unit Performance Data 4 INSTALLATION 540 Series Series 7-8 Application, Pipework 9-10 Electrical Connections Evacuating and Charging 11 WIRING CU 12 DIAGRAMS CUE DCUE KITS PTC - All 1Ph units 17 CSR - All 1Ph units Head Pressure Control - CU only Pressure Switches - CU and CUE Isolator series Isolator series Minute Timer - CU only 29 Wall Mounting - CU/CUE Wall Mounting - CU/CUE Wall Mounting - CU/CUE 180, Wall Mounting series Overload - 1Ph CU/CUE 38 Duct series 39 Plenum series Grille series 41 COMPONENT Exploded Views of Units with IDENTIFICATION Component Identification IMI Air Conditioning Ltd. Armytage Road, Brighouse, West Yorkshire. HD6 1QF Tel: (01484) Fax: (01484) A subsidiary company of IMI plc

2 IMI AIR CONDITIONING LIMITED - CONDENSING UNITS Specification Details CU/CUE/DCUE SIZE Nominal Cooling Capacity* kw Compressor - 1 Phase ( volts 50Hz) Power (Nominal) kw Starting current A Nominal current A Compressor - 3 Phase (400 volts 50Hz) Power (Nominal) kw Starting current A/phase Nominal current A/phase Crankcase heater A R22 Charge supplied g Connection sizes Suction ins odf d d d e e e : : : : f f Liquid ins odf d d d d d d d Sound Pressure Levels (SPL) at 3m distance in free field conditions. (Reference 2 x 10 N/m²) -5 Fan speed Low dba NC Fan speed High dba NC CU/CUE SIZE Condenser fan ( volts 50Hz 1ph) Airflow (high speed) m³/s Fan motor rating kw x x x x x 0.14 Starting current A x x x x x 2.30 Nominal current FLA A x x x x x 0.8 Fans:- No. x Diameter # x mm 1 x x x x x x x x x x x x x x x 508 Fans:- Max speed r.p.m Weight net (operating) kg DCUE SIZE Condenser fan ( volts 50Hz 1ph) Airflow (high speed) m³/s Max external resistance Pa Fan motor rating kw Starting current A Nominal current FLA A Weight net (operating) kg Sound Pressure Levels (SPL) at 3m distance from unit in ceiling void. (Reference 2 x 10 N/m²) -5 Fan speed Low dba NC Fan speed High dba NC NOT AVAILABLE * Nominal capacities quoted at 7.5 C saturated suction temperature and 30 C air onto the condenser. Standard features and options CONDENSING UNIT MODEL CU CUE DCUE Fully weatherproof Easy access for installation and service Suction and liquid service valves Expansion device (orifice type) * * Pre-charged with refrigerant (R22 Versions for use with R407C (zero ODP) Heat pump version available - Ductet air inlet and/or discharge - - Ceiling suspendable - - Capacitor start relay (1phase) PTC resistor (1 phase) Fan speed head pressure control STD STD LP cut-out STD STD HP cut-out STD Isolator 3 minute start time delay STD STD Wall mounting brackets Contactor STD STD STD Overload (standard on 3ph) Low ambient start STD STD = Standard Feature, * (up to size 165), = Option -2-

3 PART NUMBERS 540 Series CONDENSING UNITS (CU/CUE) Electromechanical CU 10 CU 15 CU 20 CU 30 CU 40 CU 50 CU 60 CU 80 Unit CU 1Ph Electromechanical CU 30 CU 40 CU 50 CU 60 CU 80 Unit CU 3Ph Electronic CUE 1Ph CUE 10 CUE 15 CUE 20 CUE 30 CUE 40 CUE 50 CUE 60 CUE Electronic CUE 3Ph CUE 30 CUE 40 CUE 50 CUE 60 CUE Electromechanical CU Unit CU 1Ph Electromechanical CU 90 CU 100 CU 130 CU 150 CU 165 CU 180 CU 200 Unit CU 3Ph Electronic CUE 1Ph CUE Electronic CUE 3Ph CUE 90 CUE 100 CUE 130 CUE 150 CUE 165 CUE 180 CUE Series DUCTED CONDENSING UNITS (DCUE) Electronic DCUE 1Ph DCUE 10 DCUE 15 DCUE 20 DCUE 30 DCUE 40 DCUE 50 DCUE 60 DCUE Electronic DCUE 3Ph DCUE 30 DCUE 40 DCUE 50 DCUE 60 DCUE UNPACKED WEIGHTS (for unpacked dimensions, refer to the relevant installation section) Model CU/E 10 CU/E 15 CU/E 20 CU/E 30 CU/E 40 CU/E 50 CU/E 60 CU/E 80 WEIGHT kg Model CU/E 90 CU/E 100 CU/E 130 CU/E 150 CU/E 165 CU/E 180 CU/E 200 WEIGHT kg Model DCUE 10 DCUE 15 DCUE 20 DCUE 30 DCUE 40 DCUE 50 DCUE 60 DCUE 80 WEIGHT kg DIMENSIONS AND WEIGHTS (Packed) CONDENSING UNITS Model CU/E 10 CU/E 15 CU/E 20 CU/E 30 CU/E 40 CU/E 50 CU/E 60 CU/E 80 HEIGHT* mm WIDTH mm DEPTH mm WEIGHT kg Model CU/E 90 CU/E 100 CU/E 130 CU/E 150 CU/E 165 CU/E 180 CU/E 200 HEIGHT* mm WIDTH mm DEPTH mm WEIGHT kg DUCTED CONDENSING UNITS Model DCUE 10 DCUE 15 DCUE 20 DCUE 30 DCUE 40 DCUE 50 DCUE 60 DCUE 80 HEIGHT mm WIDTH mm DEPTH mm WEIGHT kg

4 CU, CUE & DCUE Condensing Unit Capacities MODEL Air on to Condenser C Saturated Suction Temperature C Cooling capacity and power input kw Cap. Power Cap. Power Cap. Power Cap. Power Cap. Power Cap. Power CU/CUE / DCUE CU/CUE / DCUE 15 CU/CUE / DCUE 20 CU/CUE / DCUE 30 CU/CUE / DCUE 40 CU/CUE / DCUE 50 CU/CUE / DCUE 60 CU/CUE / DCUE 80 CU/CUE 90 CU/CUE 100 CU/CUE 130 CU/CUE 150 CU/CUE 165 CU/CUE CU/CUE Note: Operation in the shaded areas of the tables will result in unacceptably high condensing temperatures and should be avoided. -4-

5 INSTALLING 540 Series CONDENSING UNITS CU = electromechanical condensing unit CUE = electronic condensing unit The unit is supplied with 2 cable glands which should be used to secure all mains and interconnecting wiring. For solid sheathed cables, the installer will need to supply a method of securing the cables to the unit. Note: It is easier to fit kits prior to mounting the unit. These units are designed to stand on a flat surface. If the unit is to be wall mounted the following kits are available (IMI Air Conditioning cannot accept liability for installers own mounting arrangements). Model CU/CUE CU/CUE CU/CUE CU/CUE Kit 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: CU/CUE All dimensions are in millimetres. (The wall brackets shown are available as an optional kit). MODEL A B C D E F G H Weight (kg) CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE

6 MOUNTING: CU/CUE All dimensions are in millimetres. (The wall brackets shown are available as an optional kit). MODEL A B C D E F G H Weight CU/CUE CU/CUE CU/CUE MOUNTING: CU/CUE 180 to 200 All dimensions are in millimetres, (the wall mounting brackets shown are available as an optional kit). -6-

7 INSTALLING 542 SERIES DUCTED CONDENSING UNITS Mounting Units are supplied with a polystyrene packing piece separating 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 B A E F D K J C H G Model A B C D E F G H J K Weight DCUE DCUE DCUE DCUE DCUE DCUE DCUE DCUE 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. Model A B 10 to to

8 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 backpanel 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 Specially designed brackets to enable ducted units to be wall mounted are available as an optional kit ( ). Ductwork Each unit is supplied with air inlet and discharge spigots, models 10 to mm (14") dia., models 50 to mm (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 Model mm. 10 to to 80 A B C

9 APPLICATION -- CU, CUE and DCUE 1 To maximise performance, pipe runs should be kept as short as possible, avoiding sharp bends. However, individual pipe runs to a maximum of 45m on air conditioners are permissible provided good refrigeration practice is followed. Performance ratings are based on 6m pipe runs. Correctly sized pipes for each installation will result in no significant loss of capacity on extended pipe runs. a) Pipe sizes are based on:- Minimum of 3.8 m/s (750 fpm) suction gas velocity for horizontal or downflow. Minimum of 7.6 m/s (1500 fpm) suction gas velocity for upflow. 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 (Shell 7366 or Suniso 3GS or equivalent) 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. 3 For systems with capillary control at the indoor unit; the table below shows the suggested pipe sizes (in inches). Equivalent Suction Line Size Liquid Line Size length of run Horizontal or Downflow Upflow CU/CUE/DCUE 0-6m 6-15m 15-21m 21-45m Up to 15m 0-21m 21-45m 10 3/8 1/2 1/2 * 3/8 1/4 * 15 3/8 1/2 1/2 * 3/8 1/4 * 20 3/8 1/2 1/2 * 3/8 1/4 * 30 1/2 5/8 5/8 5/8 1/2 1/4 3/8 40 1/2 5/8 5/8 3/4 1/2 3/8 3/8 50 1/2 5/8 3/4 3/4 5/8 3/8 1/2 60 5/8 3/4 3/4 7/8 5/8 3/8 1/2 80 5/8 3/4 3/4 7/8 5/8 3/8 1/2 90 5/8 3/4 3/4 7/8 5/8 3/8 1/ /4 7/8 7/8 1 1/8 3/4 1/2 5/ /4 7/8 7/8 1 1/8 3/4 1/2 5/ /4 7/8 7/8 1 1/8 3/4 1/2 5/ /4 7/8 7/8 1 1/8 3/4 1/2 5/ /8 1 1/8 1 1/8 1 3/8 1 1/8 1/2 5/ /8 1 1/8 1 1/8 1 3/8 1 1/8 1/2 5/8 4 In calculating equivalent lengths of pipe runs, the effect of bends and fittings must be taken into account. Information concerning 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). Pipe Size (outside diameter in inches) Fitting 3/8 1/2 5/8 3/4 7/8 1-1/8 45 Bend Bend R/d = Bend R/d = Bend C/d = Bend C/d = Elbow 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). -9-

10 PIPE CONNECTIONS/RESTRICTORS 1 Outdoor units are supplied with the following male flare connections (sizes in inches); Model CU/CUE/DCUE Size Liquid 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 Suction 3/8 3/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 3/4 3/4 3/4 3/4 7/8 7/8 NOTE: Ensure that both service valves on the outdoor unit are closed (IN, fully clockwise) before commencing installation. ALL THE ABOVE UNITS ARE SUPPLIED FITTED WITH EXPANSION DEVICES THESE ARE FOR USE ON IMI AIR CONDITIONING SYSTEMS NOT UTILISING CAPILLARY EXPANSION. ON SYSTEMS WITH REFRIGERANT CONTROL FITTED TO THE INDOOR UNIT, REMOVE AND DISCARD THE EXPANSION DEVICE FITTED TO THE VALVE. 2 Remove both flare nuts from the service valves. 3 Ensure that the suction line is fully insulated. 4 Place the flare nuts over the incoming pipework and flare the pipe ends. 5 Connect the pipework between the units. Do not leave pipe ends, valves etc. open to the atmosphere. Always use two spanners when tightening the flare nuts. 6 If a filter drier is used, site this in the liquid line. If a sight glass is fitted it should be as close to the indoor unit as possible. BRAZING (if applicable) NOTE: IT IS IMPERATIVE THAT THE VALVE IS COOLED DOWN DURING BRAZING. THIS IS DONE BY WRAPPING THE VALVE IN A WET RAG AS SHOWN BELOW. COOLING DOWN THE VALVE DURING BRAZING CONNECTIONS ELECTRICAL All mains, control and interconnecting cables must be supplied and fitted by the installer. The installer wiring must be carried out in accordance with IEE regulations and local codes. All 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. Cable glands for use with stranded cables are supplied and should be used to secure all incoming/outgoing cables. Installers must supply a method of securing any solid sheathed cables. -10-

11 OUTDOOR UNIT WIRING Cable entry for the outdoor unit electrics is through the cabinet to a terminal block. Outdoor unit fan motors have a high speed (black) wire and a low speed (red) wire; the speed not being used is wired into a dummy terminal. Electromechanical condensing units (CU) are supplied wired for low fan speed, which is suitable for temperate climates. If continuous running is expected at ambient temperatures greater than 35 C change to high speed by interchanging the black and red wires, i.e. black to live terminal, red to dummy terminal. All Electronic outdoor units (CUE and DCUE) are supplied wired for high speed to give maximum control. Ensure that all connections are secure and that both units are earthed. DATA PLATES Because of the ability to mix-match indoor and outdoor units, the data plate only gives information on outdoor units. To obtain the system details, input power and currents from indoor and outdoor units should be added together. Data plates show basic units only, and do not include kit loads, e.g. electric heater loads. EVACUATING and CHARGING Each outdoor unit is charged with R22. The amount of charge is detailed in the tables below. Refer to the indoor unit installation instruction to calculate the amount of refrigerant required for the whole system. Charge CU/CUE/DCUE gms ozs Evacuate the interconnecting pipework and indoor unit by connecting a vacuum pump to the service ports on the outdoor unit valves and evacuate to 1000 microns (1 Torr) or better and allow to be held for a minimum of 15 minutes. 2 If the system does not require any additional charge, replace the caps on the service ports and open the valves using a 4 or 5mm Allen key. 3 If additional charge is required: a Start unit, (on highest evaporator fan setting and appropriate outdoor unit fan speed), and allow the compressor to run for approximately 10 seconds. NOTE: b c CUE and DCUE are supplied programmed using link JP6 on the outdoor unit pcb, to accept additional refrigerant and override the alarms during the charging process. This ensures that, with indoor and outdoor units powered, the outdoor unit fans will run at high speed. Indoor units should be set to operate in cooling mode. When JP6 is linked, any indicator lights should be ignored. Allow system pressures to stabilize. Any additional charge needed should be introduced through the Schrader valve on the indoor unit or service port on the suction service valve on the outdoor unit. Where possible, charge to a sweat line on the evaporator. Care should be taken when the compressor is first started in the field to ensure that the system is not overcharged, in which case liquid return to the compressor could result. IMPORTANT: On electronic systems, once refrigerant has been added OR if the system is adequately charged as supplied, REMOVE link JP6 from the outdoor unit circuit board situated to the left of the terminals. JP6 is identified by a white label stating "Remove this link when R22 charging is completed to commence normal operation". 4 If a manual HP cutout is fitted, ensure that the reset button is depressed. NOTE: A random start delay of up to 1 minute occurs when mains is first applied. A 3 minute delay occurs between successive compressor operations. 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 the fan rotates freely. -11-

12 ELECTROMECHANICAL CU WIRING DIAGRAMS 1 Phase CU 10 to 60 1 Phase CU 80 to 90 3 Phase CU 30 to Phase CU 130 to

13 ELECTRONIC CUE WIRING DIAGRAMS 1 Phase CUE 10 to 60 1 Phase CUE 80 to

14 3 Phase CUE 30 to Phase CUE 130 to

15 ELECTRONIC DCUE WIRING DIAGRAMS 1 Phase DCUE Phase DCUE

16 3 Phase DCUE 30 to

17 PTC DEVICE, COMPRESSOR START KIT This kit is for use on single phase 540 series Condensing Units and 542 series Ducted Condensing Units. The Positive Temperature Coefficient Device (PTC) kit may be used to increase the torque to a single phase compressor, to assist those installations where the standard PSC compressor needs higher starting torque. It reduces the duration of high start current, but not the peak value. ITEM QT DESCRIPTION 1 1 PTC Device 2 1 PTC Clip 3 1 White Lead 4 1 Blue Lead 5 1 Double Spade Terminal 6 3 Cable Tie ISOLATE ELECTRICALLY PRIOR TO INSTALLATION OF KIT. 1 Remove the six (three on Ducted Units) front access panel retaining screws to reveal the electrics box. 2 The PTC device is to be located centrally on the back face of the electrics tray, (Fig. 1, Fig. 2 for Ducted Units). 3 Remove the clip from the PTC bobbin and slide the clip into the larger hole in the back panel to the right of the compressor capacitor (to the left of the Contactor on Ducted Units. Fig Connect the flag connectors to the PTC device (which is non-polar). Press the PTC device into the clip and connect the in-line connectors to the compressor capacitor, using the double spade terminal on the neutral side of the capacitor if necessary. 5 Secure the wires to the existing loom using the cable ties provided. -17-

18 CSR COMPRESSOR START KITS to 406, 415 and 423 This kit may be used on single phase 540 series Condensing Units and 542 series Ducted Condensing Units. The Capacitor Start Relay (CSR) kit may be used to increase the torque to a single phase compressor, to assist those installations where the 'as supplied' PSC compressor has insufficient torque. It performs a similar function to the PTC kit but gives a higher torque to the compressor, further reducing the time during which high starting current is experienced, but not the peak value. It should be used when a PTC kit is likely to be insufficient such as for systems with long pipe runs or in extremely cold ambient conditions. UNIT SIZE KIT ITEM QT DESCRIPTION ITEM QT DESCRIPTION 10, 15, 20, Capacitor Clip 7 1 Orange Lead Capacitor 8 1 White Lead Relay Mounting Bracket (not 403/404) 9 1 Black Lead 60, Relay 10 1 Blue Lead 90, (FH5538E Comp.) BA Screw (not 403/404) 11 1 Double Spade Terminal 90, (AH5540E Comp.) No. 10 Screw 12 3 Cable Tie ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT CU(E) MODELS 1 Release the six access panel retaining screws and remove the panel to reveal the electrics tray. 2 Secure the capacitor clip into the hole nearest the front left hand side of the electrics box base (Fig. 1) using one No. 10 screw and press in the capacitor with the terminals facing right. 3 Identify whether the relay terminals are to be horizontal or vertical when mounted, from the tables below and overleaf. RELAYS -- TERMINALS VERTICAL Fig. 1. ELECTRICA or AMF RELAY GE RELAY UNIT SIZE TYPE TYPE RVA 3ARR3 10, 15, 20, U6AU2 60, U10AS2 Fig U4AA2 Fit the relay to the bracket using two 4BA screws (Fig. 2). Fig. 3. Secure the bracket to the electrics tray using one No 10 screw (Fig. 3). RELAYS -- TERMINALS HORIZONTAL ELECTRICA or AMF RELAY GE RELAY UNIT SIZE TYPE TYPE RVA 3ARR3 10, 15, 20, 40 3G3C B10AS3 30 4L3C B6AV3 50 4IOD -- 60, 80 3GOD Fig. 4. Secure the relay directly to the electrics tray using one No. 10 screw (Fig. 4). 4 Connect the wires as shown in the table and figure 5: WIRE TERMINATIONS FROM TO Orange Flag and Female Relay 1 CSR Cap White Flag and Female Relay 2 Comp Cap Black Flag and Fork Relay 5 Cont 6 Blue Female and Female Comp Cap* CSR Cap * Use the double spade terminal on the Compressor Capacitor Neutral. Fig Tidy the wires by fastening to the existing harness using the cable ties provided. Blue Black Compressor Capacitor CSR Capacitor A2 C 1 Contactor Orange A1 White R L1 4 CSR Relay Black Red Brown Violet -18-

19 DCUE MODELS 1 Release the four side access panel retaining screws (valve end). Also removing the lid will make fitting this kit easier. 2 Secure the capacitor clip into the hole nearest the front left hand side of the electrics box using one No. 10 screw and press in the capacitor with the terminals facing right (Fig. 6). CSR CAPACITOR 3 Identify whether the relay terminals are to be horizontal or vertical when mounted, from the tables below, and secure the relay to the electrics plate (Figs 7 and 8). Fig. 6. RELAYS -- TERMINALS VERTICAL ELECTRICA or AMF RELAY GE RELAY UNIT SIZE TYPE TYPE RVA 3ARR3 10, 15, 20, U6AU2 60, U10AS2 Fig U4AA2 Fit the relay to the bracket using two 4BA screws (Fig. 7). Secure the bracket to the electrics tray using one No 10 screw (Fig. 8). RELAYS -- TERMINALS HORIZONTAL ELECTRICA or AMF RELAY GE RELAY UNIT SIZE TYPE TYPE RVA 3ARR3 10, 15, 20, 40 3G3C B10AS3 30 4L3C B6AV3 50 4LOD -- 60, 80 3GOD Fig. 8. Secure the relay directly to the electrics tray using one No. 10 screw (Fig. 8). 4 Connect the wires as shown in the table and figure 9: WIRE TERMINATIONS FROM TO Orange Flag and Female Relay 1 CSR Cap White Flag and Female Relay 2 Comp Cap Black Flag and Fork Relay 5 Cont 6 Blue Female and Female Comp Cap* CSR Cap * Use the double spade terminal on the Compressor Capacitor Neutral. 5 Tidy the wires by fastening to the existing harness using the cable ties provided. Blue Black Compressor Capacitor CSR Capacitor A2 C 1 Contactor Orange A1 White R L1 4 CSR Relay Black Red Brown Violet Fig

20 HEAD PRESSURE CONTROL KIT This kit is for use on 540 series condensing units to maintain a sufficiently high head pressure in cool ambient conditions by reducing the speed of the fan. This will keep the suction pressure high enough to prevent frosting of the evaporator, which might otherwise occur. The use of this kit is recommended to minimise latent cooling on all high sensible systems and for all systems likely to operate at ambient temperatures below 10 C. A separate kit is available for 60Hz models (part number ). CONTENTS ITEM QTY DESCRIPTION 1 1 Head Pressure Control PCB 2* 1 Sensor (Thermistor) 3 4 PCB Mounting Foot 4 2 Sensor Lead 5 1 Large Cable Tie (Sensor) 6 1 Double Spade Terminal 7 4 Small Cable Tie * One of two interchangeable types supplied FULLY COMMISSION THE SYSTEM WITHOUT THE HEAD PRESSURE CONTROL. IF THIS IS NOT DONE, THE HEAD PRESSURE CONTROL WILL OPERATE INCORRECTLY. ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT. 1 Release the front access panel retaining screws and remove the panel to reveal the electrics box. 2 Transfer the blue and red wires from the parking terminal to the Head Pressure Control PCB as shown in figures 1 and 2. Fig. 2. CU Fig. 1. CU Remove and discard the parking terminal. 4 Press the mounting feet into the four holes in the rear upper left hand corner of the electrics box and push the PCB onto the feet, with the PCB terminals on the right hand side. 5 Remove the white wire(s) from the fan motor capacitor(s) and reroute to the PCB terminal 2. (Use the double spade terminal on CU models). 6 CU 10 to 100: Interchange the fan motor black and red leads at the fused terminal block (i.e., black lead to the fused terminal block, red lead to the dummy terminal block). CU 130 to 200: Interchange the fan motor red leads at terminal block No. 9 with the fan motor black leads at dummy terminal blocks No's 8 and 4. This will give maximum range of control. -20-

21 POSITIONING THE SENSOR 1 The sensor should be positioned after the first bend of the liquid line as shown in figures 3 and 4. Fig. 3. CU PLAN VIEWS Fig. 4. CU Clean the pipe locally with steel wool. Note that if the sensor is not held fully onto the pipe, the temperature sensed will be incorrect resulting in high head pressure and low fan speed. SENSOR TYPE A: SENSOR TYPE B: Heat sink compound is provided in the resealable plastic bag and should be used to improve thermal contact -- snip off the corner of the bag and squeeze onto the sensor after the 'O' ring is positioned. Thread the two cable ties through the slots in the sensor body and fix securely, with the 'O' ring provided in the sensor head groove, by pulling the cable ties with pliers, then trimming to 1/2" tails. Note that the sensor is a glass bead -- NEVER slide the sensor along the pipe. Connect the two black sensor wires to PCB terminals 4 and 5. Discard the two grey sensor wires supplied in the kit. Place the curved face of the sensor against the pipe (ideally using heat sink compound) and secure tightly in place with the large cable tie provided. Connect the grey sensor leads in the kit between the recessed sensor terminals and PCB terminals 4 and 5. COMMISSIONING The minimum speed is factory set to suit the majority of condensing units and is sealed. On models CU 10 to CU 30 the minimum speed may need to be increased. CAUTION: The following adjustments are done with the equipment LIVE. 1 Run the unit in cooling mode with the sensor disconnected. When the hard start is over (approximately 7 seconds) the motor will slow down. -21-

22 2 If the motor stops completely, turn the potentiometer (RV2) marked "Min. Speed" slowly in a clockwise direction This ensures the widest range of speed control. with a small screwdriver until the motor just runs. 3 Switch off the supply and reconnect the sensor. THE FOLLOWING SHOULD ONLY BE CARRIED OUT IF THE HEAD PRESSURE CONTROL IS OUT OF CALIBRATION. Method for Restoring Calibration of Head Pressure Controllers 1 The system must be correctly charged before fitting the Head Pressure Control kit to ensure satisfactory operation. 2 Connect pressure gauges to the suction and discharge lines. 3 Check the minimum speed setting (see the previous section). 4 With the sensor connected, switch on electrical supply. The fan motor will run at full speed for several seconds, then reduce, (to a speed determined by the RV1 setting and the prevailing ambient/pressure conditions). 5 Adjust RV1 (Set Temp. potentiometer) fractionally (typically 1/8 turn) to obtain a head pressure of approximately psig, ( bar), if ambient conditions allow. Turning in the direction + (counter-clockwise) increases the fan speed, hence reducing head pressure; turning in the direction - (clockwise) reduces the fan speed and increases head pressure. Wait 2-3 minutes before making further adjustments. If the fan speed oscillates over a wide range and, after 5 minutes, shows no tendency to stabilize, slightly increase the minimum fan speed as described above. Head pressure control is an automatic "closed loop" process. Within limits, any subsequent change in head pressures, due to reducing ambients for instance, will be corrected by an automatic adjustment in fan speed. -22-

23 HIGH AND LOW PRESSURE SWITCH KITS , 417 and 418 KIT NUMBER PRESSURE CUT OUT CUT IN USED AS A KIT SWITCH PRESSURE PRESSURE ON HP Manual 2760kPa 2410kPa All CU (400psig) (350psig) (electromechanical) LP Auto 195kPa 295kPa All CU (28.4psig) (42.7psig) (electromechanical) HP Auto 2760kPa 2410kPa All CUE (400psig) (350psig) (electronic) ITEM QTY DESCRIPTION 1 1 Pressure Switch 2 2 M4 Screw, Switch to Panel 3 1 Mounting Bracket (HP kit only) 4 2 No 8 Screw, Bracket to Unit (HP kit only) 5 1 Violet Wire (HP kit only) Manual high pressure switches are reset by pushing the button on the front face. Low pressure switches are not recommended for use on CU models in ambient temperatures of less than 10 C (50 F), unless outdoor unit head pressure control is used. ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT 1 Release the access panel retaining screws and remove the panel to reveal the electrics box. LOW PRESSURE (LP) SWITCH 1 This is fitted on all electronic condensing units. 2 Release the lid retaining screws and remove the lid. 3 The LP switch is to be located on the left hand side on the fixed panel behind the electrics tray as shown in Fig See overleaf for switch wiring prior to securing the switch to the panel using the two screws provided, tightening the screws from the fan chamber side. HIGH PRESSURE (HP) SWITCH 1 The HP switch is to be located on the mounting bracket as shown in Fig Secure the HP switch to the bracket using the two screws provided. CU/CUE CU/CUE LP Switch position 2 Suction service port 3 HP Switch position 4 Discharge service port Fig. 1. Pressure Switch Mounting Positions. -23-

24 ALL SWITCHES 1 Remove the wires from their parking terminals on the bottom surface of the electrics box and route through the appropriate grommetted holes. 2 Connect to the pressure switch(es) as shown in the table below and the relevant wiring diagram. CONNECTIONS WIRE COLOUR CU CU CU CUE (From Parking Terminal) HP Switch LP Switch HP and LP Switch HP Switch BROWN C C (LP) C C GREY L Not Used (HP) L L VIOLET H PINK H L (HP) H Not Used WHITE Not Used H (LP) H -- VIOLET (Supplied in HP Kit) (LP) L to (HP) C -- 3 When wiring of the HP switch is complete, secure the mounting bracket to the electrics box using the No. 8 screw provided. CU (LP Switch) CU (HP Switch) CU (HP and LP Switches) CUE (HP Switch) 4 Remove and discard the knurled brass cap(s) on suction and discharge service ports and connect the pressure switch capillary(ies); it is recommended that a little refrigeration oil is used for lubrication. Use two open ended spanners on the hexagonal connectors and avoid twisting, kinking or overlapping the capillaries; bends must have a minimum 25mm (1") radius. 5 Ensure that the reset button on the HP switch is depressed prior to start up. -24-

25 ISOLATOR KIT This kit is for use on ALL 540 Series condensing units to give electrical isolation of all live or potentially live conductors within the unit. ITEM QTY DESCRIPTION 1 1 Isolator 2 2 Blue Wire 3 3 Black Wire 4 1 Cable Tie ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT. 1 Remove the access panel retaining screws and remove the panel to reveal the electrics box. 2 Remove the supply terminal block cover by releasing two screws on the front flange of the electrics box. 3 Remove the three 8mm diameter knockouts on the electrics support panel by knocking inwards (Fig. 1). 4 Remove the cable tie from the wires to the incoming mains terminal blocks. uppermost 1 Access panel 2 Knockouts 3 Odd terminals 4 ON position uppermost Fig SINGLE PHASE UNITS CU/CUE 10-60, (refer to Fig. 2). a b c d e Remove the black and blue wires from the top of the incoming mains terminal block and reconnect the black wire to isolator terminal 1 and the blue wire to isolator terminal N. Connect one of the blue wires in the kit between isolator terminal N and the top of the incoming mains terminal N. Connect one of the black wires in the kit between isolator terminal 2 and the top of the incoming mains terminal L. Discard the remaining kit wires. Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Phase Wiring Diagram CU/CUE Fig. 2. Single -25-

26 SINGLE PHASE UNITS CU/CUE 80-90, (refer to Fig. 3). a b c d e Remove the two black wires and the two blue wires from the top of the incoming mains terminal block and reconnect the black wires to isolator terminals 1 and 3 and the blue wires to isolator terminals 5 and N. Connect the two blue wires in the kit between isolator terminals N and 6 and the top of the two incoming mains terminals N. Connect two of the black wires in the kit between isolator terminals 2 and 4 and the top of the two incoming mains terminals L. Discard the remaining black wire in the kit. Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Single Phase Wiring Diagram CU/CUE Fig. 3. THREE PHASE UNITS ALL MODELS, (refer to Fig. 4). a b Remove the three black wires from the top of the incoming mains terminal blocks L1, L2 and L3 and reconnect to isolator terminals 1, 3 and 5 respectively. Remove the blue wire from the top of the incoming mains terminal N and reconnect to isolator terminal N. c d e f Connect the three black leads in the kit between isolator terminals 2, 4 and 6 and the top of the incoming mains terminals L1, L2 and L3 respectively. Connect one of the blue wires in the kit between isolator terminal N and the top of the incoming mains terminal N. Discard the remaining blue kit wire. Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Three Phase Wiring Diagram ALL MODELS Fig Secure the wires with the cable tie and replace the supply terminal cover and access panel. 7 It is essential that the unit is always isolated prior to commencing maintenance of any kind. 8 If it is desirable to lock the isolator in the 'OFF' position to deter unauthorised operation, fit a padlock through the holes provided. 9 IMI AIR CONDITIONING DO NOT RECOMMEND THAT THE ISOLATOR IS LOCKED IN THE 'ON' POSITION. -26-

27 ISOLATOR KIT This kit is for use on ALL 542 series Ducted Condensing Units to give electrical isolation of all live or potentially live conductors within the unit. ITEM QTY DESCRIPTION 1 1 Isolator 2 2 Blue Wire 3 3 Black Wire 4 1 Cable Tie 5 1 Cover 6 2 Screw ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT. 1 Remove the rear access panel (5 screws) and the side access panel (3 screws) at the valve end. 2 Remove the supply terminal block cover (1 screw) located on the vertical electric panel directly above the auxiliary terminals. 3 Remove the three 8mm diameter knockouts on the electrics support panel by knocking inwards (Fig. 1). 4 Remove the cable tie from the wires to the incoming mains terminal blocks. 1 = Isolator Cover 2 = ODD terminals uppermost 3 = Knockouts 4 = ON position uppermost Fig SINGLE PHASE UNITS DCUE 10-60, (refer to Fig. 2). a b c d e Remove the black and blue wires from the top of the incoming mains terminal block and reconnect the black wire to isolator terminal 1 and the blue wire to isolator terminal N. Connect one of the blue wires in the kit between isolator terminal N and the top of the incoming mains terminal N. Connect one of the black wires in the kit between isolator terminal 2 and the top of the incoming mains terminal L. Discard the remaining kit wires. Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Fig

28 5.2 SINGLE PHASE UNIT DCUE 80, (refer to Fig. 3). a b c d e Remove the two black wires and the two blue wires from the top of the incoming mains terminal block and reconnect the black wires to isolator terminals 1 and 3 and the blue wires to isolator terminals 5 and N. Connect the two blue wires in the kit between isolator terminals N and 6 and the top of the two incoming mains terminals N. Connect two of the black wires in the kit between isolator terminals 2 and 4 and the top of the two incoming mains terminals L. Discard the remaining black wire in the kit. Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Fig THREE PHASE UNITS ALL MODELS, (refer to Fig. 4). a Remove the three black wires from the top of the incoming mains terminal blocks L1, L2 and L3 and reconnect to isolator terminals 1, 3 and 5 respectively. b Remove the blue wire from the top of the incoming mains terminal N and reconnect to isolator terminal N. c Connect the three black leads in the kit between isolator terminals 2, 4 and 6 and the top of the incoming mains terminals L1, L2 and L3 respectively. d Connect one of the blue wires in the kit between isolator terminal N and the top of the incoming mains terminal N. e Discard the remaining blue kit wire. f Position the isolator as shown in Fig 1. ensuring that the odd numbered terminals and 'ON' position are uppermost, and that the handle is square, then secure to the unit. Fig Secure the wires with the cable tie and replace the supply terminal cover and access panels. Fit the cover in the kit over the rear of the isolator (2 screws). 7 It is essential that the unit is always isolated prior to commencing maintenance of any kind. 8 If it is desirable to lock the isolator in the 'OFF' position to deter unauthorised operation, fit a padlock through the holes provided. 9 IMI AIR CONDITIONING DO NOT RECOMMEND THAT THE ISOLATOR IS LOCKED IN THE 'ON' POSITION. -28-

29 3 MINUTE TIMER KIT This kit is for use on 540 Series Electromechanical Condensing Units to provide a nominal 3 minute time delay between the compressor switching OFF and back ON. This allows the system pressures to equalize and thus protects the compressor. The timer also features a random delay of between 6 and 20 seconds at initial start up of the compressor, to stagger switch on of multiple units. ITEM QTY DESCRIPTION 1 1 PCB 2 1 Pink Wire 3 1 Violet Wire 4 1 Blue Wire 5 3 Mounting Foot 6 1 Cable Tie ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT 1 Remove the front access panel retaining screws to reveal the electrics box. 2 The 3 minute timer is to be located on the rear face of the electrics box at the left hand side, (Fig. 1). 3 Press the mounting feet firmly into the holes in the rear face of the electrics box and press the 3 minute timer into position with the terminals to the right hand side. 4 Remove the two way link from the terminal blocks marked 1 and 2. 5 Connect the wires as described in the table and wiring diagram figure 2 below. WIRE COLOUR CONNECT FROM CONNECT TO Pink PCB Terminal L Terminal Block 1 Violet PCB Terminal N/O Terminal Block 2 Blue PCB Terminal N Fan Motor Capacitor Neutral Fig. 2. Fig

30 WALL MOUNTING KITS /420. Model Kit ITEM QTY DESCRIPTION CU/E Upper Bracket 2 2 Lower Bracket CU/E Fixing Pin 4 4 Safety Clip 5 4 M8 Bolt 6 4 M8 Flat Washer 7 4 M8 Spring Washer Ensure 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 as shown on the unit installation instructions. 1 Mark out the four mounting fixture positions and drill to suit M8 rawlbolt shields or fasteners of equivalent strength. ensions are in millimetres. All dim MODEL A B C D E F G H Weight (kg) CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE CU/CUE