IMI 542 SERIES Technical Manual Download

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TECHNICAL MANUAL

for 550 SERIES CONDENSING UNITS

and 542 SERIES DUCTED CONDENSING UNITS

from IMI AIR CONDITIONING LTD

This manual provides technical and installation information for

550 series condensing units and 542 series ducted

condensing units

INDEX

PAGE

GENERAL

Specification details

Features and options

Part numbers

Dimensions and weights

SELECTION

MCU / MCU+ performance data

DCUE performance data

INSTALLATION

MCU / MCU+ 550 series

DCUE 542 series

Application, pipe sizing

Pipe connections

Electrical connections

Evacuating and charging

WIRING

MCU

DIAGRAMS

MCU+

DCUE

KITS

PTC: 1 phase units

CSR: 1 phase MCU / MCU+ 550 series

CSR: 1 phase DCUE 542 series

Head pressure control - 550 series MCU only

Compressor jacket: MCU / MCU+ 550 series

HP pressure switches MCU / MCU+

Isolator: DCUE 542 series

3 minute timer: 550 series MCU only

Wall mounting MCU / MCU+ 550 series

Wall mounting: DCUE 542 series

Overload: MCU / MCU+ 1 phase 550 series

Overload: DCUE 1 phase 542 series

Volt free relay

Duct: DCUE 542 series

Plenum: DCUE 542 series

Grille: DCUE 542 series

COMPONENT

Exploded views of units with

IDENTIFICATION

component identification

IMI Air Conditioning Ltd.

Armytage Road, Brighouse,

West Yorkshire. HD6 1QF

Tel: (01484) 405600

Fax: (01484)

405620

A subsidiary company of IMI plc

55008275-0

Heronhill - for all your IMI requirements

Tel: 01823 665660

www.heronhill.co.uk

Fax: 01823 665807

Summary of Contents for 542 SERIES

Page 1: ...se units 17 CSR 1 phase MCU MCU 550 series 18 CSR 1 phase DCUE 542 series 19 Head pressure control 550 series MCU only 20 Compressor jacket MCU MCU 550 series 22 HP pressure switches MCU MCU 23 Isolator DCUE 542 series 25 3 minute timer 550 series MCU only 27 Wall mounting MCU MCU 550 series 28 Wall mounting DCUE 542 series 30 Overload MCU MCU 1 phase 550 series 31 Overload DCUE 1 phase 542 series...

Page 2: ... 15 20 30 40 50 60 80 90 100 130 150 165 180 200 Condenser fan 1Ph 230V 50Hz Airflow max speed m s 0 813 0 813 0 813 0 723 0 783 0 783 0 783 1 140 1 140 1 740 1 740 1 740 2 407 2 407 Fan motor rating kW 0 13 0 13 0 13 0 13 0 13 0 13 0 13 0 24 0 24 2 x 0 13 2 x 0 13 2 x 0 13 2 x 0 24 2 x 0 24 Nominal current FLA A 0 6 0 6 0 6 0 6 0 6 0 6 0 6 1 0 1 0 2 x 0 60 2 x 0 60 2 x 0 60 2 x 1 00 2 x 1 00 Fans...

Page 3: ...CU 150 MCU 165 MCU 180 MCU 200 R407C 55022055 55022056 55022057 55022058 55022059 55022060 55022061 55022062 55022063 55022064 R22 55022076 55022077 55022078 55022079 55022080 55022081 55022082 55022083 55022084 55022085 MCU 1Ph Rotary Obs MCU 15 MCU 20 MCU 30 MCU 40 MCU 1Ph Recip MCU 15 MCU 20 MCU 30 MCU 40 R407C R407C 55022002 55022003 55022004 55022005 R22 55099024 55099025 55099026 55099027 R2...

Page 4: ...65 565 565 565 565 565 WEIGHT kg 66 69 70 70 72 81 81 84 PACKED DIMENSIONS and WEIGHTS MCU MCU CONDENSING UNITS Model 15 20 30 40 50 60 80 90 100 130 150 165 180 200 HEIGHT mm 620 620 620 620 720 720 720 820 820 1080 1080 1080 1280 1280 WIDTH mm 980 980 980 980 1080 1080 1080 1090 1090 1090 1090 1090 1215 1215 DEPTH mm 340 340 340 340 340 340 340 390 390 465 465 465 465 465 1 Ph kg 47 41 48 42 50 ...

Page 5: ... 91 3 01 40 4 90 3 03 5 39 3 10 5 88 3 16 6 37 3 23 6 86 3 29 7 35 3 36 45 4 52 3 35 4 97 3 42 5 43 3 49 5 88 3 56 6 33 3 63 MCU 90 25 7 16 2 89 7 71 2 95 8 26 3 01 8 81 3 06 9 36 3 12 9 91 3 18 30 6 69 3 17 7 21 3 24 7 74 3 30 8 27 3 36 8 79 3 42 9 32 3 48 35 6 22 3 46 6 72 3 52 7 22 3 59 7 72 3 65 8 23 3 72 8 73 3 78 40 5 80 3 79 6 27 3 86 6 74 3 93 7 22 4 00 7 69 4 07 8 17 4 14 45 5 38 4 12 5 8...

Page 6: ...3 2 53 1 83 2 84 1 91 DCUE 40 25 3 81 1 80 4 23 1 91 4 46 2 01 4 75 2 07 5 09 2 17 5 47 2 26 30 3 56 1 87 3 97 1 97 4 27 2 04 4 57 2 13 4 79 2 23 5 16 2 32 35 3 27 1 91 3 63 2 00 3 93 2 09 4 32 2 17 4 59 2 27 4 83 2 37 40 3 17 1 96 3 41 2 05 3 31 2 13 4 03 2 22 4 28 2 34 45 2 98 2 02 3 20 2 09 DCUE 50 25 4 57 1 87 5 09 2 03 5 51 2 14 5 97 2 25 6 41 2 38 6 79 2 51 30 4 34 1 95 4 75 2 09 5 25 2 19 5...

Page 7: ...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 MCU 15 100 Dimensions in mm MODEL A B C D E F G H J K Weight kg 1 Ph 3 Ph MCU 15 900 300 560 525 185 60 333 308 290 260 45 39 MCU 20 900 300 560 525 185 60 333 308 290 260 46 40 MCU 30 900 300 560 525 18...

Page 8: ...5 101 MCU 150 1000 425 1020 495 251 100 458 433 415 385 103 MCU 165 1000 425 1020 495 251 100 458 433 415 385 103 MCU 180 1100 425 1215 675 211 95 458 433 415 385 118 MCU 200 1100 425 1215 675 211 95 458 433 415 385 173 o o O O O o o Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 9: ... 15 930 510 495 1004 490 65 65 210 317 717 354 69 DCUE 20 930 510 495 1004 490 65 65 210 317 717 354 70 DCUE 30 930 510 495 1004 490 65 65 210 317 717 354 70 DCUE 40 930 510 495 1004 490 65 65 210 317 717 354 72 DCUE 50 1100 510 560 1174 490 65 65 240 392 865 404 81 DCUE 60 1100 510 560 1174 490 65 65 240 392 865 404 81 DCUE 80 1100 510 560 1174 490 65 65 240 392 865 404 84 FLOOR MOUNTING Using th...

Page 10: ...ckets 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 Wall mounting brackets are available as an optional kit 53200407 DUCTWORK Each unit is supplied with air inlet and discharge spigots Models 10 to 40 354mm 14 dia Models 50 to 80 404mm 16 dia These may be used for connecting instal...

Page 11: ...NTROL MAXIMUM EQUIVALENT LENGTH OF SUCTION LINE PIPES m EXPANSION LINE PIPE SIZES MAXIMUM EQUVALENT LENGTH OF SUCTION LINE PIPES m LIQUID LINE PIPE SIZES HORIZONTAL OR DOWNFLOW UPFLOW UNIT 3 8 1 2 5 8 3 4 7 8 1 1 8 1 3 8 3 8 1 2 5 8 3 8 1 2 5 8 3 4 7 8 1 1 8 1 3 8 MAX 15m 1 4 3 8 1 2 5 8 MCU 15 7 5 50 50 8 21 3 8 21 MCU 20 50 50 8 21 3 8 21 MCU 30 12 40 80 50 80 8 45 1 2 21 45 MCU 40 8 25 80 7 5 8...

Page 12: ...er 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 It is imperative that the valve is not ...

Page 13: ... service ports on the outdoor unit valves and evacuate the interconnecting pipework and indoor unit to 1000 microns 1 Torr or better and allow to be held for a minimum of 15 minutes 2 If NO additional refrigerant charge is required Replace the caps on the service ports tighten to a torque of 25NM and open the valves using a 4 or 5mm Allen key On DCUE REMOVE link JP6 identified by a white label oth...

Page 14: ...VES FOR LEAK DETECTION 2 All pipe work and fittings for insulation 3 All bolts are secure and that the fan rotates freely MCU WIRING DIAGRAMS 1 Phase MCU 15 to 90 3 Phase MCU 30 to 100 3 Phase MCU 130 to 180 3 Phase MCU 200 Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 15: ... 15 MCU WIRING DIAGRAMS 1 Phase MCU 15 to 90 3 Phase MCU 30 to 100 3 Phase MCU 130 to 180 3 Phase MCU 200 Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 16: ... 16 ELECTRONIC DCUE WIRING DIAGRAMS 1 Phase DCUE 10 60 1 Phase DCUE 80 3 Phase DCUE 30 to 80 Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 17: ...Remove the three front access panel retaining screws to reveal the electrics box 2 The PTC device is fitted to the base of the electrics tray on the left hand side for MCU Fig 1 centrally on the back face for DCUE Fig 2 3 Remove the clip from the PTC bobbin and slide the clip into the larger hole in the base of the electrics tray MCU and the larger hole in the back panel to the left of the contact...

Page 18: ...LY PRIOR TO INSTALLATION OF THE KIT MCU MODELS 1 Release the three access panel retaining screws and remove the panel to reveal the electrics tray 2 Secure the capacitor clip to the base of the electrics box in the small hole to the left of the grommeted hole using a No 10 screw Ensure that the capacitor clip is positioned with the long end to the left hand side Press in the capacitor with the wir...

Page 19: ... kit easier 2 Ensuring that the capacitor clip is positioned with the long end to the left hand side 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 1 3 Identify whether the relay terminals are to be horizontal or vertical when Fig 1 mounted from the tables below and s...

Page 20: ...tly 2 Isolate the unit electrically prior to installation of the kit 3 Release the front access panel retaining screws and remove the panel to reveal the electrics box 4 Remove the blue and red wires from the plastic parking head terminal on the rear face of the electrics box Remove and discard the parking head 5 a If the rear of the electrics box has 4 fixing holes that line up with those in the ...

Page 21: ...d line Use a little refrigerant oil on the mating surfaces and tighten using two spanners If the liquid line connection has a pressure switch already fitted cut the cable ties holding the pressure switch wires to the compressor harness and remove the pressure switch discard the copper gasket Fit the pressure switch and head pressure control capillary to the TEE piece using the new copper gaskets F...

Page 22: ...Description 1 1 Compressor Jacket It is easier to fit this kit prior to installing the unit If the unit is already installed ensure that the electrical supply to the unit is fully isolated 1 Release the 3 front access panel retaining screws and remove the panel 2 The compressor jacket used on any of the units listed below needs shortening before fitting Dimension A should be cut from the bottom of...

Page 23: ...sing two open ended spanners on the hexagonal connectors typical torque 9Nm Ensure that the switch depressor connects properly this will be accompanied by a slight hiss of refrigerant 4 Ensure that there are no leaks around the connection using a suitable leak detector ELECTRICAL CONNECTIONS Route the pressure switch flying leads through a grommet hole in the base of the electrics box ensuring tha...

Page 24: ... wire and strip back 10mm of insulation 5 Connect the blue HP switch wire to terminal rail terminal 5 6 Secure all wires neatly using cable ties MCU 1Ø 3Ø 1 Locate the in line connector connecting the two violet wires Disconnect the two wires leaving the in line connector on the violet wire connected to the LP bypass off cycle timer terminal 95 2 Connect the red HP switch wire to the in line conne...

Page 25: ...one of the blue wires in the kit between isolator terminal N and the top of the incoming mains terminal N c Connect one of the black wires in the kit between isolator terminal 2 and the top of the incoming mains terminal L d Discard the remaining kit wires e 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 ...

Page 26: ...rd 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 3 6 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 alw...

Page 27: ...ith the PCBA terminals facing right press the mounting feet into the holes in the rear face of the electrics box 4 Cut the cable ties securing the harness and locate the violet and red wires black and violet on all units with a high pressure switch fitted Split these wires and connect as detailed in the tables below CONNECTIONS FOR UNITS WITHOUT HP SWITCH WIRE CONNECT FROM CONNECT TO Red PCBA Term...

Page 28: ... 25 7 2 Screw M5 x 12 3 2 Nut M8 8 2 Washer M5 4 4 Anchor bolt nut M10 5 4 Tee bolt nut washer M8 kg 15 20 30 40 50 60 80 90 100 130 150 165 180 200 MCU 39 40 41 45 64 65 66 76 81 101 103 103 118 173 ISOLATE THE SYSTEM ELECTRICALLY PRIOR TO INSTALLATION OF THIS KIT Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 29: ... 29 o o O O O o o Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 30: ...the ducted unit packing box as a template centres marked B mark the wall and drill to suit M10 Rawlbolts or fasteners of equivalent strength Secure the mounting feet assemblies to the wall installer supplied fasteners Weight kg DCUE 15 20 30 40 50 60 80 69 70 70 72 81 81 84 Rest the unit on the mounting feet ensuring that there is a washer between the unit and each mounting foot fit the M8 bolts s...

Page 31: ...cted between terminals 95 and 97 using the supplied black wire if necessary Discard other wires supplied in the kit Check correct compressor rotation on 3Ø units KIT FITTING 1 Remove the front access panel three screws to reveal the electrics box 2 Set the overload as close as possible to the nominal figures in the above table 3 Locate the contactor and transfer the wires from terminals 2 4 and 6 ...

Page 32: ...he additional violet link wire supplied in the kit ISOLATE THE UNIT ELECTRICALLY PRIOR TO INSTALLATION OF THE KIT 1 Release the three retaining screws in the front access panel and remove to reveal the electrics box 2 Locate the contactor and transfer the wires one at a time from terminals 2 4 and 6 to the corresponding terminals on the overload 3 Secure the overload to the contactor by inserting ...

Page 33: ...the left if necessary 5 Loosen the end clamp on the terminal rail and slide to create a gap With the yellow wires uppermost fit the four way terminal between the existing terminals and the end clamp Slide the end clamp to close the gap and tighten the screw Fig 1 VOLT FREE RELAY WIRING Fig 2 Note Terminals 11 14 close on active alarm terminals 21 22 open on active alarm 6 Yellow wires Connect from...

Page 34: ...ended ceilings should always be independently supported Always make any bend radius as large as possible and never less than 0 8 times the duct diameter Double bends should be avoided however if unavoidable ensure that each radius is not less than twice the duct diameter Hanging straps should have a minimum of half the circumference in contact Recommended minimum width for hanging straps is 25mm o...

Page 35: ...mounting the unit directly up to one or two plenums fitted through an adjacent wall i e without ductwork then refer to the dimensions below IMPORTANT Remember that the following are internal dimensions before lining the holes with wood IT WILL BE NECESSARY TO FIT AN INFILL PANEL BETWEEN THE TWO GRILLES HOLE REQUIRED DOUBLE PLENUM KIT HOLE REQUIRED SINGLE PLENUM KIT For the distance from the horizo...

Page 36: ...53200421 The grille is supplied with a flange which slots inside the plenum if fitted woodscrews should then be used to secure the plenum and the grille in place Model A B C D E F G H DCUE 10 40 226 595 520 335 620 400 85 265 DCUE 50 80 251 630 560 380 655 445 95 265 o o O O O o o Heronhill for all your IMI requirements Tel 01823 665660 www heronhill co uk Fax 01823 665807 ...

Page 37: ...cover 18 Handle 30 Earth terminal 7 Fan capacitor 19 Front access panel 31 Head pressure control pcb MCU 8 Bulkhead panel 20 Fan guard 32 3 minute timer pcb MCU 9 HP switch manual option 21 Fascia panel 33 Compressor capacitor 10 Expansion assy inc restrictor 22 Corner panel 34 Electrics box 11 Service valve liquid 23 Support bracket 12 Service valve suction 24 Fan motor assy Heronhill for all you...

Page 38: ...valve expansion 29 Support bracket 6 Contactor 18 Service valve suction 30 Fan motor assembly 7 Earth terminal 19 Valve panel 31 Head pressure control pcb 8 End clamp 20 Base 32 Power board MHPUE 9 Overload 21 Mounting foot 33 3 minute timer pcb 10 Heat exchanger 22 LP switch 34 Compressor capacitor 1Ph 11 Fan capacitor 23 Compressor 35 Electrics box 12 Mains terminal cover 24 Handle Heronhill for...

Page 39: ...lve 7 Switch HP auto 23 Isolator 8 Terminal 4 way 24 End clamp 9 Terminal fused 25 Terminal 10 Compressor 26 Reversing valve DHPUE 11 Crankcase heater 27 Solenoid 12 Cover sump housing 28 Power board 13 Condensate pump pcb 29 Overload 3ph 14 Condensate pump 30 Contactor 15 Filter 31 Fan capacitor 16 Condensate sump 32 Compressor capacitor 1ph Heronhill for all your IMI requirements Tel 01823 66566...

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