EMI WLCA Air Conditioner User Manual
Contents
1. CAHW 9 000 ONLY CAF 8 000 12 000 gl Z Q N 99 4 8 000 ONLY 1 A 2 1 24 L P 11 25 4 13 E m i q H i 5 m zd x d E amp Ci v N VA 1 y A usw SN eres TE Jj A OPTIONAL DISCHARGE KNOCKOUT 3 5 3 OFF deem B FRESH AIR INLET KNOCKOUT 3 2 C CONDENSATE DISCHARGE 1 2 OF wr zx pook CONTROL BOX D CONDENSATE SUMP INSPECTION as DL OF HOLE x L9 ig E AUXILIARY DRAIN TRAY INLET TO 39 MAIN TRAY 1 2 ES F CHILLED WATER COIL VENT 5 G CAH 09 12 OUTLET 1 2 CAH 09 12 INLET 1 2 6 J 1 2 LPHW INLET CHILLED WATER HANGING BRACKET K 1 2 LPHW OUTLET CHILED WATER CENTERS L 09 12 LIQUID 1 47 1 19 1 11 TT x 2o zi lt x o lt d amp i LN ENVIROMASTER INTERNATIONAL LLC 8 EMI ENVIROMASTER COM EMI CASSETTE DIMENSIONS MEDIUM CABINET CAH 15 000 24 000 CAHW 12 000 24 000 N CAF 18 000 20 000 CAF4 12 000 20 000 Fresh Air Ducts 45 LARGE CABINET N CAH W 30 0002. Bu foiea Series Comfort Where It Counts 2 AA ZA gt 722 CAA 222 gt c vA V X 4 D NOMINAL CAPACITIES CAH CAHW 9 000 48 000 Btuh CAF CAF4 8 000 36 000 Btuh GENERAL STATEMENT IMPORTANT The information contained in this manual is critical to the correct operation and main tenance of the EMI cassette and should be read by all persons responsible for the installation start up and maintenance of the unit SAFETY The equipment has been designed and manufac tured to meet international safety standards but like any mechanical electrical equipment care must be taken if you are to obtain the best results 1 Service and maintenance of this equipment should only be carried out by skilled personnel 2 When working with any air conditioning unit ensure that the electrical disconnect supplying the unit is switched off prior to servicing or repair work and that there is no power to any part of the equipment In the case of a DX system both the indoor and outdoor units should be switched off 3 Also ensure that there are no other power feeds to the unit such as fire alarm circuits BMS circuits etc 4 Electrical installation start up and maintenance work on this equipment should be undertaken by competent and trained personnel in accordance with local relevant standards and codes of practice ENVIROMASTER INTERNATIONAL LLC EMI D
3. 48 000 x CAF 4 33 000 36 000 j i K iea Ducts Fresh Air On Both Ends CASSETTE DIMENSIONS INCHES EG E EE E ee 33 N MEDIUM 33 ENVIROMASTER INTERNATIONAL LLC EMI ENVIROMASTER COM MICROPROCESSOR CONTROLLER The following pages contain a brief overview ofthe optional cassette microprocessor control system and its components The Infra Red Remote Control manual is available from the unit manufacturer and provides a more comprehensive ex planation of the operation and application of the Cassette microprocessor control system The microprocessor controller has built in software to limit the number of starts per hour This operates by having a minimum period of ten minutes between consecutive starts A four minute delay period between the compressor stop ping and starting is also included to allow refrigerant pres sures to equalize between high and low sides during the compressor off period IMPORTANT Before applying main power to the unit please ensure jumper link JMP2 is in the correct position JMP2 should be open for DX Non Heat Pump or Chilled Water systems and closed for Heat Pump systems A jumper link settings guide can be found on the Cassette unit s wiring schematic 230V AC TERMI 10A FUSE COMPRESSOR TERMINAL COMPRESSOR CONDENSATE VANE MOTOR OUTPUT DOOR EAN 230V AC TRANSFORMER REVERSING VAL
4. 32 1 4 32 1 4 44 1 2 44 1 2 22 1 2 32 1 4 32 1 4 32 1 4 32 1 4 40 LBS 64LBS 64LBS 97 LBS 97 LBS 3 3 49 1 4 49 1 4 37 37 21LBS 21LBS CONNECTIONS 5 8 3 4 3 8 3 8 CONDENSATE j 1 2 1 2 BRANCH DUCT DIAMETER 5 FRESH AIR DUCT DIAMETER 3 HOT WATER INLET 1 2 HOT WATER OUTLET 1 2 HLTRATION 09 12 15 18 24 30 36 42 48 C AMET EE CONDENSATE PUMP 09 12 18 24 30 36 42 48 MAXIMUM HEAD 18 18 18 ig NOMINAL FLOW RATE GPM 0 1 0 1 0 1 0 1 0 1 3 4 SUCTION AT EMI CONDENSER 7 8 SUCTION AT EMICONDENSER CAF 4 TECHNICAL DATA CABINET DIMENSIONS 10 34 9 1 2 9 1 2 9 2 11 1 2 11 1 2 22 1 2 32 14 32 1 4 32 1 4 44 1 2 44 1 2 22 12 32 14 32 1 4 32 14 32 14 32 1 4 40LBS 64LBS 64LBS 64LBS 97LBS 97 LBS FASCIA DIMENSIONS 3 49 1 4 37 21 LBS CONNECTIONS CHILLED WATER INLET CHILLED WATER OUTLET CONDENSATE BRANCH DUCT DIAMETER FRESH AIR DUCT DIAMETER HOT WATER INLET HOT WATER OUTLET FILTRATION 12 18 QUANTITY 1 2 2 2 3 3 scene CONDENSATE PUMP 08 12 18 20 33 36 MAXIMUM HEAD 18 18 18 18 18 18 NOMINAL FLOM RATE GPM UNITS FITTED WITH OPTIONAL HOT WATER COIL ONLY ENVIROMASTER INTERNATIONAL LLC 7 EMI ENVIROMASTER COM EMI CASSETTE DIMENSIONS SMALL CABINET 9 000 12 000
5. 800 232 9364 MODEL SERIAL NO PROJECT HTTP WWW EN VIROM A STER COM 1 0 PRE START UP CHECKLIST 1 1 UNIT CONDITION SATISFACTORY COMMENT 1 2 PRESSURE TEST WITH DRY NITROGEN INITIAL TEST FINAL TEST TEST DURATION PRESSURE PRESSURE 1 3 DESIGN WATER FLOW AVAILABLE IF GPM CHILLED WATER UNIT 1 4 VOLTAGE AT OUTDOOR UNIT V 1 5 VOLTAGE AT INDOOR UNIT V 1 6 ELECTRICAL CONNECTIONS TIGHT YES NO 1 7 JUMPERS SET CORRECTLY MICRO ONLY YES NO 2 0 START UP CHECKLIST INDOOR UNIT 2 1 DISABLE COMPRESSOR SIGNAL 2 2 ON OFF WORKS YES NO 2 3 INDOOR UNIT THREE FANS SPEEDS YES NO AVAILABLE MICRO ONLY 2 4 VANE SWEEP FUNCTIONS YES NO 2 5 TIMER FUNCTIONS OPERATE MICRO ONLY YES NO 2 6 CONDENSATE PUMP OPERATES YES NO 3 0 START UP CHECKLIST OUTDOOR UNIT REFER TO THE RELEVANT OUTDOOR UNIT MANUAL AND IN ADDITION NOTE THE FOLLOWING 3 1 OPERATING PRESSURES 3 2 SUCTION PSIG 3 3 DISCHARGE PSIG 3 4 AMBIENT TEMPERATURE 9 35 INDOOR AIR TEMPERATURE 9 NOTE A START UP SHEET FOR EVERY UNIT MUST BE RETURNED TO EMI TO VALIDATE THE WARRANTY ENVIROMASTER INTERNATIONAL LLC 6 EMI ENVIROMASTER COM EMI CASSETTE MECHANICAL DATA NOTE Due to EMI s ongoing product development program all designs and specifications are subject to change without notice CAH W TECHNICAL DATA REFRIGERATION 09 12 18 24 30 36 42 48 NUMBER OF CIRCUITS EPS CABINET DIMENSIONS 09 12 18 24 30 36 42 48 10 3 4 9 1 2 11 1 2 11 1 2 22 1 2
6. Low Medium High Highlights Mode of Operation and Auto CLK TIMER Selects and adjusts the clock or weekly pro gram Stop Start times FAN MODE INDICATOR Highlights Fan Speed TEMP Adjusts temperature setpoint in intervals of 1 F CLOCK TIMER DISPLAY beftween 58 90 F Shows current day time or weekly program Stop Start times SLEEP Selects Deselects sleep mode Using the On Send button the temperature setpoint will set back 2 F after 1 hour 4 F after 2 hours SETPOINT DISPLAY Indicated temperature setpoint SWING INDICATOR Indicates operation of the motorized air vanes where fitted SWING Causes the motorized air vanes to oscillate when selected not applicable to all models SLEEP INDICATOR OFF Wide when Switches the unit off in certain instances the Sleep mode is selected fan may be subject to a 2 minute run on time to dissipate residual heat ENVIROMASTER INTERNATIONAL LLC 11 EMI ENVIROMASTER COM SETTING UP THE BUILT IN TIME CLOCK HOW TO SET THE PRESENT TIME 1 Press CLK Timer Clock Set highlights NOTE Display will stop flashing after 15 seconds 2 Select Hour with either or figure will flash 3 Press or to change hour 4 Press CLK Timer to confirm and advance 5 Repeat steps 3 and 4 for minutes and day of week 6 Press CLK Timer to confirm 2 53 Clock Sel CLK TIMER HOW TO SET COOL HEAT OR AUTO MODE 1 Press Mode bu
7. Red Timer Alarm flashes once every 5 seconds return air sensor failure Refer to the Troubleshooting section of this manual for further instruction on dealing with alarms EMI ENVIROMASTER COM THE INFRARED TRANSMITTER STANDARD HAND HELD TRANSMITTER Small light and practically de signed the hand held transmitter takes 2 AAA batteries that can be easily fitted by removing the sliding lid on the underside of the transmitter Please pay attention to the polarity and correct orientation of the batteries during fitting When using the infrared handheld transmitter always point the transmitter head directly at the receiver Use the On Send button to transmit settings to the microprocessor At the time of transmission the zi symbol will display and an audible buzzer will sound if the signal has been correctly received After changing any of the settings in the transmitter s LCD display the new settings must be transmitted to the unit using the On Send button before the changes will take effect ON SEND DISPLAY INDICATORS Press this button to switch the unit on and transmit SELECTOR BUTTONS the system settings The unit will confirm receipt of the adjustment by producing a short audible tone MODE OF OPERATION Selects the mode options Heat Cool Auto Heat Cool Dry Coooling and Fan Only TRANSMIT INDICATOR Flashes when system settings are transmitted MODE INDICATOR FAN aa Selects fan speed options
8. prevent any air locks DUCT COLLARS Branch duct and fresh air duct collars can be attached to the Cassette chassis by following the steps below 1 Refer to the relevant illustration for your Cassette pages 6 7 in this IOM to become familiarized with knock out hole locations 2 The insulation is pre cut to aid location and removal of the relevant section Rub hand across surface of insulation to reveal exact location of knock out 3 Remove the metal knockout from the chassis 4 Attach the duct collar to the chassis using self tapping screws NOTE Branch ducts are round and 5 6 in diameter Fresh Air ducts are square and 3 in diameter INSULATION Refrigerant chilled water and condensate pipes should be insulated right up to the Cassette chassis Chilled water valves must also be insulated to prevent sweat ing ASSEMBLY Once the services have been connected the four fascia mounting bolts can be unscrewed approximately 1 from the condensate tray support channels The fascia can now be unpacked ready for fitting to the Cas sette chassis Ensure the black fir tree fasteners holding the fascia polystyrene are pushed in firmly in case of transit vibration If a fascia aperture needs blanking off then take one of the polystyrene blanking pieces and push it into the recess in the polystyrene fascia insulation Fit by removing the inlet grilles and filters locating the four fascia mounting bolts on the chassis
9. D CONTROL INTERCONNECT DIAGRAM HEATPUMP COOLING W ELECTRIC HEAT 0 0 SECTION E 1 1 YEL Mi eq meon L m 1 9 T Kua 0 1 IT IS EXTREMELY IMPORTANT THAT THE WIRE S gt ee sny is ARE CONNECTED PROPERLY OTHERWISE ARCING rr rr MAY RESULT IN ELECTRICAL DAMAGE OR FIRE uH d cm Mom Hed NEC AND LOCAL CODES NEC AND LOCAL CODES STRAIGHT COOL W ELECTRIC HEAT 0 0 SECTION AIR HANDLER ra a po TO rr NE Jl ENVIROMASTER INTERNATIONAL LLC 18 EMI ENVIROMASTER COM APPENDIX B EXPLODED UNIT DRAWING AND PARTS LIST SMALL CABINET 9 000 12 000 CAHW 9 000 ONLY CAF 8 000 12 000 CAF4 8 000 ONLY Cassette Chassis Evaporator Assembly Electric Heater Element Assembly Condensate Tray Condensate Tray Supports 2 Condensate Pump High Level Switch Condensate Pump Assembly Fan Motor Assembly 10 Coil Return Air Sensors 11 Grille 12 Label 13 Air Deflector Vanes 4 14 Freeze Protection Thermostat DX Electro Mechanical Version only 15 Filter 16 Fascia Assembly 17 Receiver Microprocessor Version 18 Terminal Rail Relays amp Timer Micro amp Electro Mechanical Version 19 Control Box Lid 20 Control Box 21 PCB Controller Microprocessor Only 22 Coil Support Brackets 23 Remote Handset Microprocessor Only OANDOARWN ENVIROMASTER INTERNATIONA
10. EL Red alarm LED on Micro Unit will flash at one second intervals POSSIBLE CAUSES REMEDIES MAXIMUM PUMP LIFT EXCEEDED Check that the con densate pump head is no greater than 18 See installation section of this manual for more information BLOCKED KINKED CONDENSATE PIPE See section Wa ter Leaking From Unit EMI ENVIROMASTER COM TROUBLESHOOTING SECTION CONDENSATE PUMP BLOCKED OR FAILED See sec tion Water Leaking From Unit COIL FREEZE UP A coil freeze condition may have caused excessive condensate to collect in the drip tray See sec tion Freeze Protection COIL FREEZE POSSIBLE CAUSES REMEDIES COOLING COIL FREEZE PROTECTION THERMOSTAT TRIPPED AUTO RESET WHEN FREEZE CLEARED Freeze statis normally closed opens during freeze Where fitted the stat will disable cooling action sometimes the entire system during coil freeze conditions Use the unit s wiring schematic to investigate CONDENSING UNIT RUNNING WITH CASSETTE UNIT SWITCHED OFF DX SYSTEMS ONLY System installed such that it is possible for condensing unit to run with Cas sette unit switched off Check system wiring and discon nect switches DIRTY OR BLOCKED AIR FILTER Clean replace filters as necessary See maintenance instructions for more informa tion SYSTEM HEAD PRESSURE SET TOO LOW Check con densing pressure installation of low ambient kit may be re quired LOSS OF REFRIGERANT Check system for refrigera
11. L LLC 19 EMI ENVIROMASTER COM APPENDIX C EXPLODED UNIT DRAWING AND PARTS LIST MEDIUM CABINET 15 000 24 000 CAHW 12 000 24 000 CAF 18 000 20 000 CAF4 12 000 20 000 LARGE CABINET CAH W 30 000 48 000 CAF 4 33 000 36 000 Cassette Chassis Evaporator Coil Condensate Tray Condensate Tray Support Condensate Pump High Level Switch Fan amp Motor Assembly Fan Inlet Ring Grille 10 Infrared Receiver 11 Vane 12 Vane Motor Assembly 13 Filter 14 Fascia 15 Remote Handset 16 Control Box Lid 17 Control Box PCB 18 Control Box 19 Coil Bracket 20 Expansion Valve O NTERTE w Comfort Where It Counts m Enviromaster International LLC 5780 Success Drive Rome NY 13440 C US Phone 1 800 228 9364 FAX 1 800 232 9364 Email emi enviromaster com Web http www enviromaster com LISTED ENVIROMASTER INTERNATIONAL LLC 20 EMI ENVIROMASTER COM
12. ON NOTE f the ceiling is not level or even it is important that the Cassette is installed level to ensure correct pump operation and to maintain fan clearances Any slight discrepancy between the Cassette and ceiling will be taken up by the fascia foam seal Secure unit in position with locknuts and washers on either side of the Cassette bracket Ensure threaded rod does not protrude more than 2 dimension C below the mounting bracket The unit can now be piped up in accordance with good refrig eration and or plumbing practices CONDENSATE PIPEWORK The Cassette is supplied with a 1 2 diameter flexible PVC hose for connection to copper or plastic drain pipework When installing the Cassette the following points should be remembered 1 Maximum pump lift is 18 2 The highest point in the condensate pipework should be as close to the unit as possible This prevents a large volume of water draining back into the unit when it is switched off AL EMI ENVIROMASTER COM 3 Condensate pipework should slope downwards in the direction of water flow with a minimum gradient of 1 per 10 There must not be any uphill gradients other than in the first 18 of pipework from the Cassette 4 When multiple Cassettes are connected to a common condensate drain ensure the drain is large enough to cope with the volume of condensate from several Cassettes It is also recommended to have an air ventin the condensate pipework to
13. OW TO SET THE WEEKLY PROGRAM Saturday 1 Press CLK Timer three times Program and SA highlight CLK TIMER Program NOTE Display will stop flashing after 15 seconds 2 Repeat as per Monday Friday above HOW TO SET THE WEEKLY PROGRAM Sunday 1 Press CLK Timer four times Program and SU highlight NOTE display will stop flashing after 15 seconds 2 Repeat as per Monday Friday above IMPORTANT The built intime clock provides ON OFF functionality The time clock does not pro vide occupied unoccupied time control Refer to the separate Infrared Controller manual for fur ther details EMI ENVIROMASTER COM UNIT START UP INDOOR UNIT CONTROL CIRCUIT CHECKS DX Units NOTE Apply power to the Condensing Unit s crankcase heater for 24 hours before start up to boil off any liquid that may be present in the compressor After 24 hours the compressor should be isolated by removing the connection at the Y terminal on the outdoor unit Main power can now be applied to the indoor and outdoor units A system electrical check can now be carried out Switch on the indoor Cassette unit and check that the fan cycles correctly NOTE n some models there is a two minute fan run on time to remove residual heat from the Cas sette if the unit is switched off during the heating mode On models with microprocessor controls check that the High Medium and Low fan speeds are op erating
14. POWER SUPPLY ELECTRIC HEAT CAPACITY HEATER AMPS 230V 1PH 60HZ 0 6 0 75 15 230V 1PH 60HZ 3 0 13 1 230V 1PH 60HZ 0 9 1 13 15 230V 1PH 60HZ 5 0 21 7 FULL LOAD AMPS MIN CIRCUIT AMPACITY MCA REC FUSE WITH HEAT WITH OPTIONAL BOOST TRANSFORMER POWER SUPPLY FULL LOAD AMPS MIN CIRCUIT AMPACITY MCA REC FUSE 18 7 115V 1PH 60HZ 1 8 2 26 15 1 STANDARD UNIT FITTED WITH OPTIONAL ELECTRIC HEATING ELEM ENTS AVAILABLE WITH 230V MODEL UNITS ONLY 2 STANDARD UNIT FITTED WITH OPTIONAL BOOST TRANSFORM ER FOR CONNECTION TO 115V ELECTRICAL SUPPLY ELECTRIC HEAT IS NOT AVAILABLE WITH THIS OPTION REFRIGERATION SYSTEM DX UNITS PIPE INSTALLATION NOTES 1 When cooling only or heat pump units are being installed it is usually only necessary to insulate the suction line However if the liquid line is subject to high temperature or exposed to direct sunlight this should also be insulated 2 Maximum equivalent pipe run should be no more than 100 with a maximum rise of 35 3 Horizontal pipe runs should be slightly inclined so as to encourage oil to flow in the direction of the compressor for better oil return 4 Good refrigeration practices must be employed to ensure the correct pressure drop and good oil return PRESSURE TESTING When installation is complete fill the Cassette and interconnecting pipework with dry nitrogen to apressure of 150 PSIG Record the pressure over a pe
15. ROPROCESSOR Optional A custom designed mi croprocessor is fitted to the cassette to enable room condi tions to be maintained at a user defined setpoint Communi cation to the controller is by a hand held infrared transmitter which includes a wall mounting bracket as standard The microprocessor allows five operating modes These modes are fan only dry cooling cooling only heating only and heating cooling auto changeover for maximum versatil ity Atemperature setpoint between 58 F 90 F can also be selected The microprocessor monitors indoor coil temperature and return air temperature In heat pump units a 24VAC signal from the condensing unit is also monitored to signal the in door unit that defrost of the outdoor coil is taking place This allows the same micro to control both heat pump and cool ing only units The receiver contains a self diagnostic fea ture When a low indoor coil temperature is detected the cooling action is stopped If a sensor fails then an alarm is EMI ENVIROMASTER COM displayed on the fascia mounted receiver The microproces sor also limits the number of compressor starts per hour to reduce wear on the compressor The infrared transmitter is used to switch the unit on off change temperature settings fan speed operating mode and to toggle the motorized air sweep where fitted The micro processor also has a built in clock which can be activated to enable the unit to be programmed with up t
16. UCTLESS SPLIT SYSTEM CASSETTE EVAPORATOR INSTALLATION MANUAL OPERATING INSTRUCTIONS P N 240 4235 Rev 1 6 1 05 SPARE PARTS For ease of identification when ordering spare parts or contacting Enviromaster International LLC about your unit please quote the model number and serial number This information can be found on the rating plate attached to your unit PRODUCT DESCRIPTION The EMI Cassette series is available in nominal capacities of 9 000 to 48 000 Btuh in DX refrigeration and reverse cycle heat pump CAH or DX with hot water coil CAHW ver sions also available are two pipe chilled water CAF and four pipe chilled and hot water versions in 8 000 to 36 000 Btuh capacities and depending on the model elec tric heat can also be factory fitted as an option Designed for low noise levels easy installation and maintenance and a slimline fascia all ensure minimum obtrusion into the work ing environment CONTROLS AND COMPONENTS LOW VOLT TRANSFORMER Standard 24 Volt ELECTRO MECHANICAL Standard Thermostat options are cooling only cooling and one stage auxiliary heat cool ing and one stage mechanical heating heat pump system or cooling and two stage heating heat pump amp second stage auxiliary heat An optional thermostat can be obtained through EMI or your local distributor NOTE Make sure the thermostat is suitable for unit opera tion i e cooling only cooling electric heat etc MIC
17. VE IR RE SENSOR T1 2 ROOM SENSOR T2 DEFROST INPUT INFRARED RECEIVER amp FASCIA DISPLAY PANEL The infrared receiver is an extension of the control board and is located on the fascia of the unit connected by a 7 pin plug and socket INFRA RED RECEIVER WINDOW UNIT ON OFF INDICATION ON OFF BUTTON The green On Off indicator will remain lit when the unit is running or will flash if heating or cooling is required but the compressor anti cycle timer is delaying compressor opera tion Yellow indicators will illuminate to show when the unit is in cool or heat mode These indicators will flash when the battery on the main circuit board requires changing ENVIROMASTER INTERNATIONAL LLC The red indicator will be lit when the in built time clock func tion is activated To disable the time clock all start stop times must be set to 12am via the transmitter see program ming instructions in this installation manual The red indi cator is also used to diagnose operational alarms SELF DIAGNOSTICS The microprocessor controller has a built in diagnostics feature so that in the event of an alarm the nature of the fault can be determined The red timer alarm LED flashes on the fascia in a pre determined fre quency depending on the fault These are identified below 1 Red Timer Alarm flashes once every second in door coil sensor failure low coil temperature or condensate high level trip
18. correctly by changing the fan speed via the transmitter On models 15 48 check that the motorized vane sweep functions correctly by toggling the function on or off either via the transmitter micro units or via the toggle switch on the back of the electrical panel lid electro mechanical units On micro controlled units if required check that the built in timer function is programmed and oper ating correctly When the timer is activated the red LED on the fascia display panel should be lit Check the operation of the condensate pump by pouring 7 8 ounces of water down the pump outlet switch the unit on select cooling mode and the lowest possible temperature setpoint then observe the water being pumped from the Cassette Where fitted check the operation of the hot water valve or the electric heat elements by switching the system to the heating mode and selecting the highest possible temperature setpoint Ensure that the Condensing Unit start up proce dure has been carried out as detailed in the corre sponding installation manual The compressor signal Y disconnected from the outdoor unit in step 1 can now be reconnected and main power applied to the system ENVIROMASTER INTERNATIONAL LLC 13 IMPORTANT As of 12 01 04 EMIair handlers will be manu factured with a low Volt transformer installed At the same time EMI outdoor condensers will be manufactures with outa low Volt transformer When connectin
19. d be lit Check the operation of the condensate pump by pouring 7 8 ounces of water down the pump outlet switch the unit on select cooling mode and the lowest possible temperature setpoint then observe the water being pumped from the Cassette 7 Allow chilled water to enter the Cassette and vent air from the unit by opening the 1 4 air bleed Re tighten the bleed screw once all air has been re moved Repeat steps 1 4 above for all Cassettes in the same systems The Cassettes are now ready for the system balance to be performed EMI ENVIROMASTER COM TROUBLESHOOTING SECTION RED ALARM LED FLASHING AT 1 SECOND INTERVALS Microprocessor units only POSSIBLE CAUSES REMEDIES FAULTY FLOAT SWITCH See section Condensate High Level FAN TRIP See section Fans Will Not Run INDOOR COIL SENSOR FAILURE CONNECTED TO MI CRO TERMINAL T3 After checking the above use the unit wiring schematic to isolate the indoor coil sensor and measure the resistance Sensor is 50K 72 F type Check and replace if necessary RED ALARM LED FLASHING AT 5 SECOND INTERVALS Microprocessor units only POSSIBLE CAUSES REMEDIES RETURN AIR SENSOR FAILURE CONNECTED TO MICRO TERMINAL T1 Use the unit wiring schematic to isolate the return air sensor and measure the resistance Sensor is 50K 72 F type Check and replace if necessary UNIT WILL NOT OPERATE POSSIBLE CAUSES REMEDIES NO POWER MAIN POWER Ch
20. e tray For small units only remove the fascia by loosening the four fascia mounting bolts and then slide the fascia horizontally until it releases from the chas sis Drain the condensate tray by removing the small black rubber drain plug catching the con densate if any in a suitable container Remove the self tapping screws securing the two insulated metal condensate tray support channels and pull the channels away from the condensate tray Pull the condensate tray downwards away from the chas sis ENVIROMASTER INTERNATIONAL LLC o vent it from falling The fan can now be dropped down from the unit CONDENSATE TRAY REMOVAL Unclip the grille catches and remove the grille s from the fascia Remove the fascia by loosening the fascia mount ing bolts and sliding the fascia horizontally until it releases from the chassis If unit is micropro cessor controlled remove display panel cable from within the electrical panel before remov ing the fascia Remove electrical panel lid by unscrewing the single self tapper and pull the lid horizontally away from the control box On medium and large sized units disconnect the main wiring from the incoming terminal block and disconnect the fan wires from their connection points within the electrical panel Separate any two part connectors coming from the electrical panel Drain the condensate tray by removing the small black rubber drain plug catching an
21. eat pumps be fitted with the electric heat option to offset the defrost cycle Electric heaters are fitted with over heat cut out switches FRESH AIR CONNECTION Fresh air may be introduced to the unit by the addition of ducts connected to the fresh air knockouts on the Cassette case It is usually advised that the fresh air volume is approximately 10 of the unit s pub lished maximum air flow SITE INSTALLATION UNPACKING The cassette fascia and main chassis are supplied together for increased protection Remove the band ing straps and lift the cardboard lid Remove the bubble wrap and polystyrene packing pieces to expose the unit The fas cia should be unpacked first by unclipping the inlet grille and ENVIROMASTER INTERNATIONAL LLC loosening the four M5 screws retaining the fascia in place The fascia can now be slid sideways and pulled away from the chassis When removing the Cassette chassis from the box the four corner brackets should be utilized for lifting In order to protect the fascia from dirt and damage it should be returned to the box until it is ready to be installed BLANKING OFF When branch ducting is to be used two polystyrene pieces for blanking off fascia open ings are Included with the fascia packing Up to two opposing sides may be blanked off POSITIONING CASSETTE The Casseite installation position should be selected with the following points in mind 1 Pipe work electrical connections and conde
22. eat condition Possible low airflow check filter condition See maintenance instructions for more information Possible fan failure Check fans See section Fans Will Not Run Remove power from unit and reset manual overheat cut out by rubbing DO NOT PRESS Consult EMI technical support for instruction if necessary HEATER ELEMENT FAILED Investigate and replace if necessary FAULTY HEATER RELAY Check signals to relay and check action of relay contacts Replace relay or PCB if nec essary NO HEATING Hot Water POSSIBLE CAUSES REMEDIES INCORRECT MODE SETTING MICRO UNITS ONLY Check that the transmitter MODE is set to Heat or Auto Mode SET POINT TOO LOW Check the set point on the trans mitter or wall mounted thermostat and adjust if necessary BLOCKED OR DIRTY FILTERS CAUSING LOW AIRFLOW Check filter condition See maintenance instructions for more information NO HOT WATER PUMPS FAILED Check hot water source and supply to unit FAULTY VALVE ACTUATOR Check actuator by manu ally opening and closing valve replace if faulty FAULTY HEATER RELAY Check signals to relay and check action of relay contacts Replace relay or PCB if nec essary ENVIROMASTER INTERNATIONAL LLC POSSIBLE CAUSES REMEDIES LOOSE WIRE Check all fan wire connections Use unit s electrical schematic to verify that fan is wired correctly FAULTY FAN CAPACITOR Check fan capacitors replace if necessa
23. eck power supply to the unit For micro units check power to the micro and check the on board micro fuse NO 24V CONTROL CIRCUIT POWER For DX and chilled water systems first check that the condensing unit is switched on then check the 24V feed from the control trans former If not present check transformer windings replace if necessary CONTROL CIRCUIT DISABLED BY UNIT PROTECTION DEVICE In some models particularly electro mechanical units some protection devices such as freeze stats fan trips etc are wired in line with the 24V control circuit feed to cause the unit to shut down in an alarm condition Use the unit s wiring schematic to identify these devices and investi gate accordingly INFRARED RECEIVER FAILURE MICRO UNITS ONLY If audible bleep is heard on signal transmission from transmit ter and the green LED is lit or flashing receiver is OK If there are no LEDs lit and the unit will not respond to the transmitter press the On Off button on the fascia display panel If the unit responds to the On Off button receiver is OK Check transmitter ENVIROMASTER INTERNATIONAL LLC TRANSMITTER FAILURE MICRO UNITS ONLY Try new batteries first if receiver bleeps on transmitting signal trans mitter is OK If no response press On Off button on unit fascia If the unit responds to the On Off button transmitter is faulty MICROPROCESSOR FAILURE MICRO UNITS ONLY The microprocessor is the least likely component
24. g an EMI evapo rator to a non EMI condenser check to ensure that there is a 24V control transformer in either in the indoor unit or outdoor unit Only one transformer is required If a transformer is not present then one should be added to the indoor unit If both the indoor unit and outdoor unit contain a transformer one must be remover from the system CONTROL CIRCUIT CHECKS Chilled Water Units A thorough pipe work check and pressure test should be performed before the Cassette controls are set up 1 Isolate the Cassette from the chilled water supply A system electrical check can now be carried out 2 Switch on the indoor Cassette unit and check that the fan cycles correctly NOTE n some models there is a two minute fan run on time to remove residual heat from the Cassette if the unit is switched off during the heating mode 3 On models with microprocessor controls check that the High Medium and Low fan speeds are op erating correctly by changing the fan speed via the transmitter On models 15 48 check that the motorized vane sweep functions correctly by toggling the function on or off either via the transmitter micro units or via the toggle switch on the back of the electrical panel lid electro mechanical units On micro controlled units if required check that the built in timer function is programmed and oper ating correctly When the timer is activated the red LED on the fascia display panel shoul
25. nd drafts from windows and doors 4 Avoid positioning near shelves and curtains as these restrict air movement 5 Avoid heat sources direct sunlight heaters dimmer switches etc CEILING OPENING Before beginning the installation in spect the unit location test the strength of the unit mountings see Mechanical Information in this An opening in the false ceiling will then have to be cut to the following sizes Small Cabinet 23 1 4 x 23 1 4 Medium Cabinet 33 7 8 x 33 7 8 Large Cabinet 46 x 33 7 8 A template for ceiling cut out and rod positions can be found with the Cassette unit NOTE Make sure the ceiling grid is supported separately from the Cassette The ceiling must not be supported by any part of the Cassette unit fascia or any associated wir ing or pipe work The hanger bolts can now be installed use 3 8 all thread rod at the centers shown below CABINET SMALL MEDIUM LARGE Prepare the installation guides by folding the metal bracket by hand along the row of holes wt FOLDED GUIDE 33572349 The Cassette can now be lifted onto the hanging rods and leveled atthe correct distance from the ceiling with the aid of the installation guides as shown ENVIROMASTER INTERNATIONAL LLC OUTER CASE sa INSULATIO LA SA CASSETTE CASE ER INNER CASE INSULATION ET woo RA pm FALSE CEILING GUIDE IN POSITI
26. nsate pump access panel should be readily accessible 2 When installing a unit with an externally mounted electrical control panel ensure that sufficient access to the panel is provided for maintenance purposes Access to the condensate pump access panel should be provided on all model sizes 3 The unit should not be positioned less than 5 ft from a wall or similar obstruction or in a position where the discharge air could blow directly on the thermostat 4 The unit should not be positioned directly above any obstructions 5 The condensate drain should have sufficient fall 1 per 10 in any horizontal run between Cassette and drain Maximum condensate pump lift is 18 6 There should be sufficient room above the false ceiling for installing the Cassette as shown below see dimensions in this IOM for cabinet sizing Small Cabinet A 12 3 4 min Medium Cabinet A 11 1 2 min Large Cabinet A 13 1 2 min ELECTRO MECHANICAL THERMOSTAT In addition to po sitioning the Cassette correctly it is very important to locate the wall mounted thermostat in the optimum position to en sure good temperature control Therefore the installation should be selected with the following points in mind EMI ENVIROMASTER COM 1 Position the thermostat approximately 5 ft above floor level 2 Do not position thermostat where it can be directly affected by the unit s discharge air stream 3 Avoid external walls a
27. nstruc tions All power and interconnecting wiring between units should be carried outto conform with local national electrical codes A fused and dedicated electrical supply of the appropriate phase frequency and voltage should be installed by the cus tomer It is also recommended that a local disconnect switch be connected within 3 of the unit In some areas this may be acode requirement EMI equipment in its standard form is designed for an elec trical supply of 208 230V 1Ph 60Hz When connection to a 115V 1Ph 60Hz supply is necessary a factory mounted buck boost transformer will be fitted to the unit The wires should be capable of carrying the maximum load current under non fault conditions at the stipulated voltages Avoid large voltage drops on cable runs particularly in low voltage wiring The correct cable size must be used to en sure a voltage drop of less than 1 volt in the control wiring Once the refrigeration pipe work is complete the electrical supply can be connected by routing the cable through the appropriate casing hole and connecting the supply and ground cables to the unit s power terminals On the medium and large cabinets it will be necessary to remove the insulated condensate tray support rail adjacent to the casing hole EMI ENVIROMASTER COM ELECTRICAL SPECIFICATIONS STANDARD UNIT DATA POWER SUPPLY FULL LOAD AMPS MIN CIRCUIT AMPACITY MCA REC FUSE WITH OPTIONAL ELECTRIC HEAT
28. nt leaks and repair before recharging NO COOLING POSSIBLE CAUSES REMEDIES INCORRECT MODE SETTING MICRO UNITS ONLY Check that the transmitter MODE is set to Cooling or Auto Mode SET POINT TOO HIGH Check the set point on the trans mitter or wall mounted thermostat and adjust if necessary COMPRESSOR PROTECTION DELAY MICRO UNITS ONLY Check that the green On Off LED is not flashing If it is flashing wait for ten minutes then recheck if cooling is operating Applies to chilled water units also COMPRESSOR PROTECTION DELAY ELECTRO ME CHANICAL DX UNITS ONLY Wait for ten minutes and then recheck if cooling is operating DIRTY OR BLOCKED AIR FILTER See section Coil Freeze ENVIROMASTER INTERNATIONAL LLC HIGH CONDENSATE LEVEL TRIP Drain the condensate tray and investigate See section Condensate high Level erating pressures Check filter condition See maintenance instructions for more information SENSOR FAILURE MICRO UNITS ONLY If any of the sensors are faulty the microprocessor will disable the cool ing operation OUTDOOR UNIT TRIPPED Check outdoor unit refer to outdoor unit troubleshooting section FAULTY VALVE ACTUATOR CHILLED WATER UNITS ONLY Check cooling signal present at actuator Check actuator by manually opening the valve Replace actuator if necessary NO HEATING HEAT PUMP POSSIBLE CAUSES REMEDIES INCORRECT MODE SETTING MICRO UNITS ONLY Check that the transmitte
29. o two separate operating periods for the days of the week Mon Fri The clock provides On Off unit operation and is not a night set back or occupied unoccupied control function Mon Fri will operate as a block of days and cannot be programmed independently of one another Saturdays and Sundays can each be programmed with up to two separate operating pe riods and are programmed independently of weekdays and each other A fascia mounted receiver displays On Off cool or heat and timer alarm status FILTERS Wire framed filters are fitted These are reusable and may be vacuum cleaned CONDENSATE PUMP A condensate pump is fitted to carry water out of the unit The pump is fixed to a mounting bracket which can be withdrawn from the side of the chassis and incorporates an inspection hole to allow a visual check of the pump during operation A float switch is fitted to stop the cooling action should the pump become blocked or fail IMPORTANT TOTAL LIFT FOR THIS PUMP IS 18 OR LESS AIR VANES Air outlet vanes are manufactured from alumi num and covered with nylon flock to prevent condensation from forming Vanes are manually adjustable on the 2 x 2 model units or driven by an electric motor on all other model units Where fitted the motorized air vanes can be set to auto sweep or can be stopped in a fixed position HEATING The cassette may be fitted with either electric heaters or a hot water coil It is recommended that h
30. ons for security check condensate pump operation and check the heating and cooling action to en Remove the electrical panel lid and disconnect the fan connections from within the electrical panel Rotate the fan by hand until two M6 nuts are visible through the fan mounting access holes Remove the two nuts Rotate the fan 90 until the remaining two nuts are visible and remove while supporting the fan to pre sure proper operation FILTER REMOVAL AND CLEANING Ensure the unit is isolated from the electrical sup ply and ensure that the fan s has come to a com plete stop Unclip the catches along the edge of each grille and allow them to hang from the fascia by the molded plastic hinges located along the opposite edge If desired the grilles can be removed from the fas cia completely The filter can now be easily slid out of the small plastic retaining clips on the back of each grille 5 Gently vacuum clean the filters on a medium power CAUTION solate from the electrical supply before vacuum Replace filters by reversing steps 2 to 4 NOTE EMI recommends you keep at least one full set of cassette air filters as spares FAN REMOVAL commencing work 1 Unclip the grille catches and remove the grille s from the fascia 2 For medium and large sized units remove the M6 screws from the black plastic inlet ring and pull the inlet ring downwards from the condensat
31. pipe work have been evacuated correctly and the Condensing Unit s service valves are open DX units only 4 All electrical connections both power and control are properly terminated o All condensate drains are installed correctly o The power supply is of the correct voltage and fre quency 7 The units are properly grounded in accordance with current electrical codes EMI ENVIROMASTER COM f START UP PROCEDURES 8 For microprocessor controlled units check that Once the above pre start checks have been carried out sat the display panel cable is properly connected to isfactorily the main start up operation can begin the microprocessor main circuit board and that the jumper links are correctly set refer to unit wiring IMPORTANT The jumper links referenced in step schematic If the links are set incorrectly remove 8 must be correctly set before applying mains main power before making any changes power to ensure correct operation of unit micro units only 9 For microprocessor controlled units check that the battery on the main circuit board is in place and properly connected Check also that the bat teries are installed in the infrared unit START UP SHEET EXAMPLE EMI CASSETTE CAH W CAF 4 ot SUCCESS DANE TO BE COMPLETED IN CONJUNCTION WITH START UP PROCEDURE ROME NY 13440 RETURN ONE COPY TO EMIAND RETAIN ORIGINAL FOR YOUR RECORDS TEL 800 228 9364 ANCIAN COMPANY DATE FAX
32. r MODE is set to Heat or Auto Mode JUMPER LINK SETTINGS INCORRECT MICRO UNITS ONLY Check that JMP2 jumper link header on the micro processor is in the ON position Remove power before making changes SET POINT TOO LOW Check the set point on the trans mitter or wall mounted thermostat and adjust if necessary DEFROST MODE Unit is defrosting the outdoor coil Heat ing will continue automatically after defrosting COMPRESSOR PROTECTION DELAY MICRO UNITS ONLY Check that the green On Off Led is not flashing If it is flashing wait for a maximum of 10 minutes then re check if heating is operating COMPRESSOR PROTECTION DELAY ELECTRO ME CHANICAL DX UNITS ONLY Wait for ten minutes and then re check if cooling is operating OUTDOOR UNIT TRIPPED Refer to outdoor unit trouble shooting section INDOOR COIL TEMPERATURE TOO HIGH MICRO UNITS ONLY Check refrigerant charge by measuring operating pressures Check filter condition See maintenance instruc tions for more information EMI ENVIROMASTER COM TROUBLESHOOTING SECTION NO HEATING Electric Heat FANS WILL NOT RUN POSSIBLE CAUSES REMEDIES INCORRECT MODE SETTING MICRO UNITS ONLY Check that the transmitter Mode is set to Heat or Auto Mode SET POINT TOO LOW Check the set point on the trans mitter or wall mounted thermostat and adjust if necessary OVERHEAT CUT OUT TRIPPED See section Electric Overheat Investigate cause of over h
33. riod of time a minimum period of 60 minutes should be suf ficient to detect any major leaks however ideally 24 hours should be allowed If there is any reduction in pressure trace the leak and repair before conducting a further pres sure test EVACUATION Evacuation should be carried out with a high vacuum pump The pump should be connected to the high and low pressure sides of the system via a gauge manifold fitted with compound gauges A high vacuum gauge should be fitted to the system at the furthest point from the vacuum pump Triple evacuation should be used to ensure that all contami nants are removed or at least reduced to significantly low proportions ENVIROMASTER INTERNATIONAL LLC The vacuum pump should be operated until a pressure of 500 microns absolute pressure is reached at which time the vacuum pump should be stopped and the vacuum bro ken with oxygen free nitrogen until the pressure rises above zero The above operation should be repeated a second time The system should then be evacuated a third time but this time to 100 microns absolute pressure After stopping the pump open the condensing unit s service valves to break the vacuum START UP PROCEDURES PRE START Once installation is complete it is important that the following pre start checks are made All pipe work is complete and insulated where nec essary 2 All fans are able to rotate freely 3 The Cassette and interconnecting
34. ry FAULTY FAN MOTOR Check fan motor protector for open circuit replace if necessary ELECTRIC OVERHEAT The electric heat circuit contains one automatic reset and one manual reset overheat cut out protection switch for each electric heat element fitted to the unit The cut outs are wired in line with the mains power flowing in each element and operate as described below AUTO CUT OUT If the auto cut out trips the elec tric heat is temporarily disabled until the unit tem perature falls and causes the overheat cut out to automatically reset MANUAL CUT OUT If the manual cut out trips the electric heat is disabled until the unit temperature falls and the overheat cut out is manually reset It will typically take five minutes for the unit tempera ture to fall sufficiently to allow the cut out to be re set The cut out should only be reset by a qualified and competent electrician and with the main power switched off Ensure the elements have cooled suf ficiently THIS EQUIPMENT CONTAINS LIVE ELECTRICAL AND MOVING PARTS ISOLATE ALL ELECTRICAL EQUIP MENT BEFORE ANY MAINTENANCE WORK IS CAR RIED OUT EMI ENVIROMASTER COM MAINTENANCE EVERY 3 MONTHS Check the air filter condition and clean 3 if necessary see below EVERY 6 MONTHS Same as 3 months plus clean conden 4 sate tray with biocide suitable for polystyrene and clean fas cia EVERY 12 MONTHS Same as 6 months plus check all 5 electrical connecti
35. through the four keyhole brackets on the fascia and then sliding the fascia sideways until it locks into position NOTE Up to two non adjacent sides can be blanked off NOTE On electro mechanical units the fascia must be installed with the EMI logo along the same edge of the unit as the electrical panel On units fitted with microprocessor controls orient the fascia with the dis play panel along the same edge of the unit as the electrical panel ENVIROMASTER INTERNATIONAL LLC ny FASCIA BLANKING PIECE SECTION THROUGH FASCIA Before tightening the fascia to the unit connect the two halves ofthe vane motor s plug and socket connection where ap plicable On microprocessor controlled units ensure that the display panel cable is routed to the electrical panel and securely fastened to its connector on the microprocessor circuit board Refer to the unit s electrical wiring schematic Take care to ensure that the connector is connected in the proper ori entation and that the wires are not routed such that they may become trapped cut broken or chaffed The fascia can now be tightened up to the Cassette chassis until a good seal is obtained between fascia and chassis NOTE Do not over tighten the bolts To do so may cause damage to the fascia With filters in place the inlet grilles can now be fitted to the fascia to complete the installation ELECTRICAL DATA See Appendix 1 on page 18 for wiring charts and i
36. to be at fault Investigate all other possibilities in every section of this troubleshooting guide first Replace the micro only after all other avenues of investigation are exhausted WATER LEAKING FROM UNIT See Condensate High Level POSSIBLE CAUSES REMEDIES CONDENSATE PLUG LOOSE OR MISSING Check that the rubber condensate plug is securely fitted to the under side of the unit s polystyrene drip tray On some models this is located underneath the fascia support rails on the pump side of the unit UNIT INSTALLED UNEVENLY With fascia removed ensure that the unit chassis is level at the face both front to back and left to right to ensure correct condensate flow CONDENSATE DRAIN PIPING INSTALLED INCORRECTLY Check that the site installed condensate gravity drain slopes downhill away from the unit See installation section of this manual for more information BLOCKED KINKED CONDENSATE PIPE Check conden sate pipework for blocks kinks and clear as necessary Check for a water tight connection between the PVC condensate outlet and the site installed condensate gravity drain CONDENSATE PUMP BLOCKED OR FAILED Clear any blockages and ensure that power is being applied to the pump If the pump still does not run replace the pump FLOAT SWITCH FAILURE Check that the float switch op erates correctly and is properly positioned Float switch is normally closed opens on rise of water level CONDENSATE HIGH LEV
37. tton until desired mode is highlighted 2 Select temperature with Temp buttons range 58 F to 90 F 3 Select desired fan speed with Fan button 4 Press the On Send to switch unit on and transmit system settings COOL HEAT FAN DRY HOW TO SET DRY MODE Repeat Steps 1 2 and 4 NOTE During the dry mode the system operates in cooling only mode and the indoor fan is fixed at low speed HOW TO SET FAN ONLY MODE Repeat Steps 1 2 and 4 NOTE During the fan only mode only the indoor fan will operate cooling and heating will be disabled HOW TO SET THE WEEKLY PROGRAM Monday Friday 1 Press CLK Timer twice Program highlights CLKITIMER Program ENVIROMASTER INTERNATIONAL LLC 12 NOTE Display will stop flashing after 15 seconds 2 Select Program 1 by pressing or Program 1 and Start Time will flash 1253 e CLKITIMER Program 1 Start Time 3 Press or to select and change hours 4 Press CLK Timer to move to minutes 5 Repeat steps 3 and 4 Stop Time will flash 6 Repeat steps 3 4 and 5 Program 2 and Start Time will flash 7 Repeat steps 3 4 and 5 Send will flash 8 Press On Send to switch unit on and transmit sys tem settings NOTE A small clock symbol will appear in the trans mitter display and the red LED indicator on the fascia display panel will illuminate to indicate the weekly pro gram is in operation H
38. y condensate in a suitable container 6 Remove the self tapping screws securing the two insulated metal condensate tray support channels and pull the channels away from the condensate tray Pull the condensate tray complete with inlet ring on medium and large sized units only down wards away from chassis CONDENSATE PUMP REMOVAL Disconnect condensate pump and float switch wires from inside electrical panel Unscrew the three M4 screws holding the pump inspection plate in place and pull the pump and mounting bracket away from the chassis while feed ing the pump wires between condensate tray and insulation EMI ENVIROMASTER COM APPENDIX WIRING CHARTS AND INSTRUCTIONS TERMINAL BLOCK INSTRUCTION FOR THE CONNECTION OF HIGH LOW VOLTAGE WIRES When connecting line and or low voltage wires to the CAH terminal block s a 3 32 screw driver thermostat type is required FIELD CONNECTIONS DX HEATPUMP SINGLE SPEED CASSETTE 1 CASSETTE 1 CONDENSING UNIT 1 Insert the screwdriver into the square hole until 1 THERMOSTAT SINGLE FAN SPEED you hit bottom This will open the terminal block so that it will accept your wire s CONDENSING 2 Insert the stripped wire into the oval or round hole T STAT 3 Remove screwdriver to allow the terminal block R o clamp down on the wire s Y G W 0 aM N CAH 09 48 INFARE
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