EMI CAHV09, CAHV18, CAHV12, CAHV24 Installation, Operation And Maintenance Manual

CAHV

Variable Speed Cassette Ductless

ariable S

Split System Air Handlers

Split System Air Handler

Straight Cool / Heat Pump Nominal Capacities

CAHV09 CAHV12 CAHV18 CAHV24 Units

eed Cassette Ductless

9,000 12,000 18,000 24,000 Btuh

2.6 3.5 5.3 7.0 kW

8400 8800 17000 19000 Btuh

2.5 2.6 5.0 5.6 kW

Installation, Operation and

Maintenance Manual

COOL

HEAT

An ISO 9001-2008 Certiﬁ ed Company

ECRInternational,Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N# 240009099, Rev. C [08/08/2012]

TABLE OF CONTENTS

Receiving Information .................................................................................................................. 3

Important Safety Information ........................................................................................................ 4

General Product Information ......................................................................................................... 5

Dimensional/Physical Data ............................................................................................................ 6

Installation Considerations ............................................................................................................ 8

Mounting The Unit ....................................................................................................................... 9

Condensate Piping ......................................................................................................................12

Duct Connections .......................................................................................................................13

Refrigerant Piping .......................................................................................................................14

Refrigerant Processing .................................................................................................................15

Final Assembly ...........................................................................................................................17

Electrical Wiring .........................................................................................................................19

Optional Wired Wall Controller ......................................................................................................21

Optional (CAHV) Wired Wall Controller Operation ............................................................................22

Initial Start-Up — CAHV Units ......................................................................................................24

CAHV Controller Overview ...........................................................................................................28

Wired Wall Controller Conﬁ guration ...............................................................................................31

Setting The Controller ................................................................................................................33

Hand Held Controller Operation ....................................................................................................35

Wired Wall Controller Operation ....................................................................................................39

CAHV Controller Features ............................................................................................................40

Maintenance ..............................................................................................................................42

Troubleshooting - General ............................................................................................................43

Troubleshooting - CAHV Units .......................................................................................................44

Frequently Asked Questions .........................................................................................................47

Speciﬁ cations .............................................................................................................................48

System Performance ...................................................................................................................49

Test Unit Performance Data Sheet .................................................................................................50

Check our website frequently for updates: www.enviromaster.com

Information and speciﬁ cations outlined in this manual in effect at the

time of printing of this manual. Manufacturer reserves the right to

discontinue, change speciﬁ cations or system design at any time without

notice and without incurring any obligation, whatsoever.

RECEIVING INFORMATION

Shipping damage MUST be reported to the carrier IMMEDIATELY.

Examine exterior.

Remove cover and examine compressor and piping for signs of damage.

General Information

Installation shall be completed by qualiﬁ ed agency. Retain this manual and warranty for future reference. Installer review this manual to verify unit has been installed correctly. Run unit for one complete cycle to verify proper function. To obtain technical service or warranty assistance during or after installation, contact your local representative.

Visit our web site www.enviromaster.com for local representative listing.

For further assistance call 1-800-325-5479. When calling for assistance, please have following

information ready: Model Number_________________________

Serial Number_________________________

Date of installation______________________

IMPORTANT SAFETY INFORMATION

Become Familiar With Symbols Identifying Potential Hazards.

All ﬁ eld wiring shall conform to requirements of authority having jurisdiction or in absence of such requirements:

• United States - National Electrical Code, ANSI/NFPA 70

• Canada - CSA C22.1 Canadian Electrical Code Part 1.

WARNING

Fire, explosion, and electrical shock hazard. Improper assembly and/or installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

Become Familiar With Symbols Identifying Potential Hazards.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

Safety Information

• Installation by qualiﬁ ed personnel.

• Turn off electrical supply before servicing unit.

• Inspect all parts for damage prior to installation and start-up.

Do not use unit if it has damaged wiring, is not working properly, or has been damaged or dropped.

• Connect to properly grounded electrical supply with proper voltage as stated on rating plate.

• Have proper over-current protection (i.e. time-delay fuse/HACR Breaker) as listed on Rating Plate.

• Connect unit to properly grounded electrical supply.

• Check rating plate on unit before installation. Verify voltage shown is same as electric supply to unit. Rating plate is located on top panel only.

• Tampering voids all warranties.

WARNING

Tampering with this unit is dangerous and could result in serious injury or death. Do not modify or change this unit.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information which should be followed to ensure proper installation and operation.

Product Description

• EMI Cassette Air handlers are available in two cabinet sizes with four output capacities from 9,000–24,000 Btuh.

• Features include condensate pump with safety switch and 36” (0.9 m) lift, measured from base or bottom of unit, fresh air inlet, branch duct knockouts, and motorized air vanes (models 18 and 24 only).

• Factory installed electric heat option. No ﬁ eld installed electric heat kits are available.

• Cassette air handler accepts optional wired wall control.

• Designed for low noise levels, easy installation, easy maintenance and slim line fascia, insure minimum intrusion into the conditioned environment.

• Cassette air handlers produce system SEER’s exceeding 13 when matched with EMI outdoor units:

Single-zone condensing units — S1CV/S1HV 09–24.

GENERAL PRODUCT INFORMATION

Standard Features

CAHV units

• Remote or optional wired wall control is required to adjust settings and conﬁ gure controller.

• When operated by optional wired wall control, controller offers most functions. Hand held controller is required for “Test” mode.

Materials of Construction

• Galvanized steel cabinet with ﬁ re-resistant thermal and acoustic foam insulation.

• Light grey high-impact ABS fascia.

• Expanded polystyrene drain pan with tough, ﬁ re- retardant thermoplastic liner.

Air Systems

• Fans are backward-curved impeller centrifugal design; dynamically and statically balanced; and mounted on integral mounting rails.

Single-fan models 9 - 24 are designed with ﬁ re- retardant plastic or aluminum impellers. Multispeed motors are enclosed type with thermal protection and sealed lifetime bearings.

• User accessible permanent, washable ﬁ lter.

• Branch duct knockouts on three sides for remote discharge locations; using no more than two nonadjacent sides.

• Fresh air intake capability on three sides of cabinet; only two on models 9–12.

• Four plastic air vanes, motor driven with auto sweep or ﬁ xed position stop setting on models 18 - 24. Models 9–12 are equipped with manually-adjusted air vanes.

Coil

• Coil is seamless, copper tubing, arranged in staggered conﬁ guration, with enhanced aluminum ﬁ ns, tested to 700 psig.

• Tubes are mechanically expanded for secure bonding to ﬁ n shoulder.

Refrigeration Circuit

Condensing units equipped with Electronic Expansion Valve (EXV) and uses R410A refrigerant only.

System Options

Electric Heat Option

EMI heat option - heat pumps are intended to operate with indoor air handler, with electric heat. If indoor air handler without electric heat is matched with heat pump condenser system delivers cold air during defrost.

Wired Wall Control Applications

Mechanical Characteristics

Condensate Pump

Air Vanes

Heating

Fresh Air Connection

Controls and Components - factory installed or

supplied

• Connections for optional wired wall control.

• Custom control board featuring programmability, conﬁ guration, and multiple modes of operation.

• Controls also feature anti-short-cycle timer, post purge fan relay, and an on-board 30-amp electric heat relay.

• Condensate pump with 36” (0.9 m) lift (measured from base of unit).

• 24V Transformer.

• Wired wall control.

• Electric Heat (@ 230V)

1.5 kW — models 9–12 3 kW — model 18 - 24

• CAHV units allow, optional wired wall control operation.

• Obtain wired control through EMI only.

• Metal framed ﬁ lters are ﬁ tted, reusable and may be vacuum cleaned.

• Designed to carry water out of unit. Pump is ﬁ xed to mounting bracket which can be withdrawn from side of chassis and incorporates inspection hole which allows for visual check of pump during operation.

• Float switch stops cooling action, shuts off compressor if pump becomes blocked or fails.

• Pump total lift is 36” (0.9 m) or less measured from base or bottom of unit.

• Air outlet vanes are manually adjustable on models 9 and 12. Electrically motor driven on models 18 and 24.

• Motorized air vanes where ﬁ tted can be set to auto sweep or stopped in a ﬁ xed position.

• Cassette may be ﬁ tted with optional electric heaters equipped with over-temperature limit switches. Consult factory for available models with electric heat.

• Fresh air may be introduced to unit by addition of ducts connected to fresh air knockouts on cassette case.

• Recommended maximum length is 10’ (3m) of 4” (0.1m) diameter duct. Fresh air volume is approximately 7–10% of unit’s published maximum air ﬂ ow if more than 10% make up air is needed fresh air booster fan is required.

• Refer to Performance Data section of this manual for further information.

• Cassette is best installed in new construction or existing construction with suspended or false ceiling with enough clearance to accommodate concealing piping and electrical connections to unit.

DIMENSIONAL/PHYSICAL DATA

Figure 1 - Dimensions: Models 9, 12, 18, & 24 (see Table 1, Page 7 )

Model 9-12

Model 18-24

Features

Optional discharge knockouts

5¼-inch diameter (3) available

Fresh air inlet knockouts

1¼ x 2½ inches

- 9/12 (2) available 3x3 18/24

Condensate discharge

½-inch diameter

Suction

connection

Liquid connection

Condensate pump

access panel

DIMENSIONAL/PHYSICAL DATA

Table 1 Dimensions — Models 9, 12, & 24 (see Figure 1, Page 6 )

Dimension

A B C D E F G H

J (ref)

K L

N (ref)

P (ref)

R (typical)

R1 R2 R3

S T

Models 9 & 12 Model 18 & 24 Model 42

Inches mm Inches mm Inches mm

25.00 635 37.00 940 37.00 940

25.00 635 37.00 940 49.26 1251

22.50 572 32.44 824 32.44 824

2.04 52 2.00 51 2.04 52

22.57 573 30.40 772 44.68 1135

1.41 36 1.41 36 1.41 36

2.88 73 3.65 93 3.65 93

8.13 207 8.90 226 8.90 226

2.67 68 3.38 86 3.38 86

25.86 657 35.61 904 47.78 1214

12.76 324 18.69 475 24.73 628

1.73 44 1.97 50 1.97 50

2.16 55 2.72 69 2.72 69

5.12 130 5.12 130 5.12 130

11.34 288 12.05 306 14.01 356

1.50 38 1.63 41 1.63 41

19.50 495 29.19 741 29.19 741

23.27 591 31.20 792 42.66 1084

22.47 571 30.41 772 43.45 1104

7.19 183 6.87 174 6.87 174

3.73 95 2.58 66 4.98 126

4.88 124 5.50 140 5.47 139

3.50 89 4.93 125 5.00 127

2.50 64 3.97 101 4.00 102

4.69 119 4.37 111 4.37 111

INSTALLATION CONSIDERATIONS

Before Installing

• Determine best location for mounting unit for room air circulation.

• Locate outdoor and indoor units as close together as possible.

• Determine how power wires high and low-voltage, condensate drainage, and refrigerant piping may be run to and from unit.

• Insure interconnect tubing is within limits given in Table 2 .

Table 2 - Tubing Speciﬁ cations

S1CV

S1HV

Model

09 12 1/4” 1/2" 18 3/8” *5/8"

24 3/8" *5/8 “

*Bush to 5/8” @ Air Handler

Max.

Length

Equivalent

feet

100’

(30 m)

Max.

Lift

“H” “P” O.D. O.D.

35’

(11 m)

Max. Trap

Height

20’

(6 m)

Liquid

Line

1/4” 1/2"

Suction

Line

Unpacking

Cassette fascia and main chassis are packaged together for increased protection.

NOTICE

Do not throw template away with packaging.

Remove banding straps and lift cardboard lid.

Fascia is packed in bubble wrap on top of chassis. Fascia is not attached to chassis for shipping.

Cardboard template is between chassis and fascia.

Lift fascia and template from box and set aside.

Remove cassette chassis from box utilizing four corner brackets for lifting.

Do not use drain or refrigerant connections for lifting.

In order to protect fascia from dirt and damage return them to box until ready to install.

Do not throw away two polystyrene blanking-off pieces with packaging.

Piping may be roughed in before wallboard or panels are placed in new construction. PVC pipe (3” or 4” I.D.) may be used as pipe chase.

MOUNTING THE UNIT

Blanking off

Fascia discharge slot(s) need blanking off when ducts are used to channel conditioned air to other areas.

• Position two polystyrene blanking off strips (provided) in fascia discharge slots to direct air to ducts.

• Up to two non-adjacent sides may be blanked off.

If fascia discharge slot needs blanking off —

Remove inlet grilles and ﬁ lters. See Figure 4 and Figure 2, Page 9 .

Turn fascia over to expose polystyrene insulation. See Figure 3 .

Push one polystyrene blanking-off pieces into recess in polystyrene fascia insulation.

Figure 4 Models 9–12 — One Grille & One Filter

Figure 2 - Model 18 - 24 — Two Hinged Grilles

And Two Filters

Hinge

Figure 3 - Applying Blanking-Off Pieces

Blanking-Off

Pieces

MOUNTING THE UNIT

Positioning

Select cassette installation position.

Pipe work, electrical connections, control box and condensate pump access panels should be readily accessible. Refer to cassette dimensions. See Figure 1, Page 6 and Table 1, Page 7 .

Position unit at least 5 ft. (1.5m) from wall or similar obstruction.

Position unit as close to center of room as possible to insure even air distribution.

Position unit so discharge air does not blow directly on remote wall wired thermostat, if used.

Do not position unit directly above any obstructions.

Condensate drain should have sufﬁ cient fall — 1” per 10’ (8 mm/m) in any horizontal run between cassette and drain.

Maximum condensate pump lift is 36” (0.9m) from bottom of unit.

Maintain minimum 1” (25.4mm) clearance above cassette depth and false ceiling for proper installation.

Wired Wall Control Optional wired wall control contact

EMI for availability. Locate optional wired wall mounted thermostat to insure good temperature control. Select installation position.

Position thermostat approximately 5 ft. (1.5m) above ﬂ oor level.

Avoid external walls and drafts from windows and doors.

Avoid positioning near shelves and curtains as these restrict air movement.

Avoid heat sources (direct sunlight, heaters, dimmer switches, etc.)

Seal wiring holes in wall behind thermostat to avoid drafts.

Ceiling Opening

NOTICE

Verify ceiling grid is supported separately from the cassette. Do not support ceiling by any part of cassette unit, fascia or any associated wiring or pipe work.

Cut opening in false ceiling with size. See Table 4.

Table 4 - Ceiling Opening Sizes

Model Dimensions

9 & 12 23¼” x 23¼” (591 x 591 mm) 18 & 24 337/8” x 337/8” (860 x 860 mm)

Figure 5 - Spacing Requirements

Dimension A + 1” = Minimum Space Above False

Ceiling For Installation

+1”

Figure 6 - Ceiling Cutout/Rod Placement

Template (Shipped With Unit)

Rod

Positions

1.500 TYP

(51MM X 45°)

2.000 X 45° TYP

Model Dimension A

9 & 12 11.84” (0.3 m) min.

18 & 24 12.55” (0.32 m) min.

(38MM TYP)

Positions

Rod

MOUNTING THE UNIT

MAXIMUM

2”

(51mm)

Mounting Method

• In existing construction, remove enough ceiling panels to provide clearance space for mounting unit to ceiling joists.

• Before beginning installation, inspect unit location, test strength of ceiling joists to insure they will support unit weight.

• Determine mounting method: A. Wooden beams use threaded rods, washers, and

nuts to suspend support brackets.

B. Metal structures, secure threaded rods on an

existing angle or install new support angle.

C. Newly built concrete slabs secure threaded rods

with inserts and embedded bolts.

D. For previously built concrete slabs install hanging

bolts with expansion anchor.

E. Follow local building codes for required safety

cables, braces, etc.

Mounting

Use template to cut ceiling opening and determine rod positions. See Figure 6, Page 10 .

Install hanger bolts using 3/8” (10mm) all-thread rod at centers. See Figure 6, Page 10.

Figure 7 - Mounting Brackets

Fold

bracket along

perforations

Table 5 - Ceiling Rod Positions

Model Dimension A Dimension B

9 & 12 19.50” (495mm) 22.87” (581mm)

18 & 24 29.19” (740mm) 30.80” (782mm)

Prepare installation guides by folding metal bracket by hand along perforations. See Figure 7 .

Lift cassette onto hanging rods.

Level at correct distance from ceiling with aid of installation guides. See Figure 8 .

Secure unit in position with locknuts and washers on either side of cassette bracket.

Insure threaded rod does not protrude more than 2” (51mm) below mounting bracket. See Figure 9 .

If ceiling is not level or even, it is important to install cassette level to insure correct pump operation and to maintain fan clearances.

Place carpenter’s level on unit. Maximum slope of 1/8” (3mm) over length of chassis toward condensate drain is allowed. Slight discrepancy between cassette and ceiling will be taken up by fascia foam seal.

Figure 8 - Positioning Installation Guides

CASSETTE CASE

INNER CASE INSULATION

Figure 9 -Threaded Rods Must Not Protrude

More Than 2 Inches Below Mounting Brackets

2”

(51mm)

MAXIMUM

Correct

Incorrect

CONDENSATE PIPING

Cassette is supplied with 1/2” I.D. ﬂ exible PVC hose for connection to copper or plastic drain piping.

Cassette installation considerations

Maximum pump lift is 36” (0.9m) from base or bottom of unit.

Highest point in condensate piping should be as close to unit as possible. Prevents large volume of water draining back into unit when it is switched off.

Check valve at pump discharge to prevent water from draining back into unit. Piping technique minimizes issues should check valve become stuck open from airborne debris.

Slope condensate pipe-work downward from highest point in direction of water ﬂ ow with minimum gradient of 1” per 10’ (8mm/1m). No uphill gradients other than in ﬁ rst 18” (0.45m) of pipe-work from cassette.

When multiple cassettes are connected to common condensate drain, insure drain is large enough to handle total volume of condensate.

Drain line vent may be required to prevent siphoning of water from drain pan and associated noise.

Figure 10 - Highest Point Of Condensate Piping

Should Be As Close To Unit As Possible

Correct

Incorrect

Figure 11 - Condensate Drain

Condensate Drain Connection

Cassette 9-12

CASSETTE 18 -24

DUCT CONNECTIONS

Attach branch duct and fresh air duct collars to cassette chassis using following steps.

Recommend install no more than 10 feet (3m) of branch duct or fresh air duct.

Locate knock-out holes. See Figure 12 . Number of knockouts vary with unit size.

• Branch duct knock-outs are 5¼” (133mm) round.

• Fresh air knockouts are: a. 1¼” x 2½” (32 x 64mm) rectangular models 9

& 12.

b. 3” (76mm) square models 18 & 24

Cut black insulation around knock-out. See Figure 13 .

Snip tabs holding knock-out in place.

Remove metal knock-out and black insulation behind it.

Attach ﬁ eld supplied duct collars to chassis using self- drilling screws.

Figure 12 - Knockouts

Branch Duct Knockout

Cassette 9-12

CASSETTE 18 -24

Fresh Air Knockout

Figure 13 - Cut Insulation And Snip Out

Knockouts

Repeat above steps for remaining duct work.

REFRIGERANT PIPING

Add heat shield behind valve when brazing to

prevent damage to unit.

Add wet rag over valve to keep from

melting internal valve components.

Piping Preparation

• Avoid piping on wet and rainy days.

• Use only clean, refrigeration-grade copper tubing.

• Use tubing benders to guard against kinking.

• Verify no burrs remain on ﬁ ttings.

• Cap ends of lines until ready for connections. Verify plastic end caps remain in place when inserting through wall openings.

• Insulate both lines.

• Isolate tubing from transmitting vibration to building or unit and avoid contact with sharp edges.

• Wrap refrigeration valves with wet rag “heat sink” to protect valves while brazing. See Figure 31, Page 20 .

Refrigerant Piping

Clean tubing ends. Insert into ﬁ ttings. See Figure 15 .

Protect valves by wrapping with wet rag “heat sink” before brazing. See Figure 16 .

Use shield to protect paint. Shield may be made from scrap metal. See Figure 14.

Braze tubing into ﬁ ttings.

Figure 14 - Piping Connections At Unit

(When a reducing bushing is required, install only at the indoor suction-line connection.)

Suction Line Liquid Line

Figure 15 - Clean Ends Of Tubing

Figure 16 - Wet Rag “Heat Shield Over Valves

Add heat shield behind valve when brazing to

prevent damage to unit.

Install all panels removed to this point. Panels are required for proper air ﬂ ow.

Figure 17 - Make Shield To Protect Paint

Add wet rag over valve to keep from

melting internal valve components.

REFRIGERANT PROCESSING

S1HV

Shown

Charging Unit

Attach manifold set, vacuum pump, & micron Gauge. See Figure 18 .

Evacuate line to 500 microns or less to insure all moisture has been removed and there are no leaks. See Figure 19 .

• Evacuate

• Pressurize with 100psi

N2 or Nitrogen

• Evacuate again

• Charge with R410A

Verify evacuation and leak free joints. Back-seat valves (counter-clockwise) to open and allow factory charge to ﬁ ll lines and indoor unit. See Figure 20 .

Refer to refrigerant charge table for speciﬁ ed charge.

Charge to proper weight. Charge based on feet of interconnect. Only add/remove R410A in liquid form. See Table 6, Page 16 .

Refer to charts beginning on page 16 to “ﬁ ne tune” the refrigerant charge to meet your conditions.

Systems require ﬁ eld charge adjustments. Refer to “Refrigerant Charge Tables” for proper weight charge and Operation Charts for proper system pressures and temperatures at different outdoor conditions. Sub-cool should be used for ﬁ nal system charge.

Charging should be suitable charge weighed in with scale.

NOTICE

Figure 18 - Manifold Set Connections At Unit

HIGH PRESSURE

RED

LOW PRESSURE

BLUE

S1HV

Shown

Figure 19 - Manifold Set Up For Evacuation

S1HV

Shown

Manifold

Micron Gage

Vacuum Pump

Figure 20 - Charging

High Pressure

Switch

Straight Cool Condenser Use

Valves

It is illegal to discharge refrigerant into the atmosphere. Use proper reclaiming methods & equipment when installing or servicing this unit.

• Measure all heat pump saturated suction pressures at the Common Suction Port not vapor Service Valve.

• Common Suction Port includes pressure drop and temperature increase through reversing valve resulting in a more accurate and complete system charge.

• Port may also be used to charge system in heating mode when both sides of line set are at high system pressures or to determine saturated evaporator pressure while in heating mode.

High Pressure

Switch

Common

Suction

Heat Pump Unit Use Common

Suction

Figure 21 - Common Suction, Discharge, and

High Pressure Switch

COMMON

DISCHARGE

HIGH

PRESSURE

SWITCH

COMMON SUCTION

PORT

REFRIGERANT PROCESSING

Use following example to ﬁ nd charge adjustment and system charge for any air handles and tubing length.

Line Adjustment = (Line Charge/FT) x Line Length

System Total = Factory Charge + Line Adjustment

Round to nearest ounce and allow for gauges and hoses.

Table 6 - S1CV / S1HV R410A Refrigerant

Charge Table

Condenser Cassette

Pairing

S1CV9000 CAHV09 .25 oz./ft (23 g/m) 39.5oz (1120g) S1CV2000 CAHV12 .25 oz./ft (23 g/m) 39.5oz (1120g) S1CV8000 CAHV18 .64 oz./ft 59 g/m) 54.0oz (1531g)

S1CV4000 CAHV24 .64 oz./ft (59 g/m) 54.0oz (1531g) S1HV9000 CAHV S1HV2000 CAHV S1HV8000 CAHV S1HV4000 CAHV

09 12 18 24

Line Charge

Per Foot

.25 oz./ft (23 g/m) 39.5oz (1120g) .25 oz./ft (23 g/m) 39.5oz (1120g) .64 oz./ft (59 g/m) 54.0oz (1531g)

.64 oz./ft 59 g/m) 54.0oz (1531g)

Factory

Charge

+ 36 hidden pages

EMI CAHV09, CAHV18, CAHV12, CAHV24 Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual