EMI WLCA User Manual

NOMINAL CAPACITIES:

CAH/CAHW: 9,000 - 48,000 Btuh

CAF/CAF4: 8,000 - 36,000 Btuh

EMI DUCTLESS 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) ver­sions; also available are two pipe chilled water (CAF) and
four pipe chilled and hot water versions (CAF4) in 8,000 to
36,000 Btuh capacities; and, depending on the model, elec­tric 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 work­ing environment.

CONTROLS AND COMPONENTS

GENERAL STATEMENT

IMPORTANT: The information contained in this
manual is critical to the correct operation and main­tenance 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.

LOW VOL T TRANSFORMER (Standard): 24 V olt.
ELECTRO-MECHANICAL (Standard): Thermostat options

are cooling only , cooling and one stage auxiliary heat, cool­ing and one stage mechanical heating (heat pump system)
or cooling and two stage heating (heat pump & second stage
auxiliary heat). An optional thermost at can be obtained through
EMI or your local distributor.

NOTE: Make sure the thermostat is suitable for unit opera­tion (i.e., cooling only , cooling/electric heat, etc.)

MICROPROCESSOR (Optional): A custom designed mi­croprocessor is fitted to the cassette to enable room condi­tions to be maintained at a user defined setpoint. Communi­cation 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 versatil­ity . A temperature 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 24V AC signal
from the condensing unit is also monitored to signal the in­door unit that defrost of the outdoor coil is taking place. This
allows the same micro to control both heat pump and cool­ing only units. The receiver contains a self diagnostic fea­ture. When a low indoor coil temperature is detected the
cooling action is stopped. If a sensor fails then an alarm is

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displayed on the fascia mounted receiver. The microproces­sor 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 micro­processor also has a built-in clock which can be activated to
enable the unit to be programmed with up to 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 pe­riods and are programmed independently of weekdays and
each other.

A fascia mounted receiver displays On/Off, cool or heat and
timer/alarm status.

FIL TERS: Wire framed filters are fitted. These are reusable
and may be vacuum cleaned.

CONDENSA TE 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.

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 open­ings are Included with the fascia packing. Up to two
opposing sides may be blanked off.

POSITIONING

CASSETTE - The Cassette installation position should

be selected with the following points in mind:

1. Pipe work, electrical connections and condensate 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.

IMPORTANT: TOT AL LIFT FOR THIS PUMP

IS 18” OR LESS.

AIR V ANES: 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 heat
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 pub­lished maximum air flow.

SITE INSTALLATION

UNPACKING: The cassette fascia and main chassis are

supplied together for increased protection. Remove the band­ing straps and lift the cardboard lid. Remove the bubble wrap
and polystyrene packing pieces to expose the unit. The fas­cia should be unpacked first by unclipping the inlet grille and

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 = 1 1-1/2” min.
Large Cabinet A = 13-1/2” min.

ELECTRO-MECHANICAL THERMOST AT - In addition to po­sitioning the Cassette correctly , it is very important to locate
the wall mounted thermostat in the optimum position to en­sure good temperature control. Therefore the installation
should be selected with the following points in mind:

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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. A void external walls and drafts from windows and doors.

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

OUTER CASE
INSULATION

CASSETTE CASE

INNER CASE INSULATION

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

CEILING OPENING: Before beginning the installation, in­spect the unit location, test the strength of the unit
mountings (see “Mechanical Information” in this IOM). 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 wir­ing or pipe work.

The hanger bolts can now be installed (use 3/8 all thread
rod) at the centers shown below:

FALSE CEILING

GUIDE IN
POSITION

NOTE: If 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.

CABINET A B

SMALL

MEDIUM

LARGE

19-1/2" 23"
29-5/8" 31-1/2"
29-5/8" 43-11/16"

Prepare the installation guides by folding the metal bracket
by hand along the row of holes.

FOLDED GUIDE

The Cassette can now be lifted onto the hanging rods and
leveled at the correct distance from the ceiling with the aid of
the installation guides as shown.

The unit can now be piped up in accordance with good refrig­eration and/or plumbing practices.

CONDENSA TE 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.

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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 vent in
the condensate pipework to 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 sweat­ing.

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 Cas­sette 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 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 dis­play panel along the same edge of the unit as the
electrical panel.

FASCIA BLANKING PIECE

SECTION THROUGH FASCIA

Before tightening the fascia to the unit, connect the two halves
of the vane motor’s plug and socket connection (where ap­plicable).

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 ori­entation 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 instruc­tions.)

All power and interconnecting wiring between units should
be carried out to conform with local/national electrical codes.
A fused and dedicated electrical supply of the appropriate
phase, frequency and voltage should be installed by the cus­tomer. It is also recommended that a local disconnect switch
be connected within 3’ of the unit. In some areas this may
be a code requirement.

EMI equipment in its standard form is designed for an elec­trical 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 en­sure 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.

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ELECTRICAL SPECIFICATION S

E

E

STANDARD UNIT DATA

POWER SUPPLY 230V/1PH/60HZ 230V/1PH/60HZ 230V/1PH/60HZ
FULL LOAD AMPS A 0.4 0.6 0.9
MIN. CIRCUIT AMPACITY (MCA) A 0.5 0.75 1.13
REC. FUS

WITH OPTIONAL ELECTRIC HEAT

POWER SUPPLY 230V/1PH/60HZ 230V/1PH/60HZ 230V/1PH/60HZ
ELECTRIC HEAT CAPACITY KW 1.5 3.0 5.0
HEATER AMPS A 6.52 13.1 21.7
FULL LOAD AM PS A 7.0 13.7 22.6
MIN. CIRCUIT AMPACITY (MCA) A 8.8 17.1 28.3
REC. FUSE WITH HEAT A 15 20 30

WITH OPTIONAL BOOST TRANSFORMER

POWER SUPPLY 115V/1PH/60HZ 115V/1PH/60HZ 115V/1PH/60HZ
FULL LOAD AMPS A 0.8 1.2 1.8
MIN. CIRCUIT AMPACITY (MCA) A 1.0 1.5 2.26
REC. FUS

(1) STANDARD UNIT FITTED WITH OPTIONAL ELECTRIC HEATING ELEMENTS. AV AILABLE WITH 230V M ODEL UNITS ONLY.
(2) STANDARD UNIT FITTED WITH OPTIO NAL BOOS T TRANSFORMER FOR CONNECTI O N TO A 115V ELECTRICAL SUP P LY. ELECTRIC HEAT

IS NO T AVAILABLE WITH THIS O PTION.

1

A151515

2

A151515

SMALL MED IU M LARGE

SMALL MED IU M LARGE

SMALL MED IU M LARGE

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 a pressure of 150 PSIG . Record the pressure over a pe­riod of time (a minimum period of 60 minutes should be suf­ficient 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 pres­sure 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 contami­nants are removed or at least reduced to significantly low
proportions.

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 bro­ken 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.

1. All pipe work is complete and insulated where nec­essary.

2. All fans are able to rot ate freely .

3. The Cassette and interconnecting 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.

5. All condensate drains are inst alled correctly .

6. The power supply is of the correct voltage and fre­quency .

7. The units are properly grounded in accordance with
current electrical codes.

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E

O

CO

OJEC

START UP PROCEDURES

8. For microprocessor controlled units, check that
the display panel cable is properly connected to

Once the above pre-start checks have been carried out sat­isfactorily , the main start up operation can begin.

the microprocessor main circuit board and that the
jumper links are correctly set (refer to unit wiring
schematic). If the links are set incorrectly , remove
main power before making any changes.

9. For microprocessor controlled units, check that
the battery on the main circuit board is in place
and properly connected. Check also that the bat­teries are installed in the infrared unit.

STAR T UP SHEET EXAMPLE

EMI CASSETTE - CAH/W, CAF/ 4

TO BE COMPLETED IN CONJUNCTION WIT H START UP PROCEDUR

TECHNICIAN:
M

DEL/SERIA L NO:

1.0 PRE START UP CHECKLIST

1.1 UN I T CONDITI ON SATIS FA CTORY

1.2 PRESSURE TEST WI T H DRY NIT RO G EN

1.3 DESIGN WATER FLOW AVAILABLE IF
CHILLED W ATER UNIT

1.4 VOLTAGE AT O UT D O OR UNIT

1.5 VOLTAGE AT I NDOOR UNI T

1.6 ELECTRICA L CO NNECTI O NS T IGHT

1.7 JUMPERS SET CORRECTLY (MICRO ONLY)

2.0 START UP CHECKLIST - INDOOR UNIT

2.1 DISA BLE COMPRESSOR SIGNAL

2.2 ON/OFF WORKS

2.3 INDOOR UNIT : THREE F ANS SPEEDS
AVAIL ABLE (MICRO ONLY)

2.4 VA NE SWEEP FUNCTIONS

2.5 TIMER FUNCTIONS OPERATE (MI CRO ONLY)

2.6 CONDENSATE PUMP OPERATES

3.0 START UP CHECKLIST - OUTDOOR UNIT

3.1 OPERA T I NG PRESSURES

3.2 SUCTI O N

3.3 DISCHARGE

3.4 AM BIENT TEM PERAT URE

35. INDOOR AI R TEMPERATURE

: A START UP SHEET FOR EVERY UNIT MUST BE RETURNED TO EMI TO VALIDATE THE WARRANTY .

NOTE

RETURN ONE COPY TO EM I AND RETAIN ORIGINAL FOR YOUR REC OR DS

(REFE R TO THE RELE VANT O UTDOOR UNIT M ANUAL AND, IN ADDITION, NO TE THE FOLLOW ING:

MPANY:

PR

T:

COMMENT:
INITIAL TEST
PRESSURE

IMPORTANT: The jumper links referenced in step
8 must be correctly set before applying mains
power, to ensure correct operation of unit. (micro
units only)

DATE:

FINAL TEST
PRESSURE

ENVIROMASTER INTERNATIONAL LLC

HT TP://WWW.ENVIROMASTER.C OM

TE S T DU RATIO N

5780 SUCCESS DRIVE

ROM E, NY 13440

TEL: [phone]

FAX: [phone]

YES/NO
YES/NO

YES/NO
YES/NO

YES/NO
YES/NO
YES/NO

GPM

V
V

PSIG
PSIG

ºF
ºF

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