EMI WLHG09, WLHG24, WLHG12 Installation, Operation And Maintenance Manual

WLCG/WLHG
High-Efciency Ductless Split System High-Wall Air Handlers
Straight cool / Heat pump nominal capacities
WLHG09 WLHG12 WLHG24
Units
9,000 12,000 18,000 23,800 Btuh
2.6 3.5 5.3 7.0 kW
WLCG30 WLCG36
Units
28,200
33,600
Btuh
8.3 9.8 kW
Installation, Operation and
Maintenance Manual
ECR International Inc 2201 Dwyer Ave. Utica, NY 13501 www.enviromaster.com
An ISO 9001-2008 Certified Company
P/N 240008111, Rev. G [06/18/10]
WLCG/WLHG
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 2 P/N 240008111, Rev. G [06/18/10]
Contents
To the Installer
Retain this manual and warranty for future reference. Before leaving the prem­ises, review this manual to be sure the unit has been installed correctly and run the unit for one complete cycle to make sure it functions properly.
To obtain technical service or warranty assistance during or aer the installation of this unit, contact your local representa­tive. For a local representative listing, visit our web site:
www.enviromaster.com
For further assistance call:
1-800-228-9364
When calling for assistance, please have the following information ready:
Model Number _____________ Serial Number _____________ Date of installation ___________
IMPORTANT
Shipping damage MUST be reported to the carrier IMMEDIATELY.
Examine the exterior. Remove cover and examine piping for signs of damage.
NOTICE
The EMI series high efficiency air handler is backed by EMI and ECR International is tested, rated, and certi­ed in accordance with AHRI Standard 210/240-2008 and UL-1995.
Due to ongoing product development, product designs and specications may change without notice.
Please contact the factory for more information.
Contents . . . . . . . . . . . . . . . . . . . . . . 2
Read Before Proceeding . . . . . . . . . . . . 3
Verify Unit Before Installing . . . . . . . . . . 4
Piston/Orifice Replacement
(when required). . . . . . . . . . . . . . . . . . 6
Mounting the Unit . . . . . . . . . . . . . . . . 7
Electrical Wiring. . . . . . . . . . . . . . . . . . 9
Refrigerant Piping . . . . . . . . . . . . . . . 14
Refrigerant Processing . . . . . . . . . . . . 17
Reassemble the WLCG/WLHG Cabinet . . 18
Initial Start-Up. . . . . . . . . . . . . . . . . . 19
WLCG/WLHG Controller Overview . . . . . 20
Setting the Controller . . . . . . . . . . . . . 22
Unit-Mounted Controller Operation . . . . 25
Wall Thermostat Operation . . . . . . . . . 29
Controller Features. . . . . . . . . . . . . . . 32
Controller Fault Conditions . . . . . . . . . 33
Maintenance. . . . . . . . . . . . . . . . . . . 34
Troubleshooting . . . . . . . . . . . . . . . . 36
Frequently Asked Questions. . . . . . . . . 40
Specifications and Dimensions . . . . . . . 42
WLCG/WLHG System Options . . . . . . . . 44
Test Unit Performance Data Sheet . . . . . 46
EMI’s Product Line . . . . . . . . . . . . . . . 47
Indoor Units . . . . . . . . . . . . . . . . . . . 47
Outdoor Units . . . . . . . . . . . . . . . . . . 47
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 3
Read Before Proceeding
Recognize this symbol as an indication of
important safety information.
WARNING
Completely read all instructions prior to assembling, installing, oper­ating, or repairing this product.
Inspect all parts for damage prior to installation and start-up. e EMI se­ries high eciency air handler must be installed ONLY by qualied installation personnel.
DANGER
Tampering with this unit is danger-
ous
. Tampering voids all warranties.
DO NOT aempt to modify or change
this unit in any way.
DANGER
e EMI series must:
Be connected to a properly grounded • electrical supply with the proper voltage as stated on the rating plate.
Have proper overcurrent protection • (time-delay fuse/HACR Breaker) as listed on the rating plate.
Failure to follow these instructions can result in a re, explosion, or electrical shock causing property damage, personal injury, or death.
Safety Instructions
is manual is intended as an aid to quali­ed service personnel for proper installa­tion, operation, and maintenance of the EMI series high efficiency air handler. Read these instructions thoroughly and carefully before aempting installation or operation.
Failure to follow these instructions may result in improper installation, operation, service, or maintenance, possibly resulting in re, electrical shock, property damage, personal injury, or death.
Read all instructions before using this unit. Install or locate this unit only in ac­cordance with these instructions. Use this unit only for its intended use as described in this manual.
Check the rating plate on the unit before installation to make certain the voltage shown is the same as the electric supply to the unit. e rating plate is located on the top panel only.
This unit must be connected only to a properly grounded electrical supply. Do not fail to properly ground this unit.
Turn o the electrical supply before servic­ing the unit.
Do not use the unit if it has damaged wir­ing, is not working properly, or has been damaged or dropped.
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 4 P/N 240008111, Rev. G [06/18/10]
NOTICE
Check equipment for damage prior to installation, if damaged contact the wholesale distributor.
Product description
The WLCG/WLHG is available as a • (DX) direct expansion straight cool or heat pump.
It offers a contemporary design in a • ductless type air handler and combines aractive appearance with high eciency conditioning for small to medium size commercial or residential spaces.
The WLCG/WLHG is equipped with • unit mounted infrared compatible con­trols which also supports 24V wall ther­mostat operation. Optional handheld remote is available.
Heat pump models prov ide up to • 24,000 Btuh of cooling and 20,600 Btuh of heating. Electric heat options are available for up to 5 kW of supplemental heat.
is air handler oers ease of installation, • operation, and service.
It can be matched with EMI’s:•
Single-zone condensing units  – S1CG/S1HG 09–24 and S1CG 30-36.
Dual-zone condensing units  – S2CH/S2HH side discharge.
Multi-zone, top discharge condens- – ing units  T2CG/T2HG, T3CG/ T3HG, or T4CG/T4HG.
All EMI air handlers are backed by ECR • International Inc. and are tested, rated, and certied in accordance with AHRI standards 210/240-2008 and UL 1995.
Verify Unit Before Installing
Controls and components (Factory-installed or supplied)
Large LCD Backlit Display• Single unit-mounted control package, •
congurable to either unit mount or wall thermostat operation, increasing installa­tion exibility.
NOTICE
Unit mount control — If the control is
congured for unit mount control DO NOT connect a wall thermostat to the unit. See Figure 28, Page 22.
Unit mount control can be used in cool-• ing only, cooling with electric heat, heat pump, or heat pump with second stage electric heat applications.
Operational range set point temperature • adjustable between 55°F(13°C) and 90°F (32°C)in one-degree increments.
Infrared-compatible controller allows use • of optional IR hand held controller.
NOTICE
Unit-mounted controls are fully func­tional without the handheld remote.
Operation modes include Heat, Cool, • Dry, Fan and Auto Change-over.
Fan Operation – Auto/On. High or Low • speed fan
Fan Purge – Fan remains on for 60 sec-• onds aer Heat/Cool call is dropped for improved eciency (Auto mode only)
Room air sampling  Selectable time • intervals ensure the fan will cycle on peri­odically, in Auto Fan Mode to help elimi­nate room temperature stratication.
Selectable Fahrenheit (°F) or Celsius (°C) • temperature scale.
Dry mode – Operates cooling and electric • heat simultaneously to remove humidity. Optional electric heat must be selected.
Anti-Short Cycle Compressor Protec-• tion.
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 5
Verify Unit Before Installing (continued)
Minimum on time for heating and cooling • Helps eliminate room temperature droop and system short cycling.
Freeze Protection – Prevents air handler • freeze up.
Test operation – Allows ease of testing af-• ter installation (all timers are reduced).
Non-volatile back-up memory will main-• tain control seings for an indenite pe­riod during a power outage. When power is restored the equipment will resume operation aer a three-minute compres­sor time delay.
7-day programmable with copy feature.• Filter change indicator: A timer feature •
indicates when the lter should be cleaned according to the selected time.
Motorized supply louver with optional • sweep or six stationary seings.
Modular design – reduces parts required • for control package. Deco panel, relay board, ribbon cables and microprocessor are combined into one package.
Integral condensate pump safety-switch • connection where-by the microproces­sor monitors the condensate pump safety switch and displays an error code when a fault occurs. (Applies only with optional condensate pump)
CEC (California Energy Commission) • compliant
Condensate drain pan over ow protec-• tion
Cabinet Features:
Durable ABS plastic cabinet with a galva-• nized steel sub-chassis.
Easily accessible, washable, reusable, • nylon mesh lter.
Horizontal discharge louver, constructed • of high temperature ABS plastic, that can be set to oscillate, or can be parked in six pre-set positions.
Manually adjustable vertical discharge • ns.
Easy access to pipe chase area from cabi-• net boom allows piping connections and condensate pump installation with the unit mounted on the wall.
Easily removable end-cap for access to • control area for installation and service.
Condensate drain pan constructed of gal-• vanized steel (G90U), with anti-corrosion coating.
Modular snap-in, 7-day programmable • control with large backlit LCD display, a “Change lter” display feature and se­lectable Fahrenheit (°F), or Celsius (°C) temperature scale.
Optional Equipment
Condensate pump (eld installed only)• 24V wall thermostat • Electric heat with automatic reset high •
temperature cutout and redundant high temperature fuse link (when heat option is selected, factory installed only)
Hand-held infrared controller.•
Installer Supplied Items
Low voltage wiring (18 AWG minimum • required)
High voltage power supply wiring• Mounting screws and fasteners• Condensate piping• Refrigerant piping (if not supplied)• Refrigerant (for interconnect charge)•
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 6 P/N 240008111, Rev. G [06/18/10]
Piston/Orifice Replacement (when required)
NOTICE — WLHG24 ONLY
Piston/ Orifice replacement  e factory-installed piston/orice must be replaced on Air-Handler / Condenser combitnations noted in table below
. All other applications are to use the factory-installed orice. To replace the orifce in the noted models use instruc­tions and chart as follows.
Replacing the piston/orifice
Follow the instructions on page 9 to remove the le end cap.1. e piston orice (Figure 1, pg. 6) is located in the upper le corner of the unit.2. Disassemble the orice joint, remove the factory-installed orice, and replace with the 3.
orice listed in Figure 1 (supplied in the Kit Bag). Make sure o-ring is in good condition and properly installed.
e end cap can remain o while mounting and installing the unit.4.
Piston/orifice replacementFigure 1
Model Condenser Factory-installed orifice size
(Inches)
Replacement orifice size
(Inches)
WLH_24
T2C/T2HG2400 T2C/T2HG4400 T3C/T3HG2240
0.054” 0.056”
WLH_24
T2C/T2HG9800 T2C/T2HG8800 T3C/T3HG9980
0.054” 0.049”
WLHA12
T2C/T2HG2400 T3C/T3HG2240 T3C/T3HG2220 T4C/T4HG9992 T4C/T4HG9922 T4C/T4HG2222
0.042” 0.044”
WLH_24 S1C/S1HG8000 0.054” 0.047”
To Air
Handler
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 7
Mounting the Unit
Before installing, consider:
Determine the best location for mounting • the unit for room air circulation.
Locate outdoor and indoor units as close • together as possible.
Determine how power wire (high and • low voltage) condensate drainage, and refrigerant piping may be run to and from the unit.
WLCG/WLHG - Ensure that intercon-• nect tubing is within the limits given in (Table 1, pg. 7)
Tubing specificationsTable 1
S1CG
or
S2CG
Model
Max.
Length
Equivalent
Feet
Max.
Lift
Max.
Trap
Height
Liquid
Line
Suction
Line
“H” “P” O.D. O.D.
09
50’
(15 m)
20’
(6 m)
15’
(5 m)
1/4" 1/2"
12 1/4" 1/2"
18
100’
(30 m)
35’
(11 m)
20’
(6 m)
3/8" 5/8"
24 3/8" 3/4"
30 3/8" 3/4"
36 3/8" 3/4"
To ensure serviceability and proper air • distribution, the unit should be posi­tioned as close as possible to the center (left-to-right) of the wall. Minimum distance from the ceiling is stated on the template provided with the unit packag­ing. e cabinet le and right end caps must be accessible for removal without obstruction. (See Figure 2, Page 7.)
Site preparation
e WLCG/WLHG must be mounted plumb and level to a vertical surface to prevent unit vibration and/or unwanted noise. It is recom­mended that the unit be mounted directly to a
NOTICE
If excessive noise or vibration is experi­enced from a unit mounted to a masonry block wall, check to ensure the unit is plumb and level. If noise or vibration per­sists, contact the wholesale distributor.
Minimum service clearancesFigure 2
Ceiling
wall
wall
4” Minimum
10”
Minimum
6”
Min.
Mounting templateFigure 3
NOTICE
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 a pipe chase.
smooth surface such as Sheetrock® wallboard or similar material. If mounting to a masonry block wall, there should be a smooth bar­rier between the unit and the masonry block surface to absorb any potential vibration and prevent the formation of condensate on the wall.
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 8 P/N 240008111, Rev. G [06/18/10]
Mounting the Unit (continued)
Unit Mounting Instructions
Aer determining the best location for 1. the unit, use the cardboard template provided in the packaging (Figure 3, Page 7).
Mark where the piping, electrical wiring 2. and condensate drain should penetrate the wall.
Determine the appropriate hole size and 3. cut through the wall.
Use the supplied wall bracket. For 4. shipping purposes, the wall bracket is fastened to the back of the unit.
Secure the bracket to the wall with 5. the appropriate screws (for wood) or anchors (for masonry). Ensure the bracket is mounted in a manner that will support the weight of the unit (Figure 4, Page 8).
To mount the unit to the bracket, align 6. the mounting slot on the back of the unit over the bracket and make certain it ts properly (Figure 5, Page 8).
WARNING
Replace all panels aer installation or servicing. Panels must remain on the unit at all times while powered and in operation.
Wall hanging bracketFigure 4
Remove and discard
these screws
NOTICE
e wall hanging bracket is not located in the center of the unit.
Mounting to wall bracketFigure 5
Mounting
slot
Slot for piping
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 9
Electrical Wiring
Before removing end capFigure 6
Helpful Tip:
Prior to remov-
ing the end
cap and
bottom use a
small
board to
prop the unit
away from the wall.
Removing end cap
Figure 7
Rotate louver down to expose Figure 8 screw
NOTICE
All electrical wiring must be run accord­ing to NEC and local codes.
Site preparation for wiring
WARNING
Electrical shock hazard  Make sure the power is o before proceeding.
Check the unit rating plate for minimum 1. circuit ampacity and breaker or time delay fuse size. Use only HACR type breakers. Select the proper wire for the ampacity rating.
Each unit must have a separate branch 2. circuit protected by a time delay fuse or breaker. Refer to the unit rating plate for the proper wire and breaker or time delay fuse size.
Inspect the existing wiring for any defects 3. such as cut or frayed wires. Replace if any such wiring if found.
e le end cap of the unit needs to be 4. removed to access wiring diagram and electrical wiring. is requires removal of three screws (Figure 6, Page 9 and Figure 7, Page 9).
Rotate louver down to expose the third 5. screw (Figure 8, Page 9).
Once the screws are removed, slide the 6. le end cap o to expose control box and locate the wiring diagram on the inside of the end cap.
NOTICE
On units rated 208/230V, the primary side of the transformer is factory wired for 230V. For a 208V power supply, the transformer tap must be changed from orange to red. Refer to the wiring diagram located on the inside of the le end cap of the unit.
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 10 P/N 240008111, Rev. G [06/18/10]
Electrical Wiring (continued)
Wiring diagram locationFigure 9
control box
Remove screw
Wiring connectionsFigure 10
Low Voltage
connections
Ground L1 L2
Connect wiring
To access High and Low volt wiring re-1. move the screw on the front of the control box. (Figure 9, pg. 10)
High voltage electrical wiring
Refer to the wiring diagram to connect the 1. power wire to Black L1 and the other wire to Red or White (115V) L2 at the power connector location. (Figure 10, pg. 10)
Connect the ground wire to the ground 2. lug or lead at the same location in the control box.
WARNING
Terminate ALL unused wires with a wire nut or crimp connector.
Low voltage electrical wiring
(for unit-mounted controls)
The 24V control transformer is located 1. in the air handler. is provides low Volt
control power to both the air handler and condenser. Depending on the mod­els selected, the low volt interconnect control wiring may be eected. (Figure 10, pg. 10)
NOTICE
All low voltage interconnect wiring must be at least 18 AWG.
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 11
Electrical Wiring (continued)
Units with or without heat
NOTICE
All low voltage interconnect wiring must be at least 18 AWG.
Cooling-only
Cooling only units utilize two low volt in­terconnecting wires between the indoor and outdoor units.
Wires designated “Y” (yellow) and “C” (brown) of the air handler should be con­nected to the corresponding “Y” (yellow) and “C” (brown) wires or terminals of the condenser (Figure 11, Page 11).
Other wires or terminals such as “R” (red) or “O” (orange) may not be needed and should be protected by a wire nut from making contact with the junction box or other metal surfaces.
Heat pump connection
Heat Pump Connection: In addition to the “Y” and “C” connections required for cooling, heat pumps require a reversing valve control wire “O” (orange) that is energized in the cooling mode.
If the indoor unit has an electric heater, then a ”W” (white) wire connection will also be needed to energize the indoor electric heat. If a wall thermostat is used.
Heat pumps models require an “R” connec­tion between the indoor and outdoor unit to provide power to the defrost control board in the condenser (Figure 12, Page 11).
Unit-mounted controls — Figure 11 cooling only
Unit-mounted controls — Figure 12 heat pump connection, two­stage heating
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 12 P/N 240008111, Rev. G [06/18/10]
Electrical Wiring (continued)
Wall thermostat controls
For remote wall mounted thermostat layout see ­(Figure 13, pg. 12)
NOTICE
All low voltage interconnect wiring must be at least 18 AWG.
NOTICE
Unit mount control — If the control
is configured for unit mount control DO NOT connect a wall thermostat to the unit.
The 24V control transformer is located in the air handler unit
. is provides low volt control power to both the air handler and condenser. Depending on the models selected, the inter­connect control wiring may be eected.
NOTICE
For wall thermostat mode, the key pad will have limited operation (see Se­quence of Operation  Wall-mounted thermostat, page 29).
Choosing a remote wall-mounted thermostat
See page 29 for wall thermostat selection information.
Depending on the thermostat required or se­lected, air handlers may utilize four to six low volt interconnecting wires between the indoor unit, thermostat and outdoor unit.
Some thermostats do not require the use of the “C” (brown) connection. In this case, ensure that any unused wires are insulated with a wire nut to prevent them from making contact with the junction box or other metal surfaces.
Wall-mounted thermostat Figure 13 configuration — cooling only
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 13
Electrical Wiring (continued)
Electric heat applications
(Figure 14, Page 13) If the indoor unit has electric heat then a “W”
connection is required between the thermo­stat and indoor unit.
Some thermostats do not require the use of the “C” (brown) connection.
Heat pump applications
(Figure 15, Page 13) Heat pump operation requires the connection
of the “O” (orange) terminal from the outdoor unit to the thermostat.
e reversing valve is energized in the cool­ing mode for EMI models S1HG heat pump condensers.
NOTICE
Heat pumps only: Two-stage heating
requires the combination of a heat pump condenser and an indoor unit that is equipped with an electric strip heater. e indoor electric heater will energize as the second stage heat source (the tem­perature is dependent on the thermostat selected) and also during the defrost mode for all heat pump models.
Finishing
Ensure that any unused wires are insulated with a wire nut to prevent contact with the junction box or other metal surfaces.
Once certain all electrical connections are made replace control box cover.
control box
Replace screw
Wall-mounted thermostat Figure 14 configuration — cooling + electric heat
Wall-mounted thermostat Figure 15 configuration — cooling + heat pump
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
Comfort where it counts 14 P/N 240008111, Rev. G [06/18/10]
Refrigerant Piping
CAUTION
Avoid piping on wet and rainy days.• Use only clean, refrigeration-grade •
copper tubing. Use tubing benders to guard against •
kinking. Be certain no burrs remain on the •
ings. Cap ends of lines until ready for con-•
nections. Be certain that plastic end caps remain in place when inserting through wall openings.
Insulate the suction line.• Isolate tubing from transmiing vibra-•
tion to the building or unit and avoid contact with sharp edges.
Wrap refrigeration valves with a wet • rag “heat sink” to protect valves while brazing. (See Figure 14, Page 15.)
DO NOT use a suction line size larger • than the condenser service valve con­nection. is can harm the compres­sor. Install a reducer, when used, only on the inside connection.
Preparing for piping
With the unit mounted and leveled per 1. instructions beginning on page 7.
Leave the le end cap o of the unit to 2. allow removal of the boom panel.
Remove the Phillips-heads screws on the 3. boom of the unit and remove the boom panel (Figure 16, Page 14).
See (Figure 17, Page 14) for locations of 4. the piping connections in the WLCG/ WLHG unit.
Removing bottom panelFigure 16
Piping connections at unitFigure 17
Suction line (When a reducing bushing is required, install only here, at the indoor suction-line connec­tion.)
Liquid line
condensate drain
WLCG/WLHG
High-Wall Air Handlers
Installation, Operation and Maintenance Manual
P/N 240008111, Rev. G [06/18/10] 15
Refrigerant Piping (continued)
Clean ends of tubingFigure 18
Place wet rag “heat shield” over Figure 19 valves plus a sheet metal shield to protect paint
Wet rag heat sink
Shield
NOTICE
e WLCG/WLHG is equipped with a Flo Rater piston expansion device or TXV. Connections are sweat type.
Line sizing
Size lines per (Table 7, Page 43).1. e suction line size must match the con-2.
denser service valve connection.
When matching the WLHG24 with a. an 18,000-Btuh condenser, you must use a 5/8-inch suction line, with a reducer installed as shown in (Fig­ure 17, Page 14).
Refrigerant piping
Clean the ends of tubing and insert into 1. ings (Figure 18 page 15).
Before brazing (Figure 19 page 15):2.
Protect valves by wrapping with a wet a. rag “heat sink” before brazing. Use a shield to protect the paint as b. shown. (e shield can be made from scrap metal.)
Braze tubing into ings, using a continu-3. ous nitrogen purge.
e suction line must be insulated the 4. entire length with closed cell, foam tube insulation.
Do not insulate the liquid line.5. Connect the outdoor unit according to 6.
the instructions supplied with unit. All horizontal piping runs must be level 7.
and without dips to trap the oil.
CAUTION
Pressure test all eld installed piping with nitrogen. Using a suitable vacuum pump,
evacuate the tubing and indoor unit to 500 microns or less, with service valves remaining front seated (closed).
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