EMI CAC User's Manual
Contents
1. CFM CFM CFM Faces 1900 1160 960 CAC TECHNICAL DATA REFRIGERATION 09 12 18 24 30 36 Refrigerant Type INDOOR SOUND LEVELS dBa Ses eel en ieee ae sa O I SE Em 30 36 Branch Duct 6o 6 o Type Washable Mesh WEIGHT CONDENSATE PUMP 09 12 1824 30 36 Must bushdown to 5 8 interconnect for 18K system Mesured from bottom of unit CAC Cassette Evaporator www enviromaster com CAC CASSETTE DIMENSIONS Small Cabinet e CAC 9 000 12 000 m 22 50 FEATURE QTY SIZE Optional Discharge 3 SHS Knockout Fresh Air Inlet 498 A Condensate iam D suction 1 wo ef uu __ 1 wo Condensate 1 Pump Access CAC Cassette Evaporator www enviromaster com CAC CASSETTE DIMENSIONS Medium Cabinet e CAC 18 000 24 000 30 40 FEATURE Long SIZE Optional Discharge DE a Lee Fresh Air Inlet n r 1 631 Sl eee sz Condensate W a Poy sein ee eren i wo Condensate Pump i mar Access CAC Cassette Evaporator www enviromaster com CAC CASSETTE DIMENSIONS Large Cabinet e CAC 30 000 36 000 d Di A 47 76 DU IU d ETE _ SS ees p eg EH eg YN Ld SS LL TF EH Y _ e ld eee ___ _ CC m Ld Leg T c Ld l FEATURE QTY SIZE Optional Discharge v A gel2. Suction Line Liquid Line Any change in the diameter of the tubing MUST be made at the indoor connec tion Line set diameter is determined by the condenser valve size Use of a larger line can harm the compressor PIPE INSTALLATION NOTES 1 Maximum equivalent pipe run should be no more than 100 with a maximum rise of 35 2 Horizontal pipe runs should be slight ly inclined so as to encourage oil to flow in the direction of the compres sor for better oil return Good refrigeration practices must be employed to ensure the correct pressure drop and good oil return When matching a the CAC24 with an 18 000 Btuh condenser the interconnecting suction line needs to be 5 8 O D to match the condenser service valve connection Therefore the 3 4 O D suction connection of the CAC24 unit needs to be reduced to 5 8 at the CAC24 unit connection to match the 5 8 line of the condenser 5 8 bushing goes on suction line Only when matched to an 18 000 Btuh condenser www enviromaster com CAC Cassette Evaporator CAC CASSETTE EVAPORATOR FASCIA INSTALLATION INSTRUCTIONS Assembly Instructions 1 To install the four fascia mounting bolts a Remove the bolts and wash ers from the supplied kit bag de b Put washers onto the bolts N c Screw the mounting bolt with washer into the chassis leav R ing approximately 1 to hang e the fascia 7 2 Ensure the white fir tre
3. improper servicing unauthorized alteration or improper operation e Damage as a result of floods winds fires lightening accidents corrosive atmosphere or other conditions beyond the control of EMI Parts not supplied or designated by EMI Products installed outside the United States or Canada Any damages to person or property of whatever kind direct or indirect special or consequential Whether resulting from use or loss of use of the product LIMITATION OF WARRANTIES This warranty is exclusive and in lieu of any implied warranties of merchantability and fitness for a particular purpose and all other warranties express or implied The remedies provided for in this warranty are exclusive and shall constitute the only liabilities on the part of EMI including any statements made by any individual which shall be of no effect FOR SERVICE OR REPAIR 1 Contact the Installer 2 Call the nearest Distributor 3 Call or write E E Evan Comfort Where It Counts Enviromaster International LLC 5780 Success Drive Rome NY 13440 www enviromaster com CAC Cassette Evaporator www enviromaster com EMI S HIGH EFFICIENCY PRODUCT LINE EVAPORATORS WLC WLH CAC High Wall Evaporator Cassette Evaporator i dhe e b nn MMA R SS E ee IE I if ie L E m e Fe Ce sss S1C amp S1H Single Zone S2C Dual Zone Side Discharge Side Discharge eup nm RR T2C T3C amp T4C 2 3 amp 4 Zone Top Di
4. aluminum fins tested to 600 psig The tubes are mechanically expanded for secure bonding to fin shoulder AY Refrigeration Circuit Units are equipped with a serviceable fixed orifice expansion device ar Controls and Components factory installed or supplied Connections for 24V remote wall ther mostat Custom control board featuring anti short cycle timer 60 second post purge fan relay and on board 30 amp electric heat relay e Relays and connectors to condensing unit e Condensate Pump with 36 lift mea sured from base of unit 24V Transformer a System Options 24V remote wall thermostat Electric Heat 230V 1 5KW 9 000 12 000 Btuh 3KW 18 000 24 000 Btuh SKW 30 000 36 000 Btuh CAC Cassette Evaporator www enviromaster com CAC CASSETTE CONTROLS AND COMPONENTS Continued AY Electromechanical Operation Stan dard An optional thermostat can be ob tained through EMI or your local distributor NOTE make sure the thermostat is suitable for unit operation i e cool ing only cooling electric heat etc AY Filters Metal framed filters are fitted These are reusable and may be vacuum cleaned AY Condensate pump A condensate pump is designed 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
5. cuit will open and low Volt power to the CAC Cassette Evaporator 23 symptom of another problem CAC air handler units are equipped with freeze protection to prevent freeze up from occurring If freeze up does occur then check the following e Check that the freeze sensor inserted fully and snug in the coil fin If not an other location may need to be select ed Be careful not to insert the sensor directly into the coil tube rather insert the sensor between two tubes Check the indoor air filter It should be clean and free of dirt A dirty filter will reduce airflow and efficiency Also check that the coil is clean If the coil is dirty then it should be cleaned us ing an appropriate coil cleaner or mild detergent www enviromaster com TROUBLESHOOTING PROCEDURE Continued Frequently Asked Questions Continued Is the equipment being operated in Is the equipment being operated in cooling mode when outdoor tempera cooling mode when outdoor tempera tures are below 65 F If it is then the tures are below 65 F If it is then the condenser should be fitted with low condenser should be fitted with low ambient control so that the proper ambient control so that the proper system pressures are maintained system pressures are maintained CAC PERFORMANCE DATA NOTE Due to EMI s ongoing product development program all designs and specifications are subject to change without notice DISCHARGE AIR VOLUME Dry Coil
6. to better 1 800 228 9364 serve you please complete and have Test Unit Performance Data Date Model Number Technician Serial Number Cooling Indoor Section Evaporator Entering Air DB Evaporator Entering Air WB Evaporator Leaving Air DB Evaporator Leaving Air WB Outdoor Section Entering Air Leaving Air Temperature Split Operating Pressures Compressor Suction PSIG Compressor Discharge PSIG Power Input Compressor Volts Compressor Amps OD Fan Motor Volts OD Fan Motor Amps D Fan Motor Volts ID Fan Motor Amps Total Volts Total Amps Temperatures Degrees F Compressor Suction Compressor Discharge Liquid Out Cond Liquid before Expansion Suction out Evaporator Capacity Calculations DB Temp Split at evap Test Summary Compressor Supemeat T ar BSG CAC Cassette Evaporator www enviromaster com MAINTENANCE AND TROUBLESHOOTING PROCEDURE MAINTENANCE WARNING 3 Lift the filter off the grille Place filter on a flat surface and vacuum any away dust and debris vacuum all filters and grills also vacuum any accessable parts on the unit Turn the POWER OFF to the unit be fore servicing or cleaning Service should be performed by a qualified service agency An annual sys tem check is recommended EMI units are designed and constructed for reliability and long life with minimal maintenance To insure peak operating efficiency 1 Clean air filter s on a monthly basis a Th
7. 2C dual zone side discharge condensing units or with T2C T3C or T4C top discharge multi zone condensing units Refer to specifications contained in this document All EMI Air Handlers are backed by Enviromaster International LLC and are tested and rated in accordance with ARI standards 210 240 and UL 1995 STANDARD FEATURES AY Materials of Construction Galva nized steel cabinet with fire resistant thermal and acoustic foam insulation and light grey high impact ABS fascia A Styro foam drain pan with a tough fire retardant thermoplastic liner AY pir Systems Fans are backward curved impeller centrifugal design dynamically and statically balanced and mounted on integral mounting rails STANDARD FEATURES Continued Single Fan models 09 24 designed with fire retardant plastic or aluminum impellers Twin Fan models 30 36 designed with fire retardant plastic impellers Motors are multispeed enclosed type with thermal protection and sealed life time bearings Permanent washable filter user ac cessible Branch duct knockouts on two sides for remote discharge locations Fresh air intake capability on three sides of cabinet 2 on CAC 09 12 Four plastic air vanes motor driven with auto sweep or fixed position stop setting on models 18 36 models 09 12 eguipped with manually adjusted air vanes ax Coil Coil is seamless copper tubing arranged in staggered configuration with enhanced
8. 9364 and one can be faxed or mailed Please have the full model and serial number available prior to calling EMI America Series evaporators are de signed to operate with EMI America Se ries condensers The evaporator indoor unit and condenser outdoor unit are to be independently connected to the electri cal service panel and protected by sepa rate time delay fuse or HACR breakers See the unit name plate for the correct breaker type and size The indoor and outdoor units are also connected to each other via a 24V interconnect wiring A transformer provides the low Volt power source for the controls The number of low Volt interconnect conductors will be three to five depending on heating options and or thermostat selection Interconnect wire should be at least 18awg Refer to the unit wiring diagram for the interconnect diagram that matches your system Figure 1 LOW VOLTAGE INTERCONNECT DIAGRAM L D UNIT O D UNIT WALL T STAT WHT W U SOME T STATS MAY NOT HAVE A C TERMINAL OPTIONAL Power Supply Check Power supply check When troubleshooting any EMI product it is important to first check the rating plate for proper field Voltage and breaker size Secondly using a Voltmeter check the incoming power supply to see that it agrees with the rating plate The incoming power should not exceed the nameplate Voltage Also the incoming power should not be below the minimum Voltage stated on th
9. CAC CASSETTE DUCTLESS SPLIT SYSTEM EVAPORATOR STRAIGHT COOL Es M Nominal Circuit Capacities lr w IW Ii U I 9 000 12 000 18 000 24 000 Comfort Where It Counts 30 000 36 000 Btuh S gt S 7 S S S S z 9 12 Model Shown CAC Enviromaster International LLC AY cR Int 7 l 5780 Success Dr An n ernationa Brand Rome NY 13440 An ISO 9001 2000 Certified Company RP yg www enviromaster com P N 240006022 Rev 1 1 08 06 CAC CASSETTE HIGH EFFICIENCY EVAPORATOR INSTALLATION OPERATION AND MAINTENANCE MANUAL P N 240006022 Rev 1 1 08 06 This manual is intended as an aid to a qualified service personnel for proper installation operation and maintenance of EMI AmericaSeries high efficiency evaporators Carefully read these instructions before attempting installation or operation Failure to follow these instructions may result in improper installation operation service or maintenance possibly resulting in fire electrical shock property damage personal injury or death Shipping Damage MUST be Report ed to the Carrier IMMEDIATELY Examine the exterior Remove cover and examine compressor and piping for signs of damage TO THE INSTALLER EMI AmericaSeries Unit are Certified for R 22 Refrigerant ONLY 1 Retain this manual and warranty for future reference 2 Before leaving the premises review this manual to be sure the unit has been installed correctly and run t
10. Only one transformer is required Q How long will the fan run If both the indoor unit and outdoor unit contain a transformer one must be re A While the unit is in cooling or heating mover from the system The condenser will not start although the indoor unit appears normal What should I do At the indoor thermostat make sure that the control is in cooling and the and auto fan mode is selected the fan will cycle with the call for cooling or heating When the room tempera ture reaches setpoint temperature the heat cool call is dropped The fan will then stay on for an additional 60 sec to purge unit of any residual energy setpoint temperature is below room Q What causes my indoor unit to freeze up temperature Next using a Volt meter check for 24V across the yellow Y A Evaporator freeze up is usually the and brown C wires If 24V is present then check for wiring breaks or improp er connections between the indoor and outdoor units Some EMI condensers are eguipped with a manual reset high pressure switch It is located on the high side of the system usually on the discharge line of the compressor To reset sim ply push the red button in If the switch was tripped there will be a click when it resets CAC air handlers are equipped with an internal condensate pump with a high level safety switch If the condensate reaches a critical level or if power is lost to the indoor unit the safety cir
11. U CACA12 T4CA9992 39 000 13 0 CACA12 T4CA9922 42 000 11 8 N WT ER T ATER TE i CE a L l e ARI Standard LISTE Listed 210 240 UAC CAC Cassette Evaporator 29 www enviromaster com ALL PRODUCT LIMITED WARRANTY Enviromaster International LLC EMI warrants to the purchaser owner that EMI prod ucts will be free from defects in material and workmanship under the normal use and maintenance for a period of twelve months for all components and sixty months on unit compressors from the date of original installation or fifteen months for all components and sixty three months on unit compressors from the date of manufacture whichever comes first WHAT WE WILL COVER EMI will replace any defective part returned to EMI s approved service organization with a new or rebuilt part at no charge The replacement part assumes that unused portion of this warranty WHAT WE DON T COVER THIS WARRANTY DOES NOT INCLUDE LABOR or other costs incurred for repairing removing installing shipping servicing or handling of either defective or replacement parts EMI IS NOT RESPONSIBLE FOR Normal maintenance Damage or repairs required as a consequence of faulty installation or application by others Failure to start due to Voltage conditions blown fuses open circuit breakers or other damages due to the inadeguacy or interruption of electrical service Damage or repairs needed as a conseguence of any misapplication abuse
12. a so Fresh Air Inlet 3 3 Knockout c Condensate 4 Discharge Suction D E Liquid Condensate Pump Access CAC Cassette Evaporator www enviromaster com CAC ELECTRICAL SPECIFICATIONS NOTE Due to EMI s ongoing product development program all designs and specifications are subject to change without notice CAC ELECTRICAL SPECIFICATIONS modei Fen Motor 1 ElectHeat Total Min Tue x HACR ge ren RLA H P KW LAMPS AMPS Volt BRKR Small Cabinet 09 12 eane 2o 035 ino 04 ur os 15 aen oee 025 mo 151652 69 i as 15 Medium Cabinet 18 24 TET oss 18 oe wr or 15 Large Cabinet 30 36 TEE 05 05 110 wel 10 rr 12 15 CAC CASSETTE SYSTEM MATCHES S2C Side Discharge COOLING SYSTEMS WITH CASSETTE UNITS Condenser Cassette Btuh SEER SHR R22 R R R22 R22 COOLING SYSTEMS WITH S2C SIDE DISCHARGE e Condenser stun SEER SH CAC Cassette Evaporator www enviromaster com CAC CASSETTE SYSTEM MATCHES T2C T3C amp T4C Top Discharge P SYSTEM OPTIONS WITH T2C TOP DISCHARGE _Cassette s Condenser Btuh SEER SHR EER SYSTEM OPTIONS WITH T3C TOP DISCHARGE Cassette s Condenser SEER SHR Te 3 CACA12 CACA24 R22 CACA12 11 8 R22 CACA12 CACA24 T3CA928 39 000 13 0 80 11 7 R22 CACA12 CACA24 11 7 R22 CACA12 CACA24 R22 SYSTEM OPTIONS WITH T4C TOP DISCHARGE O O H
13. be blanked off Hing Large Unit Not Shown The large units have three hinged grills and three filters CAC Cassette Evaporator www enviromaster com PISTON ORIFICE INSTALLATION INSTRUCTION Evaporator Importent Replace the existing piston before installing the unit with the piston supplied in the Kit Bag when a CACA24 evaporator is matched with a T2CA4400 T2CA2400 T2CA8400 or T3CA9240 T3CA2240 T3CA9940 condenser which has a 24 000 Btuh compressor 4 in the capacity decoding field the piston will need relacement only on the 24 000 Btuh zone Your EMI evaporator unit contains the appropriate piston for your model Refer to this document to determine if a change is required based on your condenser rating If your match is not listed below no piston change is required See chart Model Condenser Factory Installed Field Changeover Evaporator Btuh Piston Orifice Size Piston Orifice Size T2CA4400 T2CA8400 T3CA9240 CACA24 T3CA2240 059 063 T3CA9940 4 in the capacity decoding field 24 000 Btuh CAC CASSETTE PREPARATION AND POSITIONING POSITIONING 6 There should be a minimum 1 clear ance above the depth of the Cassette The Cassette installation position should be and the false ceiling for proper instal selected with the following points in mind lation shown below see the CAC Di 1 Pipe work electrical connections con mensions section in the back of this trol box and co
14. ck the unit s rating plate for your models electrical requirements The wires should be capable of carry ing the maximum load current under non fault conditions at the stipulated Voltages Avoid large Voltage drops on cable runs particularly in low Voltage wir ing 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 Low Volt wiring must be at least 18 awg All wiring should be in accordance with the National Electric Code NEC and the local building codes 1 Make sure power is off 2 Inspect the existing wiring for any de ficiencies such as cut or frayed wires Replace if any such wiring if found 3 Remove the 4 screws securing the control box cover 4 Slide cover up and out to remove 9 Therating plate is located on the outside of control box cover see Low Volt Inter connecting Wiring section for location of wiring diagram ees MOVING PARTS sau DO NOT OPEMATE UNIT WITH _ SABINET REMOVED i CAUTION SE POWER BCURCE BEFORE SERVICING E ann rwg AW emeng 6 Check the unit rating plate for circuit ampacity and breaker or fuse size Use only HACR type breakers Select the proper wire for the ampacity rating 7 Each unit must have a separate branch circuit protected by a fuse or breaker Refer to the unit rating plate for the prope
15. e fasteners holding the fascia polystyrene are pushed firmly in they may have loosened in transit 3 Lift the fascia onto the chassis mount ing bolts Align the key hole brackets with the mounting bolts and slide the fascia forward to lock into position Note The fascia only fits correctly one way Position the fascia so that the AmericaSeries logo is on the control box end of the chassis CAC Cassette Evaporator 4 On 18 36k units connect the vane motor plug by plugging it into the socket con nection on the chassis a Ensure that the connector is in the proper orientation Female vane motor plug on chassis Male vane motor plug on fascia b Route the wires in a way that en sures they won t become trapped cut broken or chaffed 5 The fascia can now be tight ened up to the Cassette chassis Make sure a good seal is obtained between fascia and chassis this is neces sary to prevent recir culation Note Do not over tight en the bolts To do so may cause damage to the fascia With filter s in place the inlet grille s can now be installed onto the fascia To complete the installation adjust the lou ver position to 30 from plumb this is recom mended for optimum system per formance 11 www enviromaster com CAC CASSETTE EVAPORATOR INSTALLATION INSTRUCTIONS Electrical Wiring The standard unit Voltage is 208 230V 60Hz 1Ph Che
16. e filter s are accessed by removing the air intake access grille s 4 Replace the filter V by sliding under retainer clips 5 Or use a garden hose Remove the grille and filter and hose off Let filter s and grille s dry before replacing Allowing dust to collect on the filter will cause the unit to lose efficiency and may eventually malfunction 6 The unit may be wiped with a damp cloth when needed 2 Remove the filter by carefully twisting and lifting to clear the retaining clips 7 Be sure to replace filters and grill before running the unit Note Do not run the unit without the filter s or the grille s 20 www enviromaster com CAC Cassette Evaporator TROUBLESHOOTING PROCEDURE For CAC Air Handlers With Remote Thermostat Controls WARNING All service should be performed by a qualified service technician Before re moving access panels or control covers to expose moving parts of non insulate live electrical components for service disconnect all high Volt power supplies to both the indoor unit and outdoor unit Failure to do so could result in physical injury and or electrical shock When troubleshooting the indoor unit please refer to the wiring diagram that is supplied with the equipment It is located on the back of the control access panel If you are unable to locate the wiring dia gram please feel free to call the factory technical service line at 800 228
17. e rating plate 197V for units rated 208 230V A check for low Voltage power should also be made By placing a Voltmeter across low Volt terminals R and C at the indoor unit there should be a reading of 24V www enviromaster com CAC Cassette Evaporator TROUBLESHOOTING PROCEDURE Continued Low Volt Controls av Cooling Only Units Cooling only units require 18awg low Volt interconnecting wires between the indoor unit outdoor units and thermostat Ter minals designated Y1 yellow and C brown of the indoor air handler should be connected to the corresponding Y yellow and C brown wires or termi nals of the outdoor condenser Other wire s or terminals such as R red may not be needed and should be protect from making contact with the junction box or other metal surfaces Terminals R Y G W and C need to connect to the indoor wall mounted thermostat NOTE W is required for units with electric heat only C may not be needed on some thermostats Refer to low Volt interconnect diagram interconnect diagram figure 1 for remote thermostat connection A 24V transformer located in the indoor air handler unit provides low Volt control power to both the indoor air handler and outdoor condenser The 24v power sup ply can be measured by placing a meter across the R and C low Volt termi nals of the air handler The remot
18. e wall mounted thermostat will switch on and off the condenser through the yellow Y and black Y1 wires When the thermostat is calling for cooling 24V can be measured between terminals wires Y and C The indoor unit contains an electronic anti short cycle timer feature ASCT that will prevent the outdoor condenser from short cycling After the thermostat is satisfied there will be a three minute delay before the condenser is allowed to re start AY Electric Heat Units with electric heat utilize a control relay located on the circuit board in the control box As a safety feature an auto resetting limit switch located on the heat er assembly will interrupt power to the heater should an over temperature condi tion occur Each electric heat assembly is also equipped with a one time fuse link Should electric heat temperatures rise above the auto resetting limit switch a non resetting one time fuse link will open and the heater will remain off If this oc curs the limit switch assembly must be re placed Contact EMI technical service for a replacement The following current values apply when the unit is connected to a 230V power supply These values include fan motor current If the supply power is different this will in turn affect the amp draw of the heater Skw 22 3 amps 3kw 13 5 amps 1 5kw 6 9 amps ay Units with Condensation Pumps EMI CAC is equipped with an internal condensate pump capable of removi
19. electrical supply before AY servicing the EMI AmericaSeries evaporator Ensure that there is no power to any part of the equipment and both the indoor and outdoor units are switched off Do not use the EMI AmericaSeries evaporators if it has damaged wiring is not working properly or has been damaged or dropped Save These Instructions Ensure there are no power feeds to the unit such as fire alarm circuits BMS circuits etc www enviromaster com PRODUCT DESCRIPTION The EMI AmericaSeries Cassette Evaporator is available in three cabinet sizes with six cooling output capacities from 9 000 36 000 Btuh in DX refrigeration Key features include a condensate pump with safety switch and a 36 lift electric heat is a factory installed option ONLY there are no field installed electric heat kits available fresh air inlet and branch duct knockouts and motorized air vanes 18 36 only The CAC accepts a 24 Volt thermo stat control thermostat not included De signed for low noise levels easy installation and maintenance and a slim line fascia all ensure minimum intrusion into the working environment Due to ongoing product development all designs and specifications are subject to change without notice Condensate pump lift measured from the base or bottom of the unit This American made CAC Cassette Evaporator produces system SEER s meet ing or exceeding 13 when matched with EMI s S1C single zone or S
20. h duct and fresh air dance with good refrigeration and or duct collars can be attached to the Cas plumbing practices sette chassis by following the steps below The Cassette is supplied with a 1 2 I D flexible PVC hose for connection to Condensate Drain Connection copper or plastic drain pipework When installing the Cassette the following points should be remembered 1 Maximum pump lift is 36 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 NOTE There is a check valve at the pump discharge to prevent water from draining back into the unit This piping technique will minimize any is sues Should the check valve become stuck open from airborne debris 1 Locating the knock out holes Branch Duct Knockout Medium amp Ss Large Units Incorrect Fresh Air Knockout 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 36 of pipework from the Cassette Notes The number of knock outs var ies depending on unit size e Branch duct knock outs are 574 round e Fresh air knock outs are 1 x 2 4 When multiple Cassettes are connect rectangular on 12k and 3 sguare on ed to a common condensate drain 24 36k ensure the drai
21. he unit for one complete cycle to make sure it functions properly To obtain technical service or warranty assistance during or after the installation of this unit check our website www enviromaster com or call your installing contractor or distributor Our technical service department may be contacted at 1 800 228 9364 When calling for assistance please have the following information ready e Model Number e Serial Number e Date of installation DANGER Tampering with the EMI America Series condensing unit is danger ous and may result in serious injury or death Tampering voids all war ranties Do not attempt to modify or change this unit in any way CAC Cassette Evaporator SAFETY INSTRUCTIONS This unit has been designed and manu factured to meet international safety standards ay AN Read all instructions before installing or using the EMI AmericaSeries high efficiency evaporator Locate and in stall this unit only in accordance with these instructions Use this unit only for its intended purpose as described in this manual Care must be taken to obtain the best results Check the rating plate on the EMI AmericaSeries evaporator before installation to make certain the Volt age shown is the same as the electric supply to the unit Y The EMI AmericaSeries evaporator must be connected only to a properly grounded electrical supply Do not fail to properly ground this unit Y Turn off the
22. hermostat ay Selecting a Thermostat By Oth ers When selecting a thermostat other than those offered by EMI it is important to choose a 24V thermostat that matches your application EMI equipment is com patible with most mercury bulb digital or power stealing thermostats av Cooling Only With Electric Heat or Hydronic Heat Select a thermostat that is compatible with a cooling electric heat system The thermostat should have R Y W and G terminals The thermo stat may also have a C terminal AN Fan Operation Some thermostats are equipped with an auto on fan switch When this switch is placed in the on po sition the indoor fan will run continuous When the switch is in the auto position the indoor fan will cycle with the call for heating or cooling AY Fan Purge The indoor unit is equipped an electronic circuit board with a purge feature After the room thermostat has been satisfied the purge feature al lows the indoor fan to remain on for an additional 60 seconds This increases ef ficiency by pulling the remaining energy from the unit av Cooling Operation The electronic circuit board of the indoor unit also has an anti short cycle timer ASCT feature designed to protect the compressor from short cycling The ASCT is activated im mediately following the off cycle of the outdoor unit Once the room temperature is satisfied and the outdoor unit switches off the ASCT will pre
23. is fitted to stop the cooling action shut off the compressor should the pump be come blocked or fail IMPORTANT Total lift for this pump is 36 or less AY Air vanes Air outlet vanes are manu ally adjustable on the 9 12K 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 AY Heating The cassette may be fitted with electric heaters which are equipped with over temperature limit switches AY 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 7 10 of the unit s published maximum air flow The cassette is best installed in new con struction or existing construction with a sus pended or false ceiling with enough clear ance to accommodate concealing the piping and electrical connections to the unit PREPARATION FOR INSTALLATION AY Unpacking The cassette fascia and main chassis are packaged together for increased protection Remove the banding straps and lift the cardboard lid Fascia is packed in bubble wrap and on top of the chassis fascia is not at tached to the chassis for shipping e Cardboard template is between the chassis and the fascia DO NOT throw template away with packaging e Lift the fascia and template from the box and se
24. n is large enough to handle the volume of condensate from several Cassettes It is also rec Recommendation No more then ommended to have an air vent in the 10 of branch duct or fresh air duct condensate pipe work to prevent any should be installed air locks CAC Cassette Evaporator www enviromaster com CONDENSATE PIPING 2 Cut the black insulation around the knock out 3 Snip the tabs holding the knock out in place 4 Remove the metal knock out and the black insulation behind it 5 Attach the duct collars field sup plied to the chassis using self tap ping screws Repeat steps 1 5 for remaining duct work REFRIGERATION PIPING Once the unit is mounted and level the Cassette piping connections can be made PIPING DO S AND DON TS Avoid piping on a rainy day Use refrigerant grade copper tubing Use a tubing bender and avoid unnec essary bending Cap ends of lines until ready for final connections NOTE Refrigerant and condensate pipes should be insulated right up to the Cassette chassis The CAC is eguipped with a Flo Rater Piston Expansion device Connections are sweat type The suction line large must be insulated the entire length with closed cell foam tube insulation Do not insulate the liquid line small Connect the outdoor unit according to the instructions supplied with unit All horizontal piping runs must be level and without dips to trap the oil
25. n or off via the toggle switch on the side of the electri cal box Toggle Switch KL gt n WS H 1 05 t e SC d r m MOVING J PART oo wer er enar Q SO Ln CABINET For units with electric heat check the operation of the heat elements by switching the system to the heating mode and set the room temperature above the set point Ensure that the Condensing Unit start up procedure has been carried out as detailed in the corresponding installa tion manual The compressor signal Y disconnect ed in step 1 can now be reconnected and main power applied to the outdoor unit CAC Cassette Evaporator www enviromaster com START UP FOR WALL THERMOSTAT CONTROL 7 To check the operation of the condensate pump remove an adjacent ceiling tile to access the condensate pump access Insert a squeeze water bottle nozzle through the opening in the condensate pump access panel and fill drain pan ly with condensate pump energized If water does not check the pipe slope or see if there are any pipe restrictions Ensure that all covers panels and fil ters are in place and discharge louvers are correctly positioned Refer to Figure 4 9 Turn the system power on and set the cooling mode to the lowest thermostat set point to run the compressor NOTE The unit is equipped with a Safety switch that will activate the pump when the condensate reaches a critical level The safety swi
26. ndensate pump access IOM for cabinet sizing panels should be readily accessible Figure 1 2 The unit should be positioned at least 5 ft from a wall or similar obstruction Dimension A 1 minimum space Position the unit as close to the center above the false ceiling for installation of the room as possible to insure air is distributed evenly 3 Position the unit so that the discharge air does not blow directly on the thermostat 4 The unit should not be positioned di rectly above any obstructions 5 The condensate drain should have suf ficient fall 1 per 10 in any horizontal run between Cassette and drain Maxi mum condensate pump lift is 36 Small Cabinet Dimension A 12 min Medium Cabinet Dimension A 111 min Large Cabinet Dimension A 1372 min CAC Cassette Evaporator www enviromaster com CAC CASSETTE CHASSIS POSITIONING AND INSTALLATION ELECTROMECHANICAL THERMOSTAT An optional thermostat can be obtained through EMI or your local distributor In addition to positioning the Cassette cor rectly it is very important to locate the wall mounted thermostat in the optimum posi tion to ensure good temperature control Therefore the installation should be se lected with the following points in mind 1 Position the thermostat approximately 5 ft above floor level 2 Avoid external walls and drafts from windows and doors 3 Avoid positioning near shelves and cu
27. ng condensate up to a three foot vertical lift Condensation generated by the evapo rator will collect in the pumps reservoir When the water level is high enough a float switch will close and energize the pump motor clearing the water from the reservoir Should for any reason the wa ter exceed the maximum preset level a safety switch will open there by interrupt ing the Y1 signal to the condenser This will prevent the evaporator from generat ing additional condensation and spilling out of the unit CAC Cassette Evaporator www enviromaster com TROUBLESHOOTING PROCEDURE Continued Frequently Asked Questions Q The system has just been installed using condenser terminal Y1 will be re an EMI indoor unit and a non EMI con denser and the unit will not operate The CAC air handlers is manufactured with a low Volt transformer installed EMI outdoor condensers are manufac tured without a low Volt transformer When connecting an EMI evaporator to a non EMI condenser check to ensure that there is a 24V control transformer in either in the indoor unit or outdoor moved The condensate pump should be checked for obstruction The con densate pump assembly can be re moved through the side access panel After removal inspect the drain pan to determine if the condensate is not being removed properly from the unit Inspect all drain lines to ensure there is no blockage preventing condensate removal unit
28. not be sup ported by any part of the Cassette unit fascia or any associated wiring or pipe work Use the template provided to cut the ceiling opening and determining the rod positions CAC Cassette Evaporator www enviromaster com CAC CASSETTE CHASSIS POSITIONING AND INSTALLATION 2 Install hanger bolts using 3 8 all thread Figure 3 rod at the centers shown in Figure 2 K CASSETTE 3 Prepare the installation guides by fold CASE ing the metal bracket by hand along the perforations INNER CASE INSULATION DA C aa E Haa a Fold E bracket along gt perforations NOTE lf the ceiling is not level or even it is important that the Cas sette is installed level to ensure cor rect pump operation and to maintain 4 Lift the Cassette onto the hanging rods fan clearances Place a carpenter s Leveled at the correct distance from level on the unit A maximum slope the ceiling with the aid of the installa of 1 8 toward the condensate drain tion guides as shown Figure 3 is allowed Any slight discrepancy 5 Secure unit in position with locknuts and between the Cassette and ceiling will washers on either side of the Cassette be taken up by the fascia foam seal bracket 6 Ensure threaded rod does not pro trude more than 2 below the mounting bracket CAC Cassette Evaporator www enviromaster com CONDENSATE PIPING The unit can now be piped up in accor _ AY Duct collars Branc
29. r tains as these restrict air movement 4 Avoid heat sources direct sunlight heaters dimmer switches etc 5 Seal wiring holes in the wall behind the thermostat to avoid drafts MOUNTING THE CAC CASSETTE CEILING EVAPORATOR AY Ceiling opening In existing construction Remove enough ceiling panels to provide clearance space for mounting unit to ceiling joists e Before beginning the installation inspect the unit location test the strength of the ceiling joists to insure they will support the weight of the unit Determine mounting method On wooden beams use threaded rods washers and nuts to suspend support brackets With metal structures secure thread ed rods on an existing angle or install a new support angle On newly built concrete slabs secure threaded rods with inserts and em bedded bolts For previously built concrete slabs install hanging bolts with an expansion anchor Follow local building codes for required safety cables braces etc An opening in the false ceiling will have to be cut to the following sizes Small cabinet 23 x 23 Medium cabinet 33 x 33 Large cabinet 46 x 3378 Figure 2 Cabinet A mU oe Z medium 2 T A template for ceiling cut out and rod posi tions can be found with the Cassette unit 2 000 X 45 TYP MM NOTE Make sure the ceiling grid is supported separately from the Cas sette The ceiling must
30. r wire and breaker or fuse size 8 It is also recommended that a local dis connect switch be connected within 3 of the unit In some areas this may be a code reguirement CAC Cassette Evaporator www enviromaster com CAC CASSETTE EVAPORATOR INSTALLATION INSTRUCTIONS High Volt Electrical Wiring 1 Route the cable through the appropriate L1 hole in the control box for the High Volt electrical wiring L2 High Volt Electric Cable Rach si Pa P lt 2 a ke GA Low Volt Electrical Connections Ground Wire Ground Lug ER 4 Then refer to the wiring diagram to 3 Refer to the wiring diagram see below connect the power wire to L1 and the to connect the ground wire to the ground other wire to L2 at the power connector lug location terminal block Low Volt Interconnect Wiring Refer to the wiring diagram to connect the low Volt wiring to _ _ the appropriate terminals The wiring even Ge Sp on the inside of the con trol box cover Once the connections are made replace control box cover with the wiring diagram facing in and secure with the four screws NOTE All low Volt interconnect wiring must be at least 18 awg The 24V control transformer is located in the air handler unit This 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 different CAC Cassette Evaporator ww
31. scharge CAC Cassette Evaporator www enviromaster com
32. t aside Remove the Cassette chassis from the box utilizing the four corner brackets for lifting DO NOT use the drain or re frigerant connections 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 AY 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 oppos ing sides may be blanked off DO NOT throw the two polystyrene blanking off pieces out with packaging www enviromaster com CAC Cassette Evaporator BLANKING OFF Optional The fascia discharge slot s will need blanking off when ducts are used to channel the conditioned air to other areas The two polystyrene blanking off strips provided will need to be positioned in the fascia discharge slots to direct the air to the ducts If the fascia discharge slot needs blanking off 2 Once the grille s and filter s are re 1 Remove the inlet grille s and filter s moved turn the fascia over so the poly styrene insulation is exposed The small unit has is one grille and one filter 3 Take one of the polystyrene blanking off pieces and push it into the recess in the polystyrene fascia insulation Blanking Off Bi Pieces Medium units have two hinged grills that open in the middle and two filters P k de Medium Unit Shown NOTE Up to two non adjacent sides can
33. t charge CAC Cassette Evaporator www enviromaster com REFRIGERANT PROCESSING 8 Charge to proper weight charge based on your feet of interconnect see below NOTE Charging should be done with a dial a charge or weighed in with a scale Referito Refrigerant Charge Table for specified line charge IMPORTANT NOTES To find the charge adjustment and system charge for any evaporator and tubing length Line Adjustment Line Chg Ft x Line Length System Total Factory Charge Line Adjustment 2 Round to the nearest ounce and allow for gauges and hoses 3 Use R22 refrigerant S1C REFRIGERANT CHARGE TABLE Evaporator Pairing Line Chg Ft Factory Charge Ref S1CA9 CACA12 S1CA2 CACAT2 S2C REFRIGERANT CHARGE TABLE Condenser Evaporator Paing Line Chg Ft Factory Charge Ref TOP DISCHARGE REFRIGERANT CHARGE CHART Circuit Capacity Line Chg Ft__ Factory Charge Ref o ne moe R2 a se oz R CAC Cassette Evaporator www enviromaster com REMOTE THERMOSTAT OPERATION for CAC Ductless Split Air Handler av Choosing a Thermostat EMI offers several remote thermostats that are com patible with the Ductless split system air handlers See the latest price list for a list of available thermostats It is important to choose a thermostat that will match the equipment that you have selected For single stage cooling or hearting choose a single stage Heat Cool t
34. tch will also de energize the compressor if the water level becomes too high 10 Repeat the above procedure for all Cassettes in the same systems Adding water will activate the float switch and the pump Water must flow regular www enviromaster com CAC Cassette Evaporator REFRIGERANT PROCESSING WARNING It is illegal to discharge refrigerant into the atmosphere Use proper reclaiming methods and equipment when installing or servicing this unit Finish all pipe connecting before proceeding to charging the system Follow the instructions in the outdoor unit for line evacuation opening service valves and final charge adjustments Op eration charts and charge tables can be found in the EMI Condenser IOMs 1 Clean the ends of tubing and insert into fittings 2 Protect the valves by wrapping with a wet rag heat sink before brazing Shield Heat sink 3 We recommend the use of a shield can be made from some scrap metal to protect the paint 4 Braze tubing into fittings 5 Attach manifold set Manifold Vaccum Pump Micron Gage 6 Evacuate line to 500 microns or less to ensure all moisture has been removed and there are no leaks 7 Once certain of a good evacuation and leak free joints back seat the valves counter clockwise to open and allow fac tory charge to fill lines and indoor unit Refer to Charts in condenser manual to fine tune the refrigeran
35. vent the outdoor from restarting unit after a three minute time period has elapsed After connecting the thermostat to the unit place the system switch in cool mode Ad just the set point temperature below the room temperature The compressor and fan motors will start and cooling will begin For chilled water systems the coldwater valve will open allowing the flow of water Place the set point temperature above the room temperature The outdoor con denser will stop or CW valve will close while the indoor fan will remain on for an additional sixty seconds av Electric Heat Operation Optional Place the thermostat system switch in heat mode Adjust the set point tempera ture above the room temperature The electric heat will energize along with the indoor fan motor Heating will continue so long as the set point remains above room temperature Next place the set point temperature below room temperature The Electric heater will switch off and the indoor fan will remain on for an additional sixty seconds www enviromaster com CAC Cassette Evaporator TEST UNIT PERFORMANCE DATA SHEET The Test Unit Performance Data sheet this information ready when calling Make below is provided for use by a qualified sure to include the Model Number Serial service professional in the eventthatthere Number Date of Installation is a problem with the unit In order for our Call our Technical Support Department Technical Service Department
36. w enviromaster com LOW VOLTAGE INTERCONNECT WIRING Figure 1 Depending on the thermostat required or selected cooling only air handlers may utilize three to five low Voltage intercon necting wires between the indoor unit thermostat and the outdoor unit Some thermostats do not require the use of the C brown connection In this case en sure that any unused wires are insulated to prevent them from making contact with the junction box or other metal surfaces If the indoor unit has electric heat then a W connection is required between the thermostat and the indoor unit LOW VOLTAGE INTERCONNECT DIAGRAM O D UNIT I D UNIT WALL T STAT SOME T STATS MAY NOT HAVE A C TERMINAL OPTIONAL START UP FOR WALL THERMOSTAT CONTROL Refer to low Voltage interconnect dia gram Figure 1 for remote wall thermostat controls NOTE Apply power to the Condens ing Unit s crankcase heater for 24 hours before start up to boil off any liquid that may be present in the compressor 1 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 elec trical check can now be carried out 2 Switch on the indoor Cassette unit and check that the fan cycles correctly 3 On models 18 36 check that the motor ized vane sweep functions correctly by toggling the function o
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