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EMI CAHG09 Installation, Operation And Maintenance Manual

High-efficiency cassette ductless split system air handlers
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ECR International LLC
2201 Dwyer Ave.
Utica, NY 13504
www.enviromaster.com
An ISO 9001-2000 Certified Company
CACG/CAHG &
CACH/CAHH
High-Efficiency Cassette Ductless Split System Air Handlers
Straight cool / Heat pump nominal capacities
CAHG09
CAHG12
CAHH09
CAHH12
9,000
12,000
2.6
3.5
Straight cooling only — circuit load — two circuits
CACG-36 & CACH-36
30,000
8.8
Installation, Operation and
Maintenance Manual
CAHH12
CAHG24
CAHH24
18,000
24,000
5.3
7.0
36,000
10.5
P/N 240008108, Rev. B [082509]
Units
Btuh
kW
Units
Btuh
kW

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Summary of Contents for EMI CAHG09

  • Page 1 CACG/CAHG & CACH/CAHH High-Efficiency Cassette Ductless Split System Air Handlers Straight cool / Heat pump nominal capacities CAHG09 CAHG12 CAHG24 Units CAHH09 CAHH12 CAHH24 9,000 12,000 18,000 24,000 Btuh Straight cooling only — circuit load — two circuits CACG-36 & CACH-36...

  • Page 2: Table Of Contents

    For a local representative listing, visit NOTICE our web site: www.enviromaster.com The EMI Ductless Series of high effi- ciency evaporators are backed by EMI For further assistance call: and ECR International and are tested, 1-800-228-9364...

  • Page 3: Read Before Proceeding

    Inspect all parts for damage prior to installation and start-up. The EMI Duct- EMI Ductless high efficiency evaporator. less high efficiency evaporator must be Read these instructions thoroughly and...

  • Page 4: Verify Unit Before Installing (Continued)

    Refer to specifications contained in with thermal protection and sealed this document. lifetime bearings. • All EMI air handlers are backed by En- • Permanent, washable filter (user acces- viromaster International LLC and are sible). tested, rated, and certified in accordance •...

  • Page 5: Controls And Components

    600 psig. • The tubes are mechanically expanded for NOTICE secure bonding to fin shoulder. Electric heat option — EMI heat pumps Refrigeration Circuit are intended to operate with an indoor • Units are equipped with a serviceable air handler, with electric heat.
  • Page 6 • A thermostat can be obtained through EMI or your local distributor. Heating NOTICE • The cassette may be fitted with electric heaters which are equipped with over- Make sure the thermostat is suitable for temperature limit switches.

  • Page 7: Piston/Orifice Replacement (When Required)

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Piston/Orifice Replacement (when required) NOTICE — model 24 with T2, T3 or T4 condenser — The factory-installed piston/orifice must be replaced Piston/orifice replacement when a model 24 air handler is matched with a T2CG/T2HG4400, T2CG/T2HG2400 or T2C/T3CG/T3H2240 condenser that has a 24,000 Btuh compressor (designated by a “4”...

  • Page 8: Mounting The Unit

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Mounting the Unit Before installing, consider: Unpacking • Determine the best location for mounting The Cassette fascia and main chassis are pack- the unit for room air circulation. aged together for increased protection.
  • Page 9 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Mounting the Unit (continued) Blanking off Model 24 — two hinged grilles Figure 3 and two filters (Model 36, not The fascia discharge slot(s) will need blank- shown has three grilles and ing off when ducts are used to channel the conditioned air to other areas.
  • Page 10 Remote thermostat thermostat, if used. A remote thermostat can be obtained through The unit should not be positioned directly EMI or your local distributor. The remote above any obstructions. thermostat is required for CACG/CAHG The condensate drain should have suf- units, optional for CACH/CAHH units.

  • Page 11: Mounting Method

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Mounting the Unit (continued) Mounting method Ceiling cutout/rod placement Figure 6 • In existing construction, remove enough template (shipped with unit) ceiling panels to provide clearance space for mounting unit to ceiling joists. 1.500 TYP •...
  • Page 12 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Mounting the Unit (continued) Mounting Positioning installation guides Figure 8 Use the template (see Figure 6, Page 11) to cut the ceiling opening and determin- ing the rod positions. CAssette Install hanger bolts using 3/8”...

  • Page 13: Condensate Piping

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Condensate Piping The unit can now be piped up in accordance The highest point of the con- Figure 10 with good refrigeration and/or plumbing densate piping should be as practices.

  • Page 14: Duct Connections

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Duct Connections Branch duct and fresh air duct collars can be Figure 12 Knockouts attached to the cassette chassis by following the steps below. branch Duct knockout NOTICE Cassette 12 Recommendation —...

  • Page 15: Refrigerant Piping

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Refrigerant Piping Piping connections at unit Figure 14 CAUTION • Avoid piping on wet and rainy days. • Use only clean, refrigeration-grade copper tubing. • Use tubing benders to guard against kinking.
  • Page 16 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Refrigerant Piping (continued) Refrigerant piping Clean ends of tubing Figure 15 Clean the ends of tubing and insert into fittings (Figure 15). Before brazing ( Figure 16): Protect valves by wrapping with a wet rag “heat sink”...

  • Page 17: Refrigerant Processing

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Refrigerant Piping (continued) Refrigerant processing Manifold set connections at unit Figure 17 Attach manifold set ( Figure 17). Evacuate line to 500 microns or less to ensure all moisture has been removed and there are no leaks.
  • Page 18 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Refrigerant Processing NOTICE – to find charge adjustment To find the charge adjustment and system charge for any evaporator and tubing length: Line Adjustment = (Line Charge/FT) x Line Length System Total = Factory Charge + Line Adjustment Round to the nearest ounce and allow for gauges and hoses.

  • Page 19: Final Assembly

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Final Assembly Assembly instructions Mounting bolts Figure 20 To install the four fascia mounting bolts: Remove the bolts and washers from the supplied kit bag. Put washers onto the bolts. Screw the mounting bolt with washer into the chassis leaving approximately 1”...

  • Page 20: Final Assembly (Continued)

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Final Assembly (continued) Connect vane motor plug into Figure 23 Figure 25 Secure fascia to chassis socket on chassis CAUTION female vane motor plug on chassis DO NOT over-tight- en the bolts —...

  • Page 21: Remote Thermostat Selection (Optional For Cach/ Cahh)

    (optional for CACH/CAHH) Field-supplied thermostats NOTICE When selecting a thermostat other than one CACG/CAHG units offered by EMI, it is important to choose a • All are operated by a remote ther- 24V thermostat that matches your applica- mostat. tion.

  • Page 22: Electrical Wiring

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Electrical Wiring NOTICE Removing control box cover Figure 27 All electrical wiring must be run accord- ing to NEC and local codes. General requirements WARNING — Make sure the Electrical shock hazard power is off before proceeding.
  • Page 23 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Electrical Wiring (continued) It is also recommended that a local discon- Wiring diagram location Figure 29 nect switch be connected within 3 feet of the unit. In some areas this may be a code Wiring diagram (on inside requirement.

  • Page 24: Initial Start-Up - Cacg/Cahg Units Only

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Initial Start-Up — CACG/CAHG Units ONLY NOTICE CAHG/CACG louver toggle Figure 30 switch CACH/CAHH units • These units require setting of DIP switches and controller functions before proceeding with start-up. •...
  • Page 25 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Initial Start-Up — CACG/CAHG Units ONLY (continued) Checking condensate pump Figure 31 WARNING operation — Turn off Electrical shock hazard power to indoor and outdoor units is off before proceeding.

  • Page 26: Remote Thermostat Operation

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Remote Thermostat Operation (optional for CACH/CAHH) (continued) FAN operation COOLING operation The remote thermostat will control the call The remote thermostat will control the call for fan operation (on or off ) through the for cooling operation (on or off) through the low-voltage terminals “R”...

  • Page 27: Electric Heat Operation

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Remote Thermostat Operation (optional for CACH/CAHH) (continued) Electric heat operation Optional HEAT PUMP WITH ELECTRIC HEAT (Two-stage heating) For remote thermostat operation with electric heat the control must be configured properly For remote thermostat operation for two- (Remote Thermostat ON) [Table 6, pg.

  • Page 28: Initial Start-Up - Cach/Cahh Units Only

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Initial Start-Up — CACH/CAHH Units ONLY Set DIP switches NOTICE DO NOT turn on power until the DIP To test cooling operation switches have been set and the control Operation of the unit depends on the panel cover replaced.
  • Page 29 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • SEND button for 2 seconds. This will Be sure to return DIP switch #1 (Test transmit information from the remote mode) to OFF before leaving the sys- to the cassette. The cassette will respond tem.

  • Page 30: Notice

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Verify operation. Verify heat pump operation (no electric heat) Check condensate pump This arrangement uses a heat pump operation outdoor unit with no heat source in the cassette (indoor) unit. Remove an adjacent ceiling tile to access The configuration ( Figure 36, Page 35)

  • Page 31: Cach/Cahh Microprocessor Controller Overview

    Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview Figure 33 EMI Ductless unit-mounted microprocessor controller — control panel WARNING Electrical shock hazard — Before removing the control box cover, make sure that all power is re-...
  • Page 32 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview (continued) Table 6 CACH/CAHH Microprocessor controller — dip switch settings Factory DIP Switch Setting Operation Setting mode All timers are shortened, Enables Test allowing quicker operational testing •...

  • Page 33: Cach/Cahh Microprocessor Controller Overview

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview (continued) Figure 34 Ductless unit-mounted controller — chassis-mounted keypad/display Infrared receiver window — Power LED In Remote Thermostat mode — on when power is applied to the unit. In Hand Held Controller mode —...

  • Page 34: Cach/Cahh Microprocessor Controller Overview

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview (continued) Figure 35 CACH/CAHH Microprocessor Controller — infrared remote control Press to turn unit on or off. Press and hold for POWER SEND 2 seconds to transmit all settings to the unit- mounted controller.

  • Page 35: Setting The Cach/Cahh Controller

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Setting the CACH/CAHH Controller Configuration settings for CACH/CAHH Figure 36 Possible Value Factory Setting Item Display Overview (flashing) Settings To access: Press MODE and PROGRAM together for 5 seconds, repeat to exit Navigating through settings: Press PROGRAM to move to the next setting or CLOCK to move to the previous setting;...
  • Page 36 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Setting the CACH/CAHH Controller (continued) 7-day programming options for CACH/CAHH Figure 37 Item Setting Values Overview To access: Press and hold PROGRAM and CLOCK buttons simultaneously for 3 seconds; use arrow keys to select position;...
  • Page 37 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Setting the CACH/CAHH Controller (continued) Table 7 Programming schedule (when using 7-day programming) to copy the settings from any day to the entire week: 1) select the day to be copied. 2) simultaneously press the “FAn”...

  • Page 38: Cach/Cahh Microprocessor Controller Operation

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation • Alternatively, hold the POWER/SEND NOTICE button for two seconds. All of the optional When power is first applied to the con- remote’s settings will be transmitted to the trol or after a power outage there is a cassette.
  • Page 39 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) are constant fan settings. The POWER/SEND High fan operates continuously, regardless of set- Pressing the POWER/SEND button momen- point or room temperatures. tarily will switch the unit either on or off. fan mode is for auto ramping of fan Auto In the OFF mode, the liquid crystal dis-...

  • Page 40: Notice

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) Cooling mode Heating mode For cooling operation, first turn the unit on Optional Electric heat operation (Air via the POWER/SEND button. Conditioning unit outdoors) Select Cooling mode via the MODE For operation with electric heat the control button.

  • Page 41: Notice

    For heat pump operation with electric heat NOTICE the control must first be configured properly EMI heat pumps are intended to operate (Heat source – ON Table 6, pg. 32, Heat pump with an indoor air handler, with electric – OFF Figure 36, pg. 35).

  • Page 42: Auto Changeover Mode

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) At that time the electric heat will switch If the room temperature is within ± two off and the heat pump (compressor) will degrees of setpoint, the unit will cycle take over the heating demand.

  • Page 43: Notice

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) Configuration mode, the unit will run the control will save the new settings and heating operation as described under return to the previous interface mode. Heat mode.
  • Page 44 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) control through the 7-Day Programming Clean Filter Alarm mode. To aid in filter maintenance, the cassette con- The Pre-Program Run mode can be en- troller will indicate when a scheduled filter tered from Cooling mode, Heating mode cleaning is required by flashing the Timer/...

  • Page 45: Operation

    With DIP switch #3 set to OFF, the fan speed is set to Low. Reversing Valve Table 6, Page 32 for other available EMI outdoor heat pump units utilize a DIP switch selections. reversing valve that is energized in Cooling The remote thermostat will control the call mode.
  • Page 46 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Remote Thermostat Operation (continued) to call for second stage heating. (See Electric heat operation the thermostat owner’s manual for this The remote thermostat will control the call for feature).

  • Page 47: Cach/Cahh Controller Features

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Controller Features • If Intermittent is selected, the backlight Short Cycle Protection (ASCT) will remain for 10 seconds after the The electronic control incorporates an anti- push of any button while the control is short-cycle timer (ASCT) feature designed in the On mode or after the push of the to protect the compressor from short cycling.

  • Page 48: Cach/Cahh Controller Fault Conditions

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Controller Fault Conditions Table 8 CACH/CAHH microprocessor controller fault indications Timer/Alarm Fault condi- LED — number Description tion of flashes: Room air sen- If the room air sensor is disconnected, damaged or mal- functions the Timer/Alarm LED will flash one (1) time to sor fault signify that a fault has occurred.

  • Page 49: Maintenance

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Maintenance Remove the grille Figure 38 WARNING Service should be performed by a quali- and an annual system fied service agency Model 12 check is recommended. shown — Before re- Electrical shock hazard moving the access panels, make sure that all power is disconnected from the unit.

  • Page 50: Troubleshooting - General

    • The wiring diagram is located on the Power supply check inside surface of the control panel cover When troubleshooting any EMI product, it (see Figure 29, Page 23). is important to first check the rating plate for • If you are unable to locate the wiring proper field voltage and breaker size.
  • Page 51 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Troubleshooting — General (continued) Models CACG/CAHG — Low-voltage interconnections — remote thermostat Figure 42 operation Models CACH/CAHH — Low-voltage interconnections — with/without optional Figure 43 remote thermostat operation P/N 240008108, Rev.

  • Page 52: Troubleshooting - Cacg/Cahg Units

    • “Y1” and “C” of the cassette. The wall mounted thermostat will switch the EMI heat pump systems utilize a revers- outdoor unit on and off through the black ,“Y,” ing valve is that is energized in the cooling and yellow, “Y1,” wires.
  • Page 53 “G” and “C” of the cassette (fan signal). If this occurs the limit switch assembly must be replaced. Electric heat (optional) Contact EMI technical service for a re- placement. Units with electric heat utilize a control relay located on the circuit board in the control Checking fuse link box.
  • Page 54 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Troubleshooting — CACG/CAHG Units (continued) Next, place the setpoint further above room Two-stage heating temperature to activate second stage heat- Two-stage heating combines heat pump and ing. electric heat operation. Heat pump units Electric heat will energize (along with require an 18 AWG low-voltage intercon- the compressor) when the deviation...

  • Page 55: Troubleshooting - Cach/Cahh Units

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Troubleshooting — CACH/CAHH Units power can be measured between the relay NOTICE output and the L2 terminal of the incoming Cassette operation can be controlled power supply. through either a remote thermostat or an For optional remote thermostat operation, optional infrared handheld controller.

  • Page 56: Frequently Asked Questions

    Q: The system has just been installed us- condensate removal. ing an EMI indoor unit and a non-EMI condenser. There is no display and the Q: How long will the fan run? unit will not operate.
  • Page 57 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Frequently Asked Questions (continued) Q: What causes my indoor unit to freeze- A: Air handler freeze up is usually the symptom of another problem. The Cas- sette air handler is equipped with freeze protection to prevent freeze up from occurring.

  • Page 58: Dimensions (Continued)

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Dimensions Dimensions — Models 9, 12, 24 and 36 (see dimensions, Table 9, Page 59) Figure 44 Features Optional discharge knockouts 5¼-inch diameter (3) available Fresh air inlet knockouts 1¼...

  • Page 59: Notice

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Dimensions (continued) Table 9 Dimensions — Models 9, 12, 24 and 36 (see drawing, Figure 44, Page 58) Models 9 & 12 Model 24 Model 36 Dimension Inches Inches Inches 25 00...

  • Page 60: Specifications

    2 5 GPH (9 5 l/h) *Must bush down to 5/8” interconnect for 18K system ** Measured from bottom of unit NOTICE Due to EMI’s ongoing product develop- ment program, all designs and specifi- cations are subject to change without notice.

  • Page 61: System Options

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • System Options Cassette(s) s1CG/s1HG s2CG/s2HG side Discharge side Discharge Cooling systems ( Table 13 CAC_ refers to CACG/CACH; CAH_ refers to CAHG/CAHH Condenser Cassette Btuh SEER S1C9000 CAH_09 9,000 13 0 0 72...
  • Page 62 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • System Options (continued) Cassettes t2CG, t3CG & t4CG t2HG, t3HG & t4HG top Discharge CAC_ refers to CACG/CACH; CAH_ refers to CAHG/CAHH System options with T2C, T3C or T4C top discharge Table 15 Condenser Cassette...

  • Page 63: Test Unit Performance Data Sheet

    CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Test Unit Performance Data Sheet NOTICE The Test Unit Performance Data sheet is provided Have this information ready when calling. Make sure to include the model Number, Serial Number, and Date for use by a qualified service professional in the event of installation.

  • Page 64: Emi's Product Line

    EMI’s Product Line Indoor Units WLCG/WLHG CACG/CAHG High Wall Air Handler Cassette Air Handler UnCG/UnHG Universal Floor or Ceiling Air Handler Outdoor Units s2CG/s2HG Dual Zone side Discharge t2CG, t3CG and t4CG 2, 3 and 4 Zone top Discharge s1CG & s1HG...

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