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ECR International LLC
5780 Success Drive
Rome, NY 13440
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-30 & CACH-30
30,000
8.8
Installation, Operation and
Maintenance Manual
CAHH12
CAHG18
CAHG24
CAHH18
CAHH24
18,000
24,000
5.3
7.0
CACG-36 & CACH-36
36,000
10.5
P/N 240007756, Rev. A [051509]
Units
Btuh
kW
Units
Btuh
kW
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Table of Contents
Troubleshooting
Related Manuals for ECR EMI America Series
Summary of Contents for ECR EMI America Series
- Page 1 Straight cooling only — circuit load — two circuits CACG-30 & CACH-30 CACG-36 & CACH-36 Units 30,000 36,000 Btuh 10.5 Installation, Operation and Maintenance Manual ECR International LLC 5780 Success Drive Rome, NY 13440 CAHH12 www.enviromaster.com An ISO 9001-2000 Certified Company P/N 240007756, Rev. A [051509]...
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Page 2: Table Of Contents
For a local representative listing, visit NOTICE our web site: The EMI AmercaSeries high efficiency www.enviromaster.com evaporator is backed by EMI and ECR For further assistance call: International and is tested and rated in accordance with AHRI Standard 1-800-223-9364 210/240 and UL-1995. -
Page 3: Read Before Proceeding
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Read Before Proceeding Recognize this symbol as an indication of important safety information. WARNING Safety Instructions Completely read all instructions prior to assembling, installing, oper- This manual is intended as an aid to quali- ating, or repairing this product. -
Page 4: Verify Unit Before Installing (Continued)
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Verify Unit Before Installing Product description Standard features • The EMI AmericaSeries Cassette Air CACG/CAHG units handlers are available in three cabinet • “G” units require a remote thermostat sizes with four output capacities from for operation. - Page 5 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Verify Unit Before Installing (continued) • Four plastic air vanes, motor driven with System options auto sweep or fixed position stop setting • 24V remote remote thermostat. on models 24 and 36. Models 9–12 are •...
- Page 6 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Verify Unit Before Installing (continued) Remote thermostat applications Air vanes • Air outlet vanes are manually adjustable • CACG/CAHG units require a remote on the models 9 and 12 or driven by an thermostat for operation.
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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 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Mounting the Unit (continued) Positioning Spacing requirements Figure 5 The cassette installation position should be Dimension A + 1” = minimum space selected with the following in mind: above the false ceiling for installation Pipe work, electrical connections, control box and condensate pump access panels...
- Page 11 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”...
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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”...
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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.
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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)
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Remote Thermostat Selection (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. -
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.
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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 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 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, heat source ON).
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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 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)
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Page 31: Cach/Cahh Microprocessor Controller Overview
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview Figure 33 AmericaSeries unit-mounted microprocessor controller — control panel WARNING Electrical shock hazard — Before removing the control box cover, make sure that all power is re- moved from both the indoor cas- sette unit and outdoor condenser unit. - 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 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Overview (continued) Figure 34 AmericaSeries unit-mounted controller — chassis-mounted keypad/display — Press to turn on or off. Infrared receiver window — Power LED In Remote Thermostat mode — on when power is applied to the unit. In Hand Held Controller mode —...
- Page 34 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.
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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”...
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Page 38: Cach/Cahh Microprocessor Controller
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-...
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Page 40: Operation
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 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Microprocessor Controller Operation (continued) Optional Heat pump without Electric Optional Heat pump with Electric heat heat (Heat Pump unit outdoors) (2-stage heating) For heat pump operation with electric heat NOTICE the control must first be configured properly EMI heat pumps are intended to operate...
- Page 42 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 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/...
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Page 45: Cach/Cahh Remote Thermostat Operation
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • CACH/CAHH Remote Thermostat Operation Set DIP switch #4 to ON Cooling operation For Remote Thermostat Operation the The remote thermostat will control the call control must be configured through the DIP for cooling operation (on or off) through the switches located on the control board located low-voltage terminals R and Y. - 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).
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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 incoming power must not be below EMI America Series evaporators are de- the minimum voltage stated on the rating signed to operate with EMI America Series plate (197V for units rated 208/230V and condensers. 104V for units rated 115V). - 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 Made in the USA P/N 240007756, Rev.
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Page 52: Troubleshooting - Cacg/Cahg Units
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Troubleshooting — CACG/CAHG Units Cooling-only units Heat pump units Cooling only units require 18 AWG low- Heat pump units require 18 AWG low-voltage voltage interconnecting wires between the interconnecting wire between the indoor and indoor and outdoor units. - Page 53 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Troubleshooting — CACG/CAHG Units (continued) The indoor unit contains an electronic anti- As a safety feature, an auto-reset limit switch short-cycle timer feature (ASCT) that will is located on the heater assembly. prevent the outdoor condenser from short The limit will interrupt power to the cycling.
- 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...
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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
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Frequently Asked Questions Q: The system has just been installed us- Q: The condenser will not start although ing an EMI indoor unit and a non-EMI the indoor unit appears normal. What condenser. - Page 57 CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Frequently Asked Questions (continued) Q: How long will the fan run? Q: What causes my indoor unit to freeze- A: While the unit is in cooling or heating A: Air handlers freeze up is usually the and auto fan mode is selected, the fan will cycle with the call for cooling or heating.
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Page 58: Dimensions
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 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...
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Page 60: Specifications
CACG/CAHG & CACH/CAHH Air Handlers • Installation, Operation and Maintenance Manual • Specifications Table 10 CACG/CAHG/CACH/CAHH electrical specifications Fan Motor Elect Heat Total HACR Model M.C.A. AMPS Volt BRKR Volts/HZ/PH H.P. AMPS CAHG/H 12 208/230/60/1 0 35 1/10 – – CAHG/H 12 208/230/60/1 0 35... -
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...
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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 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 single Zone side Discharge Phone: 1-800-228-9364...