ECR International CACG, CAHG, CAHJ, CACH, CAHH Installation, Operation And Maintenance Manual
...
CACG/CAHG/CAHJ
&
CACH/CAHH/CAHK
High-Effi ciency Cassette Ductless Split System Air Handlers
Straight cool / Heat pump nominal capacities
CAHJ09
CAHK09
9,000 12,000 18,000 24,000 Btuh
2.6 3.5 5.3 7.0 kW
Installation, Operation and
Maintenance Manual
CAHJ12
CAHK12
Straight cooling only
CACG36 & CACH36
30,000 36,000 Btuh
8.8 10.5 kW
CAHG24
CAHH24
Units
Units
ECR International Inc
2201 Dwyer Ave.
Utica, NY 13501
www.enviromaster.com
An ISO 9001-2008 Certified Company
CAHK12
P/N 240008108, Rev. G [07/08/10]
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
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Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . 2
Read Before Proceeding . . . . . . . . . . . . . . . 3
Verify Unit Before Installing . . . . . . . . . . . . . 4
Piston/Orifi ce Replacement (when required) . . 7
Mounting the Unit . . . . . . . . . . . . . . . . . . . 8
Condensate Piping. . . . . . . . . . . . . . . . . . .13
Duct Connections . . . . . . . . . . . . . . . . . . .14
Refrigerant Piping . . . . . . . . . . . . . . . . . . .15
Refrigerant Processing . . . . . . . . . . . . . . . .18
Final Assembly . . . . . . . . . . . . . . . . . . . . .19
Final Assembly (continued) . . . . . . . . . . . . .20
Electrical Wiring. . . . . . . . . . . . . . . . . . . . .21
Wall Thermostat Selection (optional for CACG/CAHG/
CAHJ) . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Initial Start-Up — CACG/CAHG/CAHJ Units ONLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Initial Start-Up — CACH/CAHH/CAHK Units ONLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Air Handlers
CACH/CAHH/CAHK Microprocessor Controller
Overview . . . . . . . . . . . . . . . . . . . . . . . . .31
Setting the CACH/CAHH/CAHK Controller . . . .35
CACH/CAHH/CAHK Microprocessor Controller
Operation . . . . . . . . . . . . . . . . . . . . . . . .38
CACH/CAHH/CAHK Wall Thermostat Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
CACH/CAHH/CAHK Controller Features. . . . . .47
CACH/CAHH/CAHK Controller Fault Conditions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Maintenance. . . . . . . . . . . . . . . . . . . . . . .49
Troubleshooting — General . . . . . . . . . . . . .50
Troubleshooting — CACG/CAHG/CAHJ Units . .52
Troubleshooting — CACH/CAHH/CAHK Units. .55
Frequently Asked Questions. . . . . . . . . . . . .56
Dimensions . . . . . . . . . . . . . . . . . . . . . . .58
Specifi cations . . . . . . . . . . . . . . . . . . . . . .60
System Options . . . . . . . . . . . . . . . . . . . . .61
Test Unit Performance Data Sheet . . . . . . . . .63
EMI’s Product Line . . . . . . . . . . . . . . . . . . .64
NOTICE
Shipping damage MUST
be reported to the carrier
IMMEDIATELY.
Examine the exterior. Remove
cover and examine compressor
and piping for signs of damage.
NOTICE
The EMI Series of high efficiency air
handlers are backed by EMI and ECR
International and are tested, rated, and
certi ed in accordance with AHRI Standard 210/240-2008 and UL-1995.
Due to ongoing product development,
product designs and speci cations may
change without notice.
Please contact the factory for more
information.
To the Installer
Retain this manual and warranty for
future reference. Before leaving the premises, review this manual to be sure the unit
has been installed correctly and run the
unit for one complete cycle to make sure
it functions properly.
To obtain technical service or warranty
assistance during or a er the installation
of this unit, contact your local representative. For a local representative listing, visit
our web site:
www.enviromaster.com
For further assistance call:
1-800-228-9364
When calling for assistance, please have
the following information ready:
Model Number _____________
Serial Number _____________
Date of installation ___________
Comfort where it counts 2 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
Read Before Proceeding
Recognize this symbol as an indication of
important safety information.
ir Handler
Completely read all instructions
prior to assembling, installing, operating, or repairing this product.
WARNING
Inspect all parts for damage prior to
installation and start-up. e EMI high
e ciency air handler must be installed
ONLY by quali ed installation personnel.
Tampering with this unit is danger-
ous
. Tampering voids all warranties.
DO NOT a empt to modify or change
DANGER
this unit in any way.
Safety Instructions
is manual is intended as an aid to quali ed service personnel for proper installation, operation, and maintenance of the
EMI Series high e ciency air handler.
Read these instructions thoroughly and
carefully before a empting installation or
operation.
Failure to follow these instructions may
result in improper installation, operation,
service, or maintenance, possibly resulting
in re, electrical shock, property damage,
personal injury, or death.
Read all instructions before using this
unit. Install or locate this unit only in accordance with these instructions. Use this
unit only for its intended use as described
in this manual.
DANGER
e EMI unit must:
Be connected to a properly grounded •
electrical supply with the proper
voltage as stated on the rating plate.
Have proper overcurrent protection •
(time-delay fuse/HACR Breaker) as
listed on the rating plate.
Ensure there are no power feeds to the
unit such as fire alarm circuits, BMS
circuits, etc.
Failure to follow these instructions can
result in a re, explosion, or electrical
shock causing property damage, personal
injury, or death.
P/N 240008108, Rev. G [07/08/10] 3
Check the rating plate on the unit before
installation to make certain the voltage
shown is the same as the electric supply to
the unit. e rating plate is located on the
top panel only.
This unit must be connected only to a
properly grounded electrical supply. Do
not fail to properly ground this unit.
Tur n o the electrical supply before servicing the unit.
Do not use the unit if it has damaged wiring, is not working properly, or has been
damaged or dropped.
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
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Verify Unit Before Installing
Air Handlers
NOTICE
Check equipment for damage prior
to installation, if damaged contact the
wholesale distributor.
Product description
e EMI Casse e Air handlers are avail-•
able in three cabinet sizes with four output capacities from 9,000–24,000 Btuh,
and two cooling only capacities from
30,000–36,000 Btuh.
Key features include a condensate pump •
with safety switch and a 36” (0.9 m) li
(measured from the base or bo om of
the unit), fresh air inlet and branch duct
knockouts, and motorized air vanes models 24 and 36 only).
Electric heat is a factory-installed option •
ONLY (there are no eld installed electric
heat kits available). (See NOTICE on
next page.)
The cassette air handler accepts a 24 •
volt thermostat control (thermostat not
included).
Designed for low noise levels, easy instal-•
lation and maintenance and a slim line
fascia, all ensure minimum intrusion into
the conditioned environment.
Due to ongoing product development, all •
designs and speci cations are subject to
change without notice.
These cassette air handlers produce •
system SEER’s meeting or exceeding 13
when matched with EMI outdoor units:
Single-zone condensing units –
S1CG/S1HG 09–24 and S1CG 30–
36.
Dual-zone condensing units –
S2CH/S2HH side discharge.
Multi-zone, top discharge condens- –
ing units T2CG/T2HG, T3CG/
T3HG, or T4CG/T4HG.
Refer to speci cations contained in –
this document.
All EMI air handlers are backed by ECR •
International Inc and are tested, rated,
and certi ed in accordance with AHRI
standards 210/240-2008 and UL 1995.
Standard features
CACG/CAHG/CAHJ units
“G” or “J” units require a remote thermo-•
stat for operation. ey do not include an
onboard controller.
External thermostat required.•
CACH/CAHH/CAHK units
“H” or “K” units include an on-board •
microprocessor controller with infrared
remote.
e remote is required to adjust se ings •
and con gure the controller.
Also included is a bank of DIP switches for •
se ing operating behavior. ese can be
used to select operation by the on-board
controller or by a remote thermostat.
When operated by remote thermostat, the •
controller o ers limited options.
Materials of Construction
Galvanized steel cabinet with re-resistant •
thermal and acoustic foam insulation.
Light grey high-impact ABS fascia.•
Expanded polystyrene drain pan with a •
tough, re-retardant thermoplastic liner.
Air Systems
Fans are backward-curved impeller •
centrifugal design; dynamically and statically balanced; and mounted on integral
mounting rails.
Single-fan models 9, 12 & 24 are –
designed with re-retardant plastic
or aluminum impellers.
Twin-fan model 36 is designed with –
re-retardant plastic impellers.
Motors are multispeed, enclosed type –
with thermal protection and sealed
lifetime bearings.
Permanent, washable lter (user acces-•
sible).
Branch duct knockouts on three sides •
for remote discharge locations (using no
more than two non-adjacent sides).
Comfort where it counts 4 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
Verify Unit Before Installing (continued)
ir Handler
Fresh air intake capability on three sides of •
cabinet (only two on models 9–12).
Four plastic air vanes, motor driven with •
auto sweep or xed position stop se ing
on models 24 and 36. Models 9–12 are
equipped with manually-adjusted air
vanes.
Coil
Coil is seamless, copper tubing, arranged •
in staggered con guration, with enhanced
aluminum ns, tested to 600 psig.
e tubes are mechanically expanded for •
secure bonding to n shoulder.
Refrigeration Circuit
Units are equipped with a serviceable •
fixed orifice expansion device and use
R410A refrigerant only.
Controls and Components
(factory installed or supplied)
System options
24V wall thermostat.•
Electric Heat (@ 230V) •
1.5 kW models 9–12 –
3 kW model 24 –
5 kW model 36. –
Heat pump applications
NOTICE
Electric heat option EMI heat pumps
are intended to operate with an indoor
air handler, with electric heat. If an indoor air handler without electric heat is
matched with a heat pump condenser,
the system will deliver cold air during
defrost.
Connections for 24V wall thermostat.•
Custom control board featuring program-•
mability, configuration, and multiple
modes of operation. (CACH/CAHH/
CAHK only)
Controls also feature anti-short-cycle •
timer, post purge fan relay, and an onboard 30-amp electric heat relay.
Condensate pump with 36” (0.9 m) li •
(measured from base of unit).
24V Transformer.•
P/N 240008108, Rev. G [07/08/10] 5
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
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Verify Unit Before Installing (continued)
Air Handlers
Remote thermostat applications
CACG/CAHG/CAHJ units require a •
wall thermostat for operation. CACH/
CAHH/CAHK units can be operated by
a wall thermostat by con guring the unit’s
DIP switches.
A thermostat can be obtained through •
EMI or your local distributor.
NOTICE
Make sure the thermostat is suitable for
unit operation (i.e., cooling only, cooling/electric heat, heat pump.) See thermostat requirements in this manual.
Mechanical characteristics
Filters
Metal framed lters are ed. ese are •
reusable and may be vacuum cleaned.
Condensate pump
A condensate pump is designed to carry •
water out of the unit. e pump is xed
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 oat switch stops the cooling action (shuts off the compressor)
should the pump become blocked or fail.
(Important: Total li for this pump is 36”
(0.9 m) or less.)
Air vanes
Air outlet vanes are manually adjustable •
on the models 9 and 12 or driven by an
electric motor on the models 24 and 36.
Where ed, the motorized air vanes can •
be set to auto sweep or can be stopped in
a xed position.
Heating
e casse e may be ed with electric •
heaters which are equipped with overtemperature limit switches. Consult
factory for available models with electric
heat.
Fresh air connection
Fresh air may be introduced to the unit •
by the addition of ducts connected to the
fresh air knockouts on the casse e case.
Recommended maximum length is 10’ •
(3m) of 4” (0.1m) diameter duct. e
fresh air volume is approximately 7–10%
of the unit’s published maximum air ow
(if more than 10% make up air is needed,
a fresh air booster fan is required).
Refer to Performance Data section of this •
manual for further information.
e casse e is best installed in new con-•
struction or existing construction with a
suspended or false ceiling with enough
clearance to accommodate concealing
the piping and electrical connections to
the unit.
Comfort where it counts 6 P/N 240008108, Rev. G [07/08/10]
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ir Handler
Piston/Orifi ce Replacement (when required)
NOTICE
Piston/ Orifi ce replacement e factory-installed piston/ori ce must be replaced on
Air-Handler / Condenser combitnations noted in table below
. All other applications are
to use the factory-installed ori ce. To replace the orifce in the noted models use instructions and chart as follows.
Replacing the piston/orifi ce
Diassemble the ori ce joint, remove the factory installed ori ce, and replace with the 1.
ori ce listed in Figure 1 (Supplied in the Kit Bag)
Make sure the o-ring is in good condition and properly installed.2.
Piston/orifi ce replacementFigure 1
To A ir
Handler
Model Condenser Factory-installed orifi ce size
(Inches)
T2C/T2H8800
CAHG/CAHH 24
T2C/T2H9800
0.056 0.049
T3C/T3H9980
CACG/CACH 36
S1CG3000
0.070 0.063
Replacement orifi ce size
(Inches)
CACG/CAHH 24
CAHJ/CAHK 12
P/N 240008108, Rev. G [07/08/10] 7
S1CG8000
S1HG8000
T2C/T2H 2400
T3C/T3H 2240
T3C/T3H 2220
T4C/T4H 9922
T4C/T4H 9992
T4C/T4H 2222
0.056 0.047
0.041 0.044
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
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Mounting the Unit
Air Handlers
Before installing, consider:
Determine the best location for mounting •
the unit for room air circulation.
Locate outdoor and indoor units as close •
together as possible.
Determine how power wire (high and •
low-voltage) condensate drainage, and
refrigerant piping may be run to and from
the unit.
Ensure that interconnect tubing is within •
the limits given in Table 1 .
Tubing specifi cationsTable 1
S1CG
or
S2CG
Model
09
12 1/4" 1/2"
Max.
Length
Equivalent
feet
50’
(15 m)
Max.
Lift
“H” “P” O.D. O.D.
20’
(6 m)
Max.
Trap
Height
15’
(5 m)
Liquid
Line
1/4" 1/2"
Suction
Line
Unpacking
e Casse e fascia and main chassis are packaged together for increased protection.
Remove the banding straps and li the 1.
cardboard lid.
Fascia is packed in bubble wrap and on 2.
top of the chassis (fascia is not a ached
to the chassis for shipping).
Cardboard template is between the chas-3.
sis and the fascia.
NOTICE
Do not throw template away with packaging
Li the fascia and template from the box 4.
and set aside.
Remove the cassette chassis from the 5.
box utilizing the four corner brackets
for li ing.
18
24 3/8" 3/4"
30 3/8" 3/4"
36 3/8" 3/4"
100’
(30 m)
35’
(11 m)
20’
(6 m)
3/8" 5/8"
NOTICE
Piping may be roughed in before wallboard or panels are placed in new construction. PVC pipe (3” or 4” I.D.) may
be used as a pipe chase.
WARNING
Do not use the drain or refrigerant connections for li ing.
In order to protect the fascia from dirt and 6.
damage, it should be returned to the box
until it is ready to be installed.
NOTICE
Do not throw away the two polystyrene
blanking-o pieces with packaging
Comfort where it counts 8 P/N 240008108, Rev. G [07/08/10]
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Mounting the Unit (continued)
ir Handler
Blanking off
e fascia discharge slot(s) will need blanking o when ducts are used to channel the
conditioned air to other areas.
Position the two polystyrene blanking o •
strips (provided) in the fascia discharge
slots to direct the air to the ducts.
Up to two non-adjacent sides may be •
blanked o .
If the fascia discharge slot needs
blanking off —
Remove the inlet grilles and lters (see 1.
Figure 2, Page 9 ) and ( Figure 3, Page 9 ).
Once the grilles and lters are removed, 2.
turn the fascia over so the polystyrene
insulation is exposed ( Figure 4, Page 9 ).
Push one of the polystyrene blanking-o 3.
pieces into the recess in the polystyrene
fascia insulation.
Model 24 — two hinged grilles Figure 3
and two fi lters (Model 36, not
shown has three grilles and
three fi lters)
Hinge
Models 9–12 — one grille & one Figure 2
fi lter
Applying blanking-off piecesFigure 4
Blanking-Off
Pieces
P/N 240008108, Rev. G [07/08/10] 9
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
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Mounting the Unit (continued)
Air Handlers
Positioning
e casse e installation position should be
selected with the following in mind:
Pipe work, electrical connections, control 1.
box and condensate pump access panels
should be readily accessible. Refer to the
casse e dimensions in the back of this
manual.
e unit should be positioned at least 5 2.
. (1.5m) from a wall or similar obstruction.
Position the unit as close to the center 3.
of the room as possible to ensure air is
distributed evenly.
Position the unit so that the discharge 4.
air does not blow directly on the remote
thermostat, if used.
e unit should not be positioned directly 5.
above any obstructions.
e condensate drain should have suf-6.
cient fall 1” per 10’ (8 mm/m) in
any horizontal run between casse e and
drain.
Maximum condensate pump li is 36” 7.
(0.9m).
ere should be a minimum 1” (25.4mm) 8.
clearance above the depth of the casse e
and the false ceiling for proper installation. See ( Figure 5, Page 10 ). (See the
casse e dimensions in the back of this
manual for cabinet sizing).
Spacing requirementsFigure 5
Dimension A + 1” = minimum space
above the false ceiling for installation
A +1”
Model Dimension A
9 & 12 11.84” (0.3 m) min.
24 12.55” (0.32 m) min.
36 14.51” (0.37 m) min.
A
Wall thermostat
A wall thermostat can be obtained through
EMI or your local distributor. The wall
thermostat is required for CACG/CAHG/
CAHJ units, optional for CACH/CAHH/
CAHK units.
In addition to positioning the casse e correctly, it is very important to locate the wall
mounted thermostat in the optimum position
to ensure good temperature control. The
installation should be selected with the following points in mind:
Position the thermostat approximately 5 1.
. (1.5m) above oor level.
Avoid external walls and dra s from win-2.
dows and doors.
Avoid positioning near shelves and cur-3.
tains as these restrict air movement.
Avoid heat sources (direct sunlight, heat-4.
ers, dimmer switches, etc.)
Seal wiring holes in the wall behind the 5.
thermostat to avoid dra s.
Comfort where it counts 10 P/N 240008108, Rev. G [07/08/10]
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Mounting the Unit (continued)
ir Handler
Mounting method
In existing construction, remove enough •
ceiling panels to provide clearance space
for mounting unit to ceiling joists.
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 embedded bolts.
For previously built concrete slabs –
install hanging bolts with an expansion anchor.
Follow local building codes for required •
safety cables, braces, etc.
Rod
Positions
Ceiling cutout/rod placement Figure 6
template (shipped with unit)
1.500 TYP
(51MM X 45°)
2.000 X 45° TYP
(38MM TYP)
Rod
Positions
Ceiling rod positionsTable 3
Ceiling opening
NOTICE
Make sure the ceiling grid is supported
separately from the Casse e. e ceiling
must not be supported by any part of the
Casse e unit, fascia or any associated
wiring or pipe work.
Cut an opening in the false ceiling with the
size shown in ( Table 2, Page 11 ).
Ceiling opening sizesTable 2
Model Dimensions
9 & 12 23¼” x 23¼” (591 x 591 mm)
24 33/” x 33/” (860 x 860 mm)
36 46” x 33/” (1168 x 860 mm)
Model Dimension A Dimension B
9 & 12 19.50” (495mm) 22.87” (581mm)
24 29.19” (740mm) 30.80” (782mm)
36 29.19” (740mm) 43.06” (1094mm)
Mounting bracketsFigure 7
Fold
bracket along
perforations
P/N 240008108, Rev. G [07/08/10] 11
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
MAX
2”
(51mm)
nstallation, Operation and Maintenance Manual •
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Mounting the Unit (continued)
Air Handlers
Mounting
Use the template (see 1. Figure 6, Page 11 )
to cut the ceiling opening and determining the rod positions.
Install hanger bolts using 3/8” (10mm) 2.
all-thread rod at the centers shown in
( Table 3, Page 11 ).
Prepare the installation guides by fold-3.
ing the metal bracket by hand along the
perforations ( Figure 7, Page 11 ).
Li the casse e onto the hanging rods. 4.
Level at the correct distance from the ceil-5.
ing with the aid of the installation guides
as shown in ( Figure 8, Page 12 ).
Secure the unit in position with locknuts 6.
and washers on either side of the casse e
bracket.
Ensure threaded rod does not protrude 7.
more than 2” (51mm) below the mounting bracket see ( Figure 9, Page 12 ).
Positioning installation guidesFigure 8
CASSETTE
CASE
INNER CASE
INSULATION
Threaded rods must not pro-Figure 9
trude more than 2 inches below
the mounting brackets
NOTICE
If the ceiling is not level or even, it is
important that the casse e is installed
level to ensure correct pump operation
and to maintain fan clearances.
Place a carpenter’s level on the unit.
A maximum slope of 1/8” (3mm) over
the length of the chassis toward the condensate drain is allowed.
Any slight discrepancy between the casse e and ceiling will be taken up by the
fascia foam seal.
2”
MAX
(51mm)
Comfort where it counts 12 P/N 240008108, Rev. G [07/08/10]
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Incorrect
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nstallation, Operation and Maintenance Manual •
Condensate Piping
ir Handler
e unit can now be piped up in accordance
with good refrigeration and/or plumbing
practices.
The Cassette is supplied with a 1/2” I.D.
exible PVC hose for connection to copper
or plastic drain piping.
When installing the cassette, consider the
following:
Maximum pump li is 36” (0.9m).1.
The highest point in the condensate 2.
piping should be as close to the unit as
possible. is prevents a large volume of
water draining back into the unit when it
is switched o .
NOTICE
ere is a check valve at the pump discharge to prevent water from draining
back into the unit. is piping technique
will minimize any issues should the
check valve become stuck open from
airborne debris.
The highest point of the con-Figure 10
densate piping should be as
close to unit as possible
Condensate drainFigure 11
Condensate Drain Connection
Correct
Incorrect
Condensate pipe-work should slope 3.
downwards in the direction of water ow
with a minimum gradient of 1” per 10’
(8mm/1m). There must be no uphill
gradients other than in the rst 36” (0.9m)
of pipe-work from the casse e.
When multiple casse es are connected to 4.
a common condensate drain, ensure the
drain is large enough to handle the total
volume of condensate.
NOTICE
A drain line vent may be required to prevent siphoning of water from the drain
pan and associated noise.
P/N 240008108, Rev. G [07/08/10] 13
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
Cassette 12
CASSETTE 24 & 36
nstallation, Operation and Maintenance Manual •
•
Duct Connections
Air Handlers
Branch duct and fresh air duct collars can be
KnockoutsFigure 12
a ached to the casse e chassis by following
the steps below.
NOTICE
Branch Duct Knockout
Cassette 12
Recommendation no more than
10 feet (3m) of branch duct or fresh air
duct should be installed.
Locate the knock-out holes ( 1. Figure 12,
Page 14 ).
CASSETTE 24 & 36
NOTICE
e number of knockouts varies with
unit size.
Branch duct knock-outs are 5¼”
(133mm) round.
Fresh air knockouts are:
1¼” x 2½” (32 x 64mm) rectangular •
on models 9 & 12.
3” (76mm) square on models 24 •
Cut insulation and snip out Figure 13
knockouts
and 36.
Fresh Air
Knockout
Cut the black insulation around the 2.
knock-out ( Figure 13, Page 14 ).
Snip the tabs holding the knock-out in 3.
place ( Figure 13, Page 14 ).
Remove the metal knock-out and the 4.
black insulation behind it.
A ach the duct collars ( eld supplied) to 5.
the chassis using self-drilling screws.
Repeat steps above for remaining duct 6.
work.
Comfort where it counts 14 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
Refrigerant Piping
ir Handler
CAUTION
Avoid piping on wet and rainy days.•
Use only clean, refrigeration-grade •
copper tubing.
Use tubing benders to guard against •
kinking.
Be certain no burrs remain on the •
ings.
Cap ends of lines until ready for con-•
nections. Be certain that plastic end
caps remain in place when inserting
through wall openings.
Insulate the suction and condensate •
lines all the way to the casse e.
Isolate tubing from transmi ing vibra-•
tion to the building or unit and avoid
contact with sharp edges.
Wrap refrigeration valves with a wet •
rag “heat sink” to protect valves while
brazing. (See Figure 16, Page 16 .)
DO NOT use a suction line size larger •
than the condenser service valve connection. is can harm the compressor. Install a reducer, when used, only
on the inside connection.
Piping connections at unitFigure 14
Suction Line Liquid Line
(When a reducing bushing is required, install
only at the indoor suction-line connection.)
Line sizing
Size lines per ( 1. Table 11, Page 60 ).
e suction line size must match the con-2.
denser service valve connection.
When matching the model 24 with an a.
18,000-Btuh condenser, you must use
a 5/8-inch suction line, with a reducer
installed as shown in ( Figure 14,
Page 15 ).
NOTICE
e casse e is equipped with a Flo Rater
piston expansion device. Connections
are sweat type.
P/N 240008108, Rev. G [07/08/10] 15
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Refrigerant Piping (continued)
Air Handlers
Refrigerant piping
Clean the ends of tubing and insert into 1.
ings ( Figure 15 ).
Before brazing ( 2. Figure 16 ):
Protect valves by wrapping with a wet a.
rag “heat sink” before brazing.
Use a shield to protect the paint as b.
shown. ( e shield can be made from
scrap metal.)
Braze tubing into ings, using a continu-3.
ous nitrogen purge.
e suction line must be insulated the 4.
entire length with closed cell, foam tube
insulation.
Do not insulate the liquid line.5.
Connect the outdoor unit according to 6.
the instructions supplied with unit.
NOTICE
Maximum equivalent pipe run should 1.
comply with ( Table 1, Page 8 ).
Horizontal pipe runs should be 2.
slightly inclined, so as to encourage
oil to flow in the direction of the
compressor, for be er oil return.
Good refrigeration practices must be 3.
employed to ensure the correct pressure drop and good oil return.
Clean ends of tubingFigure 15
Place wet rag “heat shield over Figure 16
valves plus a sheet metal shield
to protect paint
Wet rag heat sink
Shield
Pressure test all eld installed piping with nitrogen. Using a suitable vacuum pump,
evacuate the tubing and indoor unit to 500 microns or less, with service valves remaining
front seated (closed).
Comfort where it counts 16 P/N 240008108, Rev. G [07/08/10]
CAUTION
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
A
s
S1CG
Shown
A
C
B
S1CG
Shown
S2CH
S1CG
Refrigerant
S1CG
Shown
•
nstallation, Operation and Maintenance Manual •
Refrigerant Piping (continued)
ir Handler
Refrigerant processing
A ach manifold set ( 1. Figure 17 ).
Evacuate line to 500 microns or less to 2.
ensure all moisture has been removed and
there are no leaks.
Once certain of a good evacuation and 3.
leak free joints, back-seat the valves
(counter-clockwise) to open and allow
factory charge to ll lines and indoor unit
( Figure 18, Page 17 ).
NOTICE
Refer to refrigerant charge table for speci ed charge.
Use only R410A refrigerant. Add and 4.
remove only liquid, never vapor.
Charge to proper weight, charge based on 5.
feet of interconnect ( Figure 19, Page 17 ).
See tables on page 18 .
S1CG
Shown
S1CG
Shown
Manifold set connections at unitFigure 17
Manifold set up for evacuationFigure 18
A
C
B
CAUTION
Refer to the charts in the condenser
manual to “fine tune” the refrigerant
charge.
CAUTION
Charging should be done with a dial-acharge or weighed in with a scale.
WARNING
It is illegal to discharge refrigerant into
the atmosphere. Use proper reclaiming
methods & equipment when installing
or servicing this unit.
ManifoldA Vacuum pumpB
Micron gageC
Figure 19
S1CG
Charging the unit
S1CG
Shown
S2CH
P/N 240008108, Rev. G [07/08/10] 17
Refrigerant
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Refrigerant Processing
Air Handlers
NOTICE –
To nd the charge adjustment and system charge for any air handler and tubing 1.
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.2.
Table 4
Condenser
S1CG9 CAH_09
S1CG2 CAH_12
S1CG8 CAH_24
S1CG/S1HG and top discharge R410A refrigerant charge table
(
CAC_ refers to CACG/CACH; CAH_ refers to CAHG/CAHH/CAHJ/CAHK
Cassette
pairing
Line charge
per foot
.25 oz./ft
(23 g/m)
.25 oz./ft
(23 g/m)
.64 oz./ft
(59 g/m)
to fi nd charge adjustment
Factory
charge
39.5 oz.
(1119 g)
33.75 oz.
(956 g)
65.25 oz.
(1764 g)
Circuit capacity
9,000 Btuh CAH_09
Top discharge, Multi-zone
Wall Unit
Paring
)
Line charge
per foot
.25 oz./ft
(23 g/m)
Factory
charge
46.5 oz.
(1318 g)
S1CG4 CAH_24
S1CG3 CAC_36
S1CG6 CAC_36
S1HG9 CAH_
S1HG2 CAH_
S1HG8 CAH_
S1HG4 CAH_
09
12
24
24
.64 oz./ft
(59 g/m)
.64 oz./ft
(59 g/m)
.64 oz./ft
(59 g/m)
.25 oz./ft
(23 g/m)
.25 oz./ft
(23 g/m)
.64 oz./ft
(59 g/m)
.64 oz./ft
(59 g/m)
63.0 oz.
(1786 g)
97.5 oz.
(2764 g)
80.0 oz.
(2267 g)
51.52 oz.
(1460 g)
45.75 oz.
(1296 g)
63.0 oz.
(1786 g)
60.75 oz.
(1722 g)
12,000 Btuh CAH_12
18,000 Btuh CAH_24
24,000 Btuh CAH_24
Side Discharge Multi-zone
Circuit capacity
9,000 CAH_09
12,000 CAH_12
Wall Unit
Paring
.25 oz./ft
(23 g/m)
.64 oz./ft
(59 g/m)
.64 oz./ft
(59 g/m)
Line charge
per foot
.25 oz./ft
(23 g/m)
.25 oz./ft
(23 g/m)
45.25 oz.
(1282 g)
96.75 oz.
(2742 g)
78.5 oz.
(2225 g)
Factory
charge
44 oz.
(1247 g)
39 oz.
(1105 g)
Comfort where it counts 18 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
Final Assembly
ir Handler
Assembly instructions
To install the four fascia mounting bolts:1.
Remove the bolts and washers from a.
the supplied kit bag.
Put washers onto the bolts. b.
Screw the mounting bolt with washer c.
into the chassis leaving approximately
1” (25mm) to hang the fascia.
Ensure the white panel fasteners holding 2.
the fascia polystyrene are pushed rmly in
(fasteners may have loosened in transit).
Li the fascia onto the chassis mounting 3.
bolts. Align the key hole brackets with
the mounting bolts and slide the fascia
forward to lock into position.
On Casse e 24 and 36 units connect the 4.
vane motor plug by plugging it into the
socket connection on the chassis.
Ensure that the polarized connector a.
(2 position) is in the proper orientation and connected.
Route the wires in a way that ensures b.
they won’t become trapped, cut, broken or cha ed.
ONLY Cassette “H” or “K” models 5.
(CACH/CAHH/CAHK) contain a second cable connection to the control box
for the Infrared Unit Mount Control.
Ensure that the polarized (10 position) 6.
connector is in the proper orientation and
connected.
Route the wires in a way that ensures that 7.
they won’t become trapped, cut, broken,
or cha ed ( Figure 22, Page 19 ).
e fascia can now be tightened up to the 8.
Casse e chassis. make sure a good seal is
obtained between fascia and chassis, this
is necessary to prevent recirculation.
With lter(s) in place, the inlet grille(s) 9.
can now be installed onto the fascia.
Mounting boltsFigure 20
White panel fasteners must be Figure 21
pushed in
Wire routingFigure 22
P/N 240008108, Rev. G [07/08/10] 19
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Final Assembly (continued)
Air Handlers
Connect vane motor plug into Figure 23
socket on chassis
Female vane motor plug on
chassis
Secure fascia to chassisFigure 25
CAUTION
DO NOT over-tight-
en the bolts is
could cause damage
to the fascia and drain
pan.
Adjust louver position to 30° Figure 26
from plumb
Male vane motor plug on fascia
Connect infrared unit cable (“H” Figure 24
or “K” units only)
Polarized
10 Position
Connector
Red stripe is
Conductor #1
Comfort where it counts 20 P/N 240008108, Rev. G [07/08/10]
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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Low-voltage
connections
•
nstallation, Operation and Maintenance Manual •
Electrical Wiring
ir Handler
NOTICE
All electrical wiring must be run according to NEC and local codes.
General requirements
Electrical shock hazard Make sure the
WARNING
power is o before proceeding.
e standard unit voltage is 208/230V 1.
(60Hz, 1Ph). Check the unit’s rating plate
for your model’s electrical requirements.
The wires should be capable of carry-2.
ing the maximum load current under
non-fault conditions at the stipulated
voltages.
Avoid large voltage drops on cable runs, 3.
particularly in low-voltage wiring.
e correct cable size must be used to 4.
ensure a voltage drop of less than 1 volt
in the control wiring.
Once the refrigeration pipe work is 5.
complete, the electrical supply can be
connected.
Low-voltage wiring must be at least 6.
18 awg.
Removing control box coverFigure 27
Rating plate
Electrical connectionsFigure 28
High-voltage cable
L2
L1
Ground lug
Ground wire
Connect wiring
To access high-voltage wiring, loosen the 1.
four screws on the front of the control
box cover. en slide the cover up and o
( Figure 27, Page 21 ).
The rating plate is located on the out-2.
side of control box cover ( Figure 27,
Page 21 ).
Each unit must have a separate branch 3.
circuit protected by a fuse or breaker.
Check the rating plate for circuit ampacity
and breaker or fuse size. Use only HACR
type breakers. Select the proper wire for
the ampacity rating.
P/N 240008108, Rev. G [07/08/10] 21
Low-voltage
connections
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
Wiring diagram (on inside
of control panel cover)
nstallation, Operation and Maintenance Manual •
•
Electrical Wiring (continued)
Air Handlers
It is also recommended that a local discon-4.
Wiring diagram locationFigure 29
nect switch be connected within 3 feet of
the unit. In some areas this may be a code
requirement.
High-voltage electrical wiring
Wiring diagram (on inside
of control panel cover)
Inspect the existing wiring for any de-1.
ficiencies such as cut or frayed wires.
Replace if any such wiring if found.
Refer to the wiring diagram (2. Figure 29,
Page 22 ).
Route the cable through the appropriate 3.
hole in the control box for the high-voltage electrical wiring. Connect the power
wire to L1 and the neutral wire to L2 at
the power connector location. ( Figure 28,
Page 21 ).
Connect the ground wire to the ground 4.
lug or lead at the same location in the
control box.
Depending on the thermostat required or 4.
selected, cooling-only air handlers may
utilize three to ve low-voltage interconnecting wires between the indoor unit,
WARNING
thermostat and the outdoor unit. Some
thermostats do not require the use of the
Terminate ALL unused wires with a wire
nut or crimp connector.
“C” (brown) connection. For these applications, ensure that any unused wires
are insulated to prevent them from making
Low-voltage electrical wiring
contact with the junction box or other
metal surfaces.
If the indoor unit has electric heat, then a 5.
NOTICE
All low-voltage interconnect wiring must
“W” connection is required between the
thermostat and the indoor unit.
be at least 18 AWG.
e 24V control transformer is located in 1.
the air handler. is provides low-voltage
control power to both the air handler and
condenser. Depending on the models
selected, the low-voltage interconnect
control wiring may be di erent.
Refer to the wiring diagram to connect 2.
the low-voltage wiring to the appropriate
terminals.
Once the connections are made, replace 3.
control box cover with the wiring diagram facing in and secure with the four
screws.
Comfort where it counts 22 P/N 240008108, Rev. G [07/08/10]
NOTICE
On units rated 208/230V, the primary
side of the transformer is factory wired
for 230V. For a 208V power supply, the
transformer tap must be changed from
orange to red. Refer to the wiring diagram located on the inside of the control
box cover ( Figure 29, Page 22 ).
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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nstallation, Operation and Maintenance Manual •
Wall Thermostat Selection (optional for CACH/CAHH/CAHK)
ir Handler
NOTICE
CACG/CAHG/CAHJ units
All are operated by a wall thermo-•
stat.
CACH/CAHH/CAHK units
e unit’s DIP switch #4 must be set •
to OFF to enable wall thermostat
operation.
e controller will con guration will •
have to be set for the unit’s cooling/
heating functions.
Follow instructions beginning on •
page 28 to set up the controller and
DIP switches before proceeding.
THERMOSTAT selection
EMI thermostats
EMI offers several wall thermostats that
are compatible with EMI split system air
handlers.
See the latest price list for available ther-•
mostats.
It is important to choose a thermostat •
that will match the equipment that you
have selected.
For single-stage cooling or heating, choose •
a single-stage heat/cool thermostat.
If you have selected an outdoor heat pump •
unit and an indoor unit with electric heat,
then chose a two-stage heating, singlestage cooling thermostat.
Field-supplied thermostats
When selecting a thermostat other than one
o ered by EMI, it is important to choose a
24V thermostat that matches your application.
EMI equipment is compatible with most
mercury bulb, digital or power-stealing thermostats.
Cooling only
Select a thermostat that is compatible with a
cooling system.
e thermostat should have “R”, “Y” and “G”
terminals and may also have a “C” terminal.
Cooling only with electric heat
Select a thermostat that is compatible with a
cooling/electric heat system.
e thermostat should have “R”, “Y ”, “W ” and
“G” terminals. e thermostat may also have
a “C” terminal.
Heat Pump with electric heat
Select a thermostat that is compatible with
a single-stage cooling, two-stage heat, heat
pump system.
e thermostat should have “R”, “Y”, “O”, “W
(or W2)” and “G” terminals. e thermostat
may also have a “C” terminal.
If the indoor unit is not equipped with electric
heat, then a single-stage heat pump thermostat
is adequate.
P/N 240008108, Rev. G [07/08/10] 23
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Air Handlers
Wall Thermostat Operation (optional for CACH/CAHH/CAHK) (continued)
FAN operation
e wall thermostat will control the call for
fan operation (on or o ) through the lowvoltage terminals “R” and “G”. When the
wall thermostat connects “R” to “G” the fan
will energize. A er the thermostat has been
satis ed and the call for heating or cooling
has been removed, the indoor fan will remain
on for an additional sixty (60) seconds. is
increases e ciency by pulling the remaining
energy from the unit.
Some thermostats are equipped with an
AUTO/ON fan switch. When this switch
is placed in the ON position 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.
CACH/CAHH/CAHK units only e
indoor unit utilizes a two speed motor. For
wall ermostat Operation, fan speed selection can be made through the DIP switch
se ings located on the main control board. By
se ing DIP switch #3 Remote ermostat Fan
Speed Selection to ON, the fan speed will be
set to High. Switching to OFF, the fan speed
is set to Low.
COOLING operation
e wall thermostat will control the call for
cooling operation (on or o ) through the
low-voltage terminals, R and Y.
A er connecting the thermostat to the unit,
place the system switch in Cool mode.
Adjust the set-point temperature below •
the room temperature.
e compressor and fan motors will start •
and cooling will begin.
Next, place the set-point temperature above
the room temperature.
e outdoor condenser will stop.•
e fan will operate as described in FAN •
operation.
NOTICE
Once cooling has cycled o or following
a power outage, the compressor will not
start for at least three minutes (shortcycle protection).
Comfort where it counts 24 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
ir Handler
Wall Thermostat Operation (optional for CACH/CAHH/CAHK) (continued)
Electric heat operation
For wall thermostat operation with electric
heat the control must be con gured properly
(Remote ermostat ON) [Table 6, pg. 32],
Heat Source ON [Figure 36, pg. 35].
e wall thermostat will control the call for
electric heat operation (On or O ) through
the low-voltage terminals, R and W.
A er connecting the thermostat to unit, place
the system switch in Heat mode.
Adjust the set-point temperature above •
the room temperature.
e electric heat will energize along with •
the indoor fan motor.
Heating will continue as long as the set-•
point remains above room temperature.
Next, place the set-point temperature below
room temperature.
e Electric heater will switch o and the •
indoor fan will remain on for an additional
sixty seconds.
NOTICE
Once heating has cycled o or following
a power outage, heating will not start
for at least three minutes (short-cycle
protection).
Optional HEAT PUMP WITH
ELECTRIC HEAT
(Two-stage heating)
For wall thermostat operation for two-stage
heating including a heat pump condenser and
indoor electric heat, the control must rst be
configured properly (Remote Thermostat
ON) [Table 6, pg. 32], Heat Source ON
[Figure 36, pg. 35]
e wall thermostat will control the call for
electric heat operation (on or o ) through
the low-voltage terminals, R and W, and
compressor (heat pump) heating through
terminals R and Y.
A er connecting the two-stage heating thermostat to the unit, place the system switch in
Heat mode.
Adjust the set-point temperature above •
the room temperature. e compressor
and fan motors will start and heating
will begin.
Depending on the thermostat selected, •
electric heat will also energize when the
deviation between room temperature
and set point temperature is high enough
to call for second stage heating. (See
the thermostat owner’s manual for this
feature.)
Place the set-point temperature below the
room temperature.
e outdoor condenser and electric heat •
will stop while the indoor fan will remain
on for an additional sixty seconds.
P/N 240008108, Rev. G [07/08/10] 25
NOTICE
Once heating has cycled o or following
a power outage, heating will not start
for at least three minutes (short-cycle
protection).
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Initial Start-Up — CACG/CAHG/CAHJ Units ONLY
Air Handlers
NOTICE
CACG/CAHH/CAHK units
ese units require se ing of DIP •
switches and controller functions
before proceeding with start-up.
Follow instructions beginning on •
page 28 .
NOTICE
To test cooling operation
Operation of the unit depends on the
room temperature. It may be necessary
to warm the room before testing the
unit’s cooling abilities.
NOTICE
When power is rst applied to the control or a er a power outage there is a
three minute delay before the compressor or electric heat will energize. is is
to protect the unit from short cycling due
to loss of power.
CAHG/CACG louver toggle Figure 30
switch
Toggle Switch
Remove any tools or other obstructions.1.
Inspect all electrical connections.2.
Separate any lines that contact each 3.
other.
Replace the control panel cover, lters 4.
and grilles.
Electrical shock hazard — Turn off
WARNING
power to indoor and outdoor units is o
before proceeding.
Perform complete inspection
NOTICE
To perform a system electrical check:
Turn o all power to the indoor and •
outdoor units.
Isolate the compressor (to prevent •
it from operating until the check is
completed) by removing the connection at the “Y” terminal on the
outdoor unit.
Test each power and circuit connection 5.
before powering up the system.
Perform electrical circuit checks
Switch on the casse e unit and verify that 1.
the fan cycles correctly.
Models CAHG24 and CACG36 only 2.
Check motorized vane operation by turning on with the toggle switch located on
the side of the electrical box ( Figure 30,
Page 26 ).
For units with electric heat, check opera-3.
tion of the heating elements by switching
the system to the heating mode. Adjust
the thermostat setpoint above room
temperature.
Ensure that the outdoor unit start-up 4.
procedure has been completed as directed
in the unit’s instruction manual.
Comfort where it counts 26 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
ir Handler
Initial Start-Up — CACG/CAHG/CAHJ Units ONLY (continued)
Electrical shock hazard — Turn off
WARNING
power to indoor and outdoor units is o
before proceeding.
Reconnect the wire to “Y ” on the outdoor 5.
unit to enable the compressor.
Turn on power to the indoor and outdoor 6.
units.
Check condensate pump
operation
Remove an adjacent ceiling tile to access 1.
the condensate pump cover panel.
Insert a squeeze water bottle nozzle 2.
through the opening in the condensate
pump access panel and ll drain pan. See
Figure 31, Page 27 .
Adding water will activate the oat switch 3.
and the pump. Water must ow regularly
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 lters 4.
are in place and discharge louvers are
correctly positioned.
Checking condensate pump Figure 31
operation
Check heat pump operation
Heat pump systems Turn up the 1.
system setpoint to activate heat pump
(compressor) operation.
Place the system controls into heating 2.
mode, with the setpoint 1°F above room
temperature (or meeting the requirements for 1st stage heating operation).
Verify compressor start up, noise, vibration, and overall system operation.
NOTICE
e unit is equipped with a safety switch
that will activate the pump when the
condensate reaches a critical level. e
safety switch will also de-energize the
compressor if the water level becomes
too high.
Check cooling operation
Cooling-only systems Turn the system 1.
power on and turn down the system setpoint to activate the compressor.
P/N 240008108, Rev. G [07/08/10] 27
Next, alter the setpoint until the 2nd stage 3.
of heat is called (this action is dependent
on both options and controls contained
in the system).
NOTICE
Second state heating requires both
optional electric heat and a means of
control.
Additional cassette units
Repeat the start-up procedure for all cas-1.
se e units in the system.
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Initial Start-Up — CACH/CAHH/CAHK Units ONLY
Air Handlers
NOTICE
To test cooling operation
Operation of the unit depends on the
room temperature. It may be necessary
to warm the room before testing the
unit’s cooling abilities.
NOTICE
When power is rst applied to the control or a er a power outage there is a
three minute delay before the compressor or electric heat will energize. is is
to protect the unit from short cycling due
to loss of power.
Electrical shock hazard — Turn off
WARNING
power to indoor and outdoor units is o
before proceeding.
Perform complete inspection
Set DIP switches
DO NOT turn on power until the DIP 1.
switches have been set and the control
panel cover replaced.
To access the DIP switches, remove the 2.
control panel cover ( Figure 27, Page 21 ).
See Figure 33, Page 31 for location of the
switches on the control board.
Model CACH/CAHH/CAHK units 3.
have four DIP switches, as described in
Table 6, Page 32 .
DIP switch #1, Test mode, is used a.
only during start-up and servicing,
to reduce time required for automatic
timers.
DIP switches #2, #3 and #4 are b.
related to the (optional) use of a
remote thermostat. Switches #2 and
#3 are operational only if switch #4 is
set to NO, enabling wall thermostat
operation.
Set the switches as desired for the ap-4.
plication.
NOTICE
To perform a system electrical check:
Turn o all power to the indoor and •
outdoor units.
Isolate the compressor (to prevent •
it from operating until the check is
completed) by removing the connection at the “Y” terminal on the
outdoor unit.
Remove any tools or other obstructions.1.
Inspect all electrical connections.2.
Separate any lines that contact each 3.
other.
Replace the control panel cover, lters 4.
and grilles.
Test each power and circuit connection 5.
before proceeding further.
Set controller confi guration
Review the information in 1. Figure 34,
Page 33 through Figure 37, Page 36 for
general operation of the controller and
handheld remote.
2. Figure 35, Page 34 explains how to set up
the controller using the handheld infrared
remote. (NOTE that the remote is a lineof-sight device, and must be pointed at the
receiver on the unit-mounted display.)
Turn on power to the indoor unit so the 3.
controller can be operated.
Press and hold both the MODE and 4.
PROG M bu ons on the remote for
5 seconds to enter
Confi guration mode
(as shown in Figure 35, Page 34 ).
Con gure the controller using 5. Figure 36,
Page 35 .
After the configuration is completed, 6.
point the remote at the casse e unit’s display. en press and hold the POWER/
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SEND button for 2 seconds. This will
transmit information from the remote
to the casse e. e casse e will respond
with a beep, indicating it has received
the information. ( is step is necessary,
because it is possible that information entered into the remote may not have been
received if the remote was not pointed
directly at the receiver.)
Do not set the time or 7-day program 7.
settings yet. This should be done after
start-up is completed.
Perform electrical circuit checks
Turn on power to the casse e unit.1.
Verify fan and louver operation using the 2.
handheld remote. Use the procedures
given in Figure 35, Page 34 .
Make sure the fan can be set to high, a.
low and auto.
Make sure the louver can be set to run b.
at full open or oscillation.
Electrical shock hazard — Turn off
WARNING
power to indoor and outdoor units is o
before proceeding.
Reconnect the wire to “Y ” on the outdoor 3.
unit to enable the compressor.
Turn on power to the indoor and outdoor 4.
units.
Verify compressor operation — all
systems
Place the system controls into cooling 1.
mode, with the setpoint below room
temperature.
Verify compressor start up, noise, vibra-2.
tion, and overall system operation.
Then place the control setpoint above 3.
room temperature.
Verify that the compressor shuts down.4.
Wait for the blower post purge to com-5.
plete. en verify that the system shuts
down properly.
Be sure to return DIP switch #1 (Test 6.
mode) to NO before leaving the system.
Verify cooling-only operation
This arrangement uses a cooling-only 1.
outdoor unit with no heat source in the
casse e (indoor) unit.
e con guration ( 2. Figure 36, Page 35 )
should be set for Heat Source OFF, Heat
Pump OFF.
Use the remote to set MODE to Cool (see 3.
Figure 35, Page 34 ).
Use the remote to adjust setpoint tem-4.
perature below the room temperature (at
the casse e unit).
e compressor should come on. Verify 5.
that supply air is cooler than room air.
Verify cooling with electric heat
This arrangement uses a cooling-only 1.
outdoor unit with electric heat option in
the casse e unit.
e con guration ( 2. Figure 36, Page 35 )
should be set for Heat Source ON, Heat
Pump OFF.
Use the remote to set MODE to Cool (see 3.
Figure 35, Page 34 ).
Use the remote to adjust setpoint tem-4.
perature below the room temperature (at
the casse e unit).
e compressor should come on. Verify 5.
that supply air is cooler than room air.
Use the remote to set MODE to Heat (see 6.
Figure 35, Page 34 ).
Use the remote to adjust setpoint tem-7.
perature above the room temperature (at
the casse e unit).
The electric heaters should come on. 8.
Verify that supply air is warmer than
room air.
For automatic changeover between 9.
heat/cool, use the remote to enable auto
changeover (see Figure 35, Page 34 ).
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Air Handlers
Verify heat pump operation (no
electric heat)
This arrangement uses a heat pump 1.
outdoor unit with no heat source in the
casse e (indoor) unit.
e con guration ( 2. Figure 36, Page 35 )
should be set for Heat Source OFF, Heat
Pump ON.
Use the remote to set MODE to Cool (see 3.
Figure 35, Page 34 ).
Use the remote to adjust setpoint tem-4.
perature below the room temperature (at
the casse e unit).
e compressor should come on. Verify 5.
that supply air is cooler than room air.
Use the remote to adjust setpoint tem-6.
perature above the room temperature (at
the casse e unit).
Verify that supply air is warmer than 7.
room air.
Verify operation.10.
Check condensate pump
operation
Remove an adjacent ceiling tile to access 1.
the condensate pump cover panel.
Insert a squeeze water bottle nozzle 2.
through the opening in the condensate
pump access panel and ll drain pan. See
Figure 32, Page 30 .
Adding water will activate the oat switch 3.
and the pump. Water must ow regularly
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 lters 4.
are in place and discharge louvers are
correctly positioned.
Checking condensate pump Figure 32
operation
Verify heat pump operation (with
electric heat option)
is arrangement uses a heat pump out-1.
door unit with the optional electric heat
source in the casse e (indoor) unit.
e con guration ( 2. Figure 36, Page 35 )
should be set for Heat Source ON, Heat
Pump ON.
Use the remote to set MODE to Cool (see 3.
Figure 35, Page 34 ).
Use the remote to adjust setpoint tem-4.
perature below the room temperature (at
the casse e unit).
e compressor should come on. Verify 5.
that supply air is cooler than room air.
Use the remote to adjust setpoint temper-6.
ature 1°F above the room temperature (at
the casse e unit), or just enough needed
to activate rst stage heating.
e compressor should come on. 7.
Verify that supply air is warmer than 8.
room air.
Increase the setpoint until the second 9.
stage heating (electric heaters) activates.
NOTICE
e unit is equipped with a safety switch
that will activate the pump when the
condensate reaches a critical level. e
safety switch will also de-energize the
compressor if the water level becomes
too high.
Additional cassette units
Repeat the start-up procedure for all cas-1.
se e units in the system.
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CACG/CAHH/CAHK Microprocessor Controller Overview
EMI unit-mounted microprocessor controller — control panelFigure 33
WARNING
Electrical shock hazard Before
removing the control box cover,
make sure that all power is removed from both the indoor casse e unit and outdoor condenser
unit. Failure to comply could
result in severe personal injury
or death.
Dip
switches
Control
panel
P/N 240008108, Rev. G [07/08/10] 31
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CACH/CAHH/CAHK Microprocessor Controller Overview (continued)
CACG/CAHH/CAHK Microprocessor controller — dip switch settingsTable 6
DIP Switch Setting Operation
Enables Test mode. All timers are shortened,
allowing quicker operational testing.
Anti-short-cycle time reduces from 3 minutes to •
45 seconds.
Minimum on-time reduces from 2 minutes to 30 •
seconds.
#1
Test mode
ON
Postpurge time reduces from 60 to 15 seconds.•
Stagger start time reduces from 30 to 7.5 •
seconds.
CAUTION — DO NOT cycle the unit on and
off repeatedly in Test mode. This will damage
the compressor. DO NOT leave the unit in Test
mode after setup. Return dip switch #1 to the OFF
position for normal operation.
Disables Test mode.
If DIP Switch #4 is ON,
during operation.
If DIP Switch #4 is ON,
during operation.
#2
Louver oscillation
(for wall thermostat
mode only)
#3
OFF
ON
OFF
ON While DIP Switch #4 is ON, selects fan speed
Fan speed setting
(for wall thermostat
mode only)
OFF While DIP Switch #4 is ON, selects fan speed
Factory
Setting
OFF
enables louver oscillation
OFF
disables louver oscillation
HIGH.
ON
LOW.
#4
Select infrared
handheld controller or
wall thermostat control
ON
OFF
Disables infrared hand controller and enables wall
thermostat operation and enables dip switches #3
and #2.
Clean fi lter time automatically defaults to
1000 hours.
Enables infrared hand controller and disables wall
thermostat operation.
ON
Comfort where it counts 32 P/N 240008108, Rev. G [07/08/10]
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CACH/CAHH/CAHK Microprocessor Controller Overview (continued)
Unit-mounted controller — chassis-mounted keypad/displayFigure 34
3
2
6
1
5
4
1
Infrared receiver window .
Power LED
In Wall ermostat mode on when power is applied to the unit.
2
In Infrared Controller mode on while the casse e unit is in the ON mode; o while unit is
in the OFF mode.
3
Cooling LED On when the unit is in cooling operation.
4
Heating LED On during calls for heat.
Timer/Alarm LED On steady while the unit is in Sleep Timer mode; ashes to indicate
5
fault codes.
Clear Filter warning button Hold for 3 seconds to clear the Clean Filter warning (indi-
6
cated when Timer/Alarm LED, item 5, ashes 4 times)
P/N 240008108, Rev. G [07/08/10] 33
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CACH/CAHH/CAHK Microprocessor Controller Overview (continued)
CACH/CAHH/CAHK Microprocessor Controller — infrared remote controlFigure 35
POWER
SEND
MODE
CLOCK
LOUVER
UP
DOWN
Press to turn unit on or o . Press and hold for
2 seconds to transmit all se ings to the unitmounted controller.
Press to toggle through operating modes
Heat, Cool, Auto Changeover, Dry or Fan.
Normal operation hold for 3 seconds to
enter Set Time mode; press again to nish
and exit.
In programming mode press to enter the
selection displayed.
CAHH24 & CACH36 only press to toggle
motorized louver on or o .
Normal operation press to increase the
setpoint temperature.
Con guration, Set Time or Programming
mode press to increase the se ing.
Normal operation press to decrease the
setpoint temperature.
Con guration, Set Time or Programming
mode press to decrease the se ing.
FAN
PROGRAM
TIMER
MODE +
PROGRAM
PROGRAM +
CLOCK
FAN +
PROGRAM
Press to toggle between fan modes High,
Low or Auto.
Normal operation Press to toggle between
manual operation and Pre-programmed (7day) run mode.
Con guration, Set Time or Programming
mode press to enter the next selection.
Press to toggle Timer mode on/o .
With unit in OFF mode Press and hold
for 5 seconds to enter
Confi guration mode;
press again to exit.
Press and hold 3 seconds to enter 7-Day
Programming mode
; press again to exit.
With unit in 7-Day Programming mode
Press and hold 3 seconds to copy the se ings
for the selected day to all other days.
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Setting the CACH/CAHH/CAHK Controller
Confi guration settings for CACH/CAHH/CAHK Figure 36
Setting Item Display
Possible Value
(fl ashing)
Factory
Settings
Overview
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; to change values, use the UP and DOWN keys; when value is reached, move to the next
setting using the PROGRAM or CLOCK button; values are stored on exit from programming mode.
Temperature
scale
01 F-C
Heat source 02 HEAT
Heat pump
(see Note 1)
03 H-P
F CFahrenheit
Celsius
Available
ON
OFF
ON
OFF
Not
available
Available
Not
available
Note 3
OFF
Select temperature scale for display and operating se ings.
F
Set this to ON if the unit is equipped with the electric heater
option, or matched with a heat pump condenser.
See
e electric heater is required for DRY mode operation and for
automatic changeover operation.
Set this to ON if the unit is built for heat pump operation and
connected to an appropriate compressor unit.
Auto changeover automatically operates the unit in heating or
cooling based on room temperature versus setpoint.
is se ing is the dead band temperature:
Auto
changeover
diff erential
(see Note 2)
04 d-b x 2° – 6° 2°
Cooling is on while room temperature is at setpoint PLUS •
dead band.
Heating is on while room temperature is at setpoint MINUS •
dead band.
Example: setpoint = 68°F, dead band is 3°F — cooling is on •
with room temperature at or above 71°F — heating is on
with room temperature at or below 65°F.
Check fi lter
time
Note 2 04, Auto changeover, is SKIPPED if se ing 02, Heat source, is OFF. is se ing is for operation with handheld
Note 3
P/N 240008108, Rev. G [07/08/10] 35
05 F:Lt
Se ing Note 1 03, Heat pump, is SKIPPED if se ing 02, Heat source, is OFF.
Se ing
controller.
Factory se ing is ON if electric heat is installed in unit, or OFF if electric heat is not installed.
250 hours
2
500 hours
5
750 hours
7
1000 hours
10
1250 hours
12
Set this time for automatic notice of time to change the lter. At
the end of the time period, the control will display a FILTER
CHECK warning. is warning will also appear if four coil
freeze-ups should occur in a 24-hour period.
10
Reset the warning, restarting the time period, by pressing
MODE and FAN bu ons together for 3 seconds.
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Setting the CACH/CAHH/CAHK Controller (continued)
7-day programming options for CACH/CAHH/CAHKFigure 37
Item Setting Values Overview
To access: Press and hold PROGRAM and CLOCK buttons simultaneously for 3 seconds; use arrow keys to
select position; save selection and exit by repeating the button press.
Quick copy — Hold FAN and PROGRAM buttons for 3 seconds to copy current day’s settings to all other
days.
Navigating through settings: Press PROGRAM to move to the next setting or CLOCK to move to the
previous setting; to change values, use the UP and DOWN keys; when value is reached, move to the next
setting using the PROGRAM or CLOCK button; values are stored on exit from programming mode.
7-Day programming
(use Table 7, Page 37 to record settings)
Day of week
Mon, Tue, Wed,
Thu, Fri, Sat, Sun
Morning
Period of day
Day
Evening
Night
Hour
0–12 a
0–12 p
Minute 0–59
Cooling
setpoint
Heating
setpoint
55–90 F
55–90 F
Auto setpoint 55–90 F
e louver is closed when the fan is o .
e periods provide four time se ings to initiate a change in
cooling/heating setpoints. ey allow adjustments for setback
(such as night setback, daytime setback and occupied se ings
for residential applications). Set the hour/minute for each time
as well as the cooling and heating setpoints below.
Set the time to begin the period.
e unit will default to this setpoint when set to Cooling in preprogrammed run mode.
e unit will default to this setpoint when set to Heating in preprogrammed run mode.
e unit will default to this setpoint when set to Auto in
pre-programmed run mode. ( e unit will auto changeover
between heating and cooling.)
Comfort where it counts 36 P/N 240008108, Rev. G [07/08/10]
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Setting the CACH/CAHH/CAHK Controller (continued)
Programming schedule (when using 7-day programming)Table 7
ir Handler
Night
Evening
Day
Cool
Heat
Auto
Cool
Heat
Auto
Cool
Heat
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Morning
Auto
Cool
Heat
Auto
:
:
:
:
:
:
Time
Monday
To copy the settings from any day to the entire week:
1) Select the day to be copied.
2) Simultaneously press the “FAN” and “PROG” buttons for three seconds.
Temp
Time
Temp
Tuesday
Time
Wednesday
Temp
Time
Thursday
Temp
Time
Temp
Friday
Time
Saturday
Temp
:
Time
Sunday
Temp
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CACH/CAHH/CAHK Microprocessor Controller Operation
NOTICE
When power is rst applied to the control or a er a power outage there is a
three minute delay before the compressor or electric heat will energize. is is
to protect the unit from short cycling due
to loss of power.
NOTICE
e controller must be con gured with
Remote Thermostat NO to operate us-
ing the infrared remote controller. See
(Table 6, pg. 32) for details. (Remote
ermostat YES means the unit will be
controlled by a wall thermostat.)
Handheld remote operation
When power is rst applied to the control or
a er a power outage there is a three minute
delay before the compressor or electric heat
will energize. is is to protect the unit from
short cycling.
Pointing the remote
When entering commands into the remote,
make sure it is pointed toward the casse e’s
infrared receiver window (see Figure 34,
Page 33 ). e casse e will respond with a
beep indicating that it has successfully received the transmi ed information.
Synchronization
There may be occasions when the remote
and the casse e’s main control board mode
synchronization or are not in the same mode.
is can happen if commands are entered
into the remote, but it is not pointed at the
casse e.
Alternatively, hold the POWER/SEND •
bu on for two seconds. All of the optional
remote’s se ings will be transmi ed to the
casse e. e casse e will respond with a
beep, indicating that it has successfully
received the transmi ed information.
Temperature indication
e room temperature displayed on the remote is the temperature at the remote. e
microprocessor control located in the casse e
does not read the remote’s temperature it
uses a sensor located in the return air of the
casse e.
Therefore, the warming or cooling of the
remote alone will not e ect the operation of
the Casse e. e Casse e will react to its local
temperature sensing element and the setpoint
selected and transmi ed by the remote.
Transmission limits
e remote has a useful transmission distance
approximately twenty (20) feet when perpendicular to the face of the Casse e. However,
this distance will vary and decrease when the
angle of transmission is not perpendicular.
is distance may also vary depending on the
lighting in the room.
Hibernate mode
If there is no activity on the remote for ten
minutes, it will enter a hibernate mode and the
display will go dark. While in hibernate mode,
pressing any bu on will awaken the remote.
e remote will return to the mode it was in
prior to entering hibernate mode.
To re-synchronize:
Enter any command into the remote •
while pointing it at the casse e’s infrared
receiver window.
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CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
POWER/SEND
Pressing the POWER/SEND bu on momentarily will switch the unit either on or o .
In the OFF mode, the liquid crystal dis-1.
play (LCD) will display the time of day
and day of the week.
In the ON mode the LCD will also display 2.
the room temperature, mode of operation
Cooling, Heating, Auto (Auto changeover), Dry or Fan mode.
While in the ON mode, the setpoint 3.
temperature will display momentarily
with the push of any bu on except the
POWER/SEND bu on.
Also, when POWER/SEND is held down 4.
for two (2) seconds, the remote transmits
all optional Infrared Hand Held Controller information to the Casse e.
Mode
NOTICE
Heating, Auto Changeover (Auto)
or Dry modes will not display if Heat
Source is set to OFF in the Con guration mode.
e MODE bu on allows the selection of the
mode of operation Cooling, Heating, Auto
Changeover (ACO), Dry or Fan mode.
High and Low are constant fan se ings. e
fan operates continuously, regardless of setpoint or room temperatures.
Auto fan mode is for auto ramping of fan
speeds.
Auto fan mode can only be selected if 1.
the unit is in Heating, Cooling or Auto
Changeover modes.
In Auto fan mode, the speed is determined 2.
by the microprocessor.
Speed adjustment will be made ac-a.
cording to room and setpoint temperatures.
The fan will switch to High speed b.
when room temperature deviates
by more than two degrees from
setpoint.
e fan will switch to Low speed if the c.
deviation is one degree or less.
Louver operation — CAHH 24 and
CACH 36 only
e louver can be set to oscillate during fan
operation or open to a xed se ing.
When LOUVER is pressed, the word “Lou”,
will display for two seconds along with “ON
or “OFF” to indicate that the louver se ing
has been changed.
In Fan mode either “HIGH” or “LOW” will
appear on the LCD.
Fan Operation
e indoor unit utilizes a two-speed motor
with three operational fan modes High,
Low and Auto.
e FAN bu on will allow the selection of
the desired fan se ing in all modes except
Dry mode.
Dry mode, the fan will operate constantly
In
at low speed. e LCD will indicate the fan
speed selection.
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CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
Cooling mode
For cooling operation, rst turn the unit on
via the POWER/SEND bu on.
Select Cooling mode via the MODE 1.
bu on.
The room temperature and set point 2.
temperature will be displayed.
e setpoint temperature will change by 3.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the button in will change the
temperature rapidly.
Place the setpoint temperature below the 4.
room temperature.
e compressor will start and cooling will 5.
continue for a minimum of two minutes
and as long as the setpoint remains below
room temperature.
e Cooling LED will illuminate as long 6.
as the unit is calling for cooling.
Once the room temperature is satis ed for 7.
at least sixty seconds and the two-minute
minimum run time has elapsed the compressor will cycle o .
e fan will operate as described in “Fan 8.
Operation.” see pg. 39
NOTICE
Once the cooling has cycled o or following a power outage, the compressor
will not restart for at least three minutes
(anti-short-cycle timer).
Heating mode
Optional Electric heat operation (Air
Conditioning unit outdoors)
For operation with electric heat the control
must first be configured properly (Heat
Source – ON (Table 6, pg. 32), Heat Pump –
OFF (Figure 36, pg. 35).
For electric heat operation, rst turn the unit
on via the POWER/SEND bu on.
en select Heating mode via the MODE 1.
bu on.
e room temperature and setpoint tem-2.
perature will be displayed.
Press either the UP or DOWN ARROW 3.
bu ons to change the setpoint temperature.
e setpoint temperature will change by 4.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the bu on down will change the
temperature rapidly.
Place the setpoint temperature above 5.
room temperature.
e electric heat will energize and heat-6.
ing will continue as long as the setpoint
remains above room temperature.
e Heating LED will illuminate as long 7.
as the unit is calling Heating mode.
When the room temperature has been 8.
satisfied for at least sixty seconds and
the two-minute minimum on-time has
expired, the electric heat will switch o .
e fan will operate as described in “Fan 9.
Operation.” see pg. 39
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CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
Optional Heat pump without Electric
heat (Heat Pump unit outdoors)
NOTICE
EMI heat pumps are intended to operate
with an indoor air handler, with electric
heat. If an indoor air handler without
electric heat is matched with a heat pump
condenser, the system will deliver cold
air during defrost.
For heat pump operation without electric heat
the control must rst be con gured properly
(Heat Source – ON Table 6, pg. 32, Heat
Pump – OFF Figure 36, pg. 35).
For heat pump operation, turn the unit on via
the POWER/SEND bu on.
Select Heating mode via the MODE 1.
bu on.
e room temperature and setpoint tem-2.
perature will be displayed.
Press either the UP or DOWN ARROW 3.
bu ons to change the setpoint temperature.
e setpoint temperature will change by 4.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the bu on down will change the
temperature rapidly.
Place the setpoint temperature above 5.
room temperature.
e outdoor unit will energize in heat 6.
pump mode and heating will continue as
long as the setpoint remains above room
temperature.
e Heating LED will illuminate as long 7.
as the unit is calling for heat.
When the room temperature has been 8.
satisfied for at least sixty seconds and
the two-minute minimum on-time has
expired, the compressor will switch o .
e fan will operate as described in “Fan 9.
Operation.” see pg. 39
Optional Heat pump with Electric heat
(2-stage heating)
For heat pump operation with electric heat
the control must rst be con gured properly
(Heat source – ON Table 6, pg. 32, Heat pump
– OFF Figure 36, pg. 35).
For heat pump operation with optional electric heat, turn the unit on via the POWER/
SEND bu on.
en select Heating mode via the MODE 1.
bu on.
e room temperature and setpoint tem-2.
perature will be displayed. Press either
the UP or DOWN ARROW bu ons to
change the setpoint temperature.
e setpoint temperature will change by 3.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the bu on down will change the
temperature rapidly.
Place the setpoint temperature above the 4.
room temperature by one degree. The
compressor will start and heating will
continue for a minimum of two-minutes
and as long as the setpoint remains above
room temperature.
e Heating LED will illuminate as long 5.
as the unit is calling for Heating mode.
When the room temperature has been 6.
satisfied for at least sixty seconds and
the two-minute minimum on-time has
elapsed, the compressor will switch o .
e fan will operate as described in “Fan 7.
Operation.” see pg. 39
Next, place the setpoint temperature 8.
above the room temperature by at least
two degrees.
e compressor will start and, the electric 9.
will also energize a er a thirty-second
delay, thus two-stage heating.
e electric heat will run for a minimum 10.
of two minutes and until the deviation
between room temperature and setpoint
temperature is less than two degrees.
P/N 240008108, Rev. G [07/08/10] 41
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Air Handlers
CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
At that time the electric heat will switch 11.
o and the heat pump (compressor) will
take over the heating demand.
e electric heater will not restart until a 12.
three-minute delay has elapsed.
Once the room temperature is satis ed 13.
and the two-minute minimum run time
has elapsed, the compressor will cycle
o .
e compressor will not restart until a 14.
three-minute delay has elapsed.
e fan will operate as described in “Fan 15.
Operation.” see pg. 39
Dry mode
Dry mode will remove humidity from the air
while maintaining a speci c setpoint temperature. is is done by cycling Cooling mode.
Dry mode will NOT maintain a speci c humidity level. e fan will remain on constantly
at low speed while in Dry mode.
For Dry mode operation, rst turn the unit on
via the POWER/SEND bu on.
Select Dry mode via the MODE bu on.1.
e room temperature and setpoint tem-2.
perature will be displayed.
Press either the UP or DOWN ARROW 3.
bu ons to change the setpoint temperature.
e setpoint temperature will change by 4.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the bu on down will change the
temperature rapidly.
Place the setpoint temperature at a desired 5.
room temperature.
Depending on the difference between 6.
room temperature and setpoint temperature, the compressor will either remain on
constantly, cycle on/o , or remain o .
If the room temperature is greater than 7.
the setpoint temperature by more than
two degrees, the unit will run Cooling
mode constantly.
If the room temperature is within ± two 8.
degrees of setpoint, the unit will cycle
cooling on seven minutes and o seven
minutes to remove humidity from the air
while not over cooling the room.
If the room temperature is less than the 9.
setpoint temperature by more than two
degrees, cooling will remain o .
Auto Changeover mode
For Auto Changeover mode (ACO), the unit
must have a heat source. e control must rst
be con gured properly (Heat source – ON).
(Table 6, pg 32).
In Auto Changeover mode, the casse e will
operate in either Cooling mode or Heating
mode. e control will select the mode of
operation depending on the setpoint temperature, room temperature and the di erential
se ing selected in the Con guration mode.
For Auto Changeover mode, rst turn the unit
on via the POWER/SEND bu on.
Select Auto mode via the MODE but-1.
ton.
e room temperature and setpoint tem-2.
perature will be displayed.
Press either the UP or DOWN ARROW 3.
bu ons to change the setpoint temperature.
e setpoint temperature will change by 4.
one degree with each successive press
of the UP or DOWN ARROW bu ons.
Holding the bu on down will change the
temperature rapidly.
Place the setpoint temperature below the 5.
room temperature by the auto change
over di erential amount selected in the
Con guration mode.
e compressor will start and the unit will 6.
run cooling operation as described under
Cooling mode.
If the setpoint temperature is above the 7.
room temperature by the auto change
over di erential amount selected in the
Comfort where it counts 42 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
ir Handler
CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
Configuration mode, the unit will run
heating operation as described under
Heat mode.
Set Time mode
e clock is used by the 7-day programming
mode.
e 1.
CLOCK bu on is used to enter
or exit the Set Time mode.
e Set Time mode can be entered while 2.
the control is in any mode, including the
O mode.
To enter the Set Time mode, press the 3.
CLOCK bu on for three (3) sec-
onds.
Pressing the PROG M 4.
bu on will
advance to the next item.
e order is (1) Day of week, (2) Hour 5.
and (3) Minute.
e time of day and day of week can be 6.
changed using the UP or DOWN ARROW bu ons.
When the 7.
CLOCK bu on is pressed
again or le idle for twenty (20) seconds,
the control will save the new se ings and
return to the previous mode.
NOTICE
e unit will not automatically adjust for
Day Light Savings time.
the control will save the new se ings and
return to the previous interface mode.
While in the 7-Day Programming mode, 3.
the words “7-DAY PROG M” are displayed on the LCD.
Use the UP or DOWN ARROW bu ons 4.
to change the time, temperature or period
se ings.
Use the 5.
CLOCK or PROGRAM
buttons to select the mode to be
changed.
Se ings can be entered for:6.
Day of weeka.
Period of dayb.
Hourc.
Minuted.
Cooling setpoint temperaturee.
Heating setpoint temperaturef.
Auto setpoint temperature.g.
Quick Copy
Quick copy is a feature of the 7-Day Programming mode. It is used to copy the se ings of
any day to the rest of the week.
While in 7-Day Programming, select the day
to be copied. en press the FAN + PROG M bu ons simultaneously for three
seconds. e selected day will be copied to
the rest of the week.
Manual Run mode
7-Day Programming mode
e 7-day Programming mode is used to store
the se ings for Pre-Program Run mode.
When the unit is in either the O or On 1.
mode, the 7-Day Programming mode can
be entered by pressing the PROG M
+ CLOCK bu ons simultane-
ously for three seconds.
When the PROGRAM 2.
CLOCK bu ons are pressed simultaneously again or le idle for twenty seconds,
P/N 240008108, Rev. G [07/08/10] 43
+
is is the normal operating non Pre-Program
Run mode. Se ings for temperature, mode
and fan speed are selected by the user and
will not change with the passing of time. e
word “PROG M” does NOT display on
the LCD.
Pre-Program Run mode
is feature allows the setpoint temperature
to be changed according to the pre-program
setpoint and time of day se ings. e setpoint
and time se ings are programmed into the
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Air Handlers
CACH/CAHH/CAHK Microprocessor Controller Operation (continued)
control through the 7-Day Programming
mode.
e Pre-Program Run mode can be en-1.
tered from Cooling mode, Heating mode
or Auto mode only.
Pre-Program Run mode cannot be en-2.
tered from Dry or Fan modes.
Pressing the PROGRAM 3.
button
momentarily will enter or exit the PreProgram Run mode.
e word “PROG M” will appear in 4.
the LCD display.
The setpoint will change to the pro-5.
grammed se ing at the selected time.
To use the Pre-Program Run mode rst enter
the program se ings through the 7-Day Programming mode.
Select a mode of operation (Cooling, 1.
Heating, Auto) and press the PROG M
bu on to enter Pre-Program Run
mode.
As time passes, the setpoint temperature 2.
will be selected according to the time of
day and 7-Day Program se ings.
To override the setpoint while in Pre-3.
Program Run mode, adjust the temperature using the UP or DOWN ARROW
bu ons. e override se ing will remain
in e ect until the next scheduled event.
(Morning, Day, Evening, Night) At that
time, the setpoint will be the value selected in 7-Day Programming mode.
Clean Filter Alarm
To aid in lter maintenance, the casse e controller will indicate when a scheduled lter
cleaning is required by ashing the Timer/
Alarm LED. During normal operation, the
microprocessor will keep track of the units
run time.
When the clean lter time has elapsed, 1.
the Timer/Alarm LED will flash four
times to indicate that the lter needs to
be cleaned.
e clean lter time is selectable through 2.
the Con guration mode of the Optional
Infrared Hand Held Controller.
Available se ings are 250, 500, 750, 1000, 3.
and 1250 hours.
If a coil freeze condition is detected four 4.
times within a 24-hour period, the Clean
Filter Alarm will appear.
A er lter maintenance has been performed,
press the Clear Filter Warning bu on for three
seconds. e control will respond with a beep
to indicate that the timer has been reset.
Sleep timer
e sleep timer feature allows the user, with
the push of a single bu on, to have the unit
switch off using the preset timer. When
the control is in the On mode, pressing the
TIMER bu on will enter or exit the Sleep
Timer mode.
When in Sleep Timer mode, the word “TIMER” will appear on the LCD display. e unit
will continue to operate for thirty minutes ,
then switch o .
Comfort where it counts 44 P/N 240008108, Rev. G [07/08/10]
To turn the unit back on, press the POWER/
SEND bu on momentarily.
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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nstallation, Operation and Maintenance Manual •
CACH/CAHH/CAHK Wall Thermostat Operation
ir Handler
Set DIP switch #4 to ON
For Wall ermostat Operation the control
must be con gured through the DIP switches
located on the control board located in the
control box.
Set DIP switch #4 to YES (see 1. Table 6,
Page 32 ).
In wall thermostat mode, the control will 2.
not accept commands from the infrared
remote control.
The filter check timer will default to 3.
1000 Hrs.
Cooling operation
e wall thermostat will control the call for
cooling operation (on or o ) through the
low-voltage terminals R and Y.
A er connecting the thermostat to the 1.
unit, place the system switch in Cooling
mode.
Adjust the setpoint temperature below the 2.
room temperature.
e compressor and fan motors will start 3.
and cooling will begin.
Next, place the setpoint temperature 4.
above the room temperature. e outdoor
Fan Operation
e casse e unit utilizes a two-speed motor.
In wall thermostat operation, fan speed selection can be made through the DIP switch
condenser will stop.
e fan will operate as described in “Fan 5.
Operation.” pg. 39
NOTICE
se ings located on the main control board
(Figure 33, Page 31).
Once the cooling has cycled o or following a power outage, the compressor
With DIP switch #3 set to HIGH, the fan 1.
speed will be set to High.
will not restart for at least three minutes
(anti-short-cycle timer).
With DIP switch #3 set to LOW, the fan 2.
speed is set to Low.
See 3. Table 6, Page 32 for other available
DIP switch selections.
e wall thermostat will control the call for
fan operation (on or o ) through the lowvoltage terminals “R” and “G”.
Reversing Valve
EMI outdoor heat pump units utilize a
reversing valve that is energized in Cooling
mode. Make sure that the thermostat selected
will energize the reversing valve in Cooling
mode.
When the wall thermostat connects “R” 1.
to “G” the fan will energize.
A er the thermostat has been satis ed and 2.
the call for heating or cooling has been
removed, the indoor fan will remain on
for an additional sixty (60) seconds. is
increases e ciency by pulling the remaining energy from the unit.
Some thermostats are equipped with an
AUTO/ON fan switch. When this switch is
placed in the ON position, the fan will run
continuous. When the switch is in the AUTO
position, the fan will cycle with the call for
heating or cooling.
P/N 240008108, Rev. G [07/08/10] 45
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Air Handlers
CACH/CAHH/CAHK Wall Thermostat Operation (continued)
Electric heat operation
e wall thermostat will control the call for
electric heat operation (on or o ) through the
low-voltage terminals “R” and “W”.
A er connecting the thermostat to the 1.
unit, place the system switch in Heating
mode.
Adjust the setpoint temperature above the 2.
room temperature.
e electric heat will energize along with 3.
the indoor fan motor.
Heating will continue as long as the set-4.
point remains above room temperature.
Place the set-point temperature below 5.
room temperature.
e electric heater will switch o and the 6.
indoor fan will remain on for an additional
sixty seconds.
NOTICE
Once the cooling has cycled o or following a power outage, the compressor
will not restart for at least three minutes
(anti-short-cycle timer).
Optional Heat pump with Electric
heat (Two-stage heating)
e wall thermostat will control the call for
electric heat operation (on or o ) through
the low-voltage terminals “R” and “W” and
for compressor (heat pump) heating through
terminals “R” and “Y”.
to call for second stage heating. (See
the thermostat owner’s manual for this
feature).
Place the setpoint temperature below the 11.
room temperature.
e outdoor Heat Pump unit and electric 12.
heat will stop while the indoor fan will remain on for an additional sixty seconds.
Clean Filter Alarm (Wall
Thermostat mode)
To aid in lter maintenance, the casse e controller will indicate when a scheduled lter
cleaning is required by ashing the Timer/
Alarm LED.
During normal operation, the microprocessor
will keep track of the unit’s run time.
When the clean lter time has elapsed, •
the Timer/Alarm LED will flash four
times to indicate that the lter needs to
be cleaned.
For wall thermostat operation, the default •
clean lter time is 1000 hours.
Also, if a coil freeze condition is detected •
four times within a 24-hour period, the
Clean Filter Alarm will appear on the
casse e display.
A er lter maintenance has been performed,
press the Clear Filter Warning Bu on for three
seconds. e control will respond with a beep
to indicate that the timer has been reset.
A er connecting the two (2) stage heating 7.
thermostat to the unit, place the system
switch in Heating mode.
Adjust the setpoint temperature above the 8.
room temperature.
e compressor and fan motors will start 9.
and heating will begin.
Depending on the thermostat selected, 10.
electric heat will also energize when the
deviation between room temperature
and setpoint temperature is high enough
Comfort where it counts 46 P/N 240008108, Rev. G [07/08/10]
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nstallation, Operation and Maintenance Manual •
CACH/CAHH/CAHK Controller Features
ir Handler
Short Cycle Protection (ASCT)
e electronic control incorporates an antishort-cycle timer (ASCT) feature designed
to protect the compressor from short cycling.
e ASCT is activated immediately following
the o cycle of the outdoor unit. Once the
room temperature is satis ed and the outdoor
unit switches o , the ASCT will not allow the
outdoor unit to restart unit a three-minute
time period has elapsed.
This feature will prevent the compressor
and heat source from rapid restarts. Once
switched o , or following a power outage, the
compressor or heat source shall not restart for
a minimum of three minutes.
Staggered Start protection
Designed for systems with electric heat, in
heat pump and dry modes the staggered-start
feature will prevent the compressor and electric heater from starting simultaneously. ere
is a thirty-second delay between the start of
the compressor and start of the electric heater
while in Dry mode and Heat pump mode.
Minimum run time
Once started, the minimum on-time prevents
either the compressor or heat source from
cycling o prematurely. e minimum ontime for both the compressor and electric
heat is two minutes. Minimum on-time is
available only while the control is con gured
for Unit mounted keypad operation. Minimum on-times are disabled while in Remote
thermostat mode.
LCD Back Light
e LCD display can be illuminated using the
LCD back light feature. e selectable se ings
are O , On, and Intermi ent, and can be set
in the Con guration.
By selecting OFF, the backlight will re-•
main o at all times.
By selecting ON, the backlight will remain •
on at all times, including while in the O
mode interface.
If Intermi ent is selected, the backlight •
will remain for 10 seconds after the
push of any bu on while the control is
in the On mode or a er the push of the
ON/OFF bu on while in the O mode
interface.
Drain Pan Sensor
e drain pan sensors monitor the condensate
level in each of the units drain pans. Should
the water in either pan reach a critical level,
the monitor will automatically signal the main
control unit. The controls microprocessor
will, in turn, switch o the condensing unit
for a minimum of three minutes and until the
fault condition has been cleared, to prevent
further condensate production. A fault code,
E02, will then ash on the controller’s LCD
display and will automatically reset once the
fault condition is cleared.
Annunciation
e unit is equipped with an annunciation feature the controller will beep, providing the
user with audio feedback con rming that the
microprocessor has received its commands.
e annunciation feature must be activated
in the con guration. e selections are OFF
and ON. If OFF is selected, annunciation will
remain o . If ON is selected, then annunciation will beep with the push of any bu on in
the On mode or with the push of the ON/
OFF bu on while in the o mode.
While in Wall thermostat mode, only the FAN
and TIME bu ons are activated and will beep
when pressed.
Memory Backup
In the event of a power failure the control will
retain all of it’s se ings, including the mode
of operation. When power is restored, the
control will return to the mode of operation
that it was in prior to the power failure, a er
a three minute time delay.
P/N 240008108, Rev. G [07/08/10] 47
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
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CACH/CAHH/CAHK Controller Fault Conditions
CACH/CAHH/CAHK microprocessor controller fault indicationsTable 8
Air Handlers
Timer/Alarm
LED — number
of fl ashes:
1
2
3
Fault condition
Room air sensor fault
Condensate
fault
ID coil sensor
fault
Description
If the room air sensor is disconnected, damaged or malfunctions the Timer/Alarm LED will ash one (1) time to
signify that a fault has occurred. Operation of heating and
cooling will stop. e fan will continue to operate.
If the control senses a condensate fault condition, either
through the condensate pumps safety switch or the drain
pan sensors, the Timer/Alarm LED will flash two (2)
times to signify that a fault has occurred. e compressor
will switch o for a minimum of three (3) minutes AND
until the fault condition is corrected. A er that, as long as
the thermostat is calling for cooling the compressor will
restart.
e indoor coil sensor monitors the temperature of the
indoor coil. If a freeze condition is detected continuously
for three (3) minutes, the Timer/Alarm LED will ash three
(3) times to signify that a fault has occurred. e compressor will switch o for a minimum of three (3) minutes AND
until the fault condition is corrected. Also, if the microprocessor detects a coil freeze condition four (4) times within a
24 hour period, the clean lter indicator will appear.
4
Clean lter
To aid in lter maintenance, the casse e controller will
indicate when a schedule lter cleaning is required by ashing the Timer/Alarm LED. During normal operation the
microprocessor will keep track of the unit’s run time. When
the clean lter time has elapsed, the Timer/Alarm LED
will ash four (4) times to indicate that the lter needs to
be cleaned. e clean lter time is selectable through the
Con guration mode. Available se ings are 250, 500, 750,
1000, and 1250 hours. For Wall ermostat mode, the
default time is 1000 hrs. is cannot be changed. If a coil
freeze condition is detected four (4) times within a 24 hour
period, the Clean Filter Alarm will appear.
A er lter maintenance has been performed, press the
Clear Filter Warning Bu on for three (3) seconds. e
control will respond with a beep to indicate that the timer
has been reset.
5
Test mode
See Table 6, Page 32 for information.
Comfort where it counts 48 P/N 240008108, Rev. G [07/08/10]
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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Model 12
shown
Model 12
shown
•
nstallation, Operation and Maintenance Manual •
Maintenance
ir Handler
WARNING
Service should be performed by a quali-
fi ed service agency
and an annual system
check is recommended.
Electrical shock hazard Before re-
moving the access panels, make sure that
all power is disconnected from the unit.
Failure to do so could result in injury or
electric shock.
Clean the fi lter
Clean air lter on a monthly basis: 1.
Access the filters by removing the a.
air intake access grilles ( Figure 38,
Page 49 ).
Remove the lter by carefully twisting b.
and li ing to clear the retaining clips
( Figure 39, Page 49 ).
Li the lter o the grille. Place lter c.
on a at surface and vacuum any away
dust and debris (vacuum all filters
and grills). Also vacuum any accessible parts on the unit. ( Figure 40,
Page 49 )
Or use a garden hose: d.
Wash the grille and filter with a –
hose.
Let filters and grilles dry before –
replacing.
Replace lters, clips and front grille e.
before operating the unit. (Replace
the lters by sliding under retainer
clips.)
e unit may be wiped with a damp cloth 2.
when needed ( Figure 41, Page 49 ).
Figure 39
Remove the grilleFigure 38
Model 12
shown
Removing the fi lter
Cleaning with a vacuumFigure 40
Model 12
shown
WARNING
DO NOT operate the unit without the
lters and grilles in place.
P/N 240008108, Rev. G [07/08/10] 49
Figure 41
Cleaning with a damp cloth
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Troubleshooting — General
Air Handlers
WARNING
Service should be performed by a quali-
fi ed service agency
check is recommended.
Electrical shock hazard Before re-
moving access panels or control covers
to expose moving parts of non-insulated
live electrical components for service,
disconnect all high-voltage power supplies
to both the indoor unit and outdoor unit.
Failure to do so could result in physical
injury and/or electrical shock.
and an annual system
Wiring diagram
When trouble shooting the indoor unit, please
refer to the wiring diagram that is supplied
with the equipment.
The wiring diagram is located on the •
inside surface of the control panel cover
(see Figure 29, Page 22 ).
If you are unable to locate the wiring •
diagram, please call the factory technical
service line at (800) 228-9364, and one
can be faxed, mailed or e-mailed. Please
have the full model and serial number
available prior to calling.
Wiring requirements
EMI air handlers are designed to operate with
EMI condensers.
e air handle (indoor unit) and con-•
denser (outdoor unit) must be independently connected to the electrical service
panel and protected by separate time
delay fuse or HACR breakers. (See the
unit name plate for the correct breaker
type and size).
e indoor and outdoor units are also •
connected to each other via a 24V interconnect wiring. ( Figure 42, Page 51 or
Figure 43, Page 51 )
A transformer provides the low-voltage •
power source for the controls. The
number of low-voltage interconnect
conductors will be two to six depending
on heating options and or thermostat
selection.
Interconnect wire should be at least •
18 awg.
Refer to the unit wiring diagram for the •
interconnect diagram that matches your
system.
Power supply check
When troubleshooting any EMI product, it
is important to rst check the rating plate for
proper eld voltage and breaker size.
en use a voltmeter to check the incoming
power supply to verify that it agrees with the
rating plate.
e incoming power must not exceed the •
nameplate voltage.
e incoming power must not be below •
the minimum voltage stated on the rating
plate (197V for units rated 208/230V and
104V for units rated 115V).
Also verify low-voltage power place a voltmeter across low-voltage terminals R and C at
the indoor unit. e voltage should be 24V.
Comfort where it counts 50 P/N 240008108, Rev. G [07/08/10]
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Models CACG/CAHG/CAHJ — Low-voltage interconnections — wall thermostat Figure 42
operation
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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nstallation, Operation and Maintenance Manual •
Troubleshooting — General (continued)
ir Handler
Models CACH/CAHH/CAHK — Low-voltage interconnections — with/without Figure 43
optional wall thermostat operation
P/N 240008108, Rev. G [07/08/10] 51
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nstallation, Operation and Maintenance Manual •
•
Troubleshooting — CACH/CAHG/CAHJ Units
Air Handlers
Cooling-only units
Cooling only units require 18 AWG lowvoltage interconnecting wires between the
indoor and outdoor units. Also, interconnect
wiring is required between the indoor unit
and wall thermostat. Refer to low-voltage
interconnect diagram, Figure 42, Page 51 , for
low-voltage connections.
NOTICE
Terminal “W” is required for units with
electric heat only.
Terminal “C” may not be needed on
some thermostats.
e wall mounted thermostat will switch the
outdoor unit on and o through the black ,“ Y,”
and yellow, “Y1,” wires.
When the thermostat is calling for cooling,
24 Vac can be measured across terminals:
“Y” and “C” of the outdoor unit.•
“Y1” and “C” of the casse e.•
e casse e contains an electronic anti- short
-cycle timer feature (ASCT) that will prevent
the outdoor unit from short cycling. A er the
thermostat is satis ed there will be a three
minute delay before the outdoor unit is allowed to restart.
While the wall thermostat is calling for cooling and the ASCT delay has elapsed, 24 Vac
can be measured between terminals:
“Y” and “C” of the outdoor unit.•
“Y1” and “C” of the casse e.•
“G” and “C” of the casse e (fan signal).•
Heat pump units
Heat pump units require 18 AWG low-voltage
interconnecting wire between the indoor and
outdoor units. Also, interconnect wiring is
required between the indoor unit and wall
thermostat. Refer to low-voltage interconnect
diagram, Figure 42, Page 51 , for low-voltage
connections.
e wall mounted thermostat will switch the
outdoor unit on and o through the black ,“ Y,”
and yellow, “Y1,” wires.
When the thermostat is calling for cooling or
heating, 24 Vac can be measured:
“Y” and “C” of the outdoor unit.•
“Y1” and “C” of the casse e.•
EMI heat pump systems utilize a reversing valve is that is energized in the cooling
mode.
Heat pump units will operate the com-1.
pressor in heating mode while the reversing valve is de-energized.
The reversing valve signal is provided 2.
through the orange, “O,” low-voltage
wire of the thermostat. It should remain
energized constantly as long as the thermostat’s system switch remains in Cooling
mode.
To check for 24 Vac reversing valve volt-3.
age at the outdoor unit, place a voltmeter
across the brown, “C,” and orange, “O,”
wires while in the Cooling mode. The
meter should read 24 Vac.
NOTICE
Terminal “O” is required for heat pump
operation. e reversing valve is energized in cooling.
Comfort where it counts 52 P/N 240008108, Rev. G [07/08/10]
Terminal “W” is required for units with
electric heat only.
Terminal “C” may not be needed on
some thermostats.
CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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nstallation, Operation and Maintenance Manual •
ir Handler
Troubleshooting — CACG/CAHG/CAHJ Units (continued)
e indoor unit contains an electronic antishort-cycle timer feature (ASCT) that will
prevent the outdoor condenser from short
cycling. A er the thermostat is satis ed there
will be a three (3) minute delay before the
condenser is allowed to restart.
While the wall thermostat is calling for cooling and the ASCT delay has elapsed, 24 Vac
can be measured between terminals:
“Y” and “C” of the outdoor unit.•
“Y1” and “C” of the casse e.•
“G” and “C” of the casse e (fan signal).•
Electric heat (optional)
Units with electric heat utilize a control relay
located on the circuit board in the control
box. When the wall thermostat is calling for
electric heat the relay will energize.
To check for electric heat operation, place the
wall thermostat in Heat mode with the setpoint temperature above room temperature.
en place a clamp-on type ammeter on 1.
one leg of the incoming power supply.
When the unit is working correctly, the 2.
amp reading should correspond with the
values in the table below.
e following current values apply when 3.
the unit is connected to a 230 Vac power
supply. ese values include fan motor
current. If the supply voltage is different, this will a ect the amp draw of the
heater.
5kW = 22.7 A 3kW = 13.6 A 1.5kW = 6.9 A
e electric heat relay can also be veri ed 4.
by placing a voltmeter across the highvoltage relay output terminal and the
incoming power L2 terminal.
If the unit is working correctly, the reading 5.
should be the same as measured across the
incoming power supply.
As a safety feature, an auto-reset limit switch
is located on the heater assembly.
The limit will interrupt power to the 1.
heater if an over-temperature condition
occurs.
Each limit switch is also equipped with a 2.
one-time fuse link.
Should electric heat temperatures rise 3.
above the auto rese ing limit switch, the
non-resetting, one-time fuse link will
open and the heater will remain o .
If this occurs the limit switch assembly 4.
must be replaced.(Contact EMI technical
service for a replacement.)
Checking fuse link
WARNING
Electrical shock hazard Make sure
to fully disconnect all power to both the
indoor casse e and outdoor unit where
indicated in these instructions.
To check if the fuse link has failed requires an
Ohmmeter reading across the limit switch.
A er disconnecting all power to the unit, 1.
disconnect the wires from the fuse link.
With an ohmmeter, check the continuity 2.
across the fuse link.
If the fuse link is open, it must be re-3.
placed.
For optional wall thermostat operation, 24
Vac can also be measured across the Casse es
low-voltage terminals:
“G” and “C” (fan signal).•
“W” and “C” (electric heat signal).•
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Air Handlers
Troubleshooting — CACG/CAHG/CAHJ Units (continued)
Two-stage heating
Two-stage heating combines heat pump and
electric heat operation. Heat pump units
require an 18 AWG low-voltage interconnecting wire between the indoor unit and
the condenser. Also, interconnect wiring is
required between the indoor unit and wall
thermostat. Refer to low-voltage interconnect
diagram, Figure 42, Page 51 , for low-voltage
connections.
A er connecting a two-stage heating thermostat to the unit, place the system switch
in Heat mode.
Adjust the setpoint temperature above 1.
the room temperature so that rst stage
heating is activated.
e compressor and fan motors will start 2.
and heating will begin.
Heating will continue as long as the set-3.
point temperature remains above room
temperature.
To check for a low-voltage signal, place a
voltmeter across terminals :
“Y” and “C” of the outdoor unit.•
“Y1” and “C” of the casse e.•
Next, place the setpoint further above room
temperature to activate second stage heating.
Electric heat will energize (along with 1.
the compressor) when the deviation
between room temperature and setpoint
temperature is high enough to call for
second stage heating. (See the thermostat
owner’s manual for this feature).
Heating will continue as long as the 2.
setpoint temperature is above the room
temperature and the thermostat is calling
for second stage heating.
To check for an electric heat signal, place 3.
a voltmeter across terminals “W” and “C”
of the indoor unit.
When the unit is working correctly, there 4.
should be a reading of 24 Vac.
To stop heating operation, place the 5.
setpoint temperature below the room
temperature.
e outdoor unit and electric heat will 6.
stop while the indoor fan will remain on
for an additional sixty seconds.
When the unit is working correctly, there
should be a reading of 24 Vac.
Comfort where it counts 54 P/N 240008108, Rev. G [07/08/10]
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Troubleshooting — CACH/CAHH/CAHK Units
ir Handler
NOTICE
Cassette operation can be controlled
through either a wall thermostat or an
optional infrared handheld controller.
To select control method, refer to DIP
switch options, Table 6, Page 32 .
Cooling-only units, Model CACH
Cooling only units require an 18 AWG
minimum low-voltage interconnecting wires
between the indoor and outdoor units. If the
casse e controller is con gured for wall thermostat operation, then a wiring connection is
also required between the air handler and wall
thermostat. Refer to low-voltage interconnect
diagram, Figure 43, Page 51 , for low-voltage
connections.
NOTICE
Terminal “W” is required for units with
electric heat only.
Terminal “C” may not be needed on
some thermostats.
e casse e controller or wall thermostat will
switch the outdoor unit on and o through the
yellow, “Y,” low-voltage terminal.
power can be measured between the relay
output and the L2 terminal of the incoming
power supply.
For optional wall thermostat operation, 24 Vac
can also be measured across low-voltage terminals “G” and “C” of the casse e.
Heat Pump Units, Model CAHH/
CAHK
Heat pump units require an 18 AWG minimum low-voltage interconnecting wire between the indoor unit and outdoor units. If
the casse e controller is con gured for wall
thermostat operation, then a wiring connection is also required between the air handler
and wall thermostat. Refer to low-voltage
interconnect diagram, Figure 43, Page 51 , for
low-voltage connections.
NOTICE
Terminal “O” is required for heat pump
operation. e reversing valve is ener-
gized in cooling.
Terminal “W” is required for units with
electric heat only.
Terminal “C” may not be needed on
some thermostats.
When the thermostat is calling for cooling,
24 Vac can be measured across terminals “Y”
and “C” of the indoor or outdoor units.
For optional wall thermostat operation, 24 Vac
can also be measured across low-voltage terminals “Y I” and “C” of the casse e.
e indoor unit contains an electronic antishort-cycle timer feature (ASCT) that will
prevent the outdoor unit from short cycling.
A er the room temperature is satis ed there
will be a three-minute delay before the outdoor unit is allowed to restart.
The cassette controller or wall thermostat
will also control the indoor fan by switching
high-voltage power to the fan motor with
the fan relay. When energized, high-voltage
P/N 240008108, Rev. G [07/08/10] 55
Checking fuse link
WARNING
Electrical shock hazard Make sure
to fully disconnect all power to both the
indoor casse e and outdoor unit where
indicated in these instructions.
To check if the fuse link has failed requires an
Ohmmeter reading across the limit switch.
A er disconnecting all power to the unit, 1.
disconnect the wires from the fuse link.
en with an ohmmeter, check the con-2.
tinuity across the fuse link.
If the fuse link is open, it must be re-3.
placed.
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
Frequently Asked Questions
Air Handlers
Q: e condenser will not start although
the indoor unit appears normal. What
should I do?
A: At the indoor thermostat, make sure that
the control is in cooling and the setpoint
temperature is below room temperature.
Next, using a Voltmeter, check for 24V
across the yellow (Y) and brown (C)
wires. If 24V is present then check for
wiring breaks or improper connections
between the indoor and outdoor units.
A: EMI condensers are equipped with a
manual reset high-pressure switch. It is
located on the high side of the system
usually on back panel above service
valves. To reset, push the red bu on in.
If the switch was tripped there will be a
click when it resets.
A: e casse e 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 circuit will
open and low Volt power to the condenser (terminal “Y1”) will be removed.
e condensate pump should be checked
for obstruction. e condensate pump
assembly can be removed through the
side access panel. A er 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.
Q: How long will the fan run?
A: While the unit is in cooling or heating
and auto fan mode is selected, the fan will
cycle with the call for cooling or heating.
When the room temperature reaches
setpoint temperature, the heat/cool call
is dropped. e fan will then stay on for
an additional 60-second to purge unit
of any residual energy. Placing the fan
selection switch on the wall mounted
thermostat in the ON position will cause
the fan to run continuously regardless of
the set point temperature.
Q: What causes my indoor unit to freeze-
up?
A: Air handler freeze up is usually the
symptom of another problem. e Casse e air handler is equipped with freeze
protection to prevent freeze up from
occurring. If freeze up does occur then
check the following.
Check that the freeze sensor inserted –
fully and snug in the coil ns. If not
another location may need to be
selected. Be careful not to insert the
sensor directly into the coil tube
rather insert the sensor between two
tubes.
Check the indoor air lter. It should –
be clean and free of dirt. A dirty lter
will reduce airflow and efficiency.
Also check that the coil is clean. If the
coil is dirty then it should be cleaned
using an appropriate coil cleaner or
mild detergent.
Is the equipment being operated in –
cooling mode when outdoor temperatures are below 35°F (2°C)? If
it is, then the condenser should be
fitted with low ambient control so
that the proper system pressures are
maintained.
Does the system have the proper –
refrigerant charge? A system low on
refrigerant can cause air handlers
freeze-up. To check system charge
you will need to contact a quali ed
refrigeration service technician.
Refrigerant charge information can
be found in IOM for the outdoor
condensing unit.
Q: e system has just been installed us-
ing an EMI indoor unit and a non-EMI
condenser. ere is no display and the
unit will not operate.
Comfort where it counts 56 P/N 240008108, Rev. G [07/08/10]
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Frequently Asked Questions (continued)
A: EMI air handlers are manufactured with a
low-voltage transformer installed. When
connecting an EMI air handler to a nonEMI condenser, check to ensure that
there is no 24v control transformer in
the outdoor unit. Only one transformer
is required. If both the indoor unit and
outdoor unit contain a transformer, one
must be removed from the system.
ir Handler
P/N 240008108, Rev. G [07/08/10] 57
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nstallation, Operation and Maintenance Manual •
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Air Handlers
Dimensions
Dimensions — Models 9, 12, 24 and 36 (see dimensions, Figure 44 Table 9, Page 59 )
Features
Optional discharge
knockouts
1
5¼-inch diameter
(3) available
Fresh air inlet
knockouts
1¼ x 2½ inches
2
- 9/12
(2) available
3x3 24/36
Condensate discharge
3
½-inch diameter
4
Suction connection
5
Liquid connection
Condensate pump
6
access panel
NOTICE
Due to ongoing product development, designs, speci cations, and performance are
subject to change without notice. Please consult the factory for further information.
Comfort where it counts 58 P/N 240008108, Rev. G [07/08/10]
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Dimensions (continued)
Dimensions — Models 9, 12, 24 and 36 (see drawing, Table 9 Figure 44, Page 58 )
Models 9 & 12 Model 24 Model 36
Dimension
Inches mm Inches mm Inches mm
A 25.00 635 37.00 940 37.00 940
B 25.00 635 37.00 940 49.26 1251
C 22.50 572 32.44 824 32.44 824
D 2.04 52 2.00 51 2.04 52
E 22.57 573 30.40 772 44.68 1135
F 1.41 36 1.41 36 1.41 36
G 2.88 73 3.65 93 3.65 93
ir Handler
H 8.13 207 8.90 226 8.90 226
(ref) 2.67 68 3.38 86 3.38 86
J
K 25.86 657 35.61 904 47.78 1214
L 12.76 324 18.69 475 24.73 628
M 1.73 44 1.97 50 1.97 50
(ref) 2.16 55 2.72 69 2.72 69
N
O 5.12 130 5.12 130 5.12 130
(ref) 11.34 288 12.05 306 14.01 356
P
(typical) 1.50 38 1.63 41 1.63 41
R
R1 19.50 495 29.19 741 29.19 741
R2 23.27 591 31.20 792 42.66 1084
R3 22.47 571 30.41 772 43.45 1104
S 7.19 183 6.87 174 6.87 174
T 3.73 95 2.58 66 4.98 126
U 4.88 124 5.50 140 5.47 139
V 3.50 89 4.93 125 5.00 127
W 2.50 64 3.97 101 4.00 102
X 4.69 119 4.37 111 4.37 111
NOTICE
Due to ongoing product development, designs, speci cations, and performance are
subject to change without notice. Please consult the factory for further information.
P/N 240008108, Rev. G [07/08/10] 59
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Air Handlers
Specifi cations
Electrical Specifi cations (Table 10 CAC_ refers to CACG/CACH; CAH_ refers to CAHG/CAHH/CAHJ/CAHK)
Model
Volts/HZ/PH RLA H.P. kW AMPS
CAH 9/12 208/230/60/1 0.35 1/10 – – 0.4 197 0.5 15
CAH 9/12 208/230/60/1 0.35 1/10 1.5 6.52 6.9 197 8.6 15
CAH 24 208/230/60/1 0.55 1/8 – – 0.6 197 0.7 15
CAH 24 208/230/60/1 0.55 1/8 3 13.04 13.6 197 17.0 20
CAC 36 208/230/60/1 0.5, 0.5 1/10, 1/10 – – 1.0 197 1.2 15
CAC 36 208/230/60/1 0.5, 0.5 1/10, 1/10 5 21.74 22.7 197 28.3 30
Fan Motor Elect Heat
Technical dataTable 11
Refrigerant Type R410A
CONNECTIONS
Suction ½” ¾” * ¾”
Liquid ¼” /” /”
Condensate Drain ½” I.D. ½” I.D. ½” I.D.
Branch Duct 5¼” Ø 5¼” Ø 5¼” Ø
Fresh Air Duct
FILTRATION
Type Washable Mesh
Quantity 1 2 3
Effi ciency 80%
9 &12 24 36
1¼ x
2½”
9 & 12 24 36
Model
3” x 3” 3” x 3”
Model
Model
9 & 12 380 (180) 335 (158)
24 700 (330) 620 (293)
36 1,300 (614) 1,160 (548)
Model Shipping weight — lbs (kg)
9 & 12 70 (31.8 kg)
24 108 (49.1 kg)
36 146 (66.4 kg)
Total
AMPS
Discharge air volume (dry coil)Table 12
High Speed
CFM (L/S)
Shipping weightsFigure 45
Min
Volt
M.C.A.
Low Speed
CFM (L/S)
HACR
BRKR
CONDENSATE
PUMP
Maximum Head 36” (0.9 m) **
Min. Flow Rate 2.5 GPH (9.5 l/h)
*Must bush down to 5/8” interconnect for 18K system.
** Measured from bottom of unit.
Comfort where it counts 60 P/N 240008108, Rev. G [07/08/10]
9 & 12 24 36
Model
Indoor sound levels (dBa)Figure 46
Model High Speed Low Speed
9 & 12 41 39
24 44 42
36 51 49
NOTICE
Due to EMI’s ongoing product development program, all designs and speci cations are subject to change without
notice.
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System Options
Cassette(s)
S1CG/S1HG/S2CH/S2HH
Side Discharge
ir Handler
Cooling systems (Table 13 CAC_ refers to CACG/CACH; CAH_ refers to CAHG/CAHH/CAHJ/CAHK)
Condenser Cassette Btuh SEER SHR EER Ref.
S1CG9000 CAH_09 9,000 13.0 0.72 11.4 R410A
S1CG2000 CAH_12 12,000 13.0 0.67 11.5 R410A
S1CG8000 CAH_24 18,000 13.0 0.75 12.7 R410A
S1CG4000 CAH_24 24,000 13.0 0.69 12.1 R410A
S1CG3000 CAC_36 30,000 13.0 0.77 12.4 R410A
S1CG6000 CAC_36 36,000 13.0 0.72 11.5 R410A
S2CH9900 (2) (2)CAH_09 18,000 13.0 0.76 11.5 R410A
S2CH9200 (1)
S2CH2200 (2)
1 CAH_09
1 CAH_12
(2)CAH_12
21,000 13.0 0.72 11.5 R410A
24,000 13.0 0.68 11.5 R410A
Heat pump systems (Table 14 CAH_ refers to CAHG/CAHH/CAHJ/CAHK)
Condenser Cassette
S1H9000 CAH_09 9,000 8,200 13.0 7.7 0.74 11.8 3.2 R410A
S1H2000 CAH_12 12,000 9,600 13.0 7.7 0.67 11.5 3.0 R410A
S1H8000 CAH_24 18,000 16,400 13.0 7.7 0.76 12.1 3.4 R410A
S1H4000 CAH_24 24,000 20,400 13.0 7.7 0.69 12.0 3.3 R410A
S2HH9900 (2) CAH_09
S2HH9200
S2HH2200 (2) CAH_12
1 CAH_09
1 CAH_12
Cooling
Btuh
18,000 16,000
21,000 17,600
24,000 19,000
Heating
Btuh
SEER HSPF SHR EER COP Ref.
13.0 7.7 0.76 11.5 3.0 R410A
13.0 7.7 0.72 11.5 3.0 R410A
13.0 7.7
0.68
11.5 3.0 R410A
P/N 240008108, Rev. G [07/08/10] 61
CACG/CAHG/CAHJ & CACH/CAHH/CAHK
nstallation, Operation and Maintenance Manual •
•
T2CG/T2HG, T3CG/
Cassette(s)
2CG/T2HG, T3CG/
T4CG/T4HG 2, 3 and 4
Top Discharge
Heat pump systems with cassette units (_Table 15 _ = G, H, J, or K)
Air Handlers
T3HG and
Zone
Condenser Cassette
T2HG2400 CAH_12/CAH_24 35,800 32,200 13.0 7.7 0.70 11.5 3.1 410A
T2HG4400 (2)CAH_24 47,500 42,000 13.0 7.7 0.70 11.6 3.2 410A
T2HG9800 CAH_09/CAH_24 27,000 24,600 13.0 7.7 0.74 11.6 3.2 410A
T2HG8800 (2)CAH_24 36,000 33,000 13.0 7.7 0.78 11.9 3.4 410A
T3HG9980 (2) CAH_09/CAH_24 36,000 32,500 13.0 7.7 0.77 11.5 3.3 410A
T3HG2240 (2) CAH_12/CAH_24 47,500 39,400 13.0 7.7 0.70 11.5 3.0 410A
T3HG2220 (3)CAH_12 36,000 27,600 13.0 7.7 0.70 11.5 3.0 410A
T3HG9920 (2) CAH_09/CAH_12 30,000 25,200 13.0 7.7 0.75 11.5 3.0 410A
T3HG9990 (3)CAH_09 28,400 24,000 13.0 7.7 0.77 11.5 3.1 410A
T4HG2222 (4)CAH_12 48,000 32,800 13.0 7.7 0.70 11.5 3.0 410A
T4HG9922
T4HG9992 (3)CAH_09/CAH_12 39,600 33,200 13.0 7.7 0.75 11.5 3.0 410A
T4HG9999 (4)CAH_09 36,000 32,000 13.0 7.7 0.77 11.5 3.1 410A
(2)CAH_09/(2)
CAH_12
Cooling
Btuh
42,900 29,400 13.0 7.7 0.75 11.5 3.0 410A
Heating
Btuh
SEER HSPF SHR EER COP Ref.
Straight cool systems with cassette units (_Table 16 _ = G, H, J, or K)
Condenser Cassette Cooling Btuh SEER SHR EER Ref.
T2CG2400 CAH_12/CAH_24 35,800 13.0 0.70 11.5 410A
T2CG4400 (2)CAH_24 47,500 13.0 0.70 11.6 410A
T2CG9800 CAH_09/CAH_24 27,000 13.0 0.74 11.6 410A
T2CG8800 (2)CAH_24 36,000 13.0 0.78 11.9 410A
T3CG9980 (2) CAH_09/CAH_24 36,000 13.0 0.77 11.5 410A
T3CG2240 (2) CAH_12/CAH_24 47,500 13.0 0.70 11.5 410A
T3CG2220 (3)CAH_12 36,000 13.0 0.70 11.5 410A
T3CG9920 (2) CAH_09/CAH_12 30,000 13.0 0.75 11.5 410A
T3CG9990 (3)CAH_09 28,400 13.0 0.77 11.5 410A
T4CG2222 (4)CAH_12 48,00 13.0 0.70 11.5 410A
T4CG9922
T4CG9992 (3)CAH_09/CAH_12 39,600 13.0 0.75 11.5 410A
T4CG9999 (4)CAH_09 36,000 13.0 0.77 11.5 410A
(2)CAH_09/(2)
CAH_12
42,900 13.0 0.75 11.5 410A
Comfort where it counts 62 P/N 240008108, Rev. G [07/08/10]
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Test Unit Performance Data Sheet
NOTICE
The Test Unit Performance Data sheet is provided
for use by a quali ed service professional in the event
that there is a problem with the unit. In order for our
Technical Service Department to better serve you,
please complete.
Model Number Date:
Serial Number Mode: Cooling
Indoor Section Notes
Cassette Entering Air – DB
Cassette Entering Air – WB
Cassette Leaving Air – DB
Cassette 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
ID Fan Motor – Volts
ID Fan Motor – Amps
Total Volts
Total Amps
Temperatures – Degrees F
Compressor Suction
Compressor Discharge
Have this information ready when calling. Make sure to
include the model Number, Serial Number, and Date
of installation.
Call our Technical Support Department
@ 1-800-228-9364.
Technician:
ir Handler
Liquid Out Cond.
Liquid before Expansion
Suction out Air handler
Capacity Calculations
DB – Temp Split at Air handler
Compressor Superheat
Sub Cooling
P/N 240008108, Rev. G [07/08/10] 63
Test Summary
EMI’s Product Line
800
936
800-232-9364
w
wy
wy
v
ca,
NY
0
Indoor Units
WLCG/WLHG
High Wall Air Handler
Universal Floor or Ceiling
UNCG/UNHG
Air Handler
CACG/CAHG/CAHJ
Cassette
Air Handler
S2CH/S2HH Dual Zone
Side Discharge
Phone: 1-800-228-9364
ne: 1-
Fax: 1-800-232-9364
x: 1-
-228-
4
Outdoor Units
S1CG/S1HG
1CG/S1HG
Single Zone
Side Discharge
T2CG/T2HG, T3CG/
T3HG and
T4CG/T4HG 2, 3 and 4
Zone
Top Discharge
2201 Dwyer Ave
Utica, NY 13504
135
r A
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