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  5. Installation, Operation And Maintenance Manual

ECR International CACG Installation, Operation And Maintenance Manual

Manual is about: High-Efficiency Cassette Ductless Split System Air Handlers

Summary of CACG

  • Page 1

    Cacg/cahg/cahj & cach/cahh/cahk high-ef fi ciency cassette ductless split system air handlers straight cool / heat pump nominal capacities cahj09 cahk09 cahj12 cahk12 cahg24 cahh24 units 9,000 12,000 18,000 24,000 btuh 2.6 3.5 5.3 7.0 kw straight cooling only cacg36 & cach36 units 30,000 36,000 btuh...

  • Page 2: Contents

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 2 p/n 240008108, rev. G [07/08/10] contents to the installer retain this manual and warranty for future reference. Before leaving the prem- ises, review this manual to be sure the ...

  • Page 3: Read Before Proceeding

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 3 read before proceeding recognize this symbol as an indication of important safety information. Warning completely read all instructions prior to assembling, installing, ...

  • Page 4

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 4 p/n 240008108, rev. G [07/08/10] product description th e emi cassett e air handlers are avail- • able in three cabinet sizes with four out- put capacities from 9,000–24,000 btuh...

  • Page 5

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 5 verify unit before installing (continued) fresh air intake capability on three sides of • cabinet (only two on models 9–12). Four plastic air vanes, motor driven with • ...

  • Page 6

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 6 p/n 240008108, rev. G [07/08/10] remote thermostat applications cacg/cahg/cahj units require a • wall thermostat for operation. Cach/ cahh/cahk units can be operated by a wall th...

  • Page 7

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 7 piston/orifi ce replacement (when required) notice piston/ orifi ce replacement — th e factory-installed piston/orifi ce must be replaced on air-handler / condenser combit...

  • Page 8: Mounting The Unit

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 8 p/n 240008108, rev. G [07/08/10] mounting the unit before installing, consider: determine the best location for mounting • the unit for room air circulation. Locate outdoor and i...

  • Page 9: Mounting The Unit

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 9 mounting the unit (continued) blanking off th e fascia discharge slot(s) will need blank- ing off when ducts are used to channel the conditioned air to other areas. Posit...

  • Page 10: Mounting The Unit

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 10 p/n 240008108, rev. G [07/08/10] mounting the unit (continued) positioning th e cassett e installation position should be selected with the following in mind: pipe work, electri...

  • Page 11: Mounting The Unit

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 11 mounting the unit (continued) mounting method in existing construction, remove enough • ceiling panels to provide clearance space for mounting unit to ceiling joists. B...

  • Page 12: Mounting The Unit

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 12 p/n 240008108, rev. G [07/08/10] mounting the unit (continued) mounting use the template (see 1. Figure 6, page 11 ) to cut the ceiling opening and determin- ing the rod positio...

  • Page 13: Condensate Piping

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 13 condensate piping th 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. Fl exible pvc...

  • Page 14: Duct Connections

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 14 p/n 240008108, rev. G [07/08/10] duct connections branch duct and fresh air duct collars can be att ached to the cassett e chassis by following the steps below. Notice recommend...

  • Page 15: Refrigerant Piping

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 15 refrigerant piping caution avoid piping on wet and rainy days. • use only clean, refrigeration-grade • copper tubing. Use tubing benders to guard against • kinking. Be ...

  • Page 16: Refrigerant Piping

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 16 p/n 240008108, rev. G [07/08/10] refrigerant piping (continued) clean ends of tubing figure 15 place wet rag “heat shield over figure 16 valves plus a sheet metal shield to prot...

  • Page 17: Refrigerant Piping

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 17 refrigerant piping (continued) refrigerant processing att ach manifold set ( 1. Figure 17 ). Evacuate line to 500 microns or less to 2. Ensure all moisture has been rem...

  • Page 18: Refrigerant Processing

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 18 p/n 240008108, rev. G [07/08/10] s1cg/s1hg and top discharge r410a refrigerant charge table table 4 ( cac_ refers to cacg/cach; cah_ refers to cahg/cahh/cahj/cahk ) condenser ca...

  • Page 19: Final Assembly

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 19 final assembly 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...

  • Page 20: Final Assembly

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 20 p/n 240008108, rev. G [07/08/10] final assembly (continued) connect vane motor plug into figure 23 socket on chassis female vane motor plug on chassis male vane motor plug on fa...

  • Page 21: Electrical Wiring

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 21 electrical wiring removing control box cover figure 27 rating plate electrical connections figure 28 l2 high-voltage cable l1 ground lug ground wire low-voltage low-vol...

  • Page 22: Electrical Wiring

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 22 p/n 240008108, rev. G [07/08/10] electrical wiring (continued) wiring diagram location figure 29 wiring diagram (on inside wiring diagram (on inside of control panel cover) of c...

  • Page 23: Wall Thermostat Selection

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 23 wall thermostat selection (optional for cach/cahh/cahk) notice cacg/cahg/cahj units all are operated by a wall thermo- • stat. Cach/cahh/cahk units th e unit’s dip swit...

  • Page 24: Wall Thermostat Operation

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 24 p/n 240008108, rev. G [07/08/10] wall thermostat operation (optional for cach/cahh/cahk) (continued) fan operation th e wall thermostat will control the call for fan operation (...

  • Page 25: Wall Thermostat Operation

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 25 wall thermostat operation (optional for cach/cahh/cahk) (continued) electric heat operation for wall thermostat operation with electric heat the control must be confi g...

  • Page 26: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 26 p/n 240008108, rev. G [07/08/10] initial start-up — cacg/cahg/cahj units only cahg/cacg louver toggle figure 30 switch toggle switch notice cacg/cahh/cahk units th ese units req...

  • Page 27: Warning

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 27 initial start-up — cacg/cahg/cahj units only (continued) warning electrical shock hazard — turn off power to indoor and outdoor units is off before proceeding. Reconnec...

  • Page 28: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 28 p/n 240008108, rev. G [07/08/10] initial start-up — cach/cahh/cahk units only set dip switches do not turn on power until the dip 1. Switches have been set and the control panel...

  • Page 29: Warning

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 29 send button for 2 seconds. This will transmit information from the remote to the cassett e. Th e cassett e will respond with a beep, indicating it has received the info...

  • Page 30: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 30 p/n 240008108, rev. G [07/08/10] verify heat pump operation (no electric heat) this arrangement uses a heat pump 1. Outdoor unit with no heat source in the cassett e (indoor) un...

  • Page 31: Warning

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 31 cacg/cahh/cahk microprocessor controller overview emi unit-mounted microprocessor controller — control panel figure 33 dip switches control panel warning electrical sho...

  • Page 32

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 32 p/n 240008108, rev. G [07/08/10] cach/cahh/cahk microprocessor controller overview (continued) cacg/cahh/cahk microprocessor controller — dip switch settings table 6 dip switch ...

  • Page 33

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 33 unit-mounted controller — chassis-mounted keypad/display figure 34 cach/cahh/cahk microprocessor controller overview (continued) 1 5 4 3 2 6 1 infrared receiver window ...

  • Page 34

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 34 p/n 240008108, rev. G [07/08/10] cach/cahh/cahk microprocessor controller — infrared remote control figure 35 power send press to turn unit on or off . Press and hold for 2 seco...

  • Page 35

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 35 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 ac...

  • Page 36

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 36 p/n 240008108, rev. G [07/08/10] 7-day programming options for cach/cahh/cahk figure 37 item setting values overview to access: press and hold program and clock buttons simultan...

  • Page 37

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 37 setting the cach/cahh/cahk controller (continued) programming schedule (when using 7-day programming) table 7 night cool heat : : : : : : : auto evening cool heat : : :...

  • Page 38: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 38 p/n 240008108, rev. G [07/08/10] cach/cahh/cahk microprocessor controller operation notice when power is fi rst applied to the con- trol or aft er a power outage there is a thre...

  • Page 39: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 39 cach/cahh/cahk microprocessor controller operation (continued) power/send pressing the power/send butt on momen- tarily will switch the unit either on or off . In the o...

  • Page 40: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 40 p/n 240008108, rev. G [07/08/10] cach/cahh/cahk microprocessor controller operation (continued) cooling mode for cooling operation, fi rst turn the unit on via the power/send bu...

  • Page 41: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 41 cach/cahh/cahk microprocessor controller operation (continued) optional heat pump without electric heat (heat pump unit outdoors) notice emi heat pumps are intended to ...

  • Page 42

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 42 p/n 240008108, rev. G [07/08/10] at that time the electric heat will switch 11. Off and the heat pump (compressor) will take over the heating demand. Th e electric heater will n...

  • Page 43: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 43 configuration mode, the unit will run heating operation as described under heat mode. Set time mode th e clock is used by the 7-day programming mode. Th e 1. Clock butt...

  • Page 44

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 44 p/n 240008108, rev. G [07/08/10] control through the 7-day programming mode. Th e pre-program run mode can be en- 1. Tered from cooling mode, heating mode or auto mode only. Pre...

  • Page 45: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 45 set dip switch #4 to on for wall th ermostat operation the control must be confi gured through the dip switches located on the control board located in the control box....

  • Page 46: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 46 p/n 240008108, rev. G [07/08/10] electric heat operation th e wall thermostat will control the call for electric heat operation (on or off ) through the low-voltage terminals “r...

  • Page 47

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 47 cach/cahh/cahk controller features short cycle protection (asct) th e electronic control incorporates an anti- short-cycle timer (asct) feature designed to protect the ...

  • Page 48

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 48 p/n 240008108, rev. G [07/08/10] cach/cahh/cahk controller fault conditions cach/cahh/cahk microprocessor controller fault indications table 8 timer/alarm led — number of fl ashe...

  • Page 49: Warning

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 49 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 pa...

  • Page 50: Troubleshooting — General

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 50 p/n 240008108, rev. G [07/08/10] troubleshooting — general warning service should be performed by a quali- fi ed service agency and an annual system check is recommended. Electri...

  • Page 51: Troubleshooting — General

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 51 troubleshooting — general (continued) models cacg/cahg/cahj — low-voltage interconnections — wall thermostat figure 42 operation models cach/cahh/cahk — low-voltage int...

  • Page 52: Notice

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 52 p/n 240008108, rev. G [07/08/10] troubleshooting — cach/cahg/cahj units cooling-only units cooling only units require 18 awg low- voltage interconnecting wires between the indoo...

  • Page 53: Warning

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 53 th e indoor unit contains an electronic anti- short-cycle timer feature (asct) that will prevent the outdoor condenser from short cycling. Aft er the thermostat is sati...

  • Page 54

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 54 p/n 240008108, rev. G [07/08/10] two-stage heating two-stage heating combines heat pump and electric heat operation. Heat pump units require an 18 awg low-voltage intercon- nect...

  • Page 55: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 55 troubleshooting — cach/cahh/cahk units notice cassette operation can be controlled through either a wall thermostat or an optional infrared handheld controller. To sele...

  • Page 56: Frequently Asked Questions

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 56 p/n 240008108, rev. G [07/08/10] q: th e condenser will not start although the indoor unit appears normal. What should i do? A: at the indoor thermostat, make sure that the cont...

  • Page 57: Frequently Asked Questions

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 57 a: emi air handlers are manufactured with a low-voltage transformer installed. When connecting an emi air handler to a non- emi condenser, check to ensure that there is...

  • Page 58: Dimensions

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 58 p/n 240008108, rev. G [07/08/10] dimensions dimensions — models 9, 12, 24 and 36 (see dimensions, figure 44 table 9, page 59 ) notice due to ongoing product development, designs...

  • Page 59: Dimensions

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 59 dimensions (continued) dimensions — models 9, 12, 24 and 36 (see drawing, table 9 figure 44, page 58 ) dimension models 9 & 12 model 24 model 36 inches mm inches mm inc...

  • Page 60: Specifi Cations

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 60 p/n 240008108, rev. G [07/08/10] specifi cations electrical specifi cations ( table 10 cac_ refers to cacg/cach; cah_ refers to cahg/cahh/cahj/cahk ) model fan motor elect heat to...

  • Page 61: System Options

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 61 system options s1cg/s1hg/s2ch/s2hh side discharge cassette(s) cooling systems ( table 13 cac_ refers to cacg/cach; cah_ refers to cahg/cahh/cahj/cahk ) condenser casset...

  • Page 62

    Cacg/cahg/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • comfort where it counts 62 p/n 240008108, rev. G [07/08/10] t2cg/t2hg, t3cg/ t3hg and t4cg/t4hg 2, 3 and 4 zone top discharge t2cg/t2hg, t3cg/ cassette(s) heat pump systems with cassette units (_ table 15...

  • Page 63: Notice

    Cach/cahh/cahj & cach/cahh/cahk air handlers • installation, operation and maintenance manual • p/n 240008108, rev. G [07/08/10] 63 model number date: technician: serial number mode: cooling indoor section notes cassette entering air – db cassette entering air – wb cassette leaving air – db cassette...

  • Page 64: Emi’S Product Line

    Phone: 1-800-228-9364 fax: 1-800-232-9364 2201 dwyer ave utica, ny 13504 emi’s product line indoor units outdoor units s1cg/s1hg single zone side discharge s2ch/s2hh dual zone side discharge wlcg/wlhg high wall air handler uncg/unhg universal floor or ceiling air handler cacg/cahg/cahj cassette air ...