ECR International CACG User manual

CACG/CAHG/CAHJ
&
CACH/CAHH/CAHK
High-Efficiency 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
8.8 10.5 kW
Installation, Operation and
Maintenance Manual
ECR International Inc
2201 Dwyer Ave.
Utica, NY 13501
www.enviromaster.com
An ISO 9001-2008 Certified Company
P/N 240008108, Rev. G [07/08/10]
CAHK12

CACG/CAHG/CAHJ & CACH/CAHH/CAH
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Air Handlers
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Op
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Comfort where it counts 2P/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 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 representa-
tive. 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 ___________
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 Stan-
dard 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.
Contents . . . . . . . . . . . . . . . . . . . . . . . . . 2
Read Before Proceeding . . . . . . . . . . . . . . . 3
Verify Unit Before Installing . . . . . . . . . . . . . 4
Piston/Orifice 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
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
Specifications . . . . . . . . . . . . . . . . . . . . . .60
System Options . . . . . . . . . . . . . . . . . . . . .61
Test Unit Performance Data Sheet . . . . . . . . .63
EMI’s Product Line . . . . . . . . . . . . . . . . . . .64

CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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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, oper-
ating, or repairing this product.
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 person-
nel.
DANGER
Tampering with this unit is danger-
ous. Tampering voids all warranties.
DO NOT aempt to modify or change
this unit in any way.
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.
Safety Instructions
is manual is intended as an aid to quali-
ed service personnel for proper installa-
tion, 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 ac-
cordance with these instructions. Use this
unit only for its intended use as described
in this manual.
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.
Turn o the electrical supply before servic-
ing the unit.
Do not use the unit if it has damaged wir-
ing, is not working properly, or has been
damaged or dropped.

CACG/CAHG/CAHJ & CACH/CAHH/CAH
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Comfort where it counts 4P/N 240008108, Rev. G [07/08/10]
Product description
e EMI Cassee Air handlers are avail-•
able in three cabinet sizes with four out-
put 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 mod-
els 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.
Verify Unit Before Installing
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 includedis abankof DIP switchesfor•
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 stati-
cally 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).
NOTICE
Check equipment for damage prior
to installation, if damaged contact the
wholesale distributor.

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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•
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)
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 on-
board 30-amp electric heat relay.
Condensate pump with 36” (0.9 m) li•
(measured from base of unit).
24V Transformer.•
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 in-
door air handler without electric heat is
matched with a heat pump condenser,
the system will deliver cold air during
defrost.

CACG/CAHG/CAHJ & CACH/CAHH/CAH
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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, cool-
ing/electric heat, heat pump.) See ther-
mostat 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 cool-
ing 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 over-
temperature 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.
Verify Unit Before Installing (continued)

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Piston/Orifice Replacement (when required)
NOTICE
Piston/ Orifice 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 instruc-
tions and chart as follows.
Replacing the piston/orifice
Diassemble the orice joint, remove the factory installed orice, and replace with the1.
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/orifice replacementFigure 1
To Air
Handler
Model Condenser Factory-installed orifice size
(Inches)
Replacement orifice size
(Inches)
CAHG/CAHH 24
T2C/T2H8800
T2C/T2H9800
T3C/T3H9980
0.056 0.049
CACG/CACH 36 S1CG3000 0.070 0.063
CACG/CAHH 24 S1CG8000
S1HG8000 0.056 0.047
CAHJ/CAHK 12
T2C/T2H 2400
T3C/T3H 2240
T3C/T3H 2220
T4C/T4H 9922
T4C/T4H 9992
T4C/T4H 2222
0.041 0.044

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Mounting the Unit
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 specificationsTable 1
S1CG
or
S2CG
Model
Max.
Length
Equivalent
feet
Max.
Lift
Max.
Trap
Height
Liquid
Line
Suction
Line
“H” “P” O.D. O.D.
09 50’
(15 m)
20’
(6 m)
15’
(5 m)
1/4" 1/2"
12 1/4" 1/2"
18
100’
(30 m)
35’
(11 m)
20’
(6 m)
3/8" 5/8"
24 3/8" 3/4"
30 3/8" 3/4"
36 3/8" 3/4"
NOTICE
Piping may be roughed in before wall-
board or panels are placed in new con-
struction. PVC pipe (3” or 4” I.D.) may
be used as a pipe chase.
Unpacking
e Cassee fascia and main chassis are pack-
aged together for increased protection.
Remove the banding straps and li the1.
cardboard lid.
Fascia is packed in bubble wrap and on2.
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 pack-
aging
Li the fascia and template from the box4.
and set aside.
Remove the cassette chassis from the5.
box utilizing the four corner brackets
for liing.
WARNING
Do not use the drain or refrigerant con-
nections for liing.
In order to protect the fascia from dirt and6.
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

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Mounting the Unit (continued)
Blanking off
e fascia discharge slot(s) will need blank-
ing 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 (see1.
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.
Models 9–12 — one grille & oneFigure 2
filter
Model 24 — two hinged grillesFigure 3
and two filters (Model 36, not
shown has three grilles and
three filters)
Hinge
H
H
i
H
Applying blanking-off piecesFigure 4
Blanking-Off
Pieces

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Mounting the Unit (continued)
Positioning
e cassee installation position should be
selected with the following in mind:
Pipe work, electrical connections, control1.
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 52.
. (1.5m) from a wall or similar obstruc-
tion.
Position the unit as close to the center3.
of the room as possible to ensure air is
distributed evenly.
Position the unit so that the discharge4.
air does not blow directly on the remote
thermostat, if used.
e unit should not be positioned directly5.
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 installa-
tion. 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
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.
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 cor-
rectly, 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 fol-
lowing points in mind:
Position the thermostat approximately 51.
. (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 the5.
thermostat to avoid dras.

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Mounting the Unit (continued)
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 em-
bedded bolts.
For previously built concrete slabs–
install hanging bolts with an expan-
sion anchor.
Follow local building codes for required•
safety cables, braces, etc.
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)
Ceiling cutout/rod placementFigure 6
template (shipped with unit)
(51MM X 45°)
2.000 X 45° TYP
Rod
Positions
1.500 TYP
Rod
Positions
(38MM TYP)
Ceiling rod positionsTable 3
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

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Mounting the Unit (continued)
Mounting
Use the template (see1. Figure 6, Page 11)
to cut the ceiling opening and determin-
ing 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 locknuts6.
and washers on either side of the cassee
bracket.
Ensure threaded rod does not protrude7.
more than 2” (51mm) below the mount-
ing bracket see (Figure 9, Page 12).
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 con-
densate drain is allowed.
Any slight discrepancy between the cas-
see and ceiling will be taken up by the
fascia foam seal.
Positioning installation guidesFigure 8
INNER CASE
INSULATION
CASSETTE
CASE
Threaded rods must not pro-Figure 9
trude more than 2 inches below
the mounting brackets
MAX
MAX
2”
2”
(51mm)
(51mm)

CACH/CAHH/CAHJ & CACH/CAHH/CAHK
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Op
eration and Maintenance Manual •
P/N 240008108, Rev. G [07/08/10] 13
Condensate Piping
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 condensate2.
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 dis-
charge 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.
Condensate pipe-work should slope3.
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 to4.
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 pre-
vent siphoning of water from the drain
pan and associated noise.
The highest point of the con-Figure 10
densate piping should be as
close to unit as possible
Correct
Correct
Incorrect
Incorrect
Condensate drainFigure 11
Condensate Drain Connection

CACG/CAHG/CAHJ & CACH/CAHH/CAH
K
Air Handlers
•
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nstallation,
Op
eration 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
aached to the cassee chassis by following
the steps below.
NOTICE
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).
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• and 36.
Cut the black insulation around the2.
knock-out (Figure 13, Page 14).
Snip the tabs holding the knock-out in3.
place (Figure 13, Page 14).
Remove the metal knock-out and the4.
black insulation behind it.
Aach the duct collars (eld supplied) to5.
the chassis using self-drilling screws.
Repeat steps above for remaining duct6.
work.
KnockoutsFigure 12
Fresh Air
Knockout
F
re
F
F
K
n
K
K
Branch Duct Knockout
Cassette 12
Cassette 12
CASSETTE 24 & 36
CASSETTE 24 & 36
Cut insulation and snip outFigure 13
knockouts

CACH/CAHH/CAHJ & CACH/CAHH/CAHK
A
ir Handler
s
•
I
nstallation,
Op
eration 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 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 con-
nection. is can harm the compres-
sor. Install a reducer, when used, only
on the inside connection.
NOTICE
e cassee is equipped with a Flo Rater
piston expansion device. Connections
are sweat type.
Piping connections at unitFigure 14
Suction Line Liquid Line
S
uction
L
in
n
e
Li
qu
id
L
i
n
e
Li
q
(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 ana.
18,000-Btuh condenser, you must use
a 5/8-inch suction line, with a reducer
installed as shown in (Figure 14,
Page 15).

CACG/CAHG/CAHJ & CACH/CAHH/CAH
K
Air Handlers
•
I
nstallation,
Op
eration and Maintenance Manual •
Comfort where it counts 16 P/N 240008108, Rev. G [07/08/10]
Refrigerant Piping (continued)
Clean ends of tubingFigure 15
Place wet rag“heat shield overFigure 16
valves plus a sheet metal shield
to protect paint
Wet rag heat sink Shield
Refrigerant piping
Clean the ends of tubing and insert into1.
  ings (Figure 15).
Before brazing (2. Figure 16):
Protect valves by wrapping with a weta.
rag “heat sink” before brazing.
Use a shield to protect the paint asb.
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 the4.
entire length with closed cell, foam tube
insulation.
Do not insulate the liquid line.5.
Connect the outdoor unit according to6.
the instructions supplied with unit.
NOTICE
Maximumequivalentpiperunshould1.
comply with (Table 1, Page 8).
Horizontal pipe runs should be2. slightly inclined, so as to encourage
oil to flow in the direction of the
compressor, for beer oil return.
Good refrigeration practices must be3. employed to ensure the correct pres-
sure drop and good oil return.
CAUTION
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).

CACH/CAHH/CAHJ & CACH/CAHH/CAHK
A
ir Handler
s
•
I
nstallation,
Op
eration and Maintenance Manual •
P/N 240008108, Rev. G [07/08/10] 17
Refrigerant Piping (continued)
Refrigerant processing
Aach manifold set (1. Figure 17).
Evacuate line to 500 microns or less to2.
ensure all moisture has been removed and
there are no leaks.
Once certain of a good evacuation and3.
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 and4.
remove only liquid, never vapor.
Charge to proper weight, charge based on5.
feet of interconnect (Figure 19, Page 17).
See tables on page 18.
CAUTION
Refer to the charts in the condenser
manual to “fine tune” the refrigerant
charge.
CAUTION
Charging should be done with a dial-a-
charge 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.
Manifold set connections at unitFigure 17
S1CG
S1CG
Shown
Shown
Manifold set up for evacuationFigure 18
A
A
C
C
B
B
S1CG
S1CG
Shown
Shown
ManifoldA Vacuum pumpB
Micron gageC
Charging the unit
Figure 19
S2CH
S2CH
S1CG
S1CG
Refrigerant
Refrigerant
S1CG
S1CG
Shown
Shown

CACG/CAHG/CAHJ & CACH/CAHH/CAH
K
Air Handlers
•
I
nstallation,
Op
eration 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 Cassette
pairing
Line charge
per foot
Factory
charge Top discharge, Multi-zone
S1CG9 CAH_09 .25 oz./ft
(23 g/m)
39.5 oz.
(1119 g)
Circuit capacity Wall Unit
Paring
Line charge
per foot
Factory
charge
S1CG2 CAH_12 .25 oz./ft
(23 g/m)
33.75 oz.
(956 g)
S1CG8 CAH_24 .64 oz./ft
(59 g/m)
65.25 oz.
(1764 g) 9,000 Btuh CAH_09 .25 oz./ft (23 g/m)
46.5 oz.
(1318 g)
S1CG4 CAH_24 .64 oz./ft
(59 g/m)
63.0 oz.
(1786 g) 12,000 Btuh CAH_12 .25 oz./ft (23 g/m)
45.25 oz.
(1282 g)
S1CG3 CAC_36 .64 oz./ft
(59 g/m)
97.5 oz.
(2764 g) 18,000 Btuh CAH_24 .64 oz./ft (59 g/m)
96.75 oz.
(2742 g)
S1CG6 CAC_36 .64 oz./ft
(59 g/m)
80.0 oz.
(2267 g) 24,000 Btuh CAH_24 .64 oz./ft (59 g/m)
78.5 oz.
(2225 g)
S1HG9 CAH_
09
.25 oz./ft
(23 g/m)
51.52 oz.
(1460 g) Side Discharge Multi-zone
S1HG2 CAH_
12
.25 oz./ft
(23 g/m)
45.75 oz.
(1296 g) Circuit capacity Wall Unit Paring
Line charge
per foot
Factory
charge
S1HG8 CAH_
24
.64 oz./ft
(59 g/m)
63.0 oz.
(1786 g) 9,000 CAH_09 .25 oz./ft (23 g/m)
44 oz.
(1247 g)
S1HG4 CAH_
24
.64 oz./ft
(59 g/m)
60.75 oz.
(1722 g) 12,000 CAH_12 .25 oz./ft (23 g/m)
39 oz.
(1105 g)
Refrigerant Processing
NOTICE – to find charge adjustment
To nd the charge adjustment and system charge for any air handler and tubing1.
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.

CACH/CAHH/CAHJ & CACH/CAHH/CAHK
A
ir Handler
s
•
I
nstallation,
Op
eration 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 froma.
the supplied kit bag.
Put washers onto the bolts.b.
Screw the mounting bolt with washerc.
into the chassis leaving approximately
1” (25mm) to hang the fascia.
Ensure the white panel fasteners holding2.
the fascia polystyrene are pushed rmly in
(fasteners may have loosened in transit).
Li the fascia onto the chassis mounting3.
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 the4.
vane motor plug by plugging it into the
socket connection on the chassis.
Ensure that the polarized connectora.
(2 position) is in the proper orienta-
tion and connected.
Route the wires in a way that ensuresb.
they won’t become trapped, cut, bro-
ken or chaed.
ONLY Cassette “H” or “K” models5.
(CACH/CAHH/CAHK) contain a sec-
ond 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 that7.
they won’t become trapped, cut, broken,
or chaed (Figure 22, Page 19).
e fascia can now be tightened up to the8.
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 beFigure 21
pushed in
Wire routingFigure 22

CACG/CAHG/CAHJ & CACH/CAHH/CAH
K
Air Handlers
•
I
nstallation,
Op
eration and Maintenance Manual •
Comfort where it counts 20 P/N 240008108, Rev. G [07/08/10]
Final Assembly (continued)
Connect vane motor plug intoFigure 23
socket on chassis
Female vane motor plug on
chassis
Male vane motor plug on fascia
Connect infrared unit cable (“H”Figure 24
or “K” units only)
Red stripe is
Conductor #1
Polarized
10 Position
Connector
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