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Canadian Air Handler Installation and Operation Manual
Thank you for purchasing Rinnai’s Hydronic Air Handler. Before installing and operating the air handler, be sure to read these instructions completely and carefully to familiarize yourself with the features and functionality. This manual provides instructions for installing the air handler and is a supplement to the Rinnai Tankless Water Heater or Boiler Installation and Operations Manual supplied with the system.
This manual contains the following important safety symbols. Always read and obey all safety messages. Safety alert symbol. Alerts you to potential hazards that can kill or hurt you and others. • Suitable fire extinguishing equipment should be immediately available in the work area and be maintained in a state of readiness for instant use. • Do not use this air handler if any part has been under water.
The hydronic air handler is designed to work with Rinnai tankless water heaters and boilers (models listed below) to deliver a wide variety of heating capacities for residential and light commercial applications. NOTE Refer to section “3.7 Specifications” for a complete list of product specifications. It is the responsibility of the installer to follow all national codes, standards and local ordinances, in addition to the instructions in this manual.
When transporting components of the hydronic air handler, follow the guidelines below: • Choose the correct hand truck to support the weight and size of the system components. Refer to section “3.7 Specifications” for specific weights and dimensions. • Use safe lifting and material handling principles to prevent workplace accidents. Example: CAH050CE CAH 050 C E Blower Motor • Use proper lifting techniques to load the equipment onto a hand truck.
TOP Water Inlet Hot Water From Water Heater/Boiler into Air Handler Hydronic Coil Water Outlet Cold Water Returning to Water Heater/Boiler Control Panel 120V Terminal 24V Thermostat Cable Knockout Access Port (available on left or right side) ECM Blower Motor and Housing 120V Power Supply Knockout Access Port (available on left or right side) Left or Right Side HVAC Duct Return Acoustic Wool NOTE Bottom HVAC Duct Return BOTTOM Canadian Air Handler Installation and Operation Manual • Reference to t
A-Coil and Ductwork (Field-Supplied) Refrigerant Lines (FieldSupplied) to Condensing Unit Water Inlet/Outlet From Water Heater/Boiler (they are co-linear and cannot both be seen on the side profile) Air Handler 8 Canadian Air Handler Installation and Operation Manual
Example Vertical (Upflow with Side Return) Configuration SUPPLY (Air Flows Out) Supply Ductwork Rinnai Tankless Water Heater or Boiler Thermostat A call for heat from the thermostat activates the air handler Hot Cold Water Inlet RETURN Water Outlet Front Panel (Air Flows In) Hot Water From Water Heater/Boiler into Air Handler Cold Water From Air Handler Returning to Water Heater/Boiler Return Ductwork Air Handler IMPORTANT The above image is for representation purposes only; it is not a complet
CAH050E CAH050CE Hydronic Air Handler Hydronic Air Handler (Without Accessory Circulation (With Accessory Circulation Pump) Pump) Installation Indoor Suitable for Potable Water Systems Yes Configurations Multi-position Circulation Pump Included No, Accessory Yes (to be field installed) Product Weight - lb. (kg) (approximate) 100 (45.5), Shipped 120 (54.5) 105 (47.6), Shipped: 125 (56.
Values shown in following tables may vary depending on the static pressure of the duct system.
Copper Diameter Fitting 3/4 in. 1 in. 90 Degree Elbow 2 0.75 45 Degree Elbow 0.75 0.3 Straight Through Tee 0.4 0.135 3 1.35 Reducer Coupling 0.5 0.18 Gate Valve 0.25 0.09 Ball Valve 2.2 1.29 Swing Check Valve 3 1.35 Multiplier Per Linear Foot of Pipe 1 0.3 Fitting 3/4 in. 1 in. 90 Degree Elbow 19.44 6.9 2.7 0.78 Side Port Tee 28.08 7.62 Reducer Coupling 4.68 1.62 Ball Valve 5.94 2.58 PEX x NPT 4.86 2.28 Multiplier Per Linear Foot of Pipe 1.8 0.6 3/4 in.
Measurements: in. (mm) 18.5 (470) 14.38 (365) 17 (432) 39.25 (997) 20.5 (521) Canadian Air Handler Installation and Operation Manual 21.
Domestic Priority Switch Part # Normally Closed (NC) switch that connects to the PC Board in the Rinnai tankless water heater or boiler. Allows the tankless water heater or boiler to give priority to domestic hot water by shutting off the air handler when necessary. When used with a hydronic air handler, the switch gives priority to domestic hot water. When domestic hot water demand exceeds a certain point, the air handler will turn off to ensure the demand is met.
Carefully unpack the air handler. If the unit is damaged, contact your local dealer/distributor. Do not attempt to use the air handler if it appears damaged. The blower section is factory assembled and all components are performance tested. The air handler consists of a blower assembly and controls in an insulated, galvanized steel factory finished enclosure. Knockouts are provided for thermostat electrical wiring entrance.
• Unsuitable heating system water can cause the formation of scale or sludge, which affects system efficiency. It can also cause corrosion and reduce life of the heat exchanger. • Clearances to combustible material is 0 in. to plenum and duct for first 36 in. (914 mm) and throughout the remaining ductwork system. Never use water that has been treated by a reverse osmosis, deionized, or distilled water to soften the water to fill the heating system.
• This air handler is certified for installation in residential and light commercial applications and approved for the following configurations: − Vertical: Upflow with bottom or side (left or right side) return − Vertical: Downflow with bottom or side (left or right side) return − Horizontal (Upflow with bottom return) • All models are designed for indoor installation only. • These instructions are intended as a general guide only and do not supersede national or local codes.
• Install ductwork in accordance with NFPA 90B and any local codes. • Install the conditioned air plenum, ducts and air filters (not provided) in accordance with NFPA 90B Standard for the installation of Warm Air Heating and AirConditioning Systems (latest edition). • Isolation connectors (if utilized) must be nonflammable. • A return air duct system is recommended. If the unit is installed in a confined space or closet, a return connection must be run, full size, to a location outside the closet.
WARNING • Use copper conductors only. • All field wiring must be done in accordance with National Electrical Code, applicable requirements of UL and local codes, where applicable. • Electrical wiring, disconnect means and over-current protection are to be supplied by the installer. Refer to the air handler rating plate for maximum over-current protection, minimum circuit ampacity, as well as operating voltage.
Pipe Sizing Considerations WARNING Solder joints on domestic water lines must be made with NO-LEAD SOLDER. IMPORTANT Use only approved piping and fitting materials. If used in an open loop system with domestic hot water, potable, lead-free piping must be used. Thermal Expansion of Piping In all hydronic systems, piping undergoes temperature swings as the system operates. This causes changes in the length of the piping due to thermal expansion.
IMPORTANT Vertical (downflow with bottom, back, or side return) Read section “4. Installation Preparation” before starting installation steps. RETURN Air flows in through bottom, back, or side (left or right side) Refer to the previous section (section “4. Installation Preparation”) for more information on location and configuration requirements. 1. Place the air handler in the desired location and configuration.
The air handler is not approved for the following configurations: • Do not position the air handler on its front or back panel. Front • Back Multiple air handlers configured for installation with a single Rinnai tankless water heater or boiler is prohibited. Refer to section “4.7 Electrical Requirements” for complete electrical requirements.
Air Handler Thermostat Wiring Block LOW VOLTAGE/BASSE TENSION R V/W2 W1 Y2 Y1 G C DH O 1 2 Rinnai Domestic Priority Switch: Rinnai REU-OPU3 (accessory installed in Rinnai Engine) Field Supplied Thermostat Connections to the Air Handler PC Board. Other thermostat wires removed for clarity. 1. Disconnect all power supplies. 2. Remove the air handler front panel by removing the 6 screws that secure the top panel and the 9 screws that secure the front panel. 3.
The CAH050CE model air handler will have an included accessory Grundfos UPS 15-78 circulator pump. The CAH050E model air handler does not have an included circulator pump. If utilizing the air handler with a Rinnai I-Series combi boiler, the accessory pump is not necessary as the boiler already has a pump included inside the boiler. If desired to install a pump other than the Grundfos UPS 15-78, this would need to be a field-supplied component.
LOW VOLTAGE/BASSE TENSION R V/W2 W1 Y2 Y1 G C DH O 1 2 120V Pump Supply 120V Power Supply 24V Thermostat Terminals A single stage or two stage thermostat must be installed with the air handler. Thermostat Field Connections (use depends on the application) • Dh—Used for dehumidification contact. • R—signal is 24V hot to thermostat. • W1—signal controls first stage heat from the thermostat. If a single stage thermostat is used, connect W to W2. • W2—signal from a two-stage thermostat.
Single Stage Hot Water Heat Only Application Two Stage Hot Water Heat Only Application Air Handler Thermostat Air Handler Thermostat R R R R V/W2 V/W2 V/W2 V/W2 W1 W1 W1 Y2 G Y2 G Y1 C Y1 C G G C C DH DH O O 1 1 2 2 NOTE Connect common (C) wire only if required. See thermostat installation instructions for more information.
Heat Pump Application with Hot Water Heat Cooling Application with Hot Water Heat Air Handler Thermostat Air Handler Thermostat R R R R V/W2 V/W2 V/W2 V/W2 Outdoor Unit W1 W1 Y2 Y2 Y2 Y2 Y2 Y1 Outdoor Unit Y2 Y1 Y1 Y1 Y1 Y1 G G G G C C C DH C C DH C O O O 1 1 2 2 O NOTE Connect common (C) wire only if required. See thermostat installation instructions for more information.
Heating Application with I-Series Boiler R R V/W2 V/W2 W1 OPU Y2 G Y1 C I Series Boiler T/T 1 Terminals G C DH 2 1 5 0 1 3 4 2 28 Canadian Air Handler Installation and Operation
Hot Water Heat with Rinnai REU-OPU3 R R V/W2 V/W2 W1 Install the Rinnai Tankless Water Heater or Boiler by following the Installation and Operation Manual supplied with the unit. Water Potability OPU Y2 G Y1 C G This unit can be installed in hot water domestic loop. The hot water coil is certified to NSF 372. At install, make sure all components are certified and that all materials and solders are free of lead and contaminants.
IMPORTANT • • • • Refer to section “4.8 Plumbing Requirements” for complete plumbing requirements. For standard installations, refer to the piping diagrams in sections 5.7.1 and 5.7.2. For more information on the tankless water heater or boiler plumbing connections, refer to the unit’s Installation and Operation Manual. Water connections to the air handler should follow all state and local plumbing codes. 1.
This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional engineering project drawings. This drawing is not intended to describe a complete system. It is up to the contractor or engineer to determine the necessary components and configuration of the particular system to be installed. The drawing does not imply compliance with local building code requirements.
This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional engineering project drawings. This drawing is not intended to describe a complete system. It is up to the contractor or engineer to determine the necessary components and configuration of the particular system to be installed. The drawing does not imply compliance with local building code requirements.
Outdoor Reset Sensor This is not an engineering drawing; it is intended only as a guide and not as a replacement for professional engineering project drawings. This drawing is not intended to describe a complete system. It is up to the contractor or engineer to determine the necessary components and configuration of the particular system to be installed. The drawing does not imply compliance with local building code requirements.
Flushing the hot water coil prior to start up is required to remove any residual material from the installation or manufacturing processes as well as remove any air from the system. Use an external purge valve or other mechanism to flush hot water coil after installation. Take precautions while flushing the air handler to keep the multi-function control board and other electrical components from getting wet. Hot water is preferred for flushing. Follow the flushing steps listed below.
Air Flow Inspection: • For proper cooling operation, the airflow through the indoor coil should be between 350 and 450 CFM per ton of cooling capacity (or 350 – 450 CFM per 12,000 BTU/HR) based on the rating of the outdoor unit. • If the outdoor unit is smaller than the maximum cooling capacity rating for the air handler, the cooling capacity may need to be changed. Refer to section “8.3 Controller Input Options” for more information.
The blower motor is a true variable speed motor designed to deliver constant CFM. Constant CFM is valid, up to 1600cfm, with total static pressure up to 0.7 in. w.c. Constant CFM is valid, up to 1200cfm, with total static pressure up to 1.2 in. w.c. Single Stage Thermostat Single Stage Thermostat • • • • • • When the thermostat calls for cooling, the thermostat circuit between R and G is completed. The normally open contacts close, causing the indoor blower motor to operate.
WARNING Electrical Shock: • Before servicing the air handler, turn off power to unit. There may be more than one disconnect switch. • Improper installation, modification, service, maintenance or use of the air handler can cause electrical shock, burns or other conditions which may cause electrical shock, personal injury, property damage or death. WARNING • It is recommended that a trained and qualified professional who has attended a Rinnai installation training class perform service to the air handler.
WHITE N BLACK L C-R1 PUMP P BLACK BLACK INDUCTOR WHITE BLOWER MOTOR (120V) MOTOR ECM 16 PIN CONTROL CONNECTOR GREEN RED 12 16 1 10 9 BLACK BLACK 3 BLUE 8 120V WHITE TRANSFORMER 120-24V 40VA RED BLACK RED C 24V Y2 Y2 Y1 Y1 G R R W1 W1 W2 W2 DH BLUE YELLOW GREEN G WHITE PURPLE DH O O RED 1 RED 3 RED BLUE YELLOW BLUE 38 1 GREY 2 BROWN 5 21 15 24 20 CONTROL BOARD THERMOSTAT 9 19 17 23 16 18 13 PINK PURPLE WHITE GREEN BLACK BLACK BLACK R1 22 Canadian Air
Canadian Air Handler Installation and Operation Manual 39
Menu Parameter Description Min Max Default Switch between English and French - - English AC/HP Tons Set the cooling/heat pump capacity (Tons) 0 10 0 CFM/TON Airflow adjustment per ton of cooling (CFM) 300 500 400 Configuration Language Cooling/HP Dehum ON State Set the active state of the DH signal LOW HIGH HIGH Dehumidification cooling fan ratio 50% 100% 85% Fan ratio for 1st cooling stage 50% 90% 70% Continuous Fan Ratio 15% 100% 50% 35% 100% 75% Fan ratio for 1st h
FAN MENU The fan menu allows to modify the options related to the comfort fan of the appliance: SOFTWARE SETTINGS Configuration and installer menus allow you to modify both display and operational parameters of the unit. Navigation within the menus can be achieved using the up, down and select buttons. The up and down buttons allow to change menu, line or to modify a value. The center button allows to select or validate a parameter.
COOLING / HP MENU The Cooling / HP menu allows to modify the options regarding the behavior with an outdoor unit. SYSTEM MENU The system menu allows to modify the following parameters: Parameter Description Parameter Description AC/HP TONS Allows you to specify the tonnage of the outdoor unit. CFM/TON Allows you to set a precise CFM per TON ratio. FURNACE This parameter allows to manually MODEL select the model of the unit. This parameter must be used when the control board is replaced.
31 32 14 Item # Part Number 1 609000064 Description FLOOR PANEL BLOWER SEPARATOR ASSEMBLY RIGHT PANEL ASSEMBLY BACK PANEL ASSEMBLY THRU PIPE GROMMET Item # 16 17 Part Number 609000075 605000046 18 609000076 19 20 607000035 605000047 21 22 23 605000048 605000049 609000077 24 605000050 25 605000051 24V RELAY TRANSFORMOR CONTROL TERMINAL LABEL REPLACEMENT CONTROL LABEL ELECTRICAL POWER HARNESS 26 27 28 29 605000052 605000053 605000054 609000078 CONTROL HARNESS CONTROL TERMINAL POWER TERMINAL
