Rinnai CAH Series, Instalation And Operating Manual

Page 1: ...C US ...

Page 2: ...2 Canadian Air Handler Installation and Operation Manual ...

Page 3: ... requirements in the Tankless Water Heater or Boiler Installation and Operations Manual as well as the requirements in this manual It is recommended that a trained and qualified professional who has attended a Rinnai installation training class install the air handler inspect it and leak test it before use Improper installation may void the warranty The trained and qualified professional should ha...

Page 4: ... Electrical shock can cause personal injury or death WARNING 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 Immediately call a licensed professional to inspect the air handler and replace any part that has been under water Do not use substit...

Page 5: ...tems Sheet Metal and Air Conditioning Contractors National Association SMACNA American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16 US and CANADA Air Conditioning Contractors Association ACCA Manual D Acoustical Lining and Fibrous Glass Duct US and CANADA Current edition of...

Page 6: ...the weight is evenly balanced Use personal protective equipment such as gloves and steel toed boots If storing components of the hydronic air handler follow the guidelines below Store system components in a clean dry environment Components must be protected from direct sunlight Do not store components outdoors If transported or stored at temperatures below 32 F 0 C the components must be warmed up...

Page 7: ...bove image to show the air handler internal components NOTE 120V Power Supply Knockout Access Port available on left or right side 24V Thermostat Cable Knockout Access Port available on left or right side ECM Blower Motor and Housing Hydronic Coil Water Outlet Cold Water Returning to Water Heater Boiler Water Inlet Hot Water From Water Heater Boiler into Air Handler Left or Right Side HVAC Duct Re...

Page 8: ...ation and Operation Manual A Coil and Ductwork Field Supplied Water Inlet Outlet From Water Heater Boiler they are co linear and cannot both be seen on the side profile Refrigerant Lines Field Supplied to Condensing Unit Air Handler ...

Page 9: ...lows In SUPPLY Air Flows Out Thermostat Supply Ductwork Return Ductwork Air Handler Rinnai Tankless Water Heater or Boiler Front Panel A call for heat from the thermostat activates the air handler IMPORTANT Water Inlet Water Outlet Hot Cold Hot Water From Water Heater Boiler into Air Handler Cold Water From Air Handler Returning to Water Heater Boiler Example Vertical Upflow with Side Return Confi...

Page 10: ...t 140 F1 50 000 Nominal Cooling Capacity Up to 4 tons Rated Voltage 120 V 60 Hz 1 Ph Motor 9 6A FLA Pump 3A max 15A MOA 20A MOP Blower Motor Type ECM fully variable Coil Material Copper Coil Aluminum Fins Blower Motor Horsepower HP 3 4 Water Connection 1 2 in Sweat Control Board Factory Installed Thermostat connections Adjustable time delay for blower activation for heating Pump timer circulates w...

Page 11: ...00 32 37 500 29 43 900 25 4 38 140 2 33 700 39 42 000 32 47 500 28 1 41 3 37 300 43 48 300 37 56 500 33 2 34 4 38 400 44 54 000 42 62 700 36 4 38 160 2 43 100 50 54 800 42 62 600 36 1 41 3 48 000 56 62 100 48 73 100 42 2 34 4 51 200 59 66 200 51 80 000 46 4 38 Engine Entering Water Temperature F 50 800CFM 75 1200 CFM 100 1600 CFM SENSEI 120 26 600 34 700 41 400 I Series 28 500 38 400 44 600 SENSEI...

Page 12: ...oot of Pipe 1 0 3 PEX Fitting 3 4 in 1 in 90 Degree Elbow 19 44 6 9 Straight Through Tee 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 CPVC Fitting 3 4 in 1 in 90 Degree Elbow 2 2 1 45 Degree Elbow 1 21 0 56 Straight Through Tee 1 54 0 68 Side Port Tee 5 5 2 4 Male Female Adapter 1 65 0 8 Multiplier ...

Page 13: ...Canadian Air Handler Installation and Operation Manual 13 Measurements in mm 17 432 14 38 365 18 5 470 39 25 997 20 5 521 21 38 543 ...

Page 14: ...llows 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 REU OPU3 Product images are for illustrative purposes only ...

Page 15: ...m its anchorage the air handler must be immediately examined by the receiving party before removal If damage is found the receiving party must sign the driver s delivery receipt noting all damage i e carton damage and or product damage as well as contact the last carrier immediately preferably in writing requesting inspection by the carrier s agent To prevent loss or damage leave all parts in orig...

Page 16: ... remaining ductwork system Clearance for servicing is 24 in 610 mm in front of air handler FRONT 0 in SIDE 0 in BACK 0 in TOP 0 in BOTTOM 0 in SERVICING 24 in 610 mm Images are not to scale and are for illustration purposes only Images do not show a complete system with plenums duct pipes etc IMPORTANT If the free area is not known assume a 25 free area for wood or a 75 free area for metal louvers...

Page 17: ...completely assembled For ease in installation it is best to make any necessary evaporator coil configuration changes before connecting the air handler to the evaporator coil Do not remove the cabinet knockouts until it has been determined which knockouts need to be removed for the installation Select the final installation position that best suits the site conditions Consider required clearances s...

Page 18: ...r before turning or branching off plenum into duct runs The plenum forms an extension of the blower housing and minimizes air expansion losses from the blower All wiring must conform to local and national electrical codes Improper wiring or installation may damage thermostat Air Conditioner Model The Standard Model A C thermostat may be wired with or without connecting a common wire between the in...

Page 19: ...in clear site accessible and in close proximity to the unit Correct polarity MUST be maintained for 120 V wiring If polarity is incorrect unit will NOT operate Electrical Shock Disconnect power before servicing Replace all parts and panels before operating Electrically ground the air handler Connect ground wire to the green ground wire in the air handler electrical panel Failure to do so can resul...

Page 20: ...for a given flow rate the resulting average flow velocity should be between 2 ft 0 61 m and 4 ft 1 22 m per second At water flow velocities of approximately 2 ft 0 61 m per second flowing water will carry air bubbles along a vertical pipe Average flow velocities of 2 ft 0 61 m per second or higher can draw along air bubbles in a downward flow At the above stated velocities air bubbles shall be rou...

Page 21: ...on of the air handler Refer to section 4 5 Ductwork Requirements for complete ductwork installation requirements 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 The isolation connector if used must be nonflammable IMPORTANT RETURN SUPPLY Example Vertical Installation SUPPLY Upf...

Page 22: ... single Rinnai tankless water heater or boiler is prohibited Refer to section 4 7 Electrical Requirements for complete electrical requirements Power Supply Knockout Thermostat Connection Knockout Thermostat and Power Supply Knockouts available on both sides L1 N N P Air Handler 120V Power Supply Electrical cables go through the knockout holes on the left or right side of the cabinet See the images...

Page 23: ... hole and connect to the air handler PC Board 5 If installing the Domestic Priority Switch REU OP3 recommended optional accessory purchased separately connect it to the air handler PC Board see above image 6 Connect the following A Connect ground wire to the supplied green ground wire B Connect black to black and white to white power supply terminal 7 Replace the air handler access panel Connectio...

Page 24: ...itioning wall or a section of wall without pipes or duct work 2 Connect the thermostat to the air handler Follow the wiring diagrams in the next section 5 4 1 Thermostat Wiring Diagrams Refer to section 4 6 Thermostat Requirements for thermostat installation requirements All capacity and performance data is based on the Grundfos UPS 15 78 If other pumps are in use results will vary The pump does n...

Page 25: ...t 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 Y1 Connection for the low speed compressor operation Y Y2 Connection for the Y signal or high speed Y2 signal from the thermostat G Connection for the G fan signal is energized from the thermostat O Not used with this...

Page 26: ...pplication Two Stage Hot Water Heat Only Application R V W2 W1 Y2 Y1 G C DH O 1 2 R V W2 G C Air Handler Air Handler Thermostat Thermostat R V W2 W1 Y2 Y1 G C DH O 1 2 R V W2 W1 G C Connect common C wire only if required See thermostat installation instructions for more information NOTE ...

Page 27: ...ation with Hot Water Heat R V W2 W1 Y2 Y1 G C DH O 1 2 R V W2 Y2 Y1 G C Y2 Y1 C R V W2 W1 Y2 Y1 G C DH O 1 2 R V W2 Y2 Y1 G C O Y2 Y1 C O Air Handler Air Handler Thermostat Thermostat Outdoor Unit Outdoor Unit Connect common C wire only if required See thermostat installation instructions for more information NOTE ...

Page 28: ...28 Canadian Air Handler Installation and Operation I Series Boiler T T 1 Terminals 5 4 3 2 1 R V W2 W1 Y2 Y1 G C DH 0 1 2 R V W2 OPU G C Heating Application with I Series Boiler ...

Page 29: ...d contaminants To satisfy many jurisdictions regulations the con trol allows to set a time of pump inactivity to initi ate a pumping cycle and avoid stagnating water Make sure to set this parameter according your local and codes Biocontamination hazard When the unit is off for a long period of time precautions to flush clean and disinfect the hot water loop shall be made Failure to do so can resul...

Page 30: ...he air handler should follow all state and local plumbing codes 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 ...

Page 31: ...ly 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 It is the responsibility of the contractor o...

Page 32: ...drawing does not imply compliance with local building code requirements It is the responsibility of the contractor or engineer to ensure the installation is in accordance with all local building codes Confer with local building officials before installation Outdoor Reset Sensor Optional Low Water Cut Off LWCO DHW Recirculation Timer Optional Domestic Hot Water Supply Line Cold Water Supply Line Th...

Page 33: ...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 It is the responsibility of the contractor or engineer to ensure the in...

Page 34: ...nstallation instructions for system start up instructions and refrigerant charging instructions Is unit properly located secure and serviceable Is the unit protected from vehicular or other physical damage Is the return air not obtained from areas where there may be objectionable odors flammable vapors or products of combustion such as carbon monoxide CO which may cause serious personal injury or ...

Page 35: ... 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 proper cooling or heat pump tons is to be selected see section 8 3 Controller Input Options ...

Page 36: ...2 Stage Thermostat Thermostat closes circuit R to W1 or W2 Unit delivers the selected heat airflow Unit delivers W1 or W2 heating airflow and pump is exercised Continuous Fan Thermostat closes circuit R to G Blower runs at continuous fan airflow During installation use caution to prevent the control board and other controls from getting wet IMPORTANT The blower motor is a true variable speed motor...

Page 37: ... Do not use substitute materials Use only parts certified for the air handler Any alteration to the air handler can be dangerous and will void the warranty Maintenance To maintain reliability and optimal performance of this unit perform an annual complete verification of the system Do not attempt to repair the unit or its controls Call a qualified technician At the beginning of each heating season...

Page 38: ... WHITE BLACK C Y2 Y1 G W1 W2 DH O Y2 Y1 G W1 W2 DH O BLUE YELLOW GREEN WHITE PURPLE 9 19 17 23 16 18 13 PINK PURPLE WHITE GREEN BLACK BLACK BLACK R1 CONTROL BOARD 1 3 5 21 15 24 20 22 RED RED RED BLUE YELLOW BLUE GREY BROWN THERMOSTAT R R TRANSFORMER 120 24V 40VA RED 1 2 MOTOR ECM 16 PIN CONTROL CONNECTOR 8 16 3 1 12 10 9 GREEN RED BLUE BLACK ...

Page 39: ...Canadian Air Handler Installation and Operation Manual 39 ...

Page 40: ...lays AC HP On Fan delay when heat pump starts 5 120 5 AC HP Off Fan delay when heat pump stops 5 240 90 Heat On Fan delay when engine starts 5 120 5 Heat Off Fan delay when boiler stops 0 240 120 1 Ratio in percentage of max airflow Y2 2 Ratio in percentage of max airflow of 1600 CFM 3 Ratio in percentage of max hydronic heating airflow W W2 4 Ratio in percentage of heating airflow W1 or W2 5 Redu...

Page 41: ...dify the airflow dur ing the heat off delay Parameter Description Recirculation Allows you to set the time before the unit will recirculate the water for one minute W1 RATIO Allows you to modify the pump ratio speed on the first stage of heating Purge Cycle Time during which the pump will operate after a call for heat to recu perate the residual heat from the water heater heat exchanger Purge Rati...

Page 42: ...to set the wait time before the fan starts when a call is made on Y1 or Y2 AC HP OFF This parameter allows to set the time the fan will keep running after the end of a call on Y1 or Y2 HEAT ON This parameter allows to set the wait time before the fan starts when a heating call is made on W1 or W2 HEAT OFF This parameter allows to set the time the fan will keep running after the end of a call on W1...

Page 43: ...609000073 FILTERT RACK END 13 609000074 FILTER RACK FRAME 14 608000033 BLOWER 15 605000045 MOTOR 3 4 HP Item Part Number Description 16 609000075 SCREW TEKS WSH 8 18 X 1 2 17 605000046 CAPACITANCE 18 609000076 LEG AND BELLY BAND ASSEMBLY 19 607000035 PUMP KIT 20 605000047 CONTROL PANEL 21 605000048 24V RELAY 22 605000049 TRANSFORMOR 23 609000077 CONTROL TERMINAL LABEL 24 605000050 REPLACEMENT CONT...

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