Rinnai CAH Series User manual

CUS

2 Canadian Air Handler Installation and Operation Manual

Canadian Air Handler Installation and Operation Manual 3
• You must read the entire manual to
properly operate the air handler.
• It is recommended that a trained and
qualified professional who has attended a
Rinnai installation training class complete
your installation.
• Keep this manual for future reference.
Dealer Name:
Located on top of unit
Dealer Phone:
Purchase Date:
Serial #:
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.
The air handler must satisfy all the
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 have skills such as:
− Connecting water lines, valves,
electricity
− Knowledge of applicable national,
state, and local codes
− Installing ductwork and other HVAC
equipment
− Training in installation of air handlers.
Training on Rinnai’s hydronic air
handler is accessible at www.rinnai-
lms.com.
• Read all instructions in this manual before
installing the hydronic air handler. The
hydronic air handler must be installed
according to the exact instructions in this
manual.
• When installation is complete, leave this
manual with the air handler or give the
manual directly to the consumer.
• Proper installation is the responsibility of
the installer.

4 Canadian Air Handler Installation and Operation Manual
Indicates an imminently hazardous
situation which, if not avoided, will result
in personal injury or death.
Indicates a potentially hazardous situation
which, if not avoided, could result in personal
injury or death.
Indicates a potentially hazardous situation
which, if not avoided, could result in minor
or moderate injury. It may also be used to
alert against unsafe practices.
DANGER
WARNING
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.
CAUTION
The following precautions apply to the installer
and consumer. Read and follow all instructions in
this section.
• Before any work is undertaken, it is
imperative to observe all precautions as
stated in this manual.
• Wear safety glasses and work gloves.
Before installing or servicing the air handler,
turn off the power to unit. There may be more
than one disconnect switch. 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 substitute materials. Use only
parts certified for the air handler.
• Do not use an extension cord or adapter plug
with this air handler.
• Any alteration to the air handler can be
dangerous and will void the warranty.
• This air handler must be installed indoors.
• Improper installation, modification, service,
maintenance or use of the air handler can
cause electrical shock, burns or other
conditions which may cause personal injury
or property damage.
• It is recommended that a trained and
qualified professional who has attended a
Rinnai installation training class complete
your installation.
• Read these installation instructions carefully
and adhere to all warning and caution
statements. Consult local building codes,
Occupational Safety and Health
Administration (OSHA), and National
Electrical Code (NEC) for special
requirements.

Canadian Air Handler Installation and Operation Manual 5
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.
The hydronic air handler works with the following
Rinnai products:
• Rinnai Tankless Water Heaters:
− SENSEI™ SE+ Series
(RU Condensing Models)
It is the responsibility of the installer to follow all
national codes, standards and local ordinances,
in addition to the instructions in this manual. The
installation must comply with regulations of the
local building, heating, plumbing, and other
codes. Where local codes are not applicable, the
installation must comply with the national codes
and all authorities having jurisdiction.
The following is a suggested list of codes and
standards for the United States and Canada:
General Installation
• Installation of Air Conditioning and
Ventilating Systems NFPA 91 (latest edition)
• CSA B214-01 Installation Code for Hydronic
Heating Systems
Duct Systems
• 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
SMACNA; NFPA 90B as tested by UL
Standard 181 for Class I Rigid Air Ducts
Electrical Connections
• US: National Electrical Code (NEC) ANSI/
NFPA 70 (latest edition)
• CANADA: Canadian Electrical Code CSA
C22.1 (latest edition)
Plumbing Systems
• US and CANADA: ICC International
Plumbing Code (IPC); Uniform Mechanical
Code (UMC); Uniform Plumbing Code
(UPC), National Plumbing Code (NPC)
Refer to section “3.7 Specifications” for a
complete list of product specifications.
NOTE
NOTE
Tankless water heaters must have a
minimum input rate of 160,000 Btu/hr.
RUR condensing model water heaters
are not approved for use with this is air
handler.
• Rinnai Boilers:
− I-Series (Condensing) Combi Models
If utilizing a boiler, ensure the output of
the boiler exceeds the capacity of the
air handler in use (the boiler Btu/hr
rating must be greater than the air
handler Btu/hr rating).
NOTE

6 Canadian Air Handler Installation and Operation 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.
• Use proper lifting techniques to load the
equipment onto a hand truck.
• Position the equipment onto the hand
truck so 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 to 60°F (15°C) before the
start of assembly.
• All components must be stored in the
original packaging.
Example:
CAH050CE
CAH 050 E
Blower Motor
E = ECM Motor
Nominal Heating Capacity
at 3GPM and 140° F
050 = 50,000 BTU
Series
CAH Series
C
Accessory
Circulator Pump
included with the
air handler (if
applicable)

Canadian Air Handler Installation and Operation Manual 7
Bottom HVAC
Duct Return
TOP
BOTTOM
• Reference to the "top" and "bottom"
are referring to the location in this
image and will not change based on
orientation of the product.
• Cover is removed in above 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 Return
Control Panel
120V Terminal
Acoustic Wool

8 Canadian Air Handler Installation 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

Canadian Air Handler Installation and Operation Manual 9
The above image is for representation purposes only; it is not a complete system.
Please follow standard design protocols for installation.
RETURN
(Air Flows 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) Configuration

10 Canadian Air Handler Installation and Operation
CAH050E CAH050CE
Appliance Type
Hydronic Air Handler
(Without Accessory Circulation
Pump)
Hydronic Air Handler
(With Accessory Circulation
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 (56.7)
Construction
Cabinet: 22 Gauge powder coated steel
Inner panels: 22 Gauge galvanized steel
Insulation: 1/2” inside blower compartment and door
Nominal CFM (Cubic Feet/Minute) 1600 up to 0.7 in. W.C.
1200 up to 1.2 in. W.C.
Nominal Output Btu/hr at 140°F150,000
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 water for one minute every 24 hours
to prevent stagnation of water in the system (default)
P9-11 Energy Efficiency Rating (TPF) 0.88 with RU160i tankless water heater*
Certifications CSA 22.2 No 236, UL-1995, NSF 372 (hydronic coil)
Rinnai products are continually being updated and improved; therefore, specifications are subject to
change without prior notice.
1 Reference tables in sections 3.7.2 for specific BTU output.
* Refer to P9-11 listings for latest information and results.

Canadian Air Handler Installation and Operation Manual 11
Values shown in following tables may vary depending on the static pressure of the duct system.
Coil Entering
Water
Temperature
(°F)
Flow Rate
(GPM)
Heat Fan Ratio (Air Flow)
Coil Pressure
Drop (PSI)
50%
(800CFM)
Temperature
Differential (°F)
75%
(1200 CFM)
Temperature
Differential (°F)
100%
(1600 CFM)
Temperature
Differential (°F)
120
223,100 27 27,500 21 35,400 21 1.42
326,000 30 33,600 26 40,300 23 2.36
428,000 32 37,500 29 43,900 25 4.38
140
233,700 39 42,000 32 47,500 28 1.41
337,300 43 48,300 37 56,500 33 2.34
438,400 44 54,000 42 62,700 36 4.38
160
243,100 50 54,800 42 62,600 36 1.41
348,000 56 62,100 48 73,100 42 2.34
451,200 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 140 37,500 49,100 57,400
I-Series 39,100 54,900 64,100
SENSEI 160 47,600 61,600 72,400
I-Series 52,000 67,500 81,700
Maximum Equivalent Piping
Distance (ft)
Flow (GPM) Sensei I-Series
2200 ft 200 ft
3150 ft 150 ft
With 20ft or less equivalent piping

12 Canadian Air Handler Installation and Operation
NOTE
• All values have
been normalized to
3/4 in. copper pipe
as a baseline.
• It is not
recommended to
use ½ in. piping as
the pressure drop is
considerably larger
than ¾ in. piping.
Copper
Diameter
Fitting 3/4 in. 1 in.
90 Degree Elbow 20.75
45 Degree Elbow 0.75 0.3
Straight Through Tee 0.4 0.135
Side Port Tee 31.35
Reducer Coupling 0.5 0.18
Gate Valve 0.25 0.09
Ball Valve 2.2 1.29
Swing Check Valve 31.35
Multiplier Per Linear Foot of Pipe 10.3
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 Per Linear Foot of Pipe 1.1 0.4
• 50 ft. of 3/4 in. CPVC pipe
• Four (4) 90 degree elbows
• Two (2) straight through tees
Total
Equivalent
Length
= 50 x 1.1 (Total linear foot equivalency)
+ 4 x 2.2 (Total for 90 degree elbows)
+ 2 x 1.54 (Total for tees)
Approximately 67 Equivalent Feet of Piping

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)

14 Canadian Air Handler Installation and Operation
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.
REU-OPU3
Product images are for illustrative purposes only.

Canadian Air Handler Installation and Operation Manual 15
Gather the required tools and parts before
starting installation. Read and follow the
instructions provided with any tools listed below.
• 1/4 in. nut driver
• Level
• Screwdriver
• Adjustable wrench
• Tape Measure
• Hammer
• AHRI Approved Duct Sealant
• UL listed wire nuts
When choosing an installation location, you
must ensure proper clearances will be met; the
installation environment; water quality; and the
need for freeze protection.
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.
Inspect the following:
• Check the air handler rating plate to confirm
specifications are as ordered.
• Upon receipt of air handler, thoroughly
inspect the system for possible shipping
damage. If the carton appears damaged,
closely examine the air handler inside the
carton.
• If the air handler appears to be damaged or is
torn loose from 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
original packages until installation.
Contaminant Maximum Level
Total Hardness Up to 200 mg/L
Aluminum * Up to 0.2 mg/L
Chlorides * Up to 250 mg/L
Copper * Up to 1.0 mg/L
Dissolved Carbon Dioxide
(CO2) Up to 15.0 mg/L
Iron * Up to 0.3 mg/L
Manganese * Up to 0.05 mg/L
pH * 6.5 to 8.5
TDS (Total Dissolved
Solids) * Up to 500 mg/L
Zinc * Up to 5 mg/L
* Source: Part 143 National Secondary
Drinking Water Regulations
This section provides information on the
importance of water quality to the air handler. The
information is intended to serve as general
guidelines only and is not a complete list of water
quality guidelines.
Consideration of care for the air handler should
include evaluation of water quality.
• The water must be potable, free of corrosive
chemicals, sand, dirt, or other contaminants.
• It is up to the installer to ensure the water
does not contain corrosive chemicals or
elements that can affect or damage the boiler
or tankless water heater.
• Water that contains chemicals exceeding the
levels below can damage the boiler or
tankless water heater.

16 Canadian Air Handler Installation and Operation
Replacement of components due to water
quality damage is not covered by the warranty.
• 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.
• Never use water that has been treated by a
reverse osmosis, deionized, or distilled
water to soften the water to fill the heating
system.
• Louvers or return air grilles are field-supplied.
Local codes may limit application of systems
without a ducted return to single-story
buildings.
• For a unit installed in a closet with a louvered
return opening, the minimum open area for
the louvers are:
Non-Ducted Return Closet Installation
• Clearances to combustible material is 0 in.
from unit casing, and 0 in. to plenum and
duct for first 36 in. (914 mm) and throughout
the 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 or grilles. Using the louver dimensions
and the 25% or 75% assumption, determine if
the louver open area meets the minimum open
area listed above.
• If the return air plenum is used, the return air
grille should be immediately in front of the
opening in the plenum to allow for the free flow
of return air.
• When not installed in front of the opening, there
must be adequate clearance around the air
handler to allow for the free flow of return air.
Air Handler Models Minimum Opening Area
• CAH050E
• CAH050CE
360 square inches
(0.23 square meters)
Clearances to
combustible
material is 0 in. to
plenum and duct for
first 36 in. (914 mm)
and throughout the
remaining ductwork
system.

Canadian Air Handler Installation and Operation Manual 17
• 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. Compliance with all local, state, or
national codes pertaining to this type of
equipment should be determined prior to
installation.
• Read this entire manual, as well as the
instructions supplied in separate equipment,
before starting installation.
• It is recommended that a trained and qualified
professional who has attended a Rinnai
installation training class complete your
installation.
• Installation of the air handler, field wiring, warm
air ducts, etc. must conform to the requirements
of the Canadian Electrical Code CSA 22.1,
National Electrical Code, ANSI/NFPA No. 70
(latest edition) in the United States, and any
state laws, and local ordinances (including
plumbing or wastewater codes). Local
authorities having jurisdiction should be
consulted before installation begins. Such
applicable regulations or requirements take
precedence over the general instructions in this
manual.
• 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 Air-Conditioning Systems (latest
edition). The blower section is provided with
flanges for the connection of the plenum and
ducts. Air filters must be listed as Class 2
furnace air filters. The blower section is shipped
from the factory 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, space, and routing requirements
for refrigerant line, condensate disposal,
filters, ductwork, wiring, and accessibility for
service. Refer to the rating plate for specific
information.
• When the unit is installed in a humid space
and used in cooling applications, excessive
sweating may occur on outside of unit. To
prevent excessive sweating wrap unit with
1 in. (25 mm) fiberglass insulation. All
openings should be sealed to prevent air
leakage that could cause condensate to form
inside the cabinet.
• Electrical wires should be sealed on the
inside where they exit the conduit opening.
Sealant is required to prevent air leakage and
condensate from forming inside the blower,
control box, and on the electrical controls.
• Glycol is permitted in installations with the
I-Series boiler up to 50% concentration. Refer
to the I-Series Condensing Boiler Installation
and Operation Manual for approved glycol
manufacturers.
• The air handler and its complementing
cooling coil must be installed in such a way
as to allow free access to the air handler/
control compartment.
The Clean Air Act of 1990 bans the
intentional venting of refrigerant (CFC’s and
HFC’s) as of July 1, 1992. Approved
methods of reclaiming must be followed.
Fines and/or incarceration may be levied for
non-compliance.
IMPORTANT
• Do not install this air handler if it is
damaged.
• Do not install this air handler if any part
or all of the unit has been under water.
Explosion Hazard:
• Keep flammable materials and vapors,
such as gasoline, away from this unit.
• Failure to follow these instructions can
result in death, explosion or fire.
WARNING

18 Canadian Air Handler Installation and Operation
• 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 Air-
Conditioning 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.
• The air handler is provided with flanges for
the connection of the plenum and ducts.
• Air filters must be listed as Class 2 furnace
air filters.
• Supply and return ductwork must be
adequately sized to meet the system’s air
requirements and static pressure
capabilities. Ductwork should be insulated
with a minimum of 1 in. (25 mm) thick
insulation with a vapor barrier in
conditioned areas or 2 in. (51 mm)
minimum in unconditioned areas.
• Supply plenum should be the same size as
the flanged opening provided around the
blower outlet and should extend ideally at
least 3 ft. (1 m) from the air handler 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
indoor equipment and the thermostat.
However, it is recommended to use a
common wire whenever possible to prevent
power stealing by the thermostat.
• Heat Pump Model: The standard model
heat pump thermostat is not "power
stealing" and must have both ‘R’ and ‘C’
wires connected to operate properly. The
thermostat should have an indicator for
when auxiliary heat is in use.
• The thermostat should NOT be mounted:
− Close to a window, on an outside wall,
or next to a door leading to the outside
− Exposed to direct light and heat from a
lamp, sun, fireplace, or other heat-
radiating objects which may cause a
false reading
− Close to or in direct airflow from supply
registers and return-air grilles
− In areas with poor air circulation, such
as behind a door or in an alcove
Before installing or servicing the air handler,
turn off power to unit. There may be more
than one disconnect switch. Electrical shock
can cause personal injury or death.
WARNING

Canadian Air Handler Installation and Operation Manual 19
• 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.
• The power supply must be sized and
protected according to the specifications
supplied on the product.
• This air handler is factory-configured for 120
Volts, single phase, 60 Hz.
• Prior to making any electrical connections,
ensure that supply voltage, frequency, and
phase are as specified on unit rating plate.
• Check to ensure that the existing electrical
service is adequate to handle the additional
load imposed by the Hydronic Furnace.
Refer to unit wiring diagram for proper
electrical connections.
• All electrical connections MUST comply with
NEC or CEC and any other local codes or
ordinances having jurisdiction. USE
COPPER WIRE ONLY. Provide separate
branch electric circuit with field supplied
disconnect switch.
• Location of disconnect switch to be 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 result in death or
electrical shock.
• Before installing or servicing the air
handler, turn off power to unit. There may
be more than one disconnect switch.
• If a disconnect switch is to be mounted on
the unit, select a location where a drill or
fastener will not contact electrical or
hydronic components.
• Electrical shock can cause personal injury
or death.
WARNING
Explosion Hazard:
• Keep flammable materials and vapors,
such as gasoline, away from this unit.
• Failure to follow these instructions can
result in death, explosion or fire.
WARNING
Line-Voltage Connections:
• U.S. Installations: Make all electrical
connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70 and all
local codes or ordinances having jurisdiction.
• Canadian Installations: Make all electrical
connections in accordance with Canadian
Electrical Code CSA C22.1 and all authorities
having jurisdiction.
• Check all factory wiring per unit wiring
diagram and inspect factory wiring
connections to be sure none were loosened in
transit.

20 Canadian Air Handler Installation and Operation
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.
If the piping is rigidly mounted, this expansion
can cause annoying popping or squeaking
sounds and in extreme cases, the piping can
even buckle.
To counter expansion movement, design piping
circuits with sufficient elbows, tees or expansion
loops (only used in large systems) or piping
supports that allow the tubing to expand and
contract freely.
Another alternative is to install an expansion
compensator fitting capable of absorbing the
movement.
Hydraulic Resistance of Fittings, Valves, and
Other Devices
Before the total hydraulic resistance of a piping
circuit can be found, the individual hydraulic
resistances of all fittings, valves, or other such
components must be determined. One approach
is to consider each fitting, valve, or other device
as an equivalent length of copper tube of the
same pipe size.
By using the equivalent length of piping for all
components in the circuit, the circuit can be
treated as if it were a single piece of pipe having
a length equal to the sum of the actual pipe
length, the total equivalent lengths of all fittings,
valves, or other devices.
Pipe Sizing Considerations
When selecting a pipe size 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 routed to an air separator where they can be
collected and discharged from the system.
Average flow velocities higher than 4 ft. (1.22 m)
per second could cause flow noise and
premature wear of piping and fittings and should
be avoided.
Expansion Tanks
All liquids used in hydronic heating systems
expand when heated. For all practical purposes,
liquids are incompressible. Any container
completely filled with a liquid and sealed from
the atmosphere will experience a rapid increase
in pressure as the liquid is heated. To prevent
this from occurring, all hydronic systems MUST
be equipped with an expansion tank. See the
following sections for the expansion tank
plumbing location:
• 5.9.1 Rinnai Tankless Water Heater and
Air Handler Piping Diagram
• 5.9.2 Domestic Hot Water Recirculation
Piping Diagram
• 5.9.3 Rinnai I-Series Boiler and Air
Handler Piping Diagram
• 5.9.4 I-Series Boiler with Hydraulic
Separation and Air Handler Piping
Diagram
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.
IMPORTANT
Solder joints on domestic water lines must be
made with NO-LEAD SOLDER.
WARNING