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8 

 

 

Hydronic Air Handler Installation and Operation Manual 

 

The ductwork in the above image is for representation purposes only; it is not a 
complete system. Please follow standard duct 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 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

 

Summary of Contents for AH083CP

Page 1: ...Hydronic Air Handler Installation and Operation Manual 1 ...

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

Page 3: ...fy 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...

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: ...oning and Ventilating Systems NFPA 91 latest edition 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 L...

Page 6: ... 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 store...

Page 7: ...s water heater boiler Water Outlet Cold Water Returning to Water Heater Boiler Bottom HVAC Duct Return 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 TOP BOTTOM 1 120V Power Supply Knockout Access Port Located on right side panel for ...

Page 8: ...on 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 Water From Water Heater Boiler into Air Handler Cold Water From Air Handler Returning to Water Heater Boiler Example Vertical Upflow with Side Return...

Page 9: ...an air return opening Securely attach the air handler to the supporting frame The air handler is approved for the following configurations Vertical Upflow with bottom or side left or right side return Horizontal Upflow with bottom return SUPPLY Upflow RETURN The air handler is not approved for the following configurations The air inlet is not allowed in the front or back of the air handler Front B...

Page 10: ... Voltage 120 V 60 Hz 1 Ph Transformer Size and Type 40 VA Class 2 Blower Wheel Diameter x Width 9x6 in 9x6 in 10x8 in 10x8 in 10x10 in Blower Motor Type 3 Speed PSC Blower Motor Hot Water Coil Rows 3 4 3 Blower Motor Coil Material Copper Coil UV Resistant Pan Blower Motor Horsepower HP 1 3 1 3 1 2 3 4 3 4 Blower Full Load Amps FLA 5 3 5 3 7 1 7 5 10 5 Water Connection 3 4 in Sweat Pump Voltage 120...

Page 11: ...nal Output Btu hr at 140 F1 30 000 40 000 50 000 60 000 60 000 Rated Voltage 120 V 60 Hz 1 Ph Transformer Size and Type 40 VA Class 2 Blower Wheel Diameter x Width 9x6 in 9x6 in 10x8 in 10x8 in 10x10 in Blower Motor Type 3 Speed PSC Blower Motor Hot Water Coil Rows 3 4 3 Coil Material Copper Coil UV Resistant Pan Blower Motor Horsepower HP 1 3 1 3 1 2 3 4 3 4 Blower Full Load Amps FLA 5 3 5 3 7 1 ...

Page 12: ...r models AH083P CP and AH206P CP Domestic hot water recirculation circulates hot water through the plumbing system so that instant hot water is available Domestic hot water recirculation operates between calls for heat to ensure a balance of comfort for HVAC heating and domestic hot water If pairing a Rinnai Hydronic Air Handler with a tankless water heater for domestic hot water recirculation cap...

Page 13: ...ing Water Temperature Blower Speed Btu hr Low Medium High AH083CP 120 F 21 000 23 000 25 000 140 F 29 000 32 000 34 000 160 F 38 000 41 000 45 000 AH084CP 120 F 23 000 26 000 28 000 140 F 32 000 35 000 39 000 160 F 41 000 45 000 49 000 AH125CP 120 F 32 000 34 000 35 000 140 F 44 000 46 000 49 000 160 F 57 000 60 000 63 000 AH166CP 120 F 42 000 43 000 44 000 140 F 57 000 59 000 61 000 160 F 74 000 ...

Page 14: ... 000 32 000 35 000 160 F 38 000 41 000 45 000 AH084P 120 F 23 000 25 000 27 000 140 F 32 000 35 000 39 000 160 F 41 000 46 000 50 000 AH125P 120 F 32 000 34 000 35 000 140 F 45 000 47 000 50 000 160 F 58 000 61 000 64 000 AH166P 120 F 41 000 43 000 44 000 140 F 58 000 60 000 62 000 160 F 75 000 78 000 80 000 AH206P 120 F 41 000 42 000 43 000 140 F 58 000 60 000 61 000 160 F 76 000 77 000 79 000 IM...

Page 15: ... 4 543 I 17 5 445 17 5 445 16 5 419 H A I G F B Water In Water Out Line Voltage1 120V Supply Low Voltage Thermostat 24V Supply 2 RIGHT SIDE 2 8 71 16 406 1 6 41 16 406 FRONT TOP C NOTE CP Models with Internal Circulation Pump P Models without Internal Circulation Pump 1 Line Voltage knockout is located at the specified height on the cabinet right side panel for models AH083P CP AH084P CP AH125P CP...

Page 16: ...n domestic hot water demand exceeds a certain point the air handler will turn off to ensure the demand is met REU OPU3 Pipe Cover Enclosure Part Encloses the piping below the tankless water heater or boiler for aesthetic purposes Pipe cover for HE Series RL Non Condensing Tankless Water Heater Models PCD03 SM2 Pipe cover for SENSEI SE Series RU Condensing Tankless Water Heater Models and I Series ...

Page 17: ...8 Blower Motor 1 3 HP 120 Volt 60 Hz 605000040 1 1 0 0 0 1 1 0 0 0 Blower Motor 1 2 HP 120 Volt 60 Hz 605000041 0 0 1 0 0 0 0 1 0 0 Blower Motor 3 4 HP 120 Volt 60 Hz 605000042 0 0 0 1 0 0 0 0 1 0 Blower Motor 3 4 HP 120 Volt 60 Hz 605000043 0 0 0 0 1 0 0 0 0 1 9 9 x 6 Blower Housing Assembly 608000029 1 1 0 0 0 1 1 0 0 0 10 x 8 Blower Housing Assembly 608000030 0 0 1 1 0 0 0 1 1 0 10 x 10 Blower ...

Page 18: ...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 p...

Page 19: ... 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 Clearances to combustible material is 0 in to plenum and duct for first 36 in 914 mm and throughout the remaining ductwork system IMPORTANT If the free area is not known...

Page 20: ...binet 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 on the blower section for specific informat...

Page 21: ...wer 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 therm...

Page 22: ...witch 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 ground terminal marked GRD Failure to do so can result in death or elect...

Page 23: ...r 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...

Page 24: ...twork 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 Example Horizontal Installation SUPPLY RETURN Vertical Upflow with bottom or side left or r...

Page 25: ...r handler black to black and white to white Note Electrical cables go through the knockout holes on the left or right side of the cabinet See the images below for specific locations Models AH083P CP AH084P CP AH125P CP AH166P CP Left Side Right Side Power Supply Knockout Thermostat Connection Knockout Model AH206P CP Left Side Right Side Power Supply Knockout Thermostat Connection Knockout 7 Conne...

Page 26: ...eeding this value may cause the air handler control board to operate abnormally Hot Water Heat Only Application Cooling Application with Hot Water Heat R R G W G W RED Thermostat Air Handler GRN WHT R R G W G W1 C C Y1 Y1 Y1 Y2 Y2 Y2 RED GRN WHT YEL YEL BLU BLU Thermostat Air Handler Condensing Unit NOTE Connect common C wire only if required See thermostat installation instructions for more infor...

Page 27: ...demand exceeds a certain point the air handler will turn off to ensure the demand is met The Domestic Priority Switch is a Normally Closed NC switch that connects to the PC Board in the Rinnai tankless water heater or boiler To install the Domestic Priority Switch open the contents of the Domestic Priority Switch shipping package and follow the remaining instructions in this section You Will Need ...

Page 28: ...nect one end of the accessory cable to the accessory port on the PC Board Connect the other end of the cable to the switch circuit board accessory port PC Board accessory port Switch circuit board accessory port Accessory cable Internal Indoor Units External Outdoor Units 6 Install the switch circuit board to the controller bracket using the hooks at the top of the controller bracket ...

Page 29: ...pply to the water heater and hydronic air handler is disconnected before starting installation Removing the front cover will expose live mains voltage connections 1 Power OFF the tankless water heater or boiler by unplugging the power cord or turning off the circuit breaker The controller on the water heater or boiler does not control the electrical power 2 Remove the front panel of the water heat...

Page 30: ...at Wiring Using the provided crimp connectors B in image on previous page connect the white and black leads of the switch circuit board to the W contact on the indoor thermostat and air handler polarity is not important See Table 1 below and the wiring diagrams in this section for additional details The final crimp connector should be connected to the unused red wire lead on the switch circuit boa...

Page 31: ...allation and Operation Manual for more information 1 Power OFF the boiler by unplugging the power cord or turning off the circuit breaker The controller on the boiler does not control the electrical power 2 Remove the front panel of the boiler by removing the four screws that secure the panel in place 3 Locate the PC Board in the bottom left corner of the boiler 4 Connect one end of the boiler air...

Page 32: ...escribed in Table 2 2 Check all wiring and reattach the front cover 3 Reconnect power Table 2 Domestic Priority Configuration Switch Configuration Required Leads Wires Function Generic Air Handler White Black Normally Closed External Pump Connection 1 To Domestic Priority Switch PC Board Wiring for the above application example 5 6 3 2 Wiring Instructions 5 6 3 3 Next Steps Proceed to the next sec...

Page 33: ...s 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 To test this function 1 Turn on the water heater boiler and air handler 2 Open the hot water taps until the air handler turns off 3 Close the hot water taps 4 The air handler should turn back on if the thermostat is calling for heat Rinnai Tankless Water...

Page 34: ...lation and Operation Manual Single Stage A C Cooling with Single Stage Heating Single Stage Heat Pump Y Y Domestic Priority Switch Domestic Priority Switch Single Stage Heat Pump with Auxiliary Backup Heat Y Domestic Priority Switch ...

Page 35: ...formation 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 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 s...

Page 36: ...essary 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 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 Reci...

Page 37: ...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 Cold Water Supply Line Gas Supply Line Hot Water Outlets Thermostat Thermostatic Mixing Valve Rinnai Hydronic Air Handler with Integrated Pump and Check Valve Aquastat Connection Condensation Drain Line as Appropriate Re...

Page 38: ...the contractor or engineer to ensure the installation is in accordance with all local building codes Confer with local building officials before installation Demand Circulation Cold Water Supply Line Thermostat Thermostatic Mixing Valve Rinnai Hydronic Air Handler with Integrated Pump and Check Valve Condensation Drain Line as Appropriate Recommended Rinnai Domestic Priority Switch Gas Supply Line...

Page 39: ...ondensing unit installation instructions for system start up instructions and refrigerant charging instructions Is unit properly located secure and serviceable Is the unit elevated when installed in a garage or where flammable vapers may be present Is the unit protected from vehicular or other physical damage Is the return air not obtained from areas where there may be objectionable odors flammabl...

Page 40: ...125P CP AH206P CP 1 Disconnect all power supplies 2 Remove the air handler access panel 3 Locate the blue wire Med running from the blower motor to the control board 4 Remove this blue wire from the control board and cover this loose end of this wire now with an insulating cap 5 Locate the Red or Black wires connected to the blower motor Connect the Red Low to the control board at its respective t...

Page 41: ...to the pump directly or to an isolation valve supplying hot water to the air handler using the control board s 24V relay switch A similar 24V dry switching relay labeled TT can be used to activate a boiler or water heater valve A time delay of 60 seconds follows before the thermostat circuit between R and G are complete activating the blower motor The thermostat circuit between R and W is complete...

Page 42: ...ctrical shock burns or other conditions which may cause electrical shock personal injury property damage or death WARNING To service the air handler follow the steps below 1 Turn off power to the unit 2 Remove the four screws securing the front panel 3 Perform service or maintenance to the air handler and then reinstall the four screws to secure the front panel Maintenance At the beginning of each...

Page 43: ...Hydronic Air Handler Installation and Operation Manual 43 Specific blower wire connections may vary by model IMPORTANT ...

Page 44: ... personal injury or death WARNING Fan Motor Speed Wire Lead Color Code Speed Color High Black Medium Blue Low Red 6 Connect the unused wire lead to the Blank tap 7 Replace the air handler access panel The speed of the air handler is factory default set as per the table to the right To adjust speed settings follow the steps below 1 Disconnect power to the air handler 5 Remove the desired wire lead ...

Page 45: ...gree Elbow 34 56 18 4 Straight Through Tee 4 8 2 08 Side Port Tee 49 92 20 32 Reducer Coupling 8 32 4 32 Ball Valve 10 56 6 88 PEX x NPT 8 64 6 08 Multiplier Per Linear Foot of Pipe 3 2 1 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...

Page 46: ...000 37 000 36 000 50 70 Medium 21 000 24 000 32 000 38 000 37 000 High 23 000 26 000 33 000 39 000 37 000 140 F Low 25 000 31 000 42 000 53 000 51 000 Medium 30 000 34 000 45 000 54 000 52 000 High 32 000 37 000 46 000 56 000 53 000 160 F Low 33 000 40 000 55 000 68 000 66 000 Medium 39 000 44 000 58 000 70 000 68 000 High 42 000 48 000 60 000 72 000 69 000 120 F 4 Low 21 000 23 000 32 000 41 000 ...

Page 47: ...3 000 41 000 High 24 000 28 000 36 000 44 000 42 000 140 F Low 29 000 32 000 46 000 58 000 57 000 Medium 32 000 36 000 48 000 60 000 58 000 High 35 000 39 000 51 000 62 000 60 000 160 F Low 38 000 42 000 59 000 75 000 74 000 Medium 41 000 47 000 62 000 78 000 76 000 High 45 000 51 000 66 000 80 000 77 000 Models i060C i090C i120C 1 Refer to section 8 3 1 Equivalent Feet of Pipe Per Fitting for mor...

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