MODEL: EX38DT (RHFE-1006FTA) Direct Vent Wall Furnace Installation and Operation Manual RHF1006-1750(02)
WARNING — If the informa on in these instruc ons is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. — Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. — WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone.
Contents 1. Welcome ......................................................................................................................................4 1.1 To The Installer ..................................................................................................................4 1.2 To The Consumer ..............................................................................................................4 1.3 Acronyms and Abbreviations ........................................................
1. Welcome Thank you for purchasing a Rinnai Direct Vent Furnace. Before installing and operating the direct vent furnace, be sure to read these instructions completely and carefully to familiarize yourself with the direct vent furnace's features and functionality. 1.1 To The Installer It is recommended that a trained and qualified professional who has attended a Rinnai training class complete the installation. The warranty may be voided due to any improper installation.
2. Safety 2.1 Safety Symbols 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. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in personal injury or death. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in personal injury or death.
WARNING CAUTION When an existing Category I heater is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. Instructions shall also indicate effects of an improperly sized venting system (formation of condensate, leakage, spillage, etc.) and shall specify the following test procedure. Do not block the warm air discharge. Do not allow anyone to sleep directly in front of the furnace.
3. About the Direct Vent Furnace Topics in this section Main Components Specifications Dimensions 3.1 Main Components Front View Back View ❼ ❻ ❶ ❺ ❽ ❾ ❿ ⓯ ⓮ ❷ ❹ ⓫ ❸ Figure 1: Front View ⓭ ⓬ Figure 2: Back View ❻ Air Filter ❼ Gas Connection (1/2 in.
3.2 Specifications Table 2: Specifications EX38DT Application Approved for manufactured home (USA only) or mobile home or residential installation convertible for use with natural gas and liquefied petroleum gases (propane) when provision is made for the simple conversion from one gas to the other. Approved for commercial setting. Approved for installation at altitudes up to 10,200 feet (3,109 m). Natural Gas Liquid Propane Gas Min. Supply Gas Pressure 3.5 in. (89 mm) wc 8.0 in. (203 mm) wc Max.
3.3 Dimensions IMPORTANT A full size wall template is provided on the furnace carton box. Do not discard until installation is complete. Measurements: inches (mm) Front View (Including Sample Wall Template Located on Furnace Carton Box) Center of Furnace Wall Bracket Wall Opening Position The hole center should be within the shaded area.
4. Installation Topics in this section Installation Guidelines What You Will Need Choose an Installation Location Installation Steps Post-Installation Checklist THIS SECTION IS INTENDED FOR THE INSTALLER Installer qualifications: A trained and qualified professional must install the furnace, inspect it, and leak test the direct vent furnace before use. The warranty may be voided due to any improper installation.
4.2 What You Will Need 4.2.1 Items Included Unpack the Rinnai Direct Vent Furnace package and verify the following contents are included. If any items are damaged or missing, contact your local dealer/distributor or call Rinnai Customer Care at 1-800-621-9419. IMPORTANT A full size wall template is provided on the furnace carton box. Do not discard until installation is complete.
4.2.
4.3.2 Clearances Flue Terminal Clearances Clearance in Ref.
Clearances to Combustibles When determining where to install the direct vent furnace, the clearances to combustibles shown in the figures below must be followed. CAUTION If clearances are not met, damage to the property or direct vent furnace may occur. Top Table 6: Clearance to Combustibles Location Front Back Clearances to Combustibles Top 0 in. (0 mm) Bottom/Ground 0 in. (0 mm) 40 in. (1 m)* Side Front (Panel) *Does not include flooring material or carpeting less than 1.2 in.
4.3.3 Installation Location Checklist Use this checklist to ensure you have selected the correct location for the direct vent furnace. The furnace is not exposed to corrosive compounds in the air. The furnace location complies with the required clearances. The planned venting termination/air intake location meets the clearances. Indoor air is not being used for combustion. A standard 3 prong 120 VAC, 60 Hz properly grounded wall outlet is available.
4.4 Installation Steps 4.4.1 Drill the Flue Hole Ensure that there are no gas or water lines, or electrical circuits in the wall location where the flue hole is to be drilled. Drill the flue hole using a Ø3 1/8 in. (Ø80 mm) drill. A template is provided on the furnace carton box. The center of the hole must be located anywhere within the shaded area, unless extension kits are used. See the dimensions diagram.
4.4.3 Attach Back Spacers Attach side back spacers to both sides of the furnace with 2 screws each. Instructions: 1. Disassemble the flue manifold The flue consists of 3 parts: sleeve inside connection outside terminal Disassemble the flue manifold by first pulling out the inside connection. To remove the outer terminal pull and release the two internal ties and then pull out the outer terminal. Clearance to combustibles for the sleeve and flanges is zero inches.
3. Install the Sleeve. Attach the sleeve to the inside wall using 3 screws arranging the flange so that the marking “TOP” is at the top. The flange is offset 2° to allow the condensate drain to the outside. Apply silicone sealing evenly around the perimeter of the outside sleeve to avoid water intrusion. Sleeve should extend 3/16 - 3/8 in (5-10 mm) Outdoor Indoor Apply silicone sealing evenly around the perimeter. 3 screws Figure 14 4. Install the Terminal. Check that the terminal seal is in place.
5. Lock the ties. Pulling hard on the left and right hand ties, clip the ties over the notches inside the sleeve. You should be able to pull the ties 2 or 3 notches past the starting point. Cut the ties, leaving about 1 1/4 inch (30 mm) past the notch. Bend the ties back into the sleeve and parallel to the wall. Locking ties Sleeve Locking tie Clip the ties over the inside sleeve and cut the ties sticking out. Pull hard on the left and right hand ties.
4.4.5 Install the Optional Extension Kit Extension kits are available to extend the exhaust line and air intake hose between the manifold and direct vent furnace. Follow the steps in this section if the optional extension kit was purchased for your Direct Vent Furnace model.
Guidelines 1. The maximum vent length is 13 feet (4 m) with 3 bends. The bent pipe attached to the furnace does not count toward the max limit of 3 bends. 2. Horizontal sections should be sloped 3º to drain condensate. (3º equals 2/3 inch drop per foot of vent.) The direction should be to the outside (if local codes allow) or toward the furnace. 3. Do not allow any low points in the exhaust line where condensate will collect. 4. Vent extensions installed in unconditioned air space. 5.
Incorrect Configurations NOT CORRECT NOT CORRECT Back of Furnace Too many bends (limit is 3) Air intake hose is above exhaust pipe. Do not allow any low points in the exhaust line.
Instructions: CAUTION Female end Male end Pipe stopper B Use the pipe stoppers, connectors, clamps, and screws according to these instructions in order to ensure no leakage of exhaust gases. 1. Install the Clamps: Both the exhaust line and air intake hose are supported by clamps which are attached to the wall. A wall fixture can be used to offset the clamp from the wall. Use Screw B to attach the wall fixture to the wall.
4.4.6 Connect the Direct Vent Furnace 1. Attach flue adapter to the flue manifold with pipe stopper S. 5. Attach the furnace to the wall brackets, using 2 screws at each bracket. 2. Attach the air inlet hose to the flue manifold. Secure with plastic tie. The unused inlet is plugged with the rubber cap supplied on the manifold. Pipe Stopper S Flue Manifold Flue Adapter Screw (M5) Plastic Tie Figure 30 Inlet Hose 6. Attach the back spacer with 3 screws to the top of the furnace.
4.4.7 Connect the Gas WARNING When connecting the gas valve or other gas components in the gas line, use a backup wrench to ensure the connection is gas tight. The gas supply line shall be gas tight, sized and so installed as to provide a supply of a gas sufficient to meet the maximum demand of the furnace without loss of pressure. A shut off valve and appliance connector valve should be installed in the upstream of the gas line to permit servicing.
Instructions: 1. Turn off the gas and the power supply. 2. Remove the 3 screws that hold the front panel. Lift the panel straight up and then remove. PCB Test Switch 3. Remove test port screws (1/8 NPT tap) with 3/16 Allen wrench located at gas valve and burner cover. Install two 1/8 in. barb fittings (fieldsupplied). Attach dual port manometer to the test ports as shown. Ensure that the manometer is properly calibrated. Positive Port 4. Turn on the gas and power supply to the furnace. 5.
8. Press the Test Switch twice to enter the gas code into memory. The LED display turns blank and the unit returns to the normal off mode. You are now ready to program your correct low fire and high fire gas pressure setting. Follow the procedure below for setting the manifold gas pressure. Do not adjust gas pressure on this furnace using the screw on top of the gas valve. 9. Press the ON/OFF button to operate the furnace. 10. Press the Test Switch twice to change to the low pressure mode.
4.5 Post-Installation Checklist Complete the following checklist when installation is complete. You should be able to answer YES to each question. If you answer NO to any question, installation is not complete. Refer to the applicable section in this manual for additional information. For assistance, contact your local dealer or distributor, or call Rinnai Customer Care at 1-800-621-9419.
5. Operation Topics in this section Safety Precautions Operating Instructions Control Panel Basic Operation Settings Add Water to the Humidifier Adjust Air Flow Direction Restart Function Diagnostic Codes 5.1 Safety Precautions WARNING — If the informa on in these instruc ons is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
5.2 Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas.
5.3 Control Panel The direct vent furnace includes a controller integrated into the front cover. Each feature on the control panel is described in the following sections. Figure 35: Control Panel Sensible Temperature Control The sensible temperature control feature allows comfortable heating which matches the conditions in the room.
5.4.2 Lock The Lock feature will help to prevent accidental operation of the furnace and to prevent children from operating the furnace. To activate Lock, press the Lock button. The indicator will light and a beep will sound. To deactivate Lock, press the Lock button and hold for about 2 seconds. The indicator light will go out and a beep will sound. The lock can be activated when the furnace is ON or OFF. If activated while the furnace is ON, all controls other than the OFF switch will be locked.
5.4.5 Remote Thermostat Mode (Optional Accessory) A remote thermostat can be installed for the furnace with the Remote Thermostat Installation Kit (Part # 204000045 for US installations, Part # 204000048 for Canadian installations). Once installed, the furnace must be placed in Remote Thermostat mode by following the steps below: 1. Ensure the furnace is plugged in but is turned OFF. 2. Ensure the Set back feature is turned OFF. 3. Press and hold the Economy + Up + Program buttons for 2.
5.4.6 Setting and Operating the Timers 5. Press the “Program” button again to set the times for Timer 2. Follow the same steps above to set the start and end times. 6. Press the “Program” button until none of the time options are flashing up. Confirm the clock is correct. NOTE: The clock will have to be reset in case of a power failure. However the timers will retain their settings. The furnace will start before the programmed starting time in order to heat the room by the programmed starting time.
5.4.8 Economy (Energy Saving Mode) The Economy mode can only be set while the furnace is operating (heating). Once it is set, it will remain in the system memory until deactivated. 1. To turn the Economy mode on, press the “Economy” button. The Economy indicator is lit. Figure 49 The Economy mode now remains in the system memory. 5.4.
5.5 Add Water to the Humidifier Do not bend repeatedly (no more than 5 times) or else the louver may break. The horizontal louvers (which determines the vertical air flow direction) are fixed and cannot be adjusted. CAUTION Do not fill the tray while the furnace is in operation. Close the door after filling. The humidifier tray and surrounding area are hot when the furnace is on.
5.8 Diagnostic Codes If there is a malfunction the furnace may shut down as a safety precaution and display a fault code to assist in diagnosing the problem. The fault code will flash in the display on the control panel. When making a service call, this code will assist with diagnosing the fault. You may be able to clear the fault code by turning the furnace off and then on again.
6. Maintenance This direct vent furnace must be inspected annually by a trained and qualified professional. Repairs and maintenance must be performed by a trained and qualified professional. The trained and qualified professional must verify proper operation after servicing. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners, and circulating air passage ways of the furnace be kept clean.
7. Troubleshooting Before making a service call, please check the following: AT IGNITION: Heater does not operate. Is the heater plugged in? Have the fuses or breaker blown at the fuse box / breaker panel? Is there a power failure? Is the air filter blocked? Is anything blocking the outlet for the hot air? Is the flue blocked? Warm air does not flow when the burner lights. The fan is started automatically after a short delay.
Additional Troubleshooting Remedies Table 10: Troubleshooting Remedies Issue No ON Indicator No Burner Ignition Not Plugged in Power Failure (Initial Installation) Air in Gas Pipe Gas Filter Blocked Missed Ignition Abnormal Loss of Gas Noisy Takes too Combustion Combustion Smell Ignition Long to Warm Room Plug in Restart Unit Purge Air (Installer) Service Call Service Call Flue Terminal Obstructed Remedy Flue Manifold Not Connected Clear Obstruction
8.
Exploded View of Service Parts Figure 59 42 EX38DT Installation and Operation Manual
Exploded View of Service Parts Figure 60 EX38DT Installation and Operation Manual 43
Exploded View of Service Parts Figure 61 44 EX38DT Installation and Operation Manual
Exploded View of Service Parts Figure 62 EX38DT Installation and Operation Manual 45
Exploded View of Service Parts Figure 63 46 EX38DT Installation and Operation Manual
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9. Appendices Topics in this section Massachusetts State Gas Regulations Wiring Diagram Ladder Diagram 9.1 Massachusetts State Gas Regulations For Gas Models Sold in Massachusetts NOTICE BEFORE INSTALLATION: This direct-vent appliance must be installed by a state qualified or licensed contractor and a properly trained Rinnai Installer. If you are not properly trained, you must not install this unit. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 and 5.
9.2 Wiring Diagram CAUTION Mark Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Parts Name Mark Parts Name MS Main Switch W.TH R.TH Room Thermistor OH.
9.3 Ladder Diagram A: DC5V B: DC12V C: DC15V D: DC24V E: DC170V F: AC24V Mark Parts Name Mark Parts Name MS Main Switch SP Sparker R.TH Room Thermistor OH.
10. Warranty Models EX08DT, EX11DT, EX17DT, EX22DT, EX38DT What is Covered? The Rinnai Standard Limited Warranty covers any defects in materials or workmanship when the product is installed and operated according to Rinnai written installation instructions, subject to the terms within this Limited Warranty document. This Limited Warranty applies only to products that are installed correctly in the United States and Canada. Improper installation may void this Limited Warranty.
What Is Not Covered? This Limited Warranty does not cover any failures or operating difficulties due to the following: Accident, abuse, or misuse Alteration of the product or any component part Misapplication of this product Force majeure Improper installation (such as but not limited to, condensate damage, improper venting, Incorrect gas type, or incorrect gas pressure) Improper conversion (including conversions for inventory adjustment) Improper maintenance (such as but not lim
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