Rinnai EX38DT, Installation And Operation Manual

Page 1: ...MODEL EX38DT RHFE 1006FTA RHF1006 1750 02 Direct Vent Wall Furnace Installation and Operation Manual ...

Page 2: ...struc ons If you cannot reach your gas supplier call the fire department Installa on and service must be performed by a licensed professional WARNING Copyright 2022 Rinnai America Corporation Rinnai is a registered trademark of Rinnai Corporation used under license by Rinnai America Corporation Rinnai America Corporation continually updates materials and as such content is subject to change withou...

Page 3: ...es 10 4 2 What You Will Need 11 4 3 Choose an Installation Location 12 4 4 Installation Steps 16 4 5 Post Installation Checklist 28 5 Operation 29 5 1 Safety Precautions 29 5 2 Operating Instructions 30 5 3 Control Panel 31 5 4 Basic Operation Settings 31 5 5 Add Water to the Humidifier 36 5 6 Adjust Air Flow Direction 36 5 7 Restart Function 36 5 8 Diagnostic Codes 37 6 Maintenance 38 7 Troublesh...

Page 4: ...n The warranty may be voided due to any improper installation A trained and qualified professional should have skills such as Gas sizing Connecting gas lines valves and electricity Knowledge of applicable national state and local codes Installing venting through a wall Training in installation of direct vent furnaces Training on Rinnai Direct Vent Furnaces is accessible at rinnaipro myabsorb com R...

Page 5: ...ned and qualified professional Keep the area around the furnace clear and free from combustible materials gasoline and other flammable vapors and liquids Never store liquid propane containers indoors Do not use this furnace if any part has been under water Immediately call a trained and qualified professional to inspect the furnace and to replace any part of the control system and any gas control ...

Page 6: ... 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CSA B149 1 9 After...

Page 7: ...Cover Humidifier open panel to access Rating plate includes model number serial number gas type etc English is on the right side French is on the left side Air Filter Gas Connection 1 2 in 13 mm Male NPT Combustion Air Intake Hose Plastic Tie for Air Inlet Room Temperature Sensor Thermistor Power Cord and Plug Flue Manifold Combustion Exhaust Bent Elbow Exhaust Pipe Pipe Stopper Figure 2 Back View...

Page 8: ...n 1 2 in 13 mm Male NPT Gas Control Electronic Burners Stainless Steel Bunsen Burner Temperature Control Electronic Thermostat Low 60 80ºF 16 26 C in 2ºF 1 C Increments High Ignition System Electronic Spark Ignition Flue System The flue must be terminated to atmosphere with only flue components listed with the furnace s certification Warranty will be voided if non listed components are installed H...

Page 9: ...the furnace carton box Do not discard until installation is complete IMPORTANT Figure 3 Front View Figure 4 Side View Side View Front View Including Sample Wall Template Located on Furnace Carton Box Center of Furnace Wall Bracket Wall Opening Position Wall Opening Position The hole center should be within the shaded area ...

Page 10: ... 1 2 psi 3 5 kPa The furnace must be isolated from the gas supply piping system by closing its equipment shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 5 kPa If the flooring is carpet or other combustible material other than wood then the furnace must be installed on a metal or wood panel extending the full width and dept...

Page 11: ...acket Screws 7 Wall Brackets 2 Flue Adapter Attached to Unit 1 Rinnai Direct Vent Wall Furnace Installation and Operation 1 Image not shown For Weatherboard Installation Table 3 Items Included Name Kit No Fits Walls S Vent Kit FOT 150 3 4 1 2 in 75 115 mm A Vent Kit FOT 151 4 1 2 9 1 2 in 115 240 mm B Vent Kit FOT 152 9 1 2 15 3 4 in 240 400 mm C Vent Kit FOT 153 15 3 4 23 5 8 in 400 600 mm D Vent...

Page 12: ...ese vents when air is not being brought in through them Chemicals that are corrosive in nature should not be stored or used near the furnace or vent termination Damage and repair due to corrosive compounds in the air is not covered by warranty Pipe Wrenches x2 Adjustable Pliers Screwdrivers x2 Wire Cutters Gloves Safety Glasses Level Soap or Gas Leak Detector Solution Approved Venting Teflon Tape ...

Page 13: ...y 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 12 inches 30 cm 9 inches 23 cm C Clearance to permanently closed window D Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet 61 cm from the center line of the terminal E Clearance to unventilated soffit F Clearance to outside corner G Clearance to inside corner ...

Page 14: ...ft Rinnai recommends 10 in 254 mm clearance from the top and on both sides for servicing Location Clearances to Combustibles Top 0 in 0 mm Bottom Ground 0 in 0 mm Front Panel 40 in 1 m Does not include flooring material or carpeting less than 1 2 in 30 mm in height Back Including Back Spacer 0 in 0 mm Sides Left and Right 2 in 50 mm Top Bottom Back If clearances are not met damage to the property ...

Page 15: ... is not being used for combustion A standard 3 prong 120 VAC 60 Hz properly grounded wall outlet is available The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CSA B149 1 If installed in a manufactured home the installation must conform with the Manufactured Home Const...

Page 16: ... The center of the hole must be located anywhere within the shaded area unless extension kits are used See the dimensions diagram For weatherboard walls drill through the center of the weatherboard from the outside first and then through the plasterboard Figure 8 4 4 2 Attach Wall Brackets Attach the wall brackets as shown A template is provided Figure 9 Example template located on furnace carton ...

Page 17: ...d beyond the red line For other than the S type flue manifold if a shorter length is necessary an extension can be removed Cut the outer plastic laminate with a utility knife or similar and remove the extension The metal should not be cut Inside Connection Sleeve Terminal Remove extension if necessary Guidelines The flue manifold must exhaust to the outside Do not exhaust into other rooms The flue...

Page 18: ...seal to compensate for weather board angle Adjust the second seal to make sure Top marking of the second seal is located at the top or Ʌ marking is aligned with V marking on the terminal From the outside insert the terminal into the sleeve with the marking TOP at the top The left hand side locking tie should be marked LEFT 3 screws Sleeve should extend 3 16 3 8 in 5 10 mm Figure 14 Indoor Outdoor ...

Page 19: ...he ties back into the sleeve and parallel to the wall 6 Insert Inside Connection Assembly Push the assembly into the terminal tube ensuring that the seal is in place on the inner tube Attach the inside connection with 3 screws The inner connection can still be turned to install the screws 3 screws Figure 17 Locking ties Sleeve Figure 16 Top Sleeve Clip the ties over the inside sleeve and cut the t...

Page 20: ...000 130 f 1 4 Bent Elbow FOT 025 4 1 5 Hose Joint RFOT 226 001 1 1 1 6 Pipe Stopper A 1001F 250 1 1 2 2 7 Pipe Stopper B FOT 111 6 1 1 1 8 Top Stopper FOT 062 7 1 1 1 9 Pipe Clamp FOT 064 11 2 Sets 3 Sets 4 Sets 10 Wall Fixture FOT 064 12 2 3 4 11 Nut FOT 062 10 2 3 4 12 Screw A ZAA0420SC 2 3 4 13 Screw B CP 30408 4 6 8 Extension kits are available to extend the exhaust line and air intake hose be...

Page 21: ...tside 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 Clearances Exhaust pipe to combustibles 1 in 25 4 mm Exhaust pipe to non combustibles 0 in 0 mm Figure 19 NOTE Configurations The EX38DT is capable of two vent length settings Short Vent 0 7 ft 1 elbow Long Vent 7 ...

Page 22: ...ose is above exhaust pipe Do not allow any low points in the exhaust line Incorrect Configurations NOT CORRECT Back of Furnace NOT CORRECT CORRECT NOT CORRECT Figure 21 Figure 22 Figure 23 90 Elbow Up Configuration Slope horizontal sections 3 downward 3 Intake Exhaust Intake Exhaust ...

Page 23: ...n the flue manifold To connect exhaust pipes with other straight pipes or bends fit the male end into the female end Use pipe stopper A to clamp the connection Use pipe stopper B to fix the length on the adjustable exhaust pipes Do not extend these pipes beyond the red line Do not cut the exhaust pipe Use the adjustable pipes if necessary To bend the elbow insert exhaust pipes into both ends for a...

Page 24: ...eve up to the flue manifold and slip the securing clip over the sleeve as shown 5 Attach the furnace to the wall brackets using 2 screws at each bracket 6 Attach the back spacer with 3 screws to the top of the furnace 7 If necessary the furnace can be leveled using the adjustable legs under the front right and left legs Up to 3 8 in 10 mm Adjustable Leg Pipe Stopper S Flue Adapter Flue Manifold Pl...

Page 25: ...ust be within the limits shown in section 3 2 Specifications Refer to an approved pipe sizing chart if in doubt about the size of the gas line Complete these instructions for altitude and vent length Default altitude 0 2 000 ft Default vent length 0 7 ft 1 Elbow For altitudes greater than 2 000 ft or installations with vent lengths longer than 7 ft refer to Table 8 Gas Pressure on the next page Fo...

Page 26: ...igh 3 8 in 96 mm 3 0 in 76 mm 2 7 in 68 mm 2 5 in 62 mm 6 4 in 162 mm 5 6 in 143 mm 5 1 in 129 mm 4 6 in 116 mm 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 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 field supplied Attach dua...

Page 27: ...ust the high fire pressure using the and buttons 14 Press the ON OFF button again The LED display turns blank and the furnace returns to the normal OFF mode 15 Remove manometer and two barb fittings and install Allen head screws Operate the unit and follow steps A B and C below A Check for Gas Leaks at the Test Points 16 Install the front panel 17 If doing a gas type conversion place the new conve...

Page 28: ...that listed on the rating plate ELECTRICITY YES NO Did you confirm that the electricity is supplied from a 120 VAC 60 Hz power source is in a properly grounded circuit and turned on Have you confirmed that an extension cord or an adapter plug has NOT been used with the furnace FINAL ITEMS YES NO Did you install the front panel Have you explained to the customer the importance of not blocking the v...

Page 29: ...arge Do not allow anyone to sleep directly in front of the furnace Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition Young children should be carefully supervised when they are in the same room as the furnace Clothing or other flammable material should not be placed on or near the furnace Any safety screen or g...

Page 30: ...tions 1 STOP Read the safety information above 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance using the ON OFF button on the control panel 4 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 5 Turn Manual valve clockwise to the full OFF position 6 Wait five ...

Page 31: ...y will dim The display will turn off when the furnace is turned off While programming the timers the display will turn off several sec onds after a button is last pushed Display Note The factory default is F 1 The furnace must be turned off 2 Press the Timer 1 and Timer 2 button at the same time for about 5 seconds The display will show ºC or ºF 3 Use the arrow keys to select the temperature scale...

Page 32: ...deactivated Deactivating the lock releases the control buttons 1 Press the Program button 2 The light next to Clock should be flashing Press the up and down arrows to set the time Holding down either of the arrow keys will change the time more quickly 3 Press the Program button until none of the time options are flashing 1 Turn the furnace on by pressing the ON OFF button 2 Press the up or down ar...

Page 33: ... is turned OFF 3 Press and hold the Economy Up Program buttons for 2 5 seconds and then release 00 appears in the display 4 Press the UP button 01 appears in the display 5 Press the ON OFF button the display will go blank The furnace is now in Remote Thermostat mode Do not unplug the furnace within two hours of entering Remote Thermostat mode This will cause the furnace to revert back to the Defau...

Page 34: ...tart time Holding down either of the arrow keys will change the time more quickly Operating the timers To operate the furnace using a Timer press the ON OFF button and the appropriate Timer button The furnace will operate from the start to end times you have entered for that Timer It will operate at the temperature setting that has been set for the furnace The timer can be set while the furnace is...

Page 35: ...always prevent the room temperature from falling below the pre set minimum temperature as long as electric power and gas is supplied To turn this feature off press the Set back button The unit will retain its ON or OFF setting after a power failure Default setting at the factory is on 5 4 9 Set Back 5 4 8 Economy Energy Saving Mode IMPORTANT Figure 50 Economy Mode Figure 53 Figure 51 Figure 49 The...

Page 36: ...shed during forced combustion then the furnace will attempt to restart after 1 hour If the flame is extinguished after this period then the furnace will immediately attempt ignition The vertical louvers may be adjusted to move the air flow more to the right or to the left Use a screw driver or similar object to bend each louver to the desired position To fill the tray open the door as shown in the...

Page 37: ...ean filter Service call if repeated 1 16 Room Overheat More than 104 F 40 C Lower the room temperature 30 Overheat Temperature Thermistor 2 Disconnection open circuit 31 Room Temperature Thermistor Disconnection Open Circuit 32 Room Temperature Thermistor Short Circuit 33 Overheat Thermistor 1 Disconnection Open Circuit 34 Overheat Thermistor 1 Short Circuit 35 Overheat Temperature Thermistor 2 Sh...

Page 38: ...r and fan blades 4 Use a soft dry cloth to wipe the cabinet Do not use wet cloth or spray cleaners on the burner The flue should be inspected annually for blockages or damage Motors are permanently lubricated and do not need periodic lubrication Keep fan and motor free of dust and dirt by cleaning annually Verify proper operation after servicing When attaching the front panel do not clip or pinch ...

Page 39: ...rumbling noise when the thermostat operates This is the sound of the solenoid gas valves opening and closing Unit is not heating room Is the air filter blocked Is the set temperature high enough Is the warm air outlet blocked by anything Are the doors and windows of the room closed Was the appliance correctly sized for the space Air filter is blocked or the louvers are blocked or obstructed Allow ...

Page 40: ...allation Air in Gas Pipe Purge Air Installer Gas Filter Blocked Service Call Missed Ignition Service Call Flue Terminal Obstructed Clear Obstruction Flue Manifold Not Connected Service Call Louver Obstructed Clear Obstruction Air Filter Blocked Clean Filter Gas Escape Service Call Lock Set Cancel Lock Gas Off at Meter Tank or Valve Turn Gas On ON Timer is set Cancel ON Timer Additional Troubleshoo...

Page 41: ...EX38DT Installation and Operation Manual 41 8 Parts Cut Away Diagram Figure 58 ...

Page 42: ...42 EX38DT Installation and Operation Manual Exploded View of Service Parts Figure 59 ...

Page 43: ...EX38DT Installation and Operation Manual 43 Exploded View of Service Parts Figure 60 ...

Page 44: ...44 EX38DT Installation and Operation Manual Exploded View of Service Parts Figure 61 ...

Page 45: ...EX38DT Installation and Operation Manual 45 Exploded View of Service Parts Figure 62 ...

Page 46: ...46 EX38DT Installation and Operation Manual Exploded View of Service Parts Figure 63 ...

Page 47: ...FILLER HINGE 209000192 1 1 013 WATER FILLER 209000153 1 1 017 BACK SPACER LEFT G 209000155 1 017 BACK SPACER LEFT J 209000193 1 018 BACK SPACER RIGHT G 209000157 1 018 BACK SPACER RIGHT J 209000194 1 019 BACK SPACER TOP ASSY B 209000159 1 019 BACK SPACER TOP ASSY E 209000195 1 020 AIR FILTER ASSY 208000054 2 2 021 BACK SPACER SUPPORT 1001F 092X02 2 2 022 WALL BRACKET 209000196 2 2 025 LEG ASSY 209...

Page 48: ...ION PACKING A 206000046 1 1 105 COMBUSTION CHAMBEr CONNECTION PACKING B 206000047 1 1 106 BURNER LID ASSY B 206000048 1 1 107 BURNER LID MOUNTING PLATE A 206000049 1 1 108 BURNER LID MOUNTING PLATE B 206000050 1 1 109 WIRE CLIP 205000067 8 8 110 SLEEVE 3022 0344 1 1 111 CLAMP 209000177 1 1 112 FLAME ROD 205000068 2 2 113 ELECTRODE FIXING PLATE A 205000069 1 1 114 ELECTRODE FIXING PLATE B 205000070...

Page 49: ...209000087 2 2 150 Hose Band N 209000088 2 2 152 LID PACKING 209000209 1 1 153 FLUE ASSY FOT 151 1 1 154 ON OFF VALVE ASSEMBLY 206000023 1 1 400 CONVECTION FAN TOTAL ASSY 208000067 1 1 401 CONVECTION FAN MOTOR 208000068 1 1 402 MOTOR MOUNTING PLATE 209000210 1 1 403 CUSHION RUBBER 308F 8273 6 6 404 FAN MOTOR BEARING FC824 908000009 1 1 405 BEARING MOUNTING PLATE 209000211 1 1 406 HEAT SHIELD BOARD ...

Page 50: ... Conversion Kits Optional 712 DVF SUB PCB HARNESS A 205000092 1 1 715 MOTOR HARNESS 205000106 1 1 800 WATER LEVEL LINE LABEL B 209000213 1 1 888 OPERATION MANUAL 200000088 1 1 890 OPERATION LABEL 209000214 1 1 952 FRONT PANEL EMBLEM 209000215 1 952 FRONT PANEL EMBLEM 209000216 1 NO NAME PART NUMBER EX38DT Beige EX38DT White Parts List Continued ...

Page 51: ...e property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the r...

Page 52: ...en yellow r red gr green w white y yellow gy gray or orange Mark Parts Name MS Main Switch R TH Room Thermistor TF1 2 Thermal Fuse 1 2 F Fuse ER Electrode POV Modulating Solenoid Valve PS Pressure Sensor Mark Parts Name W TH Wall Thermostat OH TH1 2 Over Heat Thermistor 1 2 FM Convection Fan Motor SP Sparker SV1 2 Main Solenoid Valve 1 2 SV3 Solenoid Valve 3 BL Combustion Fan Motor FR1 2 Flame Rod...

Page 53: ...ting Solenoid Valve FR1 2 Flame Rod 1 2 CF Convection Fan FM Convection Fan Motor Mark Parts Name SP Sparker OH TH1 2 Over Heat Thermistor 1 2 SV1 3 Solenoid Valve 1 3 BL Combustion Fan Motor FCC Fan Control Circuit B1 4 Burner 1 4 PS Pressure Sensor W TH Wall Thermostat Main CPU Central Processing Unit Sub CPU Central Processing Unit for Safety A DC5V B DC12V C DC15V D DC24V E DC170V F AC24V ...

Page 54: ...erformed by a qualified professional who is properly trained to do the type of repair Replacement of the product may only be authorized by Rinnai at its sole discretion Rinnai does not authorize any person or company to assume for it any obligation or liability in connection with the replacement of the product If Rinnai determines that repair of a product is not possible Rinnai may replace the pro...

Page 55: ... there are no other warranties expressed or implied including but not limited to warranties of merchantability or fitness for a particular purpose which extend beyond the description of the warranty herein Any implied warranties of merchantability and fitness arising under state law are limited in duration to the period of coverage provided by this Limited Warranty unless the period provided by st...

Page 56: ...103 International Drive Peachtree City GA 30269 Tel 1 800 621 9419 Web rinnai us rinnai ca Rinnai America Corporation 200000082 01 1 2022 RHF1006 1750 02 ...