Rinnai ENERGYSAVER Installation Manual

Rinnai ENERGYSAVER® Direct Vent

Wall Furnace Installation

Fundamentals

This instructional presentation is provided by Rinnai America Corporation

as a service to demonstrate common techniques used in installing and/or servicing Rinnai America products. An effort has been made to represent accurate and complete information at the time of publication; however,

the information contained herein may not be current or applicable to

specific products so review all available information and applicable codes.

Rinnai America expressly disclaims all liability (i) for any licensed

professional or dealer relying solely on the information contained in this video without referencing the most recent information available from Rinnai America, for the latest and most detailed information as well as

applicable plans and specifications, manuals of practice, codes, safety

and health regulations with respect to Rinnai America products and (ii) for the installation or servicing of Rinnai America products by someone who is not a licensed professional familiar with all applicable codes.

NOTICE: This video course will require approximately 90 minutes to complete. If at any time you need to

stop the course, click the pause button at the bottom

of the screen. You can review any previous slide during the presentation by clicking the desired slide in the outline pane to the left. You may not, however, advance to any unviewed slides. If you need to leave the presentation, you will be allowed to resume where you left off when you return.

Additionally, it is recommended that you take notes throughout the presentation as there will be an assessment to test your knowledge at the end.

Product Model Numbers and Specifications

NEW

MODELS

EX08C ES08, RHFE 201 FA 55.5-82.0 41-42 W 27-36dB 3,000-8,000 NG/LP

EX11C ES11, RHFE 263 FAII 69.3-102.5 44-47 W 31-38dB

EX17C

EX22C

ES38 RHFE 1004 FA 203.4-360.6 121 W 37-47dBA

PREVIOUS MODELS CFM*

ES17, RHFE 431 FAIII

111.3-137.8 40-46 W 33-38dB 8,200-16,700 NG/LP

EX17, RHFE 431 WTA ES22, RHFE 556 FAIII

111.3-162.7 52 W 32-42dB

EX22, RHFE 556 WTA

Ensure the correct part number is identified for service / parts support

*Current model specifications-previous models may slightly vary

MAX

POWER*

DECIBELS*

INPUT BTU

RANGE*

5,500-11,000 NG

5,700-11,000 LP

8,200-21,500NG 8,200-20,700 LP

10,500-38,400 NG

10,500-36,500 LP

All models available in beige EX22(C) and ES38 models are also available in white.

AFUE

(Efficiency)*

NG-82%

LP 83%

NG-81%

LP-82%

NG-81%

LP-82%

NG-81%

LP-82%

NG-80.6%

LP-82%

ES38

EX17C EX22C

EX08C EX11C

White Beige

Features and Benefits

• When sized correctly, the ENERGYSAVER® Furnace can

be used as a whole house/primary heat source.

• Easy Control and Operation

• One-touch ignition

• Programmable thermostat with a temperature range between 55°F to

95°F (13°C to 35°C)

• During normal operation, the display will dim to save power

• Display available in Fahrenheit or Celsius

• Setback and Frost Protection allows a minimum temperature to be

maintained even when off or between scheduled heating events

• Adjustable maximum temperature setting

• Energy saving economy setting

Features and Benefits

• The unit’s standby power consumption is less than 1

watt.

• Seven-stage Intelligent Modulating Gas Valve and

blower control.

• Warm air discharge at floor level.

o Directional louvers to optimize direction of air flow.

• Ultra-quiet operation-Decibel range of 27-47 is

comparable to a normal conversation.

• Gas type is field convertible.

• Restart Functions allow automatic restart after ignition,

combustion, or power failures.

• Small 3” diameter concentric vent.

Safety Features

• Self Diagnostic Circuitry-Should the ENERGYSAVER® detect an

unsafe operating condition, the unit will shut down and a fault code will display indicating the specific issue.

o If the shutdown is due to an ignition or combustion failure, the

unit will attempt to relight automatically.

• Function/Child Lock

• Cool to the touch Cabinets.

• Restricted air filter indication lamp and audible reminder-Current

model ENERGYSAVERS will flash a reminder lamp and emit an audible beep if it detects operational conditions indicative of a restricted air filter.

• Sealed Heat Exchanger-flame and combustion is sealed

from the heating area.

Safety Features

• Overheat protection- Multiple temperature sensors monitor the

appliance’s temperature. Shut down occurs if an unsafe

operational temperature is detected.

• Combustion and convection fan validation-should either of these

fans fail to maintain the proper speed (likely due to a restriction), the PCB will not allow the unit to operate.

• Electronic ignition-no standing pilot.

• Power failure protection-Should the ENERGYSAVER lose power,

the gas supply will automatically close. Upon resumption of power, the unit will automatically attempt to restart.

• ENERGYSAVERS are equipped with an inline glass fuse and surge

protection to protect from over-current or power surge.

ENERGYSAVER® Sizing

To ensure the ENERGYSAVER operates as designed, an industry standard Btu heat loss calculation must be performed on the area to be heated.

• This calculation considers all factors that contribute to heat loss such as:

• Area and volume of the space to be heated

• Geographical location and climate where the furnace will be located

• Structural characteristics of the building such as number of windows, exterior doors,

construction material, etc

• The Air Conditioning Contractors’ Association (ACCA) has an

industry standard Btu calculation in their “Manual J” publication.

• A qualified and licensed installer should be familiar with this type

of calculation.

• Visit http://www.acca.org/ for more information.

• Rinnai also offers a basic DV sizing calculator at

http://www.rinnai.us/heat_selector_2007.swf

• NOTE: Incorrectly sized applications can lead to the ENERGYSAVER shortcycling or failing to bring the area to the desired set point temperature.

ENERGYSAVER®—Whole House Furnaces Key concepts

The ENERGYSAVER has the ability to heat an entire structure from a central room. Here’s how:

• 2nd law of thermodynamics – Heat seeks cold

• Once the main room approaches the set point temperature, the heat begins to move to other rooms—seeking cold.

• The variable gas valve and blower control modulate to

ensure heat reaches the

remainder of the structure without overheating the main area.

• Cold air is detected quickly by the thermistor—mounted

two inches above the floor

and able to detect changes as small as 6/10 degree (Fahrenheit).

• These features aid in

reducing stratification in the

atmosphere (different layers of room temperature).

’s of a

(Click here to watch animation)

ENERGYSAVER®—Whole House Furnaces Key concepts

• Variable speed technology – Modulating gas and air based on the heat loss at that moment

• With on/off single stage operation, gas usage

can be high due to alternating periods between maximum flame and no flame at all.

On / Off Single Stage Heating Appliance

74°

72°

70°

68°

66°

• This results in different layers of temperatures throughout the structure leading to a less than comfortable living environment.

Gas

Usage

Gas

Usage

Gas

Usage

• The Energysaver’s modulating technology has the

ability to replace only the heat escaping the structure by continuously operating at heating levels based on the demand at that moment.

Continuous-Run Modulating Technology

74°

72°

70°

68°

66°

Continuous gas usage but at much lower levels

• This leads to lower gas usage and higher levels of comfort.

ENERGYSAVER® Direct Vent Furnaces

Operation Sequence

1. Combustion fan purges heat chamber, PCB verifies fan rotation

2. Ignition spark begins

3. When sensing electrode detects spark, gas valve assembly opens

4. Ignition occurs and heat exchanger warms

5. Spark stops as flame rod & PCB verify flame

6. When heat exchanger is warm enough, convection room blower circulates warm air into the structure.

7. When filled, the humidifier tray ensures the

air is not too dry (if needed)

8. Thermistor & PCB determine gas and fan settings

9. When temperature set point is reached, if needed, gas valves close &

combustion fan stops. Convection fan

continues to run to cool down unit.

Convection Fan

Heat Exchanger

Humidifier Tray

Concentric Termination

Flame Rod

Combustion Fan

POV SV1 & 2

Spark and sensing electrodes

Thermistor

PCB

10.When temperature drops, process starts over

Control Panel Review (C-Series models)

Description Key

The following pages will cover each topic in

detail

1. Child Safety Lock

2. Economy Feature

1 2

3. Timer 1 and 2

Note: While off, pressing Timer 1 and 2 together will change the display

from Fahrenheit to Celsius

4. Override

Temporarily bypasses timers

5. Temperature Control and Display-

Display will enter a power saving dimmer mode during normal operation

6. Timer and Clock Setup

7. Setback Feature

8. Restricted Filter Indicator

This lamp is on the front panel of the ES38

9. Operation Lamp

Green = standby Solid red = when flame is present

Flashing red = fault code is present

This lamp is on the front panel of the ES38

10. On/Off Button

3 6

EX08C, 11C, 17C, 22C MODELS

ES38 MODELS (Production after 7/2011)

Control Panel Review (all other current models)

Fahrenheit

L (approx. 55)

ES38 MODELS Production before 7/2011

Economy Feature

The below table shows the

Temperature Control and Display

Room temp lamp stays on Room temp displays only when adjusted

Function Lock - Pressing both arrows will engage

Celsius L (approx. 13) 16 17 18 19 20 21 22 23 24

temperature range of all models

60 62 64 66 68 70 72 74 76

80 H (approx. 95)

26 H (approx. 35)

Economy Function

Economy Mode is designed to save gas usage over time.

• The Economy Function is based on the theory that the human body cannot detect small

temperature changes over an extended period of time.

• 30 minutes after the set point temperature is achieved, the unit will reduce the temperature by 2°F. After 30 additional minutes, the unit will reduce the temperature an additional 2°F.

• The maximum temperature reduction will not exceed 4°F.

• This reduction will not occur if the unit is undersized and cannot maintain the initial set point.

72°F

Initial Set point is 70°F

70°F

After 30 minutes of maintaining

68°F

66°F

Operation Temperature

Minutes of Operation at Set Point

70°F, the unit will maintain 68°F

After 30 minutes of maintaining 68°F, the unit will maintain 66°F. No further reduction will occur

30 60

Clock, Timer, and Setback Functions

(C-Series)

C-Series ENERGYSAVERS® have two primary methods of operation:

• Exclusively as a thermostatically controlled furnace.

• When left to operate on a continuous-run basis using feedback from its

thermostat, the ENERGYSAVER will achieve an optimum balance between comfort and efficiency.

• As a programmable furnace with two separate timers and a setback function

• The timers allow two separate heating events to be set.

• Timer 1 and Timer 2 (individually or both as needed) can then be engaged to

allow the unit to turn on and off for those events.

• The ENERGYSAVER is designed to attempt to have the area at the set point temperature when the timer event begins—meaning it could turn on several minutes earlier to achieve set point temperature.

• To set the clock and timers, see the installation manual.

Clock, Timer, and Setback Functions

(C-Series)

• If needed, the Override button can be selected to temporarily turn on or off the timers to allow manual operation.

• If the unit is operating during a Timer’s event, pressing Override will turn

the unit off until the next Timer’s event.

• If the unit is off between Timer events, pressing Override will turn it on. It

will continue to run until the end of the next Timer’s event and return to

Timer operation.

• If Override is turned off, the unit will return to Timer operation.

Clock, Timer, and Setback Functions

(C-Series)

Setback allows a minimum temperature to be pre-set and maintained between timer events or while the unit is turned off.

• This feature’s primary function is to slightly reduce the temperature (and gas usage) during

extended periods of nonuse or inactivity—such as sleeping or when the home is empty.

• NOTE: When this feature is used as a setback function for energy savings, it is not advisable to reduce

setback more than 4-6°F from the regular set point. This could cause the ENERGYSAVER® to use more gas to return to the set point and cancel any savings achieved.

• This feature can also be used as frost protection during longer periods of vacancy (such as

in a second home). For this use the setback temperature can be set as low as 38°F.

• Even when off, if the setback feature is engaged, the setback temperature will be maintained.

• If power is lost and setback is ON, it will be ON at the resumption of power.

The following example shows how, when used together, the timer and setback functions can maximize comfort and efficiency:

• Daily schedule:

• Occupants wake at 5am

• Home is empty from 9am until 4pm

• Occupants are asleep from 11pm until 5am

12am

Between timer events, the Setback temp of

66°F is maintained

2am

4am 2pm 12noon 8am 6am 4pm 8pm 10pm 6pm

Timer 1 70°F temp is maintained

• Operation temperature is set to 70°F

• Timer 1 is set from 5am to 9am

• Timer 2 is set from 4pm to 11pm

• Setback is set to 66°F

10am 12am

Between timer events, the Setback temperature of 66°F is maintained

Timer 2 70°F temp is maintained

Restart Features

All ES, EX, and C-Series models will attempt restart after a

power failure or flame failure to ensure heating is not

interrupted for extended periods of time.

• If there is a power failure while the appliance is operating,

the unit will attempt to restart automatically when the power is restored.

• The timers will retain their settings after a power outage.

• After an outage, the clock will retain the time at that

moment until power resumes. Therefore, a short power outage (a few minutes) will have virtually no effect on timer

operations whereas a longer outage will require the clock to

be reset. Dashes will initially display to indicate an outage occurred.

Restart Features

• Should a high gust of wind, gas outage, etc. occur that affects the flame

characteristic, the unit will automatically shut down, purge the combustion

chamber, and attempt to re-ignite.

• If the unit cannot ignite or maintain flame for 15 seconds after ignition, code 11 will flash and the unit will try to ignite again in one hour.

• This code will not be stored in the fault code history.

• If at some point after 15 seconds of established flame the flame fails,

the unit will immediately attempt to relight with no code flashing.

• If the unit cannot relight after this flame failure, code 11 will flash and

the unit will try to ignite again in one hour.

• If the unit continually or intermittently fails to ignite, a qualified service

technician may be needed to determine the cause.

• Each manual has a section named “Restart Function” that explains this

procedure.

• Flame failure fault codes (code 12’s) are no longer needed due to this

enhancement.

Fault Codes

• A fault code will flash on the unit when a fault occurs. The unit will stop operating.

• Operation intervention is required for all codes EXCEPT a code 11.

• To view the last nine fault codes, with the unit OFF, press the UP, DOWN, and, ECONOMY buttons simultaneously

CODE PROBABLE CAUSE COMMENTS

11 14

31 32 33 34 49 53 61 62 70 71

72 73

Ignition or Flame failure

Overheat Safety Device Overheat safety bimetal(s) or thermal fuse has activated

Over temperature cut off Room temperature is sensed as being above 104°F for longer than 10 minutes

Room temperature thermistor disconnection Room temperature thermistor open circuit Room temperature thermistor short circuit Room temperature thermistor wire shorted or touching bare metal High limit thermistor disconnection High limit thermistor open circuit High limit thermistor short circuit High limit thermistor shorted or touching bare metal Pressure sensor disconnect or breakdown Check sensor connection to PCB & hoses to blower motor Abnormal spark sensed Spark not sensed correctly Abnormal combustion fan motor rpm Fan speed not achieved within time or goes over speed Convection fan failure Ensure convection fan can turn freely ON/OFF switch failure ON/OFF switch connects continuously for more than 15 seconds Solenoid valve check Solenoid valve(s) (SV1 & SV2) signal and response signal are different Flame rod failure PCB fails to sense microamps within 20 seconds

Communication failure Data transfer within PCB fails

Flame current inadequate; Unit will attempt to relight (see Manual-Restart Feature)

Flue block or venting disconnect Check intake and exhaust inside and outside for blockage or freezing

Warranty and Maintenance

• Warranty

Rinnai ENERGYSAVER® Furnace Warranty

Heat Exchanger Coverage Parts Reasonable Labor

10 years 5 years 2 years

Refer to each model’s installation and owner manual for full warranty details

• Maintenance and Service

• The appliance should be inspected at least annually by

a qualified service technician—see the installation manual for full details.

• The exterior can be cleaned with a damp, warm cloth.

• Ensure the vent termination is kept free of snow, ice, or

any other obstructions.

• Ensure the filter(s) are kept clean to ensure proper operation.

• If the filter(s) become blocked, the filter indicator light

will illuminate and the unit will beep every five minutes. If ignored, the unit will eventually cease operation and display a fault code 14.

• Ensure the unit is OFF while the filter is removed—

this will also allow the filter lamp and beep to reset.

Rinnai Service and Support (800-621-9419)

Rinnai America’s phone support structure consists of the following departments:

• CRC – Consumer Response Center – Fielding general calls, consumer questions, etc.

• Available in office from 8 a.m. to 8 p.m. EST, Monday - Friday

• Parts and Warranty Department – Fielding parts orders and warranty issues

• Available in office from 8 a.m. to 5 p.m. EST, Monday – Friday

• Technical Support Department– Fielding technical issues related to the function of all

Rinnai Products

• Available in office from 8 a.m. to 8 p.m. EST, Monday – Friday AND 24/7/365 on call support for technicians who are at the service location.

• Engineering / Applications Department – Fielding issues related to product applications including sizing

• Available in office from 8 a.m. to 5 p.m. EST (The engineering dept. does not perform heat loss calculations —an industry accepted Btu heat loss calculation must be performed by the installer)

Rinnai America also provides the following web sites for support:

• www.rinnai.us – The Partner Portal on our main site contains product, sales, and service information. Of Note—a

comprehensive documents library and on-line parts ordering system is available. Website registration is required for access.

High Altitude and Gas Conversion

• All units are approved up to 10,200 feet.

• The Installation manual and the conversion

manual supplied with each unit has instructions for high altitude settings.

• High altitude applications do not require

additional or replacement parts—only a simple

manifold gas pressure adjustment.

• Only a dual port manometer will be required to complete the altitude adjustment.

• All EnergySaver® furnaces can be field converted from NG to LP or LP to NG.

• Depending on model and year of manufacture,

a conversion kit may be included with the product. If not, contact Rinnai for information on acquiring the proper kit (1-800-621-9419).

+ 54 hidden pages