Rinnai ENERGYSAVER EX08C, ENERGYSAVER EX11C, ENERGYSAVER EX17C, ENERGYSAVER EX22C, ENERGYSAVER ES38 Installation Fundamentals

Rinnai ENERGYSAVER® Direct Vent

Wall Furnace Installation

Fundamentals

2

Rinnai ENERGYSAVER® Direct Vent Wall Furnace

Installation Fundamentals

The following course is approved for NATE

continuing education hours (CEH’s).

This course will earn the following CEH’s:

Warm Air Heating-Gas-Installer – 2 hours

Warm Air Heating-Gas-Service – 2 hours

If you require credit for NATE, please notify the
instructor at this time.

3

Rinnai Service and Support (800-621-9419)

Rinnai America also provides the following web sites for support:

• www.rinnai.us – our main site for all product, sales, and service information. Of Note—a comprehensive documents library is

available at the sales/service link. Website registration is required for access.

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 size heating appliance applications—an industry
accepted Btu heat loss calculation must be performed by the installer)

4

EX17C
EX22C

ES38

EX08C
EX11C

Product Model Numbers and Specifications

NEW

MODELS

PREVIOUS MODELS CFM*

MAX

POWER*

DECIBELS*

INPUT BTU

RANGE*

AFUE

(Efficiency)*

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

NG-82%

LP 83%

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

5,500-11,000 NG

5,700-11,000 LP

NG-81%

LP-82%

EX17C

ES17, RHFE 431 FAIII
EX17, RHFE 431 WTA

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

NG-81%

LP-82%

EX22C

ES22, RHFE 556 FAIII
EX22, RHFE 556 WTA

111.3-162.7 52 W 32-42dB

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

NG-81%

LP-82%

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

10,500-38,400 NG

10,500-36,500 LP

NG-80.6%

LP-82%

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

*Current model specifications-previous models may slightly vary

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

White Beige

5

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

6

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.

7

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 code 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.

8

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.

9

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

ENERGYSAVER® Sizing

• 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.

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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

th

’s of a

degree (Fahrenheit).

• These features aid in

reducing stratification in the

atmosphere (different layers
of room temperature).

1

2

3

(Click here to watch animation)

ENERGYSAVER®—Whole House Furnaces
Key concepts

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

74°

72°

70°

68°

66°

74°

72°

70°

68°

66°

On / Off Single Stage Heating Appliance

Continuous-Run Modulating Technology

Gas

Usage

Gas

Usage

Gas

Usage

Continuous gas usage but at much lower levels

• With on/off single stage operation, gas usage

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

• 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

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

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

ENERGYSAVER®—Whole House Furnaces
Key concepts

12

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.

10.When temperature drops, process starts over

ENERGYSAVER® Direct Vent Furnaces

Operation Sequence

Spark and sensing
electrodes

PCB

Humidifier Tray

Heat Exchanger

Combustion
Fan

Thermistor

POV SV1 & 2

Convection Fan

Flame Rod

Concentric Termination

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Control Panel Review (C-Series models)

Child
Safety
Lock

Temperature Control and Display­Display will enter a power saving dimmer mode
during normal operation

Restricted
Filter
Indicator

Operation Lamp

Green = standby
Solid red = when flame is present
Flashing red = fault code is present

Economy
Feature

Setback
Feature

Timer and Clock
Setup

Override
Temporarily bypasses timers

EX08C, 11C, 17C,
22C MODELS

Temperature Control and Display

Room temp lamp stays on
Room temp displays only when adjusted

ES38 MODELS
Production after
7/2011

Economy Feature

Timer 1 and 2

Note: While off, pressing Timer
1 and 2 together will change the
display from F° to C°

Function Lock -
Pressing both arrows will engage

1. Child Safety Lock

2. Economy Feature

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

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Control Panel Review (C-Series models)

ES38 MODELS (Production after 7/2011)

5

EX08C, 11C, 17C, 22C MODELS

1 2

3 6

4

7

8

10

9

Description Key

The following pages
will cover each topic in

detail

5

1

2

3

6

4

7

10

9

15

Control Panel Review (all other current models)

Fahrenheit

L (approx. 55)

60 62 64 66 68 70 72 74 76 78

80 H (approx. 95)

Celsius L (approx. 13) 16 17 18 19 20 21 22 23 24 25

26 H (approx. 35)

Temperature Control and Display

Room temp lamp stays on
Room temp displays only when adjusted

ES38 MODELS
Production before 7/2011

Economy Feature

Function Lock -
Pressing both arrows will engage

The below table shows the

temperature range of all models

16

After 30 minutes of maintaining
70°F, the unit will maintain 68°F

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.

Economy Function

Initial Set point is 70°F

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

30 60

90

0

Minutes of Operation at Set Point

Operation Temperature

66°F

68°F

70°F

72°F

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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)

18

• 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)

19

• Daily schedule:

• Occupants wake at 5am

• Home is empty from 9am until 4pm

• Occupants are asleep from 11pm until 5am

12am

2am

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

10am 12am

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

Timer 2
70°F temp is maintained

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

Between timer events,
the Setback temp of

66°F is maintained

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:

Clock, Timer, and Setback Functions

(C-Series)

20

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

21

• 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 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.

Restart Features

22

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

Ignition or Flame failure

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

14

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

16

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

31

Room temperature thermistor disconnection Room temperature thermistor open circuit

32

Room temperature thermistor short circuit Room temperature thermistor wire shorted or touching bare metal

33

High limit thermistor disconnection High limit thermistor open circuit

34

High limit thermistor short circuit High limit thermistor shorted or touching bare metal

49

Pressure sensor disconnect or breakdown Check sensor connection to PCB & hoses to blower motor

53

Abnormal spark sensed Spark not sensed correctly

61

Abnormal combustion fan motor rpm Fan speed not achieved within time or goes over speed

62

Convection fan failure Ensure convection fan can turn freely

70

ON/OFF switch failure ON/OFF switch connects continuously for more than 15 seconds

71

Solenoid valve check Solenoid valve(s) (SV1 & SV2) signal and response signal are different

72

Flame rod failure PCB fails to sense microamps within 20 seconds

73

Communication failure Data transfer within PCB fails

99

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

23

• Warranty

Warranty and Maintenance

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.

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• 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 conversion does not require

additional or replacement parts—only a simple

manifold gas pressure adjustment.

• Only a dual port manometer will be required to
complete this 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).

High Altitude and Gas Conversion

25

• All ENERGYSAVER® models now have the ability to set a maximum temperature limit directly
from the control panel. This procedure is NOT in the manuals to allow property owners and

managers to control this setting as needed.

• This is beneficial to landlords and property management to conserve energy and reduce
unnecessary gas consumption.

• To perform this adjustment, do the following:

Maximum Temperature Limit

Procedure for Setting Maximum Temperature Limit for ENERGYSAVER Furnaces

ES08,

ES11

EX08C,

EX11C

ES17,

ES22

EX17C,

EX22C

EX17, EX22

(WTA Models)

ES38

1. While the unit is off, press the “Function Lock”

or “Child Lock” and “Up” arrow buttons at the
same time for about 3 seconds until the unit
beeps

1. While the unit is off, press the

“Economy” and “Select” buttons at

the same time for about 3 seconds
until the unit beeps

1. While the unit is off, press the

“Economy” and “Up” buttons at the

same time for about 3 seconds until
the unit beeps

2. Select the maximum temperature with the up and down arrows

3. Press the On/Off button to save the new setting

26

This overview is not meant as a substitute for the installation and owner’s
manual. Every furnace is shipped with a manual that should be followed
completely. The following is a supplemental presentation and is intended as
a tool for the first time installer.

QUALIFIED INSTALLING AGENCY

The installation must conform to local codes, in the absence of local codes, the installation

must conform with American National Standard (National Fuel Gas Code) known as NFPA 54

and ANSI Z223.1

• A qualified service technician should install the appliance and inspect it before use.

• Follow all applicable national and local codes. For additional information, see the installation / owner’s

manual and the product’s rating plate.

Installation Overview

DANGER

WARNING

CAUTION

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and others.
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.
Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

SAFETY DEFINITIONS

27

•A manufactured home (USA only) or mobile home OEM installation must

conform with the Manufactured Home Construction and Safety Standard,

Title 24 CFR, Part 3280, or, when such a standard is not applicable, the

standard for Manufactured Home Installations, ANSI/NCSBCS A225.1, or
the standard for Gas Equipped Recreational Vehicles and Mobile Housing.
CSA Z240.4

•Appliance input ratings are based on sea level operation and need not be

changed for operation up to 2000 ft (607 m) elevation. For operation at
elevations above 2000 ft (609.9), manufactured to specified deration
conditions for Canada and the United States. Refer to the high altitude

adjustment procedure(s).

•If the flooring is carpet, tile, or other combustible material other than wood,

then the appliance must be installed on a metal or wood panel extending
the full width and depth of the appliance.

Installation Guidelines

The following guidelines are from the installation / owner’s manual.
Before beginning the installation process, please review the following:

28

Installation Guidelines

• This appliance discharges a large volume of warm air next to the floor. Any particles

in the air such as cigarette smoke could cause discoloration in carpet. The warm air

flow could discolor nylon carpets containing dyes or vinyl surfaces. To prevent

discoloration of the floor covering a mat may be placed under the appliance which
extends about 30 inches (750 mm) in front of it.

• This appliance is not designed to be built in.

• This appliance is only for use with the type of gas indicated on the rating plate. This

appliance is not convertible for use with other gases unless a certified kit is used. If
a conversion of the unit is needed, conversions must be performed by a qualified

service provider at the owner’s expense.

• This appliance must not be connected to a chimney flue serving a separate solid-

fuel burning appliance.

• A shut off valve (and appliance connector valve) should be installed in the upstream

of the gas line to permit servicing. This valve is included.

The following guidelines are from the installation / owner’s manual.
Before beginning the installation process, please review the following:

29

Always wear personal safety equipment when using power tools

• Cordless / Electric drill

• 3 inch hole saw

• 5/8 inch X 18 inch pilot drill bit

• 1/8 inch drill bit (not shown)

• No. 2 Phillips bit

• No. 2 Phillips screwdriver

• 2 adjustable wrenches

• Pipe wrench

• Channel locks

• Needle nose pliers

• Side cutters

• Leak detector

• Pipe dope or LP Gas approved

Teflon Tape

• Tape measure

• Jig saw

Recommended Tools Needed for Installation

Eye protection is required

30

View of Properly Installed Unit

31

All hardware needed for *standard
installation is included in package with
furnace.

*Included with furnace:

• Installation and owner’s manual

• Wall termination that will fit wall thickness of 4.5”-9.5”

• Wall mounting back spacers

• Mounting screws

• Vent locking clamps

• Wall mounting template included

• ½” Jo-Mar shut-off gas valve

• Packing board to place under unit if installed on carpet

(unit must be installed on an approved surface)

* Extension venting, vent covering, and nonstandard wall
terminations are available separately

Furnace Packaging and All Hardware

Ensure correct gas type is on package!

NOTE: Do not discard or cut into box—

the wall template for termination is now

on the back side of the cardboard.

32

Inspect packaging to ensure all parts and
installation materials are removed before
discarding.

Furnace Packaging and Hardware

Top of box contains screw
hardware, back-spacers, vent
termination, etc.

Documentation packet
contains: installation manual
and Warranty registration

Installer: Leave all
documentation with unit
Consumer: Retain all

documentation for future use

WARNING

DO NOT USE SUBSTITUE MATERIALS

USE ONLY PARTS CERTIFIED WITH THE APPLIANCE

33

Furnace Packaging and all Hardware

Back spacer
mounting
brackets

Exhaust pipe
stoppers and
clamps

Sheet metal screws for
attaching back spacers to
furnace

Machine screws for attaching
exhaust pipe to termination

sleeve

Sheet metal screws for
attaching air intake clamps
(not used on all models)

Screws for attaching exhaust
sleeve (3) and top back
spacer (2) to wall

HARDWARE PACKET

Use the pipe stoppers, connectors, clamps, and screws according to the installation
instructions in order to ensure no leakage of exhaust gases.

CAUTION

Longer tie wrap
for securing
intake hose to
back frame

Shorter tie wrap for securing
air intake hose to termination

34

1. The packing board used for

shipping can also be used to place
under the unit if needed when
installing on carpet.

• When the furnace is installed directly on carpeting or other combustible
material (excluding wood flooring), it must be installed on a metal or wood panel
extending the full width and depth of the heater.

• The furnace may be installed on combustible wood flooring.

Installing On Combustible Flooring

2. Place furnace on board

• Remove toe plate from furnace

• Mark board to fit under furnace with

no visible excess.

3. Cut board to fit full width of
unit.

CAUTION

Practice good safety

habits when using

power equipment

35

Identifying the Installation Location

2”
(50 mm)

40” (1 m)

Maintain 9” (225 mm)

above for filter removal

2”
(50 mm)

Zero clearance to back wall
and above

Maintain 10” (250mm) per side for future servicing

FURNACE
LOCATION

Furnace must be

installed where the
proper clearances
from combustibles

can be maintained.

Also ensure
installation location
is not in an area of

excessive cold or

warm air
conduction.

36

Identifying the Installation Location

VENT LOCATION

Consider the following requirements when locating the outside vent termination:

• 12” clearance from grade or anticipated snow level (ANSI Z223.1)

• 9” clearance from a door or window that may be opened (ANSI Z223.1)

• 3 feet clearance above a forced air inlet located within 10 feet (ANSI Z223.1)

• Any other local, state or national code requirements

• Avoid vent locations over public walkways or near dryer vents

• Ensure any wall drilling will not compromise support studs, existing electrical, plumbing, or HVAC systems, etc.

12” from

grade or
snow level

24” from any flammable obstruction
10” from any non-flammable obstruction

20” from

any
obstruction

20” from

any
obstruction

24” from an

opposing
wall

37

Interior Wall Preparation

1. Cut the template out of the

box.

2. Ensure bottom of template is
cut correctly.

3. Temporarily tape the
template to the wall at floor

level.

4. Ensure template does not
slip.

TEMPLATE
PLACEMENT

Included with each
furnace is a wall template
to simplify mounting and
vent hole location—2010
and newer models have
the template printed on
the cardboard packaging.

Ensure the cardboard is cut at the

bottom of template

38

Interior Wall Preparation

SCORING THE WALL

1. Ensure vent hole will NOT

compromise any structure
support (stud), electrical,
plumbing, HVAC system, etc.

2. Score the template anywhere in

the shaded arc for the pilot bit.

3. Also score the two screw holes
for the mounting wall bracket

with a ⅛” bit.

4. Drill the vent hole with a pilot bit
long enough to extend through
the entire wall and no larger

than the center bit of the hole

saw being used.

CAUTION

Practice good safety
habits when using
power equipment

Score two mounting
screw holes (⅛” bit)

39

Interior Wall Preparation

INSTALLING THE

MOUNTING BRACKET

Using the two previous

scored screw holes,
mount the rear mounting
bracket to the wall.

40

Interior Wall Preparation

1. Interior:

Using a 3” inch

hole saw, drill the
vent hole guided
by the previously
drilled pilot hole.

2. Exterior:
Continue drilling hole
guided by the
previously drilled pilot
hole.

DRILLING THE VENT HOLE

NOTE: Drill holes level or
sloped downward 2°to the
outside. Vent termination
must have outward pitch to
ensure condensation
drains to the outside.

41

1. Prepare the drip leg for furnace
connection. NOTE: Do not

attach the right side back
spacer yet to allow enough
space for tightening these
fittings.

Initial Gas Line Preparation

ATTACHING THE GAS CONNECTION (Part 1)

2. Attach the drip leg to the
furnace. Use two wrenches to
prevent damage to the furnace.

3. If using appliance flex

gas line (recommended),

attach flair adaptor to the
drip leg. NOTE: The

connection of the
flexible gas line will be
covered in a following

procedure.

IMPORTANT: Ensure all code and gas line sizing requirements are followed!
All connections should be properly tightened and sealed with pipe dope or Teflon tape.

42

Furnace Preparation

INSTALLING THE LEFT AND
RIGHT BACK SPACERS

The left and right back spacers are
installed with a tab and slot at the
top and middle and single screws
at the bottom of the panels.

Ensure two locking
tabs align correctly

Secure one screw at
the bottom of each
side back spacer

ROOM AIR THERMISTOR

NOTE: The room air thermistor

comes with approximately 14” of

wire. It can be moved higher if
needed if there is an excessive
amount of cold air conduction
present. This should be a last

resort—ideally, the cold air

conduction should be eliminated.

Room air
thermistor
(yellow wires)­can be raised
several inches
if needed

43

Furnace Preparation

INSTALLING THE AIR INTAKE HOSE CLIP

Mount the hose clip at the bottom of the furnace as shown below.

Models prior to 2010 use a clip in this

location-see manual for details.

Use the longer tie-wrap
included with hardware

44

Vent Termination

VENT TERMINAL PREPARATION

• The flue manifold (vent) must exhaust to the outside. Do not exhaust into other rooms.

• The flue is not designed to be positioned under floors or below the furnace.

• Clearance to combustibles for the vent sleeve and flanges is zero inches.

• This appliance can only be used with one of the five types of Rinnai vent kits. These kits and
their dimensions are listed below and in each owner’s/installation manual.

NAME KIT NUMBER KIT WALL DIMENSIONS

S Vent Kit FOT-150 3”-4 ½” (75 – 115 mm)
*A Vent Kit FOT-151 4 ½”-9 ½” (115 – 240 mm)
B Vent Kit FOT-152 9 ½”-15 ¾“ (240 – 400 mm)
C Vent Kit FOT-153 15 ¾ -23 5/8“ (400 – 600 mm)
D Vent Kit FOT-154 23 5/8”-31 ½” (600 – 800 mm)

*Vent Kit A (FOT-151) is
included with each furnace

45

FLUE MANIFOLD DISASSEMBLY

Vent Termination

• The flue manifold consists of 3 parts:

• Inside connection

• Sleeve

• Outside terminal

1. Disassemble the flue manifold by first

pulling out the inside connection.

2. To remove the outer terminal

pull and release the two

internal stainless steel ties
and then pull out the outer
terminal.

NOTE: Make sure the
black gasket is always
on the interconnector

piece as shown.

46

1. Measure the wall thickness through the
previously drilled hole. The end of the

sleeve should protrude 3/16” – 3/8” (5-

10mm) from the outside wall. The
sleeve is threaded for adjustment.
Adjust the sleeve length to wall
thickness PLUS 3/16” – 3/8”(5-10mm).

NOTE: Do not extend beyond the

red line on the sleeve.

ADJUSTING THE SLEEVE LENGTH

2. If a shorter length is

necessary an extension can
be removed. Cut the plastic
at the pre-existing mark and
remove the extension.

NOTE: Vent Kit “S” does

not have the removable
extension

IMPORTANT:
Only cut the plastic
green film with a knife.
The vent itself is NOT
designed to be cut!

Practice good safety habits
when using sharp tools!

CAUTION

Do not extend vent

beyond the red line!

Vent Termination

47

Vent Termination

ATTACHING THE SLEEVE

1. Slide the sleeve through
the interior side of hole.

Ensure label “Top” is

installed at the top of hole.

3. Attach the sleeve to the
inside wall using 3
screws. If needed, use
sheet rock anchors to
secure to wall.

Practice good safety habits when using
power equipment tools!

CAUTION

2. Ensure the
sleeve extends

3/16” to 3/8” (5-

10 mm)

NOTE: The flange

is offset 2°to

allow condensate

to drain outside

48

Vent Termination

INSTALLING THE OUTER VENT TERMINAL

1. 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.”

2. For weather

board walls (lap

siding), add the
second seal next
to the terminal
seal to
compensate for

siding angle.

Practice good safety habits when using
power equipment and sharp tools!

CAUTION

3. On the inside,
pull hard on the
left and right
hand ties. Clip
the ties over the
notches inside

the sleeve. The

ties should pull 2
or 3 notches
past the starting
point.

4. Cut the ties,

leaving about ¾”

(20mm) past the
notch. Bend the
excess back and
parallel to the

wall.

Terminal Seal

Additional angled
seal for lap siding

Lock in notches

49

Vent Termination

INSTALLING THE INSIDE CONNECTION ASSEMBLY

1. Push the

assemble into
the terminal
tube with the

label “top”

matching the
location on the
sleeve. Ensure
that the seal is
in place on the
inner tube.

2. Attach the inside

connection with 3
screws.

NOTE: The inner
connection can still

be turned to install

the screws.

50

Vent Termination

OUTSIDE VIEW OF CORRECTLY INSTALLED TERMINATION

51

Final Gas Line Preparation

IMPORTANT: Ensure all code and gas line sizing requirements are followed. Shut off

valve should be located in a manner that allows the unit to be removed for field service.

NOTE: If flexible gas line is not used, first complete the next step (sliding the furnace

into place), then attach gas line accordingly.

1. Ensure all connections
are properly tightened
and sealed with pipe
dope or Teflon tape.

2. Attach the included shut off
valve and field supplied
flexible gas line to the wall
supply and furnace. Leak test

all connections.

3. NOTE: Many models will
allow the gas valve to be
positioned behind the back
spacer but still accessible

by the consumer.

ATTACHING THE GAS CONNECTION (Part 2)

Tip: Using a flexible appliance gas line will enable the furnace to be slid into place with minimal effort.

52

Sliding the Furnace into Place

SLIDING THE FURNACE INTO PLACE

1. If necessary, the unit can be

leveled using the adjustable legs

under the front right and left
hand sides.

2. Slide the furnace into place. Ensure
furnace is level and aligned to vent
termination, back spacer mounting
bracket, and gas line (if necessary).

53

Connecting the Vent Flue

CONNECTING THE VENT FLUE

1. Slide the stainless steel exhaust tube
until it is fully inserted into the manifold.

NOTE: Never bend the exhaust pipe that

exits the furnace.

The following components can be connected by reaching behind the appliance as it is positioned against the wall

2. When sliding the tube, ensure it does not
extend beyond the red line.

3. Connect the flue outlet to the manifold.

NOTE:
NEVER bend the

exhaust pipe that

exits the furnace!

54

CONNECTING THE VENT FLUE (continued)

The following components can be connected by reaching behind the appliance as it is positioned against the wall

3. Fit the locking clamp over the connection between the

sliding tube and manifold. Engage the hook and rotate it
until it snaps against the body of the clamp.

4. Slide the insulation sleeve up to

the flue manifold. Slip the securing
clips over the sleeve as shown.

Insulation
sleeve

Connecting the Vent Flue

55

Connecting the Air Intake

CONNECTING THE AIR INTAKE

The following components can be connected by reaching behind the appliance as it is positioned against the wall:

1. Connect the air intake hose to

the side of the termination.

NOTE: NEVER cut the gray

air intake hose. It is sized to
length for a standard
termination.

2. Using the zip tie provided,
fasten the air intake to the
termination.

56

1. Install the bracket on the rear of
the top spacer with 2 decorative
sheet metal screws.

2. Place top back spacer on the back of furnace, clipping
the spacer bracket into the wall bracket.

The following components can be connected by reaching behind the appliance as it is
positioned against the wall.

Installing the Top Back Spacer

57

1. Insert screws
for top spacer
on right and left
side of back
spacers.

2. Tighten two sheet metals

screws on top back
spacer.

Installing the Top Back Spacer (continued)

58

Prepare for Operation

1. If needed remove the

toe kick plate to fill
the humidifier tray.

2. Fill the humidifier
tray according to the

installation manual.

Replace toe kick
plate.

1. To direct air flow, if
needed, the front

louvers can be

adjusted after
removing louver
plate (5 screws).

2. Install the filter.

3. Open all gas valves.

4. Turn unit on and set

temperature.

5. Educate consumer
on use and care.

5 screws secure
louver plate

Vertical louvers can be gently turned to
direct air flow

59

ES38 Vent and Gas Connection Differences

Shipped with each ES38 is a vent adaptor that

reduces the 50 mm diameter exhaust to 30

mm for connection to vent termination.

NOTE: If using extension sets, this reducer
must be connected to the VENT
TERMINATION ONLY! Do not use the

smaller extension sets with this reducer

installed at the furnace. The ES38 will not
operate correctly.

Included with the ES38 is male

to female “street” elbow to

attach to the unit before a
union or flex line. This allows

the installer to select the

direction in which the gas line
will be connected.

60

Extended Venting And High

Altitude Installation Procedures

61

Vent Extension Installation Requirements

The following is an overview of guidelines and installation of Rinnai Direct
Vent Furnace vent extensions. This is not a substitute for any current
installation / owner’s manual or vent instructions.

• The 08 series can not use vent extensions.

• See each model’s owner’s / installation manual for permissible vent lengths.

• The vent termination must ALWAYS be horizontal.

• Vent extensions installed in ANY unconditioned air space MUST be insulated with high

temperature insulation and must be accessible.

• All pipe stoppers, connectors, screws and hangars must be used in accordance to their
instructions. The seals must be air tight for both the intake and exhaust air supply hoses.

• The intake air hose must equal the exhaust hose length to maintain a balanced flue system.

• The humidifier trays are made of enamel covered steel to resist rust and corrosion from the

condensate draining back to the unit.

• The 38 series tray cannot be removed from the unit.

• The 08, 11, 17, and 22 series trays can be removed for cleaning but must be replaced before

operation of the unit.

• Overflow of the humidifier tray is an indication that the venting extension was possibly installed

incorrectly. No warranty claim will be approved covering overflow.

62

Vent Extension Installation Requirements

The following is an overview of guidelines and installation of Rinnai Direct
Vent Furnace vent extensions. This is not a substitute for any current
installation / owner’s manual or vent instructions

• The exhaust elbow assembly attached on the back of the unit must remain as a 90° elbow. Never bend
or straighten this component.

• Do not shorten the intake air hose attached to unit from factory.

This hose can never

be cut or altered in

length. The

extension that is

added to this hose

can be cut.

The exhaust elbow

exiting the unit should

never be straightened
(although it appears it

may be possible).

63

• The table below illustrates each model’s permissible vent length and kit part numbers

Specific Venting Changes

MODEL

ES08/EX08C ES11/EX11C

ES17/EX17(C)
ES22/EX22(C)

ES38

Extended

Vent

Guidelines

Total extended vent limit 0 13 feet 13 feet 13 feet

Total vertical limit 0

8 feet (unless greater

than 2000’ altitude then

only 5’ for the ES11

10 feet 13 feet

Type of Extended venting kit needed

12” to 20” (0.3-0.5m) extension

from exhaust to termination

The 08

series can not

use

extensions

Use kit FOT-155 Use kit FOT-219 Use kit FOT-102

21” to 40” (0.5-1m) extension

from exhaust to termination

Use kit FOT-156 Use kit FOT-220 Use kit FOT-103

61” to 80” (1-2m) extension
from exhaust to termination

Use kit FOT-157 Use kit FOT-221 Use kit FOT-114

Standard bent elbow

(can be straightened for

extensions less than 12”)

Use kit FOT-

158 (only 1)

Use kit FOT-158 Use kit FOT-158 Use kit FOT-115

Long bent elbow

(can be straightened for

extensions less than 24”)

Not available

for the ES08

Use kit FOT-190

or FOT-201

Use kit FOT-190

or FOT-201

Not available for

the ES38

FOT-201 now includes an intake hose . It replaces FOT-190

• Each extension kit comes with piping, mounting hardware and pipe connection accessories.

• See the installation / owner’s manual for a complete listing for the kit contents and detailed installation instructions.

• No more than two (2) elbows may be used on any furnace.

64

PCB Adjustments for extended venting or high altitude

MODELS: EX08C, EX17C, EX22C, ES38

These models do not require an adjustment for vent length—only for high altitude

With power off,

remove front cover

and press the test

button on the PCB.

Use the

temperature

arrows on the

control panel to set

as follows

NG

For installations from 0-2000’ above sea level Set code to A1* or A5
For installations from 2001-5200’ above sea level Set code to A2 or A6
For installations from 5201-7700’ above sea level Set code to A3 or A7

For installations from 7701-10,200’ above sea level Set code to A4 or A8

LP

For installations from 0-2000’ above sea level Set code to L1* or L5
For installations from 2001-5200’ above sea level Set code to L2 or L6
For installations from 5201-7700’ above sea level Set code to L3 or L7

For installations from 7701-10,200’ above sea level Set code to L4 or L8

*default setting

A1

Test
Button

65

PCB Adjustments for extended venting or high altitude

MODEL: EX11C

With power off, remove front cover and press the test button on the PCB. Use the

temperature arrows on the control panel to set as follows

(See the previous slide for an illustration)

NG

For installations from 0-2000’ above sea level

with a vent length of 0 to 7 ft Set code to A1*

with a vent length of 7 to 13 ft Set code to A5

For installations from 2001-5200’ above sea level

with a vent length of 0 to 7 ft Set code to A2

with a vent length of 7 to 13 ft Set code to A6

For installations from 5201-7700’ above sea level

with a vent length of 0 to 7 ft Set code to A3

with a vent length of 7 to 13 ft Set code to A7

For installations from 7701-10,200’ above sea level

with a vent length of 0 to 7 ft Set code to A4

with a vent length of 7 to 13 ft Set code to A8

LP

For installations from 0-2000’ above sea level with a vent length of 0 to 13 ft Set code to L1* or L5
For installations from 2001-5200’ above sea level with a vent length of 0 to 13 ft Set code to L2 or L6
For installations from 5201-7700’ above sea level with a vent length of 0 to 13 ft Set code to L3 or L7

For installations from 7701-10,200’ above sea level with a vent length of 0 to 13 ft Set code to L4or L8

*default setting

66

FOT-155 EXTENSION
SET: 12-20 INCHES

Selecting the Correct Vent Extension Kit

EXAMPLES OF EXTENSION SETS

• The following examples are for ES11 /EX11C Models.

• Other models will vary.

• Instructions and all hardware are included.

FOT-157 EXTENSION SET: 61-80 INCHES

67

Use the pipe stoppers, connectors, clamps, and screws according to each extension
set and model’s installation instructions to ensure no leakage of exhaust gases!

CAUTION

Vent Extension Installation Guidelines

PROPER VENTING INSTALLTION GUIDELINES

Example: Using 2 sets of extensions

and 1 standard bent elbow

Example: Using the 80” extension set

VERTICAL RISE
OF EXTENSION
FROM TOP OF THE
FURNACE TO THE
TERMINATION OR
ELBOW CANNOT
EXCEED 10 FEET
ON THE 17 OR 22
MODELS!

(Other models may

vary, see Owner’s /

Installation Manual)

68

Use the pipe stoppers, connectors, clamps, and screws according to each extension set
and model’s installation instructions to ensure no leakage of exhaust gases!

CAUTION

Vent Extension Installation Guidelines

PROPER VENTING INSTALLTION GUIDELINES

INCORRECT!

• Only two elbows are

allowed!

• Venting cannot be turned
down!

INCORRECT!

• Never arrange elbows

where condensation
can collect in the
venting!

CORRECT!

• Slope venting where
condensation is

allowed to drain!

69

Flexibility for venting terminations is engineered into every Rinnai unit. Note below where the
exhaust alignment position can be changed by moving the stainless steel plug for two additional
positions depending on the application. Likewise note the two positions for intake air flexibility.

Alternate Vent Termination Options

ALTERNATIVE TERMINATION CONNECTION

1. Remove the plug from the back
of the termination

2. Reposition the plug to the
bottom of the termination

where labeled “exhaust”

3. Extension venting or
elbows can now be

connected to the back of

the termination

NOTE: The elbow that is integrated into the termination DOES NOT count as one of the two elbows allowable

70

Vent Extension Installation Guidelines

PREPARING FOR EXTENSION INSTALLATION

3. Measure from the end of the
furnace exhaust to the point
of termination or extension
elbow. NOTE: Refer to

each model’s manual to

ensure the vertical rise
limit is not surpassed!

1. Located on the top back

spacer are two sets of
two punch outs (one on
the left and one on the
right). Remove the two
that the extension will
travel thru. Discard the
excess sheet metal.

2. If the top back spacer is

already secured to the
furnace, temporarily remove
it to allow fastening of the
extension components to
the furnace air intake and
exhaust.

71

Vent Extension Installation Guidelines

INSTALLING THE EXHAUST EXTENSION

1. The exhaust is

connected between

the bent pipe at the
rear of the furnace
and the exhaust
port on the flue
manifold.

2. Connect exhaust
pipes with other
straight pipes or
bends (including
the furnace
exhaust) by fitting
the male end into

the female end.

3. If needed, extend
the telescopic
portion of the
extension to the
desired length. Do
not extend beyond
the red line.

Male
end

Female
end

Telescopic
extension

NOTE: Never cut the
exhaust extension

4. Use pipe stopper A to clamp the connection of two pipes.

5. Use pipe stopper B to
secure the length of the
telescopic pipe.

Pipe Stopper A

Pipe Stopper B

72

Vent Extension Installation Guidelines

CONNECTING THE AIR INTAKE EXTENSION

3. Remove the air
intake elbow from
the furnace intake
hose (reverse
threaded). Move
this elbow to the
end of the air

intake extension.

4. Connect the air
intake hoses by
screwing (reverse
thread) the hose
joint half of its
length into the air
intake hose and
the screwing
another air intake
hose into the hose
joint.

Hose
Joint

Air

intake
hoses

Air

intake
elbow

1. The air intake
extension is
connected
between the air
connection at the
rear of the heater
and the air intake

port on the flue

manifold.

2. Cut the air intake
extension to the
desired length.
The lengths of the
air intake hose
and the exhaust
pipe must be the
same in order for
the appliance to
operate properly.
Deburr all rough

edges.

NOTE: Never cut the hose

attached to the appliance!

Practice good safety habits when
using sharp tools!

CAUTION

73

Vent Extension Installation Guidelines

MOUNTING COMPONENTS

1. Both the exhaust and air intake extensions are supported by clamps which are
attached to the wall. A wall fixture can be used to offset the clamp from the wall. A
one inch clearance from combustibles should always be maintained from the

exhaust. The clamps provided with the extension kit ensure this clearance is

maintained from the wall and the air intake.

2. If extension are installed horizontally, the air intake hose should be underneath the
exhaust so in the event the air intake sags, it will not contact the exhaust.

74

Decorative Covers For

Vent Extension Kits

75

Vent Cover with Elbow Vent Cover and Termination Cover Basic Installation

Vent Extension Decorative Cover

EXAMPLES OF VENT COVERS

76

Basement Installation

painted vent cover

Painted without

priming

Basement Installation

rough in stage

Basement Installation

finishing stage

Vent Extension Decorative Cover

EXAMPLES OF VENT COVERS

77

• The simple design provides an easy and attractive way to cover vent extensions

• The mounting bracket is installed to the wall behind the extension venting

• The cover is mounted to the bracket from the sides

• The cover is paintable aluminum and can be custom cut.

• All covers are sold as kits.

Side View

Mounting Bracket

Vent Extension Decorative Cover

INSTALLATION OVERVIEW

78

MODEL ES38 ES11, EX11C,

ES/EX17(C),

ES/EX22(C)

DIAGRAM WITH DIMENSIONS

TYPE OF VENT
COVER

Flue Manifold
Cover

Use kit FOT-132

Manifold Kit A

Use kit FOT-140

Manifold Kit B

Vent Cover

Use kit FOT-133

Straight Cover Kit A

Use kit FOT-141

Straight Cover Kit B

Vent Cover
Elbow

Use kit FOT-134

Elbow Cover Kit A

Use kit FOT-142

Elbow Cover Kit B

NOTES:

• ES08/EX08 models cannot use extended venting

• Each kit comes with all required mounting hardware

Vent Extension Decorative Covers –
New ES Series

79

This completes the direct vent

installation course. Please contact

technical support with any

questions or issues.

1-888-746-6247

DV Installation Fundamentals-Level2-#201102 - 081611