Rinnai EX22C, EX17C User Manual

Owner’s Operation and Installation Manual for the

EX17C (RHFE-434FTA) EX22C (RHFE-559FTA)

Energysaver®

Gas Direct Vent Wall Furnace

WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

— Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.

•Do not touch any electrical switch; do not use any phone in

your building.

•Immediately call your gas supplier from a neighbor’s phone.

Follow the gas supplier’s instructions.

•If you cannot reach your gas supplier, call the fire department.

— Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

Table of Contents .......................... 2

Consumer Safety Information ....... 3

Specifications ................................ 4

Operating Instructions ................... 6

Installation Instructions ............... 15

Adjust Gas Pressure Settings ..... 28

Consumer Support ...................... 44

French Version ............................ 46

INSTALLER: Leave this manual with the appliance. CONSUMER: Retain this manual for future reference.

This appliance may be installed in an aftermarket, permanently located, manufactured home (USA only) or mobile home, where not prohibited by local codes.

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.

Table of Contents

Consumer Safety Information

Safety Definitions ............................................. 3

Safety Behaviors and Practices ....................... 3

Safety Features ................................................ 4

Specifications

Appliance Specifications .............................. 4, 5

Features ........................................................... 5

Flue Manifolds .................................................. 5

Operating Instructions

Getting to Know your

New Heating Appliance ................................... 6

Control Panel ................................................... 7

ON/OFF ............................................................ 7

Child Lock ......................................................... 7

Setting the Clock .............................................. 8

Operating the Heater Manually ........................ 8

Setting and Operating the Timers .................... 8

Override Function ............................................. 9

Economy (Energy Saving Mode) ..................... 9

Set back ......................................................... 10

Humidifier and Airflow Direction ..................... 10

Adding Water to the Humidifier ................. 10

Adjusting Air Flow Direction ...................... 10

Care and Maintenance ................................... 11

Maintenance ............................................. 11

Care of Exterior ......................................... 11

Snow Accumulation .................................. 11

Filters ........................................................ 11

Visual Inspection of Flame ........................ 11

Before Making a Service Call ......................... 12

Fault Codes .................................................... 13

Restart Function ............................................. 14

Troubleshooting ............................................. 14

Installation Instructions

General Instructions ....................................... 15

Gas Connection ............................................. 16

Clearances to Combustibles .......................... 16

Attach Back Covers (Sides Only) .................. 16

Dimensions .................................................... 17

Flue Terminal Clearances ........................ 18,19

Installation Parts ........................................... 20

Drilling Flue Hole ........................................... 21

Flue Manifold Installation ......................... 22, 23

Extension Kit Installation .......................... 24-26

Connecting the Appliance .............................. 27

Adjust Gas Pressure Settings .................. 28, 29

Normal Operating Sequence ..................... 29

Visual Inspection of Flame ........................ 29

Final Assembly .......................................... 29

Operating Instructions ................................... 30

Cut-Away Diagram ......................................... 31

Wiring Diagram .............................................. 32

Ladder Diagram ............................................. 33

Parts List ................................................... 34-43

Consumer Support

Warranty Information ..................................... 44

Limited Warranty ...................................... 44, 45

French Version ............................................. 46-80

2 Rinnai Corporation EX17C / EX22C Manual

Consumer Safety Information

Safety Definitions

This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and

others.

DANGER

WARNING CAUTION

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

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

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.

Safety Behaviors and Practices

WARNING

• Repairs should be performed by a qualified service technician. Consumer should not repair by yourself.

• Keep the area around the appliance clear and free from combustible materials, gasoline, and other flammable vapors and liquids.

• Never store liquid propane containers indoors.

• Do not use this appliance if any part has been under

water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

• This appliance is equipped with a three-prong plug for your protection against shock hazard and should be plugged directly into a properly grounded threeprong receptacle. Do not cut or remove the ground prong from this plug.

• Any alteration to the appliance or its controls can be dangerous.

• Do not operate appliance with the panels removed, cracked or broken. Replacement of the panels should be done by a licensed or qualified service person.

CAUTION

• Do not block the warm air discharge. Do not allow anyone to sleep directly in front of the appliance.

• Due to high temperatures, the appliance should be located out of traffic and away from furniture and draperies.

• 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 appliance.

• Clothing or other flammable material should not be placed on or near the appliance.

• Any safety screen or guard removed for servicing must be replaced prior to operating the appliance.

• Do not insert items into the louvers.

Rinnai Corporation EX17C / EX22C Manual 3

• Do not spray aerosols near the appliance while it is operating. Most aerosols contain butane gas which is flammable.

• Do not unplug the appliance while it is operating or while the fans are on.

• Do not use bare hands to touch the front louvers due to high temperatures which may cause burns.

• Prevent dust from accumulating on the power cord, side covers, and parts behind the appliance.

• Do not sit on the heater.

• Do not place containers of liquid on top of the

heater. Water spillage can cause extensive damage to the appliance and may result in electric shock.

Safety Features

• Overheat: The appliance will automatically shut

down when the appliance exceeds a predetermined temperature.

• Power Surge Fuse: A glass fuse on the PC board

protects against overcurrent. If the fuse blows then all indicator lamps will be off.

• Flame Failure: The appliance will automatically

shut down if the burner flame is extinguished.

• Power Failure: The appliance will shut off the gas

if it loses electrical power.

• Spark Detector: The appliance automatically

shuts down if there is an abnormal spark at ignition.

• Fusible Link: In case the overheat feature does

not prevent an overheat then the fusible link could break, shutting off the appliance.

Specifications

Appliance Specifications

Application For manufactured home (USA only) or mobile home or residential installation convertible

for use with natural gas and liquefied petroleum gases (propane / LPG) when provision is made for the simple conversion from one gas to the other. For commercial setting. For installation at altitudes up to 10,200 feet (3109 m).

General Description Forced combustion, forced convection, flued gas furnace

Operation Push button electronic

Gas Connection 1/2 in male NPT

EX17C EX22C

Gas Control Electronic

Burners Stainless steel Bunsen burner

Temperature Control Electronic thermostat, (Low, 60-80ºF in 2ºF increments, High)

Ignition System Electronic spark ignition

Flue System The flue must be terminated to atmosphere with only flue components listed with the

appliance’s certification. Warranty will be voided if non listed components are installed.

Humidifier Tray Capacity - 2.1 pints (1000 cc)

Electrical Connection AC 120V, 60 Hz, 46 watts AC 120V, 60 Hz, 56 watts

Standby Power 0.5 watt

Weight

Noise Level 33-38 dB 33-42 dB

AFUE Rating Natural Gas: 81% Propane: 82% Natural Gas: 80% Propane: 82%

Rinnai is continually updating and improving products. Therefore, specifications are subject to change without prior notice.

The efficiency rating of this appliance is a product thermal efficiency rating determined under continuous operating conditions and was determined independently of any installed system.

57 lbs (26 kg)

4 Rinnai Corporation EX17C / EX22C Manual

Appliance Specifications

Minimum supply gas pressure 3.5 in (89 mm) W.C. 8.0 in (203 mm) W.C.

Maximum supply gas pressure 10.5 in (267 mm) W.C. 13.0 in (330 mm) W.C.

Natural Gas Propane Gas

EX17C

BTU/hour input Low 8200

BTU/hour output Low 6560

Natural Gas Propane Gas

High 16700

High 13360

Low 8200 High 16700

Low 6560 High 13360

BTU/hour input Low 8200

BTU/hour output Low 6560

EX22C

Natural Gas Propane Gas

Low 8200

High 21500

High 17200

High 20700

Low 6560 High 16560

Features

• Restarts automatically when ignition or combustion fails.

• Clean Heating Forced Flue Type

• Easy Operation One-Touch Ignition

• Programmable Thermostat

• Warm Air Outlet at Floor Level (keeps your feet

warm)

• Child Lock

• Room Temperature Setting Memory

• Clean the Air Filter - Indicator Lamp

• Energy Saving Economy Setting

• Humidifier Tray

• Air Flow Directional Louvers

• Direct Vent Easily Installed

• Proportional Heating Variable Capacity

• Hush! Quiet Operation

• Modern Design Minimizes Floor Space

Requirements

• Fault Code Message Display

• Timers 1 and 2

• Dimmer

• Set back (setting a minimum temperature)

• Temperature settings in Fahrenheit or Celsius

Flue Manifolds

See the installation instructions for the parts list of the vent kit.

The “A” Vent Kit is included with the appliance. The following flue manifold sizes are available:

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 - 400mm)

C Vent Kit FOT-153 15 3/4 - 23 5/8 in (400 - 600 mm)

D Vent Kit FOT-154 23 5/8 - 31 1/2 in (600 - 800 mm)

Rinnai Corporation EX17C / EX22C Manual 5

Operating Instructions

Getting to Know your New Heating Appliance

CONTROL PANEL

WARM AIR OUTLET

HUMIDIFIER

REMOVE BOTTOM COVER AND PULL OUT TO REFILL

BOTTOM COVER

HOLD BOTH SIDES AND PULL TOWARD YOU

RATING PLATE

MODEL NUMBER, SERIAL NUMBER, GAS TYPE, ETC.

ENGLISH IS ON THE RIGHT; FRENCH IS ON THE LEFT

GAS CONNECTION

1/2” MALE NPT

POWER CORD

PLUG 120V AC, 60 Hz

ROOM TEMPERATURE SENSOR/THERMISTOR

AIR FILTER

VENT TERMINAL

COMBUSTION AIR/ EXHAUST

EXHAUST PIPE

COMBUSTION AIR INTAKE HOSE

6 Rinnai Corporation EX17C / EX22C Manual

Control Panel Control Panel

Sensible Temperature Control

The sensible temperature control feature allows comfortable heating which matches the conditions in the room.

Based on the information collected by the room temperature thermistor when the heating starts, the heating capacity is automatically adjusted to achieve a

comfortable heating effect and to reach the temperature setting quickly.

Occasionally, the room temperature may briefly exceed the temperature setting due to the layout of the room or heating area.

Display

After the heater is turned on and begins operating, the display will dim. The display will turn off when the heater is turned off. While programming the timers the display will turn off several seconds after a button is last pushed.

Fahrenheit or Celsius

1. The heater 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.

4. Press the ON/OFF button.

ON / OFF

Press the ON/OFF button to operate the heater. The ON indicator will glow green. Once the burner ignites the ON indicator will glow red. When the heater warms up, the fan will automatically start.

To turn the heater off, press the ON/OFF button. The ON indicator light will go out. The fan will continue to operate for several minutes after the burner has gone out in order to cool the heater. Do not unplug the heater while the fan is running.

Child Lock

The Child Lock will help to prevent accidental operation of the appliance and to prevent children from operating the appliance.

To activate Child Lock, press the Child Lock button. The indicator will light and a beep will sound.

To deactivate Child Lock, press the Child Lock button and hold for about 2 seconds. The indicator light will go out and a beep will sound.

• The lock can be activated when the heater is ON or OFF.

• If activated while the heater is ON, all controls other than the OFF switch will

be locked.

• If activated while the heater is OFF, then all controls will be locked.

• If the heater is turned off while the Child Lock is activated, it cannot be turned

on again until the lock is deactivated.

• Deactivating the lock releases the control buttons.

Rinnai Corporation EX17C / EX22C Manual 7

Setting the Clock

1. Press the “Set Times” button.

2. The light next to “Clock” should be lit. 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 “Set Times” button until none of the time options are lit

up.

Operating the Heater Manually

1. Turn the heater on by pressing the “ON/OFF” button.

2. Press the up or down arrows to set the temperature. The left side

of the display shows the temperature setting. The right side of the display shows the room temperature.

Setting and Operating the Timers

Confirm the clock is correct. NOTE: The clock will have to be reset in case of a power failure.

However the timers will retain their settings. The heater will start before the programmed starting time in order to

heat the room by the programmed starting time. The timers can be set while the heater is on or off. To operate the

timer, the heater must be on.

Setting the timers:

1. Press the “Set Times” button twice to set Timer 1.

2. The light next to “Timer 1 on” should be lit. Press the up or down

arrows to set the start time. Holding down either of the arrow keys will change the time more quickly.

3. Press the “Set Times” button again so that the Timer 1 off

position is lit. Press the up or down arrows to set the end time. Holding down either of the arrow keys will change the time more quickly.

4. Press the “Set Times” button again to set the times for Timer 2.

Follow the same steps above to set the start and end times.

5. Press the “Set Times” button until none of the time options are lit

up.

Operating the timers:

To operate the heater using a Timer, press the ON/OFF button and the appropriate Timer button. The heater 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 heater. The timer can be set while the heater is operating.

8 Rinnai Corporation EX17C / EX22C Manual

Override Function

This function is used only when the heater is in Timer operation.

It allows you to “override” the reset timer setting until the beginning of the next Timer period.

For example, if the heater is ON, pressing the “Override” button will turn the heater OFF until the next period. If the heater is OFF, pressing the “Override” button will turn the heater ON, and allow you to select a temperature setting, until the next period. The heater will remain on until the next timer period or until the Override function is turned off.

When in override function, pressing the “Override” button will return the heater to the operation of the current timer period.

Economy (Energy Saving Mode)

The Economy mode can only be set while the heater is operating (heating). Once it is set, it will remain in the system memory until deactivated.

1. To turn the Economy mode on, press the

“Economy” button. The Economy indicator is lit.

• The Economy mode now remains in the system memory.

• If the appliance is turned off manually, or stops heating as a result of an OFF timer period, the “Economy “ indicator will go out.

• Whenever the appliance starts heating again, the “Economy” indicator will light.

2. To turn the Economy mode off, press the “Economy” button. The “Economy “ indicator will go out.

• The Economy mode can only be turned off while

the heater is operating (heating) and when the “Economy” indicator is lit.

Economy Mode Information

After the room is heated initially, the air temperature may be dropped to a lower level without affecting comfort. The Economy Mode reduces the temperature by 2 ºF, 30 minutes after the room temperature setting is reached. After another 30 minutes, it reduces the temperature setting by another 2 ºF, effectively saving energy. The room temperature setting will drop up to a total of 4 ºF.

The Economy Mode will not operate if the heater is under capacity for the room size.

Preset Temperature

2°F reduction

30 min

Rinnai Corporation EX17C / EX22C Manual 9

Set back

This function allows a minimum room temperature to be pre-set, between 38ºF and 78ºF (in 2ºF increments). This temperature should be set below the room temperature setting. The default setting is 60ºF. Once the Set back function is selected the appliance will start heating whenever the room temperature falls below the selected temperature, regardless of timer or manual settings.

Follow these steps to set and operate the Set back feature:

1. Make sure the heater is turned OFF.

2. Press the “Set back” button. The light above the button will come on.

3. Press the up and down buttons to set the minimum temperature.

When the “Set back” indicator is on, frost protection is operating, and will 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.)

Humidifier and Air Flow Direction

Adding Water to the Humidifier

Do not remove the bottom

CAUTION

Warm air is humidified when it passes over the water in the tray.

To fill the tray, remove the bottom panel by pushing on both sides and pulling it toward you. Pull the tray out and fill with water. Do not exceed the fill line. Push the tray back in and attach the bottom panel. Do not operate the appliance unless the humidifier tray is installed.

During operation a small amount of condensation is produced in the flue system and drains into the humidifier tray.

trim panel or the humidifier tray while warm air is flowing. Wait 5 minutes after turning the unit off.

Adjusting Air Flow Direction

Do not adjust the air flow

CAUTION

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.

Do not bend repeatedly (no more than 5 times) or else the louver will break.

The horizontal louvers (which determines the vertical air flow direction) are fixed and cannot be adjusted.

louvers while warm air is flowing.

10 Rinnai Corporation EX17C / EX22C Manual

Care and Maintenance

Maintenance

Filters

All maintenance and service are to be performed by a qualified service technician, preferably one who has attended Rinnai service training classes on the Direct Vent products.

The appliance should be inspected annually by a qualified service technician. More frequent cleaning may be required due to excessive lint from carpeting, bedding material, etc. It is imperative that control compartments, burners, and circulating air passage ways of the appliance be kept clean.

CAUTION

Any screen or guard removed for servicing the appliance must be replaced prior to operating the appliance. Clean as follows:

1. Turn heat off. Allow to cool for an half hour.

2. Remove the front panel by removing five screws.

3. Use pressurized air to remove dust from the main

burner, heat exchanger, and fan blades.

4. Use soft dry cloth to wipe cabinet.

Do not use wet cloth or spray cleaners on the burner. The flue should be inspected annually for blockages or

damage.

Prevent dust from accumulating on the power cord, side covers, and parts behind the appliance.

Dirty filters reduce the air flow and the appliance’s ability to produce heat. The filters should be cleaned frequently during the heating season.

If the filters become blocked the filter indicator lamp will flash red and a beep will sound five time. This beeping will repeat every 5 minutes. Eventually the appliance will turn off and display fault code 14 on the control panel display.

To clean the filters, the appliance should be OFF and cool. Remove the filter and clean it using a soft dry cloth or vacuum. If the filter is greasy wash with warm soapy water, rinse, and dry completely.

Do not use the appliance without the filter installed.

Visual Inspection of Flame

Check that the burner flames are operating normally. The flame can be seen through the circular window.

When operating normally the burner flame should appear as long, clear, blue, stable, streaks. Yellow flames or an orange color is abnormal and maintenance is required.

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, take care not to clip or

pinch any electric cords to prevent electric shock.

Care of Exterior

Dampen soft cloth with warm water. Wring water out well and wipe the unit.

Do not use volatile substances such as benzene or thinners. They cause fading of the paint and deformation of the resin.

Snow Accumulation

Keep the area around flue terminal free of snow and ice. The appliance will not function properly if the intake air or exhaust is impeded by obstructions.

Refer to the Flue Terminal Clearances, page 18. The clearance in Ref. A should be maintained from any snow accumulation.

NORMAL

Flame Rod

Long, clear, blue, stable flames

ABNORMAL

Flame Rod

Yellow flames or orange color

Rinnai Corporation EX17C / EX22C Manual 11

Before Making a Service Call

Before making a service call please check the following:

At Ignition:

Heater does not operate.

Warm air does not flow when the burner lights.

Smoke or strange smells are produced on the first trial light up after installation.

Sharp clicking noises at ignition

During Combustion:

Clicking noise when the thermostat operates.

Unit is not heating room.

Is the heater plugged in? Have the fuses or breaker blown at the fuse box / breaker panel? Is there a power failure? Is the air filter blocked? Is anything blocking the outlet for the hot air? Is the flue blocked?

The fan is started automatically after a short delay. This is to allow the heat exchanger to warm up, helping to avoid cold draughts.

This is caused by grease or oil and dust on the heat exchanger and will stop after a short time.

This is simply expansion noise from the heat exchanger.

This is the sound of the solenoid gas valves opening and closing.

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.

Heater will not re-ignite after overheating.

When the unit is turned off.

Convection fan continues to run after turning OFF.

Other Points:

Steam is discharged from the flue terminal .

Unit shuts off without apparent reason.

Allow heater to cool, clean air filter, operate again.

Even after unit has cooled down, the heater does not ignite again. Repair is necessary. Contact a qualified / authorized service provider.

This is to remove the residual heat from the heat exchanger. The fan will stop when the heater cools down.

High efficiency appliances tend to discharge water vapor on cold days. This is normal.

Check whether filters are blocked. Dirty filters will cause the heater to overheat.

12 Rinnai Corporation EX17C / EX22C Manual

Fault Codes

If there is a malfunction the appliance may shut down as a safety precaution and display a fault code to assist in diagnosing the problem. The fault code will flash in the display on the control panel. When making a service call, this code will assist with diagnosing the fault.

CODE DISPLAYED FAULT REMEDY

11 [1] Ignition Failure

You may be able to clear the fault code by turning the heater off and then on again. If the fault code remains or returns on the next operation, contact Rinnai or your nearest service agent and arrange for a service call.

Check that gas is turned ON.

Check that the vent termination is not blocked.

Refer to the Restart Function explanation.

Service call if repeated.

14 Overheat

16 Room Overheat Ensure that room temperature is less than 104°F (40°C).

49 Sensor Breakdown Service call.

53 Sparker Failure Service call.

61 Combustion Fan Failure Service call.

62 Convection Fan Failure Service call.

71 Faulty Solenoids Service call.

72 Faulty Flame Rod Service call.

73 Communication Error Service call.

99 Flue Block Check around the flue terminal for blockage. [3]

Room Temperature Sensor

Faulty

Overheat Temperature

Sensor Faulty

Faulty ON/OFF Switch or Faulty “Set back” Switch

Service call if repeated. [2]

Clean filter.

Service call.

[1]Only this code is dim. [2]If the fusible link needs replacement, it must be done by a qualified service agency. In addition, the cause of

the overheat needs to be determined. The fusible link is a one use safety device that breaks to shut off the appliance.

[3]Remove any obstructions. The flue needs to be kept clear to expel exhaust gases. If the appliance fails to

operate contact a qualified service agency.

Rinnai Corporation EX17C / EX22C Manual 13

Restart Function

If there is a power failure while the appliance is on, then the appliance will start automatically when the power is restored.

If the appliance fails to ignite, the appliance will attempt ignition after 1 hour. The “Ignition Failure” fault code, 11, will appear during that hour and disappears after a successful ignition. If ignition fails again, then the fault code will remain and another attempt to ignite will occur in 1 hour. The fault code is not stored in the fault code history.

If the flame is extinguished during forced combustion then the appliance will attempt ignition after 1 hour. The “Ignition Failure” fault code, 11, will appear during that hour and disappears after a successful ignition. Forced combustion takes place for about 15 seconds before ignition. After this time, the temperature control logic controls the combustion.

If the flame is extinguished (burner combustion failure) while the temperature control logic is operating the appliance, then the appliance will immediately attempt ignition. No fault code will appear.

Troubleshooting

Problem

Cause

Not Plugged In

Power Failure

(Initial Installation) Air In Gas Pipe

Gas Filter Blocked

Miss Ignition

Flue terminal obstructed

Flue manifold not connected

Louver obstructed

Air filter blocked

Gas Escape

No ON indicator

Burner doesn’t ignite

Unusual combustion

Combustion stops

Remedy

during operation

Smell of gas

Takes too long to

Noisy ignition

warm the room

Plug In

Push On/Off button to attempt restart after power is restored.

Purge air (Installer)

Service Call

Clear obstruction

Service Call

Clear obstruction

Clean filter

Service Call

Child Lock Set

Gas turned off at meter, tank, or valve.

ON Timer is set

Cancel Child Lock

Turn gas on

Cancel “ON” Timer or push override button

14 Rinnai Corporation EX17C / EX22C Manual

Installation Instructions

General Instructions

WARNING

Do not use substitute materials. Use only parts certified with the appliance.

• A qualified service technician should install the

appliance and inspect it before use.

• If you move, check the gas type in your new area.

The local gas authority will be able to advise on local regulations.

• 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.

• 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.

• The appliance, when installed, must be electrically

grounded in accordance with local codes or, in the absence of local codes, with the National Electrical

Code, ANSI/NFPA 70, or the Canadian Electrical Code, CSA C22.1.

• Appliance input ratings are based on sea level

operation and need not be changed for operation up to 2000 ft (610 m) elevation. For operation at elevations above 2000 ft (610 m), follow the procedure in the section, Adjust Gas Pressure Settings.

• The appliance and its appliance main gas valve

must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psi (3.5 kPa).

• The appliance must be isolated from the gas supply

piping system by closing its equipment shut off 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, 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.

• Rinnai suggests that a dedicated electrical circuit

with a 120V AC, 60 Hz, 10 amp power source be used.

• 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. (Wood is included in the shipping container that can be cut to size and used if needed.)

• This appliance is not designed to 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.

• Follow the Adjust Gas Pressure Settings (page

28) and confirm that the correct code is used for your gas type and altitude.

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

• Two 1/8 in test plugs are provided for testing of manifold differential pressure. They are located on the modulating gas valve and on the burner manifold.

• The appliance should be correctly sized for the space it is required to heat. It is recommended that an industry standard BTU Heat Loss Calculation be conducted to determine the proper sizing.

• Follow the installations instructions and those in Care and Maintenance for adequate combustion and ventilation air.

• The flow of combustion and ventilation air shall not be obstructed.

• Clearances to access the appliance during servicing are 2 inches (50 mm) from the sides, 40 inches (1 m) from the front, and 9 inches (225 mm) from the top.

• Locate the heater where outdoor air does not affect the room air thermistor. Otherwise, the sensible temperature control feature will be affected.

NOTICE

If installation is at a location above 2001 ft (611 m), then follow the Adjust Gas Pressure Settings section.

If installation is at or below 2000 ft (610 m) then the pressure settings do not need to be adjusted.

Rinnai Corporation EX17C / EX22C Manual 15

Gas Connection

• The gas supply line shall be gas tight, sized and so installed as to provide a supply of a gas sufficient to meet the maximum demand of the heater without loss of pressure.

• Check the gas supply pressure immediately upstream at a location provided by the gas company. Supplied gas pressure must be within the limits shown in the Specifications section.

• A shut off valve and appliance connector valve should be installed in the upstream of the gas line to permit servicing.

• Flexible pipe and any appliance connector valve used for gas piping shall be types approved by nationally recognized agencies.

• Any compound used on the threaded joint of the gas piping shall be a type which resists the action of liquefied petroleum gas (propane / LPG).

• After completion of gas pipe connections all joints including the heater must be checked for gas tightness by means of leak detector solution, soap and water, or an equivalent nonflammable solution, as applicable. (Since some leak test solutions, including soap and water, may cause corrosion or stress cracking, the piping shall be rinsed with water after testing, unless it has been determined that the leak test solution is non-corrosive.)

• Refer to an approved pipe sizing chart if in doubt about the size of the gas line.

• Install the provided manual gas shut-off valve so that it can be accessed for easy operation. Do not conceal manual cut-off valve behind back spacer.

Manual gas shut-off valve

Clearances to Combustibles

When determining where to install the appliance the clearances to combustibles shown in the figure must be followed. Also refer to the Safety Behaviors and Practices section.

2 in (50 mm)

Zero - See Notice

Zero

NOTICE

9 in (225 mm) are necessary from the top of the appliance to remove the filter for cleaning

2 in

(50 mm) 40 in (1 m)

Attach Back Covers (Sides Only)

Attach back covers as shown.

16 Rinnai Corporation EX17C / EX22C Manual

Engage lugs

Dimensions

22.9 in

(582 mm)

10.1 in

257 mm

6.8 in

172 mm

29.9 in

(760 mm)

3.3 in

85 mm

NOTICE

A full size template is provided on the cardboard packaging.

DO NOT DISCARD until installation is completed.

Rinnai Corporation EX17C / EX22C Manual 17

Flue Terminal Clearances

AIR SUPPLY INLET

VENT TERMINAL AREA WHERE

TERMINAL IS NOT

PERMITTTED

FIXED

CLOSED

OPERABLE

INSIDE

CORNER DE TAIL

FIXED

CLOSED

OPERABLE

Clearance in

Ref. A also

applies to

anticipated

snow line

SNOW

TERMINATION

18 Rinnai Corporation EX17C / EX22C Manual

Flue Terminal Clearances

Ref

Clearance above grade, veranda, porch, deck, or balcony. (Take into account the anticipated snow line)

Description Canadian Installations US Installations

12 inches (30 cm) 12 inches (30 cm)

6 inches (15 cm) for

appliances <

E Clearance to unventilated soffit * * F Clearance to outside corner * *

G Clearance to inside corner 20 inches (50 cm) 20 inches (50 cm)

Clearance to window or door that may be opened

Clearance to permanently closed window

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

Clearance to each side of center line extended above meter/regulator assembly

Clearance to service regulator vent

outlet

12 inches (30 cm) for

appliances > 10,000 BTUh

and <

36 inches (91 cm) for

appliances > 100,000 BTUh

3 feet (91 cm) within a height

15 feet (4.5 m) above the meter/regulator assembly

10,000 BTUh;

100,000 BTUh,

* *

3 feet (91 cm) *

6 inches (15 cm) for

appliances <

9 inches (23 cm) for

appliances > 10,000 BTUh

and <

12 inches (30 cm) for

appliances > 50,000 BTUh

10,000 BTUh;

50,000 BTUh,

6 inches (15 cm) for

appliances <

Clearance to nonmechanical air supply

1 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single

family dwellings and serves both dwellings.

2 Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. ∗For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances are in accordance with local

installation codes and the requirements of the gas supplier.

inlet to building or the combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk or paved driveway located on public property

Clearance under veranda, porch, deck, or balcony

12 inches (30 cm) for

appliances > 10,000 BTUh

and <

36 inches (91 cm) for

appliances > 100,000 BTUh

7 feet (2.13 m) 1 *

12 inches (30 cm) to non-

24 inches (60 cm) to

10,000 BTUh;

100,000 BTUh,

6 feet (1.83 m)

flammables 2

6 inches (15 cm) for

appliances <

9 inches (23 cm) for

appliances > 10,000 BTUh

and <

12 inches (30 cm) for

appliances > 50,000 BTUh

3 feet (91 cm) above if within

10 feet (3 m) horizontally

12 inches (30 cm) to non-

24 inches (60 cm) to

10,000 BTUh;

50,000 BTUh,

flammables 2

Rinnai Corporation EX17C / EX22C Manual 19

Installation Parts

The following items are included with the appliance:

Flue Manifold Slaesrebburerap1 1

“A” Vent Kit, FOT-151

(‘A’ Flue units only)

(For weatherboard installations)

Back Spacer Set

Screw

(M4)

Screw

(M4)

Wall Bracket

Owner’s Manual

For Back Spacer Set

For Spacer Bracket

Pipe Stopper A

Ring

Manual Valve

Set

Plastic tie for air inlet

Screw

(M4)

For Flue Manifold

Wall Bracket Screws

Plastic tie

(L=250mm)

Wood Screw

(M4.8× 32)

Spacer Bracket 1

* This plastic tie should be located here

20 Rinnai Corporation EX17C / EX22C Manual

Drilling Flue Hole

Ensure that there are no gas or water lines, or electrical circuits in the wall location where the flue hole is to be drilled.

Drill the flue hole using a 3 1/8 inch (80 mm) drill. The center of the hole must be located anywhere within the shaded area, unless extension kits are used. See diagram.

For weatherboard walls, drill through the center of the weatherboard from the outside first and then through the plasterboard. A template is provided.

For installation without using extension kits, the configuration of the flue manifold, air intake hose, and exhaust slide pipe should be as shown when installation is completed. The shaded area shows where the flue manifold can be located.

Flue Hole

NOTICE

3 1/8"

(80 mm)

Use a template (included) to determine allowable location of the flue hole.

Configuration viewed from behind the appliance.

Rinnai Corporation EX17C / EX22C Manual 21

Flue Manifold Installation

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

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

• The termination cannot be vertical.

1. Disassemble the flue manifold

• This appliance can only be used with one of the five types of Rinnai flue kits. The flue kits and their dimensions are listed on the previous page.

• Refer to the Flue Terminal Clearances section.

The flue consists of 3 parts:

• sleeve

• inside connection

• outside terminal

Disassemble the flue manifold by first pulling out the inside connection. To remove the outer terminal pull and release the two internal ties and then pull out the outer terminal.

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

2. Adjust the sleeve length Measure wall thickness through previously

drilled 3 1/8 inch (80 mm) hole. The end of the sleeve should protrude 3/16 -

3/8 inch (5-10 mm) from the outside wall. The sleeve is threaded for adjustment. Adjust

the sleeve length to wall thickness plus 3/16 3/8 inch (5-10 mm).

NOTE: Do not extend beyond the red line.

Inside Connection

Terminal

Sleeve

Remove extension if necessary

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.

3. Attach the sleeve Attach to the inside wall using 3 screws

arranging the flange so that the marking “TOP” is at the top.

The flange is offset 2° to allow the condensate drain to the outside.

3 screws

22 Rinnai Corporation EX17C / EX22C Manual

sleeve should extend 3/16 3/8 in (5-10 mm)

Flue Manifold Installation

4. Install the Terminal

Check that the terminal seal is in place. For

weatherboard walls, add the second seal next to the terminal seal to compensate for weather board angle.

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”.

5. Lock the ties

Terminal seal

Terminal

Locking tie

Pulling hard on the left and right hand ties,

clip the ties over the notches inside the sleeve. You should be able to pull the ties 2 or 3 notches past the starting point. Cut the ties, leaving about 3/4 inch (20 mm) past the notch. Bend the 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

Locking ties

Sleeve

Rinnai Corporation EX17C / EX22C Manual 23

Extension Kit Installation

If necessary, extension kits are available to extend the exhaust line and air intake hose between the manifold and the appliance.

(1) The maximum vent length is 13 feet (4 m) with 2

bends. The bent pipe attached to the appliance does not count toward the max limit of 2 bends.

(2) Maximum vertical length allowed is 10 feet (3 m). (3) If the extension is longer than 10 feet (3 m), the

condensate may overflow the condensation pan. Therefore, extension exceeding this length should drain to the outside and sloped 3° downward.

(4) Do not allow any low points or sagging in the

exhaust line. Otherwise, condensate may block the exhaust and affect combustion.

(5) Vent extensions installed in unconditioned air space

must be insulated with high temperature insulation and must be accessible.

(6) Vent extensions must not be concealed per NFPA

54 and must be accessible allowing inspection and repair. Decorative covers are available from Rinnai.

These figures show the 3 possible ways that the extension exhaust line and air intake hose may be directed away from the appliance. All 3 views are from behind the appliance. For your configuration, position the air intake hose as shown.

• Extension lines are through the side panel of the appliance.

• It is not possible to position the extension lines through the other side panel of the appliance.

• One elbow is shown. One additional elbow may be added.

• Instructions (1)-(6) must be followed.

INCORRECT

• Too many bends (limit is 2)

• Air intake hose is above

exhaust pipe

CASE A

Exhaust Line

Pipe Stopper A

Pipe Clamp

Air Intake Hose

Plastic Tie

CASE B

Exhaust Line

Pipe Stopper A

Pipe Clamp

Air Intake Hose

Plastic Tie

• Extension lines are through the top panel of the appliance above where the air intake enters the appliance.

• Two elbows are shown. No additional elbows may be added.

• Instructions (1)-(6) must be followed.

24 Rinnai Corporation EX17C / EX22C Manual

• Extension lines are through the top panel of the appliance above where the exhaust exits the appliance.

• No elbows are shown. Two additional elbows may be added.

• Instructions (1)-(6) must be followed.

CASE C

Exhaust Line

Pipe Stopper A

Pipe Clamp

Air Intake Hose

Plastic Tie

Extension Kit Installation

CAUTION

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

Clearances

exhaust pipe to combustibles 1 inch (25.4 mm)

exhaust pipe to non-combustibles zero

Clamps

Both the exhaust line and air intake hose are supported by clamps which are attached to the wall. A wall fixture can be used to offset the clamp from the wall. Use Screw B to attach the wall fixture to the wall. If the wall fixture is not used then use Screw A and the nut to attach the clamp to the wall.

The air intake hose should always be underneath the exhaust line so that in case the air intake hose sags it will not come into contact with the exhaust line.

Installing the Exhaust Line

The exhaust line is connected between the bent pipe at the rear of the heater and the exhaust port on 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.

Air intake hose

Male end

Exhaust pipe

Female end

Exhaust pipe

Air intake hose

Pipe stopper B

Pipe stopper A

Do not cut the exhaust pipe. Use the adjustable pipes if necessary.

To bend the elbow, insert exhaust pipes into both ends for additional leverage. Bend to desired angle.

Do not straighten the bent pipe attached to the appliance.

Connecting the Air Intake Hose

The air intake hose is connected between the air connection at the rear of the heater and the air intake port on the flue manifold.

Push the air intake hose onto the flue manifold and secure with the plastic cable tie.

Join air intake hoses by screwing the hose joint half of its length into the air intake hose and then screwing another air intake hose into the hose joint.

NOTICE

Do not cut the intake hose. Cutting the intake hose may result in noise.

Adjust the angle

The lengths of the air intake hose and the exhaust pipe must be the same in order for the appliance to operate properly. The hose can be cut to the required length. Deburr all rough edges. Do not cut the hose attached to the appliance.

Support the air intake hose with pipe clamps.

Hose joint

Air intake hoses

Rinnai Corporation EX17C / EX22C Manual 25

Extension Kit Installation

Extension Kits and Parts

EXHAUST PIPE (ADJUSTABLE) EXHAUST PIPE(NON ADJUSTABLE) AIR INTAKE HOSE

PIPE STOPPER A

BENT ELBOW LONG BENT ELBOW

HOSE JOI NT

⑥

⑦

PIPE STOPPER B

⑧

NUT

PIPE CLAMP

⑨

Item Description FOT-219 FOT-220 FOT-221 FOT-158 FOT-190

WALL-FIXTURE

⑩

FOT-201

1 Exhaust Pipe (adjustable)

⑪

SCREW A

⑫

SCREW B

⑬

11.4-20.3 in (290-515 mm)

1 Exhaust Pipe (adjustable)

1 1

21.0-39.6 in (533-1005 mm)

2 Exhaust Pipe - 40 in (1016 mm) 1

3 Air Intake Hose - 29.5 in (750 mm) 1

3 Air Intake Hose - 49.2 in (1.25 m) 1

3 Air Intake Hose - 90.6 in (2.3 m) 1

4 Bent Elbow 1

5 Long Bent Elbow 1

6 Hose Joint 1 1 1

7 Pipe Stopper A 1 1 2 1 1

8 Pipe Stopper B 1 1 1

9 Pipe Clamp 2 sets 3 sets 4 sets

10 Wall Fixture 2 3 4

11 Nut 2 3 4

12 Screw A 2 3 4

13 Screw B 4 6 8

26 Rinnai Corporation EX17C / EX22C Manual

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