Rinnai EX38CT Installation Manual

Installation and Operation Manual

EX38CT............... (RHFE-1005FTA2)

Installer: Leave this manual with the appliance. Consumer: Retain this manual for future reference.

Direct Vent Wall Furnace

READ ALL OF THE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR OPERATING THIS HEATER.

This manual provides information on the installation, operation, and maintenance of the heater. For proper operation and safety, it is important to follow the instructions and adhere to the safety precautions.

A licensed professional must install the fan convection heater according to the exact instructions within this manual.

The consumer must read the entire manual to properly operate the heater and to have regular maintenance performed.

WARNING

— Do not store or use gasoline or other ammable 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 instrucons.  If you cannot reach your gas supplier, call the re department.

If the informaon in these instrucons is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

— Installaon and service must be performed by a licensed professional.

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

Safety Definitions ............................................. 2

Safety Behaviors and Practices for the Consumer

and Installer ...................................................... 3

Installation Instructions (for the licensed professional)

State Regulations ............................................. 4

Included Installation and Vent Components .... 5

Installation Instructions..................................... 6

Prepare for Installation ..................................... 7

Determine Installation Location ........................ 7

Flue Terminal Clearances ................................ 8

Clearances to Combustibles ............................ 9

Checklist to Determine Installation Location .... 9

Drilling Flue Hole ............................................ 10

Attach Wall Brackets ...................................... 10

Attach Back Spacers ...................................... 10

Flue Manifold Installation ............................... 11

Extension Kit Installation ................................ 13

Connecting the Appliance .............................. 16

Gas Connection ............................................. 17

Adjust Gas Pressure Settings ........................ 17

Dimensions .................................................... 21

Specifications ................................................. 22

Direct Vent Furnace Operation Instructions

Safe Operation .............................................. 24

Getting to Know Your Appliance .................... 25

Control Panel ................................................. 26

ON / OFF ........................................................ 26

Child Lock ...................................................... 26

Table of Contents

Required Care and Maintenance

Consumer Information

Remote Thermostat Mode

(Optional Accessory) ..................................... 27

Setting the Clock ............................................ 28

Setting and Operating the Timers .................. 28

Override Function .......................................... 29

Economy (Energy Saving Mode) ................... 29

Set Back ......................................................... 29

Humidifier and Air Flow Direction .................. 30

Care and Maintenance .................................. 31

Before Making a Service Call ........................ 32

Diagnostic Codes Remedies ......................... 33

Restart Function............................................. 34

Troubleshooting ............................................. 34

Cut-Away Diagram ......................................... 35

Wiring Diagram .............................................. 36

Ladder Diagram ............................................. 37

Parts List ........................................................ 38

Warranty ........................................................ 46

French Version............................................... 49

NOTICE: Rinnai sometimes shares customer contact information with businesses that we believe provide

products or services that may be useful to you. By providing this information, you agree that we can share your contact information for this purpose. If you prefer not to have your information shared with these businesses, please contact customer service and ask not to have your information shared. We will however, continue to contact you with information relevant to the product(s) you registered and/or your account with us.

If you have any questions or feel that the manual is incomplete contact Rinnai at 1-800-621-9419.

Important 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.

2 Rinnai Corporation EX38CT Manual

Safety Behaviors and Practices for the Consumer and Installer

WARNING

 Repairs should be performed by a qualified service

technician.

 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.

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.

 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.

 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.

 Wear hand protection when touching the side back

covers, front louver, and rear intake for the convection fan.

 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.

 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.

Rinnai Corporation EX38CT Manual 3

Installation Instructions (for the licensed professional)

State Regulations

NOTICE BEFORE INSTALLATION

Rinnai direct-vent appliance must be installed by a state qualified or licensed contractor and a properly

trained Rinnai Installer. If you are not properly trained, you must not install this unit.

IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.00)

For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal

vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon

monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is

to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard

wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or

structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the

property owner to secure the services of qualified licensed professionals for the installation of hard wired

carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an

attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of

installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in

accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS

certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building

at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the

horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than

one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall

not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

4 Rinnai Corporation EX38CT Manual

Included Installation and Vent Components

The following items are included with the appliance:

(Attached to unit)

Flue Manifolds

The following flue manifold sizes are available for different wall thicknesses:

Vent A Kit is included with the appliance.

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 EX38CT Manual 5

Installation Instructions

Installer Qualifications

A licensed professional must install the appliance, inspect it, and leak test it before use. The warranty will be voided due to any improper installation. The installer should have skills such as:

 Gas sizing.

 Connecting gas lines, valves, and electricity.

 Knowledge of applicable national, state, and local

codes.

 Installing venting through a wall.

 Training in installation of direct vent furnaces.

(Training can be accessed on-line at www.trainingevents.rinnai.us)

Type of installaon

 For installation in residential and commercial

applications.

 Certified for installation in manufactured (mobile)

homes.

This appliance may be installed as an OEM installation in a manufactured home (USA only) or mobile home and must be installed in accordance with the manufacturer’s instructions and the Manufactured

Home construction and Safety Standard, Title 24 CFR, Part 3280, in the United States, or the Mobile Home Standard, CAN/CSA Z240 MH Series, in

Canada.

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.

NOTICE

If installation is at a location above 2001 ft (610 m), then follow the Adjust Gas Pressure Settings procedure.

Appliance input ratings are based on sea level operation and need not be changed for operation up to 2000 ft (610 m) elevation.

General Instructions

 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 nylon carpets containing dyes or vinyl surfaces.

 Rinnai suggests that a dedicated electrical circuit

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

 A test plug is provided for testing of manifold

differential pressure. It is located on the modulating gas valve.

MUST DO

 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 Z225.1, 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.

 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 shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psi (3.5 kPa).

 If the flooring is carpet or other combustible materi-

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

 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 conversion of the unit is needed, conversions must be performed by a qualified service provider at the owner’s expense.

 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.

6 Rinnai Corporation EX38CT Manual

DO NOT

 This appliance is not designed to built in.

 This appliance must not be connected to a chimney

flue serving a separate solid-fuel burning appliance.

 The flow of combustion and ventilation air shall not

be obstructed.

WARNING

Do not use substitute materials.

Use only parts certified with the appliance.

Prepare for Installation

Tools needed

 Pipe wrenches (2)  Adjustable pliers  Screwdrivers (2)  Wire cutters  Gloves

 Safety glasses  Level

Determine Installation Location

You must ensure that clearances will be met and that the vent length will be within required limits. Consider the installation environment. Requirements for the gas line and electrical connection can be found in their respective installation sections of this manual.

Environment

Air surrounding the venting, and vent termination(s) is used for combustion and must be free of any compounds that cause corrosion of internal components. These include corrosive compounds that are found in aerosol sprays, detergents, bleaches, cleaning solvents, oil based paints/ varnishes, and refrigerants.

The furnace, venting, and vent termination(s) should not be installed in any areas where the air may contain these corrosive compounds. If it is necessary for a furnace to be located in areas that may contain corrosive compounds, the following instructions are strongly recommended.

IMPORTANT CONSIDERATIONS FOR:

Tools that might be needed

 Hammer drill with

concrete bits

 Saw  Threading machine with

heads and oiler

 Core drill with diamond

head

 Torch set  Copper tubing cutter  Steel pipe cutter

Materials needed

 Soap or gas leak

detector solution

 Approved venting

 Teflon tape

(recommended) or pipe compound

Materials that may be needed

 Heat tape  Pipe insulation  Concrete wall anchors  Optional pipe cover  Optional temperature

controller

 2 conductor 22 AWG

wire for controller

 Single gang electrical

box

 Wire nuts

 DO NOT Install in areas where air for combustion

might be contaminated with chemicals.

 Before installation, consider where air has the

ability to travel within the building to the furnace.

 Terminate the unit as far away as possible from

any air inlet vents. Corrosive fumes may be released through these vents when air is not being brought in through them.

 Chemicals that are corrosive in nature should not

be stored or used near the furnace or vent termination.

Damage and repair due to corrosive compounds in the air is not covered by warranty.

Rinnai Corporation EX38CT Manual 7

Flue Terminal Clearances

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED CLOSED

OPERABLE

SNOW

TERMINATION

Clearance in Ref. A also applies to anticipated snow line

AIR SUPPLY INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED

[1] A vent shall not terminate directly above a sidewalk or paved

[2] Permitted only if veranda, porch, deck, or balcony is fully open on

8 Rinnai Corporation EX38CT Manual

Ref Description

Canadian Installations US Installations

A Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 12 inches (30 cm)

B Clearance to window or door that may be opened 12 inches (30 cm) 9 inches (23 cm)

C Clearance to permanently closed window * *

Vertical clearance to ventilated soffit, located above the terminal

within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

E Clearance to unventilated soffit * *

* *

F Clearance to outside corner * *

G Clearance to inside corner * *

Clearance to each side of center line extended above meter/

regulator assembly

3 feet (91 cm) within a height

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

I Clearance to service regulator vent outlet 36 inches (91 cm) *

Clearance to nonmechanical air supply inlet to building or the

combustion air inlet to any other appliance

K Clearance to a mechanical air supply inlet 6 feet (1.83 m)

Clearance above paved sidewalk or paved driveway located on

public property

12 inches (30 cm) 9 inches (23 cm)

7 feet (2.13 m)  *

3 feet (91 cm) above if within

10 feet (3 m) horizontally

M Clearance under veranda, porch, deck, or balcony 12 inches (30 cm)  *

driveway that is located between two single family dwellings and serves both dwellings.

a minimum of two sides beneath the floor.

 For clearances not specified in ANSI Z223.1/NFPA 54, clearances

are in accordance with local installation codes and the requirements of the gas supplier.

Clearance to opposite wall is 24 inches (60 cm).

clearance for

maintenance

10"(250mm)

(50mm)

40" (1m)

Additional Clearances

Clearances to access the appliance during servicing are 10 inches (254 mm) from the sides, 40 inches (1 m) from the front, and the area shown above the appliance in the picture.

3”

10”

(254 mm)

(76 mm)

6”

(153 mm)

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.

Rinnai recommends 10” (254 mm) clearance from the top and on both sides for servicing.

Checklist to Determine Installation Location

□ The furnace is not exposed to corrosive

compounds in the air.

□ The furnace location complies with the clearances. □ The planned venting will not exceed the maximum

length for the number of elbows used.

□ The planned venting termination/air intake location

meets the clearances.

□ Indoor air is not being used for combustion. □ A standard 3 prong 120 VAC, 60 Hz properly

grounded wall outlet.

□ The installation must conform with local codes or,

in the absence of local codes, with the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1. If installed in a manufactured home, the installation must conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280 and/or CAN/SCA Z240 MH Series, Mobile Homes.

□ Leave the entire manual with the consumer.

0” (0 mm)

NOTICE

Rinnai Corporation EX38CT Manual 9

The 40 inch (1 meter) clearance from the front of the appliance does not include flooring material or carpeting that is less than 1.2 inches (30 mm) in height.

Flue Hole

3 1/8"

(80 mm)

8 7/16"

(214 mm)

R11"

(R27

)

R8.0"

(R206 mm

)

8 9/16"

(217 mm)

11"

(280 mm)

Cavity Opening

Drilling Flue Hole

Ensure that there are no gas 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. A template is provided on the appliance carton/box. The center of the hole must be located anywhere within the shaded area, unless extension kits are used. See the dimensions diagram.

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

Template is on the appliance carton/box.

Attach Wall Brackets

Attach the wall brackets as shown. A template is provided.

Attach Back Spacers

Attach side back spacers to both sides of the appliance with 2 screws each.

10 Rinnai Corporation EX38CT Manual

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 furnace.

 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 plastic and remove the extension.

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

Rinnai Corporation EX38CT Manual 11

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

12 Rinnai Corporation EX38CT Manual

Extension Kit Installation

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

Horizontal sections should be sloped 3º to drain condensate. (3º equals 2/3 inch drop per foot of vent.) The direction should be to the outside (if local codes allow) or toward the appliance. Do not allow any low points in the exhaust line where condensate will collect.

Vent extensions installed in unconditioned air space

Slope horizontal sections 3º (2/3 inch drop per foot of vent.)

CORRECT

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

Vent extensions must not be concealed per NFPA 54 and must be accessible allowing inspection and repair. Decorative covers are available from Rinnai.

NOTE The EX38CT is capable of two vent length settings: Short Vent: 0 - 7ft + 1 elbow Long Vent: 7ft + 1 elbow - 13ft + 2 elbows

INCORRECT

 Too many bends (limit is 2)  Air intake hose is above

exhaust pipe

Rinnai Corporation EX38CT Manual 13

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 furnace 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

Pipe stopper A

Exhaust pipe

Air intake hose

Pipe stopper B

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 furnace 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

14 Rinnai Corporation EX38CT Manual

Extension Kit Installation

A FOT-102 (12.2-21.1 inch) B FOT-103 (21.9-40.4 inch)

A FOT-102 (21.1 inch) B FOT-103 (51.2 inch) C FOT-114 (90.6 inch)

Extension Kits and Parts

Item Description Part No. FOT-102 FOT-103 FOT-114 FOT-115

1 Exhaust Pipe (adjustable)

12.2-21.1 in (311-536 mm)

1 Exhaust Pipe (adjustable)

21.9-40.4 in (556-1026 mm)

2 Exhaust Pipe - 39.4 in (1000 mm) FOT 114-3 1

3 Air Intake Hose - 29.5 in (750 mm) RHF 1000-130-e 1

3 Air Intake Hose - 51.2 in (1.3 m) RHF 1000-130-b 1

3 Air Intake Hose - 90.6 in (2.3 m) RHF 1000-130-f 1

4 Bent Elbow FOT 025-4 1

5 Hose Joint RFOT 226-001 1 1 1

6 Pipe Stopper A 1001F-250 1 1 2 2

7 Pipe Stopper B FOT 111-6 1 1 1

8 Top Stopper FOT 062-7 1 1 1

9 Pipe Clamp FOT 064-11 2 sets 3 sets 4 sets

10 Wall Fixture FOT 064-12 2 3 4

11 Nut FOT 062-10 2 3 4

FOT 111-1 1

FOT 112-1 1 1

12 Screw A ZAA0420SC 2 3 4

13 Screw B CP-30408 4 6 8

Rinnai Corporation EX38CT Manual 15

Inlet hose

Inlet elbow

Plastic tie

Pipe stopper S

Flue Manifold

Flue Adapter

Connecting the Appliance

1. Attach flue adapter to the flue manifold with pipe stopper S.

2. Attach the air inlet hose to the flue manifold. Secure with plastic tie. The unused inlet is plugged with the rubber cap supplied on the manifold.

3. Connect the vent sliding tube with pipe stopper S and E. The sliding tube should not be extended beyond the red line. The red line should not be visible after sliding the tube into the vent outlet.

4. Slide the insulation sleeve up to the flue manifold and slip the securing clip over the sleeve as shown.

5. Attach the appliance to the wall brackets, using 2 screws at each bracket.

6. Attach the back spacer with 3 screws to the top of the appliance.

7. If necessary, the appliance can be leveled using the adjustable legs under the front right and left legs.

Up to 3/8” (10mm)

Adjustable Leg

16 Rinnai Corporation EX38CT Manual

Checklist for Venting

Adjust Gas Pressure Settings

□ Verify proper clearances around the vents and air

intakes.

□ Ensure you have used the correct venting

products for the model installed and that you have completely followed the venting manufacturer’s installation instructions and these installation instructions.

□ Verify that the vent system does not exceed the

maximum length for the number of elbows used.

Gas Connection

WARNING

When connecting the gas valve or other gas components in the gas line, use a backup wrench to ensure the connection is gas tight.

 The gas supply line shall be gas tight, sized and so

installed as to provide a supply of a gas sufficient to meet the maximum demand of the furnace without loss of pressure.

 A shut off valve and appliance connector valve

should be installed in the upstream of the gas line to permit servicing.

Complete these instructions for altitude and vent length. (Default altitude: 0ft - 2,000ft. Default vent length:

0 - 7ft+1 elbow )

For high altitude installations in Canada, the conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of CAN/CGA-B149.1 or CAN/CGA-B149 installation codes.

CAUTION

Do not touch any other areas on the PC board besides the “SW” switches while power is supplied to the appliance. Parts of the PC board are supplied with 120 volts AC.

CAUTION

Do not insert hands or objects into the circulation fans while they are running. Injury or mechanical malfunction may occur.

 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 furnace 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.)

 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.

 Refer to an approved pipe sizing chart if in doubt

about the size of the gas line.

 Install manual gas cut-off valve so that it can be

accessed for easy operation. Do not conceal manual cut-off valve behind back spacer.

CAUTION

Do not touch the areas at or near the exhaust. This area becomes very hot and could cause burns.

NOTICE

The regulator has been factory pre-set. If the pressure is incorrect, check the supply pressure first, before making any adjustments to the appliance. Also, if the low control pressure cannot be obtained, adjust the adjustment screw on the proportional valve to roughly set pressure and then recheck both the low and high fire pressures.

Rinnai Corporation EX38CT Manual 17

Adjust Gas Pressure Settings

1. Turn off the gas and the power supply.

2. Remove test port screws (1/8 NPT tap) with 3/16 Allen wrench located at gas valve and burner cover. Attach dual port manometer to these test ports as shown. Ensure that the manometer is properly calibrated.

3. Turn on the gas and power supply to the appliance.

4. Ensure “Set Back” feature has been deactivated. (“Set Back” feature is active by default.)

5. With the unit in the Off position, press the SW1 switch at the top of PC board until it beeps.

6. Select the correct code for gas type, altitude, and vent length on the LED display using ▲ and ▼ buttons:

Positive Port

PCB Test Switch

Negative Port

Code

Altitude

Manifold test

pressure -

W.C. Low

Manifold test

pressure -

W.C. High

Natural Gas

Short Vent Lengths: 0 - 7ft+1 elbow

(A1 - A4)

Long Vent lengths: 7ft +1 elbow - 13ft + 2 elbows

(A5 - A8)

A1 / A5 A2 / A6 A3 / A7 A4 / A8 L1 / L5 L2 / L6 L3 / L7 L4 / L8

0-2000 ft

0-610 m

1.69 in

(43 mm)

3.77 in

(96 mm)

2001-5200 ft

611-1585 m

1.59 in

(40 mm)

2.99 in

(76 mm)

5201-7700 ft

1586-2347 m

1.49 in

(38 mm)

2.69 in

(68 mm)

7701-10200 ft

2348-3109 m

1.43 in

(36 mm)

2.45 in

(62 mm)

Short Vent Lengths: 0 - 7ft+1 elbow

Long Vent lengths: 7ft +1 elbow - 13ft + 2 elbows

0-2000 ft

0-610 m

3.21 in

(82 mm)

6.38 in

(162 mm)

Propane Gas

(L1 - L4)

(L5 - L8)

2001-5200 ft

611-1585 m

3.01 in

(76 mm)

5.62 in

(143 mm)

5201-7700 ft

1586-2347 m

2.85 in

(72 mm)

5.06 in

(129 mm)

7701-10200 ft

2348-3109 m

(69 mm)

(116 mm)

7. Press the SW1 switch twice to enter the gas code into memory.

The LED display turns blank and the unit returns to the normal off mode. You are now ready to

program in your correct low fire and high fire gas pressure setting. Follow the procedure below for setting the manifold gas pressure. Do not adjust gas pressure on this appliance using the screw on top of the gas valve.

8. Press the ON/OFF button to operate the appliance.

9. Press the SW1 switch. The LED will display a “7”.

10. Press the SW1 switch again to change to the low pressure mode. The LED will display “PL”.

2.73 in

4.58 in

11. Compare the pressure reading on the manometer to the correct table for your gas type. If necessary adjust the low fire pressure using the ▲ and ▼ buttons. Press the SW1 switch again.

12. The LED will display “PH” indicating high fire mode.

13. Compare the pressure reading on the manometer to the correct table for your gas type. If necessary adjust the high fire pressure using the ▲ and ▼ buttons.

14. Press the ON/OFF button again. The LED display turns blank and the appliance returns to the normal OFF mode.

18 Rinnai Corporation EX38CT Manual

Adjust Gas Pressure Settings

15. Remove manometer and install Allen head screws. Operate the unit and

16. Return unit to normal functioning.

17. Reactivate “Set Back” feature.

 check the normal operating sequence  visually inspect the flame  check for gas leaks at the test points

NOTE: If the LED display shows “HF” or “LF” do not

touch the ▲ and ▼ buttons or Economy button. In this case push SW1.

Normal Operating Sequence

When you press the ON/OFF button, the LED display will illuminate, the combustion fan will begin to run, and the spark will ignite the main burner.

This furnace has an automatic ignition system. When the main burner has lit, the combustion lamp will glow red, and the spark will stop.

Visual Inspection of Flame

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

Final Assembly

1. Install the front panel and bottom cover.

2. Place the conversion plate (label) on the front cover.

Checklist for Gas and Electricity

□ A manual gas control valve is placed in the gas

line to the heater.

□ Check the gas lines and connections for leaks. □ Confirm that the gas inlet pressure is within limits. □ Confirm that the heater is rated for the gas type

supplied.

□ Confirm that the electricity is supplied from 120

VAC, 60 Hz power source and is in a properly grounded circuit.

□ Confirm that an extension cord or an adapter plug

has NOT been used with the heater.

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.

NORMAL

Flame Rod

Long, clear, blue, stable flames

ABNORMAL

Flame Rod

Yellow flames or orange color

Rinnai Corporation EX38CT Manual 19

Final Checklist

□ The heater is not subject to corrosive compounds

in the air.

□ Clearances from the heater unit are met. □ Clearances from the vent termination are met. □ Ensure you have used the correct venting

products for the model installed and that you have completely followed the venting manufacturer’s installation instructions and these installation instructions.

□ Verify that the vent system does not exceed the

maximum length for the number of elbows used.

□ A manual gas control valve has been placed in the

gas line to the heater.

□ Check the gas lines and connections for leaks. □ Confirm that the gas inlet pressure is within limits. □ Confirm that the heater is rated for the gas type

supplied.

□ Confirm that the electricity is supplied from a 120

VAC, 60 Hz power source, is in a properly grounded circuit, and turned on.

□ Verify the system is functioning correctly by

connecting your manometer to the gas pressure test port on the water heater. Operate all gas appliances in the home or facility at high fire. The inlet gas pressure at the heater must not drop below that listed on the rating plate.

□ Install the front panel. □ Explain to the customer the importance of not

blocking the vent termination.

□ Explain to the customer the operation of the

heater, safety guidelines, maintenance, and warranty.

□ The installation must conform with local codes or,

in the absence of local codes, with the National

□ Leave the entire manual with the consumer.

20 Rinnai Corporation EX38CT Manual

Dimensions

inches (mm)

12.63 (320)

8.1 (205)

4.5 (113)

Exhaust Pipe

13 (330)

36.63 (930)

Gas Connection

3.63 (92)

Air Inlet

20.69 (526)

9.31 (250)

5.13 (130)

.31 (20)

Rinnai Corporation EX38CT Manual 21

21.63 (550)

26.38 (670)

12.31 (313)

Safety Features

Specifications

 Overheat: The appliance will automatically shut

down when the appliance exceeds a predetermined temperature.

 Flame Failure: The appliance will automatically

shut down if the burner flame is extinguished.

 Power Failure: The appliance will cut off the gas if

it loses electrical power.

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

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

 Spark Detector: The appliance automatically shuts

down if there is an abnormal spark at ignition.

 Fusible Link: In case the overheat feature

prevents the temperature from rising then the fusible link will break shutting off the appliance.

Appliance Specifications

EX38CT

Approved for manufactured home (USA only) or mobile home or residential installation convertible for use with natural gas and liquefied petroleum gases (propane / LPG)

Application

Min. Supply Gas Pressure

Max. Supply Gas Pressure 10.5 in (267 mm) W.C. 13.0 in (330 mm) W.C.

BTU/hour input Low 13,200 High 38,400 Low 13,200 High 36,500

BTU/hour output Low 10,560 High 30,720 Low 10,560 High 29,200

General Description Forced combustion, forced convection, flued gas furnace

Operation Push button electronic

Gas Connection 1/2 in NPT

Gas Control Electronic

Burners Stainless steel Bunsen burner

Temperature Control Electronic thermostat

Temperature Range Low, 60 - 80°F (in 2°F increments), High

Ignition System Electronic spark ignition

Flue System

Humidifier Tray Capacity - 6.3 pints (3000 cc)

Electrical Connection AC 120V, 60 Hz, 117 watts

Weight 88 lbs (40 kg)

Noise Level 39 - 46dB

when provision is made for the simple conversion from one gas to the other. Approved for commercial setting. Approved for installation at altitudes up to 10,200 feet (3109 m).

Natural Gas Propane Gas

3.5 in (89 mm) W.C. 8.0 in (203 mm) W.C.

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.

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.

22 Rinnai Corporation EX38CT Manual

Direct Vent Furnace Operaon Instrucons

EX38CT .............. (RHFE-1005FTA2)

Important Facts about your Direct Vent Furnace

Thank you for purchasing a Rinnai Direct Vent Furnace. For proper operation and safety, it is important to follow the instructions and adhere to all safety precautions.

Read all of the instructions and the warranty thoroughly before operating this heater. Keep this manual in a safe place.

NOTICE: Rinnai sometimes shares customer contact information with businesses that we believe provide

WARNING

If the informaon in these instrucons is not followed exactly, a re or explosion may result causing property damage, personal injury, or death.

— Do not store or use gasoline or other ammable vapors and liquids in the vicinity of this or any

other appliance.

— WHAT TO DO IF YOU SMELL GAS

instrucons.

 If you cannot reach your gas supplier, call the re department.

— Installaon and service must be performed by a licensed professional.

Rinnai Corporation EX38CT Manual 23

Manual Valve

OPEN

Safe Operation

If you do not follow these instructions exactly, a fire or explosion

WARNING

FOR YOUR SAFETY READ BEFORE OPERATING

may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.  Do not touch any electric 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.

 STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance using the ON/OFF button on the control panel.

4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

5. Turn Manual valve clockwise to the full OFF position.

OPERATING INSTRUCTIONS

 If you cannot reach your gas supplier, call

the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. 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.

safety information above. If you don’t smell gas go to the next step.

7. Turn the manual gas valve counterclockwise to the full ON position.

8. Turn on all electric power to the appliance using the ON/OFF button.

9. Set the thermostat to desired setting.

10. Burner is lit when indicator lamp “ON” turns red.

11. “ON” indicator and fault code 11, flash when burner fails to ignite.

12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier. See manual for additional information.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP ! Follow “B” in the

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed (Using the ON/OFF button located on control panel.)

3. Locate the manual gas valve.

4. Turn the manual valve clockwise to the full OFF position.

24 Rinnai Corporation EX38CT Manual

TO TURN OFF GAS TO APPLIANCE

NOTE: The fan will continue to operate until the

appliance is cool. Do not turn the appliance off by unplugging it from the wall. Keep burner and control compartment clean. See installation and operating instructions.

Getting to Know Your Appliance

WARM AIR OUTLET

CONTROL PANEL

OPERATION /

TEMPERATURE

CONTROL DISPLAY

FILTER LAMP

OPERATION LAMP

RATING PLATE MODEL NUMBER, SERIAL NUMBER, GAST TYPE, ETC.

HUMIDIFIER

OPEN THE DOOR

AND POUR WATER

INTO THE TRAY

GAS CONNECTION

1/2” NPT

COMBUSTION AIR

INTAKE HOSE

PLASTIC TIE

FOR AIR INLET

THERMISTOR

AIR FILTER

PIPE STOPPER

EXHAUST PIPE

AIR FILTER

POWER CORD

PLUG 120V AC

VENT TERMINAL

COMBUSTION /

EXHAUST

BENT ELBOW

Rinnai Corporation EX38CT Manual 25

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

Fahrenheit or Celsius (Factory default is °F)

1. The furnace must be turned off.

2. Press the Timer 1 and Timer 2 button at the same time for about 5 seconds. The display will show “°C” or “°F”.

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 furnace. The ON indicator will glow green. Once the burner ignites, the ON indicator will glow red. When the furnace warms up, the convection fan will automatically start.

To turn the furnace 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 furnace. Do no unplug the furnace 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 the 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 furnace is ON or OFF.

 If activated while the furnace is ON, all controls other than the OFF switch will be

locked.

 If activated while the furnace is OFF, then all controls will be locked.

 If the furnace 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.

26 Rinnai Corporation EX38CT Manual

Remote Thermostat Mode (Optional Accessory)

A remote thermostat can be installed for the furnace with the Remote Thermostat Installation Kit (Part # 204000045). Once installed, the furnace must be placed in Remote Thermostat mode by following the steps below:

1. Ensure the furnace is plugged in but is turned OFF.

2. Ensure the Set back feature is turned OFF.

3. Press and hold the Economy + Up + Program buttons for 2.5 seconds and then release (00 appears in the display).

4. Press the UP button (01 appears in the display).

5. Press the ON/OFF button; the display will go blank. The furnace is now in Remote Thermostat mode.

ATTENTION

Note: To return the furnace back to Control Panel mode, repeat steps 1-3. At step 4, press the UP button until 02 appears in the display. Next, press the ON/OFF button; the display will go blank. The furnace is now in Control Panel mode.

Do not unplug the furnace within two hours of entering Remote Thermostat mode. This will cause the furnace to revert back to Control Panel mode (default).

00 - Default Factory Setting 01 - Remote Thermostat Mode 02 - Control Panel Mode

ECONOMY UP PROGRAM

ATTENTION

DO NOT place the furnace back into 00 (default factory setting) without the wall thermostat connection

components. Failure to do so may cause the furnace to not function properly.

The following control panel buttons/indicators will remain functional in both modes (Remote Thermostat and Control Panel modes)

 ON/OFF button

 Filter indicator

 ON indicator

 Display (the display will be blank except in the event of an error code. All error codes will appear on the

display in either mode. Error codes will not appear on the remote thermostat even when the furnace is in Remote Thermostat mode.)

ATTENTION

Rinnai Corporation EX38CT Manual 27

The remote thermostat will NOT control the heaters ability to power on or power down. This must still be done by using the ON/OFF button of the heater.

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