Rinnai Water Heater EX38CTP User Manual

Direct Vent Wall Furnace

Installation and Operation Manual

— 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.

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

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.

WARNING

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.

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

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

2 Rinnai Corporation EX38CT Manual

Table of Contents

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.

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.

DANGER

CAUTION

WARNING

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

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

Required Care and Maintenance

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

Consumer Information

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.

Rinnai Corporation EX38CT Manual 3

WARNING

CAUTION

Safety Behaviors and Practices for the Consumer and Installer

• 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.

• 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.

• 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.

• 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.

• 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.

WARNING

California law requires this notice to be provided:

California Proposition 65:

This product can expose you to chemicals including Di (2-ethylhexyl) phthalate (DEHP) and carbon bisulfide which are known to the State of California to cause cancer, birth defects or other reproductive harm. For more information, visit www.P65Warnings.ca.gov.

4 Rinnai Corporation EX38CT Manual

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.

When an existing Category I heater is removed or replaced, the original venting system may no longer be sized to properly vent the attached appliances. Instructions shall also indicate effects of an improperly sized venting system (formation of condensate, leakage, spillage, etc.) and shall specify the following test procedure.

WARNING: CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 or the Natural Gas and Propane Installation Code, CSA B149.1 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CSA B149.1.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

WARNING

Rinnai Corporation EX38CT Manual 5

Included Installation and Vent Components

The following items are included with the appliance:

(Attached to unit)

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

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)

Flue Manifolds

Vent A Kit is included with the appliance.

6 Rinnai Corporation EX38CT Manual

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.

Installation Instructions

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.

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.

NOTICE

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)

Installer Qualifications

General Instructions

Type of installaon

• For installation in residential and commercial applications.

• Certified for installation in manufactured (mobile) homes.

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 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.

• 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.

• 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.

Rinnai Corporation EX38CT Manual 7

WARNING

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

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.

Prepare for Installation

Tools needed

Materials needed

• Pipe wrenches (2)

• Adjustable pliers

• Screwdrivers (2)

• Wire cutters

• Gloves

• Safety glasses

• Level

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 that may be needed

• Soap or gas leak

detector solution

• Approved venting

• Teflon tape

(recommended) or pipe compound

• 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

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:

• 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.

8 Rinnai Corporation EX38CT Manual

Flue Terminal Clearances

INSIDE

CORNER DE

TAIL

FIXED

CLOSED

OPERABLE

FIXED CLOSED

OPERABLE

[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, clearances

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

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

AIR SUPPLY INLET VENT TERMINAL AREA WHERE TERMINAL IS NOT PERMITTTED

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

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

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

3 feet (91 cm) above if within

10 feet (3 m) horizontally

Clearance above paved sidewalk or paved driveway located on public property

7 feet (2.13 m)  *

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

SNOW

TERMINATION

Clearance in Ref. A also applies to anticipated snow line

Rinnai Corporation EX38CT Manual 9

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.

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.

NOTICE

clearance for

maintenance

10"(250mm)

(50mm)

40" (1m)

0” (0 mm)

10”

(254 mm)

3”

(76 mm)

6”

(153 mm)

Clearances to Combustibles

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.

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.

10 Rinnai Corporation EX38CT Manual

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.

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

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

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

Template is on the appliance carton/box.

Drilling Flue Hole

Attach Wall Brackets

Attach Back Spacers

Rinnai Corporation EX38CT Manual 11

1. Disassemble the flue manifold 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.

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.

• 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.

• 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.

3 screws

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

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.

Inside Connection

Sleeve

Terminal

Remove extension if necessary

Flue Manifold Installation

12 Rinnai Corporation EX38CT Manual

5. Lock the ties

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.

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”.

Terminal seal

Locking tie

Terminal

Locking ties

Sleeve

3 screws

Flue Manifold Installation

Rinnai Corporation EX38CT Manual 13

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

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.

INCORRECT

• Too many bends (limit is 2)

• Air intake hose is above

exhaust pipe

CORRECT

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

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

Extension Kit Installation

14 Rinnai Corporation EX38CT Manual

Clearances

exhaust pipe to combustibles 1 inch (25.4 mm) exhaust pipe to non-combustibles zero

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.

Clamps

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

Installing the Exhaust Line

To connect exhaust pipes with other straight pipes or bends, fit the male end into the female end. Use pipe stopper A to clamp the connection.

Use pipe stopper B to fix the length on the adjustable exhaust pipes. Do not extend these pipes beyond the red line.

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

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

Do not straighten the bent pipe attached to the appliance.

Pipe stopper A

Pipe stopper B

Male end

Female end

Adjust the angle

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.

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

CAUTION

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

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

NOTICE

Extension Kit Installation

Exhaust pipe

Air intake hose

Rinnai Corporation EX38CT Manual 15

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

1 Exhaust Pipe (adjustable)

12.2-21.1 in (311-536 mm)

FOT 111-1 1

1 Exhaust Pipe (adjustable)

21.9-40.4 in (556-1026 mm)

FOT 112-1 1 1

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

12 Screw A ZAA0420SC 2 3 4

13 Screw B CP-30408 4 6 8

Extension Kits and Parts

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 Kit Installation

16 Rinnai Corporation EX38CT Manual

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.

Inlet hose

Inlet elbow

Plastic tie

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

Pipe stopper S

Flue Manifold

Flue Adapter

Connecting the Appliance

Up to 3/8” (10mm)

Adjustable Leg

Rinnai Corporation EX38CT Manual 17

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

WARNING

Gas Connection

□ 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.

Checklist for Venting

• 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.

• 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).

• 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.

Adjust Gas Pressure Settings

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.

CAUTION

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

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.

NOTICE

18 Rinnai Corporation EX38CT Manual

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:

Natural Gas

Short Vent Lengths: 0 - 7ft+1 elbow

(A1 - A4)

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

(A5 - A8)

Propane Gas

Short Vent Lengths: 0 - 7ft+1 elbow

(L1 - L4)

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

(L5 - L8)

Code

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

Altitude

0-2000 ft

0-610 m

2001-5200 ft

611-1585 m

5201-7700 ft

1586-2347 m

7701-10200 ft

2348-3109 m

0-2000 ft

0-610 m

2001-5200 ft

611-1585 m

5201-7700 ft

1586-2347 m

7701-10200 ft

2348-3109 m

Manifold test

pressure -

W.C. Low

1.69 in

(43 mm)

1.59 in

(40 mm)

1.49 in

(38 mm)

1.43 in

(36 mm)

3.21 in

(82 mm)

3.01 in

(76 mm)

2.85 in

(72 mm)

2.73 in

(69 mm)

Manifold test

pressure -

W.C. High

3.77 in

(96 mm)

2.99 in

(76 mm)

2.69 in

(68 mm)

2.45 in

(62 mm)

6.38 in

(162 mm)

5.62 in

(143 mm)

5.06 in

(129 mm)

4.58 in

(116 mm)

PCB Test Switch

Positive Port

Negative Port

Adjust Gas Pressure Settings

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

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”.

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

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.

Rinnai Corporation EX38CT Manual 19

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.

1. Install the front panel and bottom cover.

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

Final Assembly

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.

NORMAL

Flame Rod

Long, clear, blue, stable flames

ABNORMAL

Yellow flames or orange color

Flame Rod

• 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.

Adjust Gas Pressure Settings

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.

mode.

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

16. Return unit to normal functioning.

20 Rinnai Corporation EX38CT Manual

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,

□ Leave the entire manual with the consumer.

Rinnai Corporation EX38CT Manual 21

inches (mm)

12.63 (320)

8.1 (205)

4.5 (113)

36.63 (930)

Gas Connection

3.63 (92)

13 (330)

Air Inlet

21.63 (550)

12.31 (313)

9.31 (250)

.31 (20)

Exhaust Pipe

5.13 (130)

20.69 (526)

26.38 (670)

Dimensions

22 Rinnai Corporation EX38CT Manual

Specifications

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.

Safety Features

• 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

Application

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

Min. Supply Gas Pressure

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

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

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 - 6.3 pints (3000 cc) Electrical Connection AC 120V, 60 Hz, 117 watts Weight 88 lbs (40 kg) Noise Level 39 - 46dB

Rinnai Corporation EX38CT Manual 23

Direct Vent Furnace Operaon Instrucons

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

— 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.

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

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.

WARNING

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

24 Rinnai Corporation EX38CT Manual

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

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

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.

• 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.

TO TURN OFF GAS TO APPLIANCE

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.

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.

OPERATING 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.

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

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.

Manual Valve

OPEN

Safe Operation

Rinnai Corporation EX38CT Manual 25

Getting to Know Your Appliance

GAS CONNECTION

1/2” NPT

PLASTIC TIE

FOR AIR INLET

POWER CORD

PLUG 120V AC

AIR FILTER

VENT TERMINAL

COMBUSTION /

EXHAUST

EXHAUST PIPE

COMBUSTION AIR

INTAKE HOSE

AIR FILTER

PIPE STOPPER

THERMISTOR

BENT ELBOW

WARM AIR OUTLET

HUMIDIFIER

OPEN THE DOOR

AND POUR WATER

INTO THE TRAY

CONTROL PANEL

OPERATION /

TEMPERATURE

CONTROL DISPLAY

FILTER LAMP

OPERATION LAMP

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

26 Rinnai Corporation EX38CT Manual

Sensible Temperature Control

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.

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.

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.

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.

Control Panel

ON / OFF

Child Lock

Rinnai Corporation EX38CT Manual 27

Remote Thermostat Mode (Optional Accessory)

ECONOMY UP PROGRAM

A remote thermostat can be installed for the furnace with the Remote Thermostat Installation Kit (Part # 204000045 for U.S. installations, Part # 204000048 for Canadian Installations). 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.

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.

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

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

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.

ATTENTION

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).

ATTENTION

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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