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Rinnai EX17CT Training Program

Direct vent wall furnace
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Rinnai Direct Vent Wall Furnace
Training Program
Level III – Service Fundamentals
Enhancing Lives By Changing The Way Water Is Heated
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
1
7/21/2017

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Summary of Contents for Rinnai EX17CT

  • Page 1 Rinnai Direct Vent Wall Furnace Training Program Level III – Service Fundamentals Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 2  Warranty Department – warranty claim issues. Available from 8 a.m. to 5 p.m. EST, Monday- Friday.  Technical Support Department – technical issues related to the function and repair of Rinnai products. Available in the office from 8 a.m. to 8 p.m. EST, Monday – Friday AND 24/7/365 on call support for...
  • Page 3  First two letters – Year & Month of Manufacture.  Second two letters – Product category & manufacturing facility.  Last six numbers – Production sequence number. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 4 Manometer (Volt/Ohm Meter) Should you need to contact Rinnai technical support please have these tools available to speed up the troubleshooting process. Also Rinnai needs to know the full model and serial number, have the front cover removed from the product, provide any relevant information such as gas pressures, set temperatures, error codes etc.
  • Page 5 PRODUCT DISASSEMBLY AND COMPONENT REVIEW The following procedures are for EX17CT / EX22CT Service Procedures for other models will vary. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 6 2.Slide the humidifier tray out from the bottom of the cabinet. The tray can be completely removed Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 7: Front Cover Removal

    1. Remove 5 screws from the louver plate on the front cover. 2. Slide the front panel upwards to free the side and top mounting tabs. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 8 Should you need to call Rinnai tech support for assistance you can also record any case number or other important data inside the cover. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 9 PCB from spills on 4. Pull forward, then up on the top top of unit. panel to release the tabs and to remove the panel. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 10: Pressure Sensor

    6. NOTE: Do not confuse the pressure sensor hose with the gas valve pressure balancing hose. The gas valve hose is a thicker/heavier hose. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 11: Pc Board Removal

    5. Remove two screws on right of PCB assembly. 6. Lift up on PCB and unhook tab on left side freeing PCB from unit. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 12: Combustion Fan Removal

    5:00 o’clock position. 5. The fan assembly should now pull out from the combustion air inlet assembly and free of the cabinet. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 13 3. For reassembly purposes make note of any tabs used to help secure the panel and note the position of any wire protection grommets. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 14 (see electrode and spark sensing probe are one previous slide) and assembly) will open at 421⁰F. Flame rod disconnect for measuring current Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 15: Component Review

    3. The sparker and spark sensing connectors are the same. Interchanging these wires will not affect performance. 4. The sparker and spark sensing wires are both white. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 16: Convection Fan Removal

    Should there be a problem with the operation of the fan or if it is disconnected an error code 62 will be displayed. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 17 4 screws holding the motor to the housing. Individual fan parts can be replaced at this time. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 18 (A tab fitted into slot secures the rear of transformer) and disconnect the wiring from the PCB. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 19 3. Remove the 4 screws securing the gas vale to the back of the cabinet. 4. Ensure gaskets and o-rings remain intact and replace if necessary. 5. NOTE: POV screw should ONLY be adjusted during replacement or under Rinnai direction. Enhancing Lives By Changing The Way Water Is Heated ©...
  • Page 20 Ensure the gas tube is clear. Also the gas orifices can be removed and cleaned if necessary. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 21 3. Pull panel free. 4. Panel gasket must remain intact. Replace if the gasket has been compromised in any way. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 22 4. Cover and burner box can now be removed (the assembly will slide out). 5. Burner box can be separated from the cover by removing the two front screws. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 23 (For 2009 and newer models the flame rod has been lengthened and the flame capture plate eliminated. For those models all burners are identical and can be interchanged). Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 24: Heat Exchanger Removal

    4. Remove two screws behind right side of heat exchanger (above and below the burner area). 5. Remove single screw attaching rubber air intake boot to heat exchanger Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 25 2. At this point the heat exchanger assembly can be lifted free and removed from the cabinet. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 26 Reassembly can be accomplished in the reverse order of disassembly. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 27: Electrical Diagnostic Points

    For metering values, reference Rinnai’s Tankless Water Heater Service Manual —the “Electrical Diagnostic Points” section (model dependent) or each unit’s technical data sheet located inside the front cover.
  • Page 28 Meter setting for measuring Probe less than configuration 20,000 Ohms for measuring (20KΩ) but Volts or more than Ohms. 2,000 Ohms (2KΩ). Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 29 VΩ connection to the 200mA Max (mili amps) connection (see picture 1), then set the meter to the correct range (Flame rod current will be measured in DC µA, see picture 2). Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 30 PCB on the Black – Blue wires. 6. Measure output voltage from the transformer to the PCB on the Black – Yellow wires. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 31 3. Measure resistance of the thermistors. (disconnect from the PCB first). a. Room temperature thermistor, Yellow – Yellow wires. b. Overheat thermistor, White – White wires. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 32 Up/Down Temperature buttons together while the unit is OFF. • Refer to each model’s operation and installation manual or service manual for more information on error codes and their remedy. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 33: Fault Codes

    Solenoid valve failure Solenoid valve circuit failure Flue block or venting disconnect Check intake and exhaust inside and outside for blockage or freezing Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 34 72 – 76 – 80 – HI Communication failure Solenoid valve failure 60 – 64 – 68 – 72 - 76 Flue block or venting disconnect Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 35 • The model’s gas type is converted. • Gas pressure setting instructions are in the Direct Vent Service Manual and the unit’s conversion manual. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 36 Follow each model’s specific conversion model and gas type. See each model’s conversion procedure! procedure as outlined in the conversion manual. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 37 PCB test button at the same time and in that order. • The “FF” will then be recorded as the most recent fault code. • The FF code cannot be erased. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 38 2.4°F (1.33°C) 2.4°F (1.33°C) room temp 1.8°F (1.0°C) 1.8°F (1.0°C) read lower 1.2°F (0.66°C) 1.2°F (0.66°C) 0.6°F (0.33°C) 0.6°F (0.33°C) Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 39: Remote Thermostat

    A remote thermostat may be installed on Rinnai DV furnaces (Only for models ending with the letter “T”. For example” EX38CT) • The Rinnai Remote Thermostat Installation Kit must be utilized and the furnace placed in the Remote Thermostat Mode. To place the furnace in the Remote Thermostat mode: With power applied but with the unit in the Off mode, press and HOLD the ECONOMY button, the UP button and the SET TIMES button at the same time for 2.5 seconds...
  • Page 40 If the furnace posts a code 14, the convection fan will run 255 seconds regardless of the combustion stage when the fault occurred. Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 41: Special Notes

    SPECIAL NOTES - EX08CT and EX11CT Models Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 42 Overheat bimetal Overheat thermal fuse behind panel (opens at 421⁰F) (opens at 263⁰F) Gas Valve Assembly Manifold Overheat bimetal (opens at 194⁰F) Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 43 APPENDIX A MODEL QUICK REFERENCE GUIDE Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 44 29 7/8" x 22 7/8" x 10 1/8" RHFE-1004RFA† * Product weight 36 5/8" x 26 3/8" x 13" No Changes ES38 † Includes white models Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 45 Cartons were color coded by model and gas type - label includes model number Gas type and model numbers are now located on label - Enhancing Lives By Changing The Way Water Is Heated and serial number cartons no longer color coded © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 46 New extension kit - replaces FOT-190 and FOT-201 includes intake hose Maximum Temperature Setting Special Order - or from PCB From Control Panel From Control Panel Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

  • Page 47: Quick Reference

    The location of these components were altered creating the need to alter the activation temperature *These changes were implemented on the 08/11 series several years ago Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 48 APPENDIX B 2000 - 2008 RETROFIT PROGRAM Enhancing Lives By Changing The Way Water Is Heated © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...
  • Page 49 While there have been no reports of serious injury or death, as part of MODELS Rinnai’s continuing effort to ensure a safe and efficient product for our customers, we are implementing a Voluntary Corrective Action Plan to AFFECTED: locate and retrofit affected product with a different gasket and burner cover plate.
  • Page 50 This completes the Rinnai Direct Vent Furnace Training Program. Level III Service Fundamentals. Enhancing Lives By Changing The Way Water Is Heated 201103 5/2014 © 2014 Rinnai America Corporation PROPRIETARY and CONFIDENTIAL 7/21/2017...

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