Rinnai EX17CT Troubleshooting guide

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

27/21/2017 Rinnai Proprietary & Confidential 27/21/2017 Rinnai Proprietary & Confidential
Rinnai Service and Support (800-621-9419)
CRC –Consumer Response Center –general calls, consumer questions, etc.
Available from 8 a.m. to 8 p.m. EST, Monday –Friday.
Parts Department –parts orders.
Available from 8 a.m. to 8 p.m. EST, Monday –Friday.
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
technicians who are at the service location. Technicians only, call 1-888-RINNAIS ( 888-746-6247)
Engineering / Applications Department –calls related to product use and applications
including sizing.
Available from 8 a.m. to 5 p.m. EST, Monday - Friday.
Rinnai America also provides the following websites for support:
•www.rinnai.us –for installation manuals, product specifications and supporting documents. More technical information is
available in the “Partner Portal” section of the website. Registration is required for access.
•www.trainingevents.rinnai.us –to register for Rinnai product training live and online classes and videos. Service manuals,
installation manuals and other technical documents are available under the “Resources” section of the site.

3 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
The model & serial numbers will be located on both sides of the product.
The serial number will also be located on the back of the cabinet for some models.
Product model and serial number locations:
Rinnai Model
Number
Factory Model
Number
Serial Number
Label from the back of cabinet.
Serial number format:
First two letters –Year & Month of Manufacture.
Second two letters –Product category & manufacturing facility.
Last six numbers –Production sequence number.

4 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Primary Service Tools:
For service, troubleshooting, and component replacement, the following primary service
tools will be needed (other tools could be needed on occasion).
#2 Phillips
Head
(magnetic)
Small
Phillips
Head U-
Tube Digital 3/16” Allen Wrench Multimeter
(Volt/Ohm Meter)
Screw Drivers Manometer
and or
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. as well as have
utilized the tech sheet and/or service manual to troubleshoot the product as much as
possible prior to the call.

5 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
The following procedures are for
EX17CT / EX22CT
Service Procedures for other models will vary.
PRODUCT DISASSEMBLY AND
COMPONENT REVIEW

6 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1.Remove the toe kick panel
from the bottom of the
cabinet by pressing inward
on the latches on the left
and right sides.
Disassembly:
2.Slide the humidifier tray
out from the bottom of the
cabinet. The tray can be
completely removed.
1
2

7 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Front cover removal:
1
2
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.
1

8 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Inside front cover:
Inside the front
cover is a ------
a. Wiring diagram.
b. Part name chart.
c. Wire color code
chart.
d. Basic operating
and safety
information.
Should you need to
call Rinnai tech
support for
assistance you can
also record any case
number or other
important data
inside the cover.

9 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1. Remove the 5 top panel screws.
2. Note the black plastic alignment
piece on the center screw (some
models may have three alignment
pieces on the three middle
screws).
3. Disconnect control panel wiring
from PCB.
4. Pull forward, then up on the top
panel to release the tabs and to
remove the panel.
1
4
Control Panel / top panel removal:
5
3
2
5. The control panel has a
plastic drip pan
underneath it to protect
the PCB from spills on
top of unit.

10 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1. All current models use a pressure
sensor to ensure there is proper air
movement through the burner, heat
exchanger, and vent system.
2. The pressure sensor snaps into the
PCB case. A pressure sensor is not
included with a replacement PCB. The
existing sensor should be moved to the
new PCB’s casing if it is replaced.
3. The black pressure hose connects on
the front of the sensor.
4. The clear pressure hose connects on
the back of the sensor.
5. On the back of the unit, these hoses
connect to the intake of the vent
system—the black hose connection is
labeled, “BLK”.
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.
Pressure Sensor:
2
3
4
5
6

11 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
PC Board Removal:
1. Disconnect the unit from the electrical power source.
2. Remove all wire harness connectors from the PCB. All
connectors will have a latch. The latch will need to be
released in order to remove the connector.
3. For ease of reassembly mark any connections on the
board that may not be used.
4. Remove ground wires from the right lower side of the
unit.
5. Remove two screws on right of PCB assembly.
6. Lift up on PCB and unhook tab on left side freeing PCB
from unit.
6
4
5
3

12 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1. Disconnect the unit from the electrical
power source. Otherwise the fan
feedback circuitry could be damaged.
An inoperative combustion fan will
post a code 61 on the control panel
display.
2. Disconnect the electrical connector in
the fan wiring harness.
3. Remove the four screws on the
combustion motor mounting plate.
4. Note the fan alignment indicator
marks at the 5:00 o’clock position.
5. The fan assembly should now pull out
from the combustion air inlet
assembly and free of the cabinet.
2
3
Combustion Fan Removal:
1

13 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Inside Panel Removal:
1. Disconnect the overheat thermal fuse connector.
2. Remove the 8 screws that secure the heat shield panel to the frame.
3. For reassembly purposes make note of any tabs used to help secure the panel and note
the position of any wire protection grommets.
2
3
1

14 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Sparker electrode
Flame rod
Overheat bimetals
one on the front & one on the back
(front opens at 266⁰F )
Spark sensing probe. (sparker
electrode and spark sensing probe are one
assembly)
Filter light thermistor
(install flat in the 3:00 position)
17 Series-180⁰F will illuminate filter light
22 Series-183⁰F will illuminate filter light
17 or 22 Series-198⁰F will cause code 14 overheat All bimetal switches
are installed in series
with the thermal fuse
assembly. Any open
or break in this circuit
will cause an
overheat code.
NOTE: The thermal
fuse is located on the
inside panel (see
previous slide) and
will open at 421⁰F.
Flame rod disconnect for measuring current
Heat exchanger component review:
Remove 2 screws to
access bimetal behind this
plate (opens at 185⁰F)

15 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1. The flame rod has a single screw accessible from
the front.
2. This flame rod is held in place by a metal plate. The
plate has two tabs at the back that must seat into
corresponding slots on heat exchanger.
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.
Component Review (cont.):
1 2
3

16 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Convection Fan Removal:
1. Note: Ensure electrical power is
removed from the unit before
connecting or disconnecting the
fan assembly. Otherwise the fan
feedback circuitry could be
damaged.
The fan assembly provides a
feedback signal to the main circuit
board. Should there be a problem
with the operation of the fan or if it
is disconnected an error code 62
will be displayed.
1

17 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Convection Fan Removal:
1. Remove the top control panel (shown in a previous slide), remove 2 screws securing
the left side cabinet panel to the frame. Slide the panel forward to remove.
2. Once the side panel is removed you can access the single screw securing the left
side of fan assembly to the frame (on some models this single screw is installed from the
inside and does not require side panel removal).
3. Remove the 3 screws securing the fan to the right side (one is located toward the front of
the cabinet, the other two are at the back of the cabinet with one above and one below the fan
motor). Now the complete fan assembly can be removed from the unit.
4. If necessary the motor can be removed from the fan assembly. To accomplish this,
loosen the set screw on motor shaft and remove the 4 screws holding the motor to
the housing. Individual fan parts can be replaced at this time.
2
3
1 5

18 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
1. Ensure all power,
gas and
grounding screws
are removed.
2. The spark module
is attached to the
PCB casing.
Spark Module / Transformer Removal:
1
4
3
3. To remove, release the
two tabs securing the
module sub PCB to the
plastic casing and
disconnect the wire
connectors.
4. To remove the
transformer, remove the
single screw securing
transformer to the frame (A
tab fitted into slot secures
the rear of transformer)
and disconnect the wiring
from the PCB.
2

19 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Gas Valve Assembly Removal:
1. Turn off power and gas. Disconnect the gas supply, vent tube and electrical connectors.
2. Remove the single screw securing the gas tube to the valve assembly.
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.
2
3
5
1

20 7/21/2017
© 2014 Rinnai America Corporation
PROPRIETARY and CONFIDENTIAL
Enhancing Lives By Changing The Way Water Is Heated
Gas Manifold Removal:
1. Remove the single screw that secures the gas tube to the manifold. Ensure o-ring remains intact.
Note: the gas tube can be disconnected from the gas valve also (previous slide #2) if necessary for
ease of manifold removal.
2. Remove the two screws securing the manifold to the burner area of the heat exchanger.
3. Gently pull manifold out for access to the burner openings and orifices.
4. For reassembly, ensure alignment pins are seated correctly.
5. For flame related errors, blow out the burners with high air pressure. This will help remove any
spider webs or debris that may have gotten into the openings. Ensure the gas tube is clear. Also
the gas orifices can be removed and cleaned if necessary.
2
1
4