Rinnai ES38 User Manual

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Owner’s Operation and Installation Manual for the

ES38 (RHFE-1004RFA)

Energysaver

Gas Direct Vent Wall Furnace

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

Safety Information .......... 3

Operating Instructions .... 6

Care and Maintenance ... 10

Fault Codes .................... 12

Installation Instructions ... 14

Parts List ........................ 32

Consumer Support ......... 42

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

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

liquids in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

your building.

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

Follow the gas supplier’s instructions.

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

department.

— Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

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

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 is only for use with types of gas indicated on the rating plate. A conversion kit is supplied with the appliance.

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

This appliance is only for use with the type of gas indicated on the rating plate. This appliance is not convertible for use with other gases, unless a certified kit is used.

Table of Contents

Consumer Safety Information

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

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

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

Specifications

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

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

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

Operating Instructions

Getting to Know your New Heating Appliance 6

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

Operating the Heater .................................. 8, 9

Care and Maintenance ................................... 10

Before Making a Service Call ......................... 11

Fault Codes .................................................... 12

Restart Function ............................................. 13

Troubleshooting ............................................. 13

Installation Instructions

General Instructions ....................................... 14

Gas Connection ............................................. 15

Clearances to Combustibles .......................... 15

Flue Terminal Clearances ....................... 16, 17

Dimensions .................................................... 18

Installation Parts ........................................... 19

Drilling Flue Hole ........................................... 20

Attach Wall Brackets ...................................... 20

Attach Back Spacers ..................................... 20

Flue Manifold Installation ......................... 21, 22

Extension Kit Installation .......................... 23-25

Connecting the Appliance .............................. 26

Operating Instructions ................................... 27

Cut-Away Diagram ......................................... 28

Wiring Diagram .............................................. 29

Ladder Diagram ............................................. 30

Parts List ................................................... 31-41

Consumer Support

Warranty Information ..................................... 42

Limited Warranty ...................................... 42, 43

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Consumer Safety Information

Safety Definitions

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

others.

DANGER

WARNING CAUTION

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

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

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices.

Safety Behavior and Practices

WARNING

• 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 three-prong receptacle. Do not cut or remove the ground prong from this plug.

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

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

CAUTION

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

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

• Children and adults should be alerted to the hazards of high surface temperature and should stay away to avoid burns or clothing ignition.

• Young children should be carefully supervised when they are in the same room as the appliance.

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

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

Rinnai Corporation ES38 Manual 3

• 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.

Safety Features

• Overheat: The appliance will automatically shut down when the appliance exceeds a predetermined temperature.

• Power Surge Fuse: A glass fuse on the PC board protects against overcurrent. If the fuse blows then all indicator lamps will be off.

• Flame Failure: The appliance will automatically shut down if the burner flame is extinguished.

• Power Failure: The appliance will cut off the gas if it loses electrical power.

• Spark Detector: The appliance automatically shuts down if there is an abnormal spark at ignition.

• Fusible Link: In case the overheat feature prevents the temperature from rising then the fusible link will break shutting off the appliance.

Specifications

Appliance Specifications

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

convertible for use with natural gas and liquefied petroleum gases (propane / LPG) when provision is made for the simple conversion from one gas to the other. For commercial setting.

For installation at altitudes up to 10,200 feet (3109 m). General Description Forced combustion, forced convection, flued gas furnace Operation Push button electronic Gas Connection 1/2 in female NPT Gas Control Electronic Burners Stainless steel Bunsen burner Temperature Control Electronic thermostat 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 - 7 pints (3000 cc)

Electrical Connection AC 120V, 60 Hz, 121 watts Weight 90 lbs (41 kg) Noise Level 37-47 dB AFUE Rating Natural Gas: 80.6% Propane: 82.0%

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.

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Appliance Specifications

Minimum supply gas pressure 5.0 in (127 mm) W.C. 11.0 in (280 mm) W.C.

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

BTU/hour input Low 10,500 High 38,400 Low 10,500 High 36,500

BTU/hour output Low 8,400 High 30,720 Low 8,400 High 29,200

Natural Gas Propane Gas

Features

• Restarts automatically when ignition or combustion fails.

• Clean Heating Forced Flue Type

• Easy Operation One-Touch Ignition

• Sensible Temperature Control Feature

• Comfortable Room Temperature Control and

Display

• Warm Air Outlet at Floor Level (keeps your feet warm)

• Function Lock

• Room Temperature Setting Memory

• Clean the Air Filter - Indicator Lamp

• Energy Saving Economy Setting

• Humidifier Tray

• Air Flow Directional Louvers

• Direct Vent Easily Installed

• Proportional Heating Variable Capacity

• Hush! Quiet Operation

• Modern Design Minimizes Floor Space

Requirements

• Fault Code Message Display

Flue Manifolds

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

Rinnai Corporation ES38 Manual 5

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)

Operating Instructions

Getting to know your new heating appliance

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Control Panel

All buttons beep when operated.

〈CONTROL PANEL 〉

Economy

TEMPERATURE DISPLAY SHOWS EITHER THE TEMPERATURE OR CODED ERROR MESSAGES.

Set Temp

Room Temp

Temp

Control

Function Lock

ON/OFF BUTTON Easy operation One touch ignition

ON/OFF

ENERGY SAVING BUTTON Lamp is "green" when this feature is activated.

〈INDICATOR DISPLAY 〉

FUNCTION LOCK Lamp is "green" when this feature is on.

FILTER LAMP Flashes when filter is dirty.

TEMPERATURE BUTTONS

" " adjust temp. to lower setting. " " adjust temp. to

a higher setting.

OPERATION LAMP This lamp turns "green" when power is on. Lamp will change to "red" when burner is on.

Filter

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Operating the Heater

Turning the heater ON

When you press and release the ON/OFF button, the Temperature Level lamps will illuminate, the combustion fan will begin to run, and the spark will ignite the main burner.

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

If ignition does not occur after 15 seconds, the appliance will automatically turn off and the Temperature Level lamps will flash indicating a fault code. This may occur when using the appliance for the first time or if it has not been used for a while. Try operating the appliance again.

There may be a smell of burning dust or oil the first time the heater is lit or when the heater has been out of operation for a long time.

The appliance may make noises after ignition or when it is turned off. This is normal and is due to the thermal expansion or contraction of its components.

ON/OFF

Adjusting the Temperature

Set Temp

Room Tem p

Temp

Control

F unc tion Loc k

The first time that the appliance is turned on, the preset temperature of 72° F will be shown on the display. Every time the temperature setting is changed, that temperature setting will be the latest data appearing on the display the next time the appliance is turned on.

To change the temperature setting, adjust the temperature control buttons until the desired setting is indicated.

When the desired temperature has been set, 10 seconds later, the display will show the current room temperature.

Turning the heater OFF

Press the ON/OFF button. Do not turn off by unplugging at the power outlet.

The fan will continue to run for a short time to prevent the internal components from overheating.

ON/OFF

The thermostat automatically modulates the burner and the fan to maintain the temperature setting.

The temperature settings available are:

• LO - burner is on minimum combustion

• 60° F - 80° F in two degree increments

• HI - burner is on maximum combustion

Economy Mode

Pressing the Economy button will cause the appliance to go into Economy Mode and the green lamp will glow. This results in the temperature setting being reduced by 2° F, 30 minutes after the room temperature has reached the temperature setting. After another 30 minutes the temperature setting is reduced another 2° F. This could result in the temperature setting being reduced by a maximum of 4° F. The intent of this mode is to save energy.

When the heater is running at the LO setting, the Economy Mode does not function.

Economy

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Temp

Control

F unc tion Loc k

Operating the Heater

Lock

This feature locks the buttons to prevent unintended operation.

Press the up and down buttons to activate and the lamp will glow. Pressing and holding the up and down buttons for two seconds will disengage the Lock.

If the Lock is engaged while the unit is operating, all buttons will be disabled except for the ON/OFF button.

If the Lock is engaged while the unit is off, then all buttons will be disabled. The Lock must be disengaged in order to turn the unit on.

Adding Water to the Humidifier

Do not fill the tray while the

CAUTION

appliance is in operation. Close the door after filling. The humidifier tray and surrounding area are hot when the appliance is on.

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.

Filter Lamp

If the filter lamp flashes during operation, check the air filter for dust. If dust is present, clean the filter. See the Care and Maintenance section. Turn the heater off before cleaning the filter.

Filter

Adjusting Air Flow Direction

To fill the tray, open the door as shown in the diagram and pour water into the tray using the spout built into the door. The air will be humidified as it passes over the water in the tray.

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

If the water overflows from the water level hole, then do not add any more water.

Humidifier Tray

Max. Fill Line

Access Door

Pull

Do not adjust the air flow

CAUTION

The vertical louvers may be adjusted to move the air flow more to the right or to the left.

Use a screw driver or similar object to bend each louver to the desired position.

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

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

louvers while warm air is flowing.

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Filler Spout Do not force door open too far. Close door during operation.

Care and Maintenance

Maintenance

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

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

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

1. Turn heat off. Allow to cool for one hour.

2. Remove the front panel by removing two screws.

3. Use pressurized air to remove dust from the main burner, heat exchanger, and fan blades.

4. Use soft dry cloth to wipe cabinet.

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

damage. Motors are permanently lubricated and do not need

periodic lubrication. Keep fan and motor free of dust and dirt by cleaning annually.

Filters

Dirty filters reduce the air flow and the appliance’s ability to produce heat. The filters should be cleaned frequently during the heating season. If the filters become blocked the filter indicator lamp will flash and the appliance will beep. Eventually the appliance will turn off and the Temperature Level lamp 14 will light, indicating a fault code.

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

AIR F ILTERS

Visual Inspection of Flame

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

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.

Verify proper operation after servicing.

Care of Exterior

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

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

CAUTION

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

Snow Accumulation

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

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

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Before Making a Service Call

Before making a service call please check the following:

At Ignition:

Heater does not operate.

Warm air does not flow when the burner lights.

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

Sharp clicking noises at ignition, or when unit cuts down on the thermostat, or goes out.

During Combustion:

Clunking noise when the thermostat operates.

Unit is not heating room.

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

The fan is started automatically after a short delay. This is to allow the hea t exch anger to w arm up, he lpi ng to avo id c old draugh ts.

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

This is simply expansion noise from the heat exchanger.

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

Is the air filter blocked? Is the set temperature high enough? Is the warm air outlet blocked by anything? Are the doors and windows of the room closed? Was the appliance correctly sized for the space?

Air filter is blocked or the louvers are blocked or obstructed.

Heater will n ot re-ignite after overheating.

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

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

When the unit is turned off.

Convection fan continues to run after turning OFF.

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

Other Points:

Steam is discharged from the flue terminal .

Unit cuts off without apparent reason.

Power Failure.

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

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

Switch OFF, then ON again when power is restored to re-set controls.

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Fault Codes

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

CODE DISPLAYED FAULT REMEDY

11 Ignition Failure

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

Check that gas is turned ON.

Check that the vent termination is not

blocked.

Refer to the Restart Function explanation.

Service call if repeated.

14 Overheat

16 Room Overheat 31

32 33 34 49 Sensor Breakdown Service call. 53 Sparker Failure Service call. 61 Combustion Fan Failure Service call. 70 Faulty ON/OFF Switch Service call. 71 Faulty Solenoids Service call. 72 Faulty Flame Rod Service call.

73 Communication Error Turn heater OFF, then ON again.

99 Flue Block

Room Temperature Sensor

Faulty

Overheat Temperature Sensor

Faulty

Lower room temperature to less than 104°F

Check around the flue terminal for blockage.

Service call if repeated. [1]

Clean filter.

(40°C).

Service call.

[2]

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

operate contact a qualified service agency.

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

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

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Restart Function

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

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

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

Troubleshooting

Problem

Remedy

Cause

Not Plugged In

Power Failure

(Initial Installation) Air In Gas Pipe

Gas Filter Blocked Miss Ignition Flue terminal obstructed Flue manifold not connected Louver obstructed Air filter blocked Gas Escape Function Lock Set Gas turned off at meter, tank,

or valve.

No ON indicator

Burner doesn’t ignite

Unusual combustion

Combustion stops

during operation

Smell of gas

Noisy ignition

Takes too long to

warm the room

Plug In Push On/Off button to attempt

restart after power is restored. Purge air

(Installer) Service Call Service Call Clear obstruction Service Call Clear obstruction Clean filter Service Call Cancel Function Lock

Turn gas on

Rinnai Corporation ES38 Manual 13

Installation Instructions

General Instructions

WARNING

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

• A qualified service technician should install the appliance and inspect it before use.

• If you move, check the gas type in your new area. The local gas authority will be able to advise on local regulations.

• The installation must conform with local codes or, in the absence of local codes, with the National Fuel

Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code, CSA B149.1.

• A manufactured home (USA only) or mobile home OEM installation must conform with the

Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280, or, when such a

standard is not applicable, the standard for

Manufactured Home Installations, ANSI/NCSBCS A225.1, or the standard for Gas Equipped Recreational Vehicles and Mobile Housing, CSA Z240.4.

• The appliance, when installed, must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical

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

• 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.

• This appliance is not designed to built in.

• This appliance is only for use with the type of gas

indicated on the rating plate. This appliance is not convertible for use with other gases unless a certified kit is used. If conversion of the unit is needed, conversions must be performed by a qualified service provider at the owner’s expense.

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

• Rinnai suggests that a dedicated electrical circuit with a 120VAC, 60 hz, 10 amp power source be used.

• A test plug are provided for testing of manifold differential pressure. It is located on the modulating gas valve.

• The appliance should be correctly sized for the space it is required to heat.

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

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

• Appliance input ratings are based on sea level operation and need not be changed for operation up to 2000 ft (609.9 m) elevation. For operation at elevations above 2000 ft (609.9 m), refer to the Conversion Manual.

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

14 Rinnai Corporation ES38 Manual

• Clearances to access the appliance during servicing are 2 inches (50 mm) from the sides, 40 inches (1 m) from the front, and 10 inches (250 mm) from the top.

NOTICE

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

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

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 heater 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 / LPG).

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

• 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.

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. The clearance to combustibles from the top is zero.

Rinnai recommends 10” (250 mm) clearance on both sides for servicing.

(50mm)

40" (1m)

10"(250mm)

(50mm)

Rinnai Corporation ES38 Manual 15

Flue Terminal Clearances

AIR SUPPLY INLET

VENT TERMINAL AREA WHERE

TERMINAL IS NOT

PERMITTTED

FIXED

CLOSED

OPERABLE

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

Clearance in

Ref. A also

applies to

anticipated

snow line

SNOW

TERMINATION

16 Rinnai Corporation ES38 Manual

Flue Terminal Clearances

Ref

Clearance above grade, veranda,

C Clearance to permanently closed * *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

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

porch, deck, or balcony. (Take into account the anticipated snow line)

Clearance to window or door that may be opened

Vertical clearance to ventilated soffit, located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal

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

Description Canadian Installations US Installations

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

6 inches (15 cm) for

appliances <

12 inches (30 cm) for

appliances > 10,000 BTUh

and <

36 inches (91 cm) for

appliances > 100,000 BTUh

3 feet (91 cm) within a height

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

10,000 BTUh;

100,000 BTUh,

* *

6 inches (15 cm) for

appliances <

9 inches (23 cm) for

appliances > 10,000 BTUh

and <

12 inches (30 cm) for

appliances > 50,000 BTUh

10,000 BTUh;

50,000 BTUh,

I Clearance to service regulator vent 3 feet (91 cm) *

6 inches (15 cm) for

appliances <

Clearance to nonmechanical air supply

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

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

installation codes and the requirements of the gas supplier.

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

Clearance to a mechanical air supply inlet

Clearance above paved sidewalk or paved driveway located on public

Clearance under veranda, porch, deck, or balcony

12 inches (30 cm) for

appliances > 10,000 BTUh

and <

36 inches (91 cm) for

appliances > 100,000 BTUh

7 feet (2.13 m) 1 *

12 inches (30 cm) to non-

24 inches (60 cm) to

10,000 BTUh;

100,000 BTUh,

6 feet (1.83 m)

flammables 2 flammables 2

6 inches (15 cm) for

appliances <

9 inches (23 cm) for

appliances > 10,000 BTUh

and <

12 inches (30 cm) for

appliances > 50,000 BTUh

3 feet (91 cm) above if within

10 feet (3 m) horizontally

12 inches (30 cm) to non-

24 inches (60 cm) to

10,000 BTUh;

50,000 BTUh,

flammables 2 flammables 2

Rinnai Corporation ES38 Manual 17

Dimensions

inches (mm)

14 1/16" (357.5)

36 5/8" (930)

23 3/8" (593)

9 13/16" (250)

6 1/2" (165)

6 5/16"(160)

10 7/8" (R 277)

28 7/16" (723)

11 13/16" (300)

13 3/4" (R350)

Cavit y Opening

GAS  C ONNE C TION

26 3/8" (670)

15 5/8" (397)

12 7/16" (316)

7 7/8" (200)

13" (330)

4 9/16" (116)

18 Rinnai Corporation ES38 Manual

Installation Parts

The following items are included with the appliance:

Flue Manifold.......................1

“A” Vent Kit, FOT-151

Back Spacer Set

Wall Brackets

Insulation Clip

Plastic tie for air inlet

(M4)

Spare rubber seal...........................1

(‘A’ Flue units only)

(For weatherboard installations)

For Back Spacer Set

Air inlet hose

Vent adaptor

Pipe stopper A&S

Pipe stopper E

On/Off Valve

(M4× 20)

(M4.8× 32)

Wood Screws

(M4)

Elbow (gas)

For Wall Brackets

For Flue Lock Stopper

For Flue Manifold

Wall Bracket Screws

Owner’s Manual Conversion Manual Template

4(M5)

Rinnai Corporation ES38 Manual 19

Drilling Flue Hole

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

Drill the flue hole using a 3 1/8 inch (80 mm) drill. A template is provided. 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)

Attach Wall Brackets

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

Wall bracket

723

593

Attach Back Spacers

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

20 Rinnai Corporation ES38 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 heater.

• The termination cannot be vertical.

1. Disassemble the flue manifold

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

• Refer to the Flue Terminal Clearances section.

The flue consists of 3 parts:

• sleeve

• inside connection

• outside terminal

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

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

2. Adjust the sleeve length Measure wall thickness through previously

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

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

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

NOTE: Do not extend beyond the red line.

Inside Connection

Terminal

Sleeve

Remove extension if necessary

For other than the “S” type flue manifold, if a shorter length is necessary an extension can be removed. Cut the 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 ES38 Manual 21

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”.

6. 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.

7. 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

22 Rinnai Corporation ES38 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. Any length (horizontal and vertical) in excess of 8 feet (2.4 m) must be sloped 3° downward toward the flue manifold to allow condensate to drain to the outside. 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 insul ation 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.

Examples

INCORRECT

• Too many bends (limit is 2)

• Air intake hose is above exhaust

pipe

CORRECT

Rinnai Corporation ES38 Manual 23

Extension Kit Installation

CAUTION

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

Clearances

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

Clamps

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

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

Installing the Exhaust Line

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

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

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

Exhaust pipe

Air intake hose

Male end

Air intake hose

Female end

Pipe stopper A

Exhaust pipe

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 heater and the air intake port on the flue manifold.

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

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

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

24 Rinnai Corporation ES38 Manual

Extension Kit Installation

A FOT-102(11.4-20.3 inch) B FOT-103(21.0-39.6 inch)

EXHAUST PIPE

EXHAUST PIPE(STRAIGHT) 40 in c h

Extension Kits and Parts

6 9

PIPE STOPPER A

PIPE CLAMP

SCREW A

A FOT-102(29.5 inch) B FOT-103(49.2 inch) C FOT-114(90.6 inch)

AIR INTAKE HOSE

BENT ELBOW HOSE JOINT

PIPE STOPPER B

TOP STOPPER O RING

WALL-FIXTURE

NUT

SCREW B

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

1 Exhaust Pipe (adjustable)

FOT 111-1 1

11.4-20.3 in (290-515 mm)

1 Exhaust Pipe (adjustable)

FOT 112-1 1 1

21.0-39.6 in (533-1005 mm) 2 Exhaust Pipe - 40 in (1016 mm) FOT 114-3 1 3 Air Intake Hose - 29.5 in (750 mm) RHF 1000-130-e 1 3 Air Intake Hose - 49.2 in (1.25 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 FOT 064-8 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 14 O Ring M10B-4-49 1

Rinnai Corporation ES38 Manual 25

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.

Flue Adapter

Pipe stopper S

Flue Manifold

Plastic tie

Inlet elbow

Inlet hose

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.

Screw

Sliding Tube

Flue Manifold

PIPE STOPPER S

PIPE STOPPER A

PIPE STOPPER E

SCREW （M5）

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.

26 Rinnai Corporation ES38 Manual

Operating Instructions

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 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.

1. 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.

4. This appliance is equipped with an ignition device which automatically lights the burner.

try to light the burner by hand.

Do not

5. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full OFF position.

OPERATING INSTRUCTIONS

Manual Valve

try to

OPEN

• 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.

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. Combustion indicator glows red when the burner is lit and flashes when the burner fails to ignite. 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.

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance using the ON/OFF button.

3. Locate the manual gas valve on the side of the heater. Turn the manual valve clockwise to the full OFF position.

Rinnai Corporation ES38 Manual 27

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.

Cut-Away Diagram

28 Rinnai Corporation ES38 Manual

Wiring Diagram

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with type 18 AWG wire or its equivalent.

MARK

R.TH

TF1 ～3

POV

FR 1 ～3

PARTS NAME MAIN SWIT CH THERMISTOR

THER MAL FUSE

FUSE

ELECTRODE

MODULATING S O LENOID VALVE

TR ANSFOR MER

FLAME R OD 1 ～3

MARK

OH.TH

OHS

FM SP

SV1 ～3

PARTS NAME

OVER HEAT THERMISTOR

OVE R HE AT S WITCH

CONVECTION FAN MOTOR

SPARKER

MAIN SOLENO ID VAL V E 1 ～3

COMBUSTION FAN MOTOR

PRESSURE SENSOR

Rinnai Corporation ES38 Manual 29

Ladder Diagram

30 Rinnai Corporation ES38 Manual