Rinnai ES38 User Manual
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.
Register your product at www.rinnairegistration.com
or call 1-866-RINNAI1 (746-6241)
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
2 Rinnai Corporation ES38 Manual
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.
4 Rinnai Corporation ES38 Manual
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
6 Rinnai Corporation ES38 Manual
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
ON
Rinnai Corporation ES38 Manual 7
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
8 Rinnai Corporation ES38 Manual
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
ON
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.
Rinnai Corporation ES38 Manual 9
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.
10 Rinnai Corporation ES38 Manual
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.
Rinnai Corporation ES38 Manual 11
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.
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.
12 Rinnai Corporation ES38 Manual
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.
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