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.

•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.

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3

Safety Features

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

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

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

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

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

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

		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

	Natural Gas		Propane Gas
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

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:

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)

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5

Operating Instructions

Getting to know your new heating appliance

6	Rinnai Corporation ES38 Manual

Control Panel

All buttons beep when operated.

TEMPERATURE	ON/OFF BUTTON
DISPLAY	Easy operation
SHOWS EITHER THE	One touch ignition
TEMPERATURE OR
CODED ERROR
MESSAGES.

CONTROL PANEL

	Set Temp
	Room Temp
Economy	Temp	ON/OFF
	Control
	Function Lock

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

FILTER LAMP

Flashes when filter is dirty.

INDICATOR DISPLAY

Rinnai Corporation ES38 Manual

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

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, ON/OFF 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.

Adjusting the Temperature

Set Temp

Room Temp

Temp

Control

Function Lock

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.

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

	Turning the heater OFF		Economy Mode
	Press the ON/OFF button. Do not		Pressing the Economy button will cause
	turn off by unplugging at the power		the appliance to go into Economy Mode
	outlet.		and the green lamp will glow. This
	The fan will continue to run for a	ON/OFF	results in the temperature setting being	Economy
			reduced by 2° F, 30 minutes after the
	short time to prevent the internal
			room temperature has reached the
	components from overheating.
			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.
	8	Rinnai Corporation ES38 Manual

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 will disengage the Lock.

Temp

Control

Function Lock buttons for two seconds

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

CAUTION	Do not fill the tray while the
	appliance is in operation.
	Close the door after filling.
	The humidifier tray and
	surrounding area are hot
	when the appliance is on.

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

Filler Spout

Do not force door open too far.

Close door during operation.

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	Filter						ON
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.

Adjusting Air Flow Direction

CAUTION	Do not adjust the air flow
	louvers while warm air is
	flowing.

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.

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9

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.

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.

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	AIR FILTERS
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.

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.

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.

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?

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.

The fan is started automatically after a short delay.

This is to allow the heat exchanger to warm up, helping to avoid cold draughts.

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.

During Combustion:

Clunking noise when the thermostat operates.

Unit is not heating room.

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

Heater will not re-ignite after overheating.

When the unit is turned off.

Convection fan continues to run after turning OFF.

Other Points:

Steam is discharged from the flue terminal .

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?

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.

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

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

Unit cuts off without apparent reason.		Check whether filters are blocked. Dirty filters will cause the heater to overheat.
Power Failure.		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.

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.

	CODE DISPLAYED	FAULT	REMEDY
			Check that gas is turned ON.
			Check that the vent termination is not
	11	Ignition Failure	blocked.
			Refer to the Restart Function explanation.
			Service call if repeated.
	14	Overheat	Clean filter.
			Service call if repeated. [1]
	16	Room Overheat	Lower room temperature to less than 104°F
			(40°C).
	31	Room Temperature Sensor	Service call.
	32	Faulty
	33	Overheat Temperature Sensor	Service call.
	34	Faulty
	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	Check around the flue terminal for blockage.
			[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	Burnerdoesn’t ignite	Unusualcombustion	Combustionstops duringoperation	Smellof gas	Noisyignition	Takestoo long to warmthe room
ONNoindicator
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.

Remedy

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.

•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.

•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.

•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.

14	Rinnai Corporation ES38 Manual