Rinnai Rice Cooker ES38 Installation Manual

Owner’s Operation and Installation Manual for the

ES38 (RHFE-1004FTA)

Energysaver ®

Gas Direct Vent Wall Furnace

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

Consumer Safety Information ..... 3

Specifications .............................. 4

Operating Instructions ................. 6

Installation Instructions ............. 15

Consumer Support .................... 45

State Regulations ...................... 47

French Version .......................... 48

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 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

On / Off ............................................................. 7

Child Lock ........................................................ 7

Setting the Clock .............................................. 8

Operating the Heater Manually ........................ 8

Setting and Operating the Timers .................... 8

Override Function ............................................ 9

Economy (Energy Saving Mode) ..................... 9

Set Back ......................................................... 10

Humidifier and Air Flow Direction .................. 10

Care and Maintenance ................................... 11

Before Making a Service Call ......................... 12

Fault Codes .................................................... 13

Restart Function ............................................. 14

Troubleshooting ............................................. 14

Installation Instructions

General Instructions ....................................... 15

Gas Connection ............................................. 16

Clearances to Combustibles .......................... 16

Flue Terminal Clearances ....................... 17, 18

Dimensions .................................................... 19

Installation Parts ........................................... 20

Drilling Flue Hole ........................................... 21

Attach Wall Brackets ...................................... 21

Attach Back Spacers ..................................... 21

Flue Manifold Installation ......................... 22, 23

Extension Kit Installation .......................... 24-26

Connecting the Appliance .............................. 27

Adjust Gas Pressure Settings .................. 28, 29

Operating Instructions ................................... 30

Cut-Away Diagram ......................................... 31

Wiring Diagram .............................................. 32

Ladder Diagram .............................................

Parts List ................................................... 34-44

Consumer Support

Warranty Information ..................................... 45

Limited Warranty ...................................... 45, 46

State Regulations .............................................. 47

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

• Repairs should be performed by a qualified service technician.

• 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 threeprong 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.

Rinnai Corporation ES38 Manual 3

• 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.

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

• Do not sit on the heater.

• Do not place containers of liquid on top of the

heater. Water spillage can cause extensive damage to the appliance and may result in electric shock.

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 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 - 6.3 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

• Programmable Thermostat

• Warm Air Outlet at Floor Level (keeps your feet

warm)

• Child 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

• Timers 1 and 2

• Set back (setting a minimum temperature)

Flue Manifolds

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

Vent A Kit is included with the appliance.

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 Control Panel

Clock

Timer Timer

1 2

on o

Timer 1 Time r 2

Set

Room

Te m p

Times

EconomyOverride

Set

Time

Child Lock

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.

Occasionally, the room temperature may briefly exceed the temperature setting due to the layout of the room or heating area.

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.

Set back

ON/OFF

Fi lt er

On / Off

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, 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.

To turn the heater off, press the ON/OFF button. The fan will continue to operate for several minutes after the burner has gone out in order to cool the heater. Do not unplug the heater while the fan is running.

ON/OFF

Child 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.

Te m p

Time

Child Lock

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Setting the Clock

1. Press the “Set Times” button.

2. The light next to “Clock” should be lit. Press the up and

down arrows to set the time. Holding down either of the arrow keys will change the time more quickly.

Set

Room

Clock

Timer Timer

1 2

on o

3. Press the “Set Times” button until none of the time options

are lit up.

Te m p

Set

Times

Time

Operating the Heater Manually

1. Turn the heater on by pressing the “ON/OFF” button.

2. Press the up or down arrows to set the temperature. The left display shows

the temperature setting. The right display shows the 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

ON/OFF

Set

Te m p

Room

Time

Setting and Operating the Timers

Confirm the clock is correct. NOTE: The clock will have to be reset in

case of a power failure. However the timers will retain their settings.

The heater will start before the programmed starting time in order to heat the room by the programmed starting time.

The timers can be set while the heater is on or off. To operate the timer, the heater must be on.

Setting the timers:

1. Press the “Set Times” button twice to set Timer 1.

2. The light next to “Timer 1 on” should be lit. Press the up or down arrows to set the start time. Holding down

either of the arrow keys will change the time more quickly.

3. Press the “Set Times” button again so that the Timer 1 off position is lit. Press the up or down arrows to set

the end time. Holding down either of the arrow keys will change the time more quickly.

4. Press the “Set Times” button again to set the times for Timer 2. Follow the same steps above to set the start

and end times.

5. Press the “Set Times” button until none of the time options are lit up.

Operating the timers:

To operate the heater using a Timer, press the ON/OFF button and the appropriate Timer button. The heater will operate from the start to end times you have entered for that Timer. It will operate at the temperature setting that has been set for the heater. The timer can be set while the heater is operating.

Timer 1 Timer 2

Set

Room

Te m p

Time

Clock

Timer Timer

Set

1 2

on o

Times

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Override Function

This function is used only when the heater is in Timer operation.

It allows you to “override” the reset timer setting until the beginning of the next Timer period.

For example, if the heater is ON, pressing the “Override” button will turn the heater OFF until the next period. If the heater is OFF, pressing the “Override” button will turn the heater ON, and allow you to select a temperature setting, until the next period. The heater will remain on until the next timer period or until the Override function is turned off.

When in override function, pressing the “Override” button will return the heater to the operation of the current timer period.

Override

Economy (Energy Saving Mode)

The Economy mode can only be set while the heater is operating (heating). Once it is set, it will remain in the system memory until deactivated.

1. To turn the Economy mode on, press the

“Economy” button. The Economy indicator is lit.

Economy

• The Economy mode now remains in the system memory.

• If the appliance is turned off manually, or stops heating as a result of an OFF timer period, the “Economy “ indicator will go out.

• Whenever the appliance starts heating again, the “Economy” indicator will light.

2. To turn the Economy mode off, press the “Economy” button. The “Economy “ indicator will go out.

• The Economy mode can only be turned off while

the heater is operating (heating) and when the “Economy” indicator is lit.

Economy Mode Information

After the room is heated initially, the air temperature may be dropped to a lower level without affecting comfort. The Economy Mode reduces the temperature by 2 ºF, 30 minutes after the room temperature setting is reached. After another 30 minutes, it reduces the temperature setting by another 2 ºF, effectively saving energy. The room temperature setting will drop up to a total of 4 ºF.

The Economy Mode will not operate if the heater is under capacity for the room size.

Preset Temperature

2°F reduction

30 min

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Set Back

This function allows a minimum room temperature to be pre-set, between 38ºF and 78ºF (in 2ºF increments). This temperature should be set below the room temperature setting. The default setting is 60ºF. Once the Set back function is selected the appliance will start heating whenever the room temperature falls below the selected temperature, regardless of timer or manual settings.

Follow these steps to set and operate the Set back feature:

1. Make sure the heater is turned OFF.

2. Press the “Set back” button. The light above the button will come on.

3. Press the up and down buttons to set the minimum temperature.

When the “Set back” indicator is on, frost protection is operating, and will always prevent the room temperature from falling below the pre-set minimum temperature (as long as electric power and gas is supplied).

Set back

Set

Room

Te m p

To turn this feature off, press the “Set back” button. The unit will retain its ON or OFF setting after a power failure. (Default setting at

the factory is on.)

Time

Humidifier and Air Flow Direction

Adding Water to the Humidifier

Do not fill the tray while the

CAUTION

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.

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

Humidifier Tray

Adjusting Air Flow Direction

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 louvers (which determines the vertical air flow direction) are fixed and cannot be adjusted.

louvers while warm air is flowing.

Max. Fill Line

Access Door

Pull

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

10 Rinnai Corporation ES38 Manual

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.

Do not use the appliance without the filters installed.

AIR FILTERS

Visual Inspection of Flame

Check that the burner flames are operating normally. The flame can be seen through the circular window on the right side of the heat exchanger assembly.

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. When attaching the front panel, take care not to clip or

pinch any electric cords to prevent electric shock.

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 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.

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 not 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.

12 Rinnai Corporation ES38 Manual

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

49 Sensor Breakdown

53 Sparker Failure

61 Combustion Fan Failure

71 Faulty Solenoids

72 Faulty Flame Rod

Room Temperature Sensor

Disconnection (open circuit)

Room Temperature Sensor

short circuit

Overheat Temperature Sensor

Disconnection (open circuit)

Overheat Temperature Sensor

short circuit

Faulty ON/OFF Switch or

Faulty “Set Back” Switch

Lower room temperature to less than 104°F

Service call if repeated. [1]

Clean filter.

(40°C).

Service call.

73 Communication Error Turn heater OFF, then ON again.

99 Flue Block

[1] 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.

[2] 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.

Rinnai Corporation ES38 Manual 13

Check around the flue terminal for blockage.

[2]

Restart Function

If there is a power failure while the appliance is on, then the appliance wills tart automatically when the power is restored.

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.

In summary, if the ignition fails or the flame is extinguished during forced combustion then the appliance will attempt to restart after 1 hour. If the flame is extinguished after this period then the appliance will immediately attempt ignition.

Troubleshooting

Problem

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

Remedy

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

Clear obstruction

Service Call

Clear obstruction

Clean filter

Service Call

Child Lock Set

Gas turned off at meter, tank, or valve.

ON Timer is set

Cancel Child Lock

Turn gas on

Cancel “ON” Timer or push override button

14 Rinnai Corporation ES38 Manual

Installation Instructions

General Instructions

WARNING

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

NOTICE

• 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 Z225.1, 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.

• 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.

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

Appliance input ratings are based on sea level operation and need not be changed for operation up to 2000 ft (610 m) elevation.

• 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. It is recommended that an Industry standard BTU Heat Loss Calculation be conducted to determine the proper sizing.

• 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 10 inches (254 mm) from the sides, 40 inches (1 m) from the front, and the area shown above the appliance in the picture.

10"

(254 mm)

clearance for maintenance

(76 mm)

(153 mm)

Rinnai Corporation ES38 Manual 15

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.

• An elbow is supplied to attach to the gas line if needed.

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.

Rinnai recommends 10” (254 mm) clearance from the top and on both sides for servicing.

(50mm)

NOTICE

16 Rinnai Corporation ES38 Manual

The 40 inch (1 meter) clearance from the front of the appliance does not include flooring material or carpeting that is less than 1.2 inches (30 mm) in height.

40" (1m)

0” (0 mm)

10"(250mm)

(50mm)

Flue Terminal Clearances

AIR SUPPLY INLET

VENT TERMINAL AREA WHERE

TERMINAL IS NOT

PERMITTTED

FIXED

This diagram shows the mini-

mum clearances from the flue.

CLOSED

OPERABLE

INSIDE

CORNER DE TAIL

FIXED

CLOSED

OPERABLE

Clearance in

Ref. A also

applies to

anticipated

snow line

SNOW

TERMINATION

Rinnai Corporation ES38 Manual 17

Flue Terminal Clearances

Ref

Clearance above grade, veranda,

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

Clearance to permanently closed window

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

Clearance to service regulator vent

outlet

Description Canadian Installations US Installations

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

12 inches (30 cm) 9 inches (23 cm)

* *

3 feet (91 cm) within a height

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

3 feet (91 cm) *

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 property

Clearance under veranda, porch, deck, or balcony

12 inches (30 cm) 9 inches (23 cm)

6 feet (1.83 m)

7 feet (2.13 m) 1 *

12 inches (30 cm) to non-

flammables 2

24 inches (60 cm) to

flammables 2

3 feet (91 cm) above if within

10 feet (3 m) horizontally

12 inches (30 cm) to non-

flammables 2

24 inches (60 cm) to

flammables 2

18 Rinnai Corporation ES38 Manual

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" (R277)

28 7/16" (723)

11 13/ 16" (300)

13 3/ 4" (R350)

Cavi ty Op en in g

GAS CONNECTION

26 3/8" (670)

15 5/ 8" (397)

12 7/16" (316)

7 7/8" (200)

13" (330)

4 9/16" (116)

Rinnai Corporation ES38 Manual 19

Installation Parts

The following items are included with the appliance:

20 Rinnai Corporation ES38 Manual

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 on the appliance carton/box. 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)

Template is on the appliance carton/box.

Attach Wall Brackets

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

1.2 in (30 mm)

Wall bracket

28.5 in (723 mm)

0.9 in (24 mm)

23.3 in (593 mm)

Attach Back Spacers

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

Rinnai Corporation ES38 Manual 21

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

22 Rinnai Corporation ES38 Manual

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

Rinnai Corporation ES38 Manual 23

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.

Horizontal sections should be sloped 3º to drain condensate. (3º equals 2/3 inch drop per foot of vent.) The direction should be to the outside (if local codes allow) or toward the appliance. Do not allow any low points in the exhaust line where condensate will collect.

2/3 inch

1foot

Slope horizontal sections 3º (2/3 inch drop per foot of vent.)

CORRECT

Vent extensions installed in unconditioned air space must be insulated with high temperature insulation 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.

INCORRECT

• Too many bends (limit is 2)

• Air intake hose is above

exhaust pipe

24 Rinnai Corporation ES38 Manual

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