Rinnai Water Heater EX38CP Installation Manual

EX38C ................. (RHFE-1005FTA)

Installer: Leave this manual with the appliance. Consumer: Retain this manual for future reference.

Energysaver ®

Gas Direct Vent Wall Furnace

WARNING

— Do not store or use gasoline or other ammable 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 instrucons.  If you cannot reach your gas supplier, call the re department.

— Installaon and service must be performed by a licensed professional.

READ ALL OF THE INSTRUCTIONS THOROUGHLY BEFORE INSTALLING OR OPERATING

THIS HEATER.

This manual provides information on the installation, operation, and maintenance of the heater. For proper operation and safety, it is important to follow the instructions and adhere to the safety

precautions.

A licensed professional must install the fan convection heater according to the exact instructions

within this manual.

The consumer must read the entire manual to properly operate the heater and to have regular

maintenance performed.

If the informaon in these instrucons is not followed exactly, a re or explosion may result causing property damage, personal injury or death.

This appliance may be installed in an aftermarket, permanently located, manufactured (mobile)

home, where not prohibited by local codes.

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 ............................................. 33

Parts List ................................................... 34-41

Consumer Support

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

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

State Regulations .............................................. 44

2 Rinnai Corporation EX38C 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 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.

Rinnai Corporation EX38C 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, 117 watts Weight 88 lbs (40 kg) Noise Level 39 - 46dB

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 EX38C Manual

Appliance Specifications

Natural Gas Propane Gas

Minimum supply gas pressure 3.5 in (89 mm) W.C. 8.0 in (203 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 13,200 High 38,400 Low 13,200 High 36,500

BTU/hour output Low 10,560 High 30,720 Low 10,560 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  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

 Dimmer  Fault Code Message Display  Temperature Settings in Fahrenheit or Celsius  Temperature Setting in Timer Operation  Timers 1 and 2  Set back (setting a minimum temperature)  1F°(1C°) increments

Flue Manifolds

The following flue manifold sizes are

available for different wall thicknesses:

Vent A Kit is included with

the appliance.

Rinnai Corporation EX38C 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

CONTROL PANEL

OPERATION /

TEMPERATURE

CONTROL DISPLAY

FILTER LAMP

OPERATION LAMP

RATING PLATE MODEL NUMBER, SERIAL NUMBER,

WARM AIR OUTLET

GAST TYPE, ETC.

HUMIDIFIER

OPEN THE DOOR

AND POUR WATER

INTO THE TRAY

GAS CONNECTION

1/2” NPT

COMBUSTION AIR

INTAKE HOSE

PLASTIC TIE

FOR AIR INLET

THERMISTOR

AIR FILTER

PIPE STOPPER

EXHAUST PIPE

AIR FILTER

POWER CORD

PLUG 120V AC

VENT TERMINAL

COMBUSTION /

EXHAUST

BENT ELBOW

6 Rinnai Corporation EX38C Manual

Control Panel Control Panel

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.

Display

After the heater is turned on and begins operating, the display will dim. The display will turn off when the heater is

turned off. While programming the timers the display will turn off for several seconds after a button is last pushed.

Fahrenheit or Celsius (Factory default is °F)

1. The heater must be turned off.

2. Press the Timer 1 and Timer 2 button at the same time for about 5 seconds. The display will show “°C” or “°F”.

3. Use the arrow keys to select the temperature scale.

4. Press the ON/OFF button.

On / Off

Press the ON/OFF button to operate the heater. The ON indicator will glow green. Once the burner ignites, the ON indicator will glow red. When the heater warms up,

the convection fan will automatically start.

To turn the heater off, press the ON/OFF button. The ON indicator light will go out. The fan will continue to operate for several minutes after the burner has gone out in order

to cool the heater. Do no unplug the heater while the fan is running.

Child Lock

The Child Lock will help to prevent accidental operation of the appliance and to

prevent children from operating the appliance.

To activate Child Lock, press the Child Lock button. The indicator will light and a beep

will sound.

To deactivate the Child Lock, press the Child Lock button and hold for about 2

seconds. The indicator light will go out and a beep will sound.

 The lock can be activated when the heater is ON or OFF.

 If activated while the heater is ON, all controls other than the OFF switch will be

locked.

 If activated while the heater is OFF, then all controls will be locked.

 If the heater is turned off while the Child Lock is activated, it cannot be turned on

again until the lock is deactivated.

 Deactivating the lock releases the control buttons.

Rinnai Corporation EX38C Manual 7

Setting the Clock

Setting and Operating the Timers

1. Press the “Program” button.

2. The light next to “Clock” should be flashing. Press

the up and down arrows to set the time. Holding down either of the arrow keys will change the time

more quickly.

3. Press the “Program” button until none of the time options are flashing up.

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.

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 “Program” button twice to set Timer 1.

2. The light next to “Timer 1 on” should be flashing.

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 “Program” button again so that the

Timer 1 off position is flashing. 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 “Program” button again so that the

Timer 1 Temp Position is flashing. Press the up or

down arrows to set the temperature.

5. Press the “Program” button again to set the times

for Timer 2. Follow the same steps above to set

the start and end times.

6. Press the “Program” button until none of the time options are flashing 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.

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 one degree increments  HI - burner is on maximum combustion

8 Rinnai Corporation EX38C Manual

While in standby, the timer LED will be on with a solid

light. When operating the LED will be flashing.

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.

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.

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.

1. To turn the Economy mode on, press

the “Economy” button. The Economy

indicator is lit.

 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.

Rinnai Corporation EX38C Manual 9

Set Back

Access Door

Max. Fill Line

Humidifier Tray

Filler Spout

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

Pull

This function allows a minimum room temperature to be pre-set, between 38ºF

and 78ºF (in 1ºF 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).

To turn this feature off, press the “Set back” button.

The unit will retain its ON or OFF setting after a power failure. (Set Back feature

is on by factory default.)

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.

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.

10 Rinnai Corporation EX38C Manual

AIR FILTERS

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 three 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.

Visual Inspection of Flame

Check that the burner flames are operating normally.

The flame can be seen through the circular window.

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.

CAUTION

Keep the area around flue terminal free of snow and ice. The appliance will not function properly if the in-

take 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.

NORMAL

Flame Rod

Long, clear, blue,

stable flames

ABNORMAL

Flame Rod

Yellow flames or

orange color

Rinnai Corporation EX38C Manual 11

Before Making a Service Call

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.

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 .

Unit cuts off without apparent reason.

Power Failure.

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?

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.

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.

Before making a service call please check the following:

12 Rinnai Corporation EX38C 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 [3] 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 Lower room temperature to less than 104°F (40°C). 30

35 49 Sensor Breakdown

53 Sparker Failure 61 Combustion Fan Failure

62 Convection Fan Failure

Overheat Temperature Sensor

Disconnection (open circuit)

Room Temperature Sensor

Disconnection (open circuit)

Room Temperature Sensor

short circuit

Overheat Temperature Sensor

Disconnection (open circuit)

Overheat Temperature Sensor

short circuit

Overheat Temperature Sensor

short circuit

Service call if repeated. [1]

Clean filter.

Service call.

70 71 Faulty Solenoids

72 Faulty Flame Rod 73 Communication Error Turn heater OFF, then ON again. 81 Solenoid Valve Failure Service Call 99 Flue Block Check around the flue terminal for blockage. [2]

[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.

[3] Only this code is dim.

Rinnai Corporation EX38C Manual 13

Faulty ON/OFF Switch or

Faulty “Set Back” Switch

Restart Function

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

Child Lock Set Gas turned off at meter, tank,

or valve.

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 Child Lock

Turn gas on

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

ON Timer is set

Cancel “ON” Timer or push

override button

If there is a power failure while the appliance is on, then the appliance will start 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 40-80 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

14 Rinnai Corporation EX38C Manual

clearance for

maintenance

Installation Instructions

General Instructions

WARNING

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

NOTICE

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.

 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.

 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

10”

(254 mm)

3”

(76 mm)

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

the picture.

6”

(153 mm)

Rinnai Corporation EX38C Manual 15

Gas Connection

10"(250mm)

(50mm)

40" (1m)

WARNING

When connecting the gas valve or other gas components in the gas line, use a backup wrench to

ensure the connection is gas tight.

 The gas supply line shall be gas tight, sized and so

installed as to provide a supply of a gas sufficient to meet the maximum demand of the heater without

loss of pressure.

 A shut off valve and appliance connector valve

should be installed in the upstream of the gas line to

permit servicing.

 Flexible pipe and any appliance connector valve

used for gas piping shall be types approved by

nationally recognized agencies.

 Any compound used on the threaded joint of the gas

piping shall be a type which resists the action of

liquefied petroleum gas (propane / LPG).

 After completion of gas pipe connections all joints

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

leak test solution is non-corrosive.)

 Check the gas supply pressure immediately

upstream at a location provided by the gas company. Supplied gas pressure must be within the

limits shown in the Specifications section.

 Refer to an approved pipe sizing chart if in doubt

about the size of the gas line.

 Install manual gas cut-off valve so that it can be

accessed for easy operation. Do not conceal

manual cut-off valve behind back spacer.

Clearances to Combustibles

When determining where to install the appliance the clearances to combustibles shown in the figure must be followed. Also refer to the Safety Behaviors and

Practices section.

Rinnai recommends 10” (254 mm) clearance from the

top and on both sides for servicing.

NOTICE

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.

16 Rinnai Corporation EX38C Manual

0” (0 mm)

Flue Terminal Clearances

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

OPERABLE

SNOW

TERMINATION

Clearance in

Ref. A also

applies to

anticipated

snow line

AIR SUPPLY INLET

VENT TERMINAL

AREA WHERE

TERMINAL IS NOT

PERMITTTED

This diagram shows the mini-

mum clearances from the flue.

Rinnai Corporation EX38C 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

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

family dwellings and serves both dwellings.

 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)  *

12 inches (30 cm) to non-

flammables 

24 inches (60 cm) to

flammables 

3 feet (91 cm) above if within

10 feet (3 m) horizontally

12 inches (30 cm) to non-

flammables 

24 inches (60 cm) to

flammables 

18 Rinnai Corporation EX38C Manual

Dimensions

inches (mm)

12.63 (320)

8.1 (205)

4.5 (113)

Exhaust Pipe

13 (330)

36.63 (930)

Gas Connection

3.63 (92)

Air Inlet

20.69 (526)

9.31 (250)

5.13 (130)

.31 (20)

Rinnai Corporation EX38C Manual 19

21.63 (550)

26.38 (670)

12.31 (313)

Installation Parts

The following items are included with the appliance:

(Attached to unit)

20 Rinnai Corporation EX38C Manual

Drilling Flue Hole

Flue Hole

3 1/8"

(80 mm)

8 7/16"

(214 mm)

R11"

(R27

)

R8.0"

(R206 mm

)

8 9/16"

(217 mm)

11"

(280 mm)

Cavity Opening

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.

Template is on the appliance carton/box.

Attach Wall Brackets

Attach the wall brackets as shown. A template is

provided.

Attach Back Spacers

Attach side back spacers to both sides of the

appliance with 2 screws each.

Rinnai Corporation EX38C 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 EX38C 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 EX38C 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.

Vent extensions installed in unconditioned air space

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

CORRECT

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.

NOTE The EX38C is capable of two vent length settings: Short Vent: 0 - 7ft + 1 elbow Long Vent: 7ft + 1 elbow - 13ft + 2 elbows

INCORRECT

 Too many bends (limit is 2)

 Air intake hose is above

exhaust pipe

24 Rinnai Corporation EX38C Manual

Extension Kit Installation

CAUTION

Use the pipe stoppers, connectors, clamps, and screws according to these instructions in

order to ensure no leakage of exhaust gases.

Clearances

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

Clamps

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

and the nut to attach the clamp to the wall.

The air intake hose should always be underneath the exhaust line so that in case the air intake hose sags it

will not come into contact with the exhaust line.

Installing the Exhaust Line

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

flue manifold.

To connect exhaust pipes with other straight pipes or bends, fit the male end into the female end. Use pipe

stopper A to clamp the connection.

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

red line.

Exhaust pipe

Air intake hose

Male end

Air intake hose

Female end

Pipe stopper A

Exhaust pipe

Pipe stopper B

Do not cut the exhaust pipe. Use the adjustable

pipes if necessary.

To bend the elbow, insert exhaust pipes into both

ends for additional leverage. Bend to desired angle.

Do not straighten the bent pipe attached to the

appliance.

Connecting the Air Intake Hose

The air intake hose is connected between the air connection at the rear of the heater and the air intake

port on the flue manifold.

Push the air intake hose onto the flue manifold and

secure with the plastic cable tie.

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

another air intake hose into the hose joint.

NOTICE

Do not cut the intake hose. Cutting

the intake hose may result in noise.

Adjust the angle

The lengths of the air intake hose and the exhaust pipe must be the same in order for the appliance to operate properly. The hose can be cut to the required length. Deburr all rough edges. Do not cut the hose

attached to the appliance. Support the air intake hose with pipe clamps.

Hose joint

air intake hoses

Rinnai Corporation EX38C Manual 25

Extension Kit Installation

A FOT-102 (12.2-21.1 inch) B FOT-103 (21.9-40.4 inch)

A FOT-102 (21.1 inch) B FOT-103 (51.2 inch) C FOT-114 (90.6 inch)

Extension Kits and Parts

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

1 Exhaust Pipe (adjustable)

12.2-21.1 in (311-536 mm)

1 Exhaust Pipe (adjustable)

21.9-40.4 in (556-1026 mm) 2 Exhaust Pipe - 39.4 in (1000 mm) FOT 114-3 1 3 Air Intake Hose - 29.5 in (750 mm) RHF 1000-130-e 1 3 Air Intake Hose - 51.2 in (1.3 m) RHF 1000-130-b 1 3 Air Intake Hose - 90.6 in (2.3 m) RHF 1000-130-f 1 4 Bent Elbow FOT 025-4 1 5 Hose Joint RFOT 226-001 1 1 1 6 Pipe Stopper A 1001F-250 1 1 2 2 7 Pipe Stopper B FOT 111-6 1 1 1 8 Top Stopper FOT 062-7 1 1 1 9 Pipe Clamp FOT 064-11 2 sets 3 sets 4 sets

10 Wall Fixture FOT 064-12 2 3 4 11 Nut FOT 062-10 2 3 4

FOT 111-1 1

FOT 112-1 1 1

12 Screw A ZAA0420SC 2 3 4 13 Screw B CP-30408 4 6 8

26 Rinnai Corporation EX38C Manual

Connecting the Appliance

Inlet hose

Inlet elbow

Plastic tie

Pipe stopper S

Flue Manifold

Flue Adapter

1. Attach flue adapter to the flue manifold with pipe stopper S.

2. Attach the air inlet hose to the flue manifold.

Secure with plastic tie. The unused inlet is plugged with the rubber cap supplied on the

manifold.

3. Connect the vent sliding tube with pipe

stopper S and E. The sliding tube should not be extended beyond the red line. The red line should not be visible after sliding

the tube into the vent outlet.

4. Slide the insulation sleeve up to the flue

manifold and slip the securing clip over the

sleeve as shown.

5. Attach the appliance to the wall brackets, using 2 screws at each bracket.

6. Attach the back spacer with 3 screws to the top of the appliance.

7. If necessary, the appliance can be leveled

using the adjustable legs under the front

right and left legs.

Rinnai Corporation EX38C Manual 27

Adjust Gas Pressure Settings

Complete these instructions for altitude and vent length. (Default altitude: 0ft - 2,000ft. Default vent length: 0 - 7ft+1 elbow )

For high altitude installations in Canada, the conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the requirements of the manufacturer, provincial or territorial authorities having

jurisdiction and in accordance with the requirements of CAN/CGA-B149.1 or CAN/CGA-B149 installation codes.

CAUTION

Do not touch any other areas on the PC board besides the “SW” switches while power is supplied to the appliance. Parts of the PC board are supplied

with 120 volts AC.

CAUTION

Do not touch the areas at or near the exhaust. This

area becomes very hot and could cause burns.

1. Turn off the gas and the power supply.

2. Remove test port screws (1/8 NPT tap) with 3/16

Allen wrench located at gas valve and burner cover. Attach dual port manometer to these test ports as shown. Ensure that the manometer is properly

calibrated.

3. Turn on the gas and power supply to the appliance.

4. Ensure “Set Back” feature has been deactivated.

(“Set Back” feature is active by default.)

5. With the unit in the Off position, press the SW1 switch

at the top of PC board until it beeps.

6. Select the correct code for gas type, altitude, and vent

length on the LED display using ▲ and ▼ buttons:

CAUTION

Do not insert hands or objects into the circulation fans while they are running. Injury or mechanical

malfunction may occur.

NOTICE

The regulator has been factory pre-set. If the

pressure is incorrect, check the supply pressure first, before making any adjustments to the appliance. Also, if the low control pressure cannot be obtained, adjust the adjustment screw on the proportional valve to roughly set pressure and then recheck both the low

and high fire pressures.

Positive Port

PCB Test Switch

Natural Gas

Short Vent Lengths: 0 - 7ft+1 elbow

Long Vent lengths: 7ft +1 elbow - 13ft + 2 elbows

Code

Altitude

Manifold test

pressure -

W.C. Low

Manifold test

pressure -

W.C. High

28 Rinnai Corporation EX38C Manual

A1 / A5 A2 / A6 A3 / A7 A4 / A8 L1 / L5 L2 / L6 L3 / L7 L4 / L8

0-2000 ft 2001-5200 ft 5201-7700 ft 7701-10200 ft 0-2000 ft 2001-5200 ft 5201-7700 ft 7701-10200 ft

1.69 in

(43 mm)

3.77 in

(96 mm)

(A1 - A4) (A5 - A8)

1.59 in

(40 mm)

2.99 in

(76 mm)

1.49 in

(38 mm)

2.69 in

(68 mm)

1.43 in

(36 mm)

2.45 in

(62 mm)

Short Vent Lengths: 0 - 7ft+1 elbow

Long Vent lengths: 7ft +1 elbow - 13ft + 2 elbows

3.21 in

(82 mm)

6.38 in

(162 mm)

Negative Port

Propane Gas

(L1 - L4) (L5 - L8)

3.01 in

(76 mm)

5.62 in

(143 mm)

2.85 in

(72 mm)

5.06 in

(129 mm)

2.73 in

(69 mm)

4.58 in

(116 mm)

+ 64 hidden pages