Rinnai Energysaver Es38 Users Manual (1004RFA)

ES38 to the manual 136bb72c-f6c4-4b14-bce6-c975de7272cd

2015-02-05

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— 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.

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.

Owner’s Operation and Installation Manual for the

ES38 (RHFE-1004RFA)

Energysaver

Gas Direct Vent Wall Furnace

INSTALLER: Leave this manual with the appliance.

CONSUMER: Retain this manual for future reference.

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

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

Operating Instructions .... 6

Care and Maintenance ... 10

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

Installation Instructions ... 14

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

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

or call 1-866-RINNAI1 (746-6241)

2 Rinnai Corporation ES38 Manual

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

This appliance may be installed as an OEM installation in a manufactured home (USA only) or

mobile home and must be installed in accordance with the manufacturer’s instructions and the

Manufactured Home construction and Safety Standard, Title 24 CFR, Part 3280, in the United

States, or the Mobile Home Standard, CAN/CSA Z240 MH Series, in Canada. This appliance

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

the appliance.

Consumer Safety Information

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

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

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

Specifications

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

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

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

Operating Instructions

Getting to Know your New Heating Appliance 6

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

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

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

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

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

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

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

Installation Instructions

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Consumer Support

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

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

Rinnai Corporation ES38 Manual 3

WARNING

CAUTION

Safety Behavior and Practices

• Do not block the warm air discharge. Do not allow

anyone to sleep directly in front of the appliance.

• Due to high temperatures, the appliance should be

located out of traffic and away from furniture and

draperies.

• Children and adults should be alerted to the

hazards of high surface temperature and should

stay away to avoid burns or clothing ignition.

• Young children should be carefully supervised

when they are in the same room as the appliance.

• Clothing or other flammable material should not be

placed on or near the appliance.

• Any safety screen or guard removed for servicing

must be replaced prior to operating the appliance.

• Do not insert items into the louvers.

• Do not spray aerosols near the appliance while it is

operating. Most aerosols contain butane gas which

is flammable.

• Do not unplug the appliance while it is operating or

while the fans are on.

• Do not use bare hands to touch the front louvers

due to high temperatures which may cause burns.

• Wear hand protection when touching the side back

covers, front louver, and rear intake for the

convection fan.

• 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.

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.

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.

DANGER

CAUTION

WARNING

4 Rinnai Corporation ES38 Manual

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

convertible for use with natural gas and liquefied petroleum gases (propane /

LPG) when provision is made for the simple conversion from one gas to the

other.

For commercial setting.

For installation at altitudes up to 10,200 feet (3109 m).

General Description Forced combustion, forced convection, flued gas furnace

Operation Push button electronic

Gas Connection 1/2 in female NPT

Gas Control Electronic

Burners Stainless steel Bunsen burner

Temperature Control Electronic thermostat

Ignition System Electronic spark ignition

Flue System The flue must be terminated to atmosphere with only flue components listed

with the appliance’s certification. Warranty will be voided if non listed

components are installed.

Humidifier Tray Capacity - 7 pints (3000 cc)

Electrical Connection AC 120V, 60 Hz, 121 watts

Weight 90 lbs (41 kg)

Noise Level 37-47 dB

AFUE Rating Natural Gas: 80.6% Propane: 82.0%

Specifications

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.

Safety Features

• Overheat: The appliance will automatically shut

down when the appliance exceeds a predetermined

temperature.

• Flame Failure: The appliance will automatically

shut down if the burner flame is extinguished.

• Power Failure: The appliance will cut off the gas if

it loses electrical power.

• Power Surge Fuse: A glass fuse on the PC board

protects against overcurrent. If the fuse blows then

all indicator lamps will be off.

• Spark Detector: The appliance automatically shuts

down if there is an abnormal spark at ignition.

• Fusible Link: In case the overheat feature

prevents the temperature from rising then the fusible

link will break shutting off the appliance.

Appliance Specifications

Rinnai Corporation ES38 Manual 5

Features

• Restarts automatically when ignition or combustion

fails.

• Clean Heating Forced Flue Type

• Easy Operation One-Touch Ignition

• Sensible Temperature Control Feature

• Comfortable Room Temperature Control and

Display

• Warm Air Outlet at Floor Level (keeps your feet

warm)

• Function Lock

• Room Temperature Setting Memory

• Clean the Air Filter - Indicator Lamp

• Energy Saving Economy Setting

• Humidifier Tray

• Air Flow Directional Louvers

• Direct Vent Easily Installed

• Proportional Heating Variable Capacity

• Hush! Quiet Operation

• Modern Design Minimizes Floor Space

Requirements

• Fault Code Message Display

Appliance Specifications

The following flue manifold sizes are

available for different wall thicknesses: Name Kit No. fits walls

S Vent Kit FOT-150 3 - 4 1/2 in (75 - 115 mm)

A Vent Kit FOT-151 4 1/2 - 9 1/2 in (115 - 240 mm)

B Vent Kit FOT-152 9 1/2 - 15 3/4 in (240 - 400mm)

C Vent Kit FOT-153 15 3/4 - 23 5/8 in (400 - 600 mm)

D Vent Kit FOT-154 23 5/8 - 31 1/2 in (600 - 800 mm)

Natural Gas Propane Gas

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

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

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

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

Flue Manifolds

6 Rinnai Corporation ES38 Manual

Getting to know your new heating appliance

Operating Instructions

Rinnai Corporation ES38 Manual 7

Control Panel

All buttons beep when operated.

Set Temp

Room Temp

Economy

Temp

Control

Function Lock

Filter

ON/OFF

FUNCTION

LOCK

Lamp is "green"

when this feature

is on.

FILTER LAMP

Flashes when filter

is dirty.

OPERATION LAMP

This lamp turns

"green" when power

is on. Lamp will

change to "red"

when burner is on.

TEMPERATURE

BUTTONS

" " adjust temp. to

lower setting.

" " adjust temp. to

a higher setting.

ENERGY SAVING

BUTTON

Lamp is "green"

when this feature is

activated.

〈CONTROL PANEL 〉

〈INDICATOR DISPLAY 〉

TEMPERATURE

DISPLAY

SHOWS EITHER THE

TEMPERATURE OR

CODED ERROR

MESSAGES.

ON/OFF BUTTON

Easy operation

One touch ignition

8 Rinnai Corporation ES38 Manual

Operating the Heater

Turning the heater ON

When you press and release the

ON/OFF button, the Temperature

Level lamps will illuminate, the

combustion fan will begin to run,

and the spark will ignite the main

burner.

This heater has an automatic ignition system. When

the main burner has lit, the combustion lamp will glow

red, and the spark will stop.

If ignition does not occur after 15 seconds, the

appliance will automatically turn off and the

Temperature Level lamps will flash indicating a fault

code. This may occur when using the appliance for

the first time or if it has not been used for a while. Try

operating the appliance again.

There may be a smell of burning dust or oil the first

time the heater is lit or when the heater has been out

of operation for a long time.

The appliance may make noises after ignition or when

it is turned off. This is normal and is due to the

thermal expansion or contraction of its components.

Adjusting the Temperature

The first time that the appliance is turned on, the

preset temperature of 72° F will be shown on the

display. Every time the temperature setting is

changed, that temperature setting will be the latest

data appearing on the display the next time the

appliance is turned on.

To change the temperature setting, adjust the

temperature control buttons until the desired setting is

indicated.

When the desired temperature has been set, 10

seconds later, the display will show the current room

temperature.

The thermostat automatically modulates the burner

and the fan to maintain the temperature setting.

The temperature settings available are:

• LO - burner is on minimum combustion

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

• HI - burner is on maximum combustion

Turning the heater OFF

Press the ON/OFF button. Do not

turn off by unplugging at the power

outlet.

The fan will continue to run for a

short time to prevent the internal

components from overheating.

ON/OFF

Economy Mode

Pressing the Economy button will cause

the appliance to go into Economy Mode

and the green lamp will glow. This

results in the temperature setting being

reduced by 2° F, 30 minutes after the

room temperature has reached the

temperature setting. After another 30

minutes the temperature setting is

reduced another 2° F. This could result

in the temperature setting being reduced by a

maximum of 4° F. The intent of this mode is to save

energy.

When the heater is running at the LO setting, the

Economy Mode does not function.

Economy

ON/OFF

Set Tem p

Ro o m Tem p

Temp

Control

Function Lock

Rinnai Corporation ES38 Manual 9

CAUTION

Adjusting Air Flow Direction

The vertical louvers may be adjusted to move the air

flow more to the right or to the left.

Use a screw driver or similar object to bend each

louver to the desired position.

Do not bend repeatedly (no more than 5 times) or else

the louver will break.

The horizontal louver (which determines the vertical air

flow direction) is fixed and cannot be adjusted.

Do not adjust the air flow

louvers while warm air is

flowing.

Operating the Heater

Adding Water to the Humidifier

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.

CAUTION

Do not fill the tray while the

appliance is in operation.

Close the door after filling.

The humidifier tray and

surrounding area are hot

when the appliance is on.

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.

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.

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.

Temp

Control

Function Lock

Fi lt er

Access Door

Max. Fill Line

Humidifier Tray

Filler Spout

Do not force door open too far.

Close door during operation.

Pull

10 Rinnai Corporation ES38 Manual

Care and Maintenance

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.

Maintenance

All maintenance and service are to be performed by a

qualified service technician, preferably one who has

attended Rinnai service training classes on the Direct

Vent products.

The appliance should be inspected annually by a

qualified service technician. More frequent cleaning

may be required due to excessive lint from carpeting,

bedding material, etc. It is imperative that control

compartments, burners, and circulating air passage

ways of the appliance be kept clean.

Any screen or guard removed for servicing the

appliance must be replaced prior to operating the

appliance. Clean as follows:

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

2. Remove the front panel by removing two screws.

3. Use pressurized air to remove dust from the main

burner, heat exchanger, and fan blades.

4. Use soft dry cloth to wipe cabinet.

Do not use wet cloth or spray cleaners on the burner.

The flue should be inspected annually for blockages or

damage.

Motors are permanently lubricated and do not need

periodic lubrication. Keep fan and motor free of dust

and dirt by cleaning annually.

Verify proper operation after servicing.

Visual Inspection

of Flame

Check that the burner flames are operating normally.

The flame can be seen through the circular window

through the louvers.

When operating normally the burner flame should

appear as long, clear, blue, stable, streaks. Yellow

flames or an orange color is abnormal and

maintenance is required.

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.

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.

AIR FILTERS

CAUTION

Prevent dust from accumulating on the power cord,

side covers, and parts behind the appliance.

Rinnai Corporation ES38 Manual 11

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.

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.

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.

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.

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

operate contact a qualified service agency.

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

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

appliance.

CODE DISPLAYED FAULT REMEDY

11 Ignition Failure

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 Clean filter.

Service call if repeated. [1]

16 Room Overheat

Lower room temperature to less than 104°F

(40°C).

31 Room Temperature Sensor

Faulty Service call.

33 Overheat Temperature Sensor

Faulty Service call.

49 Sensor Breakdown Service call.

53 Sparker Failure Service call.

61 Combustion Fan Failure Service call.

70 Faulty ON/OFF Switch Service call.

71 Faulty Solenoids Service call.

72 Faulty Flame Rod Service call.

73 Communication Error Turn heater OFF, then ON again.

99 Flue Block

Check around the flue terminal for blockage.

[2]

Rinnai Corporation ES38 Manual 13

Troubleshooting

Problem

Remedy

Cause

Not Plugged In

Power Failure

(Initial Installation)

Air In Gas Pipe

Gas Filter Blocked

Miss Ignition

Flue terminal obstructed

Flue manifold not connected

Louver obstructed

Air filter blocked

Gas Escape

Function Lock Set

Gas turned off at meter, tank,

or valve.

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

Cancel Function 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

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.

Restart Function

14 Rinnai Corporation ES38 Manual

Installation Instructions

• A qualified service technician should install the

appliance and inspect it before use.

• If you move, check the gas type in your new area.

The local gas authority will be able to advise on

local regulations.

• The installation must conform with local codes or, in

the absence of local codes, with the National Fuel

Gas Code, ANSI Z223.1/NFPA 54, or the Natural

Gas and Propane Installation Code, CSA B149.1.

• A manufactured home (USA only) or mobile home

OEM installation must conform with the

Manufactured Home Construction and Safety

Standard, Title 24 CFR, Part 3280, or, when such a

standard is not applicable, the standard for

Manufactured Home Installations, ANSI/NCSBCS

A225.1, or the standard for Gas Equipped

Recreational Vehicles and Mobile Housing, CSA

Z240.4.

• The appliance, when installed, must be electrically

grounded in accordance with local codes or, in the

absence of local codes, with the National Electrical

Code, ANSI/NFPA 70, or the Canadian Electrical

Code, CSA C22.1.

• Appliance input ratings are based on sea level

operation and need not be changed for operation up

to 2000 ft (609.9 m) elevation. For operation at

elevations above 2000 ft (609.9 m), refer to the

Conversion Manual.

• The appliance and its appliance main gas valve

must be disconnected from the gas supply piping

system during any pressure testing of that system at

test pressures in excess of 1/2 psi (3.5 kPa).

• The appliance must be isolated from the gas supply

piping system by closing its equipment shutoff valve

during any pressure testing of the gas supply piping

system at test pressures equal to or less than 1/2

psi (3.5 kPa).

• If the flooring is carpet, tile, or other combustible

material other than wood, then the appliance must

be installed on a metal or wood panel extending the

full width and depth of the appliance.

• This appliance discharges a large volume of warm

air next to the floor. Any particles in the air such as

cigarette smoke could cause discoloration in nylon

carpets containing dyes or vinyl surfaces.

• This appliance is not designed to built in.

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

indicated on the rating plate. This appliance is not

convertible for use with other gases unless a

certified kit is used. If conversion of the unit is

needed, conversions must be performed by a

qualified service provider at the owner’s expense.

• This appliance must not be connected to a chimney

flue serving a separate solid-fuel burning appliance.

• Rinnai suggests that a dedicated electrical circuit

with a 120VAC, 60 hz, 10 amp power source be

used.

• A test plug are provided for testing of manifold

differential pressure. It is located on the modulating

gas valve.

• The appliance should be correctly sized for the

space it is required to heat.

• Follow the installations instructions and those in

Care and Maintenance for adequate combustion

and ventilation air.

• The flow of combustion and ventilation air shall not

be obstructed.

• Clearances to access the appliance during servicing

are 2 inches (50 mm) from the sides, 40 inches (1

m) from the front, and 10 inches (250 mm) from the

top.

General Instructions

WARNING

Do not use substitute materials.

Use only parts certified with the appliance.

If installation is at a location above

2001 ft (610 m), then follow the Adjust

Gas Pressure Settings procedure in

the Conversion Manual.

If installation is at or below 2000 ft

(610 m) then the pressure settings do

not need to be adjusted.

NOTICE

Rinnai Corporation ES38 Manual 15

Gas Connection

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

installed as to provide a supply of a gas sufficient to

meet the maximum demand of the heater without

loss of pressure.

• A shut off valve and appliance connector valve

should be installed in the upstream of the gas line to

permit servicing.

• Flexible pipe and any appliance connector valve

used for gas piping shall be types approved by

nationally recognized agencies.

• Any compound used on the threaded joint of the gas

piping shall be a type which resists the action of

liquefied petroleum gas (propane / LPG).

• After completion of gas pipe connections all joints

including the heater must be checked for gas

tightness by means of leak detector solution, soap

and water, or an equivalent nonflammable solution,

as applicable. (Since some leak test solutions,

including soap and water, may cause corrosion or

stress cracking, the piping shall be rinsed with water

after testing, unless it has been determined that the

leak test solution is non-corrosive.)

• Check the gas supply pressure immediately

upstream at a location provided by the gas

company. Supplied gas pressure must be within the

limits shown in the Specifications section.

• Refer to an approved pipe sizing chart if in doubt

about the size of the gas line.

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

accessed for easy operation. Do not conceal

manual cut-off valve behind back spacer.

Clearances to Combustibles

When determining where to install the appliance the

clearances to combustibles shown in the figure must

be followed. Also refer to the Safety Behaviors and

Practices section. The clearance to combustibles from

the top is zero.

Rinnai recommends 10” (250 mm) clearance on both

sides for servicing.

10"(250mm)

(50mm)

40" (1m)

When connecting the gas valve or other gas

components in the gas line, use a backup wrench to

ensure the connection is gas tight.

WARNING

16 Rinnai Corporation ES38 Manual

Flue Terminal Clearances

AIR SUPPLY INLET

VENT TERMINAL

AREA WHERE

TERMINAL IS NOT

PERMITTTED

INSIDE

CORNER DETAIL

FIXED

CLOSED

OPERABLE

FIXED

CLOSED

OPERABLE

SNOW

TERMINATION

Clearance in

Ref. A also

applies to

anticipated

snow line

Rinnai Corporation ES38 Manual 17

Flue Terminal Clearances

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.

Ref Description Canadian Installations US Installations

A Clearance above grade, veranda,

porch, deck, or balcony. (Take into

account the anticipated snow line) 12 inches (30 cm) 12 inches (30 cm)

B Clearance to window or door that may

be opened

6 inches (15 cm) for

appliances < 10,000 BTUh;

12 inches (30 cm) for

appliances > 10,000 BTUh

and < 100,000 BTUh,

36 inches (91 cm) for

appliances > 100,000 BTUh

6 inches (15 cm) for

appliances < 10,000 BTUh;

9 inches (23 cm) for

appliances > 10,000 BTUh

and < 50,000 BTUh,

12 inches (30 cm) for

appliances > 50,000 BTUh

C Clearance to permanently closed * *

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

* *

E Clearance to unventilated soffit * *

F Clearance to outside corner * *

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

H Clearance to each side of center line

extended above meter/regulator

assembly

3 feet (91 cm) within a height

15 feet (4.5 m) above the

meter/regulator assembly *

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

J Clearance to nonmechanical air supply

inlet to building or the combustion air

inlet to any other appliance

6 inches (15 cm) for

appliances < 10,000 BTUh;

12 inches (30 cm) for

appliances > 10,000 BTUh

and < 100,000 BTUh,

36 inches (91 cm) for

appliances > 100,000 BTUh

6 inches (15 cm) for

appliances < 10,000 BTUh;

9 inches (23 cm) for

appliances > 10,000 BTUh

and < 50,000 BTUh,

12 inches (30 cm) for

appliances > 50,000 BTUh

K Clearance to a mechanical air supply

inlet 6 feet (1.83 m) 3 feet (91 cm) above if within

10 feet (3 m) horizontally

L Clearance above paved sidewalk or

paved driveway located on public 7 feet (2.13 m) 1 *

M Clearance under veranda, porch, deck,

or balcony

12 inches (30 cm) to non-

flammables 2

24 inches (60 cm) to

flammables 2

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)

12 7/16" (316)

13" (330)

7 7/8" (200)

4 9/16" (116)

36 5/8" (930)

28 7/16" (723)

26 3/8" (670)

15 5/8" (397)

11 13/16" (300)

GAS CONNECTION

10 7/8"

(R277)

9 13/16" (250)

6 1/2" (165)

6 5/16"(160)

13 3/4" (R350)

Cavit y Opening

23 3/8" (593)

Rinnai Corporation ES38 Manual 19

Installation Parts

The following items are included with the appliance:

“A” Vent Kit, FOT-151

Flue Manifold .......................1 Spare rubber seal...........................1

(‘A’ Flue units only)

(For weatherboard installations)

Back Spacer

Set 1

Air inlet hose

Vent adaptor

Pipe stopper

A&S

Pipe stopper

Wall

Brackets

Insulation

Clip

Plastic tie for

air inlet

(M4)

(M4× 20)

(M4)

(M4.8× 32)

Wood Screws

Owner’s Manual

Conversion Manual

Template

For Flue Lock Stopper

For Flue Manifold

Wall Bracket Screws

For Back Spacer Set

4(M5)

For Wall Brackets

On/Off Valve 11

Elbow (gas)

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. The center of the hole must

be located anywhere within the shaded area, unless

extension kits are used. See the dimensions

diagram.

For weatherboard walls, drill through the center of

the weatherboard from the outside first and then

through the plasterboard.

Flue Hole

3 1/8"

(80 mm)

Attach the wall brackets as shown. A template is

provided.

593

723

Wall bracket

Attach Wall Brackets

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

1. Disassemble the flue manifold

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.

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.

• 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.

• 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.

3 screws

sleeve should extend

3/16 - 3/8 in (5-10 mm)

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.

Inside Connection

Sleeve

Terminal

Remove extension

if necessary

22 Rinnai Corporation ES38 Manual

Flue Manifold Installation

6. Lock the ties

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.

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”.

Terminal seal

Locking tie

Terminal

Locking ties Sleeve

3 screws

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. Any length (horizontal and vertical) in excess of 8 feet (2.4 m)

must be sloped 3° downward toward the flue manifold to allow condensate to drain to the outside. Do not allow

any low points in the exhaust line where condensate will collect.

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

Examples INCORRECT

• Too many bends (limit is 2)

• Air intake hose is above exhaust

pipe

CORRECT

24 Rinnai Corporation ES38 Manual

Clearances exhaust pipe to combustibles 1 inch (25.4 mm)

exhaust pipe to non-combustibles zero

Extension Kit Installation

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.

Clamps Exhaust pipe Exhaust pipe

Air intake hose

The exhaust line is connected between the bent pipe

at the rear of the heater and the exhaust port on the

flue manifold.

Installing the Exhaust Line

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.

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.

Pipe stopper A

Pipe stopper B

Male end Female end

Adjust the angle

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.

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

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

order to ensure no leakage of exhaust gases.

Rinnai Corporation ES38 Manual 25

Extension Kit Installation

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

1 Exhaust Pipe (adjustable)

11.4-20.3 in (290-515 mm) FOT 111-1 1

1 Exhaust Pipe (adjustable)

21.0-39.6 in (533-1005 mm) FOT 112-1 1 1

2 Exhaust Pipe - 40 in (1016 mm) FOT 114-3 1

3 Air Intake Hose - 29.5 in (750 mm) RHF 1000-130-e 1

3 Air Intake Hose - 49.2 in (1.25 m) RHF 1000-130-b 1

3 Air Intake Hose - 90.6 in (2.3 m) RHF 1000-130-F 1

4 Bent Elbow FOT 025-4 1

5 Hose Joint FOT 064-8 1 1 1

6 Pipe Stopper A 1001F-250 1 1 2 2

7 Pipe Stopper B FOT 111-6 1 1 1

9 Pipe Clamp FOT 064-11 2 sets 3 sets 4 sets

10 Wall Fixture FOT 064-12 2 3 4

11 Nut FOT 062-10 2 3 4

12 Screw A ZAA0420SC 2 3 4

13 Screw B CP-30408 4 6 8

8 Top Stopper FOT 062-7 1 1 1

14 O Ring M10B-4-49 1

Extension Kits and Parts

A FOT-102(11.4-20.3 inch)

B FOT-103(21.0-39.6 inch)

A FOT-102(29.5 inch)

B FOT-103(49.2 inch)

C FOT-114(90.6 inch)

EXHAUST PIPE

EXHAUST PIPE(STRAIGHT) 40 inch

AIR INTAKE HOSE

BENT ELBOW HOSE JOINT

PIPE STOPPER A

PIPE STOPPER B

PIPE CLAMP

WALL-FIXTURE

NUT

SCREW A

SCREW B

TOP STOPPER O RING

6 9

26 Rinnai Corporation ES38 Manual

Connecting the Appliance

1. Attach flue adapter to the flue manifold with

pipe stopper S.

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

Secure with plastic tie. The unused inlet is

plugged with the rubber cap supplied on the

manifold.

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.

Inlet hose

Inlet elbow

Plastic tie

7. If necessary, the appliance can be leveled

using the adjustable legs under the front

right and left legs.

Screw Sliding Tube

PIPE STOPPER S

PIPE STOPPER A

Flue Manifold

PIPE STOPPER E

Pipe stopper S

Flue Manifold

Flue Adapter

SCREW

（M5）

Rinnai Corporation ES38 Manual 27

Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

If you do not follow these instructions exactly, a fire or explosion

may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is

equipped with an ignition device which

automatically lights the burner. Do not try to

light the burner by hand.

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next

to the floor because some gas is heavier than

air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call

the fire department.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will

not push in or turn by hand, do not try to

repair it, call a qualified service technician.

Force or attempted repair may result in a fire

or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified

service technician to inspect the appliance

and to replace any part of the control system

and any gas control which has been under

water.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting.

2. Turn off all electric power to the appliance

using the ON/OFF button.

3. Locate the manual gas valve on the side of

the heater. Turn the manual valve

clockwise to the full OFF position.

NOTE: The fan will continue to operate until the

appliance is cool. Do not turn the

appliance off by unplugging it from the

wall. Keep burner and control

compartment clean. See installation and

operating instructions.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance

using the ON/OFF button.

4. This appliance is equipped with an ignition

device which automatically lights the burner.

Do not try to light the burner by hand.

5. Locate the manual gas valve on the side of

the heater. Turn the manual valve

clockwise to the full OFF position.

6. Wait five (5) minutes to clear out any gas.

Then smell for gas, including near the floor. If

you smell gas, STOP! Follow “B” in the safety

information above. If you don’t smell gas, go

to the next step.

7. Turn the manual gas valve counterclockwise

to the full ON position.

8. Turn on all electric power to the

appliance using the ON/OFF button.

9. Set the thermostat to desired setting.

10. Combustion indicator glows red when the

burner is lit and flashes when the burner fails

to ignite. If the appliance will not operate,

follow the instructions “To Turn Off Gas To

Appliance” and call your service technician or

gas supplier. See manual for additional

information.

Manual Valve

OPEN

28 Rinnai Corporation ES38 Manual

Cut-Away Diagram

Rinnai Corporation ES38 Manual 29

Wiring Diagram

If any of the original wire as supplied with the

appliance must be replaced, it must be

replaced with type 18 AWG wire or its

equivalent.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation.

CAUTION

MARK

R.TH

TF1 ～3

POV

FR1 ～3

PARTS NAME

MAIN SWITCH

THERMISTOR

THERMAL FUSE

FUSE

ELECTRODE

MODULATING SOLENOID VALVE

TRANSFORMER

FLAME ROD 1 ～3

MARK

OH.TH

OHS

SV1 ～3

PARTS NAME

OVER HEAT THERMI STOR

OVER HEAT SWITCH

CONVECTION FAN MOTOR

SPARKER

MAIN SOLENOID VALVE 1 ～3

COMBUSTION FAN MOTOR

PRESSURE SENSOR

30 Rinnai Corporation ES38 Manual

Ladder Diagram