Rinnai Energysaver ES38 Quick start guide

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Owner's Operation and Installation Manual for the
ES38 (RHFE-1004RFA)
Energysaver
Gas Direct Vent Wall Furnace
Table of Contents...........2
Safety Information ..........3
Operating Instructions .... 6
Care and Maintenance ... 10
Fault Codes.................... 12
Installation Instructions ... 14
Parts List ........................32
Consumer Support ......... 42
WARNING: If the information in these instructions is not
followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
-Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
-WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in
your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire
department. ·
-Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
INSTALLER: Leave this manual with the appliance.
CONSUMER: Retain this manual for future reference.
Register your product at www.rinnairegistration.com
or call 1-866-RINNAl1 (746-6241)

This appliance may be installed as an OEM installation in a manufactured home (USA only) or
mobile home and must be installed in accordance with the manufacturer's instructions and the
Manufactured Home construction and Safety Standard, Title 24 CFR, Part 3280, in the United
States, or the Mobile Home Standard, CAN/CSA Z240 MH Series, in Canada. This appliance
is only for use with types of gas indicated on the rating plate. A conversion kit is supplied with
the. appliance. ·
This appliance may be installed in an aftermarket, permanently located, manufactured home
(USA only) or mobile home, where not prohibited by local codes.
This appliance is only for use with the type of gas indicated on the rating plate. This appliance
is not convertible for use with other gases, unless a certified kit is used.
Table of Contents
Consumer Safety Information Installation Instructions
Safety Definitions.............................................3 General Instructions....................................... 14
Safety Behaviors andPractices.......................3 Gas Connection............................................. 15
Safety Features................................................4 Clearances to Combustibles.......................... 15
Flue Terminal Clearances ....................... 16, 17
Specifications Dimensions.................................................... 18
Appliance Specifications.............................. 4, 5 Installation Parts ........................................... 19
Features...........................................................5 Drilling Flue Hole ........................................... 20
Flue Manifolds..................................................5 Attach Wall Brackets......................................
20
Attach Back Spacers ..................................... 20
Operating Instructions Flue Manifold Installation......................... 21, 22
Getting to Know your NewHeating Appliance 6 Extension Kit Installation .......................... 23-25
Control Panel ...................................................7 Connecting the Appliance.............................. 26
Operating the Heater .................................. 8, 9 Operating Instructions ................................... 27
Care and Maintenance................................... 10 Cut-Away Diagram......................................... 28
Before Making a Service Call......................... 11 Wiring Diagram.............................................. 29
Fault Codes.................................................... 12 LadderDiagram............................................. 30
Restart Function............................................. 13 Parts List...................................................31-41
Troubleshooting ............................................. 13 Consumer Support
Warranty Information..................................... 42
Limited Warranty...................................... 42, 43
2 Rinnai Corporation ES38 Manual

Safety Definitions
/i\ This is the safety alert symbol. This symbol alerts you to potential hazards that can kill or hurt you and
L.l.:J others.
ADANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
!A.WARNlNG j 1nd~cate~ ~ potentially hazardous situation which, if not avoided, could result in death or
_ - -- ·-·-·· -serious mJury.
f~cAuf1'0>N j Indicates a potentially hazardous situation which, if not avoided, could result in minor or
L- · - - moderate injury. It may also be used to alert against unsafe practices.
Safety Behavior and Practices
• 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.
A·cAuflC;}N]
• 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 oftraffic 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.
• 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.
• Do not insert items into the louvers.
• Do not spray aerosols nearthe 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.
Rinnai Corporation ES38 Manual 3

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 burnerflame is ~xtinguished. • Spark Detector: The appliance automatically shuts
down ifthere is an abnormal spark at ignition.
• Power Failure: The appliance will cut offthe gas if
it loses electrical power. • Fusible Link:
In case the overheat feature
prevents the temperature from rising then the fusible
link will break shutting off the appliance.
Specifications
Appliance Specifications
Application For manufactured home (USA only)
or mobile home or residential installation
convertible for use with natural gas and liquefied petroleum gases (propane /
LPG) when provision is made for the simple conversion from one gas to the
other.
For commercial setting.
For installation at altitudes up to 10,200 feet (3109 m).
General Description Forced combustion, forced convection, flued gas furnace
Operation Push button electronic
Gas Connection 1/2 in female NPT
Gas Control Electronic
Burners Stainless steel Bunsen burner
Temperature Control Electronic thermostat
Ignition System Electronic spark ignition
Flue System The flue must be terminated to atmosphere with only flue components listed
with the appliance's certification. Warranty will be voided if non listed
components are installed.
HumidifierTray Capacity - 7 pints (3000 cc)
Electrical Connection AC 120V, 60 Hz, 121 watts
Weight 90 lbs (41 kg)
Noise Level 37-47 dB
AFUE Rating Natural Gas: 80.6% Propane: 82.0%
Rinnai is continually updating and improving products. Therefore, specifications are subject to change without
prior notice.
The efficiency rating of this appliance is a product thermal efficiency rating determined under continuous operating
conditions and was determined independently of any installed system.
4 Rinnai Corporation ES38 Manual

Appliance Specifications
Natural Gas Propane Gas
Minimum supply gas pressure 5.0 in (127 mm) W.C. 11.0 in (280 mm) W.C.
Maximum supply gas pressure 10.5 in (267 mm) W.C. 13.0 in (330 mm) W.C.
BTU/hour input Low 10,500 High 38,400 Low 10,500 High 36,500
BTU/hour output Low 8,400 High 30,720
Low8,400 High 29,200
Features
• Restarts automatically when ignition or combustion • Clean the
Air Filter -Indicator Lamp
fails.
• Clean Heating Forced Flue Type
• Easy Operation One-Touch Ignition
• Sensible Temperature Control Feature
• Comfortable Room Temperature Control and
Display
• Energy Saving Economy Setting
• Humidifier Tray
• Air Flow Directional Louvers
• Direct Vent Easily Installed
• Proportional Heating Variable Capacity
• Warm Air Outlet at Floor Level (keeps yourfeet
warm)
• Hush! Quiet Operation
• Modern Design Minimizes Floor Space
Requirements
• Function Lock
• Room Temperature Setting Memory
Flue Manifolds
The following flue manifold sizes are
available for different wall thicknesses:
• Fault Code Message Display
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)
Rinnai Corporation ES38 Manual 5

6
Getting to know your new heating appliance
WARM AIR OUTLET
HUMIDIFIER
OPEN THE DOOR
AND POUR WATER
INTO THE TRAY.
GAS CONNECTION
1/2" NPT
THERMISTOR
POWER CORD
PLUG 120V AC
Rinnai Corporation ES38 Manual
CONTROL PANEL
OPERATION/TEMPE
RATURE
CONTROL DISPLAY
FILTER LAMP
OPERATION LAMP
RA TING PLATE
MODEL NUMBER,
SERIAL NUMBER,
GAS TYPE, ETC.
AIR FILTER
EXHAUST PIPE
VENT TERMINAL
COMBUSTION/
EXHAUST
COMBUSTION AIR
INTAKE HOSE

Control Panel
All buttons beep when operated.
(CONTROL PANEL)
0
~
Economy
ENERGY SAVING
BUTTON
Lamp is "green"
when this feature is
activated.
(INDICATOR DISPLAY)
TEMPERATURE
DISPLAY
SHOWS EITHER THE
TEMPERATURE OR
CODED ERROR
MESSAGES.
Set Tempo
Room Temp 0
~-~
Function Lock
FUNCTION
LOCK
Lamp is "green"
when this feature
is on.
FILTER LAMP
Flashes when filter
is dirty.
Rinnai Corporation ES38 Manual
ON/OFF BUTTON
Easy operation
One touch ignition
ON/OFF
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TEMPERATURE
BUTTONS
"v" adjust temp. to
lower setting.
"A " adjust temp. to
a higher setting.
OPERATION LAMP
This lamp turns
"green" when power
is on. Lamp will
change to "red"
when burner is on.
7

Operating the Heater
Turning the heater ON
When you press and release the
ON/OFF button, the Temperature
Level lamps will illuminate, the
combustion fan will begin to run,
and the spark will ignite the main
burner.
This heater has an automatic ignition system. When
the main burner has lit, the combustion lamp will glow
red, and the spark will stop.
If ignition does not occur after 15 seconds, the
appliance will automatically turn offand the
Temperature Level lamps will flash indicating a fault
code. This may occur when using the appliance for
the first time or ifit 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 orwhen
it is turned off. This is normal and is due to the
thermal expansion or contraction of its components.
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.
Adjusting the Temperature
~tTemp o D
R>omTemp O
Function Lock
The first time that the appliance is turned on, the
preset temperature of 72° F will be shown on the
display. Every time the temperature setting is
changed, that temperature setting will be the latest
data appearing on the display the next time the
appliance is turned on.
To change the temperature setting, adjust the
temperature control buttons until the desired setting is
indicated.
When the desired temperature has been set, 10
seconds later, the display will show the current room
temperature.
The thermostat automatically modulates the burner
and the fan to maintain the temperature setting.
The temperature settings available are:
• LO -burner is on minimum combustion
• 60° F - 80° F in two degree increments
• HI -burner is on maximum combustion
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
0
Economy
D
in the temperature setting being reduced by a
maximum of4° F. The intent ofthis mode is to save
energy.
When the heater is running at the LO setting, the
Economy Mode does not function.
8 Rinnai Corporation ES38 Manual

Operating the Heater
Lock
This feature locks the
buttons to prevent
unintended operation.
Press the up and
down buttons to
activate and the lamp
will glow. Pressing Function Lock
and holding the up and down
will disengage the Lock. buttons for two seconds
Ifthe Lock is engaged while the unit is operating, all
buttons will be disabled except for the ON/OFF button.
Ifthe Lock is engaged while the unit is off, then all
buttons will be disabled. The Lock must be
disengaged in order to turn the unit on.
Adding Water to the Humidifier
AcAUTION!
Do not fill the tray while the
appliance is in operation.
Close the door after filling.
The humidifiertray and
surrounding area are hot
when the appliance is on.
To fill the tray, open the door as shown in the diagram
and pour water into the tray using the spout built into
the door. The air will be humidified as it passes over
the water in the tray.
During operation a small amount of condensation is
produced in the flue system and drains into the
humidifier tray.
Ifthe water overflows from the water level hole, then
do not add any more water.
Humidifier Tray l
j
Access Door
Pull
Filler Spout
Do not force door open too far.
Close door during operation.
Sensible Temperature Control
The sensible temperature control feature allows
comfortable heating which matches the conditions in
the room.
Based on the information collected by the room
temperature thermistor when the heating starts, the
heating capacity is automatically adjusted to achieve
a comfortable heating effect and to reach the
temperature setting quickly.
Filter Lamp
Ifthe filter lamp flashes
during operation, check Riter
the air filter for dust. If EE83
dust is present, clean the EE83
filter. See the Care and
Maintenance section. Turn the heater offbefore
cleaning the filter.
Adjusting Air Flow Direction
AcAUTIONl
Do not adjust the air flow
louvers while warm air is
flowing.
The vertical louvers may be adjusted to move the air
flow more to the right orto the left.
Use a screw driver or similar object to bend each
louverto the desired position.
Do not bend repeatedly (no more than 5 times) or else
the louver will break.
The horizontal louver (which determines the vertical air
flow direction) is fixed and cannot be adjusted.
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Rinnai Corporation ES38 Manual 9

Care and Maintenance
Maintenance
All maintenance and service are to be performed by a
qualified service technician, preferably one who has
attended Rinnai service training classes on the Direct
Vent products.
The appliance should be inspected annually by a
qualified service technician. More frequent cleaning
may be required due to excessive lint from carpeting,
bedding material, etc. It is imperative that control
compartments, burners, and circulating air passage
ways ofthe appliance be kept clean.
Any screen or guard removed for servicing the
appliance must be replaced prior to operating the
appliance. Clean as follows:
1. Turn heat off. Allow to cool for one hour.
2. Remove the front panel by removing two screws.
3. Use pressurized air to remove dust from the main
burner, heat exchanger, and fan blades.
4. Use soft dry cloth to wipe cabinet.
Do not use wet cloth or spray cleaners on the burner.
The flue should be inspected annually for blockages or
damage.
Motors are permanently lubricated and do not need
periodic lubrication. Keep fan and motor free of dust
and dirt by cleaning annually.
Verify proper operation after servicing.
Care of Exterior
Dampen soft cloth with warm water. Wring water out
well and wipe the unit.
Do not use volatile substances such as benzene or
thinners. They cause fading ofthe paint and
deformation ofthe resin.
AcAur10Nl
Prevent dust from accumulating on the power cord, ·
side covers, and parts behind the appliance.
Snow Accumulation
Keep the area around flue terminal free of snow and
ice. The appliance will not function properly if the
intake air or exhaust is impeded by obstructions.
Refer to the Flue Terminal Clearances. The clearance
in Ref. A should be maintained from any snow
accumulation.
Filters
Dirty filters reduce the air flow and the appliance's
ability to produce heat. The filters should be cleaned
frequently during the heating season. Ifthe 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 AJRFJLTffiS
appliance should be OFF ~~~~=:
and cool. Remove the 1
filter and clean it using a ~~5'"/I
soft dry cloth or vacuum.
Ifthe filter is greasy wash
with warm soapy water,
rinse, and dry
completely.
Visual Inspection
of Flame
Check that the burner flames are operating normally.
The flame can be seen through the circular window
through the louvers.
When operating normally the burner flame should
appear as long, clear, blue, stable, streaks. Yellow
flames or an orange color is abnormal and
maintenance is required.
VISUAL CHECK
SATISFACTORY
FRONT VIEW
BLUE FLAME
~EROC
UNSATISFACTORY
FRONT VIEW
YELLOW FLAME
10 Rinnai Corporation ES38 Manual