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Raypak 0133-4001 Boiler User Manual

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1. 24 BK 3K 120V PUMP DATA TRANS Ex Ex TRANS ACTORY FIELD 24V MODE 120V NO el BL 3 Pi NC NS AMPS BU SOLID STATE Q je DEVICE Y ag MANUAL LOW HIGH AUTO RESET GAS GAS RESET Q SEE KEY LIMIT PRESSURE LIMIT NC NO IGNITION 42 R R NO IGNITION 1 24V 120V 170V ELD WIRE RE NUI BLACK NOTES BROWN RED CHECKED BY USE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER OR GROUND MAY RESULT IN LOCK OUT APPROVED PUMP USED MUST BE RATED 12 AMPS MAX OR 1 HP MAX B ORIG EG PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES V 0 2567 IW CHECK CONTROLS PROVIDED WIRED AS SHOWN N 04 07 90 REPLACE WIRING WITH 105 C WIRE ONLY CHG E O 5548 WIRING DIAGRAM IID DUAL PILOT ECONOMASTER 3 30 01 FIRING MODE MECHANICAL MODULATION DD D Rupak UTS 51 5 ARV 1 646 000
2. SIZE 1414 1826 42 WIRING DIAGRAM WH2 2100 2500 JUNCTION BOX 120 W 120 TRANS 4 SOLID STATE E D BK W BK TERMINAL BLOCK d MANUAL BOILER GROUND CONTROLS DATA FIELD PUMP MODEL AMPS 1 120V HOT L1 w gt 120V COMM 12 L L 0 LOW HIGH o XX INN 7 Nw 7 gt NOTES CHECKED BY APPROVED BY ORIG 1947 RY CHECK CONTROLS PROVIDED WIRED AS SHOWN B 07 05 84 REPLACE WIRING WITH 105 C WIRE ONLY YE WIRING DIAGRAM ECONOMASTER GRE 5 18 99 IRING MODE MOTORIZED MODULATING E WH WG USE GROUND CLIP PR
3. N FLOW deeds SWITCH HIGH 2 2 TENSION 24V 120V 20V FELD WIRE WIRE NUI NOTES USE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER a CHECKED BY GROUND MAY RESULT IN LOCK OUT An APPROVED PUMP USED MUST BE RATED 12 AMPS MAX OR 1 HP MAX EE PUMP DELAY ADJUSTIBLE BETWEEN 3 AND 10 MINUTES RIG E 0 2567 CHECK CONTROLS PROVIDED WIRED AS SHOWN TA 04 1 8 90 REPLACE WIRING WITH 105 C WIRE ONLY CHG E O 3288 WIRING DIAGRAM IID ECONOMASTER 12 22 99 FIRING MODE MECHANICAL MODULATION 2 INPUTS 512 000 THRU 627 006 EROR IE lt SIZE 514 624 BOLLER TY 152275 NULL 40 WIRING DIAGRAM WH2 724 1336 R VON TROLS JANI 0 JO BK 120V HOT L1 HA W m 120V COMM L2 GROUND 225 L PUMP DATA FACTORY FIELD BK U
4. R GROUND p al RE SUM e PRESSURE R BR R NC NO NC NC excu 150 WIRE 24 NOTES UsE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER RAUM GROUND MAY RESULT IN LOCK OUT CHECKED BY 120 PUMP USED MUST BE RATED 12 AMPS MAX OR 1 HP MAX MM OR bus PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES WRE NUT BLACK ORIG E O 5511 CHECK CONTROLS PROVIDED WIRED AS SHOWN BROWN 08 17 00 REPLACE WIRING WITH 105 C WIRE ONLY B Mes YELLOW AN WIRING DIAGRAM IID ECONOMASTER a 01 28 02 FIRING MODE MECHANICAL MODULATING v WHITE PUTS SH JO VERY 299 000 0101 SIZE 330 400 Hi H5 W2 WH2 152506 NGULTUDC 39 WIRING DIAGRAM WH2 514 624 JUNCTION BOX CONTROLS POWER B m 120V HOT 11 O W m 120V COMM 12 E inan GROUND PUMP DATA o ji FACTORY FIELD 1297 MODEL NO i BK 1209 24V NC AMPS DAY COM SOLID STATE ECONOMASTER Y h DEVICE Y BL LOW HIGH AUTO GAS GAS RESEI PRESSURE LIMIT Q C g IGNI TION XX AN N XXX
5. PUMP USED MUST BE RATED 12 5 OR 1 HP 120V PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH ONLY PROVIDED ON INDOOR UNITS MRE NUT en BLACK ORIG E O 55511 CHECK CONTROLS PROVIDED WIRED AS SHOWN BROWN 08 15 00 REPLACE WRING WITH 105 C WRE ONLY pg YELLOW E WIRING DIAGRAM IID ECONOMASTER 01 28 02 FIRING MODE MECHANICAL MODULATING VIOLET WHITE 181 000 THRU 264 0 B TUR SIZE 182 260 H1 H5 W2 WH2 152505 2 GULIDUG 38 WIRING DIAGRAM WH2 330 400 IGNI TION VOD Solid Stevie DEVIGE FLOW 1 2 SWITCH RANS LWCO BK 120V TEST W __ BK L TENSION SWITCH BURNER TRAY BL V PROB L1 HOT o C 120V SWITCH L2 COMM
6. 3 Cris 3 PUMPANDMOTOR 3 GENERALSAFETYPRECAUTIONS 3l LIGHTINGINSTRUCTIONS 2 INSPECTIONPROCEDURES 3 BURNERS EE 3 3 INSPECTIONPROCEDURES A ADDENDA LOWNOxHEATERS181 401 D TROUBLESHOOTINGELECTRICAL 3 WIRINGDIAGRAMWMS 3 182 C 3 350100 susen needed 3 WH2 514624 40 WAR 72A Duce titia ideo 4 WH2 1414 1826 4 21002300 uM 4 WH2 3001 4001 44 WH1 181 261LOWNOX 4 WH1 331 401LOWNOX 46 TROUBLESHOOTINGMECHANICAL 4 TROUBLESHOOTINGPUMPS 4B SERVICEANDMAINTENANCEPROCEDURES 4B TUBECLEANING eee 4B BURNERTRAYREMOVAL 4 GASVALVEREMOVAL 49 MAINBURNERANDORIFICEREMOVAL 4 PILOTREMOVALANDCLEANING 4 HIGHLIMITORTANKSTATREMOVAL 4 4 COMBUSTIONCHAMBERREMOVAL D CONTROLWELLREPLACEMENT 5 TUBEREPLAGEMENT D
7. Bad 2 22 20 Inoperative thermostat Inoperative toggle switch inoperative Main gas valve closed Plugged bleed line on gas valve or gas pressure regulator Broken pump coupler Shutdown by low water cut off caused by EE Gas valve defective Temperature setting too low Low water HOW cde Interrupted pump operation Modulating control set too high Mechanical modulating control Air Toxic fumes which cause a chemical reaction with copper tubes or destroy 8 1 Improper Insufficient system flow Low water due to leaking Kn staneranm Lime in Heat Exchanger Low gas Insects or debris clogging Burner intake ports low gas pressure Venting or combustion 47 CORRECTIVE ACTION Check the circuit breaker outdoor con troller etc upstream of heater If power to Leads L1 and L2 of trans former but no power on 24V side re place Jumper thermostat re
8. 9105 TIVLSNI 17 HOV3 33S SNIZIS ONY NOISSG NI ASVA 0 16 1 OL 3186504 SY 35012 SV 331 31 201 TIYE ST13dON TYNGAIAONI ASNWOIE 513000 53002 1 201 SV HO NIVHO OL S3ATVA J3r IN3S3ud3u NOLLOANNOOD NMOHS 5 1 NOLLISOd 4835012 ALIAVHD NI 3A1VA 23HO ONIMS JANIA 31 9 5310 i AS VIVA dN MOOH 318 1 ONIZIS 1 HALVSH SSN NOLYTNOHIDIN d NOINN aunivHadWal LNOHLIM 08 3 NOILY 101208I2 38 i JAIVA 349133 NIV eC JHNSSIHd VW N dWNd LNOHLIM GTGI VLIG 1340081 NO P q 00 0012 UNV IOv 18L 51300 NO NOILV2O1 X IVISMNVL ii P SHIHLO qoo NOISNY dX3 Ny V va M1L3AONS3HL A ddns V 3ATVA dandy E YLVA maus EJ qazisvHdW3 1vVWNo4 aarvadn n 190 A8 03 NOIL dl 2S 30 A34 pese pem o JS SNOISIA 3H LOH OLA 831V 3H 9291 15 ST300N 1v393LNI TvNOILdO 21 TYPE NH INSTANTANEOUS Type NH heaters provide instant hot water without a tank and are used in applications where scaling is prevalent and where hot water demand is fairly constant throughout the day such as apartments hotels motels and industrial applications The Type NH heater should not be used
9. Fig 9336 PILOT BURNER FLAME IID atmospheric units 34 7 Check flow switch paddle 8 Clean room air intake openings to assure adequate flow of combustion and ventilation air CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty 9 Keep heater area clear and free from combustible materials gasoline and other flammable vapors and liquids Should be checked monthly Takes approximately 15 minutes ADDENDA LOW NOx HEATERS Models 181 to 401 The Raytherm Low NOx Heater is offered with WH1 firing standard or 2 stage firing optional The heaters are certified and tested under the latest edition of the ANSI Z21 10 3 CSA 4 3 standard for hot water heaters The heater should be installed to meet all local codes the National Fuel Gas Code ANSI Z223 1 and the National Electrical Code ANSI NFPA 70 latest edition DETAIL A SEE DETAIL VIEW Fig 9361 OPERATION On call for heat the ignition system consisting of an electronic spark module gas pilot system is energized Providing pilot is proven blower will start running the main gas valve will open and the heater will operate When the operating control is satisfied the heater will shut down START UP PROCEDURES S8610B Ignition Module 1 Turn on power to the heater with gas sup
10. 6 SPECIFICATIONSANDDIMENSIONS 7 OUTDOORINSTALLATIONS 10 HIGHWINDCONDITIONS 10 COMBUSTIONAIR 10 cp 11 VENTPIPING Leese 14 VENTDAMPERINSTALLATION 15 PENG M 17 GASSUPPLYCONNECTIONS 17 GASPRESSUREREGULATOR 18 VENTINGOFDIAPHRAGMGAS COMPONENTS 18 TES 19 UNITEMP80SPECIFICATIONS PIPINGDIAGRAMS 21 TYPEWHUNITEMP80 21 TYPENHINSTANTANEOUS 2 TYPENHDUALMODELS 23 0 ohc A RELIEFVALVE 2 ECONOMASTERCONTROL ELECTRONICIGNITION 2 OPERATINGCONTROLS VET CONTROLS inina 5 25 FLOWSWITCH 25 100 PILOTSAFETY 25 LOWWATERCUT OFF 25 HIGHANDLOWGASPRESSURESWITCHES 25 COMPONENTIDENTIFICATION 25 27 LOCATIONOFCONTROLS 8 START UPPROCEDURES
11. NO NC NC NOTES USE GROUND LUG PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK OUT ALL GROUND TERMINATE E APPROVED BY 8 1 7 00 REPLACE WIRING WITH 105 C WIRE ONLY I GYLDIG CHECKED BY PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH ONLY PROVIDED ON INDOOR UNITS ORIG E O 3311 M CHECK CONTROLS PROVIDED WIRED AS SHOWN EO 3422 WIRING DIAGRAM IID ECONOMASTER LOW NOX 5 21 02 FIRING MODE ON OFF FA 1 000 TARU 6400 BU SIZE 181 261 45 H4 W1 WH1 AP mb son ic lt Hx e WIRING DIAGRAM WH1 331 401 LOW NOx Y SOLID STATE ECONOMASTER DEVICE GAS VALVE BK TESI SWITCH BK V PROBE TENSION A L1 HOT A BURNER TRAY 120V SWITCH a C 112
12. 7 Remove combustion chamber clips at the four corners of the heat exchanger 8 Liftheat exchanger straight up using caution not to damage refractory HEAT EXCHANGER RE ASSEMBLY 1 Heat exchanger water header O rings should be replaced with new ones 2 Install in out and return water headers and install header retainer nuts and torque nuts evenly 3 Install the four 4 corner clips between tube sheets and refractory Replace V baffles 4 Install thermostat sensing bulbs in header wells and replace bulb retaining clips 5 Install inlet and return pipes in water headers using pipe thread sealant 6 Install water pressure relief valve flow switch and low water cut off devices if so equipped 7 Open water supply and return shut off valves Fill heater and water piping system with water Check heater and piping system for leaks at full line pres sure Run system circulating pump for a minimum of 1 2 hour with heater shut off 8 Shut down entire system and vent all radiation units and high points in system piping Check all strainers for debris Expansion tank water level should be at the 1 4 mark and the balance of the tank filled with air 9 Install flue collector jacket top and inspection panels Install top holding screws Install draft diverter and vent piping if so equipped 10 If gas piping was disconnected reconnect gas piping system and check for leakage using a soap solution 11 Check for correct water
13. CLEANINGFLUEGASPASSAGEWAYS 51 REPLACEMENTPARTS 51 WARRANTY p RECEIVING EQUIPMENT On receipt of the equipment visually check for external damage to the carton or the shipping crate If the carton or shipping crate is damaged make a note on the Bill of Lading and report the damage to the Carrier immediately Remove the heater from the carton or the shipping crate Do NOT use the shipping crate base as an instal lation base On occasion items are shipped loose Be sure that you receive the number of packages indicated on the Bill of Lading When ordering parts you must specify Model and serial Number of the heater When ordering under warranty conditions you must also specify date of installation Raypak recommends that this manual be reviewed thoroughly before installing your Raypak heater there are any questions which this manual does not answer please contact the factory or yourlocal Raypak representative Claims for shortages and damages must be filed with carrier by consignee Permission to return goods must be factory authorized and are subject to a stock ing charge Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defec tive replacement parts will not be accepted and will be replaced in kind only per our standard warranties MODEL IDENTIFICATION The model identification number and the heater seri
14. WC and a maximum of 10 5 WC upstream pressure under load and no load conditions must be provided for natural gas or a minimum of 11 WC and a maximum of 13 for propane MAXIMUM EQUIVALENT PIPE LENGTH NATURAL GAS 1000 BTU Cubic Foot 60 SPECIFIC GRAVITY 0 5 W C PRESSURE DROP PROPANE GAS 2500 BTU Cubic Foot 1 53 SPECIFIC GRAVITY 0 6 W C PRESSURE DROP 4 2 144 1427 2 2427 3 47 EN Pu EM P 15 35 60 145 2001 500 J 40 140 560 E 15 co 205500 10 15 35 65 150 130 360 800 NEM EN 25 4 926 962 15 204 45 095 110 1504 400 10831125 10 15 35 35 80 120 300 300 210 NNI 02 50 01 1 10 15 35 40 85 120 250 5001 Models 181 261 331 and 401 Low NOx units and not available in propane GAS PRESSURE REGULATOR The gas pressure regulator located in the gas valve is preset nominally at 4 WC for natural gas and 11 WC for propane Between the gas valve and the burners is a 1 8 pipe plug The pressure at this point taken with a manometer should be about 3 7 WC natural gas and 10 5 WC propane Models 181 261 331 and 401 should be 3 9
15. WH 962 WH 1125 WH 1223 WH 1336 WH 1468 WH 1631 WH 1826 Recovery based on manufacturer s rating 14 1 2 11 3 4 ELEG CONN NAL d STACKLESS TOP PUMP OPTIONAL PUMP COVER OPTIONAL COMBUSTIBLE 2 1 4 FLOOR SHIELD OPTIONAL NOTE Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 496 for each 1 000 feet above sea level A 19 1 2 INDOOR A 2 DRAFT L HOOD NN mE p 1 J BOX COMBUSTIBLE FLOOR SHIELD OPTIONAL NOTE Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 4 for each 1 000 feet above sea level MODELS 926 1758 PUMP COVER OPTIONAL PUMP OPTIONAL ELEC CONN J BOX L COMBUSTIBLE FLOOR SHIELD 1 1 8 OPTIONAL 5 Water Model Recovery Number GPH H NOTE Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 496 for each 1 000 feet above sea level Recovery based on manufacturer s rating MODELS 2100 4000 aa G GAS 36 1 2 24 1 2 23 5 8 DIMENSION VARIES FOR EACH MODEL SIZE AND TYPE CONSULT FACTORY FOR DETAILS Ugo Miele FOR REFERENCE ONLY ACTU S CONTROLS MAY VARY FO EACH MODE SIZE AND TYPE CONSULT FACTORY FOR DETAILS Dimensions Inches Overall Gas Input Height Conn MBH B
16. to the appliance or to the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict air flow In addition the heater shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replace ment etc Combustible floorshield ordering information Heater Floor Base Model Part ALTERNATE METHOD FOR PROVIDING A NON Number Number COMBUSTIBLE BASE 133 001749 182 181 058313 260 261 058314 330 331 058315 Na 400 401 058316 514 056199 624 056200 724 056201 824 056202 926 054597 Sheet Metal 1083 054598 4 24 Gauge 1178 054599 mt Hollow concrete cinder block 1287 054600 align holes and leave ends open 1414 054601 1571 058378 1758 962 1125 1223 1336 1468 1631 1826 0583 9 059233 059234 059235 059236 059237 059238 059239 Models with factory installed floor shield as standard BOLD TYPE indicates Low NOx models CLEARANCES INSTALLATION CLEARANCES All Dimensions Are In Inches CLEARANCES FROM COMBUSTIBLE SURFACES Heater Size BEEN 181to 514 926 to 2100 to Location 401 824 18 Flor See Note 1 Front See Note 2 Unobstructed Outdoor Top Note 1 Combustible floor shield is required when h
17. 625 624 2500 724 726 3001 3000 724 750 824 3500 824 875 4000 1125 1125 EN 1125 282 JEN OLD PE indicates Low NOx models BOLD TYPE indicates Low NOx models NOTE f louvers grills or screens are used on the openings obtain the net free area from their supplier or manufacturer If the design free area of a louver is not known nor available it shall be assumed that wood louvers will have 20 25 percent free area and metal louvers will have 60 75 percent free area as shown in Sec 5 3 5 National Fuel Gas Code 10 VENTING OUTDOOR INSTALLATIONS MODELS 514 824 MODEL 133 Step 1 Lower outdoor Stackless top onto unit Position top so it is centered on unit from Step 1 Remove the front 4 screws side to side and front to rear Step 2 Line up outdoor top vent opening over heater vent opening Step 3 Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top Step 4 Reinstall b screws to secure jacket top and outdoor top to unit EATER VENT Fig 8166 OPENING Fig 8114 Step 2 Tighten the 4 screws Shown below until they come in contact with the unit jacket top then evenly tighten all 4 screws to secure MODELS 181 401 and 182 400 to unit Outdoor Top OUTDOOR TOP 8 3 8 Fig 8278 1 N VENT TERMINAL Outdoor Stackless Top Installa tion OUTDOOR FLOOR BASE I FAST
18. COMM 0 n GROUND MANUAL LOW HIGH AUTO EGET BL RESET LIMIT Gas PRESSURE Gas RESET LIMIT NC NO NC NC NOTES USE GROUND LUG PROVIDED FAILURE TO PROMDE PROPER GROUND MAY RESULT IN LOCK OUT ALL GROUND TERMINATE CHECKED BY PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES ORIG L O 5511 CHECK CONTROLS PROVIDED WIRED AS SHOWN 8 17 00 REPLACE WIRING WITH 105 C WIRE ONLY ODG EU S422 WIRING DIAGRAM IID ECONOMASTER LOW NOX 5 22 02 FIRING MODE ON OFF dos OUO TARY e tU BLU SIZE 331 401 H4 W1 WH1 1929294 3 QLIL JUDDYKCIUR 46 TROUBLESHOOTING MECHANICAL PROBLEM When heater is turned on nothing happens Thermostat in ON position causes relay and pump to operate but heater does not fire Continuous shut down of manual reset High Limit Sooting CAUTION Soot may be combus tible Wet down and exercise caution when cleaning Continuous shut down of low water cut off or flow switch Low flame Outer jacket very hot blistered paint Combustion fan not running If applicable POSSIBLE CAUSE No power to the heater
19. NOTE Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 496 for each 1 000 feet above sea level 103 3 4 1 1 2 or 2 contingent on code requirements Recovery based on manufacturer s rating OUTDOOR WATER HEATERS These heaters are design certified for out door installation Heaters must not be installed under an overhang of less than three 3 feet from the top on the heater Three 3 sides must be open in the area under the overhang Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters The point from where the flue products exit the heater must be a minimum of four 4 feet below four 4 feet horizontally from or one 1 foot above any door window or gravity inlet to a building The top surface of the heater shall be at least three 3 feet above any forced air inlet or intake ducts located within ten 10 feet horizon tally Fig 48245 Forced Air Inlet HIGH WIND CONDITIONS Outdoor Units Only In areas where high winds are frequent it may be necessary to locate the heater a minimum of 3 from high vertical walls or install a wind break so the heater is not in direct wind current COMBUSTION AIR Indoor Units Only Air For Combustion And Ventilation The heater must have both combustion and ventilation air Minimum requirements for net free air supply openings are 12 inches from ceiling for ventilatio
20. Series hydraulic snap on thermostatic combination gas valves These valves have the pres sure regulator and 24 volt operator built in The hy draulic actuator will throttle the heater input to adjust the firing rate and meet the required load This in effect prevents costly fuel consumption as compared to an on off cycling heater The valve has a remote capillary bulb immersed in a well at the header outlet to main tain a constant outlet water temperature When mul tiple valves are furnished they can be staged to give greater flexibility of control Standard factory setting is at position 5 Consult the dial setting tag attached to the control for your desired temperature See chart below Robertshaw modulating setting EE valve dial setting chart AE STANDARD FACTORY SETTINGS Dial Position Temperature Degrees F Settings are approximate The temperature indicator is located on top of the modulator valve next to the valve ON OFF knob Set number for desired temperature next to setting indicator Fig 9330 1 LO 1 2 3 4 5 6 T 8 HI MODULATING VALVES WITH BUILT IN REGULATOR Fig 9332 MECHANICAL MODULATING VALVE LOCATION MODELS 0724 1336 MOTORIZED PRESSURE GAS VALVES HIGH GAS RES ER PRESSURE SWITCH y MOTORIZED GAS VALVE LOCATION MODEL 3001 i in LIMIT CONTROLS HIGH LIMIT whenever the pilot flame is interrupted Pilot flame is The heater is eq
21. any of the original wire supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent 44 I F a TH LEADS TH LEADS HEATER 1 HEATER 2 44 gt BREAK THE WIRE NUT AT THE HEATER TH CONNECTIONS AND ATTACH TO THE DUAL TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE Fig 9138 1 2 STAGE TANKSTAT 2 ON OFF UNITS LOCATION OF CONTROLS 400 WH1 WH2 WH3 HIGH LIMITS ON OFF SWITCH PRV INLET N ELECTRICAL OUTLET CONTROLS WATER LOCATION CONNECTIONS COMBINATION GAS VALVE OPTIONAL PUMP PILOT LOCATION FIG 9350 RATING PLATE 181 LOW NOx WH1 RATING PLATE ON OFF FLOW SWITCH SWITCH ELECTRICAL CONTROLS LOCATION INLET OUTLET WATER CONNECTIONS HIGH LIMITS OPTIONAL PUMP COMBINATION GAS VALVE p PILOT LOCATION Fig 9360 28 LOCATION OF CONTROLS 024 MECHANICAL MODULATION VALVES WITH BUILT IN WH1 GAS PRESSURE REGULATOR PRV PILOT PILOT GAS REGULATOR VALVE T amp P GAUGE OPTIONAL HIGH LIMITS REAR MOUNTED PUMP INLET Ue 417 17 NO CONNECTIONS _ H RATING erd PLATE SE MANUAL GAS VALVE GAS VALVE ELECTRICAL J BOX PILOT COMBINATION LOCATION GAS VALVE AND COMBINATION GAS PRESSURE REGULATOR VALVE AND PRESSURE WH3 rReGULATOR AGA DESIGN GAS TRAIN SHOWN CODE REQUIREMENTS FOR SPECIFIC JURISDICTIONS MAY NECESSITATE CHANGES 163
22. in suction line 2 Wrong direction of rotation 2 Excess air in water 3 Speed too low 3 Water seal in stuffing box not functioning 4 Total head too high 4 Excessive suction lift and pump operating too near shut off point REDUCED CAPACITY AND OR HEAD 1 Air pockets or leaks in suction line OVERLOADED DRIVING UNIT 2 Clogged impeller 1 Head much lower than that for which pump is 3 Foot valve strainer too small or clogged designed 4 Excessive suction lift over 15 feet 2 Speed too high or higher than that contem 5 Insufficient positive suction head for hot water plated 6 Total head more than that for which pump is intended MECHANICAL TROUBLES AND NOISE 7 Excessively worn impeller and wearing rings 1 Misalignment 2 Excessive suction lift or vapor binding hot RAPIDWEAR OF COUPLING water 1 Misalignment or a bent shaft 3 Bent shaft and or damaged bearings 2 Sagging motor mounts over oiling 4 Suction and discharge piping not properly supported and anchored SERVICE AND MAINTENANCE PROCEDURES Fig 8154 RAYPAK TUBE CLEANING KIT Jc Mee Extension Pieces 5 Auger with Carbide Tip Wire Brush TUBE CLEANING Establish a regular inspection schedule the frequency sure the residue does not get into the system depending on the local water condition and severity of Note that you do not remove the top pan or the service Do not let the tubes clog up solidly Clean out heat excha
23. on apartments and hotels with fewer than 30 dwelling units nor should the heater be sized smaller than a 514 Use a minimum 20 of 3 pipe on outlet REMSIONS MINIMUM RECOMMENDED m SECIRGULA ON 1 UPDATED FORMAT NH WAS AND HEATER WAS BOILER EA 3 24 03 514 HEATER MOUNTE Wo EAR MOUNTED 624 1775 26 1826 ADJUST HEATER MODULATING VALVE S INSIDE CABINET FOR DESIRED OPERATING TEMPERATURE COLD USE A MINIMUM OF 20 2 PIPE ON OUTLET NN vann AC E RECIRCULATION PUMP SUPPLY us BY OTHERS FRO RECIRCULATION LOOP NOTES UNION 1 PLUMB SWING CHECK VALVE IN G
24. pressure and water level in the system Make sure that system pump operates immediately on the call for heat The system is ready for operation 12 Within two 2 days of start up recheck all air vents and expansion tank levels RETURN HEADER V BAFFLE INLET OUTLET HEADER Fig 9337 TYPICAL HEAT EXCHANGER CONFIGURATION COMBUSTION CHAMBER REMOVAL To remove combustion chamber you must first have removed the heat exchanger Unbolt metal combustion chamber retainer from top and remove combustion chamber panels individually REFRACTORY PANELS TOP VIEW CONTROL WELL REPLACEMENT Remove top sensing bulb and clip Collapse well tube at the open and with a chisel push through into header and remove the well through header Insert a new well and roll into place If a roller is not available solder the well in place with silver solder TUBE REPLACEMENT 1 Remove heat exchanger from heater following instructions outlined under HEAT EXCHANGER REMOVAL above 2 Remove in out and return headers Remove V baffle from damaged tube 3 Remove damaged tube by cutting with a hack saw or shearing with a chisel adjacent to each tube sheet 4 Collapse stub ends in tube sheets using a chisel or screwdriver DO NOT cut into tube sheet or mar surface in tube hole in any way 5 Insert replacement tube by inserting the end with the most fins removed in the opening of one tube sheet Slide tube until the opposite end clears th
25. wc natural gas If an adjustment is needed turn adjustment screw clockwise to increase pressure or counter clockwise to decrease pressure VENTING OF DIAPHRAGM GAS COMPONENTS Gas train components that have diaphragms in their construction are supplied with a bleed line connection that must be connected to the outside atmosphere as required by the National Fuel Gas Code Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system BLEED LINE CONNECTION Fig 8185 2 18 FLOW RATES 0 3 z O 1 LL z ex lt 2 gt 1 PASS HEAT EXCHANGER 2 PASS HEAT EXCHANGER bka ba be bel kai kel i em CQ CX CN CQ CN CN TITT st 4 GPM flow rates limited by maximum acceptable velocity through heat exchanger tubes May be increased by 10 for closed heating systems 4 Pass Heat Exchanger BOLD TYPE indicates Low NOx models 19 PIPING DOMESTIC HOT WATER SUPPLY HEATERS GENERAL SPECIFICATIONS UNI TEMP 80 HOT WATER SUPPLY SYSTEMS WATER HARDNESS vous som gt Indoor outdoor T P wes sw T wes su r cem wes sm 5 1 17 13 8 2 10 22 T 22 10 514 20 42 2 0 2 4 8 16 52 3 0 2 7 1 624 624 25 41 2 0 4 7 19 54 3 4 7 9 724 724 29 41 2 1 4 9 20 4 4 9 8 824 824 30 45 2 6 2 5 9 20 68 6 0 2 12 8 BOLD indicates Lo
26. 1 RATING PILOT PILOT GAS HIGH LIMITS PLATE REGULATOR VALVE WH1 pry OPTIONAL REAR MOUNTED T amp P GAUGE 4 PI HIDDEN FROM VIEW INLET OUTLET WATER CONNECTIONS ELECTRICAL J BOX COMBINATION he VALE des on GAS VALVE AND GAS VALVE vA LOCAT PRESSURE REGULATOR 2 MECHANICAL MODULATION VALVES WH3 COMBINATION GAS VALVE WITH BUILT IN GAS PRESSURE REGULATOR GAS AND PRESSURE REGULATOR Fig 49334 29 LOCATION OF CONTROLS 3001 HIGH LIMITS GAS PRESSURE RATING WH 1 SWITCH PLATE PILOT REGULATOR INLET M OUTLET WATER T amp P GAUGE 7 HIDDEN FROM VIEW ELECTRICAL J BOX 7 MANUAL Pai PILOT GAS GAS VALVE Fig 9335 PRESSURE GAS VALVE AND PILOT REGULATOR MOTORIZED ACTUATOR LOCATION FOR WH2 OR WH3 SYSTEMS THE ONLY CHANGE IS AGA DESIGN GAS TRAIN SHOWN CODE THE ACTUATOR FOR THE SECOND VALVE REQUIREMENTS FOR SPECIFIC JURISDICTIONS MAY NECESSITATE CHANGES START UP PROCEDURES BEFORE START UP INITIAL START UP PUMP AND MOTOR Safe lighting and other performance criteria were Many pumps are now direct drive They have no met with the gas manifold and control assembly pro coupler or bearing assembly These pumps do not vided on the heater when the heater underwent tests require lubrication Others require SAE 30 non deter specified in the latest edition ofthe ANSI Z21 10 3 CSA gent oil to lubricate both the motor and the bearing 4 3 Sta
27. CATALOGNO 3000 52H Effective 07 15 06 Replaces 11 01 04 INSTALLATION AND OPERATING INSTRUCTIONS RAYTHERM HOT WATER SUPPLY HEATERS Models 0133 4001 Types WH amp NH FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier FOR YOUR SAFETY 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 This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference CERTIFIED P N 241075 Rev 1 TABLE OF CONTENTS RECEIVINGEQUIPMENT 3 MODELIDENTIFICATION 3 GENERALSPECIFICATIONS 3 GENERALSAFETYPRECAUTIONS 4 INSTALLATIONINSTRUCTIONS 5 CLEARANCES
28. DRAFTHOOD OF DRAFTHOOD Fig 8947 Step 8 Disconnect male female connector and attach to the 2 wires from drafthood vent sensor harness 12 MODELS 181 401 and 182 400 VENT TERMINAL INDOOR STACK INSTALLATION 1 2 SCREW HOLE LOCATION N 3 1 4 4 Remove the louvered jacket top by removing four 4 410 flathead screws If originally installed remove Pagoda top from the louvered jacket top Place the inner stack adapter panel over the flue collector inside the heater Make sure the flanged side of the flue opening is up Turn the stack drafthood upside down and set it down bottom side up Turn the jacket top panel removed in step 1 upside down and place it through the stack Attach the three 3 mounting brackets to the stack using the screws provided and the holes that are pre drilled in the stack Make sure the brackets are positioned with the flange near the top side of the stack see illustration 8246 5 Caution must be taken not to over tighten and strip the screw threads Turn the assembled stack and jacket top right side up The jacket top will be trapped between the brackets and the top of the stack Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position Reinstall the four 4 green 410 flathead screws removed in step 1 above DRAFTHOOD JACKET TOP PANEL part of the heater 10 SHEET METAL SCREW 3 MOUNTING BRAC
29. ED FAILURE TO PROVIDE PROPER TIU GROUND MAY RESULT IN LOCK OUT PUMP USED MUST BE RATED 12 AMPS OR 1 HP PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES ORIG E O 1947 CHECK CONTROLS PROVIDED WIRED AS SHOWN 07 05 84 REPLACE WIRING WITH 105 C WIRE ONLY CHG EO 15239 WIRING DIAGRAM IID ECONOMASTER 01 26 01 RING MODE MODULATING CILIL INPUTS 36 000 000 TARU 4 000 000 BUR lt SIZE 3001 4001 44 WIRING DIAGRAM WH1 181 261 LOW NOx SOLID STATE ECONOMASTER DE VICE TEST SWITCH GAS PV VALVE BK V PROBE HIGH T OWER TENSION i C BURNE 120V SWITCH B IH 12 ee GROUND L TEMP TEMP MANUAL LOW HIGH AUTO BK SWITCH SWITCH RESET LIMIT gas PRESSURE GAS RESET LIMIT R BR R ROLL OUT VENT NC
30. EDURE 58600 1 Turn on power to the ignition systems and turn gas supply off Check ignition module as follows a Set the thermostat or controller above room temperature to call for heat 2 b Watch for continuous spark at the pilot burner C Time the spark operation Time must be within the lockout timing period 15 or 90 seconds d Turn thermostat down to end call for heat and wait 60 seconds on lockout models before beginning step 3 INSPECTION PROCEDURES BURNERS Clean main burners and air louvers free of dust lint and debris Keep heater area clear and free from combustibles and flammable liquids Do not obstruct the flow of combustion and ventilation air Make visual check of burner and pilot flame Yellow flame indicates clogging of air openings Lifting or blowing flame indi cates excessively high gas pressure Low flame indi cates low gas pressure VW 4 Fig 8144 TYPICAL MAIN BURNER FLAME Atmospheric models NOTE Modulating burner flame varies in height from approximately 1 4 at low fire to approximately 4 at high fire 33 3 Turn on gas supply 4 Setthermostat or controller above room temp erature to call for heat 5 Systems should start as follows a Spark will turn on and pilot gas valve will open at once Pilot burner should ignite after gas reaches the pilot burner b Spark ignition should cut off when pilot flame is established c Main gas v
31. ENING SCREW 1 Insert tabs into 2 Snap tabs into keyholes keyhole 4 places 50 as not to pull out Fig 8233 MODELS 926 1758 Heaters are shipped with outdoor vent terminal factory installed MODELS 2100 4001 These units are not certified for outdoor installa tion Pagoda Top Shipped Loose with Heater Fig RP8280 1 11 INDOOR INSTALLATIONS MODEL 133 Step 1 Shut off main electrical power switch to heater Step 2 Turn heater manual switch located in upper control panel to the OFF position Step 3 Shut off gas supply and water supply to the heater Step 4 Mount drafthood on heater and attach with the 8 sheet metal screws provided Drafthood should be positioned with the vent sensor located on the front left side as shown Step 5 Remove plastic plug from left side of heater jacket and install the plastic grommet provided Step 6 Route flue sensor wire harness through the grommet installed in Step 5 TEMPERATURE SENSOR SENSOR SHIELD MOUNTING SCREWS 8 CONTROL PANEL HARNESS HEATER ON OFF ASSY SWITCH LOWER DOOR Fig 48946 Step 7 Remove door and locate wire from roll out sensor to High Limit with the male female connector CONNECT ONE VENT SENSOR WIRE TO HIGH LIMIT WIRE CONNECT ONE VENT SENSOR WIRE TO ROLL OUT SENSOR WIRE WIRE FROM TRANSFORMER WIRE TERMINAL WIRE FROM TRANSFORMER WIRE FROM HIGH LIMIT ROLL OUT SENSOR b ROLL OUT SENSOR BEFORE AFTER INSTALLATION INSTALLATION OF
32. ERMOMETER 1 TEMPERATURE REVERSE RETURN HEATER TYPE NH HEATER SIZE 514 THRU 1826 MINIMUM INPUT ADJUSTMENT Model Types NH and WH have minimum input ratings as specified on their individual rating plates Minimum input controllers have been pre set at the factory Consult with factory representatives if a minimum input problem should occur 23 CONTROLS GENERAL RELIEF VALVE A new combination temperature and pressure T amp P relief valve complying with the Standard for Relief Valves and Automatic Gas Shut Off Devices for Hot Water Supply Systems ANSI Z21 22 must be installed in the opening provided on top of the storage tank at the time of installation No valve is to be placed between the relief valve and the storage tank The pressure rating of the relief valve must not exceed the 160 maximum working pressure indicated on the water heater rating plate The BT UH rating of the relief valve must not be less than the BTUH input of the heater Connect the outlet of the relief valve to a suitable open drain The discharge line must pitch downward from the valve to allow complete draining by gravity of the relief valve and discharge line The discharge line should be no smaller than the outlet of the valve The end of the discharge line should not be threaded or concealed and should be protected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line Local codes shall gov
33. HIMNEY Optional Limit INSTALLED IN ANY POSITION ON VERTICAL PIPE HEATER Ignition System TO Power supply provide disconnect means overload protection as required 1 T i cati ONLY DO NOT D808 MOUNT ABOVE OR Controller BELOW VENT Dual Valve ACTUATOR MAY Combination Gas Control or Transformer Fig 8615 0 VENT DAMPER GENERAL WIRING DIAGRAM Fig 8183 0 INSTALLING THE VENT DAMPER INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED IF IMPROPERLY INSTALLED A HAZARDOUS CONDITION SUCH AS AN EXPLOSION OR CARBON MONOXIDE POISONING COULD RESULT VENT DAMPER For safe efficient operation the vent damper and all flue product carrying areas of the appliance must be checked annually with particular attention given to deterioration from corrosion or other sources Check vent damper operation as follows 1 When the heater is off check that the vent damper position indicator points to the closed position Fig 4 Damper Position Indicator DAMPER OPEN 2 Turnthe thermostat or controller up to call for heat and check that the vent damper indicator points to the open position Fig 4 3 the thermostat or controller down again and check that the vent damper position indicator returns to the closed position THE VENT DAMPER MUST BE INSPECTED AT LEAST ONCE A YEAR BY A TRAINED EXPERIENCED SERVICE TECHNICIAN THE NAME OF THE PER
34. KET 3 INNER STACK ADAPTER PANEL FLUE COLLECTOR part of heater COMBUSTIBLE FLOOR SHIELD optional for indoor 2 1 2 Fig 8246 5 MODELS 514 824 Locate and assemble as shown below Secure with screws supplied in envelope in carton Fig 8167 MODELS 962 1826 Locate and assemble as shown below Secure with screws supplied in envelope in carton 0 Fig 8165 MODELS 2100 4001 These models have built in drafthoods For proper operation the drafthood outlet must be connected to the venting system 13 VENT PIPING WARNING Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning Vent piping of the same size as the drafthood outlet is recommended however when the total vent height is atleast ten 10 feet drafthood relief opening to vent terminal the vent pipe size may be reduced as speci fied in the National Fuel Gas Code ANSI Z223 1 Avoid long horizontal runs of vent pipe and too many elbows installation requires horizontal non vertical runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at not more than five foot intervals Plumber s tape criss crossed will serve to space both horizontal and vertical piping Gas vents supported only by the flashing and extendi
35. N r d MODEL 12 120 5 TRANS 24V NC xk AMPS y 54 SOLID STATE ECONOMASTER 3 Y 4 DEVICE Y BL MANUAL 0 RESET LOW HIGH AUTO RESET CE LIMIT GAS PRESSURE GAS LIMIT R BR R GNITION FLOW R SWITCH HIGH TITT TENSION JUL NOTES USE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER ESKE BY GROUND MAY RESULT IN LOCK OUT APPROVED BY PUMP USED MUST BE RATED 12 AMPS MAX OR 1 HP MAX PUMP DELAY ADJUSTIBLE BETWEEN 3 AND 10 MINUTES ORIG 2681 CHECK CONTROLS PROVIDED WIRED AS SHOWN 07 11 94 REPLACE WIRING WITH 105 C WIRE ONLY CHE 1 0 5288 WIRING DIAGRAM IID ECONOMASTER 12 22 99 FIRING MODE MECHANICAL MODULATION FRONT VIEW RUE 726 000 THRU 1 447 000 BIUH 2 SIZE 724 1336 ER TYPE H1 H5 W2 152359 3 L2 NULL 41 WIRING DIAGRAM WH2 1414 1826 JUNCTION BOX BROILER CONTROLS POWER 6 e 120V HOT L1 w m 120V COMM L2 P canum GROUND LJ
36. OVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK OUT PUMP USED MUST BE RATED 12 AMPS MAX OR 1 HP MAX PUMP DELAY ADJUSTIBLE BETWEEN 3 AND 10 MINUTES INPUTS TARU 24040 p 102 2200 BOILER TYPE 43 WIRING DIAGRAM WH2 3001 4001 PUMP DATA SOLID STATE FCONOMASTER FACTORY FIE b JUNCTION APPLIANCE CONTROLS LWC Ae NO g GROUND 120V HOT L1 BK SWITCH ERMINAL 120V COMM 12 gt LOW BLOCK MANUAL NOTES USE GROUND CLIP PROVID
37. RAVITY CLOSED POSITION PIPE ALL RELIEF VALVES TO DRAI OR AS LOCAL CODES REQUIRE GATE VALVE 3 PIPE SIZE DETERMINED BY GPM REQUIREMENTS 4 PROVIDE FOR THERMAL EXPANSION OF HOT WATER IF A BACKFLOW EATERS SHOWN CHECK VALVE REVENTER CHECK VALVE WATER METER OR PRESSURE REPRESENT VARIOU REDUCING VALVE IS INSTALLED IN THE COLD WATER LINE ODELS BECAUSE 5 ESTIMATE TOTAL LENGTH OF SUPPLY AND RETURN LOOPS NDIVIDUAL MODELS BALL VALVE F MULTIPLE LOOPS ARE USED 2 NT CL A USE MULTIPLE PUMPS AND RETURN PIPES AND SIZING SEE EACH USE ONE LARGER RECIRCULATION PUMP WITH SPECIFIC HEATER TYPE THERMOM BALANCING VALVES ON EACH RETURN LINE FOR DETAILS UNLESS OTHERWISE SPECIFIED ALL UNITS ARE IN INCHES FRACTIONS 1 32 ANGLES 1 12 XX 06 OXNARD 5 03 X XXX 010 CALIFORNIA _ WALL IRICITIES 020 DIA ESS 015 IN EDGES 015 MAX DRAWI ED UNDER CONF E FINISH PER ELATIONSHIP MBODIES PRIE Y14 26M 1996 FORMATION RIGHTS RESERVED BY RAYPAK INC PIPING INSIANIANEOUS 1 HEATER SERIES MODEL DWG NO REV 5309 22 6 509 1 TYPE NH DUAL MODELS 514 1826 1 Estimate total length of supply and r
38. SON WHO ORIGINALLY INSTALLED YOUR VENT DAMPER IS SHOWN ON THE INSTALLATION LABEL DAMPER MUST BE IN THE OPEN POSITION WHEN HEATER MAIN BURNERS ARE OPERATING Damper Position Indicator Fig 8181 0 DAMPER CLOSED FIG 4 VENT DAMPER POSITON INDICATOR SHOWING OPEN amp CLOSED POSITIONS PLUMBING GENERAL Heater should be located so that any water leaks will not cause damage to any adjacent areas or struc tures GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve located outside the heater jacket All gas piping should be tested after installation in accordance with local codes GAS INLET MANUAL SHUT OFF VALVE GAS VALVE HEATER JACKET SEDIMENT TRAP Fig 8090 1 17 CAUTION The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 PSI Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES NOT COVEHED BY WARRANTY The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame NOTE Do notuse Teflon tape on gas line pipe thread A flexible sealant is recommended A minimum of 7
39. TCH GAS MANIFOLD ad Fig 48236 0 f 4 ADDENDA LOW NOx HEATERS Models 181 to 401 CONTINUED co po won GAS VALVE REMOVAL ON 9 Carefully slide out the burner tray assembly Reverse above procedure to reinstall FAN 4 Di GAS 6 VALVE BURNER BURNER HOLD DOWN BRACKET Fig 9362 LOW NOx BURNER TRAY ASSEMBLY BURNER TRAY REMOVAL 1 Shut off main electrical power switch to heater 2 Shut off gas upstream of heater 3 Remove front door 4 Disconnect gas line from gas valve 5 Remove 2 screws that mount burner tray to unit and 4 screws that secure gas valve to jacket Disconnect wires that terminate at gas valve Unscrew 4 screws that secure the control box Disconnect pilot wire from the ignition module Disconnect wire harness from the combustion blower Shut off main electrical power switch to heater Shut off gas supply to the heater Remove front door Disconnect gas line from gas valve Disconnect wires pilot tubing and bleed line If required Hemove 2 screws that secure gas valve to jacket Turn vertical gas pipe from manifold slightly and unscrew gas valve Reverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL Hemove burner tray See Burner Tray Removal procedure above Remove 8 screws from the hold down brackets Remove 8 screws from the left and right sides of the manifold assembly Detach
40. TE If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue f checks are okay replace module CALL FOR HEAT ENDS Check for proper thermostat controller operation SYSTEM SHUTS OFF Remove MILLIVOLT lead at module if valve closes recheck temperature YES controller and wiring if not replace gas valve TROUBLESHOOTING ENDS 3 WIRING DIAGRAMS WIRING DIAGRAM WH2 182 260 IGNI TION MOD SOLID me ECONOMASTER DEVICE I B TENSION BURNER TRAY L1 HOT e PE SWITCH L2 COMM R LM EP END GROUND BK 41 M DUM RESET LIMIT A FRESSURE DE BE pus R sex R ROLL OUT VENT NC NO NC NC SOG _ NOTES USE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER m GROUND MAY RESULT IN LOCK OUT ay
41. TER CUT OFF MECHANICAL MODULATING VALVE 4 ADAPTER SINGLE PASS 3 PIPE TEE RETURN HEADER WITHOUT INTERGRAL PUMP 212 PIPE TEE AND T ADAPTER 2 PASS 2 PIPE TEE 1 1 2 PIPE TEE 1 1 4 PIPE TEE Fig 9317 Fig 8925 FLOW SWITCH FLOW SWITCH PADDLE CUTTING GUIDE 26 ELECTRICAL CONNECTIONS CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is discon nected to avoid potential serious injury or damage to components The heater is normally wired for 120 Volts The voltage is indicated on the tie in leads Consult the wiring diagram shipped with the heater in the instruc tion packet The TH leads are for the remote tank TH LEADS HEATER 1 i BREAK THE WIRE NUT AT THE HEATER TH CONNECTIONS AND ATTACH TO THE SINGLE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE Fig 9138 2 SINGLE STAGE TANKSTAT control connection 24 Volts are supplied to this con nection through the heater transformer DO NOT attach line voltage to the TH leads on models 514 1826 Before starting heater check to ensure proper voltage to heater and pump Heater must be electrically grounded in accor dance with National Electrical Code ANSI NFPA No 70 NOTES 1 Field install ground wire to inside of junction box 2 If
42. a fire or explosion 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 1 STOP Read the safety information above For Honeywell Gas Valve Turn gas control knob counter 2 Set the thermostat on the lowest setting clockwise from OFF until it stops Push in gas control 3 Turn off all electric power to the appliance knob and continue rotating counter clockwise to ON 4 This appliance is equipped with an ignition device which position Make sure knob rests against stop automatically lights the pilot Do not try to light the pilot by hand 5 Remove heater door panel 6 For Robertshaw gas valve Turn gas control knob HONEYWELL clockwise to OFF EF For Honeywell Gas Valve Turn gas control knob clock Elk KNOB SHOWN wise to OFF Make sure knob rests against stop For Honeywell Gas Valve Model 400 only Push in gas control knob slightly and turn clockwise to OFF Knob cannot be turned to OFF unless knob is pushed in slightly Do not force 7 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow in the safety information previously stated If you do not smell gas go to the next step 8 For Robertshaw Gas Valve Turn gas control knob co
43. ak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility ANY PART MANUFACTURED BY RAYPAK One 1 year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED HEAT EXCHANGER WARRANTY Domestic Hot Water Five 5 years from date of heater installation Includes copper heat exchanger with bronze and cast iron waterways Ten 10 years from date of heater installation Includes only cupro nickel heat exchanger with bronze or cast iron waterways Space Heating Closed Loop System Ten 10 years from date of heater installation Includes both cupro nickel and copper heat exchanger with bronze or cast iron waterways Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature or o
44. al number are found on the heater data plate The model number will have the form WH1 0514A or simi lar depending on the heater model WH Hot Water Supply System 1 on off firing 0514 size of heater Rated inputs are suitable for up to 2000 feet eleva tion For elevations above 2000 feet reduce input 496 for each 1000 feet above sea level GENERAL SPECIFICATIONS The Raypak water heaters are design certified and tested under the latest requirements of the American National Standard ANSI Z21 10 3 CSA 4 3 Each heater has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engineers Code and factory fire tested CALIFORNIA PROPOSITION 65 WARNING This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ALL MODELS APPROVED All models are National Board approved Tem perature and pressure gauge is standard Intermittent ignition device is standard on models 0514 and up Model 0133 has 4 pass heat exchanger 1 tube per pass Models 0181 0401 have 2 pass heat exchangers 5 tubes first pass 4 tubes second pass Models 0514 1826 have 2 pass heat exchangers 5 tubes first pass 4 tubes second pass Models 2100 4001 have 2 pass heat exchangers 9 tubes per pass Models 926 4001 have optional single pass with cast iron headers only HOT WATER SUPPLY HEATERS All Raypak hot wate
45. alve should open and main burner should ignite after gas reaches the burner port CONTROLS Check all controls to see that they are operational To check electronic safety IID models turn off main burner Observe pilot burner when shutting off pilot gas Ignition spark should go on Main gas valve will also drop out High Limit Switch to check high limit switch turn dial setting down to a point slightly below the tempera ture of the water leaving the heater The reset button should snap out and the burner should shut off Reset dial to 30 F to 40 F above desired operating tempera ture and push reset button Burner should light INSPECTION PROCEDURES Inspect on the first and third month after initial start up and then on an annual basis If problems are found refer to the Troubleshooting sections of this manual for additional directions 1 Remove top of heater and inspect heat exchanger for soot and examine venting system Remove rear header and inspect for scale depos its Inspect pilot and main burner flame and firing rate Inspect and operate all controls and gas valve Visually inspect system for water leaks Oil pump motor and bearing assembly if oil cups are provided b Disconnect pump from header and check condition of pump impeller Check condition of bearing by attempting to move impeller from side to side Replace any parts showing wear Check pump coupler for wear and vibration
46. ater increases the risk of SCALDING There is a hot water scald potential if the thermostat is set too high NOTE When this heater is supplying general purpose hot water requirements for use by individuals a ther mostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION IID FOR MODELS WITH MANUAL GAS VALVES FOR YOUR SAFETY READ BEFORE OPERATING A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE OPERATING smell all around the appliance areafor gas Be sureto smell nextto 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 D Do not use any phone in your building Immediately call your gas supplier from your neighbor s phone Follow the gas supplier s instruc tions OPERATING INSTRUCTIONS If you cannot reach your gas supplier call the fire de partment 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
47. e location at least 6 in from any combustible material or the heat exchanger and that the position indicator is in a visible location The vent damper must be installed after the appli ance drafthood as close to the drafthood as practi cable and without modification of the drafthood Fig 4 8182 0 WARNING Do not use thermally actuated vent dampers on modulating heater To do so may result in asphyxiation Use only a mechanically actuated vent damper device that is electrically interlocked with the modulating heater operation MOUNTING On vertical vents the vent damper may be mounted with the actuator in any position On horizontal vents do not mount the actuator either directly above or directly below the vent pipe mount the vent damper actuator to the side of the vent The vent damper is set up for a continuous pilot system If the vent damper is installed an Intermittent Pilot or Direct Spark Ignition equipped system the energy savings of the vent damper can be improved by plugging the hole in the vent damper blade using the knockout plug Part No 105612R provided in the parts envelope DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous condition 15 HORIZONTAL INSTALLATION FLOW gt 4 7969 D808 TO CHIMNEY N O End Switch C 9 NO VERTICAL INSTALLATION INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT TO C
48. e other tube sheet and fit the tube into the hole 6 Insert the tube roller into tube opening up to stop making certain that 1 8 of tube projects beyond the tube sheet 7 Attach drill to tube roller holding it straight and level Note Use 3 8 heavy duty reversible electric drill or larger Proceed to expand tube until tool starts to grab Approximately 1 2 to 1 of the tool shank will be visible 8 Reverse drill motor and withdraw tube roller If necessary wrench out by hand 50 9 DO NOT apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0 015 10 Use same procedure on opposite end 11 Apply line pressure test Re roll if necessary 12 Reinstall as outlined under HEAT EXCHANGER REASSEMBLY CLEANING FLUE GAS PASSAGEWAYS Soot will clog areas between fins and cause even tual tube failure Any sign of soot at base of burners or around outer jacket indicates a need for cleaning 1 Lift off drafthood and flue collector by removing bolts and screws 2 Remove V baffles from heat exchanger 3 Remove burner tray 4 Take garden hose and wash heat exchanger making sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble When heater is fired some steam will form from wet refractory This is normal 6 Identify and correct reason for soot formation NOTE extreme cases it may be necessary to remove the heat exchang
49. eater is to be installed on a combustible surface See ordering info on pg 5 Note 2 servicing Clearances Provide at least 24 Models 0133 1826 48 Models 2100 4001 in front of unit for removal amp servicing of the Controls amp Burner Tray Provide at least 18 on side opposite water connec tions for deliming of Heat Exchanger Tubes Vent includes factory supplied drafthoods and does not include field supplied vent systems above the drafthood On Models 2100 4001 drafthood is built into heater CLEARANCES TO PROTECTED SURFACES Note The heater shall be installed in a space large in comparison to the size of the heater Large space is defined as having a volume at least sixteen 16 times the total volume of the heater 401 824 1826 4001 a 3 1 2in thick masonry walls Back 9 9 9 16 16 without ventilated airspace Right 5 9 5 16 16 wm 9 12 15 6 Vent 5 5 5 5 5 Outdoor 1 Unobstruced NA b 1 2 in insulation board Back 6 6 12 12 over 1 in glass fiber or Right 6 12 12 mineral wool batts 8 8 9 12 12 went 3 3 3 3 Outdoor Top Unobstruded NA 0 024 sheet metal over tin Back 4 4 4 8 8 glass fiberormineralwool Right 4 8 8 batts reinforced with wire Left 4 4 6 8 8 on rear face with ventilated Ve
50. er Feel water before bathing or show ering Temperature limiting valves are available see manual Maximum water temperatures occur just after burner has shut off To determine the water temperature being delivered turn on the hot water only place a thermometer in the stream and read the thermom eter 31 The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn 120 More than 5 minutes 125 F 1 1 2 to 2 minutes 1309 About 30 seconds 135 About 10 Seconds 140 Less than 5 seconds 145 Less than 3 seconds 150 F About 1 1 2 seconds 155 About 1 second Table courtesy of Shriners Burn Institute TIME TEMPERATURE RELATIONSHIPS SCALDS IN The temperature of the water in the heater can be regulated by setting the temperature dial on the front of the thermostat To comply with safety regulations the thermostat was set at its lowest setting before the heater was shipped from the factory The illustration below shows how to adjust the water temperature using the thermostat To adjust the water tem perature insert a small straight screwdriver into slotted screw in hole in front of thermostat and turn wheel to desired setting Thermostat is adjustable up to 190 F CAUTION Hotter w
51. er completely for cleaning The simplest method is high pressure cleaning at a local car wash DO NOT WIRE BRUSH CAUTION Soot is combustible so exercise extreme care 51 REPLACEMENT PARTS See separate parts sheet in instruction envelope NOTE To supply the correct part itis important that you state the model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 COMMERCIAL MODEL 334 THRU 824 RAYPAK REPLACEMENT PARTS MODEL SIZE 334 amp H 514 624 7 MODEL TYPE amp DATE OF MEHUFACTURE 10 1 amp 2 THAU CURRENT EXCEPT AS MODEL ELS HI T 11 884 THRE Hi HS amp BUILT F R MODELS 414 THRU E24 ONLY ILLUSTRATED PARTS LIST AVAILABLE AT WWW RAYPAK COM CATALOG MODEL NUMBER 133 9300 1 1 181 401 9300 203 334 824 9300 35 926 1826 9300 50 2001 2500 9300 60 WARRANTY LIMITED PARTS WARRANTY RAYTHERM COMMERCIAL HEATERS TYPES H NH amp WH MODELS 133 TO 4001 SCOPE Raypak Inc Rayp
52. ern installation of the relief valve ECONOMASTER CONTROL The Economaster is an electronic device that allows the operator to set the desired time for the pump to run after the heater shuts off The time is factory set at 7 minutes and it can be re adjusted in the field anywhere from 3 to 10 minutes In a conventional system when the aquastat is satisfied the main gas valve closes but the pump continues operating With the energy conserving Economaster the heater pump is programmed to continue running for an optimum period of time in order to absorb the residual heat from the combustion cham ber and use it in the system The pump then shuts off until the next call for heat is received from the aquastat NOTE Pump will come on when power is first applied to the heater Fig 9331 24 ELECTRONIC IGNITION The intermittent ignition device conserves energy by automatically extinguishing the pilot when desired temperature is reached When additional heat is needed the pilot re ignites electrically eliminating the fuel costs of maintaining a constant pilot To assure safe operation the gas valve cannot open until the pilot relights and is confirmed Without With Lockout Lockout 0133 1826 N A N A N A N A Standard Standard Standard Standard 0133 1826 2100 4001 2100 4001 OPERATING CONTROLS On models 514 1826 models with mechanical modulating controls have one or more Robertshaw Unitrol 7000
53. eturn loop 3 First fixture on supply line must be a minimum Refer to table of 20 feet from the heater 2 If multiple loops are used 4 Supply line size must be 2 minimum If not A Use multiple pumps and size return pipes possible add a tank between heater and first according to table or fixture B Use one larger recirculating pump with balancing valves on each return line MINIMUM PIPE SIZES MINIMUM CATALOG 310095 BRANCH MAN FLOW a 2 Dy 2 2 2 REPLACING 3100 72E A HEATER MOUNTED PRESSURE RELIEF HOT WA TER SUPPLY EXPANSION TANK VANG REQ D M COLD ETTEN 5 WATER RECIRCULATION PUMP SUPPLY BY OTHERS SEE MIN FLOW ABOVE FROM SUPPLY EOUP ADDITONAL HEATERS SHOWN REPRESENT VARIOUS MODELS BECAUSE PRESSURE INDIVIDUAL MODELS RELIEF VALVE WILL VARY IN DESIGN AND SIZING SEE EACH PUMP SPECIFIC HEATER TYPE z PLUMB SWING CHECK VALVE IN GRAVITY CLOSED POSITION FOR DETAILS NOTES 2 PIPE ALL RELIEF VALVES DRAIN OR AS LOCAL CODES REQUIRE Sma UNION 3 SEE CHART FOR MINIMUM PIPE SIZES PROVIDE FOR THERMAL EXPANSION OF HOT WATER IF A BACKFLOW PREVENTER CHECK VALVE WATER METER PRESSURE REDUCING VALVE 15 INSTALLED IN THE COLD WATER LINE PROVIDE 2 CLEARANCE BETWEEN HEATERS FOR CHECK VALVE SERVICE ACCESS GATE VALVE BALL VALVE PIPING 2 INSTANTANEOUS HEATERS TH
54. improper operation of the common venting Follow the lighting instructions Adjust thermostat system should be corrected so that the installation so appliance will operate continuously conforms with the latest edition of the National Fuel Gas Code ANSI Z223 1 When re sizing any e Test for spillage at the drafthood relief opening portion of the common venting system the com after 5 minutes of main burner operation Use the mon venting system should be re sized to flame of a match or candle or smoke from a approach the minimum size as determined using cigarette cigar or pipe the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 f After it has been determined that each appliance remaining connected to the common venting sys For special venting applications that require reduced tem is venting properly return doors windows vent sizes and through the wall venting the Type D exhaust fans fireplace dampers and any other gas Induced Draft Assembly can be used Consult the burning appliance to their previous conditions of factory or your local Raypak representative use VENT DAMPER INSTALLATION MODELS 133 THROUGH 180 WHERE REQUIRED LOCATION The vent damper must be located in the vent so that it serves only the appliance for which it is intended If improperly installed a hazardous condition such as an explosion or carbon monoxide poisoning could result Make certain that itis mounted in an accessibl
55. k is okay YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures If not replace module TURN GAS SUPPLY ON Check that all manual gas valves are open supply tubing and pressures are good PILOT BURNER LIGHTS and pilot burner orifice is not blocked YES Check electrical connections between module and pilot operator on gas control Check for 24 Vac across PV MV PV terminals on module If voltage is okay replace gas control if not replace module NOTE If S8600H goes into lockout reset system Lockout is used on propane models SPARK STOPS WHEN Check continuity of ignition cable and ground wire PILOT IS LIT Clean flame rod YES Check electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If problem persists replace module Check for 24 Vac across MV MV PV terminals If no voltage replace module MAIN BURNER LIGHTS Check electrical connections between module and gas control If okay replace YES gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system SYSTEM RUNS UNTIL CALL FOR HEAT ENDS Check continuity of ignition cable and ground wire YES NO
56. le 20 PIPING DIAGRAMS TYPE WH UNITEMP 80 SYSTEM IN 007 181 HM de 2908 E 9109 3HL NI Q3TIVISNI SI SNIONGSY 3M SS3Md N3LVM SATIVA MO3HO M3LN3A3Md dW3L MNVL IVOlLlLH3A GLH 08 dNIL INN ONIald MODIOVH V l LOH 30 NOISNVdX3 N03 NZ7 AYA YY GJAYISIY SLHOIM NOLLYNYOANI 242 5215501 ONidld NI 3Sv3s3ONI 3LVOONINOOOV AMVISIMdOSMd 5300943 LI SY dIHSNOILVT3M i i TYLLNIGIYNOO s3 Nn AILLINGNS SNIMVSO SIHL 375 SLO 4903 CO OL 0325 38 ISNA SI JONVISIO 3 ldVdV SSaNauvnos N 1333 G30V1d 9 8 MNVL YSLVSH NO O3SV8 9NIZIS 9 O0 S 00 6 8 0 ___ vid 3105 O NAY eC ove L4v M VINHOANVO 00 6 8 OLOF XXXX XXX SlHOd MNVI 3HL ANY 3HL INA OL OMVNXO PER e 0 ANVSS3O3N AVW LI WILSAS 931939 3 WAOWIXVAW ONY TN 1 SNOINVLINNIS SISIX3 1 22340385 ISMUIHLO SSTINN LYHL 330SN3 OL 31915504 3NIAVX3 NG 4HOdH gro 001 31 INOAYIHL M3LV3H 21412395 9291 926 1628 Qvov ANVI LIILNO YILVIH N33AML38
57. n and 12 inches from the floor for combustion air as outlined in ANSI Z223 1 and any local codes that may have jurisdiction CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ventilation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and paint removers Other harmful elements may come from bleaches air fresheners or mastics Vapors from these types of products can form corrosive acid compounds when burned in a gas flame The resulting acid condensate can damage or substantially reduce the life of the heater It may become necessary to provide outside air directly to the heater in order to avoid this problem a All Air From Inside The Building b All Air From Outdoors Each opening shall have a minimum net free square When air is supplied directly from outside of building inches as noted each opening shall have a minimum net free square inches as noted Square Square Square Square Model Inches Model Inches Model Inches Model Inches 133 1223 133 306 182 181 1337 1824881 4 136 335 260 2001 24 148 1467 260 261 66 148 367 330 331 1630 330 331 4 1631 408 400 401 1826 400 401 457 514 52 2100 2100 _ 514 525 2500 2499 624
58. n manufacturer s rating MODELS 182 400 and 181 401 OUTLET 1 1 2 NPT WATER CONNECTIONS 3 4 NPT Model Number WH 182 181 WH 260 261 WH 330 331 25 3 4 63 3 4 WH 400 401 29 1 4 65 3 8 Recovery based on manufacturer s rating Height C 62 5 8 62 718 indoor 2 Recovery GPH 18 1 4 22 3 8 STACKLESS OUTDOOR TOP CAS CONNECTION 15 3 8 INDOOR DRAFT DIVERTER OUTDOOR STACKLESS TOP UP FRONT CONTROLS ELECTRICAL CONNECTION 1 2 NPT GAS COMBUSTIBLE FLOOR SHIELD OPTIONAL Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 496 for each 1 000 feet above sea level C INDOOR DRAFT 13 1 4 GAS CONNECTION Dimensions Inches Diameter K d 1 1 8 ELECT COMBUSTIBLE SONN FLOOR SHIELD OPTIONAL NOTE Ratings are shown for elevations up to 2 000 feet For elevations over 2 000 feet reduce ratings 4 for each 1 000 feet above sea level Bold type indicates Low NOx models MODELS 514 824 DRAFT HOOD Dimensions Inches Indoor Outdoor Input Recovery MBH GPH Recovery based on manufacturer s rating MODELS 962 1826 WH 514 WH 624 WH 724 WH 824 L Lin Dimensions Inches Overall Jacket Gas Water Input Recovery Width Height Height Conn Conns MBH B C G H J 68 3 4 1 2 1 2 18
59. ndard assembly Check pump motor for type before adding oil GENERAL Clean dust and lint from pump and motor Check mM pump coupler and tighten if necessary Before lighting up a new installation water should Flush system before putting into operation to en be flowing through the heater sure that foreign material does not damage pump Water pressure regulator should be set to mini seals mum 25 PSI AST CAUTION Propane is heavier than air and sinks to A Pump must be off to check oil in bearing assembly ground Exercise extreme care in lighting heater not run pump without water in system confined areas 30 General Safety Precautions To meet commercial water use needs the thermostat on this water heater is adjustable up to 190 F How ever water temperatures over 125 can cause instant severe burns or death from scalds This is the preferred temperature setting when supplying general purpose hot water Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application N DANGER Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before set ting temperature at water heat
60. ng above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recommend use of an insulated vent pipe spacer through the roofs and walls For protection against rain or blockage by snow the vent pipe must terminate with a vent cap which com plies with the local codes or in the absence of such codes to the latest edition of the National Fuel Gas Code ANSI Z223 1 The discharge opening must be a minimum of two feet vertically from the roof surface and at least 2 feet higher than any part of the building or equipment within tenfeet The vent stack shall be at least 5 feet in vertical height above the drafthood outlet The vent cap loca tion shall have a minimum clearance of 4 feet horizon tally from and in no case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regulators and relief equipment gt 10 OR LESS P J VENT CAP 5 MIN VENT PIPE DRAFT HOOD The weight of the vent stack or chimney must not rest on heater drafthood Support must be provided in compliance with applicable codes The heater top and drafthood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from combustible construction Type B double wall or equivalent vent pipe is recommended However single wall metal vent pipe may be used as specified in
61. nger generally deposits over 1 16 in thickness After reaming with the auger mount the wire brush The heater may be cleaned from the side opposite clean out the debris remaining in the tubes the water connections as shown without breaking pipe Another method is to remove the heat exchanger connections It is preferable however to remove both ream tubes and immerse heat exchanger in non headers for better visibility through the tubes andto be inhibited de scale solvent 48 BURNER ORIFICES BURNERS COMBINATION FLAME SENSOR IGNITOR AND PILOT BURNER LOCATION BURNER HOLD DOWN LOCATION TYPICAL BURNER TRAY ILLUSTRATED BURNER TRAY REMOVAL 1 Shut off power and gas supply to the heater Disconnect union s and pilot tubing then loosen and remove burner hold down screws Disconnect wires at gas valve and slide burner drawer out GAS VALVE REMOVAL 1 2 3 4 Shut off gas supply to the heater Remove gas piping to gas valve inlet Disconnect wires pilot tubing and bleed line if required Turn vertical gas pipe from manifold slightly and unscrew gas valve Heverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL 1 Hemove screws and burner hold down bracket NOTE If the heat exchanger is sooted badly the burner hold down bracket and spacer can become distorted from direct flame impingement and this usu ally necessitates replacement of these parts 2 3 Lift bu
62. nt 3 air space 3 1 2 in thick masonry wall with ventilated air space Left Indoor Top Outdoor Top 0 024 sheet metal with ventilated air space 2 r lt a pad a Vent Indoor Outdoor 112 in thick insulation 4 amp 4 8 board with ventilated Right 4 3 8 air space 5 6 8 1 5813 3 IndoorTop 24 24 18 12 12 Outdoor NA Unobstructed NA g 0 024 sheet metal with Back 4 4 4 8 ventilated air space over Right 3 4 8 8 0 024 sheet metal with 4 4 6 8 ventilated air space Vent 3 IndoorTop 24 24 18 12 12 Outdoor Top Unobstructed NA lin glassfiberormineral Back 4 4 4 8 8 wool batts sandwiched _ Right 3 4 3 B 8 between two sheets 0 024 Left 4 4 6 8 8 sheet metal with ventilated Vent 3 3 3 3 air space Indoor Top 24 24 18 12 12 SPECIFICATIONS AND DIMENSIONS MODEL 133 14 1 2 24 1 8 7 1 4 6 9 1 4 10 1 4 1 1 4 OUTLET ius NPT e j l O 45 38 1 2 JE 30 1 8 24 1 4 f imd 4 3 4 3 378 4 7 8 1 1 4 WATER REAR VIEW INLET NOTE Model m Recovery Number m WH 133 1360 135 132 se based o
63. of installation must be presented otherwise the effective date will be based on the date of manufacture plus thirty 30 days pO WO OLIO It Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 800 872 9725 www raypak com P N 240532 52 b Kali SEL Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Litho in U S A
64. p flammable products 1 Far away from heater 2 In approved containers 3 Tightly closed and 4 Out of children s reach Installation burner and pilot flame The pilot flame 1 Is on all the time or intermit tently IID 2 Will ignite flammable va pors Vapors 1 Cannot be seen 2 Are heavier than air 3 Go a long way on the floor 4 Can be carried from other rooms to the pilot flame by air Currents Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames are at least 18 above the floor This will reduce but not eliminate the risk of vapors being ignited by the main burner or pilot flame Read and follow water heater warnings and instructions owners manual is missing contact the retailer or manufacturer 7 DANGER PROPANE MODELS Propane must be used with great caution e It is heavier than air and will collect first in lower areas making it hard to detect at nose level Make sure to look and smell for propane leaks before attempting to light appliance Use a soapy solution to check all gas fittings and connections Bubbling at a connection indicates a leak that must be corrected When smelling to detect a propane leak be sure to sniff near the floor too Gas detectors are recommended in propane applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulation
65. perating at heater temperatures exceeding 230 F ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Failure to eliminate air from or replenish water in the connected water system Chemical contamination of combustion air or use of chemical additives to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts manufactured by others but Raypak will apply any such warranty as may be provided by the parts manufacturers TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the problem The in
66. place with new if heater fires If power to toggle switch but not through switch replace If power to relay but not operating re place Open valve Loosen bleed line and clean Replace coupler Inspect bearing as sembly and if frozen lubricate or re place Bleed air from system Check for power to gas valve If valve has power but will not open check vent tube for blockage If clear replace valve Reset High Limit to higher temperature Check system water pumps Check pump oil if necessary Reset modulator to a lower setting Check and replace if necessary Refer to installation instructions regard ing combustion air requirements Set bypass valve to prevent heater inlet temperature from dropping below 105 F Hemove all sources of fumes such as freon or chloride or isolate the heater Follow recommended vent installation instructions Check pumps and piping Inspect for leaking and repair Inspect for leakage and repair Install an automatic air vent Clean Ream tubes Debris in gas line pipe dope rocks etc Gas line too small Improper size gas meter Gas regulator adjustment Clean burners Adjust gas pressure Refer to installation instructions regard ing combustion air requirement Replace refractory panels Replace fan relay Loose wire connection Failed fan motor TROUBLESHOOTING PUMPS FAILURE TO PUMP PUMP LOSES PRIME 1 Pump not properly primed 1 Airleaks
67. ply off 2 Check ignition module as follows a Set the thermostat or controller to call for heat b Watch for continuous spark at the pilot burner c Check the ignition spark operation Time must be within the lockout timing period 15 or 90 seconds d Turn control down to end call for heat and wait 60 seconds on lockout models before beginning step 3 35 3 urn on gas supply 4 Set controller to call for heat 5 System should start as follows a Spark will turn on and pilot gas valve will open and the blower will begin running b Heater will operate until call for heat is satisfied BURNER ADJUSTMENT This burner assembly does not require any primary air adjustments VISUAL INSPECTION Flame can be observed through the slot opening above the plenum Flame color is blue and evenly spread on the top surface of the burner visual inspection should be made monthly of the burners In case flame lifting is observed on the burner check gas pressure on manifold and static pressure in plenum Gas pressure in manifold should be 3 9 WC and static pressure in plenum should be greater than 0 5 WC ELECTRICAL Be sure that electrical service to the heater has proper overload fuse or circuit breaker protection and wire size and connections comply with all applicable codes HIGH GAS PRESSURE SWITCH Pressure switch senses high pressure and automati cally shuts down burner if abnormal pressure exists PRESSURE SWI
68. r supply heaters are ASME and design certified as hot water heaters with 125 PSI pressure relief valves TYPE WH1 WITH ON OFF CONTROLS Models 0133 4001 To be used with storage tank systems Available with integrally mounted pump factory mounted and wired for models 0133 1826 Models 181 261 331 and 401 are Low NOx Hot Water Heaters TYPE WH2 WITH MODULATING CONTROLS Models 0133 4001 Hot water supply heater with 110 170 F gas modulation Available with integrally mounted pump factory mounted and wired for models 0133 1826 To be used with storage tank systems TYPE WH3 WITH 2 STAGE CONTROLS Models 0181 4001 Hot water supply heater with low high fire for 2 stage control Available with integrally mounted pump factory mounted and wired for models 0181 1826 To be used with storage tank systems TYPE NH INSTANT PAK Models 0514 1826 Tankless instantaneous direct fired hot water sup ply heater with 110 170 F gas modulation factory mounted bronze body or cast iron bronze fitted pump and flow switch A General Safety Precautions Be sure to read and understand the entire Instruction Manual before attempting to install or operate this water heater Pay particular attention to the following general Safety Precautions Failure to follow these warnings could result in a fire or explosion causing property damage bodily injury or death Should you have any problems understanding the instructions in this manual STOP and ge
69. rners from slotted spacer and slide from orifices Clean with a wire brush Orifices usually do not need to be replaced To clean run either copper wire or wood through orifice Do not enlarge hole To remove orifice use a socket wrench and remove the manifold DO NOT overtighten when reinstalling 49 PILOT REMOVAL AND CLEANING 1 Disconnect pilot tubing at pilot and sensor igniter wire Remove screws holding pilot bracket to burner tray 2 Remove pilot and bracket clean pilot of debris small bugs etc with wire or small brush 3 Replace pilot pilot tubing sensor ignition wires and check for leaks HIGH LIMIT OR TANKSTAT REMOVAL 1 Turn off electrical power Hemove front inspection panel 3 Remove wires to high limit and loosen screws holding high limit to cabinet 4 Remove wedge clip holding sensing bulb in control well 5 Remove high limit and install a new one 6 Check control operation before leaving job m HEAT EXCHANGER REMOVAL 1 Shut water gas and electricity off close valves and relieve pressure remove relief valve 2 Remove side inspection panels 3 Remove top holding screws 4 Remove draft diverter lift and remove top and flue collector on stack type models Remove inspection panels 5 Loosen bolts and disconnect flange nuts on in out header loosen union s at gas pipe and slide heater away from piping until studs clear the heater 6 Remove heat exchanger corner brackets
70. s or customs e Itis recommended that more than one method be used to detect leaks in propane applications IF PROPANE IS PRESENT OR SUSPECTED DO NOT attempt to find the cause yourself DO NOT try to light any appliance e DO NOT touch any electrical switch e DO NOT use any phone in your building Leave the building immediately and make sure that every one else leaves also Leave the doors open for ventilation and contact the gas supplier a qualified service agency or the fire department Keep the area clear until the service call has been made the leak is corrected and a qualified agency has determined the area to be safe WARNING Both propane and natural gas have an odorant added to help detection Some people may not physically be able to smell or recognize this odorant If unsure or unfamiliar about the smell associated with propane or natural gas ask the gas supplier Other conditions such as Odorant Fade which causes the odorant to fade or diminish in intensity can also hide or camouflage a gas leak DANGER Water heaters utilizing propane are different from natural gas models natural gas heater will not function safely on propane and vice versa Conversion from natural gas to propane or vice versa must be done by a qualified service technician To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with
71. staller must then notify a Raypak distributor for instructions regarding the claim If either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard CA or call 805 278 5300 In all cases proper authorization must first be received from Raypak before replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date
72. t help from a qualified installer or service technician or the gas supplier WARNING Gasoline as well as other flammable materials and liquids adhesives solvents etc and the vapors they produce are extremely dangerous DO NOT handle use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater Be sure to read and follow the warning label pictured below and other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in property damage bodily injury or death DANGER Failure to install the drafthood and properly vent the water heater to the outdoors as outlined in the Venting Section of this manual can result in unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless it is properly vented and has an adequate air supply for proper operation Be sure to inspect the vent system for proper installation at initial start up and at least annually thereafter Refer to the Venting section of this manual pg 11 for more information regarding vent system inspections Vapors from flammable liquids Water heater has a main will explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline sol vents or adhesives in the same room or area near the water heater Kee
73. the latest edition of the National Flue Gas Code ANSI 2223 1 Manifolds that connect more than one heater to a common chimney must be sized to handle the com bined load Consult available guides for proper sizing of the manifold and the chimney At no time should the area be less than the area of the largest outlet LC LI 1 Fig 7043 1 At the time of removal of an existing heater the follow ing steps shall be followed with each appliance remain ing connected to the common venting system placed in operation while the other appliances remaining con nected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and make sure there is no blockage or restriction leakage corrosion or other deficiency which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will oper ate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected g Any
74. the manifold as 36 N 5 6 p sembly from the burner tray assembly Use a long gt socket wrench to remove orifices from the gas manifold Remove burners by raising the bracket on the back end of the burners up and out of their slots Reverse above procedure to re install Fig 9363 IID PILOT PILOT REMOVAL Disconnect pilot tubing from gas valve Remove 4 screws from control box Open the control box Remove the pilot wire from the ignition wire Remove 2 screws that mount the pilot bracket to the air manifold assembly Pull the pilot bracket downwards and outwards Reverse above procedure to re install COMBUSTION FAN REMOVAL Remove burner tray See Burner Tray Removal procedure above Remove 4 screws the mount the combustion blower to the manifold assembly Reverse above procedure to re install WARNING HIGH VOLTAGE TROUBLESHOOTING ELECTRICAL For qualified Technicians ONLY ELECTRONIC IGNITION IID NOTE Some heaters may be equipped with an ignition module that shuts off pilot gas if Intermittent Pilot System pilot fails to light To reset interrupt power HONEYWELL S8600 to heater TURN GAS SUPPLY OFF procedure TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT Check line voltage power low voltage transformer limit controller thermostat 24 V controller and wiring Pull ignition lead and check spark at module SPARK ACROSS IGNITER SENSOR GAP If spar
75. uipped with a manual reset High Limit Push the reset button and set the limit s to 30 F 40 above desired operating temperature Maxi mum setting is 210 FLOW SWITCH This dual purpose control shuts off the heater in case of pump failure or low water condition and is strongly recommended lt is mounted and wired in series to the main gas valve NOTE The flow switch is a safety device and not a control Do not operate the heater with flows less than the minimums stated in this manual 100 PILOT SAFETY Models 514 4001 employ electronic devices which close the main gas valve within 8 10 of a second 25 automatically lit when the device is powered Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit LOW WATER CUT OFF OPTIONAL The low water cut off automatically shuts down burner whenever water level drops below probe 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pockets Flush float type devices at beginning of each heating season HIGH AND LOW GAS PRESSURE SWITCHES OPTIONAL These switches sense either high or low gas pres sures and automatically shut down burners if abnormal pressures exist COMPONENT IDENTIFICATION Fig 8643 Fig 9314 MANUAL RESET HIGH LIMIT THERMOSTAT CONTROL Fig 9312 Fig 8929 1 HIGH and or LOW GAS PRESSURE SWITCH Fig 9316 Fig 8995 LOW WA
76. unit data plate Use propane for propane units natural gas for natural gas units These units are not certified for any other type fuel WARNING Propane appliances should not be installed below grade for example in a basement if such installation is prohibited by federal state and or local laws rules regulations or customs INSTALLATION INSTRUCTIONS INSTALLATION CODES Installation must be in accordance with local codes or in the absence of local codes with the latest editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code ANSI NFPA 70 In Canada installations must conform with the current CAN CSA B149 1 and the Canadian Electrical Code Part 1 CSA C22 2 No 1 Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Heaters CSD 1 INSTALLATION BASE The heater should be mounted on a level non combustible surface Heater must not be installed on carpeting The heater can be installed on a combustible surface only when the appropriate listed floor shield base is provided An optional listed floor shield base is available for factory installation with the heater on all indoor models Do NOT use the shipping base crate as an installation base NOTE The heater should be located in an area where water leakage will not result in damage to the area adjacent
77. unter clockwise to ON 9 10 11 12 ROBERT SHAW GAS CONTROL KNOB SHOWN IN ON POSITION GAS INLET a Fig 8080 Set the thermostat to the lowest setting 2 Turnoffallthe electric power to the appliance if service is to be performed 3 Remove door panel 4 For Robertshaw Gas Valve Turn gas control knob 5 clockwise to OFF 32 IN ON POSITION TO TURN OFF GAS TO APPLIANCE GAS INLET amp Fig 8082 Replace heater door panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier For Honeywell Gas Valve Turn gas control knob clock wise to Make sure knob rests against stop Replace heater door panel FOR MODELS WITH AUTOMATIC GAS VALVES 1 Close all gas valves Turn off electric power supply Wait five 5 minutes 2 Open manual pilot valve Turn on electric power Pilot is automatically lighted 3 Open main gas valve 4 Settemperature controls to desired temperature TO SHUT DOWN Close all manual gas valves power Turn off electric AFTER START UP PILOT SHUT OFF VALVE CONTROL SHOWN IN ON POSITION TO PILOT MAIN GAS SHUT OFF VALVE SHOWN IN THE ON POSITION GAS INLET Fig 8220 INTERMITTENT PILOT SYSTEM CHECKOUT PROC
78. w NOx models Temperature Rise Degree F GPM FLOW MPS Minimum Pipe Size GPM Gallons per Minute Flow SHL System Head Loss Pressure Drop Foot thru Heat Exchanger The table above provides data for selecting in line pumps for use in a Uni Temp 80 system for a single heater and tank according to the following 1 Flow rates are based on water hardness as measured in grains per gallon Soft 0 4 grains per gallon Medium 5 15 grains per gallon Hard 16 and over grains per gallon 2 Maximum Flow Rates 133 22 GPM 181 401 45 GPM 014 1826 90 GPM 2100 4001 200 GPM 3 Pressure drop values SHL and minimum pipe sizes are for two pass heaters 4 Sizing based on heater and tank being placed 5 feet apart The equivalent length of pipe valves and fittings in the system is as follows 1 1 2 NPT 70 Ft 181 401 2 1 2 NPT 80 Ft 926 1826 2 NPT 75 Ft 514 824 3 NPT 85 Ft 2100 4001 Additional pipe fittings will increase the system head loss 5 Select a pump based on the water hardness flow and system head loss 6 If heater is more than two stories above the tank consult the factory NOTE GPM flow rates are limited by maximum acceptable velocity through heat exchanger tubes Heater models 514 through 1826 may be provided with an integral rear mounted pump This must be specified at time of order The integral pump will provide sufficient flow to meet the conditions listed in the tab

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