Raypak 195A, 135A, 090A User Manual
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 090A, 135A, 195A
Type WH
ECONOPAK WATER
HEATERS
CATALOG NO. 3000.50D
Effective: 01-01-03
Replaces: 03- 01-97
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 kept
in a safe place for future reference.
P/N 240687
Contents
3 1. RECEIVING EQUIPMENT
3 2. GENERAL SPECIFICATIONS AND DIMENSIONS
4 General Safety Precautions
6 3. INSTALLATION PROCEDURES
6 - Code Requirements
6 - Mounting Base
6 - Clearance Requirements
6 - Combustion/Ventilation Air
7 - Venting Connections
8 - Common Vents
9 - Gas Supply Connections
10 - Water Connections & System Piping
11 - Electrical Wiring
12 - Wiring Diagrams
13 4. SERVICING PROCECURES
13 - General Locations of Controls
13 - Sequence of Operation
14 - Start Up Procedures
17 - Inspection Procedures
18 - Repair Section
20 5. TROUBLE SHOOTING GUIDE
22 - Adjustments/Replacements of Components
23 6. REPLACEMENT PARTS LIST
These instructions are provided to assure the proper
installation and operation of Raypak water heaters.
Should questions arise regarding the specifications,
installation, operation or servicing of these water heaters, we suggest that the local Sales representative or
the factory be consulted.
2
1. RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, it is suggested that a note be made
on the Bill of Lading when signing for equipment. Remove
the heater from the carton and if it is damaged report the
damage to the carrier immediately. Be sure that you
receive the number of packages indicated on the Bill of
Lading. Claims for shortages and damages must be
filed with carrier by consignee.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defective
replacement parts will not be accepted and defective
parts will be replaced in kind only per our standard
warranties.
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. If there are any questions which this manual
does not answer, please contact your local Raypak
representative.
SPECIFICATIONS AND DIMENSIONS
PIPING
CONNECTIONS
WATER GAS
NPT. NPT.
1" 1/2"
1-1/4" 1/2"
1-1/4" 1/2"
A
11"
18"
18"
MODEL
WH-0090
WH-0135
WH-0195
INPUT
MBH
90
135
195
RECOVERY
GPH
90
132
192
TANK
GAL.*
80
80
80
*May be used with other tank size capacity.
Note: Recovery GPH based on Manufacturer's rating.
B
5-3/4
6-1/4
6-1/4
K
VENT
DIA.
5"
6"
7"
2. GENERAL SPECIFICATIONS
The Raypak water heaters are design certified by the
American Gas Association, and tested under the requirements of the American National Standard, ANSI
Z21.10.3. 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.
The heaters are designed for indoor installation with
a built-in drafthood, and a built-in sub-base for combustible flooring. Models are available with standing pilot,
or with intermittent ignition device (I.I.D). The heaters are
equipped with the following components: water circulation pump, pressure relief valve, manual reset high limit
switch, fast response temperature sensor, 40 VA transformer, vent thermal switch, flame roll-out switch, and
redundant combination gas valve. A tankstat is supplied
loose for installation in the field.
Fig. #8978.5.1
3
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 get help from a qualified installer or service technician or the gas supplier.
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 draft hood 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 Maintenance section of this manual for
more information regarding vent system inspections.
LIQUEFIED PETROLEUM MODELS – Propane, or LP gas, must
be used with great caution.
• 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 LP 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 an LP leak,
be sure to sniff near the floor too.
• Gas detectors are recommended in LP applications and their
installation should be in accordance with the manufacturer's
recommendations and/or local laws, rules, regulations or
customs.
• It is recommended that more than one method be used to
detect leaks in LP applications.
IF LP GAS IS PRESENT OR SUSPECTED:
• DO NOT attempt to find the cause yourself;
• DO NOT try to light any appliance;
• DO NOT touch any electrical switch;
• DO NOT use any phone in your building.
• Leave the building immediately and make sure that everyone
else leaves also.
• Leave the doors open for ventilation and contact the gas sup
plier, 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.
Vapors from
flammable liquids will
explode and catch fire
causing death or severe
burns.
Do not use or store flammable
products such as gasoline
solvents or adhesives in the
same room or area near the
water heater.
Keeflammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. out of childrens reach.
Installation:
Do not install water heater
where flammable products
will be stored or used unless
the main burner and pilot flames
Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.
Water heater has a main
burner and pilot flame.
The pilot flame:
1. is on all the timeand
2. will ignite flammable
vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the
floor,
4. can be carried from other
room to the pilot flame by
their currents.
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.
Both LP 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 LP 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.
Water heaters utilizing Liquefied Petroleum gas (LP) are different from natural gas models. A natural gas heater will not
function safely on LP gas and vice versa. Conversion from
Natural gas to LP gas (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 unit data plate. Propane for
propane units. Natural gas for natural gas units. These units are
not certified for any other type fuel.
LP 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.
4
General Safety Precautions
To meet commercial hot water requirements, the
tankstat is adjustable up to 190°F. However, water
temperatures over 125°F. can cause severe burns instantly or death from scalds. This is the preferred
starting point for setting the control for supplying general
purpose hot water.
Safety and energy conservation are factors to be considered when setting the water temperature on the tankstat.
The most energy efficient operation will result when the
temperature setting is the lowest that satisfies the needs
consistent with the application.
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°F. More than 5 minutes
125°F. 1-1/2 to 2 minutes
130°F. About 30 seconds
135°F. About 10 Seconds
140°F. Less than 5 seconds
145°F. Less than 3 seconds
150°F. About 1-1/2 seconds
155°F. About 1 second
Table courtesy of Shiners Burn Institute
TIME/TEMPERATURE RELATIONSHIPS IN SCALDS
The temperature of the water in the storage tank can be
regulated by setting the temperature dial on front of the
tankstat. To comply with safety regulations, the
tankstat was set at its lowest setting before shipment
from the factory. The illustration below illustrates the
tankstat and how to adjust the water temperature.
Water temperature over 125°F can cause
severe burns instantly or death from
scalds.
Children, disabled and elderly are at highest risk of being scalded.
See instruction manual before setting temperature at tankstat.
Feel water before bathing or showering.
Temperature limiting valves are available,
see manual.
Maximum water temperatures occur just after burner
has shut off. To find hot water temperature being
delivered, turn on a hot water faucet and place a
thermometer in the hot water stream and read the
thermometer.
To adjust the water temperature,
insert a small straight screwdriver
into slotted screw in hole in front
of tankstat and turn wheel to
desired setting. Tankstat is
adjustable up to 190°F.
CAUTION!! - Hotter water
increases the risk of
SCALDING!
There is a Hot Water SCALD Potential if the tankstat is
set too high.
NOTE: When this water heater is supplying general
purpose hot water requirements for use by individuals, a
thermostatically 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.
5
3. INSTALLATION PROCEDURES
CODE REQUIREMENTS
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/CGA B149.1 or .2 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, No. CSD-1.
operation and service (circulator replacement, control
replacement, etc.)
CLEARANCE REQUIREMENTS
1) Minimum Clearances From Combustible Materials
Model Floor Front Back Right Left Top Flue
No. Vent
0090
0135 Comb. Alcove 6" 6" 6" 16" 6"
0195
2) A front clearance of at least 24" is recommended
for adequate service of burner-tray and controls.
MOUNTING BASE
Heater should be mounted on a level surface. Each
heater is designed with a built-in sub-base approved for
mounting the heater on combustible flooring. Heater
must NOT be installed on carpet flooring.
Fig.# 8193.1
Fig.# 8196.0
NOTE: The heater should be located in an area where
water leakage will not result in damage to the area
adjacent 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
3) Except for carpeted flooring, heaters are certified
for installation on combustible floors.
4) For un-insulated hot water pipes, maintain a 2"
clearance, or consult local authority having
jurisdiction.
COMBUSTION/VENTILATION AIR
WARNING: Air supply to the heater room must not be
affected by mechanical exhaust vents located in other
parts of the house, such as kitchen or bathroom fans, or
attic blowers. Mechanical exhaust vents may create a
negative pressure condition in the heater room that can
become a hazard of asphyxiation, explosion or fire.
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, drycleaning 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 be
necessary to provide outside air directly to the heater in
order to avoid this problem.
1) The heater must be provided with adequate supply
of air for proper combustion and ventilation in
accordance with Sec. 5.3, of the latest edition of
the National Fuel Gas Code, ANSI Z223.1, or
applicable provisions of the local building codes.
6
2) If the heater room is located against an outside wall
and air openings can communicate directly with the
outdoors, the two openings on the outside wall
must each have a net free area, in square inches as
follows:
Model Sq. In. Of Free Area
0090 24
0135 35
0195 50
Location of the openings is the same as in the
previous case - that is, within 12 inches of the top, and
within 12 inches of the bottom of the enclosure. If
horizontal ducts are used, the area must be doubled and
the duct area shall not be less than the area of the
openings they connect, and in no case shall the smallest
dimension be less than 3 inches.
VENTING CONNECTIONS
These heaters have built-in drafthoods. Vent piping
the same size or larger than the draft hood outlet is
recommended; however, when the total vent height
(drafthood outlet to vent terminal) is at least ten (10) feet,
the vent pipe size may be reduced by one size
specified in Chapter 10 of the latest edition of the National
Fuel Gas Code, ANSI Z 223.1. As much as possible
avoid long horizontal runs of vent pipe and too many
elbows. If installation requires horizontal runs, the vent
pipe must have a minimum of 1/4 inch per foot rise and
should be supported at not less than five foot intervals.
Maximum vent connector horizontal length shall be 1-1/
2 feet (18 inches) for each inch of connector diameter as
follows.
only as
The discharge opening must be a minimum of two
feet vertically from the roof surface and at least two (2) feet
higher than any part of the building within ten (10) feet.
Vent stack shall be at least five (5) feet in vertical height
above the drafthood outlet. The vent cap location shall
have a minimum clearance of four (4) feet horizontally
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.
The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately supported 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 the latest edition of the National
Flue Gas Code ANSI Z 223.1.
Heater Size Vent Connector Max Horizontal
Diameter Length - FT
90 5" 7.5
135 6" 9
195 7" 10.5
Gas Vents supported only by the flashing and
extending above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. We recommend use of insulated vent pipe spacer
through the roofs and walls.
For protections against rain or blockage by snow, the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas Code,
ANSI Z 223.1.
7
Fig.# 8191.1
WARNING: These heaters must not be connected into
any portion of mechanical draft systems operating under
positive pressure. To do so may cause the flue products
to be discharged into the living space causing serious
health injury.
For connections to gas vents or chimneys, vent
installations shall be in accordance with Part 7, Venting
of Equipment, of the National Fuel Gas Code, ANSI
Z223.1, or applicable provisions of the local building
codes.
COMMON VENTS
Manifolds that connect more than one
heater to a common chimney must be
sized to handle the combined 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.
Fig. #9001
8
At the time of removal of an existing heater, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remaining connected 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 determine there is no
blockage or restriction, leakage, corrosion and
other deficiencies 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 operate
at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust tankstat
so appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe to visually check spillage.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(g) Any improper operation of the common venting
system should be corrected so the installation
conforms with the latest edition of the National Fuel
Gas Code, ANSI Z 223.1. When resizing any
portion of the common venting system, the com-
mon venting system should be resized to approach
the minimum size as determined using the
appropriate tables in Chapter 10 and in
Appendix G of the National Fuel Gas Code,
ANSI Z 223.1 and CAN/CGA - B149.1 -B149.2.
GAS SUPPLY CONNECTIONS
The inlet gas connection of the heater gas valve is
1/2". Provide an adequate gas piping supply line no
smaller than 1/2", according to the chart below:
Maximum Equivalent Pipe Length (Feet)
1/2" Pipe 3/4" Pipe 1" Pipe 1-1/4" Pipe
MODEL NAT PROP NAT PROP NAT PROP NAT PROP
0090 30 80 125 300 400 - - 0135 15 40 60 150 200 500 0195 - 20 35 70 100 250 400 -
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shutoff valve located
outside the jacket. All gas piping should be tested after
installation in accordance with local codes.
Manual Union
Valve
Sediment Trap Gas Valve
Fig. # 8192.0
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 psig (3.45 KPA). 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 ARE NOT COVERED 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 not use teflon tape on gas line pipe thread.
A flexible sealant suitable for use with Natural and
Propane gases is recommended.
NOTE: These boilers are also certified to operate on
Propane gas, when equipped with the combination gas
valve and orifices (pilot and main burners) sized for
Propane gas.
GAS PRESSURE-SPECIFICATIONS
Inches W.C. Regulator
Min. Max. Setting
Natural 4.5 10.5 3.5
Propane 12.0 13.0 11.0
Note: Do not exceed maximum inlet gas pressure. The
minimum value shown is for input adjustment.
9
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