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.
Fig. #9166
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 240726 Rev. 1
CONTENTS
TABLE OF CONTENTS
31.RECEIVING EQUIPMENT
32.GENERAL SPECIFICATIONS AND DIMENSIONS
4General Safety Precautions
63.INSTALLATION PROCEDURES
6- Code Requirements
6- Clearance Requirements for all Models
6- Combustion/Ventilation Air
7- Venting Connections
8- Common Vents
10- Gas Supply Connections
11- Water Connections & System Piping
13- Electrical Wiring
14- Wiring Diagrams
194.SERVICING PROCEDURES
19- Sequence of Operation
19- Start Up Procedures
24- Inspection Procedures
25- Repair Section
265.TROUBLE SHOOTING GUIDE
30- Adjustments/Replacements of Components
336.REPLACEMENT PARTS LIST
35WARRANTY
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.
2. GENERAL SPECIFICATIONS
The Raypak water heaters are design certified by the 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.
These heaters are designed for indoor and outdoor installations, and can be installed on combustible flooring
when the appropriate listed floor shield base is used. Models are available with standing pilot or with intermittent
ignition device (IID), and are equipped with the following components as standard: water circulation pump, pressure
relief valve, manual reset high limit switch, fast response temperature controller, vent thermal and flame roll-out
switches (except for models 330 and 400), a solid state Economaster pump control relay, 40VA transformer, and
redundant combination gas valve for use with either Natural or Propane gases. A tankstat is supplied loose for
installation in the field.
SPECIFICATIONS AND DIMENSIONS
*May be used with other tank size capacity.
‡
Recovery based on manufacturer's rating
Fig. #9464
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.
!
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 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.
!
DANGER
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
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.
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.
!
WARNING
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.
!
DANGER
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.
!
WARNING
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 boiler
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. Thermostat 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 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/CSA B149.1 and the Canadian ElectricalCode Part 1CSA 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.
MOUNTING BASE
The heater should be mounted on a level, noncombustible 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.
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 operation and service (circulator replacement, control replacement,
etc.).
(1 ) Except for carpeted flooring, heaters are certified for installation on combustible floors, when equipped
with listed floor shield base.
(2 ) A front clearance of at least 24" is recommended for adequate service of burner-tray and controls.
COMBUSTION/VENTILATION AIR (Indoor models only)
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, 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 be necessary to provide outside air directly to the heater in order to avoid this problem.
6
1) The heater must be provided with adequate supply
of air for proper combustion and ventilation in
accordance with the latest edition of the NationalFuel Gas Code, ANSI Z223.1, or applicable provi
sions of the local building codes.
2) When the heater is installed in a confined space
where all air is supplied from inside the building, the
heater room must be provided with two openings,
each one having a minimum net free area, in square
inches as follows:
ModelSq. In. Of Free Area
260264
330333
400399
OUTDOOR MODELS
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
heater 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 horizontally.
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.
One opening shall be within 12 inches of the top, and the
other opening within 12 inches of the floor. If additional
gas appliances are installed in the same space, the total
input of all gas appliances installed in the same space,
must be considered in the calculation. Refer to Sec.
5.3.5 of the latest edition of the National Fuel Gas Code
for additional requirements.
NOTE: If 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 the
National Fuel Gas Code.
3. If the heater room is located against an outside wall
and air openings can communicate directly with the
outdoors, the two openings on the out side wall must
each have a net free area, in square inches as follows:
ModelSq. In. Of Free Area
260/261 66
330/331 84
400/401100
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 (Outdoor Models)
Outdoor vent top is shipped separately and must be
installed on site.
Step 2: Attach mounting angles to heater jacket with
1/2" sheetmetal screws, (4 places).
Fig. #8281.1
Step 3: Lower outdoor top to heater and secure with 1"
sheetmetal screws.
LONG SIDE OF MOUNTING
ANGLE LOCATED AS SHOWN
7
VENTING CONNECTIONS (Indoor Models)
The drafthood is shipped separately and must be installed on the heater.
For Model 260/261:
1. Mount drafthood on top of heater and attach with the 4 sheet metal screws provided. Drafthood should be
positioned with the vent sensor located on the front left side as shown.
2. Remove plastic plug from left side of heater jacket and install plastic grommet provided.
3. Route flue sensor wire harness through the grommet installed in Step 2.
4. Remove door and locate wire from roll out sensor to Hi Limit with the male/female connector.
WIRE FROM TRANSFORMER
MALE/FEMALE
WIRE TERMINAL
WIRE FROM HIGH LIMIT
ROLL OUT SENSOR
Before Installation of Draft HoodAfter Installation of Draft Hood
Fig. #8947.2
WIRE FROM TRANSFORMER
CONNECT ONE VENT SENSOR WIRE
TO HIGH LIMIT WIRE
CONNECT ONE VENT SENSOR WIRE
TO ROLL OUT SENSOR WIRE
ROLL OUT SENSOR
Fig. #9351
Fig. #8947.3
5. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.
8
MODELS 330/331 AND 400/401
VENT TERMINAL/INDOOR STACK INSTALLATION
1. Remove the louvered jacket top by removing
four (4) #10 flat head screws.
2. If originally installed, remove "Pagoda" top
from the louvered jacket top.
3. Place the inner stack adapter panel over the
flue collector inside the heater. Make sure
the flanged side of the flue opening is up.
4. Turn the stack (draft hood) up side
down and set it down bottom side up.
5. Turn the jacket top panel (removed in step 1) up
side down and place it through the stack.
6. 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).
Caution must be taken not to over tighten and
strip the screw threads.
7. 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 #10
flat head screws removed in step 1 above.
Fig. # 8246.6
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 more than five foot
intervals.Plumbers tape, crisscrossed, will serve to
space both horizontal and vertical piping. Maximum
vent connector horizontal length shall be 1-1/2 feet (18
inches) for each inch of connector diameter as follows:
Heater SizeVent Connector Max Horizontal
Diameter Length - FT
260/261 8"12.0
330/331 9"13.5
400/401 10"15.0
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 protection 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 Z223.1.
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 boiler 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 Z223.1.
WARNING: Indoor heater 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 the same size or larger than the draft
hood outlet is recommended, however, when the total
vent height is at least ten (10) feet (draft hood relief
opening to vent terminal), the vent pipe size may be
reduced as specified in the National Fuel Gas Code,
ANSI Z 223.1. As much as possible avoid long horizontal
runs of vent pipe and too many elbows.
Fig. #8119.2
9
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, ANSIZ223.1, 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.
(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 system 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 Z223.1. When re-sizing any
portion of the common venting system, the common venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in Chapter 10 and in appendix
Gof the National Fuel Gas Code, ANSI Z223.1 and
CAN/CSA-B149.1.
Fig. # 9463
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 common 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.
GAS SUPPLY CONNECTIONS
The inlet gas connection to the heater gas valve is
1/2" for model 203; 3/4" for models 260 and 330; and
1" for model 400. Provide an adequate gas supply line
no smaller than 1/2", according to the chart below:
MAXIMUM EQUIVALENT PIPE LENGTH (FEET)
NATURAL GAS 1000 BTU/FT .60 SPECIFIC GRAVITY @ 0.5" W.C. PRESSURE DROP
PROPANE GAS 2500 BTU/FT 1.53 SPECIFIC GRAVITY @ 0.6" W.C. PRESSURE DROP
Gas piping must have a sediment trap ahead of the
boiler 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
Union
Fig. # 8090.1
10
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: Do not exceed maximum inlet gas pressure. The minimum value shown is for input adjustment.
GAS PRESSURE REGULATOR
The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pressure.
The gas pressure regulator is preset and sealed at 4" W.C. for natural gas, and 11" W.C. for propane gas.
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" W.C. natural gas and 10.5" W.C. propane gas. Lo NOx models should be 3.9" W.C. natural
gas only. If an adjustment is needed, remove seal and turn adjustment screw clockwise to increase pressure
or counterclockwise to decrease pressure.
WATER CONNECTIONS & SYSTEM PIPING
The pipe size and fittings between the heater and the tank should be at least 1-1/2" for all models. The tank
should be located as close to the heater as possible, as shown in the drawing below:
Hot Water SupplyT & P Relief Valve
Thermometer
City Water
Pressure Relief Valve
Check Valve
Pump
Tankstat
Recirculation WaterFig. #9166
If this water heater is installed in a closed water supply system, such as one having a back-flow preventer
in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier
or local plumbing inspector on how to control this situation.
11
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