Raypak B0520, B0770, B0670, B0870 Installation And Operating Instructions Manual
Raypak Commercial Power Vent
Water Heaters
Installation and Operating Instructions
Models
B0520
B0670
B0770
B0870
This Installation and Operating Instructions Manual is provided with the information for the installation,
operation and maintenance of your Raypak Heater. Please review and follow these procedures carefully.
Keep this manual in a safe and accessible place for easy reference in the future.
2
Notice to Victorian Customers from the Victorian Plumbing Industry Commission.
This water heater must be installed by a licensed person as required by the Victorian Building Act
1993.
Only a licensed person will give you a Compliance Certificate, showing that the work complies with all
the relevant standards. Only a licensed person will have insurance protecting their workmanship for 6
years. Make sure you use a licensed person to install this water heater and ask for your Compliance
Certificate.
CONTENTS
3
FOR YOUR SAFETY ........................................................................................................................ 4
ABOUT THE WATER HEATER ........................................................................................................ 5
WATER SUPPLIES .......................................................................................................................... 6
WATER QUALITY ......................................................................................................................... 6
INSTALLATION ................................................................................................................................ 7
WATER HEATER LOCATION ....................................................................................................... 8
RAISED OR MESH PLATFORM ................................................................................................... 8
HIGH WIND CONDITIONS ........................................................................................................... 8
WATER HEATER DIMENSIONS .................................................................................................. 9
CLEARANCES .............................................................................................................................. 9
COMBUSTION/VENTILATION AIR ............................................................................................... 9
FLUEING ..................................................................................................................................... 10
GAS INLET .................................................................................................................................. 12
PUMP SELECTION ..................................................................................................................... 13
COLD WATER SUPPLY / MAKE-UP .......................................................................................... 14
PLUMBING CONNECTIONS ...................................................................................................... 15
ELECTRICAL SUPPLY ............................................................................................................... 20
AMBIENT AIR COMPENSATION ............................................................................................... 25
COMMISSIONING .......................................................................................................................... 26
OPERATION ................................................................................................................................... 28
LIGHTING PROCEDURE ............................................................................................................ 28
TO TURN OFF THE WATER HEATER ....................................................................................... 29
ADJUSTMENT ................................................................................................................................ 30
THERMOSTATS ......................................................................................................................... 30
BURNER GAS PRESSURE ADJUSTMENT ............................................................................... 33
TEMPERATURE RISE ................................................................................................................ 34
FLOW SWITCH ........................................................................................................................... 34
HIGH LIMIT ................................................................................................................................. 34
AIR PRESSURE SWITCH ........................................................................................................... 35
FAN SPEED ADJUSTMENT ....................................................................................................... 36
TROUBLESHOOTING .................................................................................................................... 37
SERVICING .................................................................................................................................... 38
RAYPAK COMMERCIAL WATER HEATER WARRANTY ............................................................. 40
Upon completion of the installation and commissioning of the water heater, leave this guide
with the householder or responsible officer. DO NOT
leave this guide inside of the cover of
the water heater, as it may interfere with the safe operation of the water heater or ignite
when the water heater is turned on.
4
FOR YOUR SAFETY
WARNING
For your safety do not operate this appliance before reading this instruction booklet
Improper installation, adjustment, alteration, service or maintenance can cause injury or
property damage. For assistance or additional information consult the Rheem Service
Department or accredited Service Agent.
WHAT TO DO IF YOU SMELL GAS?
DO NOT try to light any gas appliance.
DO NOT touch or operate any electrical switch.
TURN OFF the gas supply at the gas meter or isolation valve.
DO NOT use a mobile phone in the vicinity. Vacate the area and call your gas supplier or qualified
gasfitter.
NOTE: Some gases are heavier than air and it may be necessary to check for gas leaks at floor
level.
SAFETY
DO NOT place articles on or against appliance.
DO NOT store chemicals or combustible materials in the same room as, or vicinity of, this
appliance.
DO NOT spray aerosols near this appliance. Gases from some aerosol sprays become corrosive
when drawn into a flame.
DO NOT operate with panels, covers, flues or guards removed from appliance.
DO NOT enclose this appliance if it is installed outdoors.
CHECK that the combustion air openings are not obstructed.
5
ABOUT THE WATER HEATER
MODEL TYPE
Congratulations for choosing a Raypak® Commercial Gas water heater. The model is an On/Off or
Modulating type suitable for indoor or outdoor installation.
Raypak heaters utilise a finned copper tube heat exchanger resulting in a low water content and
reduced ‘stand by’ heat losses. Therefore a circulator pump of sufficient capacity to match the water
heater model must be installed in the system.
Raypak water heaters are fitted with Australian Gas Association approved components and are
designed to comply with AS 3814.
HOW HOT SHOULD THE WATER BE?
The required temperature of the water will have been determined by a qualified designer to suit the
application and set during commissioning. Under normal conditions the temperature should not require
adjustment.
For potable water applications requiring temperatures no greater than 75
°
C, a water heater with On/Off
operation should be installed. For temperatures above 75
°
C or for mechanical heating a water heater
with Modulating operation must be installed.
To meet the requirements of the National Plumbing Standard, for potable water applications, the
temperature of the stored water must not be below 60
°
C.
If this water heater is installed as a booster as part of a commercial solar water heating system, to
maximise solar contribution it is recommended the thermostat is set at 60
°
C, unless sanitising
temperatures are required.
HOTTER WATER INCREASES THE RISK OF SCALD INJURY.
This water heater can deliver water at temperatures which can cause scalding. Check the water
temperature before use, such as when entering a shower or filling a bath or basin, to ensure it is
suitable for the application and will not cause scald injury.
We recommend and it may also be required by regulations that an approved temperature limiting
device be fitted into the hot water pipe work to the ablution and public areas. This will keep the water
temperature below the maximum permitted by AS/NZS 3500.4 to these areas. The risk of scald injury
will be reduced and still allow hotter water to the kitchen, laundry and other areas requiring sanitising
temperatures.
TEMPERATURE ADJUSTMENT
This appliance is not intended to be adjusted by the user. Please consult the installer if you are
concerned with the temperature of the water.
This water heater is not intended to be operated, adjusted or tampered with by young
children or infirm persons. Young children should be supervised to ensure they do not
interfere with the water heater.
Removal of the access cover(s) will expose 240 V wiring. They must only be removed by an
authorised or service person.
This water heater is supplied with a thermostat, an over-temperature cut-out, pressure switch and
pressure relief valve. These devices must not be tampered with or removed. The water heater must
not be operated unless each of these devices is fitted and is in working order.
The warranty can become void if relief valves or other safety devices are tampered with or if the
installation is not in accordance with these instructions.
6
WATER SUPPLIES
WATER QUALITY
The standard finned copper tube heat exchanger has proved to be very resilient and capable of
operating for many trouble free years on most public water supplies.
Should the installation be in an area where ‘corrosive’ or ‘hard’ water is present contact Raypak to
ensure that the quality of the water is satisfactory.
DAMAGE CAUSED BY CORROSIVE, HARD OR OTHERWISE POOR QUALITY WATER, IS NOT
COVERED BY THE WARRANTY.
7
INSTALLATION
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING.
BEFORE COMMENCING THE INSTALLATION:
1. Read these instructions in full.
2. Check that the heater you have been supplied is suitable for t he type of installati on and the
gas that is available. The gas supply pressure must be between the minimum and
maximum as shown on the water heater rating plate.
Note: In Australia, natural gas models can be connected to SNG, however the hourly gas consumption
may be reduced (typically by 10%).
This water heater must be installed by an authorised person.
The installation must comply with the requirements of AS/NZS 3500.4, AS/NZS 3000, AS 5601 and all
local codes and regulatory authority requirements. The appliance must be commissioned by a properly
licensed person in accordance with AS 3814 and certified by the state gas authority.
In New Zealand, the installation must conform with NZS 5261 Code of Practice for Installation of Gas
Burning Appliances and the New Zealand Building Code.
INSPECTION OF EQUIPMENT
Check the heater and associated equipment for any damage and notify your local representative for
any further instructions.
COMPONENTS PROVIDED WITH THE WATER HEATER
1 x 305mm x 60
o
elbow with grill
DO NOT INSTALL OR START UP THIS WATER HEATER IF IT HAS BEEN DAMAGED, WITHOUT
FIRST CONSULTING RHEEM. ANY DAMAGE OR FAULT CAUSED BY UNAUTHORISED START
UP MAY NOT BE COVERED BY WARRANTY.
This water heater is supplied with the following safety devices:
• An electronic thermostat
• A manual reset flame safeguard system
• An adjustable manual reset over-temperature device
• A pressure relief valve
• An automatic reset flame rollout sensor
• Two main burner and one pilot flame sensor
• An adjustable air pressure switch
• An adjustable water flow switch
• The flame safeguard system ensures the safe operation of the burner.
• The manual reset over-temperature device may need to be adjusted if the water heater is
operating at water temperatures above those preset by the factory.
• The air pressure switch ensures the unit does not operate without the fan running.
• The water flow switch may need to be adjusted to accommodate the specific flow rate of the
installation.
The water heater must not be operated unless each of these devices is fitted and is in
working order. Warranty may be voided any of these devices are tampered with or the
installation is not in accordance with these instructions.
INSTALLLATION
8
IMPORTANT: When installing a new water heater to an existing system, it is a Raypak requirement
that the system and its equipment be inspected, drained and flushed with clean fresh water, before the
new water heater is connected.
Failure to do this may cause blockages and/or water heater damage which is NOT COVERED BY
WARRANTY.
WATER HEATER LOCATION
This water heater is suitable for installation indoors or outdoors with the correct flue configuration. The
water heater should be installed either close to the most frequently used outlets or with a circulated
flow and return system and its position chosen with safety and service in mind. Make sure people
(particularly children) will not touch the flue outlet. The flue terminal must be clear of obstructions and
shrubbery.
Clearance must be allowed for servicing of the water heater. The water heater must be accessible
without the use of a ladder or scaffold. Make sure the pressure relief valve lever is accessible and the
front covers or panels, thermostats and burner can be removed for service.
Gas or water piping, electrical conduits, trees, fences, or other equipment, etc must not obstruct the
front or top of the heater.
You must be able to read the information on the rating plate. Remember you may have to take the
entire water heater out later for servicing.
If a safe tray is required, it should be large enough for all the equipment and must not restrict
combustion airflow.
The water heater must be mounted on a level non-combustible base such as a concrete slab, concrete
plinth, steel plate etc. Raypak water heaters must not be installed on carpeting.
RAISED OR MESH PLATFORM
Water heaters installed on a raised platform must be installed on a
solid non-combustible base to prevent wind affecting the
performance of the water heater.
If steel mesh decking is used, a base of suitable non-combustible
material must be used to cover the mesh.
The base must extend 1m on all sides of the water heater.
HIGH WIND CONDITIONS
In areas where high winds occur frequently it may be necessary
to install a wind break so that the water heater is not subject to
direct wind gusts.
High rise or multi storey installations can present problems with
excessive winds and we recommend that the common practice of
surrounding the water heater within an open top enclosure be
adhered to.
INSTALLLATION
9
WATER HEATER DIMENSIONS
Model 520 670 770 870
A 674mm 797mm 901mm 1006mm
B 821mm 944mm 1048mm 1153mm
CLEARANCES – INDOOR INSTALLATIONS
from combustible materials: from non-combustible materials:
Rear 600mm 150mm
Front (access) 750mm 750mm
Flue Outlet Side* 700mm 700mm
Left Side* 600mm 600mm
Right Side* 600mm 300mm
Top (access) 600mm 600mm
*Indoor clearances given for Left Hand Side models. For models Right Hand configured apply clearances accordingly.
Clearances for models installed outdoors must comply with AS5601.
COMBUSTION / VENTILATION AIR
Water heaters installed indoors must be provided with adequate ventilation in accordance with
AS 5601.
Note: The flue gases from this water heater have a CO
2
level of 1%. Additional ventilation will be
required.
Ventilation shall be via two permanent openings directly to outside, one at an upper level and one at
low level. The minimum dimension of any opening shall be 6mm.
The free ventilation area for all models is as shown in the table below:
Ventilation Requirement - All Models
Natural Ventilation / opening / water heater Mechanical Ventilation / water heater
Direct to Outside 1225 cm2 Low Level Air supply 770 L/sec
Via Adjacent Room 2450cm2 High Level Exhaust
Mechanical 193 – 254 L/sec
Natural 1300cm2
NOTE: Air supply to the area where the water heater is located must not be affected by mechanical
exhaust vents or other equipment, eg cooling towers, chillers, heat pumps. Incorrect ventilation may
create a negative pressure that can become a hazard by asphyxiation, explosion or fire.
INSTALLLATION
10
FLUEING
Outdoor Installations
The flue terminal location of a water heater installed outdoors must comply with figure 5.3 of AS 5601.
The supplied 60
o
bend must be fitted to the outlet of the water heater.
Semi Enclosed Outdoor Installations
Depending on the installation, eg covered areas, it may be necessary to extend the flue on an outdoor
installation to discharge in a suitable location. In this case the 60
o
bend should be fitted to the
terminating point of the secondary flue.
Indoor Installations
The secondary flue connected to this water heater may discharge horizontally or vertically.
• All indoor installations require a 250mm barometric damper to be installed in the connecter from
each water heater. A barometric damper is available from Raypak.
Horizontal Discharge
• For horizontal discharge applications where each water heater is individually
flued, the 300mm diameter flue for each water heater can be run for a total
length of 20m with 3 x 90
o
bends plus the supplied 60o terminal (see diagram
opposite).
• For horizontal discharge applications where each water heater is connected to a common flue, the
300mm connector from each water heater must join the common flue using a 45
o
swept junction
positioned so as to direct the flue gasses into the common flue in the direction of discharge. The
flue length is measured from the most disadvantaged water heater and should not exceed 20m
with up to 3 x 90
o
elbows plus the 45o swept junction. The common flue must be sized in
accordance with AS 5601 and terminate with an appropriately sized 60
o
terminal. Dampers may be
required to be installed in each connector in accordance with AS5601
Note: The flue gasses from this water heater have a CO2 level of 1%. The flue must be designed to
accommodate the amount of additional air accordingly.
Typical Installation – Common Flue Manifold
INSTALLLATION
11
Vertical discharge
For vertical discharge applications the installation must be in accordance with AS 5601.
For vertical discharge applications where each water heater is
individually flued, the 300mm diameter flue for each water heater can
be run for a total length of 20m with up to 3 x 90
o
elbows plus a 135o
terminal. N.B. Jaks cowls are NOT
to be used to terminate the flue as
they will prevent adequate venting of the flue gases. See diagram
opposite.
• For vertical discharge applications where each water heater is connected to a common flue, the
300mm connector from each water heater must join the common flue using a 30
o
swept junction
positioned so as to direct the flue gases into the common flue in the direction of discharge. The
common flue must be sized in accordance with AS 5601 and terminate with an appropriately sized
135
o
terminal. Dampers may be required to be installed in each connector in accordance with
AS5601 (see ‘Typical Installation – Common Flue Manifold’ diagram above).
Note: The flue gasses from this water heater have a CO
2
level of 1%. The flue must be designed to
accommodate the amount of excess air accordingly.
POWER FLUEING
If the flue cannot be designed as described above, then a power flue may be required. Power flues
must be designed by persons competent to do so and must be interlocked with the water heater.
Contact Raypak for power flue wiring diagrams.
INSTALLLATION
12
Flue Outlet Direction
The flue connection on this water heater can be repositioned from the left hand side to the right hand
side if required.
• Ensure the water heater is isolated from the mains power supply.
• Remove the 18 screws holding the fan cover assembly to the water heater body and the 6 screws
around the flue connection.
• Remove the fan cover assembly from the water heater.
• Lift and rotate the fan exhaust assembly through 180
o
. Sufficient electrical cable has been
provided to accommodate full rotation of the fan exhaust assembly.
Ensure the electrical cable is clear of the combustion chamber opening and cannot be
pinched when replacing the fan cover assembly.
• Replace the fan cover assembly in the new direction and replace all screws
GAS INLET
The pipe work must be cleared of foreign matter before connection and purged before attempting to
light the water heater. An isolation valve and disconnection union must be used to allow servicing and
removal of the water heater. Refer to AS 5601 for the correct pipe sizing.
Always isolate the water heater before pressure testing the gas supply system. Disconnect
the water heater after the isolating cock to prevent the risk of serious damage to the gas
train. Warranty does not cover damage of any nature resulting from failure to observe this
precaution. Refer to rating label for gas types and pressures.
The heater and its gas connection must be thoroughly leak tested before placing in operation. Use
soapy water and a manometer for leak test.
DANGER! Do not use an open flame to check for gas leaks.
INSTALLLATION
13
PUMP SELECTION
For the most efficient operation of the water heating system the circulating pump must be sized
correctly.
The pump should be installed on the inlet to the water heater especially where the system water
pressure is low.
Refer to the 'flow rate and pressure drop table' on page 13 for the minimum and maximum flow rates
for each model to determine the pressure loss through the water heater for the required temperature
rise and add this to the other system pressure losses when sizing the pump.
Note: The flow rate must never be below the minimum
stated in the Flow Rate and Pressure Drop table.
Where the water flow rate exceeds the maximum shown in
the Flow Rate and Pressure Drop table, a bypass with a
balancing valve must be installed to reduce the water flow
through the water heater (see diagram opposite).
For pump sizing where the water heating system
incorporates Rheem storage tanks, refer to the 'pump
selection and pipe size table' on page 13.
Intermittent pump operation
Where pump operation is intermittent, a remote thermostat must be fitted in the system and a pump
run on timer is required to remove residual heat from the water heater and prevent nuisance tripping of
the high limit switch. A run on timer is available as an optional kit (Rheem part No 56076874).
Flow Rate and Pressure Drop Table
Max Flow Rate
Modulating (10
°
C Rise)
Max Flow Rate
On/Off (15°C Rise)
Min Flow Rate
(20°C Rise)
Model l/sec kPa l/sec kPa l/sec kPa
520 2.87 6
1.91 3
1.43 3
670 3.58 10
2.39 4
1.79 3
770 4.06 14
2.71 6
2.03 4
870 4.66 22
3.11 8
2.33 5
* Where marked as maximum water flow, the temperature rise will be greater than 10°C or 15°C as noted.
Pipe Size and Pump Selection Table
Model
Pump
Branch
Size
Minimum Manifold Header Size (mm)
UPS
Series
Speed TP Series
1 Unit 2 Units 3 Units 4 Units
B0520 32-80B 3 1
1/4
32mm 32 50 65 80
B0670 32-80B 3 1
1/2
40mm 40 50 65 80
B0770
32-80B 3 50-30/4B 2 50mm 50 80 100 100
40-60/2B 2
1
1/2
40mm 40 50 80 80
B0870
32-80B 3 2 ½ 65mm 65 100 125 150
40-60/2B 1 50-30/4B 2 50mm 50 65 80 100
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