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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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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* TP series circulator is recommended for hard water areas in lieu of UPS series circulator
* Manifold header sizes are minimum requirements for water heater performance
Minimum Pump Inlet Pressure
Circulating pumps require a minimum inlet pressure in order to operate without cavitation. Refer to the
table below for minimum pressure requirements for Grundfos UPS series pumps. Minimum pressure
requirements for TP series pumps depend on system characteristics and need to be calculated.
Contact your pump supplier for more information.
Pump Models
Minimum Inlet Head Required at
Operating Temperature (m)
75°C 80°C 85°C 90°C 95°C
UPS32-80B 350,430,507,520,670,770,870 0.5 0.5 0.5 3.0 5.0
UPS40-60/2B 768,868,972,992,1142,1182,1242,1292 1.5 2.5 3.5 4.5 7.0
UPS50-120B
1362,1412,1492,1552,1662,1722,1852,
1922,2004,2214
4.0 5.0 6.0 7.0 9.0
UPS80-120B
2404,2634,2804,3164,3304,3694,3804,
4224
16.0 17.0 18.0 19.0 20.5
COLD WATER SUPPLY / MAKE-UP
All pipe work must be cleared of foreign matter before connection and purged before attempting to
operate the water heater. All olive compression fittings must use brass or copper olives. Use thread
sealing tape or approved thread sealant on all fittings.
Mechanical, Hydronic and Process Heating Applications
The pressure of the make up supply must be controlled. This may be achieved by the use of a
pressure limiting valve or a header tank which is designed to provide the correct operating pressure for
the system.
Where the water heater is fitted with a 60PSI relief valve, the maximum pressure setting must not
exceed 330kPa. The minimum inlet pressure is dependant on a number of factors including operating
temperature, minimum inlet pressure for circulating pumps and system pressure losses.
Backflow prevention in accordance with AS/NZS 3500.1 may be required, please check with the local
water supply authority for any local code requirements.
A suitably sized expansion vessel must be fitted to a closed heating system to prevent discharge of
system fluid during the heating cycle.
Domestic Hot Water Applications
An isolation valve and non-return valve must be installed on
the cold water line to the system. An acceptable arrangement
is shown in the diagram opposite.
The cold water supply to a domestic water heating system
must be fitted with a pressure limiting valve if the water supply
pressure exceeds 80% of the lowest rated relief valve in the
system.
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The cold water supply pressure must be sufficient to provide adequate flow at the fixtures.
EXPANSION CONTROL VALVE
Local regulations may make it mandatory to install an expansion control valve (ECV) in the cold water
line to the water heating system. In other areas, an ECV is not required unless the saturation index is
greater than +0.4 (refer to 'Water Supplies' on page 6). However, an ECV may be needed in a
corrosive water area where there are sufficient quantities of silica dissolved in the water.
The expansion control valve must always be installed after the non return valve and be the last valve
installed prior to the water heater (refer to diagram on page 13). A copper drain line must be run
separately from the drain of the relief valve.
RELIEF VALVE DRAIN
A copper drain line must be fitted to the relief valve to carry the discharge clear of the water heater.
Connect the drain line to the relief valve using a disconnection union. The pipe work from the relief
valve to the drain should be as short as possible and fall all the way from the water heater with no
restrictions. It should have no more than three right angle bends in it. Use DN20 pipe.
The outlet of the drain line must be in such a position that flow out of the pipe can be easily seen (refer
to AS/NZS 3500.4) - but arranged so hot water discharge will not cause injury, damage or nuisance.
The drain line must discharge at an outlet or air break not more than 9 metres from the relief valve.
In locations where water pipes are prone to freezing, the drain line must be insulated and not exceed
300 mm in length. In this instance, the drain line is to discharge into a tundish through an air gap of
between 75 mm and 150 mm.
For multiple installations the drain line from each water heater can discharge into a common tundish.
As the function of the temperature pressure relief valve on this water heater is to discharge
high temperature water under certain conditions, it is strongly recommended the pipe work
downstream of the relief valve be capable of carrying water exceeding 93°C. Failure to
observe this precaution may result in damage to pipe work and property.
PLUMBING CONNECTIONS
Domestic Hot Water Applications
For domestic hot water applications, one or more storage tanks are required. Connect the water
heater, pump and storage tanks in accordance with the principles shown in the diagrams below and on
pages 16 and 17 with the following in mind:
• Install the storage tanks according to Equa-flow® principles as described in the installation
instructions supplied with the storage tanks and on page 16.
• Install the water heaters according to Equa-flow® principles as shown in the diagram on page 18
• A disconnection union must always be provided at the cold water inlet and hot water outlet on the
water heater to allow for disconnection of the water heater.
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INSTALLLATION
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INSTALLLATION
17
Typical Installation one water heater one tank
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INSTALLLATION
18
Typical Installation two water heaters, two tanks
Mechanical, Hydronic and Process Heating Applications
For these applications, storage tanks are normally not required. Connect the water heaters and pumps
in accordance with the principles shown in the diagram below with the following in mind:
• Install the water heaters according to Equa-flow® principles as shown in the diagrams on page 18.
• A disconnection union must always be provided at the cold water inlet and hot water outlet on the
water heater to allow for disconnection of the water heater.
• Each high point of the system should be fitted with an air bleed valve or automatic air eliminator.
• On radiator or heating systems where thermostatic or zone valves will vary the water flow through
the load, a by-pass with a suitable control valve must be installed to control the system water flow
rate.
BY-PASS VALVES must be installed at the end of the system furthest from the water heater.
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LEGE ND
Typical Installation - Raypak mechanical heating system
CLOSED LOOP WATER SOURCE HEAT PUMP
Refer to diagram below
1. Only use a heater with on/off controls.
2. The bypass pipe diameter MUST be the same as the inlet and outlet pipes.
3. Select the pipe size between the heater and the system loop main, equal to the inlet/outlet header
connections of the water heater (as a minimum).
4. Install the correct pump. The temperature rise must be between 10°C and 15°C. Refer to 'pipe size
and pump selection table' on page 13.
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INSTALLLATION
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ELECTRICAL SUPPLY
The electrical installation must comply with AS/NZS 3000 and any local requirements.
This water heater must be hard wired to a 240V AC 50 Hz M.E.N. (multiple earthed neutral) mains
power supply with an all pole isolating switch installed adjacent to and accessible from the water
heater (refer to AS 5601, 5.2.11). A suitable warning label must be affixed to the water heater if there
are additional control circuits not isolated by this switch. This label should direct the service person to
the isolation switch for that circuit.
Do not locate conduits across the doors, control panel or the top of the water heater.
Where conduit is to be mounted on the water heater cabinet there must be a 10mm air gap between
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INSTALLLATION
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the conduit and the water heater cabinet to prevent overheating of the wiring.
The power for the pump and the water heater must be supplied from the same circuit and isolating
switch; alternatively the water heater power supply may be switched by the auxiliary contacts of the
pump contactor (refer to diagrams on page 22).
THE WATER HEATER MUST NOT OPERATE WITHOUT THE CIRCULATING PUMP RUNNING.
Access to the electrical connection of the water heater is achieved by opening the control panel
located on the front of the water heater (see diagram below).
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INSTALLLATION
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Wiring diagram Raypak water heater with 415V 3 phase circulator
Wiring diagram Raypak Water Heater with 240V Single Phase Circulator
Page 23
INSTALLLATION
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BROWN
NOTE!: This Drawing May Change WIthout Notice
This drawing remians the property of Raypak Australia
and must not be reproduced without permission.
DRG No: 159502
ISSUE DATE
APPR
E.O.
DESCRIPTION
1
FILTER
A
N
E
N
E
Flow Switch
(Optional)
High Limit
5
9
12
11
1
7
2
8
10
LAMP
8
7
FR
N
L
7
2
3
4
1
10
9
PILOT VALVE
MAIN VALVE
MAIN VALVE
IGNITION MODULE
FLAME FAILURE
RESET BUTTON
RHS FLAME ROD (MAIN BURNER)
LHS FLAME ROD (MAIN BURNER)
FLAME FAILURE
INDICATOR LIGHT
SERVICE SWITCH
6
4
PILOT BURNER
FLAME ROD
Water Heater On/Off
(INTERRUPTED PI LOT)
LME39 + RE3 + AKO
+ Run On Timer(Option)
520 to 870
Natural and Propane Gas
LME39
RE3
GRAY
BLUE
BROWN
BROWN
Orange
Brown
Whit e
BLACK
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
Orange
GRAY
BROWN
Update and finali se drawing to cur rent standards.
15/05/07
BLUE
Red
GREEN/
YELLOW
GREEN/YELL OW
GREEN/YELLOW
2
1
AKO T/Stat
A
11
12
Water Sensor
(Installed INLET
side of heater)
6
Violet
Black
BROWN
BLUE
BLUE
BLUE
BLUE
RAYPAK AUSTRALIA Pty.Ltd
RUN ON TIMER
SAIA KOL 312
To pump relay
(contactor)
240V AC
relay coil
To time switch,
tankstat, etc
240V AC
16
18
A2
Economaster run on timer option P/N56076874
4
3
BROWN
BROWN
BROWN
BROWN
BROWN
BROWN
BROWN
BLUE
BLUE
BLUE
BLUE
1
5
8
7
RR
FR
WHITE
BLUE
BLUE
Standard (240V)
RR
FR
Run Relay
Flame Fail Relay
RUN ON TIMER
SAIA KOL 312
16
18
A2
A1
15
B1
3
SERVICE SWITCH
M
Fan Motor
VIOLET
Yellow
ORANGE
BLUE
BROWN
A1
15
B1
6
PRESSURE SWITCH
(Manual Reset)
WHITE
N.B: Factory preset fan
speed is low (White)
Medium speed (Gray)
High speed (Brown)
VIOLET
High Limit
(Auto Reset)
Wiring Diagram – On/Off Water Heaters
Page 24
INSTALLLATION
24
BROWN
NOTE!: This Drawing May Change WIthout Notice
This drawing remians the property of Raypak Australia
and must not be reproduced without permission.
DRG No: 159501
ISSUE DATE
APPR
E.O.
DESCRIPTION
1
FILTER
A
N
E
N
E
Flow Switch
(Optional)
High Limit
5
9
12
11
1
7
2
8
10
LAMP
8
7
FR
N
L
7
2
3
4
1
10
9
PILOT VALVE
MAIN VALVE
MAIN VALVE
IGNITION MODULE
FLAME FAILURE
RESET BUTTON
RHS FLAME ROD (MAIN BURNER)
LHS FLAME ROD (MAIN BURNER)
FLAME FAILURE
INDICATOR LIGHT
SERVICE SWITCH
6
4
PILOT BURNER
FLAME ROD
Water Heater Modulating
(INTERRUPTED PILOT)
LME39 + RE3 + RWF40
+ Pump Run On Timer
520 to 870
Natural and Propane Gas
LME39
RE3
GRAY
BLUE
BROWN
BROWN
Orange
Brown
White
BLACK
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
Orange
GRAY
BROWN
Update and finali se drawing to current standards.
15/05/07
BLUE
Red
GREEN/
YELLOW
GREEN/YELLOW
GREEN/YELLOW
A
6
Viole t
Black
BROWN
BLUE
BLUE
BLUE
BLUE
RAYPAK AUSTRALIA Pty.Ltd
BROWN
BROWN
BLUE
1
5
8
7
RR
FR
WHITE
BLUE
BLUE
Standard (240V)
RR
FR
Run Relay
Flame Fail Relay
RUN ON TIMER
SAIA KOL 312
16
18
A2
A1
15
B1
3
SERVICE SWITCH
M
Fan Motor
VIOLET
Yellow
ORANGE
BLUE
BROWN
Optional
Outdoor Compensation
RWF 40
Y1
Y2
B9
M9
PE
Q13
N
L1
G1
M1
Q
Q14
BROWN
BROWN
BROWN
BLUE
BLACK
SQS37 Mod Motor
WATER SENSOR
RUN ON TIMER
SAIA KOL 312
TO PUMP RELAY
(CONTACTOR)
240VAC COIL
EXTERNALLY WIRED
TIME SWITCH, T/STAT
ETC.
(Remove bridge when
device is connected)
18
A2
B1
A1
15
BROWN
BROWN
BROWN
BROWN
BLUE
BROWN
VIOLET
6
PRESSURE SWITCH
(Manual Reset)
Economaster run on timer option P/N56076874
WHITE
N.B: Factory preset fan
speed is low (White)
Medium speed (Gray)
High speed (Brown)
High Limit
(Auto Reset)
Wiring Diagram – Modulating Water Heaters
Page 25
INSTALLLATION
25
AMBIENT AIR COMPENSATION
QAC22 / QAC32 Mounting and Installation
Mounting Position
Mounting instructions are printed on the packaging however the following
points should be noted
• The sensor is to be mounted externally, preferably at the mid point of
the house or building or heating zone, but at least 2.5 m above the
ground
The sensor must not be fitted at the following locations:
• Above windows, doors, air extracts or other heat sources
• Below balconies or the eave of the roof
To prevent measurement errors the sensor should:
• Be sealed.
• Not painted over
Connection
The ambient air sensor is connected to terminals B9 and M9 on the RWF40 thermostat
Programming
When utilising outdoor compensation it is necessary to reprogram some of the parameters within the
RWF 40 controller to recognise the outdoor sensor.
The table below details the parameters that require alteration and the new settings required.
Parameter Original Setting New Setting
C111 9000 9030
C112 0000 C010
SPL 0 55
SPH 95 85
AL 0 24
HYSt 0 2
H 0 4
NOTE: Prior to altering the factory settings, advice should be sought on the function of parameters,
other than those listed above, to prevent malfunction of the RWF40 controller.
Page 26
26
COMMISSIONING
COMMISSIONING MUST ONLY BE UNDERTAKEN BY A PROPERLY QUALIFIED AND IN MOST
CASES APPROPRIATELY LICENSED PERSON WHO IS FAMILIAR WITH THE COMMISSIONING
REQUIREMENTS OF AS3814. MOST REGULATORY AUTHORITIES REQUIRE THE APPLIANCE
AND ITS INSTALLATION TO BE INSPECTED AND CERTIFIED.
PRE-COMMISSIONING CHECK LIST
1. Conduct a visual inspection of the water heater and equipment for damage and report as
necessary.
2. Ensure the water heater is suitable for the type of gas available.
3. Ensure the correct power supply is available and the water heater and circulation pump are
correctly wired (Refer to page 20).
4. Ensure the pump is installed in the correct orientation, the flow direction is correct and (for three
phase pumps) the phase rotation is correct.
5. Ensure the position of the water heater complies with the installation requirements of this manual,
AS 5601 and local authority requirements.
6. Ensure the ventilation to the plant room complies with the requirements of AS 5601 and local
authority regulations. Mechanical ventilation, if provided, must be interlocked with the water heater
as required by AS 5601.
7. Ensure the flue complies with the installation requirements of this manual, AS 5601 and local
authority requirement. A power flue, if provided, must be interlocked with the water heater as
required by AS 5601.
8. Ensure flammable or combustible materials are not stored near the water heater. Flammable
liquids (such as petrol), newspapers and similar articles must be kept well away from the water
heater and the flue system.
9. Ensure swimming pool chemicals, household cleaners, etc., are not stored near the water heater.
10. Ensure nothing is placed on top of the water heater or in contact with the flue system. Ensure the
flue terminal is not obstructed in any way at any time.
11. Ensure the combustion air openings are not obstructed.
12. Ensure the system is filled with water and any air has been expelled.
13. Purge all air from gas supply piping.
14. Test ALL gas connections for leaks using soapy water (DO NOT USE A NAKED FLAME)
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
COMMISSIONING THE WATER HEATER
THE WATER HEATER MUST BE COMMISSIONED IN ACCORDANCE WITH AS 3814, appendix F.
Refer to Operation section on page 28 for instructions on lighting the water heater.
Refer to Adjustment section on page 30 for instructions on adjustment of the water heater.
Page 27
COMMISSIONING
27
CLOSED LOOP WATER SOURCE HEAT PUMP
Commissioning procedure – refer to diagram below
1 Check that both isolation valves are open.
2 Adjust balancing valve A to half open and balancing valve B to fully open.
3 Start up the heater and adjust balancing valve A to obtain a heater inlet temperature of
approximately 10°C greater than the system loop return temperature, (turning valve A in the open
direction will increase the heater inlet temperature and closing valve A will lower the heater inlet
temperature.
NOTE: The heater inlet should never be less than 41°C.
4 If the heater inlet temperature remains less than 10°C higher than the system loop return
temperature and valve A is fully open, leave valve A fully open and throttle valve B until the heater
inlet temperature rises to be 10°C higher than the system loop return temperature.
5 Main loop and heater temperatures should be checked regularly throughout the season to prevent
heater condensation. If the balancing valves are adjusted at the coldest loop temperature (typically
10°C) and the heater temperature to 41°C then the entire heating season should have a proper
41°C operation. The heater inlet temperature can be higher than 41°C without heater damage, but
operating at less than 41°C inlet can cause damage from condensation.
Page 28
28
OPERATION
FIRST FIRING OF WATER HEATER
It is quite normal for the water heater to produce some smoke, fumes and possible condensation
for the first thirty (30) minutes of firing from new.
Avoid breathing fumes. Vacate and ventilate area.
LIGHTING PROCEDURE
CAUTION
Do not use this heater if any part has been under water. Call a qualified service technician
immediately to replace any part or control system that has been under water.
Propane Gas is heavier than air and sinks to the ground, exercise extreme care in lighting the
water heater in confined areas.
STOP
refer to “For Your Safety” on page 4.
This water heater is equipped with electronic ignition and a number of other features for automatic
operation.
1. Open the gas isolation valve at the inlet to the water heater.
STOP
!
If you smell gas, follow the safety instructions. Refer to 'What To Do If You Can Smell Gas' on
page 26
If you do not smell any gas continue.
2. Ensure the pilot gas isolation valve is open.
Use only your hand to turn the pilot gas isolation valve.
Never use any tools. If the knob will not turn by hand do not try to repair it, call a qualified
service technician.
Force or attempted repair may result in a fire or explosion.
3. Ensure water heater is full of water.
4. Switch on electrical power to the water heater and ancillary equipment (if fitted).
5. The water heater will commence the start up sequence.
Note: The start up sequence will only commence if the thermostat is calling for heat and the flow
switch and all external interlocks (if fitted) are closed.
6. The fan will start and when the pressure switch is closed the pre-purge period (up to 30 seconds)
will commence.
7. The ignition sequence will commence following the pre-purge period, as follows:
Ignition of pilot burner (up to 5 seconds)
Proving of pilot flame (10 seconds)
Opening of main gas valves
Proving of main flame (2-5 seconds)
Extinction of pilot flame
Note: If the burner fails to light the water heater will lock out and the “red” reset light will illuminate,
except that for heaters with a nominal gas input less than 2000MJ/h the system will make one reignition attempt following a further pre-purge period. To reset the water heater refer to 'Resetting The
Water Hater' on page 37.
Page 29
OPERATION
29
TO TURN OFF THE WATER HEATER
1. Turn off the power supply to the water heater at the isolation switch.
EMERGENCY SHUT-DOWN
1. Turn off the power supply to the water heater at the isolation switch.
2. Turn off the gas isolation valve at the inlet to the water heater or the main gas supply.
CHECK FOR NORMAL OPERATION
• With the water heater operating, remove the door and make a visual check of the burners. The
flame should be blue with a well-defined pattern.
• A yellow or floating flame indicates restricted air openings, incorrect gas type, incorrect orifice size
or possible excessive draught.
• Observe for any indication of soot. The presence of soot accumulation would indicate an abnormal
operating condition.
Should abnormalities be observed, turn off the water heater and contact Rheem Service or your
nearest Accredited Service Agent.
Operation of the water heater due to poor combustion will result in rapid and severe
damage, which is not covered by warranty.
LOCATION OF CONTROLS
1. FLAME FAILURE RESET: This is a combination
reset button and indicator lamp. It indicates, when
illuminated, that the ignition system has shutdown
on its safety control. During normal operation the
lamp is out and the button will not require any
operation.
2. TEMPERATURE CONTROL: This may vary with
the type of Heater installed and is explained later in
this section.
3. FLOW SWITCH: (Located in the return header)
This device will shut off power to the heater internal
controls in the event of low or no water flow.
4. GAS VALVE ISOLATION SWITCH: (Located under
the control panel behind the door) Used to isolate
the gas valve during the commissioning process
only.
5. FAN ISOLATION SWITCH: (Located under the
control panel behind the door) Used to isolate the
fan during the commissioning process only.
6. FAN PROVING PRESSURE SWITCH: Used to
prove fan operation prior to ignition. Test point
located here for commissioning purposes.
(6)
Page 30
30
ADJUSTMENT
THERMOSTATS
On/Off Models
Water heaters with On/Off operation are fitted with
an AKO adjustable thermostat with the temperature
sensor located in the inlet side of the header.
This type of control is used where the system load
is constant, e.g. potable hot water supplied from a
storage tank or underfloor heating.
To adjust Set Temperature
a. Press the “À” button for 5 seconds to display the current ‘Set Point’.
b. Press the “¿”or “À”buttons to increase or decrease the set point to that required.
c. Press the “¿” and “À” buttons simultaneously to lock the new setting into the controller, the current
water temperature will be redisplayed.
To adjust Parameters
The thermostat has a number of parameters that are programmed during manufacture (refer to the
‘AKO Parameter table’ on page 31 for values); advice should be sort from your local Raypak
representative prior to altering any values other than the set point or the differential.
a. Press the “¿”and “À”buttons simultaneously until ‘C0’ is displayed (approx 10 seconds).
b. Press the “¿” or “À” buttons to display the parameter that requires setting i.e. C1 (refer to the AKO
Parameter Table on page 31 for parameter values).
c. Press the “¿”and “À”buttons simultaneously to display the current value of the parameter selected
in step b.
d. Press the “¿” or “À” buttons to alter the value of the parameter.
e. Press the “¿”and “À”buttons simultaneously to exit the parameter adjustment. The parameter
selected in step b is redisplayed
f. Press the “¿” or “À” buttons to select the next parameter that requires setting or if all parameters
are set until ‘EP’ is displayed.
g. Press the “¿”and “À”buttons simultaneously to save the setting changes and exit programming.
NOTE:
1. If a button is not pressed within any 25 second period the controller will exit programming mode
without saving any changes.
2. Failure to exit the programming mode via EP will result in the new settings not being saved
NOTE: If a remote thermostat is used to control the water temperature e.g. a Tankstat, the water
heater thermostat should be set to a slightly higher temperature than that of the remote thermostat.
Fault Codes
In the event a fault occurs with the thermostat or the temperature sensor a 2-digit code will be
displayed on the thermostat LED.
Code Fault
AL Temperature below the minimum set point parameter C3
AH Temperature above the maximum set point parameter C2
EE Memory error
E1 Temperature sensor set open circuit
Page 31
ADJUSTMENT
31
AKO Parameter Table
Parameter Operation Setting
C0 Sensor calibration 0
C1 Differential 2
C2 Upper set point limit 80
C3 Lower set point limit 20
C4 Compressor protection delay type 0
C5 Protection delay time 0
C7 Relay time ON in case of faulty sensor 0
C8 Relay time OFF in case of faulty sensor 0
d0 Defrost frequency 0
d1 Defrost maximum duration 0
d2 Type of message during defrost 0
d3 Message maximum duration 0
L5 Access password 0
L6 Parameters transfer 0
P0 Type of operation 1
P1 Delay of all functions at power up 0
P2 Allocation of password to set point 0
P3 Initial Parameters 0
P5 Address for units with communication 0
P7 Temperature display mode 0
EP Exit Program
Modulating Models
Water heaters with modulating operation are fitted with an RWF40
adjustable controlling thermostat with the temperature sensor located in
the outlet side of the header.
This type of control is used where the system load is variable e.g.
Mechanical Heating.
This type of control will cycle the burner from full fire to 30% and then off.
The thermostat has a number of parameters that are programmed during
manufacture (refer to the ‘RWF40 Parameter Table’ on page 32 for
values); advice should be sort from your local Raypak representative prior
to altering any values other than the set point or the differentials.
To adjust the Set Temperature (SP1)
1. Press and release the ‘PGM’ button momentarily, ‘SP1’ and the
current set point will be displayed.
2. Press the ▲ button to increase the set point value or the ▼ button to decrease the set point
value.
3. Press and release the ‘PGM’ button momentarily to accept the new setting
4. Press and release the ‘EXIT’ button
Page 32
ADJUSTMENT
32
To adjust the Differential (HyS1 and HyS3)
To adjust the differential it is necessary to enter the programming mode (refer to ‘To adjust
parameters’ below).
To adjust parameters
1. Press the ‘PGM’ button for 2 seconds, the display will show ‘AL’
2. Press the ‘PGM’ button again for 2 seconds. Display shows ‘C111’ and the current setting for
C111 (9000).
3. Press the ▲ button to change the value of the right hand digit.
4. Press the ▼ button to select the next digit position from right to left.
5. Press the ▲ button to change the value of the selected digit.
6. Press and release the “PGM” button to select the next parameter.
Repeat steps 3 - 6 until all parameters are set correctly. (Refer to the RWF40 PARAMETER TABLE
below)
When all parameters are set correctly press the ‘EXIT’ button to exit programming mode.
Fault Codes
In the event a fault occurs with the temperature sensor a code will be displayed on the thermostat.
Code
Fault
Upper window (red) Lower window (green)
1999 (flashing) Current set point Water temperature sensor open or short circuited
1999 (flashing) tA Outdoor compensation sensor open or short circuited
RWF40 Parameter Table
Parameter Setting Parameter Setting Parameter Setting
C111 9000 OFF 2 0
HyS1 -3
C112 0000 OFF 3 0 HyS2 0
C113 0000 DF 1
HyS3 4
SCL 0 AL 0 q 0
SCH 100 HySt 0 H 0
SCL2 0 Pb. 1 20 P 0
SCH2 0 dt 15
SP1 78
SPL 0 rt 60 SP2 0
SPH 95 db 3 Dsp 0
OFF 1 0 tt 30
Page 33
ADJUSTMENT
33
BURNER GAS PRESSURE ADJUSTMENT
On/Off Models
The burner pressure is set by adjusting the Jeavons J48 appliance regulator.
To adjust the burner pressure:
1. Fit manometer to main burner test point
2. Turn on electrical power to heater
3. Allow main burner to light
4. Remove adjustment screw cover (refer to diagram opposite)
5. To increase the burner pressure rotate the adjusting screw
clockwise, to decrease the burner pressure rotate the adjusting
screw anti-clockwise.
6. Adjust burner pressure to that indicated on the rating label.
7. Extinguish burner, refit adjustment screw cover, remove manometer
and refit test point screw.
Modulating Models
Low Gas Rate Adjustment
1. Fit manometer to main burner test point.
2. Remove the SQS37 motor drive from SKP25 actuator.
3. Light the water heater. Refer to the 'Lighting Procedure'
on page 28.
4 Adjust the low fire gas pressure to 0.3kPa (Natural Gas
Models) or 1.3kPa (propane models) by turning the
outer regulator screw on the SKP25 actuator (Refer to
diagram opposite)
High Gas Rate Adjustment
5 Press the “EXIT” button on the RWF40 controller for 5 seconds
to enter the manual mode. The red LED adjacent to the hand
symbol will illuminate.
6 Refit the SQS37 drive motor to the SKP25 actuator (Refer to
figure opposite) NOTE: The lock nut should be hand tight only
do NOT use tools
7 Drive the SQS37 motor to the high fire position by pressing the
up (▲) button until the motor cam stops turning (approximately
2 revolutions)
8 Adjust the high gas pressure to 0.92kPa (natural gas
models) or 2.75kPa (propane models) by turning the small
screw through the centre of the SQS37 drive motor (refer to
figure opposite)
9 Press the “EXIT” button for 5 seconds to re-enter the auto
mode. The red LED adjacent to the hand symbol will
extinguish.
Page 34
ADJUSTMENT
34
TEMPERATURE RISE
The correct temperature rise across the water heater heat exchanger is the result of correct pump
selection and speed, pipe sizing (refer to the section on 'Pump Selection' on page 13and good
plumbing.
The typical temperature rises for most applications will be between 10°C and 20°C.
A temperature rise of less than 10°C is indicative of excessive flow rate that can lead to erosion of the
tube bundle and/or headers. A temperature rise greater than 25°C indicates insufficient water flow
which can lead to warpage of the tube bundle and nuisance tripping of the high limit thermostat.
Damaged to the water heater caused by insufficient or excessive temperature rise across the heat
exchange is not covered by warranty.
FLOW SWITCH
Adjustment Screw
The adjustment screw alters the amount of pressure or
flow required to activate the micro-switch. To adjust the
setting:
1. Loosen the locknut
2. Turn the screw clockwise to decrease the amount of
flow required to operate the micro-switch or
anticlockwise to increase the amount of flow required
to operate the micro-switch
3. Tighten the locknut
HIGH LIMIT
The high limit thermostat senses the water temperature leaving the heat
exchanger and is typically set approximately 15°C above the controlling
thermostat ‘set’ point however for high temperature applications the setting
must not exceed
• 85°C for installations utilizing storage tanks
• 90°C for all other installations
To adjust the limit temperature:
1. Remove the front cover
2. Loosen the lock screw
3. Turn the dial until the required temperature is adjacent to the pointer
4. Tighten the lock screw
5. Refit the front cover
Lock Screw
Pointer
Page 35
ADJUSTMENT
35
AIR PRESSURE SWITCH
The air pressure switch is calibrated at the time of manufacture. The pressure switch contacts are
adjusted to close when the pressure detected at the test point is 150Pa or greater. Depending on the
installation it may be necessary to adjust the pressure switch setting.
WARNING: Under no circumstances is the pressure switch to be adjusted to cause the
contacts to close at a pressure less than 150Pa. Operation at a pressure of less than 150Pa
will cause damage to the water heater due to incomplete combustion.
If a pressure of 150Pa cannot be achieved it may be necessary to increase the fan speed from low to
medium or high. Refer to the section on ‘Fan Speed Adjustment’ on page 36.
To adjust the pressure switch
a. Remove the fan chamber top panel.
b. Remove the sealing screw from the test point in the tube between the
pressure switch and the fan (refer to figure 1 opposite).
c. Connect a digital manometer to the test point (refer to figure 2 below).
NOTE: Ensure the manometer is calibrated prior to connection.
d. Slightly loosen the union between the test point and the tube sensing
fan pressure.
e. Undo the Phillips head screw (refer to Figure 4, item 1) and remove
the cover from the pressure switch.
f. Allow the main burner to light.
The fan will be rotating during this procedure. Keep hands and
fingers will clear of the blade to prevent injury.
g. Carefully rotate the pressure tube (refer to figure 3 below) away from
the fan while observing the pressure reading on the manometer.
h. Rotate the dial (refer to figure 4, item 2) clockwise to increase the
pressure at which the contacts open or anticlockwise to decrease the
pressure at which the contacts open, the pressure setting is indicated
by the pointer (refer to figure 4, item 3). NOTE: The pressure marking
on the dial is indicative, some variance occurs due to losses in the
pressure tube.
i. Once the correct pressure setting is achieved reposition the pressure
tube to the original position and tighten the union to prevent further
movement during operation.
j. Remove manometer, refit test point screw and pressure switch cover
k. Refit top panel.
2
3
Figure 4
Figure 1
Figure 2
Figure 3
Page 36
ADJUSTMENT
36
FAN SPEED ADJUSTMENT
The fan motor has 3 possible speeds, low, medium or high. The appliance is wired for low speed at
the time of manufacture; depending on the installation it may be necessary to increase the fan speed.
To alter the fan speed
a. Isolate power to the water heater / pool heater
b. Open the control panel
c. Locate the wiring to the fan motor. (refer to picture opposite)
d. Disconnect the existing fan wire at the spade terminal and connect
the wire for the required speed (refer to the ‘Fan Speed Table’
below).
e. Insulate all unused fan connections and cable tie in a safe position.
FAN SPEED TABLE
Fan Speed Wire Colour
LOW White
MEDIUM Grey
HIGH Brown
NOTE:
Adjustment of the fan speed;
• Alters the purge period required at start up. A new submission document must be submitted to the
state gas authority detailing the revised fan speed and the new purge time calculations.
• Will require the air pressure switch opening pressure to be checked and if necessary adjusted.
Refer to the ‘Air Pressure Switch’ adjustment’ procedure on page 35.
Fan Wiring
Page 37
37
TROUBLESHOOTING
RESETTING THE WATER HEATER
If the pilot OR main burner fail to light within a prescribed time the ignition system will enter a lockout
condition, indicated by the illuminating of a RED light on the control panel.
Turning the power off and then on again will not reset this condition. To reset the water heater:
• Push the reset button for at least 1 second, the red light will extinguish and the start up sequence
will recommence (refer to the 'Lighting Procedure' page 28).
If the water heater still does not light, turn off the gas and power supplies and contact your qualified
service technician.
FAN DOES NOT OPERATE
When a call for heat occurs the fan should commence operation. If the fan does not start up check the
fan isolation switch is in the ON position (refer to 'Location Of Controls' on page 29).
If the fan still does not operate turn off the gas and power supplies and contact your qualified service
technician.
MAIN BURNER DOES NOT LIGHT
During the ignition sequence the pilot is lit and after a delay of approximately 10 seconds the main
burner is lit. Should the pilot burner light but the main burner fail to light (initiating lockout) check the
gas valve isolation switch is in the ON position ( refer to 'Location Of Controls' on page 29).
After checking the position of the gas valve isolation switch it will be necessary to reset the water
heater (refer to ‘Resetting The Water Heater’ above).
If the main burner still does not light turn off the gas and power supplies and contact your qualified
service technician.
Page 38
38
SERVICING
REPAIRS, SERVICE AND/OR COMMISSIONING OF GAS APPLIANCES MUST ONLY BE
PERFORMED BY A SUITABLY LICENSED PERSON
RECOMMENDED SERVICE PROCEDURES
It is a requirement of Raypak and all gas authorities that the heater be serviced at least once
per year. Where it is used in a specific application, e.g. mechanical heating, it would be
practical to perform the service at the commencement of the heating season, or at any time
there may be an indication of a problem.
In some installations, due to the appliance location and/or workload it may be necessary to
perform a service every six months.
Contact your nearest Rheem Service Department or Accredited Service Agent to arrange a service.
Annual Service procedure
1. Isolate gas, electricity and water as required.
2. Remove access covers and door(s) as
required.
3. Disconnect and remove Burner Tray.
4. Dismantle and clean pilot assembly(s),
including injector(s).
5. Clean and re-align electrode(s) and/or flame
rod(s) and /or thermocouple(s).
6. Clean main burner injectors and burner bars
as required.
7. Inspect, repair if minor and clean combustion
chamber.
8. Report on any major combustion chamber
damage.
9. Inspect external area of heat exchanger,
clean fins and repair if minor.
10. Check water seal area and report any
damage.
11. Operate Pressure Relief Valve manually to check that the drain is clear and the valve reseals.
12. Refit Burner Tray and reconnect gas train etc.
13. Perform gas soundness tests to the gas train (Any failures must be reported and repaired before
recommissioning appliance).
14. Check all air vents and louvres, clean as required.
15. Restore gas, electricity and water as required.
16. Recommission unit, check and prove the operation of all safety devices.
17. Check and monitor the operation of the appliance for at least ten (10) minutes.
18. Refit access covers and doors as required.
19. Clear and remove any dust and debris from the appliance and its immediate area.
Page 39
SERVICING
39
Six Monthly Service Procedure
1. Isolate gas, electricity and water as required.
2. Remove access covers and doors as required.
3. Visually inspect main burner and pilot, check operation if needed.
4. If necessary, remove Burner Tray and service as required. (Refer to Annual Service).
5. Check over the appliance thoroughly and report any damage immediately.
6. Check the heat exchanger and water seal areas and report any damage, if necessary.
7. Check air vents and louvres, clean as required.
8. Restore the gas, electricity and water as required.
9. Check operation of ignition system and all safety devices.
10. Check operation and calibration of all temperature control devices.
11. Check operation of appliance for at least ten (10) minutes.
12. Refit access covers and doors as required.
13. Clear and remove any dust and debris from the appliance and its immediate area.
FIRE TILE (REFRACTORY) HANDLING
CAUTION: Ceramic refractories are used in Raypak heaters. Please refer to the Material
Safety Data Sheet (MSDS) provided for safe handling of this insulation.
• Possible risks of irreversible effects
• Harmful by inhalation
• May be irritating to the skin, eyes and respira
tory system
When Handling
• Minimise airborne dust
• Wear an approved mask or respirator
• Avoid any contact with the skin and eyes
• Wear suitable loose-fitting. Long-sleeved clothing
• Wear gloves and eye protection
• Consult Occupational Health and Safety Authority for any further information
After Handling
• Rinse any exposed skin areas with clean water
• Wash work clothing separately
Removal of Used Product
• Wear an approved mask. Over-exposure to dust formed after service may cause respiratory
disease since cristobalite, a form of crystalline silica, may be formed above 900 degrees
Celsius.
• Consult Occupational Health and Safety Authority for further information regarding removal of
used ceramic fiber linings.
Page 40
40
RAYPAK COMMERCIAL WATER HEATER WARRANTY
Raypak Australia Pty Ltd* will:
a) repair or, if necessary, replace any Raypak water heater; or
b) replace any component (or, if necessary, arrange the installation of a new water heater),
which falls within the Warranty Periods specified below, in accordance with and subject to the following table and terms and
conditions.
Period Installation Model Warranty
Component and Heat Exchanger Warranty (From Date of Installation)
12 Months All Installations B0507 – B4224
New component, tube bundle or heat exchanger (at Raypak’s
sole discretion) free of charge, including labour**
Heat Exchanger Warranty (From Date of Installation)
Years 2 - 5 All Installations B0507 – B4224
New tube bundle or heat exchanger (at Raypak’s sole
discretion) free of charge, with installation and labour costs
being the responsibility of the owner.
Notes:
*Rheem Australia Pty Ltd provides warranty service on behalf of Raypak Australia Pty Ltd.
**Refer to item 5 of warranty conditions.
Rheem Australia Pty Ltd reserves the right to transfer fully functional components from the defective water heater to the replacement water
heater if required.
WARRANTY CONDITIONS
1. This warranty is applicable only to water heaters
manufactured from 1st June 2007.
2. The water heater must be correctly commissioned by an
authorised and licensed person and certified by the
relevant State Gas Authority.
3. The water heater must be installed in accordance with
the Raypak installation instructions, supplied with the
water heater, and in accordance with all relevant
statutory and local requirements of the State in which
the water heater is to be installed.
4. Where a failed component or water heater is replaced
under Warranty, the balance of the original warranty
period will remain effective. The replaced part or water
heater does not carry a new warranty.
5. Where the water heater is installed outside the
boundaries of a metropolitan area as defined by Rheem
Australia Pty Ltd or further than 25 km from a regional
Rheem branch office or a Rheem Accredited Service
Agent, the costs of transport, insurance and traveling
between the nearest Rheem Australia Pty Ltd
Accredited Service Agent’s premises and the installed
site shall be the owner’s responsibility.
6. The warranty only applies to the water heater and
original or genuine (company) component replacement
parts and therefore does not cover any plumbing or
electrical parts supplied by the installer and not an
integral part of the water heater, e.g. pressure limiting
valve, stop cock, non-return valve, electrical switches,
pumps, or fuse.
7. The water heater must be sized to supply the hot water
demand in accordance with the guidelines in Rheem
Water Heater literature.
WARRANTY EXCLUSIONS
1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RAYPAK WATER HEATER
WARRANTY ABOVE, BUT THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO
BECOME VOID, AND MAY INCUR A SERVICE CHARGE AND/OR COST OF PARTS.
a) Accidental damage to the water heater or any
component, including: acts of God, failure due to misuse;
incorrect installation; attempts to repair the water heater
other than by a Rheem Accredited Service Agent or Rheem
Service.
b) Where it is found there is nothing wrong with the water
heater, where the complaint is related to excessive
discharge from the pressure relief valve due to high water
pressure; where there is no flow of water due to faulty
plumbing; where water leaks are related to plumbing and
not the water heater components; where there is a failure of
gas, electricity or water supplies; where the supply of gas,
electricity or water does not comply with relevant codes or
acts.
c) Where the water heater or water heater component
failed directly as a result of; excessive water pressure,
temperature and/or thermal input; incorrect flow rate
through the heat exchanger; corrosive atmosphere.
d) Where the water heater is located in a position that
does not comply with the Raypak installation instructions or
relevant statutory requirements, causing the need for major
dismantling or removal of cupboards, doors or walls, or use
of special equipment to bring the water heater to floor level,
or to a serviceable position.
e) Repairs to the water heater due to corrosion or scale
formation in the waterways when the water heater has been
connected to a harmful water supply as outlined in the
Operating and Installation Instructions.
2. SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES ANY AND ALL
CLAIMS FOR DAMAGE TO FURNITURE, WALLS, FOUNDATIONS OR ANY OTHER CONSEQUENTIAL LOSS
EITHER DIRECTLY OR INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER.
In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner under
certain circumstances with certain minimum statutory rights in relation to your Raypak water heater. This warranty must be read
subject to that legislation and nothing in this warranty has the effect of excluding, restricting or modifying those rights.
RHEEM AUSTRALIA PTY LTD
FOR SERVICE TELEPHONE
A.B.N. 21 098 823 511
131 031 AUSTRALIA
0800 657 335 NEW ZEALAND
or refer to local Yellow Pages
NOTE: Every care has been taken to ensure accuracy in preparation of this publication. No liability can be accepted for any consequences,
which may arise as a result of its application
Page 41
41
RHEEM SERVICE 131031
WWW.RHEEM.COM.AU
Manufactured by
Raypak Australia
Ph (03) 9757 3333
Fax (03) 9757 4974
Part No. 209130.5: Effective 01/07/2007 (Replaces: 01/10/2000)
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