Raypak B1182, B1142, B0658, B1292, B1242 Owner's Manual And Installation Instructions

...

Owner’s Guide

and

Installation Instructions

Raypak Water Heaters

Models

Types

B0507

B0992

B0972

NCO, NCM PCO, PCM

B0538

B1182

B1142

B0658

B1292

B1242

B0768

B1412

B1362

B0868

B1722

B1662

B1922

B1852

B2214

B2004

B2634

B2404

B3164

B2804

B3694

B3304

B4224

B3804

This water heater must be installed and serviced by a qualified person.

Please leave this guide with a responsible officer.

Notice to Victorian Customers from the

Victorian Building Authority

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.

Warning: Upon completion of the installation and commissioning of the water heater, leave this guide with the householder or a 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.

PATENTS

This water heater may be protected by one or more patents or registered designs.

® Registered trademark of Rheem Australia Pty Ltd.

™ Trademark of Rheem Australia Pty Ltd.

Date of installation:

Model Nº:

Serial Nº:

Installed by:

Purchased from:

CONTENTS

HOUSEHOLDER OR RESPONSIBLE OFFICER – We recommend you read pages 4 to 10.

The other pages are intended for the installer but may be of interest

Contents ........................................................................................................................................................................ 3

About Your Water Heater ............................................................................................................................................. 4

How Your Water Heater Works .................................................................................................................................... 7

Save A Service Call ...................................................................................................................................................... 8

Regular Care............................................................................................................................................................... 10

Installation ................................................................................................................................................................... 11

Connections – Plumbing ............................................................................................................................................. 15

Connections – Electrical ............................................................................................................................................. 24

Location Of Controls ................................................................................................................................................... 34

Safety Precautions ...................................................................................................................................................... 35

Commissioning ........................................................................................................................................................... 36

Operating The Water Heater ...................................................................................................................................... 39

Component Checks & Adjustment Procedures .......................................................................................................... 40

Temperature Control ................................................................................................................................................... 43

Service Procedures .................................................................................................................................................... 50

Water Supplies............................................................................................................................................................ 51

Dimensions and Technical Data ................................................................................................................................. 52

Warranty ..................................................................................................................................................................... 56

ABOUT YOUR WATER HEATER

WATER HEATER APPLICATION

This water heater is designed for the purpose of heating potable water or hydronic heating applications. Its use in an application other than this may shorten its life.

MODEL TYPE

Congratulations for choosing a Raypak® water heater. Raypak water heaters are suitable for either indoor or outdoor installation depending on the model chosen.

The operation of the water heater depends on the application. Typically for hot water applications a water heater with „On/Off‟ operation will be installed. For mechanical heating or process applications a water heater with „modulating‟ operation will be installed.

HOW HOT SHOULD THE WATER BE?

The water heater features an adjustable electronic thermostat, which allows the most suitable temperature for the application to be chosen.

To meet the requirements of the National Plumbing Standard the temperature of the stored water for hot water applications must not be below 60°C.

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 be required by regulations that an approved temperature limiting device be fitted into the hot water piping to the bathroom and ensuite when this water heater is installed. This will keep the water temperature below 50C at the bathroom and ensuite. The risk of scald injury will be reduced whilst still allowing hotter water to the kitchen and laundry.

TEMPERATURE ADJUSTMENT

The electronic thermostat temperature will have been set by the installer to suit the application, adjustment should not be required. Consult your installer before making any adjustment to the electronic thermostat settings.

GENERAL WARNINGS

Warning: This water heater is only intended to be operated by persons who have the experience or the knowledge and the capabilities to do so. This water heater is not intended to be operated by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge.

Warning: Children should be supervised to ensure they do not interfere with the water heater.

Warning: The water heater uses 240 Volt AC electrical power for operation of the control systems. The removal

of the access cover(s) will expose 240 V wiring. Covers must only be removed by an authorised or qualified person.

HOT WATER INSTALLATIONS

Minimum recommended stored

water temperature

HOT WATER INSTALLATIONS

Maximum recommended

supply temperature to

bathrooms and ensuites

ABOUT YOUR WATER HEATER

SAFETY

For your safety do not operate this water heater before reading this instruction booklet. This water heater is supplied with an electronic thermostat, high limit thermostat and a 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.

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For assistance or additional information consult your Raypak distributor, qualified installer, or Rheem® Service agent.

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.

 DO NOT store flammable or combustible materials near the water heater.

Flammable liquids (such as petrol), newspapers and similar articles must be kept well away from the water heater and the draught diverter or flue terminal.

 DO NOT use aerosols, stain removers and household chemicals near the

water heater whilst it is working. Gases from some aerosol sprays, stain removers and household chemicals become corrosive when drawn into a flame.

 DO NOT store swimming pool chemicals, household cleaners, etc., near

the water heater.

 DO NOT place anything on top of the water heater or in contact with the flue

terminal. Ensure the flue terminal is not obstructed in any way at any time.

 DO NOT use Propane / Butane gas mixtures in a Propane model. A Propane model is designed to operate on

Propane only. The use of Propane / Butane mixture, such as automotive LPG fuel, in a Propane model is unsafe and can cause damage to the water heater.

 DO NOT operate with panels, covers or guards removed from the water heater.  DO NOT enclose this water heater (applies to external installations only).

Do not use the water heater if any part has been under water. Immediately call Rheem Service or Accredited service Agent to arrange for an inspection.

TO TURN ON THE WATER HEATER

Warning: If you smell gas do not attempt to turn on the water heater.

 Fill the system with water (refer to “To Fill the Water Heater” on page 39).  Open the gas isolation valve fully at the inlet to the water heater.  Switch on the electrical supply at the water heaters isolation switch. NOTE: If the water heater is correctly

installed, this will also activate the circulating pump.

The water heater will operate automatically when a call for heat occurs.

WHAT TO DO IF YOU SMELL GAS?

 DO NOT try to light any gas appliance.  DO NOT touch any electrical switch.  TURN OFF the gas supply at the gas meter immediately, call your gas supplier or licensed gasfitter.

NOTE: Some gases are heavier than air and it may be necessary to check for gas leaks at floor level.

TO TURN OFF THE WATER HEATER

If it is necessary to turn off the water heater:  Switch off the electrical supply at the water heaters isolation switch. NOTE: If the water heater is correctly

installed, this will also shut down the circulating pump.

 Close the gas isolation valve at the inlet to the water heater.  Close the cold water isolation valve at the inlet to the water heater.  Close the isolation valves on the cold and hot water branches to shut down an individual water heater in a

bank (water heating applications only).

ABOUT YOUR WATER HEATER

HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?

Installation requirements are detailed in the “Installation” section on pages 11 to 15. The water heater must be installed:

 by a qualified person, and  in accordance with the installation instructions, and  in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local

regulations, and all local codes and regulatory authority requirements.

 In New Zealand, the installation must also conform with NZS 5261, as applicable under local regulations, and

the New Zealand Building Code.

DOES THE WATER CHEMISTRY AFFECT THE WATER HEATER?

The water heater is suitable for most public water supplies, however some water chemistries may have detrimental effects on the water heater, its components and fittings. Refer to “Water Supplies” on page 51.

If you are in a known harsh water area or you are not sure of your water chemistry, have your water checked against the conditions described on page 51.

HOW LONG WILL THE WATER HEATER LAST?

The water heater is supported by a manufacturer‟s warranty (refer to “Warranty” on page 56). There are a number of factors that will affect the length of service the water heater will provide. These include but are not limited to the water chemistry, the water pressure, the water temperature (inlet and outlet) and the water usage pattern. Refer to

“Precautions” on page 6.

PRECAUTIONS

Where damage to property can occur in the event of the water heater leaking, the water heater must be installed in a safe tray. Construction, installation and draining of a safe tray must comply with AS/NZS 3500.4 and all local codes and regulatory authority requirements.

The water heater must be maintained in accordance with the Owner‟s Guide and Installation Instructions. Refer to

“Regular Care” on page 10.

If this water heater is to be used where an uninterrupted hot water supply is necessary for your application or business you should ensure that you have redundancy within the hot water system design. This should ensure the continuity of hot water supply in the event that this water heater was to become inoperable for any reason. We recommend you seek advice from your plumber or specifier about your needs and building redundancy into your hot water supply system.

SERVICING

For peak performance it is suggested that the water heater be serviced by your nearest Rheem Service Department or Accredited Service Agent prior to the winter period where light to medium hot water usage occurs, and six monthly where medium to heavy usage occurs (refer to “Regular Care” on page 10).

Warning: Servicing of a gas water heater must only be carried out by authorised personnel.

HOW YOUR WATER HEATER WORKS

The water heater consists of a gas burner, a combustion chamber lined with refractory tiles and a heat exchanger made of finned copper tubes. Hot flue gases from the burner pass between the fins on the heat exchanger tubes and heat is transferred first to the fins and then by conduction into the water. Baffles are placed between the tubes to control the flow of the hot flue gases to ensure efficient operation of the water heater. The refractory tiles insulate the combustion chamber to minimise heat loss and protect the surroundings from the temperature of the burner flames. The gas supply to the burner is controlled by an electronic thermostat which senses the water temperature.

Automatic safety controls are fitted to the water heater:

 to ensure safe ignition of the gas whenever there is a call for heating;  to continuously monitor the burner flame; and  to prevent excessive temperatures or pressures in the water system.

MAINS PRESSURE

In water heating applications, the water heater is designed to operate in conjunction with one or more hot water storage tanks which are normally connected directly to the mains water supply. If the mains water supply pressure in your area exceeds the value shown in the “Pressure Specifications” table on page 14 or exceeds the specified maximum inlet pressure for the storage tanks, a pressure limiting valve must be fitted.

In mechanical and process heating applications, the system pressure must not exceed the value shown in the

“Pressure Specifications” table on page 14.

ELECTRONIC THERMOSTAT (ON/OFF MODELS)

On/Off models are fitted with an IC902 electronic thermostat that operates the gas control by switching its power on and off so that a constant temperature is maintained. The electronic thermostat is mounted on the control panel of the water heater and the protective over temperature cut out (high limit thermostat) is mounted inside the lower front cover of the water heater.

There is no need to switch the water heater off when it is not in use. The electronic thermostat is fully automatic and only allows the gas control to open when the burner requires gas for heating.

The electronic thermostat has a number of parameters that are programmed during manufacture. To adjust the parameter settings refer to “Temperature Adjustment – On/Off Models (IC902 Electronic Thermostat)” on page 43.

Warning: Advice should be sought from your local Raypak representative prior to altering any electronic thermostat values other than the set point or differential.

ELECTRONIC THERMOSTAT (MODULATING MODELS)

Water heaters with modulating operation are fitted with an RWF55 electronic thermostat. The electronic thermostat is mounted on the control panel of the water heater and the protective over temperature cut out (high limit thermostat) is mounted inside the lower front cover of the water heater. This type of thermostat is used where the system load is variable e.g. Mechanical Heating. The RWF55 electronic thermostat will cycle the burner from full fire to 30% and then off.

There is no need to switch the water heater off when it is not in use. The electronic thermostat is fully automatic and only allows the gas control to open when the burner requires gas for heating.

The electronic thermostat has a number of parameters that are programmed during manufacture. To adjust the parameter settings refer to “Temperature Adjustment – Modulating Models (RWF55 Electronic Thermostat)” on page 46.

Warning: Advice should be sort from your local Raypak representative prior to altering any electronic

thermostat parameters other than the set point or differentials.

BURNER IGNITION

The water heater incorporates an automatic burner ignition system and an automatic pilot burner. The pilot burner ignites the main burner gas when the electronic thermostat determines a need for heating.

Both On/Off and modulating models have a spark generator that begins operating when power is applied and any external controls (if installed) call for the water heater to operate. At the same time a valve opens to supply gas to the pilot burner. After successful ignition of the pilot flame has been detected, the valves open to supply gas to the main burner when the electronic thermostat determines that a call for heating is required. If the pilot fails to ignite within 5 seconds, the ignition system will lock out.

SAVE A SERVICE CALL

Check the items below before making a service call. You will be charged for attending to any condition or fault that is not related to manufacture or failure of a part.

NOT ENOUGH HOT WATER (OR NO HOT WATER)

 Is the electricity switched on?

Inspect the isolation switch adjacent to the water heater and ensure the isolation switch is turned on.

 Is there a time clock on the power supply?

Check the settings on the time clock to ensure they are suitable to enable heating when required.

 Is the ignition system ‘locked out’?

Reset the water heater. Refer to “Water Heater Not Operating” on page 8.

 Is a code displayed on the electronic thermostat?

Check the LED display on the electronic thermostat (refer to the diagnostic features for the relevant electronic thermostat installed as detailed on page 8).

 Are you using more hot water than you think?

Are outlets (especially the showers) using more hot water than you think? Very often it is not realised the amount of hot water used, particularly when showering. Carefully review the hot water usage. Have your plumber fit a flow control valve to each shower outlet to reduce water usage.

 Pressure relief valve running

Is the relief valve discharging too much water? (Refer to “Pressure Relief Valve Running” on page 9).

 Electronic thermostat temperature setting

Ensure the electronic thermostat temperature setting (set point) is appropriate. You may choose to have your installer adjust the temperature setting upwards to gain additional hot water capacity.

Warning: Hotter water increases the risk of scald injury.

 Water heater size

Do you have the correct size water heater for your requirements? The sizing guide in the Raypak sales literature and on the Rheem website (www.rheem.com.au) suggests average sizes that may be needed.

WATER HEATER NOT OPERATING

If the system water temperature is abnormally low, the ignition system may have „locked out‟. A lockout condition is indicated by the reset button being illuminated. If this occurs, the ignition system can be reset as follows:

 Wait five (5) minutes for unburnt gas to escape which may be present from a previous failed ignition attempt.  Press and hold the reset button for approximately 1 second (the reset button light should extinguish).

If the water heater still fails to operate, call your nearest Rheem Service Department or Accredited Service Agent to arrange for an inspection.

DIAGNOSTIC FEATURES OF IC902 ELECTRONIC THERMOSTAT

On/Off models incorporate an IC902 electronic thermostat. In the event of a temperature sensor fault occurring, a code will be shown on the thermostat display to diagnose the fault.

Code

Fault

Water temperature sensor open or short circuited

DIAGNOSTIC FEATURES OF RWF55 ELECTRONIC THERMOSTAT

Modulating models incorporate an RWF55 electronic thermostat. In the event of a temperature sensor fault occurring, a code will be shown on the thermostat display to diagnose the fault.

Upper window (red)

Lower window (green)

Fault

9999 (flashing)

Current set point

Water temperature sensor open circuited

-1999 (flashing)

Current set point

Water temperature sensor short circuited

9999 (flashing)

Outdoor compensation temp sensor open circuited

-1999 (flashing)

Outdoor compensation temp sensor short circuited

SAVE A SERVICE CALL

BURNER WILL NOT LIGHT

 Is there gas to the water heater?

Check the gas isolation valve on the gas supply line is open.

 Is there a normal gas supply to the rest of the premises?

Try lighting another gas appliance. If there is no gas call your gas provider.

 Is the ignition system ‘locked out’?

Try resetting the water heater. Refer to “Water Heater Not Operating” on page 8.

 Has the High Limit Thermostat tripped?

The manual reset protective over temperature cut out (high limit thermostat) will shut down the water heater in the event of a fault with the temperature control or water flow. When the system water temperature has cooled sufficiently, the high limit reset lever can be operated to restart the water heater (refer to “High Limit

Thermostat” on page 34). Should frequent resetting be necessary, call your nearest Rheem Service

Department or Accredited Service Agent.

PRESSURE RELIEF VALVE RUNNING

 Normal Operation

It is normal and desirable that the pressure relief valve allows a small quantity of water to escape during the heating cycle. However, if the discharge is deemed excessive (more than 2% of hot water used), there may be another problem.

 Continuous dribble

Try gently raising the easing lever on the pressure relief valve for a few seconds (refer to “Pressure Relief

Valve” on page 10). This may dislodge a small particle of foreign matter and clear the fault. Release the lever

gently.

 Steady flows for long period (often at night)

This may indicate the mains water pressure sometimes rises above the designed pressure of the water heater. Ask your installing plumber to fit a pressure limiting valve.

Warning: Never replace the pressure relief valve with one of a pressure rating greater than 850 kPa.

EXPANSION CONTROL VALVE RUNNING

If an expansion control valve is fitted in the cold water line to the water heater (refer to “Cold Water Connection

Plumbing Diagram” on page 15) it may discharge a small quantity of water instead of the pressure relief valve on

the water heater. The benefit is that energy is conserved as the discharged water is cooler.

HIGH GAS BILLS

Should you at any time feel your gas account is too high, we suggest you check the following points: Is the relief valve running excessively? (Refer to “Pressure Relief Valve Running” on page 9). Are outlets (especially the showers) using more hot water than you think? (Refer to

“Not Enough Hot Water” on page 8).

Is there a leaking hot water pipe, dripping hot water tap, etc? Even a small leak will waste a surprising quantity of hot water and gas. Replace faulty tap washers, and have your plumber rectify any leaking pipe work.

Consider recent changes to your hot water usage pattern and check if there has been any increase in tariffs since your previous account.

Is there excessive heat loss from the building? Check that there are no large uncovered windows or excessive draughts and that ceiling insulation is installed. Hot water piping should be well lagged (insulated) to reduce heat loss.

IF YOU HAVE CHECKED ALL THE FOREGOING AND STILL BELIEVE YOU NEED ASSISTANCE, PHONE YOUR NEAREST RHEEM SERVICE DEPARTMENT OR ACCREDITED SERVICE AGENT

REGULAR CARE

PRESSURE RELIEF VALVE

The pressure relief valve is located in the in/out header of the water heater and is essential for its safe operation. It is possible for the pressure relief valve to release a little water through the drain line during each heating period. This occurs as the water is heated and expands by approximately 1/50 of its volume.

Continuous leakage of water from the pressure relief valve and its drain line may indicate a problem with the water heater (refer to “Pressure Relief Valve Running” on page 9).

Warning: Never block the outlet of the pressure relief valve or its drain line for any reason. Operate the easing lever on the pressure relief valve once every six months. It is very important you raise and

lower the lever gently.

Warning: Failure to do this may result in the water heater cylinder failing.

Warning: Exercise care to avoid any splashing of water, as water discharged from the drain line will be hot. Stand clear of the drain line‟s point of discharge when operating the valve‟s lever.

If water does not flow freely from the drain line when the lever is lifted, then the water heater must be checked; phone Rheem Service or their nearest Accredited Service Agent to arrange for an inspection.

The pressure relief valve should be checked for performance or replaced at intervals not exceeding 5 years, or more frequently in areas where there is a high incidence of water deposits (refer to “Water Supplies” on page 51).

EXPANSION CONTROL VALVE

In many areas, including South Australia, Western Australia and scaling water areas, an expansion control valve is fitted to the cold water line to the water heating system. The expansion control valve may discharge a small quantity of water from its drain line during the heating period instead of the pressure relief valve on the water heater.

Operate the easing lever on the expansion control valve once every six months. It is very important you raise and lower the lever gently. The expansion control valve should be replaced for performance or replaced at intervals not exceeding 5 years, or more frequently in areas where there is a high incidence of water deposits.

STORAGE TANKS (IF FITTED)

Refer to the owners guide and installation instructions supplied with the storage tank for details on regular care required.

SERVICING

Warning: Servicing of a gas water heater must only be carried out by authorised personnel.

If Servicing is performed once a year, conduct the “Annual Service Procedure”. If servicing is performed at six monthly intervals, rotate between the “Annual Service Procedure” and “Six Monthly Service Procedure”

Only genuine replacement parts should be used on this water heater. Six Monthly Service Refer to “Service Procedures” on page 50. Annual Service Refer to “Service Procedures” on page 50. Five Year Service Refer to “Service Procedures” on page 50.

INSTALLATION

THIS WATER HEATER IS NOT SUITABLE FOR DIRECT POOL HEATING

INSTALLATION STANDARDS

The water heater must be installed:

 by a qualified person, and  in accordance with the installation instructions, and  in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local

regulations, and all local codes and regulatory authority requirements.

 In New Zealand the installation must also conform with NZS 5261, as applicable under local regulations, and

the New Zealand Building Code.

PACKAGING AND INSTALLATION KIT

All packaging materials must be removed from the water heater prior to its installation. This includes the removal of the shipping pallet.

The installation kit (including the pressure relief valve and flow switch) may be supplied inside the water heater casing. These kits must be removed and the components installed before the water heater is operated.

WATER HEATER APPLICATION

This water heater is designed for the purpose of heating potable water or hydronic heating applications. Its use in an application other than this may shorten its life.

If this water heater is to be used where an uninterrupted hot water supply is necessary for the application or business, then there should be redundancy within the hot water system design. This should ensure the continuity of hot water supply in the event that this water heater was to become inoperable for any reason. We recommend you provide advice to the system owner about their needs and building backup redundancy into the hot water supply system.

Check the water heater is suitable for the gas type available. The gas type is marked on the side panel near the gas connection entry and is also shown on the water heaters rating label.

READ THESE INSTRUCTIONS IN FULL

INSPECTION OF EQUIPMENT

Check the water heater and associated equipment for any damage. DO NOT INSTALL OR OPERATE ANY WATER HEATER THAT HAS BEEN DAMAGED. ANY ADDITIONAL DAMAGE OR FAULTS CAUSED BY UNAUTHORISED START UP MAY NOT BE COVERED BY WARRANTY.

WATER HEATER LOCATION

This water heater is supplied for outdoor or indoor installation only (depending on the model). Whether located outdoor or indoor, the position of the water heater should be 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 entire front panel and burner assembly can be removed for service. Remember you may have to remove the entire water heater later for servicing.

You must be able to read the information on the rating label. The installation must comply with these installation instructions and with the requirements of AS/NZS 3500.4,

AS/NZS 3000, AS/NZS 5601 or AS/NZS 5601.1, AS 3814 and all local codes and regulatory authority requirements. 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.

The water heater must not be installed in an area with a corrosive atmosphere where chemicals are stored or where aerosol propellants are released. Remember the air may be safe to breathe, but when it goes through a flame, chemical changes take place which may attack the water heater.

INSTALLATION

The water heater must be mounted on a level fire proof base such as a concrete slab, concrete plinth, steel plate etc. Water heaters must NOT be installed on carpeting.

The front of the water heater must not be obstructed by any gas or water piping, electrical conduits, etc.

SAFE TRAY

FIRE RESISTANT MATERIALS

Fire resistant materials should comply with the requirements of AS 5601 or AS/NZS 5601.1 Appendix C. If in doubt, seek advice from your material supplier or your local regulator.

CLEARANCES

The distances set out in the following table should be observed.

Minimum Clearances from:

Non Combustible materials (mm)

Combustible Materials (mm)

507 - 1922

2004 - 4224

507 - 1922

2004 - 4224

Rear

150

300

600

Water Side

600

Front

750

1200

750

1200

Non Water Side

600

Ceiling

1200

Note: For External units . If the unit is to be installed in front of wall, ESV inspectors will require the outer rim of the cowl to be 1 metre from the wall.

The normal water heater design is with the water pipe entry from the left hand side. For servicing purposes allow the required clearance as shown in the table in front of the water heater for burner tray removal.

INDOOR INSTALLATION

The correct draught diverter must be fixed to the top of the water heater (models 507 – 1922) and connected to a properly constructed flue to discharge the combustion products outside the building. The flue must be self supporting and not impose a load on the water heater. Use a slip joint or similar to allow for disconnection and to enable the water heater top panel and/or draught diverter to be removed for servicing. There must be a vertical rise of 600 mm from the draught diverter before changing direction. The flue design and installation must comply with AS/NZS 5601 or AS/NZS 5601.1.

NOTE: Reduction of the flue diameter or alteration to the draught diverter may void the water heater warranty.

The water heater is to be installed at ground or floor level and must stand vertically upright. There are also special requirements in AS 5601 or AS/NZS

5601.1 for water heaters installed in a garage, an enclosed space or other locations. Remember all local authorities have regulations about putting water heaters into roof spaces.

INSTALLATION

COMBUSTION / VENTILATION AIR

Indoor model water heaters must be installed in a protective enclosure or properly constructed plant room with adequate ventilation in accordance with AS 5601 or AS/NZS 5601.1.

Ideally ventilation shall be via two permanent openings DIRECTLY to outside, one at an upper level and one at low level. Refer to AS 5601 or AS/NZS 5601.1 for ventilation requirements and calculations.

NOTE: The minimum dimension of any opening shall be 6 mm.

Warning: Air supply to the area where the water heater is installed must not be affected by mechanical exhaust

vents such as kitchen or bathroom fans, spa blowers, etc. Mechanical exhaust vents may create a negative pressure in the area where the water heater is installed and can become a hazard by causing asphyxiation, explosion or fire.

OUTDOOR INSTALLATION

The normal water heater design is with the water pipe entry from the left hand side. For servicing purposes allow the required clearance in front of the water heater for burner tray removal (refer to “„Clearances” on page 12). The water heater must NOT be installed inside any roofed structure or under eaves, roof overhangs, or pool decks.

When installing the water heater on a raised base, the base material MUST be solid and filled in a distance of 1 metre all around the water heater (e.g. if steel mesh decking is used, a suitable plate material must be installed to fill in the perforations) to prevent excessive drafts entering the water heater from underneath.

The following distances extracted from the Australian Gas Installations Standard AS/NZS 5601 or AS/NZS 5601.1 must be observed:

 At least 500 mm between the top of the flue terminal and the eaves.  At least 1 500 mm horizontally between the flue terminal and the edge of any opening into the building,

measured horizontally.

 At least 500 mm between the flue terminal and a return wall or external corner, measured horizontally along the

wall.

 At least 1 500 mm below any openable window.  At least 500 mm between the flue terminal and a fence, wall or other obstruction facing the terminal.

HIGH WIND CONDITIONS

In areas where high winds occur, it may be necessary to:  Locate the water heater a minimum of one (1) metre

away from high vertical walls.

 Install a wind break to protect the water heater from

the prevailing winds.

 Replace the standard flue terminal with a HIGH WIND

top (at extra cost).

COLD WATER SUPPLY

Water Heating Applications

Where the cold water supply pressure exceeds that shown in the “Pressure Specifications” table on page 14, an approved pressure limiting valve is required and should be fitted as shown in the “Cold Water Connection Plumbing

Diagram” on page 15.

Mechanical/Process Heating Applications

A cold water feed regulator (Pressure Reducing Valve) should be installed on the cold water make up line. The minimum water pressure should be as shown in the “Pressure Specifications” table on page 14. Backflow prevention in accordance with AS/NZS 3500.1 may be required.

INSTALLATION

Pressure Specifications

Operation Type

On/Off

Modulating

Relief Valve Setting

Water Heating (kPa)

850 (700)¹

850 (700)¹ ³

Mechanical Heating (kPa)

415

Expansion Control Valve (ECV²) Setting

Water Heating (kPa)

700 (550)¹

700 (550)¹ ³

Mechanical Heating (kPa)

Minimum Supply Pressure

System water temperatures up to 65°C (kPa)

System water temperatures above 65°C (kPa)

120

Maximum Supply Pressure

with ECV² fitted

Water Heating (kPa)

680 (550)¹

680 (550)¹ ³

Mechanical Heating (kPa)

330

without ECV² fitted

Water Heating (kPa)

550 (450)¹

550 (450)¹ ³

Mechanical Heating (kPa)

¹ Figures in brackets are to be used if a Wilson stainless steel storage tank is utilised in the system. ² Expansion control valve is not supplied with the water heater. ³ An 850 kPa relief valve can be fitted to modulating water heaters when used in water heating applications.

TANK WATER SUPPLY

If the water heater is supplied with water from a tank supply and a pressure pump system is not installed, then the height to the bottom of the supply tank must be as specified in the table shown opposite.

HOT WATER DELIVERY (WATER HEATING APPLICATIONS)

This water heater can deliver water at temperatures which can cause scalding. It is necessary and we recommend that a temperature limiting device be fitted between the water heating system

and the hot water outlets in any ablution and public areas such as bathrooms, ensuites or public amenities, to reduce the risk of scalding. The installing plumber may have a legal obligation to ensure the installation of this water heater meets the delivery water temperature requirements of AS/NZS 3500.4 so that scalding water temperatures are not delivered to a bathroom, ensuite, or other ablution or public area.

Where a temperature limiting device is installed adjacent to the hot water storage tanks, the cold water line to the temperature limiting device can be branched off the cold water line either before or after the isolation valve, pressure limiting valve and non return valve to the storage tanks. If an expansion control valve is required, it must always be installed after the non return valve and be the last valve prior to the water heating system.

If a pressure limiting valve is installed on the cold water line to the water heating system and the cold water line to a temperature limiting device branches off before this valve or from another cold water line in the premises, then a pressure limiting valve of an equal pressure setting may be required prior to the temperature limiting device.

REDUCING HEAT LOSSES (WATER HEATING APPLICATIONS)

The cold water line to and the hot water line from the storage cylinder must be insulated in accordance with the requirements of AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if exposed.

Keep temperature settings down. Lower temperatures reduce heat losses and prolong storage cylinder life. Do not set the electronic thermostat set point above 70°C unless it is necessary. A time clock to control the electrical supply can be used to switch off the water heater during hours or days when it is not in use.

Energy consumption can be reduced by installing a remote thermostat and Economaster run on timer (supplied separately) to turn off the primary circulating pump after a short period of time when heating has been satisfied.

Minimum Tank Height

System water temperatures up to 65°C

7 metres

System water temperatures above 65°C

12 metres

CONNECTIONS – PLUMBING

IMPORTANT: When installing a new water heater to an old or existing system, it is a requirement that the system and its equipment be thoroughly inspected and if necessary, drained and flushed with clean fresh water, before the new water heater is connected. Failure to do this may cause blockages and/or damage to the water heater which is not covered by warranty.

IF THERE IS ANY DOUBT ABOUT THE SYSTEM, DRAIN AND FLUSH AS A PRECAUTION.

CONNECTION SIZES

Model

507

538

658

768

868

Inlet/Outlet Water

RP1½/40

RC2½/65

Relief Valve

RC¾/20

Gas (Natural On/Off)

R1/25

R1½/40

(Natural Modulating)

R1/25

R1½/40

Gas (Propane On/Off)

R1/25

R1¼/32

(Propane Modulating)

R¾/20

Model

972/992

1142/1182

1242/1292

1362/1412

1662/1722

1852/1922

Inlet/Outlet Water

RC2½ 65

Relief Valve

On/Off Models

RC¾/20

Modulating Models

RC¾/20

RC1/25

Gas (Natural On/Off)

R1½/40

R2/50

(Natural Modulating)

R1½/40

R2/50

Gas (Propane On/Off)

R1¼/32

R1½/40

(Propane Modulating)

R¾/20

R1/25

R1½/40

Model

2004/2214

2404/2634

2804/3164

3304/3694

3804/4224

Inlet/Outlet Water

R3/80

Relief Valve

On/Off Models

RC¾/20

RC1/25

Modulating Models

RC1¼/32

RC1½/40

Gas (Natural On/Off)

R2/50

R2½/65

R3/80

(Natural Modulating)

R2/50

R2½/65

R3/80

Gas (Propane On/Off)

R1½/40

(Propane Modulating)

R1½/40

All plumbing work must be carried out by a qualified person and in accordance with the National Plumbing Standard AS/NZS 3500.4 and local authority requirements.

All gas work must be carried out by a qualified person and in accordance with the Australian Gas Installations Standard AS 5601 or AS/NZS 5601.1, AS3814 and local authority requirements.

WATER INLET AND OUTLET

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 other fittings.

An isolation valve and non return valve must be installed on the cold water line to the water heating system. An acceptable arrangement is shown in the diagram opposite for a water heating application.

A disconnection union must always be provided at the inlet and outlet on the water heater to allow for disconnection of the water heater.

Do not reduce the pipe work size and water heater water connections without allowing for friction loss which will occur. Low water flow will cause damage to the water heater and system components.

CONNECTIONS – PLUMBING

PIPE SIZES

The pipe sizing for water heating and mechanical heating systems should be carried out by persons competent to do so, choosing the most suitable pipe size for each individual application. Reference to the technical specifications of the water heater and local regulatory authority requirements must be made.

The table below provides indicative pipe and pump sizes between Raypak unit/s and storage tank/s for typical

water heating installations using storage tanks (DHW).

PUMP SELECTION AND PIPE SIZE

Model

Pump

Branch Size

Minimum Manifold Header

Size Required (mm)

UPS

Series

Speed

TP Series

inches

Unit

Units

507

32-80N 3

1¼

538

32-80N 3

1¼

658

32-80N 3

1½

768

32-80N

50-30/4FB

100

40-60/2B 2

1½

868

32-80N 3

2½

100

125

150

40-60/2B

50-30/4FB

100

972/992

40-60/2B

50-60/FB

100

1142/1182

40-60/2B

50-60/FB

2½

100

1242/1292

40-60/2B

50-60/FB

2½

100

1362/1412

50-120FB

50-60/FB

2½

100

1662/1722

50-120FB

80-120FB

2½

100

125

1852/1922

50-120FB

80-120FB

2½

100

125

2004/2214

50-120FB

80-120FB

100

125

2404/2634

80-120FB

100

125

150

2804/3164

80-120FB

100

150

3304/3694

80-120FB

100

125

150

3804/4224

80-120FB

100

125

150

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 “Water Flow Rate and Pressure Drop” table on page 17 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

“Water Flow Rate and Pressure Drop” table.

Where the water flow rate exceeds the maximum shown in the “Water

Flow Rate and Pressure Drop” table, a bypass with a balancing valve must be installed to reduce the water flow

through the water heater (refer to diagram above). For pump sizing where the water heating system incorporates Rheem storage tanks, refer to the “Pump Selection

and Pipe Size” table on page 16.

CONNECTIONS – PLUMBING

WATER FLOW RATE AND PRESSURE DROP

10°C Rise

15°C Rise

20°C Rise

Model

l/sec

kPa

l/sec

kPa

l/sec

kPa

507

2.75

1.83

1.37 5 538

2.87 6 1.91

1.43

658

3.58

2.39

1.79

768

4.06

2.71

2.03

868

4.66

3.11

2.33

972

5.26

3.5

2.63

992

5.38

3.58

2.69

1142

6.09

4.06

3.05

1182

6.31

4.22

3.17

1242

6.31

4.38

3.28

1292

6.31

4.54

3.4

1362

6.31

4.78

3.58

1412

6.31

5.02

3.76

1662

6.31

5.68

4.42

1722

6.31

5.68

5.54

1852

6.31

5.68

4.9

1922

6.31

5.68

5.14

2004

10.63

7.09

5.32

2214

12.06

8.04

6.03

2404

12.62

8.44

6.33

2634

12.62

9.56

7.17

2804

12.62

9.95

7.47

3164

12.62

11.47

8.6

3304

12.62

11.79

8.84

3694

12.62

10.03

3804

12.62

10.09

4224

12.62

11.47

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 thermostat. A run on timer is available as an optional kit (Rheem part No 56076874).

Minimum Pump Inlet Pressure

Circulating pumps require a minimum inlet pressure in order to operate without cavitation. For the minimum pressure requirements for Grundfos UPS series pumps, refer to the “Minimum Pressure Requirements for

Grundfos Series Pumps” table on page 18. Minimum pressure requirements for TP series pumps depend on

system characteristics and need to be calculated. Contact your pump supplier for more information.

CONNECTIONS – PLUMBING

MINIMUM PRESSURE REQUIREMENTS FOR GRUNDFOS UPS SERIES PUMPS

Pump

Models

Minimum Inlet Head Required at Operating

Temperature (m)

75°C

80°C

85°C

90°C

95°C

UPS32-80N

507,538,658,768,868

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

UPS50-120FB

1362,1412,1662,1722,1852,1922,2004,2214

4.0

5.0

6.0

7.0

9.0

UPS80-120FB

2404,2634,2804,3164,3304,3694,3804,4224

16.0

17.0

18.0

19.0

20.5

WATER HEATING

Where the water heater is supplied as part of a package, including the storage cylinder and pump, the installation must comply with the drawing provided. Failure to observe this requirement may result in ineffective hot water capacity or damage.

GAS INLET

The pipe work must be cleared of foreign matter before connection and purged at the union to the gas control or pressure regulator before attempting to light the water heater. If this procedure is not performed, a flame failure lockout may result on initial start up.

An isolation valve and disconnection union must be installed to allow servicing and removal of the water heater. Refer to AS/NZS 5601 or AS/NZS 5601.1 for the correct pipe sizing.

Warning: Before pressure testing the gas supply system always isolate and disconnect the water heater after the isolating cock to prevent the risk of serious damage to the gas control or pressure regulator. Warranty does not cover damage of any nature resulting from failure to observe this precaution. Refer to the water heaters 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 to test for gas leaks. DANGER! Do not use an open flame to check for gas leaks.

CAUTION: Care is necessary when tightening fittings into the gas control or pressure regulator. The gas control or pressure regulator casting may crack if the fittings are over tightened. Cracked castings are not covered under warranty. Damaged gas controls and pressure regulators must be replaced.

COLD WATER SUPPLY / MAKEUP

Mechanical, Hydronic and Process Heating Applications

The pressure of the makeup 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 60 PSI relief valve, the maximum supply pressure setting must not exceed 330 kPa. The minimum inlet pressure is dependent 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 “Cold Water Connection Plumbing Diagram” on page 15.

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.

The cold water supply pressure must be sufficient to provide adequate flow at the fixtures.

+ 39 hidden pages

Raypak B1182, B1142, B0658, B1292, B1242 Owner's Manual And Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual