Raypak WH-0090A Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Catalog No. 3000.50G Effective: 04-08-09 Replaces: 05-06-08 P/N 240687 Rev. 8

This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.

Models 0090A, 0135A

& 0195A – Type WH

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

WARNING: If the information in these instructions is not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.

Installation and service must be performed by a qualified installer, service agency or
the gas supplier.

Econopak
Water
Heaters

2

Rev. 8 reflects the following: Changes to: Paragraph 3 of the GENERAL SPECIFICATIONS section on page 6; Fig. 7 on
page 12; the Wiring Diagrams on pages 14 and 15; Fig. 8 on page 16; Fig. 12 on page 19; Fig. 15 on page 20; the TROU-
BLESHOOTING chart on page 23. The addition of: A note to Fig. 2 on page 7.

WARNINGS 4

Pay Attention to These Terms 4

GENERAL SAFETY 5

Time/Temperature Relationships in Scalds 5

RECEIVING EQUIPMENT 6
GENERAL SPECIFICATIONS 6
INSTALLATION 8

Code Requirements 8
Mounting Base 8
Clearances 8
Combustion & Ventilation Air 8
Venting Connections 9
Gas Supply Connections 11
Water Connections & System
Piping 12
Electrical Wiring 13
Wiring Diagram—Standing Pilot—Models
0090, 0135 & 0195 14
Wiring Diagram—IID—Models 0090,
0135 & 0195 15

CONTENTS

3

SERVICING PROCEDURES 16

Sequence of Operation 16
Start-up Procedures 16
Repair Section 22

TROUBLESHOOTING 23
ADJUSTMENTS & REPLACEMENT
OF COMPONENTS 25

Gas Valve Replacement 25
Pilot Burner Cleaning or Replacement
(Standing Pilot) 25
Flame Roll-out Switch
Replacement 25
Vent Thermal Switch
Replacement 25
Ignition Module Replacement 25
Transformer Replacement 25
Circulator Replacement 26
Replacement Parts 26

WARRANTY 27

4

DANGER:

Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.

WARNING:

Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.

WARNINGS—Pay Attention to These Terms

WARNING: Gasoline, as well as other flammable

materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
DO NOT handle, use or store gasoline or other
flammable or combustible materials anywhere near
or in the vicinity of a water heater. Be sure to read
and follow the warning label pictured below and
other labels on the water heater, as well as the
warnings printed in this manual. Failure to do so can
result in property damage, bodily injury, or death.

DANGER: Failure to install the draft hood and
properly vent the water heater to the outdoors as
outlined in the Venting section of this manual can
result in unsafe operation of the water heater. To
avoid the risk of fire, explosion, or asphyxiation from
carbon monoxide, never operate this water heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the
Maintenance section of this manual for more
information regarding vent system inspections.

DANGER: Water heaters utilizing propane gas are
different from natural gas models. A natural gas
heater will not function safely on propane gas and
vice versa. Conversion from Natural gas to propane
gas (or vice versa) must be done by a qualified
service technician. To avoid possible equipment
damage, personal injury or fire: DO NOT connect
this water heater to a fuel type not in accordance
with unit data plate. Propane for propane units,
Natural gas for natural gas units. These units are not
certified for any other type fuel.

DANGER: PROPANE MODELS: Propane gas must
be used with great caution.

• It is heavier than air and will collect first in lower
areas making it hard to detect at nose level.

• Make sure to look and smell for propane leaks
before attempting to light appliance. Use a soapy
solution to check all gas fittings and connections.
Bubbling at a connection indicates a leak that must
be corrected. When smelling to detect an propane
leak, be sure to sniff near the floor too.

• Gas detectors are recommended in propane appli­cations and their installation should be in
accordance with the manufacturer's recommenda­tions and/or local laws, rules, regulations or
customs.

• It is recommended that more than one method be
used to detect leaks in propane applications.

WARNING: Propane appliances should not be
installed below-grade (for example, in a basement) if
such installation is prohibited by federal, state and/or
local laws, rules, regulations or customs.

Vapors from
flammable liquids will
explode and catch fire
causing death or severe

burns.

Do not use or store flammable
products such as gasoline
solvents or adhesives in the
same room or area near the
water heater.
Keep flammable products:

1. far away from heater,

2. in approved containers,

3. tightly closed and

4. out of childrenʼs reach.

Installation:
Do not install water heater
where flammable products
will be stored or used unless
the main burner and pilot flames

Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.

Water heater has a main
burner and pilot flame.
The pilot flame:

1. is on all the time and

2. will ignite flammable
vapors.
Vapors:

1. cannot be seen,

2. are heavier than air,

3. go a long way on the
floor,

4. can be carried from other
room to the pilot flame by
their currents.

are at least 18" above the
floor. This will reduce, but
not eliminate, the risk of
vapors being ignited by the
main burner or pilot flame.

5

GENERAL SAFETY

To meet commercial hot water requirements, the tank­stat is adjustable up to 190°F. However, water
temperatures over 125°F can cause severe burns
instantly or death from scalds. This is the preferred
starting point for setting the control for supplying gen­eral purpose hot water.

Safety and energy conservation are factors to be con­sidered when setting the water temperature on the
tankstat. The most energy efficient operation will result
when the temperature setting is the lowest that satis­fies the needs consistent with the application.

Maximum water temperatures occur just after burner
has shut off. To find hot water temperature being deliv­ered, turn on a hot water faucet and place a
thermometer in the hot water stream and read the
thermometer.

Table A details the relationship of water temperature
and time with regard to scald injury and may be used
as a guide in determining the safest water temperature
for your applications.

Time/Temperature
Relationships in Scalds

The temperature of the water in the storage tank can
be regulated by setting the temperature dial on front of
the tankstat. To comply with safety regulations, the
tankstat was set at its lowest setting before shipment
from the factory.

Fig. 1 illustrates the tankstat. To adjust the water tem­perature, insert a small straight screwdriver into slotted
screw in hole in front of tankstat and turn wheel to
desired setting. Thermostat is adjustable up to 190°F.

Temperature Time to Produce Serious Burn

120°F More than 5 minutes

125°F 1-1/2 to 2 minutes

130°F About 30 seconds

135°F About 10 seconds

140°F Less than 5 seconds

145°F Less than 3 seconds

150°F About 1-1/2 seconds

155°F About 1 second

Table courtesy of Shriners Burn Institute.

Table A: Time to Produce Serious Burn

Fig. 1: Tankstat Adjustment

Water temperature over 125°F can
cause instant severe burns or death
from scalds.

Children, disabled, and elderly are
at highest risk of being scalded.

See instruction manual before set­ting temperature at water heater.

Feel water before bathing or show­ering.

Temperature limiting valves are
available, see manual.

6

RECEIVING EQUIPMENT

On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, it is suggested that a note be made
on the Bill of Lading when signing for equipment.
Remove the heater from the carton and if it is dam­aged report the damage to the carrier immediately. Be
sure that you receive the number of packages indicat­ed on the Bill of Lading. Claims for shortages and
damages must be filed with carrier by consignee.

Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defec­tive replacement parts will not be accepted and
defective parts will be replaced in kind only per our
standard warranties.

When ordering parts, you must specify Model and
Serial Number of the heater. When ordering under

warranty conditions, you must also specify date of
installation.

Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak heater. If
there are any questions which this manual does not
answer, please contact your local Raypak representa­tive.

GENERAL
SPECIFICATIONS

The Raypak water heaters are design certified by the
and tested under the requirements of the American
National Standard, ANSI Z21.10.3. Each heater has
been constructed and pressure tested in accordance
with the requirements of Section IV of the American
Society of Mechanical Engineers Code, and factory
fire tested.

These heaters are designed for indoor and outdoor
installations, and can be installed on combustible floor­ing when the appropriate listed floor shield base is
used.

Models are available with standing pilot or with inter­mittent ignition device (IID), and are equipped with the
following components as standard: water circulation
pump, pressure relief valve, manual reset high limit
switch, flow switch, vent thermal and flame roll-out
switches, 40VA transformer, and redundant combina­tion gas valve for use with either Natural or Propane
gases. A tankstat is supplied loose for installation in
the field.

DANGER: There is a Hot Water SCALD Potential if
the tankstat is set too high.

CAUTION: Hotter water increases the risk of
SCALDING!

NOTE: When this heater is supplying general
purpose hot water requirements for use by
individuals, a thermostatically controlled mixing
valve for reducing point of use water temperature is
recommended to reduce the risk of scald injury.
Contact a licensed plumber or the local plumbing
authority for further information.

7

Model

No.

Input

(MBH)

Recovery

(gph)

Tank

(Gal)**

Piping

Connections

(in.)

Dimensions (in.)

Water
(NPT)

Gas

(NPT)

A B

K (Vent

Dia.)

WH-0090 90 90 80 1 1/2 11 5-3/4 5

WH-0135 135 132 80 1-1/4 1/2 18 6-1/4 6

WH-0195 195 192 80 1-1/4 1/2 18 6-1/4 7

Recovery gph based on manufacturer's rating.
**May be used with other tank size capacity.

Table B: Specifications and Dimensions

Fig. 2: Dimensions

*

*Flow switch and temperature and pressure gauge must be field installed in the outlet water connection of the
heater.

8

INSTALLATION

Code Requirements

Installation must be in accordance with local codes, or,
in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1,/NFPA
54, and the National Electrical Code, ANSI/NFPA 70.
In Canada installations must conform with the current
CAN/CSA B149 and the Canadian Electrical Code
Part 1 CSA C22.2 No.1.

Where required by the authority having jurisdiction, the
installation must conform to American Society of
Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Heaters, CSD-

1.

Mounting Base

This heater should be mounted on a level, non-com­bustible surface. Heater must not be installed on
carpeting. This heater can be installed on a com­bustible surface only when the appropriate listed floor
shield base is provided. An optional listed floor shield
base is available for factory installation with the heater
on all indoor models.

In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.).

Clearances

Combustion & Ventilation Air

(Indoor models only)

NOTE: The heater should be located in an area

where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.

Heater Side

Minimum Distance

from Combustible

Surfaces

Floor Combustible*

Front Alcove**

Back 6 in.

Right 6 in.

Left 6 in.

Top (Indoor) 16 in.

Top (Outdoor) Unobstructed

Flue Vent 6 in.

*Except for carpeted flooring, heaters are certified for installation on
combustible floors, when equipped with listed floor shield base.
**A front clearance of at least 24 in. is recommended for adequate
service of burner-tray and controls.
For uninsulated hot water pipes, maintain a 2 inch clearance, or con­sult the local authority having jurisdiction.

Table C: Minimum Clearances from Combustible

Surfaces

WARNING: Air supply to the heater room must not
be affected by mechanical exhaust vents located in
other parts of the house, such as kitchen or
bathroom fans, or attic blowers. Mechanical exhaust
vents may create a negative pressure condition in
the heater room that can become a hazard of
asphyxiation, explosion or fire.

CAUTION: Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater. Measures must be taken to
prevent the entry of corrosive chemical fumes to the
combustion and ventilation air supply. Such
chemicals include, but are not limited to, chlorinated
and/or fluorinated hydrocarbons such as found in
refrigerants, aerosol propellants, dry-cleaning fluids,
degreasers, and paint removers. Other harmful
elements may come from bleaches, air fresheners,
or mastics. Vapors from these types of products can
form corrosive acid compounds when burned in a
gas flame. The resulting acid condensate can
damage or substantially reduce the life of the heater.
It may be necessary to provide outside air directly to
the heater in order to avoid this problem.

Fig. 3: Do Not Install on Carpeting

9

1. The heater must be provided with adequate sup­ply of air for proper combustion and ventilation in
accordance with Sec. 5.3 of the latest edition of
the National Fuel Gas Code, ANSI Z223.1, or
applicable provisions of the local building codes.

2. If the heater room is located against an outside
wall and air openings can communicate directly
with the outdoors, the TWO openings on the out­side wall must each have a net free area, in
square inches as shown in Table D.

Location of the openings is the same as in the pre­vious case - that is, within 12 inches of the top,
and within 12 inches of the bottom of the enclo­sure. If horizontal ducts are used, the area must
be doubled and the duct area shall not be less
than the area of the openings they connect, and in
no case shall the smallest dimension be less than
3 inches.

Venting Connections

Vent piping the same size or larger than the draft hood
outlet is recommended, however, when the total vent
height is at least ten (10) feet (draft hood relief open­ing to vent terminal), the vent pipe size may be
reduced as specified in the National Fuel Gas Code,
ANSI Z 223.1. As much as possible avoid long hori­zontal runs of vent pipe and too many elbows.

If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 inch per foot rise and
should be supported at not more than five foot inter­vals. Plumbers tape, crisscrossed, will serve to space
both horizontal and vertical piping. Maximum vent con­nector horizontal length shall be 1-1/2 feet (18 inches)
for each inch of connector diameter as shown in Table
E.

Gas vents supported only by the flashing and extend­ing above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. We recommend use of insulated vent pipe
spacer through the roofs and walls.

Model No. Sq. in. of Each Free Area

0090 24

0135 35

0195 50

Table D: Minimum Net Free Area

For protection against rain or blockage by snow, the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of
such codes, to the latest edition of the National Fuel
Gas Code, ANSI Z223.1.

The discharge opening must be a minimum of two feet
vertically from the roof surface and at least two(2) feet
higher than any part of the building within ten (10) feet.
Vent stack shall be at least five (5) feet in vertical
height above the drafthood outlet. The vent cap loca­tion shall have a minimum clearance of four (4) feet
horizontally from, and in no case above or below,
unless a 4-foot horizontal distance is maintained, from
electric meters, gas meters regulators and relief equip­ment.

The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup­ported to maintain proper clearances from combustible
construction.

Type "B" double wall or equivalent vent pipe is recom­mended. However single wall metal vent pipe may be
used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1.

For connections to gas vents or chimneys, vent instal­lations shall be in accordance with Part 7, Venting of
Equipment, of the National Fuel Gas Code, ANSI
Z223.1, or applicable provisions of the local building
codes.

Model No.

Vent

Connector

Diameter (in.)

Max.
Horizontal
Length (ft)

0090 5 7.5

0135 6 9

0195 7 10.5

Table E: Vent Piping Specifications