Raypak WH-0260 Installation Manual

INSTALLATION & OPERATING

INSTRUCTIONS

Catalog No. 3000.51F Effective: 04-08-09 Replaces: 03-25-08 P/N 240726 Rev. 7

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

Models 0260–0401

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. 7 reflects the following: Changes to: Paragraph 3 of the GENERAL SPECIFICATIONS section on page 6; Fig. 13 on
page 14; paragraph one of the Electrical Wiring section on page 16; te Wiring Diagrams on pages 17–21; the For

Intermittent Ignition (IID) with Honeywell or Robertshaw Gas Valve section on pages 24 and 25; the TROUBLESHOOT­ING chart on page 30.

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 13
Water Connections & System Piping 14
Electrical Wiring 16
Wiring Diagrams 17

CONTENTS

3

SERVICING PROCEDURES 22

Sequence of Operation 22
Start-up Procedures 22
Controls 26
Repair Section 28

TROUBLESHOOTING 30

Electrical (Electronic Ignition IID) 32
Electrical (Standing Pilot) 33

ADJUSTMENTS & REPLACEMENT
OF COMPONENTS 34
WARRANTY 36

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

DANGER: LIQUEFIED PETROLEUM MODELS:
Propane, or LP gas, must be used with great
caution.

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

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

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

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

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

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 (except for models 330 and 400), a solid
state Economaster pump control relay, 40VA trans­former, and redundant combination gas valve for use
with either Natural or Propane gases. A tankstat is
supplied loose for installation in the field.

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.

Model

No.

Input

(MBH)

Recovery

(gph)

Indoor*

Tank

(Gal)**

Piping

Connections

Dimensions (in.)***

H

(NPT)G(NPT)

A C J K

0260/0261 264 262 80 1-1/2 3/4 22-3/8 62-7/8 11-1/8 7

0330/0331 334 332 80 1-1/2 3/4 25-3/4 63-3/4 10-3/4 8

0400/0401 399 396 80 1-1/2 1 29-1/4 65-3/8 12-1/2 9

*Recovery based on manufacturer's rating.
**May be used with other tank size capacity.
***Refer to Fig. 2 for dimensions.

Table B: Specifications and Dimensions

7

11

Fig. 2: Dimensions and System Component Layout

Components should be placed as close as possible.

A
2

6-3/4

OUT

IN

8-1/2

H

G

GAS

13-1/4

40

STACKLESS

OUTDOOR TOP

21-1/4

ELEC

CONN

C

38

K

J

UP
FRONT
CONTROLS

26-1/2

OPTIONAL
COMBUSTIBLE
FLOOR SHIELD

26-1/2

LOWER

TANK

UPPER

8

HEATER

OUTDOOR

BASE

2-1/2

A

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 12 in.

Right 12 in.

Left 12 in.

Top (Indoor) 39 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.

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.

9

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

2. When the heater is installed in a confined space
where all air is supplied from inside the building,
the heater room must be provided with TWO
openings, each one having a minimum net free
area, in square inches as shown in Table D.

One opening shall be within 12 inches of the top,
and the other opening within 12 inches of the floor.
If additional gas appliances are installed in the
same space, the total input of all gas appliances
installed in the same space, must be considered in
the calculation. Refer to Sec. 5.3.5 of the latest
edition of the National Fuel Gas Code for addition­al requirements.

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

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 enclo-

Model No. Sq. in. of Each Free Area

0260/0261 264

0330/0331 334

0400/0401 399

Table D: Minimum Net Free Area

sure. 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.

Outdoor Models

Heaters must not be installed under an overhang of
less than three (3) feet from the top on the heater.
Three (3) sides must be open in the area under the
overhang. Roof water drainage must be diverted away
from the heater installed under overhangs with the use
of gutters.

The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, win­dow or gravity inlet to a building. The top surface of the
heater shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet hor­izontally.

In areas where high winds are frequent, it may be nec­essary to locate the heater a minimum of three (3) feet
from high vertical walls, or install a wind break so the
heater is not in direct wind current.

Venting Connections

Outdoor Models

Outdoor vent top is shipped separately and must be
installed on site.

Models 0260–0401

1. Insert screw retainer clip over mounting flange, (4
places).

Model No. Sq. in. of Each Free Area

0260/0261 66

0330/0331 84

0400/0401 100

Table E: Minimum Net Free Area

NOTE: If louvers, grills or screens are used on the
openings, obtain the net free area from their supplier
or manufacturer. If the design free area of a louver is
not known nor available, it shall be assumed that
wood louvers will have 20-25 percent free area and
metal louvers will have 60-75 percent free area as
shown in the National Fuel Gas Code.

Fig. 3: Location of Mounting Clips

10

2. Attach mounting angles to heater jacket with 1/2"
sheet metal screws, (4 places).

3. Lower outdoor top to heater and secure with 1"
sheet metal screws.

Indoor Models

The drafthood is shipped separately and must be
installed on the heater.

Models 0260 & 0261

1. Mount drafthood on top of heater and attach with

the 4 sheet metal screws provided. Drafthood
should be positioned with the vent sensor located
on the front left side as shown.

2. Remove plastic plug from left side of heater jacket

and install plastic grommet provided.

3. Route flue sensor wire harness through the grom-

met installed in Step 2.

Fig. 4: Location of Mounting Angles

Fig. 5: Long Side of Mounting Angle Located as Shown

4. Remove door and locate wire from roll out sensor
to Hi Limit with the male/female connector.

Fig. 6: Mounting Flue Sensor

Fig. 7: Before Installation of Drafthood

Fig. 8: After Installation of Drafthood

5. Disconnect male/female connector and attach to

the 2 wires from drafthood vent sensor harness.

TEMPERATURE
SENSOR

MOUNTING

CONNECT ONE
VENT SENSOR
WIRE TO THE
HIGH LIMIT WIRE

CONNECT ONE
VENT SENSOR
WIRE TO THE
ROLL-OUT
SENSOR WIRE

WIRE FROM
TRANSFORMER

ROLL-OUT
SENSOR

SCREWS (2)

HARNESS
ASSEMBLY

WIRE FROM TRANSFORMER

MALE/FEMALE
WIRE TERMINAL

WIRE FROM HIGH LIMIT

ROLL OUT

SENSOR

WIRE FROM TRANSFORMER

CONNECT ONE VENT SENSOR WIRE
TO HIGH LIMIT WIRE

CONNECT ONE VENT SENSOR WIRE
TO ROLL OUT SENSOR WIRE

ROLL OUT

SENSOR

11

Models 0330, 0331, 0400 & 0401

Vent Terminal/Indoor Stack Installation

1. Remove the louvered jacket top by removing four
(4) #10 flat head screws.

2. If originally installed, remove "Pagoda" top from
the louvered jacket top.

3. Place the inner stack adapter panel over the flue
collector inside the heater. Make sure the flanged
side of the flue opening is up.

4. Turn the stack (draft hood) up side down and set it
down bottom side up.

5. Turn the jacket top panel (removed in Step 1) up
side down and place it through the stack.

6. Attach the three (3) mounting brackets to the stack
using the screws provided and the holes that are
pre-drilled in the stack. Make sure the brackets are
positioned with the flange near the top side of the
stack (see Fig. 9). Caution must be taken not to
over tighten and strip the screw threads.

7. Turn the assembled stack and jacket top, right
side up. The jacket top will be trapped between the
brackets and the top of the stack. Place the stack
over the inner adapter panel flanged hole and
lower the louvered jacket top panel back into its
original position. Reinstall the four (4) green #10
flat head screws removed in Step 1 above.

L

Fig. 9: Vent Terminal/Indoor Stack Installation

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
F.

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

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

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

WARNING: Indoor heaters require a drafthood that
must be connected to a vent pipe and properly
vented to the outside. Failure to follow this procedure
can cause fire or fatal carbon monoxide poisoning.

Model No.

Vent

Connector

Diameter (in.)

Max.
Horizontal
Length (ft)

0260/0261 7 12

0330/0331 8 13.5

0400/0401 9 15

Table F: Vent Piping Specifications

DRAFTHOOD

SCREW HOLE
LOCATION

4-3/4"

JACKET TOP PANEL

(part of the heater)

#10 SHEET METAL SCREW (3)

MOUNTING BRACKET (3)

INNER STACK ADAPTER PANE

FLUE COLLECTOR

(part of heater)

COMBUSTIBLE FLOOR SHIELD

(optional for indoor)

2-1/2"

12

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.

Fig. 10: Venting Minimum Clearances

Common Vents

Manifolds that connect more than one heater to a com­mon chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
manifold and the chimney. At no time should the area
be less than the area of the largest outlet.

At the time of removal of an existing heater, the follow­ing steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain­ing connected to the common venting system are not
in operation.

(a) Seal any unused openings in the common venting

system.

(b) Visually inspect the venting system for proper size

and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.

(c) Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the com­mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will oper-

WARNING: These heaters must not be connected
into any portion of mechanical draft systems
operating under positive pressure. To do so may
cause the flue products to be discharged into the
living space causing serious health injury.

Fig. 11: Common Venting

10' OR LESS

VENT CAP

2' MIN

2' MIN

Drafthood

5' MIN

VENT PIPE

DRAFT HOOD

HEATER

Heater