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

13

ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust tankstat so
appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga­rette, cigar or pipe to visually check spillage.

(f) After it has been determined that each appliance

remaining connected to the common venting sys­tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.

(g) Any improper operation of the common venting

system should be corrected so the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When re-sizing any
portion of the common venting system, the com­mon venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in Chapter 10 and in
Appendix G of the National Fuel Gas Code, ANSI
Z223.1 and CAN/CSA-B149.

Gas Supply Connections

The inlet gas connection to the heater gas valve is
3/4" for models 260/261 and 330/331; and 1" for mod­els 400/401. Provide an adequate gas supply line
according to Table G below.

Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve locat­ed outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.

Model No.

3/4 in. 1 in. 1-1/4 in. 1-1/2 in.

Nat Pro Nat Pro Nat Pro Nat Pro

0260/0261 20 40 60 140 250 560

0330/0331 15 25 35 85 150 380 360

0400/0401 15 25 60 100 260 250

Natural gas, 1000 BTUH/ft .60 specific gravity @ 0.5 in. WC pressure drop.
Propane gas, 2500 BTUH/ft 1.53 specific gravity @ 0.6 in. WC pressure drop.

Table G: Maximum Equivalent Pipe Length (ft)

Fig. 12: Sediment Trap

CAUTION: The heater and its manual shut off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 psi (3.45 kPa). Dissipate
test pressure in the gas supply line before
reconnecting the heater and its manual shut off valve
to gas supply line. FAILURE TO FOLLOW THIS
PROCEDURE MAY DAMAGE THE GAS VALVE.
OVER PRESSURED GAS VALVES ARE NOT
COVERED BY WARRANTY. The heater and its gas
connections shall be leak tested before placing the
appliance in operation. Use soapy water for leak test
DO NOT use open flame.

NOTE: Do not use teflon tape on gas line pipe
thread. A flexible sealant suitable for use with Natural
and Propane gases is recommended.

SUPPLIED BY
INSTALLER

14

Gas Pressure Specifications

Gas Pressure Regulator

The gas valve is provided with pressure taps to meas­ure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pres­sure.

Type of

Gas

Inches WC

Regulator

Setting

Min. Max.*

Natural 7.0 10.5 4.0

Propane 12.0 13.0 11.0

*Do not exceed maximum inlet gas pressure. The minimum value
shown is for input adjustment.

Table H: Gas Pressure Specifications

The gas pressure regulator is preset and sealed at 4
in. WC for natural gas, and 11 in. WC for propane gas.
Between the gas valve and the burners is a 1/8 in. pipe
plug. The pressure at this point, taken with a manome­ter, should be about 3.7 in. WC natural gas and 10.5
in. WC propane gas. Lo NOx models should be 3.9 in.
WC natural gas only. If an adjustment is needed,
remove seal and turn adjustment screw clockwise to
increase pressure or counter-clockwise to decrease
pressure.

Water Connections & System
Piping

The pipe size and fittings between the heater and the
tank should be at least 1-1/2" for all models. The tank
should be located as close to the heater as possible,
as shown in Fig. 13 below.

Fig. 13: Heater with Storage Tank

15

If this water heater is installed in a closed water supply
system, such as one having a back-flow preventer in
the cold water supply line, means shall be provided to
control thermal expansion. Contact the water supplier
or local plumbing inspector on how to control this situ­ation.

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

Thermometer(s) should be installed so that they indi­cate the water temperature at or near the outlet of the
storage tank.

Relief Valve

A new combination temperature and pressure (T & P)
relief valve, complying with the Standard for Relief

Valves and Automatic Gas Shut Off Devices for Hot
Water Supply Systems, ANSI Z21.22, must be
installed in the opening provided on top of the storage
tank, at the time of installation. No valve is to be placed
between the relief valve and the storage tank.

The pressure rating of the relief valve must not exceed
the 160 maximum working pressure indicated on the
water heater rating plate. The BTUH rating of the relief
valve must not be less than the BTUH input of the
heater.

Connect the outlet of the relief valve to a suitable open
drain. The discharge line must pitch downward from
the valve to allow complete draining (by gravity) of the
relief valve and discharge line. The discharge line
should be no smaller than the outlet of the valve. The
end of the discharge line should not be threaded or
concealed, and should be protected from freezing. No
valve of any type, restriction or reducer coupling,
should be installed in the discharge line. Local codes
shall govern installation of relief valve.

Fig. 14: 0261 Low NOx WH1 with Pressure Relief Valve

PRV

FLOW SWITCH

RATING PLATE

ON/OFF
SWITCH

INLET/OUTLET
WATER
CONNECTIONS

OPTIONAL
PUMP

COMBINATION
GAS VALVE

ELECTRICAL
CONTROLS
LOCATION

HIGH LIMITS

PILOT LOCATION

16

Electrical Wiring

The electrical power supply requirement for these
heaters is 120 volts, 60 Hz. Field wiring connections
and electrical grounding must comply with the local
codes, or in the absence of local codes, with the latest
edition of the National Electrical Code, ANSI/NFPA 70.
Provide a separate fused circuit from the main electri­cal panel to the heater, and a disconnecting means
within sight of the heater.

Remove the control box cover and make the power
supply connections in the field wiring compartment.
The pump is supplied and factory wired to operate with
the heater. The current draw is approximately 2.0
amps. Refer to the heater internal wiring diagrams
shown on pages 17 to 21.

NOTE: If it is necessary to replace any of the
original wiring, it must be replaced with 105°C wire or
its equivalent, except 150° black wire which must be
replaced with 150° wire or its equivalent.

NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.

17

Wiring Diagrams

Fig. 15: Standing Pilot Model 0260

(FIELD INSTALLED)

18

Fig. 16: Intermittent Ignition Device (IID) Model 0260

19

Fig. 17: Intermittent Ignition Device (IID) Models 0330 & 0400

20

Fig. 18: Intermittent Ignition Device (IID) Model 0261 Low NOx

21

Fig. 19: Intermittent Ignition Device (IID) Models 0331 & 0401 Low NOx

22

SERVICING
PROCEDURES

Sequence of Operation

Intermittent Ignition Device (IID)

Heaters equipped with the IID system will automatical­ly light the pilot burner first and then the main burner,
each time there is a call for heat from the tankstat.
Whenever the tankstat calling for heat, the circulator
supplied with the heater, will be energized and should
be running.

The ignition control module will also be energized to
initiate the pilot ignition by opening the first main valve
(pilot). At the same time, the electronic spark genera­tor in the module produces a high voltage spark pulse
output that lights the pilot burner. If the pilot burner
does not light, the module will not energize the second
main valve and the burners will not light. Ignition spark
continues only until the timed trial for ignition period
ends.

Then, the module goes into safety shutdown or lock­out. Lockout de-energizes the first main valve operator
and closes the first main (pilot) valve in the gas con­trol, stopping pilot gas flow. The ignition control system
must be reset by setting the tankstat below water tem­perature for one minute or by turning off power to the
module for one minute.

When the pilot flame is established, flame rectification
circuit is completed between the sensor and burner
ground. The flame sensing circuit in the module
detects the flame current, shuts off the spark genera­tor and energizes the second main valve operator
which opens the second main valve. This allows gas to
flow to the burners where it is ignited by the pilot burn­er flame.

When the tankstat is satisfied, the valve operators are
de-energized shutting off the pilot and main burners,
and also the circulator.

Start-up Procedures

Filling the System

Fill system with water. Purge all air from the system
using purge valve sequence. After system is purged of
air, lower system pressure. Flush system before put­ting into operation to ensure that foreign material does
not damage pump seals.

Checking the Circulator

Before lighting the heater and after system is filled,
make sure that circulator is operating properly. Manual
gas valve should be off.

Lighting the Heater

For your safety read carefully before proceeding to
light the heater.

For Standing Pilot Models

A. This heater has a pilot which must be lighted by

hand. When lighting the pilot, follow these instruc­tions exactly.

B. BEFORE LIGHTING smell all around the heater

area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will set­tle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch.

• Do not use any phone in your building.

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

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

C. Use only your hand to push in, move or turn the

gas control knob or lever. Never use tools. If the
knob or lever will not push in, move or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.

D. Do not use this heater if any part has been under

water. Immediately call a qualified service techni­cian to inspect the heater and to replace any part
of the control system and any gas control which
has been under water.

NOTE: Circulator motor supplied with the heater
does not require lubrication.

WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing prop­erty damage, personal injury or loss of life.

CAUTION: Propane gas is heavier than air and
sinks to the ground. Exercise extreme care in light­ing heater in confined areas.

23

For Standing Pilot Model with
Robertshaw Gas Valve, On/Off
Operation

1. STOP! Read the safety information above.

2. Set the tankstat on the lowest setting.

3. Turn OFF all electric power to the heater.

4. Remove heater door panel.

5. Push in gas control knob slightly and turn clock-

wise to "OFF".

6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If your smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to
the next step.

7. Locate pilot mounted on the right side of the burn­er drawer, right of first burner.

8. Turn knob on gas control counter-clockwise
to "Pilot".

Fig. 20: Robertshaw Gas Valve

NOTE: Knob cannot be turned from "PILOT" to
"OFF" unless knob is pushed in slightly. Do not force.

Fig. 21: Honeywell and Robertshaw Pilots

9. Push in control knob all the way and hold in,
immediately light the pilot with a match. Continue
to hold control knob in for about one minute after
the pilot is lighted, release knob and it will pop
back up. Pilot should remain lighted. If it goes out,
repeat steps 4 through 8.
* If knob does not pop up when released, stop

and immediately call your service technician
or gas supplier.

* If the pilot does not stay lit after several tries,

turn the gas control knob to "OFF" and call
your service technician or gas supplier.

10. Stand to the side of the heater and turn the gas

control knob counter-clockwise to "ON".

11. Replace heater door.

12. Turn "ON" all electrical power to the heater.

13. Set the tankstat to the desired setting.

For Standing Pilot Model with
Honeywell Gas Valve, On/Off
Operation

1. STOP! Read the safety information.

2. Set the tankstat to the lowest setting.

3. Turn Off all electrical power to the heater.

4. Remove heater door panel.

5. Turn gas control knob clockwise to "OFF".

6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to
the next step.

7. Locate pilot mounted on the right side of the burn­er drawer, right of first burner.

8. Turn knob on gas control counter-clockwise
to "PILOT".

9. Push down and hold the red reset button in, imme­diately light the pilot with a match. Continue to hold
down red reset button for about one minute after
the pilot is lighted. Release red reset button and it
will pop back up. Pilot should remain lighted. If it
goes out, repeat steps 4 through 8.

Fig. 22: Honeywell Gas Valve

GAS CONTROL
KNOB SHOWN
IN "OFF" POSITION

GAS INLE

T

HONEYWELL PILOT ROBERTSHAW PILOT

GAS CONTROL
KNOB SHOWN
IN "OFF"
POSITION

GAS INLE

T

24

* If red reset button does not pop up when

System Shut Down Procedure

1. Set the tankstat to "OFF" or the lowest setting.

2. Turn off all electric switches to the heater.

3. Turn off all gas valves supplying gas to the heater.
Refer to operating instruction label on the heater.

4. Shut off the water supply to the heater piping sys­tem loop.

5. Open drain valve on the tank to remove water from
the heater and the piping circuits.

For Automatic Ignition Models

Please read carefully and understand the following
safety information before operating the heater.

A. This heater is equipped with an ignition device

which automatically lights the pilot. Do not try to
light the pilot by hand.

B. BEFORE OPERATING smell all around the heater

area for gas. Be sure to smell next to the floor
because some gases are heavier than air and will
settle on the floor.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electric 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.

C. Use only your hand to push in, move or turn the

gas control knob or lever. Never use tools. If the
knob or lever will not push in, move or turn by

WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing prop­erty damage, personal injury or loss of life.

hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.

D. Do not use this heater if any part has been under

water. Immediately call a qualified service techni­cian to inspect the heater and to replace any part
of the control system and any gas control which
has been under water.

For Intermittent Ignition (IID) with
Honeywell or Robertshaw Gas
Valve

1. STOP! Read the safety information above on this
label.

2. Set the tankstat on the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.

5. Remove heater door panel.

6. For Robertshaw Gas Valve: Turn gas control knob
clockwise to "OFF". For Honeywell Gas
Valve: Turn gas control knob clockwise to
"OFF". Make sure knob rest against stop. For
Honeywell Gas Valve: Push in gas control knob
slightly and turn clockwise to "OFF". Knob cannot
be turned to "OFF" unless knob is pushed in slight­ly. Do not force.

7. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "b" in the safety information
previously stated. If you do not smell gas, go to the
next step.

8. For Robertshaw Gas Valve: Turn gas control
knob counter-clockwise to "ON".

Fig. 23: Robertshaw Gas Valve

released, STOP and immediately call your
service technician or gas supplier.

* If the pilot does not stay lit after several tries,

turn the gas control knob to "OFF" and call your
Service technician or gas supplier.

10. Stand to the side of the heater and turn the gas
control knob counterclockwise to "ON".

11. Replace heater door.

12. Turn "ON" all electrical power to the heater.

13. Set the tankstat to the desired setting.

GAS CONTROL
KNOB SHOWN
IN "ON" POSITION

GAS INLET

25

For Honeywell Gas Valve: Turn gas control knob
counter-clockwise from “OFF” until it stops.
Push in gas control knob and continue rotating
counter-clockwise to “ON” position. Make
sure knob rest against stop.

For Honeywell Gas Valve: Turn gas control knob
counter-clockwise to “ON”.

9. Replace door panel.

10. Turn on all electric power to the appliance.

11. Set tankstat to desired setting.

12. If the appliance will not operate, follow the instruc­tions “To Turn Off Gas To Appliance” and call your
service technician or gas supplier.

To Turn Off Gas To Appliance

1. Set the thermostat to the lowest setting.

2. Turn off all the electric power to the appliance if
service is to be performed.

3. Remove door panel.

4. For Robertshaw IID Gas Valve: Turn gas control
knob clockwise to “OFF”.
For Honeywell Gas Valve: Turn gas control knob
clockwise to “OFF”. Make sure knob rest
against stop.

For Honeywell 24V Standing Pilot Gas Valve:

Push in gas control knob slightly and turn clock­wise to “OFF”.

5. Replace heater door panel.

Testing the Ignition Safety Shut-off

The ignition system safety shutoff must be tested by
conducting the following tests:

For Standing Pilot Systems

1. With the main burners on, remove the pilot adjust­ment cover screw.

2. Insert a small slot screw driver and turn the adjust­ment screw clockwise until pilot flame goes
out. Count and note number of turns made.

3. Gas valve will shut off main burners after about
three (3) minutes. End of test. If the gas valve will
not shut off, follow the instructions "To Turn Off
Gas To Heater" and call service technician or your
gas supplier.

4. Return pilot adjustment screw counterclockwise

same number of turns as in step (b).

5. Replace pilot adjustment cover screw, then follow
the lighting instructions to get heater ready for
operation.

For Automatic Ignition Systems

1. Turn on power to the ignition systems and turn gas
supply off at the gas valve.

2. Check ignition module as follows:
a. Set the tankstat to high setting.
b. Watch for continuous spark at the pilot burner.
c. Time the spark operation. Time must be with-

in the lockout timing period (15 or 90
seconds).

d. Turn tankstat down to end call for heat and

wait 60 seconds on lockout models before
beginning step 3.

3. Turn on gas supply.

4. Set tankstat to high setting.

5. Systems should start as follows:
a. Spark will turn on and pilot gas valve will open

at once. Pilot burner should ignite after gas
reaches the pilot burner.

b. Spark ignition should cut off when pilot flame

is established.

c. Main gas valve should open and main burner

should ignite after gas reaches the burner
port.

Fig. 24: Honeywell Gas Valve

Fig. 25: Honeywell Gas Valve

GAS CONTROL
KNOB SHOWN
IN “ON” POSITION

GAS INLET

GAS CONTROL
KNOB SHOWN
IN “ON” POSITION

GAS INLET

26

Inspection Procedures

Burners

Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com­bustibles and flammable liquids. Do not obstruct the
flow of combustion and ventilating air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame indi­cates excess high gas pressure. Low flame indicates
low gas pressure.

Fig. 26: Typical Main Burner Flame

Fig. 27: Pilot Burner Flame (IID units)

Fig. 28: Pilot Burner Flame (STG Pilot Units)

Controls

Check all controls to see that they are operational. To
check electronic safety (IID Models) , turn off main
burner. Observe pilot burner when shutting off pilot
gas. Ignition spark should go on. Main gas valve will
also drop out.

High Limit Switch - to check high limit switch, turn dial
setting down to a point slightly below the temperature
of the water leaving the heater. The reset button
should snap out and the burner should shut off. Reset
dial to 30°F to 40°F above desired operating tempera­ture, and push reset button. Burner should light.

Low NOx Heaters—Models 261–401

The Low NOx Heater is offered as a model W1-ON­OFF firing.

The heaters are certified and tested under the ANSI
Z21.10.3 Standards for hot water heaters.

The heater should be installed to meet all local codes,
the National Fuel Gas Code Z223.1 and with the
National Electrical Code, ANSI/NFPA 70.

Fig. 29: Burner Detail

DETAIL A

SEE DETAIL VIEW A

27

Operation

On call for heat, the ignition system, consisting of an
electronic spark module, gas pilot system is energized.
Providing pilot is proven blower will start running, the
main gas valve will open and the heater will operate.
When the operating control is satisfied the heater will
shut down.

Start-up Procedures (S8610B)

1. Turn on power to the heater with gas supply off.

2. Check ignition module as follows:
a. Set the thermostat or controller to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Check the ignition spark operation. Time must

be within the lockout timing period (15 or 90
seconds).

d. Turn control down to end call for heat and wait

60 seconds on lockout models before begin­ning step 3.

3. Turn on gas supply.

4. Set controller to call for heat.

5. System should start as follows:
a. Spark will turn on and pilot gas valve will open

and the blower will begin running.

b. Heater will operate until call for heat is satis-

fied.

Burner Adjustment

This burner assembly does not require any adjust­ments.

Visual Inspection

Flame can be observed through the slot opening
above the plenum. Flame color is blue and evenly
spread on the top surface of the burner. At least every
three months a visual inspection should be made of
the burners. In case flame lifting is observed on the
burner, check gas pressure on manifold and static
pressure in plenum. Gas pressure in manifold should
be 3.9 in. WC and static pressure in plenum should be
greater than 0.5 in. WC.

Electrical

Be sure that electrical service to the heater has over­load fuse or circuit breaker protection, wire size and
connections that comply with all applicable codes.

High/Low Gas Pressure Switch

Pressure switch senses high/low pressure and auto­matically shuts down burner if abnormal pressure
exists.

Burner Drawer Removal

1. Shut off main electrical power switch to heater.

2. Shut off gas upstream of heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to unit,
and (4) screws that secure gas valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the ignition module.

9. Disconnect wire harness from the combustion
blower.

Fig. 30: Gas Pressure Switch

Fig. 31: Low NOx Burner Tray Assembly

28

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

Gas Valve Removal

1. Shut off main electrical power switch to heater.

2. Shut off gas supply to the heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Disconnect wires, pilot tubing and bleed line, if
required.

6. Remove (2) screws that secure gas valve to jack­et.

7. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.

8. Reverse above procedure to re-install.

Main Burner And Orifice Removal

1. Remove burner drawer. See burner drawer
removal procedure.

2. Remove (8) screws from the hold down brackets.

3. Remove (8) screws from the left and right sides of
the Manifold assembly. Detach the manifold
assembly from the burner tray assembly.

4. Use a long 3/8” socket wrench to remove orifices
from the atmospheric gas manifold, 9/16” for Low
NOx.

5. Remove burners by raising the bracket on the
back end of the burners up and out of their slots.

6. Reverse above procedure to re-install.

Pilot Removal

1. Disconnect pilot tubing from gas valve.

2. Remove (4) screws from control box. Open the
control box.

3. Remove the pilot wire from the ignition wire.

4. Remove (2) screws that mount the pilot bracket to
the air manifold assembly.

5. Pull the pilot bracket downward and outward.

6. Reverse above procedure to re-install.

Combustion Fan Removal

1. Remove burner drawer. See burner drawer
removal procedure.

2. Remove (4) screws the mount the combustion
blower to the manifold assembly.

3. Reverse above procedure to re-install.

Normal Inspection Procedures

First and third month after initial start up and then on
an annual basis. If problems are found, refer to
Trouble Shooting Guide for additional directions.

1. Remove top of heater and inspect heat exchanger
for soot and examine venting system.

2. Remove rear header and inspect for scale
deposits.

*3. Inspect pilot and main burner flame and firing rate.
*4. Inspect and operate all controls and gas valve.
*5. Visually inspect system for water leaks.
*6. a. Oil pump motor and bearing assembly, if oil

cups are provided.

b. Disconnect pump from header and check con-

dition of pump impeller. Check condition of
bearing by attempting to move impeller from
side to side. Replace any parts showing wear.

c. Check pump coupler for wear and vibration.

7. Check flow switch paddle (if provided).

8. Clean room air intake openings to assure ade­quate flow of combustion and ventilation air.

9. Keep heater area clear and free from combustible
materials, gasoline, and other flammable vapors
and liquids.

*Should be checked monthly. (Takes approximately
15 minutes).

Repair Section

Tube Cleaning Procedure (Typical)

Establish a regular inspection schedule, the frequency
depending on the local water condition and severity of
service. Do not let the tubes clog up solidly. Clean out
deposits over 1/16" in thickness.

Fig. 32: IID Pilot

CAUTION: Combustion air must not be contami­nated by corrosive chemical fumes which can
damage the heater and void the warranty.

29

The heater may be cleaned from the side opposite the
water connections, without breaking pipe connections.
It is preferable, however, to remove both headers for
better visibility through the tubes and to be sure the
residue does not get into the system. Generally, you
do not remove the top pan or the heat exchanger .

After reaming with the auger, mount the wire brush
and clean out the debris remaining in the tubes.
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-inhib­ited de-scale solvent.

Heat Exchanger Removal

1. Shut water, gas and electricity off, close valves
and relieve pressure, remove relief valve. Remove
side inspection panels.

2. Remove top holding screws.

3. Remove draft diverter, lift and remove top and flue
collector on stack type models. Remove inspec­tion panels.

4. Loosen bolts and disconnect flange nuts on inlet­outlet header, loosen union(s) at gas pipe, and
slide heater away from piping until studs clear the
heater.

5. Remove heat exchanger corner brackets.

6. Remove combustion chamber clips at the four cor­ners of the heat exchanger.

7. Lift heat exchanger straight up using caution not to
damage refractory.

Heat Exchanger Re-assembly

1. Heat exchanger water header O-rings should be
replaced with new ones.

2. Install inlet-outlet and return water headers and
install header retainer nuts and torque nuts even­ly.

3. Install the four (4) corner clips between tube
sheets and refractory. Replace "V" baffles.

4. Install thermostat sensing bulbs in header wells
and replace bulb retaining clips.

5. Install inlet and return pipes in water headers
using pipe thread sealant.

6. Install water pressure relief valve, flow switch, and
low water cutoff devices if so equipped.

7. Open water supply and return shut-off valves. Fill
heater and water piping system with water. Check
heater and piping system for leaks at full line pres­sure. Run system circulating pump for a minimum
of 1/2 hour with heater shut-off.

8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris. Expansion tank water level

should be at the 1/4 mark and the balance of the
tank filled with air.

9. Install flue collector, jacket top and inspection pan­els. Install top holding screws. Install draft diverter
and vent piping if so equipped.

10. If gas piping was disconnected, reconnect gas pip­ing system and check for leakage using a soap
solution.

11. Check for correct water pressure and water level
in the system. Make sure that system pump oper­ates immediately on the call for heat. The system
is ready for operation.

12. Within two (2) days of start-up, recheck all air
vents and expansion tank levels.

Combustion Chamber Removal

To remove combustion chamber you must first have
removed the heat exchanger. Unbolt metal combus­tion chamber retainer from top and remove
combustion chamber panels individually.

Fig. 33: Refractory Panels—Top View

30

TROUBLESHOOTING

These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the
installation of this type of heating equipment and related system components. Installation and service personnel may
be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor
attempt repairs according to these instructions.

PROBLEM(S)

1)When tankstat is turned on, heater
does not operate.

2)When tankstat is calling for heat,
pump is on, but burners will not turn
on.

CAUSE(S)

1)No power to the heater.

2)Defective tankstat or disconnected
wire in thermostat circuit.

3)Defective transformer.

1) For Standing pilot models pilot burner
not lighted.

2)If pilot burner will not stay lighted,
thermocouple or gas valve may be
defective.

3)Gas knob in "Pilot" position.

4)Vent switch is open.

5)Roll-out switch is open.

6)Manual Reset High limit is open.

7) Defective ignition module or

defective gas valve.

SOLUTION(S)

1)Check circuit breakers, disconnect
switch. Make sure power is on.

2)Check continuity on thermostat and
wiring circuit. Replace thermostat, or
repair wiring connections.

3) Check secondary voltage. If no 24V,
replace transformer.

1)Light pilot burner. (Follow lighting
instructions on rating plate).

2)Check thermocouple MV generation.
If less than 25MV (open circuit), re­place thermocouple. If between 25­35 MV, replace gas valve.

3)Turn knob to "ON" position.

4) Check for blockage of venting sys
tem or disconnected vent piping. After
problem is corrected push button to
reset vent switch.

5)Check for blockage of flue or sooted
heat exchanger. After problem is
corrected push button to reset
roll-out switch.

6)Check water flow and adjust to
obtain 8° to 10°F temperature rise.

7)On Honeywell module, check voltage
across terminals MV and MV/PV. If
no 24V is present, replace module. If
24V is present, replace gas valve.

31

3)Pilot Outage.
(Standing pilot models)

1) Too low or too high gas
pressures.

2) Restricted pilot.

3) Weak thermocouple.

1) Adjust inlet gas pressure as
shown on rating plate.

2) Clean pilot orifice.

3) Replace thermocouple.

4)Yellow lazy flame.

5)Sooting

1) Too low gas pressure.

2) Restricted burner intake ports.

3) Restricted gas line.

1) Insufficient combustion air.

2) Improper venting.

3) Severe yellow burner flames.

1) Adjust manifold pressure as

shown on rating plate.

2) Clean burners free of debris or
insects.

3) Clean gas line or increase gas line
piping.

1) Refer to installation instructions
regarding combustion air
requirements.

2) Refer to installations instructions.

3) See yellow flame section above.

32

TROUBLESHOOTING

Electrical
(Electronic Ignition IID)

Intermittent Pilot System—
Honeywell S8600

WARNING: HIGH VOLTAGE: For qualified
technicians ONLY

NOTE: Some heaters may be equipped with an

ignition module that shuts off pilot gas if the pilot fails
to light. To reset, interrupt power to heater.

TURN GAS SUPPLY OFF.

(CONTROLLER) TO CALL

IGNITER/SENSOR GAP

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

START

TURN THERMOSTAT

FOR HEAT

POWER TO MODULE

(24 V NOMINAL)

YES

SPARK ACROSS

YES

YES

NO

NO

NO

NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.

Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.

Pull ignition lead and check spark at module.

Spark Okay?
YES

• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.

• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.

• Check that all manual gas valves are open, supply tubing and pressures are
good, and pilot burner orifice is not blocked.

• Check electrical connections between module and pilot operator on gas control.

• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.

SPARK STOPS WHEN

PILOT IS LIT?

YES

MAIN BURNER LIGHTS?

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

CALL FOR HEAT ENDS

SYSTEM SHUTS OFF?

YES

NO

NO

NO

NO

NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G.
models.

• Check continuity of ignition cable and ground wire.

• Clean flame rod.

• Check electrical connections between flame rod and module.

• Check for cracked ceramic flame rod insulator.

• Check that pilot flame covers flame rod and is steady and blue.

• Adjust pilot flame.

• If problem persists, replace module.

• Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module.

• Check electrical connections between module and gas control. If okay, replace
gas valve or gas control operator, i.e. pilot gas valve, flow switch etc.

NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.

• Check that pilot flame covers flame rod and is steady and blue.

• If checks are okay, replace module.

• Check for proper thermostat (controller) operation.

• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.

TROUBLESHOOTING

ENDS

Repeat procedure until troublefree operation is obtained.

33

Electrical (Standing Pilot)

WARNING: HIGH VOLTAGE: For qualified
technicians ONLY

START HEATER

BUT MAIN BURNERS DO SEODTON NOT LIGHT

CHECK FOR 24 V CHECK THERMOCOUPLE

AT GAS VALVE

FI.K.O FI :V 42 FI:V 42 TON FI DEFECTIVE

CHECK TRANSFORMER OUPUT REPLACE

ER EVLAV SAGV 42 ROF

GAS VALVE THERMOCOUPLE

RENRUB TOLIP FISTHGIL RENRUB TOLIP FI

ECALPER ECALP

IF NO IF 24 V:
24V:

REPLACE PROBLEM IN
TRANSFORMER LIMIT

CIRCUITS

34

ADJUSTMENTS &
REPLACEMENT OF
COMPONENTS

Gas Valve Removal

1. Shut off gas supply to the heater. Remove gas pip­ing to gas valve inlet.

2. Disconnect wires, pilot tubing and bleed line, if
required.

3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.

4. Reverse above procedure to re-install.

Pilot Removal and Cleaning

1. Disconnect pilot tubing at pilot and sensor/igniter
wire. Remove screws holding pilot bracket to burn­er drawer.

2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.

3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.

Burner Drawer Removal

1. Shut off power and gas supply to the heater.
Disconnect union(s) and pilot tubing, then loosen
and remove burner hold down screws.

2. Disconnect wires at gas valve and slide burner
drawer out.

Main Burner and Orifice Removal

1. Remove screws and burner hold down bracket.

2. Lift burners from slotted spacer and slide from ori­fices. Clean with a wire brush.

3. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood through ori­fice. Do not enlarge hole. To remove orifice, use a
socket wrench and remove the manifold. DO NOT
over tighten when reinstalling.

High Limit or Tankstat Removal

1. Turn off electrical power.

2. Remove front inspection panel.

3. Remove wires to high limit and loosen screws
holding high limit to cabinet.

4. Remove wedge clip holding sensing bulb in con­trol well.

5. Remove high limit and install a new one.

6. Check control operation before leaving job.

Flame Roll-Out Switch Replacement

1. Shut off electrical power to the heater.

2. Remove wiring connections to switch.

3. Remove screws (2) holding the switch.

4. Reverse above procedure to re-install.

Vent Thermal Switch Replacement

1. Shut off electrical power to the heater.

2. Remove wiring connections to switch.

3. Remove the screws (2).

4. Reverse above procedure to re-install.

Ignition Module Replacement

1. Shut off electrical power to the heater.

2. Remove control cover screws and open control
compartment.

3. Disconnect wiring connections to module.

4. Remove screws (2) holding module.

5. Reverse above procedure to re-install.

Transformer Replacement

1. Shut off electrical power to the heater.

2. Remove control cover screws and open control
compartment.

3. Disconnect wiring connections from transformer
leads.

4. Remove screws (2) holding transformer.

5. Reverse above procedure to re-install.

CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.

DANGER: SHOCK HAZARD: Make sure electri­cal power to the heater is disconnected to avoid
potential serious injury or damage to components.

NOTE: If the heat exchanger is sooted badly, the
burner hold down bracket and spacer can become
distorted from direct flame impingement and this
usually necessitates replacement of these parts.

35

Circulator Replacement

1. Shut off electrical power to the heater.

2. Shut off water supply and open drain valve to
remove water in the piping at the pump level.

3. Disconnect wiring and conduit connections to the
pump.

4. Remove the nuts and bolts at the inlet and outlet
flanges. Remove old gaskets.

5. Remove the pump.

6. Reverse the above procedure to re-install. Use
new gaskets and make sure they are seated prop­erly when tightening the nuts and bolts.

Control Well Replacement

Remove top, sensing bulb and clip. Collapse well tube
at the open end with a chisel, push through into head­er and remove the well through header. Insert a new
well and roll into place. If a roller is not available, sol­der the well in place with silver solder.

Tube Replacement Procedure

1. Remove heat exchanger from heater following
instructions outlined under HEAT EXCHANGER
REMOVAL.

2. Remove inlet/outlet and return headers. Remove
"V" Baffle from damaged tube.

3. Remove damaged tube by cutting with a hack saw
or shearing with a chisel adjacent to each tube
sheet.

4. Collapse stub ends in tube sheets using a chisel or
screwdriver. DO NOT cut into tube sheet or mar
surface in tube hole in any way.

5. Insert replacement tube by inserting the end with
the most fins removed in the opening of one tube
sheet. Slide tube until the opposite end clears the
other tube sheet and fits the tube into the hole.

6. Insert the tube roller into tube opening up to stop,
making certain that 1/8" of tube projects beyond
the tube sheet.

7. Attach drill to tube roller, holding it straight and
level.

8. Reverse drill motor and withdraw tube roller, if
necessary wrench out by hand.

9. DO NOT apply excessive torque during rolling
operation and avoid thinning any wall of the tube
beyond 0.015".

10. Use same procedure on opposite end.

11. Apply line pressure test. Re-roll if necessary.

12. Reinstall as outlined under HEAT EXCHANGER
REASSEMBLY.

Procedure for Cleaning Flue Gas
Passage Ways

Soot will clog areas behind fins and eventually cause
tube failure. Any sign of soot at base of burners or
around outer jacket indicates a need for cleaning.

1. Lift off draft hood and flue collector by removing
bolts and screws.

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray, see Burner Drawer Removal.

4. Take garden hose and wash heat exchanger, mak­ing sure soot is removed from between fins. (Avoid
excessive water against refractory).

5. Reassemble; when heater is fired, some steam
will form from wet refractory, which is normal.

Replacement Parts

Any part returned for replacement under standard
manufacturer warranties must be properly tagged with
a return parts tag, completely filled in with the heater
serial number, model number etc., and shipped to the
manufacturer freight prepaid.

If the manufacturer determines the part is defective
and within warranty, the part will be returned in kind or
equal substitution, freight collect. Credit will not be
issued.

RAYPAK, INC.

2151 Eastman Avenue

Oxnard, CA 93030

CAUTION: To avoid damage to electrical compo-

nents keep water from getting into the control
compartments and gas valve.

NOTE: Use a 3/8 in. heavy duty, reversible, electric
drill or larger. Proceed to expand tube until tool starts
to grab. Approximately 1/2 to 1 in. of the tool shank
will be visible.

NOTE: In extreme cases it may be necessary to
remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at a local car
wash.

CAUTION: Soot is combustible. Exercise extreme
care. Do not wire brush.

36

LIMITED PARTS WARRANTY ECONOPAK WATER HEATERS

SCOPE:

MODELS WH - 0260 TO 0

Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this water heater which are actually manufactured by Raypak
will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this
Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty
but are the owner's

HEAT EXCHANGER WARRANTY:

• Five (5) Years from date of water heater installation. This includes only the copper, bronze and cast iron waterways.

• Twenty (20) Years from date of water heater installation against "Thermal Shock" (excluded, however, if caused by operation

at large change

heater temperatures

ANY OTHER PART MANUFACTURED BY RAYPAK:

One (2) year warranty from date of installation, or eighteen (18) months from date of factory shipment based on Raypak's records,
whichever comes first.

SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID
IF THE WATER HEATER RATING PLATE IS ALTERED OR REMOVED.

ADDITIONAL WARRANTY EXCLUSIONS:

This warranty does not cover failures or malfunctions resulting from:

1. Failure to properly install, operate or maintain the water heater in accordance with our printed instructions provided;

2. Abuse, alteration, accident, fire, flood and the like;

3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding water heater design rates;

5. Failure of connected systems devices, such as pump or controller;

6. Use of non-factory authorized accessories or other components in conjunction with the water heater system;

7. Failing to eliminate air from, or replenish water in, the connected water system;

8. Chemical contamination of combustion air or use of chemical additives to water.

PARTS REPLACEMENT:

Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if
requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be
warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured
by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.

TO MAKE WARRANTY CLAIM:

Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the
problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call [phone]. In all cases proper authorization must first be
received form Raypak before replacement of any part.

EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:

This is the only warranty given by Raypak, No one is authorized to make any other warranties on Raypak's behalf. THIS WARRANTY
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK'S SOLE LIABILITY AND THE SOLE REMEDY AGAINST
RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL
HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL,
CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FORM WATER LEAKAGE. Some states do not allow limitations on how
long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not
apply to you.

This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest
that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the
effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of
manufacture plus thirty (30) days.

responsibility.

s exceeding 150°F between the water temperature at intake and water heating temperature, or operating at water

exceeding 190°F).

401

_____________________________________________________ ____________________________________________________

_____________________________________________________ ____________________________________________________

_____________________________________________________ ____________________________________________________

_____________________________________________________ ____________________________________________________

.oN laireS.oN ledoM

Date of Installation: _____________________________________ Date of Initial Operation: ________________________________

CORPORATE HEADQUARTERS:
RAYPAK, INC., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] FAX [phone]

relaeD fo emaNrenwO fo emaN

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Litho in U.S.A.

373839

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 [phone] Fax [phone]

Litho in U.S.A.