Raytherm WH-0182, WH-0331, WH-0181, WH-0330, WH-0400 Installation & Operating Instructions Manual

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INSTALLATION & OPERATING

INSTRUCTIONS

Raytherm™ Hot Water Supply Heaters

Models 0133–4001

Type WH

WARNING: Improper installation, adjustment, alteration, service or maintenance can

cause property damage, personal injury or loss of life. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.

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.

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

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

CATALOG NO. 3000.52L Effective: 09-02-09 Replaces: 03-09-09 P/N 241075 Rev. 13

Rev. 13 reflects the following: Changes to: Note on Page 13, Item (g) on Page 18

CONTENTS

WARNINGS 4

Pay Attention to These Terms 4

GENERAL SAFETY 5

Time/Temperature Relationships in Scalds 6

RECEIVING EQUIPMENT 6

Model Identification 6 General Specifications 7 All Models (Approved) 7 Hot Water Supply Heaters 7

INSTALLATION 7

Installation Codes 7 Installation Base 7 Clearances 8 Specifications and Dimensions 9 Outdoor Water Heaters 12 Combustion Air (Indoor Units Only) Air for Combustion and Ventilation 12 Venting 13 Vent Piping 17 Vent Damper Installation 18 Plumbing 20 Flow Rates 22 Piping—Domestic Hot Water Supply Heaters 23 Piping Diagram—Type WH - Unitemp 80 System 24 Controls—General 25 Limit Controls 26 Electrical Connections 27 Location of Controls 28

START-UP PROCEDURES 30

Before Start-Up 30 General 30 Initial Start-Up - Pump and Motor 30 Intermittent Pilot System Checkout Procedure (S8600) 32

INSPECTION PROCEDURES 32

Burners 32 Controls 32 Inspection Procedures 33

ADDENDA: LOW NOx HEATERS Models 0181 to 0401 33

Operation 33 Start-Up Procedures (S8610B Ignition Module) 33

Burner Adjustment 34 Visual Inspection 34 Electrical 34 High Gas Pressure Switch 34 Burner Tray Removal 34 Gas Valve Removal 34 Main Burner And Orifice Removal 35 Pilot Removal 35 Combustion Fan Removal 35

TROUBLESHOOTING 36

Electrical 36 Mechanical 37

WIRING DIAGRAMS 38

Wiring Diagram—WH2 0181/0261 38 Wiring Diagram—WH2 0331/0401 39 Wiring Diagram—WH2 0514–0724 40 Wiring Diagram—WH2 0824–1826 41 Wiring Diagram—WH2 2100–2500 42 Wiring Diagram—WH2 3001–4001 43 Troubleshooting—Pumps 44

SERVICE AND MAINTENANCE PROCEDURES 44

Tube Cleaning 44 Burner Tray Removal 45 Gas Valve Removal 45 Main Burner and Orifice Removal 45 Pilot Removal and Cleaning 45 High Limit or Tankstat Removal 45 Heat Exchanger Removal 45 Heat Exchanger Re-Assembly 46 Combustion Chamber Removal 46 Control Well Replacement 46 Tube Replacement 46 Cleaning Flue Gas Passageways 47

REPLACEMENT PARTS 47 WARRANTY 49

WARNINGS—Pay Attention to These Terms

DANGER:

WARNING:

AUTION:

NOTE:

DANGER: Failure to install the draft hood and

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

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

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.

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

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

Indicates the presence of hazards or unsafe practices which could cause

evere personal injury, death or substantial property damage if ignored.

ndicates the presence of hazards or unsafe practices which could cause

I minor personal injury or product or property damage if ignored.

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

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

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

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

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

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

IF PROPANE IS PRESENT OR SUSPECTED:

• DO NOT attempt to find the cause yourself;

• DO NOT try to light any appliance;

• DO NOT touch any electrical switch;

• DO NOT use any phone in your building.

• Leave the building immediately and make sure that everyone else leaves also.

• Leave the doors open for ventilation and contact the gas supplier, a qualified service agency or the fire department.

• Keep the area clear until the service call has been made, the leak is corrected, and a qualified agency has determined the area to be safe.

WARNING: Both propane and natural gas have an odorant added to help detection. Some people may not physically be able to smell or recognize this odorant. If unsure or unfamiliar about the smell associated with propane or natural gas, ask the gas supplier. Other conditions, such as "Odorant Fade", which causes the odorant to "fade", or diminish in intensity can also hide or camouflage a gas leak.

DANGER

Vapors from flammable liquids will explode and catch fire c

ausing 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 children's reach.

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

Read and follow water heater warnings and instructions.

Water heater has a main burner and pilot flame. T

he pilot flame:

1. Is on all the time or intermittently (IID).

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 rooms to the pilot flame by air currents.

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.

ARNING - CALIFORNIA PROPOSITION

W 65: This product contains chemicals known to the

State of California to cause cancer, birth defects or other reproductive harm.

GENERAL SAFETY

To meet commercial water use needs, the thermostat on this water heater is adjustable up to 190°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. This is the preferred temperature setting when supplying general

purpose hot water.

Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. 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 determine the water temperature being delivered, turn on the hot water only, place a thermometer in the stream, and read the thermometer.

The following chart 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.

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

Time/Temperature Relationships in Scalds

RECEIVING EQUIPMENT

he temperature of the water in the storage tank

T heater can be regulated by setting the temperature

ial on front of the tankstat. To comply with safety reg-

d ulations, 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.

Fig. 1: Tankstat Adjustment

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

WARNING: Pump motors should NOT be supported by any type of stand or support from above due to possible misalignment of pump and

otor which might occur.

On receipt of the equipment, visually check for external damage to the carton or the shipping crate. If the carton or shipping crate is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately. Remove the heater from the carton or the shipping crate.

Do NOT use the shipping crate base as an installation base. On occasion, items are shipped loose. Be sure that you receive the number of packages indicated on the Bill of Lading.

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 the factory or your local Raypak representative.

Claims for shortages and damages must be filed with carrier by consignee. Permission to return goods must be factory-authorized and are subject to a stocking charge.

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.

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

Model Identification

The model identification number and the heater serial number are found on the heater data plate. The model number will have the form WH1-0514A or similar depending on the heater model. (WH = Hot Water Supply System, 1 = on/off firing, 0514 = size of heater).

Rated inputs are suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000 feet above sea level.

General Specifications

The Raypak water heaters are design certified and tested under the latest requirements of the American National Standard, ANSI Z21.10.3/CSA 4.3. Each heater has been constructed and pressure tested in

ccordance with the requirements of Section IV of the

a American Society of Mechanical Engineers Code, and factory fire tested.

All Models (Approved)

TYPE WH3 with 2-STAGE CONTROLS Models 0181-4001

ot water supply heater with low-high fire for 2-stage

H control. Available with integrally mounted pump, factory mounted and wired for models 0181-1826. To be used with storage tank systems.

INSTALLATION

All models are National Board approved. Temperature and pressure gauge is standard. Intermittent ignition device is standard on models 0514 and up.

Model 0133 has 4-pass heat exchanger, 1 tube per pass. Models 0181-0401 have 2-pass heat exchangers, 5 tubes first pass, 4 tubes second pass. Models 0514-1826 have 2-pass heat exchangers, 5 tubes first pass, 4 tubes second pass. Models 2100-4001 have 2-pass heat exchangers, 9 tubes per pass. Models 0926-4001 have optional single pass with cast iron headers only.

Hot Water Supply Heaters

All Raypak hot water supply heaters are ASME rated and design certified as hot water heaters, with 125 PSI pressure relief valves.

TYPE WH1 with ON/OFF CONTROLS Models 0133-4001

Installation Codes

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.

Installation Base

The heater should be mounted on a level, non-combustible surface. Heater must not be installed on carpeting. The 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. Do NOT use the shipping base crate as an installation base.

To be used with storage tank systems. Available with integrally mounted pump, factory mounted and wired for models 0133-1826. Models 0181, 0261, 0331 and 0401 are Low NOx Hot Water Heaters.

TYPE WH2 with MODULATING CONTROLS Models 0133-4001

Hot water supply heater with 110°-170°F gas modulation. Available with integrally mounted pump, factory mounted and wired for models 0133-1826. To be used with storage tank systems.

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.

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.).

eater

Model

Number

loor Base

Part

Number

133 001749

182/0181 058313 0260/0261 058314 0330/0331 058315 0400/0401 058316

0514 056199 0624 056200 0724 056201

0824 056202 0926* 054597 1083* 054598 1178* 054599 1287* 054600 1414* 054601 1571* 058378 1758* 058379

0962 059233

1125 059234

1223 059235

1336 059236

1468 059237

1631 059238

1826 059239

*Models with factory installed floor shield as standard. BOLD TYPE indicates Low NOx models.

Clearances

133 0181 to 0514 to 0926 to 2100 to

Location 0401 0824 1826 4001

Floor Front Back 12 12 12 24 24 Right 6 12 6 24 24

Left 12 12 18 24 24

Vent 66666

Indoor Top 42 39 36 24 24

Outdoor Top NA

See Note 1 See Note 2

Unobstructed

Heater Size

0133 0181 to 0514 to 0926 to 2100 to

Description Location 0401 0824 1826 4001

. 3-1/2 in. thick masonr

alls Back 9991616

without ventilated air space. Right 5951616

Left 9 9 12 16 16

Vent 55555

Indoor Top 43 39 36 24 24

Outdoor Top Unobstructed NA

b. 1/2 in. insulation board Back 6661212

over 1 in. glass fiber or Right 3631212 mineral wool batts. Left 6691212

Vent 33333

Indoor Top 30 30 24 16 16

Outdoor Top Unobstructed NA

c. 0.024 sheet metal over 1 in. Back 44488

glass fiber or mineral wool Right 34388 batts reinforced with wire Left 44688 on rear face with ventilated Vent 33333 air space. Indoor Top 24 24 18 12 12

Outdoor Top Unobstructed NA

d. 3-1/2 in. thick masonr

wall Back 66688

with ventilated air space. Right 66688

Left 66688

Vent 66666

Indoor Top 42 39 36 24 24

Outdoor Top NA Unobstructed NA e. 0.024 sheet metal with Back 44488 ventilated air space. Right 24288

Left 44688

Vent 22222

Indoor Top 24 24 18 12 12

Outdoor Top Unobstructed NA f. 1/2 in. thick insulation Back 44488

board with ventilated Right 34388 air space. Left 44688

Vent 33333

Indoor Top 24 24 18 12 12

Outdoor Top NA Unobstructed NA

. 0.024 sheet metal with Back 44488

ventilated air space over Right 34388

0.024 sheet metal with Left 44688 ventilated air space. Vent 33333

Indoor Top 24 24 18 12 12

Outdoor Top Unobstructed NA h. 1 in.

lass fiber or mineral Back 44488 wool batts sandwiched Right 34388 between two sheets 0.024 Left 44688 sheet metal with ventilated Vent 33333 air space. Indoor Top 24 24 18 12 12

Outdoor Top NA Unobstructed NA

Installation Clearances (All Dimensions are in Inches)

Note 1: Combustible floor shield is required when heater is to be installed on a combustible surface. (See ordering info.) Note 2: Servicing Clearances: Provide at least 24" (Models 0133-

1826), 48" (Models 2100-4001) in front of unit for removal & servicing of the Controls & Burner Tray. Provide at least 18" on side opposite water connections for deliming of Heat Exchanger Tubes. *Vent includes factory supplied drafthoods and does not include field supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into heater.

Table C: Clearances From Combustible Surfaces

Table B: Combustible Floorshield Ordering Information

Fig. 2: Alternate Method for Providing a Non-

Combustible Base

Table D: Clearances to Protected Surfaces

MODELS 0 182-0400 and 0181-0401

MODEL 0133

NOTE: The heater shall be installed in a space large in comparison to the size of the heater. Large space is defined as having a volume at least sixteen (16) times the total volume of the heater.

Specifications and Dimensions

Indoor Outdoor

Model

Number

WH-0133 136.0 135 132

* Recovery based on manufacturer’s rating.

Input MBH

Recovery

GPH*

Recovery

GPH*

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

Indoor Dimensions (in inches)

Model Number

WH-0182/0181 181.0 180 18-1/4 62-5/8 12-1/16 6

WH-0206/0261 264.0 262 22-3/8 62-7/8 11-1/8 7

WH-0330/0331 334.0 332 25-3/4 63-3/4 10-3/4 8

WH-0400/0401 399.0 397 29-1/4 65-3/8 12-1/2 9

* Recovery based on manufacturer’s rating.

Input MBH

Recovery

GPH*

WidthAHeight

C J

Flue

Diameter

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

Bold type indicates Low NOx models.

MODELS 0514-0824

MODELS 0 962-1826

Model

Number WH-0514 511.5 508 32-3/4 1 10 25-3/8 WH-0624 627.0 623 37-1/2 1 12 29-1/2 WH-0724 726.0 722 41-5/8 1 12 34-1/4 WH-0824 825.0 820 45-3/4 1 14 38-1/2

* Recovery based on manufacturer’s rating.

Indoor/Outdoor Dimensions (in inches)

Input MBH

Recovery

GPH*

Width

Gas

Conn.

Flue

Diameter

K L

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

Model

Number

WH-0962 961.7 956 52-3/8 68-3/4 33-1/2 1 2-1/2 18 14 28

WH-1125 1124.7 1118 59-1/4 74-1/2 33-1/2 1 2-1/2 23-5/8 16 32

WH-1223 1222.5 1215 63-5/8 74-1/2 33-1/2 1-1/4 2-1/2 23-5/8 16 32

WH-1336 1336.6 1328 68-5/8 76-1/2 33-1/2 1-1/4 2-1/2 23-5/8 18 36

WH-1468 1467.0 1458 74-7/8 76-1/2 33-1/2 1-1/4 2-1/2 23-5/8 18 36

WH-1631 1630.0 1620 82-1/8 79-1/2 36-1/2 1-1/4 2-1/2 23-5/8 18 36

WH-1826 1825.6 1814 89-3/8 81-1/2 36-1/2 1-1/4 2-1/2 23-5/8 20 40

Input MBH

Recovery

GPH*

Width

* Recovery based on manufacturer’s rating.

Overall

Height

Dimensions (in inches)

Jacket Height

Gas

Conn.

Water

Conns.

H J

Flue

Diameter

K L

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

MODELS 0926-1758

MODELS 2100-4000

MODEL,

Model

umber

H-0926926.0

H-10831083.0

H-11781178.0

WH-1287 1287.0 1279 68-5/8 1-1/4 2-1/2

WH-1414 1413.0 1404 74-7/8 1-1/4 2-1/2

WH-1571 1570.0 1560 82-1/8 1-1/4 2-1/2

WH-1758 1758.0 1747 89-3/8 1-1/4 2-1/2

* Recovery based on manufacturer’s rating.

Input

Recovery

PH*

076

171

imensions (in inches)

2-3/8

9-1/4

3-5/8

idth

Gas

onn.

-1/4

1 2

Water

onns.

-1/2

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

Model

Number

WH-2100 2100.0 2087 61 68-1/4 ** 3 24

WH-2500 2499.0 2484 70 68-1/4 ** 3 26

WH-3001 3000.0 2982 81-1/4 68-1/4 2 3 28

WH-3500 3500.0 3479 92-1/2 68-1/4 2 3 30

WH-4001 4000.0 3976 103-3/4 68-1/4 2 3 32

Input MBH

Recovery

GPH*

* Recovery based on manufacturer’s rating. ** 1-1/2” or 2” contingent on code requirements

Width

Dimensions (in inches)

Overall

Height

Gas

Conn.

Water

Conns.

Flue

Diameter

NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

Outdoor Water Heaters

Model

Square

Inches

Model

Square

Inches

0133 136 1223 1223

0182/0181 181 1336 1337 0260/0261 264 1468 1467 0330/0331 334 1631 1630 0400/0401 399 1826 1826

0514 512 2100 2100 0624 627 2500 2499 0724 726 3001 3000 0824 825 3500 3500 0962 962 4001 4000 1125 1125

BOLD TYPE indicates Low NOx models.

Model

Square

Inches

Model

Square

Inches

0133 34 1223 306

0182/0181 46 1336 335 0260/0261 66 1468 367 0330/0331 84 1631 408 0400/0401 100 1826 457

0514 128 2100 525 0624 157 2500 625 0724 182 3001 750 0824 207 3500 875 0962 241 4001 1000 1125 282

BOLD TYPE indicates Low NOx models.

These heaters are design certified for outdoor installation. 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

verhang. Roof water drainage must be diverted away

o from the heaters 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.

CAUTION: Combustion air must not be

ontaminated by corrosive chemical fumes which

c can damage the heater. Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ventilation air supply. Such

hemicals include, but are not limited to, chlorinated

c and/or fluorinated hydrocarbons such as found in

efrigerants, aerosol propellants, dry-cleaning fluids,

r 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 acidic condensate can damage or substantially reduce the life of the heater. It may become necessary to provide outside air directly to the heater in order to avoid this problem.

a. All Air From Inside The Building: Each opening shall have a minimum net free square inches as noted:

Fig. 3: Outdoor Clearances from Openings

High Wind Conditions (Outdoor Units Only)

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

Combustion Air (Indoor Units Only) Air for Combustion and Ventilation

The heater must have both combustion and ventilation air. Minimum requirements for net free air supply

openings are 12 inches from ceiling for ventilation and 12 inches from the floor for combustion air as outlined in ANSI Z223.1, and any local codes that may have jurisdiction.

Table E: All Air From Inside The Building

b. All Air From Outdoors: When air is supplied directly from outside of building, each opening shall have a minimum net free square inches as noted:

Table F: All Air From Outdoors

NOTE: If louvers, grills or screens are used on the

utdoor Top

-3/8"

UTDOOR

LOOR BASE

Pagoda Top (Shipped Loose with Heater)

penings, obtain the net free area from their suppli-

o er 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

etal louvers will have 60-75 percent free area as

specified in the National Fuel Gas Code.

Venting

Outdoor Installations

Model 0133

1. Remove the front (4) screws.

2. Line up outdoor top vent opening over heater vent opening.

3. Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top.

Models 0181-0401 and 0182-0400

4. Reinstall (5) screws to secure jacket top and outdoor top to unit.

Fig. 5: Outdoor Top Installation

Vent Terminal (Outdoor) Stackless Top Installation

1. Insert tabs into keyhole (4 places).

2. Snap tabs into keyholes so as not to pull out.

Fig. 6: Outdoor Top Installation

Fig. 4: Outdoor Top Installation

Models 0514-0824

Models 0926-1758

1. Lower outdoor "Stackless" top onto unit. Position top so it is centered on unit from side-to-side and front-to-rear.

Fig. 7: Outdoor Top Installation

Heaters are shipped with outdoor vent terminal factory installed.

Models 2100-4001

These units are not certified for outdoor installation.

Indoor Installations

Model 0133

Refer to Fig. 9 on the following page.

1. Shut-off main electrical power switch to heater.

2. Turn heater manual ON/OFF switch, located in upper control panel, to the "OFF" position.

3. Shut-off gas supply and water supply to the heater.

4. Mount drafthood on heater and attach with the 8 sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side as shown.

2. Tighten the (4) screws (Shown below) until they come in contact with the unit jacket top, then evenly tighten all (4) screws to secure to unit.

5. Remove plastic plug from left side of heater jacket and install the plastic grommet provided.

6. Route flue sensor wire harness through the grommet installed in Step 5.

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

8. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.

Fig. 8: Outdoor Top Installation

Fig. 9: Indoor Top Installation

Models 0181-0401 and 0182-0400

DRAFTHOOD

JACKET TOP PANEL

(part of the heater)

#10 SHEET METAL SCREW (3)

MOUNTING BRACKET (3)

FLUE COLLECTOR

(part of heater)

SCREW HOLE LOCATION

3-1/4"

INNER STACK ADAPTER PANEL

2-1/2"

COMBUSTIBLE FLOOR SHIELD

(optional for indoor)

Models 0514-0824

Vent Terminal/Indoor Stack Installation

1. Remove the louvered jacket top by removing four (4) #10 flathead 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 (drafthood) upside down and set it down bottom side up.

5. Turn the jacket top panel (removed in step 1) upside down and place it over 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. 10). Caution must be taken not to over tighten and strip the screw threads.

Locate and assemble as shown below. Secure with screws supplied in envelope in carton.

Fig. 11: Indoor Top Installation

Models 0962-1826

Locate and assemble as shown below. Secure with screws supplied in envelope in carton.

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 flathead screws removed in step 1 above.

Fig. 10: Indoor Top Installation

Fig. 12: Indoor Top Installation

Models 2100-4001

These models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system.

Vent Piping

5' MIN

2' MIN

10' OR LESS

' MIN

VENT CAP

ENT PIPE

DRAFT HOOD

HEATER

ARNING: 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.

Vent piping of the same size as the drafthood outlet is recommended, however, when the total vent height is at least ten (10) feet (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in the National Fuel Gas Code, ANSI Z 223.1.

Avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal non-vertical 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. Plumber's tape, crisscrossed, will serve to space both horizontal and vertical piping. 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 an insulated vent pipe spacer through the roofs and walls.

For protection against rain or blockage by snow, the vent pipe must terminate with a 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 2 feet higher than any part of the building or equipment within ten feet. The vent stack shall be at least 5 feet in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 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.

Fig. 13: Vent Piping

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.

Fig. 14: Common Vent Piping

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.

The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood 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.

(a) Seal any unused openings in the common venting

system.

(b) Visually inspect the venting system for proper size

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

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 operate 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 thermostat

o appliance will operate continuously.

(e) Test for spillage at the drafthood 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.

(f) After it has been determined that each appliance

remaining connected to the common venting system is venting properly, 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 that 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 the National Fuel Gas Code, ANSI Z223.1.

WARNING: Do not use thermally actuated vent

ampers on modulating heater. To do so, may result

d in asphyxiation. Use only a mechanically actuated vent damper device that is electrically interlocked with the modulating heater operation.

Fig. 15: Vent Damper

Mounting

For special venting applications that require reduced vent sizes and through-the-wall venting, the Type D Induced Draft Assembly can be used. Consult the factory or your local Raypak representative.

Vent Damper Installation

Models 0133 Through 0180 (Where Required)

Location

The vent damper must be located in the vent so that it serves only the appliance for which it is intended.

If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. Make certain that it is mounted in an accessible location at least 6 in. from any combustible material or the heat exchanger and that the position indicator is in a visible location.

The vent damper must be installed after the appliance drafthood, as close to the drafthood as practicable, and without modification of the drafthood.

On vertical vents, the vent damper may be mounted with the actuator in any position. On horizontal vents, do not mount the actuator either directly above or directly below the vent pipe; mount the vent damper actuator to the side of the vent, as shown in Fig. 16.

The vent damper is set up for a continuous pilot system. If the vent damper is installed on an Intermittent Pilot or Direct Spark Ignition equipped system, the energy savings of the vent damper can be improved by plugging the hole in the vent damper blade using the knockout plug, Part No. 105612R, provided in the parts envelope.

DO NOT plug the hole if installing the vent damper on a continuous pilot system as this will create a hazardous condition.

YES

INSTALL VENT

DAMPER WITH

ACTUATOR TO

SIDES OF VENT

ONLY. DO NOT

MOUNT ABOVE OR

BELOW VENT.

TO CHIMNEYTO BOILER

D808

FLOW >

HORIZONTAL INSTALLATION

TO CHIMNEY

TO BOILER

D808

VERTICAL

INSTALLATION

ACTUATOR MAY BE

INSTALLED IN ANY

POSITION ON

VERTICAL PIPE.

HEATER

EATER

Motor

End

Switch

.O. N.C.

1K2

1K1

808

Thermostat or

Controller

Dual Valve

Combination Gas

Control or

Ignition System

Optional Limit

LocationLimit

Transformer

(

Hot)

Yellow Blue

Power supply provide disconnect me ans an overload protection as requ ired.

Black Orange Red

Power supply provide disconnect means an overload protection as required.

Fig. 16: Installing Vent Damper

amper Position I

ndicator

DAMPER OPEN DAMPER CLOSED

Damper Position

Indicator

Vent Damper

For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually, with particular attention given to

eterioration from corrosion or other sources. Check

d vent damper operation as follows:

1. When the heater is off, check that the vent damper position indicator points to the closed position, Fig.

18.

Fig. 18: Vent Damper position Indicator Showing Open

& Closed Positions

Fig. 17: Vent Damper General Wiring Diagram

INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED. IF IMPROPERLY INSTALLED, A HAZARDOUS CONDITION, SUCH AS AN EXPLOSION

OR CARBON MONOXIDE POISONING, COULD RESULT.

2. Turn the thermostat or controller up to call for heat and check that the vent damper indicator points to the open position, Fig. 18.

3. Turn the thermostat or controller down again and check that the vent damper position indicator returns to the closed position.

THE VENT DAMPER MUST BE INSPECTED AT LEAST ONCE A YEAR BY A TRAINED, EXPERIENCED SERVICE TECHNICIAN. THE NAME OF THE PERSON WHO ORIGINALLY INSTALLED YOUR VENT DAMPER IS SHOWN ON THE INSTALLATION LABEL. DAMPER MUST BE IN THE OPEN POSITION WHEN HEATER MAIN BURNERS ARE OPERATING.

Plumbing

General

eater should be located so that any water leaks will

H not cause damage to any adjacent areas or structures.

Gas Supply Connections

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.

CAUTION: The heater and its manual shut-off

alve must be disconnected from the gas supply

v during any pressure testing of that system at test pressures in excess of 1/2 PSIG. Dissipate test pressure in the gas supply line before reconnecting

he heater and its manual shut-off valve to gas

t supply line. FAILURE TO FOLLOW THIS

ROCEDURE MAY DAMAGE THE GAS VALVE.

P 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 approved for the fuel being used is recommended.

Fig. 19: Sediment Trap

NPNP NPNPNP NPNPNP NP

0133 15 35 60 145 200 500

0182/0181

-15306595250400-----------

*0260/0261

- 10 20 40 60 140 250 560 - - - - - - - - -

*0330/0331

- 15 25 35 85 150 380 360 - - - - - - - - -

*0400/0401

--152560100260250--------00506303105156535101-4150 ------0

4305259001545201--4260 -------

00606208157085302---4270 ------

00508458103155065251---4280 ----0926/0962 - - - 15 20 45 45 110 150 360 400 - - - - 1083/1125 - - - 10 15 35 35 80 120 300 300 - - - - 1178/1223 - - - - - 25 25 60 85 220 200 - - - - 1287/1336 - - - - - 25 20 55 75 180 170 325 560 - - 1414/1468 - - - - - 20 15 45 65 150 165 300 500 - - 1571/1631 - - - - - 15 15 35 50 120 125 250 400 - - 1758/1826 - - - - - 15 10 30 40 100 100 225 340 - - -

2100 - - - - - 10 10 25 30 80 75 175 260 - - 2500 - - - - - - - 15 20 55 55 135 160 400 600 3001 - - - - - - - 10 15 35 40 85 120 250 500 3500 - - - - - - - - 10 30 30 45 80 200 400 600 4001 - - - - - - - - 5 20 25 35 65 160 300 400

-1/2"3/4"

MAXIMUM EQUIVALENT PIPE LENGTH

NATURAL GAS 1000 BTU/Cubic Foot .60 SPECIFIC GRAVITY @ 0.5" W.C. PRESSURE DROP

" 2-1/2" 3" 4"

PROPANE GAS 2500 BTU/Cubic Foot 1.53 SPECIFIC GRAVITY @ 0.6" W.C. PRESSURE DROP

4/1-1"1"2/1

* Models 0181, 0261, 0331, and 0401 are Low NOx units and are not available in propane.

A minimum of 7" WC and a maximum of 10.5" WC upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 11" WC and a maximum of 13" for propane.

Table G: Maximum Equivalent Pipe Lengths

Gas Pressure Regulator

The gas pressure regulator located in the gas valve is preset nominally at 4" WC for natural gas, and 11" WC for propane. Between the gas valve and the burners is a 1/8" pipe plug. The pressure at this point, taken with a manometer, should be about 3.7" WC natural gas and 10.5" WC propane. Models 0181, 0261, 0331, and 0401 should be 3.9 WC natural gas. If an adjustment is needed, turn adjustment screw clockwise to increase pressure, or counter-clockwise to decrease pressure.

Venting of Diaphragm Gas Components

Gas train components that have diaphragms in their construction are supplied with a bleed line connection that must be connected to the outside atmosphere as required by the National Fuel Gas Code. Under NO circumstances shall bleed lines terminate in the gas

utilization equipment flue or exhaust system.

Fig. 20: Bleed Line Connection

RDH

SIZE GPM

T P FT

GPM

T P FT

CONN GPM

T P FT

GPM

T P FT

CONN

0133*

22 10 14.7 10 22 3.3 1-1/4"

182/0181

45 7 9.2 20 15 1.8

1-1/2"

260/0261

45 10 9.4 20 22 1.9

1-1/2"

330/0331

45 12 9.6 20 28 1.9

1-1/2"

400/0401

45 15 9.8 20 33 2.0

1-1/2"

0514

90 9 9 40 21 1.8

0624

90 12 9.5 40 26 1.9

0724

90 13 10 40 30 2.0

0824

90 15 10.5 40 34 2.1

0926

90 17 11 40 38 2.2

2 1/2"

200 8 9.7

90 17 2.1 3"

0962

90 18 11 40 39 2.2

2 1/2"

200 8 9.7

90 18 2.1 3"

1083

90 20 12 44 40 2.9

2 1/2"

200 9 10.3

90 20 2.3 3"

1125

90 20 12 46 40 3.1

2 1/2"

200 9 10.3

90 20 2.3 3"

1178

90 21 12.5 48 40 3.6

2 1/2"

200 10 11

90 21 2.4 3"

1223

90 22 12.5 50 40 3.9

2 1/2"

200 10 11

90 22 2.4 3"

1287

90 23 13.2 53 40 4.5

2 1/2"

200 11 11.7

90 23 2.5 3"

1336

90 24 13.2 55 40 4.9

2 1/2"

200 11 11.7

90 24 2.5 3"

1414

90 26 14 58 40 5.8

2 1/2"

200 12 12.2

90 26 2.7 3"

1468

90 27 14 60 40 6.2

2 1/2"

200 12 12.2

90 27 2.7 3"

1571

90 29 14.5 64 40 7.3

2 1/2"

200 13 13

90 29 2.8 3"

1631

90 30 14.5 67 40 8.1

2 1/2"

200 13 13

90 30 2.8 3"

1758

90 32 15.4 72 40 9.7

2 1/2"

200 14 14.7

90 32 3 3"

1826

90 33 15.4 75 40 10.6

2 1/2"

200 15 14.7

90 33 3 3"

2100

200 17 14.8 90 38 3.2

400 9 18

180 19 4 4"

2500

200 20 15.8 102 40 4.3

400 10 18.8

180 23 4.1 4"

3001

200 25 16.7 123 40 6.5

400 12 19.5

180 27 4.3 4"

3500

200 29 17.5 144 40 9.3

400 14 20.5

180 32 4.5 4"

4001

200 33 18.7 164 40 12.8

400 16 21.5

180 36 4.7 4"

MAXIMUM AND MINIMUM FLOW RATES

XAM MAX

-PASS HEAT EXCANGER

-PASS HEAT EXCHANGER

Flow Rates

GPM Flow rates limited by maximum acceptable velocity through heat exchanger tubes. May be increased by 10% for closed heating systems. * 4 Pass Heat Exchanger

BOLD TYPE indicates Low NOx models.

Table H: Maximum and Minimum Flow Rates

Indoor Outdoor T GPM P MPS SHL T GPM

P MPS SHL

T GPM

P MPS SHL

0133 0133 22 10 3.4 1-1/4 5.1 17 13 5.5 1-1/4 8.2 10 22 14.7 1-1/4 22.0

0182/0181 0182 15 20 1.8 1-1/2 4.6 12 26 3.1 1-1/2 7.5 7 45 9.2 1-1/2 20.8 0260/0261

0260 21 20 1.9 1-1/2 4.6 17 26 3.1 1-1/2 7.6 10 45 9.4 1-1/2 21.0

0330/

0331 0330 27 20 1.9 1-1/2 4.7 21 26 3.2 1-1/2 7.7 12 45 9.6 1-1/2 21.2

0400/

0401 0400 30 22 2.3 1-1/2 5.6 25 26 3.3 1-1/2 7.8 15 45 9.8 1-1/2 21.3

514 0514 20 42 2.0 2 4.8 16 52 3.0 2 7.1 9 90 9.0 2 19.1 0624 0624 25 41 2.0 2 4.7 19 54 3.4 2 7.9 11 90 9.5 2 20.9 0724 0724 29 41 2.1 2 4.9 20 60 4.4 2 9.8 13 90 10.0 2 21.4 0824 0824 30 45 2.6 2 5.9 20 68 6.0 2 12.8 15 90 10.5 2 21.9 0962 0926 30 53 3.8 2-1/2 5.3 20 79 8.5 2-1/2 11.5 18 90 11.0 2-1/2 15.2 1125 1083 30 61 5.5 2-1/2 7.5 20 90 12.0 2-1/2 16.2 20 90 12.0 2-1/2 16.2 1

223 1178 30 67 7.0 2-1/2 9.3 22 90 12.5 2-1/2 16.7 22 90 12.5 2-1/2 16.7 1336 1287 30 73 8.7 2-1/2 11.5 24 90 13.3 2-1/2 17.5 24 90 13.3 2-1/2 17.5 1468 1414 30 80 11.0 2-1/2 14.4 27 90 14.0 2-1/2 18.2 27 90 14.0 2-1/2 18.2 1631 1571 30 90 14.8 2-1/2 19.0 30 90 14.8 2-1/2 19.0 30 90 14.8 2-1/2 19.0 1826 1758 33 90 15.4 2-1/2 19.6 33 90 15.4 2-1/2 19.6 33 90 15.4 2-1/2 19.6 2

100 N/A 30 115 5.0 3 7.9 20 172 11.0 3 17.2 17 200 14.8 3 22.9 2500 N/A 30 137 7.5 3 11.4 20 200 15.8 3 23.9 20 200 15.8 3 23.9 3001 N/A 30 164 11.2 3 17.0 25 200 16.7 3 24.8 25 200 16.7 3 24.8 3500 N/A 30 191 16.2 3 23.7 29 200 17.5 3 25.6 29 200 17.5 3 25.6 4001 N/A 33 200 18.7 3 26.8 33 200 18.7 3 26.8 33 200 18.7 3 26.8

BOLD TYPE indicates Low NOx models.

0-4G

5-15 Gra

inPr

vrr

Gallo

WATER HARDNESS

ODELS

MUI

DEM

∆T = Temperature Rise, Degree F@GPM FLOW GPM = Gallons per Minute Flow ∆P = Pressure Drop, Foot thru Heat Exchanger MPS = Minimum Pipe Size, NPT SHL = System Head Loss

Table I: General Specifications Uni-Temp 80 Hot Water Supply Systems

Piping—Domestic Hot Water Supply Heaters

Table I above provides data for selecting in-line pumps for use in a Uni-Temp 80 system for a single heater and tank according to the following:

1. Flow rates are based on water hardness as measured in grains per gallon.

Soft: 0-4 grains per gallon.

2-1/2" NPT = 80 Ft (0926-1826) 3" NPT = 85 Ft (2100-4001)

Additional pipe fittings will increase the system head loss.

5. Select a pump based on the water hardness, flow, and system head loss.

6. If heater is more than two stories above the tank, consult the factory.

Medium: 5-15 grains per gallon. Hard: 16 and over grains per gallon.

NOTE: GPM flow rates are limited by maximum acceptable velocity through heat exchanger tubes.

2. Maximum Flow Rates:

Heater models 0514 through 1826 may be provided with an integral rear-mounted pump. This must be

0133 22 GPM

specified at time of order.

0181-0401 45 GPM

2100-4001 200 GPM

3. Pressure drop values (∆P and SHL) and minimum pipe sizes are for two-pass heaters.

4. Sizing based on heater and tank being placed 5 feet apart. The equivalent length of pipe valves and fittings in the system is as follows:

1-1/2" NPT = 70 Ft (0181-0401) 2" NPT = 75 Ft (0514-0824)

0514-1826 90 GPM

MINIMUM INPUT ADJUSTMENT: Model Types WH have minimum input ratings as specified on their individual rating plates. Minimum input controllers have been pre-set at the factory. Consult with factory representatives if a minimum input problem should occur.

0133

0181–0401

0514–0824

0926–1826

Piping Diagram—Type WH - Unitemp 80 System

Controls—General

Relief Valve

new combination temperature and pressure (T&P)

A 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 the relief valve.

Pump Time Delay

There are two versions of the Pump Time Delay. The first is the Economaster II. It is an electronic device that allows the operator to set a variable time (3 to 10 minutes) for the pump to run after the heater shuts off. See Fig. 21 (A). The time is factory-set at 7 minutes and it can be re-adjusted in the field.

(A)

(B)

Fig. 21: Economaster Time Delay Relays (TDR)

Electronic Ignition

The intermittent ignition device conserves energy by automatically extinguishing the pilot when desired temperature is reached. When additional heat is needed, the pilot re-ignites electrically, eliminating the fuel costs of maintaining a constant pilot. To ensure safe operation, the gas valve cannot open until the pilot relights and is confirmed.

The second version is a fully enclosed solid state TDR with a white jumper that selects one of two time delays. See Fig. 21 (B). If the jumper is on pins 6 and 7 (default) the delay time is 5 minutes. If the jumper is not on pins 6 and 7, the time delay is 10 minutes.

In a conventional system, when the Aquastat is satisfied, the main gas valve closes, but the pump continues operating. With either time delay relay the heater pump is programmed to continue running for an optimum period of time in order to absorb the residual heat from the combustion chamber and use it in the system. The pump then shuts off until the next call for heat is received from the Aquastat.

NOTE: Pump will come on when power is first applied to heater.

Table J: Electronic Ignition

Operating Controls

On models 0514-1826, models with mechanical modulating controls have one or more Robertshaw Unitrol 7000 Series hydraulic snap on thermostatic combination gas valves. These valves have the pressure regulator and 24-volt operator built-in. The hydraulic actuator will throttle the heater input to adjust the firing rate and meet the required load. This, in effect, prevents costly fuel consumption, as compared to an

on-off cycling heater. The valve has a remote capillary bulb immersed in a well, at the header outlet, to maintain a constant outlet water temperature. When multiple valves are furnished, they can be staged to give greater flexibility of control. Standard factory setting is at position 5. Consult the dial setting tag attached to the control for your desired temperature. See Fig. 22 below.

Fig. 24: Motorized Gas Valve Location—Model 3001

Limit Controls

High Limit

The heater is equipped with a manual reset High Limit. Push the reset button and set the limit(s) to 30°F–40°F above desired operating temperature. Maximum setting is 200°F; other options may be available.

Fig. 22: Dial Setting Tag

Fig. 23: Mechanical Modulating Valve Location—

Models 0724-1336

Fig. 25: High Limit

Flow Switch

This dual-purpose control shuts off the heater in case of pump failure or low water condition and is strongly recommended. It is mounted and wired in series to the main gas valve.

NOTE: The flow switch is a safety device and not a control. Do not operate the heater with flows less than the minimums stated in this manual.

Fig. 26: Flow Switch

100% Pilot Safety

SINGLE

STAGE

TANKSTAT

STAGE 1

CONNECTION

ATTACH STAGE 1 CONNECTIONS

ON HEATER TO THE SINGLE STAGE

TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.

2-STAGE

TANKSTAT

STAGE 1

CONNECTION

STAGE 2 CONNECTION OR

STAGE 1 CONNECTION

OF HEATER 2

ATTACH STAGE 1 CONNECTIONS ON HEATER

TO STAGE 1 CONNECTION ON TANKSTAT.

ATTACH STAGE 2 CONNECTIONS OR

STAGE 1 CONNECTION OF HEATER 2

TO STAGE 2 CONNECTIONON TANKSTAT

AS SHOWN IN THE DIAGRAM.

Models 0514-4001 employ electronic devices which close the main gas valve within 8/10 of a second whenever the pilot flame is interrupted. Pilot flame is

utomatically lit when the device is powered. Unit per-

a forms its own safety check and opens the main valve only after the pilot is proven to be lit.

Low Water Cut-Off (Optional)

The low water cut-off automatically shuts down burner whenever water level drops below probe. 5-second (max) time delay prevents premature lockout due to temporary conditions such as power failure or air pockets. Flush float type devices at beginning of each heating season.

CAUTION: Label all wires prior to disconnection

hen servicing controls. Wiring errors can cause

w improper and dangerous operation. Verify proper operation after servicing.

The heater is normally wired for 120 Volts. The voltage is indicated on the tie-in leads. Consult the wiring diagram shipped with the heater in the instruction packet. The "TH" leads are for the remote tank control connection. 24 Volts are supplied to this connection through the heater transformer. DO NOT attach line voltage to the "TH" leads on models 0514-1826. Before starting heater check to ensure proper voltage to heater and pump.

Heater must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No 70.

NOTES:

1. Field install ground wire to inside of junction box.

2. If any of the original wire supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent.

Fig. 27: Low Water Cut-Off

High and Low Gas Pressure Switches (Optional)

These switches sense either high or low gas pressures and automatically shut down burners if abnormal pressures exist.

Fig. 28: Gas Pressure Switch

Electrical Connections

DANGER - SHOCK HAZARD: Make sure

electrical power to the heater is disconnected to avoid potential serious injury or damage to components.

Fig. 29: Single-Stage Tankstat

Fig. 30: 2-Stage Tankstat (2 On/Off Units)

Location of Controls

0400 WH1, WH2, WH3

0181 (LOW NOx) WH1

0824

Location of Controls

START-UP PROCEDURES

Before Start-Up

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the heater when the heater underwent tests specified in the latest edition of the ANSI-Z21.10.3/CSA 4.3 Standard.

General

Before lighting up a new installation, water should be flowing through the heater. Water pressure regulator should be set to minimum 25 PSI.

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

Initial Start-Up - Pump and Motor

Many pumps are now direct-drive. They have no coupler or bearing assembly. These pumps do not require lubrication. Others require SAE-30 non-detergent oil to lubricate both the motor and the bearing assembly. Check pump motor for type before adding oil.

Clean dust and lint from pump and motor. Check pump coupler and tighten if necessary.

Flush system before putting into operation to ensure that foreign material does not damage pump seals.

CAUTION: Pump must be off to check oil in bearing assembly. Do not run pump without water in system.

TO TURN OFF GAS TO APPLIANCE

LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION (IID)

FOR MODELS WITH MANUAL GAS VALVES

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing p

roperty damage, personal injury or loss of life.

A. This appliance 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 appliance

area for gas. Be sureto smell next to thefloor 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 your

neighbor’s phone. Follow the gas supplier’s instruc-

tions.

* If you cannot reach your gas supplier, call the fire de-

partment.

C. Use only your hand to push in or turn the gas control

knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

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

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

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat 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 rests against stop. For Honeywell Gas Valve: (Model 400 only) Push in gas control knob slightly and turn clockwise to “OFF”. Knob cannot be turned “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”.

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

9. Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set thermostat 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.

ROBERT SHAW GAS CONTROL KNOB SHOWN IN "ON" POSITION

GAS INLET

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 Gas Valve: Turn gas control knob clockwise to “OFF”.

For Honeywell Gas Valve: Turn gas control knob clockwise to “OFF”. Make sure knob rests against stop.

5. Replace heater door panel.

HONEYWELL GAS CONTROL KNOB SHOWN IN "ON" POSITION

GAS INLET

FOR MODELS WITH AUTOMATIC GAS VALVES

GAS INLET

PILOT SHUT-OFF VALVE CONTROL S

HOWN IN "ON"

POSITION

TO PILOT

MAIN GAS SHUT-OFF VALVE SHOWN IN THE "ON" POSITION

1. Close all gas valves. Turn off electric power supply. Wait five (5) minutes.

2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted.

3. Open main gas valve.

4. Set temperature controls to desired temperature.

TO SHUT DOWN

Close all manual gas valves. Turn off electric power.

Intermittent Pilot System Checkout Procedure (S8600)

After Start-Up

1. Turn on power to the ignition systems and turn gas

supply off.

2. Check ignition module as follows:

a. Set the tankstat to call for heat. b. Watch for continuous spark at the pilot burner. c. Time the spark operation. Time must be within 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 call for heat.

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.

INSPECTION PROCEDURES

Burners

cates excessively high gas pressure. Low flame indicates low gas pressure.

Fig. 31: Typical Main Burner Flame (Atmospheric

Models)

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.

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

Inspection Procedures

SEE DETAIL VIEW A

DETAIL A

ADDENDA: LOW NOx

Inspect on the first and third month after initial startup and then on an annual basis. If problems are found, refer to the Troubleshooting sections of this manual 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 condition 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.

HEATERS MODELS 0181 TO 0401

he Raytherm Low NOx Heater is offered with WH1-

T On-Off firing (standard) or 2-stage firing (optional). The heaters are certified and tested under the latest edition of the ANSI Z21.10.3/CSA 4.3 standard for hot water heaters. The heater should be installed to meet all local codes, the National Fuel Gas Code ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70-latest edition.

Fig. 32: Pilot Burner Flame—IID (Atmospheric Models)

7. Check flow switch paddle.

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

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

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).

Fig. 33: Burner Detail

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 Ignition Module)

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

2. Check ignition module as follows: a. Set the tankstat to call for heat. b. Watch for continuous spark at the pilot burner.

c. Check the ignition spark operation. Time must

BURNER

BURNER HOLDDOWN BRACKET

GAS VALVE

COMBUSTION A

IR BLOWER

AIR SHUTTER ADJUSTMENT

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 satisfied.

Burner Adjustment

This burner assembly does not require any primary air adjustments.

Fig. 35: Low NOx Burner Tray Assembly

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. A visual inspection should be made monthly 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" WC and static pressure in plenum should be greater than 0.5" WC.

Electrical

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

High Gas Pressure Switch

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

Burner Tray 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.

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.

Fig. 34: Gas Pressure Switch

Main Burner And Orifice Removal

. Remove burner tray. (See Burner Tray Removal

procedure on page 34.)

. 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 ½” socket wrench to remove orifices from the gas manifold.

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 downwards and outwards.

6. Reverse above procedure to re-install.

Fig. 36: IID Pilot

Combustion Fan Removal

1. Remove burner tray. (See Burner Tray Removal procedure on page 34.)

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

3. Reverse above procedure to re-install.

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.

If spark is okay:

• 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. If not, replace module.

• 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.

NOTE: If S8600H goes into lockout, reset system. Lockout is used on propane 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 MILLIVOLT lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve.

START

TURN GAS SUPPLY OFF.

TURN THERMOSTAT

(CONTROLLER) TO CALL

OR HEAT

POWER TO MODULE

(24 V NOMINAL)?

YES

SPARK ACROSS

IGNITER/SENSOR GAP?

YES

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

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

TROUBLESHOOTING ENDS

TROUBLESHOOTING

WARNING—HIGH VOLTAGE: For qualified

technicians ONLY.

Electrical—Electronic Ignition IID

Intermittent Pilot System Honeywell S8600

NOTE: Some heaters may be equipped with an

gnition module that shuts off pilot gas if pilot fails to

i light. To reset, interrupt power to heater.

MECHANICAL PROBLEM

When heater is turned on nothing happens.

Thermostat in "ON" position causes relay and pump to operate, but heater does not fire.

Continuous shut down of manual reset High Limit.

Sooting CAUTION-Soot may be combustible. Wet down and exercise caution when cleaning.

Continuous shut down of low water cut-off or flow switch.

Low flame.

Outer jacket very hot (blistered paint)

Combustion fan not running. (If applicable)

POSSIBLE CAUSE

No power to the heater………………….

Bad transformer………………………….

Inoperative thermostat…………………..

Inoperative toggle switch………………..

Inoperative relay………………………….

Main gas valve closed………………......

Plugged bleed line on gas valve or gas pressure regulator………………….. Broken pump coupler……………………

Shutdown by low water cut-off, caused by air…………………………….. Gas valve defective……………………..

Temperature setting too low……………. Low water flow…………………………… Interrupted pump operation…………….. Modulating control set too high……….. Mechanical modulating control…………

Air starvation……………………………..

Condensation……………………………. Toxic fumes which cause a chemical reaction with copper tubes or destroy combustion……………………………….

Improper venting…………………………

Insufficient system flow…………………. Low water due to leaking……………….. Air in system……………………………...

Line strainer dirty………………………… Lime in Heat Exchanger…………………

Low gas supply…………………………..

Insects or debris clogging………………. Burner intake ports low gas pressure…. Venting or combustion air……………….

Broken refractory…..…………………….

Fan relay................................................

Fan.........................................................

CORRECTIVE ACTION

Check the circuit breaker, outdoor controller, etc., upstream of heater. If power to Leads L1 and L2 of transformer, but no power on 24V side, replace. Jumper thermostat, replace with new if heater fires. If power to toggle switch, but not through switch, replace. If power to relay, but not operating, replace.

Open valve.

Loosen bleed line and clean. Replace coupler. Inspect bearing assembly, and if frozen, lubricate or replace.

Bleed air from system. Check for power to gas valve. If valve has power but will not open, check vent tube for blockage. If clear, replace valve.

Reset High Limit to higher temperature. Check system water pumps. Check pump oil if necessary. Reset modulator to a lower setting. Check and replace if necessary.

Refer to installation instructions regarding combustion air requirements. Set bypass valve to prevent heater inlet temperature from dropping below 105° F.

Remove all sources of fumes, such as freon or chloride, or isolate the heater. Follow recommended vent installation instructions.

Check pumps and piping. Inspect for leaking and repair. Inspect for leakage and repair. Install an automatic air vent. Clean. Ream tubes.

Debris in gas line (pipe dope, rocks, etc.). Gas line too small. Improper size gas meter. Gas regulator adjustment. Clean burners. Adjust gas pressure. Refer to installation instructions regarding combustion air requirement.

Replace refractory panels.

Replace fan relay. Loose wire connection. Failed fan motor.

Mechanical

WIRING DIAGRAMS

Wiring Diagram—WH2 0181/0261

Wiring Diagram—WH2 0331/0401

Wiring Diagram—WH2 0514–0724

Wiring Diagram—WH2 0824–1826

Wiring Diagram—WH2 2100–2500

Wiring Diagram—WH2 3001–4001

Troubleshooting—Pumps

RAYPAK TUBE CLEANING KIT

Extension Pieces (5) Auger with Carbide Tip Wire Brush

P/N 052871F - 5/8 DIA.

P/N 052870F - 7/8 DIA.

Pump Loses Prime

Failure To Pump

. Pump not properly primed.

2. Wrong direction of rotation.

3. Speed too low.

4. Total head too high.

Reduced Capacity and/or Head

1. Air pockets or leaks in suction line.

2. Clogged impeller.

3. Foot valve strainer too small or clogged.

4. Excessive suction lift (over 15 feet).

5. Insufficient positive suction head (for hot water).

6. Total head more than that for which pump is intended.

7. Excessively worn impeller and wearing rings.

Rapid Wear of Coupling

1. Misalignment or a bent shaft.

2. Sagging motor mounts (over-oiling).

1. Air leaks in suction line.

2. Excess air in water.

3. Water seal in stuffing box not functioning. . Excessive suction lift and pump operating too near

shut-off point.

Overloaded Driving Unit

1. Head much lower than that for which pump is designed.

2. Speed too high or higher than that contemplated.

Mechanical Troubles and Noise

1. Misalignment.

2. Excessive suction lift or vapor binding (hot water).

3. Bent shaft and/or damaged bearings.

4. Suction and discharge piping not properly supported and anchored.

SERVICE AND MAINTENANCE PROCEDURES

Tube Cleaning

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.

The heater may be cleaned from the side opposite the water connections as shown, 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. Note that you do not remove the top pan or the heat exchanger generally. 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 noninhibited de-scale solvent.

Fig. 37: Raypak Tube Cleaning Procedure

COMBINATION FLAME SENSOR/ I

GNITER AND PILOT BURNER

Fig. 38: Typical Burner Tray Illustrated

Burner Tray 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.

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.

Main Burner and Orifice Removal

1. Remove screws and burner hold-down bracket. 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.

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 overtighten when reinstalling.

Pilot Removal and Cleaning

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

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.

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.

Heat Exchanger Removal

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

2. Remove side inspection panels.

3. Remove top holding screws.

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

5. Loosen bolts and disconnect flange nuts on in/out header, loosen union(s) at gas pipe, and slide

heater away from piping until studs clear the heater.

6. Remove heat exchanger corner brackets.

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

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

Heat Exchanger Re-Assembly

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

2. Install in/out 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 cut-off 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.

Fig. 39: Typical Heat Exchanger Configuration

Combustion Chamber Removal

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

Fig. 40: Refractory Panels—Top View

Control Well Replacement

Remove top, sensing bulb and clip. Collapse well tube at the open and 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

1. Remove heat exchanger from heater following instructions outlined under HEAT EXCHANGER REMOVAL on page 45.

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

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.

Cleaning Flue Gas Passageways

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

1. Lift off drafthood and flue collector by removing

bolts and screws.

2. Remove "V" baffles from heat exchanger.

3. Remove burner tray.

4. Take garden hose and wash heat exchanger, mak-

ing 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. This is normal.

6. Identify and correct reason for soot formation.

REPLACEMENT PARTS

See separate parts sheet in instruction envelope.

NOTE: To supply the correct part it is important that

ou state the model number, serial number and type

y of gas when applicable.

Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. If determined defective by the Company 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

NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is high pressure cleaning at a local car wash. DO NOT WIRE BRUSH!

CAUTION: Soot is combustible, so exercise extreme care.

LIMITED PARTS WARRANTY

RAYTHERM™ COMMERCIAL HEATERS

TYPES H & WH

MODELS 0133 TO 4001

SCOPE:

Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this 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 responsibility.

ANY PART MANUFACTURED BY RAYPAK:

One (1) year warranty from date of heater 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 HEATER RATING PLATE IS ALTERED OR REMOVED.

HEAT EXCHANGER WARRANTY:

Domestic Hot Water Five (5) years from date of heater installation. Includes copper heat exchanger with bronze and cast iron waterways. Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways. Space Heating (Closed Loop System) Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze or cast iron waterways. Thermal Shock Warranty Twenty (20) years from date of heater installation against "Thermal Shock" (excluded, however, if caused by heater operation at large changes exceeding 150°F between the water temperature at intake and heater outlet temperature, or operating at heater temperatures exceeding 230°F).

ADDITIONAL WARRANTY EXCLUSIONS:

This warranty does not cover failures or malfunctions resulting from:

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

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

3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation;

4. High velocity flow exceeding 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 heater system;

7. Failure 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 satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts manufactured by others, but Raypak will apply any such warranty as may be provided by the parts manufacturers.

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 a Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA or call (805) 278-5300. In all cases proper authorization must first be received from 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 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 FROM 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 date of manufacture plus thirty (30) days.

_____________________________________________________ ______________________________________________

relaeDfoemaNrenwOfoemaN

_____________________________________________________ ______________________________________________

sserddAsserddA

_____________________________________________________ ______________________________________________

.oNlaireS.oNledoM

Date of Installation:_____________________________________ Date of Initial Operation: ___________________________

RAYPAK, INC. • 2151 Eastman Avenue • Oxnard, CA 93030 • (805) 278-5300 • Fax (800) 872-9725 • www.raypak.com

www.raypak.com

Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468

Litho in U.S.A.

Raytherm WH-0182, WH-0331, WH-0181, WH-0330, WH-0400 Installation & Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual