Raypak WH 0195A User's Manual
Contents
1. See instruction manual before set ting temperature at water heater Feel water before bathing or show ering Temperature limiting valves are available see manual Maximum water temperatures occur just after burner has shut off To find hot water temperature being deliv ered 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 Table courtesy of Shriners Burn Institute Table A Time to Produce Serious Burn 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 tem perature 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 1 Fig 1 Tankstat Adjustment 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 thermostaticall2. 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 appli cations and their installation should be in accordance with the manufacturer s recommenda tions and or local laws rules regulations or customs It is recommended that more than one method be used to detect leaks in propane applications WARNING 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 S DANGER A Vapors from flammable liquids will explode and catch fire causing death or severe burns Water heater has a main burner and pilot flame The pilot flame 1 is on all the time and 2 will ignite flammable Do not use or store flammable vapors products such as gasoline Vapors solvents or adhesi
3. above on this label If you don t smell gas go to the next step 7 Locate pilot behind gas valve mounted on the base panel of the burner drawer 8 Turn knob on gas control counter clockwise to Pilot HONEYWELL PILOT Fig 10 Honeywell and Robertshaw Pilots ROBERTSHAW PILOT 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 lt 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 GAS CONTROL KNOB SHOWN IN OFF POSITION GASINLET Fig 11 Honeywell Gas Valve 6 Wait five 5 minutes to clear out
4. 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 1 The heater must be provided with adequate sup ply of air for proper combustion and ventilation in accordance with Sec 5 3 of the latest edition of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of the local building codes 2 If the heater room is located against an outside wall and air openings can communicate directly with the outdoors the TWO openings on the out side wall must each have a net free area in square inches as shown in Table D Model No Sq in of Each Free Area Table D Minimum Net Free Area Location of the openings is the same as in the pre vious case that is within 12 inches of the top and within 12 inches of the bottom of the enclo 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 Venting Connections Vent piping the same size or larger than the draft hood outlet is recommended however when the total vent height is at least ten 10 feet draft hood relief open ing to vent terminal the v
5. from the heater and the piping circuits Lighting the Heater For your safety read carefully before proceeding to light the heater CAUTION Propane gas is heavier than air and sinks to the ground Exercise extreme care in light ing heater in confined areas For Standing Pilot Models WARNING If you do not follow these instructions exactly a fire or explosion may result causing prop erty damage personal injury or loss of life A This heater has a pilot which must be lighted by hand When lighting the pilot follow these instruc tions 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 set tle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building e Immediately call your gas supplier from a neigh bor s telephone Follow the gas supplier s instructions e 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 techni cian to
6. on all electric power to the appliance 11 Set tankstat to desired setting 12 If the heater will not operate follow the instructions To Turn Off Gas To Appliance and call your serv ice technician or gas supplier To Turn Off Gas to Heater 1 Set the thermostat to the lowest setting Turn off all the electric power to the appliance if service is to be performed 3 Remove door panel 4 For Robertshaw Gas Valve Push in and move gas control lever to OFF position For Honeywell Gas Valve Push in gas control knob slightly and turn clockwise ON to OFF 5 Replace heater door panel Fig 14 Honeywell Pilot CAUTION Should overheating occur or the gas supply fails to shut off DO NOT turn off or discon nect the electrical supply to the pump Instead shut off the gas supply at a location external to the heater Failure to observe this precaution may aggravate the overheated condition resulting in possible damage to the heater and injury to the user 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 adjust ment cover screw NOTE There is no pilot adjustment cover on Robertshaw 7200 gas valve 2 Insert a small slot screw driver and turn the adjust ment screw clockwise until pilot flame goes out Count and note number of turns made Gas v
7. ream tubes and immerse heat exchanger in non inhib ited 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 inspec tion panels 4 Loosen bolts and disconnect flange nuts on inlet outlet 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 cor ners 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 even ly 22 3 4 Replace V baffles Install thermostat sensing bulbs in header wells and replace bulb retaining clips Install inlet and return pipes in water headers using pipe thread sealant Install water pressure relief valve sensor probe and low water cutoff devices if so equipped 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 pres sure Run system circulating pump for a minimum of 1 2 hour
8. with heater shut off 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 when using Air X Tank Install flue collector jacket top and inspection pan els Install top holding screws Install draft diverter and vent piping if so equipped If gas piping was disconnected reconnect gas pip ing system and check for leakage using a soap solution Check for correct water pressure and water level in the system Make sure that system pump oper ates immediately on the call for heat The system is ready for operation Within two 2 days of start up recheck all air vents and expansion tank levels 10 11 12 Combustion Chamber Removal To remove combustion chamber you must first have removed the heat exchanger Unbolt metal combus tion chamber retainer from top and remove combustion chamber panels individually Fig 19 Refractory Panels Top View TROUBLESHOOTING These instructions are primarily intended for the use of qualified personnel specifically trained and experienced inthe 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 instructi
9. y W FIELD INSTALLED B gt 120V COMM I i f a a n n nana GROUND wes BOX ei nr r J TR VALVE EY LOW VOLTAGE D INSTALL LINE VOLTAGE FIELD INSTALL LACK O W WwW lt lt 020X 3 R R R D A O WH YEL B B B G G R O V 14 Wiring Diagram lID Models 0090 0135 amp 0195 TRANS BL O BL 120V HOT 24V 120V O Y 120V COMM GROUND Y WIRING BOX TEMP TEMP FLOW HI LIMIT SWITCH SWITCH SWITCH 7 BK 5 BK 5 R 150 C 150 C MAN RESET VENT ROLL OUT NO IELI INSTALLED SS BK g Y M 5 O C S g G p ROBERTSHAW GAS VALVE T T il T G Oo Y BK G MV PV PV MV K HONEYWELL BURNER TRAY IH Q OW VOLTAGE ELD INSTALL NE VOLTAGE ELD INSTALL LACK TO BURNER TRAY A GE B B B G R Y G R O V W Y DM 03 O FV SOVOHQHRUUUDU 15 SERVICING PROCEDURES General Location of Controls Circulator Manual Reset Limit in heater behind panel Pressure HT a lt Relief Valve YD EN T Field Wiring H O Compartment HOJ Temperature Sensor F Ignition Module Auto Ignition Only Transformer Roll Out Sensor Gas Valve Ignition Module Auto Ignit
10. INSTALLATION amp OPERATING INSTRUCTIONS Econopak e Water Heaters Modelis 0090A 0135A amp 0195A Type WH 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 WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e 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 ble A Rheem Company Catalog No 3000 50G Effective 04 08 09 Replaces 05 06 08 P N 240687 Rev 8 Rev 8 reflects the following Changes to Paragraph 3 of the GENERAL SPECIFICATIONS section on page 6 Fig 7 on page 12 the Wiring Diagrams on pages 14 and 15 Fig 8 on page 16 Fig 12 on page 19 Fig 15 on page 20 the TROU BLESHOOTING chart on page 23 The addition of A note to Fig 2 on page 7 2 CONTENTS WARNINGS Pay Attention to These Terms GENERAL SAFETY Time Temper
11. OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from Failure to properly install operate or maintain the water heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime buildup freezing or other conditions causing inadequate water circulation High velocity flow exceeding water heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the water heater system Failing to eliminate air from or replenish water in the connected water system 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 mus
12. VES 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 ER JACKET 1 SUPPLIED BY INSTALLER Fig 6 Sediment Trap P SEDIMENT TRA jn i A j f ol t ni fa et pa RR t j J NOTE Do not use teflon tape on gas line pipe thread A flexible sealant suitable for use with Natural and Propane gases is recommended NOTE These heaters are also certified to operate on Propane gas when equipped with the combination gas valve and orifices pilot and main burners sized for Propane gas 1 1 4 in os e eo o 9 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 F Maximum Equivalent Pipe Length ft 11 Gas Pressure Specifications Water Connections amp System Piping Type of Regulator Gas Min Max Setting The pipe size and fittings between the heater and the tank should be at least 1 for model 0090 and 1 1 4 for models 0135 and 0195 This is based on the tank being located as close to the heater as possible as shown in Fig 7 below i Do not exceed maximum inlet gas pressure The minimum value shown is for input adjustment If this water heater is installed in a closed water supply Table G Gas Pressure Specifications system such as one having a back fl
13. 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 floor ing when the appropriate listed floor shield base is used Models are available with standing pilot or with inter mittent ignition device IID and are equipped with the following components as standard water circulation pump pressure relief valve manual reset high limit switch flow switch vent thermal and flame roll out switches 40VA transformer and redundant combina tion gas valve for use with either Natural or Propane gases A tankstat is supplied loose for installation in the field Piping Connections Dimensions in Model Recovery Tank in No gph Gal NPT NPT Dia ms oo fw ots mtn EEN worse 195 ve oo eae ve e em 6 pos 105 vee oo osm na e em 7 Recovery gph based on manufacturer s rating May be used with other tank size capacity Table B Specifications and Dimensions 3 4 NPT PIPE TO DRAIN 331 4 1 THERMOSTAT CONN 3 la 18 ELECTRICAL CONN ee ON OTHER SIDE 1 212 F V IGG 7 V y p 221 8 r a 26 2 Flow switch and temperature and pressure gauge must be field installed in the outlet water connection of th
14. 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 equip ment 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 sup ported to maintain proper clearances from combustible construction Type B double wall or equivalent vent pipe is recom mended However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI 2223 1 For connections to gas vents or chimneys vent instal lations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 or applicable provisions of the local building codes Fig 4 Venting Minimum Clearances 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 Common Vents Manifolds that connect more than one heater to a com mon 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 th
15. ain valve operator which opens the second main valve This allows gas to flow to the burners where it is ignited by the pilot burn er 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 put ting 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 NOTE Circulator motor supplied with the heater does not require lubrication For Standing Pilot Model with Robertshaw Gas Valve On Off Operation STOP Read the safety information Set the tankstat on the lowest setting Turn OFF all electric power to the heater Remove heater door panel Push in gas control knob slightly and turn clock wise Nto OFF AR NES GASCONTROL KNOB SHOWN IN OFF POSITION GASINLET Fig 9 Robertshaw Gas Valve NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed in slightly Do not force 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
16. alve 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 Return pilot adjustment screw counterclockwise same number of turns as in step 2 PILOT KEY Pilot Adjustment Fig 15 Robertshaw 7200 Gas Valve Models 0135 amp 0195 5 Replace pilot adjustment cover screw then follow the lighting instructions to get heater ready for operation 20 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 Flame Failure With burner operating close the manual fuel valves to simulate a flame failure Syste
17. an the area of the largest outlet At the time of removal of an existing heater the follow ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remain ing connected to the common venting system are not in operation a Seal any unused openings in the common venting system 10 Fig 5 Common Venting 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 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the com mon 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 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 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 ciga rette cigar or pipe to visually check spillage After it has bee
18. 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 behind gas valve mounted on the base panel of the burner drawer 8 Turn knob on gas control counter clockwise to PILOT 9 Push down and hold the red reset button in inme diately 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 Ifred reset button 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 counterclockwise lt to ON 11 Replace heater door 12 Turn ON all electrical power to the heater 13 Set the tankstat to the desired setting 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 sys tem loop 5 Open drain valve on the tank to remove water
19. ature Relationships in Scalds RECEIVING EQUIPMENT GENERAL SPECIFICATIONS INSTALLATION Code Requirements Mounting Base Clearances Combustion amp Ventilation Air Venting Connections Gas Supply Connections Water Connections amp System Piping 12 Electrical Wiring 13 Wiring Diagram Standing Pilot Models 0090 0135 amp 0195 14 Wiring Diagram llD Models 0090 0135 amp 0195 15 AOOOOOWOO MUWOIRR SERVICING PROCEDURES 16 Sequence of Operation 16 Start up Procedures 16 Repair Section 22 TROUBLESHOOTING 23 ADJUSTMENTS amp REPLACEMENT OF COMPONENTS 25 Gas Valve Replacement 25 Pilot Burner Cleaning or Replacement Standing Pilot 25 Flame Roll out Switch Replacement 25 Vent Thermal Switch Replacement 25 Ignition Module Replacement 25 Transformer Replacement 25 Circulator Replacement 26 Replacement Parts 26 WARRANTY 27 WARNINGS Pay Attention to These Terms 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 severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause 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 hazar
20. ds DANGER Failure to install the draft hood and properly vent the water heater to the outdoors as outlined in the Venting section of this manual can result in unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless it is properly vented and has an adequate air supply for proper operation Be sure to inspect the vent system for proper installation at initial start up and at least annually thereafter Refer to the Maintenance section of this manual for more information regarding vent system inspections DANGER Water heaters utilizing propane gas are different from natural gas models A natural gas heater will not function safely on propane gas and vice versa Conversion from Natural gas to propane gas or vice versa must be done by a qualified service technician To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel DANGER PROPANE MODELS Propane gas must be used with great caution e It is heavier than air and will collect first in lower areas making it hard to detect at nose level e 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
21. e heater Fig 2 Dimensions 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 com bustible surface Heater must not be installed on carpeting This heater can be installed on a com bustible 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 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 duri
22. e 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 ori fices Clean with a wire brush 3 Orifices usually do not need to be replaced To clean run either copper wire or wood through ori fice Do not enlarge hole To remove orifice use a socket wrench and remove the manifold DO NOT overtighten when reinstalling RAYPAK TUBE CLEANING KIT a a a ol SSS ae Extension Pieces 5 Auger with Carbide Tip Wire Brush Fig 18 Raypak Tube Cleaning Kit 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 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
23. een 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 out let of the valve The end of the discharge line should not be threaded or concealed and should be protect ed 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 Temperature amp Pressure Gauge The temperature and pressure gauge is standard equipment on all hot water heaters All temperature and pressure gauges are shipped loose for field instal lation in the outlet water connection see Fig 7 All fittings required to mount the gauge to the piping are supplied by others 13 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
24. electri cal 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 See general location of controls drawing The pump is supplied and factory wired to operate with the heater The thermostat tankstat is shipped loose to be installed in the tank at the installation site WARNING SHOCK HAZARD Line voltage is present Before servicing tankstat or heater turn off electrical power to the heater at the main disconnect or circuit breaker Failure to do so could result in severe personal injury or death 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 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 Wiring Diagram Standing Pilot Models 0090 0135 amp 0195 TEMP HI LIMIT BK 150 C suiter MAN RESET VENT BK 150 C FLOW TEMP SWITCH R TH SWITCH NO ROLL OUT NO TRANS i TANKSTAT O BL BK 120V HOT 24V 120V I I O
25. ent pipe size may be reduced as specified in the National Fuel Gas Code ANSI Z 223 1 As much as possible avoid long hori zontal 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 inter vals Plumbers tape crisscrossed will serve to space both horizontal and vertical piping Maximum vent con nector horizontal length shall be 1 1 2 feet 18 inches for each inch of connector diameter as shown in Table E Gas vents supported only by the flashing and extend ing 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 Max Horizontal Length ft Vent Connector Diameter in Model No 0090 0135 0195 Table E Vent Piping Specifications 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 2223 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 loca tion shall have
26. he 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 GAS CONTROL KNOB SHOWN IN ON POSITION GASINLET HONEYWELL Model 0090 Fig 12 Honeywell Gas Valve 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 ON 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 slight ly 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 Honeywell Gas Valve Turn gas control knob counter clockwise lt to ON For Robertshaw Gas Valve Move gas control lever to ON position GAS CONTROL KNOB SHOWN IN OFF POSITION GAS INLET ROBERTSHAW All Models Fig 13 Honeywell Gas Valve 9 Replace door panel 10 Turn
27. inspect the heater and to replace any part of the control system and any gas control which has been under water For Automatic Ignition Models Please read carefully and understand the following safety information before operating the heater WARNING If you do not follow these instructions exactly a fire or explosion may result causing prop erty damage personal injury or loss of life 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 e Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building e Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions e 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 techni cian to inspect the heater and to replace any part of t
28. installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days ONOARONS Name of Owner Name of Dealer Address Address Model No Serial No Date of Installation Date of Initial Operation CORPORATE HEADQUARTERS RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 805 278 5489 Litho in U S A 27 Registered Quality Fedre System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A
29. ion Only Fig 8 General Location of Controls Sequence of Operation Intermittent Ignition Device IID Heaters equipped with the IID system will automatical ly 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 genera 16 tor 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 lock out Lockout de energizes the first main valve operator and closes the first main pilot valve in the gas con trol stopping pilot gas flow The ignition control system must be reset by setting the tankstat below water tem perature 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 genera tor and energizes the second m
30. m should lock out after safety switch timing 15 seconds After the safety switch has cooled open the manual valves relight standing pilots and reset the safety switch the burner should restart Inspection Procedures Burners Clean main burners and air louvers of dust lint and debris Keep heater area clear and free from com bustibles 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 indi cates excess high gas pressure Low flame indicates low gas pressure F RGE OR GR ER EA ER N 4 MAX Fig 17 Pilot Burner Flame STG Pilot Units 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 p
31. n determined that each appliance remaining connected to the common venting sys tem 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 9 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 com mon 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 1 2 Provide an adequate gas supply line according to Table F below Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve locat ed 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 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 VAL
32. ng appliance operation and service circulator replacement control replacement etc CARPET Fig 3 Do Not Install on Carpeting Clearances Minimum Distance from Combustible Surfaces Heater Side Except for carpeted flooring heaters are certified for installation on combustible floors when equipped with listed floor shield base A front clearance of at least 24 in is recommended for adequate service of burner tray and controls For uninsulated hot water pipes maintain a 2 inch clearance or con sult the local authority having jurisdiction Table C Minimum Clearances from Combustible Surfaces Combustion amp Ventilation Air Indoor models only 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
33. odule check voltage across terminals MV and MV PV If no 24V is present replace module If 24V is present replace gas valve 3 Pilot Outage Standing pilot models 4 Yellow lazy flame 5 Sooting 1 Too low or too high gas pressures 2 Restricted pilot 3 Weak thermocouple 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 inlet gas pressure as shown on rating plate 2 Clean pilot orifice 3 Replace thermocouple 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 24 ADJUSTMENTS amp REPLACEMENT OF COMPONENTS 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 electri cal power to the heater is disconnected to avoid potential serious injury or damage to components Gas Valve Replacement 1 Shut off electrical power and gas supply to the heater Remove gas piping to gas valve inlet Disconnect wiring connections pilot tubing when equipped Rem
34. ons PROBLEM S 1 When tankstat is turned on heater does not operate CAUSE S 1 No power to the heater 2 Defective tankstat or disconnected wire in thermostat circuit 3 Defective transformer 2 When tankstat is calling for heat 1 For Standing pilot models pilot burner pump is on but burners will not turn not lighted on 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 23 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 re place thermocouple If between 25 35 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 m
35. ove screws 2 holding the burner tray Slide burner tray out Remove gas valve bracket screws and bracket Unscrew gas valve from gas pipe Reverse above procedure to re install oN ONO Pilot Burner Cleaning or Replacement Standing Pilot 1 Shut off electrical power and gas supply to the heater Disconnect gas piping to gas valve Disconnect wiring connections to gas valve Remove screws 2 holding the burner tray Slide burner tray out Remove screw holding pilot lighter tube Remove screws 2 holding pilot bracket on the burner tray Disconnect thermocouple and pilot tubing from the gas valve Remove pilot burner from pilot bracket Remove pilot orifice and blow away lint or dirt Clean with wire or small brush NOTE Make sure pilot orifice is clear but do not enlarge the hole 11 Reverse above procedure to re install NOah WN 25 HONEYWELL PILOT ROBERTSHAW PILOT Fig 20 Pilots 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 Shut off electrical power to the heater Remove control cover screws and open control com
36. ow preventer in the cold water supply line means shall be provided to Gas Pressure Regulator control thermal expansion Contact the water heater supplier or local plumbing inspector on how to control The gas valve is provided with pressure taps to meas this situation ure gas pressure upstream of the gas valve and downstream which is the same as the manifold pres sure Hot Water Supply v7q T amp P Relief Valve Thermometer 1 S p cca Cold Water Flow Switch Check Valve Pressure Relief Valve Pump Tankstat Install Temperature amp Pressure Gauge in the Outlet Water Connection Recirculation Water Fig 7 Heater with Storage Tank 12 When this water heater system is supplying general purpose hot water requirements for use by individuals a thermostatically controlled mixing valve is recom mended 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 indi cate the water temperature at or near the outlet of the storage tank Relief Valve A new combination temperature and pressure T amp 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 betw
37. partment Disconnect wiring connections to module Remove screws 2 holding module Reverse above procedure to re install 1 2 3 4 5 Transformer Replacement 1 Shut off electrical power to the heater 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 Circulator Replacement Replacement Parts 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 NOTE To supply the correct part it is important that you state the model number serial number and type of gas when applicable CAUTION To avoid damage to electrical compo nents keep water from getting into the control 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 3 Disconnect wiring and conduit connections to the to the Company freight prepaid compartments and gas valve pump 4 Remove the nuts and bolts at the inlet and outlet lf determined defective by the Company and within flanges Remove old gaskets warranty the part will be returned in kind or equal sub 5 Remove the pump stitution freight collect Credit will not be issued 6 Reverse the above procedure
38. t 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 805 278 5300 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 FORA 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 NOLIABILITY WHETHER UNDER THIS WARRANTY ORINCONTRACT TORT NEGLIGENCE OR OTHERWISE FORANY 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
39. to re install Use new gaskets and make sure they are seated prop RAYPAK INC erly when tightening the nuts and bolts 2151 Eastman Avenue Oxnard CA 93030 26 LIMITED PARTS WARRANTY ECONOPAK WATER HEATERS MODELS WH 0090 TO 0195 SCOPE 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 responsibility HEATEXCHANGER 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 changes exceeding 150 F between the water temperature at intake and water heating temperature or operating at water heater temperatures exceeding 190 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 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
40. ump coupler for wear and vibration 7 Check flow switch paddle if provided 8 Clean room air intake openings to assure ade quate 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 21 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 Remove V baffles from heat exchanger Remove burner tray see Burner Drawer Removal Take garden hose and wash heat exchanger mak ing sure soot is removed from between fins Avoid excessive water against refractory Reassemble when heater is fired some steam will form from wet refractory which is normal 2 3 4 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 Burner Drawer Removal 1 Shut off power and gas supply to the heater Disconnect union s and pilot tubing when present then loosen and remove burner hold down screws Disconnect wires at gas valve and slide burner drawer out Main Burner and Orific
41. ves in the 1 cannot be seen same room or area near the 2 are heavier than air water heater 3 go a long way on the Keep flammable products floor 1 far away from heater 4 can be carried from other 2 in approved containers room to the pilot flame by 3 tightly closed and their currents 4 out of children s reach 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 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 GENERAL SAFETY To meet commercial hot water requirements the tank stat 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 gen eral purpose hot water Safety and energy conservation are factors to be con sidered when setting the water temperature on the tankstat The most energy efficient operation will result when the temperature setting is the lowest that satis fies the needs consistent with the application 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
42. y 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 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 dam aged report the damage to the carrier immediately Be sure that you receive the number of packages indicat ed 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 defec tive 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 representa tive GENERAL SPECIFICATIONS The Raypak water heaters are design certified by the and tested under the requirements of the American National Standard ANSI
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