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Raypak 260-401 User's Manual

1. 7 i pie e t PROBE TI we s Fo 9 7 1 9 MT TELS To FIELD INSTALLED u 24 us ee PILOT 120 nm 320v Ee COM au NOTES USE GROUND CLIP PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT INLOCK OUT PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS 15 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODELS 330 amp 400 PUMP uv proe E MANUAL RESET a RE fast Response Thue SENSOR Dore s fesen nef a lec col TANK STAT FIELD INSTALLED HOT 80 120V COMM 3 NOTES USE GROUND CLIP PROVIDED FAILURE TO PROVICE PROPER GROUND MAY RESULT IN LOCK OUT PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODEL 261 LOW NO NOTES USE GROUND LUG PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT
2. Water temperature over 125 F can cause severe burns instantly or death from scalds Children disabled and elderly are at high est risk of being scalded See instruction manual before setting temperature at tankstat Feel water before bathing or showering Temperature limiting valves are available see manual Maximum water temperatures occur just after burner has shut off To find hot water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer General Safety Precautions The following chart details the relationship of water temperature and time with regard to scald injury and may be usedas a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn 120 More than 5 minutes 125 172102 minutes 130 About 30 seconds 1857 About 10 Seconds 140 Less than 5 seconds 145 Less than 3 seconds 150 About 1 172 seconds 155 About 1 second TIME TEMPERATURE RELATIONSHIPS IN SCALDS The temperature of the water in the storage tank boiler can be regulated by setting the temperature dial on frontofthe tankstat To comply with safety regulations the tankstat was set at its lowest setting before ship ment from the factory The illustration below illustrates the tankstat and how to adjust the water temperature To adjust
3. Gas Supply Connections Water Connections amp System Piping Electrical Wiring Wiring Diagrams SERVICING PROCEDURES Sequence of Operation Start Up Procedures Inspection Procedures Repair Section TROUBLE SHOOTING GUIDE Adjustments Replacements of Components REPLACEMENT PARTS LIST WARRANTY These instructions are provided to assure the proper installation and operation of Raypak water heaters Should questions arise regarding the specifications installation operation or servicing of these water heaters we suggest that the local Sales representative or the factory be consulted 1 RECEIVING EQUIPMENT On receipt of your equipment itis suggested that you visually check for external damage to the carton Ifthe carton is damaged itis suggested that a note be made on the Bill of Lading when signing for equipment Remove the heater from the carton and ifitis damaged report the damage to the carrierimmediately Be sure that you receive the number of packages indicated on the Bill of Lading Claims for shortages and damages must be filed with carrier by consignee Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defective replacement parts will not be accepted and defective parts will be replaced in kind only per our standard warranties When ordering parts you must specify Model and Serial Number of the heater When ordering under warranty conditions you must also specify d
4. IMPORTANT NOTICE These instructions areprimarilyintendedfortheuseofqualifiedpersonnelspecificallytrainedandexperiencedinthe installation of this type of heating equipmentand related system components Installation and service personnel may be required by some states to be licensed Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions PROBLEMS 1 When tankstat is turned on heater does not operate CAUSE S 1 Ne power to the heater 2 Detective tankstat or disconnected Wire in thermostat circuit 3 Detective transformer SOLUTIONS 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 2 When tankstat is calling for heat pump is on but burners will not turn on 1 For Standing pilot models pilot burner not lighted 2 If pilot burner will not stay lighted thermocouple or gas valve may be defective 3 Gas knob in Pilot position 4 Vent switch is open 5 Rol out switch is open 6 Manual Reset High limit is open 7 Fast Response Temperature Sensor probe is defective 8 Fast Response Temperature sensor board is defective 9 Detective ignition module or defective gas valve 1 Lightpilot burner Follow lighting instructions on rating plate 2 Check therm
5. The boilers are certified and tested under the ANSI Z21 10 3 Standards for hot water heaters The boiler should be installed to meet all local codes the National Fuel Gas Code 2223 1 and with the National Electrical Code ANSI NFPA 70 23 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 boiler will operate When the operating control is satisfied the boiler will shut down START UP PROCEDURES S8610B 1 Turn on power to the boiler with gas supply off 2 Check ignition module as follows a Set the thermostat or controller to call for heat b Watch for continuous spark at the pilot burner c Check the ignition spark operation Time must be within the lockout timing period 15 or 90 seconds d Turn control down to end call for heat and wait 60 seconds on lockout models before beginning step 3 3 Turn on gas supply 4 Set controller to call for heat 5 System should start as follows a Spark wil turn on and pilot gas valve willopen 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 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 t
6. Box LociTTD 008076 OOBDITF 0080782 Control Box Lock TTD Low Nox 008094 008005 008096F 23 Transformer sova 006532 008583 006533F 34 ignition Contat Lock ID 0048188 0048188 0048188 a i Economaster 1 Control 004675F O04675F 004675F 5 Electonic Fast Response Sensor 005197 005197F 005197F 83 Relay Low Nox Blower 007377 00777 007377 Teggle Switch 008079F 008079F 008079F FOR ALTITUDES ABOVE 2000 FEET LEVEL CONSULT THE FACTORY CALL OUT DESCRIPTION 260261 330331 400401 M MISCELLANEOUS COMPONENTS M Switch Piate ID 901613 901613 901613 2 PRV 125 PSI 007224F 007224F 007224F BM Detiming Kit 052871F 052871F 052871F 4 M Pump Brass 005574 005574 005574 EM Vertical Thermometer Not shown 600133 600133 600133 P ProT P Pilot Nat Standing 0020017 NA NA Pilot Pro Standing 002002 NA NA 2 Piot Nat ID Atmospheric 002003F 002003F 002003F Pilot Pro ID Atmospheric 002003F 002003F 002003F Pilot Nat ID Low Nox 008155F 008155F 008155F 3 P Pilot Orifice Nat Standing 600002 NIA NA Pilot Orice Pro Standing 600422 NA Pilot Orice Nat IID 020 003903F 003903F 003903F Pilot Orfice Pro 012 004308F 004308F O04308F Thermocouple Standing Plot 600003 NA NA 1 ignition Conto Lock ID 0048168 0048188 0048188 6 P Pilot Mounting Bracket Std Atmospheric 306093 NA 7 P Piot Mounti
7. Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada LAT 1G2 905 677 7999 FAX 905 677 8036 Litho in U S A
8. Olher conditions such as Odorant Fade which causes the odorant to fade or diminish in intensity can also hide or camouflage a gas leak Loc 8 Water heaters utilizing Liquefied Petroleum gas LP are different from natural gas models A natural gas heater wil no function safely on LP gas and vice versa Conversion from Natural gas to LP gas or vice versa must be done by a qualified service technician To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel A WARNING LP appliances should not be installed below grade or ex ample in a basement if such installation is prohibited by federal state andor local laws rules regulations or customs To meet commercial hot water requirements the tankstat is adjustable up to 190 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 considered 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 A DANGER
9. a neighbor s phone Follow the gas suppliers instructions Ifyou cannot reach your gas supplier call the firedepartment C Use only your hand to pushin move or turn the gas control knob or lever Never use tools Ifthe 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 a fire or explosion 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 the control system and any gas control which has beenunderwater 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 Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Removeheaterdoorpanel For Robertshaw Gas Valve Turn gas control knob clockwise to OFF For Honeywell Gas Valve Turn gas control knob clockwise 77 to OFF Make sure knob rest against stop For Honeywell Gas Valve Models 400 Push in gas control knob slightly and turn clockwise to OFF Knob cannot be turned to OFF unless knob is pushed in slightly Do not force Wait five 5 minutes to clear out any gas Then smell for gas including near the flo
10. and replace bulb retaining clips Install inlet and return pipes in water headers using pipe thread sealant Install water pressure relief valve flow switch 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 2hour with heater shut off Shutdown entire system and ventall radiation units and high points in system piping Check all strain ers for debris Expansion tank water level should be at the 1 4 mark and the balance of the tank filled with air 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 piping system and check for leakage using a soap solution Check for correct water pressure and water levelin the system Make sure that system pump operates 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 n 12 COMBUSTION CHAMBER REMOVAL Toremove combustion chamber you mustfirst have removedthe heat exchanger Unbolt metal combustion chamber retainer from top and remove combustioncham berpanels individually REFRACTORY PANELS TOP VIEW 5 TROUBLE SHOOTING GUIDE
11. 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 depos its 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 pumpimpeller Check condition of bearing by attempting to move impeller from side to side Replace any parts showing wear c Check pump coupler for wear and vibration 7 Check flow switch paddle if provided 8 Clean room air intake openings to assure ade quate 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 REPAIR SECTION TUBE CLEANING PROCEDURE TYPICAL Establish a regular inspection schedule the fre quency 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 w
12. are positioned with the flange near the top side of the stack see illustration Caution must be taken not to over tighten and strip the screw threads 7 Turn the assembled stack and jacket top right side up The jacket top will be trapped between the brackets and the top of the stack Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position Reinstall the four 4 green 10 flat head screws removed in step 1 above E DRAFTHOOD SCREW HOLE JACKET TOP PANEL LOCATION of ihe heater 10 SHEET METAL SCREW 3 MOUNTING BRACKET 3 Es INNER STACK ADAPTER PANEL FLUE COLLECTOR partot neater COMBUSTIBLE FLOOR SHIELD optional for indoor F sss Fi 82065 WARNING Indoor heater 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 the same size or larger than the draft hood outlet is recommended however when the total vent height is at least ten 10 feet draft hood relief opening to vent terminal the vent pipe size may be reduced as specified in the National Fuel Gas Code ANSIZ223 1 Asmuchaspossible avoidlonghorizontal 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 r
13. 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 CAUTIONI Hotter water increases the risk of SCALDING ADANGER There is a Hot Water SCALD Potential if the tankstat is set to high NOTE When this water is supplying general purpose hot water requirements for use by individuals a ther mostatically 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 3 INSTALLATION PROCEDURES CODEREQUIREMENTS Installation must be in accordance with local codes or in the absence of local codes with the latest editions ofthe National Fuel Gas Code ANSI Z223 1 NFPA 54 and the National Electrical Code ANSINFPA 70 In Canada installations must conform with the current CAN CSA B149 1 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 MOUNTINGBASE The heater should be mounted level noncombustible surface Heater must not be installed on carpeting The heater can be installed on a combustible surface only when the appropriate listed floor shield b
14. valve must not exceed the 160 maximum working pressure indicated on the water heater rating plate The BTUH rating of the relief valve must not be less than the BTUH input of the heater Connect the outlet of the relief valve to a suitable open drain The discharge line must pitch downward from the valve to allow complete draining by gravity of the relief valve and discharge line The discharge line should be no smaller than the outlet of the valve The end of the discharge line should not be threaded or concealed and should be protected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line Local codes shall govern installation of relief valve 261 LOW NOx WH1 RATING PLATE ONIOFF FLow swircH x PRY SWITCH I ELECTRICAL CONTROLS LOCATION INLETIOUTLET WATER CONNECTIONS HIGH LIMITS OPTIONAL PUMP COMBINATION M GASVALVE PILOT LOCATION 12 ELECTRICALWIRING The electrical power supply requirementforthesehealersis 115 volts 60 Hz Fieldwiring connections and electrical grounding must comply with the local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 Provide a separate fused circuit from the main electrical panel to the heater and a disconnecting means within sight of the heater Remove the control box cover and make the
15. CATALOGNO 3000510 Effective 07 15 06 Replaces 08 01 03 INSTALLATION ANDOPERATING INSTRUCTIONS Models 260 401 Type WH ECONOPAK WATER HEATERS 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 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 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 This manual should be maintained in legible condition and keptadjacentto the heater orkept ina safe place for future reference P N 240726 Rev 1 CONTENTS 19 19 24 25 26 30 33 35 TABLE OF CONTENTS RECEIVING EQUIPMENT GENERALSPECIFICATIONS AND DIMENSIONS General Safety Precautions INSTALLATIONPROCEDURES Code Requirements Clearance Requirements for all Models Combustion Ventilation Air Venting Connections Common Vents
16. IN LOCK QUT ALL GROUND TERMINATE AT 2 PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH ONLY PROVIDED ON INDOOR UNITS 17 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE ID MODEL 401 LOW NO eg 1 al 9 le 2 ELA m El OBEN B a NOTES USE GROUND LUG PROVIDED FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK QUT ALL GROUND TERMINATE AT PUMP USED MUST BE RATED 10 AMPS MAX OR 3 4 HP MAX PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES 18 4 SERVICING PROCEDURES SEQUENCE OF OPERATION INTERMITTENT IGNITIONDEVICE ID Heaters equipped withthe IID system will automatically light the pilot burner first and then the main burner each time there is acall forheat from the tankstat Whenever the tankstat calling for heat the circulator supplied with the heater willbe energized and should be running The ignition control module will also be energized to initiate the pilotignition by opening the first main valve pilot At the same time the electronic spark generator in the module produces a high voltage spark pulse output that lights the pilot burner Ifthe pilot burner does not light the module will not energize the second m
17. ain valve and the burners will not ight Ignition spark continues only Until the timed trial for ignition period ends Then the module goes into safety shutdown or lockout Lockout de energizes the first main valve operator andcloses the first main pilot valve in the gas control stopping pilot gas flow The ignition control system must be reset by setting the tankstat below water temperature for one minute or by turning off power to the module for one minute When the pilot flame is established flame rectification circuitis completed between the sensor and burner ground The flame sensing circuitin the module detects the flame current shuts off the spark generator and energizes the second main valve operator which opensthe second main valve Thisallows gasto flow to the burners where itis ignited by the pilot burner flame When the tankstat is satisfied the valve operators are de energized shutting off the pilot and main burners and also the circulator START UP PROCEDURES SECTION 1 Filling the System Fill system with water Purge all air from the system using purge valve sequence After system is purged of air lower system pressure Flush system before putting into operation to assure that foreign material does not damage pump seals SECTION 2 Checking the Circulator Before lighting the heater and after system is filled make sure that circulator is operating properly Manual gasvalve should be off NOTE Circulatormotorsuppl
18. as supply to the heater Remove gas piping to gas valve inlet 2 Disconnect wires pilot tubing and bleed line if required 3 vertical gas pipe from manifold slightly and unscrew gas valve 4 Reverseabove procedureto re install PILOTREMOVAL AND CLEANING 1 Disconnect pilot tubing at pilot and sensor ignitor wire Remove screws holding pilot bracket to bumerdrawer Remove pilot and bracket clean pilot of debris small bugs etc with wire or small brush Replace pilot pilot tubing sensor ignition wires and check for leaks BURNER DRAWER REMOVAL 1 Shutoff power and gas supply to the heater Disconnect union s and pilot tubing then loosen and remove burner hold down screws Disconnect wires at gas valve and slide burner drawer out MAIN BURNER AND ORIFICE REMOVAL 1 Remove screws and burner hold down bracket NOTE Ifthe heat exchanger is sooted badly the burner hold down bracket and spacer can become distorted from direct fame impingementand this usually necessi HIGH LIMITOR TANKSTAT REMOVAL 1 Tumotfelectrical power 2 Remove rontinspection panel 3 Remove wires to high limit and loosen screws holding high limit to cabinet 4 Remove wedge clip holding sensing bulb in control well 5 Remove high limit and install a new one 6 Check control operation before leaving job FLAME ROLL OUT SWITCH REPLACEMENT 1 Shutoff electrical power to the heater 2 Remove wiring connections to switch 8 R
19. ase 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 tothe appliance orto the structure When such locations cannot be avoided itis recommended thata 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 CLEARANCE REQUIREMENTS FOR ALL MODELS 1 Minimum clearances from combustible surfaces Floor Front Back Right Let Top Fiue indoor Outdoor Vent mj oz iz iz 39 Unobstructed 6 Comb Alcove 1 Except for carpeted flooring heaters are certified for installation on combustible floors when equipped with listed floor shield base 2 Afront clearance of at least 24 is recommended for adequate service of burner tray and controls COMBUSTION VENTILATION AIR Indoor models only WARNING Air supply to the heater room mustnot be affected by mechanical exhaust vents located in other parts ofthe house such as kitchen or bathroom fans or attic blowers Mechanical exhaust vents may create a negative pressure c
20. ate of installation Raypak recommends that this manual be reviewed thoroughly before installing your Raypak heater If there are any questions which this manual does not answer please contact your local Raypak representative 2 GENERAL SPECIFICATIONS The Raypakwater heaters are design certified by the and tested under the requirements of the American National Standard ANSI Z21 10 3 Each heater has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engineers Code and factory fire tested These heaters are designed for indoor and outdoor installations and can be installed on combustible flooring when the appropriate listed floor shield base is used Models are available with standing pilot or with intermittent ignition device IID and are equipped with the following components as standard water circulation pump pressure relief valve manual reset high limit switch fast response temperature controller vent thermal and flame roll out switches except for models 330 and 400 a solid state Economaster pump control relay 40VA transformer and redundant combination gas valve for use with either Natural or Propane gases A tankstat is supplied loose for installation in the field SPECIFICATIONS AND DIMENSIONS Recovery Piping Model Input GPHE Tank Connections Dimensions Inches WH MBH Indoor Gal Water NPT Ga
21. cable 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 modelnumberetc andshippedto 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 31 FORUNITS WITH A LOW NO TRAY 32 CALL our DESCRIPTION 280201 330331 400401 B BURNER TRAY Atmospheric 288 388 1 3 Bumer Tray wBumers Sea Leve 005214F 005215F 005216F Burner Tray wo Burner Sea Level oos218F 008019 005220F 2 8 Bumer SpaceriHold Down Kit 005238F 005239F 0052405 Bumer 3012109 301210724 30121029 4B Bumer Orice Nat 51 Sea Leve 350080F 19 350080F 24 350080F 29 Bumer Orifice Pro 57 Sea Leve 350083F 19 350083F 24 350083 29 BB Buner Tray wo Manifold wo burners 005266F 005267F 005268 EB BURNER TRAY Fan Assisted Low Nox 266 38i Ls 1 B8 Burner Tray wSumers Sea Leve 007995 007908F 007997F Bumer Tray wo Burner Sea Level oo7999F oosoooF 008001F 2 88 Bumer Hold Down Kit O08003F oosooaF 008005F Bune 3092555 3092556 3092557 4 88 Bumer Orifice Nat 80 Sea Leve 3615105 3515106 3515107 588 Bowe oosos
22. e at least 1 1 2 for all models The tank should be located as close to the heater as possible as shown in the drawing below Hot Water Supply un amp P Relief Valve Thermometer A Q N USP City Water S lt ed Pressure Relief Valve Check Valve Pump Tankstat Recirculation Water mo ree If this water heater is installed in a closed water supply system such as one having a back flow preventer in the cold water supply line means shall be provided to control thermal expansion Contact the water supplier or local plumbing inspector on how to control this situation When this water heater system is supplying general purpose hot water requirements for use by individuals a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Thermometer s should be installed so that they indicate the water temperature at or near the outlet of the storage tank RELIEF VALVE A new combination temperature and pressure T 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 between the relief valve and the storage tank The pressure rating of the relief
23. e flue sensor wire harness through the grommet installed in Step 2 _ TEMPERATURE SENSOR MOUNTING SCREWS 2 CONNECT ONE VENT SENSOR HARNESS WIRE TO THE ASSEMBLY HIGH LIMIT WIRE CONNECT ONE VENT SENSOR WIRE TO THE ROLL QUT SENSOR WIRE WIRE FROM TRANSFORMER ROLL OUT ROLL ou T 4 Remove door and locate wire from roll out sensor to Hi Limit with the male female connector WIRE FROM TRANSFORMER WIRE FROM TRANSFORMER MALEIFEMALE CONNECT ONE VENT SENSOR WIRE WIRE TERMINAL TO HIGH LIMIT WIRE TO ROLL OUT SENSOR WIRE ROLLOUT SENSOR HOA He Du CONNECT ONE VENT SENSOR WIRE After Installation of DraftHood 6 Disconnect male female connector and attach to the 2 wires from drafthood vent sensor hamess MODELS 330 331 AND 400 401 VENT TERMINAL INDOOR STACK INSTALLATION 1 Remove the louvered jacket top by removing four 4 10 flat head screws 2 If originally installed remove Pagoda top from the louvered jacket top 3 Place the inner stack adapter panel over the flue collector inside the heater Make sure the flanged side of the flue opening is up 4 Turn the stack draft hood up side down and set it down bottom side up 5 Tum the jacket top panel removed in step 1 up side down and place it through the stack 6 Attach the three 3 mounting brackets to the stack using the screws provided and the holes that are pre drilled in the stack Make sure the brackets
24. emove screws 2 holding the switch 4 Reverse above procedure to re install VENTTHERMALSWITCHREPLACEMENT 1 Shutoff electrical power to the heater 2 Removewiring connections to switch 3 Removethescrews 2 4 Reverse above procedure to re install IGNITIONMODULEREPLACEMENT 1 Shutoffelectrical power to the heater 2 Removecontrolcover screws and open control compartment 3 Disconnect wiring connections to module 4 Remove screws 2 holding module 5 Reverse above procedure tore install TRANSFORMER REPLACEMENT 1 Shutoff electrical power to the heater 2 Remove control cover screws and open control compartment 3 Disconnect wiring connections from transformerleads 4 Remove screws 2 holding transformer 5 Reverse above procedure to re install CIRCULATOR REPLACEMENT 1 Shutoff electrical power to the heater 2 Shutoff water supply and open drain valve to remove water in the piping at the pump level tates 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 Toclean 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 reinstall ing 30 CAUTION To avoid damage to electrical components keep water from getting into the control compartments land gas valve Disconnec
25. erto the outdoors as outlined in the Venting Section of this manual can resultin unsafe operation of the water heater To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate this water heater unless itis 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 Maintenance section of this manual for more information regarding vent system inspections A DANGER flammable liquids will explode and catch fire causing death or seve burns Do not use or store flammable Products such as gasoline Solvents or adhesives in the same room or area near the water heater Keellammable products The pilot 1 is on all the timeand 2 will ignite flammable vapors Vapors 1 cannot be seen 2 are heavier than air go a long way on the floor 4 can be carried from other to the pilot flame by thelr currents are at least 18 above the floor This will reduce but not eliminate the risk of Vapors being ignited by the main burner or flame where flammable products Will be stored or used unless the main burner and pilot flames heater warnings and instructions If owners the retailer or manufacturer manual is missing LIQUEFIED PETROLEUM MODELS Propane or LP gas must be used with g
26. he burner At least every three months a visual inspection should be made of the burners Incase 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 W C and static pressure in plenum should be greater than 0 5 W C ELECTRICAL Be sure that electrical service to the boiler has proper overload fuse or circuit breaker protection wire size and connections which comply with all applicable codes HIGH GAS PRESSURE SWITCH Pressure switch senses high pressure and automati cally shuts down burner if abnormal pressure exists e dJ T PRESSURE SWITCH GAS MANIFOLD A sumen Down BRACKET LOW NOx BURNER TRAY ASSEMBLY BURNER DRAWER REMOVAL ason SOND Shut off main electrical power switch to heater Shut off gas upstream of heater Remove front door Disconnect gas line from gas valve Remove 2 screws that mount burner tray to unit and 4 screws that secure gas valve to jacket Disconnect wires that terminate at gas valve Unscrew 4 screws that secure the control box Disconnect pilot wire from the ignition module Disconnect wire harness from the combustion blower Carefully slide out the burner tray assembly Reverse above procedure to reinstall GAS VALVE REMOVAL 8 Shut off main electrical power switch to heater Shut off gas supply to the heater Remove front d
27. ied service techni cian to inspect the heater and to replace any part of the control system and any gas control which has beenunder water FORSTANDING PILOT MODEL WITH ROBERTSHAWGAS VALVE ON OFF OPERATION 1 STOP Readthe safety information above 2 Set the tankstat on the lowest setting 3 Turn OFF all electric power to the heater 4 Removeheaterdoorpanel 5 Pushin gas control knob slightly and turn clockwise to OFF GASCONTROL KNOBSHOWN IN OFF POSITION GASINLET 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 above on this label If you don t smell gas go to the next step 7 Locatepilot mounted on the right side of the burner drawer right of first burner 8 Turm knob on gas control counterclockwise to Pilot k ROBERTSHAW PILOT HONEYWELL PILOT 9 Push in control knob all the way and hold in immediately light the pilot with a match Continue to holdcontrolknobin for about one minute afterthe 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 Ifthe pil
28. ied with the heater does not require lubrication SECTION 3 Lighting the Heater For your safety read carefully before proceeding to light theheater CAUTION Liquefied petroleum gas is heavier than air land sinks to the ground Exercise extreme care in lighting heater in confined areas For Standing Pilot Models WARNING If you do not follow these instructions ex actly a fire or explosion may result causing property damage personal injury or loss of life 19 A This heater has a pilot which must be lighted by hand When lighting the pilot follow these instruc tions exactly B BEFORELIGHTING smellallaround the heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch Donotuse any phone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas suppliers instructions It you cannot reach your gas supplier call the fire department C Useonlyyourhandto push in move ortum 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 a fire explosion D Do not use this heater if any part has been under water Immediately call a qualif
29. ise and should be supported at not more than five foot intervals Plumbers tape crisscrossed will serve to space both horizontal and vertical piping Maximum vent connector horizontal length shall be 1 1 2 feet 18 inches for each inch of connector diameter as follows Heater Size Vent Connector Max Horizontal Diameter Length FT 260 261 a 120 330 331 9 135 400 401 10 15 0 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 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 location shall have a minimum clearance of four 4 feet horizontally from and in 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 boiler draft hood Support must be provided in co
30. ithout breaking pipe connec tions Itis 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 reamtubes andimmerse heatexchangerin non inhibited de scalesolvent HEATEXCHANGER REMOVAL 1 Shutwater gas and electricity off close valves and relieve pressure removereliefvalve Remove side inspection panels 2 Removetopholding screws 3 Removedraftdiverter liftand remove topandflue collector on stack type models Remove inspection panels 4 Loosen bolts and disconnect flange nuts on inlet outletheader loosen union s at gas pipe and slide heater away from piping until studs clear the heater 5 Removeheat exchanger comer brackets 6 Remove combustion chamber clips at the four comers of the heat exchanger 7 Lift heat exchanger straight up using caution not to damage refractory 25 HEATEXCHANGERRE ASSEMBLY Heatexchanger water header O ringsshouldbe replaced with new ones Install inlet outlet and return water headers and install header retainer nuts and torque nuts evenly Install the four 4 corner clips between tube sheets and refractory Replace V baffles Install thermostat sensing bulbs in header wells
31. k 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 one INSPECTIONPROCEDURES 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 obstructthe flow of combustion and ventilating air Make visual check of burnerandpilot lame Yellow fiame indicates clogging of air openings Lifting or blowing flame indicates excess highgas pressure Low flame indicates low gas pressure TYPICAL MAIN BURNER FLAME PILOTBURNERFLAME IID UNITS PILOT BURNER FLAME STG PILOT UNITS CONTROLS Check all controls to see that they are operational To check electronic safety IID Models turn off main burner Observe pilot burner when shutting off pilot gas Ignition spark should go on Main gas valve willalso drop out High Limit Switch to check high limit switch turn dial setting down toapointslightly below the temperature of the water leaving the heater The reset button should snapoutandthe bumer should shutoff Resetdialto 30 F to 40 above desired operating temperature andpush reset button Burner should light LOW NOx HEATERS Sizes 181 to 401 The Raypak Low Nox Heateris offered as a model W1 ON OFF firing
32. l at the time of checkout Check that pilot flame covers flame rod and is steady and blue I checks are okay replace module CALL FOR HEAT ENDS Check for proper thermostat controller operation SYSTEMSHUTSOFF Remove MV lead at module if valve closes recheck temperature controller and YES wiring if not replace gas valve TROUBLESHOOTING Repeat procedure unti troublefree operationis obtained ENDS 28 ELECTRICAL STANDINGPILOT ELECTRICALTROUBLESHOOTING ForService Technicians STARTHEATER IFPILOTBURNERLIGHTS IFPILOTBURNER BUT MAIN BURNERS DONOT DOESNOTLIGHT CHECK FOR 24 V CHECKTHERMOCOUPLE AT GAS VALVE IF NOT 24 V IF 24 V IFOK IFDEFECTIVE CHECKTRANSFORMEROUPUT REPLACE FOR 24V GAS VALVE REPLACE REPLACE GAS VALVE THERMOCOUPLE IFNO IF 24 V 24V WARNING HIGHVOLTAGE REPLACE PROBLEMIN TRANSFORMER LIMIT CIRCUITS 29 ADJUSTMENTS REPLACEMENTS OF COMPONENTS CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improperand dangerous operation Verify proper operation after ser vicing DANGER SHOCKHAZARD Makesureelectricalpowertothe heateris disconnect ed to avoid potential serious injury or damage to com ponents GAS VALVE REMOVAL 1 Shut off g
33. lor 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 Reinstallas outlinedunder HEAT EXCHANGER REASSEMBLY PROCEDURE FOR CLEANING FLUE GAS PAS SAGE WAYS Soot will clog areas behind fins and cause eventual tube failure Any sign of sootat base ofburners or around outer jacket indicates a need for cleaning 1 Liftoff drafthood and flue collector by removing bolts and screws 2 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 form between fins Avoid excessive water against refractory 5 Reassemble when heater is fired some steam will form from wet refractory This is normal 3 4 NOTE Inextreme cases itmay be necessary toremove the heat exchanger completely for cleaning The sim plest method is steam cleaning at a local car wash CAUTION Scotis combustible Exercise extreme care Do not wire brush REPLACEMENT PARTS LIST NOTE To supply the correct partitis important that you state the model number serial number and type of gas whenappli
34. mon venting system should be corrected so the installation con forms with the latest edition of the National Fuel Gas Code ANSI 2223 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 Gof the National Fuel Gas Code ANSI Z223 1 and CANICSA B149 1 GASSUPPLY CONNECTIONS The inlet gas connection to the heater gas valve is 1 2 for model 203 3 4 for models 260 and 330 and 1 for model 400 Provide an adequate gas supply line no smaller than 1 2 according to the chart below NATURAL GAS NOBYLIPT ao SPECIFIC GRAVITY 805 wc PRESSURE DROP PROPANE GAS2500BTUFT 15 SPECIFIC GRAVITY Q0 W C PRESSUREDROP is a5 eo so 260 250 Gas piping must have a sediment trap ahead of the boiler gas controls and a manual shut off valve located outside the heater jacket Allgas piping should betested after installation in accordance with local codes Gas Inlet Manual Shut Off Valve Gas Heater Jacket gi Sediment non 4 Trap CAUTION The heater and its manual shut off valve must be disconnected from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 PSIG 3 45 KPA Dissipate test pressure in the gas
35. mpliance 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 recommended However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI 2223 1 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 For connections to gas vents or chimneys vent installations shall be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 2223 1 or applicable provisions of the local building codes COMMON VENTS Manifolds that connect more than one heater to a common chimney must be sized to handle the combined load Consult available guides forproper sizing of the manifold and the chimney time should the area be less than the area of the largest outlet At the time of removal of an existing heater the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remain ing connected to
36. must be diverted away from the heater installed under overhangs with the use of gutters The point from where the flue products exitthe heater must be a minimum of four 4 feet below four 4 feet horizontally from or one 1 footabove any door window or gravity inletto abuilding The top surface of the heater shallbe atleast three 3 feet above any forced air inlet or intake ducts located within ten 10 feet horizontally In areas where high winds are frequent it may be necessary to locate the heater a minimum of from high vertical walls or install a wind break so the heater is not in direct wind current VENTING CONNECTIONS Outdoor Models Outdoor vent topis shipped separately and mustbe installed on site MODELS 260 401 Step 1 Insert screw retainer clip over mounting flange 4 places Step 2 Attach mounting angles to heater jacket with 1 2 sheetmetal screws 4 places Step 3 Lower outdoor top to heater and secure with 1 sheetmetal screws I lt LONG SIDE OF MOUNTING ANGLE LOCATED AS SHOWN VENTINGCONNECTIONS IndoorModels The drafthood is shipped separately and must be installed on the heater For Model 260 261 1 Mount drafthood on top of heater and attach with the 4 sheet metal screws provided Drafthood should be positioned with the vent sensor located on the front left side as shown 2 Remove plastic plug from left side of heater jacket and install plastic grommet provided Rout
37. ng Bracket Atmospheric 306602 306692 306692 Pilot Mounting Bracket ID Low Nor O08082F O08082F 008082F BP Lighter Tube Standing Pilot 062996 NIA NA PiotTube Specify Length 400607 400607 400607 10 P Hi Tension Wire w Pilot Electrode 007864F 007864 007864 R REFRACTORY CR Refractory Gommon Left amp Right 005282F 005282 005282F Refractory Uncommon Front 8 Rear 005284 005285F 005286F DR Refractory Retainer Kit 005288F 005289F 005290F S SHEETMETAL 1 s Jacket Top Louvered 005304F 005305F 005306F DS Flue Collector 005308 005309F 005310F gt s Door Assy 005316F 005317F 005318F 4s Screw amp Retainer 006744F 006744F 006744F 5 S Control Panel OO8065F 008068 O08067F jes Access Panel 008071 008071 008071 S side Panel Right 008068 008068 008068 es Side Panel Left 008069F O08069F 008069F 18 5 Side Panel cap 008070F 008070F 008070F 10 s Rear Panel Kit 2 Pcs 005279F 005280 0052817 11 5 Sub Base for Combustible Flooring 005183 005184 005185 V VENTING T Draft Hood Kit 008085 008148 008149 2 Flue Gas Spilage Sensor 006021F NA NA BV Pagoda Top 007991 007992 007993 LIMITEDPARTSWARRANTYECONOPAKWATERHEATERS MODELS WH 260 TO 401 Inc Raypak warrants to the original owner that parts of this water heater which are actually manufactured by Raypak will bo free from failure
38. nob to OFF and call your Service technician or gas supplier Stand to the side of the heater and turn the gas control knob counterclockwise to ON Replace heater door Turn all electrical power to the heater Set the tankstat to the desired setting 10 11 12 13 SYSTEMSHUTDOWNPROCEDURE 1 Set the tankstat to OFF or the lowest setting 2 Tum off all electric switches to the heater 3 Tumoffallgas valves supplying gas to the heater Refer to operating instruction label on the heater 4 Shut off the water supply to the heater piping system loop 5 Open drain valve on the tank to remove water from the heater and the piping circuits FOR AUTOMATICIGNITION MODELS Please read carefully and understand the following safety information before operating the heater WARNING 7 you do not follow these instructions ex actly a fire or explosion may result causing property 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 around the heater area for gas Be sure to smell next to the floor because some gases are heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric swilch 21 Do not use any phone in your building Immediately call your gas supplier from
39. oF OOBOBDF 00B0B0F 8B Air Shutter 008134F 008134F 008134F CONTROLS Manual reset Lit OQ8O93F 0080032 0080032 2C Electonic Fast Response SensorwProbe NotShown 005555 0055555 005555F Probe Fast Response 006532F 006532 006532F 4C Electonic Fast Response Sensor 005197F 005197F 005197F 5 Economaster II Control 004575F 0048752 004675F GG Flame Rol Out Sensor 006035F o06035F 006035F TC Tankstat Not Shown 007448 007148F 007148F Fiow Switch 007142F 007142F 007142F G GASVAVE 1 6 Vaive Comb Step 3 4 ID Uni Nat 003900F 003900F 003900F Valve Comb Step ID Units 006058F 006058 006058F Valve Combination Step 3 4 STG Nat 004868F NA Valve Combination Step 34 STG Pro 006378 NA NA Comb Step 44 Low Nox Nat 010812 o10812F 010812F H HEAT EXCHANGER TH Heat Exchanger Assy Cast ron o08072F 0080732 008074F 2 inleiOutei Header Castiron 00607OF 006070 oosoroF 3H Return Header Cast ron 002042F o02042F 002042F H Tube Bunde 008023F 008024 008025F 5H Heat Exchange Tube O08031F O08032F 008033F 6H 008039F o0go40F 008041F Stud Bot Kit 007870F 007870 007870 Header Gasket 8002038 8002038 8002038 9H Sensor Well oo72iiF 00721F 007211F Wel Retaining 300003 300203 300203 J CONTROLBOX 1 7 Control Box STDITTD 008075F NA NA Control
40. ockwise to OFF 5 Replace heater door panel SECTION 4 Testing the Ignition Safety Shut off Theignition system safety shutoff must be tested by conducting the following method of tests For Standing Pilot Systems a With the main burners on remove the pilot adjustment cover screw b Insert a small slot screw driver and tum the adjustment screw clockwise until pilot flame goes out Note and count number of turns made c Gas valve will shut off main burners after about three 3 minutes End of test If the gas valve 22 will not shut off follow the instructions To Turn Off Gas To Heater and call service technician or your gas supplier d Return pilot adjustment screw counterclockwise same number of turns as in step b e Replace pilot adjustment cover screw then fol low the lighting instructions to get heater ready for operation FOR AUTOMATICIGNITIONSYSTEMS A Intermittent ignition IID 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 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 Turn on gas supply Set tankstat to high setting Systems should start as follows a Spar
41. ocouple MV generation H 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 temordisconnectedventpiping After problem is corrected push button to resetvent switch 5 Check for blockage of flue or sooted heat exchanger Alter problem is corrected push button to reset rol out switch 6 Check water flow and adjust to obtain 8 to 10 F temperature rise 7 Red LED on circuit board will be ON to indicate a loose sensor connection ora shorted sensor Check terminal connectors or replace sensor as re aquired NOTE Red LED will also be ON if sensor temperature exceeds 300 F or drops below 20 F It will turn OFF when sensor temperature returns to the proper range Yellow LED will be ON if temperature exceeds 210 When either Red or Yellow LED is ON heater will be shut down 8 Check voltage across output and common terminals If no 24V is present replace board 8 On Honeywell module check voltage across terminals MV and MV PV If 24V is present replace module I 24V is present replace gas valve 26 3 Pilot Outage Standing pilot models 1 Too low or too high gas pressures 2 Restricted pilot 3 Weak thermocouple 1 Adjust inlet gas pressure as shown on rating plate 2 Clean pilot orifice 3 Replace thermocouple 3 Yellow lazy flame 1 Too low gas pressure 2 Res
42. of the floor If additional gas appliances are installedin the same space the total input of all gas appliances installed in the same space must be considered in the calculation Refer to Sec 5 3 5 of the latest edition of the National Fuel Gas Code for additional requirements NOTE If louvers grills or screens are used on the openings obtain the net free area from their supplier or manufacturer If the design free area of a louver is not known nor available it shall be assumed that wood louvers will have 20 25 percent free area and metal louvers will have 80 75percentfreearea as shown inthe National Fuel Gas Code 3 Iftheheaterroomis 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 follows Model Sq In Of Free Area 260 261 66 330 331 84 400 401 100 Location of the openings is the same as in the previous case that is within 12 inches of the top and within 12 inches ofthe bottom of the enclosure If horizontal ducts are used the area must be doubled and the duct area shall not be less than the area of the openings they connect and in no case shall the smallest dimension be less than 3 inches OUTDOORMODELS Heaters must not be installed under an overhang of less than three 3 feet from the top onthe heater Three 3 sides must be open in the area under the overhang Roof water drainage
43. ondition 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 inretrigeranis aerosol propellants dry cleaning fluids degreasers andpaintremovers Otherharmfulelements may come from bleaches air fresheners or mastics Vapors from these types of products can form corrosive acid compounds when burnedin agas flame The resulting acidcondensate can damage orsubstantiallyreduce the life ofthe heater It may be necessary to provide outside air directly to the heater in order to avoid this problem 1 Theheatermustbe provided with adequate supply of air for proper combustion and ventilation in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 or applicable provi sions of the local building codes 2 When the heater is installed in a confined space where all airis supplied from inside the building the heater room must be provided with two openings each one having a minimum netfree area in square inches as follows Model Sa In Of Free Area 260 264 330 333 400 399 One opening shallbe within 12inches ofthe top andthe other opening within 12 inches
44. oor Disconnect gas line from gas valve Disconnect wires pilot tubing and bleed line it required Remove 2 screws that secure gas valve to jacket Turn vertical gas pipe from manifold slightly and unscrew gas valve Reverse above procedure to re install MAIN BURNER AND ORIFICE REMOVAL 3 2 8 Remove burner drawer See burner drawer re moval procedure Remove 8 screws from the hold down brackets Remove 8 screws from the left and right sides of the Manifold assembly Detach the manifold as sembly from the bumer tray assembly Use a long 1 2 socket wrench to remove orifices from the gas manifold Remove burners by raising the bracket on the back end of the burners up and out of their slots Reverse above procedure to re install 24 ND PILOT PILOT REMOVAL 1 Disconnect pilot tubing from gas valve 2 Remove 4 screws from control box Open the control box Remove the pilot wire from the ignition wire 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 3 4 COMBUSTION FAN REMOVAL 1 Remove drawer See burner drawer removal procedure 2 Remove 4 screws the mount the combustion blower to the manifold assembly 3 Reverse above procedure to re install NORMAL INSPECTION PROCEDURES First and third month after initial start up and then on an annual basis If problems
45. or If you smell gas STOP Follow B in the safety information previously stated If you do not smell gas go to the next step For Robertshaw Gas Valve Turn gas control knob counterclockwise to ON GASCONTROL KNOB SHOWN IN ON POSITION 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 rest against stop For Honeywell Gas Valve _ Turn gas control knob counter clockwise Y to GASCONTROL KNOB SHOWN IN ON POSITION GASINLET GAS CONTROL KNOB SHOWN IN ON POSITION less jede GASINLET 9 Replacedoorparel 10 Tum on all electric power to the appliance 11 Set tankstat to desired setting 12 Ifthe appliance will not operate follow the instruc tions To Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 2 Tum off all the electric power to the appliance if service isto be performed Removedoorpanel 4 ForRobertshaw Gas Valve Turn gas control knob clockwise 10 OFF For Honeywell Gas Valve Turn gas control knob clockwise to OFF Make sure knob rest against stop For Honeywell Gas Valve Models 403 Push in gas control knob slightly and turn cl
46. ot does not stay lit after several tries turn the gas control knob to OFF and call your service technician or gas supplier 10 Stand to the side of the heater and turn the gas control knob counterclockwise to ON 11 Replace heater door 12 Tum 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 STOP Read the safety information Set the tankstat to the lowest setting Tum Off all electrical power to the heater Remove heater door panel Turn gas control knob clockwise to OFF PSI 20 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above onthis label If you don t smell gas goto the next step Locate pilot mounted on the right side of the burner drawer right of first burner Turn knob on gas control counterclockwise to PILOT Push down and hold the red reset button in imme diately light the pilot with a match Continue to hold downredresetbutton for about one minute after the pilotis lighted Release red reset button and it will pop back up Pilot should remain lighted Ifit 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 Ifthe pilot does not stay lit after several tries tum the gas control k
47. power supply connections in the field wiring compartment The pump is supplied and factory wired to operate with the heater The current draw is approximately 2 0 amps Refer to the heater internal wiring diagrams shown on pages 13 to 15 WIRING DIAGRAM KEY NOTE fit is necessary to replace any of the original wiring it must be replaced with 105 C os wire or its equivalent except 150 black wire 341155 which must be replaced with 150 wire or its equivalent BK BLACK BL BLUE BR BROWN Pink Connector Blue Connector 28 GREEN m O ORANGE R RED Y VIOLET W WHITE 45 Y YELLOW WIRE NUT r CABINET GROUND 13 WIRING DIAGRAM STANDING PILOT MODELS 260 400 Pume souo STATE ECONOMASTER pevce prope FAST RESPONSE me TEMP MANUAL i CH H RESET LIMIT TANK STAT TEMP SENSOR Sue SMICH RESET LIMI ea fere escu ip mela oan Tie m cot 1 HOT s 120V COMM u gt T GROUND NOTES USE GROUND CLIP PROVIDED PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS ROLL OUT AND VENT SWITCHES NOT REQUIRED ON MODELS 330 AND 400 14 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODEL 260 puue souo stare ECONOMASTER pence
48. r design rates Failure of connected systems devices such as pump or controler Use of non factory authorized accessories or other components in conjunction with the water heater system Falling 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 turish a replacement for any failed part The failed part must first bo 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 paris manufacturer TO MAKE WARRANTY CLAIM Promptly notity the original installer supplying the model and serial numbers of the unit date of installation and description of the problem The installer must then his Raypak distributor for instructions regarding the claim Ii either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard 93030 or call 805 278 5300 In all cases proper authorization must first be received form Raypak before replacement of any EXCLUSIVE WARRANTY LIMITATION OF LIABILITY Thisis the only warranty given by Raypak No one is authorized to make an
49. reat caution Itis heavier than air and will collect first in lower areas making it hard to detect at nose level Make sure to look and smell for LP leaks before attempting tolightappliance Use a soapy solutionto check all gas fittings and connections Bubbling at a connection indicates a leak that must be corrected When smelling to detect an LP leak be sure to sniff near the floor too Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs Itis recommended that more than one method be used to detect leaks in LP applications IF LP GAS IS PRESENT OR SUSPECTEI 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 every one 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 untilthe service all has been made the leak is corrected and a qualified agency has determined the area to be safe A WARNING Both LP and natura 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 LP or natural gas ask the gas supplier
50. s NPT 1 K L M N 260261 264 262 80 12 34 21 1 8 8 442 542 378 330331 333 38 80 142 34 2334 10341 9 14 370 400401 399 396 80 112 a 12 41021 10 17 8 3 7 be used with other tank size capacity Recovery based on manufacturer s rating 2 n na 6 p rg itia General Safety Precautions Be sure to read and understand the entire Instruction Manual before attempting to install or operate this water heater Pay particular attention to the following general Safety Precautions Failure to follow these warnings could result in a fire or explosion causing property damage bodily injury or death Should you have any problems understanding the instructions in this manual STOP and get help from a qualified installer or service technician or the gas supplier WARNING Gasoline as well as other fammabie materials and quis adhesives solvents and the vapors they produce are extremely dangerous handle use or store gasoline or other flammable or combustible materials anywhere near or nthe vicinity of a water heater Be sure to read and follow the waming label pictured below and other labels on the water heater as well as the warnings printed inthis manual Failure todo so can resultin property damage bodily injury or death DANGER Failure to install the draft hood and properly vent the water heat
51. supply line before reconnecting the heater and its manual shut off valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY The heater and its gas connections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame NOTE Do notuse teflon tape on gas line pipe thread A flexible sealant suitable for use with Natural and Propane gases is recommended GAS PRESSURE SPECIFICATIONS Inches W C Regulator Min Max Setting Natural 70 105 40 Propane 120 130 110 Note Do not exceed maximum inlet gas pressure The minimum value shown is for input adjustment GAS PRESSURE REGULATOR The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which is the same as the manifold pressure The gas pressure regulator is preset and sealed at 4 W C for natural gas and 11 W C for propane gas 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 W C natural gas and 10 5 W C propane gas Lo NOx models should be 3 9 W C natural gas only Ifan adjustments needed remove seal and turn adjustment screw clockwise to increase pressure Or counterclockwise to decrease pressure WATER CONNECTIONS amp SYSTEM PIPING The pipe size and fittings between the heater and the tank should b
52. t from excessive temperatures TURN GAS SUPPLY ON PILOT BURNER LIGHTS YES Check that all manual gas valves are open supply tubing and pressures 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 nol replace module SPARKSTOPS WHEN PILOTIS LIT NOTE If S8600H goes into lockout reset system Lockout is used on LP G models YES Check continuity a 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 covers flame rod and is steady and blue Adjust pilot flame It problem persists replace module MAIN BURNER LIGHTS Check for 24 Vac across MV MVIPV terminals f no voltage replace module Check electrical connections between module and gas control If okay replace YES gas valve or gas control operator pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system SYSTEM RUNS UNTIL CALL FOR HEAT ENDS Check continuity of ignition cable and ground wire YES NOTE II ground is poor or erratic shuldowns may occur occasionally even though operation is norma
53. t wiring and conduit connections to the pump 4 Remove the nuls and bolts at the inlet and outlet flanges Remove old gaskets Removethe pump Reverse the above procedure to re install Use new gaskets and make sure they are seated properly when tightening the nuts and bolts CONTROLWELLREPLACEMENT Remove top sensing bulb and clip Collapse well tube at the open end with a chisel push through into headerandremovethe wellthrough header Insertanew well and roll into place If a roller is not available solder the well in place with silver solder TUBE REPLACEMENT PROCEDURE 1 Remove heat exchanger from heater following in structions outlined under HEAT EXCHANGER REMOVAL 2 Removeinlet outletandreturn 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 Insertreplacement tube by inserting the end with the most fins removed in the opening of one tube sheet Slide tube until the opposite end clears the other tube sheet and fits the tube into the hole 6 Insertthe 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 3 8 heavy duty reversible electric dril
54. the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is 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 ofthe 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 exhaustfan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust tankstat so appliance will operate continuously 7 10 e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe to visually check spillage 0 After it has been 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 g Any improper operation of the com
55. tricted burner intake ports 3 Restricted gas line 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 B Sooting 1 Insufficient combustion air 2 Improper venting 3 Severe yellow burner flames 1 Refer to installation instructions regarding combustion air requirements 2 Refer to installations instructions 3 See yellow flame section above 27 TROUBLESHOOTING WARNING HIGHVOLTAGE ELECTRICAL ELECTRONICIGNITIONIID Forqualified Technicians ONLY Intermittent Pilot System TROUBLESHOOTING HONEYWELL S8600 heater START NOTE Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light To reset interrupt power to NOTE Before troubleshooting familiarize yourself with the start up and checkout TURNGAS SUPPLY OFF procedure TURNTHERMOSTAT CONTROLLER TO CALL Check Tine voltage power low voltage transformer limit controler thermostat FORHEAT controller and wiring POWER TO MODULE 24 V NOMINAL YES Pull ignition lead and check spark at module SPARKACROSS IGNITERISENSORGAP Spark Okay YES YES Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting buckling Take protective action to shield cable and boo
56. 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 responsibilty HEATEXCHANGER WARRANTY Ese 5 Years from date of water heater instalation 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 between the water temperature at intake and water heating temperature or operating at water heater temperatures exceeding 190 ANY OTHER PART MANUFACTURED BY RAYPAK One 2 year warranty from date of installation or eighteen 18 months trom date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCHAS INSTALLER INVOICE IS REQUIRED THISWARRANTY WILL BE VOID IFTHE WATER HEATERRATINGPLATE IS ALTERED ORREMOVED 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 lke Sediment or lime buildup freezing or other conditions causing inadequate water circulation High velocity flow exceeding water heate
57. y other warranties on Raypak s behalf THIS WARRANTY 1S 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 INTHIS WARRANTY ITIS AGREED THAT RAYPAK SHALL HAVENO LIABILITY WHETHER UNDER THIS WARRANTY OR INCONTRACT TORT NEGLIGENCE OROTHERWISE FORANY SPECIAL CONSEQUENTIAL ORINCIDENTAL DAMAGE INCLUDING DAMAGE FORM WATER LEAKAGE Some states donotaliowimittionsonhowi long an implied warranty lasts or for tho 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 dato of instalation must be presented otherwise the effective dato will be based on the rate of manufacture plus thirty 30 days Name of Owner Name of Dealer Address Address ModelNo Serial No Date of Installation Date of Initial Operation CORPORATE HEADQUARTERS RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 805 278 5400 FAX 805 278 5489 Litho in U S A www raypak com Raypak

Raypak 260-401 User's Manual

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