Raypak 195A User's Manual
Contents
1. GENERAL LOCATION OF CONTROLS CONTROL BOK COMPONENT LOCATIONS Manual Reset Limit Pressure Relief Valve Field Wiring Compartment Ignition Module Temperature Sensor Auto Ignition Only Ignition Module Auto Ignition Only Transformer Roll Out Sensor SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE IID Heaters equipped with the IID system will automati cally light the pilot burner first and then the main burner each time there is a call for heat from the tankstat Whenever the tankstat is calling for heat the circulator supplied with the heater will be energized and should be running The ignition control module will also be energized to initiate the pilot ignition by opening the first main valve pilot At the same time the electronic spark generator in the module produces a high voltage spark pulse output that lights the pilot burner Ifthe pilot burner does not light the module will not energize the second main valve and the burners will not light Ignition spark continues only until the timed trial for ignition period ends Then the module goes into safety shutdown or lockout Lockout de energizes the first main valve operator and closes the first main pilot valve in the gas control stopping pilot gas flow The ignition control system must be reset by setting the tankstat below water temperature for one minute or by turning off power to the module for one minute When the pilot flame i2. condition resulting in possible damage to the heater and clockwise to On injury to the user For Robertshaw Valve Move gas control lever to On position SECTION 4 Testing the Ignition Safety Shutoff The ignition system safety shutoff must be tested by GAS CONTROL conducting the following method of tests KNOB SHOWN IN OFF For Standing Pilot Systems POSITION a With the main burners on remove the pilot GASINLET adjustment cover screw NOTE There is no pilot adjustment cover on Robertshaw 7200 gas valve b Insert a small slot screw driver and turn the NE adjustment screw clockwise until pilot ROBERTSHAW flame goes out Note and count number of turns All Models made c Gas valve will shut off main burners after about three 3 minutes End of test If the gas valve will not shut off follow the instructions To Turn Off Gas To Heater and call service technician or your gas supplier d Return pilot adjustment screw counter clock wise Same number of turns as in step b 8 Turn on all electric power to the heatler 9 Set tankstat to desired setting 10 Ifthe heater will not operate follow the instruction To Turn Off Gas To Heater and call your service technician or gas supplier 16 Fig 8935 0 Pilot Adjustment ROBERTSHAW 7200 GAS VALVE Models 135 amp 180 Replace pilot adjustment cover screw then follow the lighting instructions to get heater ready for operation e FORAUTOMATIC IG
3. 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 21 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 in sects 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 ADJUSTMENTS REPLACEMENTS OF COMPONENTS CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify properoperation after Servicing DANGER SHOCK HAZARD Make sure electrical power to the heater is disconnect ed to avoid potential serious injury or damage to com ponents 1 Gas Valve Replacement Shut off electrical power and gas supply to the heater Remove gas piping to gas valve inlet Disconnect wiring connections pilot tubing when equipped Remove screws 2 holding the burner tray Slide burner tray out Remove gas valve bracket screws and bracket Unscrew gas val
4. mounting the heater on combustible flooring Heater must NOT be installed on carpet flooring Fig 8193 1 CARPET Fig 8196 0 NOTE The heater should be located in an area where water leakage will not result in damage to the area adjacent to the appliance orto 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 thatthe gas ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc CLEARANCE REQUIREMENTS 1 Minimum Clearances From Combustible Materials No Vent 2 A front clearance of at least 24 is recommended for adequate service of burner tray and controls 3 Exceptfor carpeted flooring heaters are certified for installation on combustible floors 4 Forun insulated hot water pipes maintain a 2 clearance or consult local authority having jurisdiction COMBUSTION VENTILATION AIR WARNING Air supply to the heater room must not 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 condition in the heater room that can become a hazard of asphyxiation explosion or fire CAUTION C
5. 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 must then notify his Raypak distributor for instructions regarding the claim If either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 or call 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
6. or unfamiliar about the smell associated with LP or natural gas ask the gas supplier Other conditions such as Odorant Fade which causes the odorant to fade or diminish in intensity can also hide or camouflage a gas leak A DANGER DANGER Water heaters utilizing Liquefied Petroleum gas LP are differ ent from natural gas models A natural gas heater will not function safely on LP gas and vice versa Conversion from Natural gas to LP gas or vice versa must be done by a qualified service technician To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel WARNING LP appliances should not be installed below grade for ex ample in a basement if such installation is prohibited by federal state and or local laws rules regulations or customs General Safety Precautions To meet commercial hot water requirements the tankstat is adjustable up to 190 F However water temperatures over 125 F can cause severe burns in stantly or death from scalds This is the preferred starting point for setting the control for supplying general purpose hot water Safety and energy conservation are factors to be consid ered when setting the water temperature on the tankstat The most energy efficient operation will resu
7. recheck all air vents and expansion tank levels COMBUSTION CHAMBER REMOVAL Toremove combustion chamber you mustfirst have removed the heat exchanger Unbolt metal combustion chamber retainer from top and remove combustion cham ber panels individually 19 5 TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components Installation and service personnel may be required by some states to be licensed Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions PROBLEM S 1 When tankstat is turned on heater does not operate 2 When tankstat is calling for heat pump is on but burners will not turn on CAUSE S 1 No power to the heater 2 Defective tankstat or disconnected wire in thermostat circuit Defective transformer 1 For Standing pilot models pilot burner not lighted 2 If pilot burner will not stay lighted thermocouple or gas valve may be defective 3 Gas knob in Pilot position 4 Vent switch is open 5 Roll out switch is open 6 Manual Reset High limit is open 7 Fast Response Temperature Sensor probe is defective 8 Fast Response Temperature sensor board is defective 9 Defective ignition module or defective gas valve 20 SOLUTION S 1 C
8. 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 FORAPARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY ITISAGREED THAT RAYPAK SHALL HAVE NOLIABILITY WHETHER UNDER THIS WARRANTY ORIN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL ORINCIDENTAL DAMAGE INCLUDING DAMAGE FORM WATERLEAKAGE Some states do notallow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days 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 Cerlilied Quality System www raypak com
9. CATALOG NO 3000 50D Effective 01 01 03 Replaces 03 01 97 INSTALLATION AND OPERATING INSTRUCTIONS Models 090A 135A 195A 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 Refertothis 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 nottouch any electrical switch do notuse 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 kept adjacent to the heater or kept in a safe place for future reference P N 240687 Contents 3 1 RECEIVING EQUIPMENT 3 2 GENERAL SPECIFICATIONS AND DIMENSIONS 4 General Safety Precautions 6 3 INSTALLATION PROCEDURES 6 Code Requirements 6 Mounting Base 6 Clearance Requirements 6 Combustion Ventilation Air 7 Venting Connections 8 Common Vents 9 Gas Supply Connections 10 Water Connec
10. EFIED PETROLEUM MODELS Propane or LP gas must be used with great 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 to light appliance Use a soapy solution to check all gas fittings and connections Bubbling at a connection indicates a leak that must be corrected When smelling to detect an LP leak be sure to sniff near the floor too Gas detectors are recommended in LP applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs It is recommended that more than one method be used to detect leaks in LP applications IF LP GAS IS PRESENT OR SUSPECTED DO NOT attempt to find the cause yourself DO NOT try to light any appliance DO NOT touch any electrical switch DO NOT use any phone in your building Leavethe building immediately and make sure that everyone else leaves also Leave the doors open for ventilation and contact the gas sup plier a qualified service agency or the fire department Keep the area clear until the service call has been made the leak is corrected and a qualified agency has determined the area to be safe WARNING Both LP and natural gas have an odorant added to help detec tion Some people may not physically be able to smell or recognize this odorant If unsure
11. NITION SYSTEMS A Intermittent Ignition IID 1 Turn on power to the ignition systems and turn gas supply off at the gas valve 2 Checkignition module as follows a Setthe 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 Turntankstat down to end call for heat and wait 60 seconds on lockout models before beginning step 3 3 Turn on gas supply 4 Settankstat 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 Sparkignition should cut off when pilot flame is established c Maingas valve should open and main burner should ignite after gas reaches the burner port FLAMEFAILURE With burner operating close the manual fuel valves to simulate a flame failure System 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 17 INSPECTION PROCEDURES BURNERS Clean main burners and air louvers of dust lint and debris Keep heater area clear and free from combus tibles 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 openi
12. NLET YO AO 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas goto the next step 6 Locate pilot behind gas valve mounted on the base panel of the burner drawer 7 Turn knob gas control counter clockwise to PILOT Fig 8083 2 Fig 8041 2 HONEYWELL PILOT ROBERTSHAW PILOT 14 8 Push down and hold the red reset button in imme 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 If red reset button does not pop up when released stop and immediately call your ser vice 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 9 Stand to the side of the heater and turn the gas control knob counter clockwise to ON 10 Turn ON all electrical power to the heater 11 Set the tankstat to the desired setting SYSTEM SHUTDOWNPROCEDURE 1 Setthe 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 heatler Refer to operating instruction label on the heater 4 Shutoffthe wa
13. Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 FAX 800 872 9725 Raypak Canada LTD 2805 Slough Street Mississauga Ontario Canada L4T 1G2 905 677 7999 FAX 905 677 8036 Litho in U S A
14. be issued RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 23 Fig 8189 4 Fig 8190 3 24 EC CALL OUT a aga KS BURNER TRAY Burner Tray w o Gas Valve Sea Level Burner Tray w Gas Valve Nat STG Burner Tray w Gas Valve Pro STG Burner Tray w Gas Valve Nat IID Burner Tray w Gas Valve Pro IID Burner Spacer Hold Down Burner 301210 15 Burner Orifice Nat Sea Level 350079F 11 350079F 15 350350F 11 350350F 15 CONTROLS Manual Reset Limit 0809 008093F Electronic Fast Response Sensor w Probe 05555 5 005555F Probe Fast Response Roll Out Flue sensor Combination Valve Nat Std Honeywell Combination Valve Pro Std Honeywell Combination Valve Nat Std Robertshaw Combination Valve Pro Std Robertshaw Combination Valve Nat IID Honeywell Combination Valve Pro IID Honeywell Combination Valve Nat IID Robertshaw Combination Valve Pro IID Robertshaw HEAT EXCHANGER Heat Exchanger Cast Iron Inlet Outlet Header Cast Iron Return Header Cast Iron Tube Bundle Heat Exchanger Tube Baffle Kit Carriage Bolt Kit Stud Bolt Kit Header Gasket CONTROL BOX Control Box Std Complete Control Box IID Nat Complete Pump Inline Taco Pump Cartridge Wire Harness Standing Pilot Wire Harness IID FOR ALTITUDES ABOVE 2 000 FEET ABOVE SEA LEVEL CONSULT FACTORY 25 PILOT Pilot Nat Std Pilot Pro Std Pilot Nat IID Pilot Pro IID Pilot Orifi
15. ce Nat Std Pilot Orifice Pro Std Pilot Orifice Nat IID Pilot Orifice Pro IID Pilot Thermocouple Ignition Control IID Honeywell Pilot Mtg Bracket Std IID Pilot Tube High Tension Wire IID High Tension Wire w Pilot Electrode Jacket Top Flue Collector Access Panel Control Panel Cover Jacket Left Jacket Right Jacket Rear HONEYWELL GAS VALVE Standing Pilot Nat to Pro Standing Pilot Pro to Nat IID Nat to Pro Honeywell Pro to Nat Honeywell ROBERTSHAW GAS VALVE Standing Pilot Nat to Pro Standing Pilot Pro to Nat IID Nat to Pro Robertshaw IID Pro to Nat Robertshaw 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 004935F 306239 400275 002654B 007864F 004261F 004262F 004264F 004265F 009170F 00917 1F 009173F OUT DESCRIPTION 90 135 195 003972F 003973F 005467F 005468F 003974F 003975F 003903F 004308F 600003 004935F 306239 400275 002654 007864F 004268F 004263F 004264F 004265F 0091 70F 009171F 0091 73F 006086F 006087F 006078F 006079F 006082F 006083F GAS CONVERSIONS ARE TO BE DONE ONLY BY A QUALIFIED AGENCY 26 LIMITED PARTS WARRANTY ECONOPAK WATER HEATERS MODELS WH 90 TO 195 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
16. ce being inspected Follow the lighting instructions Adjust tankstat so appliance will operate continuously Testfor 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 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 Any improper operation of the common venting system should be corrected so the installation conforms with the latest edition ofthe National Fuel Gas Code ANSI Z 223 1 When resizing any portion of the common venting system the com mon venting system should be resized 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 Z 223 1 and CAN CGA 149 1 2 GAS SUPPLY CONNECTIONS The inlet gas connection of the heater gas valve is 1 2 Provide an adequate gas piping supply line no smaller than 1 2 according to the chart below Maximum Equivalent Pipe Length Feet MODEL WAT PROP PROP NAT PROP sl woo soo _ 0135 15 40 60 150 200 500 499 250 79 00 29 35 Gas piping must have a sediment trap ahead of the heater ga
17. cturer s rating under the manufacturer s warranty Debits for defective replacement parts will not be accepted and defective Bo parts will be replaced in kind only per our standard warranties INLET 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 re viewed 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 Raypak water heaters are design certified by the American Gas Association and tested under the require ments of the American National Standard ANSI 221 10 3 Each heater has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engi neers Code and factory fire tested The heaters are designed for indoor installation with a built in drafthood and a built in sub base for combus tible flooring Models are available with standing pilot or with intermittent ignition device 1 1 0 The heaters are equipped with the following components water circula tion pump pressure relief valve manual reset high limit 3 4 NPT PIPE O DRAIN 0 switch fast response temperature sensor 40 VA trans
18. emoval 4 garden hose and wash heat exchanger mak ing sure soot is removed from between fins Avoid excessive water against refractory 5 Reassemble when heater is fired some steam will form from wet refractory This is normal NOTE In extreme cases it may be necessary to remove the heat exchanger completely for cleaning The sim plest method is steam cleaning at a local car wash DO NOT WIRE BRUSH CAUTION Soot is combustible so exercise extreme care Extension Pieces 5 REPAIRSECTION TUBECLEANING 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 as shown without breaking pipe connections lt is preferable however to remove both headers for better visibility through the tubes and to be sure the residue does not get into the system Note that you do not remove the top pan or the heat exchanger generally After reaming with the auger mount the wire brush and clean out the debris remaining in the tubes Another method is to remove the heat exchanger ream tubes and immerse heat exchanger in non inhibited de scale solvent HEAT EXCHANGER REMOVAL 1 Shutwater gas and electricity off close valves and relieve pressure remove relief valve Remove side inspect
19. essure WATER CONNECTIONS amp SYSTEM PIPING The pipe size and fittings between the heater and the tank should be at least 1 for model 90 and 1 1 4 for models 135 and 195 This is based on the tank being located as close to the heater as possible as shown in the drawing below Da T amp P Relief Valve Hot Water Supply Thermometer Cold Water Recirculation Water Check Valve 2 6 Thermostat M Hi cw Pressure Relief Valve 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
20. force 5 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 6 Locate pilot behind gas valve mounted on the base panel ofthe burner drawer 7 Turn knob on gas control counter clockwise to Pilot Fig 8041 2 ROBERTSHAW PILOT Fig 8083 2 HONEYWELL PILOT 8 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 9 Stand to the side of the heater and turn the gas control knob counter clockwise to ON 10 Turn ON all electrical power to the heater 11 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 Setthe tankstat to the lowest setting 3 Turn Off all electrical power to the heater 4 Turn gas control knob clockwise to OFF GASCONTROL KNOB SHOWN IN OFF POSITION GASI
21. former vent thermal switch flame roll out switch and redundant combination gas valve Atankstat is supplied THERMOSTAT CONN EA 18 loose for installation in the field ELECTRICAL CONN 7 i 12 Y Fig 8978 5 1 A 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 flammable materials and liquids adhesives solvents etc and the vapors they produce are extremely dangerous DO NOT handle use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater Be sure to read and follow the warning label pictured below and other labels on the water heater as well as the warnings printed in this manual Failure to do so can result in property damage bodily injury or death DANGER 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
22. heck 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 system 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 Red LED on circuit board will be ON to indicate a loose sensor connection or a shorted sensor Check terminal connectors or replace sensor as re quired 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 F When ei ther Red or Yellow LED is ON heater will be shut down 8 Check voltage across output and common terminals If no 24V is pres ent replace board 9 On Honeywell module check voltage across terminals MV and MV PV If no 24V is present replace module If 24V is present replace
23. ion panels 2 Remove top holding screws 18 RAYPAKTUBE CLEANING KIT Te 6 4 Auger with Carbide Tip BURNER DRAWER REMOVAL 1 Shut off power and gas supply to the heater Dis connect union s and pilot tubing when present then loosen and remove burner hold down screws 2 Disconnect wires at gas valve and slide burner drawer out MAIN BURNER AND ORIFICE REMOVAL 1 Remove screws and burner hold down bracket NOTE If the heat exchanger is 500160 badly the burner hold down bracket and spacer can become distorted from directflame impingement and this usually necessi tates replacement of these parts 2 Liftburners from slotted spacer and slide from orifices Clean with a wire brush 3 Orifices usually do not need to be replaced To clean run either copper wire or wood through orifice Do not enlarge hole To remove orifice use a socket wrench and remove the manifold DO NOT overtighten when reinstalling q MM Wire Brush Fig 8185 3 Remove draft diverter liftand remove top and flue collector on stack type models Remove inspection 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 o Remove heat exchanger corner brackets 6 Remove combustion chamber clips at the four corners of the heat exchanger 7 Lift heat exchanger straight up using caution not
24. lt when the temperature setting is the lowest that satisfies the needs consistent with the application AN DANGER 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 tem perature 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 The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Temperature Time to Produce Serious Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds 135 F About 10 Seconds 140 F Less than 5 seconds 145 F Less than 3 seconds 150 F About 1 1 2 seconds 155 F About 1 second Table courtesy of Shiners Burn Institute 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 The illustration belo
25. ngs Lifting or blowing flame indicates high gas pressure Low flame indicates low gas pressure 0 0 ee Xe WELY WELA ADU XUL WU Fig 28144 MAIN BURNER FLAME Fig 8964 PILOTBURNERFLAME STG PILOTUNITS NORMAL INSPECTION PROCEDURES First and third month after initial startup and then on an annual basis If problems are found referto Trouble Shooting Guide for additional directions 1 Remove top of heater and inspect heat exchanger for soot and examine venting system Remove rear header and inspect for scale depos its Inspect pilot and main burner flame and firing rate Inspect and operate all controls and gas valve Visually inspect system for water leaks Oil pump motor and bearing assembly if oil cups are provided Checkflow switch paddle If provided Cleanroomair intake openings to assure adequate flow of combustion and ventilation air Keep heater area clear and free from combustible materials gasoline and otherflammable vapors and liquids Should be checked monthly Takes approximately 15 minutes PROCEDURE FOR CLEANING FLUE GAS PASSAGE WAYS Soot will clog areas behind fins and cause eventual tube failure Any sign of soot at base of burners or around outer jacket indicates a need for cleaning 1 Lift off draft hood and flue collector by removing bolts and screws 2 Remove V baffles from heat exchanger 3 Remove burner tray see Burner Drawer R
26. nician to inspect the heater and to replace any part of the control system and any gas control which has been under water FORAUTOMATIC IGNITION MODELS Please read carefully and understand the following safety information before operating the heater WARNING f 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 all around the heater area for gas Be sure to smell next to the floor because some gases are heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f 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 orlever Never use tools Ifthe knob orlever 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 Donotusethisheaterifany parthas been underwater Immediately call a qualified service technician to inspect the heater and to replace any part of the control
27. olding module Reverse above procedure to re install 6 Transformer Replacement a Shutoff electrical power to the heater b Remove control cover screws and open control compartment Disconnect wiring connections from transformer leads Remove screws 2 holding transformer Reverse above procedure to re install 7 Circulator Replacement a Shutoff electrical power to the heater b Shutoffwater supply and open drain valve to remove water in the piping at the pump level CAUTION avoid damage to electrical components keep water from getting into the control compartments and gas valve 22 Disconnect wiring and conduit connections to the pump Remove the nuts and bolts at the inlet and outlet flanges Remove old gaskets Remove the pump Reverse the above procedure to re install Use new gaskets and make sure they are seated properly when tightening the nuts and bolts 6 REPLACEMENT PARTS LIST NOTE To supply the correct part it is important that you state the model number serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with RAY PAK return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not
28. ombustion 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 venti lation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and paint removers Other harmful elements may come from bleaches airfreshen ers 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 Theheater must be provided with adequate supply of airfor 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 Ifthe heater room is located against an outside wall and air openings can communicate directly with the outdoors the two openings on the outside wall must each have a net free area in Square inches as follows Model Sq In Of Free Area 0090 24 0135 35 0195 50 Location of the openings is the same as in the previous case that is within 12 inches of the top and within 12 inches of the bottom of the enclosure If horizontal duct
29. 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 Maintenance section of this manual for more information regarding vent system inspections flammable liquids will Water heater has a main explode and catch fire causing death or severe burns Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater Keeflammable products 1 far away from heater 2 in approved containers 3 tightly closed and 4 out of childrens reach Installation Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames burner and pilot flame The pilot flame 1 is on all the timeand 2 will ignite flammable vapors Vapors 1 cannot be seen 2 are heavier than air 3 go a long way on the floor 4 can be carried from other room to the pilot flame by their currents are at least 18 above the floor This will reduce but not eliminate the risk of vapors being ignited by the main burner or pilot flame Read and follow water heater warnings and instructions If owners manual is missing contact the retailer or manufacturer 4 DANGER DANGER LIQU
30. s 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 These heaters have built in drafthoods Vent piping the same size or larger than the draft hood outlet is recommended however when the total vent height drafthood outlet to vent terminal is atleast ten 10 feet the vent pipe size may be reduced by one size only as specified in Chapter 10 of the latest edition of the National Fuel Gas Code ANSI Z 223 1 As much as possible avoid long horizontal runs of vent pipe and too many elbows If installation requires horizontal runs the vent pipe must have a minimum of 1 4 inch per foot rise and should be supported at not less than five foot intervals Maximum vent connector horizontal length shall be 1 1 2 feet 18 inches for each inch of connector diameter as follows Heater Size VentConnector Max Horizontal Diameter Length FT 90 5 7 5 135 6 9 195 T 10 5 Gas Vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads We recommend use ofinsulated vent pipe spacer through the roofs and walls For protections againstrain 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 tothe latest edition ofthe Na
31. s controls and a manual shutoff valve located outside the jacket All gas piping should be tested after installation in accordance with local codes Manual Valve Sediment Trap Gas Valve Fig 0 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 supply line before reconnecting the heater and its manual shutoff valve to gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE OVER PRESSURED GAS VALVES ARE NOT COV ERED BY WARRANT Y The heater and its gas connec tions shall be leaktested before placing the appliance in operation Use soapy water for leak test DO NOT use open flame NOTE Do not use teflon tape on gas line pipe thread A flexible sealant suitable for use with Natural and Propane gases is recommended NOTE These boilers 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 GAS PRESSURE SPECIFICATIONS Inches W C Regulator Min Max Setting Natural 4 5 10 5 3 5 Propane 12 0 13 0 11 0 Note Do not exceed maximum inlet gas pressure The minimum value shown is for input adjustment The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which isthe same as the manifold pr
32. s established flame rectification circuit is completed between the sensor and burner ground The flame sensing circuit in the module detects the flame current shuts off the spark generator and ener gizes the second main valve operator which opens the second main valve This allows gas to flow to the burners where it is ignited by the pilot burner flame When the tankstat is satisfied the valve operators are de energized shutting off the pilot and main burners and also the circulator Fig 8195 3 START UPPROCEDURES 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 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 above Set the tankstat on the lowest setting Turn OFF all electric power to the heater Push in gas control knob slightly and turn clockwise to OFF p Ts GAS CONTROL KNOB SHOWN IN OFF POSITION NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed in slightly Do not
33. 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 HEAT EXCHANGER WARRANTY Five 5 Years from date of water heater installation This includes only the copper bronze and cast iron waterways Twenty 20 Years from date of water heater installation against Thermal Shock excluded however if caused by operation at large 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 2 year warranty from date of installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE WATERHEATERRATING PLATEIS ALTERED 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
34. system and any gas control which has been underwater FOR INTERMITTENT IGNITION IID WITH HONEY TO TURN OFF GAS HEATER WELL OR ROBERTSHAW GAS VALVE 1 Set the tankstat at the lowest setting 1 STOP Read the safety information above 2 Turnoffall the electric power to the heater if service 2 Set the tankstat to the lowest setting is to be performed 3 Turn off all electric power to the appliance 3 For Honeywell Valve 4 This heater is equipped with an ignition device Turn gas control knob clockwise to Off which automatically lights the pilot Do not try to Make sure knob rest against stop light the pilot by hand For Robertshaw Valve Push in and move gas control lever to Off GAS CONTROL position KNOB SHOWN IN ON POSITION GASINLET HONEYWELL Models 30 90 5 For Honeywell Valve Turn gas control knob LL a clockwise to Off HONEYWELL PILOT For Robertshaw Valve Push in and move gas control lever to Off position CAUTION Should overheating occuror the gas supply 6 Wait 5 minutes to clear out any gas If you then fails to shut off DO NOT turn off or disconnect the smell gas STOP Follow in the safety informa electrical supply to the pump Instead shut off the gas tion previously stated If you don t smell gas go to supply at a location external to the heater Failure to the next step observe this precaution may aggravate the overheated 7 For Honeywell Valve turn gas control counter
35. t 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 Consultavailable guides for proper sizing of the manifold and the chimney At no time should the area be less than the area of the largest outlet Fig 49001 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 the common venting system are notin operation a b mms 0 e Seal any unused openings in the common venting system 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 operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the applian
36. ter supply to the heater piping system loop 5 Open drain valve on the tank to remove water from the heater and the piping circuits SECTION 3 Lighting the Heater CAUTION Liquefied petroleum gas is heavier than air and sinks to the ground Exercise extreme care in lighting heater in confined areas For Standing Pilot Models WARNING f 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 has a pilot which must be lighted by hand When lighting the pilot follow these instructions exactly B BEFORE LIGHTING Smellall around the heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department C Use only your hand to push in move or turn the gas control knoborlever Never use tools If the knob or lever will not push in move or turn by hand don t try to repair it calla qualified service technician Force or attempted repair may result in a fire or explosion D Donotusethis heaterif any parthas been under water Immediately call a qualified service tech
37. the time of installation No valve is to be placed between the relief valve and the storage tank The pressure rating of the relief valve must not exceed the 160 maximum working pressure indicated on the water heater rating plate The BTUH rating of the relief valve must not be less than the BTUH input of the heater Connect the outlet of the relief valve to a suitable open drain The discharge line must pitch downward from the valve to allow complete draining by gravity of the relief valve and discharge line The discharge line should be no smaller than the outlet of the valve The end of the discharge line should not be threaded or concealed and should be protected from freezing No valve of any type restriction or reducer coupling should be installed in the discharge line Local codes shall govern installation of relief valve 10 ELECTRICAL WIRING The electrical power supply requirement for these heaters is 115 volts 60 Hz Field wiring connections and electrical grounding must comply with the local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 Provide a separate fused circuit from the main electrical panel to the heater and a disconnecting means within sight of the heater Remove the control box cover and make the power supply connections in the field wiring compartment See general location of controls drawing on page 13 The pump is supplied and factory wired to operate
38. tional Fuel Gas Code ANSI Z 223 1 The discharge opening must be a minimum of two feet vertically from the roof surface and at least two 2 feet higher than any part of the building within ten 10 feet Vent stack shall be at least five 5 feet in vertical height above the drafthood outlet The vent cap location shall have a minimum clearance of four 4 feet horizontally from and in no case above or below unless a 4 foot horizontal distance is maintained from electric meters gas meters regulators and relief equipment The weight of the vent stack or chimney mustnotrest 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 recommended However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z 223 1 10 OR Less 7 Y CAP Fig 8191 1 WARNING These heaters must not be connected into any portion of mechanical draft systems operating under positive pressure Todosomay 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 Equipmen
39. tions amp System Piping 11 Electrical Wiring 12 Wiring Diagrams 13 4 SERVICING PROCECURES 13 General Locations of Controls 13 Sequence of Operation 14 Start Up Procedures 17 Inspection Procedures 18 Repair Section 20 5 TROUBLE SHOOTING GUIDE 22 Adjustments Replacements of Components 23 6 REPLACEMENT PARTS LIST 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 heat ers we suggest that the local Sales representative or the factory be consulted 1 RECEIVING EQUIPMENT On receipt of your equipmentit is suggested that you visually check for external damage to the carton Ifthe SPECIFICATIONS AND DIMENSIONS carton is damaged it is suggested that a note be made igning for equipment INPUT RECOVERY TANK the heater from the carton and if itis damaged report the MODEL MBH GAL onthe Bill of Lading when signing for equipment Remove damage to the carrier immediately Be sure that you WH 0090 90 pe fee 5 3 4 receive the number of packages indicated on the Bill of WIEDTSS x 1 4 4 1 2 18 6 1 4 Lading Claims for shortages and damages must be disi LONNEN us B filed with carrier by consignee May be used with other tank size capacity Purchased parts are subject to replacement only Note Recovery GPH based on Manufa
40. to damage refractory HEAT EXCHANGER RE ASSEMBLY 1 10 11 13 Heat exchanger water header O rings should be replaced with new ones Install inlet outlet and return water headers and install header retainer nuts and torque nuts evenly 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 with heater shut off Shut down entire system and vent all 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 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 piping 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 operates immediately on the call for heat The system is ready foroperation Within two 2 days of start up
41. ve from gas pipe Reverse above procedure to re install 2 Pilot Burner Cleaning or Replacement Standing Pilot a Shut off electrical power and gas supply to the heater b Disconnect gas piping to gas valve c Disconnect wiring connections to gas valve d Remove screws 2 holding the burner tray e Slide burner tray out f Remove screw holding pilot lighter tube g Remove screws 2 holding pilot bracket on the burner tray h Disconnect thermocouple and pilot tubing fromthe gas valve i Remove pilot burner from pilot bracket Remove pilot orifice and blow away lint or dirt Clean with wire or small brush Make sure pilot orifice is clear but do not enlarge the hole Reverse above procedure to re install HONEYWELL PILOT ROBERTSHAW PILOT PILOT AIR OPENING Fames oririce LI Fig 8102 1 Fig 8045 2 3 Flame Roll out Switch Replacement a Shut off electrical power to the heater b Remove wiring connections to switch c Remove screws 2 holding the switch d Reverse above procedure to re install 4 Vent Thermal Switch Replacement a Shutoff electrical power to the heater b Remove wiring connections to switch c Remove the screws 2 d Reverse above procedure to re install 5 Ignition Module Replacement Shut off electrical power to the heater Remove control cover screws and open control compartment Disconnect wiring connections to module Remove screws 2 h
42. w illustrates the tankstat and how to adjust the water temperature To adjust the water temperature insert a small straight screwdriver into slotted screw in hole in front of tankstat and turn wheel to desired setting Tankstat is adjustable up to 190 F CAUTION Hotter water increases the risk of SCALDING There is a Hot Water SCALD Potential if the tankstat is set too high NOTE When this water heater is supplying general purpose hot water requirements for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further infor mation 3 INSTALLATION PROCEDURES CODE REQUIREMENTS Installation must be in accordance with local codes or inthe absence of local codes with the latest editions of the National Fuel Gas Code ANSI 2223 1 NFPA 54 and the National Electrical Code ANSI NFPA70 In Canada installations must conform with the current CAN CGA B149 1 or 2 and the Canadian Electrical Code Part 1 CSA 622 2 No 1 Where required by the authority having jurisdiction the installa tion must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Heaters No CSD 1 MOUNTING BASE Heater should be mounted on alevel surface Each heater is designed with a built in sub base approved for
43. 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 WIRING DIAGRAM KEY NOTE f it is necessary to replace any of the original wiring it must be replaced with 105 C wire or its 4 V 150 equivalent except 150 black wire which must be MAAFIELD WIRE replaced with 150 wire or its equivalent BK BLACK Pink Connector Blue Connector Cabinet TT Ground Fig 8096 1 11 WIRING DIAGRAM STANDING PILOT MODELS 90 135 and 195 1 2677 D Ls 8 DHT ow L No ELM 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 WIRING DIAGRAM INTERMITTENT IGNITION DEVICE IID MODELS 90 135 and 195 Field Installed WARNING SHOCK HAZARD LINE VOLTAGE IS PRESENT BEFORE SER VICING 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 See page 11 wiring diagram key information 4 SERVICING PROCEDURES Circulator
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