Raytherm™ Hot Water Supply Heaters - Huron Valley Sales, Inc

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INSTALLATION & OPERATING INSTRUCTIONS

Raytherm™ Hot Water Supply Heaters Models 0133–4001 Type WH

L W

®

LLC

WARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Installation and service must be performed by a qualified installer, service agency or the gas supplier. This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference.

CATALOG NO. 3000.52O

Effective: 10-31-11

Replaces: 02-18-11

P/N 241075 Rev. 16

Rev. 16 reflects the following: Changes to: General Safety instructions on page 5, General Specifications on page 7, Venting of Diaphragm Gas Components on page 21 Additions: CSA Low-Lead mark on page 1

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CONTENTS WARNINGS 4 Pay Attention to These Terms 4 GENERAL SAFETY 5 Time/Temperature Relationships in Scalds 6 RECEIVING EQUIPMENT 6 Model Identification 6 General Specifications 7 All Models (Approved) 7 Hot Water Supply Heaters 7 INSTALLATION 7 Installation Codes 7 Installation Base 7 Clearances 8 Specifications and Dimensions 9 Outdoor Water Heaters 12 Combustion Air (Indoor Units Only) Air for Combustion and Ventilation 12 Venting 13 Vent Piping 17 Vent Damper Installation 18 Plumbing 20 Flow Rates 22 Piping—Domestic Hot Water Supply Heaters 23 Piping Diagram—Type WH - Unitemp 80 System 24 Controls—General 25 Limit Controls 26 Electrical Connections 27 Location of Controls 28 START-UP PROCEDURES 30 Before Start-Up 30 General 30 Initial Start-Up - Pump and Motor 30 Intermittent Pilot System Checkout Procedure (S8600) 32 INSPECTION PROCEDURES 32 Burners 32 Controls 32 Inspection Procedures 33 ADDENDA: LOW NOx HEATERS Models 0181 to 0401 33 Operation 33 Start-Up Procedures (S8610B Ignition Module) 33

Burner Adjustment 34 Visual Inspection 34 Electrical 34 High Gas Pressure Switch 34 Burner Tray Removal 34 Gas Valve Removal 34 Main Burner And Orifice Removal 35 Pilot Removal 35 Combustion Fan Removal 35 TROUbLESHOOTING 36 Electrical 36 Mechanical 37 WIRING DIAGRAMS 38 Wiring Diagram—W2/WH2 133 38 Wiring Diagram—WH1 0181/0261 39 Wiring Diagram—WH1 0331/0401 40 Wiring Diagram—WH1 0514–0724 41 Wiring Diagram—WH1 0824–1826 42 Wiring Diagram—WH1 2100–2500 43 Wiring Diagram—WH1 3001–4001 44 Troubleshooting—Pumps 45 SERVICE AND MAINTENANCE PROCEDURES 45 Tube Cleaning 45 Burner Tray Removal 46 Gas Valve Removal 46 Gas Valve Adjustment - Robertshaw (Invensys) 7000 Series 2-Stage Gas Valve with Solenoid Valve 46 Main Burner and Orifice Removal 47 Pilot Removal and Cleaning 47 High Limit or Tankstat Removal 47 Heat Exchanger Removal 47 Heat Exchanger Re-Assembly 47 Combustion Chamber Removal 48 Control Well Replacement 48 Tube Replacement 48 Cleaning Flue Gas Passageways 48 REPLACEMENT PARTS 48 WARRANTY 50

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WARNINGS—Pay Attention to These Terms DANGER:

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

WARNING:

Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored.

CAUTION:

Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.

NOTE:

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. DANGER: PROPANE MODELS: Propane gas must be used with great caution. • It is heavier than air and will collect first in lower areas making it hard to detect at nose level. • Make sure to look and smell for propane leaks before attempting to light appliance. Use a soapy solution to check all gas fittings and connections. Bubbling at a connection indicates a leak that must be corrected. When smelling to detect an propane leak, be sure to sniff near the floor too. • Gas detectors are recommended in propane applications and their installation should be in accordance with the manufacturer's recommendations and/or local laws, rules, regulations or customs. • It is recommended that more than one method be used to detect leaks in propane applications. IF PROPANE IS PRESENT OR SUSPECTED: • DO NOT attempt to find the cause yourself; • DO NOT try to light any appliance; • DO NOT touch any electrical switch; • DO NOT use any phone in your building. • Leave the building immediately and make sure that everyone else leaves also. • Leave the doors open for ventilation and contact the gas supplier, a qualified service agency or the fire department. • Keep the area clear until the service call has been made, the leak is corrected, and a qualified agency has determined the area to be safe.

DANGER: Failure to install the draft hood and properly vent the water heater to the outdoors as outlined in the Venting section of this manual can result in unsafe operation of the water heater. To avoid the risk of fire, explosion, or asphyxiation from carbon monoxide, never operate this water heater unless it is properly vented and has an adequate air supply for proper operation. Be sure to inspect the vent system for proper installation at initial start-up; and at least annually thereafter. Refer to the Maintenance section of this manual for more information regarding vent system inspections. DANGER: Water heaters utilizing propane gas are different from natural gas models. A natural gas heater will not function safely on propane gas and vice versa. Conversion from Natural gas to propane gas (or vice versa) must be done by a qualified service technician. To avoid possible equipment damage, personal injury or fire: DO NOT connect this water heater to a fuel type not in accordance with unit data plate. Propane for propane units, Natural gas for natural gas units. These units are not certified for any other type fuel. WARNING: Gasoline, as well as other flammable materials and liquids (adhesives, solvents, etc.), and the vapors they produce, are extremely dangerous. DO NOT handle, use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater. Be sure to read and follow the warning label pictured below and other labels on the water heater, as well as the warnings printed in this manual. Failure to do so can result in property damage, bodily injury, or death.

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

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

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WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

! DANGER

Vapors from flammable liquids will explode and catch fire causing death or severe burns. Do not use or store flammable products such as gasoline solvents or adhesives in the same room or area near the water heater. Keep flammable products: 1. Far away from heater, 2. In approved containers, 3. Tightly closed and 4. Out of children's reach.

Water temperature over 125°F can cause instant severe burns or death from scalds.

Water heater has a main burner and pilot flame. The pilot flame: 1. Is on all the time or intermittently (IID). 2. Will ignite flammable vapors.

Children, disabled, and elderly are at highest risk of being scalded. See instruction manual before setting temperature at water heater.

Vapors: 1. Cannot be seen, 2. Are heavier than air, 3. Go a long way on the floor, 4. Can be carried from other rooms to the pilot flame by air currents.

Feel water before bathing or showering. Temperature limiting valves are available, see manual.

Installation: Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames are at least 18" above the floor. This will reduce, but not eliminate, the risk of vapors being ignited by the main burner or pilot flame.

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.

Read and follow water heater warnings and instructions.

GENERAL SAFETY To meet commercial hot water needs, this heater is equipped with a manual reset temperature limit that does not exceed 200°F. However, water temperatures over 125°F can cause instant severe burns or death from scalds. This is the preferred temperature setting when supplying general purpose hot water. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat. The most energy-efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application. Maximum water temperatures occur just after burner has shut-off. To determine the water temperature being delivered, turn on the hot water only, place a thermometer in the stream, and read the thermometer.

Temperature

Time to Produce Serious Burn

120°F

More than 5 minutes

125°F

1-1/2 to 2 minutes

130°F

About 30 seconds

135°F

About 10 seconds

140°F

Less than 5 seconds

145°F

Less than 3 seconds

150°F

About 1-1/2 seconds

155°F

About 1 second

Table courtesy of Shriners Burn Institute.

Table A: Time to Produce Serious Burn

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RECEIVING EQUIPMENT

Time/Temperature Relationships in Scalds

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

The temperature of the water in the storage tank heater 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.

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

Fig. 1 illustrates a mechanical tankstat. To adjust the water temperature, insert a small straight screwdriver into slotted screw in hole in front of tankstat and turn wheel to desired setting. Thermostat is adjustable up to 190°F.

Do NOT use the shipping crate base as an installation base. On occasion, items are shipped loose. Be sure that you receive the number of packages indicated on the Bill of Lading. When ordering parts, you must specify Model and Serial Number of the heater. When ordering under warranty conditions, you must also specify date of installation. Raypak recommends that this manual be reviewed thoroughly before installing your Raypak heater. If there are any questions which this manual does not answer, please contact the factory or your local Raypak representative. Fig. 1: Tankstat Adjustment

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

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

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

CAUTION: Hotter water increases the risk of SCALDING! NOTE: When this heater is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.

Model Identification The model identification number and the heater serial number are found on the heater data plate. The model number will have the form WH1-0514A or similar depending on the heater model. (WH = Hot Water Supply System, 1 = on/off firing, 0514 = size of heater). Rated inputs are suitable for up to 2000 feet elevation. For elevations above 2000 feet, reduce input 4% for each 1000 feet above sea level.

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General Specifications

TYPE WH3 with 2-STAGE CONTROLS Models 0181-4001

The Raypak water heaters are design certified and tested under the latest requirements of the American National Standard, ANSI Z21.10.3/CSA 4.3. Each heater has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engineers Code, and factory fire tested. Materials are CSA-certified for lowlead content (<.25%).

Hot water supply heater with low-high fire for 2-stage control. Available with integrally mounted pump, factory mounted and wired for models 0181-1826. To be used with storage tank systems.

INSTALLATION

All Models (Approved)

Installation Codes

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

Installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and the National Electrical Code, ANSI/NFPA 70. In Canada installations must conform with the current CAN/CSA B149 and the Canadian Electrical Code Part 1 CSA C22.2 No.1. Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Heaters, CSD-1.

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

Installation base

Hot Water Supply Heaters

The heater should be mounted on a level, non-combustible surface. Heater must not be installed on carpeting. The heater can be installed on a combustible surface only when the appropriate listed floor shield base is provided. An optional listed floor shield base is available for factory installation with the heater on all indoor models. Do NOT use the shipping base crate as an installation base.

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

TYPE WH1 with ON/OFF CONTROLS Models 0133-4001

NOTE: The heater should be located in an area where water leakage will not result in damage to the area adjacent to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.

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

TYPE WH2 with MODULATING CONTROLS Models 0133-4001

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.).

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

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Clearances

Heater Floor Base Model Part Number Number 001749 0133 058313 0182/0181 0260/0261 058314 0330/0331 058315 0400/0401 058316 0514 056199 0624 056200 0724 056201 0824 056202 0926* 054597 1083* 054598 1178* 054599 1287* 054600 1414* 054601 1571* 058378 1758* 058379 0962 059233 1125 059234 1223 059235 1336 059236 1468 059237 1631 059238 1826 059239 *Models with factory installed floor shield as standard. BOLD TYPE indicates Low NOx models.

Installation Clearances (All Dimensions are in Inches)

0133 Location Floor Front Back Right Left *Vent Indoor Top Outdoor Top

12 6 12 6 42

Heater Size 0514 to 0926 to 0824 1826 See Note 1 See Note 2 12 12 24 12 6 24 12 18 24 6 6 6 39 36 24 Unobstructed

0181 to 0401

2100 to 4001

24 24 24 6 24 NA

Note 1: Combustible floor shield is required when heater is to be installed on a combustible surface. (See ordering info.) Note 2: Servicing Clearances: Provide at least 24" (Models 01331826), 48" (Models 2100-4001) in front of unit for removal & servicing of the Controls & Burner Tray. Provide at least 18" on side opposite water connections for deliming of Heat Exchanger Tubes. *Vent includes factory supplied drafthoods and does not include field supplied vent systems above the drafthood. On Models 2100-4001 drafthood is built into heater.

Table C: Clearances From Combustible Surfaces

0133 Description a. 3-1/2 in. thick masonry walls without ventilated air space.

Table B: Combustible Floorshield Ordering Information

b. 1/2 in. insulation board over 1 in. glass fiber or mineral wool batts.

c. 0.024 sheet metal over 1 in. glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space. d. 3-1/2 in. thick masonry wall with ventilated air space.

e. 0.024 sheet metal with ventilated air space.

f. 1/2 in. thick insulation board with ventilated air space.

g. 0.024 sheet metal with ventilated air space over 0.024 sheet metal with ventilated air space.

Fig. 2: Alternate Method for Providing a NonCombustible Base

h. 1 in. glass fiber or mineral wool batts sandwiched between two sheets 0.024 sheet metal with ventilated air space.

Location Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top Back Right Left Vent Indoor Top Outdoor Top

9 5 9 5 43

0181 to 0401 9 9 9 5 39

6 3 6 3 30

6 6 6 3 30

4 3 4 3 24

4 4 4 3 24

6 6 6 6 42 NA 4 2 4 2 24

6 6 6 6 39

4 3 4 3 24 NA 4 3 4 3 24

4 4 4 3 24

4 3 4 3 24 NA

4 4 4 3 24

4 4 4 2 24

4 4 4 3 24

Heater Size 0514 to 0926 to 2100 to 0824 1826 4001 9 16 16 5 16 16 12 16 16 5 5 5 36 24 24 Unobstructed NA 6 12 12 3 12 12 9 12 12 3 3 3 24 16 16 Unobstructed NA 4 8 8 3 8 8 6 8 8 3 3 3 18 12 12 Unobstructed NA 6 8 8 6 8 8 6 8 8 6 6 6 36 24 24 Unobstructed NA 4 8 8 2 8 8 6 8 8 2 2 2 18 12 12 Unobstructed NA 4 8 8 3 8 8 6 8 8 3 3 3 18 12 12 Unobstructed NA 4 8 8 3 8 8 6 8 8 3 3 3 18 12 12 Unobstructed NA 4 8 8 3 8 8 6 8 8 3 3 3 18 12 12 Unobstructed NA

Table D: Clearances to Protected Surfaces

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

Specifications and Dimensions MODEL 0133

Indoor

Outdoor

Model Number

Input MBH

Recovery GPH*

Recovery GPH*

WH-0133

136.0

135

132

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

* Recovery based on manufacturer’s rating.

MODELS 0182-0400 and 0181-0401

Indoor

Dimensions (in inches) Flue Diameter

Recovery GPH*

Width

Model Number

Input MBH

Height

A

C

J

K

WH-0182/0181

181.0

180

18-1/4

62-5/8

12-1/16

6

WH-0206/0261

264.0

262

22-3/8

62-7/8

11-1/8

7

WH-0330/0331

334.0

332

25-3/4

63-3/4

10-3/4

8

WH-0400/0401

399.0

397

29-1/4

65-3/8

12-1/2

9

* Recovery based on manufacturer’s rating.

9

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

MODELS 0514-0824

Indoor/Outdoor Model Number WH-0514 WH-0624 WH-0724 WH-0824

Input MBH 511.5 627.0 726.0 825.0

Dimensions (in inches)

Recovery GPH* 508 623 722 820

Width

Gas Conn.

A

G

K

L

32-3/4 37-1/2 41-5/8 45-3/4

1 1 1 1

10 12 12 14

25-3/8 29-1/2 34-1/4 38-1/2

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

* Recovery based on manufacturer’s rating.

MODELS 0 962-1826

Dimensions (in inches) Overall Height

Jacket Height

Gas Conn.

Water Conns.

Flue Diameter

Model Number

Input MBH

Recovery GPH*

Width

A

B

C

G

H

J

K

L

WH-0962

961.7

956

52-3/8

68-3/4

33-1/2

1

2-1/2

18

14

28

WH-1125

1124.7

1118

59-1/4

74-1/2

33-1/2

1

2-1/2

23-5/8

16

32

WH-1223

1222.5

1215

63-5/8

74-1/2

33-1/2

1-1/4

2-1/2

23-5/8

16

32

WH-1336

1336.6

1328

68-5/8

76-1/2

33-1/2

1-1/4

2-1/2

23-5/8

18

36

WH-1468

1467.0

1458

74-7/8

76-1/2

33-1/2

1-1/4

2-1/2

23-5/8

18

36

WH-1631

1630.0

1620

82-1/8

79-1/2

36-1/2

1-1/4

2-1/2

23-5/8

18

36

WH-1826

1825.6

1814

89-3/8

81-1/2

36-1/2

1-1/4

2-1/2

23-5/8

20

40

* Recovery based on manufacturer’s rating.

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

MODELS 0 926-1758

Dimensions (in inches) Model Number

Input MBH

Recovery GPH*

Width

Gas Conn.

Water Conns.

A

G

H

WH-0926

926.0

920

52-3/8

1

2-1/2

WH-1083

1083.0

1076

59-1/4

1

2-1/2

WH-1178

1178.0

1171

63-5/8

1-1/4

2-1/2

WH-1287

1287.0

1279

68-5/8

1-1/4

2-1/2

WH-1414

1413.0

1404

74-7/8

1-1/4

2-1/2

WH-1571

1570.0

1560

82-1/8

1-1/4

2-1/2

WH-1758

1758.0

1747

89-3/8

1-1/4

2-1/2

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

* Recovery based on manufacturer’s rating.

MODELS 2100-4000

MODEL,

Dimensions (in inches) Overall Height

Gas Conn.

Water Conns.

A

B

G

H

K

61

68-1/4

**

3

24

70

68-1/4

**

3

26

81-1/4

68-1/4

2

3

28

92-1/2

68-1/4

2

3

30

103-3/4

68-1/4

2

3

32

Model Number

Input MBH

Recovery GPH*

Width

WH-2100

2100.0

2087

WH-2500

2499.0

2484

WH-3001

3000.0

2982

WH-3500

3500.0

3479

WH-4001

4000.0

3976

Flue Diameter

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

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

Outdoor Water Heaters

CAUTION: Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater. Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ventilation air supply. Such chemicals include, but are not limited to, chlorinated and/or fluorinated hydrocarbons such as found in refrigerants, aerosol propellants, dry-cleaning fluids, degreasers, and paint removers. Other harmful elements may come from bleaches, air fresheners, or mastics. Vapors from these types of products can form corrosive acid compounds when burned in a gas flame. The resulting acidic condensate can damage or substantially reduce the life of the heater. It may become necessary to provide outside air directly to the heater in order to avoid this problem.

These heaters are design certified for outdoor installation. Heaters must not be installed under an overhang of less than three (3) feet from the top on the heater. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. The point from where the flue products exit the heater must be a minimum of four (4) feet below, four (4) feet horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10) feet horizontally.

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

Square Inches Model Model 0133 136 1223 0182/0181 181 1336 0260/0261 264 1468 0330/0331 334 1631 0400/0401 399 1826 0514 512 2100 0624 627 2500 0724 726 3001 0824 825 3500 0962 962 4001 1125 1125 BOLD TYPE indicates Low NOx models.

Square Inches 1223 1337 1467 1630 1826 2100 2499 3000 3500 4000

Table E: All Air From Inside The Building

Fig. 3: Outdoor Clearances from Openings

High Wind Conditions (Outdoor Units Only)

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

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

Square Inches Model Model 0133 34 1223 0182/0181 46 1336 0260/0261 66 1468 0330/0331 84 1631 0400/0401 100 1826 0514 128 2100 0624 157 2500 0724 182 3001 0824 207 3500 0962 241 4001 1125 282 BOLD TYPE indicates Low NOx models.

Combustion Air (Indoor Units Only) Air for Combustion and Ventilation The heater must have both combustion and ventilation air. Minimum requirements for net free air supply openings are 12 inches from ceiling for ventilation and 12 inches from the floor for combustion air as outlined in ANSI Z223.1, and any local codes that may have jurisdiction.

Table F: All Air From Outdoors

12

Square Inches 306 335 367 408 457 525 625 750 875 1000

Models 0181-0401 and 0182-0400

NOTE: If louvers, grills or screens are used on the openings, obtain the net free area from their supplier or manufacturer. If the design free area of a louver is not known nor available, it shall be assumed that wood louvers will have 20-25 percent free area and metal louvers will have 60-75 percent free area as specified in the National Fuel Gas Code.

Outdoor Top

Venting Outdoor Installations Model 0133 1. Remove the front (4) screws. 2. Line up outdoor top vent opening over heater vent opening. OUTDOOR FLOOR BASE

3. Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top. 4. Reinstall (5) screws to secure jacket top and outdoor top to unit.

8-3/8"

Fig. 5: Outdoor Top Installation

Vent Terminal (Outdoor) Stackless Top Installation 1. Insert tabs into keyhole (4 places). 2. Snap tabs into keyholes so as not to pull out.

Pagoda Top (Shipped Loose with Heater) Fig. 6: Outdoor Top Installation

Fig. 4: Outdoor Top Installation

13

Models 0514-0824

Models 0926-1758

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

Heaters are shipped with outdoor vent terminal factory installed. Models 2100-4001 These units are not certified for outdoor installation.

Indoor Installations Model 0133 Refer to Fig. 9 on the following page. 1. Shut-off main electrical power switch to heater. 2. Turn heater manual ON/OFF switch, located in upper control panel, to the "OFF" position. 3. Shut-off gas supply and water supply to the heater. 4. Mount drafthood on heater and attach with the 8 sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side as shown.

Fig. 7: Outdoor Top Installation

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

5. Remove plastic plug from left side of heater jacket and install the plastic grommet provided. 6. Route flue sensor wire harness through the grommet installed in Step 5. 7. Remove door and locate wire from roll out sensor to High Limit with the male/female connector. 8. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.

Fig. 8: Outdoor Top Installation

14

Fig. 9: Indoor Top Installation

15

Models 0181-0401 and 0182-0400

Models 0514-0824

Vent Terminal/Indoor Stack Installation

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

1. Remove the louvered jacket top by removing four (4) #10 flathead screws. 2. If originally installed, remove "Pagoda" top from the louvered jacket top. 3. Place the inner stack adapter panel over the flue collector inside the heater. Make sure the flanged side of the flue opening is up. 4. Turn the stack (drafthood) upside down and set it down bottom side up. 5. Turn the jacket top panel (removed in step 1) upside down and place it over the stack. 6. Attach the three (3) mounting brackets to the stack using the screws provided and the holes that are pre-drilled in the stack. Make sure the brackets are positioned with the flange near the top side of the stack (see Fig. 10). Caution must be taken not to over tighten and strip the screw threads.

Fig. 11: Indoor Top Installation

Models 0962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton.

7. Turn the assembled stack and jacket top, right side up. The jacket top will be trapped between the brackets and the top of the stack. Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position. Reinstall the four (4) green #10 flathead screws removed in step 1 above.

DRAFTHOOD SCREW HOLE LOCATION 3-1/4"

JACKET TOP PANEL (part of the heater)

#10 SHEET METAL SCREW (3) MOUNTING BRACKET (3) INNER STACK ADAPTER PANEL

Fig. 12: Indoor Top Installation

FLUE COLLECTOR (part of heater)

Models 2100-4001 COMBUSTIBLE FLOOR SHIELD

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

(optional for indoor) 2-1/2"

Fig. 10: Indoor Top Installation

16

Vent Piping

10' OR LESS VENT CAP

2' MIN

WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning.

2' MIN

5' MIN VENT PIPE

Vent piping of the same size as the drafthood outlet is recommended, however, when the total vent height is at least ten (10) feet (drafthood relief opening to vent terminal), the vent pipe size may be reduced as specified in the National Fuel Gas Code, ANSI Z223.1.

DRAFT HOOD

HEATER

Avoid long horizontal runs of vent pipe and too many elbows. If installation requires horizontal non-vertical runs, the vent pipe must have a minimum of 1/4 inch per foot rise and should be supported at not more than five foot intervals. Plumber's tape, crisscrossed, will serve to space both horizontal and vertical piping. Gas vents supported only by the flashing and extending above the roof more than five feet should be securely guyed or braced to withstand snow and wind loads. We recommend use of an insulated vent pipe spacer through the roofs and walls.

Fig. 13: Vent Piping

Manifolds that connect more than one heater to a common chimney must be sized to handle the combined load. Consult available guides for proper sizing of the manifold and the chimney. At no time should the area be less than the area of the largest outlet.

For protection against rain or blockage by snow, the vent pipe must terminate with a vent cap which complies with the local codes or, in the absence of such codes, to the latest edition of the National Fuel Gas Code, ANSI Z223.1. The discharge opening must be a minimum of two feet vertically from the roof surface and at least 2 feet higher than any part of the building or equipment within ten feet. The vent stack shall be at least 5 feet in vertical height above the drafthood outlet. The vent cap location shall have a minimum clearance of 4 feet horizontally from, and in no case above or below, unless a 4-foot horizontal distance is maintained, from electric meters, gas meters regulators and relief equipment.

Fig. 14: Common Vent Piping

At the time of removal of an existing heater, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

The weight of the vent stack or chimney must not rest on heater drafthood. Support must be provided in compliance with applicable codes. The heater top and drafthood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction Type "B" double wall or equivalent vent pipe is recommended. However single wall metal vent pipe may be used as specified in the latest edition of the National Flue Gas Code ANSI Z223.1.

(a) Seal any unused openings in the common venting system. (b) Visually inspect the venting system for proper size and horizontal pitch and make sure there is no blockage or restriction, leakage, corrosion or other deficiency which could cause an unsafe condition. (c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any 17

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.

WARNING: Do not use thermally actuated vent dampers on modulating heater. To do so, may result in asphyxiation. Use only a mechanically actuated vent damper device that is electrically interlocked with the modulating heater operation.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. (e) Test for spillage at the drafthood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. (f) After it has been determined that each appliance remaining connected to the common venting system is venting properly, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. (g) Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in the National Fuel Gas Code, ANSI Z223.1.

Fig. 15: Vent Damper

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

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

Vent Damper Installation

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

Models 0133 Through 0180 (Where Required) Location The vent damper must be located in the vent so that it serves only the appliance for which it is intended.

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

If improperly installed, a hazardous condition, such as an explosion or carbon monoxide poisoning, could result. Make certain that it is mounted in an accessible location at least 6 in. from any combustible material or the heat exchanger and that the position indicator is in a visible location. The vent damper must be installed after the appliance drafthood, as close to the drafthood as practicable, and without modification of the drafthood. 18

Vent Damper

HORIZONTAL INSTALLATION FLOW >

NO

YES HEATER TO BOILER

D808

For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually, with particular attention given to deterioration from corrosion or other sources. Check vent damper operation as follows:

YES

TO CHIMNEY NO

VERTICAL

INSTALL VENT

INSTALLATION

DAMPER WITH

TO CHIMNEY

1. When the heater is off, check that the vent damper position indicator points to the closed position, Fig. 18.

ACTUATOR TO SIDES OF VENT ONLY. DO NOT

D808

MOUNT ABOVE OR BELOW VENT.

INSTALLED IN ANY HEATER TO BOILER

Damper Position Indicator

Damper Position Indicator

ACTUATOR MAY BE POSITION ON VERTICAL PIPE.

Fig. 16: Installing Vent Damper

DAMPER OPEN

D808 N.O.

N.C.

End

Fig. 18: Vent Damper position Indicator Showing Open & Closed Positions

1K2

Switch C.

DAMPER CLOSED

1K1 Motor R

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

1K3 1R 1 Black

2

Orange

3

4 Yellow

Red

5 Blue

Optional Limit Limit

Location

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

Thermostat or Controller

L1 (Hot)

Dual Valve

L2

Combination Gas Control or

Transformer

1

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

Ignition System 1

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

Fig. 17: Vent Damper General Wiring Diagram

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

19

Plumbing

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. Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut-off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the appliance in operation. Use soapy water for leak test do NOT use open flame.

General Heater should be located so that any water leaks will not cause damage to any adjacent areas or structures.

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

NOTE: Do not use teflon tape on gas line pipe thread. A flexible sealant approved for the fuel being used is recommended.

Fig. 19: Sediment Trap

20

MAXIMUM EQUIVALENT PIPE LENGTH

0133 *0182/0181 *0260/0261 *0330/0331 *0400/0401 0514 0624 0724 0824 0926/0962 1083/1125 1178/1223 1287/1336 1414/1468 1571/1631 1758/1826 2100 2500 3001 3500 4001

NATURAL GAS 1000 BTU/Cubic Foot .60 SPECIFIC GRAVITY @ 0.5" W.C. PRESSURE DROP PROPANE GAS 2500 BTU/Cubic Foot 1.53 SPECIFIC GRAVITY @ 0.6" W.C. PRESSURE DROP 1/2" 1" 1-1/4" 2" 2-1/2" 3" 4" 3/4" 1-1/2" N P N P N P N P N P N P N P N P N P 15 35 60 145 200 500 15 30 65 95 250 400 10 20 40 60 140 250 560 15 25 35 85 150 380 360 15 25 60 100 260 250 10 15 35 65 150 130 360 500 10 25 45 100 95 250 340 20 35 80 75 180 260 600 15 25 60 55 130 185 480 500 15 20 45 45 110 150 360 400 10 15 35 35 80 120 300 300 25 25 60 85 220 200 25 20 55 75 180 170 325 560 20 15 45 65 150 165 300 500 15 15 35 50 120 125 250 400 15 10 30 40 100 100 225 340 10 10 25 30 80 75 175 260 15 20 55 55 135 160 400 600 10 15 35 40 85 120 250 500 10 30 30 45 80 200 400 600 5 20 25 35 65 160 300 400

* Models 0181, 0261, 0331, and 0401 are Low NOx units and are not available in propane. A minimum of 7" WC and a maximum of 10.5" WC upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 11" WC and a maximum of 13" for propane. Pressure drops from the no load condition to the full load condition must be no more than 30% for proper operation.

Table G: Maximum Equivalent Pipe Lengths

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

Venting of Diaphragm Gas Components Fig. 20: Bleed Line Connection

Gas train components that have diaphragms in their construction are supplied with a bleed line connection that must be connected to the outside atmosphere as required by the National Fuel Gas Code. Under NO circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system. Care should be used to prevent obstruction to the bleed lines, as blocked lines could prevent gas valves or other devices from operating. 21

Flow Rates MAXIMUM AND MINIMUM FLOW RATES 2-PASS HEAT EXCHANGER MODEL SIZE

0133* 0182/0181 0260/0261 0330/0331 0400/0401 0514 0624 0724 0824 0926 0962 1083 1125 1178 1223 1287 1336 1414 1468 1571 1631 1758 1826 2100 2500 3001 3500 4001

M AX

MIN

1-PASS HEAT EXCHANGER

T 10

P FT 14.7

GPM 10

T 22

P FT 3.3

45

7

9.2

20

15

1.8

HDR CONN 1-1/4" 1-1/2"

45 45 45 90

10 12 15 9

9.4 9.6 9.8 9

20 20 20 40

22 28 33 21

1.9 1.9 2.0 1.8

1-1/2" 1-1/2" 1-1/2" 2"

90 90 90 90

12 13 15 17

9.5 10 10.5 11

40 40 40 40

26 30 34 38

1.9 2.0 2.1 2.2

2" 2" 2" 2 1/2"

200 200 200 200 200 200

GPM 22

GPM

MIN T

HDR P FT CONN

9.7

90

17

2.1

3"

8 9 9 10 10 11

9.7 10.3 10.3 11 11 11.7

90 90 90 90 90 90

18 20 20 21 22 23

2.1 2.3 2.3 2.4 2.4 2.5

3" 3" 3" 3" 3" 3"

MAX GPM

200

T

8

P FT

90

18

11

40

39

2.2

90 90 90 90 90

20 20 21 22 23

12 12 12.5 12.5 13.2

44 46 48 50 53

40 40 40 40 40

2.9 3.1 3.6 3.9 4.5

2 1/2" 2 1/2" 2 1/2" 2 1/2" 2 1/2" 2 1/2"

90 90

24 26

13.2 14

55 58

40 40

4.9 5.8

2 1/2" 2 1/2"

200 200

11 12

11.7 12.2

90 90

24 26

2.5 2.7

3" 3"

90 90

27 29

14 14.5

60 64

40 40

6.2 7.3

2 1/2" 2 1/2"

200 200

12 13

12.2 13

90 90

27 29

2.7 2.8

3" 3"

90 90 90 200 200

30 32 33 17 20

14.5 15.4 15.4 14.8 15.8

67 72 75 90 102

40 40 40 38 40

8.1 9.7 10.6 3.2 4.3

2 1/2" 2 1/2" 2 1/2" 3" 3"

200 200 200 400 400

13 14 15 9 10

13 14.7 14.7 18 18.8

90 90 90 180 180

30 32 33 19 23

2.8 3 3 4 4.1

3" 3" 3" 4" 4"

200 200

25 29

16.7 17.5

123 144

40 40

6.5 9.3

3" 3"

400 400

12 14

19.5 20.5

180 180

27 32

4.3 4.5

4" 4"

200

33

18.7

164

40

12.8

3"

400

16

21.5

180

36

4.7

4"

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

Table H: Maximum and Minimum Flow Rates

22

WATER HARDNESS MEDIUM

SOFT

MODELS

5-15 Grains Per Gallon

0-4 Grains Per Gallon Indoor 0133 0182/0181 0260/0261 0330/0331 0400/0401 0514 0624 0724 0824 0962 1125 1223 1336 1468 1631 1826 2100 2500 3001 3500 4001

Outdoor 0133 0182 0260 0330 0400 0514 0624 0724 0824 0926 1083 1178 1287 1414 1571 1758 N/A N/A N/A N/A N/A

T 22 15 21 27 30 20 25 29 30 30 30 30 30 30 30 33 30 30 30 30 33

GPM 10 20 20 20 22 42 41 41 45 53 61 67 73 80 90 90 115 137 164 191 200

P 3.4 1.8 1.9 1.9 2.3 2.0 2.0 2.1 2.6 3.8 5.5 7.0 8.7 11.0 14.8 15.4 5.0 7.5 11.2 16.2 18.7

MPS 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3

HARD

SHL 5.1 4.6 4.6 4.7 5.6 4.8 4.7 4.9 5.9 5.3 7.5 9.3 11.5 14.4 19.0 19.6 7.9 11.4 17.0 23.7 26.8

T 17 12 17 21 25 16 19 20 20 20 20 22 24 27 30 33 20 20 25 29 33

GPM 13 26 26 26 26 52 54 60 68 79 90 90 90 90 90 90 172 200 200 200 200

P 5.5 3.1 3.1 3.2 3.3 3.0 3.4 4.4 6.0 8.5 12.0 12.5 13.3 14.0 14.8 15.4 11.0 15.8 16.7 17.5 18.7

MPS 1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3

16-25 Grains Per Gallon* SHL 8.2 7.5 7.6 7.7 7.8 7.1 7.9 9.8 12.8 11.5 16.2 16.7 17.5 18.2 19.0 19.6 17.2 23.9 24.8 25.6 26.8

T

GPM

10 7 10 12 15 9 11 13 15 18 20 22 24 27 30 33 17 20 25 29 33

22 45 45 45 45 90 90 90 90 90 90 90 90 90 90 90 200 200 200 200 200

P 14.7 9.2 9.4 9.6 9.8 9.0 9.5 10.0 10.5 11.0 12.0 12.5 13.3 14.0 14.8 15.4 14.8 15.8 16.7 17.5 18.7

MPS

SHL

1-1/4 1-1/2 1-1/2 1-1/2 1-1/2 2 2 2 2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 2-1/2 3 3 3 3 3

22.0 20.8 21.0 21.2 21.3 19.1 20.9 21.4 21.9 15.2 16.2 16.7 17.5 18.2 19.0 19.6 22.9 23.9 24.8 25.6 26.8

BOLD TYPE indicates Low NOx models.

ΔT = Temperature Rise, Degree [email protected] FLOW GPM = Gallons per Minute Flow ΔP = Pressure Drop, Foot thru Heat Exchanger MPS = Minimum Pipe Size, NPT SHL = System Head Loss * Must utilize optional cupro-nickel tubes. If over 25 grains per gallon, a water softener/treatment system must be utilized.

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

Piping—Domestic Hot Water Supply Heaters

1-1/2" NPT = 70 Ft (0181-0401) 2" NPT = 75 Ft (0514-0824) 2-1/2" NPT = 80 Ft (0926-1826) 3" NPT = 85 Ft (2100-4001)

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

Additional pipe fittings will increase the system head loss.

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

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

Soft: 0-4 grains per gallon. Medium: 5-15 grains per gallon. Hard: 16-25 grains per gallon.

6. If heater is more than two stories above the tank, consult the factory. NOTE: GPM flow rates are limited by maximum acceptable velocity through heat exchanger tubes. Heater models 0514 through 1826 may be provided with an integral rear-mounted pump. This must be specified at time of order.

2. Maximum Flow Rates: 0133 0181-0401 0514-1826 2100-4001

22 GPM 45 GPM 90 GPM 200 GPM

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

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

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

23

Piping Diagram—Type WH - Unitemp 80 System

24

Controls—General Relief Valve A new combination temperature and pressure (T&P) relief valve, complying with the Standard for Relief Valves and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22, must be installed in the opening provided on top of the storage tank at the time of installation. No valve is to be placed between the relief valve and the storage tank.

(A)

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.

(B)

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

6 1 2

Fig. 21: Economaster Time Delay Relays (TDR)

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

Pump Time Delay There are two versions of the Pump Time Delay. The first is an electronic device that allows the operator to set a variable time (3 to 10 minutes) for the pump to run after the heater shuts off. See Fig. 21 (A). The time is factory-set at 7 minutes and it can be re-adjusted in the field. The second version is a fully enclosed solid state Time Delay Relay (TDR) with a white jumper that selects one of two time delays. See Fig. 21 (B). If the jumper is on pins 6 and 7 (default) the delay time is 5 minutes. If the jumper is not on pins 6 and 7, the time delay is 10 minutes.

Table J: Electronic Ignition

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

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

NOTE: Pump will come on when power is first applied to heater. 25

on-off cycling heater. The valve has a remote capillary bulb immersed in a well, at the header outlet, to maintain a constant outlet water temperature. When multiple valves are furnished, they can be staged to give greater flexibility of control. Standard factory setting is at position 5. Consult the dial setting tag attached to the control for your desired temperature. See Fig. 22 below. Fig. 24: Motorized Gas Valve Location—Model 3001

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

Fig. 22: Dial Setting Tag Fig. 25: High Limit

Flow Switch This dual-purpose control shuts off the heater in case of pump failure or low water condition and is strongly recommended. It is mounted and wired in series to the main gas valve. NOTE: The flow switch is a safety device and not a control. Do not operate the heater with flows less than the minimums stated in this manual. Fig. 23: Mechanical Modulating Valve Location— Models 0724-1336

Fig. 26: Flow Switch

26

100% Pilot Safety

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

Models 0514-4001 employ electronic devices which close the main gas valve within 8/10 of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit.

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

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

Heater must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No 70. NOTES: 1. Field install ground wire to inside of junction box. 2. If any of the original wire supplied with the heater must be replaced, it must be replaced with 105°C wire or its equivalent. SINGLE STAGE TANKSTAT

Fig. 27: Low Water Cut-Off

High and Low Gas Pressure Switches (Optional)

STAGE 1 CONNECTION

These switches sense either high or low gas pressures and automatically shut down burners if abnormal pressures exist. ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE.

Fig. 29: Single-Stage Tankstat 2-STAGE TANKSTAT

Fig. 28: Gas Pressure Switch

STAGE 1 CONNECTION

Electrical Connections

STAGE 2 CONNECTION OR STAGE 1 CONNECTION OF HEATER 2

ATTACH STAGE 1 CONNECTIONS ON HEATER TO STAGE 1 CONNECTION ON TANKSTAT. ATTACH STAGE 2 CONNECTIONS OR STAGE 1 CONNECTION OF HEATER 2 TO STAGE 2 CONNECTION ON TANKSTAT AS SHOWN IN THE DIAGRAM.

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

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

27

Location of Controls

0400 WH1, WH2, WH3

0181 (LOW NOx) WH1

28

Location of Controls

0824

29

Location of Controls

START-UP PROCEDURES

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

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

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

General

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

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

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

CAUTION: Propane gas is heavier than air and sinks to the ground. Exercise extreme care in lighting heater in confined areas. 30

LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION (IID) FOR MODELS WITH MANUAL GAS VALVES

FOR YOUR SAFETY READ BEFORE OPERATING WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B.

* * * *

BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electric switch. Do not use any phone in your building. Immediately call your gas supplier from your neighbor’s phone. Follow the gas supplier’s instructions.

*

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

C.

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

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS 1. 2. 3. 4. 5. 6.

7.

8.

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

STOP! Read the safety information above. Set the thermostat 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. Remove heater door panel. For Robertshaw gas valve: Turn gas control knob clockwise to “OFF”. For Honeywell Gas Valve: Turn gas control knob clockwise to “OFF". Make sure knob rests against stop. For Honeywell Gas Valve: (Model 400 only) Push in gas control knob slightly and turn clockwise to “OFF”. Knob cannot be turned “OFF” unless knob is pushed in slightly. Do not force. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information previously stated. If you do not smell gas, go to the next step. For Robertshaw Gas Valve: Turn gas control knob counter-clockwise to “ON”.

HONEYWELL GAS CONTROL KNOB SHOWN IN "ON" POSITION GAS INLET

9. 10. 11. 12.

ROBERT SHAW GAS CONTROL KNOB SHOWN IN "ON" POSITION

Replace heater door panel. Turn on all electric power to the appliance. Set thermostat to desired setting. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

GAS INLET

TO TURN OFF GAS TO APPLIANCE 1. 2. 3. 4.

Set the thermostat to the lowest setting. Turn off all the electric power to the appliance if service is to be performed. Remove door panel. For Robertshaw Gas Valve: Turn gas control knob clockwise to “OFF”.

31

For Honeywell Gas Valve: Turn gas control knob clockwise to “OFF”. Make sure knob rests against stop. 5.

Replace heater door panel.

FOR MODELS WITH AUTOMATIC GAS VALVES

PILOT SHUT-OFF VALVE CONTROL SHOWN IN "ON" POSITION

1. Close all gas valves. Turn off electric power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desired temperature. TO SHUT DOWN

GAS INLET

Close all manual gas valves. Turn off electric power.

Intermittent Pilot System Checkout Procedure (S8600)

TO PILOT

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

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

After Start-Up 1. Turn on power to the ignition systems and turn gas supply off. 2. Check ignition module as follows: a. Set the tankstat to call for heat. b. Watch for continuous spark at the pilot burner. c. Time the spark operation. Time must be within the lockout timing period (15 or 90 seconds). d. Turn tankstat down to end call for heat and wait 60 seconds on lockout models before beginning step 3. 3. Turn on gas supply. 4. Set tankstat to call for heat. 5. Systems should start as follows: a. Spark will turn on and pilot gas valve will open at once. Pilot burner should ignite after gas reaches the pilot burner. b. Spark ignition should cut-off when pilot flame is established. c. Main gas valve should open and main burner should ignite after gas reaches the burner port.

Fig. 31: Typical Main Burner Flame (Atmospheric Models)

Controls Check all controls to see that they are operational. To check electronic safety (IID models), turn off main burner. Observe pilot burner when shutting off pilot gas. Ignition spark should go on. Main gas valve will also drop out. High Limit Switch - to check high limit switch, turn dial setting down to a point slightly below the temperature of the water leaving the heater. The reset button should snap out and the burner should shut-off. Reset dial to 30°F to 40°F above desired operating temperature and push reset button. Burner should light.

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

32

ADDENDA: LOW NOx HEATERS MODELS 0181 TO 0401

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

The Raytherm Low NOx Heater is offered with WH1On-Off firing (standard) or 2-stage firing (optional). The heaters are certified and tested under the latest edition of the ANSI Z21.10.3/CSA 4.3 standard for hot water heaters. The heater should be installed to meet all local codes, the National Fuel Gas Code ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70-latest edition.

1. Remove top of heater and inspect heat exchanger for soot and examine venting system. 2. Remove rear header and inspect for scale deposits. *3. Inspect pilot and main burner flame and firing rate. *4. Inspect and operate all controls and gas valve. *5. Visually inspect system for water leaks. *6. a. Oil pump motor and bearing assembly, if oil cups are provided. b. Disconnect pump from header and check condition of pump impeller. Check condition of bearing by attempting to move impeller from side to side. Replace any parts showing wear. c. Check pump coupler for wear and vibration.

DETAIL A SEE DETAIL VIEW A

Fig. 33: Burner Detail Fig. 32: Pilot Burner Flame—IID (Atmospheric Models)

Operation

7. Check flow switch paddle. 8. Clean room air intake openings to ensure adequate flow of combustion and ventilation air.

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

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

Start-Up Procedures (S8610b Ignition Module)

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

1. Turn on power to the heater with gas supply off. 2. Check ignition module as follows: a. Set the tankstat to call for heat. b. Watch for continuous spark at the pilot burner.

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

33

c. Check the ignition spark operation. Time must be within the lockout timing period (15 or 90 seconds). d. Turn control down to end call for heat and wait 60 seconds on lockout models before beginning step 3. 3. Turn on gas supply. 4. Set controller to call for heat. 5. System should start as follows: a. Spark will turn on and pilot gas valve will open and the blower will begin running. b. Heater will operate until call for heat is satisfied.

COMBUSTION AIR BLOWER AIR SHUTTER ADJUSTMENT GAS VALVE BURNER

BURNER HOLDDOWN BRACKET

burner Adjustment This burner assembly does not require any primary air adjustments.

Fig. 35: Low NOx Burner Tray Assembly

Visual Inspection

burner Tray Removal

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

1. 2. 3. 4. 5. 6. 7. 8. 9.

Electrical

10. 11.

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

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

High Gas Pressure Switch

1. 2. 3. 4. 5.

Shut-off main electrical power switch to heater. Shut-off gas supply to the heater. Remove front door. Disconnect gas line from gas valve. Disconnect wires, pilot tubing and bleed line, if required. 6. Remove (2) screws that secure gas valve to jacket. 7. Turn vertical gas pipe from manifold slightly and unscrew gas valve. 8. Reverse above procedure to re-install.

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

Fig. 34: Gas Pressure Switch

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Main burner And Orifice Removal 1. Remove burner tray. (See Burner Tray Removal procedure on page 34.) 2. Remove (8) screws from the hold-down brackets. 3. Remove (8) screws from the left and right sides of the manifold assembly. Detach the manifold assembly from the burner tray assembly. 4. Use a long ½” socket wrench to remove orifices from the gas manifold. 5. Remove burners by raising the bracket on the back end of the burners up and out of their slots. 6. Reverse above procedure to re-install.

Fig. 36: IID Pilot

Combustion Fan Removal

Pilot Removal

1. Remove burner tray. (See Burner Tray Removal procedure on page 34.) 2. Remove (4) screws that mount the combustion blower to the manifold assembly. 3. Reverse above procedure to re-install.

1. Disconnect pilot tubing from gas valve. 2. Remove (4) screws from control box. Open the control box. 3. Remove the pilot wire from the ignition wire. 4. Remove (2) screws that mount the pilot bracket to the air manifold assembly. 5. Pull the pilot bracket downwards and outwards. 6. Reverse above procedure to re-install.

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TROUbLESHOOTING

WARNING—HIGH VOLTAGE: For qualified technicians ONLY.

Electrical—Electronic Ignition IID

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 heater.

Intermittent Pilot System Honeywell S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL)? YES

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

NO

Check line voltage power, low voltage transformer, limit controller, thermostat (controller) and wiring. Pull ignition lead and check spark at module.

SPARK ACROSS IGNITER/SENSOR GAP? YES

NO

TURN GAS SUPPLY ON PILOT BURNER LIGHTS? YES

NO

SPARK STOPS WHEN PILOT IS LIT? YES

NO

MAIN BURNER LIGHTS? YES

NO

SYSTEM RUNS UNTIL CALL FOR HEAT ENDS? YES

NO

If spark is okay: • Check ignition cable, ground wiring, ceramic insulator and gap, and correct. • Check boot of the ignition cable for signs of melting or buckling. Take protective action to shield cable and boot from excessive temperatures. If not, replace module.

• Check that all manual gas valves are open, supply tubing and pressures are good, and pilot burner orifice is not blocked. • Check electrical connections between module and pilot operator on gas control. • Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay, replace gas control; if not, replace module. NOTE: If S8600H goes into lockout, reset system. Lockout is used on propane models. • Check continuity of ignition cable and ground wire. • Clean flame rod. • Check electrical connections between flame rod and module. • Check for cracked ceramic flame rod insulator. • Check that pilot flame covers flame rod and is steady and blue. • Adjust pilot flame. • If problem persists, replace module. • Check for 24 Vac across MV-MV/PV terminals. If no voltage, replace module. • Check electrical connections between module and gas control. If okay, replace gas valve or gas control operator, i.e. pilot gas valve, flow switch etc. NOTE: IF S8600H goes into lockout, reset system. • Check continuity of ignition cable and ground wire. NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though operation is normal at the time of checkout. • Check that pilot flame covers flame rod and is steady and blue. • If checks are okay, replace module.

CALL FOR HEAT ENDS SYSTEM SHUTS OFF? YES

NO

• Check for proper thermostat (controller) operation. • Remove MILLIVOLT lead at module; if valve closes, recheck temperature controller and wiring; if not, replace gas valve.

TROUBLESHOOTING ENDS

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Mechanical CORRECTIVE ACTION

MECHANICAL PROBLEM

POSSIBLE CAUSE

When heater is turned on nothing happens.

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

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

Main gas valve closed………………...... Open valve. Plugged bleed line on gas valve or gas pressure regulator………………….. Loosen bleed line and clean. Broken pump coupler…………………… Replace coupler. Inspect bearing assembly, and if frozen, lubricate or replace. Shutdown by low water cut-off, caused by air…………………………….. Bleed air from system. Gas valve defective…………………….. Check for power to gas valve. If valve has power but will not open, check vent tube for blockage. If clear, replace valve.

Continuous shut down of manual reset High Limit.

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

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

Refer to installation instructions regarding combustion air requirements. Condensation……………………………. Set bypass valve to prevent heater inlet temperature from dropping below 105° F. Toxic fumes which cause a chemical reaction with copper tubes or destroy combustion………………………………. Remove all sources of fumes, such as freon or chloride, or isolate the heater. Improper venting………………………… Follow recommended vent installation instructions.

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

Insufficient system flow…………………. Check pumps and piping. Low water due to leaking……………….. Inspect for leaking and repair. Air in system……………………………... Inspect for leakage and repair. Install an automatic air vent. Line strainer dirty………………………… Clean. Lime in Heat Exchanger………………… Ream tubes.

Low flame.

Low gas supply………………………….. Debris in gas line (pipe dope, rocks, etc.). Gas line too small. Improper size gas meter. Gas regulator adjustment. Insects or debris clogging………………. Clean burners. Burner intake ports low gas pressure…. Adjust gas pressure. Venting or combustion air………………. Refer to installation instructions regarding combustion air requirement.

Outer jacket very hot (blistered paint)

Broken refractory…..……………………. Replace refractory panels.

Combustion fan not running. (If applicable)

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

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

Air starvation……………………………..

37

WIRING DIAGRAMS

Wiring Diagram—W2/WH2 133

38

Wiring Diagram—WH1 0181/0261

39

Wiring Diagram—WH1 0331/0401

40

Wiring Diagram—WH1 0514–0724

41

Wiring Diagram—WH1 0824–1826

42

Wiring Diagram—WH1 2100–2500

43

Wiring Diagram—WH1 3001–4001

44

Troubleshooting—Pumps

Pump Loses Prime

Failure To Pump

1. 2. 3. 4.

1. 2. 3. 4.

Pump not properly primed. Wrong direction of rotation. Speed too low. Total head too high.

Air leaks in suction line. Excess air in water. Water seal in stuffing box not functioning. Excessive suction lift and pump operating too near shut-off point.

Overloaded Driving Unit

Reduced Capacity and/or Head

1. Head much lower than that for which pump is designed. 2. Speed too high or higher than that contemplated.

1. 2. 3. 4. 5. 6.

Air pockets or leaks in suction line. Clogged impeller. Foot valve strainer too small or clogged. Excessive suction lift (over 15 feet). Insufficient positive suction head (for hot water). Total head more than that for which pump is intended. 7. Excessively worn impeller and wearing rings.

Mechanical Troubles and Noise 1. 2. 3. 4.

Rapid Wear of Coupling

Misalignment. Excessive suction lift or vapor binding (hot water). Bent shaft and/or damaged bearings. Suction and discharge piping not properly supported and anchored.

1. Misalignment or a bent shaft. 2. Sagging motor mounts (over-oiling).

SERVICE AND MAINTENANCE PROCEDURES

The heater may be cleaned from the side opposite the water connections as shown, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the residue does not get into the system. Note that you do not remove the top pan or the heat exchanger generally. After reaming with the auger, mount the wire brush and clean out the debris remaining in the tubes. Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in noninhibited de-scale solvent.

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

RAYPAK TUBE CLEANING KIT Extension Pieces (5)

Auger with Carbide Tip

P/N 052871F - 5/8 DIA.

Wire Brush

P/N 052870F - 7/8 DIA.

Fig. 37: Raypak Tube Cleaning Procedure

45

COMBINATION FLAME SENSOR/ IGNITER AND PILOT BURNER

Fig. 38: Typical Burner Tray Illustrated

burner Tray Removal

6. Remove the spring and store in a safe place. 7. Using an Allen wrench, turn the screw clockwise to increase or counterclockwise to decrease high fire manifold pressure –see Fig. 39. 8. Install the spring, weight and aluminum cap –tighten the cap using same # of turns as was used in removing the cap. 9. For low fire adjustment, tighten the aluminum cap to increase and loosen to decrease low fire manifold pressure. 10. Install 2-stage solenoid valve and turn heater on, check manifold pressures. 11. Repeat steps 3 to 10 until correct manifold pressures are obtained. 12. Secure 2-stage solenoid valve by tightening the 3/8” nut or #10 Torx screw.

1. Shut-off power and gas supply to the heater. Disconnect union(s) and pilot tubing, then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner drawer out.

Gas Valve Removal 1. Shut-off gas supply to the heater. Remove gas piping to gas valve inlet. 2. Disconnect wires, pilot tubing and bleed line, if required. 3. Turn vertical gas pipe from manifold slightly and unscrew gas valve. 4. Reverse above procedure to re-install.

Gas Valve Adjustment - Robertshaw (Invensys) 7000 Series 2-Stage Gas Valve with Solenoid Valve NOTE: Attach a manometer and check the manifold pressures –both high fire and low fire– before making any adjustments. 1. Turn the heater off. 2. Remove the 3/8” nut or the #10 Torx screw. 3. Lift solenoid valve up, keeping the wires connected to the solenoid valve. 4. If only low fire adjustment is needed, go to Step 9. 5. Using a 3/8” wrench, carefully remove the aluminum cap that was under the solenoid valve-count # of turns when removing the cap. Be careful not to drop the cylinder (weight) or the small spring that is under the cap –see Fig. 39.

Fig. 39: 2-Stage Gas Valve Adjustment (Invensys)

46

Main burner and Orifice Removal

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

Heat Exchanger Re-Assembly

1. Remove screws and burner hold-down bracket. NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts. 2. Lift burners from slotted spacer and slide from orifices. Clean with a wire brush. 3. Orifices usually do not need to be replaced. To clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling.

1. Heat exchanger water header O-rings must be replaced with new ones. 2. Install in/out and return water headers and install header retainer nuts and torque nuts evenly. 3. Install the four (4) corner clips between tube sheets and refractory. Replace "V" baffles. 4. Install thermostat sensing bulbs in header wells and replace bulb retaining clips. 5. Install inlet and return pipes in water headers using pipe thread sealant. 6. Install water pressure relief valve, flow switch, and low water cut-off devices (if so equipped). 7. Open water supply and return shut-off valves. Fill heater and water piping system with water. Check heater and piping system for leaks at full line pressure. Run system circulating pump for a minimum of 1/2 hour with heater shut-off. 8. Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris. Expansion tank water level should be at the 1/4 mark and the balance of the tank filled with air. 9. Install flue collector, jacket top and inspection panels. Install top holding screws. Install draft diverter and vent piping if so equipped. 10. If gas piping was disconnected, reconnect gas piping system and check for leakage using a soap solution. 11. Check for correct water pressure and water level in the system. Make sure that system pump operates immediately on the call for heat. The system is ready for operation. 12. Within two (2) days of start-up, recheck all air vents and expansion tank levels.

Pilot Removal and Cleaning 1. Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burner tray. 2. Remove pilot and bracket, clean pilot of debris, small bugs, etc., with wire or small brush. 3. Replace pilot, pilot tubing, sensor ignition wires and check for leaks.

High Limit or Tankstat Removal 1. Turn off electrical power. 2. Remove front inspection panel. 3. Remove wires to high limit and loosen screws holding high limit to cabinet. 4. Remove wedge clip holding sensing bulb in control well. 5. Remove high limit and install a new one. 6. Check control operation before leaving job.

Heat Exchanger Removal 1. Shut water, gas and electricity off, close valves and relieve pressure, remove relief valve. 2. Remove side inspection panels. 3. Remove top holding screws. 4. Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels. 5. Loosen bolts and disconnect flange nuts on in/out header, loosen union(s) at gas pipe, and slide heater away from piping until studs clear the heater. 6. Remove heat exchanger corner brackets. 7. Remove combustion chamber clips at the four corners of the heat exchanger.

Fig. 40: Typical Heat Exchanger Configuration

47

Combustion Chamber Removal

9. DO NOT apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0.015". 10. Use same procedure on opposite end. 11. Apply line pressure test. Re-roll if necessary. 12. Reinstall as outlined under HEAT EXCHANGER REASSEMBLY.

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

Cleaning Flue Gas Passageways Soot will clog areas between fins and cause eventual tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning. 1. Lift off drafthood and flue collector by removing bolts and screws. 2. Remove "V" baffles from heat exchanger. 3. Remove burner tray. 4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid excessive water against refractory). 5. Reassemble: When heater is fired, some steam will form from wet refractory. This is normal. 6. Identify and correct reason for soot formation.

Fig. 41: Refractory Panels—Top View

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

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

Tube Replacement 1. Remove heat exchanger from heater following instructions outlined under HEAT EXCHANGER REMOVAL on page 45. 2. Remove in/out and return headers. Remove "V" baffle from damaged tube. 3. Remove damaged tube by cutting with a hack saw or shearing with a chisel adjacent to each tube sheet. 4. Collapse stub ends in tube sheets using a chisel or screwdriver. DO NOT cut into tube sheet or mar surface in tube hole in any way. 5. Insert replacement tube by inserting the end with the most fins removed in the opening of one tube sheet. Slide tube until the opposite end clears the other tube sheet and fit the tube into the hole. 6. Insert the tube roller into tube opening up to stop, making certain that 1/8" of tube projects beyond the tube sheet. 7. Attach drill to tube roller, holding it straight and level. Note: Use a 3/8" heavy duty, reversible, electric drill or larger. Proceed to expand tube until tool starts to grab. Approximately 1/2 to 1" of the tool shank will be visible. 8. Reverse drill motor and withdraw tube roller, If necessary wrench out by hand.

CAUTION: Soot is combustible, so exercise extreme care.

REPLACEMENT PARTS See separate parts sheet in instruction envelope. 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 RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued. RAYPAK, INC. 2151 Eastman Avenue Oxnard, CA 93030 48

LIMITED PARTS WARRANTY RAYTHERM™ COMMERCIAL HEATERS TYPES H & WH MODELS 0133 TO 4001 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty but are the owner's responsibility. ANY PART MANUFACTURED BY RAYPAK: One (1) year warranty from date of heater installation, or eighteen (18) months from date of factory shipment based on Raypak's records, whichever comes first. SATISFACTORY PROOF OF INSTALLATION DATE, SUCH AS INSTALLER INVOICE, IS REQUIRED. THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED. HEAT EXCHANGER WARRANTY: Domestic Hot Water Five (5) years from date of heater installation. Includes copper heat exchanger with bronze and cast iron waterways. Ten (10) years from date of heater installation. Includes only cupro-nickel heat exchanger with bronze or cast iron waterways. Space Heating (Closed Loop System) Ten (10) years from date of heater installation. Includes both cupro-nickel and copper heat exchanger with bronze or cast iron waterways. Thermal Shock Warranty Twenty (20) years from date of heater installation against "Thermal Shock" (excluded, however, if caused by heater operation at large changes exceeding 150°F between the water temperature at intake and heater outlet temperature, or operating at heater temperatures exceeding 230°F). ADDITIONAL WARRANTY EXCLUSIONS: This warranty does not cover failures or malfunctions resulting from: 1. Failure to properly install, operate or maintain the heater in accordance with our printed instructions provided; 2. Abuse, alteration, accident, fire, flood and the like; 3. Sediment or lime build-up, freezing, or other conditions causing inadequate water circulation; 4. High velocity flow exceeding heater design rates; 5. Failure of connected systems devices, such as pump or controller; 6. Use of non-factory authorized accessories or other components in conjunction with the heater system; 7. Failure to eliminate air from, or replenish water in, the connected water system; 8. Chemical contamination of combustion air or use of chemical additives to water. PARTS REPLACEMENT: Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts manufactured by others, but Raypak will apply any such warranty as may be provided by the parts manufacturers. TO MAKE WARRANTY CLAIM: Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the problem. The installer must then notify a Raypak distributor for instructions regarding the claim. If either is not available, contact Service Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA or call (805) 278-5300. In all cases proper authorization must first be received from Raypak before replacement of any part. EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY: This is the only warranty given by Raypak. No one is authorized to make any other warranties on Raypak's behalf. THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. RAYPAK'S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY. IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY, WHETHER UNDER THIS WARRANTY, OR IN CONTRACT, TORT, NEGLIGENCE OR OTHERWISE, FOR ANY SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGE, INCLUDING DAMAGE FROM WATER LEAKAGE. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not apply to you. This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the date of manufacture plus thirty (30) days. _____________________________________________________ Name of Owner _____________________________________________________ Address _____________________________________________________

______________________________________________ Name of Dealer ______________________________________________ Address ______________________________________________

_____________________________________________________ Model No.

______________________________________________ Se ri al No.

Date of Installation:_____________________________________

Date of Initial Operation: ___________________________

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

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www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.

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Raytherm™ Hot Water Supply Heaters - Huron Valley Sales, Inc

INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Hot Water Supply Heaters Models 0133–4001 Type WH L W ® LLC WARNING: Improper installation, adjus...

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