Raypak RAYTHERM 0133 4001 User Manual

CATALOGNO. 3000.52H

Effective:

Replaces:

07-15-06

11-01-04

INSTALLATION

AND OPERATING

INSTRUCTIONS

RAYTHERM

HOT WATER SUPPLY

HEATERS

Models 0133-4001

Types WH & NH

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids or other combustible

materials in the vicinity of this or any other appliance. To do so may result in an explosion

or fire.

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

property damage, personal injury or loss of life. Refer to this manual. Installation and service

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

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

*Do not try to light any appliance.

*Do not touch any electrical switch; do not use any phone in your building.

*Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's

instructions.

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

This manual should be maintained in legible

condition and kept adjacent to the heater or in a

safe place for future reference.

P/N241075Rev. 1

RECEIVING EQUIPMENT

ALL MODELS (APPROVED)

On receipt of the equipment, visually check for

All models are National Board approved. Tem-

external damage to the carton or the shipping crate. If perature and pressure gauge is standard. Intermittent

the carton or shipping crate is damaged, make a note ignition device is standard on models 0514 and up.

on the Bill of Lading and report the damage to the

Carrier immediately. Remove the heater from the pass.

carton or the shipping crate.

Model 0133 has 4-pass heat exchanger, 1 tube per

Models 0181-0401 have 2-pass heat exchangers,

Do NOT use the shipping crate base as an instal- 5 tubes first pass, 4 tubes second pass.

lation base. Models 0514-1826 have 2-pass heat exchangers,

On occasion, items are shipped loose. Be sure that 5 tubes first pass, 4 tubes second pass.

you receive the number of packages indicated on the

Bill of Lading.

Models 2100-4001 have 2-pass heat exchangers,

9 tubes per pass.

When ordering parts, you must specify Model and

Serial Number of the heater. When ordering under

warranty conditions, you must also specify date of

installation.

Raypak recommends that this manual be reviewed

thoroughly before installing your Raypak heater. If

there are any questions which this manual does not

answer, please contact the factory or your local Raypak

representative.

Claims for shortages and damages must be filed

with carrier by consignee. Permission to return goods

must be factory-authorized and are subject to a stock-

ing charge.

Purchased parts are subject to replacement only

under the manufacturer's warranty. Debits for defec-

tive replacement parts will not be accepted and will be

replaced in kind only per our standard warranties.

Models 926-4001 have optional single pass with

cast iron headers only.

HOT WATER SUPPLY HEATERS

All Raypak hot water supply heaters are ASME and

design certified as hot water heaters, with 125 PSI

pressure relief valves.

TYPE WH1 WITH ON/OFF CONTROLS

Models 0133-4001

To be used with storage tank systems. Available

with integrally mounted pump, factory mounted and

wired for models 0133-1826. Models 181,261,331 and

401 are Low NOx Hot Water Heaters.

TYPE WH2 WITH MODULATING CONTROLS

Models 0133-4001

Hot water supply heater with 110°-170°F gas

modulation. Available with integrally mounted pump,

factory mounted and wired for models 0133-1826. To

be used with storage tank systems.

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 simi-

lar 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 eleva-

tion. For elevations above 2000 feet, reduce input 4%

for each 1000 feet above sea level.

TYPE WH3 WITH 2-STAGE CONTROLS

Models 0181-4001

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.

TYPE NH INSTANT-PAK

Models 0514-1826

GENERAL SPECIFICATIONS

Tankless instantaneous direct fired hot water sup-

ply heater with 110°-170°F gas modulation, factory

mounted bronze body or cast iron bronze fitted pump

and flow switch.

The Raypak water heaters are design certified and

tested under the latest requirements of the American

NationalStandard,ANSIZ21.10.3/CSA4.3. Eachheater

hasbeenconstructedandpressuretestedinaccordance

with the requirements of Section IV of the American

Society of Mechanical Engineers Code, and factory fire

tested.

CALIFORNIA PROPOSITION 65 WARNING:

This product contains chemicals known to the State

of California to cause cancer, birth defects or other

reproductive harm.

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.

DANGER

WARNING

Gasoline, as well as other flammable materials and liquids PROPANE MODELS – Propane must be used with great

(adhesives, solvents, etc.), and the vapors they produce, are caution.

extremely dangerous. DO NOT handle, use or store gasoline • It is heavier than air and will collect first in lower areas

or other flammable or combustible materials anywhere near making it hard to detect at nose level.

or in the vicinity of a water heater. Be sure to read and follow • Make sure to look and smell for propane leaks before

thewarninglabelpicturedbelowandotherlabelsonthewater attempting to light appliance. Use a soapy solution to check

heater, as well as the warnings printed in this manual. Failure all gas fittings and connections. Bubbling at a connection

to do so can result in property damage, bodily injury, or death. indicates a leak that must be corrected. When smelling to

detect a 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

DANGER

Failure to install the drafthood and properly vent the water manufacturer's recommendations and/or local laws, rules,

heater to the outdoors as outlined in the Venting Section of regulations or customs.

this manual can result in unsafe operation of the water heater. • It is recommended that more than one method be used to

To avoid the risk of fire, explosion, or asphyxiation from detect leaks in propane applications.

carbon monoxide, never operate this water heater unless it is IF PROPANE IS PRESENT OR SUSPECTED:

properly vented and has an adequate air supply for proper • DO NOT attempt to find the cause yourself;

operation. Be sure to inspect the vent system for proper • DO NOT try to light any appliance;

installation at initial start-up; and at least annually thereafter. • DO NOT touch any electrical switch;

Refer to the Venting section of this manual (pg. 11) for more • DO NOT use any phone in your building.

information regarding vent system inspections.

• Leave the building immediately and make sure that every-

one else leaves also.

• Leave the doors open for ventilation and contact the gas

supplier, a qualified service agency or the fire department.

• Keep the area clear until the service call has been made,

the leak is corrected, and a qualified agency has determined

the area to be safe.

DANGER

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.

Vapors from flammable liquids Water heater has a main

will explode and catch fire burner and pilot flame.

causing death or severe The pilot flame:

burns.

1. Is on all the time or intermit-

DANGER

Do not use or store flammable tently (IID).

products such as gasoline sol- 2. Will ignite flammable va-

ventsoradhesivesinthesame pors.

room or area near the water

heater.

Water heaters utilizing propane are different from natural gas

models. A natural gas heater will not function safely on

propane and vice versa. Conversion from natural gas to

propane (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. Use propane for

propane units, natural gas for natural gas units. These units

are not certified for any other type fuel.

Vapors:

1. Cannot be seen,

Keep flammable products:

1. Far away from heater,

2. In approved containers,

3. Tightly closed and

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.

4. Out of children's reach.

Installation:

WARNING

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

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.

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.

INSTALLATION INSTRUCTIONS

INSTALLATION CODES

Installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions

of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and the National Electrical Code, ANSI/NFPA 70. In

Canada installations must conform with the current CAN/CSA B149.1 and the Canadian Electrical Code Part 1

CSA C22.2 No.1. Where required by the authority having jurisdiction, the installation must conform to American

SocietyofMechanicalEngineersSafetyCodeforControlsandSafetyDevicesforAutomaticallyFiredHeaters,CSD-

INSTALLATION BASE

The heater should be mounted on a level, non-combustible surface. Heater must not be installed on

carpeting. The heater can be installed on a combustible surface only when the appropriate listed floor shield base

is provided. An optional listed floor shield base is available for factory installation with the heater on all indoor

models. Do NOT use the shipping base crate as an installation base.

NOTE: The heater should be located in an area where water leakage will not result in damage to the area adjacent

to the appliance or to the structure. When such locations cannot be avoided, it is recommended that a suitable

drain pan, adequately drained, be installed under the appliance. The pan must not restrict air flow.

In addition, the heater shall be installed such that the gas ignition system components are protected from water

(dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replace-

ment, etc.).

Combustible floorshield ordering information:

ALTERNATE METHOD FOR PROVIDING A NON-

COMBUSTIBLE BASE

Fig.# 8148

CLEARANCES

CLEARANCES TO PROTECTED SURFACES

INSTALLATION CLEARANCES

(All Dimensions Are In Inches)

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.

CLEARANCES FROM COMBUSTIBLE

SURFACES

Note 1:

Combustible floor shield is required when heater is to

be installed on a combustible surface. (See ordering

info. on pg.5.)

Note 2:

Servicing Clearances: Provide at least 24" (Models

0133-1826), 48" (Models 2100-4001) in front of unit for

removal & servicing of the Controls & Burner Tray.

Provide at least 18" on side opposite water connec-

tions 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.

SPECIFICATIONS AND DIMENSIONS

MODEL 133

NOTE:

Ratingsareshownforelevationsupto2,000feet. Forelevationsover

2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

* Recovery based on manufacturer's rating.

MODELS 182-400 and 181-401

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.

* Recovery based on manufacturer's rating.

MODELS 514-824

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 962-1826

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 926-1758

NOTE:

Ratingsareshownforelevationsupto2,000feet. Forelevationsover

2,000 feet, reduce ratings 4% for each 1,000 feet above sea level.

*Recovery based on manufacturer's rating.

MODELS 2100-4000

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.

OUTDOOR WATER HEATERS

These heaters are design certified for out-

door 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 horizon-

tally.

Fig. #8245

HIGH WIND CONDITIONS (Outdoor Units Only)

In areas where high winds are frequent, it may be necessary to locate the heater a minimum of 3' from high

vertical walls, or install a wind break so the heater is not in direct wind current.

COMBUSTION AIR (Indoor Units Only) Air For Combustion And Ventilation

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

openings are 12 inches from ceiling for ventilation and 12 inches from the floor for combustion air as outlined

in ANSI Z223.1, and any local codes that may have jurisdiction.

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 acid condensate can damage or substantially reduce

the life of the heater. It may become necessary to provide outside air directly to the heater in order to avoid this

problem.

a. All Air From Inside The Building:

b. All Air From Outdoors:

Each opening shall have a minimum net free square When air is supplied directly from outside of building,

inches as noted:

each opening shall have a minimum net free square

inches as noted:

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 shown in Sec. 5.3.5 National Fuel Gas Code.

VENTING

MODELS 514-824

OUTDOOR INSTALLATIONS

Step 1: Lower outdoor "Stackless" top onto unit.

Position top so it is centered on unit from

side-to-side and front-to-rear.

MODEL 133

Step 1: Remove the front (4) screws.

Step 2: Line up outdoor top vent opening over heater

vent opening.

Step 3: Lower outdoor top onto unit lining up slots in

the outdoor top with screws holes in jacket top.

Step 4: Reinstall (5) screws to secure jacket top and

outdoor top to unit.

Fig# 8166

Fig. #8114

Step 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.

MODELS 181-401 and 182-400

Fig# 8278.1

VENT TERMINAL (Outdoor) Stackless Top Installa-

tion

1. Insert tabs into

keyhole (4 places).

2. Snap tabs into keyholes

so as not to pull out.

Fig# 8233

MODELS 926-1758

Heaters are shipped with outdoor vent terminal

factory installed.

MODELS 2100-4001

These units are not certified for outdoor installa-

tion.

Pagoda Top (Shipped Loose with Heater)

Fig. #RP8280.1

INDOOR INSTALLATIONS

MODEL 133

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

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

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

Step 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.

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

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

Fig. #8946

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

BEFORE

AFTER

INSTALLATION

OF DRAFTHOOD

INSTALLATION

OF DRAFTHOOD

Fig. #8947

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

MODELS 514-824

MODELS 181-401 and 182-400

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 through the stack.

6. Attach the three (3) mounting brackets to the

stack using the screws provided and the holes

that are pre-drilled in the stack. Make sure the

bracketsarepositionedwiththeflangenearthe

top side of the stack (see illustration 8246.5).

Caution must be taken not to over tighten and

strip the screw threads.

7. Turn the assembled stack and jacket top, right side

up. The jacket top will be trapped between the

brackets and the top of the stack. Place the stack

over the inner adapter panel flanged hole and

lower the louvered jacket top panel back into its

original position. Reinstall the four (4) green #10

flathead screws removed in step 1 above.

Fig. # 8167

MODELS 962-1826

Locate and assemble as shown below. Secure with

screws supplied in envelope in carton.

Fig. # 8165

Fig. # 8246.5

MODELS 2100-4001

These models have built-in drafthoods. For proper

operation, the drafthood outlet must be connected to

the venting system.

VENT PIPING

WARNING: Indoor heaters require a drafthood that

The weight of the vent stack or chimney must not rest

must be connected to a vent pipe and properly vented on heater drafthood. Support must be provided in

to the outside. Failure to follow this procedure can compliance with applicable codes. The heater top and

cause fire or fatal carbon monoxide poisoning.

drafthood must be readily removable for maintenance

and inspection. Vent pipe should be adequately sup-

Vent piping of the same size as the drafthood outlet ported to maintain proper clearances from combustible

is recommended, however, when the total vent height construction Type "B" double wall or equivalent vent

is at least ten (10) feet (drafthood relief opening to vent pipe is recommended. However single wall metal vent

terminal), the vent pipe size may be reduced as speci- pipe may be used as specified in the latest edition of the

fiedintheNationalFuelGasCode,ANSIZ223.1. Avoid

longhorizontalrunsofventpipeandtoomanyelbows. If

installationrequireshorizontalnon-verticalruns,thevent

pipe must have a minimum of

National Flue Gas Code ANSI Z223.1.

Manifolds that connect more than one heater to a

common chimney must be sized to handle the com-

bined load. Consult available guides for proper sizing

1/4 inch per foot rise and should be supported at not of the manifold and the chimney. At no time should the

more than five foot intervals. Plumber's tape, criss- area be less than the area of the largest outlet.

crossed, will serve to space both horizontal and vertical

piping. Gas vents supported only by the flashing and

extending above the roof more than five feet should be

securely guyed or braced to withstand snow and wind

loads. We recommend use of an insulated vent pipe

spacer through the roofs and walls.

For protection against rain or blockage by snow, the

vent pipe must terminate with a vent cap which com-

plies 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

Fig. #7043.1

feet vertically from the roof surface and at least 2 feet

higher than any part of the building or equipment within

At the time of removal of an existing heater, the follow-

tenfeet. Theventstackshallbeatleast5feetinvertical

ing steps shall be followed with each appliance remain-

height above the drafthood outlet. The vent cap loca-

ing connected to the common venting system placed in

tion shall have a minimum clearance of 4 feet horizon-

operation, while the other appliances remaining con-

tally from, and in no case above or below, unless a 4-

nected to the common venting system are not in

foot horizontal distance is maintained, from electric

operation.

meters, gas meters regulators and relief equipment.

(a) Seal any unused openings in the common venting

system.

10' OR LESS

VENT CAP

(b) Visually inspect the venting system for proper size

2' MIN

and horizontal pitch and make sure there is no

blockage or restriction, leakage, corrosion or

2' MIN

other deficiency which could cause an unsafe

condition.

5' MIN

VENT PIPE

windows and all doors between the space in which

the appliances remaining connected to the com-

mon venting system are located and other spaces

DRAFT HOOD

of the building. Turn on clothes dryers and any

appliance not connected to the common venting

system. Turn on any exhaust fans, such as range

hoods and bathroom exhausts, so they will oper-

HEATER

ate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected. (g) Any improper operation of the common venting

Follow the lighting instructions. Adjust thermostat

so appliance will operate continuously.

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 com-

mon venting system should be re-sized to

approach the minimum size as determined using

the appropriate tables in Part 11 of the National

Fuel Gas Code, ANSI Z223.1.

(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 sys- For special venting applications that require reduced

tem is venting properly, return doors, windows, vent sizes and through-the-wall venting, the Type D

exhaust fans, fireplace dampers and any other gas Induced Draft Assembly can be used. Consult the

burning appliance to their previous conditions of

use.

factory or your local Raypak representative.

VENT DAMPER INSTALLATION

MODELS133THROUGH180

(WHERE REQUIRED)

LOCATION

The vent damper must be located in the vent so

that it serves only the appliance for which it is intended.

If improperly installed, a hazardous condition, such

as an explosion or carbon monoxide poisoning, could

result. Make certain that it is mounted in an accessible

location at least 6 in. from any combustible material or

the heat exchanger and that the position indicator is in

a visible location.

The vent damper must be installed after the appli-

ance drafthood, as close to the drafthood as practi-

cable, and without modification of the drafthood.

Fig. # 8182.0

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.

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.

The vent damper is set up for a continuous pilot system. If the vent damper is installed on an Intermittent

Pilot or Direct Spark Ignition equipped system, the energy savings of the vent damper can be improved by

plugging the hole in the vent damper blade using the knockout plug, Part No. 105612R, provided in the parts

envelope.

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

condition.

HORIZONTAL INSTALLATION

D808

FLOW >

N.O.

N.C.

End

Switch

1K2

YES

1K1

HEATER

TO BOILER

D808

TO CHIMNEY

Motor

1K3

VERTICAL

INSTALLATION

INSTALL VENT

DAMPER WITH

ACTUATOR TO

SIDES OF VENT

ONLY. DO NOT

TO CHIMNEY

D808

Yellow Blue

Black

Orange

Red

Optional Limit

Location

Limit

Thermostat or

Controller

MOUNT ABOVE OR

BELOW VENT.

(Hot)

Dual Valve

Combination Gas

Control or

ACTUATOR MAY BE

INSTALLED IN ANY

POSITION ON

Transformer

Ignition System

HEATER

TO BOILER

P^Poo^ww^ere^sr^ups^pu^lyp^pp^roly^vidp^er^do^isv^ci^odⁿe^ned^ctis^mc^eonnect mea^an^nss^aaⁿn^oveo^rv^loe^adrlo^pra^otd^ecp^tiorⁿot^ae^sc^reti^qo^un as requiⁱr^ree^dd^..

VERTICAL PIPE.

Fig. # 8615.0

Fig. # 8183.0

INSTALLING THE VENT DAMPER

VENT DAMPER GENERAL WIRING DIAGRAM

INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED.

IF IMPROPERLY INSTALLED, A HAZARDOUS CONDITION, SUCH AS AN EXPLOSION OR CARBON

MONOXIDE POISONING, COULD RESULT.

2. Turn the thermostat or controller up to call for heat

and check that the vent damper indicator points to

the open position, Fig. 4.

3. Turn the thermostat or controller down again and

check that the vent damper position indicator

returns to the closed position.

VENT DAMPER

For safe, efficient operation, the vent damper and

all flue product carrying areas of the appliance must be

checked annually, with particular attention given to

deterioration from corrosion or other sources. Check

vent damper operation as follows:

THE VENT DAMPER MUST BE INSPECTED AT

LEAST ONCE

YEAR BY

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.

1. When the heater is off, check that the vent

damper position indicator points to the closed

position, Fig. 4.

Damper

Position

Indicator

Damper

Position

Indicator

Fig. # 8181.0

DAMPER OPEN

DAMPER CLOSED

FIG. 4 - VENT DAMPER POSITON INDICATOR SHOWING OPEN & CLOSED POSITIONS.

PLUMBING

GENERAL

CAUTION: The heater and its manual shut-off valve

must be disconnected from the gas supply during any

pressure testing of that system at test pressures in

excess of 1/2 PSI. 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.

Heater should be located so that any water leaks

will not cause damage to any adjacent areas or struc-

tures.

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 notuseTeflontapeongaslinepipethread.

A flexible sealant is recommended.

Fig. # 8090.1

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.

* Models 181, 261, 331, and 401 are Low NOx units and are not available in propane.

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 181, 261, 331, and 401

should be 3.9 wc natural gas. If an adjustment is needed, turn adjustment screw clockwise to increase pressure,

or counter-clockwise to decrease pressure.

VENTING OF DIAPHRAGM GAS COMPONENTS

Gas train components that have diaphragms in their construction are supplied with a bleed line connection

that must be connected to the outside atmosphere as required by the National Fuel Gas Code. Under NO

circumstances shall bleed lines terminate in the gas utilization equipment flue or exhaust system.

Fig # 8185.2

FLOW RATES

PIPING - DOMESTIC HOT WATER SUPPLY HEATERS

GENERAL SPECIFICATIONS

UNI-TEMP 80 HOT WATER SUPPLY SYSTEMS

T = Temperature Rise, Degree F@GPM FLOW

GPM = Gallons per Minute Flow

P = Pressure Drop, Foot thru Heat Exchanger

MPS = Minimum Pipe Size, NPT

SHL = System Head Loss

The table above provides data for selecting in-line pumps for use in a Uni-Temp 80 system for a single heater

and tank according to the following:

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

Soft: 0-4 grains per gallon.

Medium: 5-15 grains per gallon.

Hard: 16 and over grains per gallon.

2. Maximum Flow Rates:

133

22 GPM

45 GPM

90 GPM

200 GPM

181-401

514-1826

2100-4001

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

4. Sizing based on heater and tank being placed 5 feet apart. The equivalent length of pipe

valves and fittings in the system is as follows:

1-1/2" NPT = 70 Ft (181-401)

2" NPT = 75 Ft (514-824)

2-1/2" NPT = 80 Ft (926-1826)

3" NPT = 85 Ft (2100-4001)

Additional pipe fittings will increase the system head loss.

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

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

NOTE:

GPM flow rates are limited by maximum acceptable velocity through heat exchanger tubes. Heater models 514

through 1826 may be provided with an integral rear-mounted pump. This must be specified at time of order. The

integral pump will provide sufficient flow to meet the conditions listed in the table.

PIPING DIAGRAMS

TYPE WH - UNITEMP 80 SYSTEM

TYPE NH - INSTANTANEOUS

Type NH heaters provide instant hot water without a tank and are used in applications where scaling is

prevalent and where hot water demand is fairly constant throughout the day, such as apartments, hotels, motels

and industrial applications. The Type NH heater should not be used on apartments and hotels with fewer than

30 dwelling units, nor should the heater be sized smaller than a 514.

Use a minimum 20' of 3" pipe on outlet.

TYPE NH - DUAL MODELS 514-1826

1. Estimate total length of supply and return loop.

Refer to table.

3. First fixture on supply line must be a minimum

of 20 feet from the heater.

2. If multiple loops are used:

4. Supply line size must be 2" minimum. If not

possible, add a tank between heater and first

fixture.

(A) Use multiple pumps and size return pipes

according to table; or

(B) Use one larger recirculating pump with

balancing valves on each return line.

MINIMUM INPUT ADJUSTMENT

Model Types NH and 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.

CONTROLS - GENERAL

RELIEF VALVE

ELECTRONIC IGNITION

A new combination temperature and pressure

The intermittent ignition device conserves energy

(T&P) relief valve, complying with the Standard for by automatically extinguishing the pilot when desired

Relief Valves and Automatic Gas Shut-Off Devices for temperature is reached. When additional heat is

Hot Water Supply Systems, ANSI Z21.22, must be needed, the pilot re-ignites electrically, eliminating the

installed in the opening provided on top of the storage fuel costs of maintaining a constant pilot. To assure

tank at the time of installation. No valve is to be placed safe operation, the gas valve cannot open until the pilot

between the relief valve and the storage tank.

The pressure rating of the relief valve must not

exceed the 160 maximum working pressure indicated

onthewaterheaterratingplate. TheBTUHratingofthe

relief valve must not be less than the BTUH input of the

heater.

relights and is confirmed.

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.

OPERATING CONTROLS

On models 514-1826, models with mechanical

modulating controls have one or more Robertshaw

Unitrol 7000 Series hydraulic snap on thermostatic

combination gas valves. These valves have the pres-

sure regulator and 24-volt operator built-in. The hy-

draulic actuator will throttle the heater input to adjust the

firing rate and meet the required load. This, in effect,

prevents costly fuel consumption, as compared to an

on-off cycling heater. The valve has a remote capillary

bulb immersed in a well, at the header outlet, to main-

tain a constant outlet water temperature. When mul-

tiple 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 chart below.

ECONOMASTER CONTROL

The Economaster II is an electronic device that

allows the operator to set the desired time for the pump

to run after the heater shuts off. The time is factory-set

at 7 minutes and it can be re-adjusted in the field

anywhere from 3 to 10 minutes.

In a conventional system, when the aquastat is

satisfied, the main gas valve closes, but the pump

continues operating. With the energy-conserving

Economaster II, the heater pump is programmed to

continue running for an optimum period of time in order

to absorb the residual heat from the combustion cham-

ber and use it in the system. The pump then shuts off

until the next call for heat is received from the aquastat.

NOTE: Pump will come on when power is first applied

to the heater.

Fig# 9331

Fig # 9330.1

Fig # 9332

MECHANICAL MODULATING VALVE LOCATION

MODELS 0724-1336

MOTORIZED GAS VALVE LOCATION

MODEL 3001

Fig # 9333.1

LIMIT CONTROLS

HIGH LIMIT

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 equipped with a manual reset High

Limit. Push the reset button and set the limit(s) to

30°F-40°Fabove desiredoperatingtemperature. Maxi-

mum setting is 210°F.

LOW WATER CUT-OFF (OPTIONAL)

FLOW SWITCH

The low water cut-off automatically shuts down

burner whenever water level drops below probe. 90-

second 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.

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.

HIGH AND LOW GAS PRESSURE

SWITCHES (OPTIONAL)

100% PILOT SAFETY

These switches sense either high or low gas pres-

sures and automatically shut down burners if abnormal

pressures exist.

Models 514-4001 employ electronic devices which

close the main gas valve within 8/10 of a second

COMPONENT IDENTIFICATION

Fig# 8643

Fig# 9314

MANUAL RESET HIGH LIMIT

THERMOSTAT CONTROL

Fig# 9312

Fig# 8929.1

HIGH and/or LOW

IGNITION CONTROL MODULE

GAS PRESSURE SWITCH

Fig# 9316

Fig# 8995

LOW WATER CUT-OFF

MECHANICAL MODULATING VALVE

Fig# 9317

Fig# 8925

FLOW SWITCH

FLOW SWITCH PADDLE CUTTING GUIDE

ELECTRICAL CONNECTIONS

control connection. 24 Volts are supplied to this con-

nection through the heater transformer. DO NOT

attach line voltage to the "TH" leads on models 514-

1826. Before starting heater check to ensure proper

voltage to heater and pump.

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper

and dangerous operation. Verify proper operation after

servicing.

Heater must be electrically grounded in accor-

dance with National Electrical Code ANSI/NFPA No

70.

DANGER - SHOCK HAZARD

Make sure electrical power to the heater is discon-

nected to avoid potential serious injury or damage to

components.

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.

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 instruc-

tion packet. The "TH" leads are for the remote tank

Fig # 9138.2

Fig # 9138.1

SINGLE-STAGE TANKSTAT

2- STAGE TANKSTAT

(2 ON/OFF UNITS)

LOCATION OF CONTROLS

400

WH1, WH2, WH3

181 (LOW NOx)

WH1

Fig # 9360

LOCATION OF CONTROLS

Fig. #9334

LOCATION OF CONTROLS

Fig # 9335

START-UP PROCEDURES

INITIAL START-UP - PUMP AND MOTOR

BEFORE START-UP

Safe lighting and other performance criteria were

Many pumps are now direct-drive. They have no

met with the gas manifold and control assembly pro- coupler or bearing assembly. These pumps do not

vided on the heater when the heater underwent tests require lubrication. Others require SAE-30 non-deter-

specifiedinthelatesteditionoftheANSI-Z21.10.3/CSA

4.3Standard.

gent oil to lubricate both the motor and the bearing

assembly. Check pump motor for type before adding

oil.

Clean dust and lint from pump and motor. Check

pump coupler and tighten if necessary.

Flush system before putting into operation to en-

sure that foreign material does not damage pump

seals.

GENERAL

Before lighting up a new installation, water should

be flowing through the heater.

Water pressure regulator should be set to mini-

mum 25 PSI.

CAUTION:

Propane is heavier than air and sinks to the

ground. Exercise extreme care in lighting heater in

confined areas.

A. Pump must be off to check oil in bearing assembly.

B. Do not run pump without water in system.

General Safety Precautions

To meet commercial water use needs, the thermostat The following chart details the relationship of water

on this water heater is adjustable up to 190°F. How- temperature and time with regard to scald injury and

ever, water temperatures over 125°F can cause instant

severeburnsordeathfromscalds. Thisisthepreferred

temperaturesettingwhensupplyinggeneralpurposehot

water.

may be used as a guide in determining the safest water

temperature for your applications.

Temperature

120°F

Time to Produce Serious Burn

More than 5 minutes

1-1/2 to 2 minutes

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.

125°F

130°F

About 30 seconds

135°F

About 10 Seconds

140°F

Less than 5 seconds

Less than 3 seconds

About 1-1/2 seconds

About 1 second

145°F

150°F

155°F

Table courtesy of Shriners Burn Institute

TIME/TEMPERATURE RELATIONSHIPS IN

SCALDS

The temperature of the water in the heater can be

regulated by setting the temperature dial on the front of

the thermostat. To comply with safety regulations, the

thermostat was set at its lowest setting before the

heater was shipped from the factory. The illustration

below shows how to adjust the water temperature

using the thermostat.

To adjust the water tem-

perature, insert a small

straight screwdriver into

slotted screw in hole in front

of thermostat and turn

wheel to desired setting.

Thermostat is adjustable

up to 190°F.

Water temperature over 125°F can

causeinstantsevereburnsordeath

from scalds.

Children, disabled, and elderly are

at highest risk of being scalded.

CAUTION!! - Hotter water

increases the risk of

SCALDING!

See instruction manual before set-

ting temperature at water heater.

There is a hot water scald potential if the thermostat is

set too high.

Feel water before bathing or show-

ering.

NOTE: When this heater is supplying general purpose

hot water requirements for use by individuals, a ther-

mostatically controlled mixing valve for reducing point

of use water temperature is recommended to reduce

the risk of scald injury. Contact a licensed plumber or

the local plumbing authority for further information.

Temperature limiting valves are

available, see manual.

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 thermom-

eter.

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.

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

partment.

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

knob. Never use tools. If the knob will not push in or turn

by hand, do not try to repair it. Call a qualified service

technician. Force or attempted repair may result in a fire

or explosion.

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 instruc-

tions.

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

water. Immediately call a qualified service technician to

inspect the appliance and to replace any part of the

control system and any gas control which has been

under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat on the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which

automatically lights the pilot. Do not try to light the pilot

by hand.

For Honeywell Gas Valve: Turn gas control knob counter-

clockwise from “OFF” until it stops. Push in gas control

knob and continue rotating counter-clockwise

position. Make sure knob rests against stop.

to “ON”

5. Remove heater door panel.

6. For Robertshaw gas valve: Turn gas control knob

HONEYWELL

clockwise

For Honeywell Gas Valve: Turn gas control knob clock-

wise to “OFF". Make sure knob rests against stop.

to “OFF”.

GAS CONTROL

KNOB SHOWN

IN "ON" POSITION

For Honeywell Gas Valve: (Model 400 only)

Push in gas control knob slightly and turn clockwise

GAS INLET

to “OFF”. Knob cannot be turned to

“OFF”

unless knob is pushed in slightly. Do not force.

7. Wait five (5) minutes to clear out any gas. Then smell for

gas, including near the floor. If you smell gas, STOP!

Follow “B” in the safety information previously stated. If

you do not smell gas, go to the next step.

Fig. # 8082

8. For Robertshaw Gas Valve: Turn gas control knob

counter-clockwise

to “ON”.

Replace heater door panel.

10. Turn on all electric power to the appliance.

11. Set thermostat to desired setting.

12. If the appliance will not operate, follow the instructions

“To Turn Off Gas To Appliance” and call your service

technician or gas supplier.

ROBERT SHAW

GAS CONTROL

KNOB SHOWN

IN "ON" POSITION

GAS INLET

Fig. # 8080

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn off all the electric power to the appliance if service

is to be performed.

ForHoneywellGasValve: Turngascontrolknobclock-

wise

stop.

to “OFF”. Make sure knob rests against

3. Remove door panel.

4. For Robertshaw Gas Valve: Turn gas control knob 5. Replace heater door panel.

clockwise to “OFF”.

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.

TO PILOT

4. Set temperature controls to desired temperature.

MAIN GAS

SHUT-OFF

VALVE

SHOWN IN

THE "ON"

POSITION

TO SHUT DOWN

Close all manual gas valves. Turn off electric

power.

GAS INLET

Fig# 8220

AFTER START-UP

INTERMITTENT PILOT SYSTEM CHECKOUT PROCEDURE (S8600)

1. Turn on power to the ignition systems and turn

gas supply off.

3. Turn on gas supply.

4. Set thermostat or controller above room temp-

erature 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.

2. Check ignition module as follows:

a. Set the thermostat or controller above

room temperature 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 thermostat down to end call for heat

and wait 60 seconds on lockout models

before beginning step 3.

c. Main gas valve should open and main

burner should ignite after gas reaches the

burner port.

INSPECTION PROCEDURES

BURNERS

CONTROLS

Clean main burners and air louvers free of dust, lint

Check all controls to see that they are operational.

and debris. Keep heater area clear and free from To check electronic safety (IID models), turn off main

combustibles and flammable liquids. Do not obstruct burner. Observe pilot burner when shutting off pilot

the flow of combustion and ventilation air. Make visual gas. Ignition spark should go on. Main gas valve will

check of burner and pilot flame. Yellow flame indicates also drop out.

clogging of air openings. Lifting or blowing flame indi-

High Limit Switch - to check high limit switch, turn

cates excessively high gas pressure. Low flame indi- dial setting down to a point slightly below the tempera-

cates low gas pressure.

ture 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 tempera-

ture and push reset button. Burner should light.

Fig# 8144

TYPICAL MAIN BURNER FLAME (Atmospheric models)

NOTE: Modulating burner flame varies in height from

approximately 1/4" at low fire to approximately 4" at

high fire.

INSPECTION PROCEDURES

7. Check flow switch paddle.

8. Clean room air intake openings to assure

adequate flow of combustion and ventilation air.

Inspect on the first and third month after initial start-

up and then on an annual basis. If problems are found,

refer to the Troubleshooting sections of this manual for

additional directions.

CAUTION: Combustion air must not be contaminated

by corrosive chemical fumes which can damage the

heater and void the warranty.

1. Remove top of heater and inspect heat exchanger

for soot and examine venting system.

2. Remove rear header and inspect for scale depos-

its.

9. Keep heater area clear and free from combustible

materials, gasoline, and other flammable vapors

and liquids.

*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.

*Should be checked monthly.

(Takes approximately 15 minutes).

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.

Fig# 9336

PILOT BURNER FLAME-IID

(atmospheric units)

ADDENDA: LOW NOx HEATERS Models 181 to 401

The Raytherm Low NOx Heater is offered with WH1-

On-Off firing (standard) or 2-stage firing (optional).

3.Turn on gas supply.

4.Set controller to call for heat.

The heaters are certified and tested under the latest

edition of the ANSI Z21.10.3/CSA 4.3 standard for hot

waterheaters.

5.System should start as follows:

a. Spark will turn on and pilot gas valve will open and

the blower will begin running.

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.

b. Heater will operate until call for heat is satisfied.

BURNER ADJUSTMENT

This burner assembly does not require any primary air

adjustments.

VISUAL INSPECTION

Flame can be observed through the slot opening above

the plenum. Flame color is blue and evenly spread on

the top surface of 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

Fig # 9361

ELECTRICAL

OPERATION

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.

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.

HIGH GAS PRESSURE SWITCH

Pressure switch senses high pressure and automati-

cally shuts down burner if abnormal pressure exists.

START-UP PROCEDURES

(S8610B Ignition Module)

PRESSURE

SWITCH

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

2.Check ignition module as follows:

GAS MANIFOLD

a. Set the thermostat or controller to call for heat.

b. Watch for continuous spark at the pilot burner.

c. Check the ignition spark operation. Time must be

within the lockout timing period (15 or 90 seconds).

d. Turn control down to end call for heat and wait 60

seconds on lockout models before beginning step

Fig. #8236.0

ADDENDA: LOW NOx HEATERS Models 181 to 401 (CONTINUED)

sembly 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 # 9362

LOW NOx BURNER TRAY ASSEMBLY

Fig # 9363

BURNER TRAY REMOVAL

IID PILOT

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

2. Shut-off gas upstream of heater.

3. Remove front door.

PILOT REMOVAL

4. Disconnect gas line from gas valve.

5. Remove (2) screws that mount burner tray to unit,

and (4) screws that secure gas valve to jacket.

6. Disconnect wires that terminate at gas valve.

7. Unscrew (4) screws that secure the control box.

8. Disconnect pilot wire from the ignition module.

9. Disconnect wire harness from the combustion

blower.

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.

10. Carefully slide out the burner tray assembly.

11. Reverse above procedure to reinstall.

COMBUSTION FAN REMOVAL

GAS VALVE REMOVAL

1. Remove burner tray. (See Burner Tray

Removal procedure above.)

2. Remove (4) screws the mount the combustion

blower to the manifold assembly.

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

2. Shut-off gas supply to the heater.

3. Remove front door.

4. Disconnect gas line from gas valve.

5. Disconnect wires, pilot tubing and bleed line,

if required.

3. Reverse above procedure to re-install.

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.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove burner tray. (See Burner Tray Removal

procedure above.)

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 as-

WARNING

HIGH VOLTAGE

For qualified Technicians ONLY

TROUBLESHOOTING - 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

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

procedure.

POWER TO MODULE

(24 V NOMINAL)?

YES

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

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.

TURN GAS SUPPLY ON

PILOT BURNER LIGHTS?

YES

• 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.

SPARK STOPS WHEN

PILOT IS LIT?

YES

• 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.

MAIN BURNER LIGHTS?

YES

NOTE: IF S8600H goes into lockout, reset system.

• Check continuity of ignition cable and ground wire.

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS?

YES

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

• 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

WIRING DIAGRAMS

WIRING DIAGRAM - WH2 182/260

WIRING DIAGRAM - WH2 330/400

WIRING DIAGRAM - WH2 514/624

WIRING DIAGRAM - WH2 724-1336

WIRING DIAGRAM - WH2 1414-1826

WIRING DIAGRAM - WH2 2100-2500

WIRING DIAGRAM - WH2 3001-4001

WIRING DIAGRAM - WH1 181/261 LOW NOx

WIRING DIAGRAM - WH1 331/401 LOW NOx

TROUBLESHOOTING

MECHANICAL PROBLEM

POSSIBLE CAUSE

CORRECTIVE ACTION

When heater is turned on nothing

happens.

No power to the heater…………………. Check the circuit breaker, outdoor con-

troller, etc., upstream of heater.

Bad transformer…………………………. If power to Leads L1 and L2 of trans-

former, but no power on 24V side, re-

place.

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, re-

place.

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 as-

sembly, and if frozen, lubricate or re-

place.

Shutdown by low water cut-off,

caused by air…………………………….. Bleed air from system.

Gas valve defective…………………….. Checkforpowertogasvalve. Ifvalvehas

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……………. Reset High Limit to higher temperature.

Low water flow…………………………… Check system water pumps.

Interrupted pump operation…………….. Check pump oil if necessary.

Modulating control set too high……….. Reset modulator to a lower setting.

Mechanical modulating control………… Check and replace if necessary.

Sooting

Air starvation…………………………….. Refer to installation instructions regard-

ing combustion air requirements.

Condensation……………………………. Set bypass valve to prevent heater inlet

CAUTION-Soot may be combus-

tible. Wet down and exercise

caution when cleaning.

Toxic fumes which cause a chemical

reaction with copper tubes or destroy

temperature from dropping below 105° F.

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 regard-

ing 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.

TROUBLESHOOTING - PUMPS

FAILURE TO PUMP

PUMP LOSES PRIME

1. Pump not properly primed.

2. Wrong direction of rotation.

3. Speed too low.

1. Air leaks in suction line.

2. Excess air in water.

3. Water seal in stuffing box not functioning.

4. Excessive suction lift and pump operating too

near shut-off point.

4. Total head too high.

REDUCED CAPACITY AND/OR HEAD

1. Air pockets or leaks in suction line.

2. Clogged impeller.

3. Foot valve strainer too small or clogged.

4. Excessive suction lift (over 15 feet).

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

6. Total head more than that for which pump is

intended.

OVERLOADED DRIVING UNIT

1. Head much lower than that for which pump is

designed.

2. Speed too high or higher than that contem-

plated.

MECHANICAL TROUBLES AND NOISE

1. Misalignment.

7. Excessively worn impeller and wearing rings.

2. Excessive suction lift or vapor binding (hot

water).

RAPIDWEAR OF COUPLING

1. Misalignment or a bent shaft.

2. Sagging motor mounts (over-oiling).

3. Bent shaft and/or damaged bearings.

4. Suction and discharge piping not properly

supported and anchored.

SERVICE AND MAINTENANCE PROCEDURES

Fig. # 8154

RAYPAK TUBE CLEANING KIT

Extension Pieces (5)

Auger with Carbide Tip

Wire Brush

TUBE CLEANING

sure the residue does not get into the system.

Note that you do not remove the top pan or the

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 heat exchanger generally.

deposits over 1/16" in thickness.

After reaming with the auger, mount the wire brush

The heater may be cleaned from the side opposite and clean out the debris remaining in the tubes.

the water connections as shown, without breaking pipe

connections. It is preferable, however, to remove both ream tubes and immerse heat exchanger in non-

headers for better visibility through the tubes and to be

Another method is to remove the heat exchanger,

inhibited de-scale solvent.

COMBINATION FLAME SENSOR/

BURNER ORIFICES

IGNITOR AND PILOT BURNER LOCATION

BURNERS

BURNER HOLD-DOWN LOCATION

TYPICAL BURNER TRAY ILLUSTRATED

BURNER TRAY REMOVAL

PILOT REMOVAL AND CLEANING

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.

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.

GAS VALVE REMOVAL

1. Shut-off gas supply to the heater. Remove gas

piping to gas valve inlet.

HIGH LIMIT OR TANKSTAT REMOVAL

2. Disconnect wires, pilot tubing and bleed line, if

required.

3. Turn vertical gas pipe from manifold slightly and

unscrew gas valve.

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. Reverse above procedure to re-install.

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.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove screws and burner hold-down bracket.

HEAT EXCHANGER REMOVAL

NOTE: If the heat exchanger is sooted badly, the

burner hold-down bracket and spacer can become

distorted from direct flame impingement and this usu-

ally necessitates replacement of these parts.

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.

2. Lift burners from slotted spacer and slide from

orifices. Clean with a wire brush.

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.

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.

8. Lift heat exchanger straight up using caution not to

damage refractory.

HEAT EXCHANGER RE-ASSEMBLY

COMBUSTION CHAMBER REMOVAL

1. Heat exchanger water header O-rings should be

replaced with new ones.

To remove combustion chamber you must first

have removed the heat exchanger. Unbolt metal

combustion chamber retainer from top and remove

combustion chamber panels individually.

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 pres-

sure. Run system circulating pump for a minimum

of 1/2 hour with heater shut-off.

REFRACTORY PANELS TOP VIEW

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.

CONTROL WELL REPLACEMENT

Remove top, sensing bulb and clip. Collapse well

tube at the open and with a chisel, push through into

header and remove the well through header. Insert a

new well and roll into place. If a roller is not available,

solder the well in place with silver solder.

TUBE REPLACEMENT

1. Remove heat exchanger from heater following

instructions outlined under HEAT EXCHANGER

REMOVAL above.

2. Remove in/out and return headers. Remove

"V" baffle from damaged tube.

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.

3. Remove damaged tube by cutting with a hack saw

or shearing with a chisel adjacent to each tube

sheet.

12. Within two (2) days of start-up, recheck all air vents

and expansion tank levels.

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.

Fig# 9337

TYPICAL HEAT EXCHANGER CONFIGURATION

8. Reverse drill motor and withdraw tube roller, If

necessary wrench out by hand.

9. DO NOT apply excessive torque during rolling

operation and avoid thinning any wall of the tube

beyond 0.015".

10. Use same procedure on opposite end.

11. Apply line pressure test. Re-roll if necessary.

12. Reinstall as outlined under HEAT EXCHANGER

REASSEMBLY.

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.

CLEANING FLUE GAS PASSAGEWAYS

Soot will clog areas between fins and cause even-

tual 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.

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.

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.

RAYPAK, INC.

2151 Eastman Avenue

Oxnard, CA 93030

NOTE: In extreme cases it may be necessary to

remove the heat exchanger completely for cleaning.

The simplest method is high pressure cleaning at a

local car wash. DO NOT WIRE BRUSH!

CAUTION:

Soot is combustible, so exercise extreme care.

ILLUSTRATED PARTS LIST

AVAILABLE AT

WWW.RAYPAK.COM

CATALOG

MODEL

NUMBER

133

9300.11

9300.203

9300.35

9300.50

9300.60

181-401

334-824

926-1826

2001-2500

WARRANTY

LIMITED PARTS WARRANTY

RAYTHERM™ COMMERCIAL HEATERS

TYPES H, NH & WH

MODELS 133 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 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

______________________________________________

Name of Dealer

_____________________________________________________

Address

______________________________________________

Address

_____________________________________________________

______________________________________________

_____________________________________________________

Model No.

______________________________________________

Serial 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

P/N: 240532

www.raypak.com

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.

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