CATALOGNO. 3000.50D
Effective: 01-01-03
Replaces: 03- 01-97
INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 090A, 135A, 195A
Type WH
ECONOPAK WATER
HEATERS
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance. To do so may result in an explosion or
fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
propertydamage,personalinjuryorlossoflife. Refertothismanual. Installationandservicemust
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.
*Ifyoucannotreachyourgassupplier, callthefiredepartment.
This manual should be maintained in legible
condition and kept adjacent to the heater or kept
in a safe place for future reference.
P/N 240687
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1. RECEIVING EQUIPMENT
Onreceiptofyourequipmentitissuggestedthatyou
visually check for external damage to the carton. If the
carton is damaged, it is suggested that a note be made
ontheBillofLadingwhensigningforequipment. Remove
theheater fromthecartonandifitisdamagedreportthe
damage to the carrier immediately. Be sure that you
receive the number of packages indicated on the Bill of
Lading. Claims for shortages and damages must be
filed with carrier by consignee.
SPECIFICATIONS AND DIMENSIONS
PIPING
K
VENT
DIA.
5"
CONNECTIONS
WATER GAS
INPUT
MBH
90
TANK
GAL.*
80
RECOVERY
MODEL
WH-0090
WH-0135
WH-0195
GPH
A
11"
18"
18"
B
NPT.
1"
1-1/4"
1-1/4"
NPT.
1/2"
1/2"
1/2"
5-3/4
6-1/4
6-1/4
90
132
192
80
135
6"
7"
80
195
*May be used with other tank size capacity.
Purchased parts are subject to replacement only
underthemanufacturer'swarranty. Debitsfordefective
replacement parts will not be accepted and defective
parts will be replaced in kind only per our standard
warranties.
Note: Recovery GPH based on Manufacturer's rating.
When ordering parts, you must specify Model and
Serial Number of the heater. When ordering under
warranty conditions, you must also specify date of
installation.
Raypak recommends that this manual be re-
viewed thoroughly before installing your Raypak
Heater. Ifthereareanyquestionswhichthismanual
does not answer, please contact your local Raypak
representative.
2. GENERAL SPECIFICATIONS
TheRaypakwaterheatersaredesigncertifiedbythe
AmericanGasAssociation,andtestedundertherequire-
ments of the American National Standard, ANSI
Z21.10.3. Each heater has been constructed and
pressure tested in accordance with the requirements of
Section IV of the American Society of Mechanical Engi-
neers Code, and factory fire tested.
Theheatersaredesignedforindoorinstallationwith
a built-in drafthood, and a built-in sub-base for combus-
tible flooring. Models are available with standing pilot,
orwithintermittentignitiondevice(I.I.D). Theheaters are
equipped with the following components: water circula-
tion pump, pressure relief valve, manual reset high limit
switch, fastresponsetemperaturesensor, 40VAtrans-
former, vent thermal switch, flame roll-out switch, and
redundantcombinationgasvalve. Atankstatissupplied
loose for installation in the field.
.#8978.5.1
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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.
LIQUEFIED PETROLEUM MODELS – Propane, or LP gas, must
Gasoline, as well as other flammable materials and liquids
be used with great caution.
(adhesives, solvents, etc.), and the vapors they produce, are
extremelydangerous. DONOThandle, useorstoregasoline
• Itisheavierthanairandwillcollectfirstinlowerareasmaking
or other flammable or combustible materials anywhere near
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 LP leaks before attempting to
the warning label pictured below and other labels on the
light appliance. Use a soapy solution to check all gas fittings
water heater, as well as the warnings printed in this manual.
and connections. Bubbling at a connection indicates a leak
Failure to do so can result in property damage, bodily injury,
that must be corrected. When smelling to detect an LP leak,
or death.
be sure to sniff near the floor too.
• Gas detectors are recommended in LP applications and their
installation should be in accordance with the manufacturer's
recommendations and/or local laws, rules, regulations or
customs.
• It is recommended that more than one method be used to
detect leaks in LP applications.
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 Maintenance section of this manual for
more information regarding vent system inspections.
IF LP GAS IS PRESENT OR SUSPECTED:
• DO NOT attempt to find the cause yourself;
• DO NOT try to light any appliance;
• DO NOT touch any electrical switch;
• DO NOT use any phone in your building.
• Leave the building immediately and make sure that everyone
else leaves also.
• Leave the doors open for ventilation and contact the gas sup
plier, a qualified service agency or the fire department.
• Keep the area clear until the service call has been made, the
leak is corrected, and a qualified agency has determined the
area to be safe.
Both LP and natural gas have an odorant added to help detec-
tion. Some people may not physically be able to smell or
recognize this odorant. If unsure or unfamiliar about the smell
associated with LP or natural gas, ask the gas supplier. Other
conditions, such as "Odorant Fade", which causes the odorant
to "fade", or diminish in intensity can also hide or camouflage
a gas leak.
Vapors from
flammable liquids will
explode and catch fire
causing death or severe
Water heater has a main
burner and pilot flame.
The pilot flame:
1. is on all the timeand
burns.
2. will ignite flammable
vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the
floor,
4. can be carried from other
room to the pilot flame by
their currents.
Do not use or store flammable
products such as gasoline
solvents or adhesives in the
same room or area near the
water heater.
Keeflammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
Water heaters utilizing Liquefied Petroleum gas (LP) are differ-
ent from natural gas models. A natural gas heater will not
function safely on LP gas and vice versa. Conversion from
NaturalgastoLPgas(orviceversa)mustbedonebyaqualified
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
propaneunits.Naturalgasfornaturalgasunits. Theseunitsare
not certified for any other type fuel.
4. out of childrens reach.
Installation:
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.
Do not install water heater
where flammable products
will be stored or used unless
the main burner and pilot flames
Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.
LP appliances should not be installed below-grade (for ex-
ample, in a basement) if such installation is prohibited by
federal, state and/or local laws, rules, regulations or customs.
4
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General Safety Precautions
To meet commercial hot water requirements, the
The following chart details the relationship of water
temperatureandtimewithregardtoscaldinjuryandmay
be used as a guide in determining the safest water
temperatureforyourapplications.
tankstat is adjustable up to 190°F. However, water
temperatures over 125°F. can cause severe burns in-
stantly or death from scalds. This is the preferred
startingpointforsettingthecontrolforsupplyinggeneral
purposehotwater.
Temperature
120°F.
Time to Produce Serious Burn
More than 5 minutes
1-1/2 to 2 minutes
Safetyandenergyconservationarefactorstobeconsid-
eredwhensettingthewatertemperatureonthetankstat.
Themostenergyefficientoperationwillresultwhenthe
temperaturesettingisthelowestthatsatisfiestheneeds
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.
TablecourtesyofShinersBurnInstitute
TIME/TEMPERATURERELATIONSHIPSINSCALDS
Thetemperatureofthewaterinthestoragetankcanbe
regulated by setting the temperature dial on front of the
tankstat. To comply with safety regulations, the
tankstat was set at its lowest setting before shipment
from the factory. The illustration below illustrates the
tankstat and how to adjust the water temperature.
To adjust the water temperature,
insert a small straight screwdriver
into slotted screw in hole in front
of tankstat and turn wheel to
desired setting. Tankstat is
adjustable up to 190°F.
CAUTION!! - Hotter water
increases the risk of
SCALDING!
Water temperature over 125°F can cause
severe burns instantly or death from
scalds.
Children, disabled and elderly are at high-
est risk of being scalded.
Seeinstructionmanualbeforesettingtem-
perature at tankstat.
Feel water before bathing or showering.
There is a Hot Water SCALD Potential if the tankstat is
set too high.
Temperature limiting valves are available,
see manual.
NOTE: When this water heater is supplying general
purposehotwaterrequirementsforusebyindividuals,a
thermostatically controlled mixing valve for reducing
point of use water temperature is recommended to
reduce the risk of scald injury. Contact a licensed
plumberorthelocalplumbingauthorityforfurtherinfor-
mation.
Maximum water temperatures occur just after burner
has shut off. To find hot water temperature being
delivered, turn on a hot water faucet and place a
thermometer in the hot water stream and read the
thermometer.
5
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operation and service (circulator replacement, control
replacement,etc.)
3. INSTALLATION PROCEDURES
CODEREQUIREMENTS
Installation must be in accordance with local
codes, or, intheabsenceoflocalcodes, withthe latest
editionsofthe NationalFuelGasCode,ANSIZ223.1,/
NFPA 54, and the National Electrical Code, ANSI/
NFPA70. InCanadainstallationsmustconformwiththe
current CAN/CGA B149.1 or .2 and the Canadian
Electrical Code Part 1 CSA C22.2 No.1. Where
requiredbytheauthorityhavingjurisdiction,theinstalla-
tion must conform to American Society of Mechanical
EngineersSafetyCodeforControlsandSafetyDevices
for Automatically Fired Heaters, No. CSD-1.
CLEARANCEREQUIREMENTS
1) MinimumClearancesFromCombustibleMaterials
Model Floor Front Back Right Left Top Flue
No.
0090
0135 Comb. Alcove 6"
0195
Vent
6"
6"
16" 6"
2) A front clearance of at least 24" is recommended
foradequateserviceofburner-trayandcontrols.
3) Except for carpeted flooring, heaters are certified
for installation on combustible floors.
MOUNTINGBASE
Heatershouldbemountedonalevelsurface. Each
heaterisdesignedwithabuilt-insub-baseapprovedfor
mounting the heater on combustible flooring. Heater
must NOT be installed on carpet flooring.
4) For un-insulated hot water pipes, maintain a 2"
clearance, or consult local authority having
jurisdiction.
COMBUSTION/VENTILATIONAIR
WARNING: Air supply to the heater room must not be
affected by mechanical exhaust vents located in other
partsofthehouse, suchaskitchenorbathroomfans, or
attic blowers. Mechanical exhaust vents may create a
negativepressureconditionintheheaterroomthatcan
become a hazard of asphyxiation, explosion or fire.
8193.1
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater. Measuresmustbetakentopreventtheentryof
corrosive chemical fumes to the combustion and venti-
lation air supply. Such chemicals include, but are not
limited to, chlorinated and/or fluorinated hydrocarbons
such as found in refrigerants, aerosol propellants, dry-
cleaningfluids, degreasers, andpaintremovers. Other
harmfulelementsmaycomefrombleaches,airfreshen-
ers, or mastics. Vapors from these types of products
can form corrosive acid compounds when burned in a
gas flame. The resulting acid condensate can damage
or substantially reduce the life of the heater. It may be
necessary to provide outside air directly to the heater in
order to avoid this problem.
Fig.#8196.0
NOTE: Theheater shouldbelocatedinanareawhere
water leakage will not result in damage to the area
adjacenttotheapplianceortothestructure. Whensuch
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.
1) The heater must be provided with adequate supply
of air for proper combustion and ventilation in
accordance with Sec. 5.3, of the latest edition of
the National Fuel Gas Code, ANSI Z223.1, or
applicable provisions of the local building codes.
Inaddition,theheatershallbeinstalledsuchthatthe
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
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2) If the heater room is located against an outside wall
and air openings can communicate directly with the
outdoors, the two openings on the outside wall
musteachhaveanetfreearea, insquareinchesas
follows:
The discharge opening must be a minimum of two
feetverticallyfromtheroofsurfaceandatleasttwo(2)feet
higher than any part of the building within ten (10) feet.
Vent stack shall be at least five (5) feet in vertical height
above the drafthood outlet. The vent cap location shall
have a minimum clearance of four (4) feet horizontally
from, and in no case above or below, unless a 4-foot
horizontal distance is maintained, from electric meters,
gas meters regulators and relief equipment.
Theweightoftheventstackorchimneymustnotrest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Model
0090
0135
0195
Sq. In. Of Free Area
24
35
50
Location of the openings is the same as in the
previous case - that is, within 12 inches of the top, and
within 12 inches of the bottom of the enclosure. If
horizontalductsareused,theareamustbedoubledand
the duct area shall not be less than the area of the
openingstheyconnect,andinnocaseshallthesmallest
dimension be less than 3 inches.
Type "B" double wall (or equivalent vent pipe is
recommended. Howeversinglewallmetalventpipemay
be used as specified in the latest edition of the National
Flue Gas Code ANSI Z 223.1.
VENTINGCONNECTIONS
Theseheatershavebuilt-indrafthoods. Ventpiping
the same size or larger than the draft hood outlet is
recommended; however, when the total vent height
(drafthoodoutlettoventterminal)isatleastten(10)feet,
the vent pipe size may be reduced by one size only as
specifiedinChapter10ofthelatesteditionoftheNational
Fuel Gas Code, ANSI Z 223.1. As much as possible
avoid long horizontal runs of vent pipe and too many
elbows. If installation requires horizontal runs, the vent
pipe must have a minimum of 1/4 inch per foot rise and
should be supported at not less than five foot intervals.
Maximumventconnectorhorizontallengthshallbe1-1/
2feet(18inches)foreachinchofconnectordiameteras
follows.
HeaterSize VentConnector
Diameter
MaxHorizontal
Length - FT
90
135
195
5"
6"
7"
7.5
9
10.5
Gas Vents supported only by the flashing and
extending above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. Werecommenduseofinsulatedventpipespacer
through the roofs and walls.
Forprotectionsagainstrainorblockagebysnow,the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of such
codes,tothelatesteditionoftheNationalFuelGasCode,
ANSI Z 223.1.
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Fig.# 8191.1
WARNING: These heaters must not be connected into
anyportionofmechanicaldraftsystemsoperatingunder
positivepressure. Todosomaycausetheflueproducts
to be discharged into the living space causing serious
healthinjury.
For connections to gas vents or chimneys, vent
installationsshallbeinaccordancewithPart7, Venting
of Equipment, of the National Fuel Gas Code, ANSI
Z223.1, or applicable provisions of the local building
codes.
COMMONVENTS
Manifolds that connect more than one
heater to a common chimney must be
sized to handle the combined load.
Consultavailableguidesforproper
sizing of the manifold and the chimney.
At no time should the area be less than
the area of the largest outlet.
Fig.#9001
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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
placedinoperation, whiletheotherappliancesremain-
ingconnectedtothecommonventingsystemarenotin
operation.
GASSUPPLYCONNECTIONS
The inlet gas connection of the heater gas valve is
1/2". Provide an adequate gas piping supply line no
smaller than 1/2", according to the chart below:
MaximumEquivalentPipeLength(Feet)
1/2" Pipe
3/4" Pipe
1" Pipe
1-1/4" Pipe
MODEL
NAT PROP NAT PROP NAT PROP NAT PROP
(a) Seal any unused openings in the common venting
system.
0090
0135
0195
30
15
-
80
40
20
125 300 400
-
-
-
400
-
(b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and
other deficiencies which could cause an unsafe
condition.
(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 com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoodsandbathroomexhausts,sotheywilloperate
at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
60 150
35 70
200 500
100 250
-
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shutoff valve located
outside the jacket. All gas piping should be tested after
installation in accordance with local codes.
Manual
Valve
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust tankstat
so appliance will operate continuously.
Valve
# 8192.0
(e) Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe to visually check spillage.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
(g) Anyimproperoperationofthecommonventing
system should be corrected so the installation
conformswiththelatesteditionoftheNationalFuel
Gas Code, ANSI Z 223.1. When resizing any
portion of the common venting system, the com-
monventing systemshouldberesizedtoapproach
the minimum size as determined using the
appropriate tables in Chapter 10 and in
CAUTION:Theheateranditsmanualshutoffvalvemust
bedisconnectedfromthegassupplyduringanypressure
testing of that system at test pressures in excess of 1/
2 psig (3.45 KPA). Dissipate test pressure in the gas
supplylinebeforereconnectingtheheateranditsmanual
shutoffvalvetogassupplyline. FAILURETOFOLLOW
THISPROCEDUREMAYDAMAGETHEGASVALVE.
OVER PRESSURED GAS VALVES ARE NOT COV-
EREDBYWARRANTY. Theheateranditsgasconnec-
tionsshallbeleaktestedbeforeplacingtheappliancein
operation. Use soapy water for leak test. DO NOT use
openflame.
NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant suitable for use with Natural and
Propane gases is recommended.
NOTE: These boilers are also certified to operate on
Propane gas, when equipped with the combination gas
valve and orifices (pilot and main burners) sized for
Propanegas.
Appendix G of the National Fuel Gas Code,
ANSI Z 223.1 and CAN/CGA - B149.1 -B149.2.
GASPRESSURE-SPECIFICATIONS
Inches
Min.
4.5
W.C.
Max.
10.5
Regulator
Setting
3.5
Natural
Propane
12.0
13.0
11.0
Note: Do not exceed maximum inlet gas pressure. The
minimum value shown is for input adjustment.
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The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pressure.
WATER CONNECTIONS & SYSTEM PIPING
The pipe size and fittings between the heater and the tank should be at least 1" for model 90, and
1-1/4"formodels135and195. Thisisbasedonthetankbeinglocatedasclosetotheheateraspossible, asshown
in the drawing below:
T & P Relief Valve
Hot Water Supply
Thermometer
Cold Water
Recirculation Water
Check Valve
Pump
Thermostat
Pressure Relief Valve
If this water heater is installed in a closed water supply system, such as one having a back-flow preventer in
the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or
local plumbing inspector on how to control this situation.
When this water heater system is supplying general purpose hot water requirements for use by individuals,
a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury. Contact a licensed
plumber or the local plumbing authority for further information.
Thermometer(s) should be installed so that they indicate the water temperature at or near the outlet of the
storage tank.
RELIEF VALVE
A new combination temperature and pressure (T & P) relief valve, complying with the Standard for Relief
Valves and Automatic Gas Shut Off Devices for Hot Water Supply Systems, ANSI Z21.22, must be installed in the
opening provided on top of the storage tank, at the time of installation. No valve is to be placed between the relief
valve and the storage tank.
The pressure rating of the relief valve must not exceed the 160 maximum working pressure indicated on the
water heater rating plate. The BTUH rating of the relief valve must not be less than the BTUH input of the heater.
Connect the outlet of the relief valve to a suitable open drain. The discharge line must pitch downward from
the valve to allow complete draining (by gravity) of the relief valve and discharge line. The discharge line should
be no smaller than the outlet of the valve. The end of the discharge line should not be threaded or concealed, and
should be protected from freezing. No valve of any type, restriction or reducer coupling, should be installed in the
discharge line. Local codes shall govern installation of relief valve.
10
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ELECTRICAL WIRING
The electrical power supply requirement for these heaters is 115 volts, 60 Hz. Field wiring connections and
electrical grounding must comply with the local codes, or in the absence of local codes, with the latest edition of
the National Electrical Code, ANSI/NFPA 70. Provide a separate fused circuit from the main electrical panel to
the heater, and a disconnecting means within sight of the heater.
Remove the control box cover and make the power supply connections in the field wiring compartment. (See
general location of controls drawing on page 13). The pump is supplied and factory wired to operate with
the heater.
The thermostat (tankstat) is shipped loose to be installed in the tank at the installation site.
WARNING: SHOCK HAZARD LINE VOLTAGE IS PRESENT. BEFORE SERVICING TANKSTAT OR HEATER,
TURN OFF ELECTRICAL POWER TO THE HEATER AT THE MAIN DISCONNECT OR CIRCUIT BREAKER.
FAILURE TO DO SO COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WIRING DIAGRAM KEY
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105°C wire or its
equivalent, except 150° black wire which must be
replaced with 150° wire or its equivalent.
Fig.# 8096.1
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WIRING DIAGRAM: STANDING PILOT
MODELS 90, 135 and 195
WARNING: SHOCK HAZARD LINE VOLTAGE IS PRESENT. BEFORE SERVICING TANKSTAT OR
HEATER, TURN OFF ELECTRICAL POWER TO THE HEATER AT THE MAIN DISCONNECT OR CIRCUIT
BREAKER. FAILURE TO DO SO COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH.
WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID)
MODELS 90, 135 and 195
*Field Installed
WARNING: SHOCK HAZARD LINE
VOLTAGE IS PRESENT. BEFORE SER-
VICING TANKSTAT OR HEATER, TURN
OFF ELECTRICAL POWER TO THE
HEATER AT THE MAIN DISCONNECT
OR CIRCUIT BREAKER. FAILURE TO
DO SO COULD RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
See page 11 wiring diagram key information.
12
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4. SERVICING PROCEDURES
GENERAL LOCATION OF CONTROLS
CONTROL BOX COMPONENT LOCATIONS
Circulator
Manual Reset Limit
Pressure
Relief Valve
Field Wiring
Compartment
Ignition Module
(Auto Ignition Only)
Temperature Sensor
Ignition Module
(Auto Ignition Only)
Transformer
Roll-Out Sensor
SEQUENCE OF OPERATION
Gas
INTERMITTENT IGNITION DEVICE (IID)
Heaters equipped with the IID system will automati-
callylightthepilotburnerfirstandthenthemainburner,
each time there is a call for heat from the tankstat.
Whenever the tankstat is calling for heat, the circulator
supplied with the heater, will be energized and should
be running. The ignition control module will also be
energizedtoinitiatethepilotignitionbyopeningthefirst
main valve (pilot). At the same time, the electronic
spark generator in the module produces a high voltage
sparkpulseoutputthatlightsthepilotburner. Ifthepilot
burner does not light, the module will not energize the
second main valve and the burners will not light.
Ignition spark continues only until the timed trial for
ignitionperiodends. Then,themodulegoesintosafety
shutdown or lockout. Lockout de-energizes the first
main valve operator and closes the first main (pilot)
valve in the gas control, stopping pilot gas flow. The
ignition control system must be reset by setting the
tankstat belowwater temperatureforoneminuteorby
turning off power to the module for one minute. When
the pilot flame is established, flame rectification circuit
is completed between the sensor and burner ground.
The flame sensing circuit in the module detects the
flame current, shuts off the spark generator and ener-
gizes the second main valve operator which opens the
second main valve. This allows gas to flow to the
burners where it is ignited by the pilot burner flame.
When the tankstat is satisfied, the valve operators are
de-energized shutting off the pilot and main burners,
and also the circulator.
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START-UPPROCEDURES
SECTION 1. Filling the System
8. Push in control knob all the way and hold in,
immediately light the pilot with a match. Continue
toholdcontrolknobinforaboutoneminuteafterthe
pilot is lighted, release knob and it will pop back up.
Pilot should remain lighted. If it goes out, repeat
steps 4 through 8.
Fillsystemwithwater. Purgeallairfromthesystem
using purge valve sequence. After system is purged of
air, lower system pressure.
Flushsystembeforeputtingintooperationtoassure
that foreign material does not damage pump seals.
* If knob does not pop up when released, stop
and immediately call your service technician or
gassupplier.
* If the pilot does not stay lit after several tries,
turn the gas control knob to "OFF" and call your
service technician or gas supplier.
SECTION 2. Checking the Circulator
Before lighting the heater and after system is filled,
make sure that circulator is operating properly. Manual
gasvalveshouldbeoff.
9. Stand to the side of the heater and turn the gas
control knob counter-clockwise to "ON".
10. Turn "ON" all electrical power to the heater.
11. Set the tankstat to the desired setting.
NOTE: Circulatormotorsuppliedwiththeheaterdoesnot
requirelubrication.
FOR STANDING PILOT MODEL WITH
ROBERTSHAWGASVALVE,ON/OFFOPERATION
FOR STANDING PILOT MODEL WITH HONEYWELL
GASVALVE,ON/OFFOPERATION
1. STOP! Read the safety information above.
2. Set the tankstat on the lowest setting.
3. Turn OFF all electric power to the heater.
4. Push in gas control knob slightly and turn clockwise
to "OFF".
1. STOP! Read the safety information.
2. Set the tankstat to the lowest setting.
3. Turn Off all electrical power to the heater.
4. Turn gas control knob clockwise to "OFF".
GASCONTROL
KNOBSHOWN
IN"OFF"
GASCONTROL
KNOBSHOWN
IN"OFF"POSITION
POSITION
GASINLET
GASINLET
5. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to the
next step.
6. Locate pilot behind gas valve, mounted on the
basepaneloftheburnerdrawer.
7. Turn knob on gas control counter-clockwise
to "PILOT".
NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed in slightly. Do not force.
5. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If your smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to the
next step.
6. Locate pilot behind gas valve mounted on the base
paneloftheburnerdrawer.
7. Turn knob on gas control counter-clockwise
to "Pilot".
Fig.# 8083.2
Fig.# 8041.2
HONEYWELL PILOT
ROBERTSHAW PILOT
Fig.# 8041.2
Fig.# 8083.2
HONEYWELLPILOT
ROBERTSHAW PILOT
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8. Push down and hold the red reset button in, imme- C. Use only your hand to push in, move or turn the gas
diately light the pilot with a match. Continue to hold controlknoborlever. Neverusetools. If theknoborlever
downredresetbuttonforaboutoneminuteafterthe will not push in, move or turn by hand, don't try to repair
pilot is lighted. Release red reset button and it will it,callaqualifiedservicetechnician. Forceor attempted
pop back up. Pilot should Remain lighted. If it goes repair may result in a fire or explosion.
out, repeat steps 4 through 8.
* If red reset button does not pop up when
released stop and immediately call your ser-
vice technician or gas supplier.
D. Donotusethisheaterifanyparthasbeenunderwater.
Immediatelycallaqualifiedservicetechniciantoinspect
the heater and to replace any part of the control system
* If the pilot does not stay lit after several tries, and any gas control which has been under water.
turn the gas control knob to "OFF" and call your
Service technician or gas supplier.
9. Stand to the side of the heater and turn the gas
control knob counter-clockwise to "ON".
10. Turn "ON" all electrical power to the heater.
11. Set the tankstat to the desired setting.
FORAUTOMATICIGNITIONMODELS.
Please read carefully and understand the following
safetyinformationbeforeoperatingtheheater.
WARNING: If you do not follow these instructions ex-
actly, a fire or explosion may result causing property
damage, personal injury or loss of life.
SYSTEMSHUTDOWNPROCEDURE
1. Set the tankstat to "OFF" or the lowest setting.
2. Turn off all electric switches to the heater.
3. Turn off all gas valves supplying gas to the heatler. A. This heater is equipped with an ignition device which
Refer to operating instruction label on the heater.
4. Shut off the water supply to the heater piping
system loop.
automatically lights the pilot. Do not try to light the pilot
by hand.
5. Open drain valve on the tank to remove water from
the heater and the piping circuits.
B. BEFORE OPERATING smell all around the heater
area for gas. Be sure to smell next to the floor because
some gases are heavier than air and will settle on the
floor.
SECTION 3. Lighting the Heater
CAUTION: Liquefied petroleum gas is heavier than air
and sinks to the ground. Exercise extreme care in WHAT TO DO IF YOU SMELL GAS
lighting heater in confined areas.
• Do not try to light any appliance.
• Do not touch any electric switch;
• Do not use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
For Standing Pilot Models
WARNING: If you do not follow these instructions ex-
actly, a fire or explosion may result causing property
damage, personal injury or loss of life.
• If you cannot reach your gas supplier, call the
fire department.
A. This heater has a pilot which must be lighted by
hand. When lighting the pilot, follow these instructions
exactly.
C. Use only your hand to push in, move or turn the gas
controlknoborlever. Never use tools. Iftheknob orlever
B. BEFORELIGHTINGSmellallaroundtheheaterarea will not push in, move or turn by hand don't try to
for gas. Be sure to smell next to the floor because some repair it, call a qualified service technician. Force or
gas is heavier than air and will settle on the floor.
attempted repair may result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch;
• Do not use any phone in your building.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
D. Donotusethisheaterifanyparthasbeenunderwater.
Immediatelycallaqualifiedservicetechniciantoinspect
the heater and to replace any part of the control system
and any gas control which has been underwater.
• If you cannot reach your gas supplier, call the
fire department.
15
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FOR INTERMITTENT IGNITION (IID) WITH HONEY- TO TURN OFF GAS TO HEATER
WELLORROBERTSHAWGASVALVE
1. Set the tankstat at the lowest setting.
1. STOP!Readthesafetyinformationabove.
2. Set the tankstat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
2. Turn off all the electric power to the heater if service
is to be performed.
3. For Honeywell Valve:
Turn gas control knob clockwise to "Off".
Make sure knob rest against stop.
For Robertshaw Valve:
Push in and move gas control lever to "Off"
position.
GASCONTROL
KNOBSHOWN
IN"ON"
POSITION
GASINLET
HONEYWELL
(Models 30 - 90)
5. For Honeywell Valve: Turn gas control knob
clockwise to "Off".
HONEYWELL PILOT
For Robertshaw Valve: Push in and move gas
control lever to "Off" position.
CAUTION:Shouldoverheatingoccuror thegassupply
6. Wait 5 minutes to clear out any gas. If you then
fails to shut off, DO NOT turn off or disconnect the
smell gas STOP! Follow "B" in the safety informa- electrical supply to the pump. Instead, shut off the gas
tion previously stated. If you don't smell gas, go to supply at a location external to the heater. Failure to
the next step.
7. For Honeywell Valve: turn gas control counter-
clockwise to "On".
observe this precaution may aggravate the overheated
conditionresultinginpossibledamagetotheheaterand
injury to the user.
For Robertshaw Valve: Move gas control lever
to "On" position.
SECTION 4. Testing the Ignition Safety Shutoff.
The ignition system safety shutoff must be tested by
conducting the following method of tests:
GASCONTROL
KNOBSHOWN
IN"OFF"
For Standing Pilot Systems
POSITION
a. With the main burners on, remove the pilot
adjustment cover screw.
* NOTE: There is no pilot adjustment cover on
Robertshaw 7200 gas valve.
GASINLET
b. Insert a small slot screw driver and turn the
adjustment screw clockwise until pilot
flame goes out. Note and count number of turns
made.
ROBERTSHAW
(All Models)
c. Gas valve will shut off main burners after about
three (3) minutes. End of test. If the gas valve
will not shut off, follow the instructions "To Turn
Off Gas To Heater" and call service technician
or your gas supplier.
8. Turn on all electric power to the heatler.
9. Set tankstat to desired setting.
10. If the heater will not operate, follow the instruction
"To Turn Off Gas To Heater" and call your service
technician or gas supplier.
d. Return pilot adjustment screw counter- clock-
wise, same number of turns as in step (b)
16
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INSPECTIONPROCEDURES
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from combus-
tiblesandflammableliquids. Donotobstructtheflow of
combustion and ventilating air. Make visual check of
burner and pilot flame. Yellow flame indicates clogging
of air openings. Lifting or blowing flame indicates high
gas pressure. Low flame indicates low gas pressure.
Fig.# 8935.0
Pilot Adjustment
4"
Max.
ROBERTSHAW7200 GASVALVE
(Models 135 & 180)
e. Replace pilot adjustment cover screw, then
follow the lighting instructions to get heater
ready for operation.
.#8144
FORAUTOMATICIGNITIONSYSTEMS
A. IntermittentIgnition(IID)
MAINBURNERFLAME
1. Turn on power to the ignition systems and turn gas
supply off at the gas valve.
2. Check ignition module as follows:
a. Set the tankstat to high setting.
b. Watch for continuous spark at the pilot burner.
c. Time the spark operation. Time must be 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.
64
3. Turn on gas supply.
4. Set tankstat to high setting.
PILOTBURNERFLAME(STG PILOTUNITS)
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.
NORMALINSPECTIONPROCEDURES
Firstandthirdmonthafterinitialstartupandthenon
an annual basis. If problems are found, refer to Trouble
ShootingGuideforadditionaldirections.
b. Spark ignition should cut off when pilot flame is
established.
1. Remove top of heater and inspect heat exchanger
for soot and examine venting system.
2. Removerearheaderandinspectforscaledepos-
its.
c. Maingasvalveshouldopenandmainburner
should ignite after gas reaches the burner port
FLAMEFAILURE
*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. Oil pump motor and bearing assembly, if oil cups
areprovided.
7. Checkflowswitchpaddle.(Ifprovided)
8. Clean room air intake openings to assure adequate
flow of combustion and ventilation air.
9. Keep heater area clear and free from combustible
materials,gasoline,andotherflammablevapors
and liquids.
Withburneroperating, closethemanualfuelvalves
to simulate a flame failure. System should lock out after
safety switch timing (15 seconds). After the safety
switch has cooled, open the manual valves (relight
standing pilots) and reset the safety switch; the burner
shouldrestart.
*Should be checked monthly. (Takes approximately 15
minutes).
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BURNERDRAWERREMOVAL
PROCEDUREFORCLEANINGFLUEGAS
PASSAGE-WAYS
1. Shut off power and gas supply to the heater. Dis-
connect union(s) and pilot tubing when present;
then loosen and remove burner hold down screws.
2. Disconnect wires at gas valve and slide burner
drawerout.
Soot will clog areas behind fins and cause eventual
tubefailure. Anysignofsootatbaseofburnersoraround
outer jacket indicates a need for cleaning.
1. Lift off draft hood and flue collector by removing
bolts and screws.
MAINBURNERANDORIFICEREMOVAL
2. Remove"V"bafflesfromheatexchanger.
3. Removeburnertray,seeBurnerDrawerRemoval.
4. Take garden hose and wash heat exchanger, mak-
ing sure soot is removed from between fins.
(Avoidexcessivewateragainstrefractory).
5. Reassemble; when heater is fired, some steam will
form from wet refractory. This is normal.
1. Removescrewsandburnerholddownbracket.
NOTE: If theheatexchangerissootedbadly,theburner
hold down bracket and spacer can become distorted
fromdirectflameimpingementandthisusuallynecessi-
tates replacement of these parts.
2. Lift burners from slotted spacer and slide from
orifices. Clean with a wire brush.
NOTE: Inextremecasesitmaybenecessarytoremove
the heat exchanger completely for cleaning. The sim-
plest method is steam cleaning at a local car wash. DO
NOT 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
NOTovertightenwhenreinstalling.
CAUTION:
Soot is combustible, so exercise extreme care.
RAYPAKTUBECLEANINGKIT
Extension Pieces (5)
Auger with Carbide Tip
Wire Brush
Fig.#8185
REPAIRSECTION
TUBECLEANINGPROCEDURE(TYPICAL)
Establish a regular inspection schedule, the fre-
quency depending on the local water condition and
severity of service. Do not let the tubes clog up solidly.
Clean out deposits over 1/16" in thickness.
The heater may be cleaned from the side opposite
the water connections as shown, without breaking pipe
connections. 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
exchangergenerally.
3. Removedraftdiverter,liftandremovetopandflue
collectoronstacktypemodels. Removeinspection
panels.
4. Loosen bolts and disconnect flange nuts on inlet-
outletheader,loosenunion(s)atgaspipe,andslide
heaterawayfrompipinguntilstudscleartheheater.
5. Removeheatexchangercornerbrackets.
6. Remove combustion chamber clips at the four
corners of the heat exchanger.
7. Lift heat exchanger straight up using caution not to
damagerefractory.
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,
reamtubesandimmerseheatexchangerinnon-inhibited
de-scalesolvent.
HEATEXCHANGERREMOVAL
1. Shut water, gas and electricity off, close valves and
relievepressure,removereliefvalve. Removeside
inspectionpanels.
2. Removetopholdingscrews.
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HEATEXCHANGERRE-ASSEMBLY
1. HeatexchangerwaterheaderO-ringsshouldbe
replaced with new ones.
2. Install inlet-outlet and return water headers and
install header retainer nuts and torque nuts evenly.
3. 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
pipethreadsealant.
6. Installwaterpressurereliefvalve,sensorprobe,
and low water cutoff 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.
8. Shut down entire system and vent all radiation units
and high points in system piping. Check all strain-
ers for debris. Expansion tank water level should
be at the 1/4 mark and the balance of the tank filled
withair (whenusingAir-X-Tank).
9. Install flue collector, jacket top and inspection pan-
els. 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
readyforoperation.
13. Within two (2) days of start-up, recheck all air vents
and expansion tank levels.
COMBUSTIONCHAMBERREMOVAL
Toremovecombustionchamberyoumustfirsthave
removed the heat exchanger. Unbolt metal combustion
chamberretainerfromtopandremovecombustioncham-
berpanelsindividually.
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5. TROUBLE SHOOTING GUIDE
IMPORTANT NOTICE
These instructions are primarily intended for the use of qualified personnel specifically trained and experienced
in the installation of this type of heating equipment and related system components. Installation and service
personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this
equipment nor attempt repairs according to these instructions.
SOLUTION(S)
PROBLEM(S)
CAUSE(S)
1)Check circuit breakers, disconnect
switch. Make sure power is on.
1)When tankstat is turned on, heater
does not operate.
1)No power to the heater.
2)Check continuity on thermostat and
wiring circuit. Replace thermostat, or
repair wiring connections.
2)Defective tankstat or disconnected
wire in thermostat circuit.
3) Check secondary voltage. If no 24V,
replace transformer.
3)Defective transformer.
1)Light pilot burner. (Follow lighting
instructions on rating plate).
2)Check thermocouple MV generation.
If less than 25MV (open circuit), re
place thermocouple. If between 25-
35 MV, replace gas valve.
2)When tankstat is calling for heat,
pump is on, but burners will not turn
on.
1)For Standing pilot models pilot burner
not lighted.
2)If pilot burner will not stay lighted,
thermocouple or gas valve may be
defective.
3)Turn knob to "ON" position.
3)Gas knob in "Pilot" position.
4)Vent switch is open.
4) Check for blockage of venting system
or disconnected vent piping. After
problem is corrected push button to
reset vent switch.
5)Check for blockage of flue or sooted
heat exchanger. After problem is
corrected push button to reset roll-out
switch.
5)Roll-out switch is open.
6)Check water flow and adjust to
obtain 8° to 10°F temperature rise.
7)Red LED on circuit board will be ON
to indicate a loose sensor connection
or a shorted sensor. Check terminal
connectors or replace sensor as re-
quired.
6)Manual Reset High limit is open.
7) Fast Response Temperature
Sensor probe is defective.
NOTE: Red LED will also be ON if
sensor temperature exceeds 300°F or
drops below - 20°F. It will turn OFF
when sensor temperature returns to the
proper range. Yellow LED will be ON, if
temperature exceeds 210°F. When ei-
ther Red or Yellow LED is ON, heater
will be shut down.
8)Check voltage across output and
common terminals. If no 24V is pres-
ent, replace board.
8) Fast Response Temperature
sensor board is defective.
9)On Honeywell module, check voltage
across terminals MV and MV/PV. If
no 24V is present, replace module. If
24V is present, replace gas valve.
9) Defective ignition module or
defective gas valve.
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3)Pilot Outage.
(Standing pilot models)
1) Too low or too high gas pressures.
1) Adjust inlet gas pressure as shown
on rating plate.
2) Restricted pilot.
2) Clean pilot orifice.
3) Weak thermocouple.
3) Replace thermocouple.
4)Yellow lazy flame.
1) Too low gas pressure.
2) Restricted burner intake ports.
3) Restricted gas line.
1) Adjust manifold pressure as shown
on rating plate.
2) Clean burners free of debris or in-
sects.
3) Clean gas line or increase gas line
piping.
5)Sooting
1) Insufficient combustion air.
1) Refer to installation instructions
regarding combustion air
requirements.
2) Improper venting.
3) Severe yellow burner flames.
2) Refer to installations instructions.
3) See yellow flame section above.
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ADJUSTMENTS/REPLACEMENTSOF
COMPONENTS
3. Flame Roll-out Switch Replacement
a) Shut off electrical power to the heater.
b) Remove wiring connections to switch.
c) Remove screws (2) holding the switch.
d) Reverseaboveproceduretore-install.
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
anddangerousoperation. Verifyproperoperationafter
servicing.
4. Vent Thermal Switch Replacement
a) Shut off electrical power to the heater.
b) Remove wiring connections to switch.
c) Removethescrews(2).
DANGER-SHOCKHAZARD
Make sure electrical power to the heater is disconnect-
ed to avoid potential serious injury or damage to com-
ponents.
d) Reverseaboveproceduretore-install.
5. Ignition Module Replacement
1. Gas Valve Replacement
a) Shut off electrical power to the heater.
b) Remove control cover screws and open
controlcompartment.
a) Shut off electrical power and gas supply to the
heater.
b) Remove gas piping to gas valve inlet.
c) Disconnect wiring connections, pilot tubing
(whenequipped).
c) Disconnect wiring connections to module.
d) Removescrews(2)holdingmodule.
e) Reverseaboveproceduretore-install.
d) Remove screws (2) holding the burner tray.
e) Slide burner tray out.
6. TransformerReplacement
f) Removegasvalvebracketscrewsand
bracket.
g) Unscrewgasvalvefromgaspipe.
h) Reverseaboveproceduretore-install.
a) Shut off electrical power to the heater.
b) Removecontrolcoverscrewsandopencontrol
compartment.
c) Disconnectwiringconnectionsfrom
transformerleads.
2. Pilot Burner Cleaning or Replacement (Standing
Pilot)
d) Removescrews(2)holdingtransformer.
e) Reverseaboveproceduretore-install.
a) Shut off electrical power and gas supply to the
heater.
7. Circulator Replacement
b) Disconnect gas piping to gas valve.
c) Disconnect wiring connections to gas valve.
d) Remove screws (2) holding the burner tray.
e) Slide burner tray out.
a) Shut off electrical power to the heater.
b) Shutoffwatersupplyandopendrainvalve
to remove water in the piping at the pump
level.
f) Remove screw holding pilot lighter tube.
g) Remove screws (2) holding pilot bracket on
the burner tray.
h) Disconnect thermocouple and pilot tubing
fromthegasvalve.
CAUTION: To avoid damage to electrical components
keep water from getting into the control compartments
and gas valve.
i) Removepilotburnerfrompilotbracket.
j) Remove pilot orifice and blow away lint or dirt.
Clean with wire or small brush.
c) Disconnect wiring and conduit connections to
the pump.
d) Remove the nuts and bolts at the inlet and
outlet flanges. Remove old gaskets.
e) Removethepump.
NOTE: Make sure pilot orifice is clear, but do not
enlargethehole.
k) Reverseaboveproceduretore-install.
f) Reversetheaboveproceduretore-install.
Use new gaskets and make sure they are
seated properly when tightening the nuts
and bolts.
HONEYWELL PILOT
ROBERTSHAW PILOT
PILOT
PILOT
AIR
OPENING
ORIFICE
ORIFICE
Fig.# 8102.1
Fig.# 8045.2
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6. REPLACEMENT PARTS LIST
NOTE: To supply the correct part it is important that you
state the model number, serial number and type of gas
whenapplicable.
Any part returned for replacement under standard
companywarrantiesmustbeproperlytaggedwithRAY-
PAK return parts tag, completely filled in with the heater
serial number, model number etc., and shipped to the
Companyfreightprepaid.
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
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5-S
HONEYWELL IID
HONEYWELL STANDING PILOT
3-P
ROBERTSHAW STANDING PILOT
3-P
1-P
2-P
1-P
1-P
2-P
2-P
6-P
6-P
8-P
9-P
6-P
8-P
Fig. # 8190.3
8-P
Fig. # 8189.4
Fig. # 9112
24
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LIMITEDPARTSWARRANTYECONOPAKWATERHEATERS
MODELS WH - 90 TO 195
SCOPE:
Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this water heater which are actually manufactured by Raypak
will be free from failure under normal use and service for the 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.
HEATEXCHANGERWARRANTY:
• Five (5) Years from date of water heater installation. This includes only the copper, bronze and cast iron waterways.
• Twenty (20) Years from date of water heater installation against "Thermal Shock" (excluded, however, if caused by operation
at large changes exceeding 150°F between the water temperature at intake and water heating temperature, or operating at water
heater temperatures exceeding 190°F).
ANYOTHERPARTMANUFACTUREDBYRAYPAK:
One (2) year warranty from date of installation, or eighteen (18) months from date of factory shipment based on Raypak's records,
whichever comes first.
SATISFACTORYPROOFOFINSTALLATIONDATE,SUCHASINSTALLERINVOICE,ISREQUIRED. THISWARRANTYWILLBEVOID
IFTHEWATERHEATERRATINGPLATEISALTEREDORREMOVED.
ADDITIONALWARRANTYEXCLUSIONS:
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the water heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding water 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 water heater system;
7. Failing 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.
PARTSREPLACEMENT:
Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if
requested, with transportation charges prepaid, and all applicable warranty conditions found satisfied. The replacement part will be
warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured
by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM:
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the
problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be
received form Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:
This is the only warranty given by Raypak, No one is authorized to make any other warranties on Raypak's behalf. THIS WARRANTY
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF
MERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE. RAYPAK'SSOLELIABILITYANDTHESOLEREMEDYAGAINST
RAYPAKWITHRESPECTTODEFECTIVEPARTSSHALLBEASPROVIDEDINTHISWARRANTY. ITISAGREEDTHATRAYPAKSHALL
HAVENOLIABILITY,WHETHERUNDERTHISWARRANTY,ORINCONTRACT,TORT,NEGLIGENCEOROTHERWISE,FORANYSPECIAL,
CONSEQUENTIAL,ORINCIDENTALDAMAGE,INCLUDINGDAMAGEFORMWATERLEAKAGE. Somestatesdonotallowlimitationsonhow
long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not
apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. We suggest
that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the
effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of
manufacture plus thirty (30) days.
_____________________________________________________
Name of Owner
____________________________________________________
Name of Dealer
_____________________________________________________
Address
____________________________________________________
Address
_____________________________________________________
____________________________________________________
_____________________________________________________
____________________________________________________
ModelNo.
Serial No.
Date of Installation: _____________________________________
Date of Initial Operation: ________________________________
CORPORATEHEADQUARTERS:
RAYPAK, INC., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (805) 278-5489
Litho in U.S.A.
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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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