CATALOGNO.
Effective:
Replaces:
3000.51D
07-15-06
08-01-03
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Models 260-401
Type WH
ECONOPAK
WATER HEATERS
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance. To do so may result in an explosion
or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury or loss of life. Refer to this manual. Installation and
service must be performed by a qualified installer, service agency or the gas supplier.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
*Do not try to light any appliance.
*Do not touch any electrical switch; do not use any phone in your building.
*Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the fire department.
This manual should be maintained in legible
conditionandkeptadjacenttotheheaterorkept
in a safe place for future reference.
P/N240726Rev. 1
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1. RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the
carton is damaged, it is suggested that a note be made on the Bill of Lading when signing for equipment. Remove
theheater fromthecartonandifitisdamagedreportthedamagetothecarrierimmediately. Besurethatyoureceive
the number of packages indicated on the Bill of Lading. Claims for shortages and damages must be filed with
carrier by consignee.
Purchased parts are subject to replacement only under the manufacturer's warranty. Debits for defective
replacementpartswillnotbeacceptedanddefectivepartswillbereplacedinkindonlyperourstandardwarranties.
Whenorderingparts, youmustspecifyModelandSerialNumberoftheheater. Whenorderingunderwarranty
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 your local Raypak
representative.
2. GENERAL SPECIFICATIONS
TheRaypakwaterheatersaredesigncertifiedbytheand testedundertherequirementsoftheAmericanNational
Standard, ANSI Z21.10.3. Each heater has been constructed and pressure tested in accordance with the
requirements of Section IV of the American Society of Mechanical Engineers Code, and factory fire tested.
These heaters are designed for indoor and outdoor installations, and can be installed on combustible flooring
when the appropriate listed floor shield base is used. Models are available with standing pilot or with intermittent
ignitiondevice(IID),andareequippedwiththefollowingcomponentsasstandard:watercirculationpump,pressure
relief valve, manual reset high limit switch, fast response temperature controller, vent thermal and flame roll-out
switches (except for models 330 and 400), a solid state Economaster pump control relay, 40VA transformer, and
redundant combination gas valve for use with either Natural or Propane gases. A tankstat is supplied loose for
installation in the field.
SPECIFICATIONS AND DIMENSIONS
‡
*May be used with other tank size capacity.
Recoverybasedonmanufacturer'srating
Fig. #9464
3
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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.
!
!
DANGER
WARNING
Gasoline, as well as other flammable materials and liquids LIQUEFIED PETROLEUM MODELS – Propane, or LP gas,
(adhesives, solvents, etc.), and the vapors they produce, are must be used with great 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 LP leaks before attempting
thewarninglabelpicturedbelowandotherlabelsonthewater tolightappliance. Useasoapysolutiontocheckallgasfittings
heater, as well as the warnings printed in this manual. Failure and connections. Bubbling at a connection indicates a leak
to do so can result in property damage, bodily injury, or death. that must be corrected. When smelling to detect an LP leak,
be sure to sniff near the floor too.
• Gas detectors are recommended in LP applications and
their installation should be in accordance with the
!
DANGER
Failure to install the draft hood and properly vent the water manufacturer's recommendations and/or local laws, rules,
heatertotheoutdoorsasoutlinedintheVentingSectionofthis regulations or customs.
manual can result in unsafe operation of the water heater. To • It is recommended that more than one method be used to
avoid the risk of fire, explosion, or asphyxiation from carbon detect leaks in LP applications.
monoxide,neveroperatethiswaterheaterunlessitisproperly IF LP GAS IS PRESENT OR SUSPECTED:
vented and has an adequate air supply for proper operation. • DO NOT attempt to find the cause yourself;
Be sure to inspect the vent system for proper installation at • DO NOT try to light any appliance;
initial start-up; and at least annually thereafter. Refer to • DO NOT touch any electrical switch;
Maintenance section of this manual for more information • DO NOT use any phone in your building.
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.
• Keeptheareaclearuntiltheservicecallhasbeenmade,the
leak is corrected, and a qualified agency has determined the
area to be safe.
!
WARNING
Both LP and natural gas have an odorant added to help
detection. Some people may not physically be able to smell
or recognize this odorant. If unsure or unfamiliar about the
smell associated with LP or natural gas, ask the gas supplier.
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
Water heater has a main
burner and pilot flame.
The pilot flame:
1. is on all the timeand
2. will ignite flammable
vapors.
flammable liquids will
explode and catch fire
causing death or severe
!
DANGER
burns.
Water heaters utilizing Liquefied Petroleum gas (LP) are
differentfromnaturalgasmodels. Anaturalgasheaterwillnot
function safely on LP gas and vice versa. Conversion from
Natural gas to LP gas (or vice versa) must be done by a
qualified service technician. To avoid possible equipment
damage, personal injury or fire: DO NOT connect this water
heater to a fuel type not in accordance with unit data plate.
Propane for propane units. Natural gas for natural gas units.
These units are not certified for any other type fuel.
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
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.
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.
!
WARNING
Do not install water heater
where flammable products
will be stored or used unless
the main burner and pilot flames
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.
Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.
4
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General Safety Precautions
To meet commercial hot water requirements, the
The following chart details the relationship of water
temperature and time with regard to scald injury and
maybeusedasaguideindeterminingthesafestwater
temperature for your applications.
tankstat is adjustable up to 190°F. However, water
temperatures over 125°F. can cause severe burns
instantly or death from scalds. This is the preferred
starting point for setting the control for supplying gen-
eral purpose hot water.
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
tankstat. Themostenergyefficientoperationwillresult
when the temperature setting is the lowest that satis-
fies 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 Shiners Burn Institute
TIME/TEMPERATURE RELATIONSHIPS IN
SCALDS
The temperature of the water in the storage tank boiler
can be regulated by setting the temperature dial on
frontofthetankstat. Tocomplywithsafetyregulations,
the tankstat was set at its lowest setting before ship-
ment from the factory. The illustration below illustrates
the tankstat and how to adjust the water temperature.
To adjust the water temperature,
insert a small straight screwdriver
into slotted screw in hole in front
of tankstat and turn wheel to
desired setting. Thermostat is
adjustable up to 190°F.
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.
See instruction manual before setting
temperature 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 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.
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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3. INSTALLATION PROCEDURES
CODEREQUIREMENTS
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-
1.
MOUNTINGBASE
The heater should be mounted on a level, noncombustible surface. Heater must not be installed on carpeting.
Theheatercanbeinstalledonacombustiblesurfaceonlywhentheappropriatelistedfloorshieldbaseisprovided.
An optional listed floor shield base is available for factory installation with the heater on all indoor models.
NOTE: The heater should be located in an area where water leakage will not result in damage to the area adjacent
totheapplianceortothestructure. Whensuchlocationscannotbeavoided,itisrecommendedthatasuitabledrain
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.)duringapplianceoperationandservice(circulatorreplacement,controlreplacement,
etc.).
CLEARANCE REQUIREMENTS FOR ALL MODELS
1. Minimum clearances from combustible surfaces.
Floor
Front Back Right Left
Top
(Indoor)
39"
Top
(Outdoor)
Unobstructed
Flue
Vent
6"
(1)
(2) 12" 12" 12"
Comb. Alcove
(1) Except for carpeted flooring, heaters are certified for installation on combustible floors, when equipped
with listed floor shield base.
(2) A front clearance of at least 24" is recommended for adequate service of burner-tray and controls.
COMBUSTION/VENTILATIONAIR(Indoormodelsonly)
WARNING: Air supply to the heater room must not be affected by mechanical exhaust vents located in other parts
of the house, such as kitchen or bathroom fans, or attic blowers. Mechanical exhaust vents may create a negative
pressure condition in the heater room that can become a hazard of asphyxiation, explosion or fire.
CAUTION:Combustionairmustnotbecontaminatedbycorrosivechemicalfumeswhichcandamagetheheater.
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
inrefrigerants,aerosolpropellants,dry-cleaningfluids,degreasers,andpaintremovers. Otherharmfulelementsmay
come from bleaches, air fresheners, or mastics. Vapors from these types of products can form corrosive acid
compoundswhenburnedinagasflame. Theresultingacidcondensatecandamageorsubstantiallyreducethelife
of the heater. It may be necessary to provide outside air directly to the heater in order to avoid this problem.
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1) The heater must be provided with adequate supply
of air for proper combustion and ventilation in
accordance with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, or applicable provi
sions of the local building codes.
2) When the heater is installed in a confined space
where all air is supplied from inside the building, the
heater room must be provided with two openings,
eachonehavingaminimumnetfreearea,insquare
inches as follows:
OUTDOORMODELS
Heaters must not be installed under an overhang of
lessthanthree(3)feetfromthetopontheheater. Three
(3) sides must be open in the area under the overhang.
Roof water drainage must be diverted away from the
heaterinstalledunderoverhangswiththeuseofgutters.
Thepointfromwheretheflueproductsexittheheater
must be a minimum of four (4) feet below, four (4) feet
horizontallyfromorone(1)footaboveanydoor,window
orgravityinlettoabuilding. Thetopsurfaceoftheheater
shall be at least three (3) feet above any forced air inlet,
Model
260
330
Sq. In. Of Free Area or intake ducts located within ten (10) feet horizontally.
264
333
399
In areas where high winds are frequent, it may be
necessarytolocatetheheateraminimumof3'fromhigh
vertical walls, or install a wind break so the heater is not
in direct wind current.
400
Oneopeningshallbewithin12inchesofthetop,andthe
other opening within 12 inches of the floor. If additional
gasappliancesareinstalledinthesamespace,thetotal
input of all gas appliances installed in the same space,
must be considered in the calculation. Refer to Sec.
5.3.5 of the latest edition of the National Fuel Gas Code
foradditionalrequirements.
VENTINGCONNECTIONS(OutdoorModels)
Outdoorventtopisshippedseparatelyandmustbe
installed on site.
MODELS 260-401
Step 1: Insert screw retainer clip over mounting flange,
(4 places).
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
louverswillhave60-75percentfreeareaasshowninthe
National Fuel Gas Code.
Fig.#8280.1
Step 2: Attach mounting angles to heater jacket with
1/2" sheetmetal screws, (4 places).
3. If the heater room is located against an outside wall
and air openings can communicate directly with the
outdoors, the two openings on the out side wall must
each have a net free area, in square inches as follows:
Model
Sq. In. Of Free Area
260/261
330/331
400/401
66
84
100
Fig.#8281.1
Step 3: Lower outdoor top to heater and secure with 1"
sheetmetal screws.
Location of the openings is the same as in the previous
case - that is, within 12 inches of the top, and within 12
inchesofthebottomoftheenclosure. Ifhorizontalducts
are used, the area must be doubled and the duct area
shall not be less than the area of the openings they
connect, andinnocaseshallthesmallestdimensionbe
less than 3 inches.
LONG SIDE OF
ANGLE LOCATED AS SHOWN
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VENTINGCONNECTIONS(IndoorModels)
The drafthood is shipped separately and must be installed on the heater.
For Model 260/261:
1. Mount drafthood on top of heater and attach with the 4 sheet metal screws provided. Drafthood should be
positioned with the vent sensor located on the front left side as shown.
2. Remove plastic plug from left side of heater jacket and install plastic grommet provided.
3. Route flue sensor wire harness through the grommet installed in Step 2.
Fig. #9351
4. Remove door and locate wire from roll out sensor to Hi Limit with the male/female connector.
WIRE FROM TRANSFORMER
WIRE FROM TRANSFORMER
MALE/FEMALE
WIRE TERMINAL
CONNECT ONE VENT SENSOR WIRE
TO HIGH LIMIT WIRE
WIRE FROM HIGH LIMIT
ROLL OUT SENSOR
CONNECT ONE VENT SENSOR WIRE
TO ROLL OUT SENSOR WIRE
ROLL OUT SENSOR
BeforeInstallationofDraftHood
AfterInstallationofDraftHood
Fig. #8947.2
Fig.#8947.3
5. Disconnect male/female connector and attach to the 2 wires from drafthood vent sensor harness.
8
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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 more than five foot
intervals.Plumbers tape, crisscrossed, will serve to
space both horizontal and vertical piping. Maximum
vent connector horizontal length shall be 1-1/2 feet (18
inches) for each inch of connector diameter as follows:
MODELS 330/331 AND 400/401
VENT TERMINAL/INDOOR STACK INSTALLATION
1. Remove the louvered jacket top by removing
four (4) #10 flat head screws.
2. If originally installed, remove "Pagoda" top
from the louvered jacket top.
3. Place the inner stack adapter panel over the
flue collector inside the heater. Make sure
the flanged side of the flue opening is up.
4. Turn the stack (draft hood) up side
Heater Size
Vent Connector
Max Horizontal
Length - FT
12.0
Diameter
260/261
330/331
400/401
8"
9"
10"
13.5
15.0
down and set it down bottom side up.
5. Turn the jacket top panel (removed in step 1) up
side down and place it through the stack.
6. Attach the three (3) mounting brackets to the
stack using the screws provided and the holes
that are pre-drilled in the stack. Make sure the
brackets are positioned with the flange near
the top side of the stack (see illustration).
Caution must be taken not to over tighten and
strip the screw threads.
7. Turn the assembled stack and jacket top, right side
up. The jacket top will be trapped between the
brackets and the top of the stack. Place the stack
over the inner adapter panel flanged hole and
lower the louvered jacket top panel back into its
original position. Reinstall the four (4) green #10
flat head screws removed in step 1 above.
Gas vents supported only by the flashing and extend-
ing above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. We recommend use of insulated vent pipe
spacer through the roofs and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1.
The discharge opening must be a minimum of two
feet vertically from the roof surface and at least two(2)
feet higher than any part of the building within ten (10)
feet. Vent stack shall be at least five (5) feet in vertical
height above the drafthood outlet. The vent cap
location shall have a minimum clearance of four (4)
feet horizontally from, and in no case above or below,
unless a 4-foot horizontal distance is maintained, from
electric meters, gas meters regulators and relief equip-
ment.
The weight of the vent stack or chimney must not rest
on boiler draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Type "B" double wall or equivalent vent pipe is
recommended. However single wall metal vent pipe
may be used as specified in the latest edition of the
National Flue Gas Code ANSI Z223.1.
Fig. # 8246.6
WARNING: Indoor heater require a drafthood that
must be connected to a vent pipe and properly vented
to the outside. Failure to follow this procedure can
cause fire or fatal carbon monoxide poisoning.
Vent piping the same size or larger than the draft
hood outlet is recommended, however, when the total
vent height is at least ten (10) feet (draft hood relief
opening to vent terminal), the vent pipe size may be
reduced as specified in the National Fuel Gas Code,
ANSIZ223.1. Asmuchaspossibleavoidlonghorizontal
runs of vent pipe and too many elbows.
Fig. #8119.2
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WARNING: These heaters must not be connected into
any portion of mechanical draft systems operating
under positive pressure. To do so may cause the flue (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.
products to be discharged into the living space causing
serious health injury.
For connections to gas vents or chimneys, vent
installations shall be in accordance with Part 7, Venting
of Equipment, of the National Fuel Gas Code, ANSI (f) After it has been determined that each appliance
Z223.1, or applicable provisions of the local building
codes.
COMMON VENTS
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.
Manifolds that connect more than one
ust be
ad.
er
mney.
s than
(g) Anyimproperoperationofthecommonventing
system should be corrected so the installation con-
forms 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
theappropriatetablesinChapter10andinappendix
Gof the National Fuel Gas Code, ANSI Z223.1 and
CAN/CSA-B149.1.
GASSUPPLYCONNECTIONS
The inlet gas connection to the heater gas valve is
1/2" for model 203; 3/4" for models 260 and 330; and
1" for model 400. Provide an adequate gas supply line
no smaller than 1/2", according to the chart below:
Fig. # 9463
At the time of removal of an existing heater, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain-
ing connected to the common venting system are not
in operation.
MAXIMUMEQUIVALENTPIPELENGTH(FEET)
NATURALGAS1000BTU/FT .60SPECIFICGRAVITY@0.5"W.C. PRESSUREDROP
PROPANE GAS 2500 BTU/FT 1.53 SPECIFIC GRAVITY @ 0.6" W.C. PRESSURE DROP
(a) Seal any unused openings in the common venting
system.
Gas piping must have a sediment trap ahead of the
boiler gas controls, and a manual shut-off valve located
outsidetheheaterjacket. Allgaspipingshouldbetested
after installation in accordance with local codes.
(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
hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
Gas Inlet
Manual Shut Off Valve
Heater Jacket
Gas
Valve
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust tankstat
so appliance will operate continuously.
Sediment
Trap
Union
Fig. # 8090.1
10
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CAUTION: The heater and its manual shut off valve must be disconnected from the gas supply during any
pressure testing of that system at test pressures in excess of 1/2 PSIG(3.45 KPA). Dissipate test pressure in
the gas supply line before reconnecting the heater and its manual shut off valve to gas supply line. FAILURE TO
FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER PRESSURED GAS VALVES ARE
NOT COVERED BY WARRANTY. The heater and its gas connections shall be leak tested before placing the
appliance in operation. Use soapy water for leak test DO NOT use open flame.
NOTE: Do notuseteflontapeongaslinepipethread. AflexiblesealantsuitableforusewithNaturalandPropane
gases is recommended.
GAS PRESSURE-SPECIFICATIONS
Inches W.C. Regulator
Min.
7.0
12.0
Max. Setting
Natural
Propane
10.5
13.0
4.0
11.0
Note: Do not exceed maximum inlet gas pressure. The minimum value shown is for input adjustment.
GAS PRESSURE REGULATOR
The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pressure.
The gas pressure regulator is preset and sealed at 4" W.C. for natural gas, and 11" W.C. for propane gas.
Between the gas valve and the burners is a 1/8" pipe plug. The pressure at this point, taken with a manometer,
should be about 3.7" W.C. natural gas and 10.5" W.C. propane gas. Lo NOx models should be 3.9" W.C. natural
gas only. If an adjustment is needed, remove seal and turn adjustment screw clockwise
or counterclockwise to decrease pressure.
to increase pressure
WATER CONNECTIONS & SYSTEM PIPING
The pipe size and fittings between the heater and the tank should be at least 1-1/2" for all models. The tank
should be located as close to the heater as possible, as shown in the drawing below:
Hot Water Supply
Thermometer
T & P Relief Valve
City Water
Pressure Relief Valve
Check Valve
Pump
Tankstat
Recirculation Water
Fig. #9166
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.
11
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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.
261 LOW NOx
WH1
Fig # 9360
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ELECTRICALWIRING
Theelectricalpowersupplyrequirementfortheseheatersis115volts,60Hz. Fieldwiringconnectionsandelectrical
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. The pump
is supplied and factory wired to operate with the heater. The current draw is approximately 2.0 amps. Refer to the
heater internal wiring diagrams shown on pages 13 to 15.
WIRING DIAGRAM KEY
NOTE: 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. #8096.2
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WIRINGDIAGRAM:STANDINGPILOT
MODELS 260 - 400
Fig.#2372
NOTES:
* USE GROUND CLIP PROVIDED.
** PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES.
*** VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS.
ROLL-OUT AND VENT SWITCHES NOT REQUIRED ON MODELS 330 AND 400.
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WIRINGDIAGRAM:INTERMITTENTIGNITIONDEVICE(IID)
MODEL 260
Fig.#2373
NOTES:
* USE GROUND CLIP PROVIDED. FAILURE TO PROVIDE PROPER GROUND MAY RESULT
IN LOCK-OUT.
** PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES.
*** VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS.
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WIRINGDIAGRAM:INTERMITTENTIGNITIONDEVICE(IID)
MODELS 330 & 400
NOTES:
* USE GROUND CLIP PROVIDED. FAILURE TO PROVICE PROPER GROUND MAY RESULT
IN LOCK-OUT.
** PUMP USED MUST BE RATED 10 AMPS MAX OR 3/4 HP MAX.
PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES.
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WIRING DIAGRAM: INTERMITTENT IGNITION
DEVICE (IID)
MODEL 261 LOW NO
x
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WIRING DIAGRAM: INTERMITTENT IGNITION
DEVICE (IID)
MODEL 401 LOW NO
x
18
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4. SERVICING PROCEDURES
START-UPPROCEDURES
SEQUENCEOFOPERATION
SECTION 1. Filling the System
INTERMITTENTIGNITIONDEVICE(IID)
Fillsystemwithwater. Purgeallairfromthesystem
using purge valve sequence. After system is purged of
air, lower system pressure.
Flushsystembeforeputtingintooperationtoassure
that foreign material does not damage pump seals.
HeatersequippedwiththeIIDsystemwillautomatically
lightthepilotburnerfirstandthenthemainburner,each
timethereisacallforheatfromthetankstat. Whenever
the tankstat calling forheat, thecirculator suppliedwith
theheater,willbeenergizedandshouldberunning. The
ignition control module will also be energized to initiate
thepilotignitionbyopeningthefirstmainvalve(pilot). At
the same time, the electronic spark generator in the
moduleproducesahighvoltagesparkpulseoutputthat
lights the pilot burner. If the pilot burner does not light,
themodulewillnotenergizethesecondmainvalveand
the burners will not light. Ignition spark continues only
until the timed trial for ignition period ends. Then, the
module goes into safety shutdown or lockout. Lockout
de-energizesthefirstmainvalveoperatorandclosesthe
first main (pilot) valve in the gas control, stopping pilot
gas flow. The ignition control system must be reset by
setting the tankstat below water temperature for one
minute or by turning off power to the module for one
minute. When the pilot flame is established, flame
rectificationcircuitiscompletedbetweenthesensorand
burnerground. Theflamesensingcircuitinthemodule
detectstheflamecurrent, shutsoffthesparkgenerator
and energizes the second main valve operator which
opensthesecondmainvalve. Thisallowsgastoflowto
the burners where it is ignited by the pilot burner flame.
When the tankstat is satisfied, the valve operators are
de-energizedshuttingoffthepilotandmainburners,and
also the circulator.
SECTION 2. Checking the Circulator
Before lighting the heater and after system is filled,
make sure that circulator is operating properly. Manual
gasvalveshouldbeoff.
NOTE: Circulatormotorsuppliedwiththeheaterdoesnot
requirelubrication.
SECTION 3. Lighting the Heater
For your safety read carefully before proceeding to light
theheater.
CAUTION: Liquefied petroleum gas is heavier than air
and sinks to the ground. Exercise extreme care in
lighting heater in confined areas.
For Standing Pilot Models
WARNING: If you do not follow these instructions ex-
actly, a fire or explosion may result causing property
damage, personal injury or loss of life.
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A. This heater has a pilot which must be lighted by
hand. When lighting the pilot, follow these instruc-
tions exactly.
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If your smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to the
next step.
7. Locate pilot mounted on the right side of the burner
drawer, rightoffirstburner.
8. Turn knob on gas control counterclockwise
to "Pilot".
B. BEFORE LIGHTINGsmell all around the heater
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
WHAT TO DO IF YOU SMELL GAS
• 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 telephone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the
firedepartment.
Fig.#8041.2
Fig.#8083.2
C. Use only your hand to push in, move or turn the gas
control knob or lever. Never use tools. If the knob
or lever will not push in, move or turn by hand, don't
try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or
explosion.
HONEYWELLPILOT
ROBERTSHAW PILOT
9. 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.
D. Do not use this heater if any part has been under
water. Immediately call a qualified service techni-
cian to inspect the heater and to replace any part of
the control system and any gas control which has
beenunderwater.
* 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.
FOR STANDING PILOT MODEL WITH
ROBERTSHAWGASVALVE,ON/OFFOPERATION
10. Stand to the side of the heater and turn the gas
control knob counterclockwise to "ON".
11. Replaceheaterdoor.
12. Turn "ON" all electrical power to the heater.
13. Set the tankstat to the desired setting.
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. Removeheaterdoorpanel.
5. Push in gas control knob slightly and turn clockwise
to "OFF".
FOR STANDING PILOT MODEL WITH HONEYWELL
GASVALVE,ON/OFFOPERATION
1. STOP! Read the safety information.
2. Set the tankstat to the lowest setting.
3. Turn Off all electrical power to the heater.
4. Removeheaterdoorpanel.
GASCONTROL
KNOBSHOWN
IN"OFF"POSITION
GASINLET
5. Turn gas control knob clockwise to "OFF".
GASCONTROL
KNOBSHOWN
IN"OFF"
NOTE: Knob cannot be turned from "PILOT" to "OFF"
unless knob is pushed in slightly. Do not force.
POSITION
GASINLET
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6. 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.
• 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
firedepartment.
7. Locate pilot mounted on the right side of the burner
drawer, rightoffirstburner.
8. Turn knob on gas control counterclockwise
to"PILOT".
C. Use only your hand to push in, move or turn the gas
control knob or lever. Never use tools. If the knob
or lever will not push in, move or turn by hand don't
try to repair it, call a qualified service technician.
Force or attempted repair may result in a fire or
explosion.
9. Push down and hold the red reset button in, imme-
diately light the pilot with a match. Continue to hold
downredresetbuttonforaboutoneminuteafterthe
pilot is lighted. Release red reset button and it will
pop back up. Pilot should remain lighted. If it goes
out, repeat steps 4 through 8.
D. Do not use this heater if any part has been under
water. Immediately call a qualified service techni-
cian to inspect the heater and to replace any part of
the control system and any gas control which has
beenunderwater.
* If red reset button does not pop up when
released, STOP and immediately call your
service technician or gas supplier.
* If the pilot does not stay lit after several tries,
turn the gas control knob to "OFF" and call your
Service technician or gas supplier.
FORINTERMITTENTIGNITION(IID)WITH
10. Stand to the side of the heater and turn the gas
HONEYWELLORROBERTSHAWGASVALVE
control knob counterclockwise
11. Replaceheaterdoor.
12. Turn "ON" all electrical power to the heater.
13. Set the tankstat to the desired setting.
to "ON".
1. STOP! Read the safety information above on this
label.
2. Set the tankstat 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.
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 heater.
Refer to operating instruction label on the heater.
4. Shut off the water supply to the heater piping
system loop.
5. Removeheaterdoorpanel.
6. For Robertshaw Gas Valve: Turn gas control
knob clockwise
to "OFF".
For Honeywell Gas Valve: Turn gas control knob
5. Open drain valve on the tank to remove water from
the heater and the piping circuits.
clockwise
against stop.
to "OFF". Make sure knob rest
For Honeywell Gas Valve: (Models 400)
Push in gas control knob slightly and turn clockwise
to "OFF". Knob cannot be turned to "OFF"
unless knob is pushed in slightly. Do not force.
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.
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.
A. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
8. For Robertshaw Gas Valve: Turn gas control
knob counterclockwise
to "ON".
B. BEFOREOPERATINGsmellallaroundtheheater
area for gas. Be sure to smell next to the floor
because some gases are heavier than air and will
settle on the floor.
GASCONTROL
KNOB SHOWN
IN "ON" POSITION
GASINLET
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch;
Fig.#8080
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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 to “ON”
will not shut off, follow the instructions "To Turn
Off Gas To Heater" and call service technician or
your gas supplier.
d.Return pilot adjustment screw counterclockwise
, same number of turns as in step (b).
e.Replace pilot adjustment cover screw, then fol-
lowthelightinginstructionstogetheaterreadyfor
operation.
position. Make sure knob rest against stop.
GASCONTROL
KNOB SHOWN
IN "ON" POSITION
FORAUTOMATICIGNITIONSYSTEMS
A. IntermittentIgnition(IID)
GASINLET
Fig.#8082
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.
For Honeywell Gas Valve: (Models 403 )
Turn gas control knob counter clockwise
to “ON”.
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.
GASCONTROL
KNOB SHOWN
IN "ON" POSITION
GASINLET
3. Turn on gas supply.
Fig.#8219.0
4. Set tankstat to high setting.
9. Replacedoorpanel.
5. Systems should start as follows:
a.Spark will turn on and pilot gas valve will open at
once. Pilotburnershouldigniteaftergasreaches
the pilot burner.
10. Turn on all electric power to the appliance.
11. Set tankstat to desired setting.
12. If the appliance will not operate, follow the instruc-
tions “To Turn Off Gas To Appliance” and call your
service technician or gas supplier.
b.Spark ignition should cut off when pilot flame is
established.
c.Maingasvalveshouldopenandmainburner
should ignite after gas reaches the burner port.
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.
INSPECTIONPROCEDURES
3. Removedoorpanel.
4. For Robertshaw Gas Valve: Turn gas control
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com-
bustiblesandflammableliquids.Donotobstructtheflow
of combustion and ventilating air. Make visual check of
burnerandpilotflame.Yellowflameindicatescloggingof
air openings. Lifting or blowing flame indicates excess
highgaspressure.Lowflameindicateslowgaspressure.
knob clockwise
For Honeywell Gas Valve: Turn gas control knob
clockwise
against stop.
For Honeywell Gas Valve: (Models 403)
Push in gas control knob slightly and turn
clockwise
to “OFF”.
to “OFF”. Make sure knob rest
to “OFF”.
5. Replaceheaterdoorpanel.
SECTION 4. Testing the Ignition Safety Shut-off
Theignitionsystemsafetyshutoffmustbetestedby
conducting the following method of tests:
4" Max.
For Standing Pilot Systems
a.With the main burners on, remove the pilot
adjustmentcoverscrew.
b.Insert a small slot screw driver and turn the
TYPICAL MAIN BURNER FLAME
Fig. # 8144
adjustment screw clockwise
until pilot flame
goes out. Note and count number of turns made.
c.Gas valve will shut off main burners after about
three (3) minutes. End of test. If the gas valve
22
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OPERATION
On call for heat, the ignition system, consisting of an
electronic spark module, gas pilot system is energized.
Providing pilot is proven blower will start running, the
main gas valve will open and the boiler will operate.
When the operating control is satisfied the boiler will
shut down.
START-UP PROCEDURES (S8610B)
1.Turn on power to the boiler with gas supply off.
2.Check ignition module as follows:
PILOTBURNERFLAME(IIDUNITS)
a. Set the thermostat or controller to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Check the ignition spark operation. Time must be
within the lockout timing period (15 or 90 seconds).
d. Turn control down to end call for heat and wait 60
seconds on lockout models before beginning step
3.
3.Turn on gas supply.
4.Set controller to call for heat.
5.System should start as follows:
a. Spark will turn on and pilot gas valve will open and
the blower will begin running.
PILOTBURNERFLAME(STG PILOTUNITS)
b. Heater will operate until call for heat is satisfied.
CONTROLS
Check all controls to see that they are operational.
To check electronic safety (IID Models) , turn off main
burner. Observepilotburnerwhenshuttingoffpilotgas.
Ignitionsparkshouldgoon.Maingasvalvewillalsodrop
out.
High Limit Switch - to check high limit switch, turn
dialsettingdowntoapointslightlybelowthetemperature
of the water leaving the heater. The reset button should
snapoutandtheburnershouldshutoff.Resetdialto30°F
to40°Fabovedesiredoperatingtemperature,andpush
reset button. Burner should light.
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. At least every three
months a visual inspection should be made 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" W.C.
and static pressure in plenum should be greater than
0.5" W.C.
LOW NOx HEATERS Sizes 181 to 401
The Raypak Low Nox Heater is offered as a model W1-
ON-OFF firing.
ELECTRICAL
The boilers are certified and tested under the ANSI
Z21.10.3 Standards for hot water heaters.
Be sure that electrical service to the boiler has proper
overload fuse or circuit breaker protection, wire size
and connections which comply with all applicable
codes.
The boiler should be installed to meet all local codes,
the National Fuel Gas Code Z223.1 and with the
National Electrical Code, ANSI/NFPA 70.
HIGH GAS PRESSURE SWITCH
Pressure switch senses high pressure and automati-
cally shuts down burner if abnormal pressure exists.
PRESSURE
SWITCH
GAS MANIFOLD
Fig # 9361
\Fig. #8236.0
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.
Fig # 9363
IIDPILOT
PILOT REMOVAL
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.
LOW NOx BURNER TRAY ASSEMBLY
BURNER DRAWER REMOVAL
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
COMBUSTION FAN 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. Remove burner drawer. See burner drawer
removal procedure.
2. Remove (4) screws the mount the combustion
blower to the manifold assembly.
3. Reverse above procedure to re-install.
NORMAL INSPECTION PROCEDURES
First and third month after initial start up and then
on an annual basis. If problems are found, refer to
Trouble Shooting Guide for additional directions.
1. Remove top of heater and inspect heat exchanger
for soot and examine venting system.
10. Carefully slide out the burner tray assembly.
11. Reverse above procedure to reinstall.
GAS VALVE REMOVAL
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.
6. Remove (2) screws that secure gas valve to
jacket.
7. Turn vertical gas pipe from manifold slightly
and unscrew gas valve.
2. Remove rear header and inspect for scale depos-
its.
*3. Inspect pilot and main burner flame and firing rate.
*4. Inspect and operate all controls and gas valve.
*5. Visually inspect system for water leaks.
*6. a.Oil pump motor and bearing assembly, if oil
cups are provided.
b. Disconnect pump from header and check
condition of 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.
7. Check flow switch paddle (if provided).
8. Clean room air intake openings to assure ade-
quate flow of combustion and ventilation air.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
8. Reverse above procedure to re-install.
MAIN BURNER AND ORIFICE REMOVAL
1. Remove burner drawer. See burner drawer re-
moval procedure.
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-
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.
9. Keep heater area clear and free from combustible
materials, gasoline, and other flammable vapors
and liquids.
*Should be checked monthly. (Takes approximately
15 minutes).
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HEATEXCHANGERRE-ASSEMBLY
REPAIR SECTION
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. 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
pipethreadsealant.
TUBE CLEANING PROCEDURE (TYPICAL)
Establish a regular inspection schedule, the fre-
quency depending on the local water condition and
severity of service. Do not let the tubes clog up solidly.
Clean out deposits over 1/16" in thickness.
The heater may be cleaned from the side opposite
the water connections, without breaking pipe connec-
tions. Itispreferable, however, toremovebothheaders
for better visibility through the tubes and to be sure the
residue does not get into the system.
6. Install water pressure relief valve, flow switch,
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.
Note that you do not remove the top pan or the heat
exchangergenerally.
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.
8. Shutdownentiresystemandventallradiationunits
and high points in system piping. Check all strain-
ers for debris. Expansion tank water level should
be at the 1/4 mark and the balance of the tank filled
with air.
HEATEXCHANGERREMOVAL
1. Shut water, gas and electricity off, close valves and
relievepressure,removereliefvalve. Removeside
inspectionpanels.
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.
2. Removetopholdingscrews.
3. Removedraftdiverter,liftandremovetopandflue
collector on stack type models. Remove inspection
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.
12. Within two (2) days of start-up, recheck all air vents
and expansion tank levels.
7. Lift heat exchanger straight up using caution not to
damagerefractory.
COMBUSTIONCHAMBERREMOVAL
Toremovecombustionchamberyoumustfirsthave
removedtheheatexchanger. Unboltmetalcombustion
chamberretainerfromtopandremovecombustioncham-
berpanelsindividually.
REFRACTORYPANELSTOPVIEW
25
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5. TROUBLE SHOOTING GUIDE
IMPORTANT NOTICE
Theseinstructionsareprimarilyintendedfortheuseofqualifiedpersonnelspecificallytrainedandexperiencedinthe
installationofthistypeofheatingequipmentandrelatedsystemcomponents. Installationandservicepersonnelmay
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,
replacetransformer.
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 sys
temordisconnectedventpiping. After
problem is corrected push button to
resetventswitch.
5)Check for blockage of flue or sooted
heat exchanger. After problem is
corrected push button to reset
5)Roll-out switch is open.
roll-out switch.
6)Check water flow and adjust to
obtain 8° to 10°F temperature rise.
7)Red LED on circuit board will be ON
to indicate a loose sensor connection
or a shorted sensor. Check terminal
connectors or replace sensor as re-
quired.
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 either Red or Yellow LED is ON,
heater will be shut down.
8)Check voltage across output and
common terminals. If no 24V is
present, replaceboard.
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.
26
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3)Pilot Outage.
(Standing pilot models)
1) Adjust inlet gas pressure as
shown on rating plate.
1) Too low or too high gas
pressures.
2) Restricted pilot.
3) Weak thermocouple.
2) Clean pilot orifice.
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
insects.
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.
27
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WARNING
HIGHVOLTAGE
TROUBLESHOOTING
ForqualifiedTechniciansONLY
ELECTRICAL(ELECTRONICIGNITIONIID)
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.
IntermittentPilotSystem
TROUBLESHOOTING HONEYWELL S8600
START
TURN GAS SUPPLY OFF.
TURNTHERMOSTAT
(CONTROLLER) TO CALL
FORHEAT
NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.
NO
NO
POWER TO MODULE
(24 V NOMINAL)
YES
Pull ignition lead and check spark at module.
SPARKACROSS
IGNITER/SENSORGAP
YES
Spark Okay?
YES
• 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.
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
• Check that all manual gas valves are open, supply tubing and pressures are
NO
NO
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 L.P.G.
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.
NO
NO
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
SYSTEMSHUTSOFF?
YES
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
NO
TROUBLESHOOTING
ENDS
Repeat procedure until troublefree operation is obtained.
28
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ELECTRICAL(STANDINGPILOT)
ELECTRICALTROUBLESHOOTING
ForServiceTechnicians
STARTHEATER
IFPILOTBURNERLIGHTS
BUTMAINBURNERSDONOT
IFPILOTBURNER
DOESNOTLIGHT
CHECK FOR 24 V
AT GAS VALVE
CHECKTHERMOCOUPLE
IF NOT 24 V:
IF 24 V:
IF O.K.
IFDEFECTIVE
CHECKTRANSFORMEROUPUT
FOR 24 V
REPLACE
GAS VALVE
REPLACE
REPLACE
GAS VALVE
THERMOCOUPLE
IFNO
24V:
IF 24 V:
WARNING
HIGHVOLTAGE
For Qualified Technicians ONLY
REPLACE
PROBLEMIN
TRANSFORMER
LIMIT
CIRCUITS
29
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ADJUSTMENTS/REPLACEMENTSOF
COMPONENTS
HIGHLIMITORTANKSTATREMOVAL
1. Turnoffelectricalpower.
2. Removefrontinspectionpanel.
3. Remove wires to high limit and loosen screws
holding high limit to cabinet.
4. Remove wedge clip holding sensing bulb in
control well.
CAUTION: Label all wires prior to disconnection when
servicingcontrols. Wiringerrorscancauseimproperand
dangerous operation. Verify proper operation after ser-
vicing.
5. Remove high limit and install a new one.
6. Checkcontroloperationbeforeleavingjob.
DANGER-SHOCKHAZARD
Makesureelectricalpowertotheheaterisdisconnect-ed
to avoid potential serious injury or damage to com- FLAMEROLL-OUTSWITCHREPLACEMENT
ponents.
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Remove screws (2) holding the switch.
4. Reverseaboveproceduretore-install.
GAS VALVE REMOVAL
1. Shut off gas supply to the heater. Remove gas
piping to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Turn vertical gas pipe from manifold slightly and
unscrewgasvalve.
VENTTHERMALSWITCHREPLACEMENT
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Removethescrews(2).
4. Reverseaboveproceduretore-install.
4. Reverseaboveproceduretore-install.
PILOTREMOVALANDCLEANING
IGNITIONMODULEREPLACEMENT
1. Shut off electrical power to the heater.
2. Remove control cover screws and open
controlcompartment.
1. Disconnect pilot tubing at pilot and sensor/ignitor
wire. Remove screws holding pilot bracket to
burnerdrawer.
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.
3. Disconnect wiring connections to module.
4. Removescrews(2)holdingmodule.
5. Reverseaboveproceduretore-install.
TRANSFORMERREPLACEMENT
1. Shut off electrical power to the heater.
2. Removecontrolcoverscrewsandopencontrol
compartment.
3. Disconnectwiringconnectionsfrom
transformerleads.
BURNERDRAWERREMOVAL
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
drawerout.
4. Removescrews(2)holdingtransformer.
5. Reverseaboveproceduretore-install.
MAINBURNERANDORIFICEREMOVAL
1. Remove screws and burner hold down bracket.
CIRCULATORREPLACEMENT
1. Shut off electrical power to the heater.
NOTE:Iftheheatexchangerissootedbadly, theburner 2. Shutoffwatersupplyandopendrainvalve
hold down bracket and spacer can become distorted
fromdirectflameimpingementandthisusuallynecessi-
tates replacement of these parts.
to remove water in the piping at the pump
level.
CAUTION: To avoid damage to electrical components
keep water from getting into the control compartments
and gas valve.
3. Disconnect wiring and conduit connections to
the pump.
4. Remove the nuts and bolts at the inlet and
outlet flanges. Remove old gaskets.
5. Removethepump.
2. Lift burners from slotted spacer and slide from
orifices. Clean with a wire brush.
3. Orifices usually do not need to be replaced.
To clean, run either copper wire or wood
through orifice. Do not enlarge hole. To remove
orifice, use a socket wrench and remove the
manifold. DONOTovertightenwhenreinstall-
ing.
6. Reversetheaboveproceduretore-install.
Use new gaskets and make sure they are
seated properly when tightening the nuts
and bolts.
30
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CONTROLWELLREPLACEMENT
PROCEDURE FOR CLEANING FLUE GAS PAS-
SAGE-WAYS
Remove top, sensing bulb and clip. Collapse well
tube at the open end with a chisel, push through into
headerandremovethewellthroughheader. Insertanew
well and roll into place. If a roller is not available, solder
the well in place with silver solder.
Soot will clog areas behind fins and cause eventual
tubefailure. Anysignofsootatbaseofburnersoraround
outer jacket indicates a need for cleaning.
TUBEREPLACEMENTPROCEDURE
1. Removeheatexchangerfromheaterfollowingin-
structionsoutlinedunderHEATEXCHANGER
REMOVAL.
2. Removeinlet/outletandreturnheaders. Remove
"V" Baffle from damaged tube.
3. Remove damaged tube by cutting with a hack saw
or shearing with a chisel adjacent to each tube
sheet.
1. Lift off draft hood and flue collector by removing
bolts and screws.
2. Remove"V"bafflesfromheatexchanger.
3. Removeburnertray,seeBurnerDrawerRemoval.
4. Take garden hose and wash heat exchanger, mak-
ing sure soot is removed form between fins. (Avoid
excessivewateragainstrefractory).
5. Reassemble; when heater is fired, some steam will
form from wet refractory. This is normal.
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 fits the tube into the hole.
6. Insert the tube roller into tube opening up to stop,
makingcertainthat1/8"oftubeprojectsbeyondthe
tube sheet.
NOTE:Inextremecasesitmaybenecessarytoremove
the heat exchanger completely for cleaning. The sim-
plest method is steam cleaning at a local car wash.
CAUTION: Sootiscombustible. Exerciseextremecare.
Do not wire brush.
REPLACEMENTPARTSLIST
NOTE: To supply the correct part it is important that you
state the model number, serial number and type of gas
whenapplicable.
7. Attach drill to tube roller, holding it straight and
level.
NOTE: Use a 3/8" heavyduty, reversible, electric drillor
larger. Proceed to expand tube until tool starts to grab.
Approximately 1/2 to 1" of the tool shank will be visible.
Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heaterserialnumber,modelnumberetc.,andshippedto
theCompanyfreightprepaid.
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".
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.
10. Use same procedure on opposite end.
11. Apply line pressure test. Re-roll if necessary.
12. ReinstallasoutlinedunderHEATEXCHANGER
REASSEMBLY.
RAYPAK,INC.
2151 Eastman Avenue
Oxnard, CA 93030
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FOR UNITS WITH A LOW NO TRAY
x
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LIMITEDPARTSWARRANTYECONOPAKWATERHEATERS
MODELS WH - 260 TO 401
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) 278-5400 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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