Table of Contents
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Owner's Guide
Installation Instructions
Raypak Water Heaters
B0507
B0538
B0658
B0768
B0868
This water heater must be installed and serviced by a qualified person.
Please leave this guide with a responsible officer.
and
Models
B0992
B1182
B1292
B1412
B1722
B1922
B2214
B2634
B3164
B3694
B4224
Types
B0972
NCO, NCM
B1142
PCO, PCM
B1242
B1362
B1662
B1852
B2004
B2404
B2804
B3304
B3804
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Table of Contents
Related Manuals for Raypak B0507
Summary of Contents for Raypak B0507
- Page 1 Owner’s Guide Installation Instructions Raypak Water Heaters Models Types B0507 B0992 B0972 NCO, NCM B0538 B1182 B1142 PCO, PCM B0658 B1292 B1242 B0768 B1412 B1362 B0868 B1722 B1662 B1922 B1852 B2214 B2004 B2634 B2404 B3164 B2804 B3694 B3304 B4224 B3804 This water heater must be installed and serviced by a qualified person.
- Page 2 Notice to Victorian Customers from the Victorian Building Authority This water heater must be installed by a licensed person as required by The Victorian Building Act 1993 Only a licensed person will give you a Compliance Certificate, showing that the work complies with all the relevant standards.
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Page 3: Table Of Contents
CONTENTS HOUSEHOLDER OR RESPONSIBLE OFFICER – We recommend you read pages 4 to 10. The other pages are intended for the installer but may be of interest Contents ..................................3 About Your Water Heater ............................. 4 How Your Water Heater Works ............................ 7 Save A Service Call .............................. -
Page 4: About Your Water Heater
® Congratulations for choosing a Raypak water heater. Raypak water heaters are suitable for either indoor or outdoor installation depending on the model chosen. The operation of the water heater depends on the application. Typically for hot water applications a water heater with „On/Off‟... - Page 5 Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. For ® assistance or additional information consult your Raypak distributor, qualified installer, or Rheem Service agent. The warranty can become void if relief valves or other safety devices are tampered with or if the installation is not in accordance with these instructions.
- Page 6 ABOUT YOUR WATER HEATER HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY? “Installation” Installation requirements are detailed in the section on pages to 15. The water heater must be installed: by a qualified person, and in accordance with the installation instructions, and ...
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Page 7: How Your Water Heater Works
“Temperature Adjustment – On/Off Models (IC902 Electronic Thermostat)” parameter settings refer to on page 43. Warning: Advice should be sought from your local Raypak representative prior to altering any electronic thermostat values other than the set point or differential. ELECTRONIC THERMOSTAT (MODULATING MODELS) Water heaters with modulating operation are fitted with an RWF55 electronic thermostat. -
Page 8: Save A Service Call
Warning: Hotter water increases the risk of scald injury. Water heater size Do you have the correct size water heater for your requirements? The sizing guide in the Raypak sales literature and on the Rheem website (www.rheem.com.au) suggests average sizes that may be needed. - Page 9 SAVE A SERVICE CALL BURNER WILL NOT LIGHT Is there gas to the water heater? Check the gas isolation valve on the gas supply line is open. Is there a normal gas supply to the rest of the premises? Try lighting another gas appliance.
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Page 10: Regular Care
REGULAR CARE PRESSURE RELIEF VALVE The pressure relief valve is located in the in/out header of the water heater and is essential for its safe operation. It is possible for the pressure relief valve to release a little water through the drain line during each heating period. This occurs as the water is heated and expands by approximately 1/50 of its volume. -
Page 11: Installation
INSTALLATION THIS WATER HEATER IS NOT SUITABLE FOR DIRECT POOL HEATING INSTALLATION STANDARDS The water heater must be installed: by a qualified person, and in accordance with the installation instructions, and in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local regulations, and all local codes and regulatory authority requirements. - Page 12 INSTALLATION The water heater must be mounted on a level fire proof base such as a concrete slab, concrete plinth, steel plate etc. Water heaters must NOT be installed on carpeting. The front of the water heater must not be obstructed by any gas or water piping, electrical conduits, etc. SAFE TRAY Where damage to property can occur in the event of the water heater leaking, the water heater must be installed in a safe tray.
- Page 13 INSTALLATION COMBUSTION / VENTILATION AIR Indoor model water heaters must be installed in a protective enclosure or properly constructed plant room with adequate ventilation in accordance with AS 5601 or AS/NZS 5601.1. Ideally ventilation shall be via two permanent openings DIRECTLY to outside, one at an upper level and one at low level.
- Page 14 INSTALLATION Pressure Specifications Operation Type On/Off Modulating Relief Valve Setting Water Heating (kPa) 850 (700)¹ 850 (700)¹ ³ Mechanical Heating (kPa) Expansion Control Valve (ECV²) Setting Water Heating (kPa) 700 (550)¹ 700 (550)¹ ³ Mechanical Heating (kPa) Minimum Supply Pressure System water temperatures up to 65°C (kPa) System water temperatures above 65°C (kPa) Maximum Supply Pressure...
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Page 15: Connections - Plumbing
CONNECTIONS – PLUMBING IMPORTANT: When installing a new water heater to an old or existing system, it is a requirement that the system and its equipment be thoroughly inspected and if necessary, drained and flushed with clean fresh water, before the new water heater is connected. - Page 16 Reference to the technical specifications of the water heater and local regulatory authority requirements must be made. The table below provides indicative pipe and pump sizes between Raypak unit/s and storage tank/s for typical water heating installations using storage tanks (DHW).
- Page 17 CONNECTIONS – PLUMBING WATER FLOW RATE AND PRESSURE DROP 10°C Rise 15°C Rise 20°C Rise Model l/sec l/sec l/sec 2.75 1.83 1.37 2.87 1.91 1.43 3.58 2.39 1.79 4.06 2.71 2.03 4.66 3.11 2.33 5.26 2.63 5.38 3.58 2.69 1142 6.09 4.06 3.05...
- Page 18 CONNECTIONS – PLUMBING MINIMUM PRESSURE REQUIREMENTS FOR GRUNDFOS UPS SERIES PUMPS Minimum Inlet Head Required at Operating Temperature (m) Pump Models ° ° ° ° ° UPS32-80N 507,538,658,768,868 UPS40-60/2B 768,868,972,992,1142,1182,1242,1292 UPS50-120FB 1362,1412,1662,1722,1852,1922,2004,2214 UPS80-120FB 2404,2634,2804,3164,3304,3694,3804,4224 16.0 17.0 18.0 19.0 20.5 WATER HEATING Where the water heater is supplied as part of a package, including the storage cylinder and pump, the installation must comply with the drawing provided.
- Page 19 CONNECTIONS – PLUMBING EXPANSION CONTROL VALVE Local regulations may make it mandatory to install an expansion control valve (ECV) in the cold water line to the water heating system. In other areas, an ECV is not required unless the saturation index is greater than + 0.4 (refer “Water Supplies”...
- Page 20 CONNECTIONS – PLUMBING ® Equa-Flow Principles ® The principle of Equa-Flow is to ensure the demand on each water heater, or storage cylinder in the bank is the same as any other. To achieve this, the following is necessary: The cold water manifold (cold header assembly) must be designed to balance the flow to each unit i.e. each branch line must be the same diameter and length and be fitted with identical ball or gate valves (refer to diagram below).
- Page 21 CONNECTIONS – PLUMBING Plumbing Diagrams Typical Installation – One Water Heater One Storage Tank RAYPAK - SINGLE WATER HEATER, SINGLE TANK LEGEND Typical Installation – Two Water Heaters, Two Storage Tanks RAYPAK - TWO WATER HEATERS, TWO TANKS...
- Page 22 On radiator or heating systems where thermostatic or zone valves will vary the water flow through the load, a by-pass with a suitable control valve must be installed to control the system water flow rate. BYPASS VALVES must be installed at the end of the system furthest from the water heater. Typical Installation – Raypak Mechanical Heating System...
- Page 23 CONNECTIONS – PLUMBING Closed Loop Water Source Heat Pump Applications Only use a water heater with on/off controls. The bypass pipe diameter MUST be the same as the inlet and outlet pipes. Select the pipe size between the heater and the system loop main, equal to the inlet/outlet header connections of the water heater (as a minimum).
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Page 24: Connections - Electrical
CONNECTIONS – ELECTRICAL The electrical installation must comply with AS/NZS 3000, AS/NZS 5601 or AS/NZS 5601.1 and any local requirements. This water heater must be hard wired to a 240V AC 50 Hz M.E.N. (multiple earthed neutral) mains power supply with an all pole isolating switch installed adjacent to and accessible from the water heater (refer to AS/NZS 5601, 5.2.11 or AS/NZS 5601.1:2010 clause 6.2.8). - Page 25 12, then a power flue may be required. Power flues must be designed by persons competent to do so and must be electrically interlocked with the water heater(s). Contact Raypak for power flue wiring diagrams. FLOW SWITCH A flow switch is provided with the water heater and is wired to prevent operation of the main burner in the event of no water flow.
- Page 26 CONNECTIONS – ELECTRICAL Wiring Diagram for Typical BMS System Interface...
- Page 27 CONNECTIONS – ELECTRICAL MULTI PUMP OPTION - MECHANICAL HEATING SYSTEMS NOTE: When connecting additional controls, any relays, timers or other electrical components must be located in an additional enclosure and must NOT be fitted within the water heater. For outdoor installations the enclosure MUST be weatherproof.
- Page 28 CONNECTIONS – ELECTRICAL WIRING DIAGRAMS ON/OFF MODELS < 1000MJ – NG...
- Page 29 CONNECTIONS – ELECTRICAL ON/OFF MODELS < 1000MJ – LPG...
- Page 30 CONNECTIONS – ELECTRICAL ON/OFF MODELS > 1000MJ...
- Page 31 CONNECTIONS – ELECTRICAL MODULATING MODELS < 1000MJ – NG DRAWING No: 96159611B...
- Page 32 CONNECTIONS – ELECTRICAL MODULATING MODELS < 1000MJ – LPG DRAWING No – 96159610C...
- Page 33 CONNECTIONS – ELECTRICAL MODULATING MODELS > 1000MJ DRAWING No: 96159613B...
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Page 34: Location Of Controls
LOCATION OF CONTROLS ELECTRONIC THERMOSTAT On/Off Models On/Off type water heaters are fitted with an Eliwell IC902 electronic thermostat that has a temperature sensor located in the inlet side of the water heater header. This type of thermostat is used where the system load is constant (e.g. -
Page 35: Safety Precautions
SAFETY PRECAUTIONS Warning: Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. DURING FIRST FIRING OF THE WATER HEATER ... -
Page 36: Commissioning
AS 3814. ALL REGULATORY AUTHORITIES REQUIRE THE APPLIANCE AND ITS INSTALLATION TO BE INSPECTED AND CERTIFIED. Warning: Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. - Page 37 COMMISSIONING COMMISSIONING THE WATER HEATER THE WATER HEATER MUST BE COMMISSIONED AND CERTIFIED IN ACCORDANCE WITH AS 3814, APPENDICES A-F. “Operating the Water Heater” Refer to section on page for instructions on filling and lighting the water heater. “Component Checks and Adjustment Procedures” Refer to on page for instructions on adjustment of the water...
- Page 38 COMMISSIONING CLOSED LOOP WATER SOURCE HEAT PUMP COMMISSIONING PROCEDURE Refer to the diagram below for the location of components described in this procedure. Check that both isolation valves are open. Adjust balancing valve A to half open and balancing valve B to fully open. Start up the water heater and adjust balancing valve A to obtain a heater inlet temperature of approximately 10°C greater than the system loop return temperature, (turning valve A in the open direction will increase the heater inlet temperature and closing valve A will lower the heater inlet temperature).
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Page 39: Operating The Water Heater
OPERATING THE WATER HEATER FOR YOUR SAFETY READ BEFORE LIGHTING TO FILL THE WATER HEATER Water Heating Applications Open all building hot water tap(s) (don‟t forget the showers) and supply cock(s) and valve(s) in the system. Open the isolation valves fully on the cold, flow / return and hot water branches to the storage tank(s). ... -
Page 40: Component Checks & Adjustment Procedures
COMPONENT CHECKS & ADJUSTMENT PROCEDURES GAS INLET PRESSURE CHECK IMPORTANT – Check the gas supply pressure at the inlet to the water heater with the water heater and all other gas burning appliances in the premises operating (burners alight). The minimum gas supply pressures are: ... - Page 41 COMPONENT CHECKS & ADJUSTMENT PROCEDURES Turn on water heater and allow main burner to light. Adjust burner pressure to that indicated on the rating label. To increase burner gas pressure rotate the adjusting screw clockwise or to decrease burner gas pressure rotate the adjusting screw anticlockwise. Turn off water heater, refit adjustment screw cover, remove manometer and refit gas test point screw.
- Page 42 COMPONENT CHECKS & ADJUSTMENT PROCEDURES FLOW SWITCH ADJUSTMENT The adjustment screw alters the amount of pressure or flow required to activate the micro switch. To adjust the setting: 1. Isolate power and remove flow switch cover. 2. Loosen adjustment screw locknut. 3.
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Page 43: Temperature Control
The following tables detail all available folders, parameters, each parameter range or option and the default (factory) setting of each parameter. Parameters MUST be set to the grey shaded „Raypak Setting‟ column for the hot water system to operate correctly. - Page 44 Tank sensor calibration (off set) -12.0 ~ 12.0 ºC or ºF Tank sensor value (detected temp) ºC or ºF Set point may differ to setting shown in „Raypak Setting‟ column. IC902 Level 1 Parameters Range or Default Unit of Raypak...
- Page 45 TEMPERATURE CONTROL Press and release the up ▲ or down ▼button to change the parameter setting (skip this step if viewing only). Continually press and release the fnc button until the display shows the current tank temperature. Checking or Adjusting IC902 Thermostat Level 1 Parameters Level 1 parameter settings can be viewed or changed (except for read only informational parameters) by performing the following procedure: Press and hold the set button for 5 seconds.
- Page 46 The following tables detail all available parameters, each parameter range and the default (factory) setting of each parameter. Parameters MUST be set to the grey shaded „Raypak Setting‟ column for the hot water system to operate correctly.
- Page 47 Press and release ‘ENTER’; ‘SP 1‟ and the current set point are displayed. Press and release ‘ENTER’; ‘SP 1‟ will start flashing Press and release (▲) or (▼) button to enter the value for SP 1 as shown in the „Raypak Setting‟ column of "RWF 55 User Level Parameters"...
- Page 48 Press and release ‘ENTER’; „Pb 1‟ and its value are displayed. Press and release ‘ENTER’; „Pb 1‟ will start flashing Press and release (▲) or (▼) to enter the value for the relevant parameter as shown in the „Raypak Setting‟ column of the "RWF55 Parameter (PArA) Level Parameters"...
- Page 49 When weather-compensated set point shifting is selected the set point is automatically adjusted according to the outdoor temperature; this function assists in reducing temperature fluctuations in the building due to additional heat being gained or lost due to the weather. Each Raypak must have its own outside sensor (no parallel connection).
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Page 50: Service Procedures
ONLY AN AUTHORISED PERSON MAY REPAIR OR SERVICE A GAS APPLIANCE Warning: Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. -
Page 51: Water Supplies
Rheem warranty to apply to the pressure relief valve on the Raypak water heater and the temperature pressure relief valve and cylinder of the storage tank connected to “Cold Water Connection Plumbing Diagram”... -
Page 52: Dimensions And Technical Data
DIMENSIONS AND TECHNICAL DATA Model 507 Models 538 - 868 Model Input (MJ/h) Natural Gas Output (kW) Input (MJ/h) Propane Gas Output (kW) Power (W) Electrical Rating 240 V 50 Hz Current (A) 0.21 0.21 0.21 0.21 0.21 Weight empty Flue Connection 1085 Dimensions... - Page 53 DIMENSIONS AND TECHNICAL DATA Indoor Models 992 - 1922 Indoor Models 2214 - 4224 Model 1182 1292 1412 1722 1922 Input (MJ/h) 1186 1289 1412 1722 1922 Natural Gas Output (kW) Input (MJ/h) 1090 1186 1296 1581 1772 Propane Gas Output (kW) Power (W) Electrical Rating...
- Page 54 Outdoor Models 972 - 1852 Outdoor Models 2004 - 3804 Model 1142 1242 1362 1662 1852 Input (MJ/h) 1142 1242 1357 1657 1854 Natural Gas Output (kW) Input (MJ/h) 1090 1186 1296 1581 1772 Propane Gas Output (kW) Power (W) Electrical Rating 240 V 50 Hz Current (A)
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Page 56: Warranty
WARRANTY RAYPAK WATER HEATER WARRANTY – AUSTRALIA ONLY RAYPAK WATER HEATER MODELS B0507-B4224 1. THE RHEEM WARRANTY – GENERAL 1.1 This warranty is given by Rheem Australia Pty Limited ABN 21 098 823 511 of 1 Alan Street, Rydalmere New South Wales. - Page 57 6.2 The Rheem warranty (set out above) is in addition to any rights and remedies that you may have under the Australian Consumer Law. RHEEM AUSTRALIA PTY LTD, A.B.N. 21 098 823 511, www.rheem.com.au www.raypak.com.au RAYPAK AUSTRALIA PTY LTD A.B.N. 65 078 743 414, For Service Telephone 131 031 AUSTRALIA or 0800 657 335 NEW ZEALAND Revision Date: August 2014 96507422C...