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INSTALLATION
AND OPERATING
INSTRUCTIONS
TM
RAYTHERM
HOT WATER SUPPLY
HEATERS
Models 0133-4001
Types WH & NH
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance. To do so may result in an explosion
or fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
property damage, personal injury or loss of life. Refer to this manual. Installation and service
must be performed by a qualified installer, service agency or the gas supplier.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
*Do not try to light any appliance.
*Do not touch any electrical switch; do not use any phone in your building.
*Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the fire department.
This manual should be maintained in legible
condition and kept adjacent to the heater or in a
safe place for future reference.
CATALOG NO. 3000.52G
Effective:
11-01-04
Replaces:
02-01-04
P/N 241075
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Summary of Contents for Raypak 0133-4001 WH
- Page 1 INSTALLATION AND OPERATING INSTRUCTIONS RAYTHERM HOT WATER SUPPLY HEATERS Models 0133-4001 Types WH & NH FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
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Page 2: Table Of Contents
TABLE OF CONTENTS RECEIVING EQUIPMENT ... 3 MODEL IDENTIFICATION ... 3 GENERAL SPECIFICATIONS ... 3 GENERAL SAFETY PRECAUTIONS ... 4 INSTALLATION INSTRUCTIONS ... 5 CLEARANCES ... 6 SPECIFICATIONS AND DIMENSIONS ... 7 OUTDOOR INSTALLATIONS ... 1 0 HIGH WIND CONDITIONS ... 1 0 COMBUSTION AIR ... -
Page 3: Receiving Equipment
Raypak recommends that this manual be reviewed thoroughly before installing your Raypak heater. If there are any questions which this manual does not answer, please contact the factory or your local Raypak representative. Claims for shortages and damages must be filed with carrier by consignee. -
Page 4: 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. -
Page 5: Installation Instructions
INSTALLATION INSTRUCTIONS INSTALLATION CODES Installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and the National Electrical Code, ANSI/NFPA 70. In Canada installations must conform with the current CAN/CGA B149.1 or .2 and the Canadian Electrical Code Part 1 CSA C22.2 No.1. -
Page 6: Clearances
CLEARANCES INSTALLATION CLEARANCES (All Dimensions Are In Inches) CLEARANCES FROM COMBUSTIBLE SURFACES Note 1: Combustible floor shield is required when heater is to be installed on a combustible surface. (See ordering info. on pg.5.) Note 2: Servicing Clearances: Provide at least 24" (Models 0133-1826), 48"... -
Page 7: Specifications And Dimensions
SPECIFICATIONS AND DIMENSIONS MODEL 133 * Recovery based on manufacturer's rating. MODELS 182-400 and 181-401 * Recovery based on manufacturer's rating. NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. NOTE: Ratings are shown for elevations up to 2,000 feet. - Page 8 MODELS 514-824 *Recovery based on manufacturer's rating. MODELS 962-1826 *Recovery based on manufacturer's rating. NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. NOTE: Ratings are shown for elevations up to 2,000 feet.
- Page 9 MODELS 926-1758 *Recovery based on manufacturer's rating. MODELS 2100-4000 *Recovery based on manufacturer's rating. NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. NOTE: Ratings are shown for elevations up to 2,000 feet.
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Page 10: Outdoor Water Heaters
OUTDOOR WATER HEATERS These heaters are design certified for out- door installation. Heaters must not be installed under an overhang of less than three (3) feet from the top on the heater. Three (3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters installed under overhangs with the use of gutters. -
Page 11: Outdoor Installations 1
VENTING OUTDOOR INSTALLATIONS MODEL 133 Step 1: Remove the front (4) screws. Step 2: Line up outdoor top vent opening over heater vent opening. Step 3: Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top. Step 4: Reinstall (5) screws to secure jacket top and outdoor top to unit. -
Page 12: Indoor Installations
INDOOR INSTALLATIONS MODEL 133 Step 1. Shut-off main electrical power switch to heater. Step 2. Turn heater manual switch, located in upper control panel, to the "OFF" position. Step 3. Shut-off gas supply and water supply to the heater. Step 4. Mount drafthood on heater and attach with the 8 sheet metal screws provided. Drafthood should be positioned with the vent sensor located on the front left side as shown. - Page 13 MODELS 181-401 and 182-400 VENT TERMINAL/INDOOR STACK INSTALLATION 1. Remove the louvered jacket top by removing four (4) #10 flathead screws. 2. If originally installed, remove "Pagoda" top from the louvered jacket top. 3. Place the inner stack adapter panel over the flue collector inside the heater.
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Page 14: Vent Piping
VENT PIPING WARNING: Indoor heaters require a drafthood that must be connected to a vent pipe and properly vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. Vent piping of the same size as the drafthood outlet is recommended, however, when the total vent height is at least ten (10) feet (drafthood relief opening to vent terminal), the vent pipe size may be reduced as speci-... -
Page 15: Vent Damper Installation
Part 11 of the National Fuel Gas Code, ANSI Z223.1. For special venting applications that require reduced vent sizes and through-the-wall venting, the Type D Induced Draft Assembly can be used. Consult the factory or your local Raypak representative. Fig. # 8182.0... - Page 16 HORIZONTAL INSTALLATION FLOW > HEATER D808 TO BOILER TO CHIMNEY VERTICAL INSTALLATION TO CHIMNEY D808 ACTUATOR MAY BE INSTALLED IN ANY HEATER TO BOILER POSITION ON VERTICAL PIPE. INSTALLING THE VENT DAMPER INSTALL THE VENT DAMPER TO SERVICE ONLY THE SINGLE APPLIANCE FOR WHICH IT IS INTENDED. IF IMPROPERLY INSTALLED, A HAZARDOUS CONDITION, SUCH AS AN EXPLOSION OR CARBON MONOXIDE POISONING, COULD RESULT.
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Page 17: Plumbing
PLUMBING GENERAL Heater should be located so that any water leaks will not cause damage to any adjacent areas or struc- tures. GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. -
Page 18: Gas Pressure Regulator
A minimum of 7" WC and a maximum of 14" WC upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 12" WC and a maximum of 14" for propane. * Models 181, 261, 331, and 401 are Low NOx units and are not available in propane. GAS PRESSURE REGULATOR The gas pressure regulator located in the gas valve is preset nominally at 4"... -
Page 19: Flow Rates
FLOW RATES... -
Page 20: Piping - Domestic Hot Water Supply Heaters
PIPING - DOMESTIC HOT WATER SUPPLY HEATERS UNI-TEMP 80 HOT WATER SUPPLY SYSTEMS T = Temperature Rise, Degree F@GPM FLOW GPM = Gallons per Minute Flow P = Pressure Drop, Foot thru Heat Exchanger The table above provides data for selecting in-line pumps for use in a Uni-Temp 80 system for a single heater and tank according to the following: 1. -
Page 21: Piping Diagrams
PIPING DIAGRAMS TYPE WH - UNITEMP 80 SYSTEM... -
Page 22: Type Nh Instantaneous
TYPE NH - INSTANTANEOUS Type NH heaters provide instant hot water without a tank and are used in applications where scaling is prevalent and where hot water demand is fairly constant throughout the day, such as apartments, hotels, motels and industrial applications. The Type NH heater should not be used on apartments and hotels with fewer than 30 dwelling units, nor should the heater be sized smaller than a 514. -
Page 23: Type Nh Dual Models
TYPE NH - DUAL MODELS 514-1826 1. Estimate total length of supply and return loop. Refer to table. 2. If multiple loops are used: (A) Use multiple pumps and size return pipes according to table; or (B) Use one larger recirculating pump with balancing valves on each return line. -
Page 24: Controls
CONTROLS - GENERAL RELIEF VALVE A new combination temperature and pressure (T&P) relief valve, complying with the Standard for Relief Valves and Automatic Gas Shut-Off Devices for Hot Water Supply Systems, ANSI Z21.22, must be installed in the opening provided on top of the storage tank at the time of installation. -
Page 25: Limit Controls
MECHANICAL MODULATING VALVE LOCATION LIMIT CONTROLS HIGH LIMIT The heater is equipped with a manual reset High Limit. Push the reset button and set the limit(s) to 30 °F - 40 °F above desired operating temperature. Maximum setting is 210 °F. FLOW SWITCH This dual-purpose control shuts off the heater in case of pump failure or low water condition and is... -
Page 26: Component Identification
COMPONENT IDENTIFICATION Fig# 9314 MANUAL RESET HIGH LIMIT Fig# 8929.1 IGNITION CONTROL MODULE Fig# 9316 LOW WATER CUT-OFF Fig# 9317 FLOW SWITCH THERMOSTAT CONTROL HIGH and/or LOW GAS PRESSURE SWITCH MECHANICAL MODULATING VALVE FLOW SWITCH PADDLE CUTTING GUIDE Fig# 8643 Fig# 9312 Fig# 8995 Fig# 8925... -
Page 27: Electrical Connections
ELECTRICAL CONNECTIONS CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. -
Page 28: Location Of Controls
LOCATION OF CONTROLS WH1, WH2, WH3 181 (LOW NOx) Fig # 9360... - Page 29 LOCATION OF CONTROLS Fig. #9334...
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Page 30: Start-Up Procedures
LOCATION OF CONTROLS START-UP PROCEDURES BEFORE START-UP Safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the heater when the heater underwent tests specified in the latest edition of the ANSI-Z21.10.3 Standard. -
Page 31: General Safety Precautions
To meet commercial water use needs, the thermostat on this water heater is adjustable up to 190°F. How- ever, water temperatures over 125 °F can cause in- stant severe burns or death from scalds. This is the preferred temperature setting when supplying general purpose hot water. -
Page 32: Operating Instructions
LIGHTING INSTRUCTIONS FOR HEATERS WITH ELECTRONIC IGNITION (IID) FOR MODELS WITH MANUAL GAS VALVES FOR YOUR SAFETY READ BEFORE OPERATING WARNING:If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. This appliance is equipped with an ignition device which automatically lights the pilot. -
Page 33: To Shut Down
FOR MODELS WITH AUTOMATIC GAS VALVES 1. Close all gas valves. Turn off electric power supply. Wait five (5) minutes. 2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted. 3. Open main gas valve. 4. Set temperature controls to desired temperature. TO SHUT DOWN Close all manual gas valves. -
Page 34: Combustion Air 1
INSPECTION PROCEDURES Inspect on the first and third month after initial start- up and then on an annual basis. If problems are found, refer to the Troubleshooting sections of this manual for additional directions. Remove top of heater and inspect heat exchanger for soot and examine venting system. -
Page 35: Addenda: Low Nox Heaters 181-401
ADDENDA: LOW NOx HEATERS The Raytherm Low NOx Heater is offered with WH1- On-Off firing (standard) or 2-stage firing (optional). The heaters are certified and tested under the latest edition of the ANSI Z21.10.3 standard for hot water heaters. The heater should be installed to meet all local codes, the National Fuel Gas Code ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70-latest edition. -
Page 36: Burner Tray Removal
ADDENDA: LOW NOx HEATERS LOW NOx BURNER TRAY ASSEMBLY BURNER TRAY REMOVAL 1. Shut-off main electrical power switch to heater. 2. Shut-off gas upstream of heater. 3. Remove front door. 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. -
Page 37: Troubleshooting - Electrical
TROUBLESHOOTING - ELECTRICAL (ELECTRONIC IGNITION IID) Intermittent Pilot System HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL)? SPARK ACROSS IGNITER/SENSOR GAP? TURN GAS SUPPLY ON PILOT BURNER LIGHTS? SPARK STOPS WHEN PILOT IS LIT? MAIN BURNER LIGHTS? -
Page 38: Wiring Diagrams
WIRING DIAGRAMS WIRING DIAGRAM - WH2 182/260... - Page 39 WIRING DIAGRAM - WH2 330/400...
- Page 40 WIRING DIAGRAM - WH2 514/624...
- Page 41 WIRING DIAGRAM - WH2 724-1336...
- Page 42 WIRING DIAGRAM - WH2 1414-1826...
- Page 43 WIRING DIAGRAM - WH2 2100-2500...
- Page 44 WIRING DIAGRAM - WH2 3001-4001...
- Page 45 WIRING DIAGRAM - WH1 181/261 LOW NOx...
- Page 46 WIRING DIAGRAM - WH1 331/401 LOW NOx...
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Page 47: Troubleshooting
TROUBLESHOOTING MECHANICAL PROBLEM When heater is turned on nothing happens. Thermostat in "ON" position causes relay and pump to operate, but heater does not fire. Continuous shut down of manual reset High Limit. Sooting CAUTION-Soot may be combus- tible. Wet down and exercise caution when cleaning. -
Page 48: Troubleshooting - Pumps
3. Bent shaft and/or damaged bearings. 4. Suction and discharge piping not properly supported and anchored. RAYPAK TUBE CLEANING KIT Auger with Carbide Tip headers for better visibility through the tubes and to be sure the residue does not get into the system. -
Page 49: Pilot Removal And Cleaning
BURNER ORIFICES BURNERS TYPICAL BURNER TRAY ILLUSTRATED BURNER TRAY REMOVAL 1. Shut-off power and gas supply to the heater. Disconnect union(s) and pilot tubing, then loosen and remove burner hold-down screws. 2. Disconnect wires at gas valve and slide burner drawer out. -
Page 50: Vent Piping 1
HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install in/out and return water headers and install header retainer nuts and torque nuts evenly. 3. Install the four (4) corner clips between tube sheets and refractory. -
Page 51: Cleaning Flue Gas Passageways
Any part returned for replacement under standard company warranties must be properly tagged with RAYPAK return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to the Company freight prepaid. If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. -
Page 52: Components 1
8. Chemical contamination of combustion air or use of chemical additives to water. PARTS REPLACEMENT: Under this Warranty, Raypak will furnish a replacement for any failed part. The failed part must first be returned to Raypak if requested, with transportation charges prepaid, and all applicable warranty conditions satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty. - Page 53 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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