Table of Contents
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INSTALLATION
AND OPERATING
INSTRUCTIONS
Models 090A, 135A, 195A
Type WH
ECONOPAK WATER
HEATERS
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids or other combustible
materials in the vicinity of this or any other appliance. To do so may result in an explosion or
fire.
WARNING: Improper installation, adjustment, alteration, service or maintenance can cause
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 kept
in a safe place for future reference.
CATALOG NO. 3000.50D
Effective:
01-01-03
Replaces:
03- 01-97
P/N 240687
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Summary of Contents for Raypak 090A
- Page 1 INSTALLATION AND OPERATING INSTRUCTIONS Models 090A, 135A, 195A Type WH ECONOPAK WATER HEATERS FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
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Page 2: Table Of Contents
Contents These instructions are provided to assure the proper installation and operation of Raypak water heaters. Should questions arise regarding the specifications, installation, operation or servicing of these water heat- ers, we suggest that the local Sales representative or the factory be consulted. -
Page 3: General Specifications
Raypak representative. 2. GENERAL SPECIFICATIONS The Raypak water heaters are design certified by the American Gas Association, and tested under the require- ments of the American National Standard, ANSI Z21.10.3. Each heater has been constructed and... -
Page 4: General Safety Precautions
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. -
Page 5: Time/Temperature Relationships In Scalds
SCALDING! There is a Hot Water SCALD Potential if the tankstat is set too high. NOTE: When this water heater is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury. -
Page 6: Installation Procedures
3. INSTALLATION PROCEDURES CODE REQUIREMENTS 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. -
Page 7: Venting Connections
2) If the heater room is located against an outside wall and air openings can communicate directly with the outdoors, the two openings on the outside wall must each have a net free area, in square inches as follows: Model 0090 0135 0195... -
Page 8: Common Vents
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 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 Z223.1, or applicable provisions of the local building... -
Page 9: Gas Supply Connections
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. -
Page 10: Water Connections & System Piping
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. -
Page 11: Electrical Wiring
ELECTRICAL WIRING The electrical power supply requirement for these heaters is 115 volts, 60 Hz. Field wiring connections and electrical grounding must comply with the local codes, or in the absence of local codes, with the latest edition of the National Electrical Code, ANSI/NFPA 70. Provide a separate fused circuit from the main electrical panel to the heater, and a disconnecting means within sight of the heater. -
Page 12: Wiring Diagrams
WIRING DIAGRAM: STANDING PILOT MODELS 90, 135 and 195 WARNING: SHOCK HAZARD LINE VOLTAGE IS PRESENT. BEFORE SERVICING TANKSTAT OR HEATER, TURN OFF ELECTRICAL POWER TO THE HEATER AT THE MAIN DISCONNECT OR CIRCUIT BREAKER. FAILURE TO DO SO COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODELS 90, 135 and 195 WARNING: SHOCK HAZARD... -
Page 13: Servicing Procecures
4. SERVICING PROCEDURES GENERAL LOCATION OF CONTROLS CONTROL BOX COMPONENT LOCATIONS Ignition Module (Auto Ignition Only) SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID) Heaters equipped with the IID system will automati- cally light the pilot burner first and then the main burner, each time there is a call for heat from the tankstat. -
Page 14: Start Up Procedures
START-UP PROCEDURES SECTION 1. Filling the System Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Flush system before putting into operation to assure that foreign material does not damage pump seals. SECTION 2. -
Page 15: System Shut Down Procedure
8. Push down and hold the red reset button in, imme- diately light the pilot with a match. Continue to hold down red reset button for about one minute after the pilot is lighted. Release red reset button and it will pop back up. -
Page 16: To Turn Off Gas To Heater
FOR INTERMITTENT IGNITION (IID) WITH HONEY- WELL OR ROBERTSHAW GAS VALVE 1. STOP! Read the safety information above. 2. Set the tankstat to the lowest setting. 3. Turn off all electric power to the appliance. 4. This heater is equipped with an ignition device which automatically lights the pilot. -
Page 17: Flame Failure
Fig.# 8935.0 ROBERTSHAW 7200 GAS VALVE (Models 135 & 180) e. Replace pilot adjustment cover screw, then follow the lighting instructions to get heater ready for operation. FOR AUTOMATIC IGNITION SYSTEMS A. Intermittent Ignition (IID) 1. Turn on power to the ignition systems and turn gas supply off at the gas valve. -
Page 18: Repair Section
Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling. RAYPAK TUBE CLEANING KIT Auger with Carbide Tip 3. Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels. -
Page 19: Heat Exchanger Re-Assembly
HEAT EXCHANGER RE-ASSEMBLY 1. Heat exchanger water header O-rings should be replaced with new ones. 2. Install inlet-outlet and return water headers and install header retainer nuts and torque nuts evenly. 3. Replace "V" baffles. 4. Install thermostat sensing bulbs in header wells and replace bulb retaining clips. -
Page 20: Trouble Shooting Guide
5. TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions. - Page 21 3) Pilot Outage. (Standing pilot models) 4) Yellow lazy flame. 5) Sooting 1) Too low or too high gas pressures. 2) Restricted pilot. 3) Weak thermocouple. ) Too low gas pressure. 2) Restricted burner intake ports. 3) Restricted gas line. 1) Insufficient combustion air.
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Page 22: Adjustments/Replacements Of Components
ADJUSTMENTS/REPLACEMENTS OF COMPONENTS 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 disconnect- ed to avoid potential serious injury or damage to com- ponents. -
Page 23: Replacement Parts List
Company freight prepaid. If determined defective by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued. RAYPAK, INC. 2151 Eastman Avenue Oxnard, CA 93030... - Page 24 HONEYWELL STANDING PILOT Fig. # 8189.4 HONEYWELL IID Fig. # 9112 ROBERTSHAW STANDING PILOT Fig. # 8190.3...
- Page 27 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 found satisfied. The replacement part will be warranted for only the unexpired portion of the original warranty.
- Page 28 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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