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INSTALLATION & OPERATING
Raytherm™
Hot Water
Supply
Heaters
Models 0133–4001
Type WH
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: 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.
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.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
CATALOG NO. 3000.52N
INSTRUCTIONS
Effective: 02-18-11
L
W
Replaces: 05-20-10
P/N 241075 Rev. 15
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Summary of Contents for Raypak 1334001
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Page 1: Hot Water
INSTALLATION & OPERATING INSTRUCTIONS Raytherm™ Hot Water Supply Heaters Models 0133–4001 Type WH 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. - Page 2 Rev. 15 reflects the following: Changes to: “Hard” water specification on page 23, Wiring Diagram headers - “W2/WH2” was “WH2” on page 38, “WH1” was “WH2” on pages 39-44 Additions: Adjustment procedure for two-stage Robertshaw gas valve (including Fig. 39) on page 46...
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Page 3: Table Of Contents
WARNINGS Pay Attention to These Terms GENERAL SAFETY Time/Temperature Relationships in Scalds 6 RECEIVING EQUIPMENT Model Identification General Specifications All Models (Approved) Hot Water Supply Heaters INSTALLATION Installation Codes Installation Base Clearances Specifications and Dimensions Outdoor Water Heaters Combustion Air (Indoor Units Only) Air for Combustion and Ventilation Venting Vent Piping... -
Page 4: Warnings
DO NOT handle, use or store gasoline or other flammable or combustible materials anywhere near or in the vicinity of a water heater. Be sure to read and follow the warning label pictured below and other labels on the water heater, as well as the warnings printed in this manual. -
Page 5: General Safety
4. Out of children's reach. currents. Installation: Do not install water heater where flammable products will be stored or used unless the main burner and pilot flames 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. -
Page 6: Time/Temperature Relationships In Scalds
Serial Number of the heater. When ordering under warranty 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 the factory or your local Raypak representative. -
Page 7: General Specifications
Models 0926-4001 have optional single pass with cast iron headers only. Hot Water Supply Heaters All Raypak hot water supply heaters are ASME rated and design certified as hot water heaters, with 125 PSI pressure relief valves. TYPE WH1 with ON/OFF CONTROLS Models 0133-4001 To be used with storage tank systems. -
Page 8: Clearances
Heater Model Number 0133 0182/0181 0260/0261 0330/0331 0400/0401 0514 0624 0724 0824 0926* 1083* 1178* 1287* 1414* 1571* 1758* 0962 1125 1223 1336 1468 1631 1826 *Models with factory installed floor shield as standard. BOLD TYPE indicates Low NOx models. Table B: Combustible Floorshield Ordering Information Fig. -
Page 9: Specifications And Dimensions
NOTE: The heater shall be installed in a space large in comparison to the size of the heater. Large space is defined as having a volume at least sixteen (16) times the total volume of the heater. Specifications and Dimensions MODEL 0133 Indoor Model... - Page 10 MODELS 0514-0824 Indoor/Outdoor Model Input Recovery Number GPH* WH-0514 511.5 WH-0624 627.0 WH-0724 726.0 WH-0824 825.0 * Recovery based on manufacturer’s rating. MODELS 0 962-1826 Width Model Input Recovery Number GPH* WH-0962 961.7 52-3/8 WH-1125 1124.7 1118 59-1/4 WH-1223 1222.5 1215 63-5/8 WH-1336...
- Page 11 MODELS 0 926-1758 Dimensions (in inches) Width Model Input Recovery Number GPH* WH-0926 926.0 52-3/8 WH-1083 1083.0 1076 59-1/4 WH-1178 1178.0 1171 63-5/8 WH-1287 1287.0 1279 68-5/8 WH-1414 1413.0 1404 74-7/8 WH-1571 1570.0 1560 82-1/8 WH-1758 1758.0 1747 89-3/8 * Recovery based on manufacturer’s rating. MODELS 2100-4000 Width Model...
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Page 12: Outdoor Water Heaters
Outdoor Water Heaters These heaters are design certified for outdoor installa- tion. 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. -
Page 13: Venting
NOTE: If louvers, grills or screens are used on the openings, obtain the net free area from their suppli- er 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 louvers will have 60-75 percent free area as specified in the National Fuel Gas Code. -
Page 14: Indoor Installations
Models 0514-0824 1. Lower outdoor "Stackless" top onto unit. Position top so it is centered on unit from side-to-side and front-to-rear. Fig. 7: Outdoor Top Installation 2. Tighten the (4) screws (Shown below) until they come in contact with the unit jacket top, then even- ly tighten all (4) screws to secure to unit. - Page 15 Fig. 9: Indoor Top Installation...
- Page 16 Models 0181-0401 and 0182-0400 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 17: 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 spec-... -
Page 18: Vent Damper Installation
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 fac- tory or your local Raypak representative. Vent Damper Installation Models 0133 Through 0180 (Where Required) -
Page 19: Vent Damper
HORIZONTAL INSTALLATION FLOW > HEATER D808 TO BOILER TO CHIMNEY VERTICAL INSTALLATION TO CHIMNEY D808 HEATER TO BOILER Fig. 16: Installing Vent Damper D808 N.O. N.C. Switch Motor Yellow Blue Black Orange Thermostat or Controller Dual Valve Combination Gas Control or Ignition System Power supply provide disconnect means an overload protection as required. -
Page 20: Plumbing
Plumbing General Heater should be located so that any water leaks will not cause damage to any adjacent areas or structures. Gas Supply Connections Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve locat- ed outside the heater jacket. -
Page 21: Gas Pressure Regulator
NATURAL GAS 1000 BTU/Cubic Foot PROPANE GAS 2500 BTU/Cubic Foot " 2 3/4" 0133 *0182/0181 *0260/0261 *0330/0331 *0400/0401 0926/0962 1083/1125 1178/1223 1287/1336 1414/1468 1571/1631 1758/1826 2100 2500 3001 3500 4001 * Models 0181, 0261, 0331, and 0401 are Low NOx units and are not available in propane. A minimum of 7"... -
Page 22: Flow Rates
Flow Rates 2-PASS HEAT EXCHANGER SIZE P FT 0133* 14.7 0182/0181 0260/0261 0330/0331 0400/0401 0514 0624 0724 0824 10.5 0926 0962 1083 1125 1178 12.5 1223 12.5 1287 13.2 1336 13.2 1414 1468 1571 14.5 1631 14.5 1758 15.4 1826 15.4 2100 14.8... -
Page 23: Piping-Domestic Hot Water Supply Heaters
MODELS 0-4 Grains Per Gallon Indoor Outdoor 0133 0133 0182/0181 0182 0260/0261 0260 0330/0331 0330 0400/0401 0400 0514 0514 0624 0624 0724 0724 0824 0824 0962 0926 1125 1083 1223 1178 1336 1287 1468 1414 11.0 1631 1571 14.8 1826 1758 15.4 2100... -
Page 24: Piping Diagram-Type Wh - Unitemp 80 System
Piping Diagram—Type WH - Unitemp 80 System... -
Page 25: Controls-General
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 26: Limit Controls
on-off cycling heater. The valve has a remote capillary bulb immersed in a well, at the header outlet, to main- tain a constant outlet water temperature. When multiple valves are furnished, they can be staged to give greater flexibility of control. Standard factory set- ting is at position 5. -
Page 27: Electrical Connections
100% Pilot Safety Models 0514-4001 employ electronic devices which close the main gas valve within 8/10 of a second whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit per- forms its own safety check and opens the main valve only after the pilot is proven to be lit. -
Page 28: Location Of Controls
Location of Controls 0400 WH1, WH2, WH3 0181 (LOW NOx) - Page 29 Location of Controls 0824...
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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 provided on the heater when the heater underwent tests speci- fied in the latest edition of the ANSI Z21.10.3/CSA 4.3 Standard. -
Page 31: For Your Safety Read Before Operating
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 32: Intermittent Pilot System Checkout Procedure (S8600)
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 33: Inspection Procedures
Inspection Procedures Inspect on the first and third month after initial startup and then on an annual basis. If problems are found, refer to the Troubleshooting sections of this manual for additional directions. 1. Remove top of heater and inspect heat exchanger for soot and examine venting system. -
Page 34: Burner Adjustment
c. Check the ignition spark operation. Time must be within the lockout timing period (15 or 90 sec- onds). 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. -
Page 35: Main Burner And Orifice Removal
Main burner And Orifice Removal 1. Remove burner tray. (See Burner Tray Removal procedure on page 34.) 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 assembly from the burner tray assembly. -
Page 36: 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? SYSTEM RUNS UNTIL... -
Page 37: Mechanical
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 38: Wiring Diagram—W2/Wh2 133
WIRING DIAGRAMS Wiring Diagram—W2/WH2 133... -
Page 39: Wiring Diagram-Wh1 0181/0261
Wiring Diagram—WH1 0181/0261... -
Page 40: Wiring Diagram-Wh1 0331/0401
Wiring Diagram—WH1 0331/0401... -
Page 41: Wiring Diagram-Wh1 0514-0724
Wiring Diagram—WH1 0514–0724... -
Page 42: Wiring Diagram-Wh1 0824-1826
Wiring Diagram—WH1 0824–1826... -
Page 43: Wiring Diagram-Wh1 2100-2500
Wiring Diagram—WH1 2100–2500... -
Page 44: Wiring Diagram-Wh1 3001-4001
Wiring Diagram—WH1 3001–4001... -
Page 45: Troubleshooting-Pumps
Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in noninhibited de-scale solvent. RAYPAK TUBE CLEANING KIT Auger with Carbide Tip Fig. 37: Raypak Tube Cleaning Procedure Wire Brush P/N 052870F - 7/8 DIA. -
Page 46: Burner Tray Removal
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. Gas Valve Removal 1. Shut-off gas supply to the heater. Remove gas pip- ing to gas valve inlet. -
Page 47: Main Burner And Orifice Removal
Main burner and Orifice Removal 1. Remove screws and burner hold-down bracket. NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessitates replacement of these parts. 2. -
Page 48: Combustion Chamber Removal
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 defec- tive by the Company and within warranty, the part will be returned in kind or equal substitution, freight collect. -
Page 49: Warranty
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 52 Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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