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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. 3000.52L
INSTRUCTIONS
Effective: 09-02-09
L
W
Replaces: 03-09-09
P/N 241075 Rev. 13
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Table of Contents
Troubleshooting
Summary of Contents for Raytherm WH-0133
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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. 13 reflects the following: Changes to: Note on Page 13, Item (g) on Page 18...
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Page 3: Table Of Contents
CONTENTS Burner Adjustment WARNINGS Pay Attention to These Terms Visual Inspection Electrical GENERAL SAFETY Time/Temperature Relationships in Scalds 6 High Gas Pressure Switch Burner Tray Removal RECEIVING EQUIPMENT Model Identification Gas Valve Removal General Specifications Main Burner And Orifice Removal All Models (Approved) Pilot Removal Hot Water Supply Heaters... -
Page 4: Pay Attention To These Terms
WARNINGS— Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe DANGER: personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause WARNING: severe personal injury, death or substantial property damage if ignored. Indicates the presence of hazards or unsafe practices which could cause CAUTION: minor personal injury or product or property damage if ignored. -
Page 5: General Safety
WARNING - CALIFORNIA PROPOSITION 65: This product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. DANGER Water temperature over 125°F can Vapors from flammable liquids Water heater has a main cause instant severe burns or death will explode and catch fire burner and pilot flame. -
Page 6: Time/Temperature Relationships In Scalds
RECEIVING EQUIPMENT Time/Temperature Relationships in Scalds WARNING: Pump motors should NOT be The temperature of the water in the storage tank supported by any type of stand or support from heater can be regulated by setting the temperature above due to possible misalignment of pump and dial on front of the tankstat. -
Page 7: General Specifications
General Specifications TYPE WH3 with 2-STAGE CONTROLS Models 0181-4001 The Raypak water heaters are design certified and tested under the latest requirements of the American National Standard, ANSI Z21.10.3/CSA 4.3. Each Hot water supply heater with low-high fire for 2-stage heater has been constructed and pressure tested in control. -
Page 8: Clearances
Clearances Heater Floor Base Installation Clearances Model Part (All Dimensions are in Inches) Number Number 0133 001749 0182/0181 058313 0260/0261 058314 Heater Size 0330/0331 058315 0133 0181 to 0514 to 0926 to 2100 to 0400/0401 058316 Location 0401 0824 1826 4001 Floor See Note 1... -
Page 9: Specifications And Dimensions
Input MBH GPH* GPH* NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations WH-0133 136.0 over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea level. * Recovery based on manufacturer’s rating. MODELS 0182-0400 and 0181-0401... - Page 10 MODELS 0514-0824 Indoor/Outdoor Dimensions (in inches) Flue Width Conn. Diameter Model Input Recovery Number GPH* NOTE: WH-0514 511.5 32-3/4 25-3/8 Ratings are shown for elevations up to WH-0624 627.0 37-1/2 29-1/2 2,000 feet. For elevations over 2,000 feet, WH-0724 726.0 41-5/8 34-1/4 reduce ratings 4% for each 1,000 feet above...
- Page 11 MODELS 0 926-1758 Dimensions (in inches) Water Width Conn. Conns. Model Input Recovery Number GPH* WH-0926 926.0 52-3/8 2-1/2 WH-1083 1083.0 1076 59-1/4 2-1/2 WH-1178 1178.0 1171 63-5/8 1-1/4 2-1/2 WH-1287 1287.0 1279 68-5/8 1-1/4 2-1/2 NOTE: WH-1414 1413.0 1404 74-7/8 1-1/4 2-1/2...
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Page 12: Outdoor Water Heaters
Outdoor Water Heaters Combustion must CAUTION: contaminated by corrosive chemical fumes which can damage the heater. Measures must be taken to These heaters are design certified for outdoor installa- prevent the entry of corrosive chemical fumes to the tion. Heaters must not be installed under an overhang combustion and ventilation air supply. -
Page 13: Venting
Models 0181-0401 and 0182-0400 NOTE: If louvers, grills or screens are used on the openings, obtain the net free area from their suppli- Outdoor Top 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 Models 0514-0824 Models 0926-1758 1. Lower outdoor "Stackless" top onto unit. Position Heaters are shipped with outdoor vent terminal facto- top so it is centered on unit from side-to-side and ry installed. front-to-rear. Models 2100-4001 These units are not certified for outdoor installation. Indoor Installations Model 0133 Refer to Fig.
- Page 15 Fig. 9: Indoor Top Installation...
- Page 16 Models 0181-0401 and 0182-0400 Models 0514-0824 Locate and assemble as shown below. Secure with Vent Terminal/Indoor Stack screws supplied in envelope in carton. 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.
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Page 17: Vent Piping
Vent Piping 10' OR LESS VENT CAP WARNING: Indoor heaters require a drafthood that 2' MIN must be connected to a vent pipe and properly 2' MIN vented to the outside. Failure to follow this procedure can cause fire or fatal carbon monoxide poisoning. 5' MIN VENT PIPE Vent piping of the same size as the drafthood outlet is... -
Page 18: Vent Damper Installation
appliance not connected to the common venting WARNING: Do not use thermally actuated vent system. Turn on any exhaust fans, such as range dampers on modulating heater. To do so, may result hoods and bathroom exhausts, so they will oper- in asphyxiation. - Page 19 Vent Damper HORIZONTAL INSTALLATION For safe, efficient operation, the vent damper and all FLOW > flue product carrying areas of the appliance must be checked annually, with particular attention given to HEATER D808 deterioration from corrosion or other sources. Check TO BOILER TO CHIMNEY vent damper operation as follows:...
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Page 20: Plumbing
Plumbing 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 General pressures in excess of 1/2 PSIG. Dissipate test pressure in the gas supply line before reconnecting Heater should be located so that any water leaks will the heater and its manual shut-off valve to gas not cause damage to any adjacent areas or structures. -
Page 21: Gas Pressure Regulator
MAXIMUM EQUIVALENT PIPE LENGTH NATURAL GAS 1000 BTU/Cubic Foot .60 SPECIFIC GRAVITY @ 0.5" W.C. PRESSURE DROP PROPANE GAS 2500 BTU/Cubic Foot 1.53 SPECIFIC GRAVITY @ 0.6" W.C. PRESSURE DROP " 2 3/4" " 1 " 4 1-1/2" 2" 2-1/2" 3"... -
Page 22: Flow Rates
Flow Rates MAXIMUM AND MINIMUM FLOW RATES 2-PASS HEAT EXCANGER 1-PASS HEAT EXCHANGER SIZE CONN P FT CONN P FT P FT P FT 0133* 14.7 1-1/4" 0182/0181 1-1/2" 0260/0261 1-1/2" 0330/0331 1-1/2" 0400/0401 1-1/2" 0514 2" 0624 2" 0724 2"... -
Page 23: Piping-Domestic Hot Water Supply Heaters
WATER HARDNESS MODELS 0-4 Grains Per Gallon 5-15 Grains Per Gallo 6 & Over Grains Per Gallon Indoor Outdoor 0133 0133 1-1/4 1-1/4 14.7 1-1/4 22.0 0182/0181 0182 1-1/2 1-1/2 1-1/2 20.8 0260/0261 0260 1-1/2 1-1/2 1-1/2 21.0 0330/0331 0330 1-1/2 1-1/2 1-1/2... -
Page 24: Piping Diagram-Type Wh - Unitemp
Piping Diagram—Type WH - Unitemp 80 System... -
Page 25: Controls-General
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 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 CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause Models 0514-4001 employ electronic devices which improper and dangerous operation. Verify proper close the main gas valve within 8/10 of a second operation after servicing. whenever the pilot flame is interrupted. -
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 Initial Start-Up - Pump and PROCEDURES Motor Many pumps are now direct-drive. They have no cou- Before Start-Up pler or bearing assembly. These pumps do not require lubrication. Others require SAE-30 non-detergent oil to lubricate both the motor and the bearing assembly. Safe lighting and other performance criteria were met Check pump motor for type before adding oil. -
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 If you cannot reach your gas supplier, call the fire de- which automatically lights the pilot. -
Page 32: Intermittent Pilot System Checkout Procedure (S8600)
FOR MODELS WITH AUTOMATIC GAS VALVES PILOT SHUT-OFF VALVE CONTROL 1. Close all gas valves. Turn off electric power supply. TO PILOT SHOWN IN "ON" Wait five (5) minutes. POSITION 2. Open manual pilot valve. Turn on electric power. Pilot is automatically lighted. 3. -
Page 33: Inspection Procedures
If problems are found, refer to the Troubleshooting sections of this manual for additional directions. The Raytherm Low NOx Heater is offered with WH1- 1. Remove top of heater and inspect heat exchanger On-Off firing (standard) or 2-stage firing (optional). The for soot and examine venting system. -
Page 34: Burner Adjustment
c. Check the ignition spark operation. Time must COMBUSTION be within the lockout timing period (15 or 90 sec- AIR BLOWER onds). d. Turn control down to end call for heat and wait AIR SHUTTER ADJUSTMENT 60 seconds on lockout models before beginning step 3. -
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
TROUBLESHOOTING WARNING—HIGH VOLTAGE: For qualified technicians ONLY. Electrical—Electronic Ignition IID NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to Intermittent Pilot System light. To reset, interrupt power to heater. Honeywell S8600 START NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout TURN GAS SUPPLY OFF. -
Page 37: Mechanical
Mechanical MECHANICAL PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION When heater is turned on nothing No power to the heater…………………. Check the circuit breaker, outdoor con- happens. troller, etc., upstream of heater. Bad transformer…………………………. If power to Leads L1 and L2 of trans- former, but no power on 24V side, re- place. -
Page 38: Wiring Diagrams
WIRING DIAGRAMS Wiring Diagram—WH2 0181/0261... -
Page 39: Wiring Diagram-Wh2 0331/0401
Wiring Diagram—WH2 0331/0401... -
Page 40: Wiring Diagram-Wh2 0514-0724
Wiring Diagram—WH2 0514–0724... -
Page 41: Wiring Diagram-Wh2 0824-1826
Wiring Diagram—WH2 0824–1826... -
Page 42: Wiring Diagram-Wh2 2100-2500
Wiring Diagram—WH2 2100–2500... -
Page 43: Wiring Diagram-Wh2 3001-4001
Wiring Diagram—WH2 3001–4001... -
Page 44: Troubleshooting-Pumps
Troubleshooting—Pumps Pump Loses Prime 1. Air leaks in suction line. Failure To Pump 2. Excess air in water. 3. Water seal in stuffing box not functioning. 1. Pump not properly primed. 4. Excessive suction lift and pump operating too near 2. -
Page 45: Burner Tray Removal
COMBINATION FLAME SENSOR/ IGNITER AND PILOT BURNER Fig. 38: Typical Burner Tray Illustrated Burner Tray Removal Pilot Removal and Cleaning 1. Shut-off power and gas supply to the heater. 1. Disconnect pilot tubing at pilot and sensor/igniter Disconnect union(s) and pilot tubing, then loosen wire. -
Page 46: Heat Exchanger Re-Assembly
Combustion Chamber Removal heater away from piping until studs clear the heater. 6. Remove heat exchanger corner brackets. To remove combustion chamber refractory you must 7. Remove combustion chamber clips at the four cor- first have removed the heat exchanger. Unbolt metal ners of the heat exchanger. -
Page 47: Cleaning Flue Gas Passageways
REPLACEMENT PARTS 9. DO NOT apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0.015". See separate parts sheet in instruction envelope. 10. Use same procedure on opposite end. 11. Apply line pressure test. Re-roll if necessary. 12. -
Page 49: Warranty
LIMITED PARTS WARRANTY RAYTHERM™ COMMERCIAL HEATERS TYPES H & WH MODELS 0133 TO 4001 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this 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. - Page 52 www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.
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