INSTALLATION & OPERATING INSTRUCTIONS Econopak Water Heaters Models 0090A, 0135A & 0195A – Type WH WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance.
Rev. 8 reflects the following: Changes to: Paragraph 3 of the GENERAL SPECIFICATIONS section on page 6; Fig. 7 on page 12; the Wiring Diagrams on pages 14 and 15; Fig. 8 on page 16; Fig. 12 on page 19; Fig. 15 on page 20; the TROUBLESHOOTING chart on page 23. The addition of: A note to Fig. 2 on page 7.
CONTENTS WARNINGS 4 Pay Attention to These Terms 4 GENERAL SAFETY 5 Time/Temperature Relationships in Scalds 5 RECEIVING EQUIPMENT 6 GENERAL SPECIFICATIONS 6 INSTALLATION 8 Code Requirements 8 Mounting Base 8 Clearances 8 Combustion & Ventilation Air 8 Venting Connections 9 Gas Supply Connections 11 Water Connections & System Piping 12 Electrical Wiring 13 Wiring Diagram—Standing Pilot—Models 0090, 0135 & 0195 14 Wiring Diagram—IID—Models 0090, 0135 & 0195 15 SERVICING PROCEDURES 16 Sequence of Operation 1
WARNINGS—Pay Attention to These Terms DANGER: Indicates the presence of immediate hazards which will cause severe personal injury, death or substantial property damage if ignored. WARNING: Indicates the presence of hazards or unsafe practices which could cause severe personal injury, death or substantial property damage if ignored. CAUTION: Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored.
GENERAL SAFETY Table A details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications. To meet commercial hot water requirements, the tankstat is adjustable up to 190°F. However, water temperatures over 125°F can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying general purpose hot water.
DANGER: There is a Hot Water SCALD Potential if the tankstat is set too high. warranty conditions, you must also specify date of installation. CAUTION: Hotter water increases the risk of SCALDING! 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 your local Raypak representative.
Model No. Input Recovery Tank (MBH) (gph) (Gal)** Piping Connections (in.) Water Gas (NPT) (NPT) Dimensions (in.) A B K (Vent Dia.) WH-0090 90 90 80 1 1/2 11 5-3/4 5 WH-0135 135 132 80 1-1/4 1/2 18 6-1/4 6 WH-0195 195 192 80 1-1/4 1/2 18 6-1/4 7 Recovery gph based on manufacturer's rating. **May be used with other tank size capacity.
INSTALLATION Clearances 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. In Canada installations must conform with the current CAN/CSA B149 and the Canadian Electrical Code Part 1 CSA C22.2 No.1.
1. The heater must be provided with adequate supply of air for proper combustion and ventilation in accordance with Sec. 5.3 of the latest edition of the National Fuel Gas Code, ANSI Z223.1, or applicable provisions of the local building codes. 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 shown in Table D. Model No. Sq. in.
Fig. 5: Common Venting (b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. Fig. 4: Venting Minimum Clearances (c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.
(g) Any improper operation of the common venting system should be corrected so the installation conforms with the latest edition of the National Fuel Gas Code, ANSI Z223.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Chapter 10 and in Appendix G of the National Fuel Gas Code, ANSI Z223.1 and CAN/CSA-B149.
Water Connections & System Piping Gas Pressure Specifications Inches WC Type of Gas Min. Max.* Regulator Setting Natural 4.5 10.5 3.5 Propane 12.0 13.0 11.0 The pipe size and fittings between the heater and the tank should be at least 1" for model 0090, and 1-1/4" for models 0135 and 0195. This is based on the tank being located as close to the heater as possible, as shown in Fig. 7 below. *Do not exceed maximum inlet gas pressure. The minimum value shown is for input adjustment.
Electrical Wiring When this water heater system is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information. The electrical power supply requirement for these heaters is 120 volts, 60 Hz.
Wiring Diagram—Standing Pilot—Models 0090, 0135 & 0195 14
Wiring Diagram—IID—Models 0090, 0135 & 0195 15
SERVICING PROCEDURES tor in the module produces a high voltage spark pulse output that lights the pilot burner. If the pilot burner does not light, the module will not energize the second main valve and the burners will not light. Ignition spark continues only until the timed trial for ignition period ends. General Location of Controls Then, the module goes into safety shutdown or lockout.
For Standing Pilot Model with Robertshaw Gas Valve, On/Off Operation 1. 2. 3. 4. 5. 9. Push in control knob all the way and hold in, immediately light the pilot with a match. Continue to hold control knob in for about one minute after the pilot is lighted, release knob and it will pop back up. Pilot should remain lighted. If it goes out, repeat steps 4 through 8. * If knob does not pop up when released, stop and immediately call your service technician or gas supplier.
10. 11. 12. 13. * If red reset button does not pop up when released, STOP and immediately call your service technician or gas supplier. * If the pilot does not stay lit after several tries, turn the gas control knob to "OFF" and call your Service technician or gas supplier. Stand to the side of the heater and turn the gas control knob counterclockwise to "ON". Replace heater door. Turn "ON" all electrical power to the heater. Set the tankstat to the desired setting. • instructions.
of the control system and any gas control which has been under water. GAS CONTROL KNOB SHOWN IN "OFF" POSITION For Intermittent Ignition (IID) with Honeywell or Robertshaw Gas Valve GAS INLET 1. STOP! Read the safety information above on this label. 2. Set the tankstat on the lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. ROBERTSHAW (All Models) Fig.
For Automatic Ignition Systems CAUTION: Should overheating occur or the gas supply fails to shut off, DO NOT turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the heater. Failure to observe this precaution may aggravate the overheated condition resulting in possible damage to the heater and injury to the user. 1. Turn on power to the ignition systems and turn gas supply off at the gas valve. 2. Check ignition module as follows: a.
Procedure for Cleaning Flue Gas Passage Ways Soot will clog areas behind fins and eventually cause tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning. 1. Lift off draft hood and flue collector by removing bolts and screws. 2. Remove "V" baffles from heat exchanger. 3. Remove burner tray, see Burner Drawer Removal. 4. Take garden hose and wash heat exchanger, making sure soot is removed from between fins. (Avoid excessive water against refractory). 5.
RAYPAK TUBE CLEANING KIT Extension Pieces (5) Auger with Carbide Tip Wire Brush Fig. 18: Raypak Tube Cleaning Kit Repair Section 3. Replace "V" baffles. 4. Install thermostat sensing bulbs in header wells and replace bulb retaining clips. 5. Install inlet and return pipes in water headers using pipe thread sealant. 6. Install water pressure relief valve, sensor probe, and low water cutoff devices if so equipped. 7. Open water supply and return shut-off valves.
TROUBLESHOOTING 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. PROBLEM(S) 1)When tankstat is turned on, heater does not operate.
3)Pilot Outage. (Standing pilot models) 1) Too low or too high gas pressures. 2) Restricted pilot. 3) Weak thermocouple. 1) Adjust inlet gas pressure as shown on rating plate. 2) Clean pilot orifice. 3) Replace thermocouple. 4)Yellow lazy flame. 1) Too low gas pressure. 1) Adjust manifold pressure as 2) Restricted burner intake ports. 3) Restricted gas line. 5)Sooting 1) Insufficient combustion air. 2) Improper venting. 3) Severe yellow burner flames. 24 shown on rating plate.
ADJUSTMENTS & REPLACEMENT OF COMPONENTS HONEYWELL PILOT PILOT ROBERTSHAW PILOT PILOT AIR OPENING CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ORIFICE ORIFICE DANGER: SHOCK HAZARD: Make sure electrical power to the heater is disconnected to avoid potential serious injury or damage to components. Fig. 20: Pilots Gas Valve Replacement Flame Roll-out Switch Replacement 1.
Circulator Replacement Replacement Parts 1. Shut off electrical power to the heater. 2. Shut off water supply and open drain valve to remove water in the piping at the pump level. NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable. CAUTION: To avoid damage to electrical components keep water from getting into the control compartments and gas valve.
LIMITED PARTS WARRANTY ECONOPAK WATER HEATERS MODELS WH - 0090 TO 0195 SCOPE: Raypak, Inc. ("Raypak") warrants to the original owner that all parts of this water 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.
www.raypak.com Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468 Litho in U.S.A.