CATALOG NO. 3000.52G Effective: 11-01-04 Replaces: 02-01-04 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.
TABLE OF CONTENTS RECEIVINGEQUIPMENT ........................................ MODELIDENTIFICATION ........................... GENERALSPECIFICATIONS ....................... GENERALSAFETYPRECAUTIONS .............. INSTALLATIONINSTRUCTIONS .............................. CLEARANCES .......................................... SPECIFICATIONSANDDIMENSIONS ........... OUTDOORINSTALLATIONS ....................... HIGHWINDCONDITIONS ........................... COMBUSTIONAIR ....................................
RECEIVING EQUIPMENT ALL MODELS (APPROVED) On receipt of the equipment, visually check for external damage to the carton or the shipping crate. If the carton or shipping crate is damaged, make a note on the Bill of Lading and report the damage to the Carrier immediately. Remove the heater from the carton or the shipping crate. Do NOT use the shipping crate base as an installation base. On occasion, items are shipped loose. Be sure that you receive the number of packages indicated on the Bill of Lading.
! 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.
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.
CLEARANCES CLEARANCES TO PROTECTED SURFACES INSTALLATION CLEARANCES (All Dimensions Are In Inches) 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. 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.
SPECIFICATIONS AND DIMENSIONS MODEL 133 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. * Recovery based on manufacturer's rating. MODELS 182-400 and 181-401 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. Bold type indicates Low NOx models. * Recovery based on manufacturer's rating.
MODELS 514-824 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. *Recovery based on manufacturer's rating. MODELS 962-1826 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. *Recovery based on manufacturer's rating.
MODELS 926-1758 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. *Recovery based on manufacturer's rating. MODELS 2100-4000 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. *Recovery based on manufacturer's rating.
OUTDOOR WATER HEATERS These heaters are design certified for outdoor 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.
VENTING OUTDOOR INSTALLATIONS MODELS 514-824 MODEL 133 Step 1: Lower outdoor "Stackless" top onto unit. Position top so it is centered on unit from side-to-side and front-to-rear. 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. Fig# 8166 Fig.
INDOOR INSTALLATIONS MODEL 133 Step 1. Step 2. Step 3. Step 4. Shut-off main electrical power switch to heater. Turn heater manual switch, located in upper control panel, to the "OFF" position. Shut-off gas supply and water supply to the heater. 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. Step 5.
MODELS 514-824 MODELS 181-401 and 182-400 VENT TERMINAL/INDOOR STACK INSTALLATION Locate and assemble as shown below. Secure with screws supplied in envelope in carton. 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. Make sure the flanged side of the flue opening is up. 4.
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 specified in Chapter 10 of the National Fuel Gas Code, ANSI Z 223.1.
(g) Any improper operation of the common venting system should be corrected so that 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 Part 11 of the National Fuel Gas Code, ANSI Z223.1. (d) Place in operation the appliance being inspected. Follow the lighting instructions.
HORIZONTAL INSTALLATION FLOW > D808 NO N.O. N.C. End YES HEATER TO BOILER D808 1K2 Switch YES C. 1K1 TO CHIMNEY Motor R NO VERTICAL 1K3 1R INSTALL VENT INSTALLATION DAMPER WITH TO CHIMNEY 1 2 3 ACTUATOR TO Black SIDES OF VENT Orange Yellow Red 5 Blue Optional Limit Limit ONLY. DO NOT D808 4 MOUNT ABOVE OR L1 Controller BELOW VENT.
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 pressures in excess of 1/2 PSI. Dissipate test pressure in the gas supply line before reconnecting the heater and its manual shut-off valve to gas supply line. FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE. OVER-PRESSURED GAS VALVES ARE NOT COVERED BY WARRANTY.
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" WC for natural gas, and 11" WC for propane. Between the gas valve and the burners is a 1/8" pipe plug.
FLOW RATES 19
PIPING - DOMESTIC HOT WATER SUPPLY HEATERS GENERAL SPECIFICATIONS 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 MPS = Minimum Pipe Size, NPT SHL = System Head Loss 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. Flow rates are based on water hardness as measured in grains per gallon.
PIPING DIAGRAMS TYPE WH - UNITEMP 80 SYSTEM 21
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. Use a minimum 20' of 3" pipe on outlet.
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. 3. First fixture on supply line must be a minimum of 20 feet from the heater. 4. Supply line size must be 2" minimum. If not possible, add a tank between heater and first fixture.
CONTROLS - GENERAL RELIEF VALVE ELECTRONIC IGNITION 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. No valve is to be placed between the relief valve and the storage tank.
Fig # 9332 MECHANICAL MODULATING VALVE LOCATION MODELS 0724-1336 MOTORIZED GAS VALVE LOCATION MODEL 3001 Fig # 9333.1 LIMIT CONTROLS whenever the pilot flame is interrupted. Pilot flame is automatically lit when the device is powered. Unit performs its own safety check and opens the main valve only after the pilot is proven to be lit. 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.
COMPONENT IDENTIFICATION Fig# 8643 Fig# 9314 MANUAL RESET HIGH LIMIT THERMOSTAT CONTROL Fig# 9312 Fig# 8929.
ELECTRICAL CONNECTIONS control connection. 24 Volts are supplied to this connection through the heater transformer. DO NOT attach line voltage to the "TH" leads on models 5141826. Before starting heater check to ensure proper voltage to heater and pump. Heater must be electrically grounded in accordance with National Electrical Code ANSI/NFPA No 70. CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
LOCATION OF CONTROLS 400 WH1, WH2, WH3 181 (LOW NOx) WH1 Fig # 9360 28
LOCATION OF CONTROLS Fig.
LOCATION OF CONTROLS Fig # 9335 START-UP PROCEDURES BEFORE START-UP INITIAL START-UP - PUMP AND MOTOR Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the heater when the heater underwent tests specified in the latest edition of the ANSI-Z21.10.3 Standard. Many pumps are now direct-drive. They have no coupler or bearing assembly. These pumps do not require lubrication.
General Safety Precautions To meet commercial water use needs, the thermostat on this water heater is adjustable up to 190°F. However, water temperatures over 125 °F can cause instant severe burns or death from scalds. This is the preferred temperature setting when supplying general purpose hot water. Safety and energy conservation are factors to be considered when setting the water temperature on the thermostat.
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. A. This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. B. * * * * BEFORE OPERATING smell all around the appliance area for gas.
FOR MODELS WITH AUTOMATIC GAS VALVES PILOT SHUT-OFF VALVE CONTROL SHOWN IN "ON" POSITION 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. power.
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. 2. Remove rear header and inspect for scale deposits. *3. Inspect pilot and main burner flame and firing rate. *4. Inspect and operate all controls and gas valve. *5. Visually inspect system for water leaks. *6.
ADDENDA: LOW NOx HEATERS Models 181 to 401 The Raytherm Low NOx Heater is offered with WH1On-Off firing (standard) or 2-stage firing (optional). 3.Turn on gas supply. 4.Set controller to call for heat. 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. 5.
ADDENDA: LOW NOx HEATERS Models 181 to 401 (CONTINUED) sembly from the burner tray assembly. 4. Use a long ½” socket wrench to remove orifices from the gas manifold. 5. Remove burners by raising the bracket on the back end of the burners up and out of their slots. 6. Reverse above procedure to re-install. Fig # 9362 LOW NOx BURNER TRAY ASSEMBLY Fig # 9363 BURNER TRAY REMOVAL IID PILOT 1. 2. 3. 4. 5. Shut-off main electrical power switch to heater. Shut-off gas upstream of heater. Remove front door.
WARNING HIGH VOLTAGE For qualified Technicians ONLY TROUBLESHOOTING - ELECTRICAL (ELECTRONIC IGNITION IID) NOTE: Some heaters may be equipped with an ignition module that shuts off pilot gas if pilot fails to light. To reset, interrupt power to heater. Intermittent Pilot System HONEYWELL S8600 START TURN GAS SUPPLY OFF. TURN THERMOSTAT (CONTROLLER) TO CALL FOR HEAT POWER TO MODULE (24 V NOMINAL)? YES NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure.
WIRING DIAGRAMS WIRING DIAGRAM - WH2 182/260 38
WIRING DIAGRAM - WH2 330/400 39
WIRING DIAGRAM - WH2 514/624 40
WIRING DIAGRAM - WH2 724-1336 41
WIRING DIAGRAM - WH2 1414-1826 42
WIRING DIAGRAM - WH2 2100-2500 43
WIRING DIAGRAM - WH2 3001-4001 44
WIRING DIAGRAM - WH1 181/261 LOW NOx 45
WIRING DIAGRAM - WH1 331/401 LOW NOx 46
TROUBLESHOOTING CORRECTIVE ACTION MECHANICAL PROBLEM POSSIBLE CAUSE When heater is turned on nothing happens. No power to the heater…………………. Check the circuit breaker, outdoor controller, etc., upstream of heater. Bad transformer…………………………. If power to Leads L1 and L2 of transformer, but no power on 24V side, replace. Inoperative thermostat………………….. Jumper thermostat, replace with new if heater fires. Inoperative toggle switch……………….. If power to toggle switch, but not through switch, replace.
TROUBLESHOOTING - PUMPS FAILURE TO PUMP 1. Pump not properly primed. 2. Wrong direction of rotation. 3. Speed too low. 4. Total head too high. PUMP LOSES PRIME 1. Air leaks in suction line. 2. Excess air in water. 3. Water seal in stuffing box not functioning. 4. Excessive suction lift and pump operating too near shut-off point. REDUCED CAPACITY AND/OR HEAD 1. Air pockets or leaks in suction line. 2. Clogged impeller. 3. Foot valve strainer too small or clogged. 4. Excessive suction lift (over 15 feet).
COMBINATION FLAME SENSOR/ IGNITOR AND PILOT BURNER LOCATION BURNER ORIFICES BURNERS BURNER HOLD-DOWN LOCATION TYPICAL BURNER TRAY ILLUSTRATED BURNER TRAY REMOVAL PILOT REMOVAL AND CLEANING 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. 1. Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burner tray. 2.
HEAT EXCHANGER RE-ASSEMBLY COMBUSTION CHAMBER REMOVAL 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. 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.
9. DO NOT apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0.015". 10. Use same procedure on opposite end. 11. Apply line pressure test. Re-roll if necessary. 12. Reinstall as outlined under HEAT EXCHANGER REASSEMBLY. REPLACEMENT PARTS See separate parts sheet in instruction envelope. NOTE: To supply the correct part it is important that you state the model number, serial number and type of gas when applicable.
WARRANTY LIMITED PARTS WARRANTY RAYTHERM™ COMMERCIAL HEATERS TYPES H, NH & WH MODELS 133 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.
www.raypak.com 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.