Raytherm WH-0133, Installation & Operating Instructions Manual

Page 1: ...lier s instructions If you cannot reach your gas supplier call the fire department 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 flamma...

Page 2: ...2 Rev 13 reflects the following Changes to Note on Page 13 Item g on Page 18 ...

Page 3: ...ers 32 Controls 32 Inspection Procedures 33 ADDENDA LOW NOx HEATERS Models 0181 to 0401 33 Operation 33 Start Up Procedures S8610B Ignition Module 33 CONTENTS 3 Burner Adjustment 34 Visual Inspection 34 Electrical 34 High Gas Pressure Switch 34 Burner Tray Removal 34 Gas Valve Removal 34 Main Burner And Orifice Removal 35 Pilot Removal 35 Combustion Fan Removal 35 TROUBLESHOOTING 36 Electrical 36 ...

Page 4: ...ne by a qualified service technician To avoid possible equipment damage personal injury or fire DO NOT connect this water heater to a fuel type not in accordance with unit data plate Propane for propane units Natural gas for natural gas units These units are not certified for any other type fuel DANGER PROPANE MODELS Propane gas must be used with great caution It is heavier than air and will colle...

Page 5: ...ty and energy conservation are factors to be con sidered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs consistent with the application Maximum water temperatures occur just after burner has shut off To determine the water temperature being delivered turn on the hot water only ...

Page 6: ...er and the heater serial number are found on the heater data plate The model number will have the form WH1 0514A or similar depending on the heater model WH Hot Water Supply System 1 on off firing 0514 size of heater Rated inputs are suitable for up to 2000 feet elevation For elevations above 2000 feet reduce input 4 for each 1000 feet above sea level Time Temperature Relationships in Scalds The t...

Page 7: ...ir flow General Specifications 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 heater has been constructed and pressure tested in accordance with the requirements of Section IV of the American Society of Mechanical Engineers Code and factory fire tested All Models Approved All models are National Bo...

Page 8: ...o 2100 to Description Location 0401 0824 1826 4001 a 3 1 2 in thick masonry walls Back 9 9 9 16 16 without ventilated air space Right 5 9 5 16 16 Left 9 9 12 16 16 Vent 5 5 5 5 5 Indoor Top 43 39 36 24 24 Outdoor Top Unobstructed NA b 1 2 in insulation board Back 6 6 6 12 12 over 1 in glass fiber or Right 3 6 3 12 12 mineral wool batts Left 6 6 9 12 12 Vent 3 3 3 3 3 Indoor Top 30 30 24 16 16 Outd...

Page 9: ...ngs 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 Model Number Indoor Outdoor Input MBH Recovery GPH Recovery GPH WH 0133 136 0 135 132 Recovery based on manufacturer s rating Model Number Indoor Dimensions in inches Input MBH Recovery GPH Width A Height C J Flue Diameter K WH 0182 01...

Page 10: ...tings 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 Model Number Input MBH Recovery GPH Dimensions in inches Width A Overall Height B Jacket Height C Gas Conn G Water Conns H J Flue Diameter K L WH 0962 961 7 956 52 3 8 68 3 4 33 1 2 1 2 1 2 18 14 28 WH 1125 1124 7 1118 59 1 4 74 1 2 33 1 2 1 2 1 2 23 5 8 16 32 WH 1223...

Page 11: ...levations over 2 000 feet reduce ratings 4 for each 1 000 feet above sea level Recovery based on manufacturer s rating Model Number Input MBH Recovery GPH Dimensions in inches Width A Overall Height B Gas Conn G Water Conns H Flue Diameter K WH 2100 2100 0 2087 61 68 1 4 3 24 WH 2500 2499 0 2484 70 68 1 4 3 26 WH 3001 3000 0 2982 81 1 4 68 1 4 2 3 28 WH 3500 3500 0 3479 92 1 2 68 1 4 2 3 30 WH 400...

Page 12: ...quare inches as noted b All Air From Outdoors When air is supplied directly from outside of building each opening shall have a minimum net free square inches as noted CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater Measures must be taken to prevent the entry of corrosive chemical fumes to the combustion and ventilation air supply Such chemica...

Page 13: ...l 0133 1 Remove the front 4 screws 2 Line up outdoor top vent opening over heater vent opening 3 Lower outdoor top onto unit lining up slots in the outdoor top with screws holes in jacket top 4 Reinstall 5 screws to secure jacket top and out door top to unit Fig 4 Outdoor Top Installation Models 0181 0401 and 0182 0400 Vent Terminal Outdoor Stackless Top Installation 1 Insert tabs into keyhole 4 p...

Page 14: ...n the following page 1 Shut off main electrical power switch to heater 2 Turn heater manual ON OFF switch located in upper control panel to the OFF position 3 Shut off gas supply and water supply to the heater 4 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 5 Remove plastic plu...

Page 15: ...15 Fig 9 Indoor Top Installation ...

Page 16: ...hreads 7 Turn the assembled stack and jacket top right side up The jacket top will be trapped between the brackets and the top of the stack Place the stack over the inner adapter panel flanged hole and lower the louvered jacket top panel back into its original position Reinstall the four 4 green 10 flathead screws removed in step 1 above DRAFTHOOD JACKET TOP PANEL part of the heater 10 SHEET METAL...

Page 17: ...rest on heater drafthood Support must be provided in compliance with applicable codes The heater top and drafthood must be readily removable for maintenance and inspection Vent pipe should be adequately sup ported to maintain proper clearances from combustible construction Type B double wall or equivalent vent pipe is recommended However single wall metal vent pipe may be used as specified in the ...

Page 18: ...such as an explosion or carbon monoxide poisoning could result Make certain that it is mounted in an accessible location at least 6 in from any combustible material or the heat exchanger and that the position indicator is in a visible location The vent damper must be installed after the appliance drafthood as close to the drafthood as practicable and without modification of the drafthood Mounting ...

Page 19: ...CARBON MONOXIDE POISONING COULD RESULT Vent Damper For safe efficient operation the vent damper and all flue product carrying areas of the appliance must be checked annually with particular attention given to deterioration from corrosion or other sources Check vent damper operation as follows 1 When the heater is off check that the vent damper position indicator points to the closed position Fig 1...

Page 20: ...ed from the gas supply during any pressure testing of that system at test pressures in excess of 1 2 PSIG 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 The heater and its gas connections shall be leak tested...

Page 21: ...60 0330 0331 15 25 35 85 150 380 360 0400 0401 15 25 60 100 260 250 0 0 5 0 6 3 0 3 1 0 5 1 5 6 5 3 5 1 0 1 4 1 5 0 0 4 3 0 5 2 5 9 0 0 1 5 4 5 2 0 1 4 2 6 0 0 0 6 0 6 2 0 8 1 5 7 0 8 5 3 0 2 4 2 7 0 0 0 5 0 8 4 5 8 1 0 3 1 5 5 0 6 5 2 5 1 4 2 8 0 0926 0962 15 20 45 45 110 150 360 400 1083 1125 10 15 35 35 80 120 300 300 1178 1223 25 25 60 85 220 200 1287 1336 25 20 55 75 180 170 325 560 1414 1468...

Page 22: ...9 2 1 2 200 11 11 7 90 24 2 5 3 1414 90 26 14 58 40 5 8 2 1 2 200 12 12 2 90 26 2 7 3 1468 90 27 14 60 40 6 2 2 1 2 200 12 12 2 90 27 2 7 3 1571 90 29 14 5 64 40 7 3 2 1 2 200 13 13 90 29 2 8 3 1631 90 30 14 5 67 40 8 1 2 1 2 200 13 13 90 30 2 8 3 1758 90 32 15 4 72 40 9 7 2 1 2 200 14 14 7 90 32 3 3 1826 90 33 15 4 75 40 10 6 2 1 2 200 15 14 7 90 33 3 3 2100 200 17 14 8 90 38 3 2 3 400 9 18 180 1...

Page 23: ... 0 4 Grains Per Gallon 5 15 Grains Per Gallo 1 n 6 Over Grains Per Gallon WATER HARDNESS MODELS D R A H M U I D E M T F O S Table I 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 Piping Domestic Hot Water Supply Heaters Table I above ...

Page 24: ...24 0 0133 0181 0401 0514 0824 0926 1826 Piping Diagram Type WH Unitemp 80 System ...

Page 25: ...n be re adjusted in the field The second version is a fully enclosed solid state TDR with a white jumper that selects one of two time delays See Fig 21 B If the jumper is on pins 6 and 7 default the delay time is 5 minutes If the jumper is not on pins 6 and 7 the time delay is 10 minutes In a conventional system when the Aquastat is satis fied the main gas valve closes but the pump continues opera...

Page 26: ...odels 0724 1336 Fig 24 Motorized Gas Valve Location Model 3001 Limit Controls 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 Maximum set ting is 200 F other options may be available Flow Switch This dual purpose control shuts off the heater in case of pump failure or low water condition and...

Page 27: ...n 24 Volts are supplied to this connection through the heater transformer DO NOT attach line voltage to the TH leads on models 0514 1826 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 NOTES 1 Field install ground wire to inside of junction box 2 If any of the original wire sup...

Page 28: ...28 Location of Controls 0400 WH1 WH2 WH3 0181 LOW NOx WH1 ...

Page 29: ...29 Location of Controls 0824 ...

Page 30: ...or Many pumps are now direct drive They have no cou 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 Check pump motor for type before adding oil Clean dust and lint from pump and motor Check pump coupler and tighten if necessary Flush system before putting into operation to ensure that forei...

Page 31: ...c 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 5 Remove heater door panel 6 For Robertshaw gas valve Turn gas control knob clockwise to OFF For Honeywell Gas Valve Turn gas control knob clock wise to OFF Make sure knob rests against stop For Honeywell Gas Valve Model 400 only Push in gas contr...

Page 32: ...e Pilot burner should ignite after gas reach es the pilot burner b Spark ignition should cut off when pilot flame is established c Main gas valve should open and main burner should ignite after gas reaches the burner port INSPECTION PROCEDURES Burners Clean main burners and air louvers free of dust lint and debris Keep heater area clear and free from com bustibles and flammable liquids Do not obst...

Page 33: ...ds Should be checked monthly Takes approximately 15 minutes ADDENDA LOW NOx HEATERS MODELS 0181 TO 0401 The Raytherm Low NOx Heater is offered with WH1 On Off firing standard or 2 stage firing optional The heaters are certified and tested under the latest edition of the ANSI Z21 10 3 CSA 4 3 standard for hot water heaters The heater should be installed to meet all local codes the National Fuel Gas...

Page 34: ...nd wire size and connections comply with all applicable codes High Gas Pressure Switch Pressure switch senses high pressure and automati cally shuts down burner if abnormal pressure exists Fig 34 Gas Pressure Switch Burner Tray Removal 1 Shut off main electrical power switch to heater 2 Shut off gas upstream of heater 3 Remove front door 4 Disconnect gas line from gas valve 5 Remove 2 screws that ...

Page 35: ...ners up and out of their slots 6 Reverse above procedure to re install Pilot Removal 1 Disconnect pilot tubing from gas valve 2 Remove 4 screws from control box Open the control box 3 Remove the pilot wire from the ignition wire 4 Remove 2 screws that mount the pilot bracket to the air manifold assembly 5 Pull the pilot bracket downwards and outwards 6 Reverse above procedure to re install Fig 36 ...

Page 36: ...lace module Check for 24 Vac across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control If okay replace gas valve or gas control operator i e pilot gas valve flow switch etc NOTE IF S8600H goes into lockout reset system Check continuity of ignition cable and ground wire NOTE If ground is poor or erratic shutdowns may occur occasionally even t...

Page 37: ... Check the circuit breaker outdoor con troller etc upstream of heater If power to Leads L1 and L2 of trans former but no power on 24V side re place Jumper thermostat replace with new if heater fires If power to toggle switch but not through switch replace If power to relay but not operating re place Open valve Loosen bleed line and clean Replace coupler Inspect bearing as sembly and if frozen lubr...

Page 38: ...38 WIRING DIAGRAMS Wiring Diagram WH2 0181 0261 ...

Page 39: ...39 Wiring Diagram WH2 0331 0401 ...

Page 40: ...40 Wiring Diagram WH2 0514 0724 ...

Page 41: ...41 Wiring Diagram WH2 0824 1826 ...

Page 42: ...42 Wiring Diagram WH2 2100 2500 ...

Page 43: ...43 Wiring Diagram WH2 3001 4001 ...

Page 44: ...Excessive suction lift or vapor binding hot water 3 Bent shaft and or damaged bearings 4 Suction and discharge piping not properly support ed and anchored SERVICE AND MAINTENANCE PROCEDURES Tube Cleaning Establish a regular inspection schedule the frequency depending on the local water condition and severity of service Do not let the tubes clog up solidly Clean out deposits over 1 16 in thickness ...

Page 45: ... clean run either copper wire or wood through ori fice Do not enlarge hole To remove orifice use a socket wrench and remove the manifold DO NOT overtighten when reinstalling Pilot Removal and Cleaning 1 Disconnect pilot tubing at pilot and sensor igniter wire Remove screws holding pilot bracket to burn er tray 2 Remove pilot and bracket clean pilot of debris small bugs etc with wire or small brush...

Page 46: ...per ates immediately on the call for heat The system is ready for operation 12 Within two 2 days of start up recheck all air vents and expansion tank levels Fig 39 Typical Heat Exchanger Configuration Combustion Chamber Removal To remove combustion chamber refractory you must first have removed the heat exchanger Unbolt metal combustion chamber retainer from top and remove refractory panels indivi...

Page 47: ...l form from wet refractory This is normal 6 Identify and correct reason for soot formation REPLACEMENT PARTS See separate parts sheet in instruction envelope 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 determi...

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Page 49: ...plicable warranty conditions satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts manufactured by others but Raypak will apply any such warranty as may be provided by the parts manufacturers TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit...

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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 ...