INSTALLATION & OPERATING
INSTRUCTIONS
Econopak
Water
Heaters
Models 0260–0401
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.
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. 3000.51F
Effective: 04-08-09
Replaces: 03-25-08
P/N 240726 Rev. 7
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CONTENTS
WARNINGS
Pay Attention to These Terms
GENERAL SAFETY
Time/Temperature Relationships in Scalds 5 Controls
RECEIVING EQUIPMENT
GENERAL
SPECIFICATIONS
INSTALLATION
Code Requirements
Mounting Base
Clearances
4 SERVICING PROCEDURES
22
22
22
26
28
30
32
33
4
5
Sequence of Operation
Start-up Procedures
6
Repair Section
TROUBLESHOOTING
Electrical (Electronic Ignition IID)
Electrical (Standing Pilot)
6
8
8 ADJUSTMENTS & REPLACEMENT
8 OF COMPONENTS
8 WARRANTY
34
36
Combustion & Ventilation Air
Venting Connections
Gas Supply Connections
Water Connections & System Piping
Electrical Wiring
8
9
13
14
16
17
Wiring Diagrams
3
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WARNINGS—Pay Attention to These Terms
Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
DANGER:
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.
Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
NOTE:
DANGER: Failure to install the draft hood and
properly vent the water heater to the outdoors as
outlined in the Venting section of this manual can
result in unsafe operation of the water heater. To
avoid the risk of fire, explosion, or asphyxiation from
carbon monoxide, never operate this water heater
unless it is properly vented and has an adequate air
supply for proper operation. Be sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the
Maintenance section of this manual for more
information regarding vent system inspections.
WARNING: Gasoline, as well as other flammable
materials and liquids (adhesives, solvents, etc.), and
the vapors they produce, are extremely dangerous.
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. Failure to do so can
result in property damage, bodily injury, or death.
WARNING: LP appliances should not be installed
below-grade (for example, in a basement) if such
installation is prohibited by federal, state and/or local
laws, rules, regulations or customs.
DANGER: Water heaters utilizing Liquefied
Petroleum gas (LP) are different from natural gas
models. A natural gas heater will not function safely
on LP gas and vice versa. Conversion from Natural
gas to LP gas (or vice versa) must be done 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: LIQUEFIED PETROLEUM MODELS:
Propane, or LP gas, must be used with great
caution.
Vapors from
Water heater has a main
flammable liquids will
burner and pilot flame.
explode and catch fire
The pilot flame:
causing death or severe
1. is on all the time and
• It is heavier than air and will collect first in lower
areas making it hard to detect at nose level.
• Make sure to look and smell for LP leaks before
attempting to light appliance. Use a soapy solution to
check all gas fittings and connections. Bubbling at a
connection indicates a leak that must be corrected.
When smelling to detect an LP leak, be sure to sniff
near the floor too.
burns.
2. will ignite flammable
vapors.
Do not use or store flammable
products such as gasoline
solvents or adhesives in the
same room or area near the
water heater.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the
floor,
Keep flammable products:
1. far away from heater,
2. in approved containers,
3. tightly closed and
4. can be carried from other
room to the pilot flame by
their currents.
4. out of childrenʼs reach.
• Gas detectors are recommended in LP applications
and their installation should be in accordance with
the manufacturer's recommendations and/or local
laws, rules, regulations or customs.
• It is recommended that more than one method be
used to detect leaks in LP applications.
Installation:
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.
Do not install water heater
where flammable products
will be stored or used unless
the main burner and pilot flames
Read and follow water heater warnings and instructions. If owners
manual is missing, contact the retailer or manufacturer.
4
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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.
GENERAL SAFETY
To meet commercial hot water requirements, the tank-
stat 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 gen-
eral purpose hot water.
Temperature
120°F
Time to Produce Serious Burn
More than 5 minutes
1-1/2 to 2 minutes
125°F
Safety and energy conservation are factors to be con-
sidered when setting the water temperature on the
tankstat. The most energy efficient operation will result
when the temperature setting is the lowest that satis-
fies the needs consistent with the application.
130°F
About 30 seconds
135°F
About 10 seconds
140°F
Less than 5 seconds
Less than 3 seconds
About 1-1/2 seconds
About 1 second
145°F
150°F
155°F
Table courtesy of Shriners Burn Institute.
Table A: Time to Produce Serious Burn
Time/Temperature
Relationships in Scalds
The temperature of the water in the storage tank can
be regulated by setting the temperature dial on front of
the tankstat. To comply with safety regulations, the
tankstat was set at its lowest setting before shipment
from the factory.
Water temperature over 125°F can
causeinstantsevereburnsordeath
from scalds.
Fig. 1 illustrates the tankstat. To adjust the water tem-
perature, insert a small straight screwdriver into slotted
screw in hole in front of tankstat and turn wheel to
desired setting. Thermostat is adjustable up to 190°F.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before set-
ting temperature at water heater.
Feel water before bathing or show-
ering.
Temperature limiting valves are
available, see manual.
Maximum water temperatures occur just after burner
has shut off. To find hot water temperature being deliv-
ered, turn on a hot water faucet and place a
thermometer in the hot water stream and read the
thermometer.
Fig. 1: Tankstat Adjustment
5
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warranty conditions, you must also specify date of
installation.
DANGER: There is a Hot Water SCALD Potential if
the tankstat is set too high.
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 representa-
tive.
CAUTION: Hotter water increases the risk of
SCALDING!
NOTE: When this heater is supplying general
purpose hot water requirements for use by
individuals, a thermostatically controlled mixing
valve for reducing point of use water temperature is
recommended to reduce the risk of scald injury.
Contact a licensed plumber or the local plumbing
authority for further information.
GENERAL
SPECIFICATIONS
The Raypak water heaters are design certified by the
and tested under the requirements of the American
National Standard, ANSI Z21.10.3. 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.
RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, it is suggested that a note be made
on the Bill of Lading when signing for equipment.
Remove the heater from the carton and if it is dam-
aged report the damage to the carrier immediately. Be
sure that you receive the number of packages indicat-
ed on the Bill of Lading. Claims for shortages and
damages must be filed with carrier by consignee.
These heaters are designed for indoor and outdoor
installations, and can be installed on combustible floor-
ing when the appropriate listed floor shield base is
used.
Models are available with standing pilot or with inter-
mittent ignition device (IID), and are equipped with the
following components as standard: water circulation
pump, pressure relief valve, manual reset high limit
switch, flow switch, vent thermal and flame roll-out
switches (except for models 330 and 400), a solid
state Economaster pump control relay, 40VA trans-
former, and redundant combination gas valve for use
with either Natural or Propane gases. A tankstat is
supplied loose for installation in the field.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defec-
tive replacement parts will not be accepted and
defective parts will be replaced in kind only per our
standard warranties.
When ordering parts, you must specify Model and
Serial Number of the heater. When ordering under
Piping
Dimensions (in.)***
Connections
Recovery
Model
No.
Input
(MBH)
Tank
(Gal)**
(gph)
H
G
Indoor*
A
C
J
K
(NPT) (NPT)
0260/0261
0330/0331
0400/0401
264
334
399
262
332
396
80
80
80
1-1/2
1-1/2
1-1/2
3/4
3/4
1
22-3/8 62-7/8 11-1/8
25-3/4 63-3/4 10-3/4
29-1/4 65-3/8 12-1/2
7
8
9
*Recovery based on manufacturer's rating.
**May be used with other tank size capacity.
***Refer to Fig. 2 for dimensions.
Table B: Specifications and Dimensions
6
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A
2
11
8-1/2
6-3/4
K
J
H
40
STACKLESS
OUTDOOR TOP
C
G
UP
GAS
OUT
IN
FRONT
CONTROLS
38
21-1/4
26-1/2
ELEC
CONN
13-1/4
2-1/2
OUTDOOR
BASE
OPTIONAL
COMBUSTIBLE
FLOOR SHIELD
8
26-1/2
A
TANK
UPPER
LOWER
HEATER
Components should be placed as close as possible.
Fig. 2: Dimensions and System Component Layout
7
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Clearances
INSTALLATION
Code Requirements
Minimum Distance
from Combustible
Surfaces
Heater Side
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.
Floor
Front
Combustible*
Alcove**
12 in.
Back
Right
12 in.
Where required by the authority having jurisdiction, the
installation must conform to American Society of
Mechanical Engineers Safety Code for Controls and
Safety Devices for Automatically Fired Heaters, CSD-
1.
Left
12 in.
Top (Indoor)
Top (Outdoor)
Flue Vent
39 in.
Unobstructed
6 in.
Mounting Base
*Except for carpeted flooring, heaters are certified for installation on
combustible floors, when equipped with listed floor shield base.
**A front clearance of at least 24 in. is recommended for adequate
service of burner-tray and controls.
This heater should be mounted on a level, non-com-
bustible surface. Heater must not be installed on
carpeting. This heater can be installed on a com-
bustible surface only when the appropriate listed floor
shield base is provided. An optional listed floor shield
base is available for factory installation with the heater
on all indoor models.
Table C: Minimum Clearances from Combustible
Surfaces
Combustion & Ventilation Air
(Indoor models only)
NOTE: The heater should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.
WARNING: Air supply to the heater room must not
be affected by mechanical exhaust vents located in
other parts of the house, such as kitchen or
bathroom fans, or attic blowers. Mechanical exhaust
vents may create a negative pressure condition in
the heater room that can become a hazard of
asphyxiation, explosion or fire.
In addition, the heater shall be installed such that the
gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement, control
replacement, etc.).
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
chemicals include, but are not limited to, chlorinated
and/or fluorinated hydrocarbons such as found in
refrigerants, aerosol propellants, dry-cleaning fluids,
degreasers, and paint removers. Other harmful
elements may come from bleaches, air fresheners,
or mastics. Vapors from these types of products can
form corrosive acid compounds when burned in a
gas flame. The resulting acid condensate can
damage or substantially reduce the life of the heater.
It may be necessary to provide outside air directly to
the heater in order to avoid this problem.
8
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1. The heater must be provided with adequate sup-
ply of air for proper combustion and ventilation in
accordance with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, or applicable provi-
sions of the local building codes.
sure. If horizontal ducts are used, the area must
be doubled and the duct area shall not be less
than the area of the openings they connect, and in
no case shall the smallest dimension be less than
3 inches.
2. When the heater is installed in a confined space
where all air is supplied from inside the building,
the heater room must be provided with TWO
openings, each one having a minimum net free
area, in square inches as shown in Table D.
Outdoor Models
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 heater installed under overhangs with the use
of gutters.
Model No.
0260/0261
0330/0331
0400/0401
Sq. in. of Each Free Area
264
334
399
The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, win-
dow or gravity inlet to a building. The top surface of the
heater shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet hor-
izontally.
Table D: Minimum Net Free Area
One opening shall be within 12 inches of the top,
and the other opening within 12 inches of the floor.
If additional gas appliances are installed in the
same space, the total input of all gas appliances
installed in the same space, must be considered in
the calculation. Refer to Sec. 5.3.5 of the latest
edition of the National Fuel Gas Code for addition-
al requirements.
In areas where high winds are frequent, it may be nec-
essary to locate the heater a minimum of three (3) feet
from high vertical walls, or install a wind break so the
heater is not in direct wind current.
Venting Connections
NOTE: If louvers, grills or screens are used on the
openings, obtain the net free area from their supplier
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
shown in the National Fuel Gas Code.
Outdoor Models
Outdoor vent top is shipped separately and must be
installed on site.
Models 0260–0401
1. Insert screw retainer clip over mounting flange, (4
places).
3. If the heater room is located against an outside
wall and air openings can communicate directly
with the outdoors, the TWO openings on the out
side wall must each have a net free area, in
square inches as shown in Table E.
Model No.
0260/0261
0330/0331
0400/0401
Sq. in. of Each Free Area
66
84
Fig. 3: Location of Mounting Clips
100
Table E: Minimum Net Free Area
Location of the openings is the same as in the pre-
vious case - that is, within 12 inches of the top,
and within 12 inches of the bottom of the enclo-
9
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2. Attach mounting angles to heater jacket with 1/2"
sheet metal screws, (4 places).
TEMPERATURE
SENSOR
MOUNTING
SCREWS (2)
CONNECT ONE
VENT SENSOR
WIRE TO THE
HARNESS
ASSEMBLY
HIGH LIMIT WIRE
CONNECT ONE
VENT SENSOR
WIRE TO THE
ROLL-OUT
SENSOR WIRE
WIRE FROM
TRANSFORMER
ROLL-OUT
SENSOR
Fig. 4: Location of Mounting Angles
Fig. 6: Mounting Flue Sensor
3. Lower outdoor top to heater and secure with 1"
sheet metal screws.
4. Remove door and locate wire from roll out sensor
to Hi Limit with the male/female connector.
WIRE FROM TRANSFORMER
MALE/FEMALE
WIRE TERMINAL
WIRE FROM HIGH LIMIT
ROLL OUT SENSOR
Fig. 5: Long Side of Mounting Angle Located as Shown
Fig. 7: Before Installation of Drafthood
Indoor Models
WIRE FROM TRANSFORMER
CONNECT ONE VENT SENSOR WIRE
TO HIGH LIMIT WIRE
The drafthood is shipped separately and must be
installed on the heater.
CONNECT ONE VENT SENSOR WIRE
TO ROLL OUT SENSOR WIRE
Models 0260 & 0261
ROLL OUT SENSOR
1. Mount drafthood on top of heater and attach with
the 4 sheet metal screws provided. Drafthood
should be positioned with the vent sensor located
on the front left side as shown.
2. Remove plastic plug from left side of heater jacket
and install plastic grommet provided.
Fig. 8: After Installation of Drafthood
3. Route flue sensor wire harness through the grom-
met installed in Step 2.
5. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.
10
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Models 0330, 0331, 0400 & 0401
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 Terminal/Indoor Stack Installation
1. Remove the louvered jacket top by removing four
(4) #10 flat head screws.
Vent piping the same size or larger than the draft hood
outlet is recommended, however, when the total vent
height is at least ten (10) feet (draft hood relief open-
ing to vent terminal), the vent pipe size may be
reduced as specified in the National Fuel Gas Code,
ANSI Z 223.1. As much as possible avoid long hori-
zontal runs of vent pipe and too many elbows.
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.
If installation requires horizontal runs, the vent pipe
must have a minimum of 1/4 inch per foot rise and
should be supported at not more than five foot inter-
vals. Plumbers tape, crisscrossed, will serve to space
both horizontal and vertical piping. Maximum vent con-
nector horizontal length shall be 1-1/2 feet (18 inches)
for each inch of connector diameter as shown in Table
F.
4. Turn the stack (draft hood) up side down and set it
down bottom side up.
5. Turn the jacket top panel (removed in Step 1) up
side down and place it through the stack.
6. Attach the three (3) mounting brackets to the stack
using the screws provided and the holes that are
pre-drilled in the stack. Make sure the brackets are
positioned with the flange near the top side of the
stack (see Fig. 9). Caution must be taken not to
over tighten and strip the screw threads.
Vent
Max.
Horizontal
Length (ft)
Model No.
Connector
Diameter (in.)
0260/0261
0330/0331
0400/0401
7
8
9
12
13.5
15
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
flat head screws removed in Step 1 above.
Table F: Vent Piping Specifications
Gas vents supported only by the flashing and extend-
ing above the roof more than five feet should be
securely guyed or braced to withstand snow and wind
loads. We recommend use of insulated vent pipe
spacer through the roofs and walls.
DRAFTHOOD
JACKET TOP PANEL
SCREW HOLE
LOCATION
(part of the heater)
For protection against rain or blockage by snow, the
vent pipe must terminate with a listed vent cap which
complies with the local codes or, in the absence of
such codes, to the latest edition of the National Fuel
Gas Code, ANSI Z223.1.
#10 SHEET METAL SCREW (3)
MOUNTING BRACKET (3)
4-3/4"
INNER STACK ADAPTER PANEL
FLUE COLLECTOR
(part of heater)
The discharge opening must be a minimum of two feet
vertically from the roof surface and at least two(2) feet
higher than any part of the building within ten (10) feet.
Vent stack shall be at least five (5) feet in vertical
height above the drafthood outlet. The vent cap loca-
tion shall have a minimum clearance of four (4) feet
horizontally from, and in no case above or below,
unless a 4-foot horizontal distance is maintained, from
electric meters, gas meters regulators and relief equip-
ment.
COMBUSTIBLE FLOOR SHIELD
(optional for indoor)
2-1/2"
Fig. 9: Vent Terminal/Indoor Stack Installation
11
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The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction.
Common Vents
Manifolds that connect more than one heater to a com-
mon chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
manifold and the chimney. At no time should the area
be less than the area of the largest outlet.
Type "B" double wall or equivalent vent pipe is recom-
mended. However single wall metal vent pipe may be
used as specified in the latest edition of the National
Flue Gas Code ANSI Z223.1.
10' OR LESS
VENT CAP
2' MIN
2' MIN
Drafthood
Heater
5' MIN
VENT PIPE
Fig. 11: Common Venting
DRAFT HOOD
At the time of removal of an existing heater, the follow-
ing steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain-
ing connected to the common venting system are not
in operation.
HEATER
(a) Seal any unused openings in the common venting
system.
Fig. 10: Venting Minimum Clearances
(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.
WARNING: These heaters must not be connected
into any portion of mechanical draft systems
operating under positive pressure. To do so may
cause the flue products to be discharged into the
living space causing serious health injury.
(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 com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will oper-
For connections to gas vents or chimneys, vent instal-
lations shall be in accordance with Part 7, Venting of
Equipment, of the National Fuel Gas Code, ANSI
Z223.1, or applicable provisions of the local building
codes.
12
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ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust tankstat so
appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga-
rette, cigar or pipe to visually check spillage.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem properly vents when tested as outlined above,
return doors, windows, exhaust fans, fireplace
dampers and any other gas burning appliance to
their previous conditions of use.
SUPPLIED BY
INSTALLER
Fig. 12: Sediment Trap
(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 com-
mon 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.
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 (3.45 kPa). 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 before placing the
appliance in operation. Use soapy water for leak test
DO NOT use open flame.
Gas Supply Connections
The inlet gas connection to the heater gas valve is
3/4" for models 260/261 and 330/331; and 1" for mod-
els 400/401. Provide an adequate gas supply line
according to Table G below.
NOTE: Do not use teflon tape on gas line pipe
thread. A flexible sealant suitable for use with Natural
and Propane gases is recommended.
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. All gas piping should be
tested after installation in accordance with local codes.
3/4 in.
Pro
1 in.
1-1/4 in.
1-1/2 in.
Nat Pro
Model No.
Nat
20
Nat
60
Pro
140
85
Nat
Pro
560
380
260
0260/0261
0330/0331
0400/0401
40
25
15
250
150
100
15
35
360
250
25
60
Natural gas, 1000 BTUH/ft .60 specific gravity @ 0.5 in. WC pressure drop.
Propane gas, 2500 BTUH/ft 1.53 specific gravity @ 0.6 in. WC pressure drop.
Table G: Maximum Equivalent Pipe Length (ft)
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Gas Pressure Specifications
The gas pressure regulator is preset and sealed at 4
in. WC for natural gas, and 11 in. WC for propane gas.
Between the gas valve and the burners is a 1/8 in. pipe
plug. The pressure at this point, taken with a manome-
ter, should be about 3.7 in. WC natural gas and 10.5
in. WC propane gas. Lo NOx models should be 3.9 in.
WC natural gas only. If an adjustment is needed,
remove seal and turn adjustment screw clockwise to
increase pressure or counter-clockwise to decrease
pressure.
Inches WC
Type of
Gas
Regulator
Setting
Min.
Max.*
10.5
Natural
7.0
4.0
Propane
12.0
13.0
11.0
*Do not exceed maximum inlet gas pressure. The minimum value
shown is for input adjustment.
Table H: Gas Pressure Specifications
Water Connections & System
Piping
Gas Pressure Regulator
The pipe size and fittings between the heater and the
tank should be at least 1-1/2" for all models. The tank
should be located as close to the heater as possible,
as shown in Fig. 13 below.
The gas valve is provided with pressure taps to meas-
ure gas pressure upstream of the gas valve and
downstream which is the same as the manifold pres-
sure.
Fig. 13: Heater with Storage Tank
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If this water heater is installed in a closed water supply Valves and Automatic Gas Shut Off Devices for Hot
system, such as one having a back-flow preventer in Water Supply Systems, ANSI Z21.22, must be
the cold water supply line, means shall be provided to installed in the opening provided on top of the storage
control thermal expansion. Contact the water supplier tank, at the time of installation. No valve is to be placed
or local plumbing inspector on how to control this situ- between the relief valve and the storage tank.
ation.
The pressure rating of the relief valve must not exceed
When this water heater system is supplying general the 160 maximum working pressure indicated on the
purpose hot water requirements for use by individuals, water heater rating plate. The BTUH rating of the relief
a thermostatically controlled mixing valve is recom- valve must not be less than the BTUH input of the
mended to reduce the risk of scald injury. Contact a heater.
licensed plumber or the local plumbing authority for
further information.
Connect the outlet of the relief valve to a suitable open
drain. The discharge line must pitch downward from
Thermometer(s) should be installed so that they indi- the valve to allow complete draining (by gravity) of the
cate the water temperature at or near the outlet of the relief valve and discharge line. The discharge line
storage tank.
should be no smaller than the outlet of the valve. The
end of the discharge line should not be threaded or
concealed, and should be protected from freezing. No
valve of any type, restriction or reducer coupling,
should be installed in the discharge line. Local codes
shall govern installation of relief valve.
Relief Valve
A new combination temperature and pressure (T & P)
relief valve, complying with the Standard for Relief
RATING PLATE
ON/OFF
PRV
FLOW SWITCH
SWITCH
ELECTRICAL
CONTROLS
LOCATION
INLET/OUTLET
WATER
CONNECTIONS
HIGH LIMITS
OPTIONAL
PUMP
COMBINATION
GAS VALVE
PILOT LOCATION
Fig. 14: 0261 Low NOx WH1 with Pressure Relief Valve
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Electrical Wiring
NOTE: Minimum 18 AWG, 105°C, stranded wire
must be used for all low voltage (less than 30 volts)
external connections to the unit. Solid conductors
should not be used because they can cause
excessive tension on contact points. Install conduit
as appropriate. All high voltage wires must be the
same size (105°C, stranded wire) as the ones on the
unit or larger.
The electrical power supply requirement for these
heaters is 120 volts, 60 Hz. Field wiring connections
and electrical grounding must comply with the local
codes, or in the absence of local codes, with the latest
edition of the National Electrical Code, ANSI/NFPA 70.
Provide a separate fused circuit from the main electri-
cal panel to the heater, and a disconnecting means
within sight of the heater.
NOTE: If it is necessary to replace any of the
original wiring, it must be replaced with 105°C wire or
its equivalent, except 150° black wire which must be
replaced with 150° wire or its equivalent.
Remove the control box cover and make the power
supply connections in the field wiring compartment.
The pump is supplied and factory wired to operate with
the heater. The current draw is approximately 2.0
amps. Refer to the heater internal wiring diagrams
shown on pages 17 to 21.
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Wiring Diagrams
(FIELD INSTALLED)
Fig. 15: Standing Pilot Model 0260
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Fig. 16: Intermittent Ignition Device (IID) Model 0260
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Fig. 17: Intermittent Ignition Device (IID) Models 0330 & 0400
19
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Fig. 18: Intermittent Ignition Device (IID) Model 0261 Low NOx
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Fig. 19: Intermittent Ignition Device (IID) Models 0331 & 0401 Low NOx
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Checking the Circulator
SERVICING
PROCEDURES
Before lighting the heater and after system is filled,
make sure that circulator is operating properly. Manual
gas valve should be off.
Sequence of Operation
NOTE: Circulator motor supplied with the heater
does not require lubrication.
Intermittent Ignition Device (IID)
Heaters equipped with the IID system will automatical-
ly light the pilot burner first and then the main burner,
each time there is a call for heat from the tankstat.
Whenever the tankstat calling for heat, the circulator
supplied with the heater, will be energized and should
be running.
Lighting the Heater
For your safety read carefully before proceeding to
light the heater.
CAUTION: Propane gas is heavier than air and
sinks to the ground. Exercise extreme care in light-
ing heater in confined areas.
The ignition control module will also be energized to
initiate the pilot ignition by opening the first main valve
(pilot). At the same time, the electronic spark genera-
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.
For Standing Pilot Models
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing prop-
erty damage, personal injury or loss of life.
A. This heater has a pilot which must be lighted by
hand. When lighting the pilot, follow these instruc-
tions exactly.
Then, the module goes into safety shutdown or lock-
out. Lockout de-energizes the first main valve operator
and closes the first main (pilot) valve in the gas con-
trol, stopping pilot gas flow. The ignition control system
must be reset by setting the tankstat below water tem-
perature for one minute or by turning off power to the
module for one minute.
B. BEFORE LIGHTING smell all around the heater
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will set-
tle on the floor.
When the pilot flame is established, flame rectification
circuit is completed between the sensor and burner
ground. The flame sensing circuit in the module
detects the flame current, shuts off the spark genera-
tor and energizes the second main valve operator
which opens the second main valve. This allows gas to
flow to the burners where it is ignited by the pilot burn-
er flame.
WHAT TO DO IF YOU SMELL GAS
•
•
•
•
Do not try to light any appliance.
Do not touch any electric switch.
Do not use any phone in your building.
Immediately call your gas supplier from a neigh-
bor's telephone. Follow the gas supplier's
instructions.
•
If you cannot reach your gas supplier, call the fire
department.
When the tankstat is satisfied, the valve operators are
de-energized shutting off the pilot and main burners,
and also the circulator.
C. Use only your hand to push in, move or turn the
gas control knob or lever. Never use tools. If the
knob or lever will not push in, move or turn by
hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.
Start-up Procedures
Filling the System
D. Do not use this heater if any part has been under
water. Immediately call a qualified service techni-
cian to inspect the heater and to replace any part
of the control system and any gas control which
has been under water.
Fill system with water. Purge all air from the system
using purge valve sequence. After system is purged of
air, lower system pressure. Flush system before put-
ting into operation to ensure that foreign material does
not damage pump seals.
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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.
For Standing Pilot Model with
Robertshaw Gas Valve, On/Off
Operation
1. STOP! Read the safety information above.
2. Set the tankstat on the lowest setting.
3. Turn OFF all electric power to the heater.
4. Remove heater door panel.
*
If knob 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.
5. Push in gas control knob slightly and turn clock-
*
wise
to "OFF".
10. Stand to the side of the heater and turn the gas
control knob counter-clockwise
11. Replace heater door.
to "ON".
GASCONTROL
KNOBSHOWN
IN"OFF"POSITION
12. Turn "ON" all electrical power to the heater.
13. Set the tankstat to the desired setting.
GASINLET
For Standing Pilot Model with
Honeywell Gas Valve, On/Off
Operation
Fig. 20: Robertshaw Gas Valve
1. STOP! Read the safety information.
2. Set the tankstat to the lowest setting.
3. Turn Off all electrical power to the heater.
4. Remove heater door panel.
NOTE: Knob cannot be turned from "PILOT" to
"OFF" unless knob is pushed in slightly. Do not force.
5. Turn gas control knob clockwise
to "OFF".
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If your smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to
the next step.
GASCONTROL
KNOBSHOWN
IN"OFF"
7. Locate pilot mounted on the right side of the burn- POSITION
er drawer, right of first burner.
GASINLET
8. Turn knob on gas control counter-clockwise
to "Pilot".
Fig. 22: Honeywell Gas Valve
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above on this label. If you don't smell gas, go to
the next step.
7. Locate pilot mounted on the right side of the burn-
er drawer, right of first burner.
8. Turn knob on gas control counter-clockwise
to "PILOT".
9. Push down and hold the red reset button in, imme-
diately light the pilot with a match. Continue to hold
down red reset button for about one minute after
the pilot is lighted. Release red reset button and it
will pop back up. Pilot should remain lighted. If it
goes out, repeat steps 4 through 8.
HONEYWELLPILOT
ROBERTSHAW PILOT
Fig. 21: Honeywell and Robertshaw Pilots
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hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in
a fire or explosion.
* 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.
D. Do not use this heater if any part has been under
water. Immediately call a qualified service techni-
cian to inspect the heater and to replace any part
of the control system and any gas control which
has been under water.
10. Stand to the side of the heater and turn the gas
control knob counterclockwise
11. Replaceheaterdoor.
to "ON".
12. Turn "ON" all electrical power to the heater.
13. Set the tankstat to the desired setting.
For Intermittent Ignition (IID) with
Honeywell or Robertshaw Gas
Valve
System Shut Down Procedure
1. Set the tankstat to "OFF" or the lowest setting.
2. Turn off all electric switches to the heater.
3. Turn off all gas valves supplying gas to the heater.
Refer to operating instruction label on the heater.
4. Shut off the water supply to the heater piping sys-
tem loop.
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.
5. Open drain valve on the tank to remove water from
the heater and the piping circuits.
5. Remove heater door panel.
6. For Robertshaw Gas Valve: Turn gas control knob
For Automatic Ignition Models
clockwise
to "OFF". For Honeywell Gas
to
Valve: Turn gas control knob clockwise
Please read carefully and understand the following
safety information before operating the heater.
"OFF". Make sure knob rest against stop. For
Honeywell Gas Valve: Push in gas control knob
slightly and turn clockwise to "OFF". Knob cannot
be turned to "OFF" unless knob is pushed in slight-
ly. Do not force.
WARNING: If you do not follow these instructions
exactly, a fire or explosion may result causing prop-
erty damage, personal injury or loss of life.
7. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "b" in the safety information
previously stated. If you do not smell gas, go to the
next step.
A. This heater is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
8. For Robertshaw Gas Valve: Turn gas control
B. BEFORE OPERATING smell all around the heater
area for gas. Be sure to smell next to the floor
because some gases are heavier than air and will
settle on the floor.
knob counter-clockwise
to "ON".
WHAT TO DO IF YOU SMELL GAS:
GAS CONTROL
KNOB SHOWN
IN "ON" POSITION
•
•
•
•
Do not try to light any appliance.
Do not touch any electric switch.
Do not use any phone in your building.
Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire
department.
GASINLET
•
C. Use only your hand to push in, move or turn the
gas control knob or lever. Never use tools. If the
knob or lever will not push in, move or turn by
Fig. 23: Robertshaw Gas Valve
24
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For Honeywell Gas Valve: Turn gas control knob
counter-clockwise from “OFF” until it stops.
Push in gas control knob and continue rotating
counter-clockwise to “ON” position. Make
Testing the Ignition Safety Shut-off
The ignition system safety shutoff must be tested by
conducting the following tests:
sure knob rest against stop.
For Standing Pilot Systems
GAS CONTROL
KNOB SHOWN
IN “ON” POSITION
1. With the main burners on, remove the pilot adjust-
ment cover screw.
2. Insert a small slot screw driver and turn the adjust-
GAS INLET
ment screw clockwise
until pilot flame goes
out. Count and note number of turns made.
3. Gas valve will shut off main burners after about
three (3) minutes. End of test. If the gas valve will
not shut off, follow the instructions "To Turn Off
Gas To Heater" and call service technician or your
gas supplier.
Fig. 24: Honeywell Gas Valve
4. Return pilot adjustment screw counterclockwise
For Honeywell Gas Valve: Turn gas control knob
same number of turns as in step (b).
5. Replace pilot adjustment cover screw, then follow
the lighting instructions to get heater ready for
operation.
counter-clockwise
to “ON”.
GAS CONTROL
KNOB SHOWN
IN “ON” POSITION
For Automatic Ignition Systems
GAS INLET
1. Turn on power to the ignition systems and turn gas
supply off at the gas valve.
2. Check ignition module as follows:
a. Set the tankstat to high setting.
b. Watch for continuous spark at the pilot burner.
c. Time the spark operation. Time must be with-
in the lockout timing period (15 or 90
seconds).
Fig. 25: Honeywell Gas Valve
9. Replace door panel.
10. Turn on all electric power to the appliance.
11. Set tankstat to desired setting.
12. If the appliance will not operate, follow the instruc-
tions “To Turn Off Gas To Appliance” and call your
service technician or gas supplier.
d. Turn tankstat down to end call for heat and
wait 60 seconds on lockout models before
beginning step 3.
3. Turn on gas supply.
4. Set tankstat to high setting.
5. Systems should start as follows:
a. Spark will turn on and pilot gas valve will open
at once. Pilot burner should ignite after gas
reaches the pilot burner.
To Turn Off Gas To Appliance
1. Set the thermostat to the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
3. Remove door panel.
4. For Robertshaw IID Gas Valve: Turn gas control
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.
knob clockwise
to “OFF”.
For Honeywell Gas Valve: Turn gas control knob
clockwise
to “OFF”. Make sure knob rest
against stop.
For Honeywell 24V Standing Pilot Gas Valve:
Push in gas control knob slightly and turn clock-
wise
to “OFF”.
5. Replace heater door panel.
25
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Inspection Procedures
Controls
Burners
Check all controls to see that they are operational. To
check electronic safety (IID Models) , turn off main
burner. Observe pilot burner when shutting off pilot
gas. Ignition spark should go on. Main gas valve will
also drop out.
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com-
bustibles and flammable liquids. Do not obstruct the
flow of combustion and ventilating air. Make visual
check of burner and pilot flame. Yellow flame indicates
clogging of air openings. Lifting or blowing flame indi-
cates excess high gas pressure. Low flame indicates
low gas pressure.
High Limit Switch - to check high limit switch, turn dial
setting down to a point slightly below the temperature
of the water leaving the heater. The reset button
should snap out and the burner should shut off. Reset
dial to 30°F to 40°F above desired operating tempera-
ture, and push reset button. Burner should light.
Low NOx Heaters—Models 261–401
The Low NOx Heater is offered as a model W1-ON-
OFF firing.
The heaters are certified and tested under the ANSI
Z21.10.3 Standards for hot water heaters.
The heater should be installed to meet all local codes,
the National Fuel Gas Code Z223.1 and with the
National Electrical Code, ANSI/NFPA 70.
Fig. 26: Typical Main Burner Flame
Fig. 27: Pilot Burner Flame (IID units)
Fig. 28: Pilot Burner Flame (STG Pilot Units)
DETAIL A
SEE DETAIL VIEW A
Fig. 29: Burner Detail
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Operation
High/Low Gas Pressure Switch
On call for heat, the ignition system, consisting of an Pressure switch senses high/low pressure and auto-
electronic spark module, gas pilot system is energized. matically shuts down burner if abnormal pressure
Providing pilot is proven blower will start running, the exists.
main gas valve will open and the heater will operate.
When the operating control is satisfied the heater will
shut down.
Start-up Procedures (S8610B)
1. Turn on power to the heater with gas supply off.
2. Check ignition module as follows:
a. Set the thermostat or controller to call for heat.
b. Watch for continuous spark at the pilot burner.
c. Check the ignition spark operation. Time must
be within the lockout timing period (15 or 90
seconds).
d. Turn control down to end call for heat and wait
60 seconds on lockout models before begin-
ning step 3.
Fig. 30: Gas Pressure Switch
3. Turn on gas supply.
4. Set controller to call for heat.
5. System should start as follows:
a. Spark will turn on and pilot gas valve will open
and the blower will begin running.
b. Heater will operate until call for heat is satis-
fied.
Burner Adjustment
This burner assembly does not require any adjust-
ments.
Visual Inspection
Flame can be observed through the slot opening
above the plenum. Flame color is blue and evenly
spread on the top surface of the burner. At least every
three months a visual inspection should be made of
the burners. In case flame lifting is observed on the
burner, check gas pressure on manifold and static
pressure in plenum. Gas pressure in manifold should
be 3.9 in. WC and static pressure in plenum should be
greater than 0.5 in. WC.
Fig. 31: Low NOx Burner Tray Assembly
Burner Drawer Removal
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
Electrical
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit,
and (4) screws that secure gas valve to jacket.
6. Disconnect wires that terminate at gas valve.
7. Unscrew (4) screws that secure the control box.
8. Disconnect pilot wire from the ignition module.
9. Disconnect wire harness from the combustion
blower.
Be sure that electrical service to the heater has over-
load fuse or circuit breaker protection, wire size and
connections that comply with all applicable codes.
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10. Carefully slide out the burner tray assembly.
11. Reverse above procedure to reinstall.
5. Pull the pilot bracket downward and outward.
6. Reverse above procedure to re-install.
Gas Valve Removal
Combustion Fan Removal
1. Shut off main electrical power switch to heater.
2. Shut off gas supply to the heater.
3. Remove front door.
1. Remove burner drawer. See burner drawer
removal procedure.
2. Remove (4) screws the mount the combustion
blower to the manifold assembly.
4. Disconnect gas line from gas valve.
5. Disconnect wires, pilot tubing and bleed line, if 3. Reverse above procedure to re-install.
required.
6. Remove (2) screws that secure gas valve to jack-
et.
Normal Inspection Procedures
7. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
First and third month after initial start up and then on
an annual basis. If problems are found, refer to
Trouble Shooting Guide for additional directions.
8. Reverse above procedure to re-install.
Main Burner And Orifice Removal
1. Remove top of heater and inspect heat exchanger
for soot and examine venting system.
1. Remove burner drawer. See burner drawer 2. Remove rear header and inspect for scale
removal procedure.
2. Remove (8) screws from the hold down brackets.
deposits.
*3. Inspect pilot and main burner flame and firing rate.
3. Remove (8) screws from the left and right sides of *4. Inspect and operate all controls and gas valve.
the Manifold assembly. Detach the manifold *5. Visually inspect system for water leaks.
assembly from the burner tray assembly.
4. Use a long 3/8” socket wrench to remove orifices
from the atmospheric gas manifold, 9/16” for Low
NOx.
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.
*6. a. Oil pump motor and bearing assembly, if oil
cups are provided.
b. Disconnect pump from header and check con-
dition of pump impeller. Check condition of
bearing by attempting to move impeller from
side to side. Replace any parts showing wear.
c. Check pump coupler for wear and vibration.
7. Check flow switch paddle (if provided).
8. Clean room air intake openings to assure ade-
quate flow of combustion and ventilation air.
CAUTION: Combustion air must not be contami-
nated by corrosive chemical fumes which can
damage the heater and void the warranty.
9. Keep heater area clear and free from combustible
materials, gasoline, and other flammable vapors
and liquids.
*Should be checked monthly. (Takes approximately
15 minutes).
Fig. 32: IID Pilot
Repair Section
Pilot Removal
Tube Cleaning Procedure (Typical)
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.
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.
28
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The heater may be cleaned from the side opposite the
water connections, without breaking pipe connections.
should be at the 1/4 mark and the balance of the
tank filled with air.
It is preferable, however, to remove both headers for 9. Install flue collector, jacket top and inspection pan-
better visibility through the tubes and to be sure the
residue does not get into the system. Generally, you
do not remove the top pan or the heat exchanger .
els. Install top holding screws. Install draft diverter
and vent piping if so equipped.
10. If gas piping was disconnected, reconnect gas pip-
ing system and check for leakage using a soap
solution.
After reaming with the auger, mount the wire brush
and clean out the debris remaining in the tubes. 11. Check for correct water pressure and water level
Another method is to remove the heat exchanger,
ream tubes and immerse heat exchanger in non-inhib-
ited de-scale solvent.
in the system. Make sure that system pump oper-
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.
Heat Exchanger Removal
Combustion Chamber Removal
1. Shut water, gas and electricity off, close valves
and relieve pressure, remove relief valve. Remove
side inspection panels.
To remove combustion chamber you must first have
removed the heat exchanger. Unbolt metal combus-
2. Remove top holding screws.
3. Remove draft diverter, lift and remove top and flue tion chamber retainer from top and remove
collector on stack type models. Remove inspec- combustion chamber panels individually.
tion panels.
4. Loosen bolts and disconnect flange nuts on inlet-
outlet header, loosen union(s) at gas pipe, and
slide heater away from piping until studs clear the
heater.
5. Remove heat exchanger corner brackets.
6. Remove combustion chamber clips at the four cor-
ners of the heat exchanger.
7. Lift heat exchanger straight up using caution not to
damage refractory.
Heat Exchanger Re-assembly
Fig. 33: Refractory Panels—Top View
1. Heat exchanger water header O-rings should be
replaced with new ones.
2. Install inlet-outlet and return water headers and
install header retainer nuts and torque nuts even-
ly.
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. Install water pressure relief valve, flow switch, and
low water cutoff devices if so equipped.
7. Open water supply and return shut-off valves. Fill
heater and water piping system with water. Check
heater and piping system for leaks at full line pres-
sure. Run system circulating pump for a minimum
of 1/2 hour with heater shut-off.
8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris. Expansion tank water level
29
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TROUBLESHOOTING
Theseinstructionsareprimarilyintendedfortheuseofqualifiedpersonnelspecificallytrainedandexperiencedinthe
installationofthistypeofheatingequipmentandrelatedsystemcomponents. Installationandservicepersonnelmay
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.
SOLUTION(S)
PROBLEM(S)
CAUSE(S)
1)Check circuit breakers, disconnect
switch. Make sure power is on.
1)When tankstat is turned on, heater
does not operate.
1)No power to the heater.
2)Check continuity on thermostat and
wiring circuit. Replace thermostat, or
repair wiring connections.
2)Defective tankstat or disconnected
wire in thermostat circuit.
3) Check secondary voltage. If no 24V,
replacetransformer.
3)Defective transformer.
1)Light pilot burner. (Follow lighting
instructions on rating plate).
2)When tankstat is calling for heat,
pump is on, but burners will not turn
on.
1)For Standing pilot models pilot burner
not lighted.
2)Check thermocouple MV generation.
If less than 25MV (open circuit), re-
place thermocouple. If between 25-
35 MV, replace gas valve.
2)If pilot burner will not stay lighted,
thermocouple or gas valve may be
defective.
3)Turn knob to "ON" position.
4) Check for blockage of venting sys
temordisconnectedventpiping. After
problem is corrected push button to
resetventswitch.
3)Gas knob in "Pilot" position.
4)Vent switch is open.
5)Check for blockage of flue or sooted
heat exchanger. After problem is
corrected push button to reset
roll-out switch.
5)Roll-out switch is open.
6)Check water flow and adjust to
obtain 8° to 10°F temperature rise.
7)On Honeywell module, check voltage
across terminals MV and MV/PV. If
no 24V is present, replace module. If
24V is present, replace gas valve.
6)Manual Reset High limit is open.
7) Defective ignition module or
defective gas valve.
30
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3)Pilot Outage.
1) Adjust inlet gas pressure as
shown on rating plate.
1) Too low or too high gas
pressures.
(Standing pilot models)
2) Restricted pilot.
3) Weak thermocouple.
2) Clean pilot orifice.
3) Replace thermocouple.
4)Yellow lazy flame.
5)Sooting
1) Too low gas pressure.
2) Restricted burner intake ports.
3) Restricted gas line.
1) Adjust manifold pressure as
shown on rating plate.
2) Clean burners free of debris or
insects.
3) Clean gas line or increase gas line
piping.
1) Insufficient combustion air.
1) Refer to installation instructions
regarding combustion air
requirements.
2) Improper venting.
2) Refer to installations instructions.
3) See yellow flame section above.
3) Severe yellow burner flames.
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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 the pilot fails
to light. To reset, interrupt power to heater.
Intermittent Pilot System—
Honeywell S8600
START
TURN GAS SUPPLY OFF.
TURNTHERMOSTAT
(CONTROLLER) TO CALL
FORHEAT
NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout
procedure.
Check line voltage power, low voltage transformer, limit controller, thermostat
(controller) and wiring.
NO
NO
POWER TO MODULE
(24 V NOMINAL)
YES
Pull ignition lead and check spark at module.
SPARKACROSS
IGNITER/SENSORGAP
YES
Spark Okay?
YES
• Check ignition cable, ground wiring, ceramic insulator and gap, and correct.
• Check boot of the ignition cable for signs of melting or buckling. Take protective
action to shield cable and boot from excessive temperatures.
TURN GAS SUPPLY ON
PILOT BURNER LIGHTS?
YES
• Check that all manual gas valves are open, supply tubing and pressures are
NO
NO
good,
and pilot burner orifice is not blocked.
• Check electrical connections between module and pilot operator on gas control.
• Check for 24 Vac across PV-MV/PV terminals on module. If voltage is okay,
replace gas control; if not, replace module.
NOTE: If S8600H goes into lockout, reset system. Lockout is used on L.P.G.
models.
SPARK STOPS WHEN
PILOT IS LIT?
YES
• Check continuity of ignition cable and ground wire.
• Clean flame rod.
• Check electrical connections between flame rod and module.
• Check for cracked ceramic flame rod insulator.
• Check that pilot flame covers flame rod and is steady and blue.
• Adjust pilot flame.
•
If problem persists, replace 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.
NO
NO
MAIN BURNER LIGHTS?
YES
NOTE: IF S8600H goes into lockout, reset system.
SYSTEM RUNS UNTIL
CALL FOR HEAT ENDS?
YES
• Check continuity of ignition cable and ground wire.
NOTE: If ground is poor or erratic, shutdowns may occur occasionally even though
operation is normal at the time of checkout.
• Check that pilot flame covers flame rod and is steady and blue.
• If checks are okay, replace module.
CALL FOR HEAT ENDS
SYSTEMSHUTSOFF?
YES
• Check for proper thermostat (controller) operation.
• Remove MV lead at module; if valve closes, recheck temperature controller and
wiring; if not, replace gas valve.
NO
TROUBLESHOOTING
Repeat procedure until troublefree operation is obtained.
ENDS
32
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Electrical (Standing Pilot)
WARNING: HIGH VOLTAGE: For qualified
technicians ONLY
STARTHEATER
IFPILOTBURNERLIGHTS
BUTMAINBURNERSDONOT
IFPILOTBURNER
DOESNOTLIGHT
CHECK FOR 24 V
AT GAS VALVE
CHECKTHERMOCOUPLE
IF NOT 24 V:
IF 24 V:
IF O.K.
IFDEFECTIVE
CHECKTRANSFORMEROUPUT
FOR 24 V
REPLACE
GAS VALVE
REPLACE
REPLACE
GAS VALVE
THERMOCOUPLE
IFNO
24V:
IF 24 V:
REPLACE
PROBLEMIN
TRANSFORMER
LIMIT
CIRCUITS
33
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2. Lift burners from slotted spacer and slide from ori-
fices. Clean with a wire brush.
3. Orifices usually do not need to be replaced. To
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
over tighten when reinstalling.
ADJUSTMENTS &
REPLACEMENT OF
COMPONENTS
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.
High Limit or Tankstat Removal
1. Turn off electrical power.
2. Remove front inspection panel.
3. Remove wires to high limit and loosen screws
holding high limit to cabinet.
DANGER: SHOCK HAZARD: Make sure electri-
cal power to the heater is disconnected to avoid
potential serious injury or damage to components.
4. Remove wedge clip holding sensing bulb in con-
trol well.
5. Remove high limit and install a new one.
6. Check control operation before leaving job.
Gas Valve Removal
1. Shut off gas supply to the heater. Remove gas pip-
ing to gas valve inlet.
Flame Roll-Out Switch Replacement
2. Disconnect wires, pilot tubing and bleed line, if
required.
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Remove screws (2) holding the switch.
4. Reverse above procedure to re-install.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Reverse above procedure to re-install.
Vent Thermal Switch Replacement
Pilot Removal and Cleaning
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Remove the screws (2).
1. Disconnect pilot tubing at pilot and sensor/igniter
wire. Remove screws holding pilot bracket to burn-
er drawer.
2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.
3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.
4. Reverse above procedure to re-install.
Ignition Module Replacement
1. Shut off electrical power to the heater.
2. Remove control cover screws and open control
compartment.
Burner Drawer Removal
3. Disconnect wiring connections to module.
4. Remove screws (2) holding module.
5. Reverse above procedure to re-install.
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.
Transformer Replacement
1. Shut off electrical power to the heater.
2. Remove control cover screws and open control
compartment.
Main Burner and Orifice Removal
1. Remove screws and burner hold down bracket.
3. Disconnect wiring connections from transformer
leads.
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.
4. Remove screws (2) holding transformer.
5. Reverse above procedure to re-install.
34
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8. Reverse drill motor and withdraw tube roller, if
necessary wrench out by hand.
Circulator Replacement
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.
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.
CAUTION: To avoid damage to electrical compo-
nents keep water from getting into the control
compartments and gas valve.
Procedure for Cleaning Flue Gas
Passage Ways
3. Disconnect wiring and conduit connections to the
pump.
4. Remove the nuts and bolts at the inlet and outlet
flanges. Remove old gaskets.
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.
5. Remove the pump.
6. Reverse the above procedure to re-install. Use
new gaskets and make sure they are seated prop-
erly when tightening the nuts and bolts.
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, mak-
ing sure soot is removed from between fins. (Avoid
excessive water against refractory).
Control Well Replacement
Remove top, sensing bulb and clip. Collapse well tube
at the open end with a chisel, push through into head-
er and remove the well through header. Insert a new 5. Reassemble; when heater is fired, some steam
well and roll into place. If a roller is not available, sol-
der the well in place with silver solder.
will form from wet refractory, which is normal.
NOTE: In extreme cases it may be necessary to
remove the heat exchanger completely for cleaning.
The simplest method is steam cleaning at a local car
wash.
Tube Replacement Procedure
1. Remove heat exchanger from heater following
instructions outlined under HEAT EXCHANGER
REMOVAL.
2. Remove inlet/outlet and return headers. Remove
"V" Baffle from damaged tube.
CAUTION: Soot is combustible. Exercise extreme
care. Do not wire brush.
3. Remove damaged tube by cutting with a hack saw
or shearing with a chisel adjacent to each tube
sheet.
Replacement Parts
4. Collapse stub ends in tube sheets using a chisel or
screwdriver. DO NOT cut into tube sheet or mar Any part returned for replacement under standard
surface in tube hole in any way.
manufacturer warranties must be properly tagged with
5. Insert replacement tube by inserting the end with a return parts tag, completely filled in with the heater
the most fins removed in the opening of one tube serial number, model number etc., and shipped to the
sheet. Slide tube until the opposite end clears the manufacturer freight prepaid.
other tube sheet and fits the tube into the hole.
6. Insert the tube roller into tube opening up to stop, If the manufacturer determines the part is defective
making certain that 1/8" of tube projects beyond and within warranty, the part will be returned in kind or
the tube sheet.
equal substitution, freight collect. Credit will not be
7. Attach drill to tube roller, holding it straight and issued.
level.
RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030
NOTE: Use a 3/8 in. heavy duty, reversible, electric
drill or larger. Proceed to expand tube until tool starts
to grab. Approximately 1/2 to 1 in. of the tool shank
will be visible.
35
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LIMITEDPARTSWARRANTYECONOPAKWATERHEATERS
MODELS WH - 0260 TO 0401
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. Labor charges and other costs for parts removal or reinstallation, shipping and transportation are not covered by this Warranty
but are the owner's responsibility.
HEATEXCHANGERWARRANTY:
•
•
Five (5) Years from date of water heater installation. This includes only the copper, bronze and cast iron waterways.
Twenty (20) Years from date of water heater installation against "Thermal Shock" (excluded, however, if caused by operation
at large changes exceeding 150°F between the water temperature at intake and water heating temperature, or operating at water
heater temperatures exceeding 190°F).
ANYOTHERPARTMANUFACTUREDBYRAYPAK:
One (2) year warranty from date of installation, or eighteen (18) months from date of factory shipment based on Raypak's records,
whichever comes first.
SATISFACTORYPROOFOFINSTALLATIONDATE,SUCHASINSTALLERINVOICE,ISREQUIRED. THISWARRANTYWILLBEVOID
IFTHEWATERHEATERRATINGPLATEISALTEREDORREMOVED.
ADDITIONALWARRANTYEXCLUSIONS:
This warranty does not cover failures or malfunctions resulting from:
1. Failure to properly install, operate or maintain the water heater in accordance with our printed instructions provided;
2. Abuse, alteration, accident, fire, flood and the like;
3. Sediment or lime buildup, freezing, or other conditions causing inadequate water circulation;
4. High velocity flow exceeding water heater design rates;
5. Failure of connected systems devices, such as pump or controller;
6. Use of non-factory authorized accessories or other components in conjunction with the water heater system;
7. Failing to eliminate air from, or replenish water in, the connected water system;
8. Chemical contamination of combustion air or use of chemical additives to water.
PARTSREPLACEMENT:
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 found satisfied. The replacement part will be
warranted for only the unexpired portion of the original warranty. Raypak makes no warranty whatsoever on parts not manufactured
by it, but Raypak will apply any such warranty as may be provided to it by the parts manufacturer.
TO MAKE WARRANTY CLAIM:
Promptly notify the original installer, supplying the model and serial numbers of the unit, date of installation and description of the
problem. The installer must then notify his Raypak distributor for instructions regarding the claim. If either is not available, contact Service
Manager, Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 or call (805) 278-5300. In all cases proper authorization must first be
received form Raypak before replacement of any part.
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY:
This is the only warranty given by Raypak, No one is authorized to make any other warranties on Raypak's behalf. THIS WARRANTY
IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF
MERCHANTABILITYANDFITNESSFORAPARTICULARPURPOSE. RAYPAK'SSOLELIABILITYANDTHESOLEREMEDYAGAINST
RAYPAKWITHRESPECTTODEFECTIVEPARTSSHALLBEASPROVIDEDINTHISWARRANTY. ITISAGREEDTHATRAYPAKSHALL
HAVENOLIABILITY,WHETHERUNDERTHISWARRANTY,ORINCONTRACT,TORT,NEGLIGENCEOROTHERWISE,FORANYSPECIAL,
CONSEQUENTIAL,ORINCIDENTALDAMAGE,INCLUDINGDAMAGEFORMWATERLEAKAGE. Somestatesdonotallowlimitationsonhow
long an implied warranty lasts, or for the exclusion of incidental or consequential damages. So the above limitation or exclusion may not
apply to you.
This Limited Warranty gives you specific legal rights. You may also have other rights which may vary from state to state. Wesuggest
that you complete the information below and retain this certificate in the event warranty service is needed. Reasonable proof of the
effective date of the warranty (date of installation) must be presented, otherwise, the effective date will be based on the rate of
manufacture plus thirty (30) days.
_____________________________________________________
Name of Owner
____________________________________________________
Name of Dealer
_____________________________________________________
Address
____________________________________________________
Address
_____________________________________________________
____________________________________________________
_____________________________________________________
____________________________________________________
ModelNo.
Serial No.
Date of Installation: _____________________________________
Date of Initial Operation: ________________________________
CORPORATEHEADQUARTERS:
RAYPAK, INC., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (805) 278-5489
Litho in U.S.A.
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Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 Fax (805) 278-5468
Litho in U.S.A.
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