Raypak 0133-4001 manual

Models 0133-4001 T ypes WH & NH CATALOG NO. 3000.52H Effective: 07-15-06 Replaces: 11-01-04 FOR YOUR SAFETY 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 i[...]

TABLE OF CONTENTS 2 RECEIVING EQUIPMENT ........................................ 3 MODEL IDENTIFICATION ........................... 3 GENERAL SPECIFICATIONS ....................... 3 GENERAL SAFETY PRECAUTIONS .............. 4 INSTALLATION INSTRUCTIONS .............................. 5 CLEARANCES .......................................... 6 SPECIFIC[...]

3 RECEIVING EQUIPMENT 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 i[...]

4 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 understand[...]

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/CSA B149.1 and the Canadian Electrical Code Part 1 CSA C22.[...]

CLEARANCES TO PROTECTED SURFACES Note 1: Combustible floor shield is required when heater is to be installed on a combustible surface. (See ordering info. on pg.5.) Note 2: Servicing Clearances: Provide at least 24" (Models 0133-1826), 48" (Models 2100-4001) in front of unit for removal & servicing of the Controls & Burner Tray. P[...]

SPECIFICATIONS AND DIMENSIONS MODELS 182-400 and 181-401 7 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. MODEL 133 NOTE: Ratings are shown for elevations up to 2,000 fe[...]

8 MODELS 514-824 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. 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[...]

9 MODELS 926-1758 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. NOTE: Ratings are shown for elevations up to 2,000 feet. For elevations over 2,000 feet, reduce ratings 4% for each 1,000 fe[...]

OUTDOOR WATER HEATERS These heaters are design certified for out- door 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[...]

11 OUTDOOR INSTALLATIONS Step 2: Tighten the (4) screws (Shown below) until they come in contact with the unit jacket top, then evenly tighten all (4) screws to secure to unit. MODELS 926-1758 Heaters are shipped with outdoor vent terminal factory installed. MODELS 2100-4001 These units are not certified for outdoor installa- tion. VENTING Fig# 816[...]

INDOOR INSTALLATIONS MODEL 133 Step 1. Shut-off main electrical power switch to heater. Step 2. Turn heater manual switch, located in upper control panel, to the "OFF" position. Step 3 . Shut-off gas supply and water supply to the heater. Step 4. Mount drafthood on heater and attach with the 8 sheet metal screws provided. Drafthood should[...]

Fig. # 8167 MODELS 962-1826 Locate and assemble as shown below. Secure with screws supplied in envelope in carton. Fig. # 8165 MODELS 2100-4001 These models have built-in drafthoods. For proper operation, the drafthood outlet must be connected to the venting system. MODELS 514-824 Locate and assemble as shown below. Secure with screws supplied in e[...]

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 (draf[...]

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously. (e) Test for spillage at the drafthood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. (f) After it has been determin[...]

INSTALLING THE VENT DAMPER VENT DAMPER GENERAL WIRING DIAGRAM Fig. # 8183.0 Fig. # 8615.0 NO YES NO YES INSTALL VENT DAMPER WITH ACTUATOR TO SIDES OF VENT ONLY. DO NOT MOUNT ABOVE OR BELOW VENT. TO CHIMNEY TO BOILER D808 FLOW > HORIZONTAL INSTALLATION TO CHIMNEY TO BOILER D808 VERTICAL INSTALLATION ACTUATOR MAY BE INSTALLED IN ANY POSITION ON VE[...]

PLUMBING Fig. # 8090.1 GENERAL Heater should be located so that any water leaks will not cause damage to any adjacent areas or struc- tures. GAS SUPPLY CONNECTIONS Gas piping must have a sediment trap ahead of the heater gas controls, and a manual shut-off valve located outside the heater jacket. All gas piping should be tested after installation i[...]

18 A minimum of 7" WC and a maximum of 10.5" WC upstream pressure under load, and no load conditions must be provided for natural gas or a minimum of 11" WC and a maximum of 13" for propane. GAS PRESSURE REGULATOR The gas pressure regulator located in the gas valve is preset nominally at 4" WC for natural gas, and 11" [...]

19 FLOW RATES[...]

20 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. Soft: 0-4 grains per gallon. Medium: 5-15 grains per gallon. Hard: 16 and over grains per gallon. 2. Maximum Flow Rates: 133[...]

21 TYPE WH - UNITEMP 80 SYSTEM PIPING DIAGRAMS[...]

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 d[...]

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[...]

OPERATING CONTROLS On models 514-1826, models with mechanical modulating controls have one or more Robertshaw Unitrol 7000 Series hydraulic snap on thermostatic combination gas valves. These valves have the pres- sure regulator and 24-volt operator built-in. The hy- draulic actuator will throttle the heater input to adjust the firing rate and meet [...]

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. LOW WATER CUT-OFF (OPTIONAL) The low water cut-off automatically shuts down burner whenever water level drops below probe. 90- second time delay p[...]

26 COMPONENT IDENTIFICATION MANUAL RESET HIGH LIMIT THERMOSTAT CONTROL HIGH and/or LOW GAS PRESSURE SWITCH IGNITION CONTROL MODULE LOW WATER CUT-OFF MECHANICAL MODULATING VALVE FLOW SWITCH FLOW SWITCH PADDLE CUTTING GUIDE Fig# 9314 Fig# 8929.1 Fig# 9316 Fig# 9317 Fig# 8643 Fig# 9312 Fig# 8995 Fig# 8925[...]

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is discon- nected to avoid potential serious injury or damage to components. The heater is normally wired for 120 V[...]

LOCATION OF CONTROLS 28 400 WH1, WH2, WH3 181 (LOW NOx) WH1 Fig # 9360[...]

29 Fig. #9334 LOCATION OF CONTROLS[...]

BEFORE START-UP Safe lighting and other performance criteria were met with the gas manifold and control assembly pro- vided on the heater when the heater underwent tests specified in the latest edition of the ANSI-Z21.10.3/CSA 4.3 Standard. GENERAL Before lighting up a new installation, water should be flowing through the heater. Water pressure reg[...]

General Safety Precautions Maximum water temperatures occur just after burner has shut-off. To determine the water temperature being delivered, turn on the hot water only, place a thermometer in the stream, and read the thermom- eter. There is a hot water scald potential if the thermostat is set too high. NOTE: When this heater is supplying general[...]

TO TURN OFF GAS TO APPLIANCE 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 [...]

FOR MODELS WITH AUTOMATIC GAS VALVES 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. Turn off electric power. 33 GAS[...]

PILOT BURNER FLAME-IID (atmospheric units) Inspect on the first and third month after initial start- up 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 [...]

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 Code ANSI Z223.1, and the National Electrical[...]

36 BURNER TRA Y REMOV AL 1. Shut-off main electrical power switch to heater . 2. Shut-off gas up stream of heater . 3. Remove front door . 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 [...]

TROUBLESHOOTING - ELECTRICAL (ELECTRONIC IGNITION IID) WARNING HIGH VOLTAGE For qualified Technicians ONLY 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. NOTE: Before troubleshooting, familiarize yourself with the start-up and checkout procedure. Chec[...]

WIRING DIAGRAM - WH2 182/260 38 WIRING DIAGRAMS[...]

WIRING DIAGRAM - WH2 330/400 39[...]

40 WIRING DIAGRAM - WH2 514/624[...]

41 WIRING DIAGRAM - WH2 724-1336[...]

42 WIRING DIAGRAM - WH2 1414-1826[...]

43 WIRING DIAGRAM - WH2 2100-2500[...]

44 WIRING DIAGRAM - WH2 3001-4001[...]

WIRING DIAGRAM - WH1 181/261 LOW NOx 45[...]

46 WIRING DIAGRAM - WH1 331/401 LOW NOx[...]

MECHANICAL PROBLEM When heater is turned on nothing happens. Thermostat in "ON" position causes relay and pump to operate, but heater does not fire. Continuous shut down of manual reset High Limit. Sooting CAUTION-Soot may be combus- tible. Wet down and exercise caution when cleaning. Continuous shut down of low water cut-off or flow swit[...]

FAILURE TO PUMP 1. Pump not properly primed. 2. Wrong direction of rotation. 3. Speed too low. 4. Total head too high. 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). 5. Insufficient positive suction head (for hot water)[...]

COMBINATION FLAME SENSOR/ IGNITOR AND PILOT BURNER LOCATION TYPICAL BURNER TRAY ILLUSTRATED BURNER TRAY REMOVAL 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. GAS VALVE REMOVAL 1. Shut-off gas supply t[...]

REFRACTORY PANELS TOP VIEW HEAT EXCHANGER RE-ASSEMBLY 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 thermost[...]

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. CLEANING FLUE GAS PASSAGEWAYS Soot will clog areas between fins and cause even- t[...]

52 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 subjec[...]

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. www .raypak.com[...]