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Raypak 260-401 manual

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Table of contents for the manual

  • Page 1

    INST ALLA TION AND OPERA TING INSTRUCTIONS CATALOG NO. 3000.51D Effective: 07-15-06 Replaces: 08-01-03 Fig. #9166 FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire. WARNING: Improper installatio[...]

  • Page 2

    2 TABLE OF CONTENTS CONTENTS 3 1. RECEIVING EQUIPMENT 3 2. GENERAL SPECIFICATIONS AND DIMENSIONS 4 General Safety Precautions 6 3. INSTALLATION PROCEDURES 6 - Code Requirements 6 - Clearance Requirements for all Models 6 - Combustion/Ventilation Air 7 - Venting Connections 8 - Common Vents 10 - Gas Supply Connections 11 - Water Connections & Sy[...]

  • Page 3

    3 1. 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 damaged report the damage to the carrier immediately. Be sure [...]

  • Page 4

    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[...]

  • Page 5

    5 General Safety Precautions To meet commercial hot water requirements, the tankstat is adjustable up to 190°F. However, water temperatures over 125°F. can cause severe burns instantly or death from scalds. This is the preferred starting point for setting the control for supplying gen- eral purpose hot water. Safety and energy conservation are fa[...]

  • Page 6

    3. INSTALLATION PROCEDURES CODE REQUIREMENTS Installation must be in accordance with local codes , or, in the absence of local codes, with the latest editions of the National Fuel Gas Code , ANSI Z223.1,/NFPA 54, and the National Electrical Code , ANSI/NFPA 70. In Canada installations must conform with the current CAN/CSA B149.1 and the Canadian El[...]

  • Page 7

    1 ) The heater must be provided with adequate supply 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. 2 ) When the heater is installed in a confined space where all air is supplied from inside the building, the heate[...]

  • Page 8

    VENTING CONNECTIONS (Indoor Models) The drafthood is shipped separately and must be installed on the heater. For Model 260/261: 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 h[...]

  • Page 9

    9 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. For protection against rain or blockage by snow, the vent pipe must terminate with a listed vent cap which comp[...]

  • Page 10

    10 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. For connections to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of Equipme[...]

  • Page 11

    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 PSIG(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 [...]

  • Page 12

    When this water heater system is supplying general purpose hot water requirements for use by individuals, a thermostatically controlled mixing valve is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information. Thermometer(s) should be installed so that they indicate the water[...]

  • Page 13

    13 ELECTRICAL WIRING The electrical power supply requirement for these heaters is 115 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 electrical pan[...]

  • Page 14

    WIRING DIAGRAM: STANDING PILOT MODELS 260 - 400 NOTES: * USE GROUND CLIP PROVIDED. ** PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES. *** VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS. ROLL-OUT AND VENT SWITCHES NOT REQUIRED ON MODELS 330 AND 400. Fig. #2372 14[...]

  • Page 15

    WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODEL 260 15 NOTES: * USE GROUND CLIP PROVIDED. FAILURE TO PROVIDE PROPER GROUND MAY RESULT IN LOCK-OUT. ** PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES. *** VENT TEMP SWITCH PROVIDED ONLY ON INDOOR HEATERS. Fig. #2373[...]

  • Page 16

    WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODELS 330 & 400 16 NOTES: * USE GROUND CLIP PROVIDED. FAILURE TO PROVICE PROPER GROUND MAY RESULT IN LOCK-OUT. ** PUMP USED MUST BE RATED 10 AMPS MAX OR 3/4 HP MAX. PUMP DELAY ADJUSTABLE BETWEEN 3 AND 10 MINUTES.[...]

  • Page 17

    17 WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODEL 261 LOW NO x[...]

  • Page 18

    18 WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODEL 401 LOW NO x[...]

  • Page 19

    4. SERVICING PROCEDURES SEQUENCE OF OPERATION INTERMITTENT IGNITION DEVICE (IID) Heaters equipped with the IID system will automatically 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 s[...]

  • Page 20

    A . This heater has a pilot which must be lighted by hand. When lighting the pilot, follow these instruc- tions exactly. 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 settle on the floor. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance.[...]

  • Page 21

    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 burner drawer, right of first burner. 8. Turn knob on gas control [...]

  • Page 22

    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 sure knob rest against stop. GAS CONTROL KNOB SHOWN IN "ON" POSITION GAS INLET Fig. #8082 For Honeywell Gas Valve: (Models 403 ) Turn gas control knob c[...]

  • Page 23

    PILOT BURNER FLAME (IID UNITS) PILOT BURNER FLAME (STG PILOT UNITS) CONTROLS 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. High Limit Switch - to check high limit sw[...]

  • Page 24

    . 24 BURNER DRA WER 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) scr[...]

  • Page 25

    HEAT EXCHANGER RE-ASSEMBLY 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 evenly. 3. Install the four (4) corner clips between tube sheets and refractory. Replace "V" baffles. 4. Install thermostat sensing bulbs in h[...]

  • Page 26

    26 5. TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified s[...]

  • Page 27

    1) Adjust inlet gas pressure as shown on rating plate. 2) Clean pilot orifice. 3) Replace thermocouple. 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) Refer to installation instructions regarding combustion air requirements. 2) Refer to installatio[...]

  • Page 28

    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. Check [...]

  • Page 29

    29 ELECTRICAL TROUBLESHOOTING For Service Technicians START HEATER IF PILOT BURNER LIGHTS IF PILOT BURNER BUT MAIN BURNERS DO NOT DOES NOT LIGHT CHECK FOR 24 V CHECK THERMOCOUPLE AT GAS VALVE IF NOT 24 V: IF 24 V: IF O.K. IF DEFECTIVE CHECK TRANSFORMER OUPUT REPLACE FOR 24 V GAS VALVE REPLACE REPLACE GAS VALVE THERMOCOUPLE IF NO IF 24 V: 24V: REPLA[...]

  • Page 30

    ADJUSTMENTS/REPLACEMENTS OF COMPONENTS CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after ser- vicing. DANGER - SHOCK HAZARD Make sure electrical power to the heater is disconnect-ed to avoid potential serious injury or damage to com- ponen[...]

  • Page 31

    CONTROL WELL REPLACEMENT Remove top, sensing bulb and clip. Collapse well tube at the open end with a chisel, push through into header and remove the well through header. Insert a new well and roll into place. If a roller is not available, solder the well in place with silver solder. TUBE REPLACEMENT PROCEDURE 1. Remove heat exchanger from heater f[...]

  • Page 32

    32 FOR UNITS WITH A LOW NO x TRAY[...]

  • Page 33

    33[...]

  • Page 34

    34[...]

  • Page 35

    LIMITED PARTS WARRANTY ECONOPAK WATER HEATERS MODELS WH - 260 TO 401 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 i[...]

  • Page 36

    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[...]