Owners Guide and Installation Instructions Raypak Water Heaters Models Types B0109 NCO, NCH PCO, PCH B0147 This water heater must be installed and serviced by an authorised person. Please leave this guide with the householder or responsible officer.
Notice to Victorian Customers from the Victorian Plumbing Industry Commission This water heater must be installed by a licensed person as required by The Victorian Building Act 1993 Only a licensed person will give you a Compliance Certificate, showing that the work complies with all the relevant standards. Only a licensed person will have insurance protecting their workmanship for 6 years. Make sure you use a licensed person to install this water heater and ask for your Compliance Certificate.
CONTENTS HOUSEHOLDER OR RESPONSIBLE OFFICER – We recommend you read pages 4 to 11. The other pages are intended for the installer but may be of interest CONTENTS ..................................................................................................................................................................3 ABOUT YOUR WATER HEATER ................................................................................................................................4 HOW YOUR WATER HEATER WORKS ..
ABOUT YOUR WATER HEATER MODEL TYPE Congratulations for choosing a Raypak® water heater. The model you have chosen is suitable for either indoor or outdoor installation depending on use of the appropriate installation kit. The operation of the water heater depends on the application. Typically for hot water applications a water heater with ‘on/off’ operation will be installed. For mechanical heating or process applications a water heater with ‘Hi/Lo’ operation will be installed.
ABOUT YOUR WATER HEATER SAFETY For your safety do not operate this water heater before reading this instruction booklet. This water heater is supplied with a thermostat, hi-limit thermostat and a pressure relief valve. These devices must not be tampered with or removed. The water heater must not be operated unless each of these devices is fitted and is in working order. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage.
ABOUT YOUR WATER HEATER TO TURN ON THE WATER HEATER WARNING! If you smell gas do not attempt to turn on the water heater. • Fill the system with water (refer to “To Fill the Water Heater” on page 32) • Open the gas isolation valve fully at the inlet to the water heater. • Plug in the power supply cord at the power outlet. • Switch on the electrical supply at the power outlet to the water heater. NOTE: If the water heater is correctly installed, this will also activate the circulating pump.
HOW YOUR WATER HEATER WORKS The water heater consists of a gas burner, a combustion chamber lined with refractory tiles and a heat-exchanger made of finned copper tubes. Hot flue gases from the burner pass between the fins on the heat exchanger tubes and heat is transferred first to the fins and then by conduction into the water. Baffles are placed between the tubes to control the flow of the hot flue gases and ensure efficient operation of the water heater.
HOW YOUR WATER HEATER WORKS 147 MODELS On/Off Operation 147 On/Off models are fitted with an electronic thermostat that operates the gas control by switching its power on and off, so a constant temperature is maintained. The thermostat is mounted on the control panel of the water heater and the protective over temperature cut out is mounted inside the lower front cover of the water heater. There is no need to switch the water heater off when it is not in use.
SAVE A SERVICE CALL Check the items below before making a service call. You will be charged for attending to any condition or fault that is not related to manufacture or failure of a part. NOT ENOUGH HOT WATER (OR NO HOT WATER) • Is the electricity switched on? Inspect the power outlet adjacent to the water heater and ensure the water heater is plugged in and the outlet is turned on.
SAVE A SERVICE CALL BURNER WILL NOT LIGHT • Is there gas to the water heater? Check the gas isolation valve on the gas supply line is open. • Is there a normal gas supply to the rest of the premises? Try lighting another gas appliance. If there is no gas call your gas provider. • Is the ignition system ‘locked out’? Try resetting the water heater. Refer to “Water Heater Not Operating” on page 9.
REGULAR CARE PRESSURE RELIEF VALVE This valve is located in the in/out header of the water heater and is essential for its safe operation. It is possible for the valve to release a little water through the drain line during each heating period. This occurs as the water is heated and expands by approximately 1/50 of its volume. Continuous leakage of water from the valve and its drain line may indicate a problem with the water heater (refer to “Pressure Relief Valve Running” on page 10).
INSTALLATION THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING Check the water heater is suitable for the gas type available. The gas type is marked on the side panel near the gas connection entry and shown on the rating label. All packaging must be removed from the water heater prior to its installation. The installation kit (including the pressure relief valve) may be supplied inside the water heater casing. This kit must be removed before the water heater is operated.
INSTALLATION CLEARANCES (INDOOR INSTALLATIONS) The distances set out in the following table should be observed.
INSTALLATION must be installed to fill in the perforations) to prevent excessive drafts entering the water heater from underneath. The following distances extracted from the Australian Gas Installations Standard AS 5601 must be observed: • At least 500 mm between the top of the flue terminal and the eaves. • At least 1 500 mm horizontally between the flue terminal and the edge of any opening into the building, measured horizontally.
INSTALLATION HIGH WIND CONDITIONS In areas where high winds frequently occur, it WILL be necessary to: • Locate the water heater a minimum of one (1) metre away from high vertical walls. • Install a wind break to protect the water heater from the prevailing winds. • 147 Models Only: Replace the standard flue terminal with a HIGH WIND top (at extra cost). A high wind top is not available for 109 models.
INSTALLATION HOT WATER DELIVERY (WATER HEATING APPLICATIONS) This water heater can deliver water at temperatures which can cause scalding. It is necessary and we recommend that a temperature limiting device be fitted between the water heating system and the hot water outlets in any ablution and public areas such as bathrooms, ensuites or public amenities, to reduce the risk of scalding.
INSTALLATION 147 Indoor Conversions DIMENSIONS AND TECHNICAL DATA 109 147 Input (MJ/h) 99 144 Output (kW) 22 32 Input (MJ/h) 99 144 Output (kW) 22 32 Power (W) 50 50 Current (A) 0.21 0.
INSTALLATION 109 Models 147 Models 18
CONNECTIONS – PLUMBING IMPORTANT: When installing a new water heater to an old or existing system, it is a requirement that the system and its equipment be thoroughly inspected and if necessary, drained and flushed with clean fresh water, before the new water heater is connected. Failure to do this may cause blockages and/or damage to the water heater which is not covered by warranty. IF THERE IS ANY DOUBT ABOUT THE SYSTEM, DRAIN AND FLUSH AS A PRECAUTION.
CONNECTIONS - PLUMBING The table below provides indicative pipe and pump sizes for typical installations Model Pump Minimum Manifold Header Size Required (mm) Branch Size UPS Series Speed inches mm 1 Unit 2 Units 3 Units 4 Units 109 20-60B 3 1 25 25 32 32 40 147 20-60B 3 1 25 20 32 32 40 PUMP SELECTION In order to obtain the best possible water flow in the system a correctly sized pump must be installed.
CONNECTIONS - PLUMBING MECHANICAL HEATING All high points of a mechanical heating system should be provided with manual bleed points or fitted with automatic air vents. The design of the system must be such that the water heater is provided with adequate water flow and pressure at all times (refer to ‘Pump Selection’ on page 20. On radiator or heating systems where thermostatic valves will vary the water flow a suitable by-pass valve must be installed to maintain the correct flow rate.
CONNECTIONS – ELECTRICAL All electrical work and permanent wiring must be carried out by a qualified person and in accordance with the Wiring Rules AS/NZS 3000 and local authority requirements. The water heater is supplied with a 1.8 metre lead and plug and requires a 240 V 50 Hz general purpose outlet (GPO) to be located within 1.0 metre of the installation. NOTE: For outdoor installations the GPO must be weatherproof.
CONNECTIONS - ELECTRICAL WIRING A POWER FLUED SYSTEM TO THE WATER HEATER An indoor model can be wired to a power flued system. A power flued system must be designed by a qualified person to suit the particular installation. The power flue system must be interlocked with the water heater(s) to prevent the water heater(s) from operating if the power flue is not working.
CONNECTIONS - ELECTRICAL WIRING DIAGRAM – 109 ON/OFF MODELS 24
CONNECTIONS - ELECTRICAL WIRING DIAGRAM – 109 HI/LO MODELS 25
CONNECTIONS - ELECTRICAL WIRING DIAGRAM – 147 ON/OFF MODELS 26
CONNECTIONS - ELECTRICAL WIRING DIAGRAM – 147 HI/LO MODELS 27
CONNECTIONS - ELECTRICAL MULTI PUMP OPTION - MECHANICAL HEATING SYSTEMS NOTE: When connecting additional controls the relays and timers etc must be located in an additional enclosure NOT fitted within the water heater. For outdoor installations the enclosure MUST be weatherproof.
LOCATION OF CONTROLS THERMOSTAT (1) On/Off Models 109 On/Off type water heaters are fitted with a Honeywell L4189A2014B mechanical thermostat with its sensor located in the inlet side of the water heater header. 147 On/Off type water heaters are fitted with an AKO 14123 electronic thermostat with its sensor located in the inlet side of the water heater header. On/Off type controls are typically used where the system load is constant (e.g. hot water supplied from a storage tank or in floor slab heating).
SAFETY PRECAUTIONS Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. DURING FIRST FIRING OF THE WATER HEATER • Fumes and smoke may be produced. • Avoid breathing fumes and ventilate the area to clear. • Production of smoke should cease within 30 minutes. WHEN HANDLING • Minimise airborne dust. • Wear an approved mask or respirator.
COMMISSIONING COMMISSIONING MUST ONLY BE UNDERTAKEN BY AN APPROPRIATELY LICENSED PERSON WHO IS FAMILIAR WITH SAFE COMMISSIONING PROCEDURES. Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. Refer to “Safety Precautions” on page 30 for the precautions to be taken when the water heater is first operated.
OPERATING THE WATER HEATER FOR YOUR SAFETY READ BEFORE LIGHTING TO FILL THE WATER HEATER Water Heating Applications • Open all of the hot water tap(s) in the building (don’t forget the showers) and supply cock(s) and valve(s) in the system. • Open the isolation valves fully on the cold, flow / return and hot water branches to the storage tank(s) installed in a bank. • Open the cold water isolation valve on the cold water line to the storage tank(s). Air will be forced out of the taps.
BURNER PRESSURE ADJUSTMENT GAS INLET PRESSURE IMPORTANT – CHECK the gas supply pressure at the inlet to the water heater with the water heater and all other gas burning appliances in the premises operating (burners alight). The minimum gas supply pressures are: Natural Gas - 1.13 kPa Propane - 2.75 kPa If this minimum cannot be achieved, it may indicate the meter or the gas line to the water heater is undersized.
BURNER PRESSURE ADJUSTMENT Hi/Lo Models To adjust the burner pressure on a water heater with a White Rodgers 36E20 Type 301 Hi/Lo gas control, proceed as follows: Regulator Cap 109 Hi/Lo Models Low fire adjustment • Remove the screw and washer from the burner feed pipe pressure tap. Pressure Tap • Attach a manometer to the pressure tap. • Remove the 20mm plug from the left hand side of the water heater and remove the cap from the high fire pressure regulator adjuster.
TEMPERATURE CONTROL HOTTER WATER INCREASES THE RISK OF SCALD INJURY. This water heater can deliver water at temperatures which can cause scalding. Water heating applications: It is necessary and we recommend that a temperature limiting device be fitted between the water heating system and the hot water outlets in any ablution and public areas such as bathrooms, ensuites or public amenities, to reduce the risk of scalding.
TEMPERATURE CONTROL 147 Hi/Low Models (CTX Thermostat) Set Point Adjustment: • Press the ‘set’ button, SE.1 will be displayed for twelve (12) seconds. • Press the ‘set’ button again, The current set point value will be displayed. • Press the down button (▼/PRG) to decrease the set point or the up button (▲/ALM) to increase the set point. • Once the required set point is selected, press the ‘set’ button to save the setting, SE.1 will be re-displayed for twelve (12) seconds.
TEMPERATURE CONTROL HIGH-LIMIT THERMOSTAT ADUSTMENT A Honeywell high limit thermostat is used on both On/Off and Hi/Lo water heaters (refer to “Location of Controls” on page 29. The thermostat has a capillary style temperature sensor located in a well (pocket) fitted in the outlet header and senses the temperature of the water leaving the water heater. The high limit temperature setting is adjusted by removing the front cover (loosen one Phillips-head screw) and turning the adjuster.
SERVICE PROCEDURES ONLY AN AUTHORISED PERSON MAY REPAIR OR SERVICE A GAS APPLIANCE. Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system. Refer to “Safety precautions” on page 30 for the precautions to be taken when servicing the water heater. Six Monthly Service Procedure 1. Isolate power to the water heater. 2.
WATER SUPPLIES WATER HEATERS NOT INSTALLED IN ACCORDANCE WITH THIS ADVICE WILL NOT BE COVERED BY THE WARRANTY. This water heater is manufactured to suit the water conditions of most public reticulated water supplies. However, there are some known water supplies which can have detrimental effects on the water heater and its operation and/or life expectancy. If you are unsure of your water quality, you may be able to obtain information from your local water supply authority.
WATER SUPPLIES Water Quality Charts Saturation index, Total Dissolved Solids (TDS), pH & Chlorides 40
WARRANTY RAYPAK WATER HEATER WARRANTY – AUSTRALIA ONLY WARRANTY CONDITIONS Accredited Service Agent’s premises and the installed site shall be the owner’s responsibility. 5. Where the water heater is installed in a position that does not allow safe, ready access, the cost of accessing the site safely, including the cost of additional materials handling and / or safety equipment, shall be the owner’s responsibility. 6.
WARRANTY RAYPAK WATER HEATER WARRANTY – AUSTRALIA ONLY Rheem will: a) Repair or, if necessary replace any Raypak water heater; or b) Replace any component (or, if necessary, arrange the installation of a new water heater), which falls within the Warranty Periods specified below, subject to the warranty conditions and exclusions. Installation Model All Components (from date of installation) Period Warranty Year New component or water heater (at Rheem’s sole 1 discretion), free of charge, including labour.
Proudly Manufactured by Raypak Australia Head Office & Sales Tel: (03) 9757 3333 Fax: (03) 9757 3350 Sales Enquiries: 1300 729 725 www.raypak.com.
