Raypak B0109 Technical Document

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.

Warning: Upon completion of the installation and commissioning of the water heater, leave

this guide with the householder or a responsible officer. DO NOT leave this guide inside of the

cover of the water heater, as it may interfere with the safe operation of the water heater or ignite

when the water heater is turned on.

PATENTS

This water heater may be protected by one or more patents or registered designs.

® Registered trademark of Rheem Australia Pty Ltd.

™ Trademark of Rheem Australia Pty Ltd.

Date of installation:

Model Nº:

Serial Nº:

Installed by:

Purchased from:

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 .....................................................................................................................7

SAVE A SERVICE CALL ..............................................................................................................................................9

REGULAR CARE........................................................................................................................................................11

INSTALLATION ..........................................................................................................................................................12

CONNECTIONS – PLUMBING ..................................................................................................................................19

CONNECTIONS – ELECTRICAL ...............................................................................................................................22

LOCATION OF CONTROLS ......................................................................................................................................29

SAFETY PRECAUTIONS...........................................................................................................................................30

COMMISSIONING......................................................................................................................................................31

OPERATING THE WATER HEATER.........................................................................................................................32

BURNER PRESSURE ADJUSTMENT ......................................................................................................................33

TEMPERATURE CONTROL ......................................................................................................................................35

SERVICE PROCEDURES..........................................................................................................................................38

WATER SUPPLIES ....................................................................................................................................................39

WARRANTY ...............................................................................................................................................................41

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.

HOW HOT SHOULD THE WATER BE?

The water heater features an adjustable thermostat, which

allows the most suitable temperature for the application to be

chosen.

To meet the requirements of the National Plumbing Standard

the temperature of the stored water for hot water applications

must not be below 60°C.

HOTTER WATER INCREASES THE RISK OF SCALD INJURY

This water heater can deliver water at temperatures which can

cause scalding. Check the water temperature before use, such

as when entering a shower or filling a bath or basin, to ensure it

is suitable for the application and will not cause scald injury.

We recommend and it may be required by regulations that an

approved temperature limiting device be fitted into the hot water

piping to the bathroom and ensuite when this water heater is

installed. This will keep the water temperature below 50°C at the

bathroom and ensuite. The risk of scald injury will be reduced

and still allow hotter water to the kitchen and laundry.

TEMPERATURE ADJUSTMENT

The thermostat temperature will have been set by the installer to suit the application, adjustment should not be

required. Consult your installer before making any adjustment to the thermostat temperature.

WARNING

This water heater is only intended to be operated by persons who have the experience or the knowledge and the

capabilities to do so. This water heater is not intended to be operated by persons (including children) with reduced

physical, sensory or mental capabilities, or lack of experience and knowledge.

Children should be supervised to ensure they do not interfere with the water heater.

The water heater uses 240 Volt AC electrical power for operation of the control systems. The removal of the access

cover(s) will expose 240 Volt wiring. They must only be removed by an authorised or qualified person.

HOT WATER INSTALLATIONS

Minimum recommended stored

water temperature

HOT WATER INSTALLATIONS

Maximum recommended

supply temperature to

bathrooms and ens

ites

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. For

assistance or additional information consult your Raypak distributor, qualified installer, or Rheem®Service agent.

The warranty can become void if relief valves or other safety devices are tampered with or if the

installation is not in accordance with these instructions.

•DO NOT store flammable or combustible materials near the water

heater. Flammable liquids (such as petrol), newspapers and similar articles

must be kept well away from the water heater and the draught diverter or

flue terminal.

•DO NOT use aerosols, stain removers and household chemicals near

the water heater whilst it is working. Gases from some aerosol sprays, stain

removers and household chemicals become corrosive when drawn into a

flame.

•DO NOT store swimming pool chemicals, household cleaners, etc.,

near the water heater.

•DO NOT place anything on top of the water heater or in contact with the

flue terminal. Ensure the flue terminal is not obstructed in any way at any

time.

•DO NOT use Propane / Butane gas mixtures in a Propane model. A Propane model is designed to operate on

Propane only. The use of Propane / Butane mixture, such as automotive LPG fuel, in a Propane model is

unsafe and can cause damage to the water heater.

•DO NOT operate with panels, covers or guards removed from the water heater.

•DO NOT enclose this water heater (applies to external installations only).

If the power supply cord or electrical conduit to the water heater is damaged, it must be replaced by an authorised

person in order to avoid a hazard. The power supply cord and plug must be replaced with a genuine replacement

part available from Rheem. Phone your nearest Rheem Service Department or Accredited service Agent to arrange

for an inspection.

Do not use the water heater if any part has been under water. Immediately call Rheem Service or Accredited

service Agent to arrange for an inspection.

WHAT TO DO IF YOU SMELL GAS?

•DO NOT try to light any gas appliance.

•DO NOT touch any electrical switch.

•TURN OFF the gas supply at the gas meter immediately, call your gas supplier or licensed gasfitter.

NOTE: Some gases are heavier than air and it may be necessary to check for gas leaks at floor level.

TO TURN OFF THE WATER HEATER

If it is necessary to turn off the water heater:

•Switch off the electrical supply at the power outlet to the water heater

NOTE: If the water heater is correctly installed, this will also shut down the circulating pump.

•Close the gas isolation valve at the inlet to the water heater.

•Close the cold water isolation valve at the inlet to the water heater.

•Close the isolation valves on the cold and hot water branches to shut down an individual water heater in a bank

(water heating applications only).

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.

The water heater will operate automatically when a call for heat occurs.

HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?

Installation requirements are shown on page 21. The water heater must be installed by an authorised person. In

Australia, the installation must comply with Standards AS/NZS 3500.4, AS/NZS 3000, AS 5601 and all local codes

and regulatory authority requirements.

DOES THE WATER QUALITY AFFECT THE WATER HEATER

The water heater is suitable for most public water supplies; however some water qualities may have detrimental

effects on the finned copper tube heat exchanger and fittings. If you are in a known harsh water area you must

read page 39. If you are not sure, have your water quality checked against the conditions described on page 39.

HOW LONG WILL THE WATER HEATER LAST?

There are a number of factors that will affect the length of service the water heater will provide. These include the

water quality, the water pressure, temperature (inlet and outlet) and the water usage pattern. However, your water

heater is supported by a comprehensive warranty (refer to page 41).

SERVICING

For safe and efficient operation, the water heater should be serviced annually by your nearest Rheem Service

Department or their Accredited Service Agent. Only genuine replacement parts should be used on this water

heater. Refer to “Service Procedures” on page 38

WARNING: Servicing of a gas water heater should only be carried out by authorised personnel.

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. The refractory tiles

insulate the combustion chamber to minimise loss of heat and protect the surroundings from the temperature of the

burner flames. The gas supply to the burner is controlled by a thermostat, which senses the temperature of the

water.

Automatic safety controls are fitted to the water heater:

•to ensure safe ignition of the gas whenever there is a call for heating;

•to continuously monitor the burner flame; and

•to prevent excessive temperatures or pressures in the water system.

MAINS PRESSURE

In water heating applications, the water heater is designed to operate in conjunction with one or more hot water

storage tanks, which would be connected directly to the mains water supply. If the mains supply pressure in your

area exceeds the value shown in the table on page 15 or the maximum inlet pressure for the storage tanks, a

pressure limiting valve must be fitted.

In mechanical and process heating applications, the system pressure must not exceed the value shown in the table

on page 15.

109 MODELS

On/Off Operation

109 On/Off models are fitted with a mechanical thermostat, adjustable from 0°C to 95°C that

operates the gas control by switching its power on and off, so a constant temperature is

maintained. The thermostat and the protective over temperature cut out are mounted on the

control panel which is located behind the lower front cover of the water heater (refer to

"Location of Controls" on page 29).

There is no need to switch the water heater off when it is not in use. The thermostat is fully

automatic and only allows the gas control to open when the burner requires gas for heating. To adjust the

thermostat settings refer to “Temperature Control” on page 35.

Hi/Lo Operation

109 Hi/Lo models are fitted with a mechanical thermostat, adjustable from 45°C - 85°C that

operates the gas control by switching its power from high fire to low fire and off, so a constant

temperature is maintained. The thermostat and the protective over temperature cut out are

mounted on the control panel which is located behind the lower front cover of the water heater

(refer to "Location of Controls" on page 29).

There is no need to switch the water heater off when it is not in use. The thermostat is fully

automatic and only allows the gas control to open when the burner requires gas for heating. To adjust the

thermostat settings refer to “Temperature Control” on page 35.

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. The thermostat is

fully automatic and only allows the gas control to open when the burner requires gas for heating. To adjust the

thermostat settings refer to “Temperature Control” on page 35.

The thermostat may flash “AH” (alarm high) and the current water temperature, or “AL” (alarm low) and the current

water temperature. This is not a cause for concern unless the temperature displayed is more than 10ºC above the

set temperature. Refer to “Diagnostic Features of Electronic Thermostat” on page 9.

Hi/Lo Operation

147 Hi/Lo models are fitted with an electronic thermostat that operates the gas control

by switching its power from high fire to low fire 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. The thermostat is fully automatic and only

allows the gas control to open when the burner requires gas for heating. To adjust the thermostat settings refer to

“Temperature Control” on page 35.

The thermostat may flash “AL3” and 130, or “AL3” and -45. This indicates a failure of the water temperature sensor.

Refer to “Diagnostic Features of Electronic Thermostat” on page 9.

BURNER IGNITION

All 109 and 147 Hi/Lo Models

The water heater utilises an automatic burner ignition system, which lights the main burner gas when the

thermostat registers a need for heating.

A hot surface igniter (HSI) heats up when there is a call for heating. When the HSI probe is up to temperature, a

valve opens allowing gas to the main burner and this is ignited by the HSI probe. Provided successful ignition of the

main burner flame is detected, the valve remains open to supply gas to the main burner. If the main burner fails to

ignite the ignition system will lock out.

147 On/Off Models

The water heater utilises an automatic burner ignition system, incorporating an automatic pilot burner, which lights

the main burner gas when the thermostat registers a need for heating.

A hot surface igniter (HSI) heats up when there is a call for heating. When the HSI probe is up to temperature, a

valve opens allowing gas to the pilot burner and this is ignited by the HSI probe. When successful ignition of the

pilot flame is detected, the valves open to supply gas to the main burner. If the pilot fails to ignite after two

attempts, the ignition system will lock out.

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.

•Is there a time clock on the power supply?

Check the settings on the time clock and ensure they are suitable to enable

heating when it is required.

•Is the ignition system ‘locked out’?

Reset the water heater. Refer to “Water Heater Not Operating” on page 9.

•Is a code displayed on the electronic thermostat?

Check the LED display on the electronic thermostat. If a code is displayed, refer

to “Diagnostic Features of Electronic Thermostat” on page 9.

•Are you using more hot water than you think?

Are outlets (especially the showers) using more hot water than you think? Very often it is not realised the

amount of hot water used, particularly when showering. Carefully review the hot water usage. Have your

plumber fit a flow control valve to each shower outlet to reduce water usage.

•Pressure relief valve running

Is the relief valve discharging too much water? (Refer to “Pressure Relief Valve Running” on page 10).

•Thermostat setting

Ensure the thermostat setting is appropriate. You may choose to have your installer adjust the thermostat

upwards to gain additional hot water capacity.

WARNING: Hotter water increases the risk of scald injury.

•Water heater size

Do you have the correct size water heater for your requirements? The sizing guide in the Raypak sales

literature and on the Rheem website (www.rheem.com.au) suggests average sizes that may be needed.

WATER HEATER NOT OPERATING

The ignition system may have ‘locked out’. To reset the water heater, switch the electrical supply off at the isolating

switch, wait five (5) minutes then switch on again. If the water heater fails to light, phone your nearest Rheem

Service Department or Accredited Service Agent to arrange for an inspection.

DIAGNOSTIC FEATURES OF ELECTRONIC THERMOSTAT

147 On/Off and Hi/Lo water heaters incorporate an electronic thermostat. In the event of a fault occurring, a code

will be displayed on the thermostat LED to diagnose the fault.

147 On/Off Models (AKO Thermostat) 147 Hi/Lo Models (CTX Thermostat)

Code Fault Code Fault

EE Memory error AL1 Memory error

E1 Temperature sensor failure AL2 Temperature below the alarm set point

AL Temperature below the minimum set point.

Refer to “147 On/Off Operation” on page 8. AL3 (130) Water temperature sensor open circuit

Refer to “147 Hi/Lo Operation” on page 8

AH Temperature above the maximum set point.

Refer to “147 On/Off Operation” on page 8. AL3 (-45) Water temperature sensor short circuit

Refer to “147 Hi/Lo Operation” on page 8

In the event of an “AL” fault on 147 On/Off water heaters, or an “AL2” fault on 147 Hi/Lo water heaters an attempt

should be made to reset the electronic control if the burner is not already alight (refer to “Water Heater Not

Operating” on page 9).

All other fault conditions should be attended to by your nearest Rheem Service Department or Accredited Service

Agent.

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.

•Is the High Limit tripped:

The manual reset over temperature switch will shut down the water heater in the event of a fault with the

temperature control or water flow. When the system water temperature has cooled sufficiently, the red button

can be pressed, this will restart the water heater. Should frequent resetting be necessary, call your nearest

Rheem Service Department or Accredited Service Agent.

PRESSURE RELIEF VALVE RUNNING

•Normal Operation

It is normal and desirable that this valve allows a small quantity of water to escape during the heating cycle.

However, if the discharge is deemed excessive (more than 2% of hot water used), there may be another

problem.

•Continuous dribble

Try gently raising the easing lever on the relief valve for a few seconds (refer to “Pressure Relief Valve” on

page 11). This may dislodge a small particle of foreign matter and clear the fault. Release the lever gently.

•Steady flows for long period (often at night)

This may indicate the mains water pressure sometimes rises above the designed pressure of the water heater.

Ask your installing plumber to fit a pressure limiting valve.

WARNING: Never replace the relief valve with one of a pressure rating greater than 850 kPa.

EXPANSION CONTROL VALVE RUNNING

If an expansion control valve is fitted in the cold water line to the water heater (refer to page 19) it may discharge a

small quantity of water instead of the pressure relief valve on the water heater. The benefit is that energy is

conserved as the discharged water is cooler.

HIGH GAS BILLS

Should you at any time feel your gas account is too high, we suggest you check the following points:

Is the relief valve running excessively? (Refer to “Pressure Relief Valve Running”

on page 10).

Are outlets (especially the showers) using more hot water than you think? (Refer to

“Not Enough Hot Water” on page 9).

Is there a leaking hot water pipe, dripping hot water tap, etc? Even a small leak will

waste a surprising quantity of hot water and gas. Replace faulty tap washers, and

have your plumber rectify any leaking pipe work.

Consider recent changes to your hot water usage pattern and check if there has

been any increase in tariffs since your previous account.

Is there excessive heat loss from the building? Check that there are no large

uncovered windows, ceiling insulation is installed and there are no excessive

draughts.

IF YOU HAVE CHECKED ALL THE FOREGOING AND STILL BELIEVE YOU NEED ASSISTANCE, PHONE

YOUR NEAREST RHEEM SERVICE DEPARTMENT OR ACCREDITED SERVICE AGENT

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