Raypak B0200 User manual

Owner’s Guide
and
Installation Instructions
Raypak Water Heaters
Models
Types
B0200
NCO, NCM
PCO, PCM
B0280
B0350
B0430
This water heater must be installed and serviced by a qualified person.
Please leave this guide with a 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:

3
CONTENTS
HOUSEHOLDER OR RESPONSIBLE OFFICER –We recommend you read pages 4 to 10.
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..............................................................................................................................................8
REGULAR CARE .......................................................................................................................................................10
INSTALLATION ..........................................................................................................................................................11
CONNECTIONS –PLUMBING ..................................................................................................................................17
CONNECTIONS –ELECTRICAL...............................................................................................................................20
LOCATION OF CONTROLS ......................................................................................................................................25
SAFETY PRECAUTIONS...........................................................................................................................................26
COMMISSIONING......................................................................................................................................................27
OPERATING THE WATER HEATER.........................................................................................................................28
TEMPERATURE CONTROL......................................................................................................................................30
SERVICE PROCEDURES..........................................................................................................................................34
WATER SUPPLIES ....................................................................................................................................................35
WARRANTY ...............................................................................................................................................................39

4
ABOUT YOUR WATER HEATER
WATER HEATER APPLICATION
This water heater is designed for the purpose of heating for potable water or hydronic heating applications. Its use
in an application other than this may shorten its life.
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
„modulating‟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 V 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 ensuites

ABOUT YOUR WATER HEATER
5
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 Raypak 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
6
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 28)
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 pages 11 to 16. The water heater must be installed:
by a qualified person, and
in accordance with the installation instructions, and
in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local
regulations, and all local codes and regulatory authority requirements.
In New Zealand, the installation must also conform with NZS 5261, as applicable under local regulations, and the
New Zealand Building Code.
DOES THE WATER CHEMISTRY AFFECT THE WATER HEATER?
The water heater is suitable for most public water supplies, however some water chemistries may have detrimental
effects on the water heater, its components and fittings. Refer to “Water Supplies” on page 35.
If you are in a known harsh water area or you are not sure of your water chemistry, have your water checked
against the conditions described on pages 35.
HOW LONG WILL THE WATER HEATER LAST?
The water heater is supported by a manufacturer‟s warranty (refer to page 39). There are a number of factors that
will affect the length of service the water heater will provide. These include but are not limited to the water
chemistry, the water pressure, the water temperature (inlet and outlet) and the water usage pattern. Refer to
“Precautions” on page 6.
PRECAUTIONS
Where damage to property can occur in the event of the water heater leaking, the water heater must be installed in
a safe tray. Construction, installation and draining of a safe tray must comply with AS/NZS 3500.4 and all local
codes and regulatory authority requirements.
The water heater must be maintained in accordance with the Owner‟s Guide and Installation Instructions. Refer to
“Regular Care” on page 10.
If this water heater is to be used where an uninterrupted hot water supply is necessary for your application or
business you should ensure that you have back up redundancy within the hot water system design. This should
ensure the continuity of hot water supply in the event that this water heater were to become inoperable for any
reason. We recommend you seek advice from your plumber or specifier about your needs and building back up
redundancy into your hot water supply system.
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 34
WARNING: Servicing of a gas water heater should only be carried out by qualified personnel.

7
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 14 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 14.
ELECTRONIC THERMOSTAT (ON/OFF MODELS)
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. 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 8. To adjust the thermostat settings refer to “Temperature Control” on
page 30.
MECHANICAL CONTROL (MODULATING MODELS)
Modulating models are fitted with a mechanical modulating gas control that varies the gas flow to the burner in
order to maintain a constant temperature. The temperature adjustment is on the body of the modulating control,
mounted inside the lower front cover of the water heater. The protective over temperature cut out is also mounted
inside the lower front cover of the water heater.
To adjust the thermostat setting refer to “Temperature Control” on page 33.
BURNER IGNITION
The water heater incorporates an automatic burner ignition system, incorporating an automatic pilot burner, which
lights the main burner gas when the thermostat registers a need for heating.
On/Off models have a hot surface igniter (HSI) that 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.
Modulating models have a spark generator that begins operating when power is applied and any external controls
call for the water heater to operate. At the same time a valve opens to supply gas to the pilot burner. After
successful ignition of the pilot flame has been detected, the valves open to supply gas to the main burner, when
there is a call for heating. If the pilot fails to ignite within 15 seconds, the ignition system will lock out.

8
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 8.
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 8.
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 9).
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 ELIWELL ELECTRONIC THERMOSTAT
The alarm condition is always signalled by the buzzer (if present) and by the led of the alarm icon
The alarm signal produced by a faulty room probe is shown as E1 on the instrument display.
Fault conditions should be attended to by your nearest Rheem Service Department or Accredited Service Agent.

SAVE A SERVICE CALL
9
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 8.
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 10). 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 17) 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 9).
Are outlets (especially the showers) using more hot water than you think? (Refer to
“Not Enough Hot Water” on page 8).
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

10
REGULAR CARE
SERVICE
For efficient operation the water heater should be serviced annually by your nearest Rheem Service Department or
Accredited Service Agent. Only genuine replacement parts should be used on this water heater.
WARNING: Servicing of a gas water heater should only be carried out by qualified personnel.
MINOR SIX MONTH MAINTENANCE
Refer to Service Procedures on page 34
ANNUAL SERVICE
Refer to Service Procedures on page 34
MAJOR FIVE YEAR SERVICE
Refer to Service Procedures on page 34
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 9).
Warning: Never block the outlet of this valve or its drain line for any reason.
Operate the easing lever on the pressure relief valve once every six months. It is very important you raise and
lower the lever gently.
Warning: Failure to do this may result in the water heater heat exchanger failing.
Warning: Exercise care to avoid any splashing of water, as water discharged from the drain line will be hot.
Stand clear of the drain line‟s point of discharge when operating the valve‟s lever.
If water does not flow freely from the drain line when the lever is lifted, then the water heater must be checked.
Phone Rheem Service or their nearest Accredited Service Agent to arrange for an inspection.
The pressure relief valve should be checked for performance or replaced at intervals not exceeding 5 years, or
more frequently in areas where there is a high incidence of water deposits (refer to “Water Supplies”on page 35).
EXPANSION CONTROL VALVE
In many areas, including South Australia, Western Australia and scaling water areas, an expansion control valve is
fitted to the cold water line to the water heating system. The expansion control valve may discharge a small
quantity of water from its drain line during the heating period instead of the pressure relief valve on the water
heater.
Operate the easing lever on the expansion control valve once every six months. It is very important you raise
and lower the lever gently. The expansion control valve should be checked for performance or replaced at
intervals not exceeding 5 years, or more frequently in areas where there is a high incidence of water deposits.
STORAGE TANKS (IF FITTED)
Refer to the owners guide and installation instructions supplied with the storage tank for details on regular care
required.

11
INSTALLATION
THIS WATER HEATER IS NOT SUITABLE FOR POOL HEATING
INSTALLATION STANDARDS
The water heater must be installed:
by a qualified person, and
in accordance the installation instructions, and
in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local
regulations, and all local codes and regulatory authority requirements.
In New Zealand the installation must also conform with NZS 5261, as applicable under local regulations, and the
New Zealand Building Code.
All packaging materials must be removed from the water heater prior to its installation. This includes the removal of
the pallet from the underside of the water heater.
WATER HEATER APPLICATION
This water heater is designed for the purpose of heating for potable water or hydronic heating applications. Its use
in an application other than this may shorten its life.
If this water heater is to be used where an uninterrupted hot water supply is necessary for the application or
business, then there should be redundancy within the hot water system design. This should ensure the continuity of
hot water supply in the event that this water heater was to become inoperable for any reason. We recommend you
provide advice to the system owner about their needs and building backup redundancy into the hot water supply
system.
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.
READ THESE INSTRUCTIONS IN FULL
INSPECTION OF EQUIPMENT
Check the water heater and associated equipment for any damage. DO NOT INSTALL OR OPERATE ANY
WATER HEATER THAT HAS BEEN DAMAGED. ANY ADDITIONAL DAMAGE OR FAULTS CAUSED BY
UNAUTHORISED START UP MAY NOT BE COVERED BY WARRANTY.
WATER HEATER LOCATION
This water heater is supplied for outdoor installation only. For indoor installations the correct indoor conversion kit
is required (refer to “Hood Conversion”on page 15). Whether located outdoor or indoor, the position of the water
heater should be chosen with safety and service in mind. Make sure people (particularly children) will not touch the
flue outlet. The flue terminal must be clear of obstructions and shrubbery.
Clearance must be allowed for servicing of the water heater. The water heater must be accessible without the use
of a ladder or scaffold. Make sure the pressure relief valve lever is accessible and the entire front panel and burner
assembly can be removed for service. Remember you may have to remove the entire water heater later for
servicing.
You must be able to read the information on the rating label.
The water heater must not be installed in an area with a corrosive atmosphere where chemicals are stored or
where aerosol propellants are released. Remember the air may be safe to breathe, but when it goes through a
flame, chemical changes take place which may attack the water heater.
The water heater must be mounted on a level fire proof base such as a concrete slab, concrete plinth, steel plate
etc. Water heaters must NOT be installed on carpeting.
The front of the water heater must not be obstructed by any gas or water piping, electrical conduits, etc.

INSTALLATION
12
SAFE TRAY
Where damage to property can occur in the event of the water heater leaking, the water heater must be installed in
a safe tray. Construction, installation and draining of a safe tray must comply with AS/NZS 3500.4 and all local
codes and regulatory authority requirements. AS/NZS 3500.4 also has particular requirements when a safe tray
must be installed.
FIRE RESISTANT MATERIALS
Fire resistant materials should comply with the requirements of AS 5601 Appendix C. If in doubt, seek advice from
your material supplier or your local regulator.
INDOOR INSTALLATION
The correct draft diverter must be fixed to the top of the water heater (Refer
to “Hood Conversion” on page 15) and connected to a properly constructed
flue, to discharge the combustion products outside the building. The flue
must be self supporting and not impose a load on the water heater. Use a
slip joint or similar to allow for disconnection and to enable the water heater
top panel and draft diverter to be removed for servicing. There must be a
vertical rise of 600 mm from the draught diverter before changing direction.
The flue design and installation must comply with AS 5601.
NOTE: Reduction of the flue diameter or alteration to the draft diverter may
void the water heater warranty.
The water heater is to be installed at ground or floor level and must stand
vertically upright. There are also special requirements in AS 5601 for water
heaters installed in a garage, an enclosed space and other locations.
Remember all local authorities have regulations about putting water heaters
into roof spaces.
CLEARANCES (INDOOR INSTALLATIONS)
The distances set out in the following table should be observed.
Minimum Clearances from:
Non-Combustible materials
(mm)
Combustible Materials
(mm)
Rear
150
500
Water Side
600
600
Front
750
750
Non Water Side
150
500
Ceiling
1200
1200
The normal water heater design is with the water pipe entry from the left hand side. For servicing purposes allow at
least 750mm in front of the water heater for burner tray removal.
COMBUSTION / VENTILATION AIR
Indoor model water heaters must be installed in a protective enclosure or properly constructed plant room with
adequate ventilation in accordance with AS 5601.
Ideally ventilation shall be via two permanent openings DIRECTLY to outside, one at an upper level and one at low
level.

INSTALLATION
13
Where the air is sourced DIRECTLY from outside the minimum free area
required for each opening is provided in the table opposite. Where the
ventilation is by an alternate method refer to AS 5601 for ventilation
calculations.
NOTE: The minimum dimension of any opening shall be 6mm
WARNING! Air supply to the area where the water heater is installed must
not be affected by mechanical exhaust vents such as kitchen or bathroom
fans, spa blowers, etc. Mechanical exhaust vents may create a negative pressure in the area where the water
heater is installed and can become a hazard by asphyxiation, explosion or fire.
OUTDOOR INSTALLATION
For servicing allow at least 750 mm in front of the water heater for burner
removal and 450 mm on the water connections side for heat exchanger
servicing.
The water heater must NOT be installed inside any roofed structure or under
eaves, roof overhangs, or pool decks.
When installing the water heater on a raised base, the base material MUST be
solid and filled in (e.g. if steel mesh decking is used, a suitable plate material
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.
At least 500 mm between the flue terminal and a return wall or external corner, measured horizontally along the
wall.
At least 1 500 mm below any openable window.
At least 500 mm between the flue terminal and a fence, wall or other obstruction facing the terminal.
HIGH WIND CONDITIONS
In areas where high winds frequently occur, it may 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 is from the prevailing
winds.
Replace the standard flue terminal with a HIGH WIND top (at extra cost).
Model
Total area (cm2)
200
585
280
825
350
1035
430
1275

INSTALLATION
14
COLD WATER SUPPLY
Water Heating Applications
Where the cold water supply pressure exceeds that shown in the table below, an approved pressure limiting valve
is required and should be fitted as shown in the installation diagram (refer to diagram on page 17).
Mechanical/Process Heating Applications
A cold water feed regulator (Pressure Reducing Valve) should be installed on the cold water make up line. The
minimum water pressure should be as shown in the table below. Backflow prevention in accordance with
AS/NZS 3500.1 may be required.
Pressure Specifications
Operation Type
On/Off
Modulating
Relief Valve Setting
Water Heating (kPa)
850 (700)¹
850 (700)¹ ³
Mechanical Heating (kPa)
-
310
Expansion Control Valve (ECV²) Setting
Water Heating (kPa)
700 (550)¹
700 (550)¹ ³
Mechanical Heating (kPa)
-
-
Minimum Supply Pressure
System water temperatures up to 65°C (kPa)
70
70
System water temperatures above 65°C (kPa)
120
120
Maximum Supply Pressure
with ECV² fitted
Water Heating (kPa)
680 (550)¹
680 (550)¹ ³
Mechanical Heating (kPa)
-
240
without ECV² fitted
Water Heating (kPa)
550 (450)¹
550 (450)¹ ³
Mechanical Heating (kPa)
-
-
¹ Figures in brackets are to be used if a stainless steel storage tank is utilised in the system.
² Expansion control valve is not supplied with the water heater.
³ An 850kPa relief valve can be fitted to modulating water heaters when used in water heating applications.
TANK WATER SUPPLY
If the water heater is supplied with water from a tank
supply and a pressure pump system is not installed then
the height to the bottom of the supply tank must be as
specified in the table opposite.
Minimum Tank Height
System water temperatures up to 65°C
7 metres
System water temperatures above 65°C
12 metres

INSTALLATION
15
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. The installing plumber may have a legal obligation to ensure the installation of this
water heater meets the delivery water temperature requirements of AS/NZS 3500.4 so that scalding water
temperatures are not delivered to a bathroom, ensuite, or other ablution or public area.
Where a temperature limiting device is installed adjacent to the hot water storage tanks, the cold water line to the
temperature limiting device can be branched off the cold water line either before or after the isolation valve,
pressure limiting valve and non return valve to the storage tanks. If an expansion control valve is required, it must
always be installed after the non return valve and be the last valve prior to the water heating system.
If a pressure limiting valve is installed on the cold water line to the water heating system and the cold water line to a
temperature limiting device branches off before this valve or from another cold water line in the premises, then a
pressure limiting valve of an equal pressure setting may be required prior to the temperature limiting device.
REDUCING HEAT LOSSES (WATER HEATING APPLICATIONS)
The cold water line to and the hot water line from the storage cylinder must be insulated in accordance with the
requirements of AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if exposed.
Keep temperature settings down. Lower temperatures reduce heat losses and prolong storage cylinder life. Do not
set the controlling electronic thermostat above 70°C unless it is necessary. A time clock to control the electrical
supply can be used to switch off the water heater during hours or days when it is not in use.
HOOD CONVERSION
To convert a water heater from an outdoor configuration to an Indoor or High Wind Top configuration, proceed as
follows:
1. Remove the flue terminal (outdoor hood) from the water heater leaving the jacket top in place.
Place the stack adaptor over the flue collector and secure into place with self tapping screws.
Fit the draft diverter over the spigot and sit squarely on the stack adapter. Secure in place using self tapping
screws.
(Indoor installations only) Install and connect the secondary flue to the draft diverter in accordance with the
requirements of AS 5601.
NOTE: For High Wind Top conversion follow steps 1 to 3 and assess whether tie downs for the High Wind Cowl
are required.

INSTALLATION
16
DIMENSIONS AND TECHNICAL DATA
200
280
350
430
Natural Gas
Input (MJ/h)
196
278
343
420
Output (kW)
44
62
76
94
Propane Gas
Input (MJ/h)
185
261
323
396
Output (kW)
41
58
72
88
Electrical Rating
240 V 50 Hz
Power (W)
50
50
50
50
Current (A)
0.21
0.21
0.21
0.21
Weight empty
Kg
91
93
103
107
Flue Connection
mm
175
205
225
255
Dimensions
A
mm
1625
1715
1715
1805
B
mm
465
570
655
745
C
mm
1955
2240
2035
2145

17
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.
CONNECTION SIZES
Inlet water connection: RC1½/40
Outlet water connection: RC1½/40
Relief valve connection: RC¾/20
Gas inlet (On/Off Models): RC¾/20
Gas Inlet (Modulating Models: RC1/25
All plumbing work must be carried out by a qualified person and in accordance with the National Plumbing
Standard AS/NZS 3500.4 and local authority requirements.
All gas work must be carried out by a qualified person and in accordance with the Australian Gas Installations
Standard AS 5601 and local authority requirements.
WATER INLET AND OUTLET
All pipe work must be cleared of foreign matter before connection and purged before attempting to operate the
water heater. All olive compression fittings must use brass or copper olives. Use thread sealing tape or approved
thread sealant on all fittings.
An isolation valve and non-return valve must be installed on the cold water
line to the water heating system. An acceptable arrangement is shown in the
diagram opposite for a water heating application.
A disconnection union must always be provided at the inlet and outlet on the
water heater to allow for disconnection of the water heater.
Do not reduce the pipe work size and water heater water connections without
allowing for friction loss which will occur. Low water flow will cause damage to
the water heater and system components.
GAS INLET
The gas connection is made to the inlet of the gas control (On/Off Models) or pressure regulator (Modulating
Models). The pipe work must be cleared of foreign matter before connection and purged before attempting to light
the water heater. An isolation valve and disconnection union must be used to allow servicing and removal of the
water heater.
Refer to the Gas Installations Standard AS 5601 for the correct method of sizing the gas supply pipe to the water
heater.
WARNING: Before pressure testing the gas supply system always isolate and disconnect the water heater after
the isolating cock to prevent the risk of serious damage to the gas control or pressure regulator. Warranty does not
cover damage of any nature resulting from failure to observe this precaution. Refer to rating label for gas types and
pressures.
Ensure the gas line is also purged at the union to the gas control or pressure regulator. If this procedure is not
followed, a retry lockout may result on initial start up.
CAUTION: Care is necessary when tightening fittings into the gas control or pressure regulator. The gas control or
pressure regulator casting may crack if the fittings are over tightened. Cracked castings are not covered under
warranty. Damaged gas controls and pressure regulators must be replaced.
PIPE SIZES
The pipe sizing for water heating and mechanical heating systems should be carried out by persons competent to
do so, choosing the most suitable pipe size for each individual application. Reference to the technical specifications
of the water heater and local regulatory authority requirements must be made.



CONNECTIONS –PLUMBING
18
The table below provides indicative pipe and pump sizes for typical installations
Model
Pump
Branch Size
Minimum Manifold Header
Size Required (mm)
UPS
Series
Speed
inches
mm
1
Unit
2
Units
3
Units
4
Units
200
20-60B
3
1
25
25
32
40
50
280
20-60B
3
1¼
32
32
32
50
50
350
32-80B
2
1¼
32
32
40
50
50
430
32-80B
3
1¼
32
32
40
50
65
PUMP SELECTION
In order to obtain the best possible water flow in the system a correctly sized pump must be installed. Refer to the
Flow Rate and Pressure Drop table below and allow for the system head pressure when sizing the pump.
The pump selected should provide a 10 to 20°C temperature difference between the water heater inlet and outlet
when the water heater is at full fire.
Mechanical heating systems with multiple zones may require additional pump(s) refer to „Multi Pump Options‟ on
page 24.
WATER FLOW RATE AND PRESSURE DROP
10°C Rise
15°C Rise
20°C Rise
Model
l/sec
kPa
l/sec
kPa
l/sec
kPa
200
1.04
3
0.69
3
0.52
3
280
1.47
8
0.98
4
0.74
3
350
1.82
13
1.22
6
0.91
3
430
2.24
17
1.49
8
1.12
4
PRESSURE RELIEF VALVE
The pressure relief valve and elbow are shipped in a plastic bag inside the water
heater. The pressure relief valve must be fitted before the water heater is operated.
Fit the elbow supplied in the plastic bag to the ¾” connection on the inlet/outlet
header then screw the relief valve onto the other end of the elbow.
Seal the treads using Teflon tape, never hemp. A drain line must be
installed in accordance with AS/NZS 3500.4 to carry the discharge
from the valve to a suitable discharge point.
Relief Valve Pressure Rating
On/Off Models
850 kPa (125 psi)
Modulating Models
310 kPa (45 psi)
When the water heater is connected to a storage cylinder for water heating
applications, a correctly sized and pressure rated TPR valve MUST be fitted to the storage cylinder.
NOTE: Where a modulating water heater is used in a water heating application it will be necessary to replace the
310 kPa relief valve provided with the water heater with one rated at 850 kPa.
RELIEF VALVE DRAIN
A copper drain line must be fitted to the relief valve to carry the discharge clear of the water heater. Connect the
drain line to the relief valve using a disconnection union. The pipe work from the relief valve to the drain should be
as short as possible and fall all the way from the water heater with no restrictions. It should have no more than
three right angle bends in it. Use DN20 pipe.
The outlet of the drain line must be in such a position that flow out of the pipe can be easily seen (refer to
AS/NZS 3500.4) - but arranged so hot water discharge will not cause injury, damage or nuisance. The drain line
must discharge at an outlet or air break not more than 9 metres from the relief valve.
Pressure
Relief Valve

CONNECTIONS –PLUMBING
19
In locations where water pipes are prone to freezing, the drain line must be insulated and not exceed 300 mm in
length. In this instance, the drain line is to discharge into a tundish through an air gap of between 75 mm and
150 mm.
WARNING: The pressure relief valve on this water heater may discharge high temperature water under certain
conditions, it is strongly recommended the pipe work downstream of the relief valve be capable of carrying water
exceeding 93 C. Failure to observe this precaution may result in damage to pipe work and property.
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 18. 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.
Typical Mechanical Heating Installation
WATER HEATING
Where the water heater is required for hot water applications, the heater MUST be used in conjunction with a hot
water storage tank, manufactured in compliance with AS 3498 under a current Watermark license. To inhibit the
growth of Legionella bacteria, the tankstat controlling the temperature of the stored water must not be set below
60°C.
Typical Water Heating Installation

20
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. The GPO must be clear of the flue exhaust, draining water, gas supply pipe and water connections.
The water heater must be properly earthed and the installation of a Residual Current Device (RCD) is
recommended for added electrical safety
CAUTION: DO NOT LOCATE CABLES IN FRONT OF OR UNDERNEATH THE BURNER.
Where conduit is mounted to the water heater a 10mm air gap must be maintained from the water heater casing to
eliminate possible overheating. DO NOT locate conduits or cables where they will obstruct or restrict removal of
panels, access doors etc.
The water heater must NOT be able to operate without the pump running.
The water heater and pump may be supplied from the same electrical circuit, alternatively the 240 volt supply to the
water heater may be provided via auxiliary contacts of the pump contactor or relay (if fitted).
Where additional control wiring is connected to the water heater, which is not isolated by the GPO, a suitable
warning label must be affixed to the water heater identifying the isolation point for that particular wiring (e.g. by
circuit breaker or fuse number and switchboard identification number or location).
THERMOSTAT SETTING
The thermostat is adjustable from 20 C to 80 C. For reasons of safety and economy, we recommend that the
thermostat is set at the lowest temperature that will provide sufficient hot water. Discuss the thermostat setting
requirements with the householder or responsible officer. Refer to “Temperature Control”on page 30.
INTERMITTENT PUMP OPERATION
For applications utilising intermittent pump operation an optional pump run on timer kit, part number 56076873,
must be fitted to the water heater to prevent nuisance tripping of the high limit thermostat due to heat build up in the
heat exchanger. The timer should be set to allow the pump to operate for at least ten (10) minutes.
EXTERNAL CONTROLS
The water heater can be wired for use with an external flow switch, remote
control thermostat or a remote time switch. To connect an external control to
the water heater it is necessary to remove the bridging wire between terminals
1 and 2 of the water heater terminal block and connect the external control
across these two terminals (refer to the diagram opposite and to the wiring
diagrams on pages 22 to 23.
Where an external thermostat is utilised the water heater thermostat should
be adjusted to a temperature higher than the setting on the remote thermostat (Refer to "Temperature Control" on
page 30.
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.
Where multiple water heaters are connected to a power flue, the control
system must be designed so that any of the water heaters can activate
the fan in the flue and none of the burners can come on until the flow in
the flue has been established.
To connect a power flue to the water heater it is necessary to remove
the bridging wire between terminals 3 and 4 of the water heater terminal
block and connect the wiring to the power flue across these two
terminals (refer to the diagram opposite and to the wiring diagrams on
pages 22 and 23