Raypak RAYTHERM 133 Manual

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CATALOG NO. 3000.52P Effective: 04-20-12 Replaces: 10-31-11 P/N 241075 Rev. 17
This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future
reference.
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• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
&! Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury or loss of life. Refer to this manual.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
!'$!"#' 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.
Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
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2
Rev. 16 reflects the following:
Changes to: ASME Mark on page 1, warnings on page 4, warning on page 27
Additions: Warnings on page 7, warning on page 13, warnings on page 14, warning on page 19, caution on page 20, warn-
ing on page 30, warning on page 48

&!" 
Pay Attention to These Terms 4
!"#' 
Time/Temperature Relationships in Scalds 6
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Model Identification 6
General Specifications 7
All Models (Approved) 7
Hot Water Supply Heaters 7
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Installation Codes 7
Installation ase 7
Clearances 8
Specifications and Dimensions 9
Outdoor Water Heaters 12
Combustion Air (Indoor Units Only) Air for
Combustion and Ventilation 12
Venting 13
Vent Piping 17
Vent Damper Installation 18
Plumbing 20
Flow Rates 22
Piping—Domestic Hot Water Supply
Heaters 23
Piping Diagram—Type WH - Unitemp 80
System 24
Controls—General 25
Limit Controls 26
Electrical Connections 27
Location of Controls 28
"#!#$!$!" 
efore Start-Up 30
General 30
Initial Start-Up - Pump and Motor 30
Intermittent Pilot System Checkout
Procedure (S8600) 32
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urners 32
Controls 32
Inspection Procedures 33
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Operation 33
Start-Up Procedures
(S8610 Ignition Module) 33
##"
3
urner Adjustment 34
Visual Inspection 34
Electrical 34
High Gas Pressure Switch 34
urner Tray Removal 34
Gas Valve Removal 34
Main urner And Orifice Removal 35
Pilot Removal 35
Combustion Fan Removal 35
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Electrical 36
Mechanical 37
&!!" 
Wiring Diagram—W2/WH2 133 38
Wiring Diagram—WH1 0181/0261 39
Wiring Diagram—WH1 0331/0401 40
Wiring Diagram—WH1 0514–0724 41
Wiring Diagram—WH1 0824–1826 42
Wiring Diagram—WH1 2100–2500 43
Wiring Diagram—WH1 3001–4001 44
Troubleshooting—Pumps 45
"!%#
!$!" 
Tube Cleaning 45
urner Tray Removal 46
Gas Valve Removal 46
Gas Valve Adjustment - Robertshaw
(Invensys) 7000 Series 2-Stage Gas Valve
with Solenoid Valve 46
Main urner and Orifice Removal 47
Pilot Removal and Cleaning 47
High Limit or Tankstat Removal 47
Heat Exchanger Removal 47
Heat Exchanger Re-Assembly 47
Combustion Chamber Removal 48
Control Well Replacement 48
Tube Replacement 48
Cleaning Flue Gas Passageways 49
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&!!#' 

4
! Indicates the presence of immediate hazards which will cause severe
personal injury, death or substantial property damage if ignored.
&! Indicates the presence of hazards or unsafe practices which could cause
severe personal injury, death or substantial property damage if ignored.
$# Indicates the presence of hazards or unsafe practices which could cause
minor personal injury or product or property damage if ignored.
# Indicates special instructions on installation, operation, or maintenance which
are important but not related to personal injury hazards.
&!"C(@;;,5;065;6#/,:,#,94:
! Failure to install the draft hood and
properly vent the water heater to the outdoors as
outlined in the Venting section of this manual can
result in unsafe operation of the water heater. To
avoid the risk of fire, explosion, or asphyxiation from
carbon monoxide, never operate this water heater
unless it is properly vented and has an adequate air
supply for proper operation. e sure to inspect the
vent system for proper installation at initial start-up;
and at least annually thereafter. Refer to the
Maintenance section of this manual for more
information regarding vent system inspections.
&! Propane appliances should not be
installed below-grade (for example, in a basement) if
such installation is prohibited by federal, state and/or
local laws, rules, regulations or customs.
&! oth propane and natural gas have an
odorant added to help detection. Some people may
not physically be able to smell or recognize this
odorant. If unsure or unfamiliar about the smell
associated with propane or natural gas, ask the gas
supplier. Other conditions, such as "Odorant Fade",
which causes the odorant to "fade", or diminish in
intensity can also hide or camouflage a gas leak.
! Make sure the gas on which the heater
will operate is the same type as that specified on the
heater rating plate.
! When servicing or replacing components
that are in direct contact with the water, be certain
that:
• There is no pressure in the heater. (Pull the release
on the relief valve. Do not depend on the pressure
gauge reading).
• The heater water is not hot.
• The electrical power is off.
&! All venting types must be of the same
material or product throughout the entire exhaust
installation to ensure proper securing and sealing.
&! Altering any Raypak pressure vessel
by installing replacement heat exchangers, tube
bundle headers, or any ASME parts not
manufactured and/or approved by Raypak will
instantly void the ASME and/or CSA ratings of the
vessel and any Raypak warranty on the vessel.
Altering the ASME and/or CSA ratings of the vessel
also violates national, state, and local approval
codes.
&! Do not use this heater if any part has
been under water. Immediately call a qualified
service technician to inspect the heater and to
replace any part of the control system and any gas
control which has been under water.
&! Risk of electrical shock. More than one
disconnect switch may be required to de-energize
the equipment before servicing.
&! Should overheating occur or the gas
supply valve fail to shut, do not turn off or disconnect
the electrical supply to the heater. Instead, shut off
the gas supply at a location external to the heater.
&! UL recognized fuel gas detectors are
recommended in all enclosed propane and natural
gas applications wherein there is a potential for an
explosive mixture of fuel gas to accumulate and their
installation should be in accordance with the
detector manufacturer's recommendations and/or
local laws, rules, regulations, or customs.

5
DANGER
!
Vapors from flammable liquids
will explode and catch fire
causing death or severe
burns.
Do not use or store flammable
products such as gasoline sol-
vent s o r a d h esiv e s i n t h e s ame
room or area near the water
heater.
Keep flammable products:
1. Far away from heater,
2. In approved containers,
3. Tightly closed and
4. Out of children's reach.
Installation:
Do not install water heater where flammable products will be
stored or used unless the main burner and pilot flames are at
least 18" above the floor. This will reduce, but not eliminate, the
risk of vapors being ignited by the main burner or pilot flame.
Read and follow water heater warnings and instructions.
Water heater has a main
burner and pilot flame.
The pilot flame:
1. Is on all the time or intermit-
tently (IID).
2. Will ignite flammable va-
pors.
Vapors:
1. Cannot be seen,
2. Are heavier than air,
3. Go a long way on the floor,
4. Can be carried from other
rooms to the pilot flame by air
currents.
!"#'
To meet commercial hot water needs, this heater is
equipped with a manual reset temperature limit that
does not exceed 200°F. However, water temperatures
over 125°F can cause instant severe burns or death
from scalds. This is the preferred temperature setting
when supplying general purpose hot water.
Safety and energy conservation are factors to be con-
sidered when setting the water temperature on the
thermostat. The most energy-efficient operation will
result when the temperature setting is the lowest that
satisfies the needs consistent with the application.
Maximum water temperatures occur just after burner
has shut-off. To determine the water temperature
being delivered, turn on the hot water only, place a
thermometer in the stream, and read the thermometer.
Water temperature over 125°F can
cau s e i nsta n t s e v e r e b u r n s o r d eath
from scalds.
Children, disabled, and elderly are
at highest risk of being scalded.
See instruction manual before set-
ting temperature at water heater.
Feel water before bathing or show-
ering.
Temperature limiting valves are
available, see manual.
The following chart details the relationship of water
temperature and time with regard to scald injury and
may be used as a guide in determining the safest
water temperature for your applications.
Temperature Time to Produce Serious Burn
120°F More than 5 minutes
125°F 1-1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1-1/2 seconds
155°F About 1 second
Table courtesy of Shriners urn Institute.
Table A: Time to Produce Serious Burn
&!  ! !"#
 This product contains chemicals known to the
State of California to cause cancer, birth defects or
other reproductive harm.

6
!% $#
On receipt of the equipment, visually check for exter-
nal damage to the carton or the shipping crate. If the
carton or shipping crate is damaged, make a note on
the ill of Lading and report the damage to the Carrier
immediately. Remove the heater from the carton or the
shipping crate.
Do NOT use the shipping crate base as an installation
base. On occasion, items are shipped loose. e sure
that you receive the number of packages indicated on
the ill of Lading.
When ordering parts, you must specify Model and
Serial Number of the heater. When ordering under
warranty conditions, you must also specify date of
installation.
Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak heater. If
there are any questions which this manual does not
answer, please contact the factory or your local
Raypak representative.
Claims for shortages and damages must be filed with
carrier by consignee. Permission to return goods must
be factory-authorized and are subject to a stocking
charge.
Purchased parts are subject to replacement only
under the manufacturer's warranty. Debits for defec-
tive replacement parts will not be accepted and will be
replaced in kind only per our standard warranties.
6+,3+,5;0-0*(;065
The model identification number and the heater serial
number are found on the heater data plate. The model
number will have the form WH1-0514A or similar
depending on the heater model. (WH = Hot Water
Supply System, 1 = on/off firing, 0514 = size of
heater).
Rated inputs are suitable for up to 2000 feet elevation.
For elevations above 2000 feet, reduce input 4% for
each 1000 feet above sea level.
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The temperature of the water in the storage tank
heater can be regulated by setting the temperature
dial on front of the tankstat. To comply with safety reg-
ulations, the tankstat was set at its lowest setting
before shipment from the factory.
Fig. 1 illustrates a mechanical tankstat. To adjust the
water temperature, insert a small straight screwdriver
into slotted screw in hole in front of tankstat and turn
wheel to desired setting. Thermostat is adjustable up
to 190°F.
Fig. 1: Tankstat Adjustment
! There is a Hot Water SCALD Potential if
the tankstat is set too high.
$# Hotter water increases the risk of
SCALDING!
# When this heater is supplying general
purpose hot water requirements for use by
individuals, a thermostatically controlled mixing
valve for reducing point of use water temperature is
recommended to reduce the risk of scald injury.
Contact a licensed plumber or the local plumbing
authority for further information.
&! Pump motors should NOT be
supported by any type of stand or support from
above due to possible misalignment of pump and
motor which might occur.

7
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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 149 and the Canadian Electrical Code
Part 1 CSA C22.2 No.1. Where required by the author-
ity having jurisdiction, the installation must conform to
American Society of Mechanical Engineers Safety
Code for Controls and Safety Devices for
Automatically Fired Heaters, CSD-1.
5:;(33(;065(:,
The heater should be mounted on a level, non-com-
bustible surface. Heater must not be installed on
carpeting. The heater can be installed on a com-
bustible surface only when the appropriate listed floor
shield base is provided. An optional listed floor shield
base is available for factory installation with the heater
on all indoor models. Do NOT use the shipping base
crate as an installation base.
# The heater should be located in an area
where water leakage will not result in damage to the
area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not restrict air flow.
,5,9(3"7,*0-0*(;065:
The Raypak water heaters are design certified and
tested under the latest requirements of the American
National Standard, ANSI Z21.10.3/CSA 4.3. Each
heater has been constructed and pressure tested in
accordance with the requirements of Section IV of the
American Society of Mechanical Engineers Code, and
factory fire tested. Materials are CSA-certified for low-
lead content (<.25%).
336+,3:7796=,+
All models are National oard approved. Temperature
and pressure gauge is standard. Intermittent ignition
device is standard on models 0514 and up.
Model 0133 has 4-pass heat exchanger, 1 tube per
pass.
Models 0181-0401 have 2-pass heat exchangers, 5
tubes first pass, 4 tubes second pass.
Models 0514-1826 have 2-pass heat exchangers, 5
tubes first pass, 4 tubes second pass.
Models 2100-4001 have 2-pass heat exchangers, 9
tubes per pass.
Models 0926-4001 have optional single pass with cast
iron headers only.
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All Raypak hot water supply heaters are ASME rated
and design certified as hot water heaters, with 125 PSI
pressure relief valves.
#'&>0;/#!"
6+,3:
To be used with storage tank systems. Available with
integrally mounted pump, factory mounted and wired
for models 0133-1826. Models 0181, 0261, 0331 and
0401 are Low NOx Hot Water Heaters.
#'&>0;/$#
#!"
6+,3:
Hot water supply heater with 110°-170°F gas modula-
tion. Available with integrally mounted pump, factory
mounted and wired for models 0133-1826. To be used
with storage tank systems.
#'&>0;/"#
#!"
6+,3:
Hot water supply heater with low-high fire for 2-stage
control. Available with integrally mounted pump, facto-
ry mounted and wired for models 0181-1826. To be
used with storage tank systems.
&! The heater shall not be located in an
area where water sprinklers, or other devices, may
cause water to spray through the cabinet louvers and
into the heater. This could cause internal rusting or
damage electrical components, and void the warran-
ty.
&! This product must be installed by a
licensed plumber or gas fitter when installed within
the Commonweatlh of Massachusetts.

8
Heater
Model
Number
Floor Base
Part
Number
0133 001749
0182/0181 058313
0260/0261 058314
0330/0331 058315
0400/0401 058316
0514 056199
0624 056200
0724 056201
0824 056202
0926* 054597
1083* 054598
1178* 054599
1287* 054600
1414* 054601
1571* 058378
1758* 058379
0962 059233
1125 059234
1223 059235
1336 059236
1468 059237
1631 059238
1826 059239
*Models with factory installed floor
shield as standard.
BOLD TYPE indicates Low NOx models.
Table B: Combustible Floorshield Ordering Information
Fig. 2: Alternate Method for Providing a Non-
Combustible Base
3,(9(5*,:
5:;(33(;0653,(9(5*,:
3304,5:065:(9,055*/,:
0133 0181 to 0514 to 0926 to 2100 to
Location 0401 0824 1826 4001
Floor
Front
Back 12 12 12 24 24
Right 61262424
Left 12 12 18 24 24
*Vent 66666
Indoor Top 42 39 36 24 24
Outdoor Top NA
See Note 1
See Note 2
Unobstructed
Heater Size
Table C: Clearances From Combustible Surfaces
Note 1: Combustible floor shield is required when heater is to be
installed on a combustible surface. (See ordering info.)
Note 2: Servicing Clearances: Provide at least 24" (Models 0133-
1826), 48" (Models 2100-4001) in front of unit for removal &
servicing of the Controls & urner Tray. Provide at least 18" on side
opposite water connections for deliming of Heat Exchanger Tubes.
*Vent includes factory supplied drafthoods and does not include field
supplied vent systems above the drafthood. On Models 2100-4001
drafthood is built into heater.
Heater Size
0133 0181 to 0514 to 0926 to 2100 to
Description Location 0401 0824 1826 4001
a. 3-1/2 in. thick masonr
y
walls Back 9991616
without ventilated air space. Right 5951616
Left 99121616
Vent 55555
Indoor Top 43 39 36 24 24
Outdoor Top Unobstructed NA
b. 1/2 in. insulation board Back 6661212
over 1 in. glass fiber or Right 3631212
mineral wool batts. Left 6691212
Vent 33333
Indoor Top 30 30 24 16 16
Outdoor Top Unobstructed NA
c. 0.024 sheet metal over 1 in. Back 44488
glass fiber or mineral wool Right 34388
batts reinforced with wire Left 44688
on rear face with ventilated Vent 33333
air space. Indoor Top 24 24 18 12 12
Outdoor Top Unobstructed NA
d. 3-1/2 in. thick masonr
y
wall Back 66688
with ventilated air space. Right 66688
Left 66688
Vent 66666
Indoor Top 42 39 36 24 24
Outdoor Top NA Unobstructed NA
e. 0.024 sheet metal with Back 44488
ventilated air space. Right 24288
Left 44688
Vent 22222
Indoor Top 24 24 18 12 12
Outdoor Top Unobstructed NA
f. 1/2 in. thick insulation Back 44488
board with ventilated Right 34388
air space. Left 44688
Vent 33333
Indoor Top 24 24 18 12 12
Outdoor Top NA Unobstructed NA
g
.0.024 sheet metal with Back 44488
ventilated air space over Right 34388
0.024 sheet metal with Left 44688
ventilated air space. Vent 33333
Indoor Top 24 24 18 12 12
Outdoor Top Unobstructed NA
h. 1 in.
g
lass fiber or mineral Back 44488
wool batts sandwiched Right 34388
between two sheets 0.024 Left 44688
sheet metal with ventilated Vent 33333
air space. Indoor Top 24 24 18 12 12
Outdoor Top NA Unobstructed NA
Table D: Clearances to Protected Surfaces

9
# The heater shall be installed in a space large in comparison to the size of the heater. Large space is
defined as having a volume at least sixteen (16) times the total volume of the heater.
MODELS 0182-0400 and 0181-0401
MODEL 0133
"7,*0-0*(;065:(5+04,5:065:
NOTE:
Ratings are shown for elevations up to 2,000 feet. For elevations
over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea
level.
NOTE:
Ratings are shown for elevations up to 2,000
feet. For elevations over 2,000 feet, reduce
ratings 4% for each 1,000 feet above sea level.
Bold type indicates Low NOx models.
Model
Number
Indoor Outdoor
Input M H
Recovery
GPH*
Recovery
GPH*
WH-0133 136.0 135 132
* Recovery based on manufacturer’s rating.
Model Number
Indoor Dimensions (in inches)
Input
M H
Recovery
GPH*
Width
A
Height
C J
Flue
Diameter
K
WH-0182/0181 181.0 180 18-1/4 62-5/8 12-1/16 6
WH-0206/0261 264.0 262 22-3/8 62-7/8 11-1/8 7
WH-0330/0331 334.0 332 25-3/4 63-3/4 10-3/4 8
WH-0400/0401 399.0 397 29-1/4 65-3/8 12-1/2 9
* Recovery based on manufacturer’s rating.

10
MODELS 0514-0824
MODELS 0962-1826
Model
Number
Indoor/Outdoor Dimensions (in inches)
Input
M H
Recovery
GPH*
Width
A
Gas
Conn.
G
Flue
Diameter
K L
WH-0514 511.5 508 32-3/4 1 10 25-3/8
WH-0624 627.0 623 37-1/2 1 12 29-1/2
WH-0724 726.0 722 41-5/8 1 12 34-1/4
WH-0824 825.0 820 45-3/4 1 14 38-1/2
NOTE:
Ratings are shown for elevations up to
2,000 feet. For elevations over 2,000 feet,
reduce ratings 4% for each 1,000 feet above
sea level.
* Recovery based on manufacturer’s rating.
* Recovery based on manufacturer’s rating.
NOTE:
Ratings are shown for elevations
up to 2,000 feet. For elevations
over 2,000 feet, reduce ratings
4% for each 1,000 feet above sea
level.
Model
Number
Input
M H
Recovery
GPH*
Dimensions (in inches)
Width
A
Overall
Height
Jacket
Height
C
Gas
Conn.
G
Water
Conns.
H J
Flue
Diameter
K L
WH-0962 961.7 956 52-3/8 68-3/4 33-1/2 1 2-1/2 18 14 28
WH-1125 1124.7 1118 59-1/4 74-1/2 33-1/2 1 2-1/2 23-5/8 16 32
WH-1223 1222.5 1215 63-5/8 74-1/2 33-1/2 1-1/4 2-1/2 23-5/8 16 32
WH-1336 1336.6 1328 68-5/8 76-1/2 33-1/2 1-1/4 2-1/2 23-5/8 18 36
WH-1468 1467.0 1458 74-7/8 76-1/2 33-1/2 1-1/4 2-1/2 23-5/8 18 36
WH-1631 1630.0 1620 82-1/8 79-1/2 36-1/2 1-1/4 2-1/2 23-5/8 18 36
WH-1826 1825.6 1814 89-3/8 81-1/2 36-1/2 1-1/4 2-1/2 23-5/8 20 40

11
MODELS 0926-1758
MODELS 2100-4000
MODEL,
Model
Number
Input
MH
Recovery
GPH*
Dimensions (in inches)
Width
A
Gas
Conn.
G
Water
Conns.
H
WH-0926 926.0 920 52-3/8 1 2-1/2
WH-1083 1083.0 1076 59-1/4 1 2-1/2
WH-1178 1178.0 1171 63-5/8 1-1/4 2-1/2
WH-1287 1287.0 1279 68-5/8 1-1/4 2-1/2
WH-1414 1413.0 1404 74-7/8 1-1/4 2-1/2
WH-1571 1570.0 1560 82-1/8 1-1/4 2-1/2
WH-1758 1758.0 1747 89-3/8 1-1/4 2-1/2
NOTE:
Ratings are shown for elevations up to 2,000 feet. For elevations
over 2,000 feet, reduce ratings 4% for each 1,000 feet above sea
level.
* Recovery based on manufacturer’s rating.
Model
Number
Input
M H
Recovery
GPH*
Dimensions (in inches)
Width
A
Overall
Height
Gas
Conn.
G
Water
Conns.
H
Flue
Diameter
K
WH-2100 2100.0 2087 61 68-1/4 ** 3 24
WH-2500 2499.0 2484 70 68-1/4 ** 3 26
WH-3001 3000.0 2982 81-1/4 68-1/4 2 3 28
WH-3500 3500.0 3479 92-1/2 68-1/4 2 3 30
WH-4001 4000.0 3976 103-3/4 68-1/4 2 3 32
NOTE:
Ratings are shown for elevations up to 2,000 feet. For
elevations over 2,000 feet, reduce ratings 4% for each
1,000 feet above sea level.
* Recovery based on manufacturer’s rating.
** 1-1/2” or 2” contingent on code requirements

12
<;+669&(;,9,(;,9:
These heaters are design certified for outdoor installa-
tion. Heaters must not be installed under an overhang
of less than three (3) feet from the top on the heater.
Three (3) sides must be open in the area under the
overhang. Roof water drainage must be diverted away
from the heaters installed under overhangs with the
use of gutters.
The point from where the flue products exit the heater
must be a minimum of four (4) feet below, four (4) feet
horizontally from or one (1) foot above any door, win-
dow or gravity inlet to a building. The top surface of the
heater shall be at least three (3) feet above any forced
air inlet, or intake ducts located within ten (10) feet hor-
izontally.
0./&05+65+0;065:<;+669
$50;:53@
In areas where high winds are frequent, it may be nec-
essary to locate the heater a minimum of 3' from high
vertical walls, or install a wind break so the heater is
not in direct wind current.
64)<:;065095+669$50;:
53@09-6964)<:;065(5+
%,5;03(;065
The heater must have both combustion and ventilation
air. Minimum requirements for net free air supply
openings are 12 inches from ceiling for ventilation and
12 inches from the floor for combustion air as outlined
in ANSI Z223.1, and any local codes that may have
jurisdiction.
Fig. 3: Outdoor Clearances from Openings
a. All Air From Inside The uilding:
Each opening shall have a minimum net free square
inches as noted:
b. All Air From Outdoors:
When air is supplied directly from outside of building,
each opening shall have a minimum net free square
inches as noted:
$# Combustion air must not be
contaminated by corrosive chemical fumes which
can damage the heater. Measures must be taken to
prevent the entry of corrosive chemical fumes to the
combustion and ventilation air supply. Such
chemicals include, but are not limited to, chlorinated
and/or fluorinated hydrocarbons such as found in
refrigerants, aerosol propellants, dry-cleaning fluids,
degreasers, and paint removers. Other harmful
elements may come from bleaches, air fresheners,
or mastics. Vapors from these types of products can
form corrosive acid compounds when burned in a
gas flame. The resulting acidic condensate can
damage or substantially reduce the life of the heater.
It may become necessary to provide outside air
directly to the heater in order to avoid this problem.
Model
Square
Inches Model
Square
Inches
0133 136 1223 1223
0182/0181 181 1336 1337
0260/0261 264 1468 1467
0330/0331 334 1631 1630
0400/0401 399 1826 1826
0514 512 2100 2100
0624 627 2500 2499
0724 726 3001 3000
0824 825 3500 3500
0962 962 4001 4000
1125 1125
BOLD TYPE indicates Low NOx models.
Model
Square
Inches Model
Square
Inches
0133 34 1223 306
0182/0181 46 1336 335
0260/0261 66 1468 367
0330/0331 84 1631 408
0400/0401 100 1826 457
0514 128 2100 525
0624 157 2500 625
0724 182 3001 750
0824 207 3500 875
0962 241 4001 1000
1125 282
BOLD TYPE indicates Low NOx models.
Table E: All Air From Inside The Building
Table F: All Air From Outdoors

13
# If louvers, grills or screens are used on the
openings, obtain the net free area from their suppli-
er or manufacturer. If the design free area of a louver
is not known nor available, it shall be assumed that
wood louvers will have 20-25 percent free area and
metal louvers will have 60-75 percent free area as
specified in the National Fuel Gas Code.
%,5;05.
<;+6695:;(33(;065:
6+,3
1. Remove the front (4) screws.
2. Line up outdoor top vent opening over heater vent
opening.
3. Lower outdoor top onto unit lining up slots in the
outdoor top with screws holes in jacket top.
4. Reinstall (5) screws to secure jacket top and out-
door top to unit.
Fig. 4: Outdoor Top Installation
6+,3:(5+
%,5; #,9405(3 <;+669 ";(*23,:: #67
5:;(33(;065
1. Insert tabs into keyhole (4 places).
2. Snap tabs into keyholes so as not to pull out.
Outdoor Top
8-3/8"
OUTDOOR
FLOOR BASE
Fig. 5: Outdoor Top Installation
Pagoda Top (Shipped Loose with Heater)
Fig. 6: Outdoor Top Installation
&! Examine the venting system at least
once a year. Check all joints and vent pipe
connections for tightness, corrosion or deterioration.

14
6+,3:
1. Lower outdoor "Stackless" top onto unit. Position
top so it is centered on unit from side-to-side and
front-to-rear.
2. Tighten the (4) screws (Shown below) until they
come in contact with the unit jacket top, then even-
ly tighten all (4) screws to secure to unit.
Fig. 7: Outdoor Top Installation
Fig. 8: Outdoor Top Installation
6+,3:
Heaters are shipped with outdoor vent terminal facto-
ry installed.
6+,3:
These units are not certified for outdoor installation.
5+6695:;(33(;065:
6+,3
Refer to Fig. 9 on the following page.
1. Shut-off main electrical power switch to heater.
2. Turn heater manual ON/OFF switch, located in
upper control panel, to the "OFF" position.
3. Shut-off gas supply and water supply to the
heater.
4. Mount drafthood on heater and attach with the 8
sheet metal screws provided. Drafthood should be
positioned with the vent sensor located on the
front left side as shown.
5. Remove plastic plug from left side of heater jacket
and install the plastic grommet provided.
6. Route flue sensor wire harness through the grom-
met installed in Step 5.
7. Remove door and locate wire from roll out sensor
to High Limit with the male/female connector.
8. Disconnect male/female connector and attach to
the 2 wires from drafthood vent sensor harness.
&!Do not use the “one permanent open-
ing” method if the equipment room is under negative
pressure conditions or the equipment is common
vented with other gas-fired appliances.
&! 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.

15
Fig. 9: Indoor Top Installation

16
6+,3:(5+
%,5;#,9405(35+669";(*2
5:;(33(;065
1. Remove the louvered jacket top by removing four
(4) #10 flathead screws.
2. If originally installed, remove "Pagoda" top from
the louvered jacket top.
3. Place the inner stack adapter panel over the flue
collector inside the heater. Make sure the flanged
side of the flue opening is up.
4. Turn the stack (drafthood) upside down and set it
down bottom side up.
5. Turn the jacket top panel (removed in step 1)
upside down and place it over the stack.
6. Attach the three (3) mounting brackets to the stack
using the screws provided and the holes that are
pre-drilled in the stack. Make sure the brackets are
positioned with the flange near the top side of the
stack (see Fig. 10). Caution must be taken not to
over tighten and strip the screw threads.
7. Turn the assembled stack and jacket top, right
side up. The jacket top will be trapped between the
brackets and the top of the stack. Place the stack
over the inner adapter panel flanged hole and
lower the louvered jacket top panel back into its
original position. Reinstall the four (4) green #10
flathead screws removed in step 1 above.
DRAFTHOOD
JACKET TOP PANEL
(part of the heater)
#10 SHEET METAL SCREW (3)
MOUNTING BRACKET (3)
FLUE COLLECTOR
(part of heater)
SCREW HOLE
LOCATION
3-1/4"
INNER STACK ADAPTER PANEL
2-1/2"
COMBUSTIBLE FLOOR SHIELD
(optional for indoor)
Fig. 10: Indoor Top Installation
6+,3:
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
6+,3:
Locate and assemble as shown below. Secure with
screws supplied in envelope in carton.
6+,3:
These models have built-in drafthoods. For proper
operation, the drafthood outlet must be connected to
the venting system.
Fig. 11: Indoor Top Installation
Fig. 12: Indoor Top Installation

17
%,5;0705.
Vent piping of the same size as the drafthood outlet is
recommended, however, when the total vent height is
at least ten (10) feet (drafthood relief opening to vent
terminal), the vent pipe size may be reduced as spec-
ified in the National Fuel Gas Code, ANSI Z223.1.
Avoid long horizontal runs of vent pipe and too many
elbows. If installation requires horizontal non-vertical
runs, the vent pipe must have a minimum of 1/4 inch
per foot rise and should be supported at not more than
five foot intervals. Plumber's tape, crisscrossed, will
serve to space both horizontal and vertical piping. Gas
vents supported only by the flashing and extending
above the roof more than five feet should be securely
guyed or braced to withstand snow and wind loads.
We recommend use of an insulated vent pipe spacer
through the roofs and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which com-
plies with the local codes or, in the absence of such
codes, to the latest edition of the National Fuel Gas
Code, ANSI Z223.1.
The discharge opening must be a minimum of two feet
vertically from the roof surface and at least 2 feet high-
er than any part of the building or equipment within ten
feet. The vent stack shall be at least 5 feet in vertical
height above the drafthood outlet. The vent cap loca-
tion shall have a minimum clearance of 4 feet
horizontally from, and in no case above or below,
unless a 4-foot horizontal distance is maintained, from
electric meters, gas meters regulators and relief equip-
ment.
The weight of the vent stack or chimney must not rest
on heater drafthood. Support must be provided in
compliance with applicable codes. The heater top and
drafthood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from combustible
construction Type " " double wall or equivalent vent
pipe is recommended. However single wall metal vent
pipe may be used as specified in the latest edition of
the National Flue Gas Code ANSI Z223.1.
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
Fig. 13: Vent Piping
Manifolds that connect more than one heater to a com-
mon chimney must be sized to handle the combined
load. Consult available guides for proper sizing of the
manifold and the chimney. At no time should the area
be less than the area of the largest outlet.
At the time of removal of an existing heater, the follow-
ing steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances remain-
ing connected to the common venting system are not
in operation.
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size
and horizontal pitch and make sure there is no
blockage or restriction, leakage, corrosion or other
deficiency which could cause an unsafe condition.
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the com-
mon venting system are located and other spaces
of the building. Turn on clothes dryers and any
Fig. 14: Common Vent Piping

18
(d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a ciga-
rette, cigar or pipe.
(f) After it has been determined that each appliance
remaining connected to the common venting sys-
tem is venting properly, return doors, windows,
exhaust fans, fireplace dampers and any other
gas burning appliance to their previous conditions
of use.
(g) Any improper operation of the common venting
system should be corrected so that the installation
conforms with the latest edition of the National
Fuel Gas Code, ANSI Z223.1. When re-sizing any
portion of the common venting system, the com-
mon venting system should be re-sized to
approach the minimum size as determined using
the appropriate tables in the National Fuel Gas
Code, ANSI Z223.1.
For special venting applications that require reduced
vent sizes and through-the-wall venting, the Type D
Induced Draft Assembly can be used. Consult the fac-
tory or your local Raypak representative.
%,5;(47,95:;(33(;065
6+,3:#/96<./
&/,9,!,8<09,+
6*(;065
The vent damper must be located in the vent so that it
serves only the appliance for which it is intended.
If improperly installed, a hazardous condition, such as
an explosion or carbon monoxide poisoning, could
result. Make certain that it is mounted in an accessible
location at least 6 in. from any combustible material or
the heat exchanger and that the position indicator is in
a visible location.
The vent damper must be installed after the appliance
drafthood, as close to the drafthood as practicable,
and without modification of the drafthood.
6<5;05.
On vertical vents, the vent damper may be mounted
with the actuator in any position. On horizontal vents,
do not mount the actuator either directly above or
directly below the vent pipe; mount the vent damper
actuator to the side of the vent, as shown in Fig. 16.
The vent damper is set up for a continuous pilot sys-
tem. If the vent damper is installed on an Intermittent
Pilot or Direct Spark Ignition equipped system, the
energy savings of the vent damper can be improved
by plugging the hole in the vent damper blade using
the knockout plug, Part No. 105612R, provided in the
parts envelope.
DO NOT plug the hole if installing the vent damper on
a continuous pilot system as this will create a haz-
ardous condition.
&! Do not use thermally actuated vent
dampers on modulating heater. To do so, may result
in asphyxiation. Use only a mechanically actuated
vent damper device that is electrically interlocked
with the modulating heater operation.
Fig. 15: Vent Damper
appliance not connected to the common venting
system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.

19
NO
YES
NO
YES
INSTALL VENT
DAMPER WITH
ACTUATOR TO
SIDES OF VENT
ONLY. DO NOT
MOUNT ABOVE OR
BELOW VENT.
TO CHIMNEYTO BOILER D808
FLOW >
HORIZONTAL INSTALLATION
TO CHIMNEY
TO BOILER
D808
VERTICAL
INSTALLATION
ACTUATOR MAY BE
INSTALLED IN ANY
POSITION ON
VERTICAL PIPE.
HEATER
HEATER
Motor
End
Switch
C.
N.O. N.C.
1K2
1K1
R
1R
1K3
12345
D808
Thermostat or
Controller
Dual Valve
Combination Gas
Control or
Ignition System
Optional Limit
LocationLimit
Transformer
L1
(Hot)
L2
1
1
Yellow Blue
Power supply provide disconnect me ans an overload protection as requ ired.
Black Orange Red
Power supply provide disconnect means an overload protection as required.
Fig. 16: Installing Vent Damper
Fig. 17: Vent Damper General Wiring Diagram
INSTA THE VENT DAMPER TO SERVICE ON Y
THE SING E APP IANCE FOR WHICH IT IS
INTENDED. IF IMPROPER Y INSTA ED, A HAZ-
ARDOUS CONDITION, SUCH AS AN EXP OSION
OR CARBON MONOXIDE POISONING, COU D
RESU T.
%,5;(47,9
For safe, efficient operation, the vent damper and all
flue product carrying areas of the appliance must be
checked annually, with particular attention given to
deterioration from corrosion or other sources. Check
vent damper operation as follows:
1. When the heater is off, check that the vent damper
position indicator points to the closed position, Fig.
18.
2. Turn the thermostat or controller up to call for heat
and check that the vent damper indicator points to
the open position, Fig. 18.
3. Turn the thermostat or controller down again and
check that the vent damper position indicator
returns to the closed position.
THE VENT DAMPER MUST E INSPECTED AT
LEAST ONCE A YEAR Y A TRAINED, EXPERI-
ENCED SERVICE TECHNICIAN. THE NAME OF THE
PERSON WHO ORIGINALLY INSTALLED YOUR
VENT DAMPER IS SHOWN ON THE INSTALLATION
LA EL. DAMPER MUST E IN THE OPEN POSI-
TION WHEN HEATER MAIN URNERS ARE
OPERATING.
Damper
Position
Indicator
DAMPER OPEN DAMPER CLOSED
Damper
Position
Indicator
Fig. 18: Vent Damper position Indicator Showing Open
& Closed Positions
&! Do not use thermally actuated vent
dampers on a modulating heater. To do so may
result in asphyxiation. Use only a mechanically
actuated vent damper device that is electrically
interlocked with the modulating heater operation.

20
3<4)05.
,5,9(3
Heater should be located so that any water leaks will
not cause damage to any adjacent areas or structures.
(:"<773@655,*;065:
Gas piping must have a sediment trap ahead of the
heater gas controls, and a manual shut-off valve locat-
ed outside the heater jacket. All gas piping should be
tested after installation in accordance with local codes.
$# The heater and its manual shut-off
valve must be disconnected from the gas supply
during any pressure testing of that system at test
pressures in excess of 1/2 PSIG. Dissipate test
pressure in the gas supply line before reconnecting
the heater and its manual shut-off valve to gas
supply line. FAILURE TO FOLLOW THIS
PROCEDURE MAY DAMAGE THE GAS VALVE.
OVER PRESSURED GAS VALVES ARE NOT
COVERED Y WARRANTY. The heater and its gas
connections shall be leak tested before placing the
appliance in operation. Use soapy water for leak test
do NOT use open flame.
Fig. 19: Sediment Trap
# Do not use teflon tape on gas line pipe
thread. A flexible sealant approved for the fuel being
used is recommended.
$# For proper operation, no more than a
30% drop in gas supply pressure from no-load to full-
load conditions is acceptable. Under no
circumstances should the pressure be outside the
listed operational range.