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Raypak 302B User's Manual

1. 45
2. LIWM IH OLNY E ta ONIYI 1NIOd TWHLN32 Ma3 m a amv unes ute E As o we EM F Lo SHO ko rese W L 3SNI er f wNousO BWA ALI4YE ave O 1 LWISNI f TT T T i n BE La dO NOUVTIWASNI 335 OL 3ovis YO JOVIS Z MITIOHINOO O LF x m di KA 2 8 IYN o kad RU dina a TOULNOD 440 NO Nouvinavi 33s 2 8 v v LM3SNI SYD LYN Z9ZI 3ldAvS START UP Pre Start up Filling System Heating Boilers Fill system with water Purge all air from the system Lower system pressure Open valves for normal sys tem operation and fill system through feed pressure Manually open air vent on the compression tank until water appears then close vent Air Purge Domestic Hot Water Heaters Purge all air from system before lighting heater This can be normally accomplished by opening a down stream valve NOTE Boil out information The oils grease and other contaminates found in some gas fired boilers are not present in the water side of a Raypak appliance
3. TOP VIEW FRONT VIEW Venting not shown for clarity Heater must be vented per instructions in this manual Fig 6 Minimum Clearances from Combustible Surfaces Indoor Installations 10 When installed according to the listed minimum clear ances from combustible construction these heaters can still be serviced without removing permanent structural construction around the heater However for ease of servicing we recommend a clearance of at least 24 in in front and at least 12 in on the water connection side This will allow the heater to be serv iced in its installed location without movement or removal of the heater Service clearances less than the minimums may require removal of the heater to service either the heat exchanger or the burner tray In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater Outdoor Installations These heaters are design certified for outdoor installa tion Heaters must not be installed under an overhang that is less than 3 ft from the top of the heater Three sides must be open in the area under the overhang Roof water drainage must be diverted away from heaters installed under overhangs Min Clearance Recommended from Combustible Service Surfaces Clearance Table F Clearances Outdoor Installations Heater Side Front Rear Water Side Other Side Top Vent
4. 56 START UP CHECKLIST FOR FAN ASSISTED RAYPAK PRODUCTS This start up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time All information may be used for warranty purposes and to ensure that the installation is correct Additionally this form will be used to record all equipment operation functions and required settings GAS SUPPLY DATA CLEARANCES Regulator Model 8 Size CFH Front Clearance In Gas Line Size in room In NPT Right Side Clearance In Length of Gas Line Eq Ft Left Side Clearance In Low Gas Pressure Setting In WC Rear Clearance In High Gas Pressure Setting In WC Overhead Clearance In Gas Shut Off Valve Type Ball Lube cock ELECTRICAL Sediment Trap Y N Voltage Supply VAC No Load Load Port Std Full Voltage 24 VAC VAC Voltage Com to Ground VAC VISUAL INSPECTION OF COMPONENTS Hot Surface Igniter Ohms Verify inspection was done and condition of components are in Auto High Limit Setting deg F good working order with a yes Manual Reset High Limit Setting deg F Wiring Harness Y N Operating Control Setting deg F Burner s flame Y N Refractory visual Y N Sketch plumbing on reverse side Remote flame sense Y N WATER SUPPLY Covers in place for outdoor Y N Flow Rate in GPM or Delta T If Avail Measure flow rate at full fire VENTING Pump Economaster setting Minutes
5. Is air pressure switch s and J2 of CPW board N O powered Does air pressure switch s have correct pressure 1 4 W C Replace air NO pressure switch Correct the air settings or you may have to clean burners heat exchanger and or air filter Readjust to 3 5 W C gas Is the unit running YES NO YES J Replace gas valve Clean or replace flame sensor Is static and dynamic inlet manifold gas pressure correct Is downdraft present 51 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency Maintenance as outlined below may be performed by the owner Daily 1 Check that the area where the heater is installed is free from combustible materials gasoline and other flammable vapors and liquids 2 Check for and remove any obstruction to the flow of combustion or ventilation air to heater Monthly 1 Check for piping leaks around circulators mixing valves relief valves and other fittings If found repair at once DO NOT use petroleum based stop leak compounds 2 Visually inspect burner flame 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Check air vents for leakage Yearly Beginning Of Each Heating Season Schedule annual service call by qualified service agency 1 Visually check top of vent f
6. Back GAS SUPPLY CONNECTION COMBUSTION AIR ELECTRICAL CONNECTION FILTER PRESSURE RELIEF CONNECTION WATER INLET WATER OUTLET TEMPERATURE AND PRESSURE GAUGE Fig 2 Component Locations Left Side GAS TRAIN OPERATIONAL CENTER CONTROL COMBUSTION AIR BLOWER PRESSURE RELIEF VALVE IGNITER HEAT EXCHANGER BURNER GROUP REMOTE SENSOR Panels removed for clarity Fig 3 Component Locations Front 6 General Information Vent Size uantity of Model No Gas Blowers Valves Table A Basic Data Burners per Yo Fire at Model Valve Stage N I2 TERT raze et d b ws 8 O 100 Fw s s 2 50 100 pasos r e KA 12 se Es a 7 KA 42 ss 100 feos e e 6 nana aje 100 Table B Manifold Data Burners Valve Firing en per Valve Staging at Stage oO pt mta tj a 2 3 2 99 pwo Valve 2 is inside the air plenum on H3 WH3 302B 402B Table C 2 Stage Design Option GENERAL SAFETY To meet commercial hot water use needs the high limit safety control on this water heater is adjustable up to 210 F However water temperatures over 125 F can cause instant severe burns or death from scalds When supplying general purpose hot water the rec ommended initial setting for the temperature control is 125 F Safety and energy conservation are factors to be con sidered when setting the water temperature on the thermostat The most en
7. 34 12 13 14 15 16 17 18 19 20 21 22 23 Power is applied to terminal P1 1 of the Universal Diagnostics Board 24 VAC power is then applied in series to all typically closed safeties wired into the heater All safeties are verified to ensure that it is safe to operate the heater The safety compo nents wired into the diagnostic board are low water cut off optional blocked vent switch man ual vent temp switch optional manual reset high limit low gas pressure switch optional high gas pressure switch optional and auto reset high limit optional If any of the safeties do not close a signal is sent to the Universal Diagnostics Board to indicate a safety fault Power is applied to terminal TP 1 of the Economaster pump delay to energize the circuit board Once all safeties are closed and verified a 24 VAC signal is output from the Auto High Limit to J5 pin 3 of the CPW board of the heater 24 VAC power is now sent to the coil of relay K 1 Relay K 1 N C will now be energized and opens the N C contacts to disable the alarm optional and turns off the red LED safety shutdown light on the front status board The common terminal of the Auto High Limit will now send a 24 VAC signal to pin 1 of the panel Switch The panel switch rocker switch located at the lower left front of the control compartment is now powered If the switch is ON and there is no ca
8. AIR FILTER T V d A a N 4 4 NT 7 7 7 Note When vertical height exceeds 25 ft consult factory prior to installation Fig 26 Direct Vent Horizontal Through the Wall Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com bustion products to the outdoors 31 The total length of the through the wall flue cannot exceed 40 equivalent ft in length for the flue outlet Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the three following arrangements e 40 of straight flue pipe 30 of straight flue pipe and one elbow 20 of straight flue pipe and two elbows The total length of air supply pipe cannot exceed the distances listed in Table O Each elbow used is equal to 10 ft of straight pipe This will allow installation in any arrangement that does not exceed the lengths shown in Table O The flue direct vent cap is not considered in the over all length of the venting system Care must be taken during assembly that all joints are sealed properly and are airtight The vent must be installed to prevent the potential ac cumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a slight downward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal 2
9. Main burner ignition Check manifold gas pressure at gas valve outlet pressure tap This should read 3 5 0 1 in WC for natural gas and 10 5 0 1 in WC for propane gas If the pressure reading differs by more than x 0 1 in WC remove screw cover from the gas pres sure regulator and adjust main burner manifold pressure Replace the screw cover Repeat steps 2 to 5 on other valves as necessary CAUTION Special manifold and air settings may be required Verify rating plate and blower housing 47 Safety Inspection 1 Check all thermostats and high limit settings 2 During the following safety checks leave manome ters hooked up check and record 3 If other gas fired appliances in the room are on the same gas main check all pressures on the Hi Delta with all other equipment running 4 Check thermostats for ON OFF operation 5 Check high limits for ON OFF operation 6 While in operation check flow switch operation 7 Check the low gas pressure switch For proper adjustment use the attached manometers if available to set pressure The scales on the switch are approximate only Low gas pressure switch must be set at 5 0 in WC for natural gas and 10 0 in WC for propane gas 8 Make sure that the high gas pressure switch op tional is set to 1 0 in WC above manifold pressure Follow Up Safety checks must be recorded as performed Turn heater on After main burner ignition 1 Check manometer for
10. These clearances are required when the outdoor vent cap is used If installing the heater outdoors with a vent stack the indoor clearances may be utilized The combustion air intake hood MUST be used for outdoor installations The hood is shipped loose and installed on the side of the heater over the filter box at the jobsite INSIDE CORNER DETAIL A E LZ A FIXED CLOSED III Pg ANI dA Wy LL Z Zo e l U S Installations Canadian Installations Clearance above grade veranda porch 1 ft 30 cm 1 ft 30 cm deck or balcony 4 ft 1 2m below or to side of opening 1 foot 30 cm 3 ft 91 cm above Be E Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis 5 ft 1 5m tance of 2 ft 61cm from the centerline of the terminal Clearance to unventilated soffit 3 9 Clearance to outside corner c G Clearance to inside corner 6 ft 1 83m 3 ft 91 cm within a Clearance to each side of center line ex height 15 ft above the tended above meter regulator assembly meter regulator assembly Clearance to service regulator vent outlet ke e n 6 ft 1 83m 4 ft 1 2m below or to side of opening 1 ft 30 cm 3 ft 91 cm above opening Clearance to non mechanical air supply inlet to building or the combustion air
11. Vent Size Stack Height Low Water Cutoff Test Category sketch vent on reverse side Number of Tanks and Size Qty Gallons Vent Material Plumbing Size Vent Termination Type Pump Size boiler Pump HP Combustion Air Openings Low in2 Impeller trim Pump Model Ventilation air High in2 Louvers Screens EMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings AT FULL FIRE Blower Pressure Setting In WC See manual or card tag Supply Gas Pressure In WC See manual or card tag Verify stable pressure static amp dynamic condition Pilot Gas Pressure Manifold Gas Pressure In WC In WC See manual or card tag See manual or card tag The following measurements must be obtained with a Combustion Analyzer NOX PPM Less than 20 PPM If required by Certifying Agency Free Oxygen See manual CO PPM Less than 150 PPM CO2 Yo See manual Model Number Serial Number Note draw venting with details such as extractors Site Altitude Above Sea Level Ft barometric dampers blast dampers or draft inducers Job Name Address Physical Location of Boiler Indoors Outdoors Ground Level Roof Below Grade Mechanical Contractor Installer Date and Time of Start up Print Name and Signature of Start up Technician Information must be faxed to 805 278 5496 in order to ensure warranty consideration Attn Service Manager 57 Important Instructions for
12. Additions Note on page 15 notes on page 16 Table R on page 39 Deletions None CONTENTS WARNINGS BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevation Component Locations General Information GENERAL SAFETY Time Temperature Relationships in Scalds INSTALLATION Installation Codes Equipment Base Stacking Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Changing the Flue Outlet Venting Installation Tips Venting Configurations 06 10010000 5 Controls Outdoor Installation Heater Sequence of Operations 87 Efficiency Boilers Special Instructions Water Piping Wiring Diagram START UP Pre Start up Start Up OPERATION Lighting Instructions To Turn Off Gas To Appliance TROUBLESHOOTING MAINTENANCE Suggested Minimum Maintenance Schedule Preventative Maintenance Schedule APPENDIX Inside Air Contamination WARRANTIES Type H and WH Type P Start Up Checklist Important Instructions for the Commonwealth of Massachusetts WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe person al 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 proper
13. Most boil out procedures require the use of an alkaline high pH cleaning agent that will damage the copper finned tubes of the heat exchanger Heat exchangers damaged due to boil out are not covered under warranty Venting System Inspection 1 Check all vent pipe connections and flue pipe ma terial 2 Make sure vent terminations are installed per code and are clear of all debris or blockage For Your Safety WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance has a hot surface igniter It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell near the floor because some gas is heavier than air and will settle on the floor 46 WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neigh bors telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified serv ice technician Forced or attempted repair may result in a fi
14. No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The stainless steel flue direct vent cap must be fur nished by the heater manufacturer in accordance with its listing sales order option D 15 Use only the special gas vent pipes listed for use with Category III gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacturer s installation instructions carefully 32 Direct Vent Vertical VENT CAP 3 MIN l EXHAUST VENT 7 3 MIN t i 1 MIN FI Z5 AM INTAKE VENT ZY NLINE AIR FILTER i NTAKE VENT SELI a SHOWN FOR AS T 7 ALTERNATE COMBUSTION CLARITY e bq A AIR INTAKE LOCATION DOUBLE ELBOW 4 heed NOT RECOMMENDED Oo Note When vertical height exceeds 25 ft consult factory prior to installation Fig 27 Direct Vent Vertical Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and force the heated flue products through the vent pipe under posi tive pressure The vent material must be in accordance with the above instructions for vent mate rials V
15. The constructions of the 84 standard and 87 efficiency optional boilers are very similar and they are installed to the same requirements except as noted in this section Water Piping An 87 efficiency boiler requires a minimum inlet water temperature of 120 F 49 C to prevent exces sive condensation in the combustion chamber An 87 efficiency boiler operated with an inlet tempera ture of less than 120 F 49 C must have a manual bypass or an approved low temperature operation system to prevent problems with condensation A man ual bypass shown in Fig 15 must be piped into the system at the time of installation This piping is like a primary secondary boiler installation with a bypass in the secondary boiler piping Raypak strongly recomm ends that a thermometer be placed into the boiler inlet piping next to the in out header to facilitate tempera ture adjustment Inlet water temperatures below 120 F 49 C can excessively cool the products of combus tion resulting in condensation on the heat exchanger Venting CAUTION Proper installation of flue venting is criti cal for the safe and efficient operation of the boiler Appliance Categories See Table T for appliance category requirements for the 87 efficiency Hi Delta NOTE For additional information on appliance categorization see appropriate code NFGC U S and B149 Canada or applicable local building codes Ho amm AP om ae c
16. The vent must be insulated through the length of the horizontal run For installations in extremely cold climate it is re quired that 1 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes The intake vent must be insulated through the length of the horizontal run Termination The flue direct vent cap MUST be mounted on the ex terior of the building The direct vent cap cannot be installed in a well or below grade The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels The direct vent cap MUST NOT be installed with any combustion air inlet directly above a direct vent cap This vertical spacing would allow the flue products from the direct vent cap to be pulled into the combus tion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the heater due to the recirculation of flue products Multi ple direct vent caps should be installed in the same horizontal plane with a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap s Combustion air supplied from outdoors must be free of particulate and chemical contaminants To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc WARNING
17. ignition module the heater performs a 15 second pre purge and then the hot surface igniter is ener gized by a 120 VAC signal from S 1 on the ignition module for approximately 30 seconds The hot surface igniter must draw greater than 3 1 amps while being energized or ignition lockout will occur after three tries Once the ignition module determines that the hot surface igniter has heated up and operating prop erly a 24 VAC signal is output from pin GV on the module 24 VAC signal is received at gas valve 1 thus ener gizing it 45 The stage 1 LED on the status display board is now illuminated 46 The coil of relay K 2 is now energized with the N O contacts closing downstream of the stage 2 connections 47 The gas coming through the burners should ignite from the heat of the hot surface igniter and the flame should carry over from one burner to the other burners of stage 1 The remote sensor is now trying to sense the flame If the flame is not sensed within 4 seconds the ignition module will shut down gas valve 1 and retry the hot surface igniter During ignition retry the heater must per form a 15 second pre purge and an approximately 30 second igniter warm up before opening gas valve 1 again The standard ignition module will attempt ignition a maximum of three times prior to ignition lockout 48 If the ignition module locks out a signal will be sent to the Universal Diagnostics Board to indicate an ignition fau
18. the air outside of the building the mechanical equip ment room must communicate directly with the outdoors 1 Ventilation of the space occupied by the heater shall be provided by an opening s for ventilation air at the highest practical point communicating with the outdoors The total cross sectional area of such an opening s shall be at least 1096 of the area required in 2 and 3 below but in no case shall the cross sectional area be less than 10 in 2 65 cm 2 Forheaters using a barometric damper in the vent system there shall be a permanent air supply opening s having a cross section area of not less than 1 in 2 per 7 000 BTUH 320 mm per kW up to and including 1 million BTUH plus 1 in 2 per 14 000 BTUH 160 mm per kW in excess of 1 million BTUH This opening s shall be either located at or ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferred to be straight down and terminated 18 in 450 mm from the floor but not near piping This air supply opening require ment shall be in addition to the air opening for ventilation air required in 1 above WARNING Care must be taken to ensure that the equipment room is not under negative pressure conditions or that the equipment is not common vented with other gas fired appliances 3 For heaters not using a barometric damper in the vent syste
19. Canada 2 STAGE TANKSTAT aa STAGE 2 CONNECTION OR SOMME Si STAGE 1 CONNECTION OF HEATER 2 4H 4 7 F jo ATTACH STAGE 1 CONNECTIONS ON HEATER TO STAGE 1 CONNECTION ON TANKSTAT ATTACH STAGE 2 CONNECTIONS OR STAGE 1 CONNECTION OF HEATER 2 TO STAGE 2 CONNECTIONON TANKSTAT AS SHOWN IN THE DIAGRAM Fig 22 2 Stage Tankstat SINGLE STAGE TANKSTAT m STAGE 1 CONNECTION _ ATTACH STAGE 1 CONNECTIONS ON HEATER TO THE SINGLE STAGE TANKSTAT AS SHOWN IN THE DIAGRAM ABOVE Fig 23 Single Stage Tankstat Consult the wiring diagram shipped with the heater in the instruction packet or at the end of this section The stage selector terminals are for the remote tank con trol through the heater s 24 VAC transformer DO NOT attach any voltage to the stage selector terminals Before starting the heater check to ensure proper volt age to the heater and pump NOTE If any of the original wire supplied with the heater must be replaced it must be replaced with similar sized 105 C wire or its equivalent Venting NOTE For 87 efficiency boilers see special instructions on page 40 CAUTION Proper installation of flue venting is criti cal for the safe and efficient operation of the heater General Flue Exhaust Tee An optional Flue Exhaust Tee is available to facilitate horizontal venting Any reference to horizontal venting that exits the back of the he
20. Follow these instructions to make sure your heater is properly installed The Hi Delta pool heater is equipped with an external pump and bypass arrangement as standard equip ment This arrangement blends outlet water with the inlet water to increase the inlet water temperature thereby reducing the likelihood of condensation form ing on the heat exchanger The pump also serves to circulate water through the heater from the main sys tem piping To complete the installation of the pool heater the pool thermostat needs to be installed in the main return wa ter line upstream of the heater This will ensure that the heater will be energized at the right time If the main water line is too far away from the heater and the capillary bulb will not reach it locate the pool thermo stat adjacent to the main line and run wires back to the heater Medium 5 15 grains per gallon Hard 16 25 grains per gallon Model dedu EAE e Fame x 4 20 2 ki amp 33 2 83 7 esl 2 rea aga wr ao 20 2 sale amp 4 2 4 o 74 5 2 564 Fes zr a zi 2 sale amp es 2 55 2 75 58 2 es Fees s 2 ze 2 ool v s 75 2 ral onal 2 ast v oo fei T8 2 97 2 T7 E78 12 rel onl 2 155 AT Temperature rise F AP Pressure drop through heat exchanger ft SHL System head loss ft Includes 50 eq ft of tubing each way total 100 eq ft gpm Gallons per minute flow rate MTS Minimum tubing
21. Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacturer s installation instructions carefully Direct Vent Horizontal Through the Wall AT KONTAN ALTERNATE COMBUSTION s sid ZO AIR INTAKE LOCATION H 7 fed 12 21 CONDENSATE TRAP 4 T a EXHAUST VENT INLINE AIR FILTER 4 r 1 I l I l l I l d 4 A 36 MIN INTAKE VENT 4 7 L 6 MIN Pi mann 7 12 MIN 4 z Fig 40 Direct Vent Horizontal Through the Wall Installation These installations utilize the boiler mounted blower to draw combustion air from outdoors and vent combus tion products to the outdoors The total length of the direct vent through the wall exhaust vent cannot exceed 40 ft in length for the flue outlet Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the three fol lowing combinations 40 of straight flue pipe 30 of straight flue pipe and one elbow e 20 of straight flue pipe and two elbows The total length air supply duct cannot exceed the dis tances listed Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the three following combinations e 40 of straight combustion air pipe 30 of straight combustion air pipe and one elbow e 20 of straight combustion air pipe and two elbows 43 The flue exha
22. Pressure should be anywhere between 0 01 and 0 08 in WC 6 After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use 7 Any improper operation of the common venting system should be corrected so that the installation conforms with the NFGC U S or B149 Canada When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Ap pendix G in the NFGC U S or B149 Canada Horizontal Through the Wall Venting Category III e 72 BO VE OPTIONAL FLUE FLUE EXHAUST NT CAP HEATER UNIT E a 000 a X i INSULATED 12 MIN N ANN oU EXHAUST VENTING N NI Z CONDENSATE TRAP S Requires optional vent tee for rear discharge Fig 25 Horizontal Through the Wall Venting Category Ill Installation These installations utilize the heater mounted blower to vent the combustion products to the outdoors Combustion air is taken from inside the room and the vent is installed horizontally through the wall to the out doors Adequate combustion and ventilation air must be supplied to the equipment room in
23. Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days Original Owner Model Number Mailing Address Serial Number Date of Installation City Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com
24. Total Dissolved Solids Total dissolved solids TDS is the measure of all min erals and solids that are dissolved in the water The concentration of total dissolved solids is usually ex pressed in parts per million ppm as measured in a water sample Water with a high TDS concentration will greatly accelerate lime and scale formation in the hot water system Most high TDS concentrations will precipitate out of the water when heated This can generate a scale accumulation on the heat transfer surface that will greatly reduce the service life of a water heater This scale accumulation can also impede adequate flow of water and may totally block the water passages in the tubes of the heat exchang er A heat exchanger that is damaged or blocked by lime scale accumulation must be replaced Failure of a water heater due to lime scale build up on the heating surface is non warrantable The manufacturer of the water heater has no control of the water quality espe cially the TDS levels in your system Total dissolved solids in excess of 2 500 ppm will accelerate lime and scale formation in the heat exchanger Heat exchang er failure due to total dissolved solids in excess of 2 500 ppm is a non warrantable condition Raypak offers basic temperature guidelines for operation of a potable water heater on normal to moderate levels of hardness and solids but levels of hardness and total dissolved solids beyond normal limits for operation will require
25. accordance with the NFGC U S or B149 Canada EXHAUST VENTING The total length of the horizontal through the wall flue system should not exceed 70 equivalent ft in length If horizontal run exceeds 70 equivalent ft an appropri ately sized extractor must be used Each elbow used is equal to 10 ft of straight pipe This will allow installa tion in one of the four following arrangements e 70 of straight flue pipe 60 of straight flue pipe and one elbow 50 of straight flue pipe and two elbows e 40 of straight pipe and three elbows The vent cap is not considered in the overall length of the venting system The vent must be installed to prevent flue gas leakage Care must be taken during assembly to ensure that all joints are sealed properly and are airtight The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a slight downward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal 2 The vent must be insulated through the length of the horizontal run For installations in extremely cold climate it is re quired that 1 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes 2 The vent must be insulated through the length
26. apm aP oe on aP 0o AT gen aP e a pese eo ee fa is as fero an to eel oo vom Te s wr or pep e m n oe ero fao oo Toa po Fesme wa wm er 44 38 20 28 11 ao 90 108 15 Emme wA wa os 61 4 ze an 1s ao 90 113 t5 oE na wa re so amp an ao 23 eo w 1m7 7 Note Basis for minimum flow is 20 gpm or 40 F AT Basis for maximum flow is 90 gpm Table S Heater Rate of Flow and Pressure Drop Combustion Exhaust Heater Venting Certified Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical Natural Draft From Inside Building Venting Non Direct Venting Direct Venting Stainless Steel Gas Tight Horizontal Through the Wall Venting pow BEzS MG Vertical Natural Draft Stainless Steel Galvanized Steel From Outside Building Venting Gas Tight Horizontal Through the Wall Venting AL29 4C Table T Category Determination for Venting Purpose and Venting Arrangement WARNING Contact the vent material manufacturer if there are any questions about the appliance category or suitability of a vent material for Category ll Ill or IV applications Using improper venting materials can result in personal injury death or property damage Vent Terminal Location NOTE During winter months check the vent cap and make sure no blockage occurs from build up of Snow Or ice 1 Condensate can freeze on the vent cap Frozen condensate
27. heat exchanger with bronze waterways Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceed ing 230 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 Year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Chemical contamination of combustion air or use of chemical additives to water Misuse or neglect including but not limited to freeze ups operating the heater with ca
28. incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty service is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the rate of manufacture plus thirty 30 days Original Owner Model Number Mailing Address Serial Number Date of Installation City State Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com 55 LIMITED PARTS WARRANTY HI DELTA TYPE P MODELS 302B 902B SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY Five 5 years from date of heater installation Includes cupro nickel
29. on the heater Gas Supply Pressure A minimum of 5 0 in WC and a maximum of 10 5 in WC upstream gas pressure is required under load and no load conditions for natural gas A minimum of 11 0 in WC and a maximum of 13 0 in WC is required for propane gas The gas pressure regulator s supplied on the heater is for low pressure service If upstream pressure exceeds 14 0 in WC an intermediate gas pressure regulator of the lockup type must be installed When connecting additional gas utilization equipment to the gas piping system the existing piping must be checked to determine if it has adequate capacity for the combined load The gas valve pressure regulator s on the heater are nominally preset at 3 5 in WC for natural gas and 10 5 in WC for propane gas The pressure at the gas valve outlet tap measured with a manometer while in Adjustment Screw Gas Valve Outlet Tap Fig 17 Gas Valve 22 operation should be 3 5 0 1 in WC for natural gas and 10 5 in 0 1 in WC for propane gas If an adjust ment is needed remove the adjustment screw cover and turn the adjustment screw clockwise to increase pressure or counter clockwise to lower pressure CAUTION For proper operation no more than a 3096 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 Electrical Power Connections Installatio
30. on the vent cap can result in a blocked flue condition 2 Give special attention to the location of the vent termination to avoid possibility of property dam age or personal injury 3 Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows 4 Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on building plants or roof 5 The bottom of the vent terminal and the air intake shall be located at least 12 in above grade includ ing normal snow line 6 Un insulated single wall metal vent pipe shall NOT be used outdoors in cold climates for venting gas utilization equipment 7 Through the wall vents for Category Il and IV appliances shall not terminate over public walk ways or areas where condensate or vapor could create a nuisance or hazard or be detrimental to the operation of regulators relief valves or other equipment 8 Locate and guard vent termination to prevent acci dental contact by people or pets 9 DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area unless previously approved by local authority 10 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations CONDENSATE TRAP 11 Locate or guard vent to prevent condensate from damaging exterior finishes Install a r
31. or a modulating two way valve to control the bypass should be utilized Model 10 FAT 20 FAT 30 FAT NOTE Individual and multi boiler Cold Water Start systems require the use of a 20 F AT boiler pump Cold Water Run Cold water run differs from cold water start in that the system water entering the heater remains below 105 F 41 C continuously Typically this is the case in swim ming pool heating and water source heat pump applications as well as some others If the system water is kept in a narrow temperature range a perma nent manual bypass can be employed and manually adjusted to achieve an inlet temperature of 105 F 41 C or higher An injector pump arrangement may also be utilized to keep the heater loop at or above 105 F 41 C An injector pump approach has the added value of being able to adjust to changes in the system water coming back to the heater take off NOTE To ensure proper operation use 20 F AT boiler flow rates when designing the heating system loop pump Temperature amp Pressure Gauge The temperature and pressure gauge is factory mounted in the in out header Hydronic Heating Pump Selection In order to ensure proper performance of your heater system you must install a correctly sized pump Ray pak recommends using a 20 F AT as design AT AT is the temperature difference between the inlet and out let water when the heater is firing at full rate If a AT of larger than 2
32. or operating at heater temperatures exceed ing 230 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY WILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected systems devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Failing to eliminate air from or replenish water in the connected water system Chemical contamination of combustion air or use of chemical additives to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only
33. proper reading 2 Cycle heater several times and re check readings 3 Remove all manometers and replace caps and Screws 4 Replace all gas pressure caps 5 Check for gas leaks one more time Pilot Turn Down Test The Hi Delta heaters depending on their size have one to three burner sections Each burner section is supplied gas by gas valves incorporated into a single valve body A maximum of three burner sections may be controlled by a single hot surface ignition system The middle of the three burner sections is ignited directly with a hot surface ignition system 48 The burner section that is ignited directly by the hot surface ignition system serves as a supervised pilot to light the burner sections on either side of it The burn er sections on either side of the supervised section pilot are electrically interlocked with the supervised ignition system so as they are not energized unless flame is proven on the center section which is acting as a pilot to light the right and left hand sections The pilot turn down test is conducted as follows 1 Turn off manual valves on non supervised burner sections 2 Turn on electrical power and adjust thermostat to call for heat 3 Wait for completion of ignition sequence to light burner section being utilized as a pilot for those turned off in step 1 above 4 Gradually reduce manifold pressure flame on supervised burner section by slowly closing man ual gas valve Wa
34. see that the high limit control is set above the design temperature requirements of the system For multiple zones Check to make sure the flow is adjusted as required in each zone Check that the heater is cycled with the thermo stat Raise to the highest setting and verify that the heater goes through the normal start up cycle Re duce to the lowest setting and verify that the heater goes off Observe several operating cycles for proper oper ation Set the room thermostat or tankstat to desired temperature Review all instructions shipped with this heater with owner or maintenance person return to enve lope and give to owner or place the instructions inside front panel on heater OPERATION Lighting Instructions 1 Before lighting make sure you have read all of the safety information in this manual Set the thermostat to the lowest setting Turn off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Remove upper front panel Turn on main manual gas valve Wait 5 minutes to clear out any gas Then smell for gas especially near the floor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step Turn on all electrical power to the appliance 50 9 Set thermostat to desired setting The applian
35. shall be determined per the NFGC U S or B149 Canada The diameter of vent flue pipe should be sized accord ing to the NFGC U S and B149 Canada The minimum flue pipe diameter for conventional negative draft venting using double wall Type B vent is 5 in for Model 302B 6 in for Models 402B and 502B and 8 in for Models 652B 752B and 902B NOTE A vent adapter field supplied must be used to connect Type B vent to the unit 10 OR LESS VENT CAP 2 MIN i 2 MIN VENT PIPE COMBUSTION AIR FILTER HEATER UNIT NEN Q Fig 24 Natural Draft Vertical Venting Category l The connection from the appliance vent to the stack must be as direct as possible and shall be the same di ameter as or larger than the vent outlet The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per linear foot from the heater to the vent terminal The horizontal portions of the vent shall also be supported for the design and weight of the material employed to maintain clear ances and to prevent physical damage or separation of joints Termination The vent terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below unless a 4 ft hori zontal distance is maintained electric meters gas meters regulators and re
36. size Must utilize optional cupro nickel tubes If over 25 grains per gallon a water softener treatment system must be utilized Caution For scale free operation with Hard Water 16 25 grains per gallon of total hardness the operating control must NOT be set higher than 130 F For higher than 130 F operation a water softener treatment system must be utilized Table l Domestic Water Heater Flow Rate Requirements TO POOL N NI 4E DIAS MAX S POOLSTAT SUPPLIED BRANCH Nj a 2X ISOLATION VALVES Row NI FROM FILTER BY OTHERS HEATER MOUNTED PRESSURE M RELIEF VALVE N X BY RAYPAK Se SIZES 502 902 MIXING VALVE U PUMP LOCATION SIZES 302 402 Fig 14 Single Pool Heater Application A thermostatically controlled mixing valve is used to mix the outlet water with the pool water This mixed water is supplied as the inlet water to the pool heater The proper configuration is shown in Fig 15 The active element of the valve adjusts the mixing ratio to maintain the inlet water above 105 F Fig 15 Mixing Valve Configuration REAR MOUNTED PUMP Automatic Chlorinators and Chemical Feeders CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty All chemicals must be introduced and completely di luted into the pool or spa water before being circulated through the heater Do not place chlorine
37. status panel A 24 VAC signal is also sent to the TH terminal located on the ignition module Once the 24 VAC TH signal is received at the ignition module the internal contacts between F1 and F2 close sending a 120 VAC signal to the 120 VAC pilot duty terminals located at J14 on the cir cuit board The 120 VAC signal continues to the coil of the blower relay K 3 N O The 120 VAC signal continues to the 120 VAC safety terminals located at J13 on the circuit board Indication Main power is on Thermostat is closed One or more safeties is inoperative Ignition module is inoperative Flow is present Blower 1 is on Stage 1 is on When the coil on relay K 3 is powered the N O relay contacts close and energizes the blower from the J8 connections on the CPW board After proper air pressure is received in the air plenum the air pressure switch will close If there is insufficient air pressure and the air pres sure switch does not close a 24 VAC signal is sent to the Universal Diagnostics Board to indicate the fault A24 VAC signal is now sent to the blower LED on the status board Power is applied to the optional equipment inter lock connection J9 normally jumpered The 24 VAC signal is then sent to the 24 VAC safe ty connector 24 VAC is now sent to the pressure switch P S terminal on the ignition module Once the pressure switch signal is received at the
38. tablets or bromine sticks in the skimmer High chemical concen trations will result when the pump is not running e g overnight Chlorinators must feed downstream of the heater and have an anti siphoning device to prevent chemical back up into the heater when the pump is shut off NOTE High chemical concentrates from feeders and chlorinators that are out of adjustment will cause very rapid corrosion of the heat exchanger in the heater Such damage is not covered under the warranty Winterizing Your Heater Heaters installed outdoors in freezing climate areas should be shut down for the winter To shut down heater turn off manual main gas valve and main gas shut off Close isolation valves and remove water pip ing from the in out header on the heater Drain the heater and any piping of all water that may experience below freezing temperatures Pool Spa Water Chemistry NOTE Chemical imbalance can cause severe damage to your heater and associated equipment Water Hardness Water hardness is mainly due to the presence of cal cium and magnesium salts dissolved in the water The concentration of these salts is expressed in mg l ppm or grains per gallon as a measure of relative hardness of water Grains per gallon is the common reference measurement used in the U S water heater industry Hardness expressed as mg L or ppm may be divided by 17 1 to convert to grains per gallon Water may be classified as very soft slightl
39. the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vent ed gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side
40. the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Raypak will apply any such warranty as may be provided to it by the parts manufacturer TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the prob lem The installer must then notify his Raypak distributor for instructions regarding the claim If either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 or call 805 278 5300 In all cases proper authorization must first be received from Raypak before replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf THIS WARRANTY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of
41. 0 F is necessary see Table H and Table for flow rate requirements 40 FAT win Flow marrow Ye apm ar om apm a om aP oe amm aP Co aom ar a aom aP m fa 402B 5 8 1 4 0 6 N A 0 5 34 90 10 0 502B 84 9 1 2 3 EE 0 6 0 6 40 90 10 4 resze wn wa ss at 36 MXN ao se ren L ILIR oe esr Cae oe ka ki oe e ka Fes wal wa re s so se 3e 22 se 22 20 oo 7 v Notes d than 20 gpm Basis for minimum flow is 20 gpm or 40 F AT Basis for maximum flow is 90 gpm Flow switch will not operate if flow is less 2 Rear mounted pumps may provide higher flow rates on smaller models than the system requirements Table H Heater Rates of Flow and Pressure Drops 16 Pressure Drop in Feet of Head Feedwater Regulator Raypak recommends that a feedwater regulator be in stalled and set at 12 psi minimum pressure at the highest point of the system Install a check valve or back flow device upstream of the regulator with a manual shut off valve as required by local codes Piping All high points should be vented Purge valves and a bypass valve should be installed A heater installed above radiation level must be provided with a low wa ter cut off device sales order option F 10 The heater when used in connection with a refrigeration system must be installed so that the chilled medium is piped in parallel with the heater with appropriate valves to pre vent the chilled medium from enter
42. 9 Protech Systems Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacturer s installation instructions carefully Direct Vent Vertical VENT CAP 3 MIN 1 EXHAUST VENT 3 MIN 1 MIN INTAKE VENT CONDENSATE TRAP INLINE AIR PTE i INTAKE VENT SHOWN FOR CLARITY DOUBLE ELBOW NOT RECOMMENDED IN ALTERNATE COMBUSTION 4 AIR INTAKE LOCATION a Note When vertical height exceeds 25 ft consult factory prior to installation Requires optional vent tee for rear discharge Fig 41 Direct Vent Vertical Certified Vertical Venting Combustion Air Air Inlet Intake Pipe Max Length Material Galvanized Steel Category II PVC or IV ABS CPVC 752B ozs Vent lengths are based on a lateral length of 2 ft Refer to the latest edition of the NFGC for further details When vertical height exceeds 25 ft consult factory prior to installation Subtract 10 ft per elbow Max 3 elbows Maximum combustion air duct length terminated at 100 equivalent ft Table V Category ll or IV Vertical Venting 44 iagram iring W 856231 oi NSTIOMINOO AVZ r LIBSNI CH L838NI SILON
43. E Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition NOTE The vent cap flow switch cover and air intake hood must be furnished by the heater manufacturer in accordance with its listing sales order option D 11 Freeze Protection When installing this heater in an outdoor location that is susceptible to freezing sales order option B 22 must be ordered The B 22 option energizes the heater pump at a preset temperature drop to circulate water and reduces the possibility of freezing and dam aging the heat exchanger or headers Controls WARNING Installation adjustment and service of heater controls including timing of various operating functions must be performed by a qualified installer service agency or the gas supplier Failure to do so may result in control damage heater malfunction property damage personal injury or death WARNING Turn off the power to the heater before installation adjustment or service of the CPW board or any heater controls Failure to do so may result in board damage heater malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one supply source To reduce the risk of electric shock disconnect all such connections before servicing CAUTION Risk of electric shock More than one disconnect switch may be required to de energize the equipment before ser
44. INSTALLATION amp OPERATING INSTRUCTIONS Models 302B 902B Types H WH amp P CERTIFIED WARNING If these instructions are not followed exactly a fire or explosion may result causing property damage personal injury or death FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire WHAT TO DO IF YOU SMELL GAS 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 Installation and service must be performed by a qualified installer service agency or the gas supplier This manual should be maintained in legible condition and kept adjacent to the heater or in another safe place for future reference ES E DiE A Rheem Company CATALOG NO 1000 501J Effective 03 29 11 Replaces 06 18 10 P N 240757 Rev 11 Rev 11 reflects the following Changes to Installations at Elevation and low lead certification on page 5 Table J on page 20 Electrical Power Connections on page 22 Table T on page 40 Wiring Diagram on page 45 Igniter check As Required Item 4 on page 53 Warranty on page 56 Fax number in Start Up Checklist on page 57
45. PA filtered vacuum to minimize airborne dust Use feasible engineering controls such as local exhaust ventilation or dust collecting systems to minimize airborne dust Wear appropriate personal protective equipment including gloves safety glasses with side shields and appropriate NIOSH certified respiratory protection to avoid inhalation of airborne dust and airborne fiber particles WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the heater Always keep the area around the heater free of combustible materials gasoline and other flam mable liquids and vapors Heater should never be covered or have any blockage to the flow of fresh air to the heater WARNING 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 WARNING Risk of electrical shock More than one disconnect switch may be required to deenergize the equipment before servicing CAUTION Operation of this heater in low temperature systems requires special piping Harmful internal condensation will occur if the inlet water temperature does not exceed 105 F Warranty claims will be denied when condensation occurs CAUTION If this heater is to be installed above radiation level it must be provided with a low water cut off device at the time of he
46. Verify proper flow rates and AT as instructed in this manual Reversing Water Connections Follow these instructions to change the water connec tions from the left hand side standard to the right hand side 1 Disconnect all electrical power from the heater if applicable 2 Label all electrical connections and conduit lines This may include the flow switch low water cut off probe and or pump 3 Disconnect or isolate the main gas pipe from the heater if applicable 4 Remove both in out and return header access panels by removing all sheet metal screws 5 Remove all plumbing fittings to the header This will include both inlet and outlet water pipe unions and the pressure relief valve and drain piping 6 Remove limits control bulbs and or thermocou ples 7 Remove the six flange nuts and the in out header from the left hand side 8 Remove the six flange nuts and the return header from the right hand side 9 Remove the header stud bolts from each tube sheet 10 Reverse the headers and stud bolts to the new location 11 Install NEW red beveled O rings flush against both tube sheets with the bevel facing outward 12 Push the header firmly against the O rings Install and tighten the flange nuts onto the stud bolts until finger tight 13 Slowly tighten the flange nuts starting from the center nut number 1 in Fig 9 and working se quentially around the header as indicated Torque all nuts t
47. ant sheet metal backing plate against brick or mason ry surfaces DO NOT extend exposed vent pipe outside of building Condensate could freeze and block vent pipe U S Installations Refer to the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below 4 ft hori zontally from or 1 ft above any door window or gravity air inlet to the building The vent must not be less than 7 ft above grade when located adjacent to public walkways Terminate vent at least 3 ft above any forced air inlet located within 10 ft Vent must terminate at least 4 ft horizontally and in no case above or below unless 4 ft horizontal distance is maintained from electric meters gas meters regulators and relief equipment Terminate vent at least 6 ft away from adjacent walls DO NOT terminate vent closer than 5 ft below roof overhang The vent terminal requires a 12 in vent terminal clearance from the wall Terminate vent at least 1 ft above grade including normal snow line Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane 27 Canadian Installations Refer to latest edition of the B149 Installation code A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings L
48. ater 6 Remove the screws flue collar and gasket from the run side of the tee located in the flue box on top of the heater 7 Reverse the components and reattach in the new location 8 Make sure that the stainless steel cover now lo cated on the run side of the tee is sealed to avoid any flue gas spillage CAUTION The silicone vent gaskets must be prop erly reinstalled to prevent flue gas leakage Replace any torn or worn vent gaskets Venting Installation Tips Support piping horizontal runs at least every 5 ft vertical runs use braces under or near elbows WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canada or applicable provisions of local building codes Natural Draft Vertical Venting Category l Installation Natural draft venting uses the natural buoyancy of the heated flue products to create a thermal driving head that expels the exhaust gases from the flue The nega tive draft must be within the range of 01 to 08 in WC as measured 12 in above the appliance flue out let to ensure proper operation Vent material must be listed by a nationally recognized test agency The maximum and minimum venting length for Cate gory appliances
49. ater installation CAUTION If this heater is to be installed in a negative or positive pressure equipment room there are special installation requirements Consult factory for details BEFORE INSTALLATION Raypak strongly recommends that this manual be re viewed thoroughly before installing your Hi Delta heater Please review the General Safety information before installing the heater Factory warranty does not apply to heaters that have been improperly installed or operated Refer to the warranty at the back of this manual Installation and service must be performed by a qualified installer service agency or gas supplier If after reviewing this manual you still have questions which this manual does not answer please contact the manufacturer or your local Raypak representative Thank you for purchasing a Raypak product We hope you will be satisfied with the high quality and durability of our equipment Product Receipt On receipt of your heater it is suggested that you visu ally check for external damage to the shipping crate If the crate is damaged make a note to that effect on the Bill of Lading when signing for the shipment Remove the heater from the shipping packaging Report any damage to the carrier immediately On occasion items are shipped loose Be sure that you receive the correct number of packages as indi cated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by
50. ater requires this tee Refer to Table L for the appropriate kit for your model 25 4028 5028 502B 01839 E 752B Table L Flue Exhaust Tee Kits Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and the likelihood of condensate production in the vent Category A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that avoids excessive condensate pro duction in the vent Category Il A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent Category Ill A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent Category IV A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table M for appliance category requirements NOTE For additional information on appliance categorization see appropriate ANSI Z21 Standard and the NFGC U S or B149 Canada applicable provisions of local building codes or CAUTION When condensate traps are installed condensate must be routed to an appropriate container for neutralization before disposal as required by local codes WARNING Contact the manufacturer of
51. ater temperature for your applications Water Time to Produce Serious Temp Burn 120 F More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds Table courtesy of The Shriners Burn Institute Table D Time to Produce Serious Burn The temperature of the water in the heater can be reg ulated by using the temperature controller To comply with safety regulations the temperature controller is set at the lowest setting when shipped from the facto ry To adjust the water temperature insert a small straight screwdriver into the adjustment screw on the front of temperature controller and turn the wheel to the desired setting See Fig 4 lt gt A ADJUSTMENT SCREW Sec elis rosae Fig 4 Temperature Controller CAUTION Hotter water increases the risk of scalding There is a hot water scald potential if the thermostat is set too high INSTALLATION Installation Codes Installations must follow these codes Local state provincial and national codes laws regulations and ordinances e National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC National Electrical Code ANSI NFPA 70 latest edition NEC e Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 when required CSD 1 e For Canada only CAN CSA B149 Installation Code B149 and CSA C22 1 C E C Part 1 C22 1 Equipment Base The heater should be mo
52. be A 5 second time delay prevents premature lockout due to temporary conditions such as power fluctuations or air pockets S af vag Fig 32 Low Water Cut Off High and Low Gas Pressure Switches The low gas pressure switch optional connection mounts upstream of the gas valve to ensure that suffi cient gas pressure is present for proper regulator performance The low gas pressure switch automati cally shuts down the heater if gas supply drops below the recommended setting of 5 0 in WC for natural gas and 10 0 in WC for propane gas The high gas pressure switch optional connection mounts downstream of the stage 1 gas valve If the gas pressure regulator fails the high gas pressure switch automatically shuts down the burner The high gas pressure switch automatically shuts down the heater if gas manifold pressure rises above the recom mended setting of 5 0 in WC for natural gas and 11 5 in WC for propane gas Fig 33 High Low Gas Pressure Switch Fig 34 Fan Proving Switch Fig 35 Blocked Vent Switch Pump Time Delay The Economaster is a fully enclosed solid state TDR with a white jumper that selects one of two time delays See Fig 36 If the jumper is on pins 6 and 7 default the delay time is 5 minutes If the jumper is not on pins 6 and 7 the time delay is 10 minutes In a conventional system when the Aquastat is satis fied the main gas valve closes but the pump continues operatin
53. binet door off having flow restrictions or obstruc tions between the heater outlet and pool spa or not maintaining proper chemical balance pH level must be between 7 2 and 7 8 and total alkalinity between 100 and 150 PPM Total Dissolved Solids TDS must be no greater than 1500 PPM or 4500 PPM in salt water chlorinated pools PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Raypak will apply any such warranty as may be provided to it by the parts manufacturer TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit date of installation and description of the prob lem The installer must then notify his Raypak distributor for instructions regarding the claim If either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 or call 805 278 5300 In all cases proper authorization must first be received from Raypak before replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on
54. ce will operate The igniter will glow after the pre purge time delay 15 seconds After igniter reaches temperature 45 seconds the main valve will open System will try for ignition three times If flame is not sensed lockout will commence 10 If the appliance will not operate follow the instruc tions To Turn Off Gas To Appliance and call your service technician or gas supplier 11 Replace access panel 12 If heater fails to start verify the following a There are no loose connections or that the service switch is off b High temperature limit switch is set above wa ter temperature c Thermostat is set above room temperature d Gas is on at the meter and the heater e Incoming gas pressure to the gas valve is NOT less than 5 0 in WC for natural gas 11 0 in WC for propane gas To Turn Off Gas To Appliance 1 Setthe thermostat to lowest setting 2 Turn off all electrical power to the appliance if serv ice is to be performed 3 Remove upper front panels 4 Turn off main manual gas valve 5 Replace access panel TROUBLESHOOTING Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 YES NO Reattach NO YES Is Disable jumper intact J1 YES YES Are the blower lights illuminated NO YES Is 24VAC at PS on ignition module Is connecting plug secure YES Is the flame sensor signal to the ignition module greater than 1 uA DC
55. connected controllers are mounted more than 50 equivalent feet 18 Ga from heater Check the Power Source 2 Turn off all power to the heater Verify that power has been turned off by testing with a multi meter WARNING Using a multi meter check the prior to working with any electrical connections or following voltages at the terminal block inside the components unit Make sure proper polarity is followed and house ground is proven See Fig 18 3 Observe proper wire colors while making electri cal connections Many electronic controls are CIRCUIT BREAKER polarity sensitive Components damaged by improper electrical installation are not covered by warranty WHITE 4 Provide overload protection and a disconnect GREEN e means for equipment serviceability as required by EE local and state code 5 Install heater controls thermostats or building management systems in accordance with the ABC applicable manufacturers instructions Fig 18 Wiring Connections 6 Conduit should not be used as the earth ground Check the power source Field Wiring Connection AC 108 VAC Minimum 132 VAC MAX NOTE A grounding electrode conductor shall be AB 108 VAC Minimum 132 VAC MAX used to connect the equipment grounding BC 1 VAC Maximum conductors the equipment enclosures and the grounded service conductor to the grounding electrode Fig 19 Multi meter If the heater does not have a factory wired stage con t
56. consignee Permission to return goods must be received from the factory prior to shipping Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts you must specify the model and serial number of the heater When ordering under war ranty conditions you must also specify the date of installation 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 Raypak s standard war ranties Model Identification The model identification number and heater serial number are found on the heater rating plate located on the lower right outside jacket of the heater The model number will have the form H9 1262B or similar depending on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating WH Domestic Hot Water DHW P Pool The number which fol lows identifies the firing mode 1 or 4 on off 3 2 stage 8 3 stage and 9 4 stage The second group of characters identifies the size of the heater four numbers representing the approximate MBTUH input and where applicable a letter indicating the manufacturing series An E suffix indicates 87 effi ciency Category II or IV venting H stamped boilers
57. d establishments new building construction remodeling areas e open pit skimmers Check for areas and products listed above before in stalling heater If found remove products permanently OR install TruSeal direct vent LIMITED PARTS WARRANTY HI DELTA TYPES H AND WH MODELS 302B 902B SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY Domestic Hot Water Five 5 years from date of heater installation Includes copper heat exchanger with bronze and cast iron waterways Ten 10 years from date of heater installation Includes only cupro nickel heat exchanger with bronze or cast iron waterways Space Heating Closed Loop System Ten 10 years from date of heater installation Includes both cupro nickel and copper heat exchanger with bronze or cast iron water ways Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature
58. e common venting system are not in operation 1 Seal any unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and verify there is no block age restriction leakage corrosion or other unsafe condition 3 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 ap pliance not connected to the common vent System Turn on any exhaust fans such as range hoods and bathroom exhausts at maximum Air Inlet Max Length Intake Pipe Material Galvanized Steel PVC ABS CPVC 100 Vent lengths are based on a lateral length of 2 ft Refer to the latest edition of the NFGC for further details When vertical height exceeds 25 ft consult factory prior to installation Subtract 10 ft per elbow Max 3 elbows Maximum combustion air duct length terminated at 100 equivalent ft Table N Category I Vertical Venting speed Do not operate summer exhaust fan Close fireplace dampers 4 Place in operation the appliances being inspected Follow the manufacturer s instructions for lighting each appliance Adjust thermostat so appliance will operate continuously 5 Check the pressure at a pressure tap located 12 in above the bottom joint of the first vertical vent pipe
59. e of the cut out on the lower right hand corner of the igni tion module case Turning off the power to the heater WILL NOT reset the ignition module Condition System OK en No faults present Possible control fault Check power Low air pressure brief flash 1 Flash ing normal on start up 2 Flashes Flame in combustion chamber No call for heat 3 Flashes Ignition lockout 4 Flashes Low igniter current Low 24VAC check control 5 Flashes supply voltage Internal fault 6 Flashes Replace control Table Q Ignition Module Diagnostic LED Codes High Limit Manual Reset The heater is equipped with a manual reset high limit temperature device Push the reset button and adjust the setting to 40 50 F above desired operating tem perature CA Fig 30 High Limit Manual Reset Flow Switch This dual purpose control mounted and wired in series with the main gas valve shuts off heater in case of pump failure or low water flow Fig 31 Flow Switch Operating Control The heater may be equipped with different types of operating controls Consult the individual control data sheets supplied with your heater paperwork See the General Safety Section for safety precautions con cerning domestic hot water applications 37 Low Water Cut Off Optional The low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing pro
60. e optional factory supplied outdoor vent kit and re quire no additional vent piping A special vent cap flow switch cover and air intake hood are provided in accor dance with CSA requirements which must be installed directly on the heater Correct clearances can be found earlier in this section Care must be taken when locating the heater out doors because the flue gases discharged from the vent cap can condense as they leave the cap Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the following precautions must be observed 1 Outdoor models must be installed outdoors and must use the outdoor vent cap flow switch cover and air intake hood available from the manufac turer sales order option D 11 2 Periodically check venting system The heater s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air Keep area clear and free of combustible and flammable materials 3 Do not locate adjacent to any window door walk way or gravity air intake The vent must be located a minimum of 4 ft horizontally from such areas 4 Install above grade level and above normal snow levels 5 Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft 6 Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate NOT
61. ent material must be listed by a nationally recognized test agency The connection from the appliance flue to the stack must be as direct as possible and should be the same size or larger than the vent outlet See Table N for Category venting guidelines It is recommended that the intake vent be insulated in colder climates Termination The flue terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof within 10 ft The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below unless a 4 ft horizontal distance is maintained electric meters gas meters regulators and relief equipment The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and building openings must be consis tent with the NFGC U S or B149 Canada Flues supported only by flashing and extended above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads The air inlet opening MUST be installed 1 ft above the roof line or above normal snow levels that might ob struct combustion air flow This dimension is critical to the correct operation of the heater and venting system and reduces the chance of blockage from snow The vent cap must have a minimum 3 ft vertical clearance from the air inlet opening Outdoor Installation Outdoor models are self venting when installed with th
62. ergy efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded Feel water before bathing or showering Temperature limiting valves are available NOTE When this water heater is supplying general purpose hot water 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 Maximum water temperatures occur just after the heater s burner has shut off To determine the water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer N D Water temperature over 125 F can cause instant severe burns or death 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 Time Temperature Relationships in Scalds 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 w
63. ess than 7 ft 2 13 m above a paved sidewalk or paved driveway located on public property Within 6 ft 1 8 m of a mechanical air supply inlet to any building Above a meter regulator assembly within 3 ft 915 mm horizontally of the vertical centre line of the regulator Within 6 ft 1 8 m of any gas service regulator vent outlet Less than 1 ft 305 mm above grade level Within the 3 ft 915 mm of a window or door which can be opened in any building any non mechani cal air supply inlet to any building or the combustion air inlet of any other appliance Underneath a verandah porch or deck unless the verandah porch or deck is fully open on a mini mum of two sides beneath the floor and the distance between the top of the vent termination and the underside of the verandah porch or deck is greater than 1 ft 305 mm Changing the Flue Outlet Follow these instructions to change the flue connec tion from the standard top location to the rear of the heater when the optional vent tee is ordered 1 Disconnect all electrical power from the heater if applicable Disconnect or isolate the main gas pipe from the heater if applicable Remove the screws gasket and dustcover from the rear of the heater Remove the screws stainless steel flue cover and gasket from the branch side of the tee located in the flue box at the rear of the heater 5 Remove the screws retaining ring and rain gasket from top of he
64. etween 9 2 to 9 8 for propane gas Carbon monoxide should be lt 150 ppm 53 Check coils for 60 cycle hum or buzz Check for leaks at all valve fittings using a soapy water solu tion Test other operating parts of all safety shut off and control valves and increase or decrease set tings depending on the type of control until the safety circuit opens Reset to original setting after each device is tested Perform leakage test on gas valves See Fig 42 Test air switch in accordance with manufacturer s instructions Turn panel switch to the On posi tion until blower is proven then turn the switch to Off As Required 1 Recondition or replace low water cut off device if equipped 2 Check drip leg and gas strainers 3 Perform flame failure detection and pilot turn down tests 4 Check igniter Resistance reading should be 40 75 ohms at 77 F 5 Check flame signal strength Flame signal should be greater than 1 microamp 6 Test safety safety relief valves in accordance with ASME Heater and Pressure Vessel Code Sections VI and VII APPENDIX Inside Air Contamination All heaters experience some condensation during start up The condensate from flue gas is acidic Combustion air can be contaminated by certain vapors in the air which raise the acidity of the condensate Higher acidity levels attack many materials including stainless steel which is commonly used in high effi ciency syste
65. g With the time delay relay the boil er pump is programmed to continue running for an optimum period of time in order to absorb the residual heat from the combustion chamber and use it in the system The pump then shuts off until the next call for heat is received from the Aquastat Fig 36 Economaster Time Delay Relay TDR 38 UDB Diagnostic Board This heater is equipped with a diagnostic board which will indicate faults as they occur Refer to the following section for instructions on accessing reviewing and clearing these faults Fig 37 UDB Diagnostic Board UDB Fault History To view the fault codes in the UDB history file 1 Press the UP or DOWN buttons on the membrane switch for 2 seconds to access the fault history Press either button to scroll through the recorded faults in history The most recent fault recorded will be the first fault displayed the last 16 faults are stored in the his tory on a rolling basis There is no time or date stamp associated with these faults When the history of faults has been exhausted pushing the UP or DOWN buttons again will roll the fault history over and it will start again To exit the fault history wait for 10 seconds and the board will automatically exit the history mode To clear the fault history press and hold both the UP and DOWN buttons for 5 seconds while the power is on NOTE Once the history has been cleared it cannot be reco
66. hrough 4 58 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for res idential purposes c MANUFACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instruc tions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting sys tem design or the venting system components and 2 A complete parts list for the venting system design or vent ing system d MANUFACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting sys tems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipme
67. ing the heater The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air must be equipped with flow control valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 10 EXPANSION TANK AIR SEPARATOR WITH BLEED VALV a Fig 10 Air Separation Expansion Tank Three Way Valves Valves designed to blend water temperatures or reduce water circulation through the heater should not be used Raypak heaters are high recovery low mass heaters which are not subject to thermal shock Raypak offers a full line of electronic sequencers that produce direct reset of heater water temperature Refer to the Controls section of the Raypak Catalog NOTE BYPASS FOR LOW TEMP SYSTEMS ONLY SYSTEM SENSOR HEAT PUMP SYSTEM SENSOR 4 1 TURNDOWN 1 OR GREATER Fig 11 Single Heater For Hydronic or Heat Pump Primary Secondary Piping SYSTEM SENSOR LESS THAN 4 1 TURNDOWN SYSTEM SENSOR 4 1 TURNDOWN OR GREATER M Fig 12 Dual Heaters Reverse Return with Primary Secondary Piping Domestic Hot Water When design
68. ing the water piping system for domestic hot water applications water hardness should be con sidered Table indicates the suggested flow rates for soft medium and hard water Water hardness is ex pressed in grains per gallon Potable Water and Space Heating CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation 1 All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water 2 Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used for space heating 3 If the heater will be used to supply potable water it shall not be connected to any heating system or components previously used with a non potable water heating appliance Fig 13 Single Domestic Hot Water Heater and Storage Tank Soft 0 4 grains per gallon 4 When the system requires water for space heating at temperatures higher than 140 F a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential Pool Heating CAUTION Power to the heater should be interlocked with the main system pump to make sure the heater does not fire without the main system pump in operation Improper flow control can damage the heater Uncontrolled flow too high or restricted flow too low can seriously damage the heater
69. inlet to any other appliance e 3 ft 91 cm above if within Clearance to mechanical air supply inlet 10 ft 3m horizontally 6 ft 1 83m Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t Clearance under veranda porch deck or 12 in 30 cm TT balcony In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code In accordance with the current CAN CSA B149 Installation Codes t Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves both dwellings TT Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and underside of veranda porch deck or balcony is greater than 1 ft 30cm Clearances in accordance with local installation codes and the requirements of the gas supplier Table G Vent Air Inlet Termination Clearances 11 6 MINIMUM 12 MINIMUM L RECOMMENDED RECOMMENDED 1 E H12 SIDE VIEW Fig 8 Minimum Clearances from Combustible Surfaces Outdoor Installations Combustion and Ventilation Air NOTE Use of the heater in construction areas where fine particulate matter such as concrete or drywall dust is present may result in damage to the heater that is no
70. is installed horizontally through the wall to the out doors Adequate combustion and ventilation air must Common venting of Category IV systems is not al be supplied to the mechanical room in accordance lowed with the NFGC U S and B149 Canada WARNING No substitutions of flue pipe or vent The total length of the horizontal through the wall ex cap material are allowed Such substitutions would haust vent system should not exceed 70 ft in length If jeopardize the safety and health of inhabitants horizontal run exceeds 70 ft an appropriately sized extractor must be used To maintain proper operation Certified Maximum Combustion Air Air Inlet Venting Vent Size Equivalent Intake Pipe Max Length Material Vent Length Material 70 100 N A 402BE i 6 ROUA Galvanized Steel 502BE Category II 40 PVC 75 ABS Ducted CPVC Combustion Air Subtract 10 ft per elbow Max 3 elbows Maximum combustion air duct length terminated at 100 equivalent ft Table U Category II and IV Venting 42 The stainless steel direct vent cap must be furnished by the boiler manufacturer in accordance with its list ing sales order option D 15 Use only double wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn ing boilers such as the stainless steel Saf T vent by Heat Fab Inc 800 772 0739 Protech Systems Inc 800 766 3473 Z Flex 800 654 5600 or American
71. lief equipment The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and building open ings must be consistent with the NFGC U S or B149 Canada Gas vents supported only by flashing and extended above the roof more than 5 ft should be se curely guyed or braced to withstand snow and wind loads CAUTION A listed vent cap terminal adequately sized must be used to evacuate the flue products from the heaters Common Venting System 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 of the common vent be less than the area of the largest heater exhaust outlet Certified Venting Material Cat Type B 652B Equivalent Vertical Venting Combustion Air WARNING Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure CAUTION Vent connectors for natural draft venting systems must be Type B or better Common venting systems may be too large once an existing unit is removed At the time of removal of an existing appliance the following steps must be fol lowed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to th
72. ll for heat CFH the heater is in standby mode After the standby switch is placed into the ON position a 24 VAC signal is sent to the enable disable connection normally jumpered 24 VAC switched power is applied to the S24V ter minal on the ignition module When the enable disable contacts are closed the 24 VAC signal travels to pin 1 of the stage 1 connection and waits for a CFH When a CFH occurs a 24 VAC signal is sent to the CFH light on the status panel located on the lower left front of the control compartment 24 25 26 27 28 29 30 31 32 33 34 External Lights Color Light Power Call For Heat Safety Ignition Green Green Green Table P Status LED Indicators 35 Flow Blower 1 Stage 1 Power is also sent from pin 2 of the stage 1 con nection to pin P1 3 of the universal diagnostic board Power is now sent to terminal TP4 of the Economaster to energize the relay and close the contacts Power is waiting at the common terminal of the flow switch waiting for closure and sufficient water flow The heater pump is energized upon relay closure of the Economaster Upon sufficient flow from the heater pump the flow switch contacts will close If there is insufficient flow and the flow switch does not close a 24 VAC signal is sent to the Universal Diagnostics Board to indicate the fault The flow light is energized located on the front
73. lt 49 Models 302B 402B only 24 VAC is now waiting at pin 3 of the stage 2 connections on the CPW board 50 Models 502B 902B only When power is sent to gas valve 1 itis also sent to time delay relay 1 TD 1 which starts a 5 second countdown 51 Models 502B 902B only After the 5 second countdown from TD 1 24 VAC is waiting at pin 3 of the stage 2 connections on the CPW board 52 After closure of the stage 2 contacts Gas valve 2 is energized 53 The stage 2 LED on the status display board is now illuminated 54 The Heater is now operating at full fire 36 Ignition Module When additional heat is needed the combustion air blower starts to purge air from the combustion cham ber for about 15 seconds On proof of air flow the Fig 29 Ignition Module air proving switch closes and the igniter is energized To ensure safe operation the gas valve cannot open until the igniter is verified The main burner is automat ically lit when the device is powered and pre purged The heater performs its own safety check and opens the main valve only after the igniter is proven to be capable of ignition The standard ignition module will attempt to light three times before locking out To reset it turn off power to the heater wait 30 seconds and re apply power The optional single try ignition module will lock out after failing to light one time To reset it press and release the small recessed black push button located insid
74. m and when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator drafthood or similar flue gas dilution device installed in the same space in addition to the opening for ventilation air required in 1 there shall be a permanent air sup ply opening s having a total cross sectional area of not less than 1 in 2 for each 30 000 BTUH mm per kW of total rated input of the burner s and the location of the opening s shall not interfere with the intended purpose of the opening s for ventilation air referred to in 1 This opening s can be ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferred to be straight down 18 in 450 mm from the floor but not near piping 4 Refer to the B149 Installation code for additional information Water Piping NOTE For 87 efficiency boilers see special instructions on page 40 General The heater should be located so that any water leaks will not cause damage to the adjacent area or struc tures CAUTION This heater requires forced water circulation when the burner is operating See Table H and Table for minimum and maximum flow rates and water pump selection The pump must be interlocked with the heater to prevent heater operation without water circulation NOTE Minimum pipe size for in out connections is 2 in
75. ms The heater can be supplied with corrosion resistant non metallic intake air vent materi al You may however choose to use outside combustion air for one or more of these reasons 1 Installation is in an area containing contaminants listed below which will induce acidic condensation 2 You want to reduce infiltration into your building through openings around windows and doors 3 You are using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated ar eas this may also experience deterioration Products causing contaminated combustion air Spray cans containing chloro fluorocarbons e permanent wave solutions e chlorinated waxes cleaners chlorine based swimming pool chemicals e calcium chloride used for thawing e sodium chloride used for water softening refrigerant leaks paint or varnish removers e hydrochloric acid muriatic acid e cements and glues antistatic fabric softeners used in clothes dryers e chloride type bleaches detergents and cleaning solvents found in household laundry rooms adhesives used to fasten building products similar products Areas where contaminated combustion air commonly exists e dry cleaning laundry areas e metal fabrication plants e beauty shops refrigeration repair shops e photo processing plants e auto body shops e plastic manufacturing plants e furniture refinishing areas an
76. ns must follow these codes National Electrical Code and any other national state provincial or local codes or regulations hav ing jurisdiction Safety wiring must be NEC Class 1 Heater must be electrically grounded as required by the NEC In Canada CSA C22 1 C E C Part 1 The heater is wired for 120 VAC 8 amps in its basic configuration Additional options may increase the amp draw of the unit The voltage is indicated on the tie in leads Consult the wiring dia gram shipped with the heater in the instruction packet The remote tank control stat thermostat or electronic heater control as applicable may be connected to the stage selector terminal See wiring diagram 24 VAC is supplied to this connection through the heater trans former DO NOT attach any voltage to the stage selector termi nals Before starting the heater check to ensure proper voltage to the heater and pump Install a separate disconnect means for each load Use appropriately sized wire as defined by NEC CSA and or local code All primary wiring should be at least 125 of minimum rating If any of the original wire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source NOTE Field supplied isolation relays should be installed when field
77. nt connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under a positive pressure Horizontal Through the Wall Venting 70 of straight flue pipe Category IV e 60 of straight flue pipe and one elbow 50 of straight flue pipe and two elbows opmonaL nu X 40 of straight pipe and three elbows LA EXHAUST VENTING w S The vent cap is not considered in the overall length of IR EINER 7 the venting system Or A L use HENTER ann The vent must be installed to prevent flue gas leakage do 7 w Care must be taken during assembly to ensure that all A INSULATED 12 MIN joints are sealed properly and are airtight The vent 4 VENTING must be installed to prevent the potential accumulation f P of condensate in the vent pipes It is recommended CONDENSATE that Requires optional vent tee for rear discharge 1 The vent must be installed with a slight upward slope of not more than 1 4 in per foot of horizontal run to the vent terminal Fig 39 Horizontal Through the Wall Venting Category IV Installation 2 The vent must be insulated through the length of These installations utilize the boiler mounted blower to the horizontal run vent the combustion products to the outdoors Combustion air is taken from inside the room and the Common Venting System vent
78. nt installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equip ment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation GAS PRESSURE SUPERVISION The Commonwealth of Massachusetts requires listed high and low gas pressure switches manual reset for any model with a maximum firing input greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 11 d A gas pressure regulator field supplied is required in the gas train ahead of the heater for heaters having input rates greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 Figure 3B requirements 59 Registered Quality anagem System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 60
79. o 25 ft lb DO NOT OVER TIGHTEN 14 Re route the capillary s wiring etc to the new location adding thermal paste and shim to the capillary well Fig 9 Torque Sequence Relief Valve Piping WARNING Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns Do not pipe to any area where freezing could occur Refer to local codes Hydrostatic Test Unlike many types of heaters this heater does not re quire hydrostatic testing prior to being placed in operation The heat exchanger has already been fac tory tested and is rated for 160 psi operating pressure However Raypak does recommend hydrostatic test ing of the piping connections to the heater and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the heater NEVER use petroleum based stop leak compounds To perform hydrostatic test 1 Connect fill water supply With bleed valve open fill heater with water When water flows from bleed valve shut off water Close bleed valve Carefully fill the rest of the system making sure to eliminate any entrapped air by using high point vents Close feed valve Test at standard operating pressure for at least 24 hour
80. od practice for all Hi Delta installations Daily 1 Check gauges monitors and indicators 2 Check instrument and equipment settings See Post Start Up Check on page 49 3 Check burner flame Should see light blue flame Weekly For low pressure heaters test low water cut off device With at least one stage of the appliance on depress the low water cut off test button appliance should shut off and ignition fault light should come on Depress reset button to reset Monthly 1 Check flue vent stack or outlet dampers 2 Testfan air pressure See Blower Adjustment on page 47 3 Test high and low gas pressure interlocks if equipped See Safety Inspection on page 48 Semi Annually 1 Recalibrate all indicating and recording gauges 2 Check flame failure detection system components See Pilot Turn Down Test Procedure page 48 3 Check firing rate control by checking the manifold pressure See Main Burner Adjustment on page 4T 4 Check piping and wiring of all interlocks and shut off valves 5 Inspect and clean burners as necessary Annually 1 Test flame failure detection system and pilot turn down See Pilot Turn Down Test Procedure page 48 2 Test high limit and operating temperature See Post Start Up Check page 49 3 Check flame sensors 4 Conduct a combustion test at full fire Carbon di oxide should be 7 5 to 8 5 at full fire for natural gas and b
81. of the horizontal run Termination The flue direct vent cap MUST be mounted on the ex terior of the building The direct vent cap cannot be installed in a well or below grade The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels The Raypak approved stainless steel flue direct vent cap must be used sales order option D 15 WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Certified Venting Material Combustion Subtract 10 ft per elbow Max 3 elbows Maximum Equivalent Vent Length Combustion Air Intake Pipe Material Air Inlet Max Length Galvanized Steel PVC ABS CPVC Air Maximum combustion air duct length terminated at 100 equivalent ft Table O Category Ill Horizontal and Direct Venting Use only the special gas vent pipes listed for use with Category III gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacturer s installation instructions carefully Direct Vent Horizontal Through the Wall AXT TA KONMEN ALTERNATE COMBUSTION N its AIR INTAKE LOCATION H 7 jue CONDENSATE TRAP EXHAUST VENT T L INLINE i l 1
82. on 1 Install combustion air direct vent in accordance with Fig 26 horizontal or Fig 27 vertical of this manual pages 31 and 32 respectively Provide adequate ventilation of the space occu pied by the heater s by an opening s for ventilation air at the highest practical point com municating with the outdoors The total cross sectional area shall be at least 1 in of free area per 20 000 BTUH 111 mm per kW of total input rating of all equipment in the room when the opening is communicating directly with the out doors or through vertical duct s The total cross sectional area shall be at least 1 in of free area per 10 000 BTUH 222 mm per kW of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a motorized sealed damper to prevent the circula tion of cold air through the heater during the non operating hours Direct Ducted Combustion Air In certain applications it may be desirable to duct the combustion air directly to the heater This should be done with PVC CPVC or single wall galvanized duct ing The duct will attach directly to the collar on the air filter housing located on the side of the heater The ducting is attached to the air filter housing collar using three or four sheet metal screws not supplied equal ly distributed ar
83. only Ratings and Certifications Standards ANSI Z21 13 CSA 4 9 latest edition Gas Fired Hot Water Boilers CAN 3 1 latest edition Industrial Commercial Gas Fired Package Boilers ANSI Z21 56 CSA 4 7 latest edition Gas Fired Pool Heaters e ANSI Z21 10 3 CSA 4 3 latest edition Gas Water Heaters e Low lead content lt 25 CSA certified and All Raypak heaters are National Board Approved and design certified and tested by the Canadian Standards Association CSA for the U S and Canada Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers ASME Heater Pressure Vessel Code and bears the ASME stamp The heater also complies with the latest edition of ASHRAE 90 1 Standard WARNING 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 CSA ratings of the vessel and any Raypak warranty on the vessel Altering the ASME or CSA ratings of the vessel also violates national state and local approval codes Installations at Elevation Rated inputs are suitable for up to 4 500 ft elevation without de rating Consult the factory for installations at altitudes over 4 500 ft above sea level Component Locations FLUE EXHAUST ALTERNATE FLUE CONNECTION COMBUSTION AIR FILTER INLET Fig 1 Component Locations
84. onnect the main gas pipe from the heater if applicable 3 Remove the left and right front panels from the heater 4 Locate the main gas line that traverses across the heater above the manifold risers 5 Remove the pipe cap from the right hand end of the main gas line ae ov owe wm ox xw N Fas 15 zs ss es 156 fas o fe pe Fas 15 2s eo woo az Fsws ss 150 100 300 500 Peze fa wo ss 2 2 s ss 9 75 s 2 600 Fus 20 5s as v0 aso 360 200 Natural gas 1 000 BTU per ft3 60 specific gravity at 0 5 in WC pressure drop Propane gas 2 500 BTU per ft3 1 53 specific gravity at 0 6 in WC pressure drop Table K Maximum Equivalent Pipe Length 21 Reinstall the pipe cap on the left hand end of the main gas line Remove plastic cap from the right hand side panel and reinstall into the standard main gas opening located on the left hand side of the heater Remove the rubber grommet from the left hand side panel and reinstall into the standard main gas opening located on the right hand side of the heater Install a coupling nipple union and sediment trap onto the right hand end of the main gas line and then install the gas line making sure that a manu al shut off valve has been installed within 10 ft of the heater 10 Replace the left and right front panels
85. or soot Call service person to clean Some sediment at bottom of vent is normal 2 Visually inspect venting system for proper func tion deterioration or leakage 3 Check that area is free from combustible materi als gasoline and other flammable vapors and liquids 52 4 Check for and remove any obstruction to the flow of combustion or ventilation air to heater 5 Follow pre start up check in the Start up section 6 Visually inspect burner flame It should be light blue Remove and visually inspect hot surface ig niter and sensor for damage cracking or debris build up 7 Check operation of safety devices Refer to manu facturers instructions 8 Follow oil lubricating instructions on circulator if required Over oiling will damage circulator Water lubricated circulators do not need oiling 9 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 10 Check blower and blower motor 11 Check for piping leaks around circulators relief valves and other fittings Repair if found DO NOT use petroleum based stop leak 12 Clean air filter Periodically 1 Check relief valve Refer to manufacturer s in structions on valve 2 Test low water cut off if used Refer to manufac turer s instructions 3 Clean screen and air filter in intake Preventive Maintenance Schedule The following is required procedure in CSD 1 states and go
86. ound the circumference of the duct All ducting should be self supported The filter housing is not designed to support the air duct CAUTION Use TrueSeal combustion air if damaging airborne contaminants are or will be present in the heater area See the Appendix regarding air contamination TruSeal Combustion Air In certain applications it may be necessary to utilize the TruSeal option sales order option D 21 or D 22 and duct the combustion air directly to the blower Combustion air may be ducted directly to the heater by using PVC CPVC or sealed single wall galvanized ducting The duct will attach directly to the air collar lo cated on the side of the heater using three or four sheet metal screws not supplied equally positioned around the circumference of the duct The screws and duct connection point must be sealed with RTV not supplied An in line intake air filter kit sales order option D 17 must be installed in the combustion air duct TruSeal is generally used when damaging con taminants are present in the mechanical room TruSeal heater connection points are available as fol lows 302B amp 402B Right side only 502B to 902B Left side standard Right side optional CAUTION This type of installation is recommended if damaging airborne contaminants are or will be present in the heater area See the Appendix regarding air contamination Conventional Combustion Air Supply U S Installation
87. re or explosion Do not use this appliance if any part has been under water immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Check around unit for debris and remove com bustible products i e gasoline etc Pre Start up Check 1 Verify heater is filled with water 2 Check system piping for leaks If found repair immediately 3 Vent air from system Air in system can interfere with water circulation 4 Purge air from gas line up to heater Initial Start up Tools Needed 1 12 0 12 24 scale U tube manometer 4 6 0 6 12 scale U tube manometers mini mum 1 Screwdriver 1 Multi meter 1 3 16 Allen wrench NOTE Digital manometers are not recommended Preparation WARNING Do not turn on gas at this time Check Power Supply With multi meter at incoming power check voltage between Hot Common 120 VAC Hot Ground 120 VAC Common Ground 1 VAC WARNING If Common Ground is gt 1 VAC STOP Contact electrician to correct ground failure Failure to do this may burn out 120V 24V transformer or may cause other safety control damage or failure Attach Manometers to Measure Pressures Turn off main gas valve 2 Attach 24 scale manometer to the first main gas shut off valve pressure tapping 3 Attach 1 12 scale manometer to the outlet side of
88. roller it is factory wired in an on off configuration with other stage terminals jumpered L MAIN POWER AND 1 PUMP POWER IN To field connect a stage controller remove factory ALTERNATE LOCATION installed jumpers and wire stage controller as shown in Fig 21 Fig 20 Wiring Location CAUTION Label all wires prior to disconnection Making the Electrical Connections when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper Refer to Fig 18 23 operation after servicing 1 Verity that circuit breaker is properly sized by CAUTION For pumps larger than 3 4 HP a referring to heater rating plate A dedicated circuit SAN separate circuit breaker may be required breaker should be provided 23 DANGER SHOCK HAZARD Installer action is required to electrically enable your Make sure electrical power to the heater is discon nected to avoid potential serious injury or damage to components STAGE SELECTOR CONTROL D STAGE B o STAGE 1 D FACTORY JUMPERED PA STAGE 2 FACTORY JUMPERED STAGE 3 FACTORY JUMPERED a SHASE dt MODELS 302B 902B 2 STAGE STAGE SELECTOR CONTROL STAGE 1 CONTROL STAGE 2 quad STAGE 3 quae _ stace 4 MODELS 302B 752B 2 STAGE STAGE SELECTOR CONTROL STAGE 1 B FACTORY JUMPERED CONTROL STAGE 2 FACTORY JUMPERED m MODEL 902B Fig 21 Wiring Connections 24 heater to operate after making
89. s 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found Cold Water Operation CAUTION Damaging internal condensation may occur if the heater inlet water temperature does not exceed 105 F 41 C within 7 minutes of start up NOTE See Raypak Catalog No 1000 57 for infor mation on Cold Water Protection A heater operated with an inlet temperature of less than 105 F 41 C must have a manual bypass or an approved low temperature operation system to pre vent problems with condensation A manual bypass shown in Fig 15 must be piped into the system at the time of installation This piping is like a primary sec ondary boiler installation with a bypass acting as the secondary boiler piping Raypak strongly recommends that thermometer s be placed into the heater piping next to the in out header to facilitate temperature adjustment Inlet water temperatures below 105 F 41 C can excessively cool the products of combus tion resulting in condensation on the heat exchanger and in the flue Failure to exceed 105 F 41 C within 7 minutes may result in the premature failure of the hot surface ignit er remote flame sensor burners and heat exchanger It can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the vent system The bypass allows part of the heater discharge water to be mixed with the cooler heater return wa
90. s supply system at test pressures in excess of 1 2 psi 3 45 kPa The heater must be isolated from the gas supply pip ing system by closing the manual shut off valve during any pressure testing of the gas supply piping system MUST BE INSTALLED Fd BY INSTALLER JACKET COUPLING FIELD SUPPLIED a Fig 16 Gas Supply Connection at test pressures equal to or less than 1 2 psi 3 45 kPa Relieve test pressure in the gas supply line prior to reconnecting the heater and its manual shut off valve to the gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVES Over pressurized gas valves are not cov ered by 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 an open flame CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare CAUTION Support gas supply piping with hangers not by the heater or its accessories Make sure the gas piping is protected from physical damage and freezing where required Reversing Gas Supply Connection Reversing the standard fuel connection from the left hand to the right hand side is a simple field operation 1 Disconnect all electrical power from the heater if applicable 2 Disc
91. s All Air from Inside the Building The confined space shall be provided with TWO per manent openings communicating directly with an additional room s of sufficient volume so that the com bined volume of all spaces meets the criteria for a room large in comparison NFGC The total input of all gas utilization equipment installed in the combined 13 space shall be considered in making this determina tion Each opening shall have a minimum free area of 1 in 2 per 1 000 BTUH 2 225 mm per kW of the total input rating of all gas utilization equipment in the con fined space but not less than 100 in 645 cm2 One opening shall commence within 12 in 305 mm of the top and one opening shall commence within 12 in 305 mm of the bottom of the enclosure The mini mum dimension of air openings shall be not less than 3 in 76 mm in any direction All Air from Outdoors The confined space shall communicate with the out doors in accordance with one of the methods below The minimum dimension of air openings shall not be less than 3 in 76 mm in any direction Where ducts are used they shall be of the same cross sectional area as the net free area of the openings to which they connect 1 Two permanent openings one commencing within 12 in 305 mm of the top and one com mencing within 12 in 305 mm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the outdoors or
92. spaces crawl or attic that freely com municate with the outdoors Where directly communicating with the out doors or where communicating to the outdoors through vertical ducts each opening shall have a minimum free area of 1 in 2 per 4 000 BTUH 550 mm per kW of total input rating of all equipment in the enclosure Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 in 2 per 2 000 BTUH 1 100 mm per kW of total input rat ing of all equipment in the enclosure One permanent opening commencing within 12 in 305 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 25 mm from the sides and back and 6 in 152 mm from the front of the appliance The opening shall directly communicate with the out doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of a 1 in per 3 000 BTUH 740 mm per kW of the total input rating of all equipment located in the enclosure and b Not less than the sum of the areas of all vent connectors in the confined space WARNING Do not use one permanent opening method if the equipment room is under negative pressure conditions or the equipment is common vented with other gas fired appliances Canadian Installations CAUTION All combustion air must be drawn from
93. special setup and operation NOTE Failure of a heat exchanger due to lime scale build up on the heating surface low pH or other chemical imbalance is non warrantable Lo pom pom om Deer os o8 8 Total Ben Solds 1500 Maximum 1500 Maximum 1500 Maximum Free Chlorine MUST NOT EXCEED 5 ppm In salt water chlorinated pools the total TDS can be as high as 4500ppm NOTE The allowable concentrations of salt and of the Total Dissolved Solids are lower for the Hi Delta than for a typical residential pool heater due to the higher water temperatures at which a Hi Delta operates Table J Water Chemistry Gas Supply DANGER Make sure the gas on which the heater will operate is the same type as specified on the heater s rating plate Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the heater jacket It is recommended that a union be installed in the gas supply piping adja cent to the heater for servicing A pounds to inches regulator must be installed to reduce the gas supply pressure to a maximum of 10 5 in WC for natural gas and 13 0 in WC for propane gas The regulator should be placed a minimum distance of 10 times the pipe diameter up stream of the heater gas controls Refer to Table K for maximum pipe lengths Gas Supply Connection CAUTION The heater must be disconnected from the gas supply during any pressure testing of the ga
94. stream manual gas valve and remove the manometer from test point A and from test point B Connect a rubber tube from test point A to test point B and open the upstream manual gas valve Make sure that test points A 8 B have been opened so as to allow gas to flow This will bring pressure to the second valve seat Open test point C and connect a second rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure In creasing pressure indicates a leaking gas valve Remove rubber tube and manometers Close each test point valve as the tubes are removed Connect a manometer to each test point one ata time and look for a build up of pressure If a build up of pressure is detected check each test point valve to see if it is tightly closed If leak persists replace test point valve s After no leakage has been verified at all valve seats and test valves open downstream leak tests valve and restore electrical power to heater RISER RISER RISER TYP 2 3 T ww ch P4 e i 1ST SEAT 5 FIRING P VALVE a 2ND SEAT GAS A MON eccl oi B 7 ee m E Xi MANUAL VALVE ALTERNATE e C TO BURNERS TYP O BURNERS Fig 42 Leak Test This completes leak testing for a single Hi Delta mani fold riser Repeat steps 1 8 for each riser Post Start Up Check Check off steps as completed 1 Verify that the heater and heat distribution units or s
95. t covered by the warranty If operated in a construction environment a clean source of combustion air must be provided directly to the heater Indoor Units The heater must be supplied with sufficient quantities of non contaminated air to support proper combustion and equipment ventilation Combustion air can be sup plied via conventional means where combustion air is drawn from the area immediately surrounding the heater or via direct vent where combustion air is drawn directly from outside All installations must com ply with the requirements of the NFGC U S and B149 Canada and all local codes CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heater and void the warranty See the Appendix NOTE It is recommended that the intake vent be insulated to minimize sweating 12 Reversing Air Filter Follow these instructions to change the air duct con nection from the left hand side standard to the right hand side 1 Remove the four screws and the dust cover from the right hand side of the heater 2 Remove the four screws and the air filter bracket from the left hand side of the heater 3 Reverse the components and reattach in the new location making sure that the air filter locking bracket is on the bottom The air filter locking bracket is reversible Direct Vent If outside air is drawn through the intake pipe directly to the unit for combusti
96. tch for shut down due to loss of supervised flame signal as pressure is being re duced Flame signal should be lost before manifold pressure goes below 2 0 in WC for nat ural gas and 6 0 in WC for propane gas Leak Test Procedure Dual Seat Gas Valves Proper leak testing requires three pressure test points in the gas train Test point A is upstream of the automatic gas valve On the first automatic valve this is a bleedle valve On the other valves this is a plugged port The bleedle valve on the first valve may be used for all the other valves as well Test point B is a bleedle valve located between the two automatic gas valve seats Test point C is located downstream of both automatic gas valve seats and upstream of the manual valve On the manual valve this is a bleedle valve Identical readings will be found at the plugged port labeled as Alternate C Refer to Fig 42 The numbers on the diagram refer to the steps below These tests are to be conducted with the electrical power to the heater turned off Manually close the downstream leak test valve Open test point A and connect a manometer to it Verify that there is gas pressure and that it is with in the proper range NOTE must not exceed 14 0 in WC Open test point B and connect a rubber tube to it Connect the other end of the tube to a manometer and look for a build up of pressure Increasing pressure indicates a leaking gas valve Next close the up
97. ter to increase the heater inlet temperature above 105 F 41 C This precautionary measure should prevent the products of combustion from con densing in most installations Warranty claims will be denied when condensation occurs Cold water operation issues are applicable to both cold water start and cold water run applications Cold water operation for 7 minutes or less on start up is acceptable Where cold water starts will last longer than 7 minutes or where cold water operation is con tinuous provisions must be made to mix higher temperature outlet water with the colder inlet water and thereby raise the inlet temperature to at least 105 F 41 C within the 7 minute time limit Cold Water Starts Frequent more than once a week cold water starts wherein the inlet water temperature remains below 105 F 41 C for more than 7 minutes must have cold water start protection Known protection methods con sist of mixing heated outlet water with the inlet water with a bypass to raise the inlet to 105 F 41 C or high er Once the system is heated up and has return water temperatures of 105 F 41 C or higher the mixing of outlet water with inlet water is no longer needed and the bypass can be shut off If the bypass is not shut off as the system heats up the outlet temperature may continue to climb and actuate the high limit thereby shutting down the heater Thus an automatic valve system such as a three way proportional valve
98. the power connections You must make a closed contact connection on Stage 1 connector of the Central Point Wiring CPW board for temperature control connections This will be done based on the controller option selected with your heater order 1 For Pool and Closed Loop Water Source Heat Pump applications your heater should be config ured to operate in an on off firing mode This means that you will connect a single pole control to stage one of the CPW board Then jumper the remaining firing stages For example if your heater is a Model 902B you will jumper stages two three and four Then your heater will either be on at full fire or it will be off 2 For 2 stage controller connections connect each stage of the control to the corresponding stage of the CPW board in the heater i e stage 1 of the heater to stage 1 of the control stage 2 of the heater to stage 2 of the control as shown in Fig 21 and 22 Set the operating control to the set point at which you want the heater to maintain Ensure that the sensing bulb of the control is at the point in the system that will best maintain the tem perature you want For example when you are heating a tank of water you want the operating control sensor bulb in the tank 3 For single stage controller connections attach the stage 1 connections on heater 1 to the tankstat per Fig 23 Heater must be electrically grounded in accordance with the NEC and CSA C22 1 C E C Part 1 in
99. the second main gas shut off valve pressure tapping 4 Attach 1 12 scale manometer near the fan prov ing switch Pull black cap from air pressure switch tee and connect the manometer NOTE Retain caps for reinstallation later Check Gas Supply Pressure 1 Slowly turn on main gas shut off valve 2 Read the gas supply pressure from the manome ter minimum supply pressure for natural gas is 5 0 in WC recommended supply is 7 0 in WC mini mum supply pressure for propane gas is 11 0 in WC dynamic readings all stages firing If the pressure is gt 14 0 in WC turn off the valve Check if the service regulator is installed and or adjust the service regulator Start Up Blower Adjustment 1 Turn off power 2 Unplug cap at pressure switches and connect ma nometer s to the tee 3 Close all manual firing valves 4 Turn power on 5 Check manometers attached to fan pressure switch The reading should be 1 4 1 in WC for propane gas and natural gas If not adjust the air shutter on the blowers to attain the correct value 6 Turn power off 7 Reconnect this cap Main Burner Adjustment 1 Turn off unit 2 Open manual firing valves Turn on the unit wait 15 seconds and the igniter should glow Look into sight glass located at each end of the heater to check igniter operation Gas valves should open in 45 60 seconds If burner does not light on first trial It will retry up to three times
100. the vent material if there is any question about the appliance categorization and suitability of a vent material for application on a Category IIl or IV vent system Using improper venting materials can result in personal injury death or property damage Support of Vent Stack The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided in compliance with applicable codes The vent should also be installed to maintain proper clearances from combustible materials Use insulated vent pipe spacers where the vent pass es through combustible roofs and walls Vent Terminal Location NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice Exhaust Configuration Combustion Air Supply Heater Venting Category Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Give special attention to the location of the vent termination to avoid possibility of property dam age or personal injury Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs The bottom of the vent terminal and the air intake shall be located at least 12 in abo
101. torage tank are filled with water Confirm that the automatic air vent if used was opened two full turns during the venting proce dure Verify that air has been purged from the system Verify that air has been purged from the gas pip ing and that the piping has been checked for leaks Confirm that the proper start up procedures were followed Inspect burner to verify flame Test safety controls If heater is equipped with a low water cut off or additional safety controls test for operation as outlined by manufacturer Burner should be operating and should go off when con trols are tested When safety devices are restored burners should re ignite after pre purge time delay Test limit control While burner is operating move indicator on high limit control below actual water temperature Burner should go off while blower and circulator continue to operate Raise setting on limit control above water temperature and burn er should re ignite after pre purge time delay Test ignition system safety device a Turn on manual gas valve Turn power on b Set thermostat to call for heat c When the heater is in operation pull cap off of tee in air switch hose The burner should go off immediately d Wait 5 minutes e Reattach cap on tee Burner should re ignite after pre purge time delay 10 11 12 13 14 15 To restart system follow lighting instructions in the Operation section Check to
102. ty damage if ignored Indicates special instructions on installation operation or maintenance which Indicates the presence of hazards or unsafe practices which could cause minor personal injury or product or property damage if ignored are important but not related to personal injury hazards DANGER Make sure the gas on which the heater will operate is the same type as that specified on the heater rating plate WARNING 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 WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING This unit contains refractory ceramic fiber RCF insulation in the combustion chamber RCF as manufactured does not contain respirable crystalline silica However following sustained exposure to very high temperatures gt 2192F the RCF can transform into crystalline silica cristabolite The International Agency for Research on Cancer IARC has classified the inhalation of crystalline silica cristabolite as carcinogenic to humans When removing the burners or heat exchangers take precautions to avoid creating airborne dust and avoid inhaling airborne fibers When cleaning spills use wet sweeping or High Efficiency Particulate Air HE
103. unted on a level structurally sound surface The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting Gas fueled equipment installed in enclosed parking garages must be located at least 18 in above the floor Stacking Hi Delta units can be stacked two units high with an optional stacking rack A stacking kit is available from Raypak for this type of installation CAUTION The heaters should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure When such locations cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under the appliance The pan must not restrict air flow NOTE A use A_SINGLE ACTING BAROMETRIC DAMPER IN CATEGORY WHEN THE VERTICAL RISE EXCEEDS 25 FEET A REQUIRES OPTIONAL VENT TEE A REQUIRES OPTIONAL VENT TEE IF VENTED OUT BACK OF HEATER Fig 5 Typical Stacked Installation In addition the heater shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation or service circulator replacement control replacement etc Clearances Indoor Installations Heater Side Floor Rear Minimum Clearance Recommended from Combustible Service Surfaces Clearance DO NOT install on carpeting Table E Clearances Indoor Installations
104. ust direct vent cap is not considered in the overall length of the venting system Care must be taken during assembly that all joints are sealed properly and are airtight The vent must be installed to prevent the potential ac cumulation of condensate in the vent pipes It is recommended that 1 The vent must be installed with a slight downward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal 2 The vent must be insulated through the length of the horizontal run For installations in extremely cold climate it is rec ommended that 1 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal In this case an approved condensate trap must be installed per applicable codes 2 The intake vent must be insulated through the length of the horizontal run Common Venting System Common venting of Category IV systems is not al lowed WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants The stainless steel flue exhaust direct vent cap must be furnished by the boiler manufacturer in accordance with its listing sales order option D 15 Use only double wall vent pipe and the special gas vent pipes listed for use with category II or IV gas burn ing boilers such as the stainless steel Saf T vent by Heat Fab Inc 800 772 073
105. ust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building Condensate could freeze and block vent pipe Condensate Management Condensate must be routed from the condensate trap to an appropriate container for neutralization before disposal as required by local codes Vertical Venting Category II VENT CAP Lr EXHAUST VENT 3 MIN DAL BOOT TEE OR EQUIVALENT ALTERNATE VENT EET em CONFIGURATION AIR FILTER e MOTO AM TAOMAAAAAA AAA ATAN AT IT AATITTATIIT Note When vertical height exceeds 25 ft consult factory prior to installation Requires optional vent tee for rear discharge Fig 38 Vertical Venting Category Il CAUTION A properly sized listed vent cap terminal must be used to evacuate the flue products from the boilers Common Venting System Manifolds that connect more than one boiler to a com mon chimney must be engineered to handle the combined load Consult available guides for proper sizing of the manifold and the chimney At no time should the area of the vent be less than the area of the largest boiler exhaust outlet pressure reading must be between 0 01 and 0 1 in WC as measured 12 in from the appliance flue outlet Each elbow used is equal to 10 ft of straight pipe This will allow installation in one of the four following com binations WARNING Ve
106. ve grade includ ing normal snow line Un insulated single wall metal vent pipe shall not be used outdoors in cold climates for venting gas fired equipment Through the wall vents for Category Il and IV appliances and non categorized condensing appli ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen tal to the operation of regulators relief valves or other equipment Where local experience indi cates that condensate is a problem with Category and IIl appliances this provision shall also apply Certified Materials Combustion Air Inlet Material Vertical Natural up s A B Vent From Inside Building Draft Venting Non Direct Venting Horizontal Through Stainless Steel the Wall Venting Gas Tight Galvanized Steel Vertical Natural B Vent From Outside Building Draft Venting PVC Direct Venting Horizontal Through Stainless Steel ABS the Wall Venting Gas Tight CPVC Table M Venting Category Requirements 10 11 12 Locate and guard vent termination to prevent acci dental contact by people or pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resist
107. vered Diagnostic information is provided any time a fault is recorded This information is intended to assist in locating the problem with the heater but is not exhaus tive If multiple fault conditions occur at the same time only the fault that caused the heater to shut down will be recorded in the history Detection tots Dey LOD Display Readout with Fault eee Fa Cond Drain Blocked Vent Temp Limit Err PVC Vent Limit CHX 1 Check Drain Switch Check Drain Check Vent System Auto Hiah Limit 1 Confirm Settings Check Pump Lo Water Cutoff Err Purge Air Check Pump Chk Isolation Valve Low Water Cut off Reset LWCO ae n e Vent Pressure Low Gas Pressure m Hiah Gas Pressure Controller Alarm Flow Switch Blower Switch EN Check Factory Data Check Wiring Diagram Check Freeze Control Check Water Pressure Factorv Option Check Louvers Check Comb Damper Check Extractor Sw External Interlock Recycle Reset Control Push Reset Button lanition Lockout See Table Below Field Interlock Flashes LCD Display Readout With Fault ERE Low Air Low Air Fault Flame No CFH Ignition Lockout p Low HSI Current Internal Cntrl Fault Recycle Reset Cntrl Replace Control LCD Display Without Fault Svstem Normal Power On No CFH Standby WebSite Svstem Normal Power On CFH CFH Active WebSite Toagles Between Table R UDB Fault Messages 39 87 Efficiency Boilers Special Instructions NOTE
108. vicing 33 POWER Qv Ane antion STAGE rcov STAGE 2 Lower i STANDBY P N 901587 Fig 28 Status LED Indicator Decal Heater Sequence of Operation Models 302B 902B 1 10 11 The black hot wire lead goes directly to the main power switch This black toggle switch is located at the middle front of the control compartment When the main power switch is placed in the ON position 120 VAC is applied to the 120 VAC termi nal block on the circuit board and the 120 24 VAC transformer is powered 120 VAC is waiting at the N O contacts of the Economaster pump delay Terminals L1 and F1 of the ignition module are powered with 120VAC 120 VAC power is also applied to the control power connector on the circuit board 120 VAC power is waiting at the N O contacts of K 3 relay to energize the heater blower The 120 24 VAC transformer outputs 24 VAC 24 VAC is sent to pin L1 of the low water cut off optional and the red power light is energized 24 VAC is applied to the blue power light located on the status display board 24 VAC is also applied to the red LED safety shut down light on the front status board until the safeties have been proven 24 VAC is applied to the alarm circuit optional If the E 5 sales option Alarm is included a 5 sec ond time delay relay will not allow the alarm to sound unless a safety or limit circuit stays ener gized for more than 5 seconds
109. wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a min imum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspec tor observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 t
110. y hard moderately hard or hard based on its hardness number The salts in water will precipitate out when the water is heated and will cause accelerated lime and scale accumulation on a heat transfer surface Raypak water heaters can operate lime scale free using potable water with a hardness not exceeding 25 grains per gallon Proper operation is achieved by set ting the temperature rise water flow per the guidelines in the installation instructions If the hardness of the water exceeds the maximum level of 25 grains per gal lon special measures must be taken to adjust flow and temperature rise Water should be softened to a hard ness level no lower than 5 grains per gallon Water softened as low as 0 to 1 grain per gallon may be under saturated with respect to calcium carbonate resulting in water that is aggressive and corrosive pH of Water pH is a measure of relative acidity neutrality or alka linity Dissolved minerals and gases affect water s pH The pH scale ranges from 0 to 14 Water with a pH of 7 0 is considered neutral Water with a pH lower than 7 is considered acidic Water with a pH higher than 7 is considered alkaline A neutral pH around 7 is desir able for most potable water applications Corrosion damage and water heater failures resulting from water pH levels of lower than 6 or higher than 8 are non war rantable The ideal pH range for water used in a storage tank or a copper water heater system is 7 2 to 7 8

Raypak 302B User's Manual

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